DS 19 OPERATION No. DS 100-2 : Stripping and assembling an engine-gearbox assembly for replacement of the engine 42
TOOLS
16 Fit the fixing plates for the exhaust manifold shield, the smaller at the rear. Tighten the nuts (spring washer) 12 mm box spanner
17 Fit the low pressure pump feed pipe, (spanner 2220-T, see Pl. 72, fig. 4) . . . . . . . . . . . . . . . . . . . . . . . . . Spanner 2220-T
18 Align the water pump pulley (see Op. DS 231-0).
Fit the pulley, tighten the nut to 18 to 22 ft/lbs (2.5 to 3 m. kg), insert a plain washer and a lockwasher.
Turn over the lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 mm box spanner
19 Fit the fan. Tighten the screws to 6.5 ft/lbs (0.9 m. kg).
IMPORTANT - Do not exceed this tightening torsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm box spanner
20 Tension the water pump and dynamo belts (see Op. DS 231-0). Tighten the screw fixing the tie-rod on the
water pump (spring washer and the nut, on the high pressure pump (plain and spring washers) . . . . . 12 mm box spanner
STRIPPING AND ASSEMBLING (for replacement of the gearbox).
Stripping.
21 Remove the bracket for the expansion chamber. Do not mislay the distance piece for the left-hand14 mm
box spanner fixing plate
22 Disconnect the flexible pipes from the water pump cover and the steel tube. Remove the tie-rod from the
radiator and remove the radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12-14 mm box spanners
23 Remove the dynamo tie-rod and remove the dynamo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14 mm spanners
12-14 mm box spanners
24 Remove the screw from the plate fixing the pump - regulator connecting pipe on the gearbox and
disconnect the pipe from the pressure control valve (spanner 2220-T, see Pl. 72, fig. 4, or 14 mm spanner).
Remove the pressure control valve and its bracket from the crossmember . . . . . . . . . . . . . . . . . . . . . Spanner 2220-T
14 mm spanner
12 mm box spanner
25 Remove the lower nuts from the tie- rods supporting the brake units.
Remove the fixing screws from the crossmember on the support arms of the box (knock down the 21 mm box spanner
lockwashers) and disengage the crossmember . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm spanner
14 mm box spanner
26 To remove the brake unit.
a) Remove the adjusting nuts disengage the stops of the sheath and remove the connecting cable from the
right-hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm spanner
12 mm box spanner
b) Remove the fixing screws of the rear supports of the brake unit . . . . . . . . . . . . . . . . . . . . . . 14-19 mm box spanners
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