torque DATSUN PICK-UP 1977 Service Manual

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

r

Engine
Tune

up

A
T

C
air

cleaner

Operating
temperature
OC
OF

30

to
54

86
to
129

Tightening
torque

Cylinder
head

bolts

1st

turn

2nd
turn

3rd
turn

Spark
plugs
kg
m
ft
b

kg
lll
ft
lb

kg
m
ft
lb

kg
m
ft

lb

kg
m

ft
lb

kg
m
ft

lb
4
0

29

6
0

43

6
5

to
8
5
47
to

61

1
2

to
1

6
8
7

to
11
6

0
5

to
1
0

3
6
to
7

2

1

5
to
2
0
II
to
14
Manifold
nuts

Carburetor
nuts

ET

26

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

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

Standard

Taper
and
out
of
round

of

journal
and
crank

pin

mm
in
less
than

0
01
0

0004

3
Crankshaft
bend
can
be
checked

by

placing
it

on
V
blocks
and

using
a

dial

gauge
with
its

indicating
finger

resting
on
center

journal

Standard

Crankshaft
bend
mm

in
less
than

0
05
0

0020

Note

When
measuring
bend
use
a

dial

gauge
Bend
value
is

half
of
the

reading
obtained
when
crankshaft
is

turned
one
full
revolution
with
a

dial

gauge
attached
to
its
center

journal

4

After

regrinding
crankshaft
finish

it
to

the
necessary
size
indicated
on

page
EM
18

by
using
an

adequate

undersize

bearing
according
to

the

extent
of

required
repair

5

Install
crankshaft
in
cylinder

block
and
measure
crankshaft
free
end

play
Engine
Mechanical

Maximum

0
Q25
0
0010

EM137

Fig
EM
64

Checking
crankshaft
bend

Maximum

0
10
0
0039

Fig
EM

65
Checking
crankshaft
end

play

Standard
Wear

limit

Crankshaft
free
end

play
mm
in
0
05
to
0

18

0
0020
to
0

0071
0
3
0
0118

6
At
the
rear
end
of
crankshaft

check
crankshaft

pilot
bushing
for

wear
or

damage
Replace
it
if

any
fault

is
detected
To

replace
crankshaft
rear

pilot

bushing
pro
ceed
as
follows

I
Pull
out

bushing
using
Pilot

Bushing
Puller
STl66
1000
I

EM

17
STl6610001

EM425

Fig
EM

66
Pulling
out

pilot

bushing

2
Before

installing
a
new

bushing

thoroughly
clean

bushing
hole

Press

fit

bushing
so
that
its

height
above

flange
end
is
4
5

to
5
0

mm
0
177

to

0
197
in
Do
not

oil

bushing

EM418

Fig
EM
67
Press

fitting
new

pilot

bush

ng

BUSHING
AND

BEARING

MEASUREMENT
OF

MAIN
BEARING
CLEARANCE

I

Thoroughly
clean
all

bearings
and

check
for
scratches
melting
score
or

wear

Replace
bearings
if
any
fault
is

detected

2

Crankshaft

journals
and

bearings

should
be

clean
and
free
from
dust
and

dirt
before
oil
clearance
is
measured

3

Set
main

bearing
on
cap
block

4

Cut
a

plastigage
to
width
of
bear

ing
and

place
it
in

parallel
with
crank

pin
getting
clear
of
the
oil
hole
Install

cap
on
the
assembly
and

tighten
them

together
to
the

specified
torque

Tightening
torque

4
5
to
5
5

kg
m
33
to

40
ft
lb

Fig
EM
68
P14stigage

Note
Do

not
tum
crankshaft
while

plastigage
is

being
inserted

5
Remove

cap
and

compare
width

of
the

plastigage
at
its
widest

part
with

the
scale

printed
in

plastigage
enve

lope

Fig
EM

69

Measuring
bearing

clearance

MEASUREMENT
OF

CONNECTING
ROD

BEARING

CLEARANCE

I

Measure

connecting
rod

bearing

clearance
in
the

same
manner
as
above

Tightening
torque

4
5

to
5
5

kg
m
33

to
40
ft
lb
Engine
Mechanical

Bearing
011
clearance

Standard
Wear
limit

Main

bearing
clearance

mm
in
0
020
to

0
062

0
0008
to
0
0024
0
12
0
0047

Connecting
rod

bearing

clearance
mm
in
0

025
to
0
055

0
0010
to
0
0022
0

12
0
0047

2
If

clearance
exceeds

specified

value

replace
bearing
with
an
under

size

bearing
and

grind
crankshaft

jour

nal

adequately

FiniNG
BEARINGS

Bearings
are
manufactured
with

crush
to

make

bearing
snug
down
into

its

bore
To

measure
this

proceed
as

follows

I
Set
main

bearing
in
main

bearing

cap
recess
or

cylinder
block

bearing

recess

correctly

2
Lock
one
side
of

bearing
and

press
other
side
until

bearing
back

surface
touches
the
recess

Bearing
crush

All
main

bearings
mm
in

All

connecting
rod

bearings
mm
in

4

Handle

connecting
rod

bearing
in
3
Then

measure

bearing
crush
H

with
a
feeler

gauge
See

Figure
EM
70

The
standard

bearing
crush
value
is

listed
below

Weight

H

Fig
EM
70

Checking
bearing
crum

o
to
0
03
0
to

0
0012

0
015
to
0
045
0
0006
to

0
0018

the
same
manner
as
above

Main

bearing
undersize

Unit
mm
in

Bearing
top
thickness
Crank

journal
diameter

1

827
to

1
835
59
942
to

59
955

SID

0
0719
to

0
0722
2

3599
to
2

3604

0
25
0
0098

1
952
to
1
960

59
692
to

59
705

Undersize
0
0769
to
0
0772
2

3501
to
2
3506

0
50
0
0197
2
077
to

2
085
59442
to
59
455

Undersize
0

0818
to
0

0821
2
3402
to

2
3407

0
75
0
0295
2
202
to
2
210

59
192

to
59
205

Undersize
0
0867
to
0
0870

2
3304
to
2
3309

EM

18

PRECAUTIONS

CYLINDER
HEAD

PRECAUTIONS

I
Use

thoroughly
cleaned

parts

Especially
make

sure
that
oil
holes
are

clear
of

foreign
matter

2

When

installing
sliding
parts
such

as

bearings
be
s
uIe
to

apply
engine
oil

to
them

3
Use

new

packing
and

oil
seals

4
Do
not

reuse
lock
washers

5

Keep
tools
and

work
benches

clean

6

Keep
necessary
parts
and
tools

near
at
hand

7
Be

sure
to
follow

specified
tight

ening

torque
and
order

8

Applying
sealant

Use
sealant
to
eliminate
water
and

oil
leaks
Parts

requiring
sealant
are

I
Front

cover
and
corners
of

cyl

inder
block
See

Figure
EM

78

EM153

Fig
EM
78

Applying
alant

Front
cover
and

cylinder
block

2
Main

bearing
cap
and

cylinder

block
Each

side
of
rear

main
bearing

cap
and
each
corner
of

cylinder
block

See

Figure
EM
79
Engine
Mechanical

ENGINE
ASSEMBLY

CONTENTS

EM
21

EM
21
PISTON
AND

CONNECTING
ROD

ENGINE
ASSEMBLY
EM

22

EM
22

Cylinder
block

Rear
main

bearing
cap

20to2Smm

Ill

Points

to
be

applied
sealant

EM151
s

e

00

000

o

Fig
EM
79

Applying
sealanl

Main

bearing
cap
and

cylinder
block

3

Cylinder
block

Step
portions
at

four

mating
surfaces

cylinder
block
to

front
chain

cover
and

cylinder
block

to
rear
main

bearing
cap
See

Figure

EM
80

Note
Do
not

apply
too

much
sealant

J

Apply
sealant
at
hese

points

EM152

Fig
EM
80

Applying
sealant

Cylinder
block

CYLINDER
HEAD

Valve
assembly
and
valve

spring

Using
Valve
Lifter
STl2070000
set

valve

pring
seat
in

position
and
fit

valve

guide
with
oil
seaL

Assemble
valve
in
the
order
shown

below
valve
inner
and
outer
valve

springs
spring
retainer

valve
collet

and
valve
rocker

guide

EM
21
Fig
EM
81

Installing
valves

Notes

a
Ensure

that
valve

face
is

free
from

foreign
matter

b
The
L20B

engine
uses
double

type

valve

springs

2
Valve
rocker

pivot
assembly

Screw
valve
rocker

pivots
joined

with
lock
nuts
into

pivot
hushing

3
Camshaft

assembly

Set

locating

plate
and

carefully

install
camshaft
in

cylinder
head
Do

not

damage
the

bearing
inside

Oblong

groove
of

locating

plate
must
be

directed
toward
front
side
of

engine

Camshaft
bracket

tightening

torque

1

8
to
2
0

kg
in

13
to

15
ft
lb

4

Install
camshaft

sprocket
on
earn

shaft
and

tighten
it

together
with

fuel

pump
drive
cam
to

specified
torque

Tightening
torque

12
tol6

kg
m

87
to
116
ft

lb

this
time
check
camshaft
end

Fig
EM
82

Installing
camshaft

sprocket

5
Install
rocker
arms

by

pressing

valve

springs
down
with
a
screwdriver

6
Install
valve
rocker

springs

7
After

assembling
cylinder
head

turn
camshaft
until
No
I

piston
is
at

T
D
C
on
its

compression
stroke

EM1S5

Fig
EM
83

A
embling
cylinder
head

PISTON
AND

CONNECTINGROD

1

Assemble

pistons
piston
pins
and

connecting
rods

on
the
de
ignated

cylinder

STl3030001

EM156

Fig
EM
84
Installing
piston
pin

EM157

Fig
EM
85
Assembling
piston
and

connecting
rod

Notes

a
Piston

is

pressed
into

connecting

rod
with

fitting
force
of
0
5
to
5

tons
aid
of
Piston
Pin
Press

Stand
STl303000
I
is

necessary

When

pressing
piston
pin
into
con

necting
rod

apply
engine
oil
to

pin

and
small
end
of

connecting
rod
Engine
Mechanical

b

Arrange
so
that
oil

jet
of
connect

ing
rod
big
end
is
directed
toward

right
side
of

eylinder
block

c

Be
sure
to
install

piston
in

cylinders

with
notch
mark
of

piston
head

toward
front
of

engine

2

Install

piston
rings

InstalI

top
and
second

rings
in

right

position
with
marked
side

up

Notes

a

Top
ring
is

chromium

plated
on

liner

contacting
face

b
Second

ring
has

larger
taper
surface

than

top
ring

c
In
the
combined
oil

ring
upper
rail

is
the
same
as

lower
one

j

c6J

EM158

Fig
EM
86

lalling
pidon
rings

3

Fix

bearings
on

connecting
rod

and

connecting
rod

cap

Note
Clean
back
side
of

bearing
care

fully

ENGINE
ASSEMBLY

The
first

step
in

engine
assembly

is

to
bolt

Engine
Attachment

ST0526000
I

to

right
hand
ide
of

cylinder
block
Next
install
block
on

another

Engine
Stand
ST0501S000

with

engine
bottom

up

2

Set
main

bearings
at

the

proper

portion
of

cylinder
block

Rear
Front

III
III

m
It
IlL

D

D

D
D
D

1
5
1
4
1
3
1
2
1
1

EM159

Fig
EM
87
Main

bearings

EM
22
3
Install
baffle

plate
including

cyl

inder
block
net

Notes

a

Only
center

bearing
No
3

is
a

flanged
type

b
All
inter
bearings
No
2

and
No
4

are
the
same

type

c
Front

bearing

No
I
is

also
the

same

type
as
rear

bearing
No
5

The
difference
is

that
an
oil
hole
is

provided
in
the
front

bearing

d
All

upper
and
lower

bearings
are

interchangeable

4

Apply
engine
oil

to
main

bearing

surfaces
on
both
sides
of

cylinder

block
and

cap
and
then
install
crank

shaft

5
Install
main

bearing

cap
and

tight

en

bolts
to

specified

torque

Tightening
torque

4
5
to
5
5

kg
m
33

to
40
ft
lb

Notes

a

Apply
sealant
to
each
side
of
rear

main

bearing
cap
and
each
comer

of

eylinder
block
as
shown
in

Figure
EM
79

b

Arrange
parts
so
arrow
mark
on

bearing
cap
faces
toward
front
of

engine

c

Prior
to

tightening
bearing
cap

bolts

place
bearing
cap
in

proper

position
by
shifting
crankshaft
in

the
axial
direction

d

Tighten
bearing
cap
bolts

gradually

in
two
to
three

stages
outwardly

from
center

bearing
in
the

sequence

as
shown
in

Figure
EM
88

e
After

securing
bearing

cap
bolts

ascertain
that
aankshaft
turns

smoothly

@

i

d

l

j
1

@EM543

Fig
EM
8S
Torque

sequence
0

cap
bolt

6
Make

sure
that

crankshaft
has

proper
end

play

Crankshaft
end

play

0
05
to
0
18

mm

0

0020
to
0
0071
in

Fig
EM
89

Checking
crankshaft

end

play

7

Install
side
oil
seals
into

rear
main

bearing

cap
Prior
to

installing
apply

sealant
to
seals

Fig
EM
90

Driving
side
oil
seal

8
Install
rear
oil
seal

using
Crank

shaft
Rear

Oil
Seal
Drift

STI5310000

r

STl5310000

r

EM163

Fig
EM
91

Installing
rear
oi
seal
Engine
Mechanical

Note
When

installing
oil
seal

give

coating
of

engine
oil
to

mating

shaft
to

prevent
scratches
and

fold

ed

lip
Also

give

coating
of
oil
to

periphery
of
oil

seal

9

Install
rear
end

plate

10
Install

flywheel
securely
and

tighten
bolts
to

specified

torque

Tightening

torque

14

to
16

kg
m

101
to
116
ft
lb

I
I

Insert

pistons
in

corresponding

cylinder

using
Piston

Ring
Compressor

EM03470000

EM03410000

I

EM544

Fig
EM
92

Installing
pi8ton
rod

a
Sembly

Notes

a

Apply
engine
oil

to

sliding
parts

b

Arrange
80

that
notch
mark
on

piston
head
faces
to
front
of
en

gine

c
Install

piston
rings
at
1800
to

each

other

avoiding
their
fit
in
the

thrust
and

piston
pin
directions

6
Top
ring

I
iilring

Piston

pin
ireClioJ

EM165

Fig
EM

93
PUtan

ring
direction

12
Install

connecting
rod

caps

Tightening
torque

4
5
to
5
5

kg
m
33
to
40
ft
lb

EM
23
Fig
EM

94

Installing
connecting
rod

cap

Note
Install

connecting
rods

and
con

necting
rod

caps
80
that
their

as

signed
numbers
are

positioned
on

the

same
side
and
in
the
SlIme

direction
with

respect
to

cylinders

13
Make
sure
that

connecting
rod

big
end
has

proper
end

play

Fig
EM

95

Checking
big
end

play

Big
end

play

0
2
to
0
3
mm

0
008
to
0
Ql2
in

14

Install

cylinder
head

assembly

Fig
EM
96

Tightening
sequence

01

cylinder
head
bolts

J
Thoroughly
clean

cylinder
block

and

head
surface

Do

not

apply
sealant
to

any
other

part
of

cylinder
block
and
head

sur

face

2
Turn
crankshaft
until
No
I

pis

ton
is
at
T
D
C

on
its

compression

stroke

3
Make

sure
thai
camshaft
sprock

et
location
notch
and

plate
oblong

groove
are

aligned
at
their
correct

positions

4

When

installing
cylinder
head

make
sure

that
all
valves
are

apart

from
heads
of

pistons

5
Do

not
rotate
crankshaft
and

camshaft

separately
or
valves
will
hit

heads
of

pistons

6

Temporarily
tighten
two
bolts

CD

V
sJiown

in
Fig

re
EM
96

Tightening
torque

2

kg
m

14
ft
b

15
Install
crankshaft

sprocket
and

oil

pump
drive

gear
and
fit
oil

thrower

Note
Make
sure
lhat

maling
marks
of

crankshaft

sprocket
face
10
Cront

16
Install

timing
chain

Noles

a
Make

sure
that
crankshaft
and
cam

shaft

keys
point

upwards

Fuel

pump
drive

earn

2
Chain

guide

3

Chain
tensioner

4

Crank

sprocket

5
earn

sprocket

6
Chai

guide

EM439

b
Set

timing
chain

by

OOgning
its

mating
marks
with
those
oC
crank

shaft

sprocket
and
camshaft

sprock

et
at
the

right
hand
side
There
are

forty
four
chain
links
between
two

mating
marks
of

timing
chain

c
NO
2
hole
is

Cactory

adjusted

When
chain
stretches

excessively

adjust
camshaft

sprocket
at

No
3

hole

d
Use
a

set
of

timing
marks
and

location
hole

numbers
Engine
Mechanical

17
Install
chain
slack
side

guide
to

cylinder
block

18
Install
chain
tensioner

Note

Adjust
protrusion
oC
chain
ten

sioner

spindle
to
0
mm
0
in

Fig
EM
98

lmtalling
chain
tensioner

19
Press
new
oil
seal
in

front
cover

Notes

a
Front

cover
oil
seal
should
be
reo

placed
when
Cront
cover
is

disas

sembled

b
BeCore

pressing
oil
seal
into
Cront

cover

give
coating
of

engine
oil
to

periphery
of
oil
seal

c
This
oil
seal
is
a
threaded
seal

type

which
has

improved
sealing
charac

teristics
Do
not

apply
grease
to

sealing

lip

20
Install
front
cover
with

gasket
in

place

1

Timing
mark

2

Timing
mark

EM545

Fig
EM

99

Installing
fronl
COlHlr

Notes

a

Apply
sealant
to
Cront
cover
and

corners
oC

upper
section
of

cylinder

block

as
shown

in

Figure
EM
78

EM
24
b
Install
Cront
cover
with
head

gasket

in

place

c

Check

height
diCCerence
between

cylinder
block

upper
Cace
and
Cront

cover

upper
Cace
DifCerence
must

be
less
than
0
15

mm
0
0059
in

d

Note
that
difCerent

types
oC
bolts

are
used

e

Before

installing
front
cover
on

cylinder
block

apply

coating
oC

engine
oil
10

sealing
lip
of
oil

seal

EMS11

Fig
EM
lOD
Front

cover
bolts

Tightening
torque

Size
M8
0
315
in

1
0
to
1
3

kg
m
7

2
to
9
4

ft
lb

Size
M6
0
236
in

0
4
to
0
6

kg
m
2

9
to
4

3
ft
lb

21
Install
crankshaft

pulley
and

water

pump
assembly
then
set
No
I

piston
at
ToO
C
on
its

compression

stloke

Crankshaft

pulley
nu
I

tightening
torque

12
to
16

kg
m
B7
to
116
ft

lb

EM546

Fig
EM
Ol

lnstallingcran
haft

pulley
and

water

pump

22

Finally

tighten
head

bolts
to

the

specified
torque
in

three

steps

according
to
the

lightening
sequence

shown
in

Figure
EM
96

Note
thai
Iwo

types
of
bolts

are

used