lock DATSUN PICK-UP 1977 Owner's Manual

5
Install
rocker
arms

by

pressing

valve

springs
down
with
a
screwdriver

6
Install
valve
rocker

springs

7
After

assembling
cylinder
head

turn
camshaft
until
No
I

piston
is
at

T
D
C
on
its

compression
stroke

EM1S5

Fig
EM
83

A
embling
cylinder
head

PISTON
AND

CONNECTINGROD

1

Assemble

pistons
piston
pins
and

connecting
rods

on
the
de
ignated

cylinder

STl3030001

EM156

Fig
EM
84
Installing
piston
pin

EM157

Fig
EM
85
Assembling
piston
and

connecting
rod

Notes

a
Piston

is

pressed
into

connecting

rod
with

fitting
force
of
0
5
to
5

tons
aid
of
Piston
Pin
Press

Stand
STl303000
I
is

necessary

When

pressing
piston
pin
into
con

necting
rod

apply
engine
oil
to

pin

and
small
end
of

connecting
rod
Engine
Mechanical

b

Arrange
so
that
oil

jet
of
connect

ing
rod
big
end
is
directed
toward

right
side
of

eylinder
block

c

Be
sure
to
install

piston
in

cylinders

with
notch
mark
of

piston
head

toward
front
of

engine

2

Install

piston
rings

InstalI

top
and
second

rings
in

right

position
with
marked
side

up

Notes

a

Top
ring
is

chromium

plated
on

liner

contacting
face

b
Second

ring
has

larger
taper
surface

than

top
ring

c
In
the
combined
oil

ring
upper
rail

is
the
same
as

lower
one

j

c6J

EM158

Fig
EM
86

lalling
pidon
rings

3

Fix

bearings
on

connecting
rod

and

connecting
rod

cap

Note
Clean
back
side
of

bearing
care

fully

ENGINE
ASSEMBLY

The
first

step
in

engine
assembly

is

to
bolt

Engine
Attachment

ST0526000
I

to

right
hand
ide
of

cylinder
block
Next
install
block
on

another

Engine
Stand
ST0501S000

with

engine
bottom

up

2

Set
main

bearings
at

the

proper

portion
of

cylinder
block

Rear
Front

III
III

m
It
IlL

D

D

D
D
D

1
5
1
4
1
3
1
2
1
1

EM159

Fig
EM
87
Main

bearings

EM
22
3
Install
baffle

plate
including

cyl

inder
block
net

Notes

a

Only
center

bearing
No
3

is
a

flanged
type

b
All
inter
bearings
No
2

and
No
4

are
the
same

type

c
Front

bearing

No
I
is

also
the

same

type
as
rear

bearing
No
5

The
difference
is

that
an
oil
hole
is

provided
in
the
front

bearing

d
All

upper
and
lower

bearings
are

interchangeable

4

Apply
engine
oil

to
main

bearing

surfaces
on
both
sides
of

cylinder

block
and

cap
and
then
install
crank

shaft

5
Install
main

bearing

cap
and

tight

en

bolts
to

specified

torque

Tightening
torque

4
5
to
5
5

kg
m
33

to
40
ft
lb

Notes

a

Apply
sealant
to
each
side
of
rear

main

bearing
cap
and
each
comer

of

eylinder
block
as
shown
in

Figure
EM
79

b

Arrange
parts
so
arrow
mark
on

bearing
cap
faces
toward
front
of

engine

c

Prior
to

tightening
bearing
cap

bolts

place
bearing
cap
in

proper

position
by
shifting
crankshaft
in

the
axial
direction

d

Tighten
bearing
cap
bolts

gradually

in
two
to
three

stages
outwardly

from
center

bearing
in
the

sequence

as
shown
in

Figure
EM
88

e
After

securing
bearing

cap
bolts

ascertain
that
aankshaft
turns

smoothly

@

i

d

l

j
1

@EM543

Fig
EM
8S
Torque

sequence
0

cap
bolt

6
Make

sure
that

crankshaft
has

proper
end

play

Crankshaft
end

play

0
05
to
0
18

mm

0

0020
to
0
0071
in

Fig
EM
89

Checking
crankshaft

end

play

7

Install
side
oil
seals
into

rear
main

bearing

cap
Prior
to

installing
apply

sealant
to
seals

Fig
EM
90

Driving
side
oil
seal

8
Install
rear
oil
seal

using
Crank

shaft
Rear

Oil
Seal
Drift

STI5310000

r

STl5310000

r

EM163

Fig
EM
91

Installing
rear
oi
seal
Engine
Mechanical

Note
When

installing
oil
seal

give

coating
of

engine
oil
to

mating

shaft
to

prevent
scratches
and

fold

ed

lip
Also

give

coating
of
oil
to

periphery
of
oil

seal

9

Install
rear
end

plate

10
Install

flywheel
securely
and

tighten
bolts
to

specified

torque

Tightening

torque

14

to
16

kg
m

101
to
116
ft
lb

I
I

Insert

pistons
in

corresponding

cylinder

using
Piston

Ring
Compressor

EM03470000

EM03410000

I

EM544

Fig
EM
92

Installing
pi8ton
rod

a
Sembly

Notes

a

Apply
engine
oil

to

sliding
parts

b

Arrange
80

that
notch
mark
on

piston
head
faces
to
front
of
en

gine

c
Install

piston
rings
at
1800
to

each

other

avoiding
their
fit
in
the

thrust
and

piston
pin
directions

6
Top
ring

I
iilring

Piston

pin
ireClioJ

EM165

Fig
EM

93
PUtan

ring
direction

12
Install

connecting
rod

caps

Tightening
torque

4
5
to
5
5

kg
m
33
to
40
ft
lb

EM
23
Fig
EM

94

Installing
connecting
rod

cap

Note
Install

connecting
rods

and
con

necting
rod

caps
80
that
their

as

signed
numbers
are

positioned
on

the

same
side
and
in
the
SlIme

direction
with

respect
to

cylinders

13
Make
sure
that

connecting
rod

big
end
has

proper
end

play

Fig
EM

95

Checking
big
end

play

Big
end

play

0
2
to
0
3
mm

0
008
to
0
Ql2
in

14

Install

cylinder
head

assembly

Fig
EM
96

Tightening
sequence

01

cylinder
head
bolts

J
Thoroughly
clean

cylinder
block

and

head
surface

Do

not

apply
sealant
to

any
other

part
of

cylinder
block
and
head

sur

face

2
Turn
crankshaft
until
No
I

pis

ton
is
at
T
D
C

on
its

compression

stroke

3
Make

sure
thai
camshaft
sprock

et
location
notch
and

plate
oblong

groove
are

aligned
at
their
correct

positions

4

When

installing
cylinder
head

make
sure

that
all
valves
are

apart

from
heads
of

pistons

5
Do

not
rotate
crankshaft
and

camshaft

separately
or
valves
will
hit

heads
of

pistons

6

Temporarily
tighten
two
bolts

CD

V
sJiown

in
Fig

re
EM
96

Tightening
torque

2

kg
m

14
ft
b

15
Install
crankshaft

sprocket
and

oil

pump
drive

gear
and
fit
oil

thrower

Note
Make
sure
lhat

maling
marks
of

crankshaft

sprocket
face
10
Cront

16
Install

timing
chain

Noles

a
Make

sure
that
crankshaft
and
cam

shaft

keys
point

upwards

Fuel

pump
drive

earn

2
Chain

guide

3

Chain
tensioner

4

Crank

sprocket

5
earn

sprocket

6
Chai

guide

EM439

b
Set

timing
chain

by

OOgning
its

mating
marks
with
those
oC
crank

shaft

sprocket
and
camshaft

sprock

et
at
the

right
hand
side
There
are

forty
four
chain
links
between
two

mating
marks
of

timing
chain

c
NO
2
hole
is

Cactory

adjusted

When
chain
stretches

excessively

adjust
camshaft

sprocket
at

No
3

hole

d
Use
a

set
of

timing
marks
and

location
hole

numbers
Engine
Mechanical

17
Install
chain
slack
side

guide
to

cylinder
block

18
Install
chain
tensioner

Note

Adjust
protrusion
oC
chain
ten

sioner

spindle
to
0
mm
0
in

Fig
EM
98

lmtalling
chain
tensioner

19
Press
new
oil
seal
in

front
cover

Notes

a
Front

cover
oil
seal
should
be
reo

placed
when
Cront
cover
is

disas

sembled

b
BeCore

pressing
oil
seal
into
Cront

cover

give
coating
of

engine
oil
to

periphery
of
oil
seal

c
This
oil
seal
is
a
threaded
seal

type

which
has

improved
sealing
charac

teristics
Do
not

apply
grease
to

sealing

lip

20
Install
front
cover
with

gasket
in

place

1

Timing
mark

2

Timing
mark

EM545

Fig
EM

99

Installing
fronl
COlHlr

Notes

a

Apply
sealant
to
Cront
cover
and

corners
oC

upper
section
of

cylinder

block

as
shown

in

Figure
EM
78

EM
24
b
Install
Cront
cover
with
head

gasket

in

place

c

Check

height
diCCerence
between

cylinder
block

upper
Cace
and
Cront

cover

upper
Cace
DifCerence
must

be
less
than
0
15

mm
0
0059
in

d

Note
that
difCerent

types
oC
bolts

are
used

e

Before

installing
front
cover
on

cylinder
block

apply

coating
oC

engine
oil
10

sealing
lip
of
oil

seal

EMS11

Fig
EM
lOD
Front

cover
bolts

Tightening
torque

Size
M8
0
315
in

1
0
to
1
3

kg
m
7

2
to
9
4

ft
lb

Size
M6
0
236
in

0
4
to
0
6

kg
m
2

9
to
4

3
ft
lb

21
Install
crankshaft

pulley
and

water

pump
assembly
then
set
No
I

piston
at
ToO
C
on
its

compression

stloke

Crankshaft

pulley
nu
I

tightening
torque

12
to
16

kg
m
B7
to
116
ft

lb

EM546

Fig
EM
Ol

lnstallingcran
haft

pulley
and

water

pump

22

Finally

tighten
head

bolts
to

the

specified
torque
in

three

steps

according
to
the

lightening
sequence

shown
in

Figure
EM
96

Note
thai
Iwo

types
of
bolts

are

used

Speci
ol

Cylinder
Head
Bolt

Wren
h

8110120000

Tightening
torque

1st
turn

4

0

kg
m
29

ft
lb

2nd
turn

6
0

kg
m
43
ft
lb

3rd
turn

6
5

to
8
5

kg
m

47
to
61
ft
lb

B
O

A

A

B

A

A
B
O

B
O

R
O

EM
176

Fig
EM
I02

Cylinder
head
boll

Notes

a
Be
sure
to

tighten
two
small
bolts

b
After

engine
has
been

operated
for

several
minutes

retighten
if
neces

sary

23
Install
oil

pump
and
distr
butor

driving

spindle
in

front
cover

Tightening
torque

1
1
to
1
5

kg
m

8
0

to
10
8
ft
lb

Notes

a
Assemble
oil

pump
and
drive

spin

die
aligning
driving

spindle
face

with
oil

pump
hole

b
Install
oil

pump
together
with

drive

spindle
so
that
the

projection
on
its

top
is
located
at
the
II
25
a
m

position
At
this

point
the
smaller

bow
shape
will
be

facing
toward
the

front

c
Do
not

forget
to
install

gas
et
Engine
Mechanical

I

Fig
EM

I04

11l6lalling
oil

pump

24
Install
fuel

pump
water
inlet

elbow
and
front

engine
slinger
in

their

positions

Fuel

pump
tightening
torque

1
2

to
1
8

kg
m

8
7

to
13

0
ft
lb

Note
Do
not

forget
to
install
fuel

pump
spacer
and

packing
between

spacer
and
block

spacer
and

fuel

pump

25
Install
oil
strainer
oil

pan
gasket

and
oil

pan

27

Install
rocker
cover
to

cylinder

head

Note
Make

sure
that
one
of
the

rocker
cover
bolts
is

longer
than
the

others
It
secures
F
I
C
D
assist

bracket

28
Install
air

pump
bracket
and

cooler

compressor
to

cylinder
block

EM
25
Tightening
torque

Oil
strainer

bolts

0

8
to
I
l

kg
m
5

8
to
8
0
ft

lb

Oil

pan
bolts

0
6
to
0
9

kg
m
4
3

to
6
5
ft

lb

Notes

a

Apply
sealant
to
the

step
portions

at

four

mating
surfaces

as
shown

in

Figure
EM
80

b

Oil

pan
should
be

tigh
tened
in

criss
cross

pattern
to
a
final

torque

of
0
6
to
0

9

kg
m
4
3
to
6
5
ft
lb

26

Adjust
valve
clearance
to
the

specified
dimensions

Special
tool

Pivot

Adj
iier
STl064000l

Tightening
torque

5

0
to
6
0

kg
m

36
to
43
ft
lb

Fig
EM
I05

Adjusting
valve
clearance

b
After

engine
has
been
assembled

run
it
for
at
least
several
minutes

and

finally
adjust
clearance
to
the

warm

specifications

29

Install
intake
manifold
to

ex

haust
manifold
The
intake
manifold

face
which
comes
into
contact
with

gasket
should
be
even
with
that
of

exhaust
manifold
Note
that
two
dif

ferent

sizes
of

attaching
bolts
are
used

Tightening
torque

2
5

kg
m

18
0
ft

lb

30
Install
heatshieid

plate
on
mani

fold
assembly

31
Install
air

gallery
pipe
on
ex

haust
manifold

32
Install
manifold

gasket
and

manifold

assembly
on

cylinder
head

Tightening
torque

1
2to
1

6kg
m

8
7
to
11
6
ft
lb

33

Install
blow

by
gas

pipe
on

cyl

inder

block
and
tighten
with
rear

engine
slinger

34
Install
thermostat
housing

gas

ket
thermostat

housing
and

thermo

stat

35
Install
thermal
vacuum
valve
on

thermostat

housing
Before

installing

apply
a

liquid
packing
slightly
to
the

threads

36

Install
FJ

C
D
bracket
on

cylin

der

head

37

Install
E
G
R

passage
and

E
G
R
valve
on
intake
manifold

38
Connect
E

G
R
tube
to
E

G
R

tube
and

exhaust
manifold

39
Install
check
valve

on
air

gallery

pipe

40
Install
air
cleaner
bracket
on

intake
manifold

41
Install
air
control
valve
on
air

cleaner
bracket
California
models

42
Install
vacuum
and
fuel
tubes

combined
on

cylinder
head

43
Install
distributor

assembly

44
Install

heatshield
plate

joint

seat

and
carburetor

Carbure10r
tightening

torque

0
5

to
1

0

kg
m
3

6
to
7
2

ft
lb

Note
When

instalUng
joint
seat
be

sure
to

put
the
duct
into

primary

hole
in

intake
manifold

S

J

Heatshield

plate
4
Joint

seat

2

Primary
hole
5

Secondary
hole

3
Duct

EM534

Fig
EM
I06

Installing
carburetor

joint
seat
Engine
Mechanical

45
Install
dash

pot
bracket
and

dash

pot
to
intake

manifold

46
Connect
all
air

vacuum
and
fuel

hoses

and
then

secure
with

clamps

I
Cylinder
block
to

P
C
V
valve

hose

2
A
B

valve
to
E

G
R

passage
vac

uum
hose

3
A
B

valve
to
E
G

R

passage
air

hose

4
Vacuum
tube
to
carburetor
vac

uum
hoses

5
Fuel
ube

to
carburetor
fuel

hose

6
Fuel
tube
to
fuel

pump
fuelhose

7
Distributor
to
vacuum
switch
or

spark
delay
valve
vacuum
hose

8
Air
control
valve
vacuum
hose

9
Check
valve

to
air

control
valve

hose

10
Thermal
vacuum
valve
to

E
G
R
valve
vacuum
hose

I
I
Thermal
vacuum
valve
to

vacuum
tube
hose

47
Install
carburetor
air

cleaner
on

carburetor
and
then
connect
air

and

vacuum
hoses

as
follows

I

Air
cleaner
to

exhaust
manifold

hot

air
duct

2

Air
c1eaner
to
air

pump
hose

3

Air
cleaner
to
rocker

cover
hose

4

Air
cleaner

to
air
control
valve

hose

5

6

48
Install

spark
plugs
in

place

49
Connect
all
distributor

high
ten

sion

cables
to

spark
plugs

50
Install
air

pump
drive
belt
cool

er

compressor
and
idler

pulley

51

Install
left

engine
mounting

bracket

52
Install
clutch

assembly
on

flywheel
with
Clutch

Aligning
Bar

KV30100200
Air

cleaner
to
A
B

valve

hose

Other
vacuum
hoses

Tightening
torque

1
2
to
2
2

kg
m

8

7
to
15
9

ft
lb

EM
26
I

I

KV30100200

EM440

Fig
EM
I07
In

talling
clutch
embly

53

Using
an
overhead
hoist
and

lifting
cable
hoist

engine
away
from

engine
stand
and

then
down
onto

engine
carrier

54
Install

right
engine
mounting

bracket
oil
filter
oil

pressure
switch

oil

level

gauge
and
water

drain

plug

When

installing
oil

filter
fasten
it
to

cylinder
block

by
hand

Note
Do
not

overtighten

flit
or
oil

leakage
may
occur

55
Install
alternator
bracket

adjust

ing
bar
alternator

cooling
fan

and

belt

56

Adjust
the
deflection
of
drive

belts
when

thumb

pressure
is

applied

midway
between

pulleys
A

pressed

force
is
above
10

kg
22
0
lb

Deflection

of
drive
belts

8
to
12
mm

0
315

to
0
472
in

EM613

Fig
EM
lOB
Fan
belt
tension

57
Fill

engine
oil

up
to

specified

level

Engine
Mechanical

g
Piston

ring

Ring
height

Top
and

second

Side
clearance

Top

Second

Ring
gap

Top

Second

Oil
mm
in

mrn
in

mm
in

h
Cylinder
block

Cylinder
bore
inner
diameter
mm
in

Wear
limit
of
dittoed
inner

diameter

Cylinder
bore

taper
and
out
of
round

Difference
in

cylind
bore

Surface
flatness
mm
in

mm
in

mm
in

mm
in

i

Cylinder
head

Surface
flatness

mm
in

TIGHTENING
TORQUE

Cylinder
head

bolts

kg
m
fl
lb

Connecting
rod

big
end

nuts
kg
m
ft
Ib

Flywheel
fixing
bolts

kg
m
ft
Ib

Main

bearing
cap
bolts

kg
m
ft
lb

Camshaft
bracket
bolts

kg
m
ft
lb

Camshaft

sprocket
bolt

kg
m
ft
lb

Oil

pan
bolts

kg
m

ft
1b

Oil

pump
bolts

kg
m
ft
lb

Oil
strainer

bolts
kg
m

ft
lb

Oil

pan
drain

plug
kg
m
ft
lb

Rocker

pivot
lock
nuts

kg
m

ft
Ib

Camshaft

locating
plate
bolts

kg
m
ft
lb

Carburetor
nuts

kg
m

ft
lb

Manifold
bolts

kg
m
ft
lb

Fuel

pump
nuts

kg
m

ft
lb

Crank

pulley
bolt

kg
m
ft
lb

Water

pump
bolts

kg
m
ft
Ib

Front
cover
bolts

kg
m
ft

lb

EM

30
1
977
to
1
990
0

0778
to

0
0783

0
040
to
0
073
0
0016
to

0
0029

0

030
to
0

070
0
0012
to
0

0028

0
25
to

0
40
0
0098
to
0

0157

0

30
to
0

50
0
0118
to

0
0197

0
30
to
0

90
0

0118
to
0
0354

85
000
to
85
050

3
3465

to
3
3484

0
2

0
0079

om
5
0

0006

0
05
0
0020

less
than
0

05
0

0020

less
than
0
05

0
0020

6
5
to
8
5

47
to
61

4
5
to
5
5

33
to
40

14

to
16

101
to
116

4
5
to

5
5
33
to
40

1

8
to
2

0

13
to
15

12
to

16
87
to
116

0
6

to
0
9
4
3
to
6
5

I
J
to
1
5

8
0
to

10
8

0
8
to
1
1
5
8
to
8
0

2
0

to
3
0

14
to
22

5
0
to

6
0

36
to
43

0
6

to
0
9

4
3
to
6
5

0
5
to
1

0
3
6

to
7
2

1
2
to
1
6
8
7

to
11

6

1
2
to
1
8
8
7
to
13

0

12
to

16
87
to
116

0
4
to

0
5
2
9

to
3
6

8
mm
0
315
in

dia

6
mm
0

236
in
dia
1

0
to
1
3
7
2
to

9
4

0
4
to
0
6
2

9
to
4
3

Engine
Mechanical

SPECIAL
SERVICE
TOOL

No
Tool
number

tool
name
Description

Unit
mm
in

Engine
stand

assembly
This

engine
stand
assembly
is
used
for

disassembling
or

assembling
engine
block

or
differential
carrier

throughout

3600
in

all
directions
ST050lS000

ST050
11000

Engine
stand

ST050

12000

Base
For

use

on
Reference

page
or

Figure
No

All

Fig
EM
II

models

SE184

2
ST0526oo0l
This

engine
attachment
is
installed
to

engine
stand
Ll6

Fig
EM
II

ST0501S000
in

disassembling
or
assembling
engine
Ll8

Engine
attachment

L20B

Q

li

SE185

3
STl
0120000
Special
hollow
set
bolts
are
used
in

tightening
cylinder
heads
All

Fig
EM

18

in

L
series

engines
This
wrench
is
used
to

torque
cylinder
L
series

Cylinder
head
bolt

head
bolts
and
its
head
can
be
inserted
into
the

torque

1
rench

wrench

10
0
39
SE186

4
STl
064000
I
This
tool
is
used

togetller
with
a

torque
wrench
in

tightening
pivot
lock
nut
for
valve
clearance

adjustment

Pivot

adjuster

SE187

EM
33
All
Fig
EM
105

L
series

ENGINE
LUBRI
CATION
SYSTEM

Note

Pump
rotors
and

body
are
not

serviced

separately
If

pump
rotors

or
body
are

damaged
or
worn

replacement
of
the
entire
oil

pump

assembly
is

necessary

Tightening
torque

Oil

pump
mounting
bolts

Oil

pump
cover
bolts

Regulator
valve

cap
nut

Specifications

Oil

pressure
at

idling

Regulator
valve

spring

Free

length

Pressured

length

Regulator
valve

opening
pressure

OIL
FILTER

The
oil
filter
is
a

cartridge
type

The
oil
filter
element
should
be
reo

placed
periodically
with

the
use
of
Oil

Filter
Wrench
ST19320000

When

installing
an
oil
filter
fasten

it
to

cylinder
block

by
hand

Note
Do
not

overtighten
filter
or
oil

leakage
may
occur
OIL
PRESSURE

REGULATOR
VALVE

The
oil

pressure
regulator
valve
is

not

adjustable
At
the
released

position
the
valve

permits
the
oil

to

by
pass
through
the

passage
in

the

pump
cover
to
the
inlet
side
of
the

pump
Check

regulator
valve

spring
to

ensure
that

spring
tension
is

correct

kg
m
ft
Ib

kg
m
ft
lb

kg
m
ft
lb

kg
cm2

psi

mm
in

mm
in

kg
em
2

psi

RELIEF

VALVE

The
relief
valve
located
at
the

center

portion
securing
oil
fIlter
to

the

cylinder
block

by

passes
the
oil

into
the
main

gallery
when
the
oil

fIlter
element
is

excessively

clogged

STl9320000

EL015

Fig
EL
9

Removing
oil

filter

EL
4
EL014

Fig
EL
B

Regulator
value

l
l

to
1
5
8
0
to
11

0
7
to

1
0
5
Ito
7
2

4

to
5
29
to
36

0
8
to
2
8

II
to
40

52
5
2
067

34
8

1
370

35
to
5
0
50
to
71

With
oil
fIlter
removed
check

valve
unit
for

operation
Inspect
for
a

cracked
or
broken
valve
If

replace

ment
is

necessary
remove
valve

by

prying
it

out
with
a
screwdriver

Install
a
new
valve
in

place
by

tapping
it

EL016

Fig
EL
JO
Relief
lJOlue

DESCRIPTION

COOLANT
LEVEL

DRAINING
AND
FLUSHING
THE

COOLING
SYSTEM

WATER
PUMP

REMOVAL
AND

INSTALLATION

DISASSEMBLY

INSPECTION
AND
ADJUSTMENT

TORQUE
COUPLING

REMOVAL
AND

INSTALLATION

DESCRIPTION

The

cooling
system
is
of
the
con

ventional

pressure
type
A

centrifugal

pump
installed
on

the

timing
chain

cover
serves
to
circulate
the

coolant

The

pressure
type
radiator
filler

cap

installed
on
the
radiator

operates
the

cooling
system
at

higher
than

atmos

pheric
pressure

The

higher

pressure
raises
the

boiling
point
of
the

coolant
and
in
Cooling
System

COOLING
SYSTEM

CONTENTS

CO
2

CO
2
OISASSEMBL
Y

INSPECTION

TEM
COUPLlNG

INSPECTION

THERMOSTAT

REMOVAL
AND

INSTALLATION

INSPECTION

RADIATOR

REMOVAL
AND

INSTALLATION

INSPECTION
CO
2

CO
2

CO
3

CO
3

CO
3

CO
3

CO
4

creases
the

cooling
efficiency
of

the

radiator

When
the

thermostat
is
closed

the

coolant
remains
in
the

cylinder
head

and

block
for
swift

warming
up
of
the

engine
After
it
reaches

normal

oper

ating

temperature
the

coolant
circu

lates

through
the
radiator

The

cooling
fan

drive
is
of
a

coupling
type

COOLANT

LEVEL

The

coolant
level
should

be
check

ed

and
maintained
at
SO

mm
1
97
in

below

the

upper
face
of
filler

neck

when
the

engine
is
cold
C0055

Fig
CO

I
Cooling

ry
lem

Caution

To
avoid
serious

personal

injury
never
remove
I3diator

cap

quickly
when

engine
is
hot
Sudden

release
of

cooling

system
pressure
is

very

dangerous

CO
2
CO
4

CO
4

CO
4

CO
5

CO
5

CO
5

CO
5

CO
5

CO
5

CO
6

If
it
is

necessary
to
remove
radiator

cap
wben
radiator
is
hot
turn

cap

slowly
counterclockwise

to
the
r

step
After
all

pressure
in
the
cool

ing
system
is
released
tom

cap

passing
the

stop
and
remove
it

DRAINING

AND
FLUSHING

THE

COOLING

SYSTEM

To
drain

the

cooling
system
re

move
radiator

cap
release
drain

cock

at
the
bottom

of
radiator
and
drain

plug
on

the

right
side
of

cylinder

block
If
the

heater

system
is
installed

set
heater

temperature
control
valve
to

open
position
After
the

coolant
is

drained

completely
close
drain

cock

and

plug
and
refill
the

system
with

clean
soft
water

WATER
PUMP

The

water

pump
cooling
fan

pulley

and

torque

coupling
are

a
unitized

construction

The
water

pump
is
of

a

centrifugal

type
which

is
mounted
on
the

engine

front
cover

Condition

Loss

of
water

Poor
circulation

Corrosion

Overheating

Overcooling
Cooling
System

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Probable
cause

Damaged
radiator
seams

Leaks
at
heater
connections
or

plugs

Leak
at

water

temperature
gauge

Loose

joints

Damaged
cylinder
head

gasket

Cracked

cylinder
block

Cracked

cylinder
head

Loose

cylinder
head

bolts

Restriction
in

system

Insufficient
coolant

Inoperative
water

pump

Loose

fan
belt

Inoperative
thermostat

Excessive

impurity
in

water

Infrequent
flushing
and

draining
of

system

Inoperative
thermostat

Radiator
fin
choked
with
mud
chaff
etc

Incorrect

ignition
and
valve

timing

Dirty
oil
and

sludge
in

engine

Inoperative
water

pump

Loose
fan
belt

Restricted
radiator

Inaccurate

temperature
gauge

Impurity
in

water

Inoperative
thermostat

Inaccurate

temperature
gauge

CO
7
Corrective
action

Repair

Repair

Tigh
ten

Tighten

Replace

Check

engine
oil
for
contamination
and
refill

as

necessary

Replace

Check

engine
oil
in
crankcase
for

mixing

with

water

by
pulling
oil
level

gauge

Replace

Tighten

Check
hoses

for

crimps
and

clear
the

system

of
rust
and

sludge
by
flushing
radiator

Replenish

Replace

Adjust

Replace

Use
soft
clean
water
Rain

water
is
satis

factory

Cooling

system
should
be

drained
and

flushed

periodically
Permanent
anti
freeze

Ethylene
glycol
base
can
be

used

through

out
the

seasons
of
the

year
and

change

periodically
at
intervals
recommended

Replace

Clean
out

air

passage
thoroughly
by
using
air

pressure
from

engine
side
of
radiator

Adjust

Refill

Replace

Adjust

Flush
radiator

Replace

Use
soft
clean
water

Replace

Replace