oil filter DATSUN 510 1969 Service Repair Manual

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

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

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

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

GIS

DESCRIYfION

ENGINE
Removal
and
Installation

ENGINE
MOUNTING

INSULATORS

ENGINE

Dismantling
Inspection
and
Overhaul

CHAMSHAFT

AND
CAMSHAFT
BEARINGS

CYLINDER
BLOCK

PISTONS

CONNECTING

RODS

CRANKSHAFT

ENGINE

Assembling

VALVE
CLEARANCE

Adjusting

DESCRIYfION

The
G
18

engine
is
a
short

stroke
unit
with
a

displacement

of
1
815
ce
The
aluminium

alloy
cylinder
head
has
cross
flow

ports
and
a
V

shaped
valve

layout
The

single
overhead
camshaft

is
driven
from
the
crankshaft

by
a
double
row
roller
chain
at
a

reduction

ratio
of
2
I

The
crankshaft
is
a

carbon
steel

forging
and
is

provided

with
five
main

bearings
and
four

balancing
weights
Aluminium

thrust

bearings
are
located
at

the
No
2

journal

The
cast
aluminium

alloy
pistons
have
two

comp
ression

rings
and
one
oil

ring
Gudgeon

pins
are

fully
floating
in
the

piston
bores
and
are

equipped
with

circlips
at

each
end
to
limit

the
amount

of
their
travel
The

forged
steel

connecting
rods

have
weight
adjusting
bosses
at
both

large
and
small
ends
to

insure
that
the
rods
are

correctly
balanced

during
operation

The

lubricating
system
is
of

the

pressure
feed

type
with

the
oil

pump
driven

by
a

gear
on
the
crankshaft
Oil
is
delivered

to
the
main

gallery
via
a
full
flow
ftlter

ENGINE
Removal
and
Installation

Although
the

engine
can
be
removed
as
a

single
unit
it

will

prove
an
easier

operation
to
remove

the

engine
with
the

transmission
Proceed
as
follows

Fit
the
engine
slingers
ST49760000
to
the

engine

Disconnect
the
battery
cables
and
lift
out

the

battery

Drain
the
coolant
and

engine
oil

2
Place

alignment
marks
on
the
bonnet
and

hinges
remove

the
bonnet
from
the
vehicle

3
Remove
the
blow

by
hose
from
the
rocker
cover
and
take

off
the
air
cleaner

4
Disconnect
the
accelerator

linkage
and
choke
cable
from

the
carburettor

S
Detach
the

upper
and
lower

radiator
hoses
remove
the

two
brackets
from
the
core

support
and
lift
the
radia
tor

away
from
the
vehicle
The

torque
convertor

oil

pipes
must

be
disconnected
from
the
oil
cooler
if
the
vehicle
is

equip

ped
with
automatic
transmission
Detach
the
fuel

pipe
if

fitted
from
the
engine
and

heater
hose

6
Disconnect
the
electrical

wires
from
the
alternator
thennal
EngIne

OIL
PUMP

OIL
PRESSURE
RELIEF
VALVE

OIL
FILTER

EMISSION
CONTROL
SYSTEM

IGNITION

TIMING
AND
IDLING
SPEED

Emission

control

system

EMISSION
CONTROL
SYSTEM
Maintenance

IGNITION
SYSTEM

IGNITION
TIMING

IGNITION
DISTRIBUTOR
Maintenance

SPARKING
PLUGS

transmitter
the

primary
side
of
the
distributor
oil

pressure

switch
starter

motor
and
reverse

light
switch

7

Remove
the
clutch
slave

cylinder
and
its
return

spring
from

the
transmission
as
described
in
the
section
CLUTCH

8
Disconnect
the
shift
rods
and
selector
rods
then
remove

the
cross
shaft

assembly
by
detaching
the
bracket
from

the
side
member
See
GEARBOX
section

9
Disconnect
the

speedometer
cable
and
detach
the
front

exhaust

pipe
from
the
exhaust
manifold

10
Disconnect
the

propeller
shaft
and

plug
the

gearbox
rear

extension
to

prevent
the
loss
of
oil

11
Jack

up
the

gearbox
slightly
and
remove
the
rear

engine

mounting
support
Take
out

the
bolts
which
secure
the

front

mounting
insulators
to
the
cross
member

12
Attach
chains
or
wire

rope
to
the

engine
Gradually
lower

the

jack
under
the

gearbox
and
carefully
lift
and
tilt
the

engine
and
gear
box
to
clear
the

compartment
Withdraw

the
unit

making
sure

that
it
does
not
foul
the
accessories

Installation
is
a
reversal
of
the
removal

procedure
RefIll

with
the
correct

quantities
of
oil
and
coolant
when
the

engine
is
installed

ENGINE
MOUNTING
INSULATORS

Replacing

The

front
and
rear

mounting
insulators
should
be
checked

with
the

engine
installed
to
make
sure
that
the
dimensions

conform
with
those

given
in

Figs
A
I
and
A
2

To
remove
the
front
insulator

proceed
as
follows

Position
a

jack
under
the
oil

sump
Make
sure
that
the

jack
is
clear
of
the
drain

plug
and
insert
a
wooden
block
between

the
jack
and

sump
to

prevent
the

sump
from

being
damaged

Remove
the
bolts

securing
the
insulator
to
the
front

suspension

member
and
the
nut

attaching
the
insulator
to
the

engine

mounting
bracket
Raise
the

jack
slightly
and
remove
the

insulator
To
remove
the
rear

mounting
insulator

proceed
as

follows

Position
a

jack
to
take
the

weight
of
the

gearbox
and
take

out

the
bolts

connecting
the
insulator
to

the
transmission
rear

extension

housing
Remove
the
bolts

attaching
the
cross
member

to

the
underside
of
the

body
and
withdraw
the
insulator

Installation

of
both
insulators

is
a
reversal
of
the

removal

procedures

S3

ENGINE

Dismantling

Remove

the

engine
from
the
vehicle
as

previously
described

and

carefully
clean
the
exterior

surfaces
The
alternator

distribu

tor

and
starter
motor
should
be
removed
before

washing
Plug

the
carhurettor

air
horn
to

prevent
the

ingress
of

foreign
matter

Place
the

engine
and
transmission
on

the
engine
carrier
ST4797

0000
if

available
and
dismantle
as
follows

Remove
the

gearbox
from
the

engine
Disconnect
the
intake

manifold

water
hose
the
vacuum

hose
and
the
intake
manifold

to
oil

separator
hose
Remove
the
intake
manifold
with
the

carburettor
Fit
the

engine
attachment
ST3720OG18
to
the

cylin

der
block
and

place
tre

engine
on
the
stand
ST371
00000

Remove
the
clutch

@
Ssembly
as
described
in
the
section

CLUTCH
Remove
the
exhaust
manifold
and
heat
baffle

plate

Take
off
the
fan
blades
and
remove
the
water

pump
pulley
and

fan
belt
Remove
the
rocker
cover
hose
manifold
heat
hose
and

by
pass
hoses

Remove
the

generator
bracket
and
the
oil
fIlter
Extract
the

engine
breather

assembly
from
above
Note
that
the
breather

is
fitted
to
the

guide
and
is
installed
with
a
O

ring
which
is

pressed
into
the

cylinder
block

Flatten
the
10ckwasher
and
unscrew
the
crankshaft
pulley

nut
Withdraw
the

pulley
with
the

puller
ST44820000
if
available

but
do
not
hook
it
in
the
V

groove
of
the

pulley

Remove
the
rocker
cover
and
take
off
the
rubber

plug

located
on
the
front
of
the
cylinder
head

Straighten
the
lock

ing
washer
and
remove
the
bolt

securing
the

distributor
drive

gear
and
camshaft

sprocket
to
the
camshaft
Remove
the
drive

gear
and
take
off
the

sprocket
See

Fig
A
3

Remove
the

cylinder
head
bolts
in
reverse

order
to
the

tightening

sequence
sOOwn
in

Fig
A
18
and
lift
off
the

cylinder

head
as
an

assembly
See

Fig
A
4
Note

that
in
addition
to
the

ten

cylinder
head
bolts
there
are
also
two
bolts

securing
the

chain
cover
to

the
head
Invert
the

engine
and
remove
the
oil

sump
Remove
the
chain
cover
and
oil

flinger
Take
off
the
nut

securing
the
oil

pump
sprocket
and
withdraw
the

sprocket
with

the
chain
in

position
as
shown
in

Fig
A5
Remove
the
oil

pump

and
stramer
Note

that
two
of
the

pump
mounting
bolts
are

pipe
guides

Remove
the

timing
chain
crankshaft

sprocket
chain
ten

sioner
and
chain

stop

Remove
the

connecting
rod

caps
and

push
the

piston
and

connecting
rod
assemblies

through
the
tops
of
the
bores

Keep

all

parts
in
order
so

they
can
be
assembled
in
their

original
posi

tions

Take

out
the

flywheel
retaining
bolts
and
withdraw
the

flywheel
Remove
the
main

bearing

caps
but
take
care
not
to

damage
the

pipe
guides
Lift
out

the
crankshaft
and
main
bear

ings
noting
that
the

bearings
must
be
reassembled
in
their

original

positions
Remove
the

piston
rings
with
a
suitable

expander
and

take
off
the

gudgeon
pin
clips
The

piston
should
be
heated
to

a

temperature
of
50
to
600
122
to
1400F
before

extracting

the

gudgeon
pin
Keep
the
dismantled

parts
in
order
so

they

can
be
reassembled
in
their

original
positions

Remove
the
camshaft
rocker
ann
shaft
and
rocker
ann

assemblies
from
the

head

by
taking
off
the
cam

bracket

clamp

ing
nuts
It
is
advisable
to
insert
disused
bolts
in
the
No
1

and

No
5
bracket
holes
as
the
cam
bracket
will
fall
from
the
rocker

ann
shaft
when

it
is
removed
Remove

the
valve

cotters

using

the

special
tool
ST47450000

and
dismantle
the
valve
assemblies
Keep
the

parts
together
so

they
can
be
installed
in
their

original

order

ENGINE

Inspection
and
Overhaul

Cylinder
head
and
valves

Inspection
and
overhaul

procedures
can

be
carried
out

by

following
the
instructions

previously
given
for
the
L14
LI6

and
LIB

engines
noting
the

following
points

Measure
the

joint
face
of
the

cylinder
head

using
a

straight

edge
and
feeler

gauge
The

permissible
amount
of
distortion
is

0
03
mm
0
0012
in
or
less
The
surface
of
the
head
must
be

reground
if
the
maximum
limit
of
0

1
mm

0
0039
in
is

exceeded

Oean
each
valve

by
washing
in
petrol
then

carefully
examine

the
stems
and
heads
Discard

any
valves
with
worn

or

damaged

stems
Use
a

micrometer
to
check
the
diameter
of
the
stems

which
should
be
8
0
mm
0
315
in
for
both
intake
and
exhaust

valves
If

the
seating
face
of
the
valve
is

excessively
burned

damaged
or
distorted
the
valve
must
be
discarded
The
valve

seating
face
and
valve

tip
can
be
refaced
if

necessary
but

only

the
minimum
amount
of
metal
should
be
removed
Check
the

free

length
and
tension
of
each
valve

spring
and

compare
the

figures
obtained
with
those

given
in
Technical
Data
at
the
end

of
this
section
Use
a

square
to
check
the

springs
for
deformation

and

replace
any
spring
with
a
deflection
of
1
6
mm
0
0630
in

or
more

Valve

guides

Measure
the
clearance
between
the
valve

guide
and
valve

stern
The
stem
to

guide
clearance
should

be
0
025
0
055
mm

0
0010
0
0022
in
for
the
intake
valves
and
0
04
0
077
mm

0
0016
0
0030
in
for
the
exhaust
valves
The
maximum
clear

ance

limit
is
0
1
mm
0
0039
in
The
valve

guides
are
held
in

position
with
an
interference
fit
of
0
040
0
069
mm
0
0016

0
0027
in
and
can
be
removed

using
a

press
and
valve

guide

replacer
set
ST49730000
under
2
ton

pressure
This

operation

can

be
carried
out
at
room

temperature
but
will
be
more
effec

tively

performed
at
a

higher
temperature
Valve

guides
are

available
with
oversize
diameters
of
0
2
mm
0
0079
in
The

cylinder
head
guide
bore
must
be
reamed
out
at

normal
room

temperature
and
the
new

guides
pressed
in
after

heating
the

cylinder
head
to
a

temperature
of

approximately
800
C
1760F

The
standard
valve

guide
requires
a
bore
of
14
0
14
018
mm

0
551
0
552

in
and
the
oversize
valve

guide
a
bore
of
14
2

14
218
mm
0
559
0
560
in
Ream
out
the
bore
of
the

guides

to
obtain
the
desired
finish
and
clearance
Use
the
reamer
set

ST49710000
to

ream
the
bore
to
8
000
8
015
mm
0
3150

0
3156
in
The
valve
seat

surface
must

be
concentric
with
the

guide
bore
and
must
be
corrected
if

necessary
using
the
new

valve

guide
as
axis

Valve
seat
inserts

Check
the
valve
seat

inserts
for

signs
of

pitting
The

inserts

cannot
be

replaced
but

may
be
corrected
if

necessary
using
a

valve
seat
cutter

ST49720000

Scrape
the
seat

with
the
450

cutter
then

reduce
the
width
of
the

contacting
faces

using
the

150
and
600
cutters
for
the
intake
valve
inserts
and
150
cutter

for
the
exhaust
valve
inserts
Seat
correction
dimensions
are

shown
in
millimeters
in

Fig
A
6

Lap
each
valve
into
its
seat
after

correcting
the
seat
inserts

Place
a
small

quantity
of
fme

grinding
paste
on

the

seating
face

of
the
valve

and
lap
in
as

previously
described
for
the
Ll4
LI6

and
L
18

engines

S5

pulley
should
be

aligned
with
the
T
mark
on
the
chain
cover

Install

the
cylinder
head

assembly
Coat

the

cylinder
block

side
of
the
head

gasket
with

sealing
agent
Three
Bond
No
4

or

equivalent
but
take
care
that

the
scaling
agent
does
not

enter

the

cylinders

Tighten
the
head
bolts
in
several

stages
to
a

torque
reading

of
8

0
to
9

0

kgrn
58
to
65
lb

ft
Tighten
the
bolts
to
the

sequence
shown
in

Fig
A

IB

Pull
the

timing
chain
out
of
the
chain
cover
and
set
it
on

the
camshaft

sprocket
so
that
the

timing
marks
are

aligned
then

place
the

sprocket
and
chain
on

the
camshaft

Install
the
distributor
drive

gear
on
the
camshaft
and

tighten
the
bolt
to
a

torque
reading
of
4
5
to

5
5

kgrn
32
6
to

39
8
lb
ft
Note
that
the
camshaft
bolt
has
a
left
hand
thread

Adjust
the
valve
clearances
as
described
under
the

appro

priate
heading
Fit
the
rubber

plugs
at
the
front
and
rear
of
the

cylinder
head

taking
care
to

apply
sealing
agent
to
the
rear

plug

Install
the
chain

adjusting
screw
and

adjust
the
tension

of
the
chain
in

the

following
manner

Rotate
the
crankshaft
clockwise
to
establish
the
correct

chain
tension
screw
the

adjusting
screw

fully
home
then
back

it
off

by
half
a
turn

and
secure
with
the
locknut

Install
the
valve
rocker
cover
and
fit
the
water

pump
Note

that
one
of
the
water

pump
mounting
bolts
also
secures
the

generator
adjusting
arm

Install
the
bracket
and
alternator
water

pump
pulley
fan

blades
and
fan
belt

Tighten
the
fan
bolts
and
lock
each
pair

of
bolts

together
using
wire
inserted
through
the
holes

provided

in
the
bolts

Install
the
oil
filter
and
fit
the
rocker
cover
hose
Install

the
distributor
so
that
the
vacuum
control
unit

and
rotor

arc

positioned
as
shown
in

Fig
A
19

Oil
the
distributor
driven

gear
Fit
the
breather

assembly

the
clamp
of
the

pipe
is

tightened
together
with
the
exhaust

manifold
Install
the

spark
plugs
and
connect
the

high
tension

leads

Install
the
exhaust
manifold
Fit
the
head
shield

plate
and

engine
slinger
and

tighten
them

together
Note
that
the
exhaust

manifold

gasket
must
be
fitted
with
the
steel

plate
facing
the

manifold
Install
the
clutch
as
described
in
the
section
CLUTCH

Remove
the

engine
from
the

mounting
stand
and
install

the
gearbox
intake
manifold
and
carburettor
stater
motor

engine
mounting
oil

pressure
warning
switch
etc

Fill
the

engine
and

gearbox
to
the
correct
levels
with

recommended
oils
and
refill
the

cooling
system
Adjust
the

ignition

timing
and
carburettor

as
described
in
the

appropriate

sections

VALVE
CLEARANCES

Adjusting

The
valves
clearances
can

be
adjusted
in
a
similar
manner

to
the
instructions

given
for
the
L14
LI6
L18

engines

Initially
adjust
the
clearances
with
the

engine
switched
off
and

cold
to

0
2
mm
0
0079

in
for
both
intake
and
exhaust
valves

Set
the
final
clearances
to
0
28
mm
0
011
in
for
both
intake

and
exhaust
valves
with
the

engine
warmed
up
to
its
normal

operating
temperature
OIL
PUMP

The

gear
type
oil

pump
is

chain
driven
from
a

sprocket
on

the

crankshaft
The

pump
can

be
removed
in
the

following
manner

1
Remove

the

sump
plug
and
drain
the

engine
oil
Remove

the
distributor
as
described
in
the
section
IGNITION

2
Remove
the

cylinder
head

assembly
fan
belt
crankshaft

pulley
and

oil

sump

3
Take
off
the
chain
cover
with

oil
fl

inger

4
Remove
the
oil

pump
and
crankshaft

sprockets
with
the

drive
chain
then
withdraw
the

pump
after

removing
the

four

mounting
bolts

Separate
the
cover
from
the

body
by

unscrewing
the
four

securing
bolts
and
withdraw
the
drive
and
idler

gear

assemblies
Unscrew
the
threaded

plug
and

take
out

the

relief
valve
and

spring

Clean
the

parts
thoroughly
and

inspect
them
four

signs

of
wear
or

damage
Check

the

following
clearances

Gear
backlash
0

1
to

0
5
mm
0
0039
to

0
0195

in

Side
clearance
between

gear
and

body
0
016
to
0
15
mm
0
0006
to

0

0059
in

Clearance
between

drive
shaft
and

body
0
016
to
0
1
mm
0
0006
to

0
0039
in

Clearance
between

drive
shaft
and
cover
0
02
to
0
1
mm
0
00078
to

0
0039
in

Clearance
between

idler

gear
and
idler
shaft
0
016
to

0
1
mm
0

0006
to

0
0039
in

Assembly
is
a
reversal
of
the

dismantling
procedures
taking

care
to

position
the
gears
so

that
the
dotted
mark
is
towards
the

cover

Install
the

pump
and

adjust
the
tension
of
the
drive
chain

by
ph
otting
the
pump

body
as

shown
in
Fig
A
20

When
the

chain
is

correctly
tensioned
it
should
be

capable
of
a
deflection

of
2
0
to

3
0
mm

0
079
to

0
118
in
as

indicated

OIL
PRESSURE
RELIEF
VALVE

The

pressure
relief
valve
shown
in

Fig
A
21
is
not

adjustable

This
valve

regulates
the
oil

pressure
to
4
55
4
85

kg

sq
cm

64
7
69
0
lb

sq
in
and
when

opened
allows
the
oil
to

by
pass

through
a

passage
in
the

pump
body
and
return
to
the

sump

Check
the
free

length
of
the

spring
which
should
be
64
0

to
66
0
mm
2
51
to
2
60
in
The

compressed
length
should

be
50
mm
at

7
8
to

9
7

kg
1
96
in
at
17
2
to
21
4Ibs
Renew

the
spring
if

necessary

OIL
FILTER

The
oil
filter
is
of
the
full
flow

type
with
a

replaceable

element
and

incorporates
a

by
pass
valve
in
the
cover

Oil

leaks
can
be
corrected

by
replacing
the

body
centre

shaft
or
cover

gaskets
The

body
and
centre

shaft

gaskets
should

always
be
renewed
after

dismantling
the
filter

S
1