SAFARI

ENGINE

Fig. 1

Fig.2

Fig.3

CYLINDER BLOCK

PRESSURE TESTING, INSPECTION AND REPAIR OF

CYLINDER BLOCK

(Cylinder block disassembled, timing gear housing,

clutch housing, oil cooler and water pump removed.)

PRESSURE TESTING OF CYLINDER BLOCK

1 Thoroughly de-grease, de-scale and clean cylinder

block.

2 Mount steel plate with rubber pads on cylinder

block to surface to close water jacket openings.

Similarly, mount the side sealing plate in place of

oil cooler.

3 Fit sealing plate with adaptor on the front face of

the block and connect rubber hose to the hand

operated pump dipped in a container of hot water

(70 deg C to 80 deg C).

4 Pressurise cylinder block at approx. 5 bar and

check cylinder block carefully for leaks. Fig. 1.

5 Alternately, dip the complete cylinder block with

sealing plates in position in a tank containing

water at 70 deg C to 80 deg C temperature.

Connect air hose to the front sealing plate and

pass compressed air at 5 bar and check for leakage

in block.

6 Replace cylinder block showing leakage.

INSPECTION AND REPAIR OF CYLINDER BLOCK

i. Cylinder Block

Check cylinder head mating surface of the

cylinder block for unevenness with the help of

straight edge. Fig. 2 & 3. If necessary, grind this

surface just to clear the unevenness. Ensure that

specified machining tolerance is not exceeded.

Permissible minimum height of block is

290.20 mm.

ii. Main bearing parent bores

1 Thoroughly clean main bearing\caps and

corresponding machined surface of crankcase.

2 Mount main bearing caps in position on the

crankcase taking care that grooves for bearing

shells lugs are on the same side, set numbers

on the block and caps correspond and serial

order of the caps maintained.

3 Screw in and tighten main bearing cap bolts

evenly and equally to specified torque.

4 Measure main bearing parent bores using

internal measuring gauge fig. 4 and record

readings on Engine inspection sheet 11.