engine DATSUN PICK-UP 1977 Workshop Manual

Standard

Camshaft
bend

mm
in
0

02
0
0008

CAMSHAFT

ALIGNMENT

I
Check
camshaft
camshaft

journal

and
earn
surface
for
bend
wear

or

damage
If

damage
is

beyond
limits

replace
affected

parts

2
A
bend
value
is
one
half
of
the

reading
obtained
when
camshaft
is

turned
one
full
revolution
with
a
dial

gauge

applied
to
2nd

and
3rd

journals

Standard

height

of
tam
mm
in
I
Intake

1
Exhaust

Wear

limit
of
earn

height
mm
in

Allo
able
difference
in

diam
ter

betweim
max
worn

and
min

mm
in

worn

parts
of
c

mshaft

journal
Engine
Mechanical

Bend
limit

0
05
0
0020

I

Fig
EM

50
Checking
camMa
t
bend

40
30
to
40
35

1

5866
to
1
5886

0
25
0

0098

0
05
0
0020

Maximum
tolerance
in

j01
irri

mm
in
0
1

0
0039

diameter

CamShaft
end

play
mm
in
0
08
to
0
38

0
0031
to
0
0150

Standard

Surface
flatness

mm
in
less
than

0
05
0
0020

Cy
LlNDER
BLOCK

I

Visually
check

cylinder
block
for

cracks
or
flaws

2
Measure

top
of

cylinder
block

cylinder
head

mating
face
for

warp

age
If

warpage
exceeds
limits
correct

it
Maximum
tolerance

0
10
0

0039

EM540

Fig
EM
51

Cheching
cylinder
block

au
rface

EM
13
j

Using
a
bore

gauge
measure
cyl

inder

bore
for
out
of
round
or

taper
If

out
of

round
or

taper
is
excessive

re

bore

cylinder
walls
with
a

boring

machine
Measuremen
t
should
be

taken

along
bores
for

taper
and
around

bores
for

out
of
round
See

Figure

EM
52

Qu
t
of
round

Taper
X

Y

A

B

M12

Fig
EM

52

Measuring
cylinder
bore

diameter

4
When
wear

taper
or

out
of

round

is
minor
and
within
limits

remove

step

at

topmost
portion
of

cylinder
using

a

ridge
reamer
or

other
similar
tool

HOW
TO
MEASURE

CYLINDER
BORE

A

bore

gauge
is
used
Measure

cylind
r
bore

at

top
middle
and
bot

tom

positions
toward
A
and
B
direc

tions

as
shown
in

Figure
EM
53

and

record
the
measured
values

A
I

120
0
79

IlL

60
2
36

lll

B

100
3
94

el
1

Unit
mm
m

EM
22

r

Fig
EM
53

Cylinder
bort
me08Uring

positions

Engine
Mechanical

Standard

Wear
limit

Inner
diameter
85
000

to
85
050

0

2
0
0079

3
3465
to
3
3484

Cylinder
bore

mm
in
Out
of
round
O
ot5
0
0006

Taper
0
015
0
0006

Difference
in

cylinder
bore

0
05
0
0020

0
2
0
0079

mm
in

CYLINDER

BORING

I
When

any
cylinder
needs

boring

all
other

cylinders
must
also
be
bored

at
the

same
time

Oversize

pistons

spec
Hic
etlons

Piston
diameter
mm
in

Servioe
standard

0
50
0
0197

Oversize

1
00

0
0394

oversize

3
The
size

to
which

cylinders
must

be

honed
is

determined

by

adding

piston

to
cylinder
clearance
to
the

largest
piston
diameter
at

piston
skirt

in

thrust
direction

EM126

Fig
EM
54

Measuring
piston
diamet
r
2

Determine

piston
oversize
ac

cording
to
amount
of
wear
of

cylinder

84
985
to
85
035

3
3459

to
3
3478

85
465
to
85
515

3
3648
to
3

3667

85

965
to
86
015

3
3844
to
3

3864

Standard
clearance

ffim
in

Feeler

gauge
mm

in

Extracting
force

kg
Ib

Notes

a

To

prevent
strain
due
to

cutting

heat
bore
the

cylinders
in
the
order

of

2
4
1

3

b

Before

boring
any
cylinder
install

main

bearing
caps
in

place
and

tighten
to
the

specification
so
that

the
crankshaft

bearing
bores
will

not
become
distorted

from
the
bor

ing
operation

4

Do
not
cut

too
much
out
of

cylinder
bore

at
a
time
Cut

only
0
05

mm
0
0020
in

or
so
in
diameter

at
a

time

EM
14
L

7
A

aboull
6
m

o
7323in

r

127

Fig
EM
55

MeCUJlJring
piston
skirt

diameter

Rebored
size

calculation

o
A
B
C
A
0
005
to

0
Q25
mm

0
0002
to
0
0010
in

where

D
Honed

diameter

A

Skirt
diameter
as
measured

B
Piston
to
wall

clearance

C

Machining
allowance
0
02
mm

0
0008
in

0
025

to
0

045
0

0010
to
0
0018

0
04
0

0016

0
2

to
1

5
O

44
to

3
31

5

Measurement

of
a

just
machined

cylinder
bore

requires
utmost
care

since
it

is

expanded
by

cutting
heat

6

As
a
final

step
cylinders
should

be

honed
to
size

7

Measure
the

finished

cylinder

bore
for

out
of
round
or

tapered
part

8
Measure

piston
to

cylinder
clear

ance

This

clearance
can
be
checked

easily
by
using
a
feeler

gauge
and
a

spring
balance
hooked

on
feeler

gauge

measuring
the
amount
of
force

re

quired
to

pull

gauge
out
from

between

piston
and

cylinder

Engine
Mechanical

Notes

a

When

measuring
clearance

slowly

pull
feeier

gaUge
siraight
upward

b
It
Is

reConUnended
that

piston
and

cylinder
be
hel

ted
to
200C
680F
PISTONS

PISTON
PINS
AND

PISTON
RINGS

I

Remove
carbon
from

piston
and

ring
grooves
with

a

ca
bon

scraper
and

a
curved
steel
wire

Clean
out
oil

slots

in

bottom
land
of

oil

ring
groove

2

Check
for

damage
scratches
and

wear

Replace
if

necessary

3

Meas1
1re
side

clearance
of

rings
in

ring
grooves
as
each

ring
is

installed

Side
clearance

should
be

as
follows
00

I
EM542

Fig
EM

58

Measuring
ring

gap

Notes

a
When

piston
ring
only
is
to
be

replaced
without

cylinder
bore

being
corrected
measure

gap
at

bottom
of

cylinder
where
wear
is

minor

b
Oversize

piston
rings
are
available

for

serv
ce

Oversize

0
5
mm
0

0197
in
and

1

0
mm
0
0394
in

5
Measure

piston
pin
hole
in
rela

tion

to
outer
diameter
of

pin
If
wear

exceeds
limit

replace
each

piston

pin

together
with
the

piston
on
which
it
is

installed

6
Determine
the

fitting
of

piston

pin
into

piston
pin
hole
to
such
an

extent
that
it

can
be

finger
pressed
at

room

temperature
This

piston
pin

must
be
a

tight
pre
s
fit
into

connect

ing
rod
t

J

f

rr

11

1

I

EM541

Fig
EM
56

Measuring
piaton
fit

in
cylinder

Fig
EM
57

Measuring
piston
ring

side
clearance

Side
clearance

Unit
mm
in

I

Second

ring

I

I
Wear
limit
Standard

0
040
to

0
073

0
0016

to
0
0029

0
030
to

0
070

I
0
0012
to

0
0028

I
Top
ring

0
1
0
0039

Oil

ring

f

feeler

gauge

Ring
should
be

placed
to
diameter

at

upper
or
lower
limit
of

ring
travel
4

Push

ring
into

cylinder
with

pis

ton
so
as
to

place
it

squarely
in

cylinder
measure

ring
gap
with
a

EM131

Ring
gap
Fig
EM

59
Piston

pin

fitting
Unit
rom
in

Standard
Wear

limit

0
25
to
0
40

0
0098
to
0
0157

0
30
to
0
50

0
0
II
8
to
0
0197
Top
ring

Second

ring
1

0
0
0394

EM132

0
30
to
0
90

0
0118
to
0
0354
Oil

ring

Fig
EM

60

Measuring
pi
ton
pin

diamet

EM
15

r

Piston

pin
outside
diameter

Piston

pin
hole
diameter

Piston

pin
to

piston
clearance

I

Interference
fit
of

piston

pin
to

connecting
rod

CONNECTING

ROD

I
If
a

connecting
rod
has

any
flaw

on
either
side
of
the
thrust
face
or
the

large
end

correct
or

replace
it

EM133

Fig
EM
61
Ch

cking
rod

alignment

Connecting
rod

bend

or
torsion

per
100
mm

or
3
94
in

length

mm
in

3

When

replacing

connecting
rod

select
rod

so
that

weight
difference

between
new
and
old

ones
is

within
7

gr
0
25
oz

Do

not
use

a
combination
of
new

and

former

connecting
rod

big
end

nuts
and

connecting
rod
bolts
which

affect

specified
weight
variations

4
Install

connecting
rods
with

bear

ings
on
to

corresponding
crank

pins

and

measure
thrust
clearance

Ifmeas

ured

value
exceeds

limit

replace
Engine
Mechanical

Unit

mm
in

20
993
to
20
998
0

8265
to

0
8267

21

001
to
21
008
0

8268
to
0
8271

0
003
to
0
015

0
0001
to

0
006

0
015

to
0
035
0

0006
to
0
0014

2
Check

connecting
rod
for
bend
or

torsion

using
a

connecting
rod

aligner

If
bend
or
torsion
exceeds
the

limit

q
rrect
or

replace

Standard

Maximum

0
03
0

0012
0
05

0
0020

Fig
EM
62

Checking
big
end

play

Standard

Maximum

Big
end

play
mm

in
0
2

to
0
3

0

0079
to
0
01
18
0
6
0
0236

EM

16
CRANKSHAFT

1

Whenever
crankshaft
is
removed

from

engine
it

should
be

cleaned

thoroughly
in

a
suitable

solvent

After

cleaning
check

crankshaft

journal
and

crank

pin
Jor
score
bias

wear
or

cracks

Rep
air

or

replace
as

required

If

damage
is
minor

dress
with
fine

crocus
cloth

2

Check

journals
and
crank

pins
for

taper
and

out
of

round
with
a
micro

meter

Measurement
should
be
taken

along
journals
for

taper
and
around

journals
for

out
of
round

See

Figure

EM
63
for

detailed
information

If

journals
or
crank

pins
are

tapered

or
out
of
round

beyond
limits

replace

with
a

new
shaft

A
B

Out
of

round

X
Y

Taper
A
B

Unit
mm
in

19
5

0
768

tt
30
27

32

181
1
06
1
260

43

O
l
69

I

E
1

All

main

journa

59
942
to
59
955
All
crank

pm

2

3599
l
2

3604
49
961
to
49

974

o

1
9670
to
1

9675

EM424

Fig
EM
63

Crankshaft
and

journal

dimensions

Standard

Taper
and
out
of
round

of

journal
and
crank

pin

mm
in
less
than

0
01
0

0004

3
Crankshaft
bend
can
be
checked

by

placing
it

on
V
blocks
and

using
a

dial

gauge
with
its

indicating
finger

resting
on
center

journal

Standard

Crankshaft
bend
mm

in
less
than

0
05
0

0020

Note

When
measuring
bend
use
a

dial

gauge
Bend
value
is

half
of
the

reading
obtained
when
crankshaft
is

turned
one
full
revolution
with
a

dial

gauge
attached
to
its
center

journal

4

After

regrinding
crankshaft
finish

it
to

the
necessary
size
indicated
on

page
EM
18

by
using
an

adequate

undersize

bearing
according
to

the

extent
of

required
repair

5

Install
crankshaft
in
cylinder

block
and
measure
crankshaft
free
end

play
Engine
Mechanical

Maximum

0
Q25
0
0010

EM137

Fig
EM
64

Checking
crankshaft
bend

Maximum

0
10
0
0039

Fig
EM

65
Checking
crankshaft
end

play

Standard
Wear

limit

Crankshaft
free
end

play
mm
in
0
05
to
0

18

0
0020
to
0

0071
0
3
0
0118

6
At
the
rear
end
of
crankshaft

check
crankshaft

pilot
bushing
for

wear
or

damage
Replace
it
if

any
fault

is
detected
To

replace
crankshaft
rear

pilot

bushing
pro
ceed
as
follows

I
Pull
out

bushing
using
Pilot

Bushing
Puller
STl66
1000
I

EM

17
STl6610001

EM425

Fig
EM

66
Pulling
out

pilot

bushing

2
Before

installing
a
new

bushing

thoroughly
clean

bushing
hole

Press

fit

bushing
so
that
its

height
above

flange
end
is
4
5

to
5
0

mm
0
177

to

0
197
in
Do
not

oil

bushing

EM418

Fig
EM
67
Press

fitting
new

pilot

bush

ng

BUSHING
AND

BEARING

MEASUREMENT
OF

MAIN
BEARING
CLEARANCE

I

Thoroughly
clean
all

bearings
and

check
for
scratches
melting
score
or

wear

Replace
bearings
if
any
fault
is

detected

2

Crankshaft

journals
and

bearings

should
be

clean
and
free
from
dust
and

dirt
before
oil
clearance
is
measured

3

Set
main

bearing
on
cap
block

4

Cut
a

plastigage
to
width
of
bear

ing
and

place
it
in

parallel
with
crank

pin
getting
clear
of
the
oil
hole
Install

cap
on
the
assembly
and

tighten
them

together
to
the

specified
torque

Tightening
torque

4
5
to
5
5

kg
m
33
to

40
ft
lb

Fig
EM
68
P14stigage

Note
Do

not
tum
crankshaft
while

plastigage
is

being
inserted

5
Remove

cap
and

compare
width

of
the

plastigage
at
its
widest

part
with

the
scale

printed
in

plastigage
enve

lope

Fig
EM

69

Measuring
bearing

clearance

MEASUREMENT
OF

CONNECTING
ROD

BEARING

CLEARANCE

I

Measure

connecting
rod

bearing

clearance
in
the

same
manner
as
above

Tightening
torque

4
5

to
5
5

kg
m
33

to
40
ft
lb
Engine
Mechanical

Bearing
011
clearance

Standard
Wear
limit

Main

bearing
clearance

mm
in
0
020
to

0
062

0
0008
to
0
0024
0
12
0
0047

Connecting
rod

bearing

clearance
mm
in
0

025
to
0
055

0
0010
to
0
0022
0

12
0
0047

2
If

clearance
exceeds

specified

value

replace
bearing
with
an
under

size

bearing
and

grind
crankshaft

jour

nal

adequately

FiniNG
BEARINGS

Bearings
are
manufactured
with

crush
to

make

bearing
snug
down
into

its

bore
To

measure
this

proceed
as

follows

I
Set
main

bearing
in
main

bearing

cap
recess
or

cylinder
block

bearing

recess

correctly

2
Lock
one
side
of

bearing
and

press
other
side
until

bearing
back

surface
touches
the
recess

Bearing
crush

All
main

bearings
mm
in

All

connecting
rod

bearings
mm
in

4

Handle

connecting
rod

bearing
in
3
Then

measure

bearing
crush
H

with
a
feeler

gauge
See

Figure
EM
70

The
standard

bearing
crush
value
is

listed
below

Weight

H

Fig
EM
70

Checking
bearing
crum

o
to
0
03
0
to

0
0012

0
015
to
0
045
0
0006
to

0
0018

the
same
manner
as
above

Main

bearing
undersize

Unit
mm
in

Bearing
top
thickness
Crank

journal
diameter

1

827
to

1
835
59
942
to

59
955

SID

0
0719
to

0
0722
2

3599
to
2

3604

0
25
0
0098

1
952
to
1
960

59
692
to

59
705

Undersize
0
0769
to
0
0772
2

3501
to
2
3506

0
50
0
0197
2
077
to

2
085
59442
to
59
455

Undersize
0

0818
to
0

0821
2
3402
to

2
3407

0
75
0
0295
2
202
to
2
210

59
192

to
59
205

Undersize
0
0867
to
0
0870

2
3304
to
2
3309

EM

18

Engine
Mechanical

Connectlns
rod
be

rlns
undersize

SID

0
25
0
0098
Undersize

0
50
0
0197
Undersize

0
75
0
0295

Undersize

MISCELLANEOUS

COMPONENTS

CRANKSHA
AND

CAMSHA

SPROCKETS

I
Check
tooth
surface
for
flaws
or

wear

Replace
sprocket
if
fault
is

found

2
Install
camshaft

sprocket
in

posi

tion
and
check
for
rounout
If
it

exceeds
0
1

mm
0
0039
in

total

indicator

reading
repl
ce
camshaft

sprocket
Also
check

for
end

play

Camshaft
end

play

0
08

to
0
38

mm

0
0032
to

0
0150
in

EMl48

Fig
EM
71

Checking
eam

haft

sprocket
Tunaut
Unit
mm
in

Bearing
top
thickness
Crank

pin
diameter

1
493
to
1
506

0
0588
to
0
0593
49
961
to
49
974

1

9670
to
1

9675

49711
to

49
724

1
9571

to
1
9576
1

618
to
1

631

0
0637
to
0
0642

1

743
to
1

756

0
0686

to
0
0691
49461
to
49
474

1
9473

to
1
9478

1

868
to
1

881

0
0735
to
0

0741
49
211
to

49
224

1
9374
to
1
9379

Fig
EM
72

Checking

camshaft
end

play
3

Check
chain
for

damage
exces

sive

wear
or
stretch
at
roller
links

Replace
if

faulty

4
To

properly
adjust
chain
tension

or
valve

timing
camshaft

sprocket

has
a

earn

locating
plate
and
three

location
holes
Nos
I

2
and
3

Camshaft

sprocket
is

preset
at

No
I

hole
at
the

factory
If
chain

becomes
loose

adjust
it

by

setting

camshaft

sprocket
at
NO
2
hole
If

chain
is

too
loose

adjust
it

by

setting

camshaft

sprocket
at
No
3

hole

2

3

Before

adjustment
Location

match

3

After

adju5tmen
t

EM311

Fig
EM
73

Adjuating
camshaft
aprocket
location

EM
19

I
Turn

engine
until
No

I

piston
is

at
T
D
C
on

its

compression
stroke

Determine

whether
camshaft

sprocket

location
notch
comes

off
the
left
end

of
the

oblong
groove
on
camshaft

locating
plate
If
the
location
notch

is

off
the

left
end
of
the

oblong
groove

chain

stretch
is

beyond
limits

40150

EMl46

Fig
EM
74

Camshafllocating
plate

2

Turn

engine
until
No

I

piston
is

at
T
D

C

on
its

compression
stroke

setting
camshaft
on

No
2
location

hole
in

camshaft

sprocket
This
No
2

notch

should
then
be

on
the

right
end

of
the

oblong

groove
When
No
2
hole

is

used
NO
2

timing
mark
must
also

be
used

The
amount

of
the

modifica

tion
is
a

40
rotation

of
crankshaft

3

When
modification
becomes
im

possible
even

by
transferring
camshaft

location

hole

replace
chain

assembly
Engine
Mechanical

CHAIN

TENSIONER
AND

CHAIN
GUIDE

Check
for

wear
and

breakage
Re

place
if

necessary

r

I

L

EM147

Fig
EM
75
Cam

haft
dri
mechanilm

FLYWHEEL

I

Check
clutch
disc

contact
surface

with

flywheel
for

damage
or
wear

Repair
or

replace
if

necessary

2

Measure
runout
of
clutch
disc

contact
surface

with
a
dial

gauge
fit

exceeds
0
15

mm
0
0059
in

total

indicator

reading

replace
it

EM
20
EM426

Fig
EM

76
Checking
flywheel

deviation

3

Check

tooth
surfaces
of

ring
gear

for
flaws

or
wear

Replace
if

necessary

FRONT

COVER
AND

REAR
OIL
SEAL

First
check

front
cover

an
rear
oil

seal
for

worn
or
folded
over

sealing
lip

or
oil

leakage
If

necessary
install
a

new
seal
When

installing
a
new

seal

pay
attenti
on
to

mounting
direction

Note
It
is

good
practice
to

replace
oil

seal
whenever

engine
is

overhauled

Frant
t
r

r

J
I

Front

Real

EM150

Fig
EM

77
Oil

eals

of
crank

haft

PRECAUTIONS

CYLINDER
HEAD

PRECAUTIONS

I
Use

thoroughly
cleaned

parts

Especially
make

sure
that
oil
holes
are

clear
of

foreign
matter

2

When

installing
sliding
parts
such

as

bearings
be
s
uIe
to

apply
engine
oil

to
them

3
Use

new

packing
and

oil
seals

4
Do
not

reuse
lock
washers

5

Keep
tools
and

work
benches

clean

6

Keep
necessary
parts
and
tools

near
at
hand

7
Be

sure
to
follow

specified
tight

ening

torque
and
order

8

Applying
sealant

Use
sealant
to
eliminate
water
and

oil
leaks
Parts

requiring
sealant
are

I
Front

cover
and
corners
of

cyl

inder
block
See

Figure
EM

78

EM153

Fig
EM
78

Applying
alant

Front
cover
and

cylinder
block

2
Main

bearing
cap
and

cylinder

block
Each

side
of
rear

main
bearing

cap
and
each
corner
of

cylinder
block

See

Figure
EM
79
Engine
Mechanical

ENGINE
ASSEMBLY

CONTENTS

EM
21

EM
21
PISTON
AND

CONNECTING
ROD

ENGINE
ASSEMBLY
EM

22

EM
22

Cylinder
block

Rear
main

bearing
cap

20to2Smm

Ill

Points

to
be

applied
sealant

EM151
s

e

00

000

o

Fig
EM
79

Applying
sealanl

Main

bearing
cap
and

cylinder
block

3

Cylinder
block

Step
portions
at

four

mating
surfaces

cylinder
block
to

front
chain

cover
and

cylinder
block

to
rear
main

bearing
cap
See

Figure

EM
80

Note
Do
not

apply
too

much
sealant

J

Apply
sealant
at
hese

points

EM152

Fig
EM
80

Applying
sealant

Cylinder
block

CYLINDER
HEAD

Valve
assembly
and
valve

spring

Using
Valve
Lifter
STl2070000
set

valve

pring
seat
in

position
and
fit

valve

guide
with
oil
seaL

Assemble
valve
in
the
order
shown

below
valve
inner
and
outer
valve

springs
spring
retainer

valve
collet

and
valve
rocker

guide

EM
21
Fig
EM
81

Installing
valves

Notes

a
Ensure

that
valve

face
is

free
from

foreign
matter

b
The
L20B

engine
uses
double

type

valve

springs

2
Valve
rocker

pivot
assembly

Screw
valve
rocker

pivots
joined

with
lock
nuts
into

pivot
hushing

3
Camshaft

assembly

Set

locating

plate
and

carefully

install
camshaft
in

cylinder
head
Do

not

damage
the

bearing
inside

Oblong

groove
of

locating

plate
must
be

directed
toward
front
side
of

engine

Camshaft
bracket

tightening

torque

1

8
to
2
0

kg
in

13
to

15
ft
lb

4

Install
camshaft

sprocket
on
earn

shaft
and

tighten
it

together
with

fuel

pump
drive
cam
to

specified
torque

Tightening
torque

12
tol6

kg
m

87
to
116
ft

lb

this
time
check
camshaft
end

Fig
EM
82

Installing
camshaft

sprocket

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