dimensions DATSUN 610 1969 Workshop Manual

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

it

r

inter
iJ
i

@
Pl

Fig
A
16

Correcting
the
valve
seats

Li4

lnlakt

t1

c
r

I
I
37
8

1
4882
di

410
6142
dia

Unit
rnrn

in

L14

and
L16

Exhaust

Ct

rill
I
II

ill
300
1Bll
du

l
32
6

1
2835
dia

37
1

4561

dia

Unll
In
Llb
thtwin
1
13

Ut

WiTh
Ie

ro

rLl
Incak

h

C
1

q
J

j
Exhaust

Fig
A
I
Standard
valve
seat
dimensions

U
l

and
liS

11tJ

1l
ioo

l

j
1
4
u

055i1

r

m
JA

9bIJUI4

l

9
611

559lldi
a

4L80
6457
dlll

45
J
1717

liS

311

fJ
90o

LJ
1
3
0
0512

r

1
II

I

i
30
n

Il
i1
I
tlla

32

60
2835
di
L

34
6
1
3622
dla

37
1

4561lia

Fig
A

IS
Valve
at

grinding
dimensions

10

CYUNDER
HEAD
RECESS
DIAMETER

Standard
inoerts

Engine

L14

Ll6

and
Ll8
Inlet

41
000
41
016
1
6142
1
6148
in

45
000
45
016
mm
1
77l7
1
77231n

Engine

Ll4

Ll6
and
Ll8
Exhaust

37
000
37
016mm

1
4567
1
4573
in

37
000
37

016mm
l
4567
1
4573
in

CYLINDER
HEAD
RECESS
DIAMETER

Oversize
inserts

Engine

Ll4

Ll6andLl8
Inlet

41
500
41

516mm
l
6339
1
6345in

45
S00
45
516mm
I
7913
1
7920in

Engine

L14

Ll6andLl8
Exhaust

37
500
37
516mm
1
4764
14770in

37
500
37

516mm
1
4764
l4770in

Dimensions
for
the
standard
valve
inserts
are

shown
in

Fig
A
17
Heat
the

cylinder
head
to
a

temperature
of
ISO
20DOC

302
3920F
and
drive
in
the
inserts

making
sure

that
they

bed
down
correctly
The
inserts
should
be
caulked
at
more
than

four

positions
and
then
cuf
or

ground
to

the

specified

dimensions
shown
in
Fig
A
IS

Place
a
small
amount

of
fine

grinding
compound
on
the

seating
face
of

the
valve
and
insert
the
valve
into
the
valve

guide

Lap
the
valve

against
its
seat

by
rotating
it
backwards
and

forwards

approximately
half
a
revolution
in
each
direction

until
a
continous

seating
has
been
obtained
Remove
the
valve

and
clean
all
traces
of

the

grinding
compound
from
valve
and

seat

VALVE
SPRINGS

The
valve

springs
can
be
checked
for

squareness
using
a

steel

square
and
surface

plate
If
the

spring
is
out
of

square
by

more
than
1
6mm
0
063
in
it
must

be

replaced
Check
the

free

length
and
the
load

required
to
deflect
the

spring
to

its

assembled

height
Compare
the
figures
obtained
with
those

given
in
Technical
Data

and
replace
the

spring
if
the

specified

limits
are
exceeded

CAMSHAFT
AND
CAMSHAFT
BEARINGS

Checking

Measure
the
clearance
between
the
inner
diameter
of
the

camshaft

bearing
and
the
outer
diameter
of
the
camshaft

journal
If
the
wear
limit
for
the

bearing
clearance
exceeds

O
lmm
0
0039
in
it
will
be

necessary
to

replace
the

cylinder

block
assembly
See
Technical
Data
for
all
diameters

Check
the
camshaft
and
camshaft

journals
for

signs
of

wear
or

damage

ace
the
camshaft
in
V
Blocks
as
shown
in

Fig
A
19
and

position
the

dial

gauge
to
the

journal
The
run
out
of
the
cam

shaft

must
not
exceed
0
05
mm
0
0020in
It
should
be
noted
that
the
actual
run
out
will
be
half

the
the
value
indicated
on
the

dial

gauge
When
the
camshaft
is
turned
one
full
revolution

with
the
dial

gauge
positioned
against
the
second
and
third

journals

CYLINDER
BLOCK

Inspection
and
Overhaul

Ensure
that
the

cylinder
block
is

thoroughly
clean
and

check
it
for
cracks
and
flaws

Check
the

joint
face
of
the
block
for
distortion

using
a

straight
edge
and
feeler

gauge
as
shown
in

Fig
A
20
The
surface

must

be

reground
if
the
maximum
tolerance
of
O
lmm

0
0039
in
is
exceeded

Examine
the

cylinder
bores
for
out
of
round
or

taper

using
a

bore

gauge
as

shown
in

Fig
A
21
The
readings
must

be
taken
at
the

Top
middle
and
bottom
positions
indicated

in

Fig
A
22

The
standard
bore
diameters
are

83
000
83
050
rom

3
2677
3
3697
in
for
the
1400
and
1600cc

engines
and
85
000

85
050
mm
3
3465
3
3484
in

for
the
1800
cc

engine
with
a

wear
limit
of
0
2mm
0
0079
in

Out
of
round
and

taper
must
not
exceed
0
15mm

0
0006
in
If
the
bores
are
within
the

specified
limits
remove

the
carbon
ridge
at
the

top
of
the

cylinder
bores
wring
a

suitable

ridge
reamer

If

any
of
the
bores
are
in
excess
of
the

specified
limits

then
all
the
bores
must
be
rebored
at

the
same
time
Pistons

are

available
in
five
oversizes
See
Technical
Data
and
can
be

selected
in
accordance
with
the
amount
of
wear
of

the
cylinder

When
the
oversize
of

the

pistons
has
been
decided
it
will

be
necessary
to
measure
the

piston
at
the

piston
skirt

Fig
A
23

and
add
to

this
dimension
the

specified
piston
to

cylinder
bore

clearance
to
determine
the
final
honed
measurement
of
the

cylinder

Machine
the

cylinder
bores
in

gradual
stages
taking
only

a
0
5mm
0
002

in
cut
each
time
The
bores
must

be
brought

to
the
final
size

by
honing
and
the
block

thoroughly
cleaned

to
remove
all
traces
of
metal

Measure
the
finished

bore
and
check
the
clearance
between

each

piston
and
its

cylinder
The
clearance
can

be
checked
as

shown
in

Fig
A
24
with
the
aid
of
a
feeler

gauge
and

spring

scale
The
standard
clearance
is
0
023
0
043
mm
0
0009

0
0017
in

NOTE
Cylinder
liners
can
be
fitted
if

the
cylinder
bores

are
worn

beyond
the

maximum
limit

The
liners
are
an
interference
fit
in
the
block
and

must
be
bored
to
the
correct

inner
diameter

after

fitting
Three
undersize
liners
are
available

in
the
following
sizes

11

OUTER
DIAMETER

4
0mm
0
1575
in
Undersize

4
5mm
0
1772
in
Undersize

5
Omm
0
1969
in
Undersize
87
000
87
05mm
3
4252
3
4272
in

87
50
87
55mm
3
4449
3
4468
in

88
00
88
05mm
3
4646
3
4665
in

PISTONS

Checking

Check
each

piston
for

signs
of

seizure
and
wear
Renew

BIlY
piston
which
is
unsatisfactory

Remove
all
carbon
deposits
from
the

grooves
and

piston

rings
Measure
the
side
clearance
of
each

piston
ring
and

groove

with
a
feeler

gauge
as
shown
in

Fig
A
25
If
the
side
clearance
is

excessive
new

rings
should
be
fitted
The
clearance

required
for

new

pistons
a

piston
rings
can
be
found
in
Technical
Data

Check
the

piston
ring
gap
by
placing
the

ring
in
the

cylinder

bore
as
shown
in

Fig
A
26
The

ring
can

be

squared
in
the

bore

by
pushing
it
into

position
with
the

piston
Measure
the

ring
gaps

with
a
feeler

gauge
and

compare
the
dimensions
with
the
infor

mation

given
in
Technical
Data

NOTE
If
new

piston
rings
are
to

be
fitted
and
the

cylinder

has
not
been
rebafed
check
the

piston
ring
gap
with

the

ring
positioned
at
the
bottom
of
the

cylinder

This
being
the

position
with
the
least
amount
of
wear

O1eck
the
clearance
between

gudgeon
pin
and

piston
If

the

specified
limit
is
exceeded
it
will
be

necessary
to

replace

both

piston
and

pin
It
should
be

possible
to

press
the

gudgeon

pin
into
the

piston
by
hand
at
a
room

temperature
of
200C

680F
The

pin
should
be
a
tight

press
fit
in
the

connecting

rod

CONNECTING
RODS

O1ecking

Cleck
the

connecting
rods
for
bends
or

twists

using
a

guitable

connecting
rod

aligner
The
maximum
deviation
should

not
exceed
0

05
mm
0
0020
in

per
100
mm
3
94
in

length

of
rod

Straighten
or

replace

any
rod
which
does
not

comply

with
the

specified
limit

When

replacing
the
connecting
rod
it
is
essential
to
ensure

that
the

weight
difference
between
new
and
old
rods
is
within

5

gr
0
18
oz
for
the
1400
cc

engine
and
7

gr
0
25
oz
for

the
1600
and
1800
cc

engines

Install
the
connecting
rods
with

bearings
to

the

correspond

ing
crank

pins
and
measure
the
end

play
of
the

big
ends
s
e

Fig
A
27
The
end

play
should
be
between
0
2
0
3
mm

0
0079
0
0118
in
fthe
maximum
limit
of
0
6
mm
0
Ql18

in
is
exceeded
the
connecting
rod

must
be

replaced

CRANKSHAFT

Inspection
and
Overhaul

aean
the
crankshaft

thoroughly
before

checking
the
shaft

for
distortion
and
cracks

Measure
the

journals
and

crankpins
for
our
of
round
If

the

journals
and

pins
are
found
to
be
oval
or

if
the
wear

limit

exceeds
the

specified
fUnning
clearance
it
will

be
necessary
to

re
llrind
the
crankshaft
to

the

required
undersize
See
Technical
I

INNER
DIAMETER

82
45
82
60mm
3
24613
2520
in

82
4S
82
60mm
3
24613
2520
in

82
4S
82
60mm
3
24613
2520
in

Data

Place
the
crankshaft
in
V
blocks
as
shown
in
Fig
A
28

and
check
with
the
aid
of
a
dial

gauge
that
the
shaft

bending

limit
of
0
05
mm
0
002
in
is
not
exceeded
With
the
dial

gauge

positioned
against
the
centre

journal
the
crankshaft
should
be

rotated

by
one
turn
The
actual
bend
value
will
be
a
half
of
the

reading
obtained
on
the

gauge
If
the

specified
limit
is
exceeded

it
will
be

necessary
to

replace
the
crankshaft

Install
the
crankshaft
in
the
cylinder
block
and
check
the

crankshaft
end
float
which
should
be
be
J
Yieen
0
05
0
18
mm

0
0020
0
0071
in
Make
sure
that
the
main
drive
shaft

pilot

bushing
at
the
rear
of
the
crankshaft
is
not
worn
or

damaged
in

any
way
Replace
the

bushing
if

necessary
using
the

special

puller
STl
66
1000
I

Thoroughly
clean
the
bushing
hole
before

installing
and

press
in
the
new

bushing
without

oiling
so
that
its

height

above
the

flange
end
is
4
5
5
0
mm
0
18
0
20
in

Main

bearing
clearance

The
main
bearing
clearances
can
be
checked

using
a

strip

of

plastigage
Set
the
main
bearings
on
the

caps
Cut
the

plasti

gage
to
the
width
of
the

bearing
and

place
it

along
the

crankpin

making
sure
that
it
is
clear
of

the
oil
hole
Install
the
bearing

caps
and

tighten
the
bearing

cap
bolts
to
a

torque
reading
of
4
5

5
5

kgm
33
40
Ib
ft
DO
NOT
turn
the
crankshaft
when

the

plastigage
is
inserted
Remove
the
main

bearing
cap
and
take

out
the

plastigage
which
should
be
measured
at
its
widest

po
t

with
the
scale

printed
in
the
plastigage
envelope
The
standard

clearance
is
0
020
0
062
mm
0
0008
0
0024
in
with
a
wear

limit
of
0
1
mm
0
0039
in
If
the

specified
limit
is
exceeded

an
undersize

bearing
must

be
used
and
the
crankshaft
journal

ground
accordingly
See
Technical
Data

Bearings
are
available

in
four
undersize
of
0
25
0
50
0
75
and
1
00
mm
0
0098

0
0197
0
0295
and
0
0394
in

Connecting
rod

bearing
clearance

The

connecting
rod

bearing
clearances
should
be
checked

in
a
similar
manner
to

the
main

bearing
clearances
The
standard

clearance
is
0
025
0
055
mm
0
0010
0
0022
in
with
a
wear

limit
of
0
1
mm
0
0039
in
Undersize
bearings
must
be
fitted

and
the

crankpins
reground
if
the

specified
wear
limit
is
ex

ceeded
See
Technical
Data

Bearings
are
available
in
six
under

sizes
of
0
6
0
12
0
25
0
50
0
75
and
1
00
mm
0
0236

0
0047
0
0098
0
0197
0
0295
and
0
0394
in

Fitting
the
crankshaft

bearings

Cb
eck
the
fit
of
the

bearing
shells
in
the
following
manner

Install
the
shells
on
the
main

bearing
caps
and

cylinder
block

bearing
recess

and

tighten
the

cap
bolts
to
the

specified
torque

13

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