AUTOMOBILES

C I T R O E N

AFTE R-SALES T E C H N IC A L DIVISION

T he enc losed schedu le dea ls w i th p a r t ic u la r po in ts conce rn ing

the o v e rha u l ing of a M A S E R A T I eng ine in an SM veh ic le .

T hese p a r t ic u la r po in ts are taken from WORKSHOP M A N U A L 581-3.

INFORMATION

B U L L E T I N

N° 1 S

20th A p r i l 1972

C O N F I D E N T I A L

( a l l r i g h t s r e s e r v e d )

SM V E H IC LE S

(SB series SB)

T h is schedu le con ta ins 29 cards w h ich can be used as " w orkshop

index cards

T hese may be p ro tected w i th p la s t ic s leeves .

P la ce the cards in the p ro x im ity o f the work-bench where the

ove rhau l of components is carr ied out so tha t the m echan ic can use

them fo r re ference. ENGINE

O V ER H AU LIN G

T H E

ENGINE

SM V E H I C L E S O V E R H A U L IN G T H E 'E N G IN E S 100-3 1

D I S M A N T L I N G P A R T I C U L A R POINTS ON D I S M A N T L I N G A N D ASS EMBLY

Raise the engine using the l i f t i n g at tachments

Remove :

- The engine mount ings

- The s tar ter motor

Use the s l i n g 251 7-T

F ix the engine on the d i sman t l i ng support

Stand 2509-T

Adap to r 2512-T

3Remove

- The a i r fi I ter

- The c i rc I i p s (3) of the acce le ra tor cont ro l

knuck le

- The a i r - i n take horns

- The base of the f i l t e r (1)

- The c a r b u r e t t o r / m a n i f o ld assembly ( screw 2)

REMOVE T HE O IL F I L T E R

Strap wrench | Spanner

e.g. FACOM D . 4 6 ! MR„ 6 3 0 - 1 4 / 4 9

2 SM V E H I C L E S O V E R H A U L IN G T H E ENGINE

D I S M A N T L I N G Contd.

Remove the mechanism and the c lu tch d i sc

Remove the f l y -whee l

Too l E from the set 3064-T

/f**6

Remove the mani fold

- Co l l a r (1)

- Screw (2)

7REMOVING THE C Y L IN D E R - H E A D S

Turn the engine to br ing the spr ing l i nks to the top

Loosen the chains by s l acken ing the nuts (1)

Remove the spr ing l inks

D i sengage the chains from the " e x h a u s t "

camshaf t p i n i ons .

SM V E H I C L E S O V E R H A U L IN G T H E ENGINE S 100-3

D IS M AN T L I NG Contd. P A R T I C U L A R POINTS ON D I S M A N T L I N G A N D ASSEMBLY

7 Contd.

- Remove the screw at pos i t i on " a

- Swivel the t ens ioner t owards the bot tom.

- Di sengage the screw (1) of the tens ioner .

- Remove the chain t ens ioner

- Remove the cy l i nde r heads (screws 2)

- Remove the water pump cover

(screw 1)

B Contd.

Removing the water pump

- Un lock the nut (2) and remove it.

- Remove the turb ine (be careful

w i th the cot ter) .- Remove the sea l i ng r ing of the pump

shafts

4 SM V E H I C L E S O V E R H A U L I N G T H E ENGINE S 100-3

D I S M A N T L I N G Contd.

Remove the o i l sump

10

- Remove the o i l pump f i l t e r

11

Remove the t iming case

12

- D i sengage the chain t ens ioner :

Us ing a sc rewdr i ve r appl y pressure

to the lug (1) and turn the sp ind le (2)

a quar ter of a turn.

- Remove the chain guide and the tens ioner

( take care w i t h the f la t washers between

the tens ioner and the housing) .

SM V E H I C L E S O V E R H A U L IN G T H E ENGINE S 100-3 5

D I S M A N T L I N G Contd. P A R T I C U L A R POINTS ON D I S M A N T L I N G AN D ASS EMBLY

13 REMOVING T H E I N T E R M E D I A T E T IMING S H A F T

Remove the d r i v i ng f lange from the H.P.

pump cont ro l shaf t .

Di sengage the i ntermediate t im ing s. iaf t

1 3 Contd.

- D i sengage the t iming chain between

the hous ing and the pinion,

- Remove the i ntermediate t iming shaf t .

- D i sengage the chain

- Remove the sea l i ng r ing (1)

(ext ractor tube c/j = 39 mm, length = 400mm)

14

Remove the lower hous ing and i ts gasket .

N„B„ : T h i s hous ing is held by

8 dowel s

6 SM V E H I C L E S O V E R H A U L IN G T HE ENGINE S 100-3

D IS M A N T L I N G Contd.

i J- Remove the con rod caps ( socket of 14 mm

and adaptor of 3 / 8 " ) .Remove the c ranksha f t

Remove the con rod pi ston

assembl ies

^ ^ - Remove :

- The c ranksha f t bear i ng shel ls

- The end f l oa t ad jus t i ng shims.

Contd.

C L E A N IN G

C a re fu l ly c lean a l l the parts and the jo in t su rfaces.

B low w i th compressed a ir .

NOTE : A l co ho l should be used to remove C U R T Y L O N .

SM V E H I C L E S O V E R H A U L I N G T H E ENGINE S 100-3 7

D IS M A N T L IN G Contd. P A R T IC U L A R PO IN TS ON D IS M A N T L IN G A N D A S S E M B LY

17 WORK ON T H E CON ROD PISTO N A SSEM BLIES

Remove the r ings | Remove the gudgeon pin

i T o o l G from the set 3064 - T

18 S T R IP P IN G T H E C Y L IN D E R - HEADS

Remove : I Remove the va lv e push rods and the capsu les

, I for a d ju s t in g the clearance.,,, m ark ing the ir- I he spa rk ing plugs I

I re s p ec t ive pos i t io ns *

8 SM V E H IC L E S O V E R H A U L IN G T H E ENGINE S 100-3

DISMANTLING Contd.

i 3 Contd.

Remove the f ree-play l im i t er of the chain.

Contd.

Grind the seat i ngs and the va l ves (gr i ndstone1 630-T)Width of the bear ing faces of the seat ings In let : 2,5 mm Out le t : 2 S2 mm

- Gr ind the va Ivesin .

A f te r g r ind ing in, c lean the parts c a re fu l ly and b low them w i th compres sed a i r in order to e l im in a te a l l t race of ab ras ive m a te r ia ls .

St r ipp ing the t iming case Remove ;

- The oi I pump

- The gasket (1) ( tube spanner c/> : 33 mm length : 1 0 0 mm)

- The acce lera tor cont ro l return lever (4)

- The plug (2)

- The union (3) and the by-pass va l ve

( i f necessary) .

Remove the va l ves

(universa l compressor and tool D from

the set 3064 -T)

SM V E H I C L E O V E R H A U L I N G AN ENGINE S 100-3 9

AS S E M B LY P A R T IC U L A R PO INTS ON D IS M A N T L IN G A N D AS S E M B LY

IM P O R T A N T NOTES

G ASKETS

A L L gaske ts must be s y s te m a t ic a l ly renewed

A l l gaske ts should be f i t te d greased w i th ta l lo w

(excep t the REINZ c y l in d er-head gaske ts wh ich must

be f i t te d dry).T IG H T E N IN G TORQUES

On th is eng ine , a l l t ig h te n in g torques MUST

be respec ted .

F a i lu re to do th is resu l ts in de form ation w h ich

ad ve rse ly a f fe c ts the correc t runn ing of the engine.

N O TE : Nuts and bo lts must be f i t te d w i th

th e ir threads o i led .

Check how far the barre ls are recessed .

1) In re la t io n to the jo in t face of the c y l in d e r cas ing

0.02 - 0.05 mm.

2) Am ongst th e m s e lv e s , the barre ls shou ld be

in the same plane to w i th in : 0.02 mm.

S tra igh t edge 1698-T + f o i l . C o rrec t i f

necessary w i th too l A from set 3064 - T

20 P R E P A R IN G T H E P IS T O N /C O N ROD ASS E M B LIE S

When a s se m b l ing the p is tons and con rods, the chamfer C should be on the same s ide as the longer

s lope L .

- Heat the con rod to 200° - 250°C (392-482° F) (oven).

- P o s i t io n the con rod in the p is ton (guide of assem bly G of set 3064 -T )

10 SM V E H I C L E S O V E R H A U L I N G AN ENGINE S 100-3

AS S E M BL Y Contd .

^ J Contd .

- P lace the p is to n / c o n rod assem bly on the support of assem bly G, se t 3064-T .

- F i t the sp ind le in p lace (press and mandrel of assem bly G, set 3064 -T ) .

- F i t the r ings.

a) O il con tro l r ing (2) - gap : 0.25 - 0 .40mm - " T O P " m arka t the top

b) Scraper r ing (1) - gap, 0 .3 0 -0 .4 5 mm - " T O P " mark at the top

c) Com press ion ring ( 3 ) - gap : 0 .35 - 0 .45 - unmarked

21

F ix the engine cas ing on the support

F i t the h a l f bearings in the cas ing

22

For con rods 1,2,3, chamfer C towards front

For con rods 4 ,5 ,6 , chamfer C towards rear

SM V E H IC L E S O V E R H A U L IN G AN ENGINE S 100-3 11

ASSEMBLY Contd. P A R T I C U L A R POINTS ON D I S M A N T L I N G A N D ASSEMBLY

Contd. F I T T I N G T HE ENGINE HARNESS

- Of fer up the crankshaf t . Ho ld i t above the bear ings (p lates F of set 3 0 6 4 “ T in order to avoid damaging the ha l f bear ings whose in ter ior diamater , in a free s tate, is smal l er than the d iameter of the cranksha f t pin) .

- F i t the p i s t o n / c o n rod assemb l i es (normal r ing f i t t i n g co l l a r ) in the order 1-6,2-5, 3-4 t ighten to 68 mAN

(6.8 m.kg 49 f t / l b s ) socke t 14 + reducer 3 / 8 "

' Wi thdraw the plates and lower the c ranksha f t onto i ts bear ings.

- F it the bear ing ha If she I Is (wi t hou t tongue) : c learance 0.1 5-0.22 mm : the oi I reserves should be on the c ranksha f ts ide.

23 F I T T I N G TH E SUMP

- F i t the ha l f -bear ings : the ha l f she l l s ( tongued), stuck t ogether w i th grease.

- Coat the sur face of the gasket w i t h C U R T Y L O N

- F i t the sump ha If and t igh ten the nuts A o f the bear ing to 95 - 97 mAN (9.5-9-7 m.kg, 68 '69 f t / I bs).

Observe the t igh ten ing sequence.

- T i g h t e n the bol ts (B) to 15-20 mAN (1 .5-2 m.kg. 1 0.8-1 4.4 f t / lbs).

12 SM V E H I C L E S O V E R H A U L I N G AN ENGINE S 100-3

AS S E M B LY Contd.

F IT T IN G A N O IL S E A L

(Orange-couloured ga s k e t „w i th m ic ro - tu rb ine on l ip )

L ig h t l y grease the l ip of the seal

F i t the sea l . T oo l MR. 6 3 0 -3 4 /3 2

25

- F i t the eng ine f ly w h e e l

- T ig h te n the bo lts : 120 mAN (12 m.kg, 86 f t / l b s )

- Im m ob i l ize the f ly w h e e l . T oo l E of set 3064-T .

26- B r ing the marks on the c ran ksha ft and the hous ing

in to l ine.

- F i t the con tro l cha in of the in te rm ed ia te sha ft on the p in ion .

SM V E H I C L E S O V E R H A U L I N G AN ENGINE S 100-3 13

A S S E M B LY Contd. P A R T IC U L A R PO IN TS ON D IS M A N T L IN G A N D A SSEM BLY

2 6 Contd . F IT T IN G A N D A D J U S T IN G T H E IN T E R M E D IA T E T IM IN G S H A F T

- P o s i t io n the con tro l cha in (see photo)

- F i t the in te rm ed ia te sha ft-

a) B r ing the marks on the p in ion and the hous ing in to l ine .

b) The marks (1) shou ld be v is i b le in the t im in g chain passage.

2 0 Contd.Engage the cha in on the con tro l p in ion .

Engage the in te rm ed ia te sha ft on the bear ings.

F i t the tens ione r (2) (washer between tens ione r and hous ing)

T ig h te n to 10-12 mAN (1-1.2 m.kg 7o2-8.7 f t / l b s )

F i t the runner (3) (washer between runner and hous ing).

T ig h te n to 9-11 mAN (0,9-1.1 m.kg 6 .5 -8 f t / l b s )

Set the cha in tens ione r .

F i t the free p lay I im ite r (4) C learance o f ; 0.2 mm between l im i te r and cha in .

T ig h te n to 9-11 mAN (0.9-1.1 m.kg 6 .5 -8 f t / l b s )

14 SM V E H I C L E S O V E R H A U L IN G AN ENGINE S 100-3

AS S E M B LY Contd.

27 P R E P A R IN G T H E O IL PUMP

F i t on the body of the pump :

- The p is ton (10), the spr ing (9) and the return pipe (8), the a d ju s t in g washer (6) and the copper gaske t (7). T ig h te n to 30 mAN (3 m.kg 22 f t / l b s )

- The r ing sea Is (1) (2) and (11). Grease before f i t t i n g .

- The whee l (4), the p in ion (3). N 0 T E ■ l t i s e s s e n t i a l to f i t a p i s t o n ivith- The pump cover (5). a shou lder at « «»■

- T ig h te n the bo lts (12) to 18-20 mAN (JL8-2 m.kg. 13-14.4 f t / l b s )

P R E P A R IN G T H E T IM IN G CASE

- F i t the by-pass v a lv e . Screw the va lve in to the case .

- F i t the o i l f i l t e r union (4) : 90-100 mAN (9-10 m.kg 65-72 f t / l b s ) .

- F i t the o i l sea l (2) in p lace (mandrel 0 = 36mm, length = 100mm).

- F i t the acce le ra to r con tro l return lever (3).

- T igh te n the nut to : 25-27 mAN (2 .5-2 .7 m .kg 18.1 -1 9 .5 f t / l b s ) .

SM V E H I C L E S O V E R H A U L IN G AN ENGINE S 100-3 15

ASS EM BL Y Contd. P A R T IC U L A R PO INTS ON D IS M A N T L IN G A N D A S S E M B LY

28 Contd.• F i t the plug (6), t igh ten to 70 mAN (7 m.kg

51 f t / l b s )

- F i t the o i l pump : take care in p o s i t io n in g the r ing seal : 26-28 mAN (2 .6-2 .8 m.kg19-20.3 f t / l b s )

- F i t the r ing sea l (5) in p lace .- Ho ld the p ipe (7) a g a ins t the return pipe

us ing a ring.

29 F IT T IN G T H E T IM IN G CASE

- F i t the cone (B) o f the set 3064-T on the end of the in te rm ed ia te sha ft . .

- F i t the pump d r ive sha f t (1) (w i th a l i t t l e grease)

- F i t the t im in g case. Turn the o i l pump s l i g h t l y to f a c i l i t a t e the engagement of the d r ive sha f t .

Contd.

T igh te n the bo l ts (3) to 21-23 mAN ( 2 1 - 2 3 m.kg 15.2 - 16.6 f t / l b s )

30

- F i t the breather (gasket)

- T igh te n the bo l ts : 10 mAN (1 m.kg 7.2 f t / l b s ) .

16 SM V E H I C L E S O V E R H A U L IN G AN ENGI NE S 100-3

ASSE MBL Y Contd.

31- F i t the hous ing connect i ng the oi l cooler ,

- T igh ten the bo l t s : 20 mAN (2 m.kg 14,4 f t / l b s )

- F i t the oi l temperature thermal sw i t ch (1) :

30-35 rnAN (3-3.5 m.kg, 22-25 f t / l b s )

- F i t the o i l pressure sw i t ch (2) : 30-35 mAN

(3-3.5 m,kg 22-25 f t / l b s ) ,

32- Check the so lde r i ng of the suc t i on t u b e / f i l t e r

assembly ,

- F i t the suc t i on t u b e / f i l t e r assembly. T igh ten

the bol ts (1). : 10 mAN (1 m.kg 7.2 f t / l b s ) .

- F i t the o i l basin (gasket ) : t ake care w i th the

shut ters of the ant i -emu Ision par t i t i ons .

Contd.

T igh ten the bol ts (2) : 16-18 mAN

(1.6 - 1.8 m.kg 11,6-1 3 f t / l b s ) .

o q

- F i t the in termediate shaf t o i l seal :

tube spanner : int . q> = 30mm

ext , o — 45 mm

length, (p — 1 00 mm

It should be level w i th the casing.

NOT E : To protect the l ips of the gasket , wrap

adhes i ve tape around the sp l i nes

%

SM V E H I C L E S O V E R H A U L I N G AN EN GI NE S 100-3 17

ASSE MBL Y Contd.

34

P A R T I C U L A R POINTS ON D I S M A N T L I N G A N D A S SEM BL Y

F I T T I N G T HE W A TE R PUMP

F i t the dr i ve plate of the H ,P pump

cont ro l shaf t .

F i t the nut (1) but do not t ighten.

- F i t the oi l seal (1) on the housing,

- Coat the t h rus t face (a) of the gasket and i ts

con tac t sur face on the turbine w i th ROCOL A.ScP

or M O L Y K O T E 557 grease

F i t :

- The key

- The turbine

- The washer , the stop washer.

- The nut ( thread coated w i th A D E X O L I N 56 glue)

T igh ten the nut : 30 mAN (3 m k g t 22 f t / l b s ) .

Fo ld down the stop washer l ock ing lugs.

- F i t the cover (wi th i ts r ing seal) .

- T igh ten the bol ts : 20 mAN (2 mckg 14.4 f t / lbs).

18 SM V E H I C L E S O V E R H A U L IN G AN ENGINE S 100-3

ASSEMB LY Contd.

v i 6

C H E C K I N G T HE F L A T N E S S OF T H E C Y L I N D E R HEADS

- Check the f l a tness of the cy l i nde r heads

St ra ight edge 1698-T and fo i l s t r ips

Max out of f l a t = CL05 mm.

-M in im u m height a f ter regr ind ing 110.2mm.

37

P R E P A R I N G T H E C Y L I N D E R HEADS

Make sure that the ducts (1) and (2) and the jets

for the camshaf t l ubr i ca t i ng oi l are c lean.

F i t :

- Va l ve stem o i l seals ( i n le t only)

- The cups

- The spr ings

Un ive rsa l compressor and tool D from set 3064-T,

SM V E H I C L E S O V E R H A U L IN G AN ENGINE S 100-3 19

ASSEMBL Y Contd. P A R T I C U L A R POINTS ON D I S M A N T L I N G AN D ASS EMBLY

P R E P A R A T I O N OF T HE C Y L I N D E R HEADS

F i t the f ree play l im i t er (2) (bol ts f i t ted w i t h

L O C T I T E GX 01 460 01 A)„

F i r the capsu les (1) and the push rods found

when d i sman t l i ng , back in t he i r r espec t i ve

p laces

F i t the camshaf t : i n l e t , (V), exhaus t ( ' , )

F i t the caps of the camshaf t bear ings

(marked by Nos).

T igh ten the nuts : 26-28 mAN (2 6-2.8 m kg

18.8-20.3 f t / l b s )

*3 T ... w I L on ta .

- 1 urn the camshaf ts

(spanner D from set 3185-T)

- Check the c learance between cams and pushrodsc

Cl earance in prac t i ce

Inlet : 0 3 0 - 0 . 3 5 mm

Exhaust : 0 5 0 - 0 . 5 5 mm

- Remove

- The camshaf ts

- The pushrods and the capsulesc

- Measure the th i ckn ess A of each capsu le

- From amongst the capsules sold by the rep lacement

parts, choose those that w i l l g i ve the cor rect

c learance.

T h i c k n es s A = in steps of 0 ,025 mm

20 SM V E H I C L E S O V E R H A U L IN G AN ENGINE S 100-3

ASSE MBL Y Contd,

Contd.

F i t the capsu les chosen in t he i r r espec t ive

p laces.

- F i t the pushrods ;

F i t the camshaf ts

T igh ten the bear i ng caps : 26-28 mAN

(2o6-2 *8 m .kg> 18 . 8 -2 0 ,3 f t / l b s )

Turn the camshaf ts un t i l the marks " a " and " b

are in l ine.

- B r ing cy l i nde r No. 1 to T D C

Mark " 0 ” on in termed ia te shaf t , v i s i b l e in t im ing cha in passage (st raight edge suppor t 1754-T

and gauge 2437-T) .

- Pu t the t im ing chain in pos i t i on on the i n termediate sha f t (us ing w i re) : the upper end of the chain

should stand proud of the hous ing by app rox0 200mmc

SM V E H I C L E S O V E R H A U L IN G AN ENGINE S 100-3 21

AS SE M BL Y Contd. P A R T I C U L A R POINTS ON D I S M A N T L I N G A N D AS SEM BL Y

39 "

Brass r ings : ( set of t hree ) must not be p i t t ed, scrat ched or cracked.( REI NZ ) gasket : there must be no burr ing at «a » and no ha i r l i ne f ractures.

- ' F i t the brass r ings ( 1), s l i g h t l y greased, on the bar re ls . Cent re them.

- P lace the REIN Z gasket in pos i t i on ( c o r re c t any pos s ib le ove r l a p ) . l n

- F i t the r ing seals ( 2 ) in the ho les « b ». fp

F I T T I N G R.H. C Y L I N D E R HE A D

F i t the cy l i nde r head on the b lock . Br ing

the two marks A and B i nto line*,

39 Contd.F I T T I N G R.H. C Y L I N D E R H E A D

- F i t the cy l i n de r head bo l t s in p lace (do not forget

the l i f t i n g lugs), (

- T igh ten the bo l t s in the t i gh ten ing sequence.

1st t i gh ten ing : 50 mAN (5 m.kg 36 f t / l b s )

2nd t i gh ten ing : 11 0 mAN (11 m.kg 79 f t / lbs)

F i t the chain t ens ioner (r ing seal on tens ioner

and copper washers under b l ind nuts) .(rf'S or vn 3

Pass the cha in

under the pinion

of the exhaust

camshaf t .

22 SM V E H I C L E S O V E R H A U L IN G AN ENGINE S 100-3

ASS EMBLE Contd.

Contd.

F i t the spr i ng l ink

a) T h i c k spacer in middle of chain

b) The c l i p on the side o f the hexagonal camshaf t ad just ing nut

c) Open end of c l i p t owards rear (di rec t i on of chain rotat ion). .

Tens ion the t im ing chain

20 mAN (2 mokg 14^4 f t / l b s ) i. e. 10 kg (22 lbs)

on spr i ng balance (A l l en key 6 mm,

ex tens ion MR 6 3 0 - 1 3 / 5 and spr i ng ba lance)

T igh te n the nuts (9) to 20 mAN (2 m.kg 14 4 f t / l b s ) .

39 Contd.

TO O LS R E Q U I R E D FOR C H E C K I N G A N D A D J U S T I N G TH E T IMING (SET 3185-T)

1682-T : Gauge suppor t

A : Gauge support

B : Tw o gauge pins

C : Fa Ise bear in gs C ^ JD : Spanner for t urn ing camshaf ts

E : Spanner for camshaf t nuts

F : Re ta in ing plate for suppor t A,

SM V E H IC L E S O V E R H A U L IN G AN ENGINE S 100-3 23

AS SEM BL Y Conid. P A R T I C U L A R POINTS ON D I S M A N T L I N G AN D ASS EMBLY

TIMING A D J U S T M E N T (R.bL C Y L I N D E R HE AD )

DISENGAGING CAMSH AFT S

- Loosen the nut (1) (pin spanner E of set

3185-T)

F ind top dead cent re ( T D C ) of cy l i nde r 1

(gauge support 1682-T

gauge 2437-T)

- Free toothed r ing (2)

Replace the f ront bear ings of the two c ranksha f t s

w i t h the f a l se bear ings C of the set 3185-T.

Do not t i gh ten the nuts (3)

- Put the gauge support A from set 3185-T,

and gauge 2437-T in posi t i on , w i t h the pin

press ing on the in le t pushrod of cy l i nde r

1, F i x i t in pos i t i on us ing plate F from

the set 3185-T

- Br ing the need le of the gauge to 0 .

24 SM V E H I C L E S O V E R H A U L IN G AN ENGINE S 100-3

A S S E M B LY Contd,

4 0 Contd.

IN L E T

- Push in the pushrod by 1 mm, turn the cam shaft in the ro ta t io n d i re c t io n o f the engine (spanner D from se t3 1 8 5 -T )- T igh te n the fa ls e bear ing C o f se t 3185-T.

- F ind , by tu rn ing the too thed r ing

(2), the po in t a t w h ich i t engages at

the same t im e in the s p l in e s of the

cam shaft and f u l l y in the teeth of the

p in ion .

- T igh te n the nut (1) (p in spanner E

from set 3185-T ) .

Loosen the nuts of the fa ls e bear ings.

NO TE : T he bearing caps w i l l be f i t te d and t igh tened to 26-28 mAN (2.6-2 .8 m.kg 18.8-20.3 f t / l b s )a f te r the t i mj ng ad jus tm en t has been checked .

40 Contd .

E X H A U S T

- F i t the support A ( f ixed by p la te F), the pin touch ing the exh au s t pushrod o f c y l in d e r 1.

- B r ing the need le of the gauge to 0

Push in the pushrod by 1,3 mm : turn the cam shaft in the oppos ite d i re c t io n to tha t o f the eng ine ro ta t ion ,

- T igh te n the fa ls e bear ing C from set 3185-T,

- F ind , by turn ing the toothed r ing (2), the po in t where th is engages c o r re c t ly ,

- T ig h te n the nut (1) (pin spanner E from set 3185-T ) .

SM V E H I C L E S O V E R H A U L I N G AN ENGINE S 100-3 25

A S S E M B LY Contd.

41USING M ARKING S

- With c y l in d e r 1 a t T D C and the va lves in the

" r o c k i n g " p o s i t io n , the long marks " a " on the

P A R T IC U L A R P O IN TS ON D IS M A N T L IN G A N D A S S E M B LY

C H E C K IN G T IM IN G A D J U S T M E N T (R .H . C Y L IN D E R H E A D )

USING GAUGES

cam shafts must be in l ine w i th the marks

o f the bearing caps.b "

- Turn the engine in the oppos i te d i re c t io n- B r ing the in le t cam of c y l in d e r N o „ l to the p o s i t io n

where the va lv e begins t o o p e n (however the pushrod must be ab le to ro ta te ) .

- F i t support A o f set 3185-T in po s i t io n- B r in g the need le to " 0 " (p in -p re s s in g on pushrod)- B r ing c y l in d e r 1 to T D C . T he gauge of support

A should show a t rave l of 1 mm.

41 Contd .

- F i t support A in p o s i t io n on the exh au s t push rod of c y l in d e r 1«

- B r ing the need le to " 0 " o- Turn the engine u n t i l the v a lv e is on its seat- The gauge should show a t rave l of 1.3 mm.

42F IT T IN G L .H . C Y L IN D E R H E A D

- B r ing p is ton o f c y l in d e r 6 to TD C (no mark " 0 " on

sha f t) .

- F i t the t im in g cha in on the in te rm ed ia te sha ft.

- F i t the brass r ings and the c y l in d e r head gasket in p lace.

- F i t the c y l in d e r head and t igh ten to co rrec t torque.

- F i t the cha in ten s ion e r and the chain

- F i t the spring l in k .

- T ens ion the t im ing cha in .

26 SM VE H IC L E S O V E R H A U L IN G AN ENGINE S 100-3

A S S E M B LY Contd.

43T IM IN G A D J U S T M E N T (L . H. C Y L IN D E R H E A D )

- D isengage the cam sha fts ,

- F in d TD C on c y l in d e r 6

- Rep lace the bear ing caps w i th the fa ls e bear ings

- F i t gauge support A on the e xh au s t pushrod

- B r in g the need le to " 0 "

In le t : Push in the pushrod by 1 mm (d i re c t io n o f eng ine ro ta t ion )

- T ig h te n the fa ls e bearing

- F in d the co r re c t engagement po in t of the toothed r ing .

- T igh te n the nut

E xhaus t : F i t support A in p o s i t io n on the exhaus t pushrod

- B r ing the need le to " 0 "

- Push in the pushrod by 1.3 mm (oppos i te d i re c t io n to tha t o f eng ine ro ta t ion )

- T ig h te n the fa ls e bearing

- F ind the co r re c t engagement po in t o f the too thed r ing.

- T ig h te n the nut.

44

C H E C K IN G T H E T IM IN G A D J U S T M E N T ( L .H . C Y L IN D E R H E A D )

USING MARKS

With the c y l in d e r 6 a t T D C and va lv e s in " rock ing "

p o s i t io n , the short marks on the cam shafts should

be in l ine w i th the marks on the bear ing caps.

USING GAUGES

Use the same procedure as tha t used when che ck in g

the t im in g a d ju s tm e n t o f the R .H . c y l in d e r head.

SM V E H I C L E S O V E R H A U L I N G AN ENGINE S 100-3 27

ASSEMBL Y Contd P A R T I C U L A R POINTS ON D I S M A N T L I N G AN D ASSEM BL Y

S T A T I C D I S T R I B U T O R A D J U S T M E N T ~

- Br ing cy l i nde r 1 to T DC on the compress ion s t roke

- F i t the d i s t r i bu to r (cover removed)

1) the bracket for the condensors approx ima te l y along cent ra l ax i s of engine

2) the two dogs in the pos i t i on shown below (see photo)

47

C L U T C H

- F i t the c l u tch d i s c and mechanism

(Cent rer 3106-T or used cont rol shaf t ) .

- T igh ten the secur ing bol ts (1)

36-40 mAN (3 6 - 4 m kg 26 - 29 f t / lbs)

46C Y L IN D E R H E A D COVERS

- F i t the cy l i n de r head covers

- T igh ten the nuts to 10 - 12 mAN

(1-1.2 m.kg 7.2 - 8.7 f t / lbs)

- F i t the sparking plug w i re brackets

48

W A TE R M A N IF O L D

- F i t the water mani fo ld.

- Remove the the rmos tat i c regulator , check it

Starts to open : 75° - 76° C (1 6 7 0-169° F)

Opening : 7 .5mm minimum at 85° C (185° F)

- F i t the t he rmos tat i c regulator

28 SM V E H I C L E S O V E R H A U L I N G AN ENGINE S 100-3

ASSE MBL Y Contd.

- F i t the i n l e t pi p e / c a r bu re t t o r s assemb ly , t igh ten

the bol t (1) : 5 mAN (0. 5 m.kg 3,6 f t / l b s )

- Connec t the acce le ra to r cont ro l

- F i t the o i l f i l l e r pipe, t i gh ten the bo l t

20 mAN (2 m kg 14 4 f t / l b s )

50- F i t the o i l f i l t e r ( gasket o i l ed )

- Hand t igh ten i t .

Remove the engine from the suppor t :

Sl ing 2517-T

52- F i t the star ter motor (spanner 3061 -T)

- F i t the engine suppor ts and the rubber b locks

- A d j u s t them (measurement t aken between bot tom

of s tee l suppor t and the top of the rubber b lock) .

- T igh ten the engine suppor t bol ts 40 mAN

(4 m.kg 29 f t / lbs)

SM V E H I C L E S O V E R H A U L I N G AN EN GI NE S 100-3 29

SPECI F IC A T IO N S O F TO O LS N O T ON S A L E

rJ

k i a r c n i

M R 630 _14 /4 9o i u

\ & i

MR. 630-13 5

M R 6 3 0 . 3 4 / 3 2