fuel filter DATSUN 610 1969 Workshop 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

Carburettor

type
Throttle

opening

angle

190

200
Dimension
A

213282

341

213282
221
l
3mm
0
051
in

I
4mm
0
056in

If

adjustment
is

required
the
choke
connecting
rod
can
be

carefully
bent
until
the

required
clearance
is

obtained

THROTTLE
VALVES
INTERLOCK
OPENING
ADJUSfMENT

Open
the

primary
throttle
valve
500
from
the

fully
closed

position
as
shown
in

Fig
D
I
O
At

this

angle
the
connecting

link
2
should
be
at

the
extreme

right
of
the

groove
in

the

primary
throttle
arm
The

linkage
between
the

primary
and

the

secondary
throttles
is

operating
correctly
if
the
clearance

C
between
the

primary
throttle
valve
and
the
wall
of
the

chamber
is
as
follows

Carburettor

type

213304

361

213304
421

213282
331

213282
341
Dimension
C

6
3
mm
0
248
in

6
3
mm
0
248

in

74
mm
0
291
in

74
mm
0
291
in

Adjustment
can
be
made
if

necessary
by
bending
the

connecting
link
until
the

required
clearance
is
obtained

DASHPOT
ADJUSfMENT

This

adjustment
is

only
required
on

carburettors
fitted
to

vehicles
with
automatic
transmission
Correct
contact
must
be

made
between
the
throttle
lever
and
the

dashpot
stem
See

Fig
D
II

Adjustment
can

be
carried
out
if

necessary
by

slackening
the
locknut
2
and
then

rotating
the

dashpot
in

either
direction
so
that
the
throttle
ann
touches
the
stem
at
a

throttle
valve

opening
angle
of
110
At

this
angle
the
clearance

B
between
the
throttle
valve
and
the
wall
of
the
chamber

should
be
as
follows

Carburettor

type

213304
421

213282
341
Dimension
B

0
780mm
90
0307
in

0
586mm
0
0231
in

Retighten
the
locknut
after

completing
the

adjustment

CARBURETTOR
Removal
and
Overhaul

The
carburettor
can
be
removed
from
the

engine
in
the

following
manner

Remove
the
air
cleaner

assembly

2
Disconnect
the
fuel
and
vacuum

pipes
and
the
choke
wire

from
the
carburettor

3
Remove
the
throttle
lever
and
take
off
the
nuts
and

washers

securing
the
carburettor
to

the
manifold

4
Lift
the
carburettor

away
from
the
manifold
and
discard

the

gasket

To
dismantle
the
carburettor
for
a

complete
overhaul

remove
the

primary
and

secondary
main

jets
and
needle
valves
these
are
accessible
from
the
exterior
of
the
carburettor

Remove
the
choke

connecting
rod

pump
lever
return

spring
and
set
screws
and
take
off
the
choke
chamber

The

primary
and

secondary
emulsion
tubes
can
be
with

drawn
after

removing
the
main
air
bleed
screws

If
the
accelerator

pump
is
to
be
checked
take
off
the

pump

cover
but
take
care
not
to
lose
the
return

spring
and

inlet
valve

ball
situated
at
the
lower

part
of
the

piston

Separate
the
throttle
chamber
from
the
float
chamber

by

removing
the

retaining
screws
leave
the
throttle
valve

intact

unless
otherwise

required

All

parts
of
the
carburettor
must
be
ctifefully
cleaned
and

sediment

gum
or

other

deposits
removed

Clean
the

jets
by
blowing
through
them
with

compressed

air
Never

push
wire

through
the

j
ts
or

passages
or
the
orifices

will
be

enlarged
and
the
calibration
affected

Check
all

parts
for

signs
of
wear
and

exchange
them
if

necessary

Examine
the
float
needle
and
seat
for
wear

and
make
sure

that
the
throttle
and
choke
bores
in
the
throttle

body
and

cover
are
not
worn
or
out
of
round
If
the

idling
adjustment

needles
have
burrs
or

ridges
they
must

be
replaced

Inspect
the

gaskets
to
make
sure
that

they
are
not
hard

and
brittle
or
distorted

Oean
the
filter
screen
if
it
is

clogged
or

change
it
if
it

is

otherwist

unsatisfactory

Check
the

operation
of
the
accelerator

pump
by
pouring

petrol
into
the
float
chamber
and
operating
the
throttle
lever

Petrol
should

spurt
from
the

pump
discharge
jet
if

the

pump
is

working
correctly
If

petrol
cannot
be

ejected
from
the

jet

when
the
lever
is
actuated
clean
the
discharge
jet
by
blowing

through
it
with
compressed
air

CARBURETTOR
Assembly
and
Installation

The

assembly
and
installation
of
the
carburettor
is
a

reversal
of

the
dismantling
and
removal

procedures
noting
the

following
points

Always
replace
the

gaskets
if

they
are
not

satisfactory
and

take
care
that
the
carburettor

linkage
operates
smoothly
and
is

not
bent
or
distorted

The

performance
of
the
carburettor
will

depend
on

the

condition
of

the
jets
and
air
bleeds
As

previously
stated
these

pacts
should
be
cleaned

using
petrol
and

compressed
air

only

Replacement
jets
or
air
bleed
screws
can

be
used
to

provide

greater
economy
or
to
increase

output
whatever
the
require

ment
When

the
carburettor
is
installed

adjust
the
idling
speed

as

previously
described

37

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

The

type
D3034C
carburettor
has
certain
additional

features

These
include
a

power
valve
mechanism
to

improve
the

performance

at

high
speed
a
fuel
cut
off
valve
which
cuts
the
fuel

supply

when
the

ignition
key
is
turned
to
the
off
position
and
an

idling

limiter
to

maintain
the

emissions
below
a

certain
level

Sectional
views
of
the
two

types
of

pumps
are
shown
in

Figs
8
1
and
B
2
An
EP
3
electrical
fuel

pump
is

located
in
the

centre

of
the
spare
wheel

housing
in
the
boot

Fig
B
3
shows
a

sectional
view
of
the

pump
with
its
contact

the
pump
mechanisms

solenoid

relay
and
built
in
filter

The
air
cleaner
uses
a

viscous

paper
type
element
which

should
be

replaced
every
40
000
km
24
000
miles

Cleaning

is
not

required
and
should
not
be

attempted

The

cartridge
type
fuel
strainer

incorporates
a
fibre
clement

which
should
be
renewed
at
inervals
not

exceeding
40
000
km

24
000
miles
Fit
B
4
shows
a
sectional
view
of

the
assembly

The
fuel
lines
should
not
be
disconnected
from
the
strainer
when

the
fuel
tank
is
full

unless
absolutely
necessary
as
the
strainer

is
below
the
fuel
level

FUEL
PUMP

Testing

Disconnect
the
fuel
hose
from
the

pump
outlet
Connect

a
hose
with

an
inner
diameter
of
approximately
6
mm
0
024

in
to

the

pump
outlet
and

place
a

container
under
the
end
of

the

pipe
Note
that
the
inner

diameter
of
the

pipe
must
not
be

too

small
or

the
pipe
will
be

incapable
of

delivering
the
correct

quantity
of
fuel
when

testing
Hold
the
end
of
the
hose
above
the

level
of
the

pump
and

operate
the

pump
for
more
than
IS

seconds
to
check
the

delivery
capacity
The

capacity
should
be

I
400
cc

3
24
U
S

pts
in
one
minute
or
less
The

pump
must

be
removed
from
the
vehicle
if
it
does
not

operate
or
if
a

reduced

quantity
of
fuel
flows
from
the
end
of
the
hose
Remove

the
pump
from
the
vehicle
and
test
as
follows

Connect
the

pump
to
a

fully
charged
battery
If
the

pump

now

operates
and

discharges
fuel

correctly
the
fault
does
not

lie
in
the

pump
but

may
be
attributed
to

any
of
the

following

causes

Battery
voltage
drop

poor
battery
earth
loose

wiring

loose
connections
blocked
hoses
or
a

faulty
carburettor

If
the

pump
does
not

operate
and

discharge
fuel
when

connected
to
the

battery
then
the

pump
itself
is

faulty
and

must
be
checked
as
follows

First
make
sure
that
current
is

flowing
This
will
be
indica

ted

by
sparking
at

the
tenninals
If
current
flows
the
trouble
is

caused

by
a

sticking

pump
plunger
or

piston
The

pump
must

be
dismantled
in

this
case
and
the

parts
thoroughly
cleaned
in

petrol

If

the
current
does
not
flow
a
coil
or
lead
wire
is
broken

and
the

pump
must

be
renewed
A

reduced
fuel
flow
is
caused

by
a

faulty
pump
inlet
or

discharged
valve
or
blocked
filter

mesh
The

pump
must

of
course

be
dismantled
and
serviced
as

necessary

FUEL
PUMP

Removing
and

Dismantling

Remove
the
bolts

attaching
the
fuel

pump
cover
to

the

floor

panel
see

Fig
B
S
Remove
the
bolts

attaching
the

pump
to
the
cover

2
Disconnect
the
cable
and
fuel
hoses
Withdraw

the

pump
Dismantle
as
follows

Slacken
the

locking
band
screws
and

remove
the
strainer

strainer

spring
filter
strainer
seal
and

locking
band

Remove
the

snap
ring
Withdraw
the
four
screws
from
the

yoke
and
remove

the
electromagnetic
ulJ
it
Press
the

plunger
down
and
withdraw
the
inlet
vaive

the

packing

and
the
cylinder
and

plunger
assembly

A
defective
eledrical
unit

cannot
be
dismantled
as

it
is

sealed
and
must

be
renewed
as
a

complete
unit

FUEL
PUMP

Inspection
and

Assembly

Wash
the
strainer
filter
and

gasket
in

petrol
and

dry
using

compressed
air
Renew
the
filter
and

gasket
if

necessary
Note

that
the
filter
should
be
cleaned
every
40
000

km
24
000

miles
Wash
the

plunger
piston
and
inlet
valve
in

petrol
and

make
sure
the

piston
moves

smoothly
in
the

cylinder
Replace

the

parts
if
found
to
be
defective

Insert
the

plunger
assembly
into
the

cylinder
of
the
electri

cal
unit
and
move

the

assembly
up
and
down
to

make
sure
tha
t

the
contacts
are

operated
If
the
contacts
do
not

operate
the

electrical
unit
is

faulty
and
must

be
renewed

Assembly
is
a
reversal
of

the
dismantling
procedures
tak

ing
care
to
renew
the

gaskets
as

necessary

CARBURETIOR

Idling
Adjustment

The
D3034C
carburettor
fitted
to

engines
equipped
with

an
emission
control

system
must
be

adjusted
as
described
under

the

heading
IGNITION
TIMING
AND
IDLING
SPEED
in
the

section
EMISSION
CONTROL
SYSTEM

Reference
should
be
made
to
carburettor

idling
adjustment

procedures
for
the
L14
L16

and
LI8

engines
when

adjusting

the
type
DAK
340
carburettor
fitted
to
the
G
18

engine
A
smooth

engine
speed
of

approximately
550

rpm
should
be
attained
in

this
case

FUEL
lEVEL

Adjustment
DAK
340earburettor

A
constant
fuellevcl
in
the
float
chamber
is
maintained

by

the
float
and
needle
valve
See

Fig
8
6
If

the
fuel
level
does
not

correspond
with
the
level

gauge
line
it
will
be

necessary
to

care

fully
bend
the
float
seat
until
the
float

upper
position
is

correctly

set

The
clearance
H
between
valve
stem
and
float
seat

should

be
I
5
mm
0
0059
in
with
the
float

fully
lifted

Adjustment

can
be
carried
out

by
carefully
bending
the
float
stopper
3

FUEL
lEVEL

Adjustment
D3034Ccarburettnr

The
fuel
level
should

correspond
with
the
level

gauge
line

Adjustment
can

be
carried
out
if

necessary
by
changing
the

gaskets
between
the
float
chamber

body
and
needle
valve
seat

The
gaskets
are
shown
as
item
4
in

Fig
B
7
When

correctly

adjusted
there
should
be
a

clearance
of

approximately
7
mm

0
027
in
between
float
and
chamber
as
indicated

STARTING

INTERLOCK
VALVE
OPENING

The

choke
valve
at
its

fully
closed
position
automatically

opens
the
throttle
valve
to
an

optimum
angle
of
14

degrees
on

the

type
DAK
340
carburettor
and
13
5

degrees
on
the
D3034C

carburettor
With
the
choke
valve

fully
closed
the
clearance

G

I
in

Fig
8
should
be
1

I
mm
0
0433

in
This
clearance

S19

between

primary
throttle
valve

and
the
wall
of
the
throttle

chamber
can

be

adjusted
if

necessary
by
carefully

bending
the

choke

connecting
rod
3

THROTILE

VALVE
INTERLOCK
OPENING

With

the

primary
throttle
valve
of
the

type
DAK340

carburettor

opened
to
600
as
shown

in
Fig
B
9
the

adjusting

plate
3
should
contact

the

connecting
lever

J
This

being

the

point
before
the

secondary
throttle
valve
is

brough
into

operation
The

linkage
between

primary
and

secondary
throttles

is

working
correctly
if
the
clearance

G
between

primary
throttle

valve
and
the
wall
of
the
chamber
is
738
mm
0
3937
in

Adjust
if

necessary
by
carefully

bending
the
adjusting

plate
at

point
A
until
the
correct

setting
is
obtained

With
the

primary
throttle
valve
of
the

type
D3034C
car

burettor

opened
at
an

angle
of
500
the

connecting
link
3
in

Fig
B
IO
should
ge
at
the
extreme
left
of
the
slot
in
the
throttle

ann
4
With
the

linkage

positioned
as

shown
measure

the

clearance
between

primary
throttle
valve
and
the
wall
of
the

chamber
as
described
for
the
DAK340

carburettor

Adjustment

can

be
made
if

necessary
by
bending
the

connecting
link
until

the
correct
clearance
is
obtained

CARBURElTOR

Removing
and

Dismantling

The
carburettor
can
be
removed

by
following
the

instruc

tions

previously
given
for
carburettor
removal
on
the
Ll4
L16

and
LIB

engines

Dismantle
the
type
DAK340
carburettor
as
follows

Remove
the

primary
throttle
return

spring
Take
off
the

E

ring
and
remove

the
pump
and

connecting
rod
Remove
the

split
pin
and
choke

connecting
rod
Remove
the

secondary

throttle
return

spring
Remove
the
choke
wire
arm
choke
valve

shaft
and
valve

spring
Take
off
the

clip
and
remove

the
choke

lever
and

spring
To
dismantle
the
float
chamber
take
off
the

diaphragm
cover
and
remove
the

spring
and

diaphragm
Remove
the

diaphragm
chamber
and

gasket
Take
off

the
float
chamber

cover
and
remove
the

gasket
level

gauge
rubber
seal
and
float

Remove
the
screw
from
the
filter
and
withdraw
the

nipple

and
filter
Remove
the

needle
valve
Take
off
the

cylinder

cover

and

pump
cover

and
withdraw
the

piston
piston
return

spring
and
inlet
valve
Remove
the

primary
main
air
bleed
the

secondary
main
air
bleed
and
emulsion
tube
Take

off
the

small
venturi
and
remove
the

primary
and

secondary
slow

jets

and
slow
air
bleeds
Remove
the
drain

plugs
and
take
out
the

primary
and

secondary
main

jets

To
dismantle
the
throttle
chamber
remove
the
throttle

adjusting
screw
and

spring
and
the
idling
adjusting
screw
and

spring
Withdraw
the
throttle
lever

spring
hanger
sleeve

connecting
lever
return

plate
and

adjusting
plate
Withdraw

the

primary
throttle
valve
and

primary
throttle
shaft
Withdraw

the

secondary
throttle
valve
and

secondary
throttle
shaft

The

type
D3034C
carburettor
can
be
dismantled
as
follows

Detach
the

starting
connecting
rod
from
the
choke

lever
and

accelerator

pump
connecting
rod

Remove
the
air
horn

pump
rod
slow

jets
the

primary
and

secondary
small
venturies
Detach
the

primary
and

secondary

linkages
Take
off
the

diaphragm
chambe
cover
and
take
out

the

spring
and

diaphragm
Remove
the

diaphragm
chamber
and

gasket
Separate
the
float
chamber
from
the
throttle
chamber

take
off

the
float
chamber
cover
and
remove
the

components

Remove
the
inlet
strainer
and
float
valve
seat
Remove
the
main

jets
and

take
off
the
fuel

cut
off

valve

CARBURETTOR

Assembly
and
Installation

The

assembly
and
installation
of
the
carburettor
is
a

reversal
of
the

dismantling
and
removal

procedures

Clean
and

inspect
all

components
as
described
for
the

carburettors
fitted
to
the
Ll4
Ll6
and
LI8

engines

TechnIcal
Data

CARBURETIOR
Small
ven
turi

First
7mm

8mm

Carburettor

Type
DAK340
Second
14mm
16mm

Main

jet
02
155

Primary
Secondary
Slow

jet
50
80

Main
air
bleed
60
80

Outlet
diameter
30mm
34mm
Emulsion
hole
0
5
mm
O
5mm

Venturi

diameter
23
mm

29
x
9
mm

Slow
air
bleed

Main

jet
119
165
First
160

Main
air
bleed
220
100

Second
150
220

Slow

jet
48
90

Slow
economizer
1
6
mm

dia

Slow
air
bleed
130
100

Power

jet
50

Slow
economizer
L4mm

Cushion

jet
120

Economizer
bleed
1
2mm

Air

jet
150

Carburettor

Type
D3034C
Power

system
Vacllum

acting

Vacuum

piston
diameter
9
0
mm
0
354
in

Primary

Secondary
Piston

spring
100

gr
0
220
Ibs
31
mm

1
22
in

Bore
30mm
34mm
Power
valve

spring
40

gr
0
0882
lbs
8
6mm

Large
venturi
23mm

28mm
0
34
in

52