SAFARI

4 DLT ENGINE

REMOVAL, INSTALLATION AND MACHINING OF

CYLINDER LINERS

In order to obtain optimumperformance of engine after

reconditioning with liner fitment, we are giving below

the machining procedure to be adopted in the field.

The disassembled cylinder block should be pressure

tested as per the procedure. The block with cracks

should be discarded.

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, 2654 5890

01 03 and a suitable distance piece between press

ramand the drift. Make sure that the distance piece

is also seating squarely between the drift and the

ram.

INSTALLATION OF LINERS IN CYLINDER BLOCK

Thoroughly clean bores of the cylinder block.

Thoroughly clean liners.

Place cylinder block on hydraulic press ensuring that

oil sump mating face is resting evenly and squarely

on the horizontal bed.

DO NOT SMEAR CYLINDER BORE OF BLOCK OR

LINER OUTSIDE SURFACE WITH OIL.

Place liner with proper orientation (matching minimum

/ maximum ovality axis) in the cylinder bore and make

it at right angles to cylinder block top surface in

longitudinal and crosswise directions using precision

tri-square.

Press liner using drift 2654 5890 01 02. Use a wooden

spacer about 100 mm thick between press ram and

drift. Pressing force should be within 4 to 6 tonnes.

Similarly, press all other liners.

Liners damaged during installation should be removed

and replace with new ones.

BORING OF CYLINDERS :

The cylinder liners are semifinished and it is necessary

tomachine the liners to 82.915 to 82.945mmdiameter.

NOTE :

It is very important that the axis of the bores are parallel

to each other and are at right angle to the axis of

crank shaft. Permissible shift in perpendicularity of

bore from crankshaft axis when checked at 200 mm

from crank shaft centre line is 0.040 mm. Therefore

we recommend the use of pillar type boring and honing

machines. If portable boring bar is used check and

clean mating surface of boring bar and cylinder block

and centralise the boring bar as accurately as possible

in the bore.

4 DL CYLINDER BLOCK HONING

1. PRE-MACHINING CONDITION

: Before Honing

a) After boring the barrel bore the stock (75 to 95

microns material) must be available for bore honing

option.

b) Centre line of these bores may be 0.04mm inclined

maximum in the longitudinal axis of block (crank

bore)

c) After boring taper and ovality should be within 15

um max. Surface finish 2.2 to 2.8 uRa or more.

2. CYLINDER BORE HONING :

2.1 Rough Honing :

With vertical honing machine operation to be carried

out with coolant "HONILO 480" honing oil or kerosene.

Flooded coolant to be used so that component bore

distortion should not take place.

Make the operation gently. Keep the 15 microns/

20microns stock for Base and Plateau honing. Maintain

the taper and ovality within 8 to 10 microns max. Most

preferable is within 5micronsmax. Surface finish value

at this generation must be 0.8 to 1.2 µm Ra.

Machining Data : RPM of Spindle - 100

Fig. 76