Reliant Kitten Estate, Workshop Manual

Page: 49 / 138

Page 49
Figure 29 Valve clearance - tappet
adjustment
1. Feeler gauge
2. Adjusting screw
3. Lock nut
15. Refit front engine plate with a new gasket, to the engine
block and secure with three nuts and washers.
16. Fit the crankshaft outer thrust washers with the oil slots
facing forward, followed by the steel thrust washer with its
countersunk aperture facing rearwards.
17 . Fit the woodruff key, spacer and crankshaft sprocket.
18. Using the flywheel, turn the crankshaft until the woodruff
key is pointing to 11 o'clock.
19. Turn the camshaft until the groove in the end of the
camshaft is in alignment with the woodruff key on the crankshaft.
20. Replace the camshaft sprocket along with the timing chain
and secure with two bolts and new locking plate.
21. Using a straight edge, check the camshaft sprocket is in
alignment with the camshaft sprocket. The valve timing mark on the
camshaft sprocket should now be pointing to the woodruff key on the
crankshaft.
22. Check timing chain tensioner for wear, renew if worn, and
position on the post in the timing cover.
23. Fit the timing chain with a new gasket, using centralising
tool No. RT 7481, and secure with seven bolts, two nuts and lock
washers (
Figure 11
).
24. replace crankshaft pulley and secure with bolt, plain washer
and lock washer.
25. Locate a new gasket and fit the oil pump assembly,
complete with strainer, securing to the cylinder block with two nuts
and lock washers. Refit oil pump and distributor drive shaft.
26. Fit a new gasket and then fit the sump pan, tightening the
fifteen set screws and spacers evenly.
27.
Clean the cylinder head and cylinder block faces and fit a
new gasket. Smear grease around the metal edges of the gasket bore
eyelets.
28. Carefully position the cylinder head squarely on the cylinder
block and secure with twelve nuts, plain washers and lock washers.
Replace the three bolts on the sparking plug side of the cylinder head.
Figure 30 Tappet adjustment tool
Figure 31 Stud removal tool
Check that the cylinder head nuts indicated in Figure 14 are tightened
progressively to a torque of 3.46 kg/m (25 lb/ft). The three smaller
nuts should be tightened to 2.07 kg/m (15 lb/ft).
29. Replace the push rods ensuring they are positioned in the
correct order.
30. Install the rocker shaft on the four studs and secure firmly
with four nuts and washers to a torque of 2.35 to 3.04 kg/m (17 to 22
lb/ft) Check tappet clearance (see Operation 17).
31.
Fit a new gasket and refit the rocker cover.
32.
Refit all ancillaries.
33. Install the engine and gearbox assembly (see Operation 1 ).
Operation 17 Valve clearance - tappet adjustment
Tappet clearances are:- 0.152mm (0.006 in) cold,
0.254 mm (0.010 in) hot