SAFARI

ENGINE

Fig. 4

Fig. 5

Fig. 6

Note:

Since a slight clearance exist between main

bearing cap dowel pins and the corresponding dowel

holes in the block, it is possible for the cap once

removed to be replaced off centre If measurements

'B' and 'C' are equal, the bearing cap is properly

centralised. If a difference in these two measurements

is noticed, the bearing cap can be centralised by

lightly tapping the cap with mallet in required

direction after loosening the bolts.

5 In case of very little wear only in main bearing

caps, it is possible to reclaim the crankcase by

facing the cap mating surface after removing the

dowels. The parent bore should then be re-

machined to original dimensions after refitting

new dowels on a suitable line boring machine or

with special reamers. This is an extremely

precision job and should be carried out only if

proper facilities are available. Otherwise, the

cylinder block should be replaced.

6 Unscrew main bearing cap bolts and remove

bearing caps.

iii. CYLINDER BORING AND HONING

1 Clean cylinder bores thoroughly.

2 Measure bores using internal measuring gauge fig. 5

and record readings on engine inspection sheet 1.

3 If taper and ovality of used cylinder bores is found

within 0.04 mm and 0.015 mm respectively,

cylinder bores can be finished by mere honing.

Replace liners if cylinder bore wear exceeds these

limits.

REMOVAL AND INSTALLATION OF LINERS

REMOVAL

1 Keep cylinder block upside down on hydraulic

press such that bore from which liner is to be

removed lies clear in machine table slot.

2 Ensure that the block is resting squarely on

machine bed.

3 Press out liners individually using drift, 2651 5890

02 01 and a suitable distance piece between press

ram and the drift. Fig 6. Make sure that the

distance piece is also seating squarely between

the drift and the ram.

INSTALLATION

1 Clean parent bores in the block thoroughly especially

for carbon in the counter bore for liner collar.

2 Place cylinder block on the hydraulic press

ensuring that it is resting squarely on the press

bed, and with head parting surface at the top.