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bE' Renel~tta:J of [bl!: crnnlrshan ree« vii S1e'8,~ fallfter ren'lo'~iaJof ,thel tr,ansrl1ission. dfiiflep,fB.l~or c~utrn B<Pfji,iCl1bleJ[ .8'5 C~~[R~r)r;rovai ofrhe sun.'lD tiind 00 /OUJ11P d) RenlOV8J of tfN?' p~~5;mniconl1e\ctrrn9 rod 855 e.mbj~'e5 tiltter re('nOtlB~1 o~· .~.. t:vf7nd er [he .tC.. .. n a'::J~ 81'1,{j sumpi e}[ Re,neWF;1,[~ a\l~U"W r:rarllkshah. fren.t aJf seat;
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~'BJ1~shan fFont oi/ ~a'l f~ RenfHJt/liJiJ fjf ,. ~' engfJle n1D'~lntir~ s

a set ot s pl~ned !k~'y~tr8nch es w h Meh !~\fi! be I needec to remove and refit the socket -head boils used to secure certai n itrc;rrl15,~LHt:h B~ the IcyJindEH' head Doh:s. ,8 Dra ~ni:ng of oln and 0[110 lant i5 best done

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f[c~1 o~~wrs di reel contact ~ hl ~J'ith the Icamshaft., F~'orn ,August '[~1S:5~ e"U1i eng ines are ftl1.ed ·Mith a redesi 9 n ed I:.yl ~1 der head ~ncolwporiti:~ir~g h)rd rcaulic btl G k~t ta PIPets
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in plB:ceof the prelrjoo,s sh:im hue ket tapp~ts.

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the~ type lo'r 'tappets ~ttecta sticker ]5 norrna ~[y a'ftt~oo to the 'IS I'Ve Itov'[er il,d ie-a'ting '-.~at ·'ta IVle . h l h '.. ' ~"II..:li'if""esc·~'"t~ 11"'" 'r i C 1,o.;~rCl[n-i"~l aad!,)'i..-li~s·t·m-on.·i·re 'n .,-j·t ~I u .U '!"....... g~ . ,11;1· ,.:;!y&,] ~ v\. -~-~ --_. P°"'?s~:bl~ Ani Ilter nled:!al'E: sh Sill (d:ri'~en by the toot,hed ti m~flg bel:Udr'jr\!es 'the d ~sn~b ·and c'U purnp utOi' ,roo 01' carbu!'lettor [equ.ippedi en'gines, '~he ru·eI pump. r he ,a,iiIpurm pis of t ~vin ge1lfjiftype, d ~ri ':i'en
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cY'1 i.nde.r head ·i.$ o-I~ CTQnv~fl '1a.naides~g fiE \Vj'~.h the ~'1161t.a i1 d eiChalE3i~ .In a.nif 1:) Id5 mla UJ nt erJ on th e rear s ide {.~s vie~~ed VIJth the- lengin IE'in the 1r8: . icle). Th[~ CFill n kca se 'Il0nt iIs'lilon s~{s.;tem CJo~11Iprise-5 ,S '·0 - ,e fnJrtl the fl~~wheeil nd of the e value C(n,\f\::l;f" I til·s s~de of the a'it"dooner. On fuel' injec.tio n equip ped ~ngines there: ij ~:, O~ to the ,a:ir irllb~t, manifo Id and .f] hOSlS to tha air L.h~\~nerfrom a three=·w~y, oonl1eC~O:f Ion
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'1 .·h e eng in e ~ to g eth f·r 'W'i1'., the 9 e.,iIJrbC~, ~ must be Ufted tmn1 the~eng ine com parhnent then 'Ehe eng in~1separ:a,ted 'from the gle·,a rbo~, IDIl the~ bench. Tw() pleo pie 'v.!!i II be needed. 2 ,A hais,'l of 1.50 kg ca pi1c,ity ~vi~~!be needed to lilt d'u~ [~ng in e a p pro ::drruns·1y -I m (!l're. i:'f , he n\)i ~1!:5 not pCftable II nd rt~ englrr.e ~:5 Jfted
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tf1[e air CD"ooJ'tionin.g Jil~e5 CJ, equipmenl wl Jf a'~1ypalt of .the 5y~~'lemis to' 00 ded.·,8Gi76~

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the:n sutll c ien~ .noo 111 rnu ~[ be 18ft beh,i nd [hac

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~'~ 1~lN4IiY' .~
:~~J!l . ~ .~: I luM!!!.

-_ ...- -~ .__ . - .__ ...-- _ ..._-- . --_. .. -_ ...__ . - ._-_ ...- _ ..._-_. - .__ ...-_ ... --_. --_ ...- -_ ...__ . - ._-_ - _ ..._-_. .__ . :•.. :... ..: .. :•.. I.·.: ..•: :•.. :.••:..•:.. :••.:.••:..•:•.. :•• 1.·.:.·.:•.. :.·.1.·.:.·.: : : ..: ·.1 Iu,ooir:;~e sU;ppo!t~'l so uhat the fl'ont ~iJhgels, may' be tll rnad to. undo the dr~ves haft nuts, The ieft:~,I1,andh~ft is accessible ir(HI1 ~bQ[\f.~ s bu~' Car!lurettolY equ~pped the ~[g ht -11 nd .shaf t nlU st be undone 'tr[QtTl i e , Di9{~Dnne~lh0 b~tterJ" negativ[: . li·ocL t LIrndernealth. Rlemov~~ ,0' th'e 9~r5hi-n !~nkBQB: 2 Re:mn'~ethe ooln net 3, Dr,ain dre engkte ctCiii"::d ~~'. I" tC:a-nonlly be do ne fro tn under 1l·.... aUl,. .a S C f] n [E.x.haust d(w~npi pe,~'to~ manifold detBchlrnelnt ° ·4, Pos iti:on a .5~: itabl e Iconta~nef' beneath til e
l ~

~I~'

'r~L,.;l'!!i D''''~~l
. ~;~y ~rL~
_ ..... '

i::UI ~~ iU~~JI~

d:F"I'I!t!oJnp' ~:p'.:;lii_'f-In - mi .~ n;,rn ~rl~~ ng~~ f

"_ yf'¥.I' ~l '- ~ •. \-..~ 'l. gl~ ~!Ill~I!J~~ ~'Y
-.,J :

. ','~

1i!!~1

bo. ~.-.

~.s'" ~JIi[l~I"""iI

connectio t1 is, 'S'ecured h.iS!I' fI,'h an" b -i't',e:' or IL ,. ~JlU

!",.ei ~1!;.Il

~J" .. '\J ~... ICIIJ:.....I

...

by Slpeciall spri rig lei if)';;

!9lH'1d:' II.'IIILI··,
I'M I ,~,~ Udh a.1l"R n~L·,.,;t', 'MV .. !l.<-i~

[engine. undo the sump drai:rl plug t}nd dr~~it1 the eng~:neloil - 'see ,Chapte r 1. On com pletion c~:ean the drain PI[tlg and n~'~ it Rere~~'~ ~ 0 : irlg. it 'th

'~llOBa OW~ pre'S~:iU.:lre,s;wft~Ghilocal:·on

:ill

rear

IO~'

5..80 10ili preS1sure

CJll:ind~rr'hQ,adi
5 Retnol:/.I~ the '~d ~f;n r. tooet h er wh h the 0 1(;00,1 ing fan,. ()n mod e ~, wni~nui',13,(; Lured after 1'9S6. r~ rrN.}i'J'EJ 'ms' ItrofU p J1i91 be'folre r,e "1(1~ In9

:5witc!h !Iocat:bn [111 filter mrouHt'tin,g]

the r,adi~~IJ r.. 'I R~_, Olle the' :air e~:eaner unh then disconnect the til ronle ca ble a t the ca rburertor. Po ,J~ ' ir.f th cable ou fJl~the VI/By.
hydrau;i ie pump driljebe'~t;,Unbo!l the pump. belt :too. sioner and fluid reservoi r ,Ll:U1d Ue them tOI 'a'ne side ot- the eng ins c ornpert rnent, I D ise 0 11neet ttl e fo II0 y"!}j no ~. wtn no ~ con nect j on s, ide I1dfyin 9 ea c h lead ,~S it is d etaehed tQ av.o](l comu~ion on i~~ SS0!Tlb~:
,'1!1,~'" ;~~r.#'Jj1'ir.''''V' ~'Ili'<~'_~ ~-,!Iid' (Jj.)' #"'II"""",, ~ I"'~""", ..

'1 '~~Vhel'le ower ~:teedn.' is ~tlted, remove the p

b) Ol~ p'rf,IS:SUl''e

heeld l~ee iBus rta rio,nsJ ,a,~' oi/,{Ij'F;e-r t'Jr~cli:er c} tlle,, ,m, W1ifol'd' {J,rebeat"l:f therm'''''~s:N~~:d~'

.'5 L~~¥::ch ~'e,;rd(~1~' e,1lnder a

'1'1 On I'nnl1~:1 gp~rboA

models, dlseonnect

'the' clutch c,abh~.

d) Choke c",ver, ,1ernw,- 5~~~#ch IfNhere ,fe:a1d 8PfJItCabJe} e) I~nirion HT aool L l'{eaoo ....

~'e1Jd

" :2

~Jib5C\O nnect

the

rlQ ~~jDiV!t

ing

iten15

rom

rato u nd the ca 'b UrelJO r . Id~'rnJfy th~ cormectkms '\N'here nece ",arj{- tn avoid contusion on 11e·as3Iambhi~
,~). Ihelffi'O(['mlb!i

tJ.

'

Choke.

COlfer

leed sepBfBlte

,COI,I1t"JeCto,r

a} CIOO'/E,m:: fer~peui~l,ture send~r unit lead .hJI E'ar:dl s~rsp ro gea,rbOJf fsee tl~~U5['"a ~jOI~
aJlt1 M1U~'ri -,iltnc.riQfl ~\Nl'cl:1 fa'

o~~
C',

If.aIJ1;~e kJ!lelolfeffU'tl cu ~,~(Jff '~(~~fI

""

1,15 Disc IOn" e cr the bra ke va c u urn servo hoses. ,B'r"!d the vac u' ,~1 has e s 'frorn i he inl . t rnmni k~;~d, 1 B Undo ,a:nd remove th€ gw rbox roo urn! i ~g bQlllt. 17 !=<:aise and su ppert rhe va hlcl e on a !de: sta nd 5 'see '~J'aCf(}/lg nd "en'lela 5UpP ottl
,~~O'i!<sing' s I

urn..,.!!1 ~ flit

It.

C lea

ranee
.~J~.

to

work
'I!'(,.\

geBlrbax

,;111 '1E",;iI~i'iM'" I ... - ,r,;'", , ,v .;::iill~J 'lL~ ~nPlrlV' I',:' lI"i~O\ ltl::;'",8u"j, :9 D lscormec (, the rue I s un if'il I'v has e from the .rr 'fuel pump end 'the fu e!i retu m hose ~o th rJl~el t~~nk Pl ~ the -oses to pre'/en t 'fuel ;~eti 'i' g: ~~llge.
r~

'~fL1i~t' lMlla!nlfutd ph'if~lfle,8.ter ep~'ldlta 5 Iri("njiJ~cwr d; ,Par,r ff'N"'Ort/e eJwru'JeI h\C~I,~'I~r sepal':'al'lfj
C'onr:!'ectt')1.f
,C able

u ndemeeth . 1,8 0 iscormeet

19 On '8uwlma'tk transrnisslon medels, select

p (P,~rk) then d isconnect

~'hernanua i ('~arbo:~ Iin k_ic'lne.

the til rottl e a nILl

'13, OhlcDn neet th . speeoomelJali

fnJlm

'the "trcalt~m
" ,4
'r'A,....~N,,~ ...... :I' _ ~~~1 -~r~ ...
13

j"S'SiOWl.

'Fn:u-nthe If:ngi ne,

1'01 DI~~on n et the coc~l,ant a Illdl hse ter hoses

D~;se" eet m

and remeve

the

V8;C UU m

selector cables 'fmm: the' tra nssn~sIQn. 20 Disc onn e ct the dr lves h 81ls, ~'f m t~lle 0 geI2l.r:ooJ( EJi1d tie the:m up DU~'of the ~~}~,~I. ,21 To d isconnect the e Ji Bust rns n I!rold to d01t~11 pjpe. CQIMlnoct &1011, '\111N tool no. 304,~,A will be requ ired. Although 'it rna,l" be possible to

prise til e ,(;,1ps 'fliee to SI!e' at' ate this j!oint~ the i too ,I win d~fi nite.'1y be req u i[F'ed to, re'w it the 'springs., 2 2 T~;' iiJfte h icl e c~n InO\\r be krwe red the e rernei n ing fiemO\fa I operat ions b e~ ng from
I

abOVE!'.

,2 ~

Atta c h a suitab Ie 'si'ing and h o i'st to the

a.

eng! ns', 'Igearbo' 2,4; Disconlnecl

u ndoi ng the thre e bclts (slelf: i~lusl:m~; I•. :2,!j Th e e ng h1~J'9 1fJ8 rh ox un ,Ut fron:u moul1![ij r~g
m LI st now be dets
remov ing
C

un ~land take its \~ifeilght the n:~'ar' e:ng:in~ I:...·~rer h~l

led
thro

!'J y LJJ n Si

'6\'; ing

a nd

ug h -bo i't. ~,"m<1U} be r1eCEeSS~lfY.' :rurther li:ft, ~O\Nef' Of tv~i:st ;~ u n~t tg he , )0 ,8lbw the th ough ~bGtt to' be lruit ',. r~~~rl(5'6e d
5,~:2 5b IHydr'('!I-lt~pe frornr~, :Bn,g;inle mrount:i "!1i Ref~ ,~o:S:per:iffcF.ltians tor rfll ~renef ~D~"tQ'ue raru:n serrings b, w i:llustra tion)l~ ~Joitetha~ 'Irorn Decem bar 1 9 B~t:L the f rent me U If] ti:nlg i5 changed fro m the bonded ru b be' r t~,~lp:e' a ~ vdro ~ yPtl 'V~ith to h . "., ~ -'iii , m~ us,trarblOlIl!1JI d a mpi!ng ac t~OI1 \:!ie1e "~I
1•

th e si ng:1 131'

e ,~I!n:lt

Fu'.a.,'inlia etion
.'U I iIIliUi:~~,I;."!I'

\i'11

11I!iii'1"11 -

,1lilI;'I"IIUI~rJtnA'''' \f:r';r-'~lU'

2~D On . UH ~ inj fa eli o 11 fiN1 u~pped ,~rigina s, [h~·

re . oval procedore ci!ose!'::" foll()A~'S tha' Igi~Jlen Fo. ear~~liretto r lequipped ·ehg·in e SiT Haile ver,
di'S£lelgard those items conee ning detaehmera
oil' the C~ rbu~er.tot a ~d 81ssociated ~tems. 'TIlle rO[~W!hlg injection eq wi pmeot hems ~i!1iiII need to be di scormected !nst·e~(J. Ref]er to C ha oter 4 [lor 'fu~ther deta ils: 29 Di~c on n ect the '\~ lres rrorn t:h I~ W~ rm- u p

va IVIE: (green 'It oln nector] (SfN,~' 5'tr.SIDOn). :Iiu 3~D Dh;;, .ormect the ~Ji.r~r to the cold start i:ny V~ Ive' (bl ue cannectJr,. 3,1 Olseonneet the '~liIril1g '0 the aUHi~iary' air
1

I .~
l,lY

i!J..n=-. 'V'~~
CD m

'S,2 0 lscon nect 'the thronl e ca b~e.at the 'fast

Id Ie

and braeker but do nat remove 't. he secudng ci~p I(~,te,e ustra'tl'fJ n] . ']II '313 Remc~/e! the c()~d stMt '~Ja:~li'e! but leawe ·thl9'

rui!':!i:~ 11·l"IilD'~connected
__~~ ~ ~Q..; ~.~

"~!I~~

~Ull

1ry,~1·"'"-~~ 'L1I" u r"~ r.~ o· .~ ot

.~ b.....
!j.~ ~

1l,I:V~',¥,.,• g
_f,_

3,4 OiscOi,nect the atr ~ nle;[

pi pe ~11! tbe r~exib~le

..

duet ing ~ua' hed In the 'tt:O'ou.)(~' housing.

2:5 Di'5,,~onnecJ the '~!acuum hoses Irnm the

5i.21 Wiring; con nectio Inrs,10 be detached .

'""fue~ injed ilDn mode Is

9 rhetmo,~me s PNkch ·UJ Qt.3 ,balr ciJ pre'S9$_jN~'
1"

1 ~1~~,lerrm t()t
1 1/'

inlet man ifokl and \11',8CUll m booster, 316 Leavhlg Ute !fuel I!ines conn ec ed ~undo the fJe.'[ainin 9 bioiIS ,3nd ~vj!th· -raw the IN·ann- up
~}ah!· from the cji'linder block .. lPo~lion D.U~ ,o:f the: ,\N'ay·. ::[~' Detac . the i:f~:ecto s -rro the c y Ii11d IE! r he,~d ,8nd plug the holes, Dis 00 nnect the iI]sctor Iines 'from til e IOGat~ng bracket on the throttle hou s~ng.3nd f\old ~hml Ult a the TAlat'!,. 0 olj:a 1f'1i~~. If'h ·t·m_"i1n ,fJfJ.-· U u:m·. h·I'"'I' ' '.n;IC'' t·.... .,.hiO. :tll.-....rFltTt·DID ,;,;)iI;I! ILJ~~~I ...... v! ..... ~. l_ I....,!L_~'"'"
loj:i

Warin.,upv.a~~~ 1~8 balr (Ji} pres8 se

S Dis tribUl:o" H'T (;i~bJe

,; I-la:i sende', ~disi:nJJ~rtor J

.,
iact.!:UM1 ~~ilC}i}

(tIJ.~~fnfilj,~~ ,4)

i -:.:'[,:.[,- i' j.:' , [. .

~w.ffcfl

O~~ tel~np8r9[Ure seraer

9 CooJanlt !·e.'mp€1·al~

sender

Cold s~"'Vt lVa,j!ve 12 A IJ'Xi#sry .air va~\ve

S11Yitc~l

! ~.~.! I;. I!.~I I .~.!

;'..~-2:'£-"'."...
• :!.!i'.. ,'

.' ~

.. .....

" •• ' ,

'tile 'Wit} y. 39 D tsco n Iil eet t~1e o il. tern pera ttl rs S).lNi tc h
bul khead. Fold t··e hoses bac·k out
se nder I~lkJd ~e;e m IlllHitral:rno1n)i.
40 Vl{hen U ~tln9 out the eng~rE eigearhoK
IIO'r

IJ,.~

~"'i

..

_!J~~~

'i:~i

.~i

~~. ~

9 rea te r ca re w ~I~'have to be taken in rnanoeuvri n 9 the LY n ~t IrQIm '[he eng ine

,i

unrl~

corn p~'tment. d ue to the, ctose .pre·xim ~ll' lor the, 18 ~r :ir~lettrna ni'feld to !'lie b LI.flkh,ead., Th.€! u nit w~n, neec - tO be PIUn ed I;orwali"~~'first then t\~~']5tied
I

and lUted.

,
I

,6,.32 I ~~~I j:njedtcrl1' oom!pone1nm,

tOI

be d~:ta~h~d

1 lnro~,tte ,C8bl~
,it

,C'oJd sr~JI,ri!vB/Va

.3' llocuurn lloae'.~ :4 Aif! in~is,rle'......... "i~'

'

5 h~fiC«lrs

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1' .~ •• 1 "'.'

.~••

IJ:
I
•••• ~

J) Coo'laru' ,punF~p.fJnd CD-ol=lIU- hose

'I

This proeed una i5 fu Iiy d!~scrlbed h'l Cha pter J Pal rts A or B ,85, ~lpp ~ k~ST"J e'. 1'1 is (Inly neess Si';uy 10 rsf ,I'" to -til os e panEl graphs pertin~nt to the lPartiCLJIt~f method i, '.~i1ng sed, u Tna engine mu st be: supported on blocks, OT a 11:ern a:tir.~e!y the' gSG rb 0:< ca n be s epar ate'Ll '''lith the en 9Ine sfl! Ion fJ'~lehoist,
!'
j

'~J"i[hme eng ine' removed from the wahicl e ,iJ nd sep er~te d from the tra 11Srl1! M~'O 111. th~ e'~[!6fnn~~:~ ou"~I"!.'"," a ~~il~a ",f~"'"OI~ ~ t"''''''~ I' m med ~u ~.."."'~ I'm~~IfIi,'tS ca ~ I'

j) C.'Yulc/_, men {n,~6irrJedlfJ,!'epJ.tJ,[e (mtmuaJ' g~rbad Drj[I}1S1'-1Ja,[19', r1f)\~"ing iO;(;1J tioa 0' !5ipll1(; er and
.~~I

,r:;ylin~f bkJCL~ liflCl he,~d~ A'e'iW ,D'.,rings Wni~'be ~equitlsd

CO.r~"l~ctt~tS: !,rom

stWj:~n\(sJ~~aUliCtm2U ,rran" rnJ'ssfion) ic

....... ..- _.. _....

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'the' .order ~iven ~ ~~ ,~;,,AlltemBtor and dri+/ebel~' b9 ,fnt t m\['u1ifu~d',and [c,'an~u.ge '~Of" 01' inlet
ffli3l,nitiatd aoo Ilhl(Jrr~ f1G1usJn,g
~~~'l~Orij
• ~ "• 'I

'remo'Vt3[sequence need not necesserl ty ~O!:~Of\ji~ ~

be removed pnor to el1g ine di sma'FlU ing. T~ -e

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_:. : .. : :. : ..:.: : ..:. : ..: ..:. :_: : .:_:.:

.i ••• i. i.ii ••• ii••• I.ii.i ••• ii. i .ii.i. i .ii ••• i.ii ••• ii.ii ••••• i ••• ii.i. i.ii ••• ii••• i .ii.l ii.

:::'.: .. :::. ::.... :. ,...:~!~:..~..:.:-: .:~.-.3.:1 ••• ~ •• ' ~.,:. .' ~: ,/ •• : ••• -,::.! ..... : :~::: ::::: :~. .;;;:~ ;.!:~;! ~;-1l-1Il ~t;t~:~;~:;; ._ . ..~:;. _ ..;:~;'; ~ ;:~;; ;~:;:_ .. ;:~;: !:~;: ;~:~;: !:~:;. ....;~:;; .~:!; ........ ..._ ._._ ..... ._ ;~:~;! ;:~:j; ~.~'~ .... ...._. r. ~ L!i!=~j,... .._. .... _.. _ .... ._

~::ii'::~:~"~ib~:~~il;t~~~::~~i~k~:l:~:
t~~
I '.:

- - _..

..-

-_ .._. _....

_..

_....

_ _. ..... _ .

..

.-

_ ._.. .. ._......

: .. :. : ..: : :-:.:

.: ..: '_:_:

:_: : : .. :.: .:-:.

: ..: : : ..: : :_: :_:_:

ii••• ii.ii. i .ii••• i••••• i.ii •• I,

: .. ::

.!J:

'~·.III{'Ii • • ,,':,

.. :.... :....: .: : .. :.......: : .. :- .. : .... ....: . :_-.: ..... -:-. :-.. : .... ... :.... :..- : .... . .:.....:_.._.... : . : ... : .r.: : : : : :

1 I"

c)[ rxhaL~)l'.n"Janitold

ou It '~hero~~ow~ openzrrlo'l~,: tl'l] ,af Dls(;(JI~ned tnbe ba ~1:erye,fJJJ1i1 Jead

me leng; rre is, st]U h1 the

'v!eh; C ~~ J ~fl_t ~ari1!'

d~fuel pumlp B _ ~·arrn -UJJ 'va/Ire (foeA' inject.io'iA IJ s,till

aUEtched r}l DirSlribuf.w
,~I

t~~' ,R:gI~nnve rlil;. a~' ern,a ['OJ' drive!-lfl1Tr c' UN,blatiI'na ,remQlLI~el t~le r,"Go~tJn~' p~f_'r~lpl

(JLtIJe.f' 2, Depen din 9 on ty pe~ undo t he] rata ~ ng n~

Oil

I~~'ef ~it'u~cOfJ~~F1rf~r'When;:,(fJppJj'(:8Jb~'e) I

~ . ...J iIf~lj' _ .- -_ • iUlnit.~ [II II ~

.Ii;1 011,prrE.SsUJe ,f]rld' COOl~l,'I: r~n1Peifii1J!~ID"~' ,and ser~5(Jur sv.,i(iCt~S,

,;,ier mDt.lnrlng
• ,.. ". -

.,·olt(sj/nut(s)J release! the, re~,ai,ningclip~ and li'erno~~ the uppe r t~ 8 ming c O'I~eE'" ~see iii IU5,trat,llon)" Oln 5'0 m e eing,in as it I be nec.essary to Fe move !:~e b unrq 'frClm the flfont . ...

',,~j:~

.',~
~'

[~

~a.Q'

9~6 ll!nterm.edw.ate sprocket timing mark I(.arrowe:d\) a~ rgned ~dlh no.~ch in e r,aJlV'I k'sha·ft Iptilley

o a l'.' W ~I ~

c'·' -. u: .

:·'~m· ,-,e:::h- ,e;t'liI"DiFi>!~~""". "tl~m-"-'I"iFc!Ig·,m-"-!~r-li't~'Fr"i"'"'w",,",'4~li!JlUI~It~: ~.~ l' e'M~inde'r ~,ft- ~~f.;.!!"1I! ~~'I. ,.. [15aJ \~I, ~{YJI ~I:l I:~~I! ,:J" at 'JDC ,on 'c'ompfieMJS~Cln
~J

"'!iI.r.

~HI' '-".

,U

'Il.£ll,.

'~~I

,I,

race of i,he' cove - to ia:~ access ~tolth~ A,~~el' Ic'~v type: reta in iI1-g 5c·re\~iref: essed Y/lthi n the C'O'iiI~', On lelther' ~n9irieSr 'the ~e'ta:ming $·r:re'l!! can be seen bu l It:;f. key slot is de~e p:~)1 rece ssed (~ccess 1)0 it being made ~i,athe hole in the: centre of the serew S~Irroun d). :a Un-SiC rell}, the "!.US Bincl bcl~s 'rr-om the' a lve ee ~"~,rf.u'ldr~m~~"'{~ OOI!I~talg~ther ~Mththe tM~ g,HSKle'L a - d re il1ltnr'celmen t st rl p ~:. Detach the
I.

1~1ththe ~ I'J\~cover' nang Eli (S~I E~~luS',U·I{fth'nl. in-'e-rmedi~tif.·d

,avi ng t L~ e d the eng il1e' u nt,i ~j t sese mark '5 rn agroo., IiIOf\~ look at :tne earns, f,Qlw' N,o -I c:YI inde',' [r:eare~t the Umi ngl belij. The:}/''wUi be)'''·" be in
the ·va I e closed' posnie 11

s procket {U e ~,-ol:~,;lre tig htened 'to a subSitanli al torq ue li!:Fid s

the sproc !rets 'will erefore -need -Id ."".11'. - :! :~e w~1.enund•:cungi 'LU';'_' II-. ··I'~."~ IUO ~:5,
'1,... ..
'!'. -

ca msha'ft iind era nk,shaft la'tt er i11 p-:-' rtic u ~'lu'llsecur 1"9

NOV\!' IOlok "thrc,ugl1 ;the he le ~n '1JIr;1 ien 'the: TOC

"IO'[e

~~Sl~ Ii IIILIs;tf';a'lh),n]l. e

[.0

bet-ml"

'i'I..O

se nso r Igoe's whe·re the' :tjrn~ng marks sliOWl 011

the pert ph e fY. It:I'f the 'FI heel ~nd ~tVi_ the

" '1 T o
unSCfEfW'

ernove

era nkcase 0 missi a n hCl66(S) fro m the roeke f cover, 4· fu1e:rk.the: :F'elat.~~!ep05 itlons, ~f the cran:~sharu~

pu ~~,eand cran ksnaU sprocket then undo the, \~'

Fo.ur soc k,e't-·head belts ,ano pun-ey',
''tJ ith

_~ra~~lthe

re1ad:~ng. ,B 8ef~ore remIQJlit~n.g ~he [jrn ing d ri . e:ooi:t., check its en -rect ten slo n I'r held bet~/~een the f~n.ger and thun~b haIf'iJ~:aj1bt"1\Naoo the intlern~ediale "- '! - lIi:i· the C fa n1S, hB. _'lb .h. .s.~ U GI.r~ be J~~,!! - --- - '_-if-. ~:~ s.~:la,~·l .anu b· ,.;_,. :10 U \",~ . ~
.-,..,1
jj. , :~"" --

fat fJ 1m Ul~ r'j linder head but take ca re not to da~nage' the face, Renla,'~re 'the' bolt
'\!"a:~~l'e'caver
r
_. .r ~ • I I ~ ~ . D '-T~ .",' -', ~ ,,". ~ _" ,. _ ,'"

by inse rt ing: a 5 u ita b I, meta ~ bta r thn"Jugh ,a spree kel hoi e end resti "9 it 0 n the:
U)i'

ste tiona

the

camsl N~~'~ spro c ket~, t. b olt ~,J itlh he sprocket held

I

the

.;J! "'.

51 Unbe it an d with d F·S:\l\! the IOll~~sr tim ing oo~ew," 119: The e n ~ illli9 rn u st nO~J 'be set "far ti rr~j 11~.

T empor ari~' r!:dit the- era nkshaft

"U.

pu IIey';, .(1n the

0n

"IIi.ii

:1 ermediatle~ sprocket m

For the 'Un,i ng belt one toot h has a c ant n,~'- u nch n~,are. TILl rn title, p I

eng ina' Unti ~th~ mate s "wi lh a nole 5

V,~be It pu lIe]f boit,ed (see Ulus:tr~IUon)l.
t,o

the

1-:s engi.r~e 100ver rr liS'f'oor\Jl9 lhli spar~ f,dugs [~ru~1 ' .iQ: S U ilia bI~ sp,a nnet· Otltn he Cr i1I nksh~ rt sproc ket

TY' turn

th e cr~ " ~shaJl sproc:k'et

n~~

remo~~ it a I-~' -eJ~aJrni,r.lE.: iI: !ftiil' W:Sir. r~ .is,!tt'~ O~~ ,E"lfll1.::i1 to ........ d rl,Q'I. ... one ~ e· J' 9 Lcosf~n the tens,joner then \Plrrtu'ill"aw' ~he: L L ... ,."J" Ie '[I'~ng u'E! t r'r~OH·tl hie carrf5,Hl,· I'" •Int'errneullhue ,and .;,.. n<'la, t ::;,proc k ets. ra ksl· '0 Ea c h or- "th J ti mh, 9 beit 's.proc ket 5 is ge!cwned by a C"EHr' ai bQi'~,and \l'~'a'5her. The
~ I •

111 e t~'r-lsio:rr· 'f ~ih ~: Ir ,"J,(J'. " a. fa 38li·" fled i:[' ~~'. c ~~n "". adjusted to th eo co rrect tie nSI 1(1 n ~ e
.0 .
G1 , ~'ll·.~;
,~f"

it by ~ocken:~ng the: bolt hold"g the eccentric cam

I'f ~t I'S,
!JOO

possible to :IUu1itrarUon]l.

tt~"st

it thrtC"ugh

gO~ fs,ee

slack, adjust

and 's'iJla cer 'I(;fa sher th len wUhdra \l'iI! the ,,~'r sproc ket, BI':PUlg ,it _n~e i n~:(_:.essay , e'~ I r .. !ec the 01 of 'H11B \, ~'oodr un kBj! in the! c.amshaft~ ill rf~ust re --leV'~ed ir loose in its grolo ,Et . ~~~rer h out th Ie '\Voocl LI '~f key an d keep it ~:·ifi't the h
'i;; iI

i -:.:':':.:':. i' j.:' , .

._ .... .. . .... ! ~.~.! I;. I!.~I I .~.!

co .;]II
,

Ii.:.~~ 11

lUI

~\l

~.'

JlG~.

i'Tl,;:;;o..:i-"i I ~,V~·

't::: !§n_j . d!t.:...·~!ll

II

-"

D.,...,

[,

~j

p" __

'

,~'l,'

l~

..

'"

,.,._.

w_

as e~p ~ b ~.~. Do not .nl~lov~ the p~i:c lev anksh~ ft til) tu rn lOr 1h@ pi stons 'rna)! tou c.h ,t:LI=- '\ h· ~c~. d-..e- i~J' 'i,I-,I"::' Ii'"v to<i'lI~ln"l·- "g- b:~"'"oII CIi'tc' .J ~.nGlA ItJ ~'~ U '_
t11Q'tJO f'
[lUi

roc ket. ~ ~' ~ . 160ld _!9 .~ the eran ksha-t 'stmJt le n:~if,Y~/ith,a '!ever j ~mm ed in 'I. ne Sit arter ri nQ qea r ~'ernQV1e the- sterter ...,..~ !~

'p, - rnc" .i,,-,:>,~

U
'~i

~~~~

To ~ a,! jra Am,::-· I v .... ~._

J _" ,,-~

'[N,,~ (Ii:r'arsJ\1!tL!! ~:i_ .. _ s n ~-",'~:~att cJlrJ~

"¥ _ _. ~

ICI ~'il.iilOl'
'\I'I~

""'""Q

1·.;J.I!1i

n" "'C -''''rl~~i'M' ~~. ~ I!fl¥

:Il

J'~'.

fiettalni

i1tg

bo It s,n d

tlU

rn it. in the djfect 1:011 Q.'f

I

'spacer 'wash®r the'rl 11:0-v'IBfthe Spl ackee :rree fr-Oi~l1 U,e Ic:r,ank5haf~. Checik :the ,f~~. th~ W:O'rQdruf~key' of
and r. rno'Uls it .. "og~ther
J

\!'Vith the

E1ngi nls; li,atadQin,,,

7' "A~h eJ] ,~11 eSJe rna rks, n1 ate h ~,a k ,fft [he () s:proc,:~t 'On the ca m,sha ft 0 n e tOlolth of this has a c entwe- pUI1C h mar.k .. Thi s sho·L] kJ be :~e\fe!

'Of tilted

~ 111 the crankshaft~ it ,must be pe,!1ew'ed I'r IOOSie :i n its IgrQQ~>a.Liav',fS.iif out tl1e \ll'J'IQodr ufr kl~Y' and k_oop il VJrth lh9 C ra rd<!~ha.rt:sJ~~'ocket. 131 The int'~.rmed~,"t~ s [h,arf t sproc ket is '

removed in a similar manner to that f'ar thf

c .mshaft sprocket ..

6m"Wt

._lol.I,I/lIf&

·\·O·--'II'~'

91~,7b NOI~1: cylinder Icam ~OOO6, in 'vah,e c.~ors~d posi:tjon

L~~' th~ C'MP'S~'Fafl: G~I et!t is. tell bfl' Irlena~~d ,If s JJ~lttfl tha ClUl!1'5h,.9fl ,~imJng' 5pr;toc~:e.t. f1lUS~' be r:f!'tJ70ved

n ILUJ!lratif)nS'~j rna king

,2 R.em love the cam s:h;!1'fl beer i:~~:cap

Iitted po 51tions for reference '~lhe:"I n~dl1.t1: 'g .

The' C~ ps ,eus n UUTI oored
~,I!

~ c.arlD f'ul 'OOlle Qrl~their

~'See

e, iUU6tratioll1\~ ._ut nlark U,€, SIde nei1ln~r~,t 'fro nl I~JftiMe Ic,iiin.der the ' hs.:1 d. ~~ 1 cap i:s the w'rE' "l~~Hth sma!:! oU sea i 01. a
011

it

Lippe r

IiP~' ing

",,4!~¥e ------it: ~ji~'

Ou!\fi;i'" 'Vi,'I'f'e 'S prirlfJ ----ri:~i llYlifl" ~~~

j)pi'ing

-----:I

:3 R.e move cap' no'S" 5~ 1 ,E!lnd ;} in that order NjlOl~V undo the nuts oolding 2 and ~1 in a di ,~gon ,t:'llPZJttern. The ca mshaU '~viI~ Iin. the caps up as 'U, e press ure (;4= the vahle springs. i5, exerted. \ythen lh~,)" ~we fr',ee" litt the eaps ,ot a lang 'i~tiU~ ea m sha tt The 0 iI seal O~1the the fn) nt end ctf the if!~ m'~h.a'ft ~rjII come IN i'tm, it
I

Depe nd I'ng en 'tappe~, [~' e

iOIU,(,}ws:
l

proc eed es

,Shlm ,",UCk'al' ;t.aPPifjtts' 4 The u~ ppet buckets ~!re n !:]iW'

I'

ex posed . nrl fn,a~1'be lifted our. I(:~~' mnus;trJ,adoo:~. T ·~'l-aa ach e one ou in nn n, prh:..ng LtiE3 ~:inle disc au t 0,1 thel i .r ueket by nn!:Jefting 8 srna II 5Cri!~lII.rl r~~er ~rther sid a nd lining: the dise aVilay., On its reverse each d ise is eng r,a,~.~ed '~~i~.ha 5 ize tCeg. 3. J 5). Ttl is is its !hi ckn es g. number, ote number a nd then cl ean the, d lse R nd ref It n rn .•~er sids dlD\rJn~ There are e!~'lghit lL1f '~hege end the'J' m Ust not be m ~ ~ed up. On ass B m b 1\1".1 eseh
I

r~ too!
r~
I

·' ."1' ~ Jf ILI~: I-l~ U y, 10,.;:,'~.. 3 ,Iii""'MI;~""'-:-Ia:r D,Ii'iIi,~ ~In;,~: cam

~lfr IL DI Uri b.Y.

'-"i;::ill- jUI!;I. ,~~

-d';

c . iifI;l~l-"p,n!ii!illa;'-n" .t ~ :1:;(", 1"

1~:Ii I W~ ,1II1b, ,

..

iiif"·!;i:r·lJ:.u-it'\.-.;ii!""'''''fi;-r ~"riU. U J[I. bUy [

,~,I"iJ.n;iIi"!<h, ~Ii ~ ~llIli iIl~

di~rG,mUSl go hac ...into, th e bore 'f ro m whence F.;~ C~1 e m :n i's p rob tern e'Kis:~S a lso 'For the valve'$,! so a ~'ol1tajner Ior eac . v,ah~~ asse mb1~1'

_Shfm--BWlC,m?l--~

liIpp,r.r wa~ _.
:SPring Cih.i!J!iji"~Lve' ~I, ~tJlI!Iig,·
_ 'g

~';nn9i1' ~,till,~ •.

_
- \1;.51 h/~ ----, LQ'i!ie r

~m

o~, 'S!l!~1
spriimg ~@oa,l~

it.1,I'I1f~'

.- .1 I • I I •

- .I

..
I I •••• I I

.
I. • I

I I. ••

• I

I •

.
I I I

••• I • I

..
I • .-.

.
I

••••

I.

••

.
•

-- I I ••••

.I •

.I I

.
•

Ail!"
l:~n~~'tIQfl

"

• , , • , , • , •• , • , ,.

~~~:.:

:;¢:~~~lI$t

_.

·
:.
I

_.

_.

- - .-

I: 1:;.:-: --:-:.::=.'
II~_

..
I • !

I. I : I : .'.
I • • I ••

. . . . .. . ..
I. ••

I•I
I

I•
•

I I • I •• I •
I I • •
I ~ •• ~

II
•

_,I!::
~ I

:;:. .!~. ~:~:': ~~.~I.

! I~~
~ ~~~~

!! I!!!._II
~

:-:1:_:1.

••

~i~;:
I •

.
I I • ••• I • • I I • • • I : I

• :

.- ..I •••• I I •••

- . -. . I • I I • I I : I _.1 ~: :.

I •••

"

.I • ; -,

"!Iiifll,!

~u_

-_I

T',·~, ...... b··Iil.",t ' ....!I .. ,iL,.,'. . a~~ ~,'_uc:~e, an~ ,,,~~~m
_

~nd tappet is FI!81Uired. La be:1the eonta iners

to Sf as fol iOAfS,; Confainers 1 8WW 2 wil}' be No 1 CYl!~;w~' ,,~~'r exha~:Js ,and in~ftrr ~lS).'J.~c r.'n~I!Y' ICO,\I1,;!iners 3 and' ,41 ,,~~lJ'.beNo 21 C'~l~~'rUder , ""I
~ '--if: .. - - ....".. .!'n~~ - -~ -,,-l .....o"'~:,/~1"iJ/ i '!G;~m[J,:i~t ,;any "h ~~\!;;;l, te ';;'.':"~'b ,!;II~~J"

:4 On carburettor models" re!mo~ '-'he alir (:1 eal1er uni't~ 5 [)Jisc!onnBcl 't ·I_~ a~:h:,..rnatorJorn ttu~ c\[iinlder ..,

,&,Ul

~~'~~~'n ta, ..;1;1-1 R' the h el: rl from the

'~n,
."[~j

.9.
"-J

head attachment

bra eke f'. and re mO\lr: the

removed I~~ rll i.- d er bloek. it me y need UH~ tapping to 10 (lisen it but do not uy. 'to e
1"2"ol
l~ l.!l~.

~-~'f'I ~~JI_~.

-It...:. I

~i,~ to:l 'Iii

l~

l'~i'iIoilo<'lJ ~I,~
'0;.;;' ~

II 'N':7~ ~ ~~.Il !t

!f:i,'

i . ~.,

• "r pr:1!5e, U- 005'6

-

l'

j-'

b'J; I1,dmmenng: ~ .'

"'-,
~'J ',-.-'_ ~, , -

~-I I'

~ iil!J60I
il li 1"

d .ive,belt ..
I

,6 I'f rerr~o'~iing: ~TI.5In~falkj lnltth the cylDnder the S

hefJd d isoanf1 e ct lh e vacuu m hose flfll m the inlet mani ro:fd: ~~nd th~ ~(~Cft5! h:~ir8tor "~,t!ble Irs~ d n c rna k:e c~ble i" ,al PPIica bli Ie) fro rn the carbu rettor.

th e 9 asker
J'

iifI n d.

i;~!t ~e I®Mtgi E! is; not brei fig n

a',-'., g.... Uf-F" 0 H 3!•..

-<

ICDnrajn~1~~ end 6 Vt.~ill'be ,Afo ,,3 c,,#nd:a,r lni'fJ.' r ,~nd Eitdl~UsrIf, :.;.spew:: ['~~i!r ICon~iners ., and 8 w' 1~1 l~l(J4' c,Urde,r bo

dis 1111 a ntlle:"~! cl ea n th e p iston owns ,Bnd block tace. NOle that the eylind r head bolts

ohta :ined u~hen ord eri ng th:e c.yIinde r head

Igaskst set.
~-'. _ ..~-. ..'-~.' ~ _~

m-. ~t rial'

be re-u

..,~·t·a new
- -_._.
..~-••• _._

,<0

set 'wi~~ need to be

lnm,t fl1nd'
~I

ftd'llaust'

re5pec~~~r

Note ':l he: i~h~!Ck n[.\S5 of a II :~app~t cll£far 8 nice discs, t:ron", r.~:os~ l' [ID ,S WQi' use d~,U:iig
ji\j'am~e~
~ lfw-~_ 'IJ~~ ~

1 D I'S,to nnect t.he ',~T leads f rom thl~ 5 P3 rk

pt~g:s,

!ILIl

'll'i'!Jltl
'-'

i!

4,11' Hl~~.~.',iII':I';,.....&fUjj~.L.ot" 'rt:Anp',a!lI.~ ,. -Ii.' IL~r:L- ,,~i e; U:fl aut t 11 e ta ppets one by one. e nsur ing
IAtHJTIJl~
~",I~I":
~/~i

f:u,e)," injection sqlu~ppe.d engines'

,3 Detach the injector
I

~ne~5rom the 1c.~'Und r 'f e

tha t
C-M

they' a. e k ap'~ .j n thei t: eorrec

I

t oro er and

be returned tal their or~glinal bores, '1' P lace the m earn cont.~ct 'Surrac e do"~~'riL on a clea n shoo- 0'1" pe per es they are rern!J~ed, ;9: In §pec'~ '[,h~ta p petS for '!~'ar t:~ndicEJt.led by ridging on the ch~:lil.ns~rfacle)l, pitth 9 find c'r~lck.s" QI T,rapp~ils can~,ot be l'ISpla iF. d and L worn,

hehSd and IJ(a,C';;>lti~~, i:ps arld Qlid them back cl l[Jut lOif 'the ·'!.l~'o ~ ~ 9 [)t lsc 0 nnect '[he in let duc,[ at the. fl e,!(ibh~ has e connect ion to: the throttle va i'Vie!holts Fng~
10 Det3ch the 'vacuum hoses to 'the Ihr (E1i'(:. \1,alv hOL!sJri:g, ,and at the! three -'~i!1laly en nnector' e! f):f) the bllliki ead s~de lof the cylind~~r head. F(l kI I ·ac k and serC U[f~ "[he hOSHS ou t of lI'~H
l

_._._ .. _._ .. _ .. _. .-- ._.- -- .. - .. - -_._. -- - -- .- --- .- _ .. _. 1 U sing a ,:Nlm brush. scraper an d s]~ee~wool ~ Ic~!e'aMI al ~ car bon fro m 'lh e clam bu stio n
_

.e.r. ~.~-~. :. - .. :-.. '-:.',)_ ',-_ . .. ._.. ~.~.~.-- ... .~.~ ~.~ ...~.~...~.~.~.--:.'-:-'.:--.:.--:.'.:-'.:--.:.--:.'.--'.:---.- -•••:.~.._- ".' _... ~.~. '~.I' ~ ••• ~.~. .~.~ -- ~.~.-- ~ ~ 'I.~' --•••~ _. ~.~.-_ ....~.~--_ .~. .~ _.. ~~.~. .~ -- ~--•••~.~ -- ~ .. --_. _. ~ ..- r~.~....~.~1 .~ - .~.~.
:-'.:- .:.'-:.'.:-'.:---:.'-:.'.:-'
~-~.~-. ~.~-~. .~-~. ~ ~-~-~. ~ ~-~. .~-~ ~ .-~ ~-~. .~-~. ~ ~.~-~. ~-~-~. ~-~.!

~::..:-.: ::::. ,;:.: ;:=:;: .:;;. .; .. :.-: .. ::;:: :;:=:: :=:;: ::~::; i:::: :::i:::~::::::: :::~.::~::;:::::: ::~:.;;):.~__.. i ,~"',-.: .. ,
'-:
~-~.! .~-~. .-~. ~-~-' ~-~. ~'~~. ~ ~ __

.~.' ~-: :::::' ~::: ::~: :Offef-~1aWI·::::;:::::..::.:-:::-:-:.:~ ;:::;:::r: :~::: ::r:.",--,,', ;:::;. an~~: :_=~ ':-h ~~:: :~::~ :::;:.~::: -~.:-:': ':-.' ;:::!: ::~::. ,.~;5:' ;:::; ,':.;
~::: :::':: :-~:~::~' :_.:I.~.'_~ .~~_.'._.:~

~~:: t~1j~(:a-'::: :~:i! ~:.:!::tni~: :~~~ :i.z~: i'-~;~~d: :~~ :.::~:; ~~:' ':~r:
_.~-.-~. _._ • ~ ._. ~-' ~ _ .-~. '_! • e, •. ~.• -~ '-~-' _

..

..

-~.' .~'. _

..

..~-••• _.

•• __-~ .-

~-.- '-~' .- .-

~-' ~.•• _ .. _.

..

..

..,

}I~.

chambers
!;"i,~ ~r&;:I, . . ~

2: The! \~'l:IIV'e5, fe' not e,Ei5~T 'glet 'out u nles5 rJ a to suitab~e'V8!~~~,e' 9pring complres90F B avai~[-1b!@the ·Colnets and spring 'ca PiS are 5 et 50 tao r down in the h ead ~ (i~ Ion 9 Ie la\t"!Jis ",6 ..... -.1' ,.n.1IFiI 1-" (Fj; ~~V'i'll ..... Ai"i:"Iif"-ni'\5e.:~.n.11I" "!iI.n~ ·fr, mu' ~t' t....·e J' Vo'I: ~t"'! U.
1

,~, . lk.., 'ou.nd·· rf}(~~GI:!J,50'1. P or s. Re'mO'iO~'e spa rk pi UgSl tor e!eaning. the
~

"lJ'1f

U"fI!Il,."'·ii:!i ',",'!&Ii ~"" 'W'

ill,,;! '!.o

faces
0;;;;'

oF

I"

,~ 'I;.

'way.

Bec',8use

m'1J5t be renel'~~ed..
'E".s.mll;nai!;OIlI
1j0 R.elew "0' Set'Uon 2:1 fin P,~rt A of th ~s Chlll, ptler '\.~h,U na:t ~ 51 nj3 ti1a1t an eKcha nge eng ~ne!s Qr c ~ri:ind,rar heads., 'the c,am.:llh"l ft :is sup~ led '~~'ith aring s h ~lis r nsteld O'r run.ni:ng be d iree tly in he lead ~nd blearjr~lgl ca PSI.
E~chang-e units suppi%ed

11 Dis.r:u n I. e:ct '[he IDtt! iI:i ~ tJ! ~ ir va i~e Ie~~d fro .. t he un clefS ide 0 I the inlet mani'fn~d and 'the a u ~iii~rj' ~.j_ Y',ElI~~: hose 10 the Jie~d~_ hOS13! e on the throttle lI,alve ho '. ng. 12~ D ISCOO:rI Bet the ;ger~"o,V,8CUU m ho 515 ,f· om
\0'

~~~."'ii " ~!O;;,;!I;,I;I;";~,~II'I

:_

.....

1I~~~iY!'

~_

1;,

.'.'

oiiIIl!.

~., ..

the! 9_ "@r1 Ic.(·n'lma(~tt)r on '~he-rltB.~ibh~hf()slp. Olr! the thrlltt]e hr~5Ing. , I l'f a~r conditi:oni'ng' i's -f~UedJ delaeh the.
h [11 ses from ' he au)[ IIiaf)' ,a,~ va l~l)e mnd ~u be r Iconne-ctio rB.

brJ' V~~jV mS"I' h.aI~B an urnde:f\siiled ICI<Msha:rt ~rvtthc(ure~po~~ding bea ri 119 J.he~ '5. \~i en~ t:1~~ is the c·a'~e~~ ~ h t the c.amshaft '\~i-Hiha:ve :8 )i'ello~'~' paint 5~oll on. it i3:ocithejDurnal diat1~le'~.er be· 2:5.'1'5.,mn~i.An will u nln a r:ked c a unshan Sli P plied \~"ilh be.a(fl9 5h~: Is '\f1l1'illbe IClf' standa Fd si ~e lI~Jith ~ jo urn a'l
diam.eter of
26.t[I{)

m m.

Rletil Itin:g
1i'1 RleFe'f to, Ser.'tiOn 12.

:.:': -_. n1easu re 'the, d i~la nee bei.Vlifeen the C'iav~~and i -- ...':.:':.- i'..i·:'.., . :~', ;·~2:'£'.'·"·~ "._'.., 1·'~:D et~e h the fVl F I hooe a.t 'the 5 e f\f"O h05e _th IE!': '~l2B:ive5 pri 1119 e ~rt and curl the tube- to ,8 ! ._- ... - . - ...!.~. s ~.~.;.~.;.;. . . '~lla~}'eonnel~tion", c oS ir.a b,~~!;en9'~h" :3 The ne:~ts tep ~s "01 IC ILl t t"'~'QI win dOi~iVS of 1 S De'talch th e w iri 119. on nector f"ro'm the ro~d c start t~'ahre. Sll i .a bl~lesi ire (apprlo:lf.. :2 S rnrn long: and 1G m m, '-.ei "~,,,,,i!r. 'i., ~ WIC. -J" ~n0'Ppo~fIje %~es O~·~'~;le ~i............. Th'.e ll~~e [UUi':'::, A,ll ,engines' ma"JI th e n be 'Js,ed w'ith the c!()rf'lpres iOE' to 1S ,Ramo ve '~heti m'ing CO\l'lSr :and lIIl 3 ~e carver ~ 1~'ltr,act tt coUets 'from r:;.:ae'h ilItd1tJ~· st@.M in then disc Q m1'tl ect til 81 tl m:~ng be It fr 0 m ~he· tu rn. Pla~~)e the lJ'a Ive spr ingsJ col ilet. and canl!;.;haft 'Spree IfE!1. s eats ~~~i: [he' :[ ppe'( ]~ the appropriate .h ~ 1'']1 R:emo'~e I' he Glarr~shalt. ins ,.' pit "cJe el!ep ing th~~lm ie Sltrictly' '[ogle ~her'for 18 RB'nl()\iI E tie .r:ylin d er :~1ead bo I 51. These H3UUJ ngi ~ 'the ~,~h~e l:,uidiJ 'ttorn 'lJ!Iih ie h I'h fi}:J n '~II~~i',":; tr~ :(h.'a I ~ -~e, i. ~u.,.~iI:,~li'ii'Il"LI~\1 .. are recessed in the: '~~e~of me cy~ I indelr head '1,<!:I\..,. r ~ ~" __'" I 51 '~J'
_
.,'
I

s pi i't, '$ u t!: ie,ient I~"., et, abhe 'the C Q ~Ie'ts to be tOI :l"Iernav ed ,and rnrr~en,oo. IF such, ,3: too:1 is 110't 'to h~l1d then tind 6 piece Ii)': s'~eel 'tube o"f aDCHJt ,2;;6' mm in~fde d ia meter ~1tJI~ h wi tI '~1tO'l€,_ the ie 'U'8h.re ste.m: a nd press down t " e sprin,g Ic'over I!" i~~u~s,tra'lion~. _'_.'gth:'wi I~de pend Ion The : th e 's,ize of '[1""1 C ofllpr ess; 0 r so 'tlit tn.9 e c,ompre s,s o:r oVler 'IDe e:ad '~"u:11 e.!li:tended~, y
1

I~~

,0

0;.:0

,and am

s.ocket-h ood bCllt~. They m US'[ be re mor.i!M!d u~i 11QI:l· I[:o-rrecl sp,lirwd tooll.
I

¥~'~

-'(I

!lU! n'Y'!U' I

A,II' engin,es'
1i Ir the ·{7~dindef'head is bei~n,g f€.muived: 'V~ith ~ the lengil ne au t lof t he 'v~h ich::~ pro,teed from pij rCJgraph 1'. !1 th e Ic,~'li:nd:er hea d :~s be ing ~li';dllQV'ed viJith '~he eng ine. in iJ:hle 've h lei E:. il hi

blo Its, mu s'l be u m ....rev:J~,din a p_llo:{Jress~\!i f! :mit£) rn~ rand :i 11!' t '~re: : n "", reverse seq u enGe to' that sho\.~~ "W ~f n

11 Th e

cy'l inder

h ~lld

tigh'enin·g ..

• ;.-.;.

._- .. _- -_ ..._-_ ..._- -_. -_ ...__ ..._-_ ...__ ..._-_ .. _- -_ ... -_ ..._- --_. -_ ..._-- .__ .. -_ ... __ .
'.;;;.'.;;;.'. ;.-.; .'.;;;.'.;;; ..'.; .-.;. '.;;;.'.;;;.-.; .-.;, '.;;;!!I', ;.-.; .-.;. '.;;;.'. ;.-.; .-.;;;.' .;;;.' ~;.- ••• '.;;;. '.;;;.'.; .-.;

._.

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._.
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.-

._.

. ..
_

..

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. .. _._
_ '

..
'

._.

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besl :r,(imorved
tn., nifolcls.

tlh ~,e in~tH ~ nd (X h a USl The Ilnifolds can 'hen be

~I

-:

--

.. '.: '. '.:.' ::.: .

• I • _ •

detla'c:hed 8fte f' re mcr~a I 0 f the IC1~ilner hea d d

but note that IaI speewal tool is re '_Iu'ired 'to r1eie'ase! (and 5ubsequenUy rec'oone!ct) the
1iildt'M FlIII'Cl!iiUT~~

... . ................................................._.- . . --. ._. .....-_. - ._._- _. · _. _. .- - - _. '.' -.. ._._-'.: :.' -:.' '.: .. _.- ._. '.:.: .:.:. : '.: :.' :.:.:.'. '.:.'. _._. _._- . .
-

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••

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r. ' ••• '

' ••••••••

'e~>thaus:t drnNnoine- to ·n11anHo:~dfI ilnne retal nJIl-:I eii P$, A, 5pl ined ke'"l1w'j II a ~ be Ire:qulred 'ft) so
~ ... !
l~

!I

I!~

!!lit

u ntdo ,a nd '(i:g tn.en 1l1le cyl inde' h~ad brJI~S, 2 Dils[:onneGt the: batt.en,' earth ~:eBd Drain the GOI~lling 5yS'~e:n~,r ; en di'~,c(~nnecl oooling the, ;9irlfj he,[1tle;r hoses kenn lhe~.,}l1inoor .. ,Bad.
i
~I

i 0 i5conne c t the thel'mOI5N~ itch and O'i I

J

"12,,2 ll:mpri01i sed too~ u:sed t'll [iemo'~e iU'Id

ref:iil
tC(JII ~(s '~O, Whdt!!

pr.assure: ~;ead 'It:onnelc:ti'lIJn5~

sle IDS

1 Zil 12,3

~ns fig a 'v,alYe: imOl the cyginde1r ertl

Z 121' ,C·
• : -: ••

I"J

]["!l1

he~ld
,4 Tha va Ne sprl ngs, frlU si be ren ~;~~~~ed if they' ,arQ damaged, diSitlDf ted or kn~'ljjln 'UJ h,a~'Q covered 18 h t(1h m ":IeaQB. ,~"trn data b a s to their condit ion M'/le you r V\N de 3J ler c h eck then' fa r Icorn pression e"i'ci~nc,)f using a c(dibr,ated 'v8~.~e 5pr~ng compresslor .. ~ The vC'~~'YIi;l shou ld be clea ned and check d s for sig ns of W'BEH 0 burnill1g. W . ere thi:s has ~ ~ tOC Ug"i~le ~ the Ii.' 11 (!:~ v a,~vemay' be' W', 'gfiOU nd on d ,~1nl'e~cI'"li: e J ,19des Ier. EJ; haust valves mu sl n
I
...... !I~j

,i

str a:ighl-, ed g~1 ,~Iong the Icem re o'f th e nintsd ra ce {iF ths .' ead. fVla:ke' s uta there no, rid'ge.:.i' et the extreme lends, and su re' the c ~eatance ~~th rel~~rs betwee 11 e ea c h cor nb ustlo fll chsrnber head, Th~~5~:the ,8're\a '~~there the 'arra\"~est p~,'.. of II . e cyUnder hs'a" gask at comes a nd '~~vhef:le'he g'8S kE,t i . most Iike I," [0 . a il. I ~the stra ight=,~.dge is fir mly i11 ·lac6 a ncJ f$ler's in ,8K[':005, !Of 0.1 rnm eeln bel put between the hea d ,81 d th eo n the mae are mea

m m'S be as sem bl'e~d to, the v;e,I:ve stern (see: nlu'slira.tiDn'si)'~ -t"-I' 'd'·COI~~e't- ano~ r I) uIng.' ~ i , "' ~ !lIi r'il sserru '),!,_ e u1,e, S 600n,· ·2 them careu~y tog'fJilelr in pi aeBl ease oll~'the
~~ ,Ii;
1 '::0' -

I'~""

I'

- ""~

.,'

'

eompressor

over -'he vah/,e' S'iem' ~ nd ta p the' stem wi:th a hammi~r This is EJD ensure '[l1at th ['! oDl1191.:.s sre seeted co rrecliy. I~rhe.y' aue th~Jt 'V'Ji n nolI ' 'nmlSl t
1

u n:UIthe '5pr.l Mig seats ttl e eo IIe 5 hon'le,. RelflO'v€: the C'~lmlpre'5~or, pu:[ a rtag

not be regro und QI1 the mach ine but ground in stra ight~edge. 'then the hs,ad should tl!! taken by hand. On eng ina's, fitted w~th hy'd rau'I~·c "0 a des le~flO servici ng or replacement, 91 Ii' t he. I~~,"'i er head SnD\1"J"5 5[g ns (I,t ind 'lapp eta V,aJ hies sho u~ not be re -cut as th is d '¥Iii n ad versel y a lfect the 01 peratio 11 IOf the C'f,ac king." ha ee it in'SplecWd b~f yOU'll' VVi~dealer

teppets, ,6 '~Vearin the ,'ahle gui dB'S n~ay be detected by -ri'Hi n 9 a new 'll'a lve in the 9 UJ ~dle and ehsc,king: the a moU~it. that the rim ,of :~ ~I'al'~~ he '!jJiiill: n~I~; SidE'\iVays 1w;1J ,,' en the 'vop of the \ilaiue stem ~:5flush ~!ith the to p' lot the ~I,ahfe~ de. gu' The valve roc k ~in:lilS, are: g:ivan in the Spc-,e.,riflcB tiDI1S. N eVt~va :~veg- u ~ 5 must be de
'fitted ,~' rea mad nd
V,.'j,hIAS.

to a S15e5'5· it'S (Iondition tor reuse, '1 g' 'VV~ recom me n d th at til 18' va lve stern oi ~ sea 1'5 sho ukl 1"~,,a,J'5 re newed to preve nt be pos si ble h~gh ol I conSlImp11j on. Pu I~i'9 -~ff ~,e .. o~d sea I ~5 s:imp'iE' '~"/ith ller5. ~J!itha paJcl~etO[ p neHMoi'l saels is a srna II plastic sl av's. Thi'5 is
l

by yo ur 'VVrJ' d~11Ier. J Do not spend tno I'ong gr ind~ng in the

I~

IE:}n. M~!ke sUire bOlh surr~ cas ,arle c ~:ean,~nf, .'Igrind~ _Q P' 'ste onto the va~'~n~ e~I1~:t :3 n d us ing ,a su c l~ n, C U P'j wor:k 'the "i- if! Iva 'r..J!!ii :[h an 0 lose iIL9ling mot I"on IU~lng: he va ~'8 .' waY' fro m t lhe 5eat occasionaUjt to SlOp ridl~fiflg. C~loon the s,le,a't ,snd u-a hle IrnlquelnUy and Cc8iTY on until ther:e ~5 on e\~'en !gr\B~' b8nd on b~th 5'ea1 and va~ve than 'w!'ipa aft a~~ the p~lS~SJ~ 8 Thel surface of: the n5Bd must be checked V'itt h Il, str ai 9ht,~edgt!and f '6h!H" b lade. pl~,a~e

If.' 'Ih~' '~Ja:~G: s,eat ~ l:lid i!a:1ve a!H~ noft u atisJaclo ry at~er 1 5 mi n utes lh~:n ~OtU ill probfl bl y dOl more har rn I' tilt. g.ood by Igo ing

'fi'lled o\ter- '[he ~J3~V~'stern. a nd ~ubr~tam!Ed.The ~1E:a I:sh 0 U Id the -- be pu shed over ~h pi a srdc e s:~e~e. Ulnti~ it; sears ,OJl :the' Igukle 11,·s Sl10lfid be d I:) ne Mth V!tV to'ai: "](1 ~:04 \.~hich nts snug ~y ,round the outside, of tht! sea'! and pu~he'a it 1011 5quarel.~r. It- the sea 1s. aS5em:b~rJ wi~houtthe ' pl.a 5'tk; s ~ee ~!e; ~.t Vl:rU~ ,,", dan1,~ge.d ~I nd 0 ii e IC'Orlsum pt ion will be'c'Qm:e eJ(ce'ssive. '11 BeFore re 8s5 embUng the Cll'lindlsr hood, ,check. the canditJo - of 'the ,z~ams;h(lfft
J •

out, 'Repeat unti~ (III eig ht \~~I:'~e'5 re in pesitien a wnthe G~'li ndsr head. 1,4 R efi't the tappf!ts ~nthe bores rrom l~Jhibh they carne, lubricating them :~i:',~lie- 1!1~'lh ai ~ c lea n 9'fl g'~nel ~Jti~(,s,ee i:~U5rlrlaiUlln). Lubricaftl9l I Iht1 'C2UI11rsharl bea rirI.Q surfaces 'wim oi I: and nt ... lhB ea mshaft, posilionoo ~M}1hal- r~ 1 tC,~iinder a cerns :,.oint uPlN,ards. 15 Fit a n e.w 0111 sea I at t he' sprec ket end II -i. e ." -~n, ,~Ji.t, I'H~1~ IlUL'J('OC:CGII ..,e, '~'I-' be lo.,l.eeenngs,' set me ';:),n;[;IU. h'il P"'"'"~·I"~:iOii1"io' se, l!iu """ "" -"11 ~."",;:o;iii' '"" III be ~rlno ~'''''''P'~ ru;'R;, ~ ..,! ..,g:r~ 1l3l u~· u~
I
,,! ....."
I

,i,~,-

ti yllJJl

"I

~ ~ ~K.:II~

." ..u;~l

I II ~

b~

_I

It:;

~l, ~ ~M~ ~,•

~~!!I

dgh1Jen~ng the nuts h1 a diagor-ml patrern until the sheft [, ~npiece [see ~Uus:tlriajltifon'),. N[l:\~l in :st:a iI 'ttl€" other be' rilrlg c,sps, maki ng, sure the y 4!1 e th IE! rilg ht '~~~'la'Y ~aund (ml;al rlks t~~rd s the d r'ivle p u:tle~t) and tilgme n 'the C1:1 ps dawn uSlng a d lago1na i: paltern to t. he' Sp'E!C i: -~ed
,'Oflq - B"
J'

1111 Lea Ii ~ ne'w S

'bQ

Opp11)51:te lend

rub I,Jler the spr{lck.let.

5-B ii'~ I

,,11 the

'x'amine j~ [hen ass,enlbiy oJ '[he he'ad m1ay c,o-m.rnenoe. Inse rt the ~! ah/s in th e oorroc'"

t2 ~N'hen aU ,'ompone.nts

ha~rre

belen

16 On elng iMt63 equ:i pped ~~ ~th~him buc'kel [3 pp:&['s. adj US! th€ V~d'~IE'(~lear,anc~'S.

Ig,uhje,

outer c.ap~ ,a'3,serrfble the ~'a~v· '~pri'ng Ic,ompressor and pu55i bly U,e small h~ and be lel')~'n p'feS$ :~'h ' ~a,II!:/ spri:ng: u nti I the oDllets 8 B
i

nt

'U'liI2'

inne, 5eat~ v~I'\~el 'Sj,prings and

ModUiiC8liiOln:
~ .£."

Fror1l ,At,~gU5r ~~ f),8,:~~ ,~IJlarger

',b

Di?£i I~~-J~'·l:O/~l~?~,,,, an ~rit'·iI" ti:r'I'~I"~ - '1~ !#! .'..l .... "!;!!II;,;;;s~!' t,;-'l",I1!!!,"",,_ :J i~ Iii Il,o;;1i.f _...
,K·~III!'

sU'm~l1.s ~ijrted ~'i 'Ie,ll'"e-:1' j.l1'!Gr,eaS~JiJg e'r:g,ne Vii i ~ capaC'flty' ,I' flene~~n,g '('he Slump,t ,e,tlSILH'16' ,~fk1<t
;j"

b~

nIA,~nl~!J,l'~_
ib'l!...,

il'tW' 1lr'4ilrlil'
.1

, 1

I~ 'engule '~({]e

1'5,
I.,

In

ti ~e 'ij'ei lie e 'lJm'lenC.I!ii'3,ln

k·

I 'L

~..'

b tne:

e 11'91~ t'l iI, N IrJte' th81 t h e' 5u,mp pI La 9' has ,Bn i .IE" -r ing, ~I~h ich must be r~~fa ad (sB,e ew

o..

illlu's~ratio")',
e r~lIl1 k,C,(:l'5e.
e ~;.

2 Undo ttue the SU m p

--·i·

SUll
frIO

P re{a!~',ing bolts a .d rc!mOiVle

m t he
~J~-

IO~~i er

fa OE: of

the

reta ini 1191 b 01 ts ~nd liQ\IL~e.r he t

._"'. m tilSI~i."l,"~ '. 9 ren~ I!NBCl• so 'b :3 To freiTHJi~e the 0 iI p'U mp, u nd Or
'_,;.-

Remm~'etho '

5lJn] j:J. gas

ke'n ,,~h ich

':__

e tf.ir, ~

PUln1 pun

it

1,l~1 S;umpJ gil iP:um~pland oi~ :~ifter eemponeats :~ue~ i:rirectlo:n lenglne!
!OJ

JI-,--~-==~

01 iSN,t

Oi! pump Icever 'w~th P.I [e55·U re' rl!'nef: "WJII''lfe'

IO~r-in:gi----

Inla

';'f'

piPit, ~--~~~~~~===~-

i -:.:.:.:.:.:. i' j.:.. . -

! ~.~.! I;. I!.~I I .~.!

;'._~....£-""-~ "._ .. 2:' .. . .....

.:~'
..,'

.'

."'"
'- ....

..._ ..

-.~ lELoooow.~ ~

-_
.

,.

complst e v~l'iUiW the oil streiner.

I

pick ~IJ P pipe an d

·'1 II 'fl'II,1'
I~W

I a

"llfl_!

_ lII'IJ-.,n .~'. '

[I. [~

: ~. . tr9-~~~·lit61 _: ~::~~~::.::! ~~:·:ri~1~:_J :I~:~~'·~:: .::_:~ r:<:_::·i.:~:_:_:·::~~~:· ~::.:_:: ::~.b~': : ..~}.:~::-::: ::~'~:_:.:-: ._:-;:-: ll:.'.'.~'.:_: .::~.~.::::. .... .. .=~ :~ii',: 1 :~:I::~.'.~:: .._~:: 1............... ._,.. 'g.
ii.'1i-iii I.,. .

-:..., .~:_: r;';' '§;tlWVL~'

• I •••• I III

•:.'1~;4"':

_:.: ':_:'.: .c.,

:::: :::::: :::;: :::::: ._ : .c, :_:_:.:_:.: .:_:.. ::::::::::: :_.:.:.:_: :::::: :..::: .:_:.: .:_:. :_:.:. :::~: :::::::::: ::::~: ::::.: :_:. :_:... :::::::::: _:_: ::::: :::::: ~::::::.:: _:.: .:_:~:. :_: ::::: : ::::::::::: :::: _::

Aj' :,\.\~~.' "'l1lu-ebnlrnB!C1tlll!l·~It,tiu~.:-:... :•. '-;:.JI.' : • : '-',' .:•. '.'-'.:ji. ";'.:.' :\:-'.~! .'.: ~:.

_..... . ._

:::::::::I::::~ _ ::::::~::::_.. . _ _ .::~: - ..:::I:::::::::::::::::::::::::::::::::~::::::::::::~::::: ::::::::::: : . : . _. _. . . .._ _... :.:'f.~~lr!-: 1I"_:a~,~[~~~I ..1 " ,--::!:Ii'DI-. ~I' ~In'".__ ..__ .. :I'C':'I:~~ '_~"'f.I~I ·.·.11,.·.. [1 __ .,. -_., ... I'~' .. ...
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3,' LtlI,

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'll,!llJIlH.

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'11.-1 I-.iil lii.'1i.-.II i

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4, To refit the pump, en sure 'lh at the m,~ting races ,3 re c~,.~n, ~oc.a i1: in posldon [(u1d'fit and te tighten the 5 ~IC lIr~ .00 It 5, 'to the sprac-ifL' d n9 torque"
61

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I I~.~I r:!.1 I I

. ;_;-.' r:

;:111

" R el1lCnte 'the ~~ Ind er head. 2 Rlefr~ovethe 'S Lllrnp.

l

Locate the ne\~' 3U m p 'g[E)sk et but do

not

a p'pl:V'[an adhe,~We se~JI~ntR:~nt '~hesurnp and tigh're'11 the iie:t a ini n'9 bolts eve n I.~' to the spec ift ed torque, 6 Re'ti't me oj I d~ajn p~ '~I!j''i'U!.1 0 - Iiin 9 [an d ug tllghten it to the: specl t[ed: ~orqLie.

3 U 11 screw the l~N.c]0 i[ pump reta ini ng bolts, then IlmiVer and re move the p Ulmp co mp ief.I.e ;~vi oi I pi:ck ~up pi pie from the c IIankc ase, 1.11, PI:aee, :~ o n lone side [lor G Ilea n jr~.. Ellnd
~

in~pecHon. A 'T'..::!;, piston b ~Ind-' ri'\nr'ri'O<"",g,'~lIi9Il'ii' rod rem IF"i,u'Q'-1 ~~.! precedure now' tol hJiSiJS,iU1<!1 given 'fOF 'the snlaUle-r lengine '~~riants in P - t fJ~of 'lhi's Chapter.
. ~.~~ '~~f!WIl~!II

'the fJfilj£l~ne has 'UJ be n~=movedto rernova tl, .. ~ c.rr~.nkshei't[,~ the C'y:~inde_ head, pistons and con: ~.'c'ling~ilDdiS Ic~nlbe i~Jn.n pt)s;rn;-cul" i ,2 ,At the n~he~ end! un~ro and re'mor.u,. the s ix bol ts 5 ec uri ng the oi I ~e~I 'n~ e to the ng

rOQ1s,'rron~'the cr.~~n~halt.

1 Di:scon nect the pist on sand

r~ooo tha t a Itoo1JrQ h-

C onn ecling

I~I ~.'.

IlU~y~j~ljl~-~1

~.

!bf~

YI

;~

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'!Ell

ern nkca SJe~slee· i1,1 strati 0 :.). .~~ h dr a,,, the u i.~ 'fl··_.ilfiD.~ [~~a!~:nd naske .;~ ':;:;!!""" :::;.l ~- ,"",!:\i Il.. 3i Eh;a~m'ine:the n1tdn ile~ring tapS" [t VLf'm be
.;.oI',,-,,_, ~~ __ ,

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,"

,LOIIL SEAL

L INTERM c:,CIATE;
SHiA,FiIT

seen tlEit the' caps are num .'en~d 1 to Sand that d1~number ls Cirli [he side' ,of [he engin~' lOp poske tbe 011 purnp pt)sition. ldentUy' these numb rs, If the~y __~ obscure d, then merk he '_' IC~.p Hfl:t he sa me V!Jrtl y as Lhe I:::.anner:ting rod ~ h caps. B~ 0 re remo~lngl r- ',.._ aps, pus h tie ,.._ cI!l:r,anksl~n:lt t·Q Ihe r!H311r nd check th~· end !fk~Jat a us~ng a 'fee~erb lad e bE't'l3>ee' ~he thrus:t!jf~la'sher rlanges on :~~o 3 main '~ealfiMtg and the Icr,anka.hatc tll~~ebi1ee :i: ustr ali lord. It must not b _ IBAc6ed the spec ~fi'IBdmaxi mU~T1 .. 1 The ~_termed i~te sh,~·ft can only be r ,- Rernove !thr:. be!aring cap n:~f~a~ning belts, 'front the crsnkc a sa 'w'ith th e eng:ine re m eiva the be ar~;n,g Ic;a ps and, I itt out lhe~ '\~~Uhdrawn ,(".~ '''~'ru·:",;r'liv!)i;~~h-91tS from r£'I;"'5.lCh-":~d-~ o·f tl _'1 pe-.n"t't~ n;;!moved n om tl1lEi; ~1{~hic_ !U~ _~ 5. 11".
l
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• 'if" r. rnaloUrnu n speclille d -matt n~ .5 Unci" the 'NIU se,al il1g n,EIIl1ge' retaWi ing ool5 then vJ;;ith·r~~ ttl 6 i:n:~e'rmle('ia.te' shatt, calm p~etlE! '~~!iUl sea iina 'f ~!a ge n I~''S'B~'
1

rnudeis and the ign~tilO d islr~but,,,_' n 4 B e~o~ re m o1iJi ng 't h e ir It~rrned ~ e ate sh,~~'~ t~ ~heck that the en dfloat does not e~ceed the

th'e fuel pu~n p on cerbu rertor

fiB n~g ::I nd the, O =ring must be reneV1~,ed on e· reassem b tv"

iillu.!stlti tions~l~ 6, \Mithd ra~'J the sea I:i11'9 fh~1 g'e ~ n rom the w:n:8 rrned i·ate shaft, The 0 i! sea i ·~,dtlh the' in

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mai n :be8rr~1 g:,

.2 Rerno~e the "L"lTlhtg helt'-

1!5 ~:3 C~l~ck ing! CJra'n k:sha!1t Ie ndfl o,a;t at No, :3 main bearing

16 ~51a I ntermlediata

,shaft :relawnin!g' 'Ha "ga.

~,aITOW!~1

bolts

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12 Car@fu II)~ prise out the 1!Dl'i~: seal with ~ § .re\Jvd ['1\(8r- 0' stro 119\tu Ire a nd '~~·ipe c.lean Ithe bet~Neen the Up 0'( the n e;",' seal ~"J'id1 m u hl... u rposs gr :<f;i SIB; t hen Iclt lve ,n p §iqu.ars:~J( Intlo the houslnq us~ng a block ot 'wood or su ka h Ie 111eta I tub ing. I~ at an
fE!C83.s I~!ireml i~~u~-tr,a'l:icilnJI.

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possl bl eJ

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VV~ 'f itti n g :5i,1 ee:'~~e 0, ,2~003 W' N

,Ef1l10

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~d da E"Mg:eto the o:ii se,~1 ~ p . i ,4 Ref~t:he dfi'~ileplbteor clutch .

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Timinlg bE!lt

IIUK!I

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1: 0 n fuel ~necr ion model 5, an lo:i~cool er Is [ fil"ted be,twe-e n the oil I·Uter car!J ]dgea nd m eunu r19 hra!C 'k,~~., The cooler r~: st be u

rerHf!!\lvad j f the ~n(d~~ fa :i~' ha. s, been ..,... ce n ta m inat ed 'H ith Inletal pa r1'k:,Ie 5~ 5 !]ch as,
I~

5 R·en,uYI~ (he a b e rnator - IJ)gl~t he,r vvith its, d rfvf!lbslt. ,6 R,e;mo'vethe tim ing· bel cover and timl rto ~ be III en sudng that th e ti n1~ng rn arks are correcd ~r a iig ned .
[~.

t .. 3~·
:,

It'(gh'l be the ca,'~,efoIlOVt~'ing~©b\jlair parUal

I

engine seizure. R,enew' it ar"yw'ay :if it: is Uke~:y and rS'n10\fI9 the ~Voodruff krif\L IOn 'manua~ tO eo:n ain ;a,n}( other ha milt u ~ CIO ftan"lnam, 19 le~rba.x: mode]'Si' i. t he be~t ~i ditf"i cult t[J 5
2 To lie rnloY-e tIle Ic:<oclle'r~f~rs;t re,m ave lh e 0111 k)IOSen. ha~ile an ass istant ,£ng:t'I 9 e tOIP Iglsar fUOOf' eMU i•.. ,and al p ply the bra ~e$, lO:n a Lroo r.rl~ twc. !, Dra i!ll1'~I~~coo~ing syst'l9rn ~ nd disconne-ct tr,t}'fl'smission 'no,dels~ f'emOf"e 'the st~arter the 'C.OOIIB~lL hOSIBS frofTI .>he cion Ier .. mlQde I ;:;lln d rs'S;t"il ~.' th~ d.- i\~p-i.ate· r in 9 IQ e~~r' e 4], Re m 'JIve l~heICOO ~er ret ~ini Ig n~Jt and the '~~'ttha su iwbJe: Ie!~\et C'Ooller. ,. he: 0 ~r,iWlg beh~ e:n the ICOOi~F an d B Prr~,~ CH,n '[he ~U '~r-;al olr (-;,::tr~lc,t 1I!!vi~I--: 'VV~ rn lJuncrng rnus't be nai1e~~ed., tOIO!: N o~ :2 t[J 81 r the n ~"~~ c le:t,I11' til e' rec.e'ss p'e
i

J Un scrl9W' '~: e ,bolt fro fn t h~ 'fran L of ~h9~ h Icr.ank sh a:ft '~ii'thdr.8\l!~' pu lIey and 5 prolr;ke'l the ,21,,2; F I:rwhe:ei e:£I!g!,r;:F,ank'S!h;~It owl ioomponal1~-S
l' ,lnjre.n1100i~re

5'ea.

p.iar.e

,4'

s....~Ung ring

't

,2 Bolt: ,3 ,Oi~'~S!l'Jl
'.:Ji"'i.!"Lralil: I, ~Iif!!i ~ aSlltL
rl' _~

nn:oo·

,(OO(f tiD at] n~de$~i

'U'R~ mI, '_H~II~=-!i'!G!J

Vi~~ it,ll.- N.~V~ I 1't""'~I,l'"i;I: ~.~I;;"ii _ _ ~'I ~ , ~ ~l~fk..J!~1 1:'rI~jlli

'It I'I:'I~ Ii:: ~: bile; n _ lb. 1I1;.~~! fILlA~

'n

lS, Re'l1 tti 819: i'5, revler sa I to r the reimo,",·aI pi ce - ural V'Jip'H cle&~n sea ~iig~'a of the the eelS co fJler I~u;>,d O,lj r:ni:lng and: .s:mlf-!·~. the 0- rin 9 rn

~I

,(see· i~~ustr,atiQn)'!

Ic~ean .h~ reoes'S.

5lea[ \lVim:

with el,ea·n enq'in~ oi,!. .~.

e;

()'n c(}.mpleti:o n~,to p,~upthe leng ine 0 il an d G\oolant leJ~o'je·ls. Start U1e a1'gine and Ch3Ck I:(n
v"~

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'~;,~n~''''''
,~y

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'9 Fm th~ s pa,ce oot'/ ..een the !<ips af' 1J1'''" n l~fi\l' , sea I '~iUh tn [jIti~pu rpDSe 9 reuse;1 then drh{e it 5;[1uare:~y into t he~hous in9 u si ng a b~ ock. c,1~ wn,gd 0 r :ill itable :meta I ru b~ng. ~ 1~\!I~:i~a Ie U,S!6 f ~ "tJW t1tting s!~e-v.a rJa. 3.:083., " 10 T~1 lreinCi~ jng :refi'tting: procled U:re [s f] e n re-\rersa~' ()'~ re.[in avra I, E~s'Ur ~ t ~~i'E t n e 'Unl~n 9 rn~r k§, a re a ngned bef (lire refrtt ing the 1'1tni ng

I~~

:us.o ~l~Jtii·~'t·;ng-1·~e,t.:""~e r ~,~ :~'l~l'l 1 I~ ~ 2 Uu~ ru~rn ~ "'"11_ " V V _ _ I ~~ L _ ~.

muJti-purpiJlse grease "her! dr~~~fe it sq uarel "'l irrt.o 'the c~1inder heild using a b!lx: k 'wood or '5U bbile me ~aI: tu bing. 111!B:',nlUa bl f"
l
.'.

'5 FiUthe "5p~ce belrween th e Iip .. 10' the: n e\N'

'

bet[
'1"

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d te:nsaloriingl

n..

'16, The rerna~ning refiUing procedu e i's: a ;·:>-2:'£"'·:·:·:· '~'..-.' !, .. . ... ... . ... . ... . . . .. .... .~.!, f'eVef'S,a I of Fe mtOV;(I1~, Ensure that the r.:~ in~ ! ~.~.! !.~ ,!.~,, m !'i;jI ma.rk~ a re a~ign ~d bef-ore' re~'~:'I1'i the' ti:m'~fig' ng belt ,and lens,ion~ng it.
.!!' ' ••• ' ,

i _. ... ..... i'. ..... :.:':':.:':.: j.:':'

Calmi'haiflf frani!: seal

Rem()'V-e t hel a.IN:! r;n3 ~_lclr tJiJIQether \N'it h it''S.
,

,In fernrl;edlrafa
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l

51h\i1 ft
1

s,eal'

11 R,el'nOV'B the ,aIternatfj r taget1her ~Nith its, drffv1ebe:~ , 1 Re,Mol'v'e :the oil nlt....J· alnd Ion 'fuel :in~l~c~~on drt'"vebelt , 12 Relnlove ithe 'timing belt Cit:)e'r' a nO. lJi m ing , I Re n~ove th" ti illing b!'J i co\{S _ and timing l m od~1 s~,rJ'aB ifJij ~ eoolrer. helt en5udng that ~,he imirlg m~.rks ,are bell " Ie n ,_.-ri:ng; th,~j:t "he ti m ing :mar ks ,a e 2; D i ··conn~,c't the ~)~ pre 55 U re .5\t",th~ ~Gd ,r i h 1!C"~Hmr.:Uy a~igned. Icorrect! y a iig ned. !J ndo 'tlw o'il fi~ter mounti:na 'SEcurinn bo ~t5and " :a H Q Id the c a:m shal'ft 5 p roc~.ft 5t)a' ~·i ry , 9 Hlo]d the interrn ~d t.atle '5 ha ft 's.:proc k,el ana ~rwthdnllW the m Qunting a ntd ga'5k t. ,3 T~~'~~ presS/ure, swilCh can be< uW1~lcrje"~~ed 'Nf.Jith a st:r~l~dri~~J i~1s(trted through one of ~t'5' slationary v!li'~h!iI scr~\f.~dr~'!.!er'ns~fiJed thFOU9 h on one '~)'f its holes, ~hl~nunst:reijJ!j" the blOL and f rom the~ ~Opl'face of t:he rnountilng n .~quired. holes" then lIrrsc.re;w' the b~t ,an{t ren1:QVe the :r,~move :~h 'fjlJ as;ner sproe ket ~nld 'Wnodruft" iljiBshet,. sprocket ,and 'VV'ootdruH' hJey. Ret:fiI.'!IfIl' "[he ~N~1Jch 0 ~ring~ Iom:=Y'co 1,4 F1rse ,0 U't '~he alii S fMj I: 0 r a IlJe'rnat iv-ely. i ,4· ReH l1i ng: is a revisr g~ I It} f lh.a :r ~·ri1IClvaI 20, Rene';!.' lhe (}Ji ~ 59<1 I. procsdure., Rene~ft~ the m aunti illig] ga:5k. [9t. 21 ThfJ' rem ~ in in 9 FefitfLi ng proc ad ure is a ,~.~ .,~.~, ~~.~, ~.~.~ ~ ~.~ ~~.~, .~,,~.~, ~.~'. ~ ~ ,~.I, ,~.~, ~.~.~,~ ,~.~, ~.~, '~.!'.~.~, ~ ~ , '.~,,~.~, ,~.~.~, ~ ~,~.~ ,~.~ n::r~ler'5,C] of r'em O~:aJi; En,sure .that :'·he ~:i ing I m ~~~~31,~: ~~:r.., rn~ riG a re allign d before lieft~tti 11.9the, timing' ,...~~',..:M,.~.~~·.. ~... 'I~~';~~fi-~ '.=.'. ~.•. . ~ "". ,t1 belt -31lnd len:sian~ng it.
J'
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N:ot.c: ~( ,hie

ure 5 'w'cr-e i#l carried (jU~' L1fltJ . ,the eng1ine in t"he t~hk:Je'

r(j~('O "9' ,pf1f)·G:ed ~-ri

\:illn·.~,'li!!'~\.L':~L~f;'" . ~ll!~ Cr-A[ .nl';;:'~'·lgr.l1[L ~'~e"-'tu ~

lFI)'\'Ih@-elld\r1V@lpr~teen d
1i On rna flU illl gear bO,M m,oda,ls" ra m 0 Vl1t [he c.lutch aoo pressure p'~ate., On automatic tr, .r~srni55ktr1 [nod e!~'J rernove the tran~vnisSLon 't~en un b~)~l~h e d nvsplats' tron~ t the criUl~;S:~arft noting 'the kUG'ation o'f the spac er ,~nd sh~m(5),

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Z~5102 Ex,:-cm'·nera,c'f:~t)if oU pump cover 'foj s,codng

·· ..
,ag~lrt
°1~iFor' ~~ o;.;,-~ '!1;.01_

to ?ection 2··?
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3, F:h~'m[CJNl'ttl e' qlsar:s and w a'sh them ~. i:th the e ~ bod')' -n e lea n ,par aJ:ffi n, Dry and rea 5'5-EHi1 ble
tt~8'ge~rs~ lu btk:ating the!'n with
I

··

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I.

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_a.an engine

IOU. rNt'OOs-Jr-e the .b ac~d,a5 between the: gears h

bealri 1\9, ~,f'ttl ere i'~, excess j,ve pl~y, t,hie sha ~ m u 5't be eompllred 'i~i'~th nei~v, a one. t~~ shan the

, Check th e fit of the intermed'iati9 shaft in

~,iS,

~:i:: :if;:~:i~1~~W~~~:::i:~!:~:! i:~:i: ;:~::~~:! ~:i: ::~:::i:~:~~::

.
...... I I .. I .... I .. I I .. I I ..... I I .. • • • • • • • • • • • • • • • • • • • • • ••••••••• ,.

is in Igoad order bu t !he bearings in th e block are \'~JIOI'n, then seek ex Pelt ~d~'ic,e; .2 Check the ru~faoo ~:rf the ca m ic;h dr.hte s ..................................................... hie 'fuel pump (-'Nnere ap:pl;ic6,b~e~.'f serious I idg [~g is p eseot, ~;mfl.e'iV shat i' is, ind i1r.~atocl, a ~ta I eiea ran ce belt we e n 'the gea rs and 'th<a 3 Check ~he teeth of the distri but,or dri ~regeer s!lr,a,ight-edge (tSe~1 ~1~lu~itMti~n). This must 11(;1! ftn scuf ing ,m chipping. C nee k 'the [;000 ition =.J' :j.~:=': ::••,; ,••:: ;:=j' !:;'::t:':'=::' ::;:: :=:=:;'=:;',;:;::: ;:;:1 :=:;:: t:: ::=:; :~~:: t!' ;:='~ :~: :-: 2m-:'[[ITI I" ·-~tn'~jp· z.; ~'~m mrlll fj n-a~1~:.::--: ~~-. ..: ~ or 'lite' ti m ing b!$rt. ~pFOck~t .·~e-c~rs~l 1 S mm, ( ::f::!:~: :1:1:; 4 It is unUkei~y'~hst da mag!! W the s.rs:ft has 5 IFa:U is wId t chec It that: the 'sh;;Jftis not slabk :.:': ':.:' :.:' I :.:': ':.:' :.:.:' I·:': .__ ':.;': ':·1':.:" ':.:': ':.:' :.:.:' :.:': ':.:': ':.:' I·:': ':.:': ':·1':.:', ...._-_ .. _-- .:_:.: :_:. :_:... _- .:_:. :_=_:. :_:.: .:_:.: .:_:. :_: : .:_:.: .. .r,.. :_=,.. ,..''••: -_ .. --_-_ _.~=_:.: .:_:. :_:.: .:_:.: .: .r.: ...z.: :_:.: 'happen ed but I,t it h ..s seek, ,~dvic)e from a VVII in H s bearing s and reessemb e U~i p Urn!p f() .. _ .. _. ._. _._,..-.--... -~.-.-~.-. _.__.--.... • •• II. II I ........ I ••• 11 •••••• II I •• I •• 1 I •• I II .11 ••• I •• II I ... I •••••• I II •••••• I •• I LI ... ~ •••

'w~th a 'f,ee;]er blade '(§Jeen~us'tr,IUonj. This should be 11J1.05 00' 0,:20 m rn. 4 Now pi ace [a str a ig h' -edqe ave:r "hf!: pump bad) EEl 0 1119 ,the~~i Jo~!n ne ing th e centre O'r the twu Ige~rsard measure \{,,1rth a 'reeler bl ~dlFathe

'wn

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Ic&t.:rta ined, Once '~lll5ar star ':5, lin a pump it n~lee n-11 '~l.... t:i~riI pr'fJg res, ses r&lpi d ~y ~ view [of ~~ e~'g ine .n he r- ;;;;.;;:i'..J...... tlL~ r [~,D"". ip..,. 2 R'erno~~'e the ;~~rdOI srnaU bolts .an t21llkl~ ~'he dam aga U'H~trn~ y 'rol~IOIt<;l ._ hJ,~,of oi I pres's,uf'e Ico'~erawa'l from tn-s' bod~'. , ,~;i2llilllnethe: tace s~iniping the oil pUITiJJ repair i5, a 'false ... J il"t,:r, 'l~ ~~iI ~'r ,dlLlY ii'Iii-)' u No. ~..... ~~J!'Iin' ~1 ! 'tl,~ e-canon1y'. lum 1~"Mrr.:.~ ,~I~fe A~, ~~ ·'1
I
I

" ~~~:ithe el[ p um,IJ on t he! bench prl S€ IQt'f lh 'the ca p t!\fith iI 5 crelNd rt'~~er.and c lean the stra iner gauze in fue I. Rlefi I" the ga u:ge 8 nd

'fi:~tingto th e ef1 g nl13 •

l

deeler .

'6 I't Ii. ere i5, an~~d ou bl. a~bou lhe .IU m p~:it is. t recommended ,[h nt a ,re pi acerne nt be

J,

!'~, ~
!Il.~ I~

o~ 5(';:,8 ~ ~n Ihe '1'1[[I ng1IE:' for the ~nllerrl1oclh:1te, sihaH. This rnay' nee·dilene~~·al i~' lh-SilD a~'9 signs, o:r leaJ(ag{~. To do thls, rernOr~'e I!'n~ tirnit .ng~ b;llel'~,sprocket_ _ and w~~tk'd~-r'!:Iiw . I!" ... ell, . t,;i __ ___ 'U! _ _ _ fl t'h~', ·Isnge ~romthe! shaft, The oi i sea:~rna "1' no\!IW' be rised ou l and a new ona press~.d j Fl. ,A,h~f!rJays, 5 The re is
,B n
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n 0'W 0~ii,g Ct .. the' t~ange blr~f !re r c 8'~..sem -ng ![ to the c~f der b loe k b
:it
I~ i

1 Ins p ect the ':itarter r il191 1.eleth, !f t h e'se are c h:~pped OJ vJtarn 'the n r'enfi~'the starter ri:r19. Till So m e'an'S he:[a ti 119' '[ h e rin g' until ~t rna 1be viill1dra~~~n From ~he flyv rh[eet en all:ern at~·~e[y
j

21'~:i .F! yw.:eefJdri~l\eplat:e

~ \

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GIU Inl-8'
,= =

/ ~gf1itiQ.n-~ml1g fRlrk,s,
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how ~a,· 0 't:h is 2lnd ~rou CilHn Iget a n e'~~~' r~n9 tjne.n 'til e job lean be done b ij L it ;s .. e'ycwl d ths, capacit,' .0", most o.Nners, :2 S,~rwo s '$corin Q on the n~ u wile eI cl LI t;~h lac ing relq'U ire 5 ,~ n e'~A~'n y\~heet Do not attempt :to cle.an Ule $C or~ng 'WIh~ s.crs'peJr an ,~I
kr1Or1/~
It)!"

s.plitdrng it A ne\!\$one m us:t the n be sh unk on.

~r you

fn,gline r:ocl~.El'fl.6)~flywheef R ~ 37,10 mm 1ft' BTD.r~ .£r~9'in~' code £1 (, . 6) ii.Lit,jv~i8~:6'~ '~ 42.0 finn 8'" B'TDC a .£n[j'ine COL1e £lV' .(l,Sjl ~ f~~1f~1~eeJ;~ 12~5 JIIlml 6';;1,trnJ!c v

:3 If i[ is, necessary to Ut a ;n1!Sh~V f!y~\tlee'~~[~he ~lgni'tk1+n timing ITI8rk mU'5t be 'm~de bJ' th~ owni .r. The' nm~~ ''\~lhe~d has 'on~y the rue, WI

1iJ~].

lhB race :mus[ be nl.8ch ined .

Irnark

Engine code

EnginB'rC'cde

i~v~.Mlef}i =, ,3i"Jj m'ml ~B~ ~ BTD'C'

dfil!'Iepj''at.fX a.:;:" ,~2'.I[]mm 'r8~ aTD,C

k for scr .b' t :t;' ap pro,pr " I ....... 'h ~ati;: -..' 111 9 nnar" .~ y {] ur I,~ m f'llod e!~ llo the left IrJ r the TDC rna rk at the a pprulpriate d ~'sL.~n: 'hi;ree i~~us·tr;B1,iml ~ e nl
';,Eill

as G.B1 10 on
I~" " ....

the

'outer face"
( •. ,'

Punch
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30 ..30b f iUin;g, a Itel!'t1:atlve t.ype~ centre bea ring im1to Icrlankca's1e ~

l ro .'

main.
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30,.3:dI Fitting fl\anged ~Jpe: C1eniDre:rn'~lin

be,arhlg1 to cap
4, On autlc~math; uansrnisslon rnod,ejs. check a pertu re in ~he rear end 0: the C .n ksd1.~'f, It t rh - d'~~Jeplateas descrlbsd for 'the nywhe 1 ~t ma v' a lrea ely hs ilife been rern to 'led b y d,!~ u;.rri II; H !:50 be necesear y to m~ r ( a n'ew 5lU:p,Fjlier" but check ,~l1y\Ma~, dfi';\J~ plats' tor ilgrl ~tk):ntimr-,~g. ~ C: h.~<anhe. cHlnkcase fOC, sses an l l ad ng caps thorou 9 h ~Jand fit the baa ri ng shells SOl . - _.. - . . _. . . _. - . ·· . - - -

J'fJ~3r Ensure tha '[ ends o:f bela rin,g ari~I~llsh

wi~hjointface

the crankshaft in: the c rankces€'.

...........................................................

-_ ....__ ...__ ..._-_ ...__ ..._-_ ..._- ..__ ....__ ...__ .... -_ ...__ ..._-_ ...__ ...__ ....__ ...__ ... -_ ...__ ...__ ... -- ..__ .

that the ta ng on Ul e be 8 ri ngl eng~lge5 in the rece SiS i11 'lh e c rit nk:t'a'~,~ O! D8'aring: t a Pl. En su re tha t the 'sh~ [5 . [tt... to the ere kCl!S'e =d hau o il gin) 0 'd'l8S a nd hoi,s 5 and that t hese ,t:ii i ,n; 'with the dri I ~ ng'~ iin the be!aring housings. '~\fhen f iU in9 th e baa f in 9 shel ls to .he ceps,
~ote
~I.iLoo

,5 Fit the m j n bearing etap S (vlihh cernre m,j n i -- ...':·i' i·- i'..j.:'.., :.:' i -_. b~aring thi'Uslwf.ishen;, U ~pplicl~ble~1 in their ;·~2:'£.' ~ "._' , . :~', ""· ._ - ..._ - .. ! ~.~'! !. .!.~. '~.!' . correct po ~tions (!illm~ IU'Glr,aJtllion)~~ 6 F it ~hfa bolts to the bes ring caps and tighten ttl Ie' bol rs of th:e lcentre cap "0 the specit ied torque, th€~nc hec,> nlat the cra~~~sh~-rto;~eltoo r
_
.,'

;fr-e~ty.

;r\em1J:~ni bearing ca ps in turn, checki ng 'tthat ng t;h [~ era rI ks Ib~:":Ii~<F!-. rn L:5'I't.~,iI::"" fr'~~I'y,- ,~ft~r' Ch !I;:.l!"¥-I,
__ . 'i¥ _..:_ ..
;;;I!

'1 \tJ'ork in gout frorn the cent re Highten the

m

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h at b'-=~.~,n'lf~ r'~c:~ 11: :? ~ Hi,-Y 5 ere n in ~ i ~1: ~ r""-.~~~ ,shells. '~irru15t No; 4 ha~·an ej~: f:'JOlc.r~fe, g ! he b ea-r~ '~h'"II'~ c'r 'the cer Itre be:!a~u'~ Ft.g ng (Nlc .. 3) ma,Y either be, f~anged to act ,~SI
t, __ '1,
11;. ....... :..;;: ••• ~ .'" -~. ~ •• ~ ••

Iol!.

bea'rwng has b,,:aen ,-~9ht'ened.

~~v~thifl spec-ifi cat~ons

,'.

iQ.

0;;0.

D::'i1Ii ~ ...~

11 Che,e~~, ihe end f~o~ 0 - the~cr~nksh,~f;t '9, li1at t 1

1__

,.11 , •• ," , •• ,' ,•• ,

,..

'~~.Jj

~.~_~

1~11

•.

~:ll ~_~.~.~_~.~.~_~ ~_~_~ ~_~.~.~_~.~.~_~ ._~ ~..!...!.~ ~_. ~_~.~.~_~.~.~_ •

.~:~. ~:~: ~~:!: I:~ ~ !:~: ~ !:~:!: ~ i :~:!: ~ :~:~: !:~~! :~:!' ~ .~:~:! !:~:: !:~:!':~::. i :::~: :~:~: ~:~: :~:~: ::~: .~:~:! ~:~::: :~:I -_.
· .__ ...__ .

--_ ...__ ..._-_. -_ -

..__ ... -- .__ ..._-_ ...__ ..._-_ ...__ ...__ ....__ . . -

-_. --_ .. --

.__ ... __ ...__ .

lh 'US:, ;~Na'she'!'$, or m,a}~ .. ave separate thtrU5;t'\yas·h ers" The,$e~ show Id-,.e~ fitted 01i 1'1 r-oolife (;)UW~ rds. R't 'the lY~arb,~ sheUs so tha t
'th e rend s 01' [h~ be-aring ar~ t'lu~h~h the Jloim
fee;e I{s.ee n~!lJmratiol1s]. ,4 C~i the berarings and j 0 HJ rna IS thiF:n I(jllt,fl'[S. II

·. · . . . . . . -.. . . . . _... . . . . . . . . . -. . .. . . . . . . . . . .. .-. . .

,... m.'R ••ilJ!liio!~~k ~ L:• .Io!.\Ii ,.. ~I¥',;.iI ·m-~f;-iII '. ,••.,,••,' ,•••,' ,•• ,.••,' i .:-:,,aU-:~lII-:UJ_ ....11-,..._ ...._ ...._ ....... _ ..... _ ...__ ..._._ ..._ ...__ . .:-:- .. :-: :-:. :RJ:Ii.:.U:-: "g, {.: ._.. :-:.: ...- ._.. . ..... _ ..._- .._._ ... _-_ _'~I Mi!:1 ~ _ ._.. - .:-'. -

:-~;__:::;,: :':~:':;: .:-:~:..:~ :.:-.. ~_.-:-.: ::::: ';::' ::=::.::;;: ::: .~::.;=:':':~: ::. ::: ::~: :::' ::~.. ~ ~ .~~l_~

..

betwee n '~he c rankshaft and the centre be; ring lh-rus't l;ace/~tJ~[she:r wh i:le le~eFing the 'cr,an k<$ha'U tir' in 'C'11e-d irec'tioo ~nd thf,t11 ~nthe~ ,~her. ,9 Lub r<i cat:e 11a re - t o'f the' c'ran k sh,ar[ and using a neiW9 8Stet, -- stall! the rear a II 5100,1 [Bnd 'fl nge,. 'Ti 9h" en the SiK ba'~rs Ih~eeli~~Llmral:ic'n)l.
_-i I~

b~~inserUr. 19 'fe~l£f bl ade-s,

'~·!'·'~·~':··[b·~';"··· ~.'' IIdi'W=l1 •. .. ..~.~ .__ _._ _-,, lB· '.:~I.OBi" ----~ ...~I~I~~~:'· !••.:.~.!,~.~,'.~'! .... .. 'II :.'~.<.'~,,',!.~, '~~~'I ~t; ... ~ ~- ~ ..-~~ _. [DI· •. ' ~:. ~~~~~~'~! ~:l~' ~~~; .~~: .;~;. ;:~.; ••• :.;.!~! -_... .. ~.. _._. _._. .___ .. - - _ .. - ..- - -- ._- . - .- .. -_._.... _. --- ._ ... _. ._. ..- _._. __-_. .;~. _.- .- -_ __ .. __ -.1IIII.i ••• ii.i. i.ii ••• ii••••••• 1••• ii••• I.ii. i ••••••••••••• ii.ii. i .ii••••••••••• ii. i .ii.. ii•••

e.... .__._._.__.__-_~··'._·~'-.~.'_._ _ .. .. .. ..._-. : ._ I··,. ,

~~~. . ~ .ii.i ••••• i .ii.ii. i .ii.l ••• ii. ~._

,••, ":::. ._ ..

.. .:-. . -:
ii-i

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••• '''.'!.''

.·ii-i- i-ii· i ·ii-ii· i ·ii-j· j-ii-i· .-ii· i ·ii-i· i ·ii-.· i-ii·l·ii-ii· i ·;-i· i-ii-i· i-ii· i ·ii-i

:-- : --:

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.-.

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;,,;IjI.cii'1 ~.

!Iii, I!'. ,~ I~~'jl,~, 'III iJI, t~, ~t ~I~, ~;Ir J .. .iii tlI. v

,.0':-"1' ,

,,"Ii+;:_"i i' 1L.l", .. .;;;;, I~

"''!4-.;i!' .-.,~ -,.,I\i-c.II., w~,i Q'~'lt ,~I'!f.r,. '!I...-~ ,~If.<~~i;~::ti' ~

the OeBrin:g ,s,hells are .5 fJBle:d prop,e~iy< and rl-~€Jr' tl~~ ,b~~ring.C8P J-S ,irl ~'n8 co "rer;t ~v:ay'r(Junrl, Rotarian will onl~JtN~dltfk;uU If somethin(M is ,tK~'C{ffec,~' ,llnd :IDe f{1fd~tmus t be' - '-;;"rbl~n(t ,D'irt on ,the .b~lckof ,alb@~rilf1;gl - hell i~

che-ck;

U-lii,~

..:1~'.

'~'''"'m-.:;;Jd'ij?"a~ ~11f...p;0!"":"9li'~~a. Iif"!" ~~ ~j~.]_ ~tf1~ lJjrI;f" ~-~\JJ~~' b.I'!11

1: If ~

neVi'

cranks.rudt.

a U'tO;I11,61 tk: !tran's:m i5 ro U 13r bSllF ing SoUpp Ii ad s:n d fi ul~d

~:f1g 'nu.ed tQ siiv n model5, t e neled Ie

"';nlh~h~;'n ,!b
'l~ll!

~'jlr-![;rJlil [

~I'~~I

~~ft("".J')',:!'1

~11T~1~1Il

i:~J b

"1~~~'lJIrac(,urer ~I ee,rj U) be rem10vecl ttom its Vil n

by. the

3:iQ.·g F~tting c;rankS~'lH!dt rear loi:1sea: I and Na,;rsge

',0 lubr~c al@ Lhe fnJrlt oJ tht8' cr.anksha'it and 'f h. Lh 8: front 01 I sea ~ ~ rid Us n9 e '~I'I; a ne'il~ th Ig.a·g"ket Tighten l'iu~ bolts, to lh~ correct
torque.

Lubric aile the intefmed iats sha It ~~~id1lea " c lengine~ ()iI them in s,taJI i't in lrlf l:4oc k.. ,'it ~~he10 -ring and Range,. :together vvith ,the oll seal, then ,'jig tnen 'the bolts. r~o.te~til at the
oi~ ha.Je rnusl be at the bottom of the if lenge~

3:4,2 ,e-ylinder head 'Q:fJ5ket IQ'C;~Ided on ~ock,

Usl ng '&-1 is as .e, datum inSI!E~:ia n@~l c'yl inder heij~d gask'e~: ;.0 that the 'word lOB £: N:1' 0 n the

Proce·oo as descril:l.ed
O'! thi s Chapt 'r
I

'AJ~he re'~tHn n i
threads.
1"11
'.;''':1

in Soc,1tian .... ~ Pa n: fA, O pa ra 9 ra phs, 21 to 1~ncll s-iva. u

the b ig~ end

rUJ ts ~ 0

iI

he

d mum point ~ nd on th 8 top S:idB: o.f the g'- ket (see ~i IllJ,trration~. ,3, lOI~Neft h i[; eY'~nd er head [nt,o pes it lon. i loreaUngl onto the' ce'nldng pins w 's ':e r'iUed I(see iii:luslr,a!1 j:Otn). J the ,eyHFlder bloc k, does ,no. h~~!9 [ce~'tring pins, init~ally reflfL n:~\Jvr~j . B e
and No., 1 r,) c y~hlder head bol ts, :Di"Jn at use jlJ:':~tting com pound. Check that t 'is 9~1Sket ~'3 ses];~n 9 corre:ctiy' and flt the rema ind er o'f the :n1~TIi!j,r botts, Fono\!v ~nQthe sequenc e sh own. -t~~ e bo its ul1~f he h ~d: is fir,mi)1 hetd ,. t
1

Ig';.skeel is

'Orrt:~E;!Il:Jhls

r r~~:he 'drr~tf1g,be It s proc kt~[_onto the sh~ rt.. '[ Lubricmte the re~l in ing b!JI t '\'ft~ith oJI, loca I'~ ~he:
ct·

er on to the bah the 11 f1:[ rarl d .' ghten 'jll to 'the S pee if ired tor q ue ~Jren ~ i ~er j ~g. ~ithe'~"1ighle rd rig Ijlle ool1t~ pre'?l'BrIlt :~ l he' crankshaft f.r'~ln turning: b.y u ing the S'·me method a s [hal[ tor irs removal. 3 Lor:. tie the:\~h~odrufrIU3'~~nto i~5,gr'~.~le on i I sp acsr
'It!$' ash

0 ~~ c .... rnpleton check 'Il-b'a end" oet of eac ""._!j,"""".~""'~~I'!"i.."...,y' .. connf'c,tmg rod i:n a sim~:ialf manner '0 the
,9_ "_,,,",

described 1E=I'ldfto,Bt.

'for

checkin'g

the

crenkshstt

ti 9- -'tn

of the csms haH th en flE-'fi:"t the ca rnshatt spree kat R'el~t the, rl@.tainil1,g boll toglffLh Sf ~Miththe spaeer wa shier ,and tighten to t he spec if.ied torq La e ~'ff}:rlC h satting. Hold the, sprocket 5ta.jonar}J' ,~hen !]~gh~'ening.. b'
the front

USh1'~s' uJlique wrench, l]ghten the bolts ~n stB'ge's to the. specified: tOH1UIB "rf,Jl[vv~'i.ngthe same seq iJence (~IceU 1U'5ift,r,8t~on.). 4 The CyUI~I.er head :r!J~:1i not neec f'Urt~,er tighrtming,
i

h elss ,Bnd ja mmi n g: it 1'9,9 inst the eyl ind er

"Io~,ot head.
r

iir1 sert ing: ~ scr~lI#d ff.~'er l h f'oug h o n e of

it s

4 I'I'~ removed ref~t'th~ f!j ml ..9 belt Il"e- J cove r. Ji-·I !,QCUlg ,',._.- ,-" ~.d .. e tx...JI III """a. ~lPP) I-k~-' (;'OITIpiU'LU1Y ,~~ 'i'iLo.- S,Uu ,Lora-d n iI!:' I .... ,il'" b is: tr. r'~'~' b ~fh. ~L" ii''!i ne:'u o mil 'to t h:('tr!E3 ~Y~'~~~Ii' ~I~ '_" ~'W'w ~~~~ &A~ rr. ,J '. ~"
,~,C" ~.!l;'~'o!".!:, .~ II
~~J" .: l '

"".w.,

1 ~ a new or reeeno h:ion lE,d c~rlinder h eac -r 1['v')Jnp~Jertle'~irth (;a'm!sha'l't is beLl g! HI . d, then
'Ehe, ~,51

c'y'l:i nder he G d removed lprior to re.fittin ~·I after orvre ha u I) Of' in the no rma ~ m,~,'Inler desc ,'j be d i Se'c 'UOr 11 1 ,2 of
,adjusb:d V'Jith, t ~
I

va clea rances Y~!in ha'lJc been res st, 2 'V'a~v19 claersnces can be checked and

sprOrek,et (aJig:niM;g U~[ernerks mede prevleus Iy) usi ng loru~bol:t to, ~cur,e it ternp:orn rHJ~" 6 TUr: n the m sM:fc '5 p roc ke t 'S'.:} t h,3rt ehe ~obe's, or r~ ., ICY' Iinder ca ms are po in:t~ 'C, iig
I~

lIl~llJ .ard!§,

Ghapte:r 1~

3 The re a,re

hl'i.Q '5 pee

if ired

~~'a c IleB nan c.e Ive

s£'wng~), '[hese be'ing 'for a cold (.::'yl ind'Br head . In h··~~ . ,re:mIO'Vled) or l/\!"i]rrn (lenglne ; ·J.e~.Bc.~e'"engine Icond ithJIrl. ,4 ~f ,a ~~~ ,adjustm .. t j's " sde wrth 'Lh18 ertgin~ v

cold ~then [t m~J be chelcKe.! ~'9J~El,ilJlith, the st U1 lie ng in e at no rm,a.i operating "La m p e ra Lure ~Ie, tCool!ant ,ab~I~~' q. 'Il 'the cl!iinder head ha's 35~ been overhauled, then ,., sho ... d be checked i ,aga in hQ,t" ,8 te;~ sao m U:es, ;gOO knl.j ~

hlOI~ and -ja:m m ing ~t l8 9 is] in st tl'le c ~ ~:in es, der block,. 2: locate '~he ;tU'oodrlff'f •.!:j~ (i:f' ~ Pi piilc a b le~to e the g:rOO\.fe at the 'rro.n't 0" the cra.nk shs't\ ' hen

1 Fit the ~lloodr ijjf'f k.ey ime us groove in the irf'&ermed i8t'lie 5 hait the n re'f it the 5 proeket '~O ttl e fro,n t lof fthe 'S,thl'ft.. loc a'[e' ~,he 'spacer y,~"El5her cnbJI the bo I't th e n 'f it and ti:g h:Len the bon to the '5 P f'e i.fi e d torque '\~~renh s en,j rn9 ,. c Hold the ~pnJC::~~!~ statiol11arj' 'when 'ti'9hteningl by" ~"~';:jwt~n,g s ~rewdiri~ter t hroug hone Q.'f its a

iOllL ",. t -,,,,~,, ~I 1\IRJI'S.'ra'L,IOn ;0;]. il.. tit

sprocket

~nd t he, m,~r k on th,e eramsh aft is al i1gned '~aJirh 'tile vah/"e cO~II~r - see

~i~k~ng 1?UJrre, :~hemar· '._.Ellre sUUin pl~~ce~ a pu~ sp,anner on llhs a dju'Ster and tighten t . ' bei'l' und I U ~Mn~ t\~Jl'isn (In I~ 90 d eg'ree'5 ".'h en hs ~d1 ,0lW68'n lh e fi ngef.· ane: "'humb ha Ifwa~t

1 R:ota~e the c r 8.nks ha,ft S plrock,et and the i!nlem1.ed~,a:[~~ shaft spn:J~'ket untii -'he, eliot Ion the irrtermedl,ate Sp£iOC ket a ,d the n1iark on the, '1',. bah pu I~e~~ cQ,inc.i ~ ins( a II the ~'rn'ing be~'t e. '...ns i'O~f tlOlose iy a nd the n lh l~ 't irnin 9 be It

,he~Mjrernin~rngfJcJ:t',r , DeU$~~~Dn rnUf[~lg

No:oo: ,N'~"\'~~ c)1{nder

~ ........lI' ~. ,.

n U.Js.t

11C ielon the to p fae-e ~. ihe' b ~.:u Clean ~~d .:l(. . n in sprel~'( '[h~ :barl3's i~nd lubriic,a.te' thenl w ilh ,ele,an eng~;re 0' ~I"Turn ttl e era nks haft so ~;hat

••• •••
I
, ,

the pi sto s, t~rE!'in tneJ m:id- r.y IiI1der p06~ti on,

:2 The ~fligine' number is stfmnped 'on an inc iined su rr~lce be:t·~ een No. 3 and ~Jto. 4 Ir;~'~ inders, (jln the: 5,id~ ,abo\i1C' th~ distributor.,
.;!' .

'"" oil '3C·' ,il<'f',., :: ,,' '..

'b

"j~

'!I,~r' .-!II .. IHUller

~-, -...i.li ~Ili!e\j!b i........ .ul ~llIlil1..!I!!f!o ~ .~,

'h.jD'A~n·il ~=".:..." I~~g 1n t.;ciI 1L"':':'F f1l:1e.ftCe ' , '.

.
~,~\I t

sprockets, Tighten U1 e eccer ·~tricadj uste r nu~: to the s p Bcin~~d U8: '" 'S&'0 illuu'i,'U',adon 9 Jll~ torq
1

bet'ijf!l.r~~nthe eamshert ,elnd ilflLm"rn~di',at~ s hart

,! Relit tI TE~'spark plugs" if MO' a;~",-,ady done _ '14: R~'it the gearbo;(.hran5rn~ss~on La Hue:
_.__.

.Q:

Unbo It ,- nd re n-~IOlre ~ he crank shs lt V ..bel t puUey. gi F'it the IO\~'er tirnino Ic'o~j'·er then refit the ~ era 11k sha f~ 'V ,Ie't pu me_1 a,nd '-igh en it's
=.

runn~n" ::;!i ..
:~:: &I;~~;:; l.tJ:I, ,- ."r.~:I:D j~ll~~I:~~'·,· ;:~:; :;:!:;~~:!:;:!:;:~. }Q!;' :~:;: !:;:~: :~:;:! ;,~~J :_; .. _:_;. ;_:.: :_:.; .:_: .. _:. :_:.; .:_;."" ... ~:. .. •:.: .:.:.: .:.:. I·:·:·:.: .. - :--- ._ ... -- .__ .._ .. :.:.: .:.:. I·:·:·:.:.: .:.:.: .:.:. :.:. .- .. _. . f',.i :. :·:·1·.:.:. :.:.: .:.:.: .:.:. :.:.:. -- -- - _. -- -_.. _ .. -_. :.:.: .:.: -_ .. _- ... _. -- ..l -

3; Ir ri9gu~ aI~ noises lare rl or-m'8 I 'lIlhlriff,!n sta rti :n9,: u t shou Id become qu i~t ,a"fbE~lra few min utes .,
'il~" ..

::: ,~~::::'

-i'; 'i-i'; 'i-;

-i;'

··n' :_::g.-' l~~:·~:·: :::: ~;~;,t'·~§'.~"::::: :::::: .:::: '::::: ':::: :::: :::': :::: :~~
'1 ~_
;":~ ••• _: •• _:_ .: ;_:.: .:_:. I .:_ .: ;_: •••

--_

..

;-. ; i-

. _.- - ._- ..-_.

;-i-;' ;-i ,'i-i

.__ - ._._- ..
; 'i-;

,-i·;

.. -_-_.

;-i'; 'i-;

- - _ _... _. __- ._
,-i-;·;.;

i-i ; i-;· ;-i'

..

- ._._

;-i; 'i-;

..

.•--;. ;-i ~

..

t ~e 4.. if '~, -~ ~

- ':::'

_:.:

.:_: ••

:_;.

_:.:.

reta ining bo Its to the spec it=ied'lJo~ ue. q 1:,0 La care [he ne:\!lV va I'Ve It1C)~er ep. "fl·ske't 'on the c.yl inder Ilead.. the sea I 'to the i\~'OIl 1 cams han bearin 9 (:ap ,and 'the h~iifoun d g£ionlm et rnro r
its
:~OC;8 on tl

a,'~ the rear t!,nd af the ~yli de r n

T 01 r~n~. eng:in,eitran~ml'Srs'ion.- reverse the the fa m@Jal procedores but not e the fo~Im~ing: ,;,~J ~~,rl I(lJ~~' ,rir2g tthe ln7lt i l'lQ lhe en.gr e

' are str ~II , nICUo.,ly.. c,flny out t h..... 'roIIO\l'~ing chse k '[0 id(3ntij·ry WClfn t~ p P -lT3. S Stop the engIne :and remove 'the va ~vecover 'from t --' cy~indefl head. '. Tum ~he era 11Is:15,ri ~ n (:,10(:', wi-e by' ual n~i ~, '\.~renchon th e' cren k~hampu Imey sec-uri 119 bolt. ur~tilthe Gam of t '.€' tappet to be ehec'ked is
-&;; ., . , ~. -'1. ,"" -,-.,-,

1-' s '~8:,v....

'.&1;,

fact n g' u p'w~~d en d ]5

I'HJ't

heart

'1! F~t:[he'va ~e [;OVE, imo posltlon. ~:Dc:ate'[h19 1 mlnforc ement 51ri PIS' :hen refit and t i.gh~.E:n the rets ihin~Jn u:ts e\fen~'yto the 5 plecU ~edtorq ue. 1!2 RIBfit the epper tirni ng beJt cover
+
•

me fJ#jnge~1Pi Jor to {1ti_"£ich;r~g tbe

Iii .
1I.;;.it;

c.otfJD8r{rna~t Il,iiQn the dri\flMl1}J~fls w~~"h

pr055l1 re on :the ta ppet,

ex erting

,any

b)

AssernbJe ,~1JeleJ:1gtM
t»O,[Jl1,llR~
[~ittPI'

re.5,pecooe ,r-nolJnr,irlJJ[ls

,mt~ln~i1tgt5 t(i)'oseijf'

·.'3' ' ."---n- - ~ ~ ' ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••

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1 •••••••••••••••••••••• --.

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.

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c,
rl
,m

inif';a~t~ nd ,t;!jlfl!'M !hef~mDilly aile; the ~ unl~:5 cienual ~\I'~~i1m8:1. l s~Iil7lJlning 1fJ.'",'el

J' Press the tap pet dCl"W' usin 9 a ~·Lf'oodE-n or plastic ~ft~-d'gE. :8 Ir lree travel 0 f' 'he ta;ppi! t exceeds tha t 3,psci·fisd 'the. ta P pet mu st be ra n9V1Jed ~
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1i On a utOJll~1ic tra n&m i5~on models II' ref;t lhe t dr jr,!ie.;~i:aLe tOCl~theJ '~~l1' a.,lId ,shi,_ tJrocg.,/;J h . ina:~~,\;! If" wJ' IQc~.ted betit~"eenthe crank shllft ar~dthe p lalte'T Fit' he vLfasher on the trans:mi 5sion 5 ide' of the en'''' "r. _ mt' " drl·rv~~pJ:Zitt~ u:~i~ g' '. 1J"m~t, _:he 1ii""81;l3 m ifE:I'~~'~eii;d' - ... ~ '''l;!! _ _""" "-"~" IU...;;II~ ,.., (ll'f th~ vL!l2IJsher :faces '~Cl,vcp.ardl'5 U1e drive-pilate. Use new' bo~ts. and bghten the:m to the s;pe~Uied torq u~ set!i ng t he'll us ing 'Ve rrde I' c.e ~i pers" chedk r:n Ie di:sta nCle bet;l,~leen the d I-hiep'~ate 8 n d t hel CyUnd er b loc,k ,es '5 h~,~~n ('see n~ Sit ~'''aidnJi ~ t t hre 8 po s:h:h)rl S _ I'~the u o c,loor,·1IL~e i~not betw-oon 30.5 and 32:~ rnm t1E!!mQ1Je the dd\l!-e p'.ate ~ fi t ~:h ims of 9 Yit,~ b Ie
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A(~.rU'Sftt16 cl'u~r:h 'Gab~e(msnuat gtil,arbo;d' d) Atfjust the ,~ro\t:t'e ,and'se,\&C'tor r::abls'5 (.a utOf!!18t/'C van sti.l'JIisShJn)' el Rec:v:nnect and ,:r;qjust the gell" selector i)n1.aJgVJs tmarlfi"flj'! ,gearbox)'
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at:d qlu;an~~~~ oil Df 1t!~t1e,enece-s$'alr~ rel.~'ensjQ\r1' rhe power

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Refer to 'Sect join 4,1 ~n Part /1\, of th~'sCh:gpter. if ~lew 'h:.~dliauHc b.ucket tapp-~ts hBi~'ebeen

thi·cknes s be tw ean e dr~vepJ t.e and the a cr~nkshaft the'n refit the dri\l~leplat'e a6s'e~n~:y

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a rrd reche'G k 'th 8' el earElntCe. If Uh EHl gliJ'le is a neliN or rec:Qn diit io ned short b~ock repl 3'Ce.~ - - -- iRj, F'h:a.'i'" L ~J!..- t tk.~ io-;;, - nd- ...~,.._. ~ me~:Rl!ej'.... 'l";"'oi;."lfi';.ln~tlllt: pJrCk~· ~n 'tL,p leal.If e.Y I~e:::;. : u..:~ M'iOt eor-~:,a.j.n 3 _-_eet:1Ie 1"O,ih~~r' be~r'ii,g, [' ~' does, iIo;!I.oia,1I"Ii1 il!'am~-i!i.5i, ., ".... b~ 6r-~n'g--~--I!~ ~~Sl:i~ '~'nrj..:,t;;! !oJ l'\o,n ,~'u... , .... ,~''" '~h'·E.'t:;;u II . '!.It..:!! ~u
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:it urrtl~:' e roo lator t r~""tf'l'~ I~ -i'~'nha"- ~',,",!}.~ l!...... In r1 loCI ~·'r-hE!".,I0 r~~~ '''"'9. !4J _ ~ :2 In['[n~aseengi "e' $peed to about 2500 rp'm for abou t: 't"rNO minute's.
1] Start the engine !~nd run
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h~..ad OJ tn~er mOUrftRng as appHt:able' us~ng a naw '\10 st"telr'or C'~ring~ ghten to 'the spec ii:ilsd Ti
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'VWt,~ een tra i I!;pa ker trom s Iclcations:,

1

210

en~fine are basic anlr";he5,6 me as those daser ibed 'for the ;B~,r'.",a~~ve e i _Pa rt C of ~,ngin thf. en 8pter!, The: f ollcf!J.'!Jing Sectia'ns describe r.rroc.e ' r:es whieh di:~I'e.
'I

a f"OU n d t~File p,~r'k,plug 5;

:=:~:::~:::::=::~=:~:: ::=:;: .:~:: :~:::! J::: :=:::::~:::~:=:::=:!:::~:::~:=::.=:::: :~:::::=:!:=:~:::~:~:::=::: ::t::~::

:~:~~:~~'m:-~::i'~;~~ .... ':~~~~~I_; .:;_:-;_:.~~_. ~:;: ~,~fl:I~~;~ ~~:~~'\~'l~~ Ili:~11ktl~::~ ~:~: ~:~:; .-;.~.:-;-:.~~IJ<-~~.-~~'D; ~~.). :~~J:~!_.',
'~.!" '~.!' !.~'~'••~': '•• !' '···"':~1! 'I!_.'"
.:.:. __
••••

'~:1:d'•• " ',.~,"~ ,!' '.~'! '~.!" '~.!' '.~'! ~.~ !,~ !.~" " 'l:",'!:.! ••, ,.:i" :;:::i:::r:Qim! ,I'·d:,;nu:~~~~hl i:::::,:;:,',:.,:,:::::,;:.,::::,ro:" ~- ::, ~ ( "'r.1.:
<!; ••

.~:~ !:~:! :~:;: :~::~:;:! ;:~:; :~:!: ~:~:! :~:;: :~:~:; ~:~: j:; .::~:;~ :~:~:; i:~:!. ~ :~::: :~:~:! ;:~:~: :~:!:; ::~:! :~:.: ~.-~. :-; .;-: ;-: ; :-;.;.;..;.;-:-; ._;:7-. ; :-. :-; : ;-:.;.:-;.;-;-;.;-:.;.:-; : ;-: .-: ; :..-;: ;_. ;-:·i· -..<': : '··"1'··"'··" •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• .......................................................... ..- .. -_ .. _- ._ ... - .. __. .__ .._ ... -_ .. _- ..- _. -_ .. _- .. _ .. -_ ... - .. _ .. --- . - .. _ ... _-

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: .:__ •••••• ": '_.: •• __

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:1.•:-, ~:1:.:.:.:.:.:.!.:.:.:.:.: .:.:..:.:.~.

••• •• __ ••• __ •••• __ •• __ ••• ••• __ •• __ • J.

"

c~

'

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2:. '1 Y,a~~,e iiflg marks tim

CBtn5ha~' soeocse: inner- tnar.-~s, ~',Ii'"
I.
I

provided on the outside 01: the ca mshalt sp rOickft ~fl!hi h a I ~gln:S1 \!i!i th ~ rna rk 0 n the c va Iv£:: CQlIJer (~-elE:'~;IU5 itr,artiJDn)i. rhis lrne(]tli5, thert if ~he 'Li.mi 1119 be It a[lone is be~ng renevde'd. it ~.s not neCle.5sa ry tl[l re rnove the' va h/le oover in
I

Be side s H-le t im in ma: k on th e cia mshett sprocket referred to :in P,Brl C 'OJ this C,hapter.r Section 9r. an add I:tk~nai' r ming rna rk ~5
I

A Canls~;'~~lt,ScpFock;'F1r aUher n13!k5

C Cninfffih
-_... :- ... _-.. -: ..

l'f"ibrar.ion diitJ1nperfm~rts
.:- .. - .... -: .. :- ... - -: .. -:. :-_.:. __.. -: .. __.:. __. --- .. :-.

,4 ,AliQI1 ~he,:Hmh1 if] msrks 'w'~th reterence to '... ::l P a,rr. C, 0' this 'Cha pter 'th'2 n c heck iI1:;0 Itt hat the marks on the. ,ch[! in SPJor:kets ,arlE:, 1£11 igtr~ed I(S~~' :ij lustrJ,ati'lon}. ,SI R.emlo\jle the 'Um: ing bel t and cam shart s procket W!'lh flef,erenc La piar teal: 'Ihi s ,O,,81 pter ~ '6 Nate th e Ht tied po '5 j't ions o'r the c f~ shan, ill bea ring ca ps ~ ~'f necesss rj mark ing 'lh ern to 18:nU re correct l'r!!fitUng I(see ~f1llU1~M:rrarUon~l. S 7 I'I'0g r@s's:~lIe u nscrew the n U1S and bolts !:y 'fro rTI th e end IC,fJpS arid bea ring cap N 0'5. 1
I
l'~~

-_.:._-: .. -:- ·i-_·:· -:

~ 1i'1"'~' ..;t,
~~

;i!'\,

I~,~,

if'lil"

'~'I~ ,100MI~ ~:a ~ III' I'" amshatt 13 i~ ,~~,_. ~J.~~

~. I!'!
~l~ .' ~~.

_I~~'_.

order' '~ che.c k fhe a I ig n !Trent :-nark5, W hI~n 'f itdng ttl e 'li m i,ng b 8 i't it ~s reGomrn~nded lh Jt VVtl tool 21 0 ~5used to set the te'n $ircln sec uratlely as th~ ~s more' eriHca I s
'M ith

:s pri ngs '~",~II tOf'ce the exha u:s~ ca ms haft up as the bQ113, are bose! -..Et - • Rem'o",~e''Ih~ b~arirlg: I
• ii••• ii.ii.l.ii.1 .I.ii. i ••• ii. i ."ii •• i.ii ••• ii••• ii.ii r.;'.i. i.ii.l. i.ii.l.ii.I.I.ii.: ••• ii. i 'ii."ii.' ii••• ii. .ii r.ii".:. :.ii ••• i.ii.

8 Prog iie5 -,i-veiY' u ra~c.rev~ hie, bo Itsr fiO n~ beedng ca p 'N 03. 2 ,"00: iI,. The ,exMIU s't valvoe

i -- ... _.. :.:':':.:':. i'..- .., j.:' ! :.:.: .:.:.:.

._- ... _ .. - .._ ..

. !.:..

Rle;mO"rllJ'"
" Rlenl0-ve 'i~hecam..~hBn 'SjprO,tKlet rCoV€'r. 'iF! ~ u P''r: ;:;~. i'1i!,.... """r i£ U'; b;"'~~'m' ~."....!I ,'~,u U ~: '1i"fi ~~ IJ!,:;'~ UiU,u':i U inlet nllani'folid. 3 ' n bo~ Btl d re m'DVle lhe ~;a c(rver after t hf-e d ~sco,ntl elr;thll I the Hl' lead s, fro rn 't h e- s p.ark p! ug s. Remor~ie dl a ,rna in ga s.k.at a nd the
"'!jj F!i

IG'CI keel p:ir~g P'~ thevn identified for posit ion . 'SI V~'orki n 9 0' n t he ~n~let C,r] m"Slrn a·ic~ pro ,_ Ig~:le iV's], u n5(' lieVJ the nuts and Dolts fro m 5S
J

'i"il~'

'lo! ~

6 ~I

d' _~~, p~ !1pi ' ,.....~ ~ ~_~,

I

b"

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e,;'1'i1 ni

H~ '>

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c

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~ '~",,",,-~.

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"!E!!'j;d'

'11' !L,

DC~ Hie arf:aJ1 ngem lent iSiBle iUu srtra t ion). U si ng ~h is t'o~lf th Ie tens~on shou,~ be '~,et ~o r'ec:ord a, ~ead~ng Qf be't~l~een 13 ,e!·i1d 1-4 on the $cal,e~ T~'e 1'10 01.1 can b:e obtained ironl ,2! 'f!.N dealer.
t he
1

i!

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1:.1 ~ I

-·.;",i

I~,y ',","..." Ib ~ -!,oi;;

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II I

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(,a P$ - leepiing them i~ el;-lified ~or po~it lon, , 1 l~n:b o,-tn c~m~tv~nsfrom ttl e- IC:~~;illi e~, e'ad dh then rei ease' them '[rom U:1:e drive C M:i - ,

u ns,c.relV ttl e bioit50 l'fiO rill bea'rwng Icap Nos. 6 ".' dar 't - ~,Ifl ~e:mo'Veall the

, 0' PrQ.,gre!5 shrely

I
1 I

!
,
i

tappets,

12 If r1{~'cess8rj!'1 remove the. ~1¥drauli;c: buekst

Che(;k. til e: r:. tlrrlsha f1' . a nd drhte chain

,2:0. ~R,eit. the eJ<:haus-~ cawnshs'f:'l end caps. and r bea r~ng C~p !~Jos. 1 and 3 'merl pr'iogmssive~!
J'

."I~:,: .. "n'~~lil~,~,!~IMi,~",~l~~H,iiiI,~~.,
:' :::':: ::::. '!•.
•• ".-,;, ••• ,' , •••

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11.11 ••• 1 ••• 1 ••• 11.1 •••••••• 1.11 ••• 1 •••••••••• 1 •• 1

••••••••

for u-vear
IJIi,slir&""n D R~·I'-III.[Lilr. ltl
j

dghte'n rhe nu ts
torque.
CA_m

.E}

I1d be I:t 5 to th e SI):~i8'cJri~ed

- ..~. ;••,' F:'II~1~UiitI£~1 ;•••,'·~IILIi~~l I,••c;. ,•• ,;fiil'~ J •. , ,•• ;, ,••• -_.••,' ,.; •.,;~." ,••," ,••,' ,••,' -.lllg· ~II .;, ;••," ,••,; ,•••,' ,••, ...
~ ~:.." •• ,

~~u ·--· "~.. ..... .• , , , . , , . , . , , . , , . , ., '~' ·am· . , " , . {.J ti ' ,.,,.;:!~.. , , . , , ., .. , , :lr:"~ ·m·""r.tJ\~,'t: ::": ,.~, ":·rr~.~~ :n:··~·: 'I] :::':::::':::::::::::: :::.:" :
.to!ij,

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'ft':~~~:::
." 'i ~-'
.." • ~_.I =,

; ,•• ,"

jot! rna Is ~~ilhoea n

ne 0 it. thl~n insert the' tappets in thei r 0' '~gi bores, nw

9 rtgl

, 3 lubri cate a II buc ket tappets and

shaft

beh \~lth reference to Part C o·f:,his

2'11 ~~fh If .e, camshatt sprocket ~.nd till1ing

.~: ~: ~-_ ~ I~:!: !:r.!:~:~ ~:::: :~:j--- ;:~I !~:!: j :~:~:!j:~::::~::' . - ~:~: :~: ~:~:~: Ij I~:j: ..:f:~:: I!:~:!. j I~:~:! ~:~:-_ ..:~:!. _ .. !-_. :' ','._'"' --_ ___- ..-

.2. !_~ ! !.!!!.! !!!.!. !_!!!_!. !.!!! ! !!!.! .•..•••..•..•.•..•..••

._!.

>.

•. • .. ". l,. _ i, ; .. ' • ".-" ,- •• .: ,•• ,;.-." !.!!!.!.!!! !!!.! .!!!.!. !.!!!.! !.!!! ! !!!.! .. " I, !.!!! ! .!!!.!!! ! !!!_!. !.!!!_I __ .•..•..•.•..••••. __ .•..•..•..

.•• "~ !.!!!.! .• ",

11·4i l,o cete the drive chai n on the Cia m shaft sproc kd5 510 that the tj mi mig marks ere aligned as shown ~n :itustrat ion: :I",4 then lower the
r

'canlshaits Into pes itk~n0 n the Cl'~i der head. n

dri, ~.,cha i11 sprocket ·r~18r~~· [.lIre aIlgned. .'., .23; ReFh t e '1~,rJlve cover hlgether~!'flth 11iS'\~ 'g,a'S 5 and re co n nect the sp a rk pi u 9 HT ket

,and Section 2;. 22 Che,cK thet a lID'Ilrningl marks, inel uding _he

e hapCltf

;.:~::.~.;:~:;.;:;:~:::~: ;:;.;:~:;.~.::~:::;:;:;:::::::;:;:~:;.~:;:~.::~:;:;:;:~::.~:::j.: j:;: ;::::.;:;:;:;::.:.:.:.

'-'-'.

The : i'gl=~'_- d c __l5, on 16 vahlE engrfU:~S ar -~ J .itffied 'with nl~ jet - ~t1'~~h: direct a strea m 0:( el I: .. : _' un dar si d~ ot tt h e, pistons, m iii inl"'j fur tla
cooling pu rposes t(s:ele screws

_' ·chec:k the ti m irng mark alignrne n~. 115 F~ a nelAf oi ~ 5~11 bJ t; e front Iend Oit the exhaust ca msheft. 1G '~iUh r~fltt ~ng th ~ be arln 9 C2fPSj rna ke an jure that they ,9 we located ttl e correct ~Ja'j fOU nel. The i1!Urnbars must be read~ll:bme 'Frolm the inlet rnanlto Id side of the head, The
" re;ce~'Sley . ...lII

leads. 24 R'l!lll the '~n~lC' nlfold u pp er sec't ion and rna the camshaft spree kat GOVlfaD'"_
u

\l9Ihich 111LI st be (:'0 8lte:d ~ji~ith ~i J.ie~d~!ock ing fluid be~or'8"inserUng tl'J!~ l100 m lightren~1,g QI lila specifi@d to·rq ue,

ilustr,ut.ion" The oiljets ere secured :~(J cap!3b1l3tnall the

·3

""'AI['~"iii~r~ ·~u Ii iI£. ~I

.JI"J./r' ,-,

u\~

".

.~

'b;

j"o.

the! inl et rna n ~1101d 01:the h Md. sid~: '11 Rella bee ring c t~ NI()s. 8· and P

Ezha 'list ~·:a:!veson the 16 'v'ldve eng:ine! [tir~ a~ ttll~n f iled with sodiurn to prov ide :i mprol~ d h eat prog ressl ve'l~l:[ighlBn me, bOllts ·1jO [h~J-sp ecrni3d dissipation; Sp~crn~d p.rE!c,autk)ns, ,~rlP torque, ntec~ssary ~Nhe'n d~spos,i:rng of ~hi·~ type of 11 Refit the i:niet IC2Ern'~han end c a p' ~ nd valve: plar- lc Ula rl)f w here reeyc Iing ()~;SiC r'a:p bear1111g1ca-I N~)ji5. 5 and 1~then pmgresshrel~t Ine~ is clioncerned, al lighten lW1B nuts a _d belts to the sp ~cirjed TIO, render each V'al'J~ sat~., i'[ ~l·tOluld be ·E(3 rqUte. '~Jiplle:ddry then '~ult th 0 ~~g the stem v'\fi'th 13 h 1 t Ref~t 00' iii riing r;: ap' NtO:~. 2 ~nd 4.,. ·lhe n :hac~k's.all1. ThrlOIW '[:l1e \HOlWe intol (] but ket of rro~ r.e'ssi"ft~I," 'lighll~n the· bOil· s to tMA spE~cHied '\"~',ater ke ep·ing ~/e~11 \!!~',a ..rom j'l unt II the ay
I'

~n~ I I ..ro'-[ ~u;au ~.. ""..,~ !l,.o,bllr ~~,~ ~ I~",;; ,I, U'!uIG a ~.
fFIj,\

~' &
»e-:

'tnrquis.

c.hemka·~ rf'la C't:ion has s ubs ~ cited.

4 C~p
5 ,Nuls