THE ENGINE
A
Reassembly
is
a reversal
of
the foregoing procedure,
following the instructions given in Sections A.30, A.31,
and A.32 when installing the timing
gears and the crank-
case front cover.
Section A.38
REMOVING
AND
REPLACING
THE
FLYWHEEL
HOUSING
BACK
PLATE
Remove
the
transmission,
the
starter,
the
fly-
wheel
housing,
and
the
flywheel.
The
back
plate
is
now
exposed
and
the
capscreWi\
and
locks
may
be
removed.
Tap
the
back
plate
to
loosen
it
from
the
dowels
and
gasket.
Before
replacing,
clean
gask~t
surface
carefully
and
use a
new
gasket.
It
may
be noticed
that
the
back
plate
has
a
slight
warp
when
removed
from
the
engine.
This
is
of
no
concern
as
it
will
straighten
when
the
affixing
screws
are
tightened
to
the
block
and
to
the
flywheel housing.
·When
assembling
be
sure
all d<)wels
are
in
place
to
assure
alignment
of
parts.
Section A.39
REMOVING AND REPI,ACI!'OG
THE
CRANKSHAFT AND MAIN BEARINGS
Remove the crankcase front cover, timing chain, and
timing chain wheels (Sections A.30 and A.32).
Remove the starter motor, the flywheel, and the gear-
box distance piece (Sections N.3, A.33, and A.38).
Remove the sump, oil pump, and oil strainer (Sections
A.9, A.lO, and
A.ll).
Slacken the nuts securing the fuel
injectors sufficiently to relieve the engine compression and
so facilitate rotation
of
the crankshaft.
Remove the valve rocker shaft assembly (Section
A.
14)
to prevent the pistons and valves fouling each other when
the crankshaft
is
rotated. The push-rods should be
removed for safe keeping
as
detailed
in
Section A.I8.
Disconnect the connecting rods from the crankshaft as
described in Section A.13, pushing each rod and piston
to the top
of
its cylinder bore as
~oon
as it
is
disconnected.
Unscrew and remove the six self-locking nuts and
spring
washers from the main bearing cap studs. With-
draw the main bearing caps, using tool 18G42A with
adaptor 18G42B, noting the lower halves
of
the crankshaft
thrust washers located on each side
of
the centre main
bearing cap. The centre main bearing cap is stamped with
the word
'FRONT'
to assist reassembly.
Lift the crankshaft out
of
the crankcase and remove
the upper halves
of
the crankshaft thrust washers.
Remove the bearing liners from the bearing caps and
the housings
in
the crankcase, marking the bearing
liners so that they
ma.y
be replaced in their original
positions. A punch
~hould
not be
used
for this purpose.
The bearing liners are located in their housings by a
small tag on one side
of
tile liner engaging a corresponding
groove
in
the bearing housing and cap.
In the case
of
a run bearing, the oilways in the crank-
shaft and cylinder block should be cleaned thoroughly
",ith petrol
or
paraffin and then blown clean with com-
pressed air. The oil pump and oil strainer should also
be dismantled and cleaned (Sections A.IO, A.I1.
and
A.
12),
and the
fuel
injection pump driving gear lubri-
cator filter gauze should be
removt.:
1 and cleaned
(Section A.6). It
is
also advisable to
re:1ew
the external
oil filter element (Section A.5) to ensure that all bearing
metal
is
removed from the I ubricating system.
Thoroughly clean the thrust faces
of
the crankshaft
centre main journal, the bearings, and the thrust washers
and install them
in
the crankcase. Mount a dial gauge on
the front end
of
the crankcase with its indicator resting
on the front face
of
the crankshaft front main journal.
Prcss the crankshaft as far as possible to the rear, and,
holding
it
in
this
po~ition,
zero the dial gauge. Now press
the crankshaft
forw1rd as far as possible and note the
reading on the dial gauge, the difference from zero being
the amount
of
crankshaft end-float.
If
necessary, renew tIle thrust washers, fitting them by
selective assembly and ensuring
that
the oil grooves face
outwards towards the crankshaft webs. Thrust washers
·003
in. ('076 mm.) oversize are available.
When installing new bearings no scraping
is
required
as
the bearings are machined to give the correct diametri-
cal clearance.
Reassembly
is
a reversal
of
the dismantling procedure,
noting the following points:
(I)
If
any
of
the crankshaft components are renewed,
do not jurget to aligl) the crankshaft chain wheel
with
th(:;
camshaft chain wheel as detailed in
Section A.32.
(2)
Coat the rear main bearing cap to cylinder block
horizontal joint surface with Hylomar SQ32
jointing compound.
(3)
Tighten the main bearing cap nuts
to
the figure
given
in
the 'GENERAL DATA' section, using
torque
wrench 18G372.
(4)
Remove the fuel injection pump, and check, and
adjust if necessary, the injection pump drive timing
as detailed
in
Section 0.12.
Section A.40
REMOVING AND REPLACL"IG
THE
FLYWHEEL STARTER RING
To remove the old starter ring from the flywheel drill
holes through the flange
of
the gear and then split the
gear, using a hammer and chisel and taking care
JJor
to
damage the flywheel.
A.29
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