DS 19 OPERATION No. DS 100-2 : Stripping and assembling an engine-gearbox assembly for replacement of the engine 41
TOOLS
Assembly.
7 To fit the contact breaker.
Put the metal fixing plate on the flat lever.
Position the driving dog of the contact breaker so that it corresponds to the oil pump driveshaft. Fit the
contact breaker. Tighten the metal fixing plate screw (spring washer under the head) . . . . . . . . . . . . . . 12 mm ring spanner
8 Fit the oil dipstick tube. Fit the contact breaker earth wire terminal under the fixing plate of the tube.
Tighten the screw (plain and spring washers). Fit the dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm box spanner
9 Fit the inlet manifold, insert the gaskets, progressively tighten the nuts (without washers) . . . . . . . . . . . . . . . . 12 mm box spanner
10 To fit the carburettor.
Assemble in the following order : a gasket, steel distance piece, a gasket, the carburettor (the float chamber
towards the front).
Tighten the nuts (serrated washers) (spanner 1623-T, see Pl. 16, fig. 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spanner 1623-T
11 To fit the crankcase breather.
Remove the element, wash with petrol, blow with compressed air, soak in engine oil and refit. Moderately
tighten the nut (plain washer).
Fit the breather on the engine. Insert a paper joint. Tighten the screw (spring washer) . . . . . . . . . . . . . . . . . . . 8-12 mm box spanners
NOTE - On earlier cars the filter element is omitted.
12 Fit the air cleaner and tube assembly. Tighten the nut on the cylinder head cover (serrated washer).
Tighten the nuts on the water pump cover (serrated washer). Tighten the clip on the carburettor 12-17 mm box spanners
13 Fit the petrol pump. Insert a cork joint. Tighten the nuts (serrated washers). Fit the petrol feed pipe from the
pump to the carburettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm box spanner
14 To connect the gearbox.
Fit the dowel pins together with their circlips in their housings on the engine crankcase.
Engage the gearbox resting on its truck, by turning the mainshaft by means of the starting handle relay,
also turn the driving pulley in order to engage the splines.
Tighten the fixing screws (spanner 2431-T, see Pl. 72, fig.1 for hexagon headed screws and spanner Spanner 2431-T
1677-T, see Pl. 65, fig. 4 for screws with two flats) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spanner 1677-T
15 Fit the starter motor. Fit the fixing screws, tighten moderately.
Tighten the locknuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14 mm box spanners
17 mm spanner
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