Reliant Rebel 700 1967 Workshop Manual page 33

Figure 17 Compressing rings for
refitting pistons
Note: The "top" mark on the taper compression ring must face
uppermost. The upper groove in the piston accommodates the plain
compression ring.
10. Insert the piston and connecting rod assemblies into the
appropriate bores, ensuring that the piston crown arrow or front
marking is facing the front of the cylinder block. The piston rings
should be rotated so the gaps are equally spaced around the
circumference of the pistons. Compress the rings using a piston ring
compressor (Figure 17) and gently tap the assemblies into place.
11. Fit new big end bearing shells to the rods and caps and
lubricate thoroughly using engine oil .
12. Locate the rods on to the crankshaft, position the end caps
and secure in position with the bolts and new tab washers. Tighten to
a torque of 2.9 kg/m (21 lb/ft). Ensure that the correct caps are fitted
to the corresponding rods.
13. Replace the oil pump assembly, sump and cylinder head.
Operation 12 Crankshaft removal and installation
(sump, front cover, flywheel, rear cover,
connecting rods and camshaft sprocket
removed
1. Remove two bolts and lock washers and remove camshaft
retaining plate.
2. Unscrew two nuts and lock washers and remove front
engine plate and gasket from cylinder block.
3. Unscrew four set screws and remove the rear engine plate
from the cylinder block.
4. Remove four screws and detach the two bridge pieces from
the cylinder block.
5.
Remove three main bearing caps each secured by nuts and
lock washers.
6. The crankshaft can now be lifted from the cylinder block.
Overhaul
1. Inspect and test crankshaft journals for wear.
2.
Fit new main bearing shells to crankcase and main bearing
caps. See data for reground journal undersize bearings available.
3. Position the crankshaft into the new shells and fit rear and
centre main bearing caps.
4. Locate the upper half of the thrust washer in the register on
the inside face of the crankshaft main bearing bore in the crankcase.
5. Position the front main bearing cap and locate the lower
half of the thrust washer in the register on the cap inside face.
Note: The thrust washer is fitted so that the thrust face, identified by
oil grooves, bears against the crankshaft ground face.
6. Fit new bearing cap nuts and lock washers and tighten to a
torque of 3.31 kg/m (24 lb/ft).
Check the crankshaft end float as follows:
(a) Assemble the two halves of the outer thrust washer in the
register on the outside face of the front bearing cap and block. Ensure
that the oil grooves face forwards.
(b) Position the steel countersunk thrust washer against the bi-
metal thrust washer halves, with its countersunk aperture facing
rearwards.
(c) Refit crankshaft sprocket spacer and sprocket.
(d) Refit crankshaft pulley and secure with bolt, washer and
lock washer.
(e) Rotate crankshaft to confirm freedom of movement. Secure
a dial gauge to the crank case with the pointer bearing on a machined
section of a crankshaft balance weight.
(f) Carefully tap the rear of the crankshaft forwards to force
the assembly against the dial gauge plunger. Zero the gauge.
(g) Now tap the front pulley of the crankshaft towards the rear
and note the end float on the gauge. This should indicate 0.0764 to
0.279 mm (0.003 to 0.011 in).
(h) If necessary, adjust the end float by replacing the thrust
washers with new ones of a different thickness. See data at the end of
this section. refit the front cap with the replacement thrust washers
and check the end float again.
Note: The end float can also be checked using feeler gauges between
the thrust washer and the bearing face of the crankshaft.
To re-assemble
Replace all components in reverse order. Lubricate the main bearing
shells thoroughly using engine oil before installing the bearing caps.
Note: When refitting the crankcase bridge pieces care should be taken
to ensure that they are completely flush with the crankcase flange.
Also it is essential to fit new cork seas when refitting bridge pieces.
Operation 13
1. Remove engine assembly (see operation 1)
2.
Remove rocker cover and gasket.
3. Remove rocker shaft assembly.
4. Remove 8 pushrods keeping them in their correct order.
5.
Remove cylinder head and distributor.
6. Remove sump (see operation 3)
7. Remove two nuts and lift the oil pump assembly complete
with strainer from the cylinder block.
8. Knock out the pin securing the thrust muff to the distributor
and oil pump drive shaft and remove the shaft upwards through the
distributor aperture.
9. Remove the two bolts and lock washers securing the
camshaft retaining plate.
10. Undo three nuts and washers and remove the front engine
plate from the cylinder block, complete with gasket.
11. Lift the cam followers out through the cylinder block and
carefully withdraw the camshaft.
Page 33
Camshaft removal and installation
(timing chain and sprocket removed)