engine DATSUN PICK-UP 1977 Workshop Manual

Fig
EM

3

Crankshafl

PISTON

AND

CONNECTING
ROD

The

pistons
are

of
a

special
alumi

num

casting
and
have

struts
to
control

thermal

expansion
two

compression

rings
and

one
combined
oil

ring
The

piston
heads

are
slightly
dished

The

piston
pil1S
are
a

special
hollow

steel

shaft

They
are
full

floating
fit
to
the

piston
and

press
fit
to
the

connecting

rods

The

connecting
rods
are
of
a

special

forged
steel
Oil
is

sprayed
to
the

connecting
rod
small
ends

through

drilled

passages
in

the

large
ends
of

rod

Oil
holes
in

the

connecting
rods

are
located
so
as
to
insure

optimum

lubrication
under

heavy
load

0
50
1

o

E

Moao

Fig
EM
4

Piston
and

connecting
rod

CYLINDER
HEAD

The

cylinder
head
is

made
of
a

light
strong
aluminum

alloy
with

good

cooling
efficiency
it
contains

wedge

type
combustion
chambers
A

special

aluminum
bronze
valve
seat
is

used
on

the
intake
valve
while
a
heat
resistant

steel
valve
seat
is
installed

on
the

exhaust
valve
These

parts
are

all
hot

press
fitted

EM407

Fig
EM
S

Cylinder
head
Engine
Mechanical

CAMSHAFT

The
camshaft
is

made
of
a

special

cast
iron
and
is
loca
ted
inside
the

rocker
cover
Four
aluminum

alloy

brackets

support
it
Camshaft

bearings

are
lubricated
from
oil
holes
which

lead
to
the

main
oil

gallery
of
the

cylinder
head

Concentric

passages
are
drilled
in

the

front
and

rear

parts
of
the

earn

shaft

Oil
to
each
earn
lobe
is

supplied

through
an
oil

hole
drilled
in
the
base

circle
of
each
lobe
Lubricant
is

sup

plied
to
the
front
oil

gallery
from
the

2nd
camshaft

bearing
and
to
the

rear

oil

gallery
from
the

3rd
camshaft

bearing
These

holes
on
the
base

circle

of
the

lobe

supply
lubricant
to
the

earn

pad
surface
of
the
rocker
arm

and

to
the
valve

tip
end
The
cams
feature

a

long
overlap
profile
to
reduce
NOx

emission

Fig
EM
6

Camshafl

VALVE
MECHANISM

The
valve

system
has
the

pivot
type

rocker

arms
that

are
activated

directly

by
the
earn
mechanism

this
has
made

its

moving

parts
considerably
lighter

and

provides
ideal

high
speed
perform

ance

Dual

type
valve

springs
are
in

stalled

h

@l

if

Exhaust

Intake
EM084

Fig
EM
7
Valve
mechanism

EM

3
CAMSHAFT
DRIVE

The
camshaft
is
driven

by
a
double

row
roller
chain
driven

by
the

crank

shaft
The
tension
of
the

chain
is

controlled

by
a

chain
tcosioner

which

is

operated
by
spring
and
oil

pressure

The
rubber
shoe

type
tensioner

damps

vibration

of
the

chain
and
controls
its

tension

EM537

Fig
EM

8
Chain

driving

aystem

MANIFOLDS

The
intake
manifold
is
of
an
alumi

num
cast

alloy

The
exhaust
manifold
is

of
a
dual

design
and

incorporates
a
heat
control

valve
in
it
The

heal
control
valve
is

used
to

warm
the
intake
manifold

A

plate
is
installed
on
the
outer

face
of
the
manifold
to
draw
hot

intake
air

out

through
it
The
exhaust

pipe
is
connected
to
the

flanged
sur

face
of
the
exhaust
manifold

Fig
EM

9
Intak
and
exhaust

manifolds

r

I

I

PRELIMINARY
CLEANING
AND

INSPECTION

DISASSEMBL
Y

PRELIMINARY

CLEANING
AND

INSt

ECTION

Before

disassembling

engine
note

the

following

I
Fuel

oil
or
water

may
leak

past

cylinder
head
and
block
Prior
to

disassembling
check

cylinder
head

1
1ltermal
vacuum
valve

2
Check

valve

3
Altitude

compensator

in

air
cleaner

4
Air

gallery
pipe

S

Auto
choke

6
Automatic

temperature

control
air

cleaner

7
Anti
8ackfire
valve
A
B

valve

8
Boost
Controlled

Deceleration

Device
Bee
D
D

9
P
c
v

valve

to
Air
relief
valve

11
E

G
R

control
valve

12
B
C
D
D

control
valve
and

solenoid
valve

13

Emergency
air

relief
valve

14
Air

pump
air
cleaner

IS
Carbon
canister

16
Air
control

valve

11
Air

pump
Engine
Mechanical

ENGINE

DISASSEMBLY

CONTENTS

EM
4

EM
4
PISTONS
AND
CONNECTING
RODS

CYLINDER

HE
AD
EM
7

EM
7

front
chain

cover
oil

pan
and
oil

filter

gaskets
lInd
crankshaft
and
water

pump
seals
for

signs
of

leakage
past

their

gasketed
surfaces

2
Check
carburetor
and

fuel

pump

for
condition
fuel
hoses
for

deteriora

tion
cracks

or

leakage
of
fuel

past

their

jointed
or
connected

surfaces

Fig
EM

0
Emiuion
control
devic
s

California
mod
18
E
T366

3
Remove

carburetor
air

cleaner

Remove
fresh

air
duct

Disconnect
hot
air
duct
from

air

cleaner

Disconnect
air

cleaner
to
air

pump

hose
at
air

cleaner

Disconnect
air

cleanef
to
rocker

cover

hose
at
rocker
cover

Disconnect

air
cIeaner

to
air

con

trol

valve
hose
at
air

cleaner
Cali

fornia

models

only
Disconnect
air

cleaner
to
A

B
valve

hose
at
air

cleaner

Disconnect
air

cleaner
to

related

part
vacuum
hoses
at
air

cleaner

Loosen
air

cleaner
band
bolt
and

remove
carburetor
air

cleaner
as

sembly
from

carburetor

4

Plug
up
carburetor
air

horn

to

prevent
entry
of

foreign
matter

5

Remove

alternator
drive

belt

alternator
and

alternator
bracket

EM
4
6

Remove
air

pump
drive

belt
cool

er

compressor
and
idler

pulley
if

so

equipped

7
Remove
starter
motor
from
trans

mission

8

Visually

inspect
cylinder
head

cylinder
block
rocker
C
Ner

front

chain
cover
oil

pan
and
all
other
outer

parts
for
oil
water
and
fuel
leaks

breakage
or

missing
parts
such

as
bolts

and
nuts

9

Check

piping
and
electrical
cir

cuits
for
deterioration

breakage
fit

tings
discontinuity
or
insulation

DISASSEMBLY

To

remove

engine
from
vehicle

refer
to

the
instructions
under
the

Engine
Removal

and
Installation

ER
section

I

Remove
transmission
from

en

gine

2
Remove

clutch

assembly
from

flywheeL

3

Thoroughly
drain

engine
oil
and

coolan
t

by

removing
drain

plugs

Store

engine
oil
and

coolant
if

they

are

to
be

used

again

4
Place

engine
assembly
on

engine

stand

I

Remove

cooling
fan

2

Remove

right
engine

mounting

bracket

3

Remove
oil
filter
with
Oil

Filter

Wrench
STI9320000

4

Remove
oil

pressure
swi

tch

5

Install

engine
attachment
to

cylinder
block

utilizing
bolt

holes
in

alternator

bracket
and

water
drain

hole

6
Set

engine
on
stand

Engine
Attachment

ST05260001

Engine
Stand

ST050I

SOOO

EM410

Fig
EM
II

Engine
on

engine
land

Remove

oil
level

gauge

6
Remove

carburetor
from
intake

manifold

1
Disconnect
cylinder
block
to

P
C
V
valve
hose
at
P
C
V

valve

2

Disconnect
A
B
valve
to
E

G
R

passage
hose

at
E
G
R

passage

3
Disconnect
vacuum
tube
to

carburetor

hoses
white
and

yellow
at

vacuum
tube

4
Disconnect
fuel

hose
from

carburetor

5

Remove
dash

pot
bracket
from

intake
manifold

6
Remov
carburetor

attaching

bolts
and

remove
carburetor

assembly

and

gasket

7
Disconnect
distributor

high
ten

sion
cables
from

sparkplugs

8
Disconnect
vacuum
hose

from

distributor
and

remove
distributor
as

sembly

9

Disconnect
fuel

hose
from
fuel

pump
and

remove
fuel
and

vacuum

hoses
combined

from

cylinder
head

10
Remove
fuel

pump
assembly

from

cylinder
head

EM412

Fig
EM
12

Removing
fuel
pump

IJ
Remove
in
take
and
exhaust

manifold

assembly
from

cylinder
head

1
Disconnect
vacuum
hose

from

air
control
valve
and
remove
air
con

trol

valve
for
California
and
a
r
hoses

as
an
assembly
Engine
Mechanical

1
Air
control
valve

2
Distributor
EM531

Fig
EM
13

Removing
air
control

valve

Californio
model

2
Remove
carburetor
air
cleaner

bracket

3
Disconnect
vacuum
hose
from

E
G
R
valve

4
Remove
check
valve
from
air

gallery

pipe

5
Disconnect
E
G
R

tube
from

E

G
R

passage
and
exhaust
manifold

6
Remove
E

G
R

passage
and

E
G
R
valve

from
intake

manifold

I
E

G
R

passage

2
E
G
R
tube

Fig
EM
14
EM532

Removing
E

G
R

tube
and

passage

7
Remove
F
l

C
D

bracket
from

cylinder
head

if
so

equipped

8

Disconnect
vacuum
hoses
from

thermal

vacuum
valve

and
remove

thermostat

housing
and

gasket
from

cylinder
head

EM089

Fig
EM
15

Removing
thermostat

housing

EM
5
9
Remove

cylinder
block
to

P
C
V

valve
hose
blow

by
gas
hose

from

cylinder
block

10
Remove

manifold

attaching

bolts
and
remove
intake
and

exhaust

manifold

assembly
and

gasket
from

cylinder
head

Fig
EM
16

Removing
intake
and

exhaust

manifold
assembly

11
Remove
intake

and
exhaust

manifold

attaching
bolts
and

separate

intake

manifold
from

exhaust
mani

fold

12
Remove
air

gallery
pipes
from

exhaust

manifold

12
Remove

left

engi
e

mounting

bra
et

from

cylinder

blopk

13
Remove
air

pump
and
cooler

compressor
bracket

14
Remove

crankshaft

pulley
in

stalling
bolt
and

washer
and
then

remove

pulley
with
a
two

jaw
puller

15
Remove
water

pump
assembly

16
Remove
rocker

cover

17

R
emove

spark
plugs

18
Remove
fuel

pump
drive
earn

19

Remove
camshaft

sprocket

Refer
to
the

following
note

during

operation
when

removing
camshaft

sprocket
from

engine
installed
on
car

EM091

Fig
EM
17

Removing
cammaf

sprocket

r

28
Remove

cylinder
head

assembly

Use

Cylinder
Head
Bolt
Wrench

STl0120000
to

remove

cylinder
head

bolts
Loosen
bolts

from

CD
to

@
as

shown
in

Figure
EM
18

Fig
EM
IS

Cylinder
head
bolt

loosening
equence

Notes
When

removing
cylinder
heao

from

engiJJe
installed

on
car
follow

the

instructions
below

a
Turn
crankshaft

until
No
I

pilton

is
at
T
D
C

on
its

compression

stroke

b
Remove

rocker
Cover
and
fuel

pump

c
To
facilitate

assembling
o
tion

scribe
8
mark

on

timing
c
8in

and

camshaft

sprocket
with

paint
be

fore
removal

d
Loosen
camshaft
bolt

and
remove

fuel

pump
drive
earn

e

Support
timing
chain

by

utilizing

Chain

Stopper
STl7420001
bet

ween

timiilg
chains
as
shown
in

Figure
EM
19

This
0

peration
eliminates

the

prob

lem
of

realigning

timing
marks

on

timing
chain
and
crankshaft

sprocket

EM538

Fig
EM
19

Supporting
timing
chain

f

Remove
camshaft

sprocket

g
Loosen

cylinder
head
bolts

and

remove

cylinder
head
Engine
Mechanical

29
Invert

engine

30

Remove
oil

pan
and

oil
strainer

EM094

Fig
EM
20

Removing
oil
traintir

and
oil

pump

31

Remove
oil

pump
and
its
drive

spindle
See

Figure
EM
20

32
Remove
front
cover

33

Remove
chain
tensioner

and

chain
slack
side

guide

EM095

Fig
EM
21

Removing
chain
ten
ioner

and
tim

ing
chain

34
Remove

timing
chain

See

Figure
EM
2l

35
Remove

oil
thrower
crankshaft

wonn

gear
and

chain
drive

sprocket

Fig
EM
22

Removing
chain
drive

Proc
et

EM
6
36
Remove

piston
and

connecting

rod

a

mbly
Extract

connecting
rod

bearings
keeping
them
in
order

I

Fig
EM
23

Removing

pilton
and

connecting
rod
aat
m
b

y

37

Remove

flywheel
and

rear

plate

Be

careful
not

to

drop
them

EM415

Fig
EM

24

Removing
flywheel

38
Remove
main

bearing
caps

Use
Crankshaft

Main

Bearing

Cap

Puller
KVIOI04ISO

to
remove
center

and
rear

main

bearing

caps
Keep
them

in
order

KVIOI04IS0

EM539

Fig
EM
25

Removing
rear

main

bearing

cap

39

Remove
two
side
seals
from

rear

main

bearing
ca

p

40
Remove
rear
oil

seal

EM103

EM411

Fig
EM
29

Remouingpi
tonpin

Fig
EM
26
Remouing
rear
oil
eal

41
Remove
crankshaft

42
Remove
baffie

plate
and
cyl

inder
block
net

Fig
EM
27
Removing
baffle
plate
and

nel

PISTONS
AND

CONNECTING
RODS

Remove

piston
rings
with
a

ring

remover

O

EM102

Fig
EM
28

Removing
pilton
rings

2
Press

piston
pin
out
with
Piston

Pin
Press
Stand
STl3030001
Engine
Mechanical

3

Keep
disassembled

parts
in
order

CYLINDER

HEAD

I

Remove
valve
rocker

springs

Loosen
valve

rocker

pivot
lock
nut
and

remove
rocker
arm

by
pressing
valve

spring
down

Fig
EM
3D

Removing
rockerarrm

2

Remove
locate

plate
and
remove

camshaft

EM105

Fig
EM

31
Remouing
cammaft

EM
7
Note
Be

careful
not
to

damage
eam

shaft

bearings
and
earn
lobes

3
Remove

valves

using
Valve
Lifter

STl2070000

STl2070000

Fig
EM
32

Removing
ualves

Notes

a
Take

care
not
to
lose
valve

spring

seat
oil
seal
valve
collet

and
valve

rocker

guide

b
Be
sure

to
keep
camshaft

bearings

intact

or
the

bearing
center
is

liable

to
come
out
of

alignment

61

8

Exhaust
Intake
EM101

Fig
EM
33
Value
components

r

Engine
Mechanical

INSPECTION
AND
REPAIR

PREPARATION
FOR
INSPECTION

CYLINDER
HEAD
AND
VALVE

CHECKING
CYLINDER
HEAD
MATING

FACE

VALVE
ASSEMBLY

VALVE
SPRING

ROCKER
ARM
AND
VALVE

ROCKER

PIVOT

VALVE
GUIDE

VALVE
SEAT
INSERTS

CAMSHAFT
AND
CAMSHAFT

BEARING

CAMSHAFT

BEARING
CLEARANCE

VALVE
TIMING

CAMSHAFT
ALIGNMENT

CYLINDER
BLOCK

HOW
TO
MEASURE

CYLINDER
BORE

CYLINDER

BORING

PREPARATION
FOR

INSPECTI
N

I

Before

cleaning
check

for

signs

of
water

and
oil
leaks
in

cylinder
block

and

head

2
Clean
oil
carbon

deposits
and

sealant
from
an

parts
Remove

gasket

3
Clean
all

oil
holes
with
solvent

and

dry
with

compressed
air

Make

sure
that

they
are

not
restricted

CYLINDER
HEAD

AND
VALVE

CHECKING
CYLINDER

HEAD

MATING
FACE

EM407

Fig
EM

34
Cylinder
head
CONTENTS

EM
8

EM
B

EM
8

EM
8

EM
9

EM
lO

EM
l0

EM
11

EM

12

EM
12

EM
12

EM
13

EM

13

EM
13

EM
14
PISTONS
PISTON
PINS
AND

PISTON
RINGS

CONNECTING
ROD

CRANKSHAFT

BUSHING
AND
BEARING

MEASUREMENT

OF
MAIN

BEARING

CLEARANCE

MEASUREMENT
OF

CONNECTING
ROD

BEARING
CLEARANCE

FITTING

BEARINGS

MISCELLANEOUS
COMPONENTS

CRANKSHAFT
AND

CAMSHAFT

SPROCKETS

CHAIN

TENSIONER
AND
CHAIN

GUIDE

FLYWHEEL

FRONT
COVER
AND

REAR
OIL
SEAL

Note

Never

remove
camshaft
bear

ings
unless

you
have
a

Suitable

machine

or

boring
Camshaft
bear

ing
in
line
If

you
once
remove

camshaft

bearings
bearing
centers

will
come
out

o

alignment
reo

conditioning
is

very
difficult
with

out
center

borings

L
Make

a
v

isual
check
for
cracks

and
flaws

2

Measure
the
surface
of

cylinder

head
on

cylinder
block

side
for

warpage
If
it
is

found
to
be

beyond

the
limit

designated
below

regrind
the

affected
surface

with
a
surface

grinder

Fig
EM
35

Checking
cylinder
head

8JJrface

EM
8
Head
surface
flatnes

Standard

less
than
0
05

mm
0
0020
in
O
lmm

0
0039
in
EM
15

EM
16

EM
16

EM
17

EM
17

EM
1B

EM
18

EM
19

EM
19

EM
20

EM
20

EM
20

Maximum

VALVE
ASSEMBLY

Check
each
intake

and
exhaust

valve
for
worn

damaged
or
deformed

valve

caps
or
stems

Correct
or

replace

any
valve
that
is

faulty

2
Valve

face
or
valve
stem
end

surface

should
be
refaced
with
a
valve

grinder

10

L
I
I

I

EM109

Fig
EM
36
Intak
and

exhaust
valve

dimensions

Engine
Mechanical

Valve

head
diameter

I
In
42

0
to
42

2
1

654
to
1
661
VALVE
SPRING

H
1

Check
valve

spring
for

squareness

mm
in

Ex
35
0

to
35
2
1
378

to
1
386
using
a
steel

square
and
surface

plate

In
114

9
to
115
2
4
524
to

4
535
If

spring
is

out
of

square
more
than

Valve
length
1

6
mm
0

063
in

replace

L

mm
in
2

Measure

lhe
free

length
and
ten

Ex
1157
to

116
0
4
555
to
4
567

sion
of

each

spring
If
the

measured

Valve
stem
diameter
In
7
965

to
7

980
0
3136
to

0
3142
value
exceeds

specified
limit

replace

D

mm
in
spring

Ex
7
945

to
7

960
0
3128
to

0
3134

Valve
seat

angle
In
45030

a

Intake
and
Exhaust

Ex
45030

EM110

Fig
EM
37

Checking
valve
tern

diameter

Spring

specifications

Valve

spring
free

length

Intake

and
exhaust

Outer

Inner

Valve

spring
pressured

length

valve

open

Intake
and
exhaust

Outer

Inner

Valve

spring
assembled

height

valve

close

Intake
and
exhaust

Outer

Inner
EMll1

Fig
EM

38

Regrinding
valve

face

Note

When
valve
head
has
been
worn

down
to
0
5
nun

0
0197
in
in

thickness

replace
the
valve

Grinding
allowance
for

valve
stem

end
surface
is
0

5
mm
0
0197
in

or
less

mm
in

mmlkg
in
lb

mmlkg
in

lb

EM
9
I

i

J
T

EM112

Fig
EM
39

Measuring
spring
quareneu

1

EM113

Fig
EM

40
Measuring
apring
ten
ion

49
98
1

968

44

85
1
766

29
5
49
0
1
161

108

24
5
25
5
0
965156
2

40
0

21
3
1
575
47

0

35

0
12
3
1

378
27
I

rr

ROCKER
ARM
AND

VALVE
ROCKER
PIVOT

Check

pivot
head
and
cam
contact

and

pivot
contact
surfaces
of
rocker

arm
for

damage
or
wear
If

damage
is

found

replace
them
A

faulty
pivot

must
be

replaced
together
with
its

corresponding
rocker
arm

VALVE
GUIDE

Measure
clearance
between

valve

guide
and
valve
stem
If
clearance

exceeds

designated
limit

replace
worn

parts
or
both

valve
and
valve

guide
In

this

case
it
is

essential
to
determine
if

such
a

clearance
has
been
caused

by
a

worn
or
bent
valve

stem
or
by
a
worn

valve

guide

Stem
to

guide
clearance

mm
in

Maximum
limit

of
above

clearance

mm
in
Engine
Mechanical

Exhaust
8
3
to
8
5
dia

0

327
to
0
335

4
1

3
0

I2
J
L

12

223

to
12
234

150

0
4812

to
0
4817

dia

1

P
Intake

I
I

J

10
8
0

425

S9
0

2
323
7

6
to
7

8

0
299

to
0
307
dia

1

Unit
mm

in

EM572

Fig
EM
41

Se11Jice
value

guide

In
take

valve
Exhaust

valve

0
020
to

0
053

0
0008
to
0

002

As
an

emergency
expedient
a

valve

can
be

pushed
into
valve

guide
and

moved
to
the

right
and

left
If

its

tip

deflects

about
0
2

mm
0
0079
in

or

more
it
indicates
that
the
clearance

between
stem
and

guide
exceeds
the

maximum
limit
of
0
1
mm
0
0039

in

Note
Valve
should
be
moved
in

paral

lel
with
rocker
arm

Generally
a

large
amount
of
wear
occurs
in

this

direction

Max
allowable
deflection

0
2
mm
0
0079

in

n
r

C1r
30mm
l
18Iin

r

EM115

Fig
EM

42
Mea

uring
clearance

between
valve

tern

and
valve

gu
ide
0

040
to

0
073

0
00
6
to

0
0029

0
1
0
0039
Replacement
of

valve

guide

I

To
remove
old

guides
use
a

drift

and

a

press
under

a
2
ton

pressure
or

a

hammer

Drive

them
out

from

combustion

chamber
side

toward
rocker

cover

Heated

cylinder
head
will
facilitate

the

operation

2

Ream

cylinder
head
side

guide

hole
at

room

temperature

10
6

E
e

417
5t

0

m3l
lj
10
6

O
fl

H

dl7

l
IV

II

Unit
mm
in

EM116

Fig
EM

43
Valve

guide
hole

Guide

hole
inner

diameter
an
mm
in
For

factory
standard

valve

guide
11

985
to
11

996

0
4718
to
0
4723

For
service

valve

guide

3

Carefully
press
new
valve

guide

into

valve
so
that
it
will
fit

smoothly

after

heating
cylinder
head

to
150
to

2000C

302
to

3920
F

Valve

guide
of
0
2
mm

0

0079
in

oversize

diameter
is

available
for

ser

vice

as
indicated
above

Interference
fit
of
valve

guide
to

guide
hole

0
027
to

0
049
mm

0
0011
to
0

0019
in

4

Ream
bore
with

valve

guide

press

ed
in

using
Valve
Guide

Reamer
Set

KVIOI039S0

EM
10
12

185
to
12
96

0
4797
to

0
4802

Reaming
bore

8

000
to
8

018
rnm

0
3150
to
0
3157
in

EM419

Fig
EM

44

Reaming
valve

guide

q

1

I

k

k
lO

i

I

37

9
to
38
1

eel
1
492
to
1
500
dis

co

q

0

45
597
to
45
613

1
795
to
1
796
dia
5
Correct

valve
seat
surface
with

new
valve

guide
as
the
axis

VALVE

SEAT
INSERTS

Check
valve
seat
inserts
for

any

evidence

of

pitting
at
valve
contact

surface

and
reseat
or
replace
if
worn

excessively

Valve
seat
insert
of
0
5
mm
0
0197

in
oversize
is
available
for

service
as

shown
below

Intake

Unit
mm
in
Engine
Mechanical

Fig
EM
45

Correcting
valve
seat

EM573

0

32

6
1

2835
dia

Exhaust

I
I

30

U81
dia
17
5
0
295

Unit
mm

in
37
580
to
37

596
1
4795
to
1
4802
dia

Cylinder
head
rece
diameter

For

factory
standard

insert

Intake

For
service
insert

For

factory
standard

insert

Exhaust

I
For
service
insert

Interference

fit

mm
in
Intake

Exhaust
Fig
EM
46
Seroice
valve
seat
dimensions

Unit

mm

in

45
000
to

45
016
1

7717
to
1

7723

45
500
to
45
516
1

7913
to

I
7920

37
000
to
37
016
1

4567
to
I
4573

37
500
to
37
516
1

4764
to
I
4770

0
081
to
0
113
0
0032
to
0
0044

0
064
to
0
096
0
0025
to
0
0038

EM
11
Replacln
valve
eat
In
ert

1
Old
insert
can
be
removed

by

boring
it
out
until
it

collapses
The

machine

depth
stop
should
be

set

so

that

boring
cannot
continue
beyond

the
bottom
face
of
the
insert

recess
in

cylinder
head

2

Select
a
suitable
valve
seat
insert

and

check
its
outside
diameter

3
Machine

cylinder
head
recess
to

the
concentric
circles
in

valve

guide

center
so
that
insert

will
have
the

correct
fit

4
Heat

cylinder
head
to
a

tempera

ture
of
150
to
2000C
302
to
3920
F

5
Fit
insert

ensuring
that
it
beds
on

the

bottom
face
of
its

recess
and

caulk
more
than
4

points

6

Newly
fitted
valve
seats
should
be

cut
or

ground
at
the

specified
dimen

sions

as
shown
in

Figure
EM
47

7

Apply
small
amount
of
fine

grind

ing
compound
to
valve

contacting
face

and

put
valve
into

guide
Lap
valve

against
its
seat
until

proper
valve
seat

ing
is
obtained
Remove
valve
and
then

clean
valve
and

valve
sea
1

Intake
Engine
Mechanical

I

600

38
1

496I
dia

W
39
6
I
559Ildia

1
8
1

6457
dia

45
1
71l1

Unit
mm
in

Exhaust
30

30
1
l811
di

I
32

6
2835
dia

34
6
1
3622
dia

137

1
4567
dia

Unit
mm
m

CAMSHAFT
AND

CAMSHAFT
BEARING

CAMSHAnBEARING

CLEARANCE

Measure
inside
diameter
of
earn

haft

beating
with
an
inside
dial

gauge

and
outside
diameter
of
camshaft

jour

nal
with
a
micrometer
If
wear
is

found
inside
of

bracket

replace
cyl

inder
head

assembly
EM121

Fig
EM
47
Standard
value
aeat
dimensions

EM119

Fig
EM

48

Checking
cam

haft
bearing

Camshaft

journal
to

bearing
clearance

Standard
Wear
limit

Oil

clearance
mm
in
0
038
to
0
067

0
0015
to
0

0026
0
1

0
0039

Inner
diameter
of
earn

shaft

bearing
mm
in
48
000
to
48
016

1
8898
to
1
8904

EM

12
VALVE

TIMING

This

diagram

applies
to
all

cyl

inders
If

any
valve
is
found
out
of

specifications
one

possibility
that

carn
lobe
is

worn
or

damaged
This

calls
for

replacement
of
camshaft

B
D

C

EM421

Fig
EM

49
Value
timing
diagram