2
Engine service operations
The
following
service operations give
detailed instructions for servicing and
dismantling
all the major engine assemblies.
Where
it
is necessary
to
remove ancillary
components
and.
parts refer
to
the appropriate
sections
of
the workshop manual.
Before reassembly during any operation, all
components should be thoroughly cleaned,
paying particular attention
to
joint
faces and
bearing surfaces.
Any
local high spots or burrs
on the
joint
faces should be carefully removed
using a fine file. Ensure that any piece
of
gasket or
dirt
in a blind tapped hole
is
removed during cleaning,
.as
the
bolt
or screw
may
bottom
before the
bolt
head abuts the
mating part. When tightening a
bolt
which
bottoms a characteristic springiness may be
felt.
If
this occurs the
bolt
should be removed
and the hole cleaned out.
Operation 1 - Engine removal and
installation
The engine should be removed complete
with
gearbox.
To
remove
1 Disconnect battery.
2 Drain cooling system.
3 Drain engine oil.
4 ·Slacken hose clip and disconnect the
radiator
top
hose from
the
thermostat housing.
5 Slacken hose clip and disconnect the
radiator
bottom
hose from the water pump.
6 Slacken hose clip and disconnect heater
hose at water pump.
7 Slacken hose clip and disconnect heater
hose from cylinder head adaptor and unclip
from mounting bracket attached
to
rocker
cover stud.
8 Disconnect alternator lead and remove
alternator.
9 Disconnect starter mdtor lead.
10
DiscOnnect temperature gauge sender
unit
lead at thermostat housing.
11
Disconnect the
oil
pressure warning light
lead from the sender
on
the cylinder block, or
disconnect the oil pressure pipe
if
a gauge
is
fitted.
The engine
12
Disconnect high and
low
tension leads
from the coil.
13
Remove air cleaner.
14
Disconnect the acceleratbr cable from the
carburettor bracket, and release cable from
trunnion.
15
Disconnect the choke cable at the
carburettor.
16
Slacken hose clips and disconnect the
water
pump
and thermostat housing hoses
at
the
manifold adaptor.
17
Disconnect fuel trap reduction sleeve at
the carburettor and unclip the fuel trap from
mounting bracket.
18
Disconnect the breather pipe from the
carburettor
to
the filler cap.
19
Release the accelerator cable return
spring from the abutment bracket on the
cylinder head.
20
Disconnect the fuel pipe, carburettor to
pump, taking.care not
to
damage the pipe
when removing the retaining clips. Remove
fuel pipe supporting
·p· clip from the rocker
cover stud.
21
Remove
two
nuts and lockwashers
securing the manifold adaptor and drip tray to
the manifold and remove complete
with
carburettor.
22
Disconnect petrol supply pipe at fuel
pump and plug
to
prevent loss
of
fuel and
ingress
of
dirt.
23 Disconnect the clutch cable from the
operating arm, remove the locknut and
adjusting
nut
and
withdraw
the cable from
the trunnion.
24
Pull the clutch cable outer sleeve from
the retaining hole in the engine backplate.
25
Disconnect exhaust
downpipe
at
manifold.
26
Remove starter motor.
27
Disconnect speedometer cable at
gearbox rear cover.
28
Remove heater and choke knobs from
centre console, unscrew locking nuts and
disconnect heater and choke cables.
29 Unscrew gear lever knob.
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