oil pressure 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

Engine
model

Number
of

cylinders

Arrangement
of

cylinders

Cubic

capaci
ty

Bore
x
stroke

Arrangemen
t
of

valves

Max
B
H
P

Max

torque

Firing
order

eidlingspeed

Compression
ratio

Oil

pressure

Valve
clearance

hot

Inlet

Exhaust

Valve
clearance
cold

Inlet

Exhaust

Valve
head

diameter

Inlet

Exhaust

Valve
stem

diameter

Inlet

Exhaust

Valve
lift

Valve

spring
free

length

Valve

spring
fitted

length

Valve

spring
coil
diameter

Valve

guide
length

Inlet

Exhaust

Valve

guide
protrusion
rreclll11cal
ata
L

lJEngine

LI3

4

In
line

1296

83
0
x
59
9

3
2677
x
3583
in

Overhead
camshaft

77
at
6000

rpm

II
1

kgm
at
3600

rpm

I
342

600

rpm

8
5
1

3
8
4
2

kg
sq
em

54
60Ib

sq
in

VALVES

0
25
mm
0
010
in

0
30
mm
0
01
in

0

20
mm
0
008

in

0
25
mm
O
OIJ
in

38
mm
1
50
in

33
mm

1
30
in

8
0
mm
0
31
in

8
0
mm
0
31
in

10
0

mm
0
40
in

48
12
mm

1
89
in

40
0
mm
30
7

kg

1
57
in
67

7
lb

34
9
mm
1
37
in

59
0
mm
2
32

in

59
0
mm
2
32
in

10
4
10
6
mm
0
41
0
42
in

Valve

guide
inner
diameter

Inlet

8
00
8

l
8
mm
0
315
0
3154

in

Exhaust
8
00
8
018
mm
0
315

0
3154

in

Valve

guide
outer
diameter

Inlet

Exhaust

Valve

guide
to
stem
clearance

Inlet

Exhaust

20
11
985
11
996
mm
0
472
0
4723

in

11
985
11
996
mm
0
4172
0
4723

in

0
015
0
045
mm
0
0006
0
0018

in

0
040
0
070
mm
0
0016
0
0028

in
Valve
seat
width

Inlet

Exhaust

V
lve
seat

angle

Valve
seat

insert
interference

fit

Inlet

Exhaust

Valve

guide
interference
fit

Inlet
1
4
1
8
mm
0
055
0
071
in

1
6
2
0
mm
0
063
0
079
in

450

0
08
0
11
mm
0
0031
0
0043

in

0
06
0
10

mm
0
0024
0
0039

in

0
027
0
049
mm
0
0011
0
0019

in

CAMSHAFT
AND
TIMING
GEAR

Camshaft
end

play

Camshaft
lobe
lift

Camshaft

journal
diameter

Max
camshaft
run
out

Camshaft

bearing
to

journal

clearance

Camshaft

bearing
inner

diameter
0
08
0
38
mm

0
0011
0
0019
in

6
65
mm
0
261
in

47
949
47
962
mm
fI
8877

1
8883
in

0
05
mm

0
002
in

0
038
0
076
mm
0
0015
0
0026

in

48
000
48
016
mm

1
8898

1
8904
in

CONNECTING
RODS

Distance
from
centre
to
centre
132
97

133
03
mm
5
235

5
237
in

Bearing
shell
thickness

Standard

Big
end
side

play

Connecting
rod

bearing

running
clearance

Connecting
rod

rend
or

twist
1
498
1
506
mm
0
059
0
593

in

0
20
0
30

mm
0
008
0
012
in

0
014
0
056
mm
0
0006
0
0022

in

0
03
mm

per
100
mm
0
0012

in

per
3
937

in

CRANKSHAFT
AND
MAIN

BEARINGS

Crankshaft
material

Number

of

bearings

Main

journal
diameter

Max

journal

taper

Max

journal
out
of
round

Crankshaft
end

play
Special

forged
steel

5

54
942
54
955
mm
2
1631

2
1636

in

0
03
mm
0
0012
in

0
03
mm
0
0012
in

0
05
0
015
mm
0
002
0
0059

in

Wear
limit

Crank

pin
journal
diameter

Max
crankpin
taper

Max

crankpin
out
of
round

Thickness
of
main

bearing

shells
0
3
mm
0
012

in

49
961
49
975
mm

1
967
1
9675

in

0
03
mm
0
012
in

0
03
mm
0
012
in

1
827
1
835
mm
0
072
0
0722

in

Main

bearing
running
clearance

0
020
0
062
mm
0
0008
0
0024

in

Max
main

bearing
running

clearance

Crankshaft
bend
limit

Material

Type

Piston
diameters

Standard

I
st
oversize

2nd
oversize

3rd
oversize

4th
oversize

5th
oversize

Width
of

ring
grooves

Top
and
second

Oil
control

Piston

running
clearance
0
12
mm

0
0047
in

0
05
mm
0
002
in

PISTONS

Cast
aluminium

Slipper
skirt

82
99
83
04
mm
3
267
3
269

in

83
22
83
27
mm
3
276
3
278

in

83
47
83
52
mm
3
286
3
288

in

83
72
83
77
mm
3
296
3
298

in

83
97
84
02
mm
3
305
3
308

in

84
47
84
52
mm
3
326
3
328

in

2
0
mm
0
08
in

4
0
mm

0
16
in

0
025
0
045
mm
0
001
0
002

in

PISTON
PIN

Pin
diameter
20
995
21
000
mm
0
8266

0
8268

in

Pin

length
72
00
72
25
mm
2
8346
2
8445

in

Pin

running
clearance
in

piston
0
008
0
010
mm
0
0003
0
0004

in

Pin
interference
fit
in
small
end
bush

0
015
0
033
mm
0
0006
0
0013

in

Piston

ring
height

Top
and
second

Oil
control

Side
clearance
in

grooves

Top
PISTON
RINGS

2
0
mm
0
08
in

4
0
mm
0
16
in

0
040
0
073
mm
0
0016
0
0029

in
Second

Oil
control

Piston

ring
gaps

Top

Second

Oil
control

Material

Distortion
of

sealing
face

Max
distortion

Valve
seat
insert
material

Inlet

Exhaust

Fit

Drive

Chain

Chain
tensioner
0
030
0
063
mm
0
0012
0
0025

in

0
025
0
063
mm
0
001
0
0025

in

0
23
0
38
mm
0
0091
0
0150

in

0
15
0
30
mm

0
006
0
012

in

0
15
0
30
mm
0
006
0
012
in

CYLINDER
HEAD

Aluminium

alloy

0
03
mm
0
0012
in

0
1
mm
0
004
in

Aluminium
bronze

Special
cast

Hot

pressed

CAMSHAFT
DRIVE

From
crankshaft

double
roller

type

Spring
and
oil

pressure
control

Engine
model
lWIN
CHOKE
CARBURE
ITOR

Outlet
diameter

Venturi
diameter

Main

jet

Main
air
bleed

Slow

running
jet

Power

jet

Float
level

Fuel

pressure

Weight

Altitude

setting
main

jet

1000
m
3300
ft
94

2000
m
6600

ft
92

3000
m

10
000

ft
89

4000
m

13
300
ft
87

5000
m

16
600
ft
85
PRIMARY
L13

SECONDARY

30mm

27x
12mm

150

90

180
26
mm

21
x
8
mm

96

80

43

40

23
I
mm
0
905
0
04

in

0
24

kg
sq
em
3
41b

sq
in

2
55

kg
5
61
lb

1

21

TechnIcal
Data
L
14
16
and
18

Engine

GENERAL
SPECIFICATIONS

Cylinders

Displacement

L14

L16

L18

Bore
and
stroke

L14

L16

Ll8

Compression
ratio

L14

L16

single
carburettor

L16
SU

twin
carburettor

L18

single
carburettor

Ll8

SU
twin
carburettor

Valve

arrangement

Firing
order

e

idling
speed

Engine

idling
speed
with
automatic
transmission

Oil

pressure
Hot
at
2000
r

p
m

Valve

clearance
Hot

Intake

Exhaust
0
25
mm
0
0098

in

0
25
mm
0
0098
in

Valve
clearance

Cold

Intake

Exhaust

Va
head
diameter

L14

Intake

Exhaust

Vahoe
head
diameter
L16

Intake

Exhaust
0
20

mm
0
0079

in

0
20
mm

0
0079

in

38
mm
1
5361
in

33
mm

1
2992

in

42
mm

1
6535

in

33
rom
1
2992
in

Valve
head
diameter

L18

Intake

Exhaust
42
mm

1
6535
in

35
mm
1
3780

in

Valve
stem
diameter

Intake

7
965
7
980
mm
0
3136
0
3142
in

Exhaust

7
945
7
960
mm

0
3128
0
3134
in

Valve

length
L14

Intake

Exhaust
115

6
115
9mm
4
551
4

562in

115
7
116
0
mm

4
555
4
567
in

Valve

length
L16
LIB

Intake

114

9
115
2
mm
4
524
4
535

in

Exhaust

115
7
116
0
mm

4
555
4
567
in

22
4
in
line

1428

cc
87
1
cu
in

1595
cc
97
3
cu
in

1770

cc

108
0
cu
in

83
x
66
mm

3
27
x
2
60
in

83

x
73
7
mm
3
27
x
2
90
in

85
x
7B
mm
3
35
x
3
07
in

9
0

8
5

9
5

8
5

9
5

Overhead
valve

I
3
4

600
r

p
m

single
carburettor
650
r

p
m
twin
carburettor

650

r

p
m

single
carburettor

700
r

p
m
twin

carburettor

3
5
4
0

kg
sq
cm

50
57Ib

sq
in

VALVES

Valve
lift

Single
carburettor

Valve
lift

Twin
carburettor
10
0
mm
0
3946

in

10
5
mm

0
413
in

Valve

spring
free

length
LI4

Ll4
Intake

Ll4

Exhaust
outer

L14
Exhaust
inner

Valve

sprin8
free

length
L16
LIB

Outer

Inner
49
0
mm

1
929
in

49
98
mm
1
968

in

44
85

mm

1
766
in

49
98
mm

1
968

in

44
85
mm
1
766
in

59
0
mm

2
393
in

10
6
mm

0
417
in
Valve

guide
length

Valve

guide
height
from
head
surface

Valve
guide
diameter
inner

Intake
8
018

Exhaust
8
018

Valve

guide
diameter
outer

Intake

12

034

Exhaust

12
034

Valve

guide
to
stem
clearance

Intake

Exhaust

Valve
seat
width
L14

Intake

Exhaust

Valve
seat

width
L16
LIB

Intake

Exhaust
8
000

mm
0
3154

0
3150
in
clia

8
000
mm

0
3154

0
3150
in
clia

12
023
mm
0
4738
0
4733

in
clia

12
023

mm
0
4738
0
4733

in
clia

1
8
mm

1
1024
in

I
7
mm
1
0630
in

I

4
mm

0
0551
in

1
3
mm
0
0512

in

0
020
0
053
mm
0
0008
0
0021
in

0
040
0
073

mm
0
0016
0
0029
in

liB
Oversizes

Ring

groove
width

Top
ring

Second

ring

Oil

ring

Piston
to
bore

clearanl
e

Pin
diameter

I
ength

Ll4
Ll6

Ll8

Pin
to

piston
clearance

Pin
interference
fit
in
small
end
bush

Piston

ring
height

Top

Second

Side
clearance

Ll4
Ll6

Top
ring

LI8

Top

ring

Second

ring

Ring

gap

U4

Top
ring

U4
Second

ring

Ll6

Top
ring

L
16
Second

ring

U8

Top
ring

U8
Second

ring

Oil

ring

Oil

pump

Oearance
between
inner

and
outer
rotor

Rotor

tip
clearance

Oearance
between
outer
rotor

and

body

Rotor
to

bottom
cover

clearance

Oil

pressure
at

idling

Oil

pressure
relief
valve

spring

Free
length

Fitted

length

Relief
valve

opening

pressure

24
85465485
515
mm
3
648
667
ill

86
065
86
015
mm

13
3844
33864
in

0
mm
CO
0787

in

0
mm
0
0787
in

4
0
mm
0
1
q
c
in

0
025
0
045
mm
0
0010
0
0018
in

PISTON
PIN

20
995
1
000
mm

0
8266

0
8168
in

72
00

72
25

0
001

0
Dl5
72
25
mm

2
8346
2
8445
in

73
00
mm

2
8445

2
8740
in

0
013
mm
0
00004
0
00051
in

0

033
mm
0
0006
0
0013
in

PISTON

RING

1
977
mm
0
0778

in

1
977
mm
0
0778
in

0
040
0
080
mm
0
0016
0
0031
in

0
045
0
080
mm

0
0018
0
0031
in

0
030
0
070
mm
0
0012
0
0028
in

0
23
0
38
mm
0
0091

0
0150

in

0
15
0
30
mm
0
0059
0
0118
in

0
25
0
40
mm
0

0098
0
0157
in

0
15
0
30
mm
0
0059
0
0118
in

0
35
0

55
mm
0
0138
0
0217
in

0
30
0
50mm
0
0118
0
0197
in

0
30
0

90
mm
0
0118
0
0354
in

LUBRICATION

SYSTEM

Rotor

Pump

0
05
0
12
mm
0

0020
0
0047

in

less
than
0
12
mm
0
0047
in

0
15
0
21
mm
0
0059
0
0083
in

0
03
0

13
mm
0
0012
0
0051
in

0
8
2
8

kg
sq
cm
11
40
Ib

sq
ln

52
5
mm

2
067
in

34
8
mm

1
370
in

3
5
5
0

kg
sq
cm

50
71
Ib

sq
ln

The
thermostat
can
be

tested

by
suspending
it
with
a

thermometer
in
a

container
ftlled
with
water

Heat
the
water

gradually
and
stir
it
to

obtain
a
uniform

temperature
Maintain

a
constant

check
of
the

temperature
and

make
sure

that
neither
the
thermostat

or
thermometer

touch

the
sides
of
the
container
or
false

readings
will
be
obtained

The
thermostat
should

begin
to

open
at
a

temperature
of

820C

1
50C

179
60F
2

70Fj
and
should
be

fully

open

with
a
maximum
valve
lift
of
8
mm

0
315
in
at
a

temperature

of

950C
2030F

When

installing
the
thermostat

apply
adhesive
to

both
sides

of
the

gasket
before

refitting
the
water
outlet
elbow

RADIATOR
Removal

Drain

the

cooling

system
as

previously
described
and
remove

the
front

grille

2
Disconnect

the
radiator

upper
hose
lower

hose
and
hose
to

the
reservoir
tank

3
Remove
the

radiator

securing
bolts

and
lift
out
the

radiator

Fig
B
4
It
should
be
noted
that
cars
fitted

with
automatic
transmission

incorporate
a
transmission
oil
cooler

which
must

be
disconnected

Installation

is
a

reversal
of
the
removal

procedure
refill

the

system
as

previously
described

FLUID
COUPLING

The
water

pump
is

equipped
with

a
fluid

coupling
on

vehicles
fitted
with
an

air
conditioner

The
fluid

coupling

Limits

the
maximum
fan

speed
to

approximately
3000

r

p
ro

and
eliminates
noise

and
loss
of

power
at

high
engine

speeds

A
fault
in
the

coupling
may
be
caused

by
the

entry
of

foreign
matter

If
a
fault

developes
the

oupling
must
be

removed
and
dismantled

and
the
interior
cleaned

by

washing

in
solvent
The
condition
of
the
seal

and

bearing
must
be
care

fully
checked

and
the

coupling
replaced
if
the
latter

items
have

become
blackened
If
oil
leaks
occur

it
will
be

necessary
to

replace
the

water

pump
assembly
with
the

coupling
After

cleaning
the
unit
refill

with
11
5
cc
silicon
oil

using
a

suitable

syringe

TechnIcal

Data

Radiator

Radiator

cap
working
pressure

Radiator
core

heightxwidth

x

thickness

1400

and
1600
cc

engines
510

body

1600
and
1800
cc

engines
610

body
Corrugated
fin

type

0
9

kg

sq
cm

13Ib
sq
in

280x488x38mm

I
LOx
19
2x
1
49

in

360x502x32mm

l4
2x19

8x1
26
in

Thermostat

valve

opening

temperature

Standard

B20C
l
BOOF

Cold
climates
880C

1900F

Tropical
climates

76
50C
l700F

Max
valve
lift

Cooling
system

capacity

With

heater

Without
heater

Cooling
system

capacity

With

heater
Above
8
mm
0
31
in

6
8litres

1
75
US

gall

1
5

Imp
gall

6
4litres

1
75
US

gall

1
375

Imp
gall

1600

and
1800
cc

engines
610

body

6
5litres
l
7

US

gall

1
375

Imp
gall

6
0

Iitres
1
625
US

gall

1
375

Imp

gall
Without
heater

27

CENTRIFUGAL
ADVANCE
MECHANISM

Special
equipment
is

required
to
check
the
advance

characteristics
It
is

possible
however
to

carry
out
an
exam

ination
of

the
caffi

assembly
and
the

weights
and

springs
to

ensure
that
the
earn
is
not

seizing

Lift
off
the
distributor

cap
and
turn
the
rotor
anti
clock

wise
When

the
rotor

is
released
is
should
return
to

the
fully

retarded

position
without

sticking
If
it

does
not
return
to
the

fully
retarded

position
it
will
be

necessary
to
check
for

dirt

and
weak

springs

It
should
be
noted
that

any
wear
in
the

mechanism
or

lose
of

spring
tension
will

upset
the
advance
characteristics
and

cause

unsatisfactory
engine
running
performance
over
the

speed

range

VACUUM
ADVANCE
MECHANISM

The

diaphragm
of
the
vacuum
advance

mechanism
is

mechanically
connected
to
the
contact
breaker

plate
The
rise

and
fall
of
inlet
manifold

depression
causes

the

diaphragm
to

move

the
contact
breaker

plate
to

advance
or

retard
the

ignition

If
the
vacuum

control
unit
fails
to

function

correctly
a

check
can
be
carried
out
to
ensure
that
the
contact
breaker

plate

is

moving
freely
and
that
the

three
steel

balls
at

the

top
and

oottom
of
the

plate
are

adequately
lubricated

Also
make
sure
that
the
vacuum
inlet

pipe
is
not
blocked

or

leaking
and
is

securely
tightened

Leakage
may
be
due
to
a

defective

diaphragm
which

should

be
renewed

along
with

any
other

faulty
part
of
the
mechanism

IGNITION
DlSTRffiUTOR
Removal

and

Dismantling

Disconnect
the

battery
leads

2
Disconnect
the

high
tension
lead
at

the
coil

3
Withdraw

the
high
tension
leads
from
the
distributor

cap

4
Detach
the
suction

pipe
from
the
vacuum
control
unit

5
Mark
the

position
of
the
distributor
and
rotor
remove
the

flange
mounting
bolts

and
withdraw
the
distributor

To
dismantle
the
distributor

proceed
as

follows

Take
off
the
distributor

cap
and
remove

the
rotor

Slacken

the
two
set
screws

holding
the
contact
breaker

upper
plate

Remove
the

primary
cable
terminals
and
withdraw
the
contact

set
from

the
distributor
Fig
C
S
Remove
the
vacuum
control

unit

c
Remove
the
two
screws
and
lift
out
the
contact

breaker

plate
detach
the

clamp
the
terminal
and
the
lead

To
remove
the
cam
take
out
the
centre
screw
as

shown
in

Fig
e
6
Drive
out

the
drive

pinion
retaining
pin
with
a
drift

and
hammer
Fig
e
and
remove
the

pinion
and
washer
Take

care
not
to
stretch
or
deform
the

governor
springs
when

detaching

them
from
the

weights

IGNITION
DISTRIBUTOR

Assembling
and

Installing

Assembly
is
a
reversal
of
the

dismantling
procedure

Lubricate
the

moving
contact

pivot
and
smear
the
lobes
of
the

cam
with
multi

purpose
grease

If

the
centrifugal
advance
mechanism
has
been
dismantled

the

governor
springs
and
cams
must
be
refitted
as

shown
in

Fig
e
8
The

governor
weight

pin
6
should
be
fitted
into

the

longer
of
the
two
slots

leaving
a
certain
amount
of

clearance

for
the
start

and
end
of
the

centrifugal
advance
movement

When

installing
the
distributor
take
care
to

align
the

body

and
rotor

with
the
marks
made
during
removal
The
rotor
must

be

positioned
in
its

original
location
it
will
turn

slightly
when

the
distributor
is
inserted
and
the

gear
teeth
mesh
Remove
and

replace
the
distributor
if

the
rotor
does
not

point
to
the

align

ment

mark
until
both
distributor

body
and
rotor
are
correctly

aligned

SPARKING
PLUGS

The

sparking
plugs
should
be

inspected
and
cleaned
at

regular
intervals
not

exceeding

every
10
000
km
6000
miles

New

sparking
plugs
should
be
fitted
at

approximately
20
000

km
12
000
miles

Remove
the

plugs
and
check
the
amount
of
electrode

wear
and

type
of

deposits
Brown
to

greyish
tan

deposits
with

slight
electrode
wear

indicate
that
the

plugs
are

satisfactory
and

working
in

the
correct
heat

range

Dry
fluffy
carbon

deposits
are
caused

by
too

rich
a
mixture

dirty
air
cleaner
excessive
idling
or

faulty
ignition
In
this

case

it
is
advisable
to

replace
the

plugs
with

plugs
having
a

higher
heat

range
Oily
wet
black

deposits
are
an

indication

of

oil
in

the
combustion
chambers

through
worn

pistons
and

rings
or
excessive
clearance
between
valve

guides
and
stems

The

engine
should
be
overhauled
and
hotter

plugs
installed
A

white
or

light
grey
centre

electrode
and
bluish
burned
side

electrode
indicates

engine
overheating
incorrect

ignition
timing

loose

plugs
low
fuel

pump
pressure
or
incorrect

grade
of
fuel

Colder

sparking
plugs
should
be
fitted

The

plugs
should
be
cleaned
on
a

blasting
machine
and

tested
Dress
the
electrodes
with
a
small
file
so
that
the
surfaces

of
both
electrodes
are
flat
and

parallel
Adjust
the
spark
plug

gap
to
0
8
0
9
mm
0
031
0
035
in

by
bending
the
earth

electrode
Refit
the

plugs
and

tighten
them
to
a

torque
reading

of
1
5
2
5

kgm
II
15Ib
ft

31