engine oil DATSUN 210 1979 Owner's Manual
Page 44 of 548
5
Fit
insert
ensuring
that
it
seats
on
bottom
face
of
its
recess
6
Newly
fitted
valve
seat
should
be
cut
or
ground
with
suitable
seat
cutter
or
grinding
stone
7
Apply
smalliunount
of
fine
grind
ing
compound
to
valve
contacting
face
and
put
valve
into
guide
Lap
valve
against
its
seat
ntil
proper
valve
seat
ing
is
obtained
Remove
valve
and
clean
valve
and
valve
seat
VALVE
ROCKER
ARM
1
AND
SHAFT
I
Check
rocker
arm
bore
and
shaft
for
scores
or
scuffs
2
Check
clearance
between
each
rocker
arm
and
shaft
by
measuring
inner
diameter
of
rocker
arm
bore
and
outer
diameter
of
shaft
If
either
clearance
is
not
within
spec
ification
replace
rocker
arm
and
or
shaft
3
Check
valve
end
contact
surface
of
rocker
arm
for
abnormal
wear
or
scuffs
VALVE
LIFTER
AND
PUSH
ROD
I
Check
valve
lifter
for
wear
or
scuffs
Check
bottom
end
of
valve
lifter
to
make
sure
it
has
a
slight
convex
Replace
valve
lifters
that
are
scored
worn
or
have
unsmooth
bot
tom
2
Check
clearance
between
lifter
hole
on
cylinder
block
and
valve
lifter
Replace
valve
lifter
if
clearance
ex
ceeds
wear
limit
3
Check
push
rod
for
bending
and
damage
Check
end
of
push
rod
for
rough
ness
or
excessive
wear
CAMSHAFT
AND
CAMSHAFT
BEARING
CAMSHAFT
BEARING
CLEARANCE
Journal
diameters
should
be
check
ed
with
a
micrometer
and
bearings
with
an
inside
dial
gauge
Measure
ments
should
then
be
compared
to
Engine
Mechanical
determine
whether
bearings
are
worn
If
worn
beyond
0
15
mm
0
0059
in
replace
using
Camshaft
Bearing
Drift
STl6Il0000
In
press
fitting
a
new
bearing
make
certain
that
oil
holes
in
block
and
bearing
are
properly
aligned
EM474
Fig
EM
27
Measuring
Camshaft
Bearing
Inner
Diameter
CAUTION
a
After
replacing
all
bearings
finish
bearing
inner
diameters
by
line
bor
ing
b
I
nstall
welch
plug
into
cylinder
block
applying
sealant
EM475
Fig
EM
28
Replacing
Cam
haft
Bearings
CAMSHAFT
ALIGNMENT
I
Check
camshaft
camshaft
journal
and
earn
surface
for
bending
wear
or
damage
If
fault
is
beyond
limits
replace
affected
parts
2
A
bend
value
is
one
half
of
the
reading
obtained
when
camshaft
is
turned
one
full
revolution
with
a
dial
gauge
applied
to
the
cen
ter
journal
Camshaft
bend
Total
indicator
reading
Less
than
0
10
mm
0
0039
in
EM
7
s
EM476
Fig
EM
29
Checking
Cam
haft
Bend
3
Camshaft
end
play
can
be
check
ed
by
installing
camshaft
camshaft
locating
plate
and
camshaft
sprocket
in
thier
respective
p
sitions
End
play
can
then
be
checked
with
a
dial
guage
or
feeler
gauge
If
end
play
exceeds
the
specified
limit
replace
locating
plate
Max
tolerance
of
camshaft
end
pley
0
10
mm
0
0039
in
EM477
Fig
EM
3D
Checking
Cam
haft
End
Play
VALVE
TIMING
This
diagram
applies
to
all
cyl
inders
If
any
valve
is
found
beyond
specifications
one
possibility
is
that
earn
lobe
is
worJ
1
or
damaged
exces
sively
calling
for
replacement
of
cam
shaft
CYLINDER
BLOCK
I
Visually
check
cylinder
block
for
cracks
or
flaws
2
Measure
top
of
cylinder
block
cylinder
head
mating
face
for
warp
age
If
warpage
exceeds
limits
correct
it
Warpage
of
cylinder
block
surface
Less
than
0
10
mm
0
0039
in
Page 46 of 548
Note
If
cylinder
bore
has
worn
beyond
the
wear
limit
use
cylinder
liner
Undersize
cylinder
liners
are
avail
able
for
service
Interference
fit
of
cylinder
liner
in
cylinder
block
ahould
be
0
08
to
0
09
mm
0
003
I
to
0
0035
in
PISTON
PISTON
PIN
AND
PISTON
RING
I
Remove
carbon
from
piston
and
ring
grooves
with
a
carbon
scraper
and
a
curved
steel
wire
The
wire
will
be
useful
in
cleaning
bottom
land
of
ring
groove
Clean
out
oil
slots
in
bottom
land
of
oil
ring
groove
2
Check
for
damage
scratches
and
wear
Replace
if
fault
is
detected
3
Measure
side
clearance
of
rings
in
ring
grooves
as
each
ring
is
installed
If
side
clearance
exceeds
the
speci
fied
limit
replace
piston
together
with
piston
ring
Max
tolerance
of
side
clearance
0
1
mm
0
0039
in
Engine
Mechanical
u
EM482
Fig
EM
38
Measuring
Ring
Gap
Note
a
When
piston
ring
only
is
to
be
replaced
without
cylinder
bore
be
ing
corrected
measure
the
gap
at
the
bottom
of
cylinder
where
the
wear
is
minor
b
Oversize
piston
rings
are
available
for
service
0
5
mm
0
020
in
1
0
mm
0
039
in
oversize
5
Measure
piston
pin
hole
in
rela
tion
to
the
outer
diameter
of
pin
If
wear
exceeds
limit
replace
piston
pin
together
with
piston
on
which
it
is
installed
Piston
pin
to
piston
clearance
O
OOS
to
0
012
mm
0
0003
to
0
0005
in
Note
Determine
the
fitting
of
piston
pin
into
piston
pin
hole
to
such
an
extent
that
it
can
be
pressed
smoothly
by
fmger
at
room
tem
perature
This
piston
pin
must
be
a
tight
press
fit
into
connecting
rod
EM481
Fig
EM
37
Me
suring
Piston
Ring
Side
Clearance
4
Measure
ring
gap
with
a
feeler
gauge
placing
ring
squarely
in
cyl
inder
Ring
should
be
placed
to
diameter
at
upper
or
lower
limit
of
ring
travel
If
ring
gap
exceeds
the
specified
limit
replace
ring
Max
tolerance
of
ring
gap
1
0
mm
0
039
in
EM131
Fig
EM
39
Piston
Pin
Fitting
CONNECTING
ROD
1
If
a
connecting
rod
has
any
flaw
on
either
side
of
thrust
face
and
large
end
correct
or
replace
it
Bend
and
torsion
per
100
mm
3
94
in
length
Less
than
0
05
mm
0
0020
in
EM
9
EM133
Fig
EM
40
Checking
Rod
Alignment
2
Check
connecting
rod
for
bend
or
torsion
using
a
connecting
rod
aligner
If
bend
or
torsion
exceeds
limit
cor
rect
or
replace
3
When
replacing
connecting
rod
select
rod
so
weight
difference
be
tween
new
and
old
ones
is
within
5
gr
0
180z
4
Install
connecting
rods
with
bear
iogs
on
to
corresponding
crank
pins
and
measure
thrust
clearance
If
meas
ured
value
exceeds
limit
replace
con
necting
rod
Max
tolerance
of
big
end
play
0
4
mm
0
016
in
l
Big
end
play
l
t
t
EM483
Fig
EM
41
Checking
Big
End
Pwy
CRANKSHAFT
I
Repair
or
replace
as
required
If
faults
are
minor
correct
with
fine
crocus
cloth
2
Check
with
a
micrometer
journals
and
crank
pins
for
taper
and
out
of
round
Measurement
should
be
taken
along
journals
for
taper
and
around
journals
for
out
of
round
If
out
of
round
or
taper
exceeds
the
specified
limit
replace
or
repair
Page 48 of 548
EM142
Fig
EM
48
Measuring
Bearing
Clearance
6
If
clearance
exceeds
the
specified
value
replase
bearing
with
an
under
size
bearing
and
grind
crankshaft
journal
adequately
Max
tolerance
of
main
bearing
clearance
0
10
mm
0
0039
in
MEASURING
CONNECTING
ROD
BEARING
CLEARANCE
I
Measure
connecting
rod
bearing
clearance
in
same
manner
as
above
tfl
Tightening
torque
Connecting
rod
cap
nuts
3
2
to
3
8
kg
m
23
to
27
fHb
2
If
clearance
exceeds
the
specified
value
replace
bearing
with
an
under
size
bearing
and
grind
the
crankshaft
journal
adequately
Max
tolerance
of
connecting
rod
bearing
clearance
0
10
mm
0
0039
in
Note
Since
bearings
are
precision
insert
type
it
is
not
necessary
to
file
bearing
caps
or
to
grindbeari
surfaces
with
an
emery
cloth
to
correct
bearing
clearance
MISCELLANEOUS
COMPONENTS
CRANKSHAFT
SPROCKET
AND
CAMSHAFT
SPROCKET
I
Check
tooth
surface
for
flaws
or
wear
Replace
sprocket
if
fault
is
Engine
Mechanical
found
2
Install
camshaft
sprocket
in
posi
tion
and
check
for
runout
If
runout
exceeds
the
specified
limit
replace
camshaft
sprocket
Runout
Total
indicator
reading
Less
than
0
1
mm
0
004
in
EM309
Fig
EM
49
Checking
Cam
haft
Sprocket
Runout
CHAIN
AND
CHAIN
TENSIONER
I
Check
chain
for
stepped
wear
scratches
or
other
problems
on
roller
links
Replace
if
necessary
2
Check
chain
tensioner
for
wear
breakage
or
any
other
fault
which
would
interfere
with
proper
chain
function
Replace
if
necessary
FLYWHEEL
I
Check
ring
gear
If
worn
or
dam
aged
excessively
replace
2
Clutch
contacting
face
of
fly
wheel
should
be
smooth
If
worn
damaged
or
roughened
beyond
limits
repair
or
replace
3
Before
disassembling
and
after
re
assembling
check
flywheel
run
out
with
a
dial
gauge
This
check
is
made
by
rotating
flywheel
with
dial
gauge
finger
resting
on
the
farthest
point
from
center
of
flywheel
If
it
exceeds
the
specified
limit
replace
it
EM
II
Runout
Total
indicator
reading
Less
then
0
15
mm
0
0059
in
Fig
EM
50
Checking
Flywheel
Runout
Note
Removal
and
installation
of
ring
gear
requires
use
of
hydraulic
press
It
is
also
necessary
to
heat
ring
gear
to
180
to
2000C
356
to
3920F
thus
facilitating
removal
and
installation
Do
not
heat
ring
gear
to
more
than
3000C
5nOF
To
do
so
could
result
in
impaired
hardness
of
ring
gear
CRANKSHAFT
FRONT
AND
REAR
OIL
SEAL
First
check
front
and
rear
oil
seals
for
worn
or
folded
over
sealing
lip
or
oil
leakage
If
necessary
replace
with
a
new
seal
When
installing
a
new
seal
pay
attention
to
mounting
direction
Note
It
is
good
practice
to
renew
oil
seal
whenever
engine
is
overhauled
Front
u
Front
Rear
EM487
Fig
EM
51
Cranhhaft
Oil
Seal
Page 49 of 548
PRECAUTION
Before
assembling
engine
observe
following
precautions
I
Clean
all
disass
mbled
parts
with
clean
solvent
All
611
holes
in
crank
shaft
camshaft
valve
rocker
shaft
etc
should
be
thoroughly
cleaned
to
re
move
all
traces
of
grinding
chips
or
lint
Always
use
clean
solvent
2
In
general
used
gaskets
packings
and
oil
seals
should
be
replaced
3
Under
no
circumstances
should
lockwashers
be
reuse
d
4
Place
bolts
nuts
and
woshers
back
in
their
original
parts
or
from
which
they
were
removed
5
MOst
packing
Serve
best
when
liquid
packing
is
applied
to
sealing
surfaces
When
desigiiated
use
suitable
liquid
packing
to
eliminate
possibility
of
water
oil
and
gas
leak
6
Prior
to
assemQling
all
sliding
surfaces
should
be
lioerally
oiled
7
Proper
tightening
is
essential
to
successful
performanCe
of
all
car
re
pairs
It
is
also
important
to
follow
correct
tightenig
sequence
in
pulling
up
cylinder
head
Be
on
alert
at
all
times
to
amount
of
clearance
per
mitted
8
Cleanliness
of
tools
or
parts
such
as
work
bench
used
jn
making
a
repai
is
essential
When
setting
up
a
job
every
precaution
should
be
taken
that
tools
or
parts
are
free
of
dirt
mud
and
oil
Do
not
work
in
dust
and
grit
for
they
are
primary
cause
of
wear
in
any
engine
CYLINDER
HEAD
I
Install
valve
spring
seat
Install
valve
oil
seal
by
lightly
tapping
its
head
with
a
plastic
hammer
through
Valve
Lip
Seal
Drift
KVI0104800
Engine
Mechanical
ENGINE
ASSEMBLY
m
f
if
@
@
4
1
Valve
2
Lip
seal
3
Valve
guide
4
Valve
spring
seat
EM688
Fig
EM
52
tailing
Valve
Lip
Seal
2
Insert
valve
into
valve
guide
Note
Use
care
when
inserting
valve
so
as
not
to
scratch
lip
of
oil
seal
3
Install
valve
spring
and
valve
spring
retainer
Compress
valve
pring
with
Valve
Lifter
STl2070000
and
fit
valve
collets
in
place
Release
Valve
Lifter
slowly
EM462
Fig
EM
53
Inatalling
Valve
Note
8
Do
not
interchange
valves
between
cylinders
for
their
sliding
or
seating
surfaces
have
undergone
wearing
in
or
have
been
lapped
at
assembly
forming
specific
contact
with
mat
ing
parts
b
Check
to
be
sure
that
valves
are
properly
seated
on
valve
seats
with
out
foreign
particles
stuck
in
be
tween
c
Valve
spring
is
an
uneven
pitch
type
Install
spring
facing
Wte
painted
side
to
cylinder
head
sur
face
EM
12
p
lOted
l
rJF
t
A
J
il
j
j
Wide
pilCh
l
Nallow
pitch
I
EM489
Fig
EM
54
Valve
Spring
PISTON
AND
CONNECTING
ROD
I
Assemble
pistons
piston
pins
and
connecting
rods
on
the
designated
cylinder
EM103
Fig
EM
55
Installing
Piston
Pin
EM157
Fig
EM
56
Arranging
Piaton
and
Connecting
Rod
Note
3
Piston
is
pressed
into
connecting
rod
Fitting
force
is
from
1
to
3
tons
and
aid
of
Piston
Pin
Press
Stand
KVI
01
05300
is
necessary
When
pressing
piston
pin
in
connec
ting
rod
apply
engine
oil
to
pin
and
small
end
of
connecti
8
rod
b
Arrange
so
oil
jet
hole
of
connect
ing
rod
big
end
is
directed
toward
right
side
of
cylinder
block
c
Be
Sure
to
install
piston
in
cylinders
with
notch
mark
of
piston
head
toward
front
of
engine
Page 50 of 548
2
Install
piston
rings
Install
so
that
stamped
mark
on
ring
faces
upward
Note
a
There
are
two
types
of
top
rings
One
is
conventional
special
cast
iron
ring
the
other
is
steel
ring
which
is
called
a
high
power
ring
b
Second
ring
has
larger
taper
surface
than
top
ring
c
In
combined
oil
ring
upper
rail
is
same
as
lower
one
I
lnT
10
EM158
Fig
EM
57
Installing
Piston
Ring
3
Fix
bearings
on
connecting
rod
and
connecting
rod
cap
VALVE
ROCKER
SHAFT
ASSEMBLY
Install
parts
as
shown
in
Fig
EM
58
in
place
on
rocker
shaft
@
EM491
Fig
EM
58
Valve
Rocker
Shaft
As
embly
ENGINE
ASSEMBLY
I
The
first
step
in
engine
assembly
is
to
bolt
Engine
Attachment
KV
10
102500
to
right
hand
side
of
cylinder
block
In
succession
install
block
in
Engine
Stand
ST0501S000
with
engine
bottom
up
2
Apply
a
light
coat
of
engine
oil
to
Engine
Mechanical
sliding
surfaces
of
valve
lifters
insert
lifters
in
holes
in
cylinder
block
3
To
install
camshaft
be
sure
to
coat
sliding
surfaces
of
camshaft
bush
ings
with
a
light
coat
of
engine
oil
Insert
camshaft
in
cylinder
block
from
front
side
of
engine
exercising
care
not
to
damage
camshaft
bushings
4
Install
camshaft
locating
plate
and
tighten
bolts
to
specified
torque
i
l
Tightening
torque
Camshaft
locating
plate
0
4
to
0
5
kg
m
2
9
to
3
6
ft
Ibl
Note
Set
locating
plate
so
as
the
Lower
mark
comes
to
engine
bottom
side
Fig
EM
59
Installing
Camshaft
Locating
Plate
5
Install
baffle
plate
and
steel
net
6
Set
main
bearings
at
proper
por
tion
of
cylinder
block
and
caps
No
1
2
3
0
0
0
0
0
0
I
I
J
upperW
r
Lower
J
EM492
Fig
EM
60
Main
Bearings
and
Caps
Note
a
Center
bearing
No
3
is
a
flanged
type
for
thrust
force
b
Two
internal
bearings
No
2
and
No
4
are
of
the
same
type
c
Front
bearing
No
I
is
the
same
type
as
rear
bearing
No
5
EM
13
d
All
bearings
except
No
2
and
No
4
are
not
interchangeable
between
upper
and
lower
bearings
7
Apply
engine
oil
to
main
bearing
surfaces
on
both
sides
of
cylinder
block
and
cap
Install
crankshaft
8
Install
main
bearing
cap
and
tight
en
bolts
to
specified
torque
lil
Tightening
torque
Main
bearing
cap
5
0
to
6
0
kg
m
36
to
43
ft
lb
Note
a
Apply
seal
to
each
rear
main
bear
ing
contact
comer
of
cylinder
block
as
shown
in
F
EM
61
EM493
Fig
EM
6
Applying
Sealant
b
Arrange
parts
so
arrow
mark
on
bearing
cap
faces
toward
front
of
engine
c
Prior
to
tightening
bearing
cap
bolts
place
bearing
cap
in
proper
position
by
shifting
crankshaft
in
axial
direction
d
Tighten
bearing
cap
bolts
gradually
in
two
to
three
stages
outwardly
from
center
bearing
in
the
sequence
shown
in
Fig
EM
62
e
After
securing
bearing
cap
bolts
ascertain
that
crankshaft
turns
smoothly
@I
EM494
Fig
EM
62
Torque
Sequence
of
Cap
Bolts
Page 51 of 548
9
Make
SUre
there
is
proper
end
play
at
crankshaft
Crankshaft
end
play
0
05toO
15mm
0
OO20
to
0
0059
in
laJlk
h
end
play
J
EM486
Fig
EM
63
Checking
Crank
luJft
End
Play
10
Install
rear
oil
seal
using
suitable
drift
Fig
EM
64
n
talling
Rear
Oil
Seal
II
Install
rear
plate
12
Install
flywh
el
secwely
and
tighten
bolts
to
specified
torque
dl
Tightening
torque
Flywheel
and
drive
plate
A
14
engine
fixing
bolts
8
0
to
9
0
kg
m
58
to
65
ft
Ib
Drive
plate
A
15
engine
fixing
bolts
8
5
to
9
5
kg
m
61
to
69
ft
b
Fig
EM
65
n
talling
Flywheel
13
Rotate
engine
quarter
turn
and
install
piston
rod
assembly
using
Pis
Engine
Mechanical
ton
Ring
Compressor
EM03470000
EM497
Fig
EM
66
tolling
Platon
Rod
Assem
bly
Note
a
Insert
pistons
in
L
r
nding
cyl
inders
b
Apply
engine
oil
to
sliding
parts
c
Arrange
pistons
so
number
stamped
on
piston
head
faces
to
front
of
engine
d
Before
installing
piston
piston
rings
should
be
positioned
as
shown
in
Fig
EM
67
Second
ring
Oil
ring
lower
rail
EM49B
Fig
EM
67
Positioning
Piston
Ring
Gap
14
Apply
engine
oil
to
bearing
surfaces
dl
Tighte
ning
torque
Connecting
rod
cap
nuts
3
2
to
3
8
kg
m
23
to
27
ft
b
EM499
Fig
EM
68
Tightening
Connecting
Rod
Cap
Note
Am11
connecting
rods
and
connecting
rod
caps
so
cylinder
numben
face
in
same
direction
EM
14
I
S
Make
sure
there
exists
proper
end
play
at
connecting
rod
big
end
See
Fig
EM41
Big
end
play
0
1
to
0
2
mm
0
004
to
0
008
in
16
Insert
crank
sprocket
keys
in
keyways
of
crankshaft
Install
cam
shaft
and
crankshaft
sprockets
tempo
rarily
for
adjustment
of
tooth
height
by
using
adjusting
washers
Height
dif
Less1
h
l11
0
5
mm
0
020
in
Adjusting
washer
thickness
0
5
mm
10
020
in
EM500
Fig
EM
69
Adju
ting
Sprocket
Tooth
Height
17
Install
tinting
chain
and
cam
shaft
sprocket
with
their
markings
properly
aligned
See
Fig
EM
70
Then
set
No
I
piston
at
T
D
C
on
compression
stroke
See
Fig
EM
71
Oil
sprocket
teeth
and
chain
with
engine
oil
Match
mark
Key
groove
EM501
Fig
EM
70
Aligning
Markinga
Note
Make
sure
camshaft
sprocket
dowel
hole
and
crankshaft
sprocket
key
are
in
line
and
both
dowel
hole
and
key
are
located
downward
Page 52 of 548
m
k
camSM9tJ
down
hole
Key
groove
EM767
Fig
EM
11
Setting
No
I
Piston
atT
D
C
18
Tighten
camshaft
sprocket
bolt
ifl
Tightening
torque
Camshaft
sprocket
bolt
4
to
4
8
kg
m
29
to
35
fHbl
EM502
Fig
EM
72
Tightening
Camshaft
Sprocket
Bolt
19
Install
chain
tensioner
and
tight
en
tensioner
attaching
bolts
ifl
Tightening
torque
Tensioner
enaching
bolt
0
6
to
0
8
kg
m
14
3
to
5
8
ft
b
EM503
Fig
EM
73
Installing
Chain
Tensioner
20
Check
projection
L
of
ten
sioner
spindle
If
projection
L
exceeds
the
speci
fied
limit
replace
chain
Engine
Mechanical
Correct
projection
L
Less
than
15
mm
0
59
inl
lEM504
Fig
EM
74
Checking
Projection
of
Tf
nsioner
Spindle
21
Correctly
install
oil
thrower
in
front
of
camshaft
sprocket
22
Press
new
oil
seal
in
timing
chain
cover
F
ran
t
cover
oil
seal
should
be
replaced
when
front
cover
is
disassem
bled
23
Install
timing
chain
cover
with
gasket
in
place
Note
When
inatalling
oil
seal
apply
coating
of
engine
oil
to
mating
shaft
to
prevent
scratches
and
fold
ed
lip
Also
apply
coating
of
oil
to
periphery
of
oil
seal
ifl
Tightening
torque
Timing
chain
cover
bolts
0
5
to
0
7
kg
m
3
6
to
5
1
ft
Ib
Z5
1
o
j
I
t
f
4
EM455
Fig
EM
75
Installing
Timing
Chain
Covtr
24
Install
water
pump
with
gasket
in
place
ifl
Tightening
torque
Water
pump
attaching
bolts
0
9
to
1
4
kg
m
16
5
to
10
1
ft
bl
25
Install
crank
pulley
then
con
firm
and
set
No
I
piston
at
T
D
C
on
compression
stroke
EM
15
ifl
Tightening
torque
Crank
pulley
nut
15to
20
kg
m
108
to
145
ft
b
26
Invert
engine
Install
oil
stniiner
and
oil
pan
using
new
gasket
and
oil
seal
Note
Give
coating
of
sealant
to
seam
between
oil
pan
gasket
and
oil
pan
oil
seal
ifl
Tightening
torque
Oil
pan
bolts
0
4
to
0
6
kg
m
12
9
to
4
3
ft
lb
27
Install
gasket
and
cylinder
head
Note
Do
not
apply
sealant
to
any
other
part
of
cylinder
block
and
head
surface
28
Tighten
cylinder
head
bolts
ifl
Tightening
torque
Cylinder
head
bolts
7
0
to
7
5
kg
m
51
to
54
ft
IM
Note
a
One
of
cylinder
head
bolts
is
smal
ler
in
diameter
than
others
and
has
a
hollow
head
It
should
be
install
ed
on
right
side
center
of
cylinder
head
b
Tightening
should
be
made
in
two
or
three
steps
finally
torquing
to
specification
c
Retighten
cylinder
head
bolt
after
engine
has
been
warmed
up
Refer
to
Carburetor
Idle
R
P
M
and
Mixture
Ratio
EF
Section
for
Adjustment
and
Inspection
EM505
Fig
EM
76
Cylinder
Head
Bolt
Tightening
Sequence
Page 53 of 548
29
Apply
engine
oiho
both
ends
of
push
rods
and
insert
in
proper
se
quence
30
Apply
engine
oil
to
valve
stem
end
and
rocker
arm
contact
surfaces
Position
rocker
shaft
assembly
on
cyI
inder
head
31
Tighten
rocker
shaft
bracket
bolts
to
specified
torque
fJ
Tightening
torque
Rocker
shaft
bracket
bolts
2
0
to
2
5
kg
m
14
to
18
ft
b
Note
Tightening
should
be
done
in
two
or
three
stages
outwardly
from
center
bracket
EM506
Fig
EM
77
Rocker
Shaft
Bolt
Tightening
Sequence
32
Adjust
valve
clearance
to
speci
fied
value
Note
a
First
set
clearance
to
0
25
mm
0
0098
in
when
engine
iscold
b
After
engine
has
been
assembled
warm
it
up
for
at
least
several
minutes
finally
adjust
clearance
to
specification
For
details
refer
to
Adjusting
Intake
and
Exhaust
Valve
Clearance
in
ET
Section
EM507
or
Wrench
2
Screwdriver
3
Feeler
gauge
Fig
EM
78
Adjusting
Value
Clearance
Engine
Mechanical
Valve
clearance
Intake
and
exhaust
hot
0
35
mm
0
014
in
cold
0
25
mm
0
010
in
fJ
Tightening
torque
Velve
rocker
adjusti
g
nut
1
6
to
2
2
kltm
12
to
16
ft
b
33
Install
rocker
cover
34
Install
intake
and
exhaust
mani
folds
fJ
Tightening
torque
Manifold
nuts
1
5
to
2
0
kg
m
11
to
14
fHb
Note
When
installing
intake
and
ex
haust
manifolds
locate
bolt
in
center
of
fitting
hole
EM528
Fig
EM
79
Installing
Manifolds
35
Install
E
G
R
control
valve
36
Install
baffle
plate
and
carbure
tor
fJ
Tightening
torque
Carburetor
nuts
0
4
to
0
6
kg
m
2
9
to
4
3
ft
Ibl
37
Install
vacuum
control
valve
as
sembly
and
bracket
38
Install
air
cleaner
bracket
and
air
cleaner
39
Connect
air
vacuum
and
blow
by
hoses
to
air
cleaner
40
Install
pipe
connector
to
control
valve
hose
and
engine
mounting
brack
etLR
41
Install
distributor
EM
16
CAUTION
a
8e
sure
to
set
No
1
piston
to
LD
C
of
compression
stroke
b
Before
instaliation
return
distribu
tor
rotor
approximately
30
degrees
from
its
correct
position
Insert
distributor
meshing
distributor
drive
gear
and
driven
gear
c
After
installation
distributor
rotor
should
align
with
mark
on
rotor
cap
J
No
1
mark
EM508
Fig
EM
80
Cornct
P05ition
of
Rotor
42
Dismount
engine
from
Engine
Stand
ST0501S000
and
place
it
on
suitable
engine
stand
Re
move
Engine
Attachment
KVlOI
2500
43
Install
spark
plugs
and
engine
mounting
bracket
R
H
44
Install
oil
pump
and
ftIter
assem
bly
45
Install
thermostat
and
water
outlet
46
Install
fuel
pump
and
fuel
lines
Do
not
forget
to
install
spacer
and
gasket
47
Install
distributor
vacuum
line
48
Install
distributor
cap
and
high
tension
cables
as
an
assembly
Connect
high
tension
cables
49
Insert
oil
level
gauge
50
Install
fan
fan
pulley
and
fan
spacer
Lock
bolt
by
bending
lock
washers
51
Install
alternator
bracket
adjust
ing
bar
water
pump
pulley
alternator
Page 55 of 548
Engin
Mechanical
SERVICE
DATA
AND
8PECIRCATION8
GENERAL
SPECIFICATIONS
Engine
model
AI5
Cylinder
arrangement
4
in
line
Displacement
cc
cu
in
1
397
85
24
I
488
90
80
Bore
and
Stroke
mm
in
76
0
x
77
0
76
0
x
82
0
2
992
x
3
031
2
992
x
3
228
Valve
arrangement
OR
V
Firing
order
I
3
4
2
Compression
2
Number
of
piston
rings
Oil
Number
of
main
bearings
5
Compression
ratio
California
and
FU
model
of
Non
California
Non
California
except
FU
model
and
Canada
EM
18
8
9
8
5
Page 64 of 548
Engine
Mechanical
Piston
ring
Unit
mm
in
Standard
Wear
limit
Top
0
04
to
0
07
0
0016
to
0
0028
0
10
0
0039
Side
clearance
2nd
0
03
to
0
06
0
0012
to
0
0024
Oil
Combined
Top
0
20
to
0
35
0
0079
to
0
0138
Ring
gap
2nd
0
15
to
0
30
1
00
0
0394
0
0059
to
0
0118
Oil
0
30
to
0
90
rail
ring
0
0118
to
0
0354
Piston
pin
Unit
mm
in
Interference
fit
of
piston
pin
to
connecting
rod
18
995
to
19
000
0
747
to
0
748
63
00
to
63
25
2
480
to
2
490
19
003
to
19
012
0
748
to
0
749
0
008
to
0
012
0
0003
to
0
0005
0
017
to
0
035
0
0006
to
0
0013
Piston
pin
diameter
Piston
pin
length
Piston
pin
hole
diameter
Piston
pin
to
piston
clearance
CONNECTING
ROD
Unit
mm
in
Standard
Repair
replace
limit
Center
distance
132
97
to
133
03
5
2350
to
5
2374
Bend
per
100
mm
or
3
94
in
length
Less
than
0
05
0
0020
0
10
0
0039
Torsion
per
100
mm
or
3
94
in
length
Big
end
play
Less
than
0
07
0
0028
0
1
to
0
2
0
004
to
0
008
0
4
0
016
EM
27