check engine DATSUN PICK-UP 1977 Owner's Manual

Engine
Tune

up

TROUBLE
DIAGNOSES
AND

CORRECTIONS

Condition
Probable
cause

CANNOT
CRANK

ENGINE
OR

SLOW

CRANKING
Improper
grade
oil

Discharged
battery

Faulty
battery

Loose

fan
belt

Malfunction
in

charge
system

Wiring
connection
loose
in

starting
circuit

Faulty
ignition
switch

Faulty
starler
motor

Trouble

shooting
procedure
on

starting
circuit

Switch
on
the

starting
motor
with

light
ON

When

light
goes
off
or
dims

considerably

a
Check

battery

b
Check
connection
and

cable

c
Check
starter
motor

When

light
stays
bright
Corrective
action

Replace
with

proper
grade
oiL

Charge

battery

Replace

Adjust

Inspect

Correct

Repair
or

replace

Repair
or

replace

a
Check

wiring
connection
between

battery
and
starter

motor

b
Check

ignition
switch

c
Check
starter
motor

ENGINE
WILL
CRANK

NORMALLY
BUT

WILL
NOT

START

In
this
case
the

following
trouble
causes

may
exist

but
in

many
cases

ignition

system
or
fuel

system
is
in

trouble

Ignition

system
in
trouble

Fuel

system
in
troubk

Valve
mechanism
does
not
work

properly

Low

compussion

Trouble

shooting
procedure

Check

spark
plug
firstly
by

following
procedure

Disconnect

high
tension
cable
from
one

spark
plug
and
hold
it

about
10
mm
0
39
in

from
the

engine
metal

part
and
crank

the

engine

Good

spark
occurs

Check

spark
plug

b
Check

ignition
timing

c
Check
fuel

system

d
Check

cylinder
compression

Check
the
current
f10
in

primary
circuit

Very
high
current

Inspect
primary
circuit
for
short

Check
breaker

poiIit
operation

except
tran

sistor

ignition
system
No

spark
occurs

ET

27

Engine
Tune

up

Condition

Probable

cause

Low
or
no

current

Ign
tion

system
out
of

order
Burned
distributor

point

Improper
point

gap

Faulty
condenser

Leak
at
rotor

cap
and

rotor

Faulty

spark

plug

Improper
ignition
timing

Faulty
ignition
coil

Disconnection

of

high
tension

cable

Loose
connection
or
disconnection
in

primary
circuit

Fuel

system
out
of

order
Lack
offuel

Dirty
fuel
strainer

Dirty
or

clogged
fuel

pipe

Fuel

pump
will
not
work

properly

Carburetor

choke
will
not
work

properly

Improper

adjustment
of
float
level

Improper
idling

Dirty
or

clogged
carburetor

Clogged
breather

pip
of
fuel
tank

Malfunctioning
an
ti

dieseling
solenoid
valve

Incorrect
sparle

plug
tightening
or

faulty

gasket

Improper
grade
engine
oil
or
low

viscosity

Incorrect
valve
clearance

Compression
leak
from
valve

seat

Sticky
valve

stem

Weak
or

damaged
valve

springs

Compression
leak
at

cylinder
head

gasket

Sticking
or

damaged
piston
ring

Worn

piston

ring
or

cylinder

Trouble
ooting

procedure

Pour

the

engine
oil
from

plug
hole
and
then

measure

cylinder

compression

Compression
increases

Compression
does

not

change
Low

comp
ion

ET
28
Corrective
action

Check
for
loose

terminal
or
disconnection

in

primary
circuit

Check
for

burned

points

Repair
or

replace

Adjust

Replace

Clean

or

replace

aean

adjust
plug
gap
or

replace

Adjust

Replace

Replace

Repair
or

replace

Supply

Replace

Clean

Repair
or

replace

Check
and

adjust

Correct

Adjust

Disassemble

and
clean

Repair
and
clean

Check
for

loose
terminal
or
wire
harness

Tighten
to
normal

torque
or

replace
gasket

Replace
with

proper
grade
oil

Adjust

Remove

cyljnder
head

and

lap
valves

Correct
or

replace
valve

and
valve

guide

Replace
valve

springs

Replace

gasket

Replace
piston
rings

Overhaul

engine

Malfunctiong

cylinder
or
piston
ring

Compression
leaks
from
valve

cylinder
head

or
head

gasket

Except
transistor

ignition
system

Condition

IMPROPER
ENGINE

IDLING

Fuel

system
out
of

order

Low

compression

Others

High
engine
idle

speed
Engine
Tune

up

Probable
cause

Clogged
or

damaged
carburetor

jets

Incorrect
idle

adjustment

Clogged
air
cleaner
filter

Damaged
manifold

gaskets
or
carburetor

insulator

Improper
float
level

adjustment

Loose
air

hoses
or
air

fuel
mixture
hoses
of

carburetor

Malfunctioning
carburetor
choke

Malfunctioning
anti

backfire
valve

Malfunctioning
automatic

temperature
con

trol
air

cleaner

Inoperative
idle

compensator

Carbon
canister

purge
line
hose

damaged
or

disconnected

Stick
E

F
E
valve
shaft

Incorrect
valve
clearance

Extremely
low
revolution

Faulty
malfunction
of
the

ignition
system

spark
plug

high
tension
cable
breaker

point
ignition
coil
etc

Incorrect
basic

ignition
timing

Malfunction
of
choke
valve
or

linkage

Malfunction
of
vacuum
motor
sensor
or

hoses
of
air
cleaner

Incorrect
idle

adjustment

Clogged
air
cleaner
fdter

Malfunction
of
idle

compensator
of

air

cleaner

Malfunction
of
E
G
R
control
valve

Loose
manifold
and

cylinder
head
bolts

Dragged
accelerator

linkage

Incorrect
idle

adjustment

Malfunction
of
B
CDD

system

Malfunction
of

speed
switch
and
harness

ET
29
Corrective
action

Clean
or

replace

Adjust

Replace
element

Replace
gasket
or
insulator

Adjust

Check
for
loose
connections

Check
and

adjust

Check
for
loose
connection
of
vacuum
hose

Check
A

r
C
air
cleaner

Check
for
connection
of
idle

compensator

hose

or
replace
idle

compen
tor

Connect
or

replace

Repair

Previously
mentioned

Adjust

Adjust

Replace

Adjust

Adjust

Check
for
loose
hoses

Replace
system
com

ponents
if
necessary

Adjust
idle

speed

Replace
air
cleaner
fdter

Replace

Clean
or

replace

Retighten
bolts

Check
and

correct
accelerator

linkage

Adjust
idle

speed

Check
for
loose

vacuum
hose
and
harness

connections

Adjust
or

replace
if

necessary

Check
for
loose
connections

Repair
or

replace
if

necessary

Condition

ENGINE
POWER
NOT

UP
TO
NORMAL

Low
compression

Ignition
system
out
of

order

Fuel

system
out

of

order

Air
intake

system
out

of
order

Emission
control

Overheating

O

cooIing

Others
Engine
Tune

up

Probable
cause

Incorrect

iSnition
timing

Damaged

spark
plugs

Worn
distributor

points

Malfunction
of
choke

system

Clogged
fuel

pipe
or

floating
valve

Dirty
or

clogged
fuel
strainer

Fuel

pump
will
not
work

properly

C10ssed
carburetor

jets

Malfunction
of
altitude

compensator

CIOJBed
air
cleaner

Ail

inhaling
from
manifold

gasket
or

carburetor

gasket

Malfunction
of

E
G
R
valve

Stick
E
F
E

valve
shaft

Insufficient
coolant

Loose
fan
belt

Worn
or
oiled
fan
belt

Inoperative
thermostat

Worn
water

pump

Clogged
or

leaky
radiator

Worn
radiator
filler

cap

Ail

in

cooling
system

Improper
engine
oil

grade

Incorrect

ignition
timing

Clossed
carburetor
lean
mixture

Disconnected
altitude

compensator
hOlle

Inoperative
thermostat

Improper
octane
fuel

L

j
tire

pressure

Dragging
brake

Clutch

slipping

ET

30
Corrective
action

Previously
mentioned

Adjust

Clean

adjust
or

replace
plull

Dress

or

replace
points
Also
check

condenser

Adj
lst

Clean

Replace

Repair
or

replace

Disassemble
and
clean

Check
and

replace

Replace
element

Replace
gasket

Check
and
replace

Repair

Replenish

Adjust
fan
belt

Replace

Replace

Replace

Flush

repair
or

replace

Replace

Retighten
each

part
of

cooling
system

Replace
with

proper
grade
oil

Adjust

Overhaul
carburetor

Connect

Replace

Replace
with

specified
octane
fuel

Inflate

to

specified

pressure

Adjust

Adjust

Except
transistor

ignition
system

Condition

NOISY

ENGINE

Car

knocking

Mechanical

knocking

Crankshaft

bearing

Imocking

Connecting
rod

bearing
knocking

Piston
and

cylinder

noise

Piston

pin
noise

Water

pump
noise

Air

pump
noise

Others
Engine
Tune

up

Probable
cause

Overloaded

engine

Carbon

knocking

Timing
knocking

Fuel

knocking

Preignition
misusing
of

spark
plug

This

strong
dull
noise
increases
when

engine

is

accelerated
To
locate
the

place
cause
a

misfire

on
each

cylinder
If
the
noise

stops

by
the
misfire
this

cylinder
generates
the

noise

This
is
a
little

higher
pitched
noise
than
the

crankshaft

Imocking
and
also
increases

when

engine
is
accelerated
Cause
a
misfire

on
each

cylinder
and
if
the
noise
deminishes

almost

completely
this
crankshaft

bearing

generates
the
noise

When

you
hear
an

overlapping
metalic
noise

which
increases
its

magnitude
with
the

revolution
of

engine
and
which
decreases
as

engine
is
warmed

up
this
noise
is
caused

by

piston
and
cylinder
To
locate
the

place

cause
a
misfire
on
each

cylinder

This
noise
is

heared
at
each

highest
and

lowest
dead
end
of

piston
To
locate

the

place
cause
a

misfire
on
each

cylinder

This
noise

may
be
caused

by
worn
or

damaged
earings
or
by
the
uneven
surface

of
sliding

parts

Damaged
air

pump

An
improper
adjustment
of
valve
clearance

Noise
of

timing
chain

An
excessive
end

play
on
crankshaft

Noisy
E
F
E

valve
shaft

Wear
on
clutch

pilot
bushing

Note
This
noise
will
be
heared
when

clutch
is

disengaged

ET31
Corrective
action

Use

right
gear
in
driving

Disassemble

cylinder
head
and

remove

carbon

Adjust
ignition
timing

Use

specified
octane
fuel

Use

specified
spark
plug

This
is

caused

by
worn
or

damaged
bearings

or
unevenly
worn
crankshaft
Renew

bearings
and

adjust
or

change
crankshaft

Check
lubrication

system

Same
as
the
case
of
crankshaft

bearings

This

may
cause
an
abnormal

wearing
of

cylinder
and
lower

compression
which
in

turn
will
cause
a
lower
out

put
power
and

excessive

consumption
of
oil

Overhaul

engine

This

may
cause
a
wear
on

piston
pin
or

piston
pin
hole

Renew

piston
and

piston

pin
assembly

Replace
water

pump
with
a
new
one

Repair
or

replace

Adjust

Adjust
the
tension
of
chain

Disassemble

engine
and
renew
main
bearing

Repair

Renew
bush

and

adjust
drive
shaft

Condition

ABNORMAL

COMBUSTION

backfue
afterflre

run
on
etc

Improper

ignition
timing

Fuel

system
out
of

order

Faulty
cylinder
head
etc

Others

EXCESSIVE
OIL

CONSUMPTION

Oilloak

Excessi
lo
oil

consumption

Others
Engine
Tune

up

probable
cause

Improper
ignition
timing

Improper
heat

range
of

spark
plugs

Damaged
carburetor

or
manifold

gasket

backfue
afterfire

Clol
l
ed
carburetor

jet

Improper
function
of

the
float

Uneven

idling
Run
on

Improperly
adjusted
B

C
D
D

set

pressure

Malfunction
of
anti

dieseling
solenoid
valve

Malfunction
of
auio
choke

Improperly
adjusted
valve
clearance

Excess
carbon
in

combustion
chamber

Damaged
valve

spring
backfire
afterflre

Malfunction
of

A
T
C

air
cleaner

Inoperative
ariti
backfue
valve

Loose
oil
drain

plug

Loose

or
damaged
oil

pan
gasket

Loose
or

damaged
chain
cover

gasket

Worn
oil
seal
in
front
and
rear
of
crankshaft

Loose
or

damaged
locker
cover

gasket

Improper
tightening
of
oil
filter

Loose
or

damaged
oil

pressure
switch

Cylinder
and

pioton
wear

Improper
location
of

piston
ring

gap
or

reversely
assembled

piston
ring

Damage
piston
rings

Worn

piston
ring
groove
and

ring

Fatigue
of
valve
oil
seal

lip

Worn
valve

stem

Inadequate
quality
of

engine
oil

Engine
overheat

ET32
Corrective
action

Adjust
ignition
timing

Use

specified
spark
plugs

Replace
them
with
new

parts

Disassemble
carburetor
and
check
it

Adjust
the
level
and
check
needle
valve

Adjust

Adjust

Check
or

replace

Adjust

Adjust

Remove
head
and

get
rid
of
carbon

Replace
it
with
a
new
one

Check
for
loose
vacuum
hoses

Replace
if

necessary

Replape

Tighten
it

Renew

gasket
or

tighten
it

Renew

gasket
or

tighten
it

Renew
oil
seal

Renew

gasket
or

tighten
it
but
not
too

much

Renew

gasket
and

tighten
it
with
the

proper

torque

Renew
oil

pressure
switch
or

tighten
it

Overhaul

cylinder
and
renew

piston

Remoun
t

piston
rings

Renew

rings

Repair
or
renew

piston
and

cylinder

Renew

piston
and

piston
ring

Replace
seal

lip
with
a

new
one

Renew
valve
or

guide

Use
the

designated
oil

Previously
mentioned

Condition

POOR
FUEL
ECONOMY

Se
the

xplanation

of
the
pow
r

dec

Oth
n

PROBLEM
IN

OTHER

FUNCTIONS

D
cr
d

oil

p
ssure

Excessive
wear
on
the

sliding

parts

Scuffing
of

sliding

parts

Floor

temperature
too

high
California

only
Engine
Tune

up

Probable
cause

Exceeding
idling
revolution

Inoperative
acceleration
recovery

Fuel

leakage

Malfunction
of
B

C
D
D

Malfunction
of
A
r
C
air

cleaner

Inadequate
oil

quality

Overheat

Worn

oil

pump
regulator
valve

Functional
deterioration
of
oil

pump

Blocked
oil
f1lter

Increased
clearance
in
various

sliding
parts

Blocked
oil
strainer

Inoperative
oil

gauge
pressure
switch

Oil

pressure
decreases

Improper

quality
or
contamination
of

oil

Damaged
air
cleaner

Overheat
or
overcoal

Improper
fuel
mixture

Decrease
of
oil

pressure

Insufficient
clearances

Overhea
t

Improper
fuel

mixture

Problem
in

fuel

system
Refer
to

Inspec

tion
of
Fuel

System

Problem
in

ignition
system
Refer
to
In

spection
of

Ignition
System

ET33
Corrective
action

Adjust
it

to
the

designated
rpm

Adjust
it

Repair
or

tighten
the
connection
of

fuel

pipes

Adjust

Check
and

replace

Use
the

designated
oil

Previously
mentioned

Disassemble
oil

pump
and

repair
or
renew
it

Repair
or

replace
it

with
a

new
one

Renew
it

Disassemble
and

replace
the
worn

parts
with

new
ones

Oeanit

Replace
it
with
a
new
one

Previousiy
mentioned

Exchange
the
oil
with

proper
one
and

change
element

Change
elemen
t

Previously
mentioned

Check
the
fuel

system

Previously
mentioned

Readjust
to
the

designated
clearances

Previously
mentioned

Check
the
fuel

system

Check
and

repair

Check
and

repair

r

I

I

PRELIMINARY
CLEANING
AND

INSPECTION

DISASSEMBL
Y

PRELIMINARY

CLEANING
AND

INSt

ECTION

Before

disassembling

engine
note

the

following

I
Fuel

oil
or
water

may
leak

past

cylinder
head
and
block
Prior
to

disassembling
check

cylinder
head

1
1ltermal
vacuum
valve

2
Check

valve

3
Altitude

compensator

in

air
cleaner

4
Air

gallery
pipe

S

Auto
choke

6
Automatic

temperature

control
air

cleaner

7
Anti
8ackfire
valve
A
B

valve

8
Boost
Controlled

Deceleration

Device
Bee
D
D

9
P
c
v

valve

to
Air
relief
valve

11
E

G
R

control
valve

12
B
C
D
D

control
valve
and

solenoid
valve

13

Emergency
air

relief
valve

14
Air

pump
air
cleaner

IS
Carbon
canister

16
Air
control

valve

11
Air

pump
Engine
Mechanical

ENGINE

DISASSEMBLY

CONTENTS

EM
4

EM
4
PISTONS
AND
CONNECTING
RODS

CYLINDER

HE
AD
EM
7

EM
7

front
chain

cover
oil

pan
and
oil

filter

gaskets
lInd
crankshaft
and
water

pump
seals
for

signs
of

leakage
past

their

gasketed
surfaces

2
Check
carburetor
and

fuel

pump

for
condition
fuel
hoses
for

deteriora

tion
cracks

or

leakage
of
fuel

past

their

jointed
or
connected

surfaces

Fig
EM

0
Emiuion
control
devic
s

California
mod
18
E
T366

3
Remove

carburetor
air

cleaner

Remove
fresh

air
duct

Disconnect
hot
air
duct
from

air

cleaner

Disconnect
air

cleaner
to
air

pump

hose
at
air

cleaner

Disconnect
air

cleanef
to
rocker

cover

hose
at
rocker
cover

Disconnect

air
cIeaner

to
air

con

trol

valve
hose
at
air

cleaner
Cali

fornia

models

only
Disconnect
air

cleaner
to
A

B
valve

hose
at
air

cleaner

Disconnect
air

cleaner
to

related

part
vacuum
hoses
at
air

cleaner

Loosen
air

cleaner
band
bolt
and

remove
carburetor
air

cleaner
as

sembly
from

carburetor

4

Plug
up
carburetor
air

horn

to

prevent
entry
of

foreign
matter

5

Remove

alternator
drive

belt

alternator
and

alternator
bracket

EM
4
6

Remove
air

pump
drive

belt
cool

er

compressor
and
idler

pulley
if

so

equipped

7
Remove
starter
motor
from
trans

mission

8

Visually

inspect
cylinder
head

cylinder
block
rocker
C
Ner

front

chain
cover
oil

pan
and
all
other
outer

parts
for
oil
water
and
fuel
leaks

breakage
or

missing
parts
such

as
bolts

and
nuts

9

Check

piping
and
electrical
cir

cuits
for
deterioration

breakage
fit

tings
discontinuity
or
insulation

DISASSEMBLY

To

remove

engine
from
vehicle

refer
to

the
instructions
under
the

Engine
Removal

and
Installation

ER
section

I

Remove
transmission
from

en

gine

2
Remove

clutch

assembly
from

flywheeL

3

Thoroughly
drain

engine
oil
and

coolan
t

by

removing
drain

plugs

Store

engine
oil
and

coolant
if

they

are

to
be

used

again

4
Place

engine
assembly
on

engine

stand

I

Remove

cooling
fan

2

Remove

right
engine

mounting

bracket

3

Remove
oil
filter
with
Oil

Filter

Wrench
STI9320000

4

Remove
oil

pressure
swi

tch

5

Install

engine
attachment
to

cylinder
block

utilizing
bolt

holes
in

alternator

bracket
and

water
drain

hole

6
Set

engine
on
stand

Engine
Attachment

ST05260001

Engine
Stand

ST050I

SOOO

EM410

Fig
EM
II

Engine
on

engine
land

Remove

oil
level

gauge

6
Remove

carburetor
from
intake

manifold

1
Disconnect
cylinder
block
to

P
C
V
valve
hose
at
P
C
V

valve

2

Disconnect
A
B
valve
to
E

G
R

passage
hose

at
E
G
R

passage

3
Disconnect
vacuum
tube
to

carburetor

hoses
white
and

yellow
at

vacuum
tube

4
Disconnect
fuel

hose
from

carburetor

5

Remove
dash

pot
bracket
from

intake
manifold

6
Remov
carburetor

attaching

bolts
and

remove
carburetor

assembly

and

gasket

7
Disconnect
distributor

high
ten

sion
cables
from

sparkplugs

8
Disconnect
vacuum
hose

from

distributor
and

remove
distributor
as

sembly

9

Disconnect
fuel

hose
from
fuel

pump
and

remove
fuel
and

vacuum

hoses
combined

from

cylinder
head

10
Remove
fuel

pump
assembly

from

cylinder
head

EM412

Fig
EM
12

Removing
fuel
pump

IJ
Remove
in
take
and
exhaust

manifold

assembly
from

cylinder
head

1
Disconnect
vacuum
hose

from

air
control
valve
and
remove
air
con

trol

valve
for
California
and
a
r
hoses

as
an
assembly
Engine
Mechanical

1
Air
control
valve

2
Distributor
EM531

Fig
EM
13

Removing
air
control

valve

Californio
model

2
Remove
carburetor
air
cleaner

bracket

3
Disconnect
vacuum
hose
from

E
G
R
valve

4
Remove
check
valve
from
air

gallery

pipe

5
Disconnect
E
G
R

tube
from

E

G
R

passage
and
exhaust
manifold

6
Remove
E

G
R

passage
and

E
G
R
valve

from
intake

manifold

I
E

G
R

passage

2
E
G
R
tube

Fig
EM
14
EM532

Removing
E

G
R

tube
and

passage

7
Remove
F
l

C
D

bracket
from

cylinder
head

if
so

equipped

8

Disconnect
vacuum
hoses
from

thermal

vacuum
valve

and
remove

thermostat

housing
and

gasket
from

cylinder
head

EM089

Fig
EM
15

Removing
thermostat

housing

EM
5
9
Remove

cylinder
block
to

P
C
V

valve
hose
blow

by
gas
hose

from

cylinder
block

10
Remove

manifold

attaching

bolts
and
remove
intake
and

exhaust

manifold

assembly
and

gasket
from

cylinder
head

Fig
EM
16

Removing
intake
and

exhaust

manifold
assembly

11
Remove
intake

and
exhaust

manifold

attaching
bolts
and

separate

intake

manifold
from

exhaust
mani

fold

12
Remove
air

gallery
pipes
from

exhaust

manifold

12
Remove

left

engi
e

mounting

bra
et

from

cylinder

blopk

13
Remove
air

pump
and
cooler

compressor
bracket

14
Remove

crankshaft

pulley
in

stalling
bolt
and

washer
and
then

remove

pulley
with
a
two

jaw
puller

15
Remove
water

pump
assembly

16
Remove
rocker

cover

17

R
emove

spark
plugs

18
Remove
fuel

pump
drive
earn

19

Remove
camshaft

sprocket

Refer
to
the

following
note

during

operation
when

removing
camshaft

sprocket
from

engine
installed
on
car

EM091

Fig
EM
17

Removing
cammaf

sprocket

r

Engine
Mechanical

INSPECTION
AND
REPAIR

PREPARATION
FOR
INSPECTION

CYLINDER
HEAD
AND
VALVE

CHECKING
CYLINDER
HEAD
MATING

FACE

VALVE
ASSEMBLY

VALVE
SPRING

ROCKER
ARM
AND
VALVE

ROCKER

PIVOT

VALVE
GUIDE

VALVE
SEAT
INSERTS

CAMSHAFT
AND
CAMSHAFT

BEARING

CAMSHAFT

BEARING
CLEARANCE

VALVE
TIMING

CAMSHAFT
ALIGNMENT

CYLINDER
BLOCK

HOW
TO
MEASURE

CYLINDER
BORE

CYLINDER

BORING

PREPARATION
FOR

INSPECTI
N

I

Before

cleaning
check

for

signs

of
water

and
oil
leaks
in

cylinder
block

and

head

2
Clean
oil
carbon

deposits
and

sealant
from
an

parts
Remove

gasket

3
Clean
all

oil
holes
with
solvent

and

dry
with

compressed
air

Make

sure
that

they
are

not
restricted

CYLINDER
HEAD

AND
VALVE

CHECKING
CYLINDER

HEAD

MATING
FACE

EM407

Fig
EM

34
Cylinder
head
CONTENTS

EM
8

EM
B

EM
8

EM
8

EM
9

EM
lO

EM
l0

EM
11

EM

12

EM
12

EM
12

EM
13

EM

13

EM
13

EM
14
PISTONS
PISTON
PINS
AND

PISTON
RINGS

CONNECTING
ROD

CRANKSHAFT

BUSHING
AND
BEARING

MEASUREMENT

OF
MAIN

BEARING

CLEARANCE

MEASUREMENT
OF

CONNECTING
ROD

BEARING
CLEARANCE

FITTING

BEARINGS

MISCELLANEOUS
COMPONENTS

CRANKSHAFT
AND

CAMSHAFT

SPROCKETS

CHAIN

TENSIONER
AND
CHAIN

GUIDE

FLYWHEEL

FRONT
COVER
AND

REAR
OIL
SEAL

Note

Never

remove
camshaft
bear

ings
unless

you
have
a

Suitable

machine

or

boring
Camshaft
bear

ing
in
line
If

you
once
remove

camshaft

bearings
bearing
centers

will
come
out

o

alignment
reo

conditioning
is

very
difficult
with

out
center

borings

L
Make

a
v

isual
check
for
cracks

and
flaws

2

Measure
the
surface
of

cylinder

head
on

cylinder
block

side
for

warpage
If
it
is

found
to
be

beyond

the
limit

designated
below

regrind
the

affected
surface

with
a
surface

grinder

Fig
EM
35

Checking
cylinder
head

8JJrface

EM
8
Head
surface
flatnes

Standard

less
than
0
05

mm
0
0020
in
O
lmm

0
0039
in
EM
15

EM
16

EM
16

EM
17

EM
17

EM
1B

EM
18

EM
19

EM
19

EM
20

EM
20

EM
20

Maximum

VALVE
ASSEMBLY

Check
each
intake

and
exhaust

valve
for
worn

damaged
or
deformed

valve

caps
or
stems

Correct
or

replace

any
valve
that
is

faulty

2
Valve

face
or
valve
stem
end

surface

should
be
refaced
with
a
valve

grinder

10

L
I
I

I

EM109

Fig
EM
36
Intak
and

exhaust
valve

dimensions