DS 19 OPERATION No. DS 100-3 : Overhauling an engine 48
TOOLS
16 To remove the pistons from the connecting rods :
a) Remove the gudgeon pin circlips from the groove in the piston.
b) Heat the pistons to a temperature of 60°C. approximately by immersion in an oil bath or by heating in an oven.
c) Remove the gudgeon pins. Do not mix them up since they are paired with their respective pistons.
NOTE – It is advisable to remove the small end bushes.
The machining and tolerances are of such high precision that this delicate work cannot be carried out with
normal tools.
17 To strip the cylinder head (See Pl. 3):
Remove the valves (spring compressor 1614-T and support 1616-T, see Pl. 5) . . . . . . . . . . . . . . . . . . . . . . . . . Spring compressor
Remove the rear closing plate. 1614-T
Support 1616-T
NOTE – As the cylinder head is made of aluminium, the sparking plug tubes and valve seats cannot be repaired 12 mm box spanner
without the use of special tools.
Nevertheless, in certain cases, the valve guides can be replaced (see Op. DS-112-3, paragraphs 2 to 4).
Do not remove the studs.
18 To strip the oil pump (see Pl. 3)
a) Remove the delivery pipe and remove the conical union. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14–26 mm spanners
b) Remove the filters (17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm box spanner
c) Remove the pump base (18) and the idler pinion (19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm spanner
d) Withdraw the driving pinion (20) (extractor 1964-T, see Pl. 10 fig. 4) Extractor 1964-T
Do not use the socket; insert a cylindrical pressure pad 12 mm dia. 40 mm long between the extractor screw
and the pump shaft.
Remove the assembly of the shaft (21) and the pinion (22) from the pump body. . . . . . . . . . . . . . . . . . . . . . Pressure pad12mm
dia, 40mm long
e) Move the fixed pinion (22) on the shaft, release the retaining cotters (23), take off the pinion and its key
from the shaft.
f) Remove the positioning screw from the tube support and remove the tube (24) . . . . . . . . . . . . . . . . . . . . . . 14 mm spanner
g) Drive out the spindle (25) from the idler pinion.
14 mm box spanner
h) Remove the bush (26), the spring (27) and the piston (28) from the non-return valve . . . . . . . . . . . . . . . . . 12 mm box spanner
i) Remove the bush (29) from the support tube (24) with the aid of a mandrel . . . . . . . . . . . . . . . . . . . . . . . . . Mandrel = 15 dia.
19 Remove the water and low pressure pump (see Op. DS 231-3).
x 250 long
20 Strip the inlet rockershaft assembly.
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