torque DATSUN 610 1969 Workshop Manual

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

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

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

h
W

and

connecting
rod
assemblies
Use
a

piston
ring

compressor
to

install
the

pistons
through
the

top
of
the

cylbder
bore
Make

sure
that
the

pistons
and

rings
and
the
cylinder
bores
are

lubricated
with
clean

engine
oil
The

pistons
should
be

arranged

so
that
the
F

mark
faces
to

the
front
and
with
the

piston

ring

gaps
positioned
at
1800
to
each
other
Each
piston
must

be
refitted

into
its

original
bore

NOTE

Single
inlet
valve

springs
are
used
on

the
1400
cc

engine
double

valve
springs
are
used
on
the
1600cc

and
1800
cc

engines

Screw
the
valve
rocker

pivots
with
the
locknuts
into
the

pivot
bushing
Set
the
camshaft

locating
plate
and
install
the

camshaft
in
the
cylinder
head
with
the

groove
in
the

locating

plate
directed
to

the
front
of
the

engine
Install
the
camshaft

sprocket
and
tighten
it

together
with
the
fuel

pump
earn
to
a

torque
reading
of
12
16

kgm
86
116
IbJt
a
eck
that
the

camshaft
end
play
is
within

the
specified
limits
Install
the

rocker
arms

using
a
screwdriver
to

press
down
the
valve

springs

and
fit
the
valve
rocker

springs

Gean
the

joint
faces
of
the

cylinder
block
and
head

thoroughly
before

installing
the
cylinder
head
Turn
the
crank

shaft
until
the
No
1

piston
is

at
T
D
C
on
its

compression
stroke

and
make
sure
that
the
camshaft

sprocket
notch
and
the

oblong

groove
in
the
locating
plate
are

correctly
positioned
Care

should
be
taken
to
ensure
that
the
valves
are

clear
from
the

heads
of
the

pistons
The
crankshaft
and
camshaft
must
not
be

rotated

separately
or
the
valves
will
strike
the
heads
of
the

pistons
Temporarily
tighten
the
two

cylinder
head
bolts
1
and

2
in

Fig
A
37
to
a

torque
reading
of
2

kgm
14
5
lb
ft

Fit
the
crankshaft

sprocket
and
distributor
drive

gear
and

install
the
oil
thrower
Ensure
that
the

mating
marks
on
the

crankshaft

sprocket
face
towards
the
front
Install
the

timing

chain

making
sure
that
the
crankshaft
and
camshaft

keys
are

XJinting
upwards
The
marks
on
the

timing
chain
must
be

aligned
with
the
marks
on
the

right
hand
side
of
the
crankshaft

and
camshaft

sprockets
It
should
be
noted
that
three
location

holes
are

provided
in
the
camshaft

sprocket
See

Fig
A
38
The

camshaft

sprocket
being
set
to
the
No
2
location
hole

by
the

manufacturers
A
stretched
chain
will
however
affect
the

valve

timing
and
if
this
occurs
it
will
be

necessary
to
set
the
camshaft

to
the
No
3
location
hole
in
the
camshaft

sprocket
The
chain

can

be
checked

by
turning
the

engine
until
the

No
1
piston
is

at
T
D
C
on
its

compression
stroke
In
this

position
adjustment

will
be

required
if
the
location
notch
on

the
camshaft

sprocket

is
to
the
left
of
the

groove
on
the
camshaft

locating
plate
as

shown
in
the
illustration
The
correction
is
made

by
setting
the

camshaft
on

the
No
3
location
hole
in
the
camshaft

sprocket

the
No
3
notch
should
then
be
to
the

right
of
the

groove
and

the
valve

timing
will
have
to

be
set

using
the
No
3

timing
mark

Install
the
chain

guide
and
chain
tensioner
when
the
chain

is
located

correctly
There
should
be
no

protrusion
of
the
chain

tensioner

spindle
See

Fig
A
39
A
new
tensioner
must
be

fitted
if
the

spindle

protrudes

Press
a
new
oil
seal
into
the

timing
cover
and
fit
the
cover

into

position
using
a
new

gasket
Apply
sealing
compound
to

the
front
of
the

cylinder
block
and
to
the

gasket
and
to
the

top

of

the

timing
cover

Ensure
that
the
difference
in

height
between

the

top
of
the

timing
cover
and
the

upper
face
of
the

cylinder

block
does
not

exceed
0
15
mm
0
006
in
Two
sizes
of

timing

cover
bolts
are

used
the
size
M8
0
315
in
must

be
tightened

to

a

torque
reading
of
1
0
1
6

kgm
7
2
17
Ib
ft
and
the
size
M6
0
236
in
to
a

torque
reading
of
0
4
0
8

kgm

2
9
81b
ft

Install
the
crankshaft

pulley
and
water

pump
tighten
the

pulley
nut
to
a

torque
reading
of

12
16

kgm
86
8
115
7Ib
ft

then
set

the
No
1

piston
at
T
D
C
on
its

compression
stroke

Finally
tighten
the

cylinder
head
bolts
to
the

specified

torque
reading
in
accordance
with
the

tightening
sequence
shown

in

Fig
A
3
The
bolts
should
be

tightened
in
three

stages
as

follows

First

stage

Second
stage

Third

stage
4

kgm
28
9
lbJt

6

kgm
43
4
IbJ
t

6
5
85

kgm
47
0
61
5lb
ft

The

cylinder
head
bolts
should
be

retightened
if

necessary

after
the

engine
has
been
run
for
several
minutes

Install
the
oil

pump
and
distributor
drive

spindle
into
the

front
cover
as
described
under

Engine
Lubrication

System

r
rf

i

Install
the
fuel

pump
water
inlet
elbow
and
front

engine

slinger
Fit
the
oil
strainer
into
position
coat
the
oil

sump

gasket
with
sealing
compound
and
fit
the

gasket
and
oil
sump

to
the

cylinder
block

Tighten
the
oil

sump
bolts
in
a

diagonal

pattern
to

a

torque
reading
of
0
6
0
9

kgm
4
3
6
5
IbJt

Adjust
the
valve
clearances
to
the

specified
cold

engine

ftgures
following
the

procedures
described
under
the

appropriate

heading
Final

adjustments
will

be
carried
out
after
the

engine

has
been
assembled

completely
and
warmed

up
to

its
nonnal

temperature

Install
the
rear

engine
slinger
exhaust
manifold
and
inlet

manifold
Refit

the
distributor
and
carburettor
assemblies
as

described
in
their
relevant
sections

Install
the
fuel

pipes
and

vacuum
hose

making
sure
that

they
are

securely
cl

ped
Refit

the
thermostat

housing
thermostat
and
water
outlet

together

with
the

gasket
Bond
the
rocker
cover

gasket
to
the
rocker

cover

using
sealant
and
fit
the
rocker
cover
to
the

cylinder

head

Install
the
spark
plugs
and
connect
the

high
tension
leads

Fit
the
left
hand

engine
mounting
bracket
and
install
the
clutch

assembly
using
the

alignment
tool
ST20600000
to
fit
the
clutch

to
the

flywheel
as
described
in
the
section
ClUfCR

Lift

the
engine
away
from
the

mounting
stand
and
into

the

engine

compartment
Install
the
alternator
bracket
adjusting

bar
alternator
fan

pulley
fan
and
fan
belt
in
the
order

given

Check
the
tension
of
the
fan
belt

by
depressing
the
belt
at
a

point
midw

y
between
the

pulleys
The

tension
is
correct
if

the
belt
is
deflected

by
8
12
mm
0
3
0
4
in
under
thumb

pressure

Fit
the

right
hand
engine
mounting
bracket
the
oil
filter

oil

pressure
switch
oil
level

gauge
and
water

drain
plug
Take

care
not
to

overtighten
the
oil
nIter
or

leakage
will
occur

Fill
the

engine
and

gearbox
to
the
correct
levels
with

recommended
lubricant

and
refill
the

cooling
system
Adjust

the

ignition
timing
and
carburettor
as
described
in
the

appro

priate
sections

17

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

CENTRIFUGAL
ADVANCE
MECHANISM

Special
equipment
is

required
to
check
the
advance

characteristics
It
is

possible
however
to

carry
out
an
exam

ination
of

the
caffi

assembly
and
the

weights
and

springs
to

ensure
that
the
earn
is
not

seizing

Lift
off
the
distributor

cap
and
turn
the
rotor
anti
clock

wise
When

the
rotor

is
released
is
should
return
to

the
fully

retarded

position
without

sticking
If
it

does
not
return
to
the

fully
retarded

position
it
will
be

necessary
to
check
for

dirt

and
weak

springs

It
should
be
noted
that

any
wear
in
the

mechanism
or

lose
of

spring
tension
will

upset
the
advance
characteristics
and

cause

unsatisfactory
engine
running
performance
over
the

speed

range

VACUUM
ADVANCE
MECHANISM

The

diaphragm
of
the
vacuum
advance

mechanism
is

mechanically
connected
to
the
contact
breaker

plate
The
rise

and
fall
of
inlet
manifold

depression
causes

the

diaphragm
to

move

the
contact
breaker

plate
to

advance
or

retard
the

ignition

If
the
vacuum

control
unit
fails
to

function

correctly
a

check
can
be
carried
out
to
ensure
that
the
contact
breaker

plate

is

moving
freely
and
that
the

three
steel

balls
at

the

top
and

oottom
of
the

plate
are

adequately
lubricated

Also
make
sure
that
the
vacuum
inlet

pipe
is
not
blocked

or

leaking
and
is

securely
tightened

Leakage
may
be
due
to
a

defective

diaphragm
which

should

be
renewed

along
with

any
other

faulty
part
of
the
mechanism

IGNITION
DlSTRffiUTOR
Removal

and

Dismantling

Disconnect
the

battery
leads

2
Disconnect
the

high
tension
lead
at

the
coil

3
Withdraw

the
high
tension
leads
from
the
distributor

cap

4
Detach
the
suction

pipe
from
the
vacuum
control
unit

5
Mark
the

position
of
the
distributor
and
rotor
remove
the

flange
mounting
bolts

and
withdraw
the
distributor

To
dismantle
the
distributor

proceed
as

follows

Take
off
the
distributor

cap
and
remove

the
rotor

Slacken

the
two
set
screws

holding
the
contact
breaker

upper
plate

Remove
the

primary
cable
terminals
and
withdraw
the
contact

set
from

the
distributor
Fig
C
S
Remove
the
vacuum
control

unit

c
Remove
the
two
screws
and
lift
out
the
contact

breaker

plate
detach
the

clamp
the
terminal
and
the
lead

To
remove
the
cam
take
out
the
centre
screw
as

shown
in

Fig
e
6
Drive
out

the
drive

pinion
retaining
pin
with
a
drift

and
hammer
Fig
e
and
remove
the

pinion
and
washer
Take

care
not
to
stretch
or
deform
the

governor
springs
when

detaching

them
from
the

weights

IGNITION
DISTRIBUTOR

Assembling
and

Installing

Assembly
is
a
reversal
of
the

dismantling
procedure

Lubricate
the

moving
contact

pivot
and
smear
the
lobes
of
the

cam
with
multi

purpose
grease

If

the
centrifugal
advance
mechanism
has
been
dismantled

the

governor
springs
and
cams
must
be
refitted
as

shown
in

Fig
e
8
The

governor
weight

pin
6
should
be
fitted
into

the

longer
of
the
two
slots

leaving
a
certain
amount
of

clearance

for
the
start

and
end
of
the

centrifugal
advance
movement

When

installing
the
distributor
take
care
to

align
the

body

and
rotor

with
the
marks
made
during
removal
The
rotor
must

be

positioned
in
its

original
location
it
will
turn

slightly
when

the
distributor
is
inserted
and
the

gear
teeth
mesh
Remove
and

replace
the
distributor
if

the
rotor
does
not

point
to
the

align

ment

mark
until
both
distributor

body
and
rotor
are
correctly

aligned

SPARKING
PLUGS

The

sparking
plugs
should
be

inspected
and
cleaned
at

regular
intervals
not

exceeding

every
10
000
km
6000
miles

New

sparking
plugs
should
be
fitted
at

approximately
20
000

km
12
000
miles

Remove
the

plugs
and
check
the
amount
of
electrode

wear
and

type
of

deposits
Brown
to

greyish
tan

deposits
with

slight
electrode
wear

indicate
that
the

plugs
are

satisfactory
and

working
in

the
correct
heat

range

Dry
fluffy
carbon

deposits
are
caused

by
too

rich
a
mixture

dirty
air
cleaner
excessive
idling
or

faulty
ignition
In
this

case

it
is
advisable
to

replace
the

plugs
with

plugs
having
a

higher
heat

range
Oily
wet
black

deposits
are
an

indication

of

oil
in

the
combustion
chambers

through
worn

pistons
and

rings
or
excessive
clearance
between
valve

guides
and
stems

The

engine
should
be
overhauled
and
hotter

plugs
installed
A

white
or

light
grey
centre

electrode
and
bluish
burned
side

electrode
indicates

engine
overheating
incorrect

ignition
timing

loose

plugs
low
fuel

pump
pressure
or
incorrect

grade
of
fuel

Colder

sparking
plugs
should
be
fitted

The

plugs
should
be
cleaned
on
a

blasting
machine
and

tested
Dress
the
electrodes
with
a
small
file
so
that
the
surfaces

of
both
electrodes
are
flat
and

parallel
Adjust
the
spark
plug

gap
to
0
8
0
9
mm
0
031
0
035
in

by
bending
the
earth

electrode
Refit
the

plugs
and

tighten
them
to
a

torque
reading

of
1
5
2
5

kgm
II
15Ib
ft

31