Reliant Rebel 700 1967 Workshop Manual page 37

Figure 27 Piston and liner markings
Figure 28 Sealing cylinder liners
Operation 16 Engine rebuild
The following information covers the rebuilding of an engine that has
been completely dismantled e.g. to replace liners etc.
1. Smear "Silicoset 152" sealing compound thinly around the
seating face of the liner and its location in the cylinder block, making a
thin but complete 360° seal. (Figure 28)
Figure 29 Fitting cylinder liners
2. Using a tool similar to that shown in Figure 29, insert the
liners in to the block and ensure that they stand 0.050 to 0.152 mm
(0.002 to 0.006 in) proud of the cylinder block face. Check that there is
0.381 mm (0.015 in) clearance between liners.
3. Assemble new pistons to the connecting rods securing in
position with the gudgeon pins and circlips. To facilitate this it may be
necessary to warm the pistons in hot water. Ensure that the "Front"
mark or arrow on the piston is facing forwards.
4. Before fitting the rings to the pistons check the gap in the
bore which should be 0.17 to 0.30 mm (0.007 to 0.012 in).
5. Insert the pistons in the bores with the rings in their correct
grooves and the ring gapes spaced correctly as described in operation
11. Compress the rings for installation using a compression tool similar
to that shown in Figure 17.
6. Fit new big end bearings in the connecting rods and caps.
Ensure that the correct sizes of bearing are used. see engine data.
Check crankshaft main bearing journals. see engine data.
7.
8. Fit new main bearings to crankcase and main bearing caps.
9. Fit new thrust washers to the crankshaft ensuring the thrust
face of the washers makes good contact to the ground face of the
crankshaft.
10. Refit the crankshaft to the engine block. Fit main bearing
caps in the correct order, rear centre and front. Secure with six nuts
and washers. Always use new nuts and washers and tighten to a
torque of 3.316 kg/m (24 lb/ft).
11. Fit new oil seal into the rear cover oriented as shown in
Figure 4. Position a new gasket and secure the cover to the cylinder
block. Ensure that the dowels are firmly seated in their locations.
12. Fit the front and rear bridge pieces with new cork seals
ensuring that the faces are flush with the cylinder block and secure
with four screws.
13. Replace the rear engine plate, fixing it in to position with
four set screws and lock washers.
14. Fit the flywheel assembly to the crankshaft and secure with
three bolts and a new tab washer. Tighten to a torque of 3.87 to 4.14
kg/m (28 to 30 lb/ft). Check flywheel run-out (see operation 2)
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