DS 19 OPERATION No. DS 100-3 : Overhauling an engine 47
TOOLS
7 To remove the tappets:
Hold the cylinder barrels in position by means of two washers inserted between the barrels 1-2 and 3-4 and Washers:
secure by screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal dia. = 10.5
External dia. = 46
Turn the engine over and rest it on the face for the cylinder head.
8 Remove the sump and the timing gear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm box spanner
9 Remove the oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16-17-26
mm spanners
10 To remove the timing chain and timing pinions (spanners 1667-T and 1731-T, see Pl. 15, fig. 1 and 3).
When unscrewing the nuts, wedge the pinions with the setting gauge 1680-T (see Pl. 15, fig. 2, if not available
insert a wooden wedge between one of the crank pins and the crankcase. Spanner 1731-T
Disengage the keys, the steel washer (12) the bearing thrust ring (9) and the adjusting shims (10) . . . . . . . . Setting gauge 160-T
Spanner 1667-T
11 To remove the crankshaft, connecting rod and piston assembly (see Pl. 14) :
a) Remove the assembly screws (11) from the crankshaft oil seals (13) and (14).
b) Remove the fixing screws from the bearing caps. Remove the bearing caps (make sure that the direction of
assembly is clearly marked).
NOTE – If the crankshaft and bearings are to be re-used, make a reference mark on the centre and rear half
bearing, which are of the same dimensions, so that they are not reversed on assembling.
c) Remove the crankshaft, connecting rod and piston assembly.
Remove the crankshaft bearing thrust ring (8) (see Pl. 1).
12 Remove the upper section of the crankshaft oil seal (13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm box spanner
13 To remove the camshaft (see Pl. 1)
Remove the thrust plate (15) and disengage the shaft from the crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm box spanner
14 To strip the cylinder block (see Pl. 1)
a) Remove the timing chain lubricator, oil circulation plugs and water drain plug . . . . . . . . . . . . . . . . . 5-12mm spanners
1-23mm box spanners
b) Remove the cylinder barrels.
c) Remove the conical oil circulation unions from the cylinder block.
15 To strip the crankshaft :
Remove the connecting rod caps and the connecting rods (make sure that the arts are marked). (Socket 1624-T,
see Pl. 16, fig. 3). Mark the bearings if they are to be re-used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Socket 1624-T
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