DS 19 OPERATION No. DS 111-1 : Work on the crankcase. Op. DS 111-1 62
TOOLS
12 Remove the flexible pipe and water pipe assembly, left-hand.
13 Remove the rubber and bakelite caps from the sparking plug tubes.
Remove the sparking plugs (spanner 1603-T, see Pl. 16, fig. 7).
Remove the cylinder head cover, take off the sealing cups and rubber joints from the sparking plug tubes . . . . . . . . Spanner 1603-T
12 mm box spanner
14 Remove the clutch cylinder feed pipe. Disconnect the accelerated idling pipe from the left-hand brake unit
(spanner 2219-T or 2221-T, see Pl. 72, fig. 4).
Disconnect the gearbox from the engine (spanner 1677-T, see Pl. 65, fig 4 and spanner 2431-T, see Pl. 72, fig. 1).
IMPORTANT NOTE - Do not roll the gearbox on the brake disc, use the stand 2497-T (see Pl. 19) . . . . . . . . . . . . Spanner 2219-T or
Spanner 2221-T
Spanner 1677-T
Spanner 2431-T
Stand 2497-T
15 Remove the clutch and the engine flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17 mm box spanner
16 Drain the engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 mm box spanner
17 Turn the engine over and place it on a stand (stand MR-3053-170, see Pl. 18, fig. 1).
Remove the timing cover and the sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stand MR-3053-170
12 mm box spanner
12 mm tee spanner
18 To remove the timing chain and pinion assembly :
a) Unscrew the nuts. Hold the pinions by means of the setting gauge 1680-T (see Pl. 15, fig. 2) or wedge the crank-
shaft by means of a wooden wedge placed between a crankshaft throw and the crankcase (spanner 1731-T, see
Pl. 15, fig. 3) for the camshaft nut and spanner 1667-T, (see Pl. 15, fig. 1), for the crankshaft nut . . . . . . . . . . . . Setting gauge 1680-T
Spanner 1731-T
Spanner 1667-T
b) Turn the crankshaft until the throws are horizontal.
IMPORTANT - It is essential to place the crankshaft in this position before removing the timing chain and pinion
assembly. Since the camshaft is not under control, if one of the valves is lifted and the crankshaft rotated, the
corresponding piston cannot pass top dead centre without fouling the valve.
c) Remove the timing chain and pinion assembly without displacing them. Place the chain and pinion assembly on
a bench, held by the setting gauge 1680-T (see Pl. 15, fig. 2).
Remove the keys, the thrust washer (12), the adjusting shims (10), the bearing thrust ring (9) (see Pl. 1) . . . . . . Setting gauge 1680-T
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