DS 19 OPERATION No. DS 100-3 : Overhauling an engine Op. DS 100-3 46
36 Crankshaft endfloat = 0.03 to 0.09 mm adjusted by means of a shim placed between the end cheek of the bearing and the washer on the
timing pinion.
37 Fitting the timing gear: align the reference marks (punch marks); a line passing through the centre-line of the pinions.
Tightening torsion of the nuts: camshaft nut = 110 ft/lb (15 m.kg), crankshaft nut = 145 ft /lb (20 m.kg).
38 Fitting the oil pump (tightening torsions):
Fixing screws = 11 ft/lb (1.5 m.kg) max. and locknut 22 ft lb (3 m.kg). Pipe unions = 43 ft/lb (6 m.kg) and locknuts = 29 ft/lb (4 m.kg).
39 Fitting the timing cover: liquid Hermetic or Festinol on the face of the bearing cap receiving the timing cover gasket.
Brass washer under the head or Hermetic (new screws with circular base), for the three screws projecting on the inside of the cover.
Tighten the screws to 11 ft/lb (1.5 m.kg).
40 Engine flywheel: tighten the screws to 36 ft/lb (5 m.kg) (lockwasher).
41 Clutch: tighten the screws to 14 ft/lb (2 m.kg) (spring washer).
43 Adjustment of the valves: clearance = .008 in (0.20 mm) inlet and .010 in (0.25 mm) exhaust.
Adjust the valves of a cylinder with the piston at T.D.C. (end of compression stroke), the valves of an opposite cylinder are then at the
point of balance: 1st cylinder, the valves of the 4th cylinder being at the point of balance, 3rd cylinder, the valves of the 2nd cylinder
being at the point of balance, 4th cylinder, the valves of the 1st cylinder being at the point of balance, 2nd cylinder, the valves of the 3rd
cylinder being at the point of balance.
TOOLS
DISMANTLING (see Pl. 1).
1 Place the engine on a suitable stand or on a work bench.
2 Remove the cylinder head lubrication pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17 mm box spanners
3 Remove the side engine mounting arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17 mm box spanners
4 Remove the clutch and engine flywheel. Disengage the bearings from the flywheel . . . . . . . . . . . . . . . . . . 12 mm box spanner
5 Remove the cylinder head cover. Remove the steel cup (3) and the rubber seals (4) from the sparking plug 12 mm box spanner
tubes .
6 To remove the cylinder head :
a) Unscrew the inlet rocker assembly fixing screws (5) without removing them from the brackets (6).
Remove the assembly with the screws in place in order to keep the parts in their correct position . . . . . . 14 mm box spanner
b) Remove the exhaust rocker assemblies and brackets. Remove the rocker push-rods . . . . . . . . . . . . . . . . 12 mm box spanner
c) Remove the cylinder head fixing screws, right-hand side.
Remove the cylinder head, cylinder head gasket and locating dowels . . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm box spanner
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