checking oil DATSUN 210 1979 Service Manual
[x] Cancel search | Manufacturer: DATSUN, Model Year: 1979, Model line: 210, Model: DATSUN 210 1979Pages: 548, PDF Size: 28.66 MB
Page 15 of 548
DATSUN
210
Model
8310
Series
SECTIONET
ET
ENGINE
TUNE
UP
CONTENTS
EMISSION
CONTROL
DEVICES
BASIC
MECHANICAL
SYSTEM
ADJUSTING
INTAKE
AND
EXHAUST
VALVE
CLEARANCE
CHECKING
AND
ADJUSTING
DRIVE
BELTS
CHANGING
ENGINE
OIL
REPLACING
01
L
FI
L
TER
CHANGING
ENGINE
COOLANT
CHECKING
COOLING
SYSTEM
HOSES
AND
CONNECTIONS
CHECKING
ENGINE
COMPRESSION
IGNITION
AND
FUEL
SYSTEM
CHECKING
BATTERY
CHECKING
AND
ADJUSTING
IGNITION
TIMING
CHECKING
IGNITION
WIRING
CHECKING
AND
REPLACING
SPARK
PLUGS
CHECKING
AND
ADJUSTING
CARBURETOR
IDLE
RPM
AND
MIXTURE
RATIO
CHECKING
CHOKE
MECHANISM
Choke
plate
and
linkage
CHECKING
FUEL
SHUT
OFF
SYSTEM
FU
models
ET
2
ET
3
ET
3
ET
3
ET
3
ET
3
ET
4
ET
4
ET
4
ET
5
ET
5
ET
5
ET
6
ET
6
ET
7
ET
9
ET
9
REPLACING
FUEL
FILTER
ET
10
CHECKING
FUEL
LINES
Hoses
piping
connections
etc
ET
10
REPLACING
AIR
CLEANER
FILTER
ETlO
CHECKING
AUTOMATIC
TEMPERATURE
CONTROL
AIR
CLEANER
ET
10
EMISSION
CONTROL
SYSTEM
ET
11
CHECKING
VACUUM
FITTING
HOSES
AND
CONNECTIONS
ET
11
REPLACING
AIR
PUMP
AIR
CLEANER
FILTER
Except
FU
models
and
Canada
models
E
1122i
REPLACING
AIR
INDUCTION
VALVE
FILTER
FU
models
and
Canada
models
E
tlil1r2
C
REPLACING
PCV
VALVE
AND
FILTER
ETf
CHECKING
VENTI
LATION
HOSES
E1P12
CHECKING
VAPOR
LINES
Eli
J2
CHECKING
FUEL
TANK
VACUUM
RELIEF
I
f
III
VALVE
ET
13
REPLACING
CARBON
CANISTER
W
FILTER
ET
d
SERVICE
DATA
AND
SPECIFICATIONS
ET
14
TROUBLE
DIAGNOSES
AND
CORRECTIONS
ET
16
SPECIAL
SERVICE
TOOL
ET
23
Page 17 of 548
Engine
Tune
up
BASIC
MECHANICAL
SYSTEM
ADJUSTING
INTAKE
AND
EXHAUST
VAL
fE
CLEARANCE
Note
After
tightening
cYlinder
head
bolts
adjust
intake
and
exhaust
valve
clearances
Valve
clearance
ai
ljustment
cannot
be
made
while
the
engine
is
in
opera
tion
To
adjust
proceed
as
follows
I
Start
engine
and
warm
it
up
uritil
water
temperature
indicator
points
to
the
middle
of
gauge
Then
stop
engine
2
Rotate
crankshaft
to
bring
No
I
cylinder
in
top
dead
center
on
its
compression
stroke
3
Remove
valve
rocker
cover
Adjust
valve
clearance
at
following
four
points
while
engine
is
still
hot
CD
Exhaust
valve
of
No
I
cylinder
@
Intake
valve
of
No
I
cylinder
@
Intake
valve
of
No
2
cylinder
@
Exhaust
valve
of
No
3
cylinder
Note
Numbers
in
circle
agree
with
those
in
accompanying
sketch
tiri
Fig
ET
1
Adjusting
Value
Clearanu
4
Again
rotate
crankshaft
one
turn
so
that
No
4
piston
is
in
top
dead
center
on
its
ompression
stroke
Ad
just
following
valve
s
CID
Exhaust
valve
of
No
2
cylinder
@
Intake
valve
of
No
3
cylinder
j
Intake
valve
of
No
4
cylinder
@
Exhaust
valve
of
No
4
cylinder
Adjustment
should
be
made
while
engine
is
hot
After
all
valves
have
been
adjusted
correctly
tighten
lock
nut
firmly
to
secure
ihe
adjustment
Valve
clearance
Hot
Intake
0
35
mm
0
014
inl
Exhaust
0
35
mm
0
014
in
tJl
Tightening
torque
Valve
rocker
adjusting
nut
1
6
to
2
2
kltm
12
to
16
ft
lb
Alternator
Crankshaft
pulley
Unit
mm
in
Idler
pulley
Fig
ET
2
CHANGING
ENGINE
OIL
1
Check
if
oil
is
diluted
with
water
or
gasoline
Drain
and
refill
oil
if
necessary
Note
a
A
milky
oil
iiulicates
the
presence
of
cooling
water
Isolate
the
cause
and
take
corrective
measure
b
An
oil
with
extremely
low
viscosity
indicates
dilution
with
gasoline
2
Check
oil
level
If
below
the
specified
level
raise
it
up
to
the
H
level
3
Change
engine
oil
in
accordance
with
the
maintenance
schedule
Engine
oil
capacity
A14
With
oil
filter
3
7
liters
3
U
US
qt
3
Yo
Imp
qtl
ET3
CHECKING
AND
ADJUSTING
DRIVE
BELTS
I
Check
for
cracks
or
damage
Re
place
if
necessary
2
Normal
drive
belt
deflection
is
showndI
figure
below
when
moderate
thumb
pressure
is
applied
midway
between
pulleys
Thumb
pressure
10
kg
221bl
Idler
pulley
Compressor
p1
111ey
AC710
Checking
Drive
Belts
for
Deflection
Without
oil
filter
3
2
liters
3
USqt
2
U
ImP
ltl
A15
With
oil
filter
3
3
liters
3
US
qt
2
U
Imp
qd
Without
oil
filter
2
8
liters
3
us
qt
2
Imp
qd
REPLACING
OIL
FILTER
The
oil
filter
is
a
cartridge
type
and
can
be
removed
using
Oil
Filter
Wrench
STl9320000
I
Check
for
oil
leaks
past
gasketed
Oange
If
leakage
is
found
retighten
just
enough
to
stop
leakage
If
reo
tightening
is
no
longer
effective
re
Page 18 of 548
pl
ice
mter
as
an
assembly
2
When
installing
oil
mter
tighten
by
hand
Note
Do
not
overtighten
oil
filter
lest
leakage
shoUld
occur
CHANGING
ENGINE
COOLANT
PERMANENT
ANTI
FREEZE
COOLANT
Note
The
permanent
anti
freeze
coolant
is
an
ethylene
glya
l
base
product
containing
chemical
in
hibitors
to
protect
the
cooling
system
from
rusting
and
corrosion
The
anti
freeze
does
not
cOntain
any
glycerine
or
ethyl
alcohol
It
will
not
evaporate
or
boil
a
ay
and
can
be
ilsed
with
either
high
or
low
temperature
thermostats
It
flows
freely
transfers
heat
efficiently
and
will
not
clog
the
passages
in
the
cooling
system
The
anti
freeze
must
not
be
mixed
with
other
product
This
coolant
can
be
used
throughout
the
seasons
of
the
year
Whenever
coolant
is
changed
the
cooling
system
must
be
flushed
and
refilled
with
a
new
coolant
Check
the
coolant
level
See
instructions
attached
to
the
anti
freeze
container
for
mixing
ratio
of
anti
freeze
to
water
CHECKING
COOLING
SYSTEM
HOSES
AND
CONNECTIONS
Check
hoses
and
fittings
for
loose
connections
or
deterioration
Re
tighten
or
replace
if
necessary
INSPECTION
OF
RADIATOR
CAP
Apply
reference
pressure
0
9
kgj
cm2
13
psi
to
radiator
cap
by
means
of
a
cap
tester
to
see
if
it
is
satisfactory
Replace
cap
assembly
if
necessary
I
j
ngine
Tune
up
ET012
Fig
ET
3
Testing
Radiator
Cap
COOLING
SYSTEM
PRESSURE
TEST
Witli
radiator
cap
removed
apply
reference
pressure
1
6
kgfcm2
23
psi
to
the
cooling
system
by
means
0
no
Fig
ET
4
Water
capacity
M
Tmodelsl
Without
heater
5
2
liten
5
1f
US
qt
4
Imp
qt
With
heeter
5
9
Iiten
6
4
US
qt
5
Y
Imp
qt
Water
capacity
AfT
modelsl
Without
heater
5
0
liters
5
y
US
qt
4
Imp
qt
With
heater
5
7
liten
6
US
qt
5
Imp
ill
CHECKING
ENGINE
COMPRESSION
Note
a
To
check
cylinder
compression
it
is
essential
to
remove
all
spark
plugs
The
purpose
of
this
test
is
to
ET
4
determine
whether
there
is
exces
sive
leakage
past
piston
rings
head
gasket
etc
To
test
engine
should
be
heated
to
the
operating
t
M
ture
and
throttle
valve
opened
b
Cylinder
compre
on
in
Cylinders
should
not
be
less
than
llO
of
the
highest
reading
Different
compres
sion
in
two
ore
more
cYlinder
usual
ly
indicates
an
improperly
seated
valve
or
broken
piston
ring
c
Low
compression
in
cylinders
am
result
from
worn
piston
rings
This
trouble
may
usuaDy
be
accom
panied
by
ex
ssive
fuel
consump
tion
I
Warm
up
engine
sufficiently
2
Disconnect
aU
spark
plugs
3
Disconnect
anti
dieseling
solenoid
valve
connector
4
Properly
attach
a
compression
tester
to
spark
plug
hole
in
cylinder
being
tested
FiI
ET
S
ET529
Testing
Compre
sion
Pr
s8ure
5
Depress
accelenit6r
pedal
to
open
throttle
and
choke
valves
Note
Do
not
pump
pedal
6
Start
engine
as
quickly
as
pos
sible
Compression
pressllre
kg
cm2
ii
at
rpm
Standard
13
5
192
350
Minimum
12
5
1781
350
If
cylinder
compression
in
o
e
or
more
cylinders
is
low
pour
a
small
quantity
of
engine
oil
into
cylinders
through
the
spark
plug
holes
and
retest
compression
I
If
addingoil
helps
the
compres
Page 19 of 548
sion
pressure
chances
are
that
piston
rings
are
worn
or
damaged
2
If
pressure
stays
low
the
likeli
hood
is
that
valve
is
sticking
or
seating
Engine
Tune
up
improperly
3
If
cylinder
compression
in
any
two
adjacent
cylinders
is
low
and
if
adding
oil
does
not
help
the
compres
sion
there
is
leakage
past
the
gasketed
surface
Oil
and
water
in
combustion
cham
bers
can
result
from
this
problem
IGNITION
AND
FUEL
SYSTEM
CHECKING
BATTERY
I
Remove
six
vent
plugs
and
check
electrolyte
level
in
each
battery
cell
If
necessary
pour
distilled
water
Overflow
Correct
Shortage
t
t
j
t
t
t
EE358
Fig
ET
6
Checking
Electrolyte
Level
2
Measure
the
specific
gravity
of
battery
electrolyte
E
T372
Fig
ET
7
Checking
Specific
Gravity
of
Battery
Electrolyte
Over
1
22
Full
charge
value
at
200C
680F
1
28
1
26
Permissible
value
Frigid
climates
Other
climates
Note
a
Clean
top
of
battery
and
terminals
with
a
solution
of
baking
soda
and
water
Rinse
off
and
dry
with
com
pressed
air
Top
of
battery
must
be
c1
n
to
prevent
current
leakage
between
terminals
and
from
posi
tive
terminal
to
hold
down
clamp
b
In
addition
to
current
leakage
prolonged
accumulation
of
acid
and
dirt
on
top
of
hattery
may
cause
blistering
of
the
material
covering
ronnector
straps
and
rorrosion
of
straps
c
Afte
r
tightening
terminals
coat
them
with
petrolatum
vaseline
to
protect
them
from
corrosion
CAUTION
If
the
battery
cables
are
disconnected
they
should
be
tightly
clamped
to
the
battery
terminals
to
secure
a
good
contact
Over
I
20
CHECKING
AND
ADJUSTING
IGNITION
TIMING
Check
spark
plugs
for
condition
2
Thoroughly
remove
dirt
and
dust
from
crank
pulley
at
timing
mark
location
and
front
cover
at
timing
indicator
3
Warm
up
engine
sufficiently
4
Connect
engine
tachometer
and
timing
light
in
their
proper
positions
5
Adjust
idling
speed
to
the
specifi
ed
value
Idling
speed
Manual
transmission
700
pm
Automatic
transmission
6S0
rpm
in
0
position
ET
S
WARNING
When
selector
lever
is
shifted
to
0
position
apply
parking
brake
and
block
both
front
and
rear
wheels
with
chocks
Note
a
On
FU
models
set
idling
speed
with
distributor
vacuum
hose
dis
connected
b
Disconnect
distributor
vacuum
hose
at
distributor
diaphragm
side
and
plug
hose
with
blind
plug
See
Fig
ET
8
ET501
Fig
ET
B
Disconnecting
Distributor
Vacuum
Hose
6
Check
ignition
timing
with
a
timing
light
to
ensure
that
it
is
adjust
ed
to
specifications
indicated
below
Ignition
timing
Manual
transmission
SO
B
T
0
C
f700
rpm
California
FU
models
100
B
T
0
C
f700
pm
Non
California
Canada
models
Automatic
transmission
SO
B
T
0
C
f6S0
rpm
California
models
Page 42 of 548
CYLINDER
HEAD
I
Using
Valve
lifter
STl2070000
compress
valve
spring
and
remove
valve
collet
2
Release
Valve
Lifter
and
remove
spring
retainer
spring
oil
seal
spring
seat
and
valve
PREPARATION
FOR
INSPECTION
I
8efore
cleaning
check
for
signs
of
water
and
oille
s
2
Clean
oil
and
carbon
deposits
from
all
parts
They
should
be
clean
from
gaskets
and
sealant
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
I
Make
a
visual
check
for
cracks
and
flaws
2
Measure
surface
of
cylinder
head
on
cylinder
block
sid
for
warpage
If
beyond
designated
limit
correct
s
rface
with
a
surface
grinder
Warpage
of
urfece
Less
than
0
1
mm
0
004
in
EM108
Fig
EM
IS
Checking
Cylinder
Head
Surface
Engine
Mechanical
EM462
Fig
EM
16
Removing
Value
3
Place
valve
components
in
order
INSPECTION
AND
REPAIR
Note
Surface
grinding
limit
The
grinding
limit
of
cylinder
head
is
determined
by
the
cylinder
block
grinding
in
an
engine
Depth
of
cylinder
head
grinding
is
A
Depth
of
cylinder
block
grinding
is
6B
The
limit
is
as
follows
A
B
0
2
mm
0
008
in
VALVE
i
Check
each
of
the
intake
and
exhaust
valve
for
worn
damaged
or
deformed
valve
caps
or
stems
Correct
or
replace
the
valve
that
is
faulty
For
standard
size
of
valve
refer
to
Service
Data
and
Specifications
2
Valve
face
or
valve
stem
end
surface
should
be
refaced
by
using
a
valve
grinder
Note
When
valve
head
has
been
worn
down
to
0
5
mm
0
020
in
in
thickness
replace
the
valve
Grinding
allowance
for
valve
stem
end
surface
is
0
5
mm
0
020
in
or
less
c
EM111
Fig
EM
19
Regrinding
Valve
Face
EM
5
C
vO@
lll@8
C
CQ8@
a
EM463
Fig
EM
17
Valve
Components
Note
Take
care
not
to
lose
valve
spring
seat
oil
seal
valve
collet
and
valve
rocker
guide
VALVE
SPRING
I
Check
valve
spring
for
squareness
using
a
steel
square
and
surface
plate
If
spring
is
out
of
square
S
more
than
specified
limit
replace
with
new
ones
Out
of
square
S
Less
than
1
6
mm
0
063
inl
L
1
EM296
Fig
EM
20
Measuring
Spring
Sguareness
2
Measure
the
free
length
and
the
tension
of
each
spring
If
the
measured
value
exceeds
the
specified
limit
re
place
spring
Refer
to
Service
Data
and
pecifica
tions
EMl13
Fig
EM
21
Measuring
Spring
Teruion
Page 44 of 548
5
Fit
insert
ensuring
that
it
seats
on
bottom
face
of
its
recess
6
Newly
fitted
valve
seat
should
be
cut
or
ground
with
suitable
seat
cutter
or
grinding
stone
7
Apply
smalliunount
of
fine
grind
ing
compound
to
valve
contacting
face
and
put
valve
into
guide
Lap
valve
against
its
seat
ntil
proper
valve
seat
ing
is
obtained
Remove
valve
and
clean
valve
and
valve
seat
VALVE
ROCKER
ARM
1
AND
SHAFT
I
Check
rocker
arm
bore
and
shaft
for
scores
or
scuffs
2
Check
clearance
between
each
rocker
arm
and
shaft
by
measuring
inner
diameter
of
rocker
arm
bore
and
outer
diameter
of
shaft
If
either
clearance
is
not
within
spec
ification
replace
rocker
arm
and
or
shaft
3
Check
valve
end
contact
surface
of
rocker
arm
for
abnormal
wear
or
scuffs
VALVE
LIFTER
AND
PUSH
ROD
I
Check
valve
lifter
for
wear
or
scuffs
Check
bottom
end
of
valve
lifter
to
make
sure
it
has
a
slight
convex
Replace
valve
lifters
that
are
scored
worn
or
have
unsmooth
bot
tom
2
Check
clearance
between
lifter
hole
on
cylinder
block
and
valve
lifter
Replace
valve
lifter
if
clearance
ex
ceeds
wear
limit
3
Check
push
rod
for
bending
and
damage
Check
end
of
push
rod
for
rough
ness
or
excessive
wear
CAMSHAFT
AND
CAMSHAFT
BEARING
CAMSHAFT
BEARING
CLEARANCE
Journal
diameters
should
be
check
ed
with
a
micrometer
and
bearings
with
an
inside
dial
gauge
Measure
ments
should
then
be
compared
to
Engine
Mechanical
determine
whether
bearings
are
worn
If
worn
beyond
0
15
mm
0
0059
in
replace
using
Camshaft
Bearing
Drift
STl6Il0000
In
press
fitting
a
new
bearing
make
certain
that
oil
holes
in
block
and
bearing
are
properly
aligned
EM474
Fig
EM
27
Measuring
Camshaft
Bearing
Inner
Diameter
CAUTION
a
After
replacing
all
bearings
finish
bearing
inner
diameters
by
line
bor
ing
b
I
nstall
welch
plug
into
cylinder
block
applying
sealant
EM475
Fig
EM
28
Replacing
Cam
haft
Bearings
CAMSHAFT
ALIGNMENT
I
Check
camshaft
camshaft
journal
and
earn
surface
for
bending
wear
or
damage
If
fault
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
the
cen
ter
journal
Camshaft
bend
Total
indicator
reading
Less
than
0
10
mm
0
0039
in
EM
7
s
EM476
Fig
EM
29
Checking
Cam
haft
Bend
3
Camshaft
end
play
can
be
check
ed
by
installing
camshaft
camshaft
locating
plate
and
camshaft
sprocket
in
thier
respective
p
sitions
End
play
can
then
be
checked
with
a
dial
guage
or
feeler
gauge
If
end
play
exceeds
the
specified
limit
replace
locating
plate
Max
tolerance
of
camshaft
end
pley
0
10
mm
0
0039
in
EM477
Fig
EM
3D
Checking
Cam
haft
End
Play
VALVE
TIMING
This
diagram
applies
to
all
cyl
inders
If
any
valve
is
found
beyond
specifications
one
possibility
is
that
earn
lobe
is
worJ
1
or
damaged
exces
sively
calling
for
replacement
of
cam
shaft
CYLINDER
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
Warpage
of
cylinder
block
surface
Less
than
0
10
mm
0
0039
in
Page 46 of 548
Note
If
cylinder
bore
has
worn
beyond
the
wear
limit
use
cylinder
liner
Undersize
cylinder
liners
are
avail
able
for
service
Interference
fit
of
cylinder
liner
in
cylinder
block
ahould
be
0
08
to
0
09
mm
0
003
I
to
0
0035
in
PISTON
PISTON
PIN
AND
PISTON
RING
I
Remove
carbon
from
piston
and
ring
grooves
with
a
carbon
scraper
and
a
curved
steel
wire
The
wire
will
be
useful
in
cleaning
bottom
land
of
ring
groove
Clean
out
oil
slots
in
bottom
land
of
oil
ring
groove
2
Check
for
damage
scratches
and
wear
Replace
if
fault
is
detected
3
Measure
side
clearance
of
rings
in
ring
grooves
as
each
ring
is
installed
If
side
clearance
exceeds
the
speci
fied
limit
replace
piston
together
with
piston
ring
Max
tolerance
of
side
clearance
0
1
mm
0
0039
in
Engine
Mechanical
u
EM482
Fig
EM
38
Measuring
Ring
Gap
Note
a
When
piston
ring
only
is
to
be
replaced
without
cylinder
bore
be
ing
corrected
measure
the
gap
at
the
bottom
of
cylinder
where
the
wear
is
minor
b
Oversize
piston
rings
are
available
for
service
0
5
mm
0
020
in
1
0
mm
0
039
in
oversize
5
Measure
piston
pin
hole
in
rela
tion
to
the
outer
diameter
of
pin
If
wear
exceeds
limit
replace
piston
pin
together
with
piston
on
which
it
is
installed
Piston
pin
to
piston
clearance
O
OOS
to
0
012
mm
0
0003
to
0
0005
in
Note
Determine
the
fitting
of
piston
pin
into
piston
pin
hole
to
such
an
extent
that
it
can
be
pressed
smoothly
by
fmger
at
room
tem
perature
This
piston
pin
must
be
a
tight
press
fit
into
connecting
rod
EM481
Fig
EM
37
Me
suring
Piston
Ring
Side
Clearance
4
Measure
ring
gap
with
a
feeler
gauge
placing
ring
squarely
in
cyl
inder
Ring
should
be
placed
to
diameter
at
upper
or
lower
limit
of
ring
travel
If
ring
gap
exceeds
the
specified
limit
replace
ring
Max
tolerance
of
ring
gap
1
0
mm
0
039
in
EM131
Fig
EM
39
Piston
Pin
Fitting
CONNECTING
ROD
1
If
a
connecting
rod
has
any
flaw
on
either
side
of
thrust
face
and
large
end
correct
or
replace
it
Bend
and
torsion
per
100
mm
3
94
in
length
Less
than
0
05
mm
0
0020
in
EM
9
EM133
Fig
EM
40
Checking
Rod
Alignment
2
Check
connecting
rod
for
bend
or
torsion
using
a
connecting
rod
aligner
If
bend
or
torsion
exceeds
limit
cor
rect
or
replace
3
When
replacing
connecting
rod
select
rod
so
weight
difference
be
tween
new
and
old
ones
is
within
5
gr
0
180z
4
Install
connecting
rods
with
bear
iogs
on
to
corresponding
crank
pins
and
measure
thrust
clearance
If
meas
ured
value
exceeds
limit
replace
con
necting
rod
Max
tolerance
of
big
end
play
0
4
mm
0
016
in
l
Big
end
play
l
t
t
EM483
Fig
EM
41
Checking
Big
End
Pwy
CRANKSHAFT
I
Repair
or
replace
as
required
If
faults
are
minor
correct
with
fine
crocus
cloth
2
Check
with
a
micrometer
journals
and
crank
pins
for
taper
and
out
of
round
Measurement
should
be
taken
along
journals
for
taper
and
around
journals
for
out
of
round
If
out
of
round
or
taper
exceeds
the
specified
limit
replace
or
repair
Page 47 of 548
Out
of
ound
X
Y
Less
than
0
03
mm
10
0012
in
Taper
A
B
Less
than
0
03
mm
0
0012
in
Out
of
round
X
Y
Taper
A
B
B
o
r
EM716
Fig
EM
42
Mea6Urement
Point
3
After
regrinding
crankshaft
fmish
it
t
1
t
1e
necessary
s
ize
indicated
in
the
chart
under
Service
Data
and
Specifi
cations
by
using
Ill
adequate
u
dersize
bearing
according
to
the
extent
of
required
repair
4
Crankshaft
can
be
checked
for
bend
by
placing
it
on
V
blocks
and
using
a
dial
gauge
with
its
indicating
finger
resting
on
center
journal
If
bend
exceeds
the
specified
limit
replace
or
repair
Bned
Total
indicator
reading
Less
than
0
10
mm
0
0039
in
EM137
Fig
EM
43
Checking
Crankshaft
Bend
5
Measure
crankshaft
end
play
as
shown
in
Fig
EM
44
If
beyond
the
specified
limit
replace
main
bearing
Max
tolerance
of
end
play
0
3
mm
10
012
in
Engil
e
Mechllpjcal
Crsnk5haf
end
play
EM486
Fig
EM
44
Checking
Crankshaft
End
Play
6
To
replace
crankshaft
rear
pilot
bushing
proceed
as
follows
1
Pull
out
bushing
using
Pilot
Bushing
Puller
KvloI02800
Fig
EM
45
Pulling
Out
Pilot
Bushing
2
Before
installing
a
new
bushing
thoroughly
clean
bushing
hole
3
Insert
pilot
bushing
until
dis
tance
between
flange
end
and
pilot
bushing
is
the
specified
diJ1l
nce
A
Distance
A
Approximetely
2
8
mm
0
110
in
Do
not
oil
bushing
A
Pilot
bushing
EM719
Fig
EM
46
Installing
Pilot
Bushing
Note
When
installing
pilot
bushing
be
careful
not
to
damage
edge
of
EM
l0
pilot
C
snd
not
to
imat
1
1
1
BEARING
MEASURING
MAIN
BEARING
CLEARANCE
I
Thoroughly
clean
all
bearings
Check
for
scratches
melt
score
or
wear
Replace
bearings
if
fault
is
detected
2
Crankshaft
journals
and
bearings
should
be
clean
and
free
from
dust
and
dirt
before
oil
Clearance
is
meaSured
Plastigage
EM
141
Fig
EM
47
Plastigage
3
Set
main
b
e1lfing
on
cap
block
4
Cut
a
plastigage
to
width
of
bear
ing
and
place
it
in
parallel
with
crank
pin
clear
of
oil
hole
Install
cap
on
assembly
and
tighten
them
together
to
specified
torque
fj
Tightening
torque
Main
bearing
cop
bolt
5
0
to
6
0
kg
m
36
to
43
fHb
Note
Do
not
turn
crankshaft
while
plastigage
is
being
inserted
5
Remove
cap
and
compare
width
of
plastigage
at
widest
part
with
scale
printed
in
plastigage
envelope
Page 48 of 548
EM142
Fig
EM
48
Measuring
Bearing
Clearance
6
If
clearance
exceeds
the
specified
value
replase
bearing
with
an
under
size
bearing
and
grind
crankshaft
journal
adequately
Max
tolerance
of
main
bearing
clearance
0
10
mm
0
0039
in
MEASURING
CONNECTING
ROD
BEARING
CLEARANCE
I
Measure
connecting
rod
bearing
clearance
in
same
manner
as
above
tfl
Tightening
torque
Connecting
rod
cap
nuts
3
2
to
3
8
kg
m
23
to
27
fHb
2
If
clearance
exceeds
the
specified
value
replace
bearing
with
an
under
size
bearing
and
grind
the
crankshaft
journal
adequately
Max
tolerance
of
connecting
rod
bearing
clearance
0
10
mm
0
0039
in
Note
Since
bearings
are
precision
insert
type
it
is
not
necessary
to
file
bearing
caps
or
to
grindbeari
surfaces
with
an
emery
cloth
to
correct
bearing
clearance
MISCELLANEOUS
COMPONENTS
CRANKSHAFT
SPROCKET
AND
CAMSHAFT
SPROCKET
I
Check
tooth
surface
for
flaws
or
wear
Replace
sprocket
if
fault
is
Engine
Mechanical
found
2
Install
camshaft
sprocket
in
posi
tion
and
check
for
runout
If
runout
exceeds
the
specified
limit
replace
camshaft
sprocket
Runout
Total
indicator
reading
Less
than
0
1
mm
0
004
in
EM309
Fig
EM
49
Checking
Cam
haft
Sprocket
Runout
CHAIN
AND
CHAIN
TENSIONER
I
Check
chain
for
stepped
wear
scratches
or
other
problems
on
roller
links
Replace
if
necessary
2
Check
chain
tensioner
for
wear
breakage
or
any
other
fault
which
would
interfere
with
proper
chain
function
Replace
if
necessary
FLYWHEEL
I
Check
ring
gear
If
worn
or
dam
aged
excessively
replace
2
Clutch
contacting
face
of
fly
wheel
should
be
smooth
If
worn
damaged
or
roughened
beyond
limits
repair
or
replace
3
Before
disassembling
and
after
re
assembling
check
flywheel
run
out
with
a
dial
gauge
This
check
is
made
by
rotating
flywheel
with
dial
gauge
finger
resting
on
the
farthest
point
from
center
of
flywheel
If
it
exceeds
the
specified
limit
replace
it
EM
II
Runout
Total
indicator
reading
Less
then
0
15
mm
0
0059
in
Fig
EM
50
Checking
Flywheel
Runout
Note
Removal
and
installation
of
ring
gear
requires
use
of
hydraulic
press
It
is
also
necessary
to
heat
ring
gear
to
180
to
2000C
356
to
3920F
thus
facilitating
removal
and
installation
Do
not
heat
ring
gear
to
more
than
3000C
5nOF
To
do
so
could
result
in
impaired
hardness
of
ring
gear
CRANKSHAFT
FRONT
AND
REAR
OIL
SEAL
First
check
front
and
rear
oil
seals
for
worn
or
folded
over
sealing
lip
or
oil
leakage
If
necessary
replace
with
a
new
seal
When
installing
a
new
seal
pay
attention
to
mounting
direction
Note
It
is
good
practice
to
renew
oil
seal
whenever
engine
is
overhauled
Front
u
Front
Rear
EM487
Fig
EM
51
Cranhhaft
Oil
Seal
Page 51 of 548
9
Make
SUre
there
is
proper
end
play
at
crankshaft
Crankshaft
end
play
0
05toO
15mm
0
OO20
to
0
0059
in
laJlk
h
end
play
J
EM486
Fig
EM
63
Checking
Crank
luJft
End
Play
10
Install
rear
oil
seal
using
suitable
drift
Fig
EM
64
n
talling
Rear
Oil
Seal
II
Install
rear
plate
12
Install
flywh
el
secwely
and
tighten
bolts
to
specified
torque
dl
Tightening
torque
Flywheel
and
drive
plate
A
14
engine
fixing
bolts
8
0
to
9
0
kg
m
58
to
65
ft
Ib
Drive
plate
A
15
engine
fixing
bolts
8
5
to
9
5
kg
m
61
to
69
ft
b
Fig
EM
65
n
talling
Flywheel
13
Rotate
engine
quarter
turn
and
install
piston
rod
assembly
using
Pis
Engine
Mechanical
ton
Ring
Compressor
EM03470000
EM497
Fig
EM
66
tolling
Platon
Rod
Assem
bly
Note
a
Insert
pistons
in
L
r
nding
cyl
inders
b
Apply
engine
oil
to
sliding
parts
c
Arrange
pistons
so
number
stamped
on
piston
head
faces
to
front
of
engine
d
Before
installing
piston
piston
rings
should
be
positioned
as
shown
in
Fig
EM
67
Second
ring
Oil
ring
lower
rail
EM49B
Fig
EM
67
Positioning
Piston
Ring
Gap
14
Apply
engine
oil
to
bearing
surfaces
dl
Tighte
ning
torque
Connecting
rod
cap
nuts
3
2
to
3
8
kg
m
23
to
27
ft
b
EM499
Fig
EM
68
Tightening
Connecting
Rod
Cap
Note
Am11
connecting
rods
and
connecting
rod
caps
so
cylinder
numben
face
in
same
direction
EM
14
I
S
Make
sure
there
exists
proper
end
play
at
connecting
rod
big
end
See
Fig
EM41
Big
end
play
0
1
to
0
2
mm
0
004
to
0
008
in
16
Insert
crank
sprocket
keys
in
keyways
of
crankshaft
Install
cam
shaft
and
crankshaft
sprockets
tempo
rarily
for
adjustment
of
tooth
height
by
using
adjusting
washers
Height
dif
Less1
h
l11
0
5
mm
0
020
in
Adjusting
washer
thickness
0
5
mm
10
020
in
EM500
Fig
EM
69
Adju
ting
Sprocket
Tooth
Height
17
Install
tinting
chain
and
cam
shaft
sprocket
with
their
markings
properly
aligned
See
Fig
EM
70
Then
set
No
I
piston
at
T
D
C
on
compression
stroke
See
Fig
EM
71
Oil
sprocket
teeth
and
chain
with
engine
oil
Match
mark
Key
groove
EM501
Fig
EM
70
Aligning
Markinga
Note
Make
sure
camshaft
sprocket
dowel
hole
and
crankshaft
sprocket
key
are
in
line
and
both
dowel
hole
and
key
are
located
downward