CITROEN SM Instruction manual

AUTOMOBILES
C I T R O E N
AFTER-SALES TECHNICAL DIVISION
The enclosed schedule deals with particular points concerning
the overhauling of a MASERATI engine in an SM vehicle.
These particular points are taken from ORKSHOP MANUAL 581-3.
INFORMATION
BULLETIN
N° 1 S
20th April 1972
CONFIDENTIAL
(all rights reserved)
SM VEHICLES
(SB series SB)
This schedule contains 29 cards which can be used as " workshop
index cards
These may be protected with plastic sleeves.
Place the cards in the proximity of the work-bench where the
overhaul of components is carried out so that the mechanic can use
them for reference. ENGINE
OVERHAULING
THE
ENGINE

SM VEHICLES OVERHAULING THE 'ENGINE S 1 -3 1
DISMANTLING PARTICULAR POINTS ON DISMANTLING AND ASSEMBLY
Raise the engine using the lifting attachments
Remove :
- The engine mountings
- The starter motor
Use the sling 251 7-T
Fix the engine on the dismantling support
Stand 2509-T
Adaptor 2512-T
3
Remove
- The air fi Iter
- The circ Iips(3) of the accelerator control
knuckle
- The air-intake horns
- The base of the filter (1)
- The carburettor/manifold assembly (screw 2)
REMOVE THE OIL FILTER
Strap wrench | Spanner
e.g. FACOM D.46 ! MR„ 630-14/49

2 SM VEHICLES OVERHAULING THE ENGINE
DISMANTLING Contd.
Remove the mechanism and the clutch disc
Remove the fly-wheel
Tool E from the set 3064-T
/f**
6
Remove the manifold
- Collar (1)
- Screw (2)
7
REMOVING THE CYLINDER-HEADS
Turn the engine to bring the spring links to the top
Loosen the chains by slackening the nuts (1)
Remove the spring links
Disengage the chains from the "exhaust"
camshaft pinions.

SM VEHICLES OVERHAULING THE ENGINE S 1 -3
DISMANTLING Contd. PARTICULAR POINTS ON DISMANTLING AND ASSEMBLY
7 Contd.
- Remove the screw at position "a
- Swivel the tensioner towards the bottom.
- Disengage the screw (1) of the tensioner.
- Remove the chain tensioner
- Remove the cylinder heads (screws 2)
- Remove the water pump cover
(screw 1)
B Contd.
Removing the water pump
- Unlock the nut (2) and remove it.
- Remove the turbine (be careful
with the cotter). - Remove the sealing ring of the pump
shafts

4 SM VEHICLES OVERHAULING THE ENGINE S 100-3
DISMANTLING Contd.
Remove the oil sump
10
- Remove the oil pump filter
11
Remove the timing case
12
- Disengage the chain tensioner :
Using a screwdriver apply pressure
to the lug (1) and turn the spindle (2)
a quarter of a turn.
- Remove the chain guide and the tensioner
(take care with the flat washers between
the tensioner and the housing).

SM VEHICLES OVERHAULING THE ENGINE S 1 -3 5
DISMANTLING Contd. PARTICULAR POINTS ON DISMANTLING AND ASSEMBLY
13 REMOVING THE INTERMEDIATE TIMING SHAFT
Remove the driving flange from the H.P.
pump control shaft.
Disengage the intermediate timing s.iaft
1 3 Contd.
- Disengage the timing chain between
the housing and the pinion,
- Remove the intermediate timing shaft.
- Disengage the chain
- Remove the sealing ring (1)
(extractor tube c/j = 39 mm, length = 400mm)
14
Remove the lower housing and its gasket.
N„B„ : This housing is held by
8 dowel s

6 SM VEHICLES OVERHAULING THE ENGINE S 1 -3
DISMANTLING Contd.
i J - Remove the con rod caps (socket of 14 mm
and adaptor of 3/8"). Remove the
crankshaft
Remove the
con rod pi ston
assembl ies
^ ^ - Remove :
- The crankshaft bearing shells
- The end float adjusting shims.
Contd.
CLEANING
Carefully clean all the parts and the joint surfaces.
Blow with compressed air.
NOTE : Alcohol should be used to remove CURTYLON.

SM VEHICLES OVERHAULING THE ENGINE S 100-3 7
DISMANTLING Contd. PARTICULAR POINTS ON DISMANTLING AND ASSEMBLY
17 ORK ON THE CON ROD PISTON ASSEMBLIES
Remove the rings | Remove the gudgeon pin
i Tool G from the set 3064 - T
18 STRIPPING THE CYLINDER- HEADS
Remove : I Remove the valve push rods and the capsules
, I for adjusting the clearance.,,, marking their
- I he sparking plugs I
I respective positions*

8 SM VEHICLES OVERHAULING THE ENGINE S 1 -3
DISMANTLING Contd.
i 3 Contd.
Remove the free-play limiter of the chain.
Contd.
Grind the seatings and the valves (grindstone
1 630-T)
idth of the bearing faces of the seatings
In let : 2,5 mm
Outlet : 2S2 mm - Grind the va Ives
in.
After grinding in,
clean the parts
carefully and blow
them with compres
sed air in order to
eliminate all trace
of abrasive
materials.
Stripping the timing case
Remove ;
- The oi I pump
- The gasket (1) (tube spanner c/> : 33 mm
length : 1 00mm)
- The accelerator control return lever (4)
- The plug (2)
- The union (3) and the by-pass valve
(if necessary).
Remove the valves
(universal compressor and tool D from
the set 3064-T)

SM VEHICLE OVERHAULING AN ENGINE S 1 -3 9
ASSEMBLY PARTICULAR POINTS ON DISMANTLING AND ASSEMBLY
IMPORTANT NOTES
GASKETS
ALL gaskets must be systematically renewed
All gaskets should be fitted greased with tallow
(except the REINZ cylind er-head gaskets which must
be fitted dry).
TIGHTENING TORQUES
On this engine, all tightening torques MUST
be respected.
Failure to do this results in deformation which
adversely affects the correct running of the engine.
NOTE : Nuts and bolts must be fitted with
their threads oiled.
Check how far the barrels are recessed.
1) In relation to the joint face of the cylinder casing
0.02 - 0.05 mm.
2) Amongst themselves, the barrels should be
in the same plane to within : 0.02 mm.
Straight edge 1698-T + foil. Correct if
necessary with tool A from set 3064 - T
20 PREPARING THE PISTON/CON ROD ASSEMBLIES
hen assembling the pistons and con rods, the chamfer C should be on the same side as the longer
slope L.
- Heat the con rod to 200° - 250°C (392-482° F) (oven).
- Position the con rod in the piston (guide of assembly G of set 3064-T)

1 SM VEHICLES OVERHAULING AN ENGINE S 1 -3
ASSEMBLY Contd.
^ J Contd.
- Place the piston/con rod assembly on the support of assembly G, set 3064-T.
- Fit the spindle in place (press and mandrel of assembly G, set 3064-T).
- Fit the rings.
a) Oil control ring (2) - gap : 0.25 - 0.40mm - "TOP" markat the top
b) Scraper ring (1) - gap, 0.30-0.45 mm - " TOP " mark at the top
c) Compression ring (3) - gap : 0.35 - 0.45 - unmarked
21
Fix the engine casing on the support
Fit the half bearings in the casing
22
For con rods 1,2,3, chamfer C towards front
For con rods 4,5,6, chamfer C towards rear

SM VEHICLES OVERHAULING AN ENGINE S 1 -3 11
ASSEMBLY Contd. PARTICULAR POINTS ON DISMANTLING AND ASSEMBLY
Contd. FITTING THE ENGINE HARNESS
- Offer up the crankshaft. Hold it above the bearings (plates F of set 3064“ T in order to avoid damaging the half
bearings whose interior diamater, in a free state, is smaller than the diameter of the crankshaft pin).
- Fit the piston/con rod assemblies (normal ring fitting collar) in the order 1-6,2-5, 3-4 tighten to 68 mAN
(6.8 m.kg 49 ft/lbs) socket 14 + reducer 3/8"
' ithdraw the plates and lower the crankshaft onto its bearings.
- F it the bearing ha If she I Is (without tongue) : clearance 0.1 5-0.22 mm : the oi I reserves should be on the crankshaft
s ide.
23 FITTING THE SUMP
- Fit the half-bearings : the half shells (tongued), stuck together with grease.
- Coat the surface of the gasket with CURTYLON
- Fit the sump ha If and tighten the nuts A of the bearing to 95 - 97 mAN (9.5-9-7 m.kg, 68'69 ft/ I bs).
Observe the tightening sequence.
-Tighten the bolts (B) to 15-20 mAN (1 .5-2 m.kg. 1 0.8-1 4.4 ft/ lbs).

12 SM VEHICLES OVERHAULING AN ENGINE S 1 -3
ASSEMBLY Contd.
FITTING AN OIL SEAL
(Orange-couloured gasket„with micro-turbine on lip)
Lightly grease the lip of the seal
Fit the seal. Tool MR. 630-34/32
25
- Fit the engine flywheel
- Tighten the bolts : 120 mAN (12 m.kg, 86 ft/lb s)
- Immobilize the flywheel. Tool E of set 3064-T.
26
- Bring the marks on the crankshaft and the housing
into line.
- Fit the control chain of the intermediate shaft
on the pinion.

SM VEHICLES OVERHAULING AN ENGINE S 1 -3 13
ASSEMBLY Contd. PARTICULAR POINTS ON DISMANTLING AND ASSEMBLY
2 6 Contd. FITTING AND ADJUSTING THE INTERMEDIATE TIMING SHAFT
- Position the control chain (see photo)
-Fit 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.
2 Contd. Engage the chain on the control pinion.
Engage the intermediate shaft on the bearings.
Fit the tensioner (2) (washer between tensioner and housing)
Tighten to 10-12 mAN (1-1.2 m.kg 7o2-8.7 ft/lbs)
Fit the runner (3) (washer between runner and housing).
Tighten to 9-11 mAN (0,9-1.1 m.kg 6.5-8 ft/lb s)
Set the chain tensioner.
Fit the free play Iimiter (4) Clearance of ; 0.2 mm between limiter and chain.
Tighten to 9-11 mAN (0.9-1.1 m.kg 6.5-8 ft/lb s)

14 SM VEHICLES OVERHAULING AN ENGINE S 1 -3
ASSEMBLY Contd.
27 PREPARING THE OIL PUMP
Fit on the body of the pump :
- The piston (10), the spring (9) and the return pipe (8), the adjusting washer (6) and the copper gasket (7).
Tighten to 30 mAN (3 m.kg 22 ft/lb s)
- The ring sea Is (1) (2) and (11). Grease before fitting.
- The wheel (4), the pinion (3). N0TE ■ lt is essential to fit a piston ivith
- The pump cover (5). a shoulder at « «»■
- Tighten the bolts (12) to 18-20 mAN (JL8-2 m.kg. 13-14.4 ft/lbs)
PREPARING THE TIMING CASE
- Fit the by-pass valve. Screw the valve into the case.
-Fit the oil filter union (4) : 90-100 mAN (9-10 m.kg 65-72 ft/lbs).
- Fit the oil seal (2) in place (mandrel 0 = 36mm, length = 100mm).
-Fit the accelerator control return lever (3).
- Tighten the nut to : 25-27 mAN (2.5-2.7 m.kg 18.1 -19.5 ft/lbs).

SM VEHICLES OVERHAULING AN ENGINE S 1 -3 15
ASSEMBLY Contd. PARTICULAR POINTS ON DISMANTLING AND ASSEMBLY
28 Contd.
• Fit the plug (6), tighten to 70 mAN (7 m.kg
51 ft/lbs)
- Fit the oil pump : take care in positioning the
ring seal : 26-28 mAN (2.6-2.8 m.kg
19-20.3 ft/lbs)
- Fit the ring seal (5) in place.
- Hold the pipe (7) against the return pipe
using a ring.
29 FITTING THE TIMING CASE
- Fit the cone (B) of the set 3064-T on the end
of the intermediate shaft..
- Fit the pump drive shaft (1) (with a little grease)
- Fit the timing case. Turn the oil pump slightly
to facilitate the engagement of the drive shaft.
Contd.
Tighten the bolts (3) to 21-23 mAN
(21-2 3 m.kg 15.2 - 16.6 ft/lb s)
3
- F it the breather (gasket)
- Tighten the bolts : 10 mAN (1 m.kg 7.2 ft/lbs).

16 SM VEHICLES OVERHAULING AN ENGINE S 1 -3
ASSEMBLY Contd.
31 - Fit the housing connecting the oil cooler,
- Tighten the bolts : 20 mAN (2 m.kg 14,4 ft/lbs)
- Fit the oil temperature thermal switch (1) :
30-35 rnAN (3-3.5 m.kg, 22-25 ft/lbs)
- Fit the oil pressure switch (2) : 30-35 mAN
(3-3.5 m,kg 22-25 ft/lbs),
32- Check the soldering of the suction tube/filter
assembly,
- Fit the suction tube/filter assembly. Tighten
the bolts (1).: 10 mAN (1 m.kg 7.2 ft/lbs).
- Fit the oil basin (gasket) : take care with the
shutters of the anti-emu Ision partitions.
Contd.
Tighten the bolts (2) : 16-18 mAN
(1.6 - 1.8 m.kg 11,6-1 3 ft/lbs).
o q
- Fit the intermediate shaft oil seal :
tube spanner : int. q> = 30mm
ext, o — 45 mm
length, (p — 1 00 mm
It should be level with the casing.
NOTE : To protect the lips of the gasket, wrap
adhesive tape around the splines
%

SM VEHICLES OVERHAULING AN ENGINE S 1 -3 17
ASSEMBLY Contd.
34
PARTICULAR POINTS ON DISMANTLING AND ASSEMBLY
FITTING THE ATER PUMP
Fit the drive plate of the H,P pump
control shaft.
Fit the nut (1) but do not tighten.
- Fit the oil seal (1) on the housing,
- Coat the thrust face (a) of the gasket and its
contact surface on the turbine with ROCOL A.ScP
or MOLYKOTE 557 grease
Fit :
- The key
- The turbine
- The washer, the stop washer.
- The nut (thread coated with ADEXOLIN 56 glue)
Tighten the nut : 30 mAN (3 m kgt22 ft/lbs).
Fold down the stop washer locking lugs.
- Fit the cover (with its ring seal).
- Tighten the bolts : 20 mAN (2 mckg 14.4 ft/ lbs).

18 SM VEHICLES OVERHAULING AN ENGINE S 1 -3
ASSEMBLY Contd.
v i6
CHECKING THE FLATNESS OF THE CYLINDER HEADS
- Check the flatness of the cylinder heads
Straight edge 1698-T and foil strips
Max out of flat = CL05 mm.
-Minimum height after regrinding 110.2mm.
37
PREPARING THE CYLINDER HEADS
Make sure that the ducts (1) and (2) and the jets
for the camshaft lubricating oil are clean.
Fit :
- Valve stem oil seals (inlet only)
- The cups
- The springs
Universal compressor and tool D from set 3064-T,

SM VEHICLES OVERHAULING AN ENGINE S 1 -3 19
ASSEMBLY Contd. PARTICULAR POINTS ON DISMANTLING AND ASSEMBLY
PREPARATION OF THE CYLINDER HEADS
Fit the free play limiter (2) (bolts fitted with
LOCTITE GX 01 460 01 A)„
Fir the capsules (1) and the push rods found
when dismantling, back in their respective
places
Fit the camshaft : inlet, (V), exhaust (',)
Fit the caps of the camshaft bearings
(marked by Nos).
Tighten the nuts : 26-28 mAN (2 6-2.8 m kg
18.8-20.3 ft/lbs)
*3 T ...
w I Lonta.
- 1 urn the camshafts
(spanner D from set 3185-T)
- Check the clearance between cams and pushrodsc
Cl earance in practice
Inlet : 0 30-0.35 mm
Exhaust : 0 50-0.55 mm
- Remove
- The camshafts
- The pushrods and the capsulesc
- Measure the thickness A of each capsule
- From amongst the capsules sold by the replacement
parts, choose those that will give the correct
c learance.
Thickness A = in steps of 0,025 mm