check engine DATSUN 510 1968 Service User Guide

ENGINE
AND
IGNITION
TUNE
UP
23

CD
ADJUSTING
SCREWS
FOR
THE
POSITION

OF

RETARDED
BREAKER
POINT

r

A
O
S

8

6

C

0

18

2
6
10
14

contact

pomt
assembly
from
the
dIStnbutor
and

clean
or

replace
the

pomts
Use
a

pomt
file
to

clean
the
contacts
Do
not

attempt
to
remove
all

roughness
Apply
a
trace
of

beanng
lubncant

to
the
breaker
cam

5
Once
the

pomts
have
been
cleaned
or
re

placed
mstall
the

assembly
m

the
dlstnbutor

Make
certam
to
reconnect
wires

6

Adjust
the

pomt
gap
Figure
S
With
the
use

of
a
screwdnver
and

gap
gauge
Make
certaIn

the

rubbmg
arm
on
the
contact

assembly
IS
rest

mg
on
the

hIgh
pomt
of
the
carn
Pomt

gap

should
be

adjusted
to
0
0177

through
00217

m

0
45
to
0
55mm

CD

7
Check
condenser

capacItance
for

a

readmg
of

o
22

through
0
24
mIcrofarads

Replace
If
de

fectIve
As
a
matter
of

good

practIce
the
con

r
denser
should
be

replaced
whenever
the

pomts

are

replaced

8

Inspect
the
InSulatIon
on
all
WIres
WIthIn
the

dIStributor

Replace
If
defectIve

9

Inspect
the
WIre
towers

atop
the
dIStnbutor

cap
for

SignS
of
dIrt
or
corrosIOn
A

pencIl
wIth

fine

emery
cloth

wrapped
around
the

erasl
e
end

can
be
used
to
clean
and
burnISh
the
metal
sur

faces
Make
certam
to
blowout

any
dust

10

Replace
the
rotor

md
the

cap
on
the
dIs

tnbutor
and
secure
the
two
hold
down

clamps

FI

ly
msert

IgrntIon
WIres
mto

proper
towers

ill

cap

IGNITION
TIMING

IgmtIon
tIDlIDg
is

adjusted
with
the

engine

runnmg
Use
a

strobOSCOpIC
timing
hght
and

pro

ceed
as
follows

1
Make
certam
that

spl
l
k

plug
gaps
and
dIs

tnbutor
contact

pomts
are

accurately
set

2
DISconnect
the
vacuum
hne
from
the
carbu

retor
at
the
dIstrIbutor

Plug
the
end
of
the

vacuum
hne
wIth

tape
or
a
wooden

stopper

3
Hook

up
the

trmmg
light
per
mstructIons

4
Hook

up
tachometer

per
mstructions

5
The

tImmg
marles
are
located
on
the
front

edge
of
the
crankshaft

pulley
The

grooves
are

graduated
m
5

degree
mcrements
The

top
dead

center
mark
S
located
to
the
extreme
left
hand

sIde
of
the

engme
as
vIewed
from
the
front
A

statIOnary
pomter
S
connected
to
the

cylinder

P

r
OVll

t
ate

I
l
h
l
JlA

ye
I
o

ctg
fI

O
0

I
d

1e
d
c

Ji
uo
JJ

cb
c
s
rlr
I

l
4

c
1
2

24

CHAPTER
FOUR

block

and
should
be
used
as
the
reference

point

m

II
1akmg

adjustments

6
With
a

piece
of
white
chalk
mark

a
hne
down

the
center
of
the

pomter
and
mark
the

timing

groove
on
the
crankshaft

pulley
which

IS
to
be

used
m

tImmg
the

engine
SpecIficatIon
for
tun

ing
reqUIres
trlhmg
at
10

degrees
before

top

dead
center
wluch
would
be
the

fourth
mark

from
the
left
end
of
the

row
of
marks

7
Loosen
the
hold
down
bolt
at
the
base
of
the

dlstnbutor

8
Locate
the
slow

speed
1
Ile

adjustIng
screw
on

the
carburetor

so
that
Ile

speed
can
be

adjusted

whIle

runnmg
Also
locate
throttle

adJustmg

screw

9
Start

engme
and

adjust
speed
With
the

adJust

ing
screws
to
the

readmgs
below

Smgle
pomt
dIStributor
600

rpm

Dual

pomt
trlbutor
700

rpm

10
Alternate

adjustment
of
the
two
screws

untIl
the
smoothest
Idle
at
the

proper
speed
IS

achieved

11
Pomt
the

tlIrung
lIght
at
the

stationary

pomter
When
the

lIght
flashes
the

timmg
mark

n
the
crankshaft

pulley
should

hne

up
With
the

mark
on
the

stationary
pomter
If
It
does
not

exactly
Ime

up
rotate

the
dlstnbutor

gradually

untIl
the
marks

align
mdlcatlng
correct

timmg

12
Shut
off
the

engme
remove
the

tmung
lIght

and
tachometer

tighten
the
hold
down
bolt
on

the
dlStnbutor
and
connect
the
vacuum
advance

hne
to
the
tli
tnbutor

IGNITION
TIMING

IDLE

SPEED
IDLE

MIXTURE

DUAL
POINT
DISTRIBUTOR

ONLY

The

followmg
applies
to
velucles
With
dual

pomt
distributor
and
an
exhaust
emission
con

trol
deVice
If
these

procedures
are
followed

ha
ul
exhaust

emisSion
should
be
below
the

maximum
allowable
level

1
Locate
the
Idle

and
throttle

adJustmg
screws

on
the
carburetor

2
Warm

up
the

engine
thoroughly

3
Connect

tachometer
and

tmung
light

4
Set
the

Id
le
speed
at
700

rpm
With
the
Idle

adjust
screw
5

Adjust

IgnltJ
on

tuning
at
10

degrees
before

top
dead

center

6
Increase
the

speed
of
the

engme
to
2
000

rpm

With
the
accelerator

or
throttle

hnkage
and
hold

for
about

15
seconds

7
Return
to
Idle
for
one
mmute

8
Set
the

engme
to
best
Idle
at
750

rpm
770

rpm
for
automatJ
c
transIDlsslOn
With
the
Idle

and
throttle

adJustmg
screws

9
Re

uce

engme
speed
at
700

rpm
720

rpm

for

automatic
transmission

by
turnmg
the
Idle

adJustmg
screw
clockWise
for
a
leaner
IlliXture

10
Connect
a
wife
lead
between
the
advance

ami
retard
Side
tenrunals
See

Figure
4

Speed

should

drop
from
100
to
150

rpm

11
Check

IgIl1tIon
tmung
With

tImmg
light
It

should
now
be
at

top
d
ad
center

12
If
the

tlmmg
IS

nSJt
correct

stop
the

engme

and

adjust
the
retarded
breaker

pomt

13
Start
the

engme
and
reclieck
ili

tmung
If

l

incorrect
reset
the
retarded
breaker

pomt
until

it
IS
correct

Repeat
s
nece

s

14
Disconnect
the
wife

bet
reen
the
advance

and
retard
termmals

15
Recheck

tmung
It
should

be
10

degrees

before

top
dead

center

16
If
mcorrect

repeat
the
above

procedures

un
tIl

satIsfactory

17

T
he
Idle

speed
of
automatic
transnllsslOn

vehicles
should

be
about
575

rpm
With
the

gear

j

selector

m
the

dhve

poSltlon
c

t

DWELL
ANGLE
SETIING

1
Connect

the
dwell

angle
meter

2

PLoJust
dwell

angle
to
49

to
55

degrees

OMPRESSION
TEST

I

A

compressIOn
test
IS

performed
to
check
for

worn

piston
nngs
or
to
detect
the

cause
of

a

low

speed
miss
Before

undertaking
the

test

el
llmate
the

pOSSibility
of

sticky
valves

by
usmg

one
of
the

oil
additives

deSigned
for
the

purpose

With
valves
free
test

compressIOn
as

follows

1
Run
the

engme
for
15
to
20
mmutes
untIl

normal

operating

temperatures
are
obtained

2
Shut
off

engme
remove
arr
cleaner
and

ENGINE
AND
IGNITION
TUNE
UP
4

25

block
the
throttle
and
choke
m
the
WIde

open

position

3
Remove
all
four

spark
plugs

4

Sequentially
press
a

compressIOn
test

gauge

mto
each
of
the

spark
plug
holes
and
crank
the

engme
for
at
least
four
strokes
Record
the
com

pressIOn
readmg
for
each

cylmder
Standard

compressIOn
readmg
IS
171
Ibs
m
12
0

kg
cm
Mmlmum

acceptable
readmg
IS
159

lbs
m
2

11
5

kg
cm

5
No

readmg
should
be
less
than
80
of
the

highest
cylmder
reading
ExceSSive

vanatiC
ns

between

cylmders
accompanied
by
low

speed

mlssmg
of
the

cyhnder
or

cylmders
that
read

low

usually
mdlcates

a
valve
not

properly
seat

mg
or
a
broken

piston
ring

Low

pressures
even

though
uniform

may

mdicate

worn

nngs
ThIS

IS

especlall
true
1f
ex

cessive
011

cQIlsumptlon
has
been
noticed
If
one

or
more

cylmders
read
low

or
uneven

inject

about
a

tablespoon
of

engine
ail

on

top
of
the

piston
of

that

cylinder
and
crank
the

engine

several
tlmes

noting
the

compressIOn
reading

If

compressIOn
has
nsen
the

piston

nngs
or

cylmders
are
worn
and
should

befserviced
If

compressIOn
has
not

unproved
after

addmg
oil

the
valves
are

Stlcking
or
are
not

seating

prop

erly

If
two

adjacent
cylmders
have
low

compres

sion
and

mjectmg
01

9es
not
increas
the
read

mg
the
head

gasket
between
the

cylmders
IS

probably
leaking

VALVE
CLEARANCE
ADJUSTMENT

Valve

adjustment
should
be
done
in
two

steps
first
With
the

engme
cold
and
then
at

operatmg
temperature
Refer
to

Figure
6

and

proceed
as
follows

1
Remove

arr
liter

2
Remove
rocker

arm
cover
Take

care
not
to

damage
the

gasket

3
Remove
the

spark
plugs
and

rotate
the
en

gine
unt1l
number
1

cylinder
IS
at

top
dead
center

o
l
the

compressIOn
stroke
This
can
be
de

tepnmed
w
hen
the

top
dead
center
mark
on

the
crankshaft

pulley
is

m

alignment
With
the

statIOnary

pomter
and
both
valves
for

number

1

cylmder
are
closed

I
4

Counting
from
the
front
of
the

engme
ad

Just
valves
1
2
3

and
5
as
follows
Loosen
the

pivot
lockmg
nut
and
turn
the

pivot
screw
unt1l

clearance
between
the

pivot
screw
and
the
rock

er
ann
IS
0
0079

m
0
200mm
for
the
mtake

valves
and

0
0098
in
0
25mm
for
the

exhaust

valves
Check

clearances
With

a
feeler

gauge
as

shawn
When
correct

tlghten
the

pivot
locking

nut

l

1

5
Rotate
the
crankshaft
unt1l
the
number
4

pISton
IS
at

top
dead

center
an
the

compressIOn

stroke
This

IS
one

complete
revolution
of
the

crankshaft

Agam
the
0

degree
mark
should

align
With
the

pomter
and
both

valves
on
num

ber
4

cylinder
should
be
closed

6

Adjust
valves
4
6
7
and
8

as
above

i

I

7

Replace
spark
plugs
Ignition
WIres

r
ick
r

1

arm
cover

gasket
and
air
filter

8
Start

engine
and

run
it
unt1l

operating
tem

perature
IS
reached

9
Remove
rocker

ann
cover
and

repeava
iius

ment
Clearances
should
be

0
0098

m
0

25fumj

for
the

mtake
valves
and
00Il8
m
0
30mi

for
the
exhaust
valves
Check
clearances
before

loosening
the

pivot
lockmg
nuts
as

they

may

already
be

properly
set
If

not

adjust
as
re

quir
l

ADDmONAL

CHECKS

l

Qunng
tune

ups
check
the

followmg
Ite

far

SignS
of
defects

or
excessive
wear
I

i

1

Inspect
the
carburetor
for

buildup
of

foreign

matenal

Pay
Special
attention
to
the

throat
and

linkages
Clean
or
overhaul
as

required
Det8
1ls

for
carburetor
mamtenance
are

given
in

Chapter

seven

26

CHAPTER

FOUR

2
Check
all
belts
hoses
and
fuellmes

Replace

If

reqUIred
Check
the
tensIon
of
the
belts
for

the
au

pump
and
the
alternator

Adjust
as
re

qUIred
Normal
deflection
of
the
belts
when
pushed
m

by
hand
should
be

approXImately
0
5

m

13mm
as
shown
m

Figure
7

3

Inspect
the
011
filter
for
leaks

TIghten
or
re

place
as

necessary
The
filter
should

replaced

at
least

every
6
000
mIles

4

Inspect
the

lIlr
cleaner

for
excessIve
accumu

latIon
of
dIrt

Replace
at

least

every
24
000
miles

under
normal

operatmg
cornhtIons

5

Carefully

mspect
the

water

pump
and

the

radIator
for

SIgnS
of

leaks

Repair
as

necessl
i
y

6
Check
the
emissIoo
control
deVice
If

so

eqwpped
Refer

to

Chapter
Ten
for

checks
and

tests

to
be
made

c

1

7
Check

engine
oIl

Replems
9
or

replace
as

reqUIred

8
Check
the

level
of
the
brake

fluid
m

the
brake

and

clutcJ1
master

cylmder
reservOirs

ReplenISh

as

necessary

ii
t

d

fl

tlJ

l

28

CHAPTER
FIVE

011

gallery
supphes
011
to
the
crankshaft
mam

beanngs
Dnlled

passages
m
the
crankshaft

direct
oil
from
the

mam

bearings
to
the

con

nectmg
rod

beanngs
011

mJected
from

jet
holes

in
the

connectIng
rods

IS
directed

to
the

cylmder

walls
and

piston
pins
0U
dlstnbuted
from
the

mam

gallery
enters
the
cham
tensioner
The

pad

IS
held

against
the
cham

by
011

pressure
and

spnng
tension
The

tmung
chain
receives
011

through
the

Jet
located
near
It

LubncatIon
IS

supphed
to
the

cyhnder
head

mam
011

gallery
through
the
crankshaft
center

beanngs
Camshaft

beanngs
on
the

cyhnder

head

are
fed

directly
from
the

cyhnder
head

mam

gallery
The
rocker

arms
and
valves
are

lubncated

intermittently

by
the
camshaft
011

gallery
and
the

small
channel
at
the
base
CIrcle

portIon
of
each
cam
OllIS

supphed
to
the
cam

shaft
011

gallery
through
the
No
2
and
No
3

camshaft

bearings

OIL
PUMP

The
011

pump
IS
mstalled
m
the
bottom
of

the

front
cover
as
shown
in
2
The

pump
is

held
m

place
by
four
bolts
to
the
front
cover
It

IS
a
rotor

type
dnven

by
the
011

pump
spmdle

whIch
IS
dnven
off
of
the
crankshaft
Pressure
IS

regulated
by
a
valve
shown

m

Figure
3
A
slot

at
the

top
of
the
dnve
rotor

engages
a

dog
clutch

at
the
lower
end
of
the
distnbutor
dnve
shaft

assembly
The

011

pressure
rehef
valve

IS
not

adjustable
In
the
released

pOSition
the
valve

pernnts
011
to
be

by
passed
through
a

passage
on

the

pump
cover
to
the
mlet
Side
of

the

pump

CD
CD

Oil

Pump
Removal

1
Remove
the
dIStnbutor
from
the

top
of
the

front

cover
Make
certam
to
mark
the

posItIon

of
the

dtstnbutor
relative
to
the

front
cover
so

that

It
can
be

replaced
m
the

same

posItIon

2
Drain
the

engme
od

3
Remove
the
front
stabIhzer
from
the
bottom

front
of
the

engme
compartment

4
Remove
the
front

splash
shIeld
from
the
bot

tom
front
of
the

engine
compartment

5
Remove
the
bolts

holdmg
the
oil

pump
to

the

front
cover
Remove
011

pump
and
drive

gear

spmdle
from
the
front
cover

Disassembly
Inspection
Repair
and

Assembly

Figure
4
IS
an

exploded
VIew
of
the
011

pump

assembly
Refer
to
the

figure
and
the

accom

panymg
index

1

Separate
the

body
cover
from
the

011

pump

body
by

unscreWIng
the

secunng
bolt

2
Remove
the

pump
dnve
mechamsm
and

dnver

gear
from
the

pump
body
Clean
the
dIS

assembled

parts
m
a
suitable
solvent

3

Inspect
for

Signs
of
wear
or

damage
Reparr

or

replace
as

necessary

4

Inspect
the
drive
rotor
shaft
for

excessive

wear
or

sconng
Check
the

followmg
clearances

a
Side

clearance
between
mner
and
outer

rotor
00020
to
00047
m
005
to

0
12mm

b

Tip
clearance
0
0492

m
0
12mm

c
elearance
between

outer
rotor
and

body

00059

to
0
0083
in
015
to
0
21mm

5
Check
the
relief
valve

spring
dtmenslOn
to

ensure
that
It
has
not
lost
tension

Free

length

should
be
2
24

m
57mm

Compressed

length

ENGINE
39

Figure
11
Remove
the
clutch
return

spnng
from

Its

holdmg
bracket
and
the
clutch

operatmg

cylmder
from
the
clutch
withdrawal
lever

19
Disconnect
the

speedometer
cable
from
the

side
of
the
transnnsslOn
as
shown
m

Figure
12

20
Disconnect
the
flat

attachmg
plug
connector

from
the
reverse

lamp
sWitch
on
the

translDlSSlon

housing

21
At
the
transnnsslOn

housmg
disconnect
the

shIft

and
the
select
rods
Remove
the
cross
shaft

assembly
by
remOVIng
Its
bracket
from
the
Side

member

22
DISconnect
the
front
exhaust

pipe
from
the

exhaust
manIfold

by
remoVing
the
two
connect

mg
bolts

23
Disconnect
the
center
exhaust

pipe
from
the

rear
exhaust

pipe

24
Remove
the
front
exhaust

pipe
the

pre
muffler
and
the
center
exhaust

pipe
from
the

vehicle

25
Disconnect
the
dnve
shaft
from
the

matIng

flange
of
the

gear
carner

26
Insert
a

Jack
under
the
transmiSSIOn
and

jack
It

up
Just
a
little
to
remove
some
of
the

tension
from
the
rear
motor
mounts

CAUTION

Use
care
m
the

placement
of
the

lack

head
to

prevent
transmiSSIOn

housmg

damage
A
block

of
wood
can
be
m

serted

between
the

Jack
head
and

transmISSIOn

for

protection
The
block

of
wood
should
be

long
enough
to

span
the
transmiSSion

housmg

27
Remove
the
rear

engine
mountIng
cross

member

by
remoVing
the
bolts

holdmg
the
en

gine
mountIng
msulator
the

mountIng
cross

member
and
the
handbrake

clamp

28
Remove
the
bolts

secunng
the
front

engine

mountmg
msulators
to
the
front
cross
member

NOTE
At
thiS
time
all
Wires
hoses

and

lmkages
should
have
been
dIScon

nected

from
the

engme
and
transmIS

sIOn

Recheck
thiS
and

make
sure
that

no
loose

ends
Will

hamper
actual
en

gme
removal

29

RIg
a
cham

or
cable
hOist
to
the

lifting
eyes

stnngers
located

on
the

nght
front
and
left

rear

of
the

cylmder
head
Take

up
slack
m
the
hOist

30

Figure
13
shows
the

engme
bemg
lifted
Re

move
the

engine
slowly
by
lowenng
the

jack

beneath
the
transnnssion

gradually
until
It
can

@

ENGINE
47

allowable

warpage
IS
0
0039
in
0
I
mm

Standard
should
be
less
than
0
0012
in

O
03mm
In
the
event
the
measurements
are

out
of
tolerance
the

cylmder
head
surface

should
be
milled

or
resurfaced

3

Verify
that
all
water
and
011

passages
are
free

of

foreign
matena

Use

compressed
aIr
to
clean

passages
after

scraping

4
Note
the
condition
of
all
studs
in
the

cylinder

head

Replace
damaged
ones

Valve

Assembly

I
Check
intake
and
exhaust
valve
assembhes

for
worn

damaged
or
deformed
valve

caps
and

stems
Correct
or

replace
the
valve
If
excessive

defects
exist

2
Measure
valve
stem
diameter
WIth
a
micro

meter
as
shown
in

Fignre
36

Figure
37

gives

cnncal
drmensions

@

@

Y

lm

1

0
515

r

3
Reface
the
valve
face
and
valve
stem

using
a

valve

grinder
as
18
shown
in

Fignre
38
NOTE

When
the
valve
head

1uzs

been
reduced
to
00197
in
0
Smm

or
less
In
thIckness

replace
the
valve

Grinding
allowance

for
the
valve
stem

end

surface
is
00197
In
0
Smm
or

less

4
Measure
the
free

length
and
tension
of
each

valve

spring
If
the
measured
values
exceed
the

hnuts

specified
below

replace
the

spring

SPRING
SPECIFICATIONS

Free
Length
Outel

Spring

Inner

Spring

Outer

Spring
2
0472
10

52
Omm

1
765710
44
85mm

153m
at6393
331Ib

389mm
at290

15kg

138m
at
2712
154lb

35mm
at12
3
0
7

kg

121
10
at
105
38
5
29
Ib

30
7mm
at
47
8
2
4
kg

09610
at5621
2871b

245mm
at

25
5
13

kg
Valve
Closed

I
nner

Spring

Outer

Spnng

Valve

Open

Inner
Spnng

5
Check
the

deformation
of
each

spnng
with
a

square
Replace
any
spnng
WIth
a
deflection
of

o
063
in
I

611lID
or
more

6
Check
all

workmg
surfaces
of
the
rocker
arms

for

damage
or
wear
If
defects

or

apparent
ex

cessIve
wear

are
found

replace
them
A
defective

PIvot
reqwres
It
S

replacement
along
WIth
the

correspondIng
rocker
ann

7
Measure
the
clearance
between
the

valve

gwde
and
the
valve
stem
If
the
clearance
ex

ceeds
hnuts

replace
the
worn

parts
or
both

ENGINE
49

Cylinder
Block

1
Check
the

cylmder
block
for
defects
such

as

cracks

leaky
soft

plugs
and

blocked
water

pass

ages
Blowout
all

passages
With

compressed
air

2
Measure
the
surface
of
the

cylinder
block

that
mates
with
the

cyhnder
head
for

warpage

Use
a

straight
edge
and
feeler

gauge
to
measure

clearance
as
shown

m

Figure
42
Surface
flat

ness
clearance
should
be
less
than
0
0020
m

0
05mm
Maxunum
allowable
is
0
0039
in

010mm
Resurface
the

cyhnder
block
if

beyond
hnnts

@

3
Use
a

bore

gauge
as
shown
m

Figure
43
to

measure
the
bore
of

each

cyhnder
Measure
near

the

top
at
the
center
and

near
the
bottom
If

excessive
wear

taper
or
out
of
round
exists

rebore
the

cyhnders
or

replace
the

cylinder

hners
Maxunum
wear
hnnt
of
a

cyhnder
bore
IS

o
0079
m
0

2mm
Standard
bore
IS
3
2677

0
0020
m
83
000
0
050mm
The
al

@
lowable
error
m
the

cyhnder
bore

taper
is

0
0006
in
0015mm
The
difference
between

the
four

cyhnder
bores
should
not
exceed
0
0020

in
0
05mm

NOTE
When

any
cylmder
needs
re

boring
all

foUT
must
be
rebored

4
If
the

cyhnder
bores
are
Wlthm
tolerances

use
a

ndge
reamer
to
remove
the

ndge
at
the

top
of
the

cyhnder
bores
and
then
hone
the

cyhnder
walls
to

complete
the

recolllhuonmg

Measure
the

cyhnder
bores
when

honmg
has

been
finished
to

venfy
that
allowable
tolerances

have
not
been
exceeded

Measuring
Bore

Below
is
a
method
for

checking
cntical
clear

ance
between

piston
and

cylinder
wall
Unless

you
are
familiar
With
such

work
call
m
an

expert
Clearance
should
be
between
0
0010
and

0
0018
m
0025

thrQugh
0
045mm

1
Insert
the

pISton
without

rings

upside
down

in
the

cyhnder
bore

2
Use
a
feeler

gauge
between
0
0010
and

00018
mches
thick

Insert
It
between
the

pISton

and
the

cylinder
wall
as
shown

m

Figure
and

attach
a

spring
gauge
as
illustrated

@

ENGINE
51

8

Figure
48
shows
the

pm
bemg
mserted
to

make
certam
that

It
can
be

pressed
m
at
room

temperature
by
hand
Piston

pm
clearance
to

piston
pm
should
be
between
0
0003
and
0
0004

m
0008
and
0
01Omm

NOTE
The

piston
pin
IS

fitted
to
the

connecting
rod
with
a

fitting
force
of

from
1
to
3
tons

of

pressure

Connecting
Rod

1

Inspect
all

connectmg
rods
for
flaws
or

obVIOUS

damage

2
Check
for

proper
alignment
as
shown

m

Fig

ure
49

RealIgn
as

necessary
ThIS
can
be
done

by
an
automotive
maclune

shop
Maxrmum

allowable
bend

m
the

connecting
rods
IS
0
0020

m
0
05mm

per
3
94

m
of

connecting
rod

length

@
3
Defects
m
the

piston
pm
hole

reqwre
replace

ment

of
the

connectmg
rod
Select
new
ones
so

that

weight
dIfference
between
new
and
old
IS

wlthm
0212
oz
6

gr

4
Install

beanngs
m
the
crankshaft
end
of
all

rods
Mount
the
rods
on
the
crankshaft
and

replace
beanngs
and
rod

caps
Install
bolts
and

tighten
Use
a
feeler

gauge
to
measure
end

play

between
the

connecting
rods
and
the
crankshaft

Figure
50
The
standard
measurement
should

be
between
00079
and
0
0118
m
02
and

0
3mm
Maximum
allowable
wear
IS
00118
m

0
3mm

Crankshaft

1
Check
the
crankshaft

journal
and
crank

pm

1
1

for
cracks
obVIOUS
wear
and
scratcheS

Repair

or

replace
defective

parts
I

2
Check
the
crankshaft
for
bend
If
the
bend

at
the
center

Journal
exceeds
0
0020

m

0
05mm
have
the
crankshaft

prOfeSSIOnally

straightened
or

replace
It

3
Check
crankshaft

Journals
and
crank

pms
for

out
of
round
and

taper
Figure
51
lIsts

speci

fications

Regnnd
the
crankshaft
1f
the

specIfica

tions
are
exceeded

by
more
than
00012

m

0
03mm

4

Replace
the

connecting
rod
and
mam
bear

mgs
With

proper
undersIZe

beanngs
If
the
crank

shaft
IS

reground
The

followmg
table

prOVides

data
for

beanng
replacement
based

on
the

final

sIZe
of
the
crankshaft

Journals
and
crank

pIllS

ENGINE
53

the
mam

beanng
cap
and
the

cyhnder
block

beanng
recess
and

tighten
the

cap
bolts
to
the

proper
torque
WIth
a

torque
wrench

Tig
temng

torque

Main

bearings
506
to
57
8
It
Ib

70to80kg
m

195
to
23
9
It
Ib

27
to3
3

kg
m
Rod

beanngs

9
Loosen
the

cap
bolt
on
one
Side
and
measure

the
clearance

Figure
53
between
the

cap
and

block
Side
Clearance
should
be
WIthm
the
fol

lowmg
specmcatIons
Mam

beanngs
0

through

o

0024
m
0
to
0
06mm
rod

beanngs
00012

through
0
0032
m
0
030
to
0
0024mm

Weight
@

10
If

beanng
crush
IS
not
m
tolerance

replace

the

beanngs

Crankshaft
and
Camshaft

Sprockets

1
Check
for

damaged
teeth

Replace
sprocket

1f

necessary

2
Install
the

camshaft

sprocket
and
check
for

runout
as
shown
m

Figure
54
If
over
0
04331

m
0
Imm

replace
the

sprocket
Check
for

thrust
deViation
at
the
same
tIme
Thrust
deVia

tIOn

should
be
between
0
0031
and
0
0150
m

008
to
0
38mm

3
Check
the
chain
for

damage
severe
wear

and
stretch
at
the
roller
hnks

Replace
the
cham

1f
defects
or
exceSSIve
stretch
IS
found

4
Check
the
cham
tenslOner
and
the
cham

gwdes
for
wear
and

damage

Flywheel

1
Check
the
clutch
disc
contact
surface
of
the

flywheel
for
wear
and

damage
@

2

Measure
deviation
of
the
clutch
disc
contact

surface

usmg
a
dial

gauge
If
deVIation
exceeds

004331
m
O
lmm

replace
the

flywheel

3
Check

flywheel
teeth
for

damage
Consult
a

dealer

Or
machIne

shop
1f
m
doubt

ENGINE
ASSEMBLY

This
section
covers

assembly
of
the

engme

after
corrective
mamtenance
has
been
com

pleted
SpecificatIons
and

torque
informatIon

are

given
at
the
end
of
the
sectIon
The

followmg

general
precautions
should
be
followed
m

assembhng
the

engme

1
Make
certam

all

parts
are

thoroughly
clean

and
that
all
011
and
water

passages
are
free
from

foreign
matenal

2
All

parts
that

slIde
mto
or

through
other

parts

should
be
coated
With
a
thm
film
of
new

engme

011
before

assembly

3
Don
t
reuse

gaskets
packIng
and
011
seals

Complete
lats
are
aVlUlable
for
the
entire

engme

and
for
the

cyhnder
head
and
block
assemblIes

4

Keep
tools
and
work
benches
clean
to
aVOid

contammatlon
of
delIcate

parts

5
Be

sure
to
follow

specmed
torque
tIghtenmg

values
and
order

of

tlghtenmg
where

given

6

Unless

complete
rebwld

of
the

engme
has

been
done
valves
and
associated

parts
bear

ings
pistons
and

connectIng
rods
should
be

remstalled
where

they
were
taken
from

CYLINDER

HEAD

Valve
and
Valve

Spring
Assembly

1
Insert
valve
from
bottom
of
block