engine DATSUN 610 1969 Workshop Manual

i

I

inter
llil
j

@
W
E

Hu
tol

and

Type
Identl
ficatlOn

YOUR
MANUFACTURER

The
Nissan
Motor

Company
was
founded

in
1933

under
the
name

of
Jidosha
Seizo
Co
Ltd

In
1934

the
present
title
was

adopted
and

during
1966
the

company
merged
with

Prin
c

Motors
builders
of

the
Skyline
and
Gloria
ars

With
the
head
office

and
six
main
factories
near

Tokyo
Japan
other
sister

plants
ace

also

in

production
in
various
countries

throughout
the
world

YOUR
VEHICLE

In
the

early
days
of

the

company
s

history
vehicles
constructed
were

given
the
trade
name

DA
TSDN
which
means
SON
of
DAT
the
initials
of
three
of

the
financial
backers

forming

the

syllable
DA
T
To
avoid
confusion
with
a
similar

Japanese
word
the
name
was

eventually

changed
to
DATSUN

The
various

models
covered
in
this
Manual

together
with
alternative
namt
s
used
for
the

world
markets
are
listed
below

MODELS
COVERED

MODEL
ALTERNATIVE

IDENT

510
SERIES
Datsun

1300

510
SERIES

Datsun
1400

510
SERIES

Datsun
1600

610
SERIES
Bluebird
160
B

610
SERIES
Bluebird
180
B

00
SERIES
DATSUN
ISoo
ENGINE
FITTED

1300
c
c
L
l3

1400
c

LI4

1600
c
c

LI6

1600
c

LI6

1800
c
c
L
18

181S
GIS

WUUUU

I

fl

I
lfI
r
7

I
i

I

1
11
lii

Identification

plate
location

Engine
serial
and
model
number

2
REMARKS

Superseded
by
1400
c
c

model
with
L
14

engine

Similar
to
1300
c
c
car

Similar
to
1300
1400

e
c
car

In
some
markets
identified

as
1600
SSS
1800
SSS

J
S

1

HI

I

Car
serial

number
location

inteN
j

@IP
B

Index

ENGINE

COOLING
SYSTE
l

IGNITION
SYSTE
I

FUEL
SYSTBl

CLUTCH

GEARUOX

PROPELLER
SHAFT
Id
DIFFERENTIAL

REAR
AXLE
nd
REAR
SUSPENSION

FRONT
SUSPENSION

STEERING

BRAKING
SYSTEM

ELECTRICAL

EQUIP
JENT

WIRING
JAGRA
IS

TROUBLE
SHOOTING

TIGHTENING

TORQUES

SERIES
C
30
MODEL
SUPPLEMENT

AUTOSERVlCE
DATA
CHART

PART
NA
ES
nd
ALTERNATIVES

CONVERSION

TABLES
S

15

2S

33

43

51

62

7S

83

91

9S

lOB

liB

I2S

129

51

End
of
manuir

IntroductIon

OUf
intention
in

writing
this
Manual
is
to

provide
the

reader
with

all
the
data
and
in

formation

required
to
maintain
and

repair
the
vehicle
However
it
must
be
realised
that

special
equipment
and
skills
arc

required
in
some
caseS
to

carry
out
the

work
detailed

in
the
text
and
we

do
not

recommend
that
such
work
be

attempted
unless
the
reader

possesses
the

necessary
skill

and

equipment
It
would
be
better
to

have
an

AUTHQRISED

DEALER
to

carry
out
the

work

using
the

special
tools
and

equipment
available
to

his
trained
staff
He
will
also
be
in

possession
of
the

genuine
spare
parts
which
may
be

needed
for

replacement

The
information
in
the
Manual
has
been
checked

against
that
provided
by
the
vehicle

manufacturer
and
any

peculiarities
have
been
mentioned
if

they
depart
rom
usual

work

shop
practice

A
fault

finding
and
trouble

shooting
chart
has
been
inserted
at

the
end
of
the
Manual
to

enable
the
reader
to

pin
point
faults
and
so
save

time
As
it
is

impossible
to
include

every

malfunction

only
the
more
usual
ones
have
been
included

A

composite
conversion
table
has
also
been
included
at

the
end
of
the
manual
and
we

would
recommend
that
wherever

possible
for

greater
accuracy
the
metric
system
units

are
used

Brevity
and

simplicity
have
been
our
aim
in

compiling
this
Manual

relying
on

the
number

ous
illustrations
and
clear
text

to
inform
and
instruct
the
reader
At
the

request
of
the

many
users
of
our
Manuals
we
have
slanted
the
book
towards

repair
and
overhaul
rather

than
maintenance

Although
every
care
has
been

taken
to
ensure

that
the
information
and
data
are

correct

WE
CANNOT
ACCEPT

ANY
LIABILITY
FOR
INACCURACIES
OR
OMISSIONS

OR
FOR
DAMAGE
OR
MALFUNCTIONS
ARISING
FROM
THE
USE
OF
THIS
BOOK

NO
MATTER
HOW
CAUSED

I

3

t
r

Engine
type

Ovendi
cngth
1300
L
13

Overall
width

Oyerall
height

Turning
circle
din

metres
tfeet
Supen
eded
by

Track
font

rear
1400
c
c

car

Ground
dearance
Olin

Weight
dry
I
820
808

I

Fuel
tClflk
capacity
35
29
6

150
93

Fuel
consumption

aximum
peed
Technical
Data
BLUEBIRD

400
1600
1600

U4
U6

0
4
120
162
20

1
560
6142
410
55
51

420
55
91

10
2
33
5

270
50
0

2
420
95
281

215
8
5

885
1
950
210
8
27

930
2
050

10
1
12

33
2
27
7

50
931
28
2123
5

60
99
L
16

4
215
165
941

1
600
62
99

405
55
3
Ii

0
6
34
8

290
50
79

1
300
51
18

2
500
98
43

185
7
281

955
2
1061

12
14
5

28
2
23
5

60
991
BLUEBIRD
1800
L
18

3
0
5
57

320
5
971

000
2
2051

165
103
BLUEBIRD

1800
ESTATE

U8

4
280
168
501

4
5
557

330
52
361

1
065
2
348

EngIne

INTRODUCTION

ENGINE

Removal

ENGINE

DismantUng

ENGINE

Inspection
and
Overhaul

VALVES
VALVE
GUIDES
VALVE
SEAT
INSERTS

CAMSHAFT
AND
CAMSHAFT

BEARINGS

Checking

CYliNDER

BLOCK

PtSTONS

AND
CONNECTING
RODS

INTRODUCTION

The
1400
1600
cc

and
1800
cc

engines
are
four

cylinder

in
line
units
with
a

single
overhead
camshaft

and

fully
balanced

five

bearing
crankshaft

The
valves
are

operated
through
rockers

which
are

directly
activated

by
the

earn
mechanism

The
crankshaft
is
a

special
steel

forging
with
the
centre

main

bearing

equipped
with
thrust
washers

to
take

up
the
end

thrust

of
the
crankshaft
The

special
aluminium

pistons
are
of

the
strut

construction
to

control
thermal

expansion
and

have

two

compression
rings
and
one
combined
oil

ring

The

gudgeon
pins
have

special
hollow
steel
shafts

and
are

a

fully
floating
fit
in

the

pistons
and
a

press
fit

in
the

connecting

rods

The
aluminium

alloy
cylinder
head
contains

wedge
type

combustion
chambers

and
is
fitted
with
aluminium

bronze
valve

seats

for
the
intake
valves

and
heat
resistant
steel
valve
seats

for
the
exhaust

valves

The
cast

iron
camshaft
is
driven

by
a
double
row
roller

chain
from
the
crankshaft

pulley

The

engine
is

pressure
lubricated

by
a
rotor

type
oil

pump

which
draws
oil

through
an

oil
strainer
into
the

pump
housing

and
then
forces

it

through
a
full
flow

oil
filter

into
the
main
oil

gallery

ENGINE
Removal

Place

alignment
marks
on
the
bonnet

and

hinges
remove

the
bonnet
from
the
vehicle

2

Drain
the

cooling
system
and
engine
and
transmission

lubricant
Remove

the
radiator

grille

3
Discon
ect
the

battery
cables

and
lift
out
the

battery

4
Detach
the

upper
and
lower
radiator

hoses
remove

the

radiator

mounting
bolts
and
lift
the
radiator

away
from

the
vehicle

The

torque
converter

c

jng
pipes
must

be

disconnected
from
the
radiator
on
vehicles

fitted
with

automatic
transmission

S
Remove

the

COOling
fan
and

pulley
disconnect

the
fuel

pipe
from
the
fuel

pump
and

the
heater
hoses
from

the

engine
attachments

6
Disconnect

the
accelerator
control

linkage
and
the

choke
CRANKSHAFT
AND
MAIN
BEARINGS

CAMSHAFT
AND
SPROCKET

FLYWHEEL

ENGINE

Assembling

VALVE
CLEARANCES

Adjusting

ENGINE

LUBRICATION
SYSTEM

OIL
PUMP

OIL
FILTER

CHANGING
THE
ENGINE

OIL

cable
from
the

carburettor

7
Disconnect

the

wirings
from

the
starter
alternator

ignition
coil
oil

pressure
switch

and

temperature
sender

unit

8
Remove

the
clutch
slave

cylinder
Fig
A
2

and
its
return

spring

9
Disconnect

the

speedometer
cable
and
withdraw

the

plug

connector
from
the

reversing
light
switch

10
Disconnect

the
shift
rods
and
seJector

rods
and
remove

the
cross
shaft

assembly
as
described

in
the
section
Gear

box

II
Disconnect

the
front
exhaust

pipe
from
the

exhaust

manifold
disconnect
the
centre

pipe
from

the
rear

pipe

and
remove

the
front

pipe
pre
muffler
and
centre

pipe

assembly

12
Disconnect
the

propeUer
shaft

flange
from
the

companion

flange
from
the

gear
carrier

13
Jack

up
the

gearbox
slightly
and
remove
the
rear

engine

mounting
bracket
bolts
remove
the

mounting
cross

member
and
handbrake

cable

c1amp

14
Remove
the
bolts

securing
the
front

engine
mounting

brackets
to
the
crossmember

15

Attach

lifting
cable
or

chains
to
the
hooks
installed
at

the
front
and
rear
of
the

cylinder
head

Lower
the

jack

under

the

gearbox
and

carefully
lift
and
tilt
the

engine
and

gearbox
unit
Withdraw
the

engine
and

gearbox
from
the

compartment

making
sure
that
it
is

guided

past
the

accessories
installed
on
the

body

ENGINE

Dismantling

Remove
the

engine
as

previously
described
and

carefully

clean

the
exterior
surfaces

Cbeck
for

signs
of
fuel
oil
or

water
leaks

past
the

cylinder
head
and
block
Remove
the
air

cleaner
alternator

distributor
and
starter
motor

Plug
the

carburettor
air
horn

and
distributor
hole
to

prevent
the

ingress

of

foreign
matter

Remove
the

gearbox
from

the

engine
drain
the

engine
oil

and
coolant
Mount
the

engine
in
a
suitable

stand
the

special

engine
attachment
ST05260001
and

engine
ST0501SOO0
should

be
used
if
available

Fig
A
3

5

engine

600

tb

tllroogh

Section

S
O
sef1
es
ofenll

A
o

ne
l

Right
S

0

61

ttor

bure

n
car

l
tWI

thS

hi

4

t

V

ne

of
engJ

vie

lJ
lt
side

Gene
ol

Engine

FIS

to

fl

J

J
f
1

ST052fiOOOl

Fig
A
2

Removing
the
clutch
slave

cylinder

Fig
A
3

Mounting
the

engine

STI
0

120000

CI

@

j
91

7

m
I3L

I
T

IC

t
J

i1
C

J
6
i

11

j
1

j
4

I
U
O
J

I
Ll

LJJ
1r9i

V

@
1
EM092

Fig
AA

Removing
the
camshaft

sprocket
Fig
A
5

Cylinder
head
bolt
removal

sequence

t

J1
I

J
1

1

i

I

G
qt

7

r

J

O

I

IS

Fig
A
6

Removing
the
chain
tensioner
and

timing
chain
Fig
A
7

Removing
the
drive

sprocket

7

Remove
the
fan

and
pulley
the

right
hand

engine
mounting

and
oil
filter
Remove
the
oil

pressure
switch
Remove
the

following
items
oil
level

gauge
spark
plugs
thermostat

housing

rocker
cover
carburettor
and
inlet
and
exhaust
manifolds

Remove
the
clutch

assembly
as
described
in
the
section

CLUTCH
Remove
the
left
hand

engine
mounting
crankshaft

pulley
water

pump
fuel

pump
fuel

pump
drive
earn
and
cam

shaft

sprocket
See

Fig
A
4
Remove
the

cylinder
head
bolts

in
the

sequence
shown
in

Fig
A

5
and
lift
off
the

cylinder

head
Invert
the
engine
and
remove
the
oil

sump
and
oil

strainer
oil

pump
and
drive

spindle
assembly
front
cover
and

chain
tensioner
Remove
the

timing
chain
oil
thrower
crank

shaft
worm

gear
and
chain
drive

sprocket
See

Fig
A
6
andA
7

Remove
the

connecting
rod

caps
and

push
the

pistons
and

connecting
rods
through
the

top
of
the
bores
as
shown
in

Fig

A
B

Keep
the

connecting
rod

caps
with
their
respective
rods
to

ensure

that

they
are
assembled
in
their

original
positions

Remove
the
flywheel
retaining
bolts
and
withdraw
the

fly

wheel

Fig
A
9
Remove
the
main

bearing
caps
using
the

special
puller
ST
1651
SOOO
to
withdraw
the
centre
and
rear
main

bearing
caps
as
shown
in

Fig
A

l
O
Remove
the
rear
oil
seal

and
lift
out
the
crankshaft
remove
the
baffie

plate
and

cylinder

block
net

Fig
A
II
Remove
the

piston
rings
with
a

suitable

expander
and

press
out
the

gudgeon
pins
under
an
arbor

press

using
the

special
stand
STl300001
as
shown
in

Fig
A

12

Keep

the
dismantled

parts
in
order
so
that

they
can

be
reassembled

in
their

original
positions
Slacken

the
valve
rocker

pivot
lock

nut
and
remove
the
rocker
arms

by
pressing
down
the
valve

springs

Remove
the
camshaft

taking
care
not
to

damage
the

bearings
and
earn
lobes
Withdraw
the
valves

using
the
valve

lifter
STl2070000
as
shown
in

Fig
A
13

ENGINE

Inspection
and
Overhaul

Cylinder
Head
and
Valves

Clean
all

parts
thoroughly
and
remove
carbon

deposits
with

a

blunt

scraper
Remove

any
rust
which
has
accumulated
in

the
water

passages
and
blow

through
the
oil
holes
with

compres

sed
air
to
make
sure

that

they
are

clear

Measure
the

joint
face
of
the

cylinder
head
for
out
of
true

as
shown
in

Fig
A
14

The
surface
should
be
checked
at
various

positions
using
a

straight
edge
and
feeler

gauge
The
permissible

amount
of
distortion
is
0
05
mm
0
0020
in
or
less
If
the

surface
is
out
of
true

by
more
than
the
limit
of
0
1
mm

0
0039

in
it
will
be

necessary
to

regrind
the
head

Clean
each
valve

by
washing
in

petrol
and

carefully
examine

the
stems
and
heads

If
the
stem
is
worn

damaged
or
not

straight
the
valve
must

be
discarded
Check
the

diameter
of
the
stem
with
a
micro

meter

The
diameter
of

the
inlet
valves
should
be
7
965

7
980
mm
0
3136
0
3142
in
and
the
diameter
of

the
exhaust

valves
7
945
7
960
mm
0
3128
0
3134
in

If

the
seating
face
of
the
valve
is

excessively
burned

damaged
or
distorted
it
must
be
discarded
A

badly
pitted

seating
face
should
be
refaced
on
a
valve

grinding
machine

removing
only
the
minimum
amount
of
metal
Renew
the
valve
if
the
thickness
of

the
valve
head
has

been
reduced

by
0
5
mm
0
0197
in
see
Technical
Data
for

valve
dimensions

The

valve
stem

tip

may
be
refaced
if

necessary
the
maxi

mum
allowance
however
is
0
5
mm
0
0197
in

The
valves
can
be

ground
in
to

their
seats
when

completely

satisfactory
The
valve
seats
and
valve

guides
should

be
in

good

condition
and
must
be
checked
as
described
in
the

following

paragraphs

VALVE
GUIDES

Replacement

The
valve
stem
to
valve

guide
clearance
can
be
checked

by

inserting
a
new
valve
into
the

guide
The
stem
to

guide
clearance

should
be
0
020
0
053
mm
0
0008
0
0021
in
for
the
inlet

valves
and
0
040
0
073
mm
0
0016
0
0029
in
for
the
exhaust

valves
If
the
clearance
exceeds
0
1
mm
0
0039
in
for
the

inlet
valves
and
the
exhaust
valves
then
new

guides
should
be

fitted

The
valve

guides
are
held
in

position
with
an
interference

fit
of
0
027
0
049
mm
0
0011
0
0019
in
and
can
be
removed

by
means
of
a

press
and
drift
2
ton

pressure
This
operation

can
be
carried
out
at
room

temperature
but
will
be
more

effectively
performed
at
a

higher
temperature

Valve

guides
are
available
with
oversize
diameters
of
0
2
mm

0
0079
in

if
required
The
standard
valve

guide
requires
a
bore

in
the

cylinder
head
of
11
985
11
996
mm
dia
0
4719

0
4723
in
dia
and
the
oversize
valve

guide
a
bore
of
12
185

12
196
mm
dia
0
4797
0
4802
in

dial

The

cylinder
head

guide
bore
must
be
reamed
out
at

normal
room

temperature

Heat
the

cylinder
head
to
a

temperature
of
150
2000e

302
3920F
before

pressing
in
the
new
valve

guides
Ream

out
the
bore
of
the

guides
to
obtain
the
desired
fInish
and

clearance
Fig
A
IS
The

special
valve

guid
reamer
ST
1103

SOOO
should
be
used
if
available
Valve

guide
inner
diameters

are

specified
in
Technical
Data
at

the
end
of
this
section
The

valve
seat
surface
must

be
concentric
with
the

guide
bore
and

can
be
corrected
with
the

facing
tool
STll670000

Fig
A
16

using
the
new
valve

guide
as
the
axis

VALVE
SEAT
INSERTS

Replacing

The
valve
seat
inserts
should
be
replaced
if

they
show

signs

of

pitting
and
excessive
wear

The
inserts
can
be
removed

by
boring
out
to
a

depth
which

will
cause
them
to

collapse
although
care
must
be
taken
not

to
bore
beyond
the
bottom
face
of
the
recess

in
the

cylinder

head

Select
the
valve
seat

inserts
and
check
the
outer

diameters

Machine
the
recess
in
the

cylinder
head
to

the
following

dimensions
at
room

temperature

9

CYUNDER
HEAD
RECESS
DIAMETER

Standard
inoerts

Engine

L14

Ll6

and
Ll8
Inlet

41
000
41
016
1
6142
1
6148
in

45
000
45
016
mm
1
77l7
1
77231n

Engine

Ll4

Ll6
and
Ll8
Exhaust

37
000
37
016mm

1
4567
1
4573
in

37
000
37

016mm
l
4567
1
4573
in

CYLINDER
HEAD
RECESS
DIAMETER

Oversize
inserts

Engine

Ll4

Ll6andLl8
Inlet

41
500
41

516mm
l
6339
1
6345in

45
S00
45
516mm
I
7913
1
7920in

Engine

L14

Ll6andLl8
Exhaust

37
500
37
516mm
1
4764
14770in

37
500
37

516mm
1
4764
l4770in

Dimensions
for
the
standard
valve
inserts
are

shown
in

Fig
A
17
Heat
the

cylinder
head
to
a

temperature
of
ISO
20DOC

302
3920F
and
drive
in
the
inserts

making
sure

that
they

bed
down
correctly
The
inserts
should
be
caulked
at
more
than

four

positions
and
then
cuf
or

ground
to

the

specified

dimensions
shown
in
Fig
A
IS

Place
a
small
amount

of
fine

grinding
compound
on
the

seating
face
of

the
valve
and
insert
the
valve
into
the
valve

guide

Lap
the
valve

against
its
seat

by
rotating
it
backwards
and

forwards

approximately
half
a
revolution
in
each
direction

until
a
continous

seating
has
been
obtained
Remove
the
valve

and
clean
all
traces
of

the

grinding
compound
from
valve
and

seat

VALVE
SPRINGS

The
valve

springs
can
be
checked
for

squareness
using
a

steel

square
and
surface

plate
If
the

spring
is
out
of

square
by

more
than
1
6mm
0
063
in
it
must

be

replaced
Check
the

free

length
and
the
load

required
to
deflect
the

spring
to

its

assembled

height
Compare
the
figures
obtained
with
those

given
in
Technical
Data

and
replace
the

spring
if
the

specified

limits
are
exceeded

CAMSHAFT
AND
CAMSHAFT
BEARINGS

Checking

Measure
the
clearance
between
the
inner
diameter
of
the

camshaft

bearing
and
the
outer
diameter
of
the
camshaft

journal
If
the
wear
limit
for
the

bearing
clearance
exceeds

O
lmm
0
0039
in
it
will
be

necessary
to

replace
the

cylinder

block
assembly
See
Technical
Data
for
all
diameters

Check
the
camshaft
and
camshaft

journals
for

signs
of

wear
or

damage

ace
the
camshaft
in
V
Blocks
as
shown
in

Fig
A
19
and

position
the

dial

gauge
to
the

journal
The
run
out
of
the
cam

shaft

must
not
exceed
0
05
mm
0
0020in
It
should
be
noted
that
the
actual
run
out
will
be
half

the
the
value
indicated
on
the

dial

gauge
When
the
camshaft
is
turned
one
full
revolution

with
the
dial

gauge
positioned
against
the
second
and
third

journals

CYLINDER
BLOCK

Inspection
and
Overhaul

Ensure
that
the

cylinder
block
is

thoroughly
clean
and

check
it
for
cracks
and
flaws

Check
the

joint
face
of
the
block
for
distortion

using
a

straight
edge
and
feeler

gauge
as
shown
in

Fig
A
20
The
surface

must

be

reground
if
the
maximum
tolerance
of
O
lmm

0
0039
in
is
exceeded

Examine
the

cylinder
bores
for
out
of
round
or

taper

using
a

bore

gauge
as

shown
in

Fig
A
21
The
readings
must

be
taken
at
the

Top
middle
and
bottom
positions
indicated

in

Fig
A
22

The
standard
bore
diameters
are

83
000
83
050
rom

3
2677
3
3697
in
for
the
1400
and
1600cc

engines
and
85
000

85
050
mm
3
3465
3
3484
in

for
the
1800
cc

engine
with
a

wear
limit
of
0
2mm
0
0079
in

Out
of
round
and

taper
must
not
exceed
0
15mm

0
0006
in
If
the
bores
are
within
the

specified
limits
remove

the
carbon
ridge
at
the

top
of
the

cylinder
bores
wring
a

suitable

ridge
reamer

If

any
of
the
bores
are
in
excess
of
the

specified
limits

then
all
the
bores
must
be
rebored
at

the
same
time
Pistons

are

available
in
five
oversizes
See
Technical
Data
and
can
be

selected
in
accordance
with
the
amount
of
wear
of

the
cylinder

When
the
oversize
of

the

pistons
has
been
decided
it
will

be
necessary
to
measure
the

piston
at
the

piston
skirt

Fig
A
23

and
add
to

this
dimension
the

specified
piston
to

cylinder
bore

clearance
to
determine
the
final
honed
measurement
of
the

cylinder

Machine
the

cylinder
bores
in

gradual
stages
taking
only

a
0
5mm
0
002

in
cut
each
time
The
bores
must

be
brought

to
the
final
size

by
honing
and
the
block

thoroughly
cleaned

to
remove
all
traces
of
metal

Measure
the
finished

bore
and
check
the
clearance
between

each

piston
and
its

cylinder
The
clearance
can

be
checked
as

shown
in

Fig
A
24
with
the
aid
of
a
feeler

gauge
and

spring

scale
The
standard
clearance
is
0
023
0
043
mm
0
0009

0
0017
in

NOTE
Cylinder
liners
can
be
fitted
if

the
cylinder
bores

are
worn

beyond
the

maximum
limit

The
liners
are
an
interference
fit
in
the
block
and

must
be
bored
to
the
correct

inner
diameter

after

fitting
Three
undersize
liners
are
available

in
the
following
sizes

11

OUTER
DIAMETER

4
0mm
0
1575
in
Undersize

4
5mm
0
1772
in
Undersize

5
Omm
0
1969
in
Undersize
87
000
87
05mm
3
4252
3
4272
in

87
50
87
55mm
3
4449
3
4468
in

88
00
88
05mm
3
4646
3
4665
in

PISTONS

Checking

Check
each

piston
for

signs
of

seizure
and
wear
Renew

BIlY
piston
which
is
unsatisfactory

Remove
all
carbon
deposits
from
the

grooves
and

piston

rings
Measure
the
side
clearance
of
each

piston
ring
and

groove

with
a
feeler

gauge
as
shown
in

Fig
A
25
If
the
side
clearance
is

excessive
new

rings
should
be
fitted
The
clearance

required
for

new

pistons
a

piston
rings
can
be
found
in
Technical
Data

Check
the

piston
ring
gap
by
placing
the

ring
in
the

cylinder

bore
as
shown
in

Fig
A
26
The

ring
can

be

squared
in
the

bore

by
pushing
it
into

position
with
the

piston
Measure
the

ring
gaps

with
a
feeler

gauge
and

compare
the
dimensions
with
the
infor

mation

given
in
Technical
Data

NOTE
If
new

piston
rings
are
to

be
fitted
and
the

cylinder

has
not
been
rebafed
check
the

piston
ring
gap
with

the

ring
positioned
at
the
bottom
of
the

cylinder

This
being
the

position
with
the
least
amount
of
wear

O1eck
the
clearance
between

gudgeon
pin
and

piston
If

the

specified
limit
is
exceeded
it
will
be

necessary
to

replace

both

piston
and

pin
It
should
be

possible
to

press
the

gudgeon

pin
into
the

piston
by
hand
at
a
room

temperature
of
200C

680F
The

pin
should
be
a
tight

press
fit
in
the

connecting

rod

CONNECTING
RODS

O1ecking

Cleck
the

connecting
rods
for
bends
or

twists

using
a

guitable

connecting
rod

aligner
The
maximum
deviation
should

not
exceed
0

05
mm
0
0020
in

per
100
mm
3
94
in

length

of
rod

Straighten
or

replace

any
rod
which
does
not

comply

with
the

specified
limit

When

replacing
the
connecting
rod
it
is
essential
to
ensure

that
the

weight
difference
between
new
and
old
rods
is
within

5

gr
0
18
oz
for
the
1400
cc

engine
and
7

gr
0
25
oz
for

the
1600
and
1800
cc

engines

Install
the
connecting
rods
with

bearings
to

the

correspond

ing
crank

pins
and
measure
the
end

play
of
the

big
ends
s
e

Fig
A
27
The
end

play
should
be
between
0
2
0
3
mm

0
0079
0
0118
in
fthe
maximum
limit
of
0
6
mm
0
Ql18

in
is
exceeded
the
connecting
rod

must
be

replaced

CRANKSHAFT

Inspection
and
Overhaul

aean
the
crankshaft

thoroughly
before

checking
the
shaft

for
distortion
and
cracks

Measure
the

journals
and

crankpins
for
our
of
round
If

the

journals
and

pins
are
found
to
be
oval
or

if
the
wear

limit

exceeds
the

specified
fUnning
clearance
it
will

be
necessary
to

re
llrind
the
crankshaft
to

the

required
undersize
See
Technical
I

INNER
DIAMETER

82
45
82
60mm
3
24613
2520
in

82
4S
82
60mm
3
24613
2520
in

82
4S
82
60mm
3
24613
2520
in

Data

Place
the
crankshaft
in
V
blocks
as
shown
in
Fig
A
28

and
check
with
the
aid
of
a
dial

gauge
that
the
shaft

bending

limit
of
0
05
mm
0
002
in
is
not
exceeded
With
the
dial

gauge

positioned
against
the
centre

journal
the
crankshaft
should
be

rotated

by
one
turn
The
actual
bend
value
will
be
a
half
of
the

reading
obtained
on
the

gauge
If
the

specified
limit
is
exceeded

it
will
be

necessary
to

replace
the
crankshaft

Install
the
crankshaft
in
the
cylinder
block
and
check
the

crankshaft
end
float
which
should
be
be
J
Yieen
0
05
0
18
mm

0
0020
0
0071
in
Make
sure
that
the
main
drive
shaft

pilot

bushing
at
the
rear
of
the
crankshaft
is
not
worn
or

damaged
in

any
way
Replace
the

bushing
if

necessary
using
the

special

puller
STl
66
1000
I

Thoroughly
clean
the
bushing
hole
before

installing
and

press
in
the
new

bushing
without

oiling
so
that
its

height

above
the

flange
end
is
4
5
5
0
mm
0
18
0
20
in

Main

bearing
clearance

The
main
bearing
clearances
can
be
checked

using
a

strip

of

plastigage
Set
the
main
bearings
on
the

caps
Cut
the

plasti

gage
to
the
width
of
the

bearing
and

place
it

along
the

crankpin

making
sure
that
it
is
clear
of

the
oil
hole
Install
the
bearing

caps
and

tighten
the
bearing

cap
bolts
to
a

torque
reading
of
4
5

5
5

kgm
33
40
Ib
ft
DO
NOT
turn
the
crankshaft
when

the

plastigage
is
inserted
Remove
the
main

bearing
cap
and
take

out
the

plastigage
which
should
be
measured
at
its
widest

po
t

with
the
scale

printed
in
the
plastigage
envelope
The
standard

clearance
is
0
020
0
062
mm
0
0008
0
0024
in
with
a
wear

limit
of
0
1
mm
0
0039
in
If
the

specified
limit
is
exceeded

an
undersize

bearing
must

be
used
and
the
crankshaft
journal

ground
accordingly
See
Technical
Data

Bearings
are
available

in
four
undersize
of
0
25
0
50
0
75
and
1
00
mm
0
0098

0
0197
0
0295
and
0
0394
in

Connecting
rod

bearing
clearance

The

connecting
rod

bearing
clearances
should
be
checked

in
a
similar
manner
to

the
main

bearing
clearances
The
standard

clearance
is
0
025
0
055
mm
0
0010
0
0022
in
with
a
wear

limit
of
0
1
mm
0
0039
in
Undersize
bearings
must
be
fitted

and
the

crankpins
reground
if
the

specified
wear
limit
is
ex

ceeded
See
Technical
Data

Bearings
are
available
in
six
under

sizes
of
0
6
0
12
0
25
0
50
0
75
and
1
00
mm
0
0236

0
0047
0
0098
0
0197
0
0295
and
0
0394
in

Fitting
the
crankshaft

bearings

Cb
eck
the
fit
of
the

bearing
shells
in
the
following
manner

Install
the
shells
on
the
main

bearing
caps
and

cylinder
block

bearing
recess

and

tighten
the

cap
bolts
to
the

specified
torque

13

reading
Slacken
one
of
the

cap
bolts
and
check
the
clearance

between
the

cap
and

cylinder
block
with
a
feeler

gauge
See

Fig
A
29

The

bearing
crush

nip
should
be
between
0
0
03mm

0
0
0012
in
if
this
is
not

the
case

then
the

bearing
must

be

replaced

beck
the

connecting
rod

bearings
in
a
similar
manner

after

tightening
the

caps
to
the

specified

torque
readings
The

bearing
clearance
should
be
between
0
15
0
045
mm
0
0006

0
0018
in

CAMSIIAFf
AND
SPROCKET

Inspect
the

camshaftjoumals
for

signs
of
wear
or

damage

and
check
the
camshaft
for
run
out

using
a
dial

gauge
in
a

similar
manner
to
that

previously
described
for
the
crankshaft

The

bending
limit
of
0
02
mm
0
0007
in
must
not
be

exceeded

Install
the
camshaft

sprocket
mount

the

assembly
in
V

blocks
as
shown

in
Fig
A
30
and
check
that
the
run
out
of

the

sprocket
does
not

exceed
0
1
mOl
0
04331
in
O1eck
the

timing
chain
and

sprocket
to
ensure
that
the
chain
is
not

stretched
or

damaged
or
the
teeth
of
the

sprocket
damaged
or

distorted
A

timing
chain
which
has
become
stretched
will

affect
the
valve

timing
and
be

noisy
in

operation
Check
the

chain
tensioner
and
chain

guides
for
wear
and

damage
replacing

the

parts
if

necessary

Replace
the

sprocket
if
the
run
out
is
exceeded
or
if
the

teeth
of

the

sprocket
are
worn
or

damaged
in

any
way

The
camshaft
end

play
should
be
within
0
08
0
38
mm

0
0031
O
oI50
in
If
the
clearance
limit
of
0
1
mm

0
0039
in
is
exceeded
it
will
be

necessary
to

replace
the
cam

shaft

locating
plate
See

Fig
A
3l

FLYWHEEL

Inspecting

Ensure
that
the
clutch
disc
contact
face
of

the
flywheel
is

not
worn
or

damaged
The
run
out
of
the

flywheel
contact
face

should
not
exceed
0
2
mOl
0
008
in
when
measured
with
a

dial

gauge

The

flywheel
ring
gear
can
be

replaced
if
the
teeth
are

damaged
or
worn
This

operation
will
entail

splitting
the

ring

gear
to
remove
it
A
hacksaw
should
be
used
to
cut
between
the

teeth
followed

by
splitting
with
a
cold
chisel

When

replacing
the

ring

gear
it
must
be
heated
to

a

temperature
of

approximately
1800
2000
F
before

fitting

and
then
allowed
to

cool

slowly

ENGINE

Assembling

Before

starting
to

assemble
the

engine
make
sure
that
all

components
are

perfectly
clean
It
is

always
advisable
to

pay

particular
attention
to
the

following
points
when

assembling

an

engine
Keep
the
work
bench
and
tools
clean
and
make
sure

that
the
tools
are
to
hand
Ensure
that
all

engine
oil

ways
are

clear
of

foreign
matter
fit
new

gaskets
and
oil
seals

throughout

All

sliding

parts
such
as

bearing
shells
must
be
smeared
with

engine
oil
before

installing

B
Ensure
that
the

specified
tightening

torque
readings
are

strictly
followed

A
mbling
the

cylinder
Head

To
install
the
valves
and
valve

springs
place
the
valve

spring
seats
into

position
and
fit

the
valve

guides
and
oil

lip

seals

Assemble
in
the
following
order
valve

springs
spring

retainers
valve
collets
and
valve
rocker

guides

Use
the

special
compressor
ST
12070000
as

shown
in

Fig
A
32
to

compress
the
valve
springs

Piston
and

connecting
rods

The

piston
piston
pins
and

connectiJ1
rods
must
be

assembled

in
accordance
with
the

cylinder
numbers

The
gudgeon
pin
is

press
fitted
to
the

connecting
rod
and

requires
a

fitting
force
from
0
5
to

1
5
tons
This

operation

will

require
the
use
of
the

special
tool
ST
1303000
as
shown
in

Fig
A
33

Apply
engine
oil
to
the
gudgeon

pin
and

connecting

rod
before

fitting

It
should
be
noted
that
the
oil

jet
of
the

connecting
rod

big

end
must
face

towards
the

right
hand
side
of
the

cylinder
block

See

Fig
A
34

Fit
the

piston
rings
the
oil
control

ring
in
the
bottom

groove
followed

by
the
centre
and

top
compression
rings
which

must

be
installed
with
the
marks

facing
upwards

Install
the

connecting
rod
bearings
and

caps
making
sure

that
the

markings
coincide
Ensure
that
the
backs
of

the
bearing

shells
are

perfectly
clean
otherwise

they
will
be
damaged
when

tightened

Assembling
the

engine

Fit
the
baffle

plate
and

cylinder
block
net
Install
the

crankcase
halves
of
the
main

bearing
shells
the

flanged
shell

is
fitted
to

the
centre

bearing
Smear
the
bearing
surfaces
with

engine
oil
and

carefully
lower
the
crankshaft
into

position

Install
the
main

bearing

caps
with
their
shells

making
sure

that
the
arrow
on
the

caps
faces
to

the
front
of

the

engine

Rotate
the
crankshaft
to
settle
the

caps
and

tighten
the

bearing

cap
bolts

gradually
in
two
or
three

separate
stages
Work
out

wards
from
the
centre

bearing
and
finally
tighten
to
the

specified

torque
reading
of
4
5
5
5

kgm
32
40
Ib
ft

in
the

sequence
shown
in

Fig
A
35
Ensure
that
the
crankshaft
rotates

freely
after

finally
tightening
the

cap
bolts
Check
the
crankshaft

end
float
which
should
be
between
0
05
0
18
mm
0
002

0
0071
in
see

Fig
A
36
Smear

the
side
oil
seals
with
sealant

and
fit
them
into
the
rear
main

bearing
cap
Install
the
rear
oil

seal

using
a
suitable
drift

and

grease
the
lip
of
the
seal

Place
the

flywheel
in

position
and
install
the
lock
washers

and

retaining
baits
Tighten
the
bolts

evenly
to
a

torque

reading
of
14
16

kgm
101
106Ib
ft

Rotate
the

engine
by
a

quarter
turn
and
install
the

piston

15