DS 19 OPERATION No. DS 112-1 : Replacement of a cylinder head or a cylinder head gasket. Op. DS 112-1 70
TOOLS
5 Disconnect the rubber heater tube from the inlet manifold and the rubber feed pipe from the water pump.
6 On the low pressure system :
Disconnect the feed pipe union from the low pressure pump, (lower union).
Disconnect the return pipe from the low pressure pump. Protect the clutch from any spillage of fluid.
7 Remove the water return hose.
8 Disconnect the high pressure pump feed pipe from the reservoir. Seal the opening. Disconnect the radiator
tie-rod from the radiator and water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 12 mm box spanners
9 Disconnect the dynamo tie-rod from the water pump. Unscrew the dynamo fixing screw.
Remove the fan.
Disengage the belts from the water pump pulley. Disconnect the high pressure pump tie-rod from the
water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–14 mm box spanners
10 Disconnect the flange coupling the exhaust manifold to the expansion chamber.
Disconnect the heater pipe from the water pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 12 mm box spanners
12 mm spanner
12 Remove the rubber and bakelite caps from the sparking plug tubes.
Remove the sparking plugs (spanner 1603-T, see Pl. 16, fig. 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spanner 1603-T
13 Remove the cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm box spanner
14 Remove the sealing cups and their rubber joints from the sparking plug tubes.
15 Completely unscrew the screws fixing the cylinder head. Remove the nuts and the distance pieces (early
models) or the caps (7) (new models) (see Pl. 3) from the exhaust valve rockershaft studs; raise the
rockershaft slightly to remove the push-rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ratchet spanner
12 – 14 mm sockets
16 Remove the cylinder head. Remove the cylinder head gasket (note the centring dowels).
Hold the cylinder barrels using two washers placed between the cylinder barrels 1-2 and 3-4 and fixed
by a screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Washers :
Internal dia. = 10.5
External dia. = 45
17 Strip down the cylinder head.
Remove the exhaust manifold shield and rear plate.
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