SAFARI

ENGINE 93 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 sur face 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.