DATSUN 510 1969 Service User Guide
Manufacturer: DATSUN, Model Year: 1969, Model line: 510, Model: DATSUN 510 1969Pages: 171, PDF Size: 10.63 MB
Page 11 of 171
it
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inter
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Fig
A
16
Correcting
the
valve
seats
Li4
lnlakt
t1
c
r
I
I
37
8
1
4882
di
410
6142
dia
Unit
rnrn
in
L14
and
L16
Exhaust
Ct
rill
I
II
ill
300
1Bll
du
l
32
6
1
2835
dia
37
1
4561
dia
Unll
In
Llb
thtwin
1
13
Ut
WiTh
Ie
ro
rLl
Incak
h
C
1
q
J
j
Exhaust
Fig
A
I
Standard
valve
seat
dimensions
U
l
and
liS
11tJ
1l
ioo
l
j
1
4
u
055i1
r
m
JA
9bIJUI4
l
9
611
559lldi
a
4L80
6457
dlll
45
J
1717
liS
311
fJ
90o
LJ
1
3
0
0512
r
1
II
I
i
30
n
Il
i1
I
tlla
32
60
2835
di
L
34
6
1
3622
dla
37
1
4561lia
Fig
A
IS
Valve
at
grinding
dimensions
10
Page 12 of 171
CYUNDER
HEAD
RECESS
DIAMETER
Standard
inoerts
Engine
L14
Ll6
and
Ll8
Inlet
41
000
41
016
1
6142
1
6148
in
45
000
45
016
mm
1
77l7
1
77231n
Engine
Ll4
Ll6
and
Ll8
Exhaust
37
000
37
016mm
1
4567
1
4573
in
37
000
37
016mm
l
4567
1
4573
in
CYLINDER
HEAD
RECESS
DIAMETER
Oversize
inserts
Engine
Ll4
Ll6andLl8
Inlet
41
500
41
516mm
l
6339
1
6345in
45
S00
45
516mm
I
7913
1
7920in
Engine
L14
Ll6andLl8
Exhaust
37
500
37
516mm
1
4764
14770in
37
500
37
516mm
1
4764
l4770in
Dimensions
for
the
standard
valve
inserts
are
shown
in
Fig
A
17
Heat
the
cylinder
head
to
a
temperature
of
ISO
20DOC
302
3920F
and
drive
in
the
inserts
making
sure
that
they
bed
down
correctly
The
inserts
should
be
caulked
at
more
than
four
positions
and
then
cuf
or
ground
to
the
specified
dimensions
shown
in
Fig
A
IS
Place
a
small
amount
of
fine
grinding
compound
on
the
seating
face
of
the
valve
and
insert
the
valve
into
the
valve
guide
Lap
the
valve
against
its
seat
by
rotating
it
backwards
and
forwards
approximately
half
a
revolution
in
each
direction
until
a
continous
seating
has
been
obtained
Remove
the
valve
and
clean
all
traces
of
the
grinding
compound
from
valve
and
seat
VALVE
SPRINGS
The
valve
springs
can
be
checked
for
squareness
using
a
steel
square
and
surface
plate
If
the
spring
is
out
of
square
by
more
than
1
6mm
0
063
in
it
must
be
replaced
Check
the
free
length
and
the
load
required
to
deflect
the
spring
to
its
assembled
height
Compare
the
figures
obtained
with
those
given
in
Technical
Data
and
replace
the
spring
if
the
specified
limits
are
exceeded
CAMSHAFT
AND
CAMSHAFT
BEARINGS
Checking
Measure
the
clearance
between
the
inner
diameter
of
the
camshaft
bearing
and
the
outer
diameter
of
the
camshaft
journal
If
the
wear
limit
for
the
bearing
clearance
exceeds
O
lmm
0
0039
in
it
will
be
necessary
to
replace
the
cylinder
block
assembly
See
Technical
Data
for
all
diameters
Check
the
camshaft
and
camshaft
journals
for
signs
of
wear
or
damage
ace
the
camshaft
in
V
Blocks
as
shown
in
Fig
A
19
and
position
the
dial
gauge
to
the
journal
The
run
out
of
the
cam
shaft
must
not
exceed
0
05
mm
0
0020in
It
should
be
noted
that
the
actual
run
out
will
be
half
the
the
value
indicated
on
the
dial
gauge
When
the
camshaft
is
turned
one
full
revolution
with
the
dial
gauge
positioned
against
the
second
and
third
journals
CYLINDER
BLOCK
Inspection
and
Overhaul
Ensure
that
the
cylinder
block
is
thoroughly
clean
and
check
it
for
cracks
and
flaws
Check
the
joint
face
of
the
block
for
distortion
using
a
straight
edge
and
feeler
gauge
as
shown
in
Fig
A
20
The
surface
must
be
reground
if
the
maximum
tolerance
of
O
lmm
0
0039
in
is
exceeded
Examine
the
cylinder
bores
for
out
of
round
or
taper
using
a
bore
gauge
as
shown
in
Fig
A
21
The
readings
must
be
taken
at
the
Top
middle
and
bottom
positions
indicated
in
Fig
A
22
The
standard
bore
diameters
are
83
000
83
050
rom
3
2677
3
3697
in
for
the
1400
and
1600cc
engines
and
85
000
85
050
mm
3
3465
3
3484
in
for
the
1800
cc
engine
with
a
wear
limit
of
0
2mm
0
0079
in
Out
of
round
and
taper
must
not
exceed
0
15mm
0
0006
in
If
the
bores
are
within
the
specified
limits
remove
the
carbon
ridge
at
the
top
of
the
cylinder
bores
wring
a
suitable
ridge
reamer
If
any
of
the
bores
are
in
excess
of
the
specified
limits
then
all
the
bores
must
be
rebored
at
the
same
time
Pistons
are
available
in
five
oversizes
See
Technical
Data
and
can
be
selected
in
accordance
with
the
amount
of
wear
of
the
cylinder
When
the
oversize
of
the
pistons
has
been
decided
it
will
be
necessary
to
measure
the
piston
at
the
piston
skirt
Fig
A
23
and
add
to
this
dimension
the
specified
piston
to
cylinder
bore
clearance
to
determine
the
final
honed
measurement
of
the
cylinder
Machine
the
cylinder
bores
in
gradual
stages
taking
only
a
0
5mm
0
002
in
cut
each
time
The
bores
must
be
brought
to
the
final
size
by
honing
and
the
block
thoroughly
cleaned
to
remove
all
traces
of
metal
Measure
the
finished
bore
and
check
the
clearance
between
each
piston
and
its
cylinder
The
clearance
can
be
checked
as
shown
in
Fig
A
24
with
the
aid
of
a
feeler
gauge
and
spring
scale
The
standard
clearance
is
0
023
0
043
mm
0
0009
0
0017
in
NOTE
Cylinder
liners
can
be
fitted
if
the
cylinder
bores
are
worn
beyond
the
maximum
limit
The
liners
are
an
interference
fit
in
the
block
and
must
be
bored
to
the
correct
inner
diameter
after
fitting
Three
undersize
liners
are
available
in
the
following
sizes
11
Page 13 of 171
y
t
interCE
MI
D
liPl
E
r
i
J
r
i
1
4
1
r
l
I
I
I
I
QJJ
I
ki
g
the
camshaft
for
run
out
Fig
A
19
Chec
n
I
I
I
y
Ii
der
bores
Fig
A
2
Measuring
lbe
cy
n
1
I
1l
or
r
i
r
m
O
1874
r
I
abllUI
O
I
I
Q
k
t
diameters
h
pistons
tr
F
A
23
Measunng
t
e
g
the
piston
ring
side
fi
A
25
Measurmg
g
clearance
12
k
oint
face
I
der
bloc
J
ki
gthecym
A20Chec
n
FIg
1
7
rb
I
tinder
ositions
for
the
cy
A
22
Measunng
p
F
g
bores
the
piston
ring
gap
A
26
Measunng
F
g
Page 14 of 171
OUTER
DIAMETER
4
0mm
0
1575
in
Undersize
4
5mm
0
1772
in
Undersize
5
Omm
0
1969
in
Undersize
87
000
87
05mm
3
4252
3
4272
in
87
50
87
55mm
3
4449
3
4468
in
88
00
88
05mm
3
4646
3
4665
in
PISTONS
Checking
Check
each
piston
for
signs
of
seizure
and
wear
Renew
BIlY
piston
which
is
unsatisfactory
Remove
all
carbon
deposits
from
the
grooves
and
piston
rings
Measure
the
side
clearance
of
each
piston
ring
and
groove
with
a
feeler
gauge
as
shown
in
Fig
A
25
If
the
side
clearance
is
excessive
new
rings
should
be
fitted
The
clearance
required
for
new
pistons
a
piston
rings
can
be
found
in
Technical
Data
Check
the
piston
ring
gap
by
placing
the
ring
in
the
cylinder
bore
as
shown
in
Fig
A
26
The
ring
can
be
squared
in
the
bore
by
pushing
it
into
position
with
the
piston
Measure
the
ring
gaps
with
a
feeler
gauge
and
compare
the
dimensions
with
the
infor
mation
given
in
Technical
Data
NOTE
If
new
piston
rings
are
to
be
fitted
and
the
cylinder
has
not
been
rebafed
check
the
piston
ring
gap
with
the
ring
positioned
at
the
bottom
of
the
cylinder
This
being
the
position
with
the
least
amount
of
wear
O1eck
the
clearance
between
gudgeon
pin
and
piston
If
the
specified
limit
is
exceeded
it
will
be
necessary
to
replace
both
piston
and
pin
It
should
be
possible
to
press
the
gudgeon
pin
into
the
piston
by
hand
at
a
room
temperature
of
200C
680F
The
pin
should
be
a
tight
press
fit
in
the
connecting
rod
CONNECTING
RODS
O1ecking
Cleck
the
connecting
rods
for
bends
or
twists
using
a
guitable
connecting
rod
aligner
The
maximum
deviation
should
not
exceed
0
05
mm
0
0020
in
per
100
mm
3
94
in
length
of
rod
Straighten
or
replace
any
rod
which
does
not
comply
with
the
specified
limit
When
replacing
the
connecting
rod
it
is
essential
to
ensure
that
the
weight
difference
between
new
and
old
rods
is
within
5
gr
0
18
oz
for
the
1400
cc
engine
and
7
gr
0
25
oz
for
the
1600
and
1800
cc
engines
Install
the
connecting
rods
with
bearings
to
the
correspond
ing
crank
pins
and
measure
the
end
play
of
the
big
ends
s
e
Fig
A
27
The
end
play
should
be
between
0
2
0
3
mm
0
0079
0
0118
in
fthe
maximum
limit
of
0
6
mm
0
Ql18
in
is
exceeded
the
connecting
rod
must
be
replaced
CRANKSHAFT
Inspection
and
Overhaul
aean
the
crankshaft
thoroughly
before
checking
the
shaft
for
distortion
and
cracks
Measure
the
journals
and
crankpins
for
our
of
round
If
the
journals
and
pins
are
found
to
be
oval
or
if
the
wear
limit
exceeds
the
specified
fUnning
clearance
it
will
be
necessary
to
re
llrind
the
crankshaft
to
the
required
undersize
See
Technical
I
INNER
DIAMETER
82
45
82
60mm
3
24613
2520
in
82
4S
82
60mm
3
24613
2520
in
82
4S
82
60mm
3
24613
2520
in
Data
Place
the
crankshaft
in
V
blocks
as
shown
in
Fig
A
28
and
check
with
the
aid
of
a
dial
gauge
that
the
shaft
bending
limit
of
0
05
mm
0
002
in
is
not
exceeded
With
the
dial
gauge
positioned
against
the
centre
journal
the
crankshaft
should
be
rotated
by
one
turn
The
actual
bend
value
will
be
a
half
of
the
reading
obtained
on
the
gauge
If
the
specified
limit
is
exceeded
it
will
be
necessary
to
replace
the
crankshaft
Install
the
crankshaft
in
the
cylinder
block
and
check
the
crankshaft
end
float
which
should
be
be
J
Yieen
0
05
0
18
mm
0
0020
0
0071
in
Make
sure
that
the
main
drive
shaft
pilot
bushing
at
the
rear
of
the
crankshaft
is
not
worn
or
damaged
in
any
way
Replace
the
bushing
if
necessary
using
the
special
puller
STl
66
1000
I
Thoroughly
clean
the
bushing
hole
before
installing
and
press
in
the
new
bushing
without
oiling
so
that
its
height
above
the
flange
end
is
4
5
5
0
mm
0
18
0
20
in
Main
bearing
clearance
The
main
bearing
clearances
can
be
checked
using
a
strip
of
plastigage
Set
the
main
bearings
on
the
caps
Cut
the
plasti
gage
to
the
width
of
the
bearing
and
place
it
along
the
crankpin
making
sure
that
it
is
clear
of
the
oil
hole
Install
the
bearing
caps
and
tighten
the
bearing
cap
bolts
to
a
torque
reading
of
4
5
5
5
kgm
33
40
Ib
ft
DO
NOT
turn
the
crankshaft
when
the
plastigage
is
inserted
Remove
the
main
bearing
cap
and
take
out
the
plastigage
which
should
be
measured
at
its
widest
po
t
with
the
scale
printed
in
the
plastigage
envelope
The
standard
clearance
is
0
020
0
062
mm
0
0008
0
0024
in
with
a
wear
limit
of
0
1
mm
0
0039
in
If
the
specified
limit
is
exceeded
an
undersize
bearing
must
be
used
and
the
crankshaft
journal
ground
accordingly
See
Technical
Data
Bearings
are
available
in
four
undersize
of
0
25
0
50
0
75
and
1
00
mm
0
0098
0
0197
0
0295
and
0
0394
in
Connecting
rod
bearing
clearance
The
connecting
rod
bearing
clearances
should
be
checked
in
a
similar
manner
to
the
main
bearing
clearances
The
standard
clearance
is
0
025
0
055
mm
0
0010
0
0022
in
with
a
wear
limit
of
0
1
mm
0
0039
in
Undersize
bearings
must
be
fitted
and
the
crankpins
reground
if
the
specified
wear
limit
is
ex
ceeded
See
Technical
Data
Bearings
are
available
in
six
under
sizes
of
0
6
0
12
0
25
0
50
0
75
and
1
00
mm
0
0236
0
0047
0
0098
0
0197
0
0295
and
0
0394
in
Fitting
the
crankshaft
bearings
Cb
eck
the
fit
of
the
bearing
shells
in
the
following
manner
Install
the
shells
on
the
main
bearing
caps
and
cylinder
block
bearing
recess
and
tighten
the
cap
bolts
to
the
specified
torque
13
Page 15 of 171
inter
Q1I
f
Q
I
ll
oJ
Fig
A
27
Olecking
the
big
end
play
Fig
A
28
Checking
the
crankshaft
for
run
out
Weight
Fig
A
29
Checking
the
bearing
crush
Fig
A
30
Checking
the
camshaft
sprocket
for
run
out
Fig
A
31
OIecking
the
camshaft
end
float
Fig
A
32
Installing
he
valves
14
Page 16 of 171
reading
Slacken
one
of
the
cap
bolts
and
check
the
clearance
between
the
cap
and
cylinder
block
with
a
feeler
gauge
See
Fig
A
29
The
bearing
crush
nip
should
be
between
0
0
03mm
0
0
0012
in
if
this
is
not
the
case
then
the
bearing
must
be
replaced
beck
the
connecting
rod
bearings
in
a
similar
manner
after
tightening
the
caps
to
the
specified
torque
readings
The
bearing
clearance
should
be
between
0
15
0
045
mm
0
0006
0
0018
in
CAMSIIAFf
AND
SPROCKET
Inspect
the
camshaftjoumals
for
signs
of
wear
or
damage
and
check
the
camshaft
for
run
out
using
a
dial
gauge
in
a
similar
manner
to
that
previously
described
for
the
crankshaft
The
bending
limit
of
0
02
mm
0
0007
in
must
not
be
exceeded
Install
the
camshaft
sprocket
mount
the
assembly
in
V
blocks
as
shown
in
Fig
A
30
and
check
that
the
run
out
of
the
sprocket
does
not
exceed
0
1
mOl
0
04331
in
O1eck
the
timing
chain
and
sprocket
to
ensure
that
the
chain
is
not
stretched
or
damaged
or
the
teeth
of
the
sprocket
damaged
or
distorted
A
timing
chain
which
has
become
stretched
will
affect
the
valve
timing
and
be
noisy
in
operation
Check
the
chain
tensioner
and
chain
guides
for
wear
and
damage
replacing
the
parts
if
necessary
Replace
the
sprocket
if
the
run
out
is
exceeded
or
if
the
teeth
of
the
sprocket
are
worn
or
damaged
in
any
way
The
camshaft
end
play
should
be
within
0
08
0
38
mm
0
0031
O
oI50
in
If
the
clearance
limit
of
0
1
mm
0
0039
in
is
exceeded
it
will
be
necessary
to
replace
the
cam
shaft
locating
plate
See
Fig
A
3l
FLYWHEEL
Inspecting
Ensure
that
the
clutch
disc
contact
face
of
the
flywheel
is
not
worn
or
damaged
The
run
out
of
the
flywheel
contact
face
should
not
exceed
0
2
mOl
0
008
in
when
measured
with
a
dial
gauge
The
flywheel
ring
gear
can
be
replaced
if
the
teeth
are
damaged
or
worn
This
operation
will
entail
splitting
the
ring
gear
to
remove
it
A
hacksaw
should
be
used
to
cut
between
the
teeth
followed
by
splitting
with
a
cold
chisel
When
replacing
the
ring
gear
it
must
be
heated
to
a
temperature
of
approximately
1800
2000
F
before
fitting
and
then
allowed
to
cool
slowly
ENGINE
Assembling
Before
starting
to
assemble
the
engine
make
sure
that
all
components
are
perfectly
clean
It
is
always
advisable
to
pay
particular
attention
to
the
following
points
when
assembling
an
engine
Keep
the
work
bench
and
tools
clean
and
make
sure
that
the
tools
are
to
hand
Ensure
that
all
engine
oil
ways
are
clear
of
foreign
matter
fit
new
gaskets
and
oil
seals
throughout
All
sliding
parts
such
as
bearing
shells
must
be
smeared
with
engine
oil
before
installing
B
Ensure
that
the
specified
tightening
torque
readings
are
strictly
followed
A
mbling
the
cylinder
Head
To
install
the
valves
and
valve
springs
place
the
valve
spring
seats
into
position
and
fit
the
valve
guides
and
oil
lip
seals
Assemble
in
the
following
order
valve
springs
spring
retainers
valve
collets
and
valve
rocker
guides
Use
the
special
compressor
ST
12070000
as
shown
in
Fig
A
32
to
compress
the
valve
springs
Piston
and
connecting
rods
The
piston
piston
pins
and
connectiJ1
rods
must
be
assembled
in
accordance
with
the
cylinder
numbers
The
gudgeon
pin
is
press
fitted
to
the
connecting
rod
and
requires
a
fitting
force
from
0
5
to
1
5
tons
This
operation
will
require
the
use
of
the
special
tool
ST
1303000
as
shown
in
Fig
A
33
Apply
engine
oil
to
the
gudgeon
pin
and
connecting
rod
before
fitting
It
should
be
noted
that
the
oil
jet
of
the
connecting
rod
big
end
must
face
towards
the
right
hand
side
of
the
cylinder
block
See
Fig
A
34
Fit
the
piston
rings
the
oil
control
ring
in
the
bottom
groove
followed
by
the
centre
and
top
compression
rings
which
must
be
installed
with
the
marks
facing
upwards
Install
the
connecting
rod
bearings
and
caps
making
sure
that
the
markings
coincide
Ensure
that
the
backs
of
the
bearing
shells
are
perfectly
clean
otherwise
they
will
be
damaged
when
tightened
Assembling
the
engine
Fit
the
baffle
plate
and
cylinder
block
net
Install
the
crankcase
halves
of
the
main
bearing
shells
the
flanged
shell
is
fitted
to
the
centre
bearing
Smear
the
bearing
surfaces
with
engine
oil
and
carefully
lower
the
crankshaft
into
position
Install
the
main
bearing
caps
with
their
shells
making
sure
that
the
arrow
on
the
caps
faces
to
the
front
of
the
engine
Rotate
the
crankshaft
to
settle
the
caps
and
tighten
the
bearing
cap
bolts
gradually
in
two
or
three
separate
stages
Work
out
wards
from
the
centre
bearing
and
finally
tighten
to
the
specified
torque
reading
of
4
5
5
5
kgm
32
40
Ib
ft
in
the
sequence
shown
in
Fig
A
35
Ensure
that
the
crankshaft
rotates
freely
after
finally
tightening
the
cap
bolts
Check
the
crankshaft
end
float
which
should
be
between
0
05
0
18
mm
0
002
0
0071
in
see
Fig
A
36
Smear
the
side
oil
seals
with
sealant
and
fit
them
into
the
rear
main
bearing
cap
Install
the
rear
oil
seal
using
a
suitable
drift
and
grease
the
lip
of
the
seal
Place
the
flywheel
in
position
and
install
the
lock
washers
and
retaining
baits
Tighten
the
bolts
evenly
to
a
torque
reading
of
14
16
kgm
101
106Ib
ft
Rotate
the
engine
by
a
quarter
turn
and
install
the
piston
15
Page 17 of 171
inter
Q1
jX
E
Fig
A
33
Installing
the
piston
pins
Fig
A
34
Piston
and
connecting
rod
cD
I
E
103470t
O
L
I
1
I
riC
J
lt
I
t
1
1
C
j
I
If
I
r
Fig
A
35
Bearing
cap
bolts
tightening
sequence
Fig
A
36
Installing
the
piston
and
connecting
rod
assembly
J
0
k2
CD
1
1
r
1
P
l
b
S
LM
J
Jr
T9T
J
I
J
@@@C@@
I
3
TimJn
mark
Lt
j
Location
hole
Oblonl
groon
I
I
Afteradju5tment
1
i
Before
adjustment
At
T
D
C
or
No
I
piston
Fig
A
37
Cylinder
head
bolts
tightening
sequence
Fig
A
38
Adjusting
the
camshaft
sprocket
Fig
A
39
Fitting
the
chain
tensioner
Fig
A
40
Valve
clearance
adjusting
16
Page 18 of 171
h
W
and
connecting
rod
assemblies
Use
a
piston
ring
compressor
to
install
the
pistons
through
the
top
of
the
cylbder
bore
Make
sure
that
the
pistons
and
rings
and
the
cylinder
bores
are
lubricated
with
clean
engine
oil
The
pistons
should
be
arranged
so
that
the
F
mark
faces
to
the
front
and
with
the
piston
ring
gaps
positioned
at
1800
to
each
other
Each
piston
must
be
refitted
into
its
original
bore
NOTE
Single
inlet
valve
springs
are
used
on
the
1400
cc
engine
double
valve
springs
are
used
on
the
1600cc
and
1800
cc
engines
Screw
the
valve
rocker
pivots
with
the
locknuts
into
the
pivot
bushing
Set
the
camshaft
locating
plate
and
install
the
camshaft
in
the
cylinder
head
with
the
groove
in
the
locating
plate
directed
to
the
front
of
the
engine
Install
the
camshaft
sprocket
and
tighten
it
together
with
the
fuel
pump
earn
to
a
torque
reading
of
12
16
kgm
86
116
IbJt
a
eck
that
the
camshaft
end
play
is
within
the
specified
limits
Install
the
rocker
arms
using
a
screwdriver
to
press
down
the
valve
springs
and
fit
the
valve
rocker
springs
Gean
the
joint
faces
of
the
cylinder
block
and
head
thoroughly
before
installing
the
cylinder
head
Turn
the
crank
shaft
until
the
No
1
piston
is
at
T
D
C
on
its
compression
stroke
and
make
sure
that
the
camshaft
sprocket
notch
and
the
oblong
groove
in
the
locating
plate
are
correctly
positioned
Care
should
be
taken
to
ensure
that
the
valves
are
clear
from
the
heads
of
the
pistons
The
crankshaft
and
camshaft
must
not
be
rotated
separately
or
the
valves
will
strike
the
heads
of
the
pistons
Temporarily
tighten
the
two
cylinder
head
bolts
1
and
2
in
Fig
A
37
to
a
torque
reading
of
2
kgm
14
5
lb
ft
Fit
the
crankshaft
sprocket
and
distributor
drive
gear
and
install
the
oil
thrower
Ensure
that
the
mating
marks
on
the
crankshaft
sprocket
face
towards
the
front
Install
the
timing
chain
making
sure
that
the
crankshaft
and
camshaft
keys
are
XJinting
upwards
The
marks
on
the
timing
chain
must
be
aligned
with
the
marks
on
the
right
hand
side
of
the
crankshaft
and
camshaft
sprockets
It
should
be
noted
that
three
location
holes
are
provided
in
the
camshaft
sprocket
See
Fig
A
38
The
camshaft
sprocket
being
set
to
the
No
2
location
hole
by
the
manufacturers
A
stretched
chain
will
however
affect
the
valve
timing
and
if
this
occurs
it
will
be
necessary
to
set
the
camshaft
to
the
No
3
location
hole
in
the
camshaft
sprocket
The
chain
can
be
checked
by
turning
the
engine
until
the
No
1
piston
is
at
T
D
C
on
its
compression
stroke
In
this
position
adjustment
will
be
required
if
the
location
notch
on
the
camshaft
sprocket
is
to
the
left
of
the
groove
on
the
camshaft
locating
plate
as
shown
in
the
illustration
The
correction
is
made
by
setting
the
camshaft
on
the
No
3
location
hole
in
the
camshaft
sprocket
the
No
3
notch
should
then
be
to
the
right
of
the
groove
and
the
valve
timing
will
have
to
be
set
using
the
No
3
timing
mark
Install
the
chain
guide
and
chain
tensioner
when
the
chain
is
located
correctly
There
should
be
no
protrusion
of
the
chain
tensioner
spindle
See
Fig
A
39
A
new
tensioner
must
be
fitted
if
the
spindle
protrudes
Press
a
new
oil
seal
into
the
timing
cover
and
fit
the
cover
into
position
using
a
new
gasket
Apply
sealing
compound
to
the
front
of
the
cylinder
block
and
to
the
gasket
and
to
the
top
of
the
timing
cover
Ensure
that
the
difference
in
height
between
the
top
of
the
timing
cover
and
the
upper
face
of
the
cylinder
block
does
not
exceed
0
15
mm
0
006
in
Two
sizes
of
timing
cover
bolts
are
used
the
size
M8
0
315
in
must
be
tightened
to
a
torque
reading
of
1
0
1
6
kgm
7
2
17
Ib
ft
and
the
size
M6
0
236
in
to
a
torque
reading
of
0
4
0
8
kgm
2
9
81b
ft
Install
the
crankshaft
pulley
and
water
pump
tighten
the
pulley
nut
to
a
torque
reading
of
12
16
kgm
86
8
115
7Ib
ft
then
set
the
No
1
piston
at
T
D
C
on
its
compression
stroke
Finally
tighten
the
cylinder
head
bolts
to
the
specified
torque
reading
in
accordance
with
the
tightening
sequence
shown
in
Fig
A
3
The
bolts
should
be
tightened
in
three
stages
as
follows
First
stage
Second
stage
Third
stage
4
kgm
28
9
lbJt
6
kgm
43
4
IbJ
t
6
5
85
kgm
47
0
61
5lb
ft
The
cylinder
head
bolts
should
be
retightened
if
necessary
after
the
engine
has
been
run
for
several
minutes
Install
the
oil
pump
and
distributor
drive
spindle
into
the
front
cover
as
described
under
Engine
Lubrication
System
r
rf
i
Install
the
fuel
pump
water
inlet
elbow
and
front
engine
slinger
Fit
the
oil
strainer
into
position
coat
the
oil
sump
gasket
with
sealing
compound
and
fit
the
gasket
and
oil
sump
to
the
cylinder
block
Tighten
the
oil
sump
bolts
in
a
diagonal
pattern
to
a
torque
reading
of
0
6
0
9
kgm
4
3
6
5
IbJt
Adjust
the
valve
clearances
to
the
specified
cold
engine
ftgures
following
the
procedures
described
under
the
appropriate
heading
Final
adjustments
will
be
carried
out
after
the
engine
has
been
assembled
completely
and
warmed
up
to
its
nonnal
temperature
Install
the
rear
engine
slinger
exhaust
manifold
and
inlet
manifold
Refit
the
distributor
and
carburettor
assemblies
as
described
in
their
relevant
sections
Install
the
fuel
pipes
and
vacuum
hose
making
sure
that
they
are
securely
cl
ped
Refit
the
thermostat
housing
thermostat
and
water
outlet
together
with
the
gasket
Bond
the
rocker
cover
gasket
to
the
rocker
cover
using
sealant
and
fit
the
rocker
cover
to
the
cylinder
head
Install
the
spark
plugs
and
connect
the
high
tension
leads
Fit
the
left
hand
engine
mounting
bracket
and
install
the
clutch
assembly
using
the
alignment
tool
ST20600000
to
fit
the
clutch
to
the
flywheel
as
described
in
the
section
ClUfCR
Lift
the
engine
away
from
the
mounting
stand
and
into
the
engine
compartment
Install
the
alternator
bracket
adjusting
bar
alternator
fan
pulley
fan
and
fan
belt
in
the
order
given
Check
the
tension
of
the
fan
belt
by
depressing
the
belt
at
a
point
midw
y
between
the
pulleys
The
tension
is
correct
if
the
belt
is
deflected
by
8
12
mm
0
3
0
4
in
under
thumb
pressure
Fit
the
right
hand
engine
mounting
bracket
the
oil
filter
oil
pressure
switch
oil
level
gauge
and
water
drain
plug
Take
care
not
to
overtighten
the
oil
nIter
or
leakage
will
occur
Fill
the
engine
and
gearbox
to
the
correct
levels
with
recommended
lubricant
and
refill
the
cooling
system
Adjust
the
ignition
timing
and
carburettor
as
described
in
the
appro
priate
sections
17
Page 19 of 171
inter
lmi
@
jl
Fig
A
41
Engine
lubrication
circuit
i
Punch
rmrk
Oil
hole
L
Fig
A
44
Aligning
the
oil
pump
spindle
18
II
l
o
CD
I
Fig
A
42
Component
parts
of
the
oil
pump
L
Pump
body
2
Inner
rotor
and
wft
3
OutO
rotor
4
Pump
coper
5
Reliefvalve
6
Relief
valve
Jpring
7
Washer
8
S
alp
9
ConT
613ut
I
Sideclruance
2
TIp
clearance
3
Guier
10
00
body
clearance
t
4
Rotor
to
bottom
cover
cleatance
Fig
A
43
Checking
the
rotor
clearance
Page 20 of 171
VALVE
CLEARANCES
Adjusting
Incorrect
valve
clearance
will
affect
the
performance
of
the
engine
and
may
damage
the
valves
and
valve
seats
Insuf
ficient
valve
clearance
will
result
in
loss
of
power
and
may
prevent
the
valve
from
seating
properly
Excessive
clearance
causes
the
valve
to
seat
and
reduces
the
amount
of
valve
lift
This
will
result
in
noisy
operation
with
damage
to
the
valves
and
seats
Adjustment
is
made
with
the
engine
switched
off
and
should
be
carried
out
initially
with
the
engine
cold
to
allow
the
engine
to
run
Final
adjustments
are
made
after
wanning
up
the
engine
to
its
Donnal
operating
temperature
The
engine
can
be
rotated
by
removing
the
sparking
plugs
to
release
the
cylinder
compressions
then
selecting
top
gear
and
pushing
the
vehicle
backwards
and
forwards
The
cold
valve
clearances
should
be
set
to
0
20
mm
0
0079
in
for
the
inlet
valves
and
0
25
mm
0
0098
in
for
the
exhaust
valves
Check
the
clearance
between
the
valve
and
rocker
using
a
feeler
gauge
as
shown
in
Fig
A
40
Slacken
the
locknut
and
turn
the
adjusting
screw
until
the
specified
clearance
is
obtained
then
tighten
the
locknut
and
recheck
the
clearance
The
feeler
gauge
should
just
be
free
to
move
between
the
rocker
and
valve
When
the
cold
valve
clearances
have
been
set
run
the
engine
until
it
reaches
its
normal
operating
temperature
then
switch
off
and
adjust
the
valve
clearances
with
the
engine
warm
to
0
25
mm
0
0098
in
for
the
inlet
valves
and
0
30
mm
0
0118
in
for
the
exhaust
valves
ENGINE
LUBRICATION
SYSTEM
Fig
A
41
OIL
PUMP
Removal
and
Dismantling
The
rotor
type
oil
pump
is
mounted
at
the
bottom
of
the
front
timing
cover
and
driven
by
the
distributor
drive
shaft
assembly
Overhaul
of
the
pump
will
require
careful
measurement
of
the
various
clearances
to
determine
the
amount
of
wear
which
has
taken
place
If
any
part
is
found
to
be
worn
it
may
be
neces
sary
to
replace
the
entire
oil
pump
assembly
To
remove
the
oil
pump
from
the
engine
proceed
as
follows
1
Remove
the
distributor
assembly
as
described
in
the
section
IGNITION
SYSTEM
Remove
the
oil
sump
drain
plug
and
drain
off
the
engine
oil
See
under
the
heading
CHANGING
THE
ENGINE
OIL
2
Remove
the
front
stabiliser
and
the
splash
shield
board
3
Withdraw
the
securing
bolts
and
detach
the
oil
pump
body
together
with
the
drive
gear
spindle
Take
out
the
bolts
securing
the
pump
cover
to
the
pump
body
and
withdraw
the
rotors
and
drive
shaft
See
Fig
A
42
The
pin
securing
the
driven
shaft
and
inner
rotor
must
not
00
taken
out
as
the
shaft
is
press
fitted
to
the
rotor
and
the
pin
is
caulked
Unscrew
the
threaded
plug
and
withdraw
the
regulator
valve
and
spring
Oean
each
part
thoroughly
and
examine
for
signs
of
damage
or
wear
Use
a
feeler
gauge
to
check
the
side
clearances
between
the
outer
and
inner
rotors
the
clearances
at
the
tips
of
the
rotors
and
the
clearance
between
the
outer
rotor
and
the
pump
body
See
Technical
Data
for
the
relevant
clearances
The
clearances
can
be
checked
using
a
straight
edge
as
shown
in
Fig
A
43
OIL
PUMP
Assembly
and
Installation
Assembly
is
a
reversal
of
the
dismantling
procedure
Before
installing
the
oil
pump
in
the
engine
it
will
be
necessary
to
rotate
the
engine
until
the
No
1
piston
is
at
T
D
C
on
its
compression
stroke
Fill
the
pump
housing
with
engine
oil
and
align
the
punch
mark
on
the
spindle
with
the
hole
in
the
oil
pump
as
shown
in
Fig
A
44
Install
the
pump
with
a
new
gasket
and
tighten
the
securing
bolts
to
a
torque
reading
of
1
1
1
5
kgm
8
1
Ilb
ft
Replace
the
splash
shield
board
and
the
front
stabiliser
refill
the
engine
with
the
specified
amount
of
engine
oil
OIL
FILTER
The
cartridge
type
oil
filter
can
be
removed
with
the
special
tool
ST
19320000
or
a
suitable
filter
remover
Interior
cleaning
is
not
necessary
but
the
ftIter
body
and
element
must
be
repiaced
every
10
000
km
6000
miles
Be
care
ul
not
to
overtighten
the
filter
when
replacing
or
oil
leakage
may
occur
CHANGING
THE
ENGINE
OIL
After
the
fIrst
oil
change
which
should
take
place
at
1000
km
600
miles
the
oil
should
be
changed
regularly
at
5000
km
3000
miles
intervals
Draining
is
more
easily
accomplished
after
a
lengthy
run
when
the
oil
being
thoroughly
warm
will
flow
quite
freely
Stand
the
vehicle
on
level
ground
and
place
a
suitable
container
under
the
drain
plug
Remove
the
drain
plug
carefully
as
the
hot
oil
may
spurt
out
with
considerable
force
When
refIlling
the
engine
make
sure
that
the
oil
is
to
the
H
mark
on
the
dipstick
19