oil filter DATSUN PICK-UP 1977 Service Manual
[x] Cancel search | Manufacturer: DATSUN, Model Year: 1977, Model line: PICK-UP, Model: DATSUN PICK-UP 1977Pages: 537, PDF Size: 35.48 MB
Page 19 of 537
Engine
Tune
up
BASIC
MECHANICAL
SYSTEM
ADJUSTING
INTAKE
AND
EXHAUST
VALVE
CLEARANCE
CHECKING
AND
ADJUSTING
DRIVE
BELT
RETIGHTENING
CYLINDER
HEAD
BOLTS
MANIFOLD
NUTS
AND
CARBURETOR
SECURING
NUTS
CHECKING
ENGINE
OIL
REPLACING
OIL
FILTER
CHANGING
ENGINE
COOLANT
ADJUSTING
INTAKE
AND
EXHAUST
VALVE
CLEARANCE
Note
After
tightening
cylinder
head
bolts
adjust
intake
and
exhaust
valve
clearances
Valve
clearance
adjustment
is
impossible
when
the
engine
is
in
oper
ation
1
Loosen
pivot
locking
nu
t
and
turn
pivot
screw
until
the
specified
clearance
is
obtained
while
cold
Using
service
tool
tighten
pivot
locking
nut
securely
after
adjustment
and
recheck
the
clearance
2
Warm
up
engine
for
at
least
several
minutes
and
stop
it
Measure
valve
clearance
while
hot
If
out
of
specifications
adjust
Unit
mm
in
Intake
0
20
0
008
Cold
Exhaust
0
25
0
010
Intake
0
25
OmO
Wann
I
Exhaust
0
30
0
012
STl
064000
I
ET009
Fig
ET
5
Adjusting
valve
clearance
CONTENTS
ET
7
PERMANENT
ANTI
FREEZE
COOLANT
CHECKING
COOLING
SYSTEM
HOSES
AND
CONNECTIONS
INSPECTION
OF
RADIATOR
CAP
COOLING
SYSTEM
PRESSURE
TEST
CHECKING
VACUUM
FITTINGS
HOSES
AND
CONNECTIONS
CHECKING
ENGINE
COMPRESSION
COMPRESSION
PRESSURE
TEST
TEST
RESULT
ET
7
ET7
ET
B
ET
B
ET
B
CHECKING
AND
ADJUSTING
DRIVE
BELT
ET
B
ET
B
ET
B
ET
B
ET
B
ET
9
ET
9
ET
9
2
Normal
drive
belt
deflection
is
8
to
12
mm
0
315
to
0
472
in
when
moderate
thumb
pressure
is
applied
midway
between
pulleys
1
Check
for
cracks
or
damage
Re
place
if
necessary
Compressor
pulley
8
to
12
mm
0
315
to
0
472
in
Idler
pulley
Water
pump
pulley
8
to
12
mm
0
315
to
0
472
in
Air
pump
pulley
Alternator
AC456
Fig
ET
6
Driue
belt
tension
RETIGHTENING
CYLINDER
HEAD
BOLTS
MANIFOLD
NUTS
AND
CARBURETOR
SECURING
NUTS
Tightening
torque
Cylinder
head
bolts
1st
turn
4
0
kg
m
29
ft
Ib
2nd
turn
6
0
kg
m
43
ft
Ib
3rd
turn
6
5
to
8
5
kg
m
47
to
61
ft
lb
Refer
to
the
following
tightening
torque
specifications
ET
7
Page 20 of 537
r
ManifolJ
nuts
I
2
to
1
6
kg
m
8
7
to
I
6
ft
lb
Carburelor
nuls
0
5
to
1
0
kg
m
3
6
to
7
2
fl
tb
Fig
ET
7
Tightening
s
quence
CHECKING
ENGINE
OIL
Check
if
oil
is
diluled
with
water
or
gasoline
Drain
and
refill
oil
if
necessary
Notes
a
A
milky
oil
indicates
the
presence
of
cooling
water
Isolate
the
cause
and
take
corrective
measure
b
An
oil
with
extremely
low
viscosity
indicates
dilution
with
gasoline
2
Check
oil
level
If
below
the
specified
level
raise
it
up
10
the
H
level
Engine
oil
capacity
including
oil
filter
Maximum
H
leven
4
3
liters
4
MUS
qt
3
Y
Imp
qt
Minimum
L
level
3
3
liters
3
f
US
qt
2
U
Imp
ql
REPLACING
OIL
FILTER
The
oil
mter
is
a
cartridge
type
and
can
be
removed
using
Oil
Filter
Wrench
STI9320000
I
Check
for
oil
leaks
past
gasketed
flange
If
leakage
is
found
retighten
just
enough
to
stop
leakage
If
retight
ening
is
no
longer
effective
replace
mter
as
an
assembly
Engine
Tune
up
2
When
installing
oil
filter
tighlen
by
hand
Note
Do
not
overtighten
oil
flIt
lest
leakage
should
occur
CHANGING
ENGINE
COOLANT
PERMANENT
ANTI
FREEZE
COOLANT
Permanent
anti
freeze
coolant
is
an
ethylene
glycol
base
producl
conlain
ing
chemical
inhibilors
10
protect
the
cooling
system
against
corrosion
The
anti
freeze
does
not
contain
any
glycerine
ethyl
or
methyl
alcohol
It
will
not
evaporate
or
boil
away
and
can
be
used
with
either
high
or
low
temperaturethennoslat
It
flows
freely
transfers
heat
effi
ciently
and
will
not
clog
passages
in
the
cooling
system
The
anti
freeze
must
not
be
mixed
with
other
products
This
coolant
can
be
used
through
out
the
seasons
of
the
year
Whenever
coolant
is
changed
the
cooling
syslem
should
be
flushed
and
refilled
with
a
new
coolant
Check
the
level
See
the
instruc
lions
furnished
by
the
manufacturer
for
the
mixture
ratio
of
anti
freeze
10
water
CHECKING
COOLING
SYSTEM
HOSES
AND
CONNECTIONS
Check
hoses
and
fittings
for
loose
connections
or
deterioration
Re
tighten
or
replace
if
necessary
INSPECTION
OF
RADIATOR
CAP
Apply
reference
pressure
0
9
kg
cm2
13
psi
1
to
radiator
cap
by
means
of
a
cap
tester
to
see
if
it
is
satisfactory
Replace
cap
assembly
if
necessary
ET
8
Fig
ET
fJ
Teltill
l
rod
ioto
cop
COOLNG
SYSTEM
PRESSURE
TEST
With
radiator
cap
removed
apply
reference
pressure
1
6
kg
cm2
23
psi
to
the
cooling
system
by
means
of
a
lesler
to
detect
any
leakage
Water
capacity
Without
heater
7
4
liters
7
U
US
qt
6
f
Imp
qt
With
heater
8
0
liters
8
f
US
qt
7
Imp
qt
CHECKING
VACUUM
FITTINGS
HOSES
AND
CONNECTIONS
Check
the
condition
of
filtings
and
hoses
Retighten
or
replace
if
neces
sary
All
vacuum
hoses
can
be
identified
by
colors
White
line
Vacuwn
tube
to
carburetor
E
G
R
Tube
Vacuum
tube
to
thermal
vacuum
valve
Thennal
vacuum
valve
to
E
G
R
control
valve
Page 21 of 537
Yellow
line
Spark
delay
valve
to
distributor
Spark
delay
valve
to
vacuum
tube
Distributor
to
vacuum
tube
Vacuum
tube
to
carburetor
Vacuum
tube
to
canister
Green
line
Anti
backfire
valve
to
intake
mani
fold
Air
control
valve
to
emergency
air
relief
valve
Intake
manifold
to
vacuum
hose
connector
Intake
manifold
to
canister
CHECKING
ENGINE
COMPRESSION
COMPRESSION
PRESSURE
TEST
I
Warm
up
engine
sufficiently
2
Disconnect
all
spark
plugs
3
Disconnect
anti
dieseling
solenoid
valve
connector
4
Properly
attach
a
compression
tester
to
spark
plug
hole
in
cylinder
being
tested
Engine
Tune
up
I
ET010
Different
compression
in
two
or
more
cylinders
usually
indicates
an
improperly
seated
valve
or
broken
piston
ring
9
Low
compression
in
cylinders
can
result
from
worn
piston
rings
This
condition
may
usually
be
accompanied
by
excessive
fuel
consumption
TEST
RESULT
If
compression
in
one
or
more
cylinders
is
low
pour
a
small
quantity
of
engine
oil
into
cylinders
through
the
spark
plug
holes
and
retest
com
pression
I
If
adding
oil
increases
the
com
pression
pressure
the
chances
are
that
rings
are
faulty
2
If
pressure
stays
low
probable
cause
is
that
valve
is
sticking
or
seating
improperly
3
If
cylinder
compression
in
any
two
adjacent
cylinders
is
low
and
if
adding
oil
does
not
help
the
compres
sian
there
is
leakage
past
the
gasket
surface
Oil
and
water
in
combustion
cham
bers
can
result
from
leakage
IGNITION
AND
FUEL
SYSTEM
Fig
ET
10
Teding
compression
pressure
5
Depress
accelerator
pedal
to
open
throttle
and
choke
valves
Note
Do
not
pump
pedal
6
Start
engine
as
quickly
as
pos
sible
7
Compression
pressure
kg
cm2
psi
at
rpm
Standard
12
0
171
350
Minimum
9
0
128
350
8
Cylinder
compression
in
cylinders
Should
not
be
less
than
80
of
highest
reading
CONTENTS
CHECKING
BATTERY
ET
9
CHECKING
DISTRIBUTOR
CAP
ROTOR
CHECKING
AND
ADJUSTING
IGNITION
AND
CONDENSER
ET
11
TIMING
ET
10
CONDENSER
ET
11
ADJUSTING
IGNITION
TIMING
ET10
ADJUSTING
CARBURETOR
IDLE
RPM
CHECKING
AND
REPLACING
SPARK
PLUG
ETlO
AND
MIXTURE
RATIO
ET
11
CHECKING
DISTRIBUTOR
OPERATING
IDLE
LIMITER
CAP
ET
12
PARTS
AND
IGNITION
WIRING
ETlO
CHECKING
CARBURETOR
RETURN
SPRING
ET
12
BREAKER
POINTS
lNon
California
models
ET
10
CHECKING
CHOKE
MECHANISM
AI
R
GAP
lCalifornia
models
ET11
Choke
plate
and
linkage
ET13
DISTRIBUTOR
ET
11
CHECKING
FUEL
LINES
IGNITION
WIRING
ET
11
Hoses
pipings
connections
etc
ET
13
REPLACING
FUEL
FILTER
ET
13
CHECKING
BATTERY
Check
electrolyte
level
in
each
bat
tery
cell
I
Unscrew
each
filler
cap
and
inspect
fluid
level
If
the
fluid
is
low
add
distilled
water
to
bring
the
level
up
approximately
10
to
20
mm
0
39
H
9
to
0
79
in
above
the
plates
Do
not
overfill
2
Measure
the
specific
gravity
of
battery
electrolyte
Page 26 of 537
Fresh
air
Blow
by
gas
CHECKING
VENTILATION
HOSE
1
Check
hoses
and
hose
connec
tions
for
leaks
2
Disconnect
all
hoses
and
blow
them
out
with
compressed
air
If
any
hose
cannot
be
free
of
obstructions
replace
Ensure
that
flame
arrester
is
surely
inserted
in
the
hose
between
air
cleaner
and
rocker
cover
CHECKING
EXHAUST
MANIFOLD
HEAT
CONTROL
VALVE
Run
engine
and
visually
check
counterweight
to
see
if
it
operates
properly
I
For
some
time
after
starting
engine
in
cold
weather
counterweight
turns
counterclockwise
until
it
comes
into
contact
with
stopper
pin
installed
to
exhaust
manifold
Counterweight
gradually
moves
down
clockwise
as
engine
warms
up
and
ambient
temperature
goes
higher
around
exhaust
manifold
2
When
engine
speed
is
increased
discharge
pressure
of
exhaust
gases
causes
counterweight
to
move
down
ward
clockwise
Engine
Tune
up
CoOl
1
Oil
level
gauge
2
8affle
pia
te
3
Flame
arrester
4
Filter
5
P
C
V
valve
6
Steel
net
7
Baffle
plate
1fiI
o
EC716
Fig
ET
20
Crankcaae
emi
ion
control8
tem
3
When
heat
control
valve
is
in
the
full
open
position
counterweight
moves
further
clockwise
exceeding
the
position
described
in
1
1
above
and
stops
again
coming
into
contact
with
stopper
pin
ct
t
C
EC245
1
Counterwe
ht
2
Stopper
pin
3
Heat
control
valve
Fig
ET
21
Cold
operation
of
counte
weigh
t
EC246
1
Counterweight
2
Stopper
pin
3
Heat
control
valve
Fig
ET
22
Hot
operation
of
counter
weight
ET
14
2
With
engine
stopped
visually
check
E
F
E
system
for
the
following
items
I
Thermostat
spring
for
dismount
ing
2
Stopper
pin
for
bend
and
count
er
weight
stop
position
for
dislocation
3
Check
heat
control
valve
for
malfunction
due
to
break
of
key
that
locates
counterweight
to
valve
shaft
4
Check
axial
clearance
between
heat
control
valve
and
exhaust
mani
fold
Correct
clearance
is
0
7
to
1
5
mm
0
028
to
0
059
in
5
Check
welded
portion
of
heat
control
valve
and
valve
shaft
for
any
indication
of
crack
or
flaking
6
Rotate
heat
control
valve
shaft
with
a
fmger
and
check
for
binding
between
shaft
and
bushing
in
closing
and
opening
operation
of
heat
control
valve
If
any
binding
is
felt
in
rotating
operation
move
valve
shaft
in
the
rotation
direction
several
times
If
this
operation
does
not
correct
binding
condition
it
is
due
to
seizure
between
shaft
and
bushing
and
exhaust
mani
fold
should
be
replaced
as
an
assem
bly
CHECKING
SPARK
TIMING
CONTROL
SYSTEM
This
system
is
installed
on
non
California
automatic
transmission
models
SPARK
DELAY
VALVE
Automatic
transmission
models
only
This
valve
delays
vacuum
spark
advance
during
rapid
acceleration
it
also
cuts
off
the
vacuwn
spark
advance
imme
iately
upon
deceleration
The
valve
is
designed
for
one
way
opera
tion
and
consists
of
a
one
way
umbrel
la
valve
and
sintered
steel
fluidic
restrictor
Page 41 of 537
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
Page 44 of 537
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
Page 47 of 537
Engine
Mechanical
GENERAL
DESCRIPTION
MODEL
L20B
ENGINE
CYLINDER
BLOCK
CRANKSHAFT
PISTON
AND
CONNECTING
ROD
CYLINDER
HEAD
CONTENTS
EM
2
EM
3
EM
3
EM
3
EM
3
CAMSHAFT
VALVE
MECHANISM
CAMSHAFT
DRIVE
MANIFOLDS
out
smooth
dependable
power
The
cylinder
block
is
cast
as
a
single
unit
and
featllres
deep
skirting
This
engine
is
equipped
with
a
single
2
barrel
downdraft
carburetor
that
in
corporates
a
special
device
to
control
emissions
MODEL
L20B
ENGINE
The
L20B
engine
features
O
H
C
valves
wedge
shaped
combustion
chamber
aluminum
head
and
a
fully
balanced
5
bearing
crankshaft
to
turn
Main
specifications
Oisplacemen
t
cc
cu
in
Bore
x
stroke
mm
in
Compression
ratio
Ignition
timing
Degree
B
T
O
C
rpm
MIT
AlT
MIT
Manual
Transmission
EM535
Fig
EM
Cross
sectional
view
L20B
1
952
1191
85
X
86
3
35
x
3
39
8
5
12
750
Non
California
model
10
750
California
model
12
650
in
0
position
AIT
Automatic
Transmission
EM
2
EM
3
EM
3
EM
3
EM
3
CYLINDER
BLOCK
The
cylinder
block
a
mono
block
special
casting
structure
employs
a
five
bearing
support
system
for
quiet
ness
and
higher
durability
The
cylinder
bores
are
surrounded
by
cooling
jackets
and
machined
di
rectly
in
the
block
The
oil
ways
in
the
block
are
arranged
so
that
the
full
flow
oil
filter
is
directly
attached
to
the
right
hand
side
of
the
block
EM536
Fig
EM
2
Cylinder
block
CRANKSHAFT
The
crankshaft
is
a
special
steel
forging
Fully
balanced
it
turns
out
smooth
dependable
power
at
high
speed
The
L20B
engine
uses
eight
balance
weights
Main
bearings
are
lubricated
by
oil
pumped
through
the
main
oil
gallery
and
the
oil
holes
which
run
in
parallel
with
cylinder
bores
There
are
oilways
drilled
in
the
crankshaft
for
the
lubri
cating
oil
The
center
main
bearing
is
equipped
with
thrust
washers
to
take
up
end
thrust
of
the
crankshaft
Page 49 of 537
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
Page 71 of 537
30
Install
heatshieid
plate
on
mani
fold
assembly
31
Install
air
gallery
pipe
on
ex
haust
manifold
32
Install
manifold
gasket
and
manifold
assembly
on
cylinder
head
Tightening
torque
1
2to
1
6kg
m
8
7
to
11
6
ft
lb
33
Install
blow
by
gas
pipe
on
cyl
inder
block
and
tighten
with
rear
engine
slinger
34
Install
thermostat
housing
gas
ket
thermostat
housing
and
thermo
stat
35
Install
thermal
vacuum
valve
on
thermostat
housing
Before
installing
apply
a
liquid
packing
slightly
to
the
threads
36
Install
FJ
C
D
bracket
on
cylin
der
head
37
Install
E
G
R
passage
and
E
G
R
valve
on
intake
manifold
38
Connect
E
G
R
tube
to
E
G
R
tube
and
exhaust
manifold
39
Install
check
valve
on
air
gallery
pipe
40
Install
air
cleaner
bracket
on
intake
manifold
41
Install
air
control
valve
on
air
cleaner
bracket
California
models
42
Install
vacuum
and
fuel
tubes
combined
on
cylinder
head
43
Install
distributor
assembly
44
Install
heatshield
plate
joint
seat
and
carburetor
Carbure10r
tightening
torque
0
5
to
1
0
kg
m
3
6
to
7
2
ft
lb
Note
When
instalUng
joint
seat
be
sure
to
put
the
duct
into
primary
hole
in
intake
manifold
S
J
Heatshield
plate
4
Joint
seat
2
Primary
hole
5
Secondary
hole
3
Duct
EM534
Fig
EM
I06
Installing
carburetor
joint
seat
Engine
Mechanical
45
Install
dash
pot
bracket
and
dash
pot
to
intake
manifold
46
Connect
all
air
vacuum
and
fuel
hoses
and
then
secure
with
clamps
I
Cylinder
block
to
P
C
V
valve
hose
2
A
B
valve
to
E
G
R
passage
vac
uum
hose
3
A
B
valve
to
E
G
R
passage
air
hose
4
Vacuum
tube
to
carburetor
vac
uum
hoses
5
Fuel
ube
to
carburetor
fuel
hose
6
Fuel
tube
to
fuel
pump
fuelhose
7
Distributor
to
vacuum
switch
or
spark
delay
valve
vacuum
hose
8
Air
control
valve
vacuum
hose
9
Check
valve
to
air
control
valve
hose
10
Thermal
vacuum
valve
to
E
G
R
valve
vacuum
hose
I
I
Thermal
vacuum
valve
to
vacuum
tube
hose
47
Install
carburetor
air
cleaner
on
carburetor
and
then
connect
air
and
vacuum
hoses
as
follows
I
Air
cleaner
to
exhaust
manifold
hot
air
duct
2
Air
c1eaner
to
air
pump
hose
3
Air
cleaner
to
rocker
cover
hose
4
Air
cleaner
to
air
control
valve
hose
5
6
48
Install
spark
plugs
in
place
49
Connect
all
distributor
high
ten
sion
cables
to
spark
plugs
50
Install
air
pump
drive
belt
cool
er
compressor
and
idler
pulley
51
Install
left
engine
mounting
bracket
52
Install
clutch
assembly
on
flywheel
with
Clutch
Aligning
Bar
KV30100200
Air
cleaner
to
A
B
valve
hose
Other
vacuum
hoses
Tightening
torque
1
2
to
2
2
kg
m
8
7
to
15
9
ft
lb
EM
26
I
I
KV30100200
EM440
Fig
EM
I07
In
talling
clutch
embly
53
Using
an
overhead
hoist
and
lifting
cable
hoist
engine
away
from
engine
stand
and
then
down
onto
engine
carrier
54
Install
right
engine
mounting
bracket
oil
filter
oil
pressure
switch
oil
level
gauge
and
water
drain
plug
When
installing
oil
filter
fasten
it
to
cylinder
block
by
hand
Note
Do
not
overtighten
flit
or
oil
leakage
may
occur
55
Install
alternator
bracket
adjust
ing
bar
alternator
cooling
fan
and
belt
56
Adjust
the
deflection
of
drive
belts
when
thumb
pressure
is
applied
midway
between
pulleys
A
pressed
force
is
above
10
kg
22
0
lb
Deflection
of
drive
belts
8
to
12
mm
0
315
to
0
472
in
EM613
Fig
EM
lOB
Fan
belt
tension
57
Fill
engine
oil
up
to
specified
level
Page 83 of 537
r
Engine
Mechanical
Tool
number
For
Reference
No
Description
use
page
or
tool
name
Unit
mm
in
on
Figure
No
12
STl742000l
This
tool
is
used
to
prevent
chains
from
falling
out
of
place
All
Fig
EM
19
in
removing
cylinder
heads
or
earn
gears
and
shafts
L
series
Chain
stopper
40
1
S1
r
SE196
13
STl9320oo0
This
tool
is
used
to
take
oil
filter
out
of
place
n
tightening
All
Page
EM4
Oil
filter
wrench
the
filter
do
not
use
this
tool
to
prevent
excess
tightening
models
120
4
7
SE197
14
KV30100200
This
tool
is
used
to
install
clutch
assembly
to
engine
All
Fig
EM
107
L
series
Clutch
aligning
bar
SEGOl
Piston
ring
compressor
This
tool
is
used
to
compress
piston
rings
while
piston
is
being
inserted
into
cylinder
All
Fig
EM
92
models
15
EM03470000
2
SE199
EM
36