Page 131
45, Install the clutch after having ali
tool 78 40 648.
46. Install the carburetor, together with
47, Connect the fuel lines to the Carbur
fuel pump. Fit the hose clamps.
4g, Refit the spark plugs.
49. Reinstall the fan belt pulley and fan.
Sned the disc With FITTING OF PISTONS
its gasket,
For fitti : : - ~~
etor and to the ting of pistons in cylinder bores, a feeler gaug
With a width of 1/2 in. is used, In measuring, the piston,
without rings, should be placed in the bore in the way in
which it will work subsequently, i.e. with its front mark-
einstall the alternato i : ing pointing forwards in the engine. The feeler gauge
50. la a r and its bracket, Tighten the should be connected to a ine balance and placed be-
ert a new gasket in . tween piston and bore at right angles to the piston pin.
3 ie metas ‘iat ee o one When the pull amounts to 9.8 N (2.2 Ib, 1 kp), the mean
notches in the cover, ae ene aie clearance agrees with the thickness of the feeler gauge.
Tests should be carried out at several different depth posi-
[sd tions,
| Before the valve covers of the cylinder heads are re-
fitted, the lubrication of the rocker shaft must be
checked with the engine running.
52. Reinstall the distributor. (See group 3, section 342.)
53. Reconnect the vacuum line to the distributor,
54. Install the distributor cap and attach the ignition
cables.
55. Put in the oil dipstick.
56. Install the air filter.
Febr 1977
MEASUREMENT OF PISTON CLEARANCE
Pistons obtained as spare parts are not classified, but
their diameter lies within the upper part of the tolerance
range, so that in most cases the cylinder bore will have
to be honed in order to get the right piston clearance
when a new piston is fitted.
If the clearance obtained is excessive, the cylinder bores
must be drilled to the next oversize. See group 0.
210-11
Page 132
FITTING OF PISTON RINGS
In a new or redrilled bore
Pass the piston rings one by one down into the bore. Use
a piston turned upside down so that the ring takes UP the
proper position,
Measure the piston ring gap with a feeler gaug
rect figures are given in group 0.
If the gap is too small, the ring must be trimmed with a
special file.
e. The cor-
MATNING AV KOLVRINGSGAP
In a worn bore
When fitting piston rings in a worn cylinder bore, the
ring gap must be measured in the lower reverse position,
as the bore has the smallest diameter at this point.
210—12 Sa
Febr 1977
Page 133
CYLINDER HEADS
DISASSEMBLY
(Engine removed)
1.
. ae cap and disconnect the ig.
_ Disconnect the vacuum line f ictri
Remove the distributor. So
5, Remove the valve cover,
6. Detach the fuel line from the carburetor.
7. Remove the carburetor.
8. Back off and remove the induction manifold bolts
and nuts. Separate the induction manifold from the
gasket and remove it.
9g, Remove the rocker arm assembly by alternate slack-
ening of the two bolts and remove the oil return
plates.
10. Remove the push rods and keep them in the correct
sequence.
11. Remove the cylinder head.
12. Take away the cylinder head gasket.
REASSEMBLY
1. Remove all residual gasket material from the con-
tact surfaces.
2. Place the cylinder head gasket over the two locat-
Remove the air filter.
ing sleeves on the engine block. The lefthand and
righthand cylinder head gaskets are different. They
are marked “Front” and “Top” respectively.
=
INSTALLATION OF CYLINDER HEAD GASKE
| .
San the cylinder head on the locating sleeves.
ighten the bolts in three stages to the prescribed
torque in the indicated sequence.
Nm = kpm__sftlb.
1, 54 5.5 40
2. 69 7.0 50
3. 93 9.5 68
IMPORTANT
To ensure effective sealing, the bolts must be tight-
ened in three stages to the prescribed torque in the
sequence indicated.
=
NOTE
The outer, rear bolt for the righthand cylinder head
is specially adapted for the engine earth cable.
TIGHTENING SEQUENCE, CYLINDER HEAD BOLTS
211—1
vantents
Hepetenee
sennenny
'
nee
Page 134
the surfaces of the cyl-
illustration On page
manifold gasket and
thand
4. Apply sealing compound to
inder heads as indicated in the
210—10. Install the induction
make sure that the protruding part of the righ
cylinder head gasket enters the ap
duction manifold gasket.
erture in the in-
INSTALLATION OF INDUCTION MANIFOLD GASKET
5. Fit the induction manifold. Tighten the screws and
nuts with the tightening torque specified in group 0.
IMPORTANT
To ensure effective sealing, the bolts must be tight-
ened in two stages to the prescribed torque in the
sequence indicated.
TIGHTENING SEQUENCE, INDUCTION MANIFOLD BOLTS
211-2
h rod ends in engine oil and install the
the pus
6. Dip riginal positions in the tappets,
; in their ©
ush rods In t : .
oe the ends of the rocker arms with engine
ds ‘1 and install the oil return plate and rocker arm
fe)
o doing, align the push rods under
the rocker arms and check that the oil return plate
is not in contact with the valve springs. Secure the
m assembly by alternately tightening the
assembly. In §
rocker ar
two screws.
g, Adjust the valve
justment”’. ;
Install the distributor In the engine block. (See
play. See the section ’’Valve ad-
group 3, section 342.)
Insert a new gasket in the valve cover. Press the
clamp ends of the gasket into the notches in the
cover.
S 1241
INSERTION OF NEW GASKET IN VALVE COVER
NOTE
Before the valve covers of the cylinder heads are re-
fitted, the lubrication of the rocker shaft must be
checked with the engine running.
11. Reinstall the carburetor, together with its gasket.
12. Reconnect the fuel and vacuum lines.
Le Reinstall the distributor cap and connect the igni-
tion cables.
14. Reinstall the alternator and its bracket. Tighten
the fan belt,
15, Install the air filter.
of NOTE
v : ighten the cylinder head bolts and adjust the
" ves when the car has been driven for about
,200 miles (2,000 km).
_ > mee
Page 135
VALVE MECHANISM
ROCKER ARM ASSEMBLIES
Removal
1, Remove the air cleaner.
2. Disconnect the ignition cables from the Spark plugs
and valve cover.
3, Remove the bolts and lift off the valve cover.
4, Remove the rocker arm assembly by alternate slack-
ening of the two bolts and take away the rocker arm
assembly and oil return plate.
REMOVAL OF ROCKER ARM ASSEMBLY
1, Rocker shaft with rocker arms
2. Oil return plate
Installation
1. Pour a drop of engine oil into each rocker arm cup
and onto each valve spindle.
2. Place the oil return plate on the cylinder head, put on
the rocker shaft and align the adjusting screws over
the push rods. ;
3. Check that the oil return plate is not in contact with
the valve spring. Tighten the rocker shaft retaining
screws alternately and evenly to the prescribed torque:
4. Adjust the valve play. See the section “Valve adjust-
ment’. :
5. Insert a new gasket in the valve cover. See fig. p
211-2. Press the clamp ends of the gasket into
notches in the cover.
age
the
NOTE
Before the valve covers of the cy
fitted, the lubrication of the rocker sha
checked with the engine running.
linder heads are re-
ft must be
positions.
e correct
» Reconn ignition cables in th
ect the ignitio the valve cover.
¢ Secure the ignition cable holder on
- Install the air filter.
Febr 1977
Disassembly
Drive the roll Pins out of the shaft with a drift. Remove
the spring washers, rocker arms, springs and rocker shaft
brackets,
ROCKER ASSEMBLY, DISMANTLED
1. Rocker shaft
2. Rocker arms
3. Adjusting screws
4. Rocker shaft bracket
5. Spring
6. Clamping sleeve
7. Cover plate
8. Spring washer
9. Sealing washer
Reassembly
In reassembly, the oil holes in the rocker shaft for lubri-
cation of the rocker arms must be turned downwards
against the cylinder head. This position is marked by a
grinding at the end of the rocker shaft.
First, drive a roll pin into the shaft and then install the
various parts as indicated in the illustration. The rocker
shaft bracket with the oil outlet must be positioned at
the rear on the righthand side of the engine and at the
front on the lefthand side of the engine.
214-1
venenes
seeeee
UU |
vee
Page 136
VALVE STEM SEALS
Removal
(Engine installed in the car)
1. Remove the rocker arm assembly,
2. Unscrew the spark plugs.
2. Instead of a spark plug, screw in tool 78 62 402 and
secure with same that valve of which the valve spring
is to be removed. Before inserting the tool, the piston
should however be put near the T.D.C. This for safety’s
sake, should for some reason the valve come loose and
fall down on the piston.
4. By means of tool 78 62 279 depress the valve spring
and remove the valve retainers.
REMOVAL OF VALVE SPRING
1. Tool 78 62 279
2. Tool 78 62 402
5. Carefully relax the spring tension, and remove the
valve spring and its washer.
6. Remove the valve stem seal from the valve stem.
Installation
Install new valve stem seals on the valve stems.
2. Position the valve spring and valve spring washers
and press with tool 78 62 279 down the spring.
3. Install the valve retainers and then relax the spring
tension. Check that the retainer has adopted the cor-
_
rect position.
Remove tool 78 62 402.
Screw in the spark plugs.
Install the rocker arm assembly.
Adjust the valve play.
Install the valve covers.
Reconnect the ignition cables.
Install the air filter.
SOMNOAS
VALVE GRINDING
Removal of valves
Press down the valve spring washer with valve spring pliers.
Remove the valve retainer, slowly relax the plier tension,
remove the spring washer, the spring, the oil seal and the
valve.
REMOVAL OF VALVES
——se.
tom
CYLINDER HEAD, AND DISA:
1, Retainer
2. Valve spring washer
3. Valve spring
4. Rubber Sealing
5. Cylinder head
6. Inlet valve
7. Exhaust valve
SSEMBLED VALVES
Febr 1977
Page 137
Reaming of valve guides
After prolonged running, the valve guides beco
worn on the rocker arm side. In reaming Ailes Oval-
work must always be done from the valve seat oe re
size of reamer to be chosen depends on he ae e. The
wear on the guide and the valve oversizes available | .
spare parts list). Reaming must always be Girone.
with the reamer having the smallest diameter as the work
depth of the Digger: diamstersiis too large. Use bereeane
as cutting oil for this work,
Reaming of a valve guide necessitates installation ofa
new valve corresponding to the oversize of the reamer
used. Thereafter, the valve seat must be carefully re-
ground.
REAMING OF VALVE GUIDE
NOTE
Machining of the valve seat can give a good result
only if the valve guide is in good condition. There-
fore, always check the valve clearance in the guide
before commencing any other work.
Milling the valve seat
rbon deposits and impuri-
- the cylinder head.
hine or renewed,
r in the
Clean all parts and remove F
ties from the valve and the passage !”
The valve can either be ground in a mac’ arbo
depending on its condition. Insert the pies w in the
valve guide from the valve seat side and prot valve
clamping screw until the guide is locked 1p
. ust first be
guide. The valve seats in the cylinder head m
milled clean with a 45° milling cutter-
Febr 1977
§ 1229
APPLICATION OF PILOT ARBOR FOR VALVE MILLING
CUTTER
As a rule, the width of the valve seat is excessive after
this milling operation and it is then necessary to reduce
the seat.
Reduction from inside is made with a 75° correction mil-
ling cutter and from outside with an 11° correction mil-
ling cutter. Reduction must always be performed so that
the sealing surface of the cylinder head will meet the
valve seat as close as possible to the center of the seat.
This can easily be checked with marking dye. After ad-
justment, the width of the seat shall be 0,059—0.070 in.
(1.5—1.7 mm) for both intake and exhaust valves.
S 1269
VALVE SEAT ANGLES
NOTE
Correction milling must always be limited, as it is
never permissible to remove more material than
necessary. Milling set includes milling cutters of
different sizes for intake and exhaust valve seats.
214-3
Page 138
Valve honing
Apply a thin coat of grinding paste to the valve seat and
insert the valve in the cylinder head, Make a few honing
passes with the tool, carefully clean all grinding paste
out of the seat and check the surface with marking dye.
If necessary, repeat this procedure and also do further
milling if this should prove to be required.
VALVE HONING
Installation of valves
Lubricate the valve stems and guides, and insert the valve
with oil seal, valve spring and spring washer. Press the
spring washer and spring down with the valve spring
pliers and insert the two retainers.
ADJUSTMENT OF VALVES
Set the mark on the pulley immediately opposite the
dead center mark on the transmission cover. If the crank-
shaft is turned slightly back and forth in this position,
the rocker arms at the first or fourth cylinder will move
in opposite directions (will rock).
In this position, adjust the valves with a feeler gauge in
accordance with the directions given below. Then turn
the crankshaft one revolution and adjust the remaining
valves.
If the rocker arms rock at cylinder 4, valves 1, 2, 4 and
6 must be adjusted.
If the rocker arms rock at cylinder 1, valves 3, 5, 7 and
8 must be adjusted.
DRIVING
DIRECTION
VALVE NUMBERING
VALVE ADJUSTMENT
To ens ;
of the ty smooth running and the lowest sound level
gine it Is essential that the valve play is accurate-
ly adjusted, The adj
Si adjustment to be made with the engine
Recommended valve play:
Intake valves 0.014 in, (0.35 mm)
Bie valves 0.016 in. (0.40 mm)
ie He ne a veroet may, however, be made at once
pee air cleancer and valve cover, even if the
warm. The valve play has, in fact, already
after 10 minute
S reac
of a cold engine, hed a value Corresponding to that
214—4 Sas
Febr 1977
Page 139
CHECKING THE COMPRESsIoNn PRESSURE
Before this check is Performed, all 5
removed after the engine has been oO
for it to have reached the correct w
Insert a new graph paper in the co
press the tool into the spark plug
round with the starter and with t
pressed right down, until the rea
Bleed the instrument and feed the graph paper forward
before measuring in the next cylinder. It is more impor-
tant for the pressure to be equal in all cylinders than for
a high compression figure to be obtained. If large differ-
ences in pressure are recorded, the compression pressure
should be rechecked. If too low a Pressure is due to cy!-
inder wear or leaky valves, this can be decided by inject-
ing a little engine oil into the suspected cylinder. As the
oil practically completely seals around the pistons, the
true cause of the leak can be established.
Park Plugs must be
Perated long enough
Orking temperature.
Mpression gauge and
hole. Turn the engine
he accelerator Pedal
MEASURING COMPRESSION PRESSURE
Febr 1977
ding no longer increases.
VALVE COVER
Removal and installation
1, Remove the air cleaner. Detach the ignition cables
from the plugs and valve cover. Remove the screws.
Lift off the valve cover.
2. If a new gasket is to be installed, press the gasket tabs
into the recesses in the cover. Put the valve cover on
the cylinder head, Tighten the bolts evenly to the pre-
scribed torque.
NOTE
be installed on the righthand side of the engine.
The valve cover with the oil filler cap must always
214-5
ene