clutch DATSUN 510 1969 Service Repair Manual
[x] Cancel search | Manufacturer: DATSUN, Model Year: 1969, Model line: 510, Model: DATSUN 510 1969Pages: 171, PDF Size: 10.63 MB
Page 4 of 171
inteN
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Index
ENGINE
COOLING
SYSTE
l
IGNITION
SYSTE
I
FUEL
SYSTBl
CLUTCH
GEARUOX
PROPELLER
SHAFT
Id
DIFFERENTIAL
REAR
AXLE
nd
REAR
SUSPENSION
FRONT
SUSPENSION
STEERING
BRAKING
SYSTEM
ELECTRICAL
EQUIP
JENT
WIRING
JAGRA
IS
TROUBLE
SHOOTING
TIGHTENING
TORQUES
SERIES
C
30
MODEL
SUPPLEMENT
AUTOSERVlCE
DATA
CHART
PART
NA
ES
nd
ALTERNATIVES
CONVERSION
TABLES
S
15
2S
33
43
51
62
7S
83
91
9S
lOB
liB
I2S
129
51
End
of
manuir
IntroductIon
OUf
intention
in
writing
this
Manual
is
to
provide
the
reader
with
all
the
data
and
in
formation
required
to
maintain
and
repair
the
vehicle
However
it
must
be
realised
that
special
equipment
and
skills
arc
required
in
some
caseS
to
carry
out
the
work
detailed
in
the
text
and
we
do
not
recommend
that
such
work
be
attempted
unless
the
reader
possesses
the
necessary
skill
and
equipment
It
would
be
better
to
have
an
AUTHQRISED
DEALER
to
carry
out
the
work
using
the
special
tools
and
equipment
available
to
his
trained
staff
He
will
also
be
in
possession
of
the
genuine
spare
parts
which
may
be
needed
for
replacement
The
information
in
the
Manual
has
been
checked
against
that
provided
by
the
vehicle
manufacturer
and
any
peculiarities
have
been
mentioned
if
they
depart
rom
usual
work
shop
practice
A
fault
finding
and
trouble
shooting
chart
has
been
inserted
at
the
end
of
the
Manual
to
enable
the
reader
to
pin
point
faults
and
so
save
time
As
it
is
impossible
to
include
every
malfunction
only
the
more
usual
ones
have
been
included
A
composite
conversion
table
has
also
been
included
at
the
end
of
the
manual
and
we
would
recommend
that
wherever
possible
for
greater
accuracy
the
metric
system
units
are
used
Brevity
and
simplicity
have
been
our
aim
in
compiling
this
Manual
relying
on
the
number
ous
illustrations
and
clear
text
to
inform
and
instruct
the
reader
At
the
request
of
the
many
users
of
our
Manuals
we
have
slanted
the
book
towards
repair
and
overhaul
rather
than
maintenance
Although
every
care
has
been
taken
to
ensure
that
the
information
and
data
are
correct
WE
CANNOT
ACCEPT
ANY
LIABILITY
FOR
INACCURACIES
OR
OMISSIONS
OR
FOR
DAMAGE
OR
MALFUNCTIONS
ARISING
FROM
THE
USE
OF
THIS
BOOK
NO
MATTER
HOW
CAUSED
I
3
Page 6 of 171
EngIne
INTRODUCTION
ENGINE
Removal
ENGINE
DismantUng
ENGINE
Inspection
and
Overhaul
VALVES
VALVE
GUIDES
VALVE
SEAT
INSERTS
CAMSHAFT
AND
CAMSHAFT
BEARINGS
Checking
CYliNDER
BLOCK
PtSTONS
AND
CONNECTING
RODS
INTRODUCTION
The
1400
1600
cc
and
1800
cc
engines
are
four
cylinder
in
line
units
with
a
single
overhead
camshaft
and
fully
balanced
five
bearing
crankshaft
The
valves
are
operated
through
rockers
which
are
directly
activated
by
the
earn
mechanism
The
crankshaft
is
a
special
steel
forging
with
the
centre
main
bearing
equipped
with
thrust
washers
to
take
up
the
end
thrust
of
the
crankshaft
The
special
aluminium
pistons
are
of
the
strut
construction
to
control
thermal
expansion
and
have
two
compression
rings
and
one
combined
oil
ring
The
gudgeon
pins
have
special
hollow
steel
shafts
and
are
a
fully
floating
fit
in
the
pistons
and
a
press
fit
in
the
connecting
rods
The
aluminium
alloy
cylinder
head
contains
wedge
type
combustion
chambers
and
is
fitted
with
aluminium
bronze
valve
seats
for
the
intake
valves
and
heat
resistant
steel
valve
seats
for
the
exhaust
valves
The
cast
iron
camshaft
is
driven
by
a
double
row
roller
chain
from
the
crankshaft
pulley
The
engine
is
pressure
lubricated
by
a
rotor
type
oil
pump
which
draws
oil
through
an
oil
strainer
into
the
pump
housing
and
then
forces
it
through
a
full
flow
oil
filter
into
the
main
oil
gallery
ENGINE
Removal
Place
alignment
marks
on
the
bonnet
and
hinges
remove
the
bonnet
from
the
vehicle
2
Drain
the
cooling
system
and
engine
and
transmission
lubricant
Remove
the
radiator
grille
3
Discon
ect
the
battery
cables
and
lift
out
the
battery
4
Detach
the
upper
and
lower
radiator
hoses
remove
the
radiator
mounting
bolts
and
lift
the
radiator
away
from
the
vehicle
The
torque
converter
c
jng
pipes
must
be
disconnected
from
the
radiator
on
vehicles
fitted
with
automatic
transmission
S
Remove
the
COOling
fan
and
pulley
disconnect
the
fuel
pipe
from
the
fuel
pump
and
the
heater
hoses
from
the
engine
attachments
6
Disconnect
the
accelerator
control
linkage
and
the
choke
CRANKSHAFT
AND
MAIN
BEARINGS
CAMSHAFT
AND
SPROCKET
FLYWHEEL
ENGINE
Assembling
VALVE
CLEARANCES
Adjusting
ENGINE
LUBRICATION
SYSTEM
OIL
PUMP
OIL
FILTER
CHANGING
THE
ENGINE
OIL
cable
from
the
carburettor
7
Disconnect
the
wirings
from
the
starter
alternator
ignition
coil
oil
pressure
switch
and
temperature
sender
unit
8
Remove
the
clutch
slave
cylinder
Fig
A
2
and
its
return
spring
9
Disconnect
the
speedometer
cable
and
withdraw
the
plug
connector
from
the
reversing
light
switch
10
Disconnect
the
shift
rods
and
seJector
rods
and
remove
the
cross
shaft
assembly
as
described
in
the
section
Gear
box
II
Disconnect
the
front
exhaust
pipe
from
the
exhaust
manifold
disconnect
the
centre
pipe
from
the
rear
pipe
and
remove
the
front
pipe
pre
muffler
and
centre
pipe
assembly
12
Disconnect
the
propeUer
shaft
flange
from
the
companion
flange
from
the
gear
carrier
13
Jack
up
the
gearbox
slightly
and
remove
the
rear
engine
mounting
bracket
bolts
remove
the
mounting
cross
member
and
handbrake
cable
c1amp
14
Remove
the
bolts
securing
the
front
engine
mounting
brackets
to
the
crossmember
15
Attach
lifting
cable
or
chains
to
the
hooks
installed
at
the
front
and
rear
of
the
cylinder
head
Lower
the
jack
under
the
gearbox
and
carefully
lift
and
tilt
the
engine
and
gearbox
unit
Withdraw
the
engine
and
gearbox
from
the
compartment
making
sure
that
it
is
guided
past
the
accessories
installed
on
the
body
ENGINE
Dismantling
Remove
the
engine
as
previously
described
and
carefully
clean
the
exterior
surfaces
Cbeck
for
signs
of
fuel
oil
or
water
leaks
past
the
cylinder
head
and
block
Remove
the
air
cleaner
alternator
distributor
and
starter
motor
Plug
the
carburettor
air
horn
and
distributor
hole
to
prevent
the
ingress
of
foreign
matter
Remove
the
gearbox
from
the
engine
drain
the
engine
oil
and
coolant
Mount
the
engine
in
a
suitable
stand
the
special
engine
attachment
ST05260001
and
engine
ST0501SOO0
should
be
used
if
available
Fig
A
3
5
Page 8 of 171
fl
J
J
f
1
ST052fiOOOl
Fig
A
2
Removing
the
clutch
slave
cylinder
Fig
A
3
Mounting
the
engine
STI
0
120000
CI
@
j
91
7
m
I3L
I
T
IC
t
J
i1
C
J
6
i
11
j
1
j
4
I
U
O
J
I
Ll
LJJ
1r9i
V
@
1
EM092
Fig
AA
Removing
the
camshaft
sprocket
Fig
A
5
Cylinder
head
bolt
removal
sequence
t
J1
I
J
1
1
i
I
G
qt
7
r
J
O
I
IS
Fig
A
6
Removing
the
chain
tensioner
and
timing
chain
Fig
A
7
Removing
the
drive
sprocket
7
Page 10 of 171
Remove
the
fan
and
pulley
the
right
hand
engine
mounting
and
oil
filter
Remove
the
oil
pressure
switch
Remove
the
following
items
oil
level
gauge
spark
plugs
thermostat
housing
rocker
cover
carburettor
and
inlet
and
exhaust
manifolds
Remove
the
clutch
assembly
as
described
in
the
section
CLUTCH
Remove
the
left
hand
engine
mounting
crankshaft
pulley
water
pump
fuel
pump
fuel
pump
drive
earn
and
cam
shaft
sprocket
See
Fig
A
4
Remove
the
cylinder
head
bolts
in
the
sequence
shown
in
Fig
A
5
and
lift
off
the
cylinder
head
Invert
the
engine
and
remove
the
oil
sump
and
oil
strainer
oil
pump
and
drive
spindle
assembly
front
cover
and
chain
tensioner
Remove
the
timing
chain
oil
thrower
crank
shaft
worm
gear
and
chain
drive
sprocket
See
Fig
A
6
andA
7
Remove
the
connecting
rod
caps
and
push
the
pistons
and
connecting
rods
through
the
top
of
the
bores
as
shown
in
Fig
A
B
Keep
the
connecting
rod
caps
with
their
respective
rods
to
ensure
that
they
are
assembled
in
their
original
positions
Remove
the
flywheel
retaining
bolts
and
withdraw
the
fly
wheel
Fig
A
9
Remove
the
main
bearing
caps
using
the
special
puller
ST
1651
SOOO
to
withdraw
the
centre
and
rear
main
bearing
caps
as
shown
in
Fig
A
l
O
Remove
the
rear
oil
seal
and
lift
out
the
crankshaft
remove
the
baffie
plate
and
cylinder
block
net
Fig
A
II
Remove
the
piston
rings
with
a
suitable
expander
and
press
out
the
gudgeon
pins
under
an
arbor
press
using
the
special
stand
STl300001
as
shown
in
Fig
A
12
Keep
the
dismantled
parts
in
order
so
that
they
can
be
reassembled
in
their
original
positions
Slacken
the
valve
rocker
pivot
lock
nut
and
remove
the
rocker
arms
by
pressing
down
the
valve
springs
Remove
the
camshaft
taking
care
not
to
damage
the
bearings
and
earn
lobes
Withdraw
the
valves
using
the
valve
lifter
STl2070000
as
shown
in
Fig
A
13
ENGINE
Inspection
and
Overhaul
Cylinder
Head
and
Valves
Clean
all
parts
thoroughly
and
remove
carbon
deposits
with
a
blunt
scraper
Remove
any
rust
which
has
accumulated
in
the
water
passages
and
blow
through
the
oil
holes
with
compres
sed
air
to
make
sure
that
they
are
clear
Measure
the
joint
face
of
the
cylinder
head
for
out
of
true
as
shown
in
Fig
A
14
The
surface
should
be
checked
at
various
positions
using
a
straight
edge
and
feeler
gauge
The
permissible
amount
of
distortion
is
0
05
mm
0
0020
in
or
less
If
the
surface
is
out
of
true
by
more
than
the
limit
of
0
1
mm
0
0039
in
it
will
be
necessary
to
regrind
the
head
Clean
each
valve
by
washing
in
petrol
and
carefully
examine
the
stems
and
heads
If
the
stem
is
worn
damaged
or
not
straight
the
valve
must
be
discarded
Check
the
diameter
of
the
stem
with
a
micro
meter
The
diameter
of
the
inlet
valves
should
be
7
965
7
980
mm
0
3136
0
3142
in
and
the
diameter
of
the
exhaust
valves
7
945
7
960
mm
0
3128
0
3134
in
If
the
seating
face
of
the
valve
is
excessively
burned
damaged
or
distorted
it
must
be
discarded
A
badly
pitted
seating
face
should
be
refaced
on
a
valve
grinding
machine
removing
only
the
minimum
amount
of
metal
Renew
the
valve
if
the
thickness
of
the
valve
head
has
been
reduced
by
0
5
mm
0
0197
in
see
Technical
Data
for
valve
dimensions
The
valve
stem
tip
may
be
refaced
if
necessary
the
maxi
mum
allowance
however
is
0
5
mm
0
0197
in
The
valves
can
be
ground
in
to
their
seats
when
completely
satisfactory
The
valve
seats
and
valve
guides
should
be
in
good
condition
and
must
be
checked
as
described
in
the
following
paragraphs
VALVE
GUIDES
Replacement
The
valve
stem
to
valve
guide
clearance
can
be
checked
by
inserting
a
new
valve
into
the
guide
The
stem
to
guide
clearance
should
be
0
020
0
053
mm
0
0008
0
0021
in
for
the
inlet
valves
and
0
040
0
073
mm
0
0016
0
0029
in
for
the
exhaust
valves
If
the
clearance
exceeds
0
1
mm
0
0039
in
for
the
inlet
valves
and
the
exhaust
valves
then
new
guides
should
be
fitted
The
valve
guides
are
held
in
position
with
an
interference
fit
of
0
027
0
049
mm
0
0011
0
0019
in
and
can
be
removed
by
means
of
a
press
and
drift
2
ton
pressure
This
operation
can
be
carried
out
at
room
temperature
but
will
be
more
effectively
performed
at
a
higher
temperature
Valve
guides
are
available
with
oversize
diameters
of
0
2
mm
0
0079
in
if
required
The
standard
valve
guide
requires
a
bore
in
the
cylinder
head
of
11
985
11
996
mm
dia
0
4719
0
4723
in
dia
and
the
oversize
valve
guide
a
bore
of
12
185
12
196
mm
dia
0
4797
0
4802
in
dial
The
cylinder
head
guide
bore
must
be
reamed
out
at
normal
room
temperature
Heat
the
cylinder
head
to
a
temperature
of
150
2000e
302
3920F
before
pressing
in
the
new
valve
guides
Ream
out
the
bore
of
the
guides
to
obtain
the
desired
fInish
and
clearance
Fig
A
IS
The
special
valve
guid
reamer
ST
1103
SOOO
should
be
used
if
available
Valve
guide
inner
diameters
are
specified
in
Technical
Data
at
the
end
of
this
section
The
valve
seat
surface
must
be
concentric
with
the
guide
bore
and
can
be
corrected
with
the
facing
tool
STll670000
Fig
A
16
using
the
new
valve
guide
as
the
axis
VALVE
SEAT
INSERTS
Replacing
The
valve
seat
inserts
should
be
replaced
if
they
show
signs
of
pitting
and
excessive
wear
The
inserts
can
be
removed
by
boring
out
to
a
depth
which
will
cause
them
to
collapse
although
care
must
be
taken
not
to
bore
beyond
the
bottom
face
of
the
recess
in
the
cylinder
head
Select
the
valve
seat
inserts
and
check
the
outer
diameters
Machine
the
recess
in
the
cylinder
head
to
the
following
dimensions
at
room
temperature
9
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 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 44 of 171
Clutch
DESCRIPTION
CLUTCH
Removal
and
Dismantling
CLUTCH
Inspection
and
Adjustment
CLUTCH
Installation
CLUTCH
PEDAL
Removal
and
Installation
DESCRIPTION
Either
a
diaphragm
spring
or
coil
spring
type
clutch
is
fitted
to
the
vehicle
The
component
parts
of
the
diaphragm
spring
clutch
are
shown
in
Fig
E
l
and
the
component
parts
of
the
coil
spring
clutch
are
shown
in
Fig
E
2
The
clutch
is
of
the
single
dry
plate
type
consisting
of
the
drive
plate
clutch
coveT
and
pressure
plate
and
release
bearing
The
driven
plate
comprises
a
flexible
disc
and
splined
hub
which
slides
on
the
clutch
shaft
Friction
linings
are
rivetted
to
both
sides
of
the
disc
The
clutch
cover
and
pressure
plate
are
combined
by
nine
spring
setting
bolts
The
diaphragm
is
dished
to
maintain
a
constant
pressure
on
the
pressure
plate
which
in
turn
holds
the
driven
plate
in
contact
with
the
flywheel
The
release
bearing
is
a
sealed
type
ball
bearing
mounted
on
a
bearing
sleeve
Both
bearing
and
sleeve
are
operated
by
the
withdrawalleveT
when
the
clutch
pedal
is
operated
The
clutch
pedal
actuates
a
master
cylinder
which
transmits
fluid
under
pressure
to
a
slave
cylinder
The
movement
of
the
slave
cylinder
piston
operates
the
clutch
withdrawal
lever
via
a
push
rod
See
Fig
E
14
CLUTCH
Removal
and
Dismantling
The
gearbox
must
be
removed
from
the
vehicle
before
the
clutch
can
be
withdrawn
The
procedures
for
removing
the
gearbox
can
be
found
in
the
section
GEARBOX
If
a
diaphragm
clutch
is
fitted
insert
a
spare
clutch
shaft
or
a
special
alignment
tool
ST20600000
into
the
splines
of
the
driven
plate
So
that
the
dutch
is
supported
Slacken
the
six
bolts
securing
the
clutch
cover
to
the
flywheel
by
a
single
turn
at
a
time
and
in
a
diagonal
pattern
until
the
spring
pressure
is
relieved
Remove
the
bolts
completely
and
lift
away
the
clutch
assembly
When
removing
the
coil
spring
type
clutch
it
will
be
necessary
to
insert
suitable
hooks
under
the
release
levers
to
restrain
the
tension
of
the
clutch
spring
before
removing
the
clutch
cover
lx
llts
Ensure
that
the
friction
linings
of
the
driven
plate
do
not
become
comtaminated
with
oil
or
grease
when
removing
the
plate
from
the
splined
shaft
Diaphragm
clutch
The
clutch
cover
and
pressure
plate
assembly
should
not
be
dismantled
and
must
be
replaced
if
wear
or
damage
has
occurred
Make
sure
that
the
friction
face
of
the
pressure
plate
CLUTCH
PEDAL
Adjusting
CLUTCH
MASTER
CYLINDER
CLUTCH
SLAVE
CYLINDER
CLUTCH
WITHDRAWAL
LEVER
Adjusting
CLUTCH
SYSTEM
Bleeding
is
perfectly
flat
and
smooth
Coil
spring
clutch
A
special
tool
No
ST200S0000
is
available
to
ensure
that
the
clutch
can
be
dismantled
and
accurately
reassembled
The
tool
shown
in
Fig
E
3
consists
of
a
Base
plate
I
Centre
spigot
2
Distance
pieces
3
Height
gauge
4
Operating
lever
5
Securing
bolts
6
A
chart
is
included
to
indicate
the
various
parts
to
be
used
for
each
type
of
clutch
To
dismantle
the
clutch
place
the
distance
pieces
on
the
base
plate
as
shown
and
arrange
the
clutch
cover
on
the
base
plate
so
that
the
cover
holes
coincide
with
the
threaded
holes
in
the
base
plate
Insert
the
securing
bolts
provided
in
the
kit
and
tighten
them
gradually
and
evenly
in
a
diagonal
pattern
until
the
cover
is
firmly
attached
to
the
base
plate
Mark
the
clutch
cover
the
pressure
plate
lugs
and
the
release
levers
with
a
centre
punch
so
that
they
can
be
reassembled
in
their
original
positions
Remove
the
restraining
hooks
from
the
release
levers
and
unscrew
the
three
nuts
from
the
eye
bolts
Slowly
release
the
pressure
on
the
clutch
coil
springs
by
unscrewing
the
bolts
securing
the
cover
to
the
base
plate
and
lift
off
the
cover
springs
and
pressure
plate
CLUTCH
Inspection
and
Adjustment
Use
a
solvent
to
clean
the
dismantled
parts
with
the
exception
of
the
disc
linings
and
the
release
bearing
Check
the
clutch
cover
diaphragm
spring
and
pressure
plate
assembly
for
wear
or
damage
and
renew
the
complete
assembly
if
necessary
The
pressure
plate
on
the
coil
spring
clutch
can
be
lapped
if
necessary
as
described
below
Ensure
that
the
disc
rivets
are
not
loosened
and
inspect
the
linings
for
contamination
Grease
or
oil
should
be
removed
and
the
linings
dressed
using
a
wire
brush
Check
the
disc
for
run
ut
using
a
dial
gauge
as
shown
in
Fig
E
4
Position
the
dial
gauge
at
a
point
approximately
9Smm
3
74
in
from
the
centre
of
the
disc
and
check
that
the
run
out
does
not
exceed
the
permissible
limit
of
0
5
mm
0
02in
A
slight
deflection
can
be
corrected
by
hand
pressure
with
the
disc
mounted
on
the
gearbox
shaft
The
disc
must
be
renewed
or
relined
if
the
height
of
the
linings
above
the
rivets
is
less
than
0
3mm
0
012
in
Replace
the
bearing
sleeve
if
it
shows
signs
of
wear
at
the
point
of
contact
with
the
withdrawal
lever
Replace
the
release
bearing
if
grease
is
leaking
from
it
or
if
it
is
noisy
when
turned
43
Page 45 of 171
inter
llD
i
@
p1
11
l
1
14
l
1
Clutch
driven
pc
e
2
Qutch
assembly
3
Dutch
cover
4
Pressure
plate
5
Bolt
6
Eye
bolt
pivot
pin
81
r
Fig
E
I
The
diaphragm
spring
clutch
1
C7utch
driven
platt
2
Dutch
COl
tT
with
pnsmre
plate
3
8011
4
Lock
washer
5
Withdrawal
lacr
6
Retainer
spring
7
BeaMI
u
ve
8
Relmsf
bearing
9
Beving
s
vc
holder
spring
10
Dust
co
r
11
Fig
E
2
The
coil
spring
clutch
7
Inssure
spring
8
Spring
tainer
9
Release
In
O
10
Retf
t1sc
InleT
seat
11
Locknut
12
Releme
lever
support
19
R
hmr
beDrin8
20
Retaining
clip
21
DllJt
xw0
22
Return
sprint
23
Locknut
24
Wil
u
lnrrJ
raJ
Inn
pusher
44
13
Retaining
SProw
14
8011
15
LockwruheT
16
CTutch
withdrawal
lever
17
Retainer
spring
18
B
ng
sJ
Page 46 of 171
The
coil
spring
clutch
pressure
plate
can
be
lapped
with
a
surface
grinder
to
remove
dents
or
scratches
only
the
minimum
amount
of
metal
should
be
removed
to
restore
the
surface
Check
the
plate
for
distortion
by
placing
it
on
a
surface
plate
with
the
friction
face
towards
the
surface
plate
Press
the
pressure
plate
down
and
insert
a
feeler
gauge
of
1
0mm
0
0039
in
between
the
pressure
plate
and
surface
plate
If
it
is
possible
to
insert
the
feeler
gauge
then
the
pressure
plate
must
be
repaired
or
replaced
The
plate
can
be
skimmed
but
the
maximum
amount
of
metal
that
can
be
removed
is
1
0mm
0
0039in
CLUTCH
SPRING
Diaphragm
clutch
With
the
diaphragm
spring
assembled
to
the
pressure
plate
inspect
the
spring
height
and
load
in
the
following
manner
Place
distance
pieces
of
7
8
mm
0
307
in
on
the
base
plate
as
shown
in
Fig
E
3
and
bolt
down
the
clutch
cover
using
the
special
bolts
provided
with
the
kit
Meas
Jre
the
height
B
in
Fig
E
5
at
a
diameter
of
44mm
1
732
in
The
release
fingers
should
not
exceed
a
height
of
43
45
mm
1
693
1
772
in
from
the
base
plate
Replace
the
spring
if
the
height
is
in
excess
of
the
figures
quoted
Press
the
dutch
down
as
shown
in
Fig
E
6
to
a
depth
of
7
8mm
0
307
in
or
until
the
clutch
driven
plate
upper
surface
lines
up
with
the
clutch
cover
mounting
face
If
the
load
applied
is
less
than
350
kg
770
lbs
it
will
be
necessary
to
renew
the
diaphragm
spring
Do
not
press
the
clutch
disc
down
by
more
than
9mm
0
35
in
or
the
diaphragm
spring
may
be
broken
CLUTCH
SPRINGS
Coil
spring
clutch
The
clutch
springs
must
be
replaced
as
a
set
if
any
of
the
springs
are
found
to
be
defective
Specifications
for
the
springs
are
given
in
Technical
Data
at
the
end
of
this
section
Generally
a
spring
may
be
considered
faulty
if
when
assembled
the
load
is
reduced
by
more
than
15
or
if
the
free
length
has
altered
by
more
than
1
5mm
0
0590
in
or
if
the
deflection
B
to
A
in
Fig
E
7
exceeds
5mm
per
100mm
0
2
in
per
3
94
in
Release
Bearing
The
release
bearing
should
be
renewed
if
excessively
worn
or
if
roughness
can
be
felt
when
the
bearing
is
turned
by
hand
The
bearing
should
also
be
renewed
if
the
grease
has
leaked
away
or
if
the
clearance
between
the
clutch
cover
and
inner
diameter
of
the
sleeve
is
more
than
0
5
mm
0
0197
in
The
bearing
can
be
removed
using
a
conventional
puller
as
shown
in
Fig
E
8
Two
types
of
release
bearings
are
available
and
care
must
be
taken
when
fitting
onto
the
bearing
sleeve
The
release
bearing
should
be
pressed
into
place
on
the
diaphragm
spring
type
of
clutch
with
a
force
of
400
kg
880
lbs
applied
at
the
outer
race
as
shown
in
Fig
E
9
On
the
coil
spring
clutch
the
same
force
must
be
applied
at
the
inner
race
as
shown
in
Fig
E
IO
It
should
be
possible
to
turn
the
bearing
freely
and
smoothly
when
it
is
pressed
into
place
CLUTCH
Assembly
Coil
spring
type
Press
the
pin
into
the
eyebolt
and
through
the
lug
on
the
pressure
plate
Place
the
three
distance
pieces
on
the
surface
of
the
base
plate
of
the
special
tool
ST20050000
and
position
the
pressure
plate
pressure
springs
and
retainers
on
the
plate
Set
the
retracting
springs
on
the
cover
and
insert
the
release
levers
through
the
spring
Place
the
clutch
cover
over
the
pressure
plate
and
springs
making
sure
that
the
retracting
springs
do
not
become
dislodged
or
distorted
Compress
the
pressure
springs
by
screwing
the
special
set
bolts
into
the
holes
in
the
cover
Tighten
the
bolts
gradually
in
a
diagonal
pattern
to
avoid
distorting
the
cover
Place
the
release
levers
on
the
eye
bolts
and
screw
OR
the
securing
nuts
Place
retaining
hooks
under
the
release
levers
and
remove
the
clutch
assembly
from
the
base
plate
slackening
the
set
bolts
in
a
diagonal
pattern
COIL
SPRING
CLUTCH
Adjusting
Screw
the
centre
pillar
into
the
base
plate
and
place
the
high
finger
over
the
pillar
The
height
of
the
release
levers
must
be
adjusted
by
turning
the
eye
bolt
nuts
until
the
tops
of
the
release
levers
are
just
touching
the
tip
of
the
gauge
See
Fig
E
11
Remove
the
centre
pillar
when
the
release
levers
are
correctly
adjusted
and
screw
in
the
actuating
lever
Fig
E
12
Turn
the
actuating
mechanism
several
times
to
bed
down
the
parts
and
then
recheck
the
height
of
the
release
levers
Check
for
run
out
as
near
to
the
edge
as
possible
and
readjust
if
the
deviation
is
more
than
0
5
mrn
0
020
in
CLUTCH
InsWlation
Ensure
that
the
friction
faces
are
free
from
oil
and
grease
and
place
the
driven
plate
on
the
flywheel
The
longer
chamfered
splined
end
of
the
assembly
should
face
the
gearbox
Use
a
spare
drive
shaft
to
align
the
driven
plate
The
shaft
must
be
inserted
through
the
splined
hub
of
the
driven
plate
and
into
the
pilot
bearing
of
the
flywheel
Place
the
clutch
cover
into
position
on
the
flywheel
and
tighten
the
dutch
bolts
gradually
in
a
diagonal
pattern
to
a
torque
reading
of
1
5
2
2
kgm
11
16Ib
ft
Remove
the
dummy
shaft
and
the
restraining
hooks
from
the
release
levers
Refit
the
release
bearing
and
the
bell
housing
CLUTCH
PEDAL
Removal
and
Installation
Remove
the
clevis
pin
from
the
end
of
the
master
cylinder
pushrod
and
disconnect
the
pushrod
Remove
the
return
spring
Remove
the
pushrod
after
slackening
the
pushrod
adjuster
Coil
spring
clutch
only
Remove
the
pedal
lever
securing
bolt
slacken
the
handbrake
bracket
bolts
and
lift
out
the
pedal
Clean
all
parts
thoroughly
and
check
them
for
wear
or
damage
paying
particular
attention
to
the
rubber
parts
return
spring
and
pedal
lever
bush
Installation
of
the
clutch
pedal
is
a
reversal
of
the
removal
procedures
45
Page 47 of 171
J
Ie
T
I
Baseplate
@
2
Czn
e
piUfU
i
y
3
Distance
preces
4
height
iPuge
P
5
Actuilting
mechanl
sQ
6
Set
bolt
I
e
r
ft
I
Fig
E
3
autch
assembly
tool
Fig
E
4
Checking
the
driven
plate
for
run
out
81
I
1
1111
11
I
r
A
I
1
1111111111
if
jI
4
J
J
J
FiB
E
5
Checking
the
height
of
the
diaphragm
spring
Fig
E
6
Olecking
the
load
of
the
d
t
b
spring
I
I
I
A
j
I
1
1
I
l
i
y
8
Fig
E
7
Inspecting
the
clutch
spnngs
for
distortion
Fig
E
8
Removing
the
releaSe
bearing
p
l
0
I
0
W
Illmi
i
hm
17
9
FiB
E
9
Installing
the
lea
bearing
diaphragm
spring
FiB
E
I
0
Installing
the
lease
bearing
coil
spring
46