length DATSUN 610 1969 Workshop Manual

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

VALVE
CLEARANCES

Adjusting

Incorrect
valve
clearance
will
affect
the

performance
of

the

engine
and

may
damage
the
valves
and
valve
seats
Insuf

ficient
valve
clearance
will
result
in
loss
of

power
and

may

prevent
the
valve
from

seating
properly
Excessive
clearance

causes
the
valve
to
seat
and
reduces
the
amount
of

valve
lift

This
will
result
in

noisy
operation
with

damage
to
the
valves

and
seats

Adjustment
is
made
with
the

engine
switched
off

and
should
be
carried
out

initially
with
the

engine
cold
to

allow
the

engine
to
run
Final

adjustments
are
made
after

wanning

up
the

engine
to

its
Donnal

operating
temperature
The

engine
can
be
rotated

by
removing
the

sparking
plugs
to
release

the

cylinder
compressions
then

selecting

top
gear
and

pushing

the
vehicle
backwards
and
forwards

The
cold
valve
clearances
should
be
set
to
0
20
mm

0
0079
in
for
the
inlet
valves
and
0
25
mm
0
0098
in
for

the
exhaust
valves
Check
the
clearance
between
the
valve
and

rocker

using
a
feeler

gauge
as
shown
in

Fig
A
40
Slacken
the

locknut
and
turn
the
adjusting
screw
until
the

specified
clearance

is
obtained
then

tighten
the
locknut
and
recheck
the
clearance

The
feeler

gauge
should

just
be
free
to
move
between
the
rocker

and
valve
When
the
cold
valve
clearances
have
been
set
run
the

engine
until
it
reaches
its
normal

operating
temperature
then

switch
off
and

adjust
the
valve
clearances
with
the

engine
warm

to

0
25
mm
0
0098
in
for
the
inlet
valves
and
0
30
mm

0
0118
in
for
the
exhaust
valves

ENGINE
LUBRICATION
SYSTEM
Fig
A
41

OIL
PUMP
Removal
and

Dismantling

The
rotor

type
oil

pump
is
mounted
at
the
bottom
of
the

front

timing
cover
and
driven

by
the
distributor
drive
shaft

assembly

Overhaul
of
the

pump
will

require
careful
measurement

of

the
various
clearances
to
determine
the
amount

of
wear

which

has
taken

place
If

any
part
is
found
to
be
worn
it

may
be
neces

sary
to

replace
the
entire
oil

pump
assembly
To
remove
the
oil

pump
from
the

engine
proceed
as
follows

1
Remove
the
distributor

assembly
as
described
in
the

section
IGNITION
SYSTEM
Remove
the
oil

sump
drain

plug
and
drain
off
the

engine
oil
See
under
the
heading

CHANGING
THE
ENGINE
OIL

2
Remove
the
front
stabiliser
and
the
splash
shield
board

3
Withdraw
the

securing
bolts
and
detach
the
oil

pump

body
together
with
the
drive

gear
spindle

Take
out
the
bolts
securing
the

pump
cover
to
the

pump
body

and
withdraw
the
rotors
and
drive
shaft
See
Fig
A
42

The
pin
securing
the
driven
shaft
and
inner
rotor
must
not

00
taken
out
as
the
shaft
is

press
fitted
to
the
rotor
and
the

pin

is
caulked

Unscrew
the
threaded

plug
and
withdraw
the
regulator

valve
and

spring
Oean
each

part
thoroughly
and
examine
for

signs
of

damage
or
wear
Use
a
feeler

gauge
to
check

the
side

clearances
between
the
outer

and
inner
rotors
the
clearances

at
the

tips
of
the
rotors
and
the
clearance
between
the
outer

rotor
and
the

pump
body
See
Technical
Data
for
the
relevant

clearances
The
clearances
can

be
checked

using
a

straight
edge

as

shown
in

Fig
A
43

OIL
PUMP

Assembly
and
Installation

Assembly
is
a
reversal
of
the

dismantling
procedure
Before

installing
the
oil

pump
in
the

engine
it
will
be

necessary
to

rotate

the

engine
until
the
No
1

piston
is
at

T
D
C
on

its

compression
stroke

Fill
the

pump
housing
with

engine
oil
and

align
the

punch

mark
on
the

spindle
with
the
hole
in
the
oil

pump
as
shown

in

Fig
A
44

Install
the

pump
with
a
new

gasket
and

tighten
the

securing
bolts
to
a

torque
reading
of
1
1
1
5
kgm
8
1
Ilb
ft

Replace
the

splash
shield
board
and
the
front
stabiliser
refill

the

engine
with
the

specified
amount
of

engine
oil

OIL
FILTER

The

cartridge
type
oil
filter
can
be
removed
with
the

special
tool
ST
19320000
or
a
suitable
filter
remover
Interior

cleaning
is
not

necessary
but
the
ftIter

body
and
element
must

be

repiaced
every
10
000
km
6000
miles
Be
care
ul
not
to

overtighten
the
filter
when

replacing
or

oil
leakage

may
occur

CHANGING
THE
ENGINE
OIL

After
the
fIrst
oil

change
which
should
take

place
at
1000

km
600
miles
the
oil
should
be

changed
regularly
at
5000
km

3000
miles
intervals

Draining
is
more

easily
accomplished
after
a

lengthy
run

when
the
oil

being
thoroughly
warm
will
flow

quite
freely

Stand
the
vehicle
on
level

ground
and

place
a
suitable

container
under
the
drain

plug
Remove
the
drain

plug
carefully

as
the
hot
oil

may
spurt
out
with
considerable
force
When

refIlling
the

engine
make
sure

that
the
oil
is
to
the
H
mark
on

the

dipstick

19

Engine
model

Number
of

cylinders

Arrangement
of

cylinders

Cubic

capaci
ty

Bore
x
stroke

Arrangemen
t
of

valves

Max
B
H
P

Max

torque

Firing
order

eidlingspeed

Compression
ratio

Oil

pressure

Valve
clearance

hot

Inlet

Exhaust

Valve
clearance
cold

Inlet

Exhaust

Valve
head

diameter

Inlet

Exhaust

Valve
stem

diameter

Inlet

Exhaust

Valve
lift

Valve

spring
free

length

Valve

spring
fitted

length

Valve

spring
coil
diameter

Valve

guide
length

Inlet

Exhaust

Valve

guide
protrusion
rreclll11cal
ata
L

lJEngine

LI3

4

In
line

1296

83
0
x
59
9

3
2677
x
3583
in

Overhead
camshaft

77
at
6000

rpm

II
1

kgm
at
3600

rpm

I
342

600

rpm

8
5
1

3
8
4
2

kg
sq
em

54
60Ib

sq
in

VALVES

0
25
mm
0
010
in

0
30
mm
0
01
in

0

20
mm
0
008

in

0
25
mm
O
OIJ
in

38
mm
1
50
in

33
mm

1
30
in

8
0
mm
0
31
in

8
0
mm
0
31
in

10
0

mm
0
40
in

48
12
mm

1
89
in

40
0
mm
30
7

kg

1
57
in
67

7
lb

34
9
mm
1
37
in

59
0
mm
2
32

in

59
0
mm
2
32
in

10
4
10
6
mm
0
41
0
42
in

Valve

guide
inner
diameter

Inlet

8
00
8

l
8
mm
0
315
0
3154

in

Exhaust
8
00
8
018
mm
0
315

0
3154

in

Valve

guide
outer
diameter

Inlet

Exhaust

Valve

guide
to
stem
clearance

Inlet

Exhaust

20
11
985
11
996
mm
0
472
0
4723

in

11
985
11
996
mm
0
4172
0
4723

in

0
015
0
045
mm
0
0006
0
0018

in

0
040
0
070
mm
0
0016
0
0028

in
Valve
seat
width

Inlet

Exhaust

V
lve
seat

angle

Valve
seat

insert
interference

fit

Inlet

Exhaust

Valve

guide
interference
fit

Inlet
1
4
1
8
mm
0
055
0
071
in

1
6
2
0
mm
0
063
0
079
in

450

0
08
0
11
mm
0
0031
0
0043

in

0
06
0
10

mm
0
0024
0
0039

in

0
027
0
049
mm
0
0011
0
0019

in

CAMSHAFT
AND
TIMING
GEAR

Camshaft
end

play

Camshaft
lobe
lift

Camshaft

journal
diameter

Max
camshaft
run
out

Camshaft

bearing
to

journal

clearance

Camshaft

bearing
inner

diameter
0
08
0
38
mm

0
0011
0
0019
in

6
65
mm
0
261
in

47
949
47
962
mm
fI
8877

1
8883
in

0
05
mm

0
002
in

0
038
0
076
mm
0
0015
0
0026

in

48
000
48
016
mm

1
8898

1
8904
in

CONNECTING
RODS

Distance
from
centre
to
centre
132
97

133
03
mm
5
235

5
237
in

Bearing
shell
thickness

Standard

Big
end
side

play

Connecting
rod

bearing

running
clearance

Connecting
rod

rend
or

twist
1
498
1
506
mm
0
059
0
593

in

0
20
0
30

mm
0
008
0
012
in

0
014
0
056
mm
0
0006
0
0022

in

0
03
mm

per
100
mm
0
0012

in

per
3
937

in

CRANKSHAFT
AND
MAIN

BEARINGS

Crankshaft
material

Number

of

bearings

Main

journal
diameter

Max

journal

taper

Max

journal
out
of
round

Crankshaft
end

play
Special

forged
steel

5

54
942
54
955
mm
2
1631

2
1636

in

0
03
mm
0
0012
in

0
03
mm
0
0012
in

0
05
0
015
mm
0
002
0
0059

in

Wear
limit

Crank

pin
journal
diameter

Max
crankpin
taper

Max

crankpin
out
of
round

Thickness
of
main

bearing

shells
0
3
mm
0
012

in

49
961
49
975
mm

1
967
1
9675

in

0
03
mm
0
012
in

0
03
mm
0
012
in

1
827
1
835
mm
0
072
0
0722

in

Main

bearing
running
clearance

0
020
0
062
mm
0
0008
0
0024

in

Max
main

bearing
running

clearance

Crankshaft
bend
limit

Material

Type

Piston
diameters

Standard

I
st
oversize

2nd
oversize

3rd
oversize

4th
oversize

5th
oversize

Width
of

ring
grooves

Top
and
second

Oil
control

Piston

running
clearance
0
12
mm

0
0047
in

0
05
mm
0
002
in

PISTONS

Cast
aluminium

Slipper
skirt

82
99
83
04
mm
3
267
3
269

in

83
22
83
27
mm
3
276
3
278

in

83
47
83
52
mm
3
286
3
288

in

83
72
83
77
mm
3
296
3
298

in

83
97
84
02
mm
3
305
3
308

in

84
47
84
52
mm
3
326
3
328

in

2
0
mm
0
08
in

4
0
mm

0
16
in

0
025
0
045
mm
0
001
0
002

in

PISTON
PIN

Pin
diameter
20
995
21
000
mm
0
8266

0
8268

in

Pin

length
72
00
72
25
mm
2
8346
2
8445

in

Pin

running
clearance
in

piston
0
008
0
010
mm
0
0003
0
0004

in

Pin
interference
fit
in
small
end
bush

0
015
0
033
mm
0
0006
0
0013

in

Piston

ring
height

Top
and
second

Oil
control

Side
clearance
in

grooves

Top
PISTON
RINGS

2
0
mm
0
08
in

4
0
mm
0
16
in

0
040
0
073
mm
0
0016
0
0029

in
Second

Oil
control

Piston

ring
gaps

Top

Second

Oil
control

Material

Distortion
of

sealing
face

Max
distortion

Valve
seat
insert
material

Inlet

Exhaust

Fit

Drive

Chain

Chain
tensioner
0
030
0
063
mm
0
0012
0
0025

in

0
025
0
063
mm
0
001
0
0025

in

0
23
0
38
mm
0
0091
0
0150

in

0
15
0
30
mm

0
006
0
012

in

0
15
0
30
mm
0
006
0
012
in

CYLINDER
HEAD

Aluminium

alloy

0
03
mm
0
0012
in

0
1
mm
0
004
in

Aluminium
bronze

Special
cast

Hot

pressed

CAMSHAFT
DRIVE

From
crankshaft

double
roller

type

Spring
and
oil

pressure
control

Engine
model
lWIN
CHOKE
CARBURE
ITOR

Outlet
diameter

Venturi
diameter

Main

jet

Main
air
bleed

Slow

running
jet

Power

jet

Float
level

Fuel

pressure

Weight

Altitude

setting
main

jet

1000
m
3300
ft
94

2000
m
6600

ft
92

3000
m

10
000

ft
89

4000
m

13
300
ft
87

5000
m

16
600
ft
85
PRIMARY
L13

SECONDARY

30mm

27x
12mm

150

90

180
26
mm

21
x
8
mm

96

80

43

40

23
I
mm
0
905
0
04

in

0
24

kg
sq
em
3
41b

sq
in

2
55

kg
5
61
lb

1

21

TechnIcal
Data
L
14
16
and
18

Engine

GENERAL
SPECIFICATIONS

Cylinders

Displacement

L14

L16

L18

Bore
and
stroke

L14

L16

Ll8

Compression
ratio

L14

L16

single
carburettor

L16
SU

twin
carburettor

L18

single
carburettor

Ll8

SU
twin
carburettor

Valve

arrangement

Firing
order

e

idling
speed

Engine

idling
speed
with
automatic
transmission

Oil

pressure
Hot
at
2000
r

p
m

Valve

clearance
Hot

Intake

Exhaust
0
25
mm
0
0098

in

0
25
mm
0
0098
in

Valve
clearance

Cold

Intake

Exhaust

Va
head
diameter

L14

Intake

Exhaust

Vahoe
head
diameter
L16

Intake

Exhaust
0
20

mm
0
0079

in

0
20
mm

0
0079

in

38
mm
1
5361
in

33
mm

1
2992

in

42
mm

1
6535

in

33
rom
1
2992
in

Valve
head
diameter

L18

Intake

Exhaust
42
mm

1
6535
in

35
mm
1
3780

in

Valve
stem
diameter

Intake

7
965
7
980
mm
0
3136
0
3142
in

Exhaust

7
945
7
960
mm

0
3128
0
3134
in

Valve

length
L14

Intake

Exhaust
115

6
115
9mm
4
551
4

562in

115
7
116
0
mm

4
555
4
567
in

Valve

length
L16
LIB

Intake

114

9
115
2
mm
4
524
4
535

in

Exhaust

115
7
116
0
mm

4
555
4
567
in

22
4
in
line

1428

cc
87
1
cu
in

1595
cc
97
3
cu
in

1770

cc

108
0
cu
in

83
x
66
mm

3
27
x
2
60
in

83

x
73
7
mm
3
27
x
2
90
in

85
x
7B
mm
3
35
x
3
07
in

9
0

8
5

9
5

8
5

9
5

Overhead
valve

I
3
4

600
r

p
m

single
carburettor
650
r

p
m
twin
carburettor

650

r

p
m

single
carburettor

700
r

p
m
twin

carburettor

3
5
4
0

kg
sq
cm

50
57Ib

sq
in

VALVES

Valve
lift

Single
carburettor

Valve
lift

Twin
carburettor
10
0
mm
0
3946

in

10
5
mm

0
413
in

Valve

spring
free

length
LI4

Ll4
Intake

Ll4

Exhaust
outer

L14
Exhaust
inner

Valve

sprin8
free

length
L16
LIB

Outer

Inner
49
0
mm

1
929
in

49
98
mm
1
968

in

44
85

mm

1
766
in

49
98
mm

1
968

in

44
85
mm
1
766
in

59
0
mm

2
393
in

10
6
mm

0
417
in
Valve

guide
length

Valve

guide
height
from
head
surface

Valve
guide
diameter
inner

Intake
8
018

Exhaust
8
018

Valve

guide
diameter
outer

Intake

12

034

Exhaust

12
034

Valve

guide
to
stem
clearance

Intake

Exhaust

Valve
seat
width
L14

Intake

Exhaust

Valve
seat

width
L16
LIB

Intake

Exhaust
8
000

mm
0
3154

0
3150
in
clia

8
000
mm

0
3154

0
3150
in
clia

12
023
mm
0
4738
0
4733

in
clia

12
023

mm
0
4738
0
4733

in
clia

1
8
mm

1
1024
in

I
7
mm
1
0630
in

I

4
mm

0
0551
in

1
3
mm
0
0512

in

0
020
0
053
mm
0
0008
0
0021
in

0
040
0
073

mm
0
0016
0
0029
in

liB
Oversizes

Ring

groove
width

Top
ring

Second

ring

Oil

ring

Piston
to
bore

clearanl
e

Pin
diameter

I
ength

Ll4
Ll6

Ll8

Pin
to

piston
clearance

Pin
interference
fit
in
small
end
bush

Piston

ring
height

Top

Second

Side
clearance

Ll4
Ll6

Top
ring

LI8

Top

ring

Second

ring

Ring

gap

U4

Top
ring

U4
Second

ring

Ll6

Top
ring

L
16
Second

ring

U8

Top
ring

U8
Second

ring

Oil

ring

Oil

pump

Oearance
between
inner

and
outer
rotor

Rotor

tip
clearance

Oearance
between
outer
rotor

and

body

Rotor
to

bottom
cover

clearance

Oil

pressure
at

idling

Oil

pressure
relief
valve

spring

Free
length

Fitted

length

Relief
valve

opening

pressure

24
85465485
515
mm
3
648
667
ill

86
065
86
015
mm

13
3844
33864
in

0
mm
CO
0787

in

0
mm
0
0787
in

4
0
mm
0
1
q
c
in

0
025
0
045
mm
0
0010
0
0018
in

PISTON
PIN

20
995
1
000
mm

0
8266

0
8168
in

72
00

72
25

0
001

0
Dl5
72
25
mm

2
8346
2
8445
in

73
00
mm

2
8445

2
8740
in

0
013
mm
0
00004
0
00051
in

0

033
mm
0
0006
0
0013
in

PISTON

RING

1
977
mm
0
0778

in

1
977
mm
0
0778
in

0
040
0
080
mm
0
0016
0
0031
in

0
045
0
080
mm

0
0018
0
0031
in

0
030
0
070
mm
0
0012
0
0028
in

0
23
0
38
mm
0
0091

0
0150

in

0
15
0
30
mm
0
0059
0
0118
in

0
25
0
40
mm
0

0098
0
0157
in

0
15
0
30
mm
0
0059
0
0118
in

0
35
0

55
mm
0
0138
0
0217
in

0
30
0
50mm
0
0118
0
0197
in

0
30
0

90
mm
0
0118
0
0354
in

LUBRICATION

SYSTEM

Rotor

Pump

0
05
0
12
mm
0

0020
0
0047

in

less
than
0
12
mm
0
0047
in

0
15
0
21
mm
0
0059
0
0083
in

0
03
0

13
mm
0
0012
0
0051
in

0
8
2
8

kg
sq
cm
11
40
Ib

sq
ln

52
5
mm

2
067
in

34
8
mm

1
370
in

3
5
5
0

kg
sq
cm

50
71
Ib

sq
ln

Connect
the
fuel
line
from
the
float

chamber
to
the
nozzle

nipple
and

tighten
the

retaining
clip
Pull
out

the
choke
lever

and

place
the

connecting
plaie
betw
n
the
washer
and
sleeve

collar
Screw
the

plate
to
the

nozzle
head
and
check
that
the

collar
is
installed
in
the
hole
in

the

plate
by
mo

ing
the
choke

lever
as

necessary

Recheck
the

piston
to
make

sure
that
it
falls

freely
without

binding

SU
TWIN
CARBURETTOR

Centering
the

jet

Remove
the

damper
oil

cap
nut

and
gradually
raise
the

lifter

pin
4
in

Fig
D
17

Continue
to
raise
the
lifter

pin
until
the
head
of
the

pin

raises
the

piston
by
approximately
8
mm
0
31
in
When
the

lifter

pin
is
released
the

piston
should

drop
freely
and
strike

the
venturi
with
a

light
metallic
click
If

the

pi
ston
does
not

fall

freely
it
will
be

necessary
to
dismantle
the

carburettor
in

the
manner

previously
described

SU

TWIN
CARBURETTOR

FLOAT
LEVEL

Inspection
and

Adjustment

The
fuel
level
in
the
float
chamber
can

be
checked

using

the

special

gauge
ST
19200000
Remove
the
float
chamber

drain

plug
and
install
the

special

gauge
as
shown
in

Fig
D
20

Start
the

engine
and
allow
it
to
run
at

idling
speed
The

fuel
level
is
conect
if
it
is

indicated
on

the

glass
tu

be
at
a

distance
of
22
24
mm
0
866
0
945
in
below
the

top
of
the

float
chamber

The
level
of
the
fuel
can

be
corrected
if

necessary
by

adjusting
the
float
level
in
the

following
manner
Take
out
the
float
chamber
coveT

securing
screws
and

lift
off
the
cover
and
attached
float

lever
Hold
the
cover
so
that

the
float
lev
r
is

facing
upwards
Lift
the
float
lever
and
then

lower
it
until
the
float
lever
seat

just
contacts

the
valve
stem

The
dimension
uH
in

Fig
D
1
should
be
11
12
mm
0
43

0
47
in

and
can

be
corrected

by
bending
the
float
lever
at
the

point
indicated

SU
TWIN
CARBURETTOR

Starting
interlock
valve

opening
adjustment

To

adjust
the
starting
interlock

opening
the

connecting

rod
4
in

Fig
D
22
1
must
be
bent

using
a
suitable

pair
of

pliers
The
throttle

opening
can

be
increased

by
lengthening

the

connecting
rod
or
reduced

by
shortening
the
rod

The
throttle

opening
is
correctly

adjusted
when
the

clearance
8

between
the
throttle
valve
and
throttle
chamber

is
set
to
0
6
mm
0
023
in
with
the
choke
lever
half

completely

out

HYDRAULIC
DAMPER

The

damper
oil

should
be
checked

approximately
every

5000
km
3000
miles
To
check
the
oil
level
remove
the
oil

cap
nut
as
shown

in

Fig
D
23
and
check
the
level
of
oil

against

the
two

grooves
on
the

plunger
rod

Top

up
with
SAE
20

engine
oil
if

the
oil
level
is
below
the
lower
of
the
two

grooves

Take
care

not
to
bend
the

plunger
rod
when

removing
and

replacing
the
oil

cap
nut

and
make
sure
that
the
nut
is

sufficiently

tightened
by
hand

TechnIcal
Data

Engine
Model
Ll4

I400cc

Primary
Secondary

28mm
32mm

21x7mrn
28xlOmm

96

165

60
60

I
Omm

220
100

1
6
Outlet
diameter

Venturi
diameter

Main

jet

Main
air
bleed

1
st

slow
air
bleed

2nd
slow
air
bleed

Economizer

Power

jet

Float

level

Fuel

pressure

Main
nozzle
55

22mm

0
24

kg

sq
cm
3
41b

sq
in

2
2mm

2
Smm

SU
Twin
Carburettors

Type

Bore
diameter

Piston
lift

Jet
needle

Nozzle

jet
diameter

Suction

spring
IUL
38
W6

38mm

1
4961
in

29mm

1417
in

M
76

2
34
mm

0
0921
in

No
23

Float
needle
valve

inner
diameter

Float

level
1
5mm
0

059
in

23mm
0
9055
in

42
Ll6
1600cc

Primary

Secondary

28mm
32mm

22x7mm

29xlOmm

102
165

60

60

1
0mm

180
100

1
6
Ll8

l80Occ

Primary
Secondary

30mm

34mm

23x14x7mm
30xlOmm

102
170

60
60

I
Omm

210
100

1
6

55

22mm
55

22m

2
3mm
2
5mm
2
3mm
2
8mm

Throttle

clearance
at
full

throttle

Position
at
full
throttle
0
6mm
0
0236
in

6
50

FUEL
PUMP

Type

Delivery
amount
Mechanical

1000cc
minute
at
1000

r

p
m

0
18
0
24

kg

sq
cm

2
5
3
41b

sq
in

from
eccentric
on
cam

shaft
Delivery

pressure

Drive

The
coil

spring
clutch

pressure
plate
can

be

lapped
with
a

surface

grinder
to
remove

dents
or

scratches

only
the
minimum

amount
of
metal
should
be
removed
to
restore
the
surface

Check
the

plate
for
distortion

by
placing
it

on
a
surface

plate
with

the
friction
face
towards
the
surface

plate
Press

the
pressure

plate
down
and
insert
a
feeler

gauge
of
1
0mm

0
0039
in

between
the

pressure
plate
and
surface

plate
If
it

is

possible
to
insert
the
feeler

gauge
then
the

pressure
plate
must

be

repaired
or

replaced
The

plate
can
be
skimmed
but
the

maximum
amount
of
metal
that
can
be
removed
is
1
0mm

0
0039in

CLUTCH
SPRING

Diaphragm
clutch

With
the

diaphragm
spring
assembled
to
the

pressure
plate

inspect
the

spring
height
and
load
in
the

following
manner

Place
distance

pieces
of
7
8
mm

0
307
in
on
the
base

plate
as

shown
in

Fig
E
3
and
bolt
down
the
clutch
cover

using
the

special
bolts

provided
with
the
kit
Meas
Jre
the

height
B
in

Fig
E
5

at
a
diameter
of
44mm
1

732
in
The
release

fingers

should
not

exceed
a

height
of
43
45
mm
1
693
1
772
in

from
the
base

plate
Replace
the

spring
if

the

height
is
in
excess

of
the

figures

quoted

Press
the
dutch
down
as

shown
in
Fig
E
6
to
a

depth
of

7
8mm
0
307
in
or
until
the
clutch
driven

plate

upper
surface

lines

up
with
the
clutch
cover

mounting
face
If

the
load

applied

is
less
than
350

kg
770
lbs
it
will
be

necessary
to
renew
the

diaphragm
spring
Do
not

press
the
clutch
disc
down

by
more

than
9mm
0
35
in
or
the

diaphragm
spring
may
be
broken

CLUTCH
SPRINGS
Coil

spring
clutch

The
clutch

springs
must
be

replaced
as
a

set
if

any
of
the

springs
are
found
to
be
defective
Specifications
for
the

springs

are

given
in
Technical
Data
at
the
end
of
this
section

Generally

a

spring
may
be
considered
faulty
if
when
assembled
the
load
is

reduced

by
more
than
15
or
if
the
free

length
has
altered

by

more
than
1
5mm
0
0590
in
or
if
the
deflection
B
to
A

in

Fig
E

7
exceeds
5mm

per
100mm
0
2
in

per
3
94
in

Release

Bearing

The
release

bearing
should
be
renewed
if

excessively
worn

or
if

roughness
can
be
felt
when
the

bearing
is
turned

by
hand

The

bearing
should
also
be
renewed
if
the

grease
has

leaked

away
or
if
the
clearance

between
the
clutch
cover
and
inner

diameter
of

the
sleeve
is
more
than
0
5
mm
0
0197
in

The

bearing
can
be

removed

using
a
conventional

puller

as
shown
in

Fig
E
8
Two

types
of
release

bearings
are

available

and
care
must
be
taken
when

fitting
onto

the
bearing
sleeve

The
release
bearing
should
be

pressed
into

place
on
the

diaphragm

spring
type
of
clutch
with
a
force
of
400

kg
880
lbs

applied

at
the
outer
race
as
shown

in

Fig
E
9
On
the
coil

spring
clutch

the
same

force
must

be

applied
at

the
inner
race
as
shown
in

Fig
E
IO
It
should
be

possible
to
turn
the

bearing
freely
and

smoothly
when
it
is

pressed
into

place
CLUTCH

Assembly

Coil

spring
type

Press
the

pin
into
the

eyebolt
and

through
the

lug
on

the

pressure
plate
Place
the
three
distance

pieces
on
the
surface

of
the
base
plate
of
the

special
tool
ST20050000
and

position

the

pressure
plate

pressure
springs
and
retainers

on
the

plate

Set
the

retracting
springs
on
the
cover

and
insert
the

release
levers

through
the

spring
Place

the
clutch
cover
over

the

pressure
plate
and

springs
making
sure
that
the

retracting

springs
do
not

become
dislodged
or
distorted

Compress
the

pressure
springs
by
screwing
the

special
set

bolts
into
the
holes
in

the
cover

Tighten
the
bolts

gradually

in
a

diagonal

pattern
to
avoid

distorting
the
cover
Place
the

release
levers
on

the

eye
bolts
and
screw
OR
the

securing
nuts

Place

retaining
hooks
under
the
release
levers
and
remove
the

clutch
assembly
from
the
base

plate
slackening
the
set
bolts
in

a

diagonal
pattern

COIL
SPRING
CLUTCH

Adjusting

Screw
the
centre

pillar
into
the
base

plate
and

place
the

high
finger
over
the

pillar
The
height
of
the
release
levers
must

be

adjusted
by
turning
the
eye
bolt
nuts
until
the

tops
of

the

release
levers
are

just
touching
the

tip
of
the
gauge
See
Fig
E

11
Remove
the
centre

pillar
when
the
release
levers
are

correctly
adjusted
and
screw
in
the

actuating
lever
Fig
E
12

Turn
the

actuating
mechanism
several
times
to
bed
down
the

parts
and
then
recheck
the

height
of
the
release
levers
Check

for
run
out
as
near
to
the

edge
as
possible
and

readjust
if
the

deviation
is
more

than
0
5
mrn
0
020
in

CLUTCH
InsWlation

Ensure
that
the
friction
faces
are

free
from

oil
and

grease

and
place
the
driven

plate
on
the

flywheel
The

longer
chamfered

splined
end
of
the

assembly
should
face

the

gearbox
Use
a

spare
drive
shaft
to

align
the
driven

plate
The
shaft
must

be

inserted

through
the
splined
hub
of
the
driven

plate
and
into

the

pilot
bearing
of
the

flywheel

Place
the
clutch
cover
into

position
on

the
flywheel
and

tighten
the
dutch
bolts

gradually
in
a

diagonal

pattern
to
a

torque
reading
of
1
5
2
2

kgm
11
16Ib
ft

Remove
the

dummy
shaft
and
the

restraining
hooks
from
the
release
levers

Refit
the
release

bearing
and
the
bell

housing

CLUTCH
PEDAL
Removal
and
Installation

Remove
the
clevis

pin
from
the
end
of
the
master

cylinder
pushrod
and
disconnect
the
pushrod
Remove
the

return

spring
Remove
the

pushrod
after

slackening
the

pushrod

adjuster
Coil

spring
clutch

only
Remove
the

pedal
lever

securing
bolt
slacken
the
handbrake
bracket
bolts
and
lift
out

the

pedal

Clean
all

parts
thoroughly
and
check
them
for
wear
or

damage
paying
particular
attention
to
the
rubber

parts
return

spring
and

pedal
lever
bush

Installation
of
the
clutch

pedal
is
a
reversal
of

the

removal

procedures

45