SM 20Engine 20Manual

8/2/2019 SM 20Engine 20Manual

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2 SM VEHICLES

DISMANTLING Contd, I5

OVERHAULING THE ENGINE

6

S 100-3

Remove the mechanism and the clutch discRemove the f ly-wheelToo I E from the se t 3064- T

7

Remove the manifold:-Col lar (1)- Screw (2)

[ \EMOVING THE CYLINDER-HEADS

- Turn the engine to b ring ih e sp rin g l inks to the top- Loosen the chains by slackening the nuts (1)- Remove the spring l inks- Disengage the chains hom t he" exhaust"camshaft pinions


4/30

SM VEHICLES

DISMANTLING Contd.

7 Contd.- Remove the screw at posit ion


PARTICULAR POINTS ON DISMANTLING AND ASSEMBLY

8IIa .

S 100-3

- Swivel the tensioner towards the bottom.- Disengage the screw (1) of the tensioner.- Remove the cha in tens ioner- Remove the cyl inder heads (screws 2)

8 Contd.

f ~ e m o v i n9 the water pump

- Unlock the nu t (2) and remove it .- Remove the turbine (be carefulwith the cotter).

- Remove the water pump cover(screw 1)

- Remove the sea l ing ring of the pumpshaft,


5/30

SM VEHICLES

DISMANTLING Contd.

9

Remove the oi I sump


10

Remove the oi I pump f i l ter

S 100.3

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ; ~ ......' , " ~ ~ ~ = " -

11

Remove t he t iming case

12Disengage the chain tensioner

, Using a screwdr iver apply pressureto the lug (1) and turn the spindle (2)a qua rt er o f a turn,Remove the cha in gu ide and the tens ione!'( ta ke car e with the f lat washers betweenthe tens ioner and the hous ingL


6/30

SM VEHICLES

DISMANTLING Contd.

13

OVERHAULING THE /ENGINE


REMOVING THE INTERMEDIATE TIMING SHAFT

S 100-3 5

Remove the driving flange from the H,P.pump control shaft,

13 Contd.- Disengage the timing chain betweenthe housing and the piniono

- Remove the intermediate t iming shaft .- Disengage the chain- Remove the sealing ring (1)(extractor tube


7/30

SM VEHICLES OVERHAULING THE ENGINE S 100.3

SMANTLING (Gnld. I- Remove th e con rod cap s ( so ck et of 14 mm

and adaotor of 3/8" ) ,- - - - - - _ _ _ : \ , - Remove the

cran ks haft

16 . Remove:- The crankshaft bear ing shel l s

- Remove th eco n rod pistonassemblies

- The end f lo at adjusting shims.

6 Contd.CLEANING

Carefully clean al l the parts and the joint surfaces.Blow with compressed air.

NOTE: Alcohol shou ld be used t o r emove CURTYLON.


8/30

Remove the gudgeon pinToo I G fro m th e set 3064 - T

SM VEHICLES

DISMANTLING Contd.

17

Remove the rings



WORK ON THE CON F ~ O D PISTON ASSEMBLIESIIIIII

S 100-3 7

18

Remove:- The sparking plugs- The camshafts

STRIPPING THE CYLINDER- HEADS

Remove the valve push rods and the capsulesfor adjusting the clearance" marking theirrespective positions,


9/30

SM VEHICLES OVERHAULING THE ENGINE S 100.3

u ISMANTLING Contd.

Contd.

Remove the free-play l imiter of the chain. Remove the va Ives(universal compressor and tool D fromthe se t 3064-T)

8 Contd.- Grind the seatings and the valves (gr inds tone1630-T)\Nidth of the bearing faces of the seatingsIn le t : 2.5 mmOut let : 2,2 mm

- Grind the va Ives

Stripping the timing caseRemove:- The oi I pump- The gasket (1) (tube spanner (I) : 33 mmlength: 100 mm)

- The acce lera to r con tro I return lever (4)

Valve seating Inlet

- The plug (2)- The un ion (3) and t he by-pas s va Ive

( i f necessa ry),In .After g rind ing in,c lean t he par tscareful ly and blowthem with compressed air i n o rder toeliminate all traceof abras ivematerials.

- Outletalve seating


10/30

SM VEHICLE aVERHAU LING AN ENGIN E S 100.3 9

ASSEMBLY PARTICULAR PINTS ON DISMANTLING AND ASSEMBLY

IMPORTANT NOTES Check how far the barrels are recessed.GASKETSALL gaskets must be systematically renewedAll gaskets shou Id be fitted greased wi thtallow(except the RE INZ cyl inder-head gaskets whi ch mu stbe fi tted dry).TIGHTENING TORQUESOn this engine, all t ightening torques MUSTbe respeeted .Failure to do this results in deformation whichadversely affects the correct running of the engine.

NOTE: Nuts and bolts must be fitted withthe ir threads oi led.

1) In relation to the joint face of the cylinder casing:0.02 - 0.05 mm.

2) Amongst themselves, the barrels should bein the same plane to within: 0.02 mm.Straight edge 1698-T + foil . Correct ifnecessary with tool A from se t 3064 - T

20 PREPARING THE PISTON/CON ROD ASSEMBLIES- When as sem bl ing the pistons a nd con rods, the chamfer C shou Id be on the same s ide a s the longerslope L.

- Heat the con rod to 200 - 250C (392-482 F) (oven).- Position the con rod in the piston (guide of assembly G of se t 3064-T)


11/30

SM VEHICLES

ASSEMBLY Contd.

OVERHAULING AN ENGINE S 100.3

Contd.- Place th e piston/ con rod assembly on t he suppor t of assembly G, set 3064-T.- Fit the s pind Ie in place (pres sand mandre I of assembly G, set 3064-T) .- Fit th e rings,a) Oi I control ring (2) - gap : 0.25 - 0.40 mm - "TOP" mark at th e topb) Scraper ring (1) - gap, 0.30-0.45mm - " TOP" mark at the topc)Compression ring (3 ) - gap: 0.35 - 0.45 - unma.rked

- F ix t he e ng in e casing on th e support

Support

2

22 1 2 30 0 0 REARFRONT(FLYWHEEL 0 0 0IDE) 6 5 .4

-F i t the hal f b ea ri ng s in the casing

Fo r con rods 1,2,3, chamfer C towards frontFor con rods 4,5,6, chamfer C t owards r ea r


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SM VEHICLES

ASSEMBLY Contd.

22 Contd.

OVERHAU LING AN ENGINE


FITTING THE ENGINE HARNESS

S 100-3 1

- Offer up the crankshaft. Hold i t above the bearings (plates F of se t 3064- T in order to avoid damaging the halfbearings whose inter ior diamaterr in a free state, is smaller tha n the diameter of the crankshaft pin).- Fi t the piston/con rod assemblies (normal ring f it ting cofla r) in the order 1-6 r 2-5, 3-4 tighten to 68 mAN(608 m,kg 49 ft/lbs) socket 14 + reducer 3/8"

- Withdraw the plates and lower the crankshaft onto its bearings.- F it the bearing ha If shells (without tongue) : clearance OJ 5-0022 mm: the oi I reserves should be on the crankshaftside.

23 FITTING THE SUMP- F it the ho If-bearings: the ho If shells (tongued)r stuck together with grease.- Coat the surface of the gasket with CURTYLON- Fi t the sump half and tigh ten the nuts A of the bearing to 95 - 97 m!\N (9.5-9.7 m.kg r 68-69 ft / lbs).Observe the tightening sequence,

- Tighten the bolts (B) to 15-20 rn/\N (L5-2 Inokg, 10,8-14,4 ft/lbs).


13/30

SM VEHICLES

ASSEMBLY Contd.

OVERHAULING AN ENGINE S 100-3

:l4FITTING AN OIL SEAL

(Orange-couloured gasket_with micro-turbine on lip)

- Light Iy grease the lip of the se a I- Fit the seal. Tool MR. 630-34/32

25 26- Bring the marks on the crankshaft and the housi ng

into line,- Fit the engine flywheel- Ti ghten the bo Its : 1-20 mAN (12 m.kg, 86 hi Ibs)- Immobilize the f lywheel, Tool E of se t 3064-T,

- Fi t the control chain of the intermediate shafton the pinion,


14/30

SM VEHICLES

ASSEMBLY Contd.

26 Contd.

OVE RHAU LING AN ENGINE


FITTING AND ADJUSTING THE INTERMEDIATE TIMING SHAFT

S 100.3 13

- Position the control chain (see photo)- Fi t the intermediate shaft.a) Bring the marks on the pinion and the housing into line.b) The marks (1) should be visible in the timing chain passage.

26 Contd. Engage the cha in on the control pin ion.Engage the intermediate shaft on the bearings.F it the tens ioner (2) (washer between tens ioner and hous ing)Tighten to 10-12 mAN (1-L2m.kg 7.2-8.7 ft/lbs)Fit the runner (3) (washer between runner and housing).Tighten to 9-11 mAN (0.91.1 m.kg 6.5-8 ft/lbs)Set the chain tensioner.Fi t the free play limiter (4) Clearance of: 0.2 mm between limiter and chain.Tighten to 9-11 mAN (0.9-L1 m.kg 6.5-8 ft/lbs)


15/30

SM VEHICLES aVERHAU LING AN ENGINE S 100-3

ASSEMBLY Contd.

27 PREPARING THE OIL PUMP

NOTE: It is essential to fi t a piston witha shoulder at a.

5

0-- 60 -78

Fi t on the body of the pump:- The piston (10), the spring (9) and the return pipe (8L the adjusting washer (6) and the copper gasket (7).Tighten to 30mAN (3 m.kg 22 ft/lbs)- The ring sea Is (1) (2) and (11). Grease before fitting.- The whee I (4L the pin ion (3),- The pump cover (5).- Tigh.ten the bolts (12) to 18-20 r l 1 J \ N ( J _ . ~ ~ l r T 1 . k g . 13:}4.4 ft/lbs),.-=--=---.........._ - ..........- - - - - - - - - - - - - - ' - ' - - - - - - - - - - - - ,

11

2

28PREPARING THE TIMING CASE

- Fi t the by-pass valve. Screw the valve into the case.- Fi t the oil f il ter union (4) : 90-100 mAN (9-10 m.kg 65-72 ft/lbs).- F it the oi I sea I (2) in place (ma ndrel = 36 mm, length = 100 mm).- F it the acce lerator control return lever (3).- Tighten the nut to : 25-27 mAN (2.5-2.7 m.kg 18.1 - 19.5 ft/lbs).


16/30

SM VEHICLES

ASSEMBLY Contd.

OVERHAULING AN ENGINE


S 100-3

28 Contd.. Fi t the plug (6L tighten to 70 mAN (7 m,kg51 ft/lbs)- Fit the oi I pump: t ake care in pos it ioning thering sea I : 26-28 mAN (2,6-208 mokg19-20,3 ftl Ibs)

- Fi t the ring seal (5) in place,- Hold the pipe (7) against th e return pipe

using a ring.

29 Contd.

- Tighten the bolts (3) to 21-23 mAN(2 1-23 m,kg 15,2 - 16,6 ft/lbs)

29 FITTING THE TIMING CASE- F it the cone (B) of the se t 3064-T on th'e endof the intermediate shaft"

- Fi t the pump drive shaft (1) (with a little grease- Fi t the timing case. Turn the oil pump slightlyto faci l it at e the engagement of the drive shafto

30

- Fit t he b reather (gasket )- Tighten the bol ts : 10 mAN (1 mokg 702 ft/lbs)o


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16 SM VEHICLES

ASSEMBL y c o n ~OVERHAULING AN ENGINE S 100-3

31 32- Fit th e housing connecting th e oil cooler,- Ti ghten th e bo It s : 20 mAN (2 m.kg 14A ftl Ibs )- Fit th e oi l temperature thermal switch (1) :30-35 mAN (3-3,5 m,kg, 22-25 f t / lbs)

- Fit th e oi l p re ssur e sw it ch (2): 30-35 mAN(3-3,5 m.kg 22-25 f t / lbs) ,

- Check th e soldering of th e suction t ube l fi Iterassembly,

- Fit th e suction tubelfi l ter assembly. Tightenth e bolts (1).: 10 mAN (1 mokg 7,2 f t / lbs) ,

- Fit th e oi l bas in ( ga sk et ) : tak e c are with th eshutters of th e anti-emulsion partitions

32 Contd.

Tighten the bolts (2): 16-18 mAN(L6- L8 m,kg 1L6-13 f t / lbs) .

33- Fit t he int ermed ia te shaft oi l sea l :tube spanner : into q) = 30 mm

ext, cj) = 45 mmlength, (p = 100 mm

It should be l ev el wit h th e casing.

NOTE: To p ro te ct t he lips of th e gasket, wrapadhesive tape around th e splines


18/30

SM VEHICLES

ASSEMB LY Contd.

34



35

S 100-3 1

Fi t the drive plate of the H,P pumpcontrol shafteFi t the nut (1) but do not tighten,

FITTING THE WATER PUMP

- Fi t t he oil seal (1) on the housing,- Coat the thrus t face (a) of the gasket and it scontact surface on the turbine with ROCOL A,S,Por MOL YKOTE 557 grease

35 Contd.Fit :- The key- The turbine- The washer, the stop washer- The nut ( thread coated with ADEXOLIN 56 glue)Tighten the nut: 30 m.\N (3 mkg,22 ft/lbs).Fold down the stop washer locking lugs.

- Fi t the cover (with its ring seal),- Tighten the bolts: 20 mAN (2 m,kg 14.4 ft/lbs).


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18 SM VEHICLES

ASSEMBL Y Contd.

6


CHECKING THE FLATNESS OF THE CYLINDER HEADS

S 100.3

- Check the flatness of the cylinder headsStraight edge 1698-T and f oi l s tr ip sMax out of flat = 0.05 mm,

- Minimum height after regrinding 110,2 mm,

37PREPARING THE CYLINDER HEADS

Make sure that the ducts (1) and (2) and the jetsfor the camshaft lubricating oi l are clean,

Fi t : Valve stem oil seals (inlet ~ n l y ) The cups The springsUniversa I compressor and too I D from set 3064T.


20/30

SM VEH ICLES OVERHAULING AN ENGINE S 100-3 1"""">-'.....,> " " " " " ' - ~ = ~ , ~ > ' > ' - - > ~ = - = - - ' = T " " ~ ' ~ ~ " ~ > ~ ~

_,


21/30

SM VEHICLES

ASSEMBL Y Contd,

Contd.


- F it the capsules chosen in thei r respectiveplaces

. Fit the pushrodso

- Fit the camshaftsTighten the bearing caps: 26-28 mAN(206 - 208 mo kg . 18,8 - 20"3 ft l Ibs)

- Turn the camshafts unti I the marks "a " and" b "are in linec

38. Bring cylinder No, 1 to TD CMark" 0 II on intermediate shaft, visible in t iming chain passage (straight edge support 1754-Tand gauge 2437- T)

Pu t the timing chain in position on the intermediate shaft (using wire) : the upper end of the chainshou Id stand proud of the hous ing by approx, 200 mmc


22/30

SM VEHICLES OVERHAU LING AN ENGINE


S 100.3

3 9 ~ ;Brass rings: ( se t of three) must not be pitted,scratched or cracked.REINZ) gasket: t he re mus t be no burring at a and

no hairJi ne fractures.-:Fit'the brass rings (1), slightly greased, on the

barre Is. Centre them.- Place the REINZ gasket in position (correct any

possible overlap). 7,PD- Fi t the ring seals (2) in the holes b . 'If) ~ p I J I 'oFITTING R.H. CYLINDER HEAD

- Fi t the cylinder head on the block" Bringthe two marks A and B into Iine o

39 Contd. FITTING RoH, CYLINDER HEAD- Fit the cylinder heac1 bolts in place (do not forget

th e i ift ing lugsL- Fi t the chain tensioner (ring seal on tensioner

and copper washers under blind nuts).f(1 t O/'Vi ) Tighten the bolts in the tightening sequence,

1s t tightening: 50 mAN (5 m.kg 36 ft/lbs)2nd tightening: 110 mAN (11 mokg 79 ft/lbs)

Pass the cha inunder the pirtionof the exhaustcamshafto


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22 SM VEHICLES

9 Contd.


Fit the s pr i ng li n ka) Thick space'r in middle of chainb) The clip on the side of the hexagonal camshaftadjusting nutc) Open end of c lip towards rear (direction ofchain rotation).

9 Contd.

Tens i on the tim in g c ha in20 mAN (2 m,kg 14A f t / lbs) i e, 10 kg (22 Ibs)on spring ba lance (All en key 6 mm,extension MR 630-13/5 and spring balance)Tighten the nuts (9) to 20 m/\N (2 m, kg 1,1 4 f t / lbs)

REQUIRED FOR CHECKING AND ADJUSTING THE TIMING (SET 3185-T)

1682-T --------1

A

E

1682-T: Gauge supportA : Gauge supportB : Two gauge pinsC : False bearings ( f I ~ e jl'l.p " !(4D : Spanner for turning camshaftsE : Spanner for camshaft nutsF : Retaining p'late for support A,


24/30

SM VEH OVE RHAU LING AN ENGINE


- Loosen the nu t (1) (pin spanner E of se t- Find top dead centre (TDC) of cylinder 1(gauge support 1682-T

gauge 2437-T)

TIMING ADJUSTMENT ( R c H ~ CYLINDER HEAD)IIIIIII

3185-T)- Free toothed ring (2)

D I S E N G A G I ~ , ! G CAMSHAFTS

40

14a C o n t d ~- Replace the fron t bearings of the two crankshaftswith the false bearings C of the set 3185-T,

- Do not t ighten the nuts (3)

- Put the gauge support A from se t 3185-T,and gauge 2437-T in posi tion, wi th the pinpress ing on the in le t pu shrod of cy I inder1. Fi x it in position using plate F fromthe set 3185-T

- Bring the needle o f the gauge to 0,

!


25/30

SM VEHICLES OVERHAULING AN ENGINE S 100-3

ASSEMBLY Contd,

0 Contd.INLET- Push in th e pushrod by 1 mm, turn th e camshaft in th e ro ta t ion direc tion of t he eng ine (spannerD from set 3185-T)- T ig ht en t he false bearing C of se t 3185-T.

- Find, by t urning the too thed ring(2L th e point at which i.t engages atth e s ame time in th e splines of th ecamshaft and fu lIy in t he t ee th of th epinioncExhaust

- T ig hte n t he nu t (1) (pin spanner Efrom set 3 1 8 S ~ : T L

Loosen th e nuts of th e false bearingsct ~ O T E : The bearing caps wi II be fi tted

and ti ghtened to 26-28 mAN(206-208 mokg 1808-20,3 ft l Ibs )after th e tim; ng adjustment ha sbeen checked.

Contd.

EXHAUSTpushrod of cylinder 10

direction to th at of the engine rotation,

--+!View from F 1

View from F.82 t e e t h . ~......5 9 t e e t h ~

tF1

- Fit.the support A (fixed by plate FL th e pin touching the exhaust- Bring the needle of the gauge to aPush in th e pushrod by 1, 3 mm : turn th e camshaft in t h e oppos it eighten th e false bearing Cfrom set 3185-T.

- Find, by turning t he too thedring (2L t he poi nt whe ret h i s engages correc tl y,

- Tighten the nut (1) (pinspanner E from set 3185-T)o


26/30

SM VEHICLES OVERHAULING AN ENGINE S 100.3 2

ASSEMBL Y Contd. PARTICULAR POINTS ON DISMANTLING AND ASSEMBLY

USING GAUGES- Turn the engine in the opposite direction- Bring the in le t cam of cy I inder No.1 to the posi tionwhere the valve begins to ' open (however the pushrodmust be able to rotate).Fit support A of set 3185-Tin positionBring the needle to II 0 11 (pin,pressing on pushrod)- Bring cy l inder 1 to TDC. The gauge of supportA should show a travel of 1 mm.

CHECKING TIMING ADJUSTMENT (R,H, CYLINDER HEAD)IIIIIII

USING MARKINGSWith cylinder 1 at TDC and the valves in the"rocking 11 position, the long marks 11 a II on thecamshafts must be in line with the marks l ib"of the bearing caps,

41

41 Contd. 42- Fit support A in position on the exhaust push-

rod of cylind'er 1,- Bring the need le to II all 0- Turn the engine until the valve is on its seat- The gauge should show a t rave l o f L3mm;

FITTING L.H. CYLINDER HEADBring piston of c y l i n d e ~ 6 to TDC (no mark II 0 II onshaft),

- Fit the timing in on the intermediate shafto- Fit the brass ri the cylinder head gasket

in p lace,- Fit the cylinder head and tighten to correct torque,- Fit the chain tensioner and the chain- Fit the spring link.- Tens ion the t iming chain.


27/30

SM VEHICLES

ASSEMBLY Contd.


3TIMING ADJUSTMENT (L. H. CYLINDER HEAD)

- Disengage the camshaftso-Find TDC on cylinder 6- Replace the bea ring caps wi th t he false bearings- Fit gauge suppor t A on th e exhaust pushrod- Bring th e needle to "0 "Inlet: Push in the pushrod by 1 mm (direction of engine rotation) Tighten th e false bearing- Find th e correct engagement point of the too thed ring. Tighten th e nu tExhaust: Fi t support A in position on th e exhaust pushrod Bring th e needle to "0 " Push in the pushrod by 1.3 mm (opposite direction to that of engine rotation)- Tighten th e false bearing- Find the correct engagement point of the too thed ring. Tighten t he nuL

4CHECKING THE TIMING ADJUSTMENT (LHo CYLINDER HEAD)

USING MARKS With the cyl inde r 6 at TDC and valves in "rocking"pos ition l th e short marks on th e camshafts shouldbe in line with the marks on th e bearing caps,

USING GAUGESUse th e same procedure as that used when checkingth e timing adjustment of th e R.H. cylinder heado


28/30

SM VEHICLES

ASSEMBLY Contd

45] OVERHAULING AN ENGINEPARTICULAR POINTS ON DISMANTL ING AND ASSEMBL Y

46

S 100-3 27

STATIC DISTRIBUTOR ADJUSTMENT- Bring cylinder 1 to TDC on the compression stroke- F it the distributor (cover removed)1) the bracket for tr.e condensors approximatelyalong central axis of engine

2) the two dogs in the position shown below(see photo)

47CLUTCH

- Fit the clutch disc and mechanism(Centrer 3106-T or used control shaftL

- Tighten the securing bolts (1)36-40 mAN (3 64 m kg 26 - 29 f t / lbs)

CYLINDER HEAD COVERS- F it the cylinder head covers- Tighten the nuts to 10 - 12 mAN( l -L2m,kg 7,2-8Jft / lbs)

- Fit the 'sparking plug wire brackets

48WATER MANIFOLD

- Fit the water manifold,

- Remove the thermostat ic regulator, check itStarts to open: 75 - 76C (167-169 F)Opening: 7,5 mm minimum at 85 C (185 F)

- Fit the thermostat ic regulator


29/30

28 SM VEHICLES

ASSEMBL Y Contd

OVERHAULING AN ENGINE S 100-3

49- Fit th e inlet pipe/carburettors assembly, tightenth e bolt (1) : 5 mAN (05 m,kg 3,6 f t / lbs)

- Connect th e accelerator control

- Fit th e o il filler pipe, t ighten the bolt20 m\N (2 m kg 14 4 ft l Ibs )

50- Fit th e oi l filter (gasket oiled)

- Hand tighten ito

51- Remove t he eng ine from th e support:S ling 2517-T

52- Fit th e starter motor (spanner 3061-T)- Fit the engine supports an d th e rub ber blocks- Adjust them (measurement taken between bottomof stee I support and th e top of th e rubber block),

- Tighten th e engine suppo rt bolts 40 mAN(4 m, kg 29 ftl Ibs)

23.5+0.5mm

1.01..

L,H,sideCi mm


30/30

SM VEHICLES OVERHAULING AN ENGINE S 100.3 2

MR6 3 0 . 3 ~ /32SP ECI FI CA TI ONS 0 F TOOLS NOT ON SAL E

OIL seAL. F,J(lNfi.. Toot..

70

1 Bell housing

5 045

",,12

63

50

3 Screws

20 35

MATE RI AL Semi -hardened stee l

.0.12 175 ISO

=800 ..100

~ : ; 3 - ' - ' - '

-.adiIJ sf \.

t ~ I~ ~ Ir ~ 1 - - - 0 - . - L 7 200

1 Centri ng fi xture

MR. 63013 ' 5

-r-II

IiI

180II

Hexagonal ke y 6 AI F

1520

8

40

0.1051

Documents

SM 20Engine 20Manual