Engine - complete dismantling (903 cc engine)

1 Unbolt and remove the rocker cover. 2 Unscrew the rocker pedestal securing nuts and lift away the rocker assembly. 3 Remove the pushrods, keeping them in their original fitted order. 4 Remove the cylinder head as described in Section 7. Remove the dipstick and guide tube. 5 Turn the engine on its side and unbolt and remove the sump pan. 6 Remove the piston/connecting rods as described in Section 9. 7 Unscrew and remove the crankshaft pulley nut. To prevent the crankshaft rotating while this is done, either jam the flywheel ring gear or place a block between a crankshaft counterweight and the inside of the crankcase. 8 Unbolt and remove the timing cover. 9 Remove the timing chain and sprockets as described in Section 6. 10 Unbolt and remove the oil pump as described in Section 10. 11 Unscrew and remove the camshaft front bearing lockscrew noting that the chamfer on the bearing is on the inboard side. 12 Withdraw the camshaft, taking great care not to damage the bearings with the cam lobes. 13 Lift out the cam followers and keep them in their originally fitted sequence. 14 Unbolt and remove the flywheel. Jam the ring gear teeth to prevent rotation. 15 Remove the engine rear plate. 16 Turn the cylinder block so that it is standing upside down. 17 Unbolt and remove the crankshaft rear oil seal carrier. Note the sump fixing studs. 18 The main bearing caps should be marked 1, 2 and 3 but if they are not, centre punch them and note which way round they are located. 19 Unscrew the main bearing cap bolts progressively. 20 Remove the bearing caps and half shells. If the shell bearings are to be used again, keep them with their respective caps. 21 Note the semi-circular thrust washers on either side of the centre main bearing which control crankshaft endfloat. 22 Lift the crankshaft from the crankcase.

23 Remove the bearing shells from the crankcase and mark them as to position if they are to be used again.

Fig. 1.21 Camshaft and rocker gear components (Sec 16)

1 Camshaft bush lockbolt 2 Washer
3 Camshaft front bearing 4 Exhaust valve
5 Spring cap
6 Valve guide
7 Adjuster screw
8 Rocker arm
9 Thrust washer
10 Circlip
11 Locknut
12 Washer
13 Locknut
14 Pedestal
15 Rocker arm
16 Plug
17 Rocker shaft
18 Coil spring
19 Stud
20 Split collets
21 Spring cap
22 Valve guide
23 Outer valve spring
24 Inner valve spring
25 Spring seat
26 Inlet valve
27 Camshaft bearing
28 Camshaft bearing
29 Camshaft
30 Locating dowel
31 Cam follower
32 Pushrod
33 Washer

Fig. 1.22 Cylinder head, block and crankcase (Sec 16)

1 Washer
2 Cylinder head bolt
3 Gasket
4 Rocker cover gasket
5 Rocker cover
6 Washer
7 Plate
8 Nut
9 Stud
10 Plug
11 Cylinder head
12 Plug
13 Cylinder head bolt
14 Washer
15 Dowel
16 Plug
17 Plug
18 Dowel
19 Block/crankcase
20 Plug
21 Plug
22 Bolt
23 Plug

Fig. 1.23 Timing cover, sump pan and oil seals (Sec 16)

1 Sump pan bolt
2 Washer
3 Sealing strip
4 Side gasket
5 Side gasket
6 Block/crankcase
7 Gasket
8 Bolt
9 Washer
10 Bolt and washer
11 Crankshaft front oil seal 12 Timing cover
14 Gasket
13 Fuel pump studs and bush 15 Cover plate
16 Bolt and washer
17 Bolt
18 Bolt
19 Washer
20 Crankshaft rear oil seal 21 Oil seal carrier
22 Gasket
23 Sealing strip
24 Sump pan
25 Drain plug

Fig. 1.24 Crankshaft and flywheel (Sec 16)

1 Centre main bearing shells 2 Front main bearing shells 3 Crankshaft
4 Plug
5 Starter ring gear
6 Dowel
7 Flywheel
8 Thrust plate
9 Bolt
10 Thrust washers
11 Rear main bearing shells