Reliant Kitten Estate, Workshop Manual

Page: 36 / 138

Page 36
22. Disconnect the lead from the temperature gauge sender on
the thermostat housing.
23.
Disconnect the speedometer cable at the gearbox.
24. Disconnect the clutch cable from the operating arm,
remove the locknut and adjusting nut and withdraw the cable from
the trunnion.
25. Pull the clutch outer cable from its retaining hole in the
engine back plate.
26. Remove nuts, bolts and lock washers connecting the
driveshaft to the gearbox output flange.
27. Remove the upper two bolts from the gearbox mounting
bracket and disconnect the earth braid. Slacken the lower two bolts
securing the gearbox mount to the chassis frame cross member.
28. Install the engine hoist bracket on to the rocker cover studs
(Figure 1) securing it with the rocker cover nuts.
29. Attach suitable lifting tackle to the hoist bracket.
30. Remove the two remaining gearbox mounting bolts.
Support the engine and gearbox assembly on the hoist.
31. Pull the engine and gearbox slightly forwards and lift to
clear the front engine mountings. Lift the assembly clear of the
bonnet area and lower on to a suitable base, taking care not to
damage the engine, sump etc.
32. Remove the bell housing bolts and separate the engine and
gearbox.
33. Remove ancillary components and carry out the necessary
service or repair operations.
To replace
1. Refit all ancillary components.
2. Re-assemble engine and gearbox.
3.
Position engine hoist bracket on to rocker studs.
4.
Attach suitable lifting tackle and suspend the assembly over
the engine compartment.
5. Carefully lower the engine and gearbox assembly and
manoeuvre to locate the front engine mounting lugs on to the front
engine mountings in the frame.
6. Attach the nuts and washers on the front engine mountings
and leave loose.
7. Raise the gearbox and locate the gearbox rear mounting
bracket to the frame, securing with bolts, nuts and lock washers.
8. Tighten front engine mounting nuts.
9. Refit the driveshaft securing with nuts, bolts and lock
washers.
10. Reconnect the speedometer cable to the gearbox.
11. Refit the clutch cable into the retaining hole in the engine
back plate and reconnect the clutch cable to the operating arm. Adjust
the clutch.
12. Refit the exhaust pipe to the manifold with a new gasket
and secure with new brass nuts.
13. Refit the exhaust support bracket to the bell housing.
14. Remove the engine hoist bracket and replace the heater
hose clip to the rocker cover stud.
15. Reconnect the fuel pipe top both carburettor and fuel
pump, securing with the "P" clip on the rear rocker cover stud.
16. Reconnect the fuel supply pipe to the pump.
17. Refit earth leads from harness to front timing cover bolt.
18. Reconnect starter motor lead.
19. Reconnect oil pressure light sender lead and oil pressure
gauge pipe (if fitted).
20.
Reconnect lead to temperature gauge sender.
21. Reconnect HT and LT leads to coil.
22. From inside the car, refit the gear lever and secure with the
"C" clip.
23. Refit the centre console and secure with four screws. Push
the gear lever gaiter over the lever and locate in the aperture in the
centre console.
24. Refit the gear lever knob.
25. Reconnect the choke and accelerator cables.
26. Re-assemble the air filter.
27. Refit heater hoses.
28. Replace radiator and reconnect top and bottom hoses.
29. Refit heater fresh air hose.
30. Refill engine and gearbox with recommended oils.
31 . Refill cooling system.
32. Refit bonnet.
33. Reconnect battery.
Operation 2
Flywheel and ring gear removal and
replacement
Flywheel removal
1.
Remove the gearbox (see
Section G
)
2.
Unscrew the six set screws, complete with lock washers,
and remove the clutch cover and driven plate from the flywheel.
3. Release the tab washer and unscrew the three set screws.
Remove the flywheel assembly from the flywheel.
Starter ring gear removal
1. Drill a hole 6.35 mm (0.25 in) diameter at the point of
intersection of a scribed line between any two teeth and a scribed line
mid way between the root diameter and the inside diameter of the
ring gear. Ensure that the hole is not drilled through the ring gear in to
the flywheel, as this will interfere with the subsequent balance of the
flywheel.
2.
Hold the flywheel assembly in a soft jaw vice.
3. Place a cloth over the ring gear as a precaution against
flying shrapnel.
Warning: Ensure adequate protection, particularly for the eyes to
prevent injury from the possibility of flying fragments when the ring
gear is split.
4.
Place a cold chisel immediately above the centre line of the
drilled hole and strike sharply to split the ring gear.
Figure 2 Fitting flywheel bearing