ENGINE 95 Fig. 8 Fig. 7 MAIN BEARING CAP BOLT TUBE 3 Do not smear parent bore or liner outer diameter with oil. 4 Place liner in parent bore and make it at right angles to cylinder block surface in longitudinal and perpendicular planes using precision tri-square. 5 Press liner using drift, 2651 5890 02 02 ensuring that ram is seating squarely on the drift. Note: Fully pressed in liner protrudes beyond block face by 0.5 to 0.6 mm. Utmost care should be exercised at the end of liner pressing. To make sure that the liner is pressed fully home, load should be applied very carefully with fine increments. Subjecting liner under high pressure at this stage may result in cracking of the liner at the collar. 6 Similarly press all remaining liners. CYLINDER BORE MACHINING 1 Machine all bores to 96.93 to 96.95 mm dia. leaving 0.05 to 0.07 mm stock for honing. 2 Using a face cutter tool, machine off protrusion of liner to make it flush with the block sur face. Machine a chamber of 0.5 mm x 45 deg on I.D. of the liners. The honing should be done in two stages as follows: Stage I Use honing stone of grit 180. The honing speed should be approx. 100-120 rpm and approx. 60 double strokes per minute and length of stroke 130 mm. Under these conditions, a cross hatch angle E of approx. 45 to 60 deg is obtained. Leave only 0.01 mm material for the 2nd stage honing. Stage II In the 2nd stage of honing, use honing stone of grit 240. The honing speed should be approx. 50-60 rpm, with 30 double strokes per minute and 130 mm stroke length. With this, a cross hatch angle of approx. 45 deg to 60 deg is obtained. NOTE 1. It is very important that the axis of the cylinder bores are parallel to each other and are at right angles to axis of crankshaft. Therefore, we recommend the use of pillar type boring and honing machines in preference to portable type boring bar and honing machines. If the portable boring bar must be used, check and clean mating surface of the boring bar and cylinder block, and centralise the boring bar as accurately as possible. 2 Clean cylinder block thoroughly and apply grease on machined surfaces of cylinder block especially if the engine assembly is not to be taken up immediately. 3. Adjust hone travel to ensure that the honing tool projects by approx 20-25 mm from the top and bottom during honing. Use plenty of kerosene for this operation. iv. OIL PASSAGES 1 Clean all oil passages thoroughly by using suitable wire brushes/compressed air. 2 Tubes shown in Fig. 7 prevent leakage of engine oil through main bearing bolts or oil passage to main oil gallery. If necessary, new tubes may be fitted with the drift as shown in the Fig. 8.
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