The cutaway view of the engine/gearbox (transmission) unit shown on the opposite page provides an indication of the grouping of the components and in which section of the manual they may be found.
E.1. MODEL IDENTIFICATION - Section Menu The type, index and manufacturing number are given on a number plate, which is riveted to the left-hand side of the engine. E.2 CROSS SECTIONS - Section Menu E.3 - REMOVING AND REFITTING THE ENGINE - Section Menu The engine cannot be removed as an individual unit and consequently must be removed together with the transmission as one assembly. A - REMOVING THE ENGINE Before commencing operations, place protective coverings on body sides around the engine compartment. Remove the engine compartment lid carefully by detaching the component at its hinge mountings (two nuts and penny washers per hinge).
Disconnect the battery cables (earth first). Drain the cooling system (see section K). Drain the transmission using drain plug wrench 46F 6167 (see section F). Drain the petrol tank (see section L). Remove the air filter from the (see section L). - Figure 4 -
- Figure 5 -
- Figure 6 -
- Figure 7 -
- Figure 8 -
- Figure 9 -
- Figure 10 -
- Figure 11 -
Remove the two bolts securing the silencer bracket to the gearbox. Undo the clip clamping the silencer to the front pipe and withdraw the component rearwards.
- Figure 12 -
- Figure 13 -
- Figure 14 -
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- Figure 16 -
- Figure 17 -
- Figure 18 -
- Figure 19 -
B - REFITTING THE ENGINE - Section Menu
Grease the gearbox output shaft splines. Align the pin hole in one of the splines in the transmission shaft with that on the top of one of the splines of the output shaft. - Figure 20 -
- Figure 21 -
Do not use the camshaft pulley securing bolt to turn the engine. One must therefore:
Engage 4th gear. Turn the wheel in a forward drive direction. - Figure 22 -
The engine with recommended engine oil (see section O). The cooling system (see section K) [8] adding the required quantity of antifreeze (see section K) [8] if prevailing temperatures demand.
E.4 - STANDARD SERVICE EXCHANGE - Section Menu When carrying out a standard service exchange of the engine, remove the following accessories: E.5 - DISMANTLING THE ENGINE - Section Menu Remove the following components in order to make the fitting of the dismantling support to the engine easier. - Figure 24 -
- Figure 25 -
- Figure 26 -
- Figure 27 -
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- Figure 39 -
E.6 - OVERHAULING THE SUB-ASSEMBLIES - Section Menu A/ CYLINDER HEAD. - Figure 40 -
- Figure 41 -
- Figure 42 -
- Figure 43 -
- Figure 44 -
2) - Checking. NOTE: It is very important not to scrape the gasket face of the aluminum cylinder head.
Use only Trichlorethylene to dissolve that part of the gasket, which remains sticking to the cylinder head.
Check the various parts. - Figure 45 -
3) - Replacing a valve guide. - Figure 46 -
- Figure 47 -
- Figure 48 -
- Figure 49 -
- Figure 50 -
- Figure 51 -
- Figure 52 -
4) - Tappet replacement [1] - Figure 53 -
- Figure 54 -
5) - Fitting thread inserts. 6) - Re-assembling. - Figure 55 - - Figure 56 -
- Figure 57 -
Warning: The inlet valve collets (A) are different from the exhaust valve collets (E).
B/- WATER PUMP - Section Menu The water pump cannot be overhauled so must be replaced with a new part. C/ - OIL PUMP - Section Menu 1 - First type With ball valve and a two point fastening on the strainer flange. - Figure 60 - - Figure 61 - - Figure 62 -
2 - Second type. - Figure 63 - - Figure 64 -
- Figure 65 - Important -
The strainer flange securing bolts are now 25 mm (63/64") long, instead of 20 mm (51/64"). They are made from grade YF 3 steel. The new covers are supplied complete with the pressure-limiting valve, the 25 mm (63/64") flange bolts, the gasket and locking plate.
NOTE -
New covers can be used to replace the type with ball valves, on condition that a curved bottomed sump (oil pan) is also fitted.
D/- CHECKING THE CONDITION OF THE CRANKSHAFT - Section Menu - Figure 66 -
Crank pins (connecting rod journals) IMPORTANT.
The crankshaft main bearing journals and connecting rod journals are burnished at the locations indicated at (A) on the illustration. - Figure 68 -
E/- CHECKING THE CAMSHAFT - Section Menu - Figure 69 -
- Figure 70 -
- Figure 71 -
IMPORTANT
The sprocket is to be replaced by a new one each time it is removed. Do not refit roll pins.
Important note:
IF THE CAMSHAFT IS REPIACED THE DISTRIBUTOR DRIVE PINION MUST ALSO BE REPACED. F/- LINER - PISTON - CONNECTING ROD ASSEMBLY - Section Menu The liner and piston is sold as a matched kit.
- Figure 72 -
- Figure 73 -
- Figure 74 -
- Figure 75 -
- Figure 76 -
Push in the gudgeon pin - mandrel - guide assembly by hand into the piston and the connecting rod small end, until the gudgeon pin makes contact with the connecting rod.
Important note.
The correct way round for the piston to be fitted is: - Figure 77 -
Fit the following to the piston: IMPORTANT. As the gaps in all the piston rings are prepared, they are never to be adjusted.
Oil the piston rings, set them at 120º to each other with the gap in the oil control ring covering an unpierced section of its groove. G/ - CAMSHAFT FRONT BEARINGS - Section Menu - Figure 78 - H/ - CYLINDER BLOCK - Section Menu IMPORTANT - Figure 79 -
E.7 - ASSEMBLING - Section Menu NOTE - Should it be necessary to replace the cylinder block, run-up the cylinder head securing bolts in their threads a number of times, in order to work in the threads.
- Figure 80 -
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- Figure 86 - - Figure 85 -
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- Figure 89 -
NOTE - Tool (Part No 46E 6364) must be kept in a box and the face on which the seal lip locates should have no ragged edges on it. - Figure 91 -
- Figure 92 -
The projection should be between 0.14 and 0.19 mm (.005 to .0075").
Take the reading on two opposite sides of the diameter: if the difference between these two figures is greater than 2/100 mm (.001"), turn the liner half a turn and repeat the operation.
Seals can be obtained in three [2] different thicknesses: - Figure 93 -
- Figure 94 -
- Figure 95 -
- Figure 96 -
- Figure 96a -
- Figure 97 -
- Figure 98 -
- Figure 99 -
NOTE: The filter is 20.5 mm (13/16") long for tensioners with a backplate 2 mm (.079") thick, and 19.5 mm (49/64") long for tensioners with a backplate 1 mm (.040") thick.
- Figure 100 -
- Figure 101 -
- Figure 102 -
- Figure 103 -
- Figure 104 -
- Figure 105 -
REFITTING THE CYLINDER HEAD. - Figure 106 -
NOTE - The cylinder gasket is sold together with the tappet compartment gasket.
- Figure 107 -
- Engines - U.S.A. Federal Specification. [5] - Figure 108 -
l/- Position the cylinder head gasket Engines - U.S.A. Federal Specification. - Figure 109 -
- Figure 110 -
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- Figure 117 -
NOTE - Fit only oil filters which have a crimped seal.
E.8 - REMOVING THE CYLINDER HEAD - REPLACING THE GASKET AND REFITTING THE CYLINDER HEAD - Section Menu A - REMOVING. - Figure 117 -
- Figure 120 -
- Figure 121 -
- Figure 122 -
- Figure 124 -
- Figure 125 -
Cylinder head removal operation. - Figure 126 - - Figure 127 - - Figure 128 -
- Figure 129 -
B - CLEANING THE GASKET FACES - Figure 130 -
C - REFITTING. - Figure 131 -
- Figure 132 -
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- Figure 136 -
- Figure 137 -
- Figure 138 -
- Figure 139 -
- Figure 140 -
- Figure 141 -
- Figure 142 -
D - IMPORTANT NOTE. E.9 - REPLACING A VALVE SPRING - Section Menu - Figure 143 -
- Figure 144 -
E.10 - REPLACING THE MANIFOLD GASKET - Section Menu - Figure 145 -
- Figure 146 -
- Figure 147 -
E.11 - REPLACING THE OIL FILTER - Section Menu - Figure 148 -
E.12 – REMOVING AND REFITTING THE OIL PUMP STRAINER COVER - Section Menu A/- REMOVING. B- REFITTING. E.13 - OVERHAULING THE TIMING GEAR - Section Menu A/- Dismantling - Figure 150 -
- Figure 151 -
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- Figure 159 -
ADDITIONAL INFORMATION
E.14 - ENGINE MOUNTINGS - Section Menu New engine mountings (Part No. 054 E 6000) have been introduced as a running change into current production, and consequently no chassis number introduction is available. The new mountings lower the engine by approximately ½ in.
This engine lowering is particularly important when a radio suppression kit is fitted in conjunction with a radio (see Section 'M'), as the screening plate over the engine could foul the air cleaner.
E.15 - CRANKSHAFT SPROCKET - Section Menu Commencing at Engine No. 2557 Non-Emission, and 1255 Exhaust Emission, a new crankshaft sprocket (Part No. A046 E 6072) which is a press fit on the crankshaft has been used.
The bolt (Part No. A046 E 6012), washer (Part No. A046 E 6074) and spacer (Part No. A046 E 6C73) are no longer required in the new application.
Editors Notes: Other Notes: [edit disabled for dial-up] |