ground clearance DATSUN 610 1969 Workshop Manual
[x] Cancel search | Manufacturer: DATSUN, Model Year: 1969, Model line: 610, Model: DATSUN 610 1969Pages: 171, PDF Size: 10.63 MB
Page 10 of 171

Remove
the
fan
and
pulley
the
right
hand
engine
mounting
and
oil
filter
Remove
the
oil
pressure
switch
Remove
the
following
items
oil
level
gauge
spark
plugs
thermostat
housing
rocker
cover
carburettor
and
inlet
and
exhaust
manifolds
Remove
the
clutch
assembly
as
described
in
the
section
CLUTCH
Remove
the
left
hand
engine
mounting
crankshaft
pulley
water
pump
fuel
pump
fuel
pump
drive
earn
and
cam
shaft
sprocket
See
Fig
A
4
Remove
the
cylinder
head
bolts
in
the
sequence
shown
in
Fig
A
5
and
lift
off
the
cylinder
head
Invert
the
engine
and
remove
the
oil
sump
and
oil
strainer
oil
pump
and
drive
spindle
assembly
front
cover
and
chain
tensioner
Remove
the
timing
chain
oil
thrower
crank
shaft
worm
gear
and
chain
drive
sprocket
See
Fig
A
6
andA
7
Remove
the
connecting
rod
caps
and
push
the
pistons
and
connecting
rods
through
the
top
of
the
bores
as
shown
in
Fig
A
B
Keep
the
connecting
rod
caps
with
their
respective
rods
to
ensure
that
they
are
assembled
in
their
original
positions
Remove
the
flywheel
retaining
bolts
and
withdraw
the
fly
wheel
Fig
A
9
Remove
the
main
bearing
caps
using
the
special
puller
ST
1651
SOOO
to
withdraw
the
centre
and
rear
main
bearing
caps
as
shown
in
Fig
A
l
O
Remove
the
rear
oil
seal
and
lift
out
the
crankshaft
remove
the
baffie
plate
and
cylinder
block
net
Fig
A
II
Remove
the
piston
rings
with
a
suitable
expander
and
press
out
the
gudgeon
pins
under
an
arbor
press
using
the
special
stand
STl300001
as
shown
in
Fig
A
12
Keep
the
dismantled
parts
in
order
so
that
they
can
be
reassembled
in
their
original
positions
Slacken
the
valve
rocker
pivot
lock
nut
and
remove
the
rocker
arms
by
pressing
down
the
valve
springs
Remove
the
camshaft
taking
care
not
to
damage
the
bearings
and
earn
lobes
Withdraw
the
valves
using
the
valve
lifter
STl2070000
as
shown
in
Fig
A
13
ENGINE
Inspection
and
Overhaul
Cylinder
Head
and
Valves
Clean
all
parts
thoroughly
and
remove
carbon
deposits
with
a
blunt
scraper
Remove
any
rust
which
has
accumulated
in
the
water
passages
and
blow
through
the
oil
holes
with
compres
sed
air
to
make
sure
that
they
are
clear
Measure
the
joint
face
of
the
cylinder
head
for
out
of
true
as
shown
in
Fig
A
14
The
surface
should
be
checked
at
various
positions
using
a
straight
edge
and
feeler
gauge
The
permissible
amount
of
distortion
is
0
05
mm
0
0020
in
or
less
If
the
surface
is
out
of
true
by
more
than
the
limit
of
0
1
mm
0
0039
in
it
will
be
necessary
to
regrind
the
head
Clean
each
valve
by
washing
in
petrol
and
carefully
examine
the
stems
and
heads
If
the
stem
is
worn
damaged
or
not
straight
the
valve
must
be
discarded
Check
the
diameter
of
the
stem
with
a
micro
meter
The
diameter
of
the
inlet
valves
should
be
7
965
7
980
mm
0
3136
0
3142
in
and
the
diameter
of
the
exhaust
valves
7
945
7
960
mm
0
3128
0
3134
in
If
the
seating
face
of
the
valve
is
excessively
burned
damaged
or
distorted
it
must
be
discarded
A
badly
pitted
seating
face
should
be
refaced
on
a
valve
grinding
machine
removing
only
the
minimum
amount
of
metal
Renew
the
valve
if
the
thickness
of
the
valve
head
has
been
reduced
by
0
5
mm
0
0197
in
see
Technical
Data
for
valve
dimensions
The
valve
stem
tip
may
be
refaced
if
necessary
the
maxi
mum
allowance
however
is
0
5
mm
0
0197
in
The
valves
can
be
ground
in
to
their
seats
when
completely
satisfactory
The
valve
seats
and
valve
guides
should
be
in
good
condition
and
must
be
checked
as
described
in
the
following
paragraphs
VALVE
GUIDES
Replacement
The
valve
stem
to
valve
guide
clearance
can
be
checked
by
inserting
a
new
valve
into
the
guide
The
stem
to
guide
clearance
should
be
0
020
0
053
mm
0
0008
0
0021
in
for
the
inlet
valves
and
0
040
0
073
mm
0
0016
0
0029
in
for
the
exhaust
valves
If
the
clearance
exceeds
0
1
mm
0
0039
in
for
the
inlet
valves
and
the
exhaust
valves
then
new
guides
should
be
fitted
The
valve
guides
are
held
in
position
with
an
interference
fit
of
0
027
0
049
mm
0
0011
0
0019
in
and
can
be
removed
by
means
of
a
press
and
drift
2
ton
pressure
This
operation
can
be
carried
out
at
room
temperature
but
will
be
more
effectively
performed
at
a
higher
temperature
Valve
guides
are
available
with
oversize
diameters
of
0
2
mm
0
0079
in
if
required
The
standard
valve
guide
requires
a
bore
in
the
cylinder
head
of
11
985
11
996
mm
dia
0
4719
0
4723
in
dia
and
the
oversize
valve
guide
a
bore
of
12
185
12
196
mm
dia
0
4797
0
4802
in
dial
The
cylinder
head
guide
bore
must
be
reamed
out
at
normal
room
temperature
Heat
the
cylinder
head
to
a
temperature
of
150
2000e
302
3920F
before
pressing
in
the
new
valve
guides
Ream
out
the
bore
of
the
guides
to
obtain
the
desired
fInish
and
clearance
Fig
A
IS
The
special
valve
guid
reamer
ST
1103
SOOO
should
be
used
if
available
Valve
guide
inner
diameters
are
specified
in
Technical
Data
at
the
end
of
this
section
The
valve
seat
surface
must
be
concentric
with
the
guide
bore
and
can
be
corrected
with
the
facing
tool
STll670000
Fig
A
16
using
the
new
valve
guide
as
the
axis
VALVE
SEAT
INSERTS
Replacing
The
valve
seat
inserts
should
be
replaced
if
they
show
signs
of
pitting
and
excessive
wear
The
inserts
can
be
removed
by
boring
out
to
a
depth
which
will
cause
them
to
collapse
although
care
must
be
taken
not
to
bore
beyond
the
bottom
face
of
the
recess
in
the
cylinder
head
Select
the
valve
seat
inserts
and
check
the
outer
diameters
Machine
the
recess
in
the
cylinder
head
to
the
following
dimensions
at
room
temperature
9
Page 12 of 171

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
Page 14 of 171

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
Page 20 of 171

VALVE
CLEARANCES
Adjusting
Incorrect
valve
clearance
will
affect
the
performance
of
the
engine
and
may
damage
the
valves
and
valve
seats
Insuf
ficient
valve
clearance
will
result
in
loss
of
power
and
may
prevent
the
valve
from
seating
properly
Excessive
clearance
causes
the
valve
to
seat
and
reduces
the
amount
of
valve
lift
This
will
result
in
noisy
operation
with
damage
to
the
valves
and
seats
Adjustment
is
made
with
the
engine
switched
off
and
should
be
carried
out
initially
with
the
engine
cold
to
allow
the
engine
to
run
Final
adjustments
are
made
after
wanning
up
the
engine
to
its
Donnal
operating
temperature
The
engine
can
be
rotated
by
removing
the
sparking
plugs
to
release
the
cylinder
compressions
then
selecting
top
gear
and
pushing
the
vehicle
backwards
and
forwards
The
cold
valve
clearances
should
be
set
to
0
20
mm
0
0079
in
for
the
inlet
valves
and
0
25
mm
0
0098
in
for
the
exhaust
valves
Check
the
clearance
between
the
valve
and
rocker
using
a
feeler
gauge
as
shown
in
Fig
A
40
Slacken
the
locknut
and
turn
the
adjusting
screw
until
the
specified
clearance
is
obtained
then
tighten
the
locknut
and
recheck
the
clearance
The
feeler
gauge
should
just
be
free
to
move
between
the
rocker
and
valve
When
the
cold
valve
clearances
have
been
set
run
the
engine
until
it
reaches
its
normal
operating
temperature
then
switch
off
and
adjust
the
valve
clearances
with
the
engine
warm
to
0
25
mm
0
0098
in
for
the
inlet
valves
and
0
30
mm
0
0118
in
for
the
exhaust
valves
ENGINE
LUBRICATION
SYSTEM
Fig
A
41
OIL
PUMP
Removal
and
Dismantling
The
rotor
type
oil
pump
is
mounted
at
the
bottom
of
the
front
timing
cover
and
driven
by
the
distributor
drive
shaft
assembly
Overhaul
of
the
pump
will
require
careful
measurement
of
the
various
clearances
to
determine
the
amount
of
wear
which
has
taken
place
If
any
part
is
found
to
be
worn
it
may
be
neces
sary
to
replace
the
entire
oil
pump
assembly
To
remove
the
oil
pump
from
the
engine
proceed
as
follows
1
Remove
the
distributor
assembly
as
described
in
the
section
IGNITION
SYSTEM
Remove
the
oil
sump
drain
plug
and
drain
off
the
engine
oil
See
under
the
heading
CHANGING
THE
ENGINE
OIL
2
Remove
the
front
stabiliser
and
the
splash
shield
board
3
Withdraw
the
securing
bolts
and
detach
the
oil
pump
body
together
with
the
drive
gear
spindle
Take
out
the
bolts
securing
the
pump
cover
to
the
pump
body
and
withdraw
the
rotors
and
drive
shaft
See
Fig
A
42
The
pin
securing
the
driven
shaft
and
inner
rotor
must
not
00
taken
out
as
the
shaft
is
press
fitted
to
the
rotor
and
the
pin
is
caulked
Unscrew
the
threaded
plug
and
withdraw
the
regulator
valve
and
spring
Oean
each
part
thoroughly
and
examine
for
signs
of
damage
or
wear
Use
a
feeler
gauge
to
check
the
side
clearances
between
the
outer
and
inner
rotors
the
clearances
at
the
tips
of
the
rotors
and
the
clearance
between
the
outer
rotor
and
the
pump
body
See
Technical
Data
for
the
relevant
clearances
The
clearances
can
be
checked
using
a
straight
edge
as
shown
in
Fig
A
43
OIL
PUMP
Assembly
and
Installation
Assembly
is
a
reversal
of
the
dismantling
procedure
Before
installing
the
oil
pump
in
the
engine
it
will
be
necessary
to
rotate
the
engine
until
the
No
1
piston
is
at
T
D
C
on
its
compression
stroke
Fill
the
pump
housing
with
engine
oil
and
align
the
punch
mark
on
the
spindle
with
the
hole
in
the
oil
pump
as
shown
in
Fig
A
44
Install
the
pump
with
a
new
gasket
and
tighten
the
securing
bolts
to
a
torque
reading
of
1
1
1
5
kgm
8
1
Ilb
ft
Replace
the
splash
shield
board
and
the
front
stabiliser
refill
the
engine
with
the
specified
amount
of
engine
oil
OIL
FILTER
The
cartridge
type
oil
filter
can
be
removed
with
the
special
tool
ST
19320000
or
a
suitable
filter
remover
Interior
cleaning
is
not
necessary
but
the
ftIter
body
and
element
must
be
repiaced
every
10
000
km
6000
miles
Be
care
ul
not
to
overtighten
the
filter
when
replacing
or
oil
leakage
may
occur
CHANGING
THE
ENGINE
OIL
After
the
fIrst
oil
change
which
should
take
place
at
1000
km
600
miles
the
oil
should
be
changed
regularly
at
5000
km
3000
miles
intervals
Draining
is
more
easily
accomplished
after
a
lengthy
run
when
the
oil
being
thoroughly
warm
will
flow
quite
freely
Stand
the
vehicle
on
level
ground
and
place
a
suitable
container
under
the
drain
plug
Remove
the
drain
plug
carefully
as
the
hot
oil
may
spurt
out
with
considerable
force
When
refIlling
the
engine
make
sure
that
the
oil
is
to
the
H
mark
on
the
dipstick
19
Page 136 of 171

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
Page 138 of 171

CAMSHAFT
AND
CAMSHAFT
BEARINGS
Check
the
camshaft
bearing
and
journals
for
signs
of
wear
Plastigage
should
be
used
to
check
the
clearance
between
bear
ing
and
journal
which
should
be
0
025
0
075
mm
O
OOl
0
0030
in
The
cylinder
head
assembly
must
be
renewed
if
the
wear
limit
of
0
mm
0
0039
in
is
exceeded
Place
the
camshaft
in
V
blocks
and
apply
a
dial
gauge
to
the
centre
journal
to
check
the
amount
of
camshaft
bend
The
run
out
of
the
camshaft
must
not
exceed
0
03
mm
0
0012
in
It
should
be
noted
that
the
actual
run
out
will
be
half
the
value
indicated
on
the
dial
gauge
when
the
camshaft
is
turned
one
full
revolution
Check
the
camshaft
end
play
which
should
be
within
0
07
0
148
mm
0
0028
0
0058
in
Check
the
earn
contacting
surfaces
of
the
valve
rocker
and
the
earn
heels
of
the
camshaft
Slight
damage
can
be
corrected
using
a
fine
oil
stone
It
is
advisable
at
this
stage
to
check
the
clearance
of
the
rocker
shaft
and
rocker
bushes
which
should
be
0
016
0
052
mm
0
0006
0
0020
in
The
parts
must
be
renewed
if
the
wear
limit
of
0
07
mm
0
0028
in
is
exceeded
CYLINDER
BLOCK
Inspection
and
Overhaul
Check
the
block
for
signs
of
cracks
or
flaws
Measure
the
joint
face
for
distortion
using
a
straight
edge
and
feeler
gauge
as
described
for
the
L14
Ll6
and
L18
engines
The
surface
must
be
reground
if
the
maximum
limit
of
0
10
mm
0
0039
in
is
exceeded
Check
the
cylinder
bores
for
wear
out
of
round
and
excessive
taper
Use
a
bore
gauge
to
take
readings
at
the
top
middle
and
bottom
positions
of
the
bore
as
previously
described
The
standard
bore
diameters
are
85
000
mm
0
035
0
mm
3
347
0
0014
0
in
with
a
wear
limit
of
0
2
mm
0
0079
in
Out
of
round
and
taper
must
not
exceed
0
02
mm
0
0008
in
If
any
of
the
bores
are
worn
or
in
excess
of
the
specified
limi
t
then
all
bores
must
be
rebored
at
the
same
time
Pistons
are
available
in
five
oversizes
and
should
be
selected
in
accordance
with
the
amount
of
wear
of
the
cylinder
Refer
to
the
instructions
given
for
the
Ll4
L16
and
L18
engines
and
select
pistons
from
the
table
below
PISTON
SIZE
Standard
250
5
500
5
750
S
1000
S
1250
S
OUTER
DIAMETER
84
958
84
990
mm
3
345
3
346
in
85
220
85
240
mm
3
355
3
356
in
85
470
85
490
mm
3
365
3
366
in
85720
85
740
mm
3
375
3
376
in
85
970
85
990
mm
3
3846
3
3854
in
86
220
86
240
mm
3
394
3
395
in
Cylinder
liners
can
be
fitted
if
the
bores
areworn
beyond
the
maximum
limit
Undersize
liners
are
available
with
outer
diam
ters
of
89
091
89
126
mm
3
507
3
509
in
and
inner
diameters
of
83
5
84
5
mm
3
287
3
327
in
The
liners
are
an
interference
fit
in
the
block
and
must
be
rebored
after
fitting
PISTONS
Checking
Oteck
the
pistons
for
signs
of
seizure
and
wear
measure
the
side
clearance
of
the
rings
in
the
ring
grooves
and
check
the
piston
ring
gaps
as
previously
described
for
the
L14
Ll6
and
Ll8
engines
Compare
the
figures
obtained
with
those
given
in
the
tables
opposite
Side
clearance
in
grooves
Top
ring
Second
ring
Oil
ring
Standard
0
04
0
08
mm
0
0016
0031
in
0
02
0
06
mm
0
0008
0
0024
in
0
02
0
06
mm
0
0008
0
0024
in
Limit
LO
mm
0
0039
in
LO
mm
0
0039
in
LO
mm
0
0039
in
Piston
ring
gap
Top
ring
Second
ring
Oil
ring
Top
ring
Second
ring
Oil
ring
Standard
0
35
0
55
mm
0
01
38
D
021
7
in
0
3
5
mm
0
0138
0
0197
in
0
35
55
mm
O
oJ38
0217
in
Limit
LO
mm
0
0394
in
LO
mm
0
0394
in
LO
mm
0
0394
in
Top
ring
Second
ring
Oil
ring
Measure
the
outer
diameter
of
the
gudgeon
pin
in
relation
to
the
hole
diameter
in
the
piston
Compare
the
figures
obtained
with
those
given
in
Technical
Data
and
replace
the
piston
and
pin
if
the
wear
limit
is
exceeded
CONNECTING
RODS
Checking
Check
the
connecting
rods
for
bends
or
twists
using
a
suit
able
connecting
rod
aligner
The
maximum
deviation
should
not
exceed
0
05
mm
0
0020
in
per
100
mm
3
94
in
of
rod
Straighten
or
replace
any
rod
which
does
not
comply
with
the
specified
limit
When
renewing
a
rod
make
sure
that
the
weight
difference
between
new
and
old
rods
in
within
6
gr
212
oz
Install
the
connecting
rods
with
bearings
to
the
correspond
ing
crank
pins
and
check
that
the
end
play
of
the
big
ends
is
between
0
10
0
246
mm
0
0043
0
0097
in
Replace
the
appropriate
rod
if
the
maximum
limit
of
0
3
mm
0
0118
in
is
exceeded
CRANKSHAFT
Inspection
and
Overhaul
Clean
the
crankshaft
thoroughly
and
check
the
journals
and
crank
pins
for
taper
and
out
of
round
Use
a
micrometer
to
measure
the
journals
and
crankpins
at
the
positions
shown
in
Fig
A
7
It
will
be
necessary
to
regrind
the
crankshaft
if
the
specified
limit
of
0
03
mm
0
0012
in
is
exceeded
and
then
fit
the
appropriate
undersize
bearings
Place
the
crankshaft
in
V
blocks
as
described
for
the
L14
L16
and
LIB
engines
and
apply
a
dial
gauge
to
the
centre
journal
to
check
that
the
bend
limit
of
0
05
mm
0
0020
in
is
not
exceeded
The
actual
bend
value
will
be
half
the
reading
obtained
on
the
gauge
Install
the
crankshaft
in
the
cylinder
block
and
check
the
crankshaft
end
float
which
should
be
0
060
0
192
mm
0
0024
0
0076
in
Replace
the
centre
shims
if
the
specified
figure
is
exceeded
Make
sure
that
the
main
drive
shaft
pilot
bearing
at
the
rear
of
the
crankshaft
is
not
worn
or
damaged
in
any
way
Remove
the
bearing
if
necessary
using
the
special
tool
ST49700000
as
shown
in
Fig
A
8
Clean
the
bearing
hole
oil
the
outer
side
of
the
new
bearing
and
use
a
drift
as
shown
in
Fig
A
9
to
drive
it
into
the
hole
Insert
2
grams
0
07
oz
of
multi
purpose
grease
into
the
hole
as
illustrated
Main
bearing
clearance
Check
the
main
bearing
clearances
as
described
for
the
Ll4
Ll6
and
Ll8
engines
The
Plastigage
should
be
placed
so
57
Page 140 of 171

that
it
is
clear
of
the
oil
hole
Install
the
bearing
caps
and
tighten
the
bolts
to
a
torque
reading
of
10
0
1
LO
kgm
72
3
79
51b
ft
The
standard
main
bearing
clearance
is
0
03
0
06
mm
0
0012
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
fitted
and
the
crankshaft
journal
ground
accordingly
Bearings
are
available
in
four
undersizes
See
Technical
Data
Connecting
rod
bearing
clearance
Check
the
connecting
rod
bearing
clearances
in
a
similar
manner
to
the
main
bearing
clearances
The
standard
clearance
is
0
03
0
06
mm
0
0012
0
0024
in
with
a
wear
limit
of
0
1
mm
0
0039
in
Undersize
bearings
must
be
fitted
and
the
crankpins
reground
if
the
specified
limit
is
exceeded
Bearings
are
available
in
four
undersizes
See
Technical
Data
Fitting
the
crankshaft
bearings
Check
the
fit
of
the
bearing
shells
in
the
following
manner
Install
the
bearings
on
the
main
bearing
caps
and
cylinder
block
bearing
recess
and
tighten
the
cap
bolts
to
the
specified
torque
reading
of
10
0
11
0
kgm
72
3
79
5
Ib
ft
Slacken
one
of
the
cap
baits
and
check
the
clearance
between
the
cap
and
cylinder
block
with
a
feeler
gauge
as
described
for
the
L14
Ll6
and
LIS
engines
The
bearing
crush
should
be
from
0
to
0
04
mm
0
to
0
0016
in
Replace
the
bearing
if
the
clearance
is
not
correct
Check
the
connecting
rod
bearings
in
a
similar
manner
after
tightening
the
rod
cap
bolts
to
a
torque
reading
of
4
5
5
0
kgm
32
6
36
2
Ib
ft
ENGINE
Assembling
Make
sure
that
all
components
are
perfectly
clean
before
starting
to
assemble
the
engine
Refer
to
the
instructions
given
for
the
L14
U6
and
LIS
engines
Cylinder
Head
Install
the
valve
spring
seats
and
valves
Fit
the
oil
seal
rings
on
the
valve
stems
and
place
the
seal
ring
covers
over
the
oil
seal
rings
Note
that
a
gap
of
from
0
3
to
0
7
mm
0
0118
to
0
0276
in
should
be
present
between
the
seal
ring
cover
and
spring
seat
If
the
gap
is
less
than
0
3
mm
0
0118
in
the
oil
seal
ring
or
the
cover
must
be
replaced
Assemble
the
valve
springs
and
retainers
Compress
the
valve
springs
and
install
the
cotters
See
instructions
for
the
LI4
U6
and
Ll8
engines
Assemble
the
camshaft
brackets
valve
rockers
seats
spacers
and
springs
on
the
rocker
shafts
in
the
order
shown
in
Fig
A
l
O
Note
that
the
exhaust
rocker
shaft
has
identification
marks
but
the
intake
rocker
shaft
has
not
Make
sure
that
the
oil
holes
point
in
the
direction
shown
It
may
be
advisable
to
insert
any
convenient
bolts
into
the
bolt
holes
of
the
front
and
rear
cam
shaft
brackets
to
prevent
the
assembly
from
being
displaced
Mount
the
camshaft
on
the
head
fit
the
rocker
assembly
and
tighten
the
nuts
Make
sure
that
the
mark
on
the
flange
of
the
camshaft
is
aligned
with
the
arrow
mark
on
the
No
I
earn
shaft
bracket
as
shown
in
Fig
A
II
Pistons
and
connecting
rods
Assemble
the
pistons
gudgeon
pins
and
connecting
rods
in
accordance
with
the
cylinder
numbers
Heat
the
piston
to
a
temperature
of
500
to
600
1220
to
1400F
and
press
the
gudgeon
pin
in
by
hand
The
pistons
and
connecting
rods
must
be
assembled
as
shown
in
Fig
A
12
with
the
arrow
mark
on
the
head
of
the
piston
pointing
to
the
front
of
the
engine
Fit
new
clips
to
both
ends
of
the
gudgeon
pins
as
indicated
in
Fig
A
13
Fit
the
piston
rings
with
the
marks
facing
upwards
Place
the
bearings
on
the
connecting
rods
and
caps
making
sure
that
the
backs
of
the
bearing
shells
are
perfectly
clean
Assembling
the
engine
Insert
the
oilscal
into
the
grooves
of
the
cylinder
block
and
rear
bearing
cap
Fit
the
seal
down
with
the
speCial
tool
ST49750000
if
available
as
shown
in
Fig
A
14
and
trim
off
the
excess
with
a
knife
Apply
sealing
agent
to
the
oil
plug
and
install
it
in
the
cylinder
block
Fit
the
main
bearings
lubricate
with
clean
engine
oil
and
install
the
crankshaft
Fit
the
bearing
caps
and
tighten
the
bolts
to
a
torque
reading
of
10
0
to
I
LO
kgm
72
3
to
79
5
Ib
ft
Note
that
liquid
packing
should
be
applied
to
the
rear
bear
ing
cap
surfaces
as
shown
in
Fig
A
15
Fit
the
thrust
washers
at
both
sides
of
the
No
2
bearing
with
the
oil
channel
in
the
washers
facing
the
thrust
face
of
the
crankshaft
Install
the
rear
bearing
cap
side
seal
so
that
is
projects
0
2
to
0
6
mm
0
008
to
0
024
in
from
the
lower
surface
of
the
cylind
r
block
then
apply
liquid
packing
to
the
projecting
tip
Install
the
engine
rear
plate
Fit
the
flywheel
and
tighten
the
bolts
to
a
lorque
reading
of
10
0
to
11
0
kgm
72
3
to
79
5
ib
ft
using
new
lock
washers
Lubricate
the
crankshaft
journals
pistons
and
cylinder
bores
with
clean
engine
oil
and
install
the
piston
and
connecting
rod
assemblies
The
pistons
should
be
arranged
so
that
the
arrow
marks
face
towards
the
front
and
with
the
piston
ring
gaps
at
1800
to
each
other
Make
sure
the
gaps
do
not
face
to
the
thrust
side
of
the
piston
or
in
the
same
axial
direction
as
the
gudgeon
pin
Install
the
connecting
rod
caps
o
that
the
marks
face
the
same
way
and
tighten
the
bolts
to
a
torque
reading
of
4
5
to
5
0
kgm
32
6
to
36
2
Ib
ft
Bend
the
lock
washers
as
shown
in
FigA16
Fit
the
oil
jet
to
the
front
of
the
cylinder
block
Install
the
chain
tensioner
and
stopper
crankshaft
sprocket
and
timing
chain
Note
that
the
timing
mark
on
the
chain
must
be
aligned
with
the
mark
on
the
sprocket
as
shown
in
Fig
A
17
Smear
the
mounting
face
of
the
oil
pump
with
sealing
agent
Three
Bond
No
4
or
equivalent
install
the
pump
and
tempora
rily
tighten
the
mounting
bolts
Adjust
the
tension
of
the
oil
pump
chain
using
the
pin
as
the
central
point
then
tighten
the
mounting
bolts
Install
the
oil
thrower
Fit
the
chain
cover
into
position
after
coating
the
new
cover
gasket
with
sealing
compound
Cut
off
the
projecting
parts
of
the
gasket
Fit
the
crankshaft
pulley
and
tighten
the
pulley
nut
to
a
torque
reading
of
15
0
to
20
0
kgm
108
5
to
144
61b
ft
Bend
the
lock
washer
Install
the
oil
strainer
and
oil
pump
Invert
the
engine
and
set
the
No
I
piston
to
T
D
C
of
the
compression
stroke
Note
that
the
notch
on
the
crankshaft
S9
Page 162 of 171

BrakIng
System
Description
Front
disc
brake
Friction
pads
Front
disc
brake
Removal
and
Installation
Rear
drum
brake
Removal
and
Installation
Master
Vac
Servo
Unit
Handbrake
cables
Removing
Handbrake
Adjusting
Brake
pedal
Adjusting
Rear
drum
brake
Adjusting
Bleeding
the
hydraulic
system
DESCRIPTION
The
vehicle
is
fitted
with
disc
brakes
for
the
front
wheels
and
leading
trailing
shoe
type
drum
brakes
for
the
rear
wheels
A
conventional
single
master
cylinder
is
fitted
to
the
Standard
and
DeLuxe
models
See
Fig
D
I
for
details
The
DeLuxe
models
are
however
additio
ally
equipped
with
a
Master
Vae
servo
unit
which
provides
a
much
higher
braking
performance
with
minimum
force
required
on
the
brake
pedal
A
tandem
master
cylinder
and
Master
Vac
servo
unit
are
fitted
as
standard
equipment
to
the
Datsun
CL30UA
and
CL3
OUT
models
Fig
D
2
gives
an
exploded
view
of
this
type
of
master
cylinder
The
handbrake
is
of
the
mechanical
type
with
the
handle
linked
to
the
rear
shoe
operating
lever
through
a
system
of
rods
and
wires
See
Fig
D
3
As
on
previous
models
a
brake
pressure
differential
warn
ing
light
switch
is
incorporated
with
dual
brake
circuits
The
front
and
rear
brake
systems
are
connected
to
the
switch
which
provides
a
warning
via
a
warning
light
on
the
instnllnent
panel
when
a
pressure
difference
of
13
to
17
kg
sq
cm
IB5
to
242
lb
sq
in
occurs
between
the
front
and
rear
systems
Brake
piping
layouts
of
the
single
and
tandem
master
cylinder
systems
are
shown
in
Figs
D
4
and
0
5
FRONT
DISC
BRAKE
Friction
pads
The
disc
brakes
are
self
adjusting
but
the
friction
pads
should
be
checked
for
wear
after
the
fIrst
6
000
un
4
000
miles
and
then
every
5
000
km
3
000
miles
The
pads
must
be
replaced
if
the
friction
lining
on
any
pad
has
worn
to
less
than
1
0
mm
0
04
in
The
thickness
of
the
pads
can
easily
be
checked
after
remov
ing
the
anti
rattle
clip
from
the
calliper
plate
Full
servicing
procedures
are
given
in
the
section
BRAKING
SYSTEM
for
vehicles
fitted
with
Ll4
Ll6
and
Ll8
engines
FRONT
DISC
BRAKE
Removal
and
Installation
Refer
to
the
section
BRAKING
SYSTEM
for
the
Ll4
L16
and
LIB
engines
for
full
details
of
the
removal
and
installation
procedures
Check
the
thickness
of
the
friction
pads
as
previously
described
and
replace
them
if
necessary
Check
the
brake
disc
for
scoring
and
out
of
round
The
standard
diSc
thickness
is
10
0
mm
0
394
in
and
must
not
be
reground
below
8
40
mm
0
331
in
The
run
out
of
the
disc
should
be
less
than
0
06
mm
0
0024
in
and
can
be
checked
with
a
dial
gauge
positioned
near
the
outer
diameter
of
the
disc
as
previously
described
REAR
DRUM
BRAKE
Removal
and
Installation
The
rear
drum
brakes
See
Fig
D
6
can
be
removed
and
inspected
as
described
in
the
section
BRAKING
SYSTEM
for
vehicles
fItted
with
L14
L16
LIB
engines
Examine
the
brake
drums
for
scoring
and
out
of
round
The
maximum
inner
diameter
of
the
drum
must
not
exceed
229
6
mm
9
040
in
after
reconditioning
Out
of
round
should
be
below
0
05
mm
0
002
in
Renew
the
brake
shoe
linings
if
they
are
contaminated
or
incorrectly
seated
or
if
the
thickness
of
the
lining
has
been
reduced
to
1
5
mm
0
06
in
or
less
Oil
or
grease
can
be
re
moved
from
the
linings
by
cleaning
thoroughly
with
carbon
tetrachloride
or
petrol
Check
the
shoe
return
springs
and
replace
them
if
they
have
become
weakened
Check
the
bores
of
the
wheel
cylinders
for
signs
of
wear
damage
or
corrosion
Renew
the
cylinders
and
pistons
if
the
clearance
between
the
two
parts
exceeds
to
0
15
mm
0
006
in
Renew
the
c
ps
when
overhauling
the
wheel
cylinders
MASTER
V
AC
SERVO
UNIT
Removing
and
Dismantling
The
servo
unit
should
be
removed
and
overhauled
at
yearly
intervals
A
Master
Vac
repair
kit
is
available
and
all
parts
marked
in
Fig
D
7
should
be
renewed
after
dismantling
the
unit
These
items
are
all
supplied
as
part
of
the
repair
kit
The
unit
can
be
removed
as
follows
Remove
the
clevis
pin
from
the
push
rod
and
detach
the
Master
V
ac
unit
from
the
brake
pedal
2
Disconnect
the
brake
tube
from
the
master
cylinder
and
the
vacuum
hooe
from
the
Master
Vac
3
Take
off
the
retaining
nuts
and
remove
the
Master
Vac
and
spacer
then
separate
the
master
cylinder
from
the
Master
Vac
Mark
the
front
cylinder
shell
and
the
rear
shell
and
stud
assembly
before
dismantling
the
unit
then
proceed
as
follows
S31