engine oil DATSUN 610 1969 Owner's Manual

inter
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illl

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l

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Au

y
l
ver

I

R
H

I
Equaliler
b2nd

i
b7ke

Pl
te

Iock
band
buk

able
I

I

I

T

@A
Adjuster
cable

oo

pm
Odb
k
SPd
wm

LH
able

C

Note

@
Apply
bearing

grease

@APPIYch
S

i

Pin
fulcrum
hand

brab
lever
6c

1l

Clip
cable
frout
N
nd
brake

Fill
L21
Handbrake

linkage
1400
and
1600
c
c

Saloons

1
I
J

Pull

priDg

1

Clt
vU

Balance
leve

I

I

J
c

1
1

I

I
1

l

J

L

I

iL

Note

@
Apply
engine
oil
8

S

J

@

I

Aj

Fran
able
Rear
cable

L

I
r

f
7

n
t

i

Adjust

position
A

Fig
L
22
Handbrake

linkage
1400
and
1600

c
c

Estate

cars

1
Control
sUm

2
Control
ratchet

Xing

3
O
mtrol
ratchet

4
O
mtro

guide

5

Control
bracket

6

OJntrol
yoke

7
wer

spring

8
Control
lever

Fig
L
23

Handbrake

linkage
1800

c
c
models

104
able

s

Fig
L
19

Checking
the

brake
disc
for

run
out

1

j

v

fti

r

v

r

Fig
L
20

As
embling
the

piston
seals
and

retainer

ti

J

4

Fill
L
24
The
handbrake

cable

adjuster
Saloons

9

Front
cable

10
Centre

lever

II
Rear
cable

adjuster

12
DIble

lock

plate

13

Return

spring

14

RI
fU
cabk

15
Qevis

ElectrIcal

EquIpment

DESCRIPTION

BATTERY
Maintenance

STARTER
MOTOR

Removal
and

Dismantling

STARTER
MOTOR

Testing

STARTER
MOTOR

Assembly
and
Installation

ALTERNATOR
Removal

Dismantling
and

Inspection

DESCRIPTION

A
12
volt

negative
earth
electrical

system
is
used
in
which

the

battery
is

charged
by
an
alternator
In
the
alternator
a

magnetic
field
is

produced
by
the
rotor

which
consists
of
the

alternator
shaft
field
coil

p
le

pieces
and

slip
rings

Output
current
is

generated
in
the
armature
coils
located

in
the
stator
Six
silicon
diodes
are

incorporated
in
the
alternator

caSing
to

rectify
the

alternating
current

supply
A
voltage

regulator
and

pilot
lamp
relay
are
built
in
the

regulator
box

which

nonnally
does
not

give
trouble
or

require
attention

The
starter
motor
is
a

brush

type
series
wound
motor

in

which

positive
meshing
of
the

pinion
and

ring

gear
teeth
are

secured

by
means
of
an

overrunning
clutch

BATTERY
Maintenance

The

battery
should
be
maintained
in
a
clean
and

dry

condition
at
all
times
or
a
current

leakage
may
occur

between

the
terminals
If

frequent
topping

up
is

required
it
is
an

indication
of

overcharging
or
deterioration
of
the

battery

When

refitting
the
cables
clean
them

thoroughly
and
coat

their

terminals
and
the
terminal

posts
with

petroleum
jelly

Check
the
level
of
the

electrolyte
in
the

battery
at

frequent

intervals
and

top
up
if

necessary
to

the
level
mark
on

the

battery
case
with
distilled
water
A

hydrometer
test
should
be

carried
out

to
determine
the
state

of

charge
of

the

battery
by

measuring
the

specific
gravity
of
the

electrolyte
It
should
be

pointed
out

that
the
addition
of

sulphuric
acid
will
not

normally

be

necessary
and
should

only
be
carried
out

by
an

expert
when

required

The

specific
gravity
of
the

electrolyte
should
be
ascertained

with
the

battery

fully
charged
at
an

electrolyte
temperature
of

200C
680F

The

specific
gravity
of
the

electrolyte
decreases
or
increases

by
0
0007
when
its

temperature
rises
or
falls

by
10C
1
80F

respectively

The

temperature
referred

to
is
that
of
the

electrolyte
and

not
the
ambient

temperature
to
correct
a

reading
for
an
air

temperature
it
will
be

necessary
to

add
0
0035
to
the

reading

for

every
50C
above
200C

Conversely
0
0035
must

be
deducted

for

every
SOC
below
200C
Test
each
cell

separately
and
draw

the

liquid
into
the

hydrometer
several
times
if
a
built
in

thermometer
type
is
used

The
correct

specific
gravity
readings
should
be
as
follows
ALTERNATOR

Assembly
and
Installation

HEAD
LAMPS

Replacing

HORN

INSTRUMENT
PANEL
Removal

WINDSCREEN
WIPERS

WINDSCREEN
WASHERS

IGNITION
SWITCH
AND
STEERING
LOCK

Cold
climates

Temperature
climates

Tropical
climates
Permissible

value

Over
1
22

Over
1
20

Over
1
18
Fully
charged
at
200C

680F

1
28

1

26

1
23

The

battery
should
be

recharged
if
a
low

specific
gravity

reading
is
indicated

Always
disconnect
both
terminals
of
the

battery
when

charging
and
clean
the
terminal

posts
with
a

soda

solution
Remove
the
vent

plugs
and

keep
the
electrolyte

temperature
below
450C
l130F
during
charging

Check
the

specific
gravity
after

charging
and
if
it
is
above

1
260
at

200C
680C
add
distilled
water

STARTER
MOTOR
Removal
and
Dismantling

As
previously
stated
the
starter
motor

is
brush

type
series

wound
motor
in
which
the

positive
meshing
of
the

pinion
and

ring
gear
teeth
are
secured

by
an

overrunning
clutch
The
over

running
clutch

employs
a
shift
lever
to
slide
the

pinion
into

mesh
with
the
flywheel
ring

gear
teeth
when
the
starter
is

operated

When
the
engine
starts
the

pL
lion
is

permitted
to
overrun

the
clutch
and
armature

but
is
held
in
mesh
until
the
shift
lever

is
released
An

exploded
view
of
the
starter

is
shown
in

Fig
M
2

To
remove
the
starter

motor

proceed
as
follows

Disconnect
the

battery
earth
cable

2
Disconnect
the
black
and

yellow
wire
from
the
solenoid

terminal
and
the
black
cable
from
the

battery
terminal

3
Remove
the
two
bolts

securing
the
starter
motor
to
the

clutch

housing
Pull
the
starter
motor

assembly
forwards

and
withdraw

it
from
the
v
hicle

To
dismantle
the
starter

motor
ftrst
remove
the
brush

cover
and
lift
out

the
brushes
as
shown
in

Fig
M
3

Loosen
the
nut

securing
the

connecting
plate
to

the

solenoid
M
terminal
Remove
the
solenoid

retaining
screws

take
out

the
cotter

pin
and
withdraw

the
shift
lever

pin
Remove

the
solenoid

assembly
as
shown
in

Fig
M
4

Remove
the
two

through
bolts

and
rear
cover

assembly

then
remove

the
yoke
assembly
by
lightly
tapping
it
with
a

wooden
mallet

Fig
M
S
Withdraw
the
armature
and
shift

lever

Fig
M
6
Remove
the
pinion

stopper
from
the

armature
shaft

by
removing
the

stopper
washer
pushing
the

109

stopper
to

the
overrunning
clutch

side
and
removing
the

stopper
clip
Remove
the

stopper
and

overrunning
clutch
as

shown

inFig
M
7

Oean

the
dismantled

components
and
check
them
for

wear
or

damage

Cbeck
the
brushes
and
renew

them
if
worn
below
6
5mm

0
257
in
Fit
new
brushes
if
the
brush
contact
is
loose
Cbeck

the
brush
holders
and

spring
clips
and
make
sure

that

they
are

not
bent
or
distorted
The
brushes
should
move

freely
in

their

housings
and
can
be
eased
with
a
file
if

necessary
The
brush

spring
tension
should

be
approximately
0

8kg
1
76Ib

and

can
be
checked
with
a

spring
balance
as

shown
in
Fig
M
S

Armature

assembly

Make
sure
that
the
surface
of
the
commutator

is
not

rough
or

pitted
Oean
and

lightly
polish
with
a
No
500

emery

cloth
if

necessary
If
the
commutator
is

badly
worn
or

pitted

it
should
be
skimmed
in
a
lathe

only
a

light
cut
must

be
taken

to
remove

the
minimum
amount

of
metal
If
the
commutator

diameter
wear
limit
of
0
2mm
0
OS
in

is
exceeded
the

assembly
must
be

renewed

Undercut

the
mica
between
the
commutator

segments

when
the

depth
of
mica
from
the
surface
of
the

segment
is

less
than
0
2mm
0
08

in
The

depth
should
be
between

0
5
0
8mm
0
0197
0
0315
in
as
shown
in

Fig
M
9

The
armature
shaft
should
be
checked
for

straightness

by
mounting
between

the
centres
of
lathe
and

positioning

a
dial

gauge
as
shown
in

Fig
M
I
O
Renew

the
armature

if
the

bend
of
the
shaft
exceeds
0
08mm
0
0031
in

Field
coils

testing

Test
the
field
coils
for

continuity
by
connecting
a

circuit

tester
between
the

positive
terminal
of
the
field
coil
and
the

positive
terminal
of
the
brush
holder
as
shown
in

Fig
M

I
I
If

a

reading
is
not

obtained
the
field
circuit
or
coil
is

open

Cbnnect
the
tester
to
the

yoke
and
field
coil

positive

teoninal
as

shown
in

Fig
M
12
to

check
the
field
coils
for

earthing

Unsolder
the
connected

part
of
each
coil
and
check
the

circuit
for

earthing
in
a
similar
manner

Renew
the
field

coils

if

they
are

open
earthed
or
short
circuited

Outch
assembly

The

overrunning
clutch
must
be

replaced
if
it
is

slipping

or

dragging
Examine
the

pinion
and
sleeve

making
sure
that

the

sleeve
is
able
to
slide

freely

along
the
armature
shaft

spline

Inspect
the

pinion
teeth
for

signs
of

rubbing
and
check
the

fly

wheel

ring
gear
for

damage
or
wear

Bearings

Inspect
the
metal

bearing
bushes
for
wear
and
side

play

The
bushes
must

be
renewed
if
the
clearance

between
the

bearing

bush

and
armature
shaft

is
in
excess
of
0
02mm
0
008
in

New

bearing
bushes
must
be

pressed
in
so
that

they
are
flush

with
the
end
of
the
case
and
reamed
ou
t
to

give
a
clearance
of

0
03
0
10
mm
0
0012
0
0039
in

H
Solenoid

assembly

Inspect
the
solenoid
contact
surface
and

replace
if

showing

signs
of

wear
or

roughness
Replace
the

pinion
sleeve

spring
if

weakened

Check
the
series
coil

by
connecting
an

8
12

volt

supply

between
the
Sand
M
terminals
as
shown
in

Fig
M
13
The

series
coil
is
normal
if
the

plunger
operates

Test
the
shunt
coil

by
connecting
the
S
terminal
the
M

terminal
and
the
solenoid

body
as
shown
in
the
lower
illustration

of

Fig
M
13

Open
the
M
terminal
when
the

plunger
is
operated

the
shunt
coil
is

satisfactory
if
the

plunger
stays
in
the

operated

position

Measure
the

length
L
between

theylonger
adjusting
nut

and
solenoid
cover

Press
the

plunger
against
a

firm
surface
as

shown
in

Fig
M
14
and
check
that
the
dimension
is
within

the
figures

given
Turn
the

adjusting
nut
if

necessary
until
the

required
dimension
is
obtained

STARTER
MOTOR

Assembly
and
Installation

The
assembly
and
installation

procedures
are
a
reversal

of
the
removal
and

dismantling
operations
When

assembling

the
starter
smear

the
armature
shaft

spline
with

grease
and

lightly
oil
the

bearing
bushes
and

pinion

ALTERNATOR

The
alternator
is
driven

by
the
fan
belt
and
has
an
advant

age
over
a

dynamo
in
that
it

provides
current
at

low

engine

speeds
thereby
avoiding
battery
drain
Maintenance
is
not

normally
required
but
the
tension
of
the
fan
belt
should
be

checked
and

adjusted
if

necessary
as

described
in
the

section

COOLING
SYSTEM
Care
must
be
taken
not
to

overtighten

the
fan
belt
or

the
alternator

bearings
will
be
overloaded

The
alternator

output
can
be
checked
with
the
alternator

in

the
vehicle

by
carrying
out
the

following
test
Ensure
that
the

battery
is

fully
charged
Withdraw
the
connectors
from
the

alternator
F
and
N
terminals
and
connect
a

jumper
lead
between

the
F
and
A
terminals

Connect
a
voltmeter
to
the
E

and
A
alternator
terminals

with
the

negative
lead
to

terminal
E
and
the

positive
lead
to

the
terminal
A
as
shown
in

Fig
M
IS
Switch
the

headlamps

on
to
full
beam
and
start

the

engine
Increase
the

engine
speed

gradually
and
note

the

reading
on
the
voltmeter
when
the

engine
reaches
a

speed
of

approximately
lOaD

rpm
The

alternator
is

operating

satisfactorily
if
the
voltmeter
shows
a

reading
above
12
5
volts
If

the

reading
is
below
12
5
volts
the

alternator
is
defective
and
should
be
removed
for

inspection

ALTERNATOR
Removal

Disconnect
the

negative
lead
from

the

battery
and
the
two

lead
wires
and
connector
from
the
alternator

Slacken
the
alter

nator

mounting
bolts
and
take
off

the
fan
belt
Take
out

the

mounting
bolts
and
withdraw
the
alternator
from
the
vehicle

III

N
Engme
SYMPTOMS
I

Trouble
Shooting
Lubrication
System

SYMPTOMS

bed
t
f
I
h
i
1m
0
p
q
r
I
I
II
bed
t
f
I
h
Ii
I
m
n

ENGINE
WILL
NOT
CRANK

ENGINE
CRANKS
SLOWLY

ENGINE
CRANkS
BUT
OOES
NOT
START

ENGINE
STARTS
BUT
RUNS
FOR
SHORT

PERIODS
aNL
Y

ENGINE
I
tISFIRES
AT
LOW
SPEED

ENGINE
MISFIRES
AT
HIGH
SPEED

ENGINE
MISFIRES
AT
ALL
SPEEDS

ENGINE
MISFIRES
ON
ACCELERATION

AND
FAILS
TO
REV

ROUGH
IDLE

RUNS
ROUGH
AT
HIGH
SPEED

lACK
OF
POWER

POOR
CCElERA
nON

LACK
OF
TOP
SPEED

EXCESSIVE
FUEL
CONSUMmON

EXCESSIVE
OIL
CONSUMmON

PINKING

COMPRESSION
LEAK
PROIABLE
CAUSE

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Refer
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oil
to
the
fuel
Ind

rune
lmeFnd

d
SlfIpenJine
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renew
p
ru
asn
celllry
I
bed
t
f
I
h
I
i
k
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mn
0

OVERHEATING
ENGINE
FAILS
TO
REAOI

NORMAL
OPERATING
TEMPERAt
lRE

PROIAILE
CAUSE
REMEDIES

I
RetUne
enJine

h
Trace
ndseal

Tr
Ind
seal

j
RemO
f
t
rellnction

k
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sel

I
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trice
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UIe

m
Renewguke
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t
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p
bch
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Ie

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5prLnp
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coolant

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ed

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e
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kt
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re
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thecylinden

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ffici
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uae
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v

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htenbdtorftnc

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rmify

e
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cwaterpump

f
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e
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t

h
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i
Unload
ear
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brl
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j
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uJ

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up
wlth
correct
rade
Dr
inifneceUlry

PUIl
lly
blink
off
in
winter
only

Trouble
Shooting

Ignition
System

SYMnONS
be
d
t
f
I
h

ENGINE
CRANKS
IUT
DOES
NOT
nART

ENGINE
STARTS
BUT
RUNS
FOR
SHORT

PERIODS
ONLY

ENGINE
MISfiRES
AT
LOW
SPEED

ENCINE
WlSflRES
AT
HIGH
SPEED

ENGINE
MISFIRES
AT
ALL
SPEEDS

ENCINE
MISfiRES
ON
ACCELERATION

AND
FAI
TO
REV

ROUGH
IDLE

ENGINE
RUNS
ROUCH
AT
toGH
SPEED

UCK
OF
POWER

POOR
ACCELERAnON

LACK
OF
TOP
SPEED

EXCESSIVE
FUEL
CONSUMmON

PlNKlNC
PROBABLE
CAU5E

t
Bani
dilcharFd
01
defective

b
COJlIllCl
nabr
poinb
nCiCCl
c1Unlftl
renewlna

c
Incorrect
cantlel
ltn
ktr
potftu

d
ConllCt
maker
Iprtn
wuk

Spark
plup
n
d
ch
ntnl
nnewlJIl

r
Jncorrec
llpulpl1llPpI

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h
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I
lllon
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Incorrect

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Coli
c
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defC
tl

t
g
o
o
c
o
c
t1o
t
n
h
CllIl
the
toil

H
T
lud

I
Open
cimail
lIlort
nnh
1
conneclion
Ih
spart

m
l
1ulludslnCClfRcllyc
oIIJlCC
tcd

H
T
Ink
coil
dbtribulor
elp
due
oil
din

mol
t
I
o
d
ml

C
ntrlfuplld
anee
not
unetionln
eOll
lctly

p
VKuum
Id
e
not
funclionill
cOIYKtly

q
om
datrlbutw
elm
Or
4iltributor
dldt
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off
ld

L
i
k
I
m
no
p
q
I

b
m
q

f
h
i
j

REMEDIES

I
aceh
tJe
oc
pllce
blHery

b
Clean
01
n

c
Fi
wrrecl
poin

d
Renew
blnker
ll
t

Clea
l
l
ne
plllll

f
Adjull
pt

Fit
cor
c
plu
l

h
aetUne
i
mtlon

I
a
plaCf
I
nece
r

j
Trice
Ind
recury

k
True
ndlecfity

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nd
leclity

m
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c
cOI
ct1r

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wIth
dry
hn
fne
rl

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and
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ly

p
Cheek
Ind
rectlly

q
aepllccddectkol
plnl

r
Chlnp
comct
Il
adl
of
fuel
Fuel
System

ENGINE
CRANKS
8lTf
DOES
NOT
START

ENGINE
STARTS
BUT
RUNS
FOR
SHORT

PERIODS
ONLY

ENGINE
MISARES
AT
LOW
SPEED

ENGINE
MISflRE5
AT
HIGH
SPEED

ENGINE
MISFIRES
AT
ALL
SPEEDS

ENGINE
MISAKES
ON
ACCELERA110N

AND
FAILS
TO
REV

ROUGH
IDLE

ENGINE
RUNS
ROUGH
AT
HIGH
SPEED

LACK
OF
POWER

POOR
ACCELERA110N

LACK
OF
TOP
SPEED

EXCESSIVE
flJEL
CONSUMmON

PINKING
BACKFIRE
PROBABLE
CAU5E

Fuel
tank
empty

b
Fu
llinc
blocked

Fuel
pumpd
fectiYe

d
Block
in
cllburene

Air
lock
in
fuel
line

f
Fuel
rut
r
blocked

I
Cuburetter
needle
nlve
jammed

h
Wile
CI
buRlt
r

Errltic
fllel
now
due
blocka

j
IdlinJlpeed
too
low

k
InConectlCtllnlofcttoke
conllol

1
lncorrectcarbuntterfuel
nOltlewl

m
C
muretler
Itlna

Ail
leak
It
Inlet
mlrurold

Incorrect
pade
offuet

p
Carburetter
accelerator
pumpdefect
e

q
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lintl
rrlIIl
djUlled

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of
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mutU
e

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nltef
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Incorm
t
lpiitiOlluminJ

Clrburellel
Pll
un
lIitkln

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cllburenerjetl
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YMPtO

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bell
f
1
h
I
j
k
I
m
nOli
I
I
I
0

b
f
h
i
J
k
I
m
REMEDIES
q

FLllllnk

b
Blow
ObSIf1rCllUll
ilh
compl
t
lIed

R
pll
pump

d
RemO
l
e
blockaJe

Trace
Uld
bleed
QUI

r
CIUl1fi1tef

K
Fretne
dle

h
Drlln
d
yout

Removeblockq

J
Adju
throlllelfOl

k
Reset
conllol

1
AdjUSlle
e

m
Wlit
fOI
melt
If
pt
nLS
n
nu

Tlact
lelklndse
a1

Dllu
e
fuel
with
hlah
I
rllln
ubl
ln
blc

p
Trace
fault
and
reeufy

q
AdjuII
correelly

Adju
mutufWconlrol

Clnnnlttr
Retjme
Ilftn

OdClrbulelle
Repllce
Wllh
Je

TIghtenIng
Torques

LIB

engines
Three

speed
geabox
ENGINE

2
5
4
0

kgm
18
29
Ib
ft

0
3
0
4

kgm
8
13
IbJI

Ll
1
8

kgm
8
0
12
llbJt

1
6
2

5
kgm
12
18Ib
ft

I
I
1
8

kgm
8
0
12
llbJt

0
7
I
I

kgm
5
1
8
0

IbJt

17
2

lkgm
l2
15IbJI

7
0
12
0

kgm
51

87IbJI

0
8
1
0

kgm
5
8
7
2
IbJI

0
3
0
4

kgm
2
2
2
9Ib
ft

2
3

kgm
14
22IbJI

J
9
2
2

kgm
14
16IbJI
Gearbox
to

engine

Dust
cover

Front
cover

Rear
extension

Bottom
cover

Reverse
idler
shaft

Detent
ball

plug

Mainshaft
nut

Mainshaft

bearing
retainer

Speedometer
pinion
sleeve

lock

plate

Reverse

lamp
switch

Control
lever
nut
Cylinder
head
bolts

1st

stage

2nd
stage

3rd

slage
4
0

kgm
28
9Ib
ft

6
0

kgm
43
4lb
ft

6
5
8
5

kgm
47
0
61
5

Ib
ft

Connecting
rod

big
end
nuts

Ll4
Ll8

engines

Ll6

engine

Flywheel
bolls

Main

bearing
cap
bolts

Camshaft

sprocket
bolt
4
5
5
5

kgm
33
40
Ib
fl

3
2
3
8

kgm
23
27
lb
ft

14
16

kgm
l01
106Ib
ft

4
5
5
5

kgm
33
40Ib
ft

12
16

kgm
86
8
116IbJt

0
6
0
9

kgm
4
3
6

5IbJt

I
I
1
5

kgm
8
0
10
8

Ib
fl

2
3

kgm
14
5
21
7Ib
ft

5
6

kgm
36
43
Ib
ft

0
6
0
9

kgm
4
3
6
5
Ib

ft

12

16kgm
86
8
115
7

IbJt
LIB

engines
Four

speed
gearbox
Oil

sump
bolts

Oil

pump
bolts

Oil
drain

plug

Rocker

pivot
locknuts

Camshaft

locating
plate
bolts
2
5
4
0

kgm
18
29

IbJt

0
8
1
0

kgm
5
8
7
2Ib
ft

Ll
l

7kgm
8
12IbJt

Ll
I

7kgm
8
12Ib
ft

3
3
44

kgm
24
32IbJI

1
7
2
1

kgm
12
15

IbJt

2
3

kgm
14
22Ib
ft

0
5
0
7

kgm
3
6
5
IlbJI

0
8
I
I

kgm
5
8
8
0Ib
ft

0
8
Ll

kgm
5
8
8
01b
ft

0
8
1
0

kgm
5
8
7
2Ib
ft
Gearbox
to

engine

Dust
cover

Front
cover

Bottom
cover

Rear
extension

Detent
ball

plug

Reverse

lamp
switch

Lower
bracket
bolt

Shift
rod
nut

Cross
shaft
bracket
bolt

Gear

change
lever

mounting
bolt
Crankshaft

pulley
nut

Outch

mounting
bolts

L14
Ll6

Ll8
2
4
2

6kgm
174
18
8

Ib
ft

1
6
2
2

kgm
12
16Ib
fl

PROPELLER
SHAFf
AND
DIFFERENTIAL

GEARBOX

17

20kgm
l22
145IbJI

14
17

kgm
101
123Ib
ft

13
20

kgm
94
145Ib
fI
Drive
pinion
nuts
Saloon

Drive

pinion
nuts

Estate
car

Drive

pinion
nuts
Van
Ll4
and
L16

engines
Three

speed
Gearbox

Rear
extension
to
case

bolts
2
8
4
4

kgm
20
32lb
ft

Gearbox
10

engine
2
5
4
0

kgm
18
29Ib
fI

Bnttom
cover
L1
1
7

kgm
8
0
12
3
lb

ft

Ll
1
7

kgm
8
0
12
3
lb

fl

3
5
5
0

kgm
25
3
36
2

Ib
ft

1
8
2
1

kgm
13
0
15
2

Ib
ft

2
4

kgm
14
5
29
Ib
ft

0
7
L1

kgm
5
1
8
0
lb

ft

0
7
Ll

kgm
5
1
8
0
lb

fl

9
11

kgm
65
1
79

51b
ft
Crown
wheel
bolts

1400
and
1600

cc
Saloon

1400
and
1600
cc
Eslale

1800ce
Saloon

I800cc
Estate

1800cc
Van
7
8

kgm
51
58Ib
ft

4
8
5
5

kgm
35
40
Ib
ft

7
8

kgm
51
58Ib
ft

7
8

kgm
51
58Ib
ft

4
8
5
5

kgm
35
40
Ib
ft

0
9
1
2

kgm
6
5
8
7Ib
ft

1
9
2
6

kgm
13
7
18
8

IbJI

1
9
2
6

kgm
13
7
18
8

Ib
f
Front
cover

Drain

plug

Selector
lever
bolts

Side
retainer
bolts
Saloon

Drive

flange
bolts
Saloon

Reverse

lamp
switch

Idler
shaft

screw

Rear
cover
bolts

Cross
shaft
lock

pin

Final
drive
to

mounting
member

1400
and
1600cc
models
6
8

kgm
43
4
57
8IbJI

1800cc
models
5
7

kgm
36
2
50
6Ib
fI

Final
drive
to

suspension
member
6
7

kgm
43
4
51
0
Ib
ft

Final
drive
to
drive
shafls
5
6

kgm
36
431b
ft

Final
drive

flange
to

propeller
shaft
1
6
2
4

kgm
12
17
Ib
ft

Final
drive

flange
to

propeller

shaft
Eslale
1
6
2
4

kgm
l2
17Ib
ft

Mainshafl
locknut

Ll4
and
L16

engines
Four

speed
gearbox

Rearexlension
to
case

bolts
1
6
2
5

kgm
12
18Ib
ft

Gearbox
to

engine
2
5
4
0

kgm
18
29Ib
ft

Bottnm
cnver

L1
1
8

kgm
8
13
Ib
ft

Fronl
cover
L1
1
8

kgm
8
13
IbJI

Drain

plug
3
5
5
0

kgm
25
3
36
2

Ib
f

2
4

kgm
14
5
28
9IbJt

9
11

kgm
65
1
79
5Ib
ft
Final
drive

flange
to

propeller

shaft

l800cc
610

only
Reverse

lamp
switch

Mainshaft
nut
2
0
2
7

kgm
14
5
19
5
lb

ft

4
6

kgm
29
43
Ib
ft

Oil
drain
and
flller

plug
Saloon

129

GIS

DESCRIYfION

ENGINE
Removal
and
Installation

ENGINE
MOUNTING

INSULATORS

ENGINE

Dismantling
Inspection
and
Overhaul

CHAMSHAFT

AND
CAMSHAFT
BEARINGS

CYLINDER
BLOCK

PISTONS

CONNECTING

RODS

CRANKSHAFT

ENGINE

Assembling

VALVE
CLEARANCE

Adjusting

DESCRIYfION

The
G
18

engine
is
a
short

stroke
unit
with
a

displacement

of
1
815
ce
The
aluminium

alloy
cylinder
head
has
cross
flow

ports
and
a
V

shaped
valve

layout
The

single
overhead
camshaft

is
driven
from
the
crankshaft

by
a
double
row
roller
chain
at
a

reduction

ratio
of
2
I

The
crankshaft
is
a

carbon
steel

forging
and
is

provided

with
five
main

bearings
and
four

balancing
weights
Aluminium

thrust

bearings
are
located
at

the
No
2

journal

The
cast
aluminium

alloy
pistons
have
two

comp
ression

rings
and
one
oil

ring
Gudgeon

pins
are

fully
floating
in
the

piston
bores
and
are

equipped
with

circlips
at

each
end
to
limit

the
amount

of
their
travel
The

forged
steel

connecting
rods

have
weight
adjusting
bosses
at
both

large
and
small
ends
to

insure
that
the
rods
are

correctly
balanced

during
operation

The

lubricating
system
is
of

the

pressure
feed

type
with

the
oil

pump
driven

by
a

gear
on
the
crankshaft
Oil
is
delivered

to
the
main

gallery
via
a
full
flow
ftlter

ENGINE
Removal
and
Installation

Although
the

engine
can
be
removed
as
a

single
unit
it

will

prove
an
easier

operation
to
remove

the

engine
with
the

transmission
Proceed
as
follows

Fit
the
engine
slingers
ST49760000
to
the

engine

Disconnect
the
battery
cables
and
lift
out

the

battery

Drain
the
coolant
and

engine
oil

2
Place

alignment
marks
on
the
bonnet
and

hinges
remove

the
bonnet
from
the
vehicle

3
Remove
the
blow

by
hose
from
the
rocker
cover
and
take

off
the
air
cleaner

4
Disconnect
the
accelerator

linkage
and
choke
cable
from

the
carburettor

S
Detach
the

upper
and
lower

radiator
hoses
remove
the

two
brackets
from
the
core

support
and
lift
the
radia
tor

away
from
the
vehicle
The

torque
convertor

oil

pipes
must

be
disconnected
from
the
oil
cooler
if
the
vehicle
is

equip

ped
with
automatic
transmission
Detach
the
fuel

pipe
if

fitted
from
the
engine
and

heater
hose

6
Disconnect
the
electrical

wires
from
the
alternator
thennal
EngIne

OIL
PUMP

OIL
PRESSURE
RELIEF
VALVE

OIL
FILTER

EMISSION
CONTROL
SYSTEM

IGNITION

TIMING
AND
IDLING
SPEED

Emission

control

system

EMISSION
CONTROL
SYSTEM
Maintenance

IGNITION
SYSTEM

IGNITION
TIMING

IGNITION
DISTRIBUTOR
Maintenance

SPARKING
PLUGS

transmitter
the

primary
side
of
the
distributor
oil

pressure

switch
starter

motor
and
reverse

light
switch

7

Remove
the
clutch
slave

cylinder
and
its
return

spring
from

the
transmission
as
described
in
the
section
CLUTCH

8
Disconnect
the
shift
rods
and
selector
rods
then
remove

the
cross
shaft

assembly
by
detaching
the
bracket
from

the
side
member
See
GEARBOX
section

9
Disconnect
the

speedometer
cable
and
detach
the
front

exhaust

pipe
from
the
exhaust
manifold

10
Disconnect
the

propeller
shaft
and

plug
the

gearbox
rear

extension
to

prevent
the
loss
of
oil

11
Jack

up
the

gearbox
slightly
and
remove
the
rear

engine

mounting
support
Take
out

the
bolts
which
secure
the

front

mounting
insulators
to
the
cross
member

12
Attach
chains
or
wire

rope
to
the

engine
Gradually
lower

the

jack
under
the

gearbox
and
carefully
lift
and
tilt
the

engine
and
gear
box
to
clear
the

compartment
Withdraw

the
unit

making
sure

that
it
does
not
foul
the
accessories

Installation
is
a
reversal
of
the
removal

procedure
RefIll

with
the
correct

quantities
of
oil
and
coolant
when
the

engine
is
installed

ENGINE
MOUNTING
INSULATORS

Replacing

The

front
and
rear

mounting
insulators
should
be
checked

with
the

engine
installed
to
make
sure
that
the
dimensions

conform
with
those

given
in

Figs
A
I
and
A
2

To
remove
the
front
insulator

proceed
as
follows

Position
a

jack
under
the
oil

sump
Make
sure
that
the

jack
is
clear
of
the
drain

plug
and
insert
a
wooden
block
between

the
jack
and

sump
to

prevent
the

sump
from

being
damaged

Remove
the
bolts

securing
the
insulator
to
the
front

suspension

member
and
the
nut

attaching
the
insulator
to
the

engine

mounting
bracket
Raise
the

jack
slightly
and
remove
the

insulator
To
remove
the
rear

mounting
insulator

proceed
as

follows

Position
a

jack
to
take
the

weight
of
the

gearbox
and
take

out

the
bolts

connecting
the
insulator
to

the
transmission
rear

extension

housing
Remove
the
bolts

attaching
the
cross
member

to

the
underside
of
the

body
and
withdraw
the
insulator

Installation

of
both
insulators

is
a
reversal
of
the

removal

procedures

S3

ENGINE

Dismantling

Remove

the

engine
from
the
vehicle
as

previously
described

and

carefully
clean
the
exterior

surfaces
The
alternator

distribu

tor

and
starter
motor
should
be
removed
before

washing
Plug

the
carhurettor

air
horn
to

prevent
the

ingress
of

foreign
matter

Place
the

engine
and
transmission
on

the
engine
carrier
ST4797

0000
if

available
and
dismantle
as
follows

Remove
the

gearbox
from
the

engine
Disconnect
the
intake

manifold

water
hose
the
vacuum

hose
and
the
intake
manifold

to
oil

separator
hose
Remove
the
intake
manifold
with
the

carburettor
Fit
the

engine
attachment
ST3720OG18
to
the

cylin

der
block
and

place
tre

engine
on
the
stand
ST371
00000

Remove
the
clutch

@
Ssembly
as
described
in
the
section

CLUTCH
Remove
the
exhaust
manifold
and
heat
baffle

plate

Take
off
the
fan
blades
and
remove
the
water

pump
pulley
and

fan
belt
Remove
the
rocker
cover
hose
manifold
heat
hose
and

by
pass
hoses

Remove
the

generator
bracket
and
the
oil
fIlter
Extract
the

engine
breather

assembly
from
above
Note
that
the
breather

is
fitted
to
the

guide
and
is
installed
with
a
O

ring
which
is

pressed
into
the

cylinder
block

Flatten
the
10ckwasher
and
unscrew
the
crankshaft
pulley

nut
Withdraw
the

pulley
with
the

puller
ST44820000
if
available

but
do
not
hook
it
in
the
V

groove
of
the

pulley

Remove
the
rocker
cover
and
take
off
the
rubber

plug

located
on
the
front
of
the
cylinder
head

Straighten
the
lock

ing
washer
and
remove
the
bolt

securing
the

distributor
drive

gear
and
camshaft

sprocket
to
the
camshaft
Remove
the
drive

gear
and
take
off
the

sprocket
See

Fig
A
3

Remove
the

cylinder
head
bolts
in
reverse

order
to
the

tightening

sequence
sOOwn
in

Fig
A
18
and
lift
off
the

cylinder

head
as
an

assembly
See

Fig
A
4
Note

that
in
addition
to
the

ten

cylinder
head
bolts
there
are
also
two
bolts

securing
the

chain
cover
to

the
head
Invert
the

engine
and
remove
the
oil

sump
Remove
the
chain
cover
and
oil

flinger
Take
off
the
nut

securing
the
oil

pump
sprocket
and
withdraw
the

sprocket
with

the
chain
in

position
as
shown
in

Fig
A5
Remove
the
oil

pump

and
stramer
Note

that
two
of
the

pump
mounting
bolts
are

pipe
guides

Remove
the

timing
chain
crankshaft

sprocket
chain
ten

sioner
and
chain

stop

Remove
the

connecting
rod

caps
and

push
the

piston
and

connecting
rod
assemblies

through
the
tops
of
the
bores

Keep

all

parts
in
order
so

they
can
be
assembled
in
their

original
posi

tions

Take

out
the

flywheel
retaining
bolts
and
withdraw
the

flywheel
Remove
the
main

bearing

caps
but
take
care
not
to

damage
the

pipe
guides
Lift
out

the
crankshaft
and
main
bear

ings
noting
that
the

bearings
must
be
reassembled
in
their

original

positions
Remove
the

piston
rings
with
a
suitable

expander
and

take
off
the

gudgeon
pin
clips
The

piston
should
be
heated
to

a

temperature
of
50
to
600
122
to
1400F
before

extracting

the

gudgeon
pin
Keep
the
dismantled

parts
in
order
so

they

can
be
reassembled
in
their

original
positions

Remove
the
camshaft
rocker
ann
shaft
and
rocker
ann

assemblies
from
the

head

by
taking
off
the
cam

bracket

clamp

ing
nuts
It
is
advisable
to
insert
disused
bolts
in
the
No
1

and

No
5
bracket
holes
as
the
cam
bracket
will
fall
from
the
rocker

ann
shaft
when

it
is
removed
Remove

the
valve

cotters

using

the

special
tool
ST47450000

and
dismantle
the
valve
assemblies
Keep
the

parts
together
so

they
can
be
installed
in
their

original

order

ENGINE

Inspection
and
Overhaul

Cylinder
head
and
valves

Inspection
and
overhaul

procedures
can

be
carried
out

by

following
the
instructions

previously
given
for
the
L14
LI6

and
LIB

engines
noting
the

following
points

Measure
the

joint
face
of
the

cylinder
head

using
a

straight

edge
and
feeler

gauge
The

permissible
amount
of
distortion
is

0
03
mm
0
0012
in
or
less
The
surface
of
the
head
must
be

reground
if
the
maximum
limit
of
0

1
mm

0
0039
in
is

exceeded

Oean
each
valve

by
washing
in
petrol
then

carefully
examine

the
stems
and
heads
Discard

any
valves
with
worn

or

damaged

stems
Use
a

micrometer
to
check
the
diameter
of
the
stems

which
should
be
8
0
mm
0
315
in
for
both
intake
and
exhaust

valves
If

the
seating
face
of
the
valve
is

excessively
burned

damaged
or
distorted
the
valve
must
be
discarded
The
valve

seating
face
and
valve

tip
can
be
refaced
if

necessary
but

only

the
minimum
amount
of
metal
should
be
removed
Check
the

free

length
and
tension
of
each
valve

spring
and

compare
the

figures
obtained
with
those

given
in
Technical
Data
at
the
end

of
this
section
Use
a

square
to
check
the

springs
for
deformation

and

replace
any
spring
with
a
deflection
of
1
6
mm
0
0630
in

or
more

Valve

guides

Measure
the
clearance
between
the
valve

guide
and
valve

stern
The
stem
to

guide
clearance
should

be
0
025
0
055
mm

0
0010
0
0022
in
for
the
intake
valves
and
0
04
0
077
mm

0
0016
0
0030
in
for
the
exhaust
valves
The
maximum
clear

ance

limit
is
0
1
mm
0
0039
in
The
valve

guides
are
held
in

position
with
an
interference
fit
of
0
040
0
069
mm
0
0016

0
0027
in
and
can
be
removed

using
a

press
and
valve

guide

replacer
set
ST49730000
under
2
ton

pressure
This

operation

can

be
carried
out
at
room

temperature
but
will
be
more
effec

tively

performed
at
a

higher
temperature
Valve

guides
are

available
with
oversize
diameters
of
0
2
mm
0
0079
in
The

cylinder
head
guide
bore
must
be
reamed
out
at

normal
room

temperature
and
the
new

guides
pressed
in
after

heating
the

cylinder
head
to
a

temperature
of

approximately
800
C
1760F

The
standard
valve

guide
requires
a
bore
of
14
0
14
018
mm

0
551
0
552

in
and
the
oversize
valve

guide
a
bore
of
14
2

14
218
mm
0
559
0
560
in
Ream
out
the
bore
of
the

guides

to
obtain
the
desired
finish
and
clearance
Use
the
reamer
set

ST49710000
to

ream
the
bore
to
8
000
8
015
mm
0
3150

0
3156
in
The
valve
seat

surface
must

be
concentric
with
the

guide
bore
and
must
be
corrected
if

necessary
using
the
new

valve

guide
as
axis

Valve
seat
inserts

Check
the
valve
seat

inserts
for

signs
of

pitting
The

inserts

cannot
be

replaced
but

may
be
corrected
if

necessary
using
a

valve
seat
cutter

ST49720000

Scrape
the
seat

with
the
450

cutter
then

reduce
the
width
of
the

contacting
faces

using
the

150
and
600
cutters
for
the
intake
valve
inserts
and
150
cutter

for
the
exhaust
valve
inserts
Seat
correction
dimensions
are

shown
in
millimeters
in

Fig
A
6

Lap
each
valve
into
its
seat
after

correcting
the
seat
inserts

Place
a
small

quantity
of
fme

grinding
paste
on

the

seating
face

of
the
valve

and
lap
in
as

previously
described
for
the
Ll4
LI6

and
L
18

engines

S5

CAMSHAFT
AND
CAMSHAFT
BEARINGS

Check
the
camshaft

bearing
and

journals
for

signs
of
wear

Plastigage
should
be

used
to

check
the
clearance
between
bear

ing
and

journal
which
should
be
0
025
0
075
mm
O
OOl

0
0030
in

The

cylinder
head

assembly
must
be
renewed
if
the

wear

limit
of

0
mm
0
0039
in

is
exceeded

Place
the
camshaft
in
V
blocks
and

apply
a

dial

gauge

to
the
centre

journal
to
check

the
amount
of

camshaft
bend

The

run
out

of
the
camshaft
must
not
exceed
0
03
mm
0
0012

in
It
should
be
noted
that

the
actual
run
out
will
be
half
the

value
indicated
on
the
dial

gauge
when
the
camshaft

is
turned

one

full
revolution
Check
the
camshaft
end

play
which
should

be
within
0
07
0
148
mm
0
0028

0
0058

in

Check
the
earn

contacting
surfaces
of
the
valve
rocker
and

the
earn
heels
of
the
camshaft

Slight

damage
can
be
corrected

using
a
fine
oil
stone
It
is
advisable
at
this

stage
to

check
the

clearance
of

the
rocker
shaft
and
rocker
bushes
which
should
be

0
016
0
052
mm
0
0006
0
0020

in
The

parts
must

be
renewed

if

the
wear

limit
of
0
07
mm

0
0028
in
is
exceeded

CYLINDER

BLOCK

Inspection
and
Overhaul

Check
the
block
for

signs
of
cracks
or
flaws
Measure
the

joint
face
for
distortion

using
a

straight

edge
and
feeler
gauge

as

described
for

the
L14
Ll6
and
L18

engines
The
surface

must

be

reground
if
the
maximum
limit
of
0
10
mm
0
0039
in

is
exceeded

Check
the

cylinder
bores
for
wear
out

of
round
and

excessive

taper
Use
a
bore

gauge
to
take

readings
at
the

top

middle
and
bottom

positions
of
the
bore
as

previously
described

The
standard
bore
diameters
are

85
000
mm
0
035
0
mm

3
347
0
0014
0
in

with
a
wear
limit
of
0
2
mm
0
0079
in

Out
of
round
and

taper
must
not
exceed
0
02
mm
0
0008
in

If

any
of

the
bores
are

worn
or
in
excess
of
the

specified
limi
t

then
all
bores
must
be
rebored
at
the
same
time

Pistons
are

available
in
five
oversizes
and
should
be
selected

in
accordance
with
the
amount
of
wear
of
the

cylinder
Refer

to

the
instructions

given
for
the
Ll4
L16
and
L18

engines
and

select

pistons
from
the
table
below

PISTON
SIZE

Standard

250
5

500
5

750
S

1000
S

1250
S
OUTER
DIAMETER

84
958
84
990
mm
3
345
3
346

in

85
220
85
240
mm

3
355
3
356
in

85
470
85
490
mm
3
365
3
366

in

85720
85
740
mm
3
375
3
376
in

85
970
85
990

mm
3
3846
3
3854

in

86
220
86
240
mm
3
394
3
395
in

Cylinder
liners
can

be
fitted
if
the
bores
areworn

beyond

the
maximum
limit
Undersize
liners
are
available
with
outer

diam
ters
of
89
091
89
126

mm
3
507
3
509
in

and
inner

diameters
of
83

5
84
5
mm

3
287
3
327

in
The
liners
are

an

interference
fit
in
the
block
and
must
be
rebored
after

fitting

PISTONS

Checking

Oteck
the

pistons
for

signs
of
seizure
and
wear

measure

the
side
clearance
of
the

rings
in
the

ring
grooves
and
check

the

piston
ring
gaps
as

previously
described
for
the
L14
Ll6
and

Ll8

engines
Compare
the

figures
obtained
with
those

given
in

the
tables

opposite
Side
clearance
in

grooves

Top

ring

Second

ring

Oil

ring
Standard

0
04

0
08
mm

0
0016
0031
in

0
02
0
06
mm
0
0008
0

0024
in

0
02

0
06
mm
0

0008
0
0024
in

Limit

LO

mm
0
0039
in

LO
mm

0
0039
in

LO

mm
0
0039
in

Piston

ring

gap
Top
ring

Second

ring

Oil

ring

Top

ring

Second

ring

Oil

ring
Standard

0
35
0
55
mm
0
01

38
D
021
7
in

0
3
5
mm
0
0138
0
0197

in

0
35
55

mm
O
oJ38

0217

in

Limit

LO
mm

0
0394
in

LO
mm
0
0394

in

LO
mm

0
0394
in
Top

ring

Second

ring

Oil

ring

Measure
the
outer
diameter
of
the

gudgeon
pin
in
relation

to
the
hole
diameter
in

the

piston
Compare
the

figures
obtained

with
those

given
in
Technical
Data
and

replace
the

piston
and

pin
if
the
wear
limit
is
exceeded

CONNECTING
RODS

Checking

Check
the

connecting
rods
for
bends
or

twists

using
a

suit

able

connecting
rod

aligner
The
maximum
deviation
should
not

exceed
0
05
mm
0
0020
in

per
100
mm
3
94

in
of
rod

Straighten
or

replace
any
rod
which
does
not

comply
with
the

specified
limit
When

renewing
a
rod
make

sure
that
the

weight

difference

between
new
and
old
rods
in
within
6

gr
212
oz

Install
the

connecting
rods
with

bearings
to

the
correspond

ing
crank

pins
and
check

that
the
end

play
of
the

big
ends
is

between
0
10
0
246
mm
0
0043
0
0097
in

Replace
the

appropriate
rod
if

the
maximum
limit
of
0
3
mm
0
0118

in

is
exceeded

CRANKSHAFT

Inspection
and
Overhaul

Clean
the

crankshaft

thoroughly
and
check
the

journals

and
crank

pins
for

taper
and
out
of
round
Use
a

micrometer
to

measure
the

journals
and

crankpins
at
the

positions
shown
in

Fig
A

7
It
will

be

necessary
to

regrind
the
crankshaft
if
the

specified
limit
of
0
03
mm
0
0012
in
is

exceeded
and
then

fit

the

appropriate
undersize

bearings
Place
the
crankshaft
in

V

blocks
as
described
for
the
L14
L16

and
LIB

engines
and

apply
a

dial

gauge
to
the
centre

journal
to
check

that
the
bend

limit

of
0
05
mm

0
0020
in
is
not

exceeded
The
actual
bend

value
will
be
half
the

reading
obtained
on

the
gauge
Install
the

crankshaft
in
the

cylinder
block
and
check
the
crankshaft
end

float
which
should
be
0
060
0
192
mm

0
0024
0
0076
in

Replace
the
centre

shims
if
the

specified
figure
is
exceeded

Make
sure
that
the

main
drive
shaft

pilot
bearing
at

the
rear
of

the
crankshaft
is
not
worn
or

damaged
in

any
way
Remove

the

bearing
if

necessary
using
the

special
tool
ST49700000
as

shown
in

Fig
A
8
Clean

the

bearing
hole
oil
the
outer

side
of

the
new

bearing
and
use
a
drift
as
shown
in

Fig
A
9
to

drive

it
into
the
hole
Insert

2

grams
0
07
oz

of
multi

purpose
grease

into
the
hole
as
illustrated

Main

bearing
clearance

Check
the
main

bearing
clearances

as
described
for

the

Ll4
Ll6

and
Ll8

engines
The

Plastigage
should
be

placed
so

57