DS 19 OPERATION No. DS 100-3 : Overhauling an engine. 51
TOOLS
c) Fit the support tube (24). Fit the fixed pinion (22) on the shaft (key and split cotters (23) in position). Insert the
shaft (21) in the body of the pump. Fit the support tube locking screw.
Tighten the nut to 18 ft/lbs (2.5 m.kg) and fit a split pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm box spanner
d) Grease the entry side of the bore of the driving pinion and fit on the shaft, with a press.
During this operation the shaft should be supported on a cylindrical block. The pinion should not take any strain.
When the pinion (20) is on the spindle, an end float of between 0.03 and 0.1 mm must be left. If the pinion is
pressed down too far, hold the pinion in the hand and with the aid of a copper drift and a hammer tap on the Block = 12 dia. x
end of the shaft until the pinion is in the correct position. 10 long.
e) Fit the idler pinion (19), the paper gasket and pump base (18), (with the filter support on the outlet pipe side).
Tighten the screws t 9.4 ft/lbs (1.3 m.kg) (spring washers under the head), lock the milled head screw by 12 mm spanner
tapping the metal of the pump base into the slot of the screw . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm box spanner
f) Fit the piston (28), the spring (27) and the spring retaining flange (26). Tighten the screws (lockwashers under
the heads). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm box spanner
g) On the intake opening fit : one cork seal, the top cover, the upper filter plate, a filter (large diameter hole),
the distance piece, a second filter and the lower plate.
Tighten the screws to 9.4 ft/lbs (1.3 m.kg). Tighten the locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm box spanner
h) Check the pressure on a test bench.
With SAE 20 oil heated to 60 ± 5˚C and the pump outlet through a 2.8mm diameter jet, the pressure must be
50 p.s.i. (3.5 kg/cm
2
) at 1000 r.p.m. If this pressure is not obtained, change the spring (27) (see Pl. 10)
NOTE – If a test bench is not available, use the simplified unit MR-1811 (see Pl. 11) . . . . . . . . . . . . . . . . . . . . . . Test bench or
unit MR-1811
25 To replace a starter gear ring :
a) Detach the starter gear ring from the flywheel, driving it off with a hammer.
b) To fit the starter gear ring on the flywheel.
Heat the starter ring with a blow torch fitted with a jet of 800 to 1000 litres.
Heat only the bore, at the same time rotating the ring continuously to ensure the uniform expansion. Cease
heating when the ring reaches a temperature of 200˚ to 250˚ (pale yellow colour) . Above this temperature the
heat treatment of the ring will be modified. Make sure that the flywheel is perfectly clean, offer up the starter
ring perfectly level and fit it rapidly.
26 Grinding the bearing face of the clutch disc on the flywheel (see Pl. 42):
Every time that the bearing of the flywheel is ground at “a”, remove the same amount from the bearing face “b”
of the clutch casing. Carry out these two operations without removing the flywheel from the lathe, so that both
faces reworked are parallel.
The grinding should never exceed 0.3 and 0.5 mm. The distance between the bearing face of the crankshaft and
the face of the Ferodo disc should not be less than 15.4 mm.
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