Datsun 510 series, 610 series, 1300, 1400, Bluebird 160 B Workshop Manual

i

WORKSHOP

MANUAL

for

510

series

DATSUN

130014001600

610

series

I

l

A

160B

180B

COMPILED

AND

WRlTTEN

av

CRNewton

SBN

901610

13

5

PUBUSHED

BY

OOEREUROPE

AUTODA

TA

DIVISION

NICHOLSON

HOUSE

MAIDENHEAD

BERKSHIRE

ENGLAND

C

Copyrirt

lnt

eurupe

Cktoblr

1972

WSM

137

Printed

Engl

w

i

I

inter

llil

j

@

W

E

Hu

tol

and

Type

Identl

ficatlOn

YOUR

MANUFACTURER

The

Nissan

Motor

Company

was

founded

in

1933

under

the

name

of

Jidosha

Seizo

Co

Ltd

In

1934

the present

title

was

adopted

and

during

1966

the

company

merged

with

Prin

c

Motors builders

of

the

Skyline

and

Gloria

ars

With

the

head

office

and

six

main

factories

near

Tokyo

Japan

other

sister

plants

ace

also

in

production

in

various

countries

throughout

the

world

YOUR

VEHICLE

In

the

early

days

of

the

company

s

history

vehicles

constructed

were

given

the

trade

name

DA

TSDN

which

means

SONofDAT

the

initials

of

three

of

the

financial

backers

forming

the

syllable

DATTo

avoid

confusion

with a

similar

Japanese

word

the

name

was

eventually

changed

to

DATSUN

The

various

models

coveredinthis

Manual

together

with

alternative

namt

s

used

for

the

world

markets

are

listed

below

MODELS

COVERED

MODEL

ALTERNATIVE

IDENT

510

SERIES

Datsun

1300

510

SERIES

Datsun

1400

510

SERIES

Datsun

1600

610

SERIES

Bluebird

160

B

610

SERIES

Bluebird

180

B

00

SERIES

DATSUN

ISoo

ENGINE

FITTED

1300

c c

L

l3

1400

c

LI4

1600

c

c

LI6

1600

c

LI6

1800

c c

L

18

181S

GIS

WUUUU

I

fl

I

lfI

r

7

I

i

I

1

11

lii

Identification

plate

location

Engine

serial

and

model

number

2

REMARKS

Superseded

by

1400

c

c

model

withL14

engine

Similar

to

1300

c c

car

Similar

to

1300 1400

e c

car

In

some

markets

identified

as

1600

SSS

1800

SSS

J

S

1

HI

I

Car

serial

number

location

inteN

j

@IP

B

Index

ENGINE
COOLING

SYSTE

l

IGNITION

SYSTE

I

FUEL

SYSTBl
CLUTCH
GEARUOX

PROPELLER

SHAFT

Id

DIFFERENTIAL

REAR

AXLE

nd

REAR

SUSPENSION

FRONT

SUSPENSION
STEERING
BRAKING

SYSTEM

ELECTRICAL

EQUIP

JENT

WIRING

JAGRA

IS

TROUBLE

SHOOTING

TIGHTENING

TORQUES

SERIES C30MODEL

SUPPLEMENT

AUTOSERVlCE

DATA

CHART

PART

NA

ESndALTERNATIVES

CONVERSION

TABLES

S

15

2S
33
43
51

62

7S
83
91

9S
lOB
liB
I2S

129

51

End

of

manuir

IntroductIon

OUf

intention

in

writing

this

Manual

is

to

provide

the

reader

with

all

the

data

and

in

formation

required

to

maintain

and

repair

the

vehicle

However

it

must

be

realised

that

special

equipment

and

skills

arc

required

in

some

caseS

to

carry

out

the

work

detailed

in

the

text

andwedo

not

recommend

that

such

work

be

attempted

unless

the

reader

possesses

the

necessary

skill

and

equipment

It

would

be

bettertohave

an

AUTHQRISED

DEALER

to

carry

out

the

work

using

the

special

tools

and

equipment

available

to

his

trained

staff

He

will

alsobein

possession

of

the

genuine

spare

parts

which

may

be

needed

for

replacement

The

information

in

the

Manual

has

been

checked

against

that

provided

by

the

vehicle

manufacturer

and

any

peculiarities

have

been

mentioned

if

they

depart

rom

usual

work

shop

practice

A

fault

finding

and

trouble

shooting

chart

has

been

insertedatthe

endofthe

Manual

to

enable

the

reader

to

pin

point

faults

and

so save

time

As

it

is

impossible

to

include

every

malfunction

only

the

more

usual

ones

have

been

included

A

composite

conversion

table

has

also

been

included

at

the

end

of

the

manual

and

we

would

recommend

that

wherever

possible

for

greater

accuracy

the

metric

system

units

are

used

Brevity

and

simplicity

have

been

our

aim

in

compiling

this

Manual

relying

on

the

number

ous

illustrations

and clear

text

to inform

and

instruct

the

reader

At

the

request

of

the

many

users

of

our

Manuals

we

have

slanted

the

book

towards

repair

and

overhaul

rather

than

maintenance

Although

every

care

has

been

taken

to

ensure

that

the

information

and

data

are

correct

WE

CANNOT

ACCEPT

ANY

LIABILITY

FOR

INACCURACIES

OR

OMISSIONS

OR

FOR

DAMAGE

OR

MALFUNCTIONS

ARISING

FROM

THE USE

OF

THIS

BOOK

NO

MATTER

HOW

CAUSED

I

3

t

r

Engine

type

Ovendi

cngth

1300

L

13

Overall

width

Oyerall

height

Turning

circle

din

metres

tfeet

Supen

eded

by

Track

font

rear

1400

c

c

car

Ground

dearance

Olin

Weight

dry

I

820

808

I

Fuel

tClflk

capacity

35

29

6

150

93

Fuel

consumption

aximum

peed

Technical

Data

BLUEBIRD

400

1600

1600

U4

U6

0

4

120

162

20

1

560

6142

410

55

51

420

55

91

10

2

33

5

270

50

0

2

420

95

281

215

8

5

885

1

950

210

8

27

930

2

050

10

1

12

33

2

27

7

50

931

28

2123

5

60

99

L

16

4

215

165

941

1

600

62

99

405

55

3

Ii

0

6

34

8

290

5079

1

300

51

18

2

500

9843

185

7

281

955

2

1061

12

14

5

28

2

23

5

60

991

BLUEBIRD

1800

L

18

3

0

5

57

320

5

971

000

2

2051

165103

BLUEBIRD

1800

ESTATE

U8

4

280

168

501

4

5

557

330

52

361

1

065

2

348

EngIne

INTRODUCTION

ENGINE

Removal

ENGINE

DismantUng

ENGINE

Inspection

and

Overhaul

VALVES

VALVE

GUIDES

VALVE

SEAT

INSERTS

CAMSHAFT

AND

CAMSHAFT

BEARINGS

Checking

CYliNDER

BLOCK

PtSTONS

AND

CONNECTING

RODS

INTRODUCTION

The 1400

1600

cc

and

1800

cc

engines

are

four

cylinder

in

line

units

with

a

single

overhead

camshaft

and

fully

balanced

five

bearing

crankshaft

The

valves

are

operated

through

rockers

which

are

directly

activated

by

the

earn

mechanism

The

crankshaft

is

a

special

steel

forging

with

the

centre

main

bearing

equipped

with

thrust

washerstotake

up

the

end

thrust

of

the

crankshaft The

special

aluminium

pistons

are

of

the

strut

construction

to

control

thermal

expansion

and

have

two

compression

rings

and

one

combined

oil

ring

The

gudgeon

pins

have

special

hollow

steel

shafts

and

are

a

fully

floating

fitin

the

pistons

and

a

press

fit

in

the

connecting

rods

The

aluminium

alloy

cylinder

head

contains

wedge

type

combustion

chambers

andisfitted

with

aluminium

bronze

valve

seats

for

the intake

valves

and

heat resistant

steel

valve

seats

for

the

exhaust

valves

The

cast

iron

camshaftisdriven

by

a

double

row

roller

chain

from

the

crankshaft

pulley

The

engine

is

pressure

lubricated

by

a

rotor

type

oil

pump

which

draws

oil

through

an

oil

strainer

into

the

pump

housing

and

then

forces

it

through

a

full

flow

oil

filter

into

the

main

oil

gallery

ENGINE Removal

Place

alignment

marksonthe

bonnet

and

hinges

remove

the

bonnet

from

the

vehicle

2

Drain

the

cooling

system

and

engine

and

transmission

lubricant

Remove

the

radiator

grille

3

Discon

ect

the

battery

cables

and

lift

out

the

battery

4

Detach

the

upper

and

lower

radiator

hoses

remove

the

radiator

mounting

bolts

and

lift

the

radiator

away

from

the

vehicle

The

torque

converter

c

jng

pipes

must

be

disconnected

from

the

radiator

on

vehicles

fitted

with

automatic

transmission

S

Remove

the

COOling

fan

and

pulley

disconnect

the

fuel

pipe

from

the

fuel

pump

and

the

heater

hoses

from

the

engine

attachments

6

Disconnect

the accelerator

control

linkage

and

the

choke

CRANKSHAFT

AND

MAIN

BEARINGS

CAMSHAFT

AND

SPROCKET

FLYWHEEL

ENGINE

Assembling

VALVE

CLEARANCES

Adjusting

ENGINE

LUBRICATION

SYSTEM

OIL

PUMP

OIL

FILTER

CHANGING

THE

ENGINE

OIL

cable

from

the

carburettor

7

Disconnect

the

wirings

from

the

starter

alternator

ignition

coil oil

pressure

switch

and

temperature

sender

unit

8

Remove

the

clutch

slave

cylinder

Fig

A

2

and

its

return

spring

9

Disconnect

the

speedometer

cable

and

withdraw

the

plug

connector

from

the

reversing

light

switch

10

Disconnect

the

shift rods

and

seJector

rods

and

remove

the

cross

shaft

assembly

as

described

in

the

section

Gear

box

II

Disconnect

the

front

exhaust

pipe

from

the

exhaust

manifold

disconnect

the

centre

pipe

from

the

rear

pipe

and

remove

the

front

pipe

pre

muffler

and

centre

pipe

assembly

12

Disconnect

the

propeUer

shaft

flange

from

the

companion

flange

from

the

gear

carrier

13

Jackupthe

gearbox

slightly

and

remove

the

rear

engine

mounting

bracket

bolts

remove

the

mounting

cross

member

and

handbrake

cable

c1amp

14

Remove

the

bolts

securing

the

front

engine

mounting

brackets

to

the

crossmember

15

Attach

lifting

cable

or

chainstothe

hooks

installed

at

the

front

and

rear

of

the

cylinder

head

Lower

the

jack

under

the

gearbox

and

carefully

lift

and

tilt

the

engine

and

gearbox

unit

Withdraw

the

engine

and

gearbox

from

the

compartment

making

sure

thatitis

guided

past

the

accessories

installed

on

the

body

ENGINE

Dismantling

Remove

the

engine

as

previously

described

and

carefully

clean

the

exterior

surfaces

Cbeck

for

signs

of

fuel

oil

or

water

leaks

past

the

cylinder

head

and

block

Remove

the

air

cleaner

alternator

distributor

and

starter

motor

Plug

the

carburettor

air

horn

and

distributor

hole

to

prevent

the

ingress

of

foreign

matter

Remove

the

gearbox

from

the

engine

drain

the

engine

oil

and

coolant

Mount

the

engine

in a

suitable

stand

the

special

engine

attachment

ST05260001

and

engine

ST0501SOO0

should

be

usedifavailable

Fig

A

3

5

engine

600

tb

tllroogh

Section

S

O

sef1

es

ofenll

A

o

ne

l

Right

S

0

61

ttor

bure

n

car

l

tWI

thS

hi

4

t

V

ne

of

engJ

vie

lJ

lt

side

Gene

ol

Engine

FIS

to

fl

J

J

f

1

ST052fiOOOl

Fig

A

2

Removing

the

clutch

slave

cylinder

Fig

A

3

Mounting

the

engine

STI

0

120000

CI

@

j

91

7

m

I3L

I

T

IC

t

J

i1

C

J

6

i

11

j

1

j

4

I

U

O

J

I

Ll

LJJ

1r9i

V

@

1

EM092

Fig

AA

Removing

the

camshaft

sprocket

Fig

A

5

Cylinder

head

bolt

removal

sequence

t

J1

I

J

1

1

i

I

G

qt

7

r

J

O

I

IS

Fig

A

6

Removing

the

chain

tensioner

and

timing

chain

Fig

A

7

Removing

the

drive

sprocket

7

inter

lliJ

j

@I

IJ

I

7

4

i

ll

W

f

l

rr

er

j

il

Fig

A

9

Removing

the

flywheel

Fig

A

S

Removing

the

pistons

and

connecting

rods

Fig

A

II

Removing

the

baffle

plate

and

net

c

1

1i

t1

I

c2

r

Id

f

tij

Fig

A

IO

Removing

the

Tear

main

bearing

cap

Fig

A

12

Removing

the

piston

pin

Fig

A

13

Removing

the

valves

Fig

Al4

OIecking

the

cylinder

head

joinlface

Fig

AI5

Reaming

the

valve

guide

8

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

A6andA

7

Remove

the

connecting

rod

caps

and

push

the

pistons

and

connecting

rods

through

the

top

of

the

boresasshown

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

lORemove

the

rear

oil

seal

and

lift

out

the

crankshaft

remove

the

baffie

plate

and

cylinder

block

net

Fig

A

II

Remove

the

piston

rings

withasuitable

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

ordersothat

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

carenot

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

airtomake

sure

that

they

are

clear

Measure

the

joint

faceofthe

cylinder

head

for

outoftrue

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

lessIfthe

surface

is

outoftrue

by

more

than

the

limit

of01

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

be7965

7

980

mm

0

313603142

in

and

the

diameter

of

the

exhaust

valves7945

7

960

mm

0

312803134

in

If

the

seating

faceofthe

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

shouldbe0

0200053

mm

0

0008

0

0021

in

for

the

inlet

valves

and00400073

mm

0

001600029

in

for

the

exhaust

valvesIfthe

clearance

exceeds01

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

of00270049

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

of02

mm

0

0079

in

if

required

The

standard

valve

guide

requires

a

bore

in

the

cylinder

headof11

985

11

996

mm

dia04719

0

4723

in

dia

and

the

oversize

valve

guide

a

boreof12

185

12

196

mm

dia

0

479704802

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

boreofthe

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

Dataatthe

endofthis

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

replacedifthey

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

faceofthe

recess

in

the

cylinder

head

Select

the

valve

seat

inserts

and

check

the

outer

diameters

Machine

the

recess

in

the

cylinder

headtothe following

dimensions

at

room

temperature

9

it

r

inter

iJ

i

@

Pl

Fig

A

16

Correcting

the

valve seats

Li4

lnlakt

t1

c

r

I

I

37

8

1

4882

di

410

6142

dia

Unit

rnrn

in

L14

and

L16

Exhaust

Ct

rill

I

II

ill

300

1Bll

du

l

32

6

1

2835

dia

3714561

dia

Unll

In

Llb

thtwin

1

13

Ut

WiTh

Ie

ro

rLl

Incak

h

C

1

q

J

j

Exhaust

Fig

AIStandard

valve

seat

dimensions

Uland

liS

11tJ

1l

ioo

l

j

14

u

055i1

r

m

JA

9bIJUI4

l

9

611

559lldi

a

4L80

6457

dlll

45J1717

liS

311

fJ

90o

LJ

1300512

r

1

II

I

i

30nIl

i1

I

tlla

32

60

2835

di

L

3461

3622

dla

37

1

4561lia

Fig

A

IS

Valve

at

grinding

dimensions

10

CYUNDER

HEAD

RECESS

DIAMETER

Standard

inoerts

Engine

L14
Ll6

and

Ll8

Inlet
41

000410161614216148

in

45

00045016

mm

1

77l7

1

77231n

Engine

Ll4
Ll6

and

Ll8

Exhaust
37

00037016mm1456714573

in

37

000

37

016mm

l

456714573

in

CYLINDER

HEAD

RECESS

DIAMETER

Oversize

inserts

Engine

Ll4

Ll6andLl8

Inlet
41

500

41

516mm

l

633916345in

45

S0045516mmI791317920in

Engine

L14

Ll6andLl8

Exhaust
37

50037516mm

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

driveinthe

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

Placeasmall

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

halfarevolution

in

each

direction

untilacontinous

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

than16mm0063init

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

lmm00039init

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

Blocksasshown

in

Fig

A19and

position

the

dial

gauge

to

the

journal

The

runout

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

checkitfor

cracks

and

flaws

Check

the

joint

faceofthe

block

for

distortion

using

a

straight

edge

and

feeler

gauge

as

shown

in

Fig

A20The

surface

must

be

reground

if

the

maximum

tolerance

ofOlmm

0

0039

inisexceeded

Examine

the

cylinder

bores

for

out

of round

or

taper

using

a

bore

gauge

as

shown

in

Fig

A21The

readings

must

be

takenatthe

Top

middle

and

bottom

positions

indicated

in

Fig

A

22

The

standard

bore

diameters

are

83

000

83

050

rom

3

267733697

in

for

the

1400

and

1600cc

engines

and85000

85

050

mm

3

346533484

in

for

the

1800

cc

engine

with

a

wear

limit

of02mm00079

in

Outofround

and

taper

must

not

exceed015mm

0

0006

inIfthe

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

selectedinaccordance

with

the

amount

of

wear

of

the

cylinder

When

the

oversizeofthe

pistons

has

been

decideditwill

be

necessary

to

measure

the

piston

at

the

piston

skirt

Fig

A

23

and addtothis

dimension

the

specified

pistontocylinder

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

A24with

the

aid

ofafeeler

gauge

and

spring

scale

The

standard

clearanceis0

0230043

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

fitinthe

block

and

must

be boredtothe

correct

inner

diameter

after

fitting

Three

undersize

liners

are

available

in

the

following

sizes

11

y

t

interCE

MI

D

liPl

E

r

i

J

r

i

1

4

1

r

l

I

I

I

I

QJJ

I

kigthe

camshaft

for

run

out

Fig

A19Chec

n

I

I

I

y

Ii

der

bores

Fig

A

2

Measuring

lbe

cy

n

1

I

1l

or

r

i

r

mO

1874

r

I

abllUI

O

I

I

Q

ktdiameters

h

pistons

tr

F

A

23

Measunng

t

e

g

the

piston

ring

side

fi

A

25

Measurmg

g

clearance

12

k

oint

face

I

der

bloc

J

ki

gthecym

A20Chec

n

FIg

1

7

rb

I

tinder

ositions

for

the

cy

A

22

Measunng

p

F

g

bores

the

piston

ring

gap

A

26

Measunng

F

g

OUTER

DIAMETER

4

0mm01575

in

Undersize

4

5mm01772inUndersize

5

Omm

0

1969inUndersize

87

0008705mm3425234272

in

8750

87

55mm3444934468

in

880088

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

withafeeler

gauge

as

shown

in

Fig

A

25Ifthe

side

clearance

is

excessive

new

rings

should

be

fitted

The clearance

required

for

new

pistons

a

piston

rings

can

be

foundinTechnical

Data

Check

the

piston

ring

gap

by

placing

the

ring

in

the

cylinder

boreasshown

in

Fig

A26The

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

Ifnew

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

limitisexceededitwill

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

fitinthe

connecting

rod

CONNECTING

RODS

O1ecking

Cleck

the

connecting

rods

for

bendsortwists

using

a

guitable

connecting

rod

aligner

The

maximum

deviation

should

not

exceed005

mm

0

0020

in

per

100

mm

394in

length

of

rod

Straightenorreplace

any

rod

which

does

not

comply

with

the

specified

limit

When

replacing

the

connecting

roditis

essential

to

ensure

that

the

weight

difference

between

new

and

old

rodsiswithin

5

gr

0 18

oz

for

the

1400

cc

engine

and

7gr0 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

between0203

mm

0

0079

0

0118

in

fthe

maximum

limitof0

6

mm

0

Ql18

inisexceeded

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

foundtobe

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

824S82

60mm

3

24613

2520

in

824S82

60mm

3

24613

2520

in

Data

Place

the

crankshaft

inVblocksasshown

in

Fig

A

28

and

check

with

the aid

ofadial

gauge

that

the

shaft

bending

limitof0 05

mm

0

002inis

not

exceeded

With

the

dial

gauge

positioned

against

the

centre

journal

the

crankshaft

should

be

rotated

by

one

turn

The

actual

bend

value

will

beahalfofthe

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

bebeJ

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

endis4

5 5

0

mm

018020in

Main

bearing

clearance

The main

bearing

clearances

can

be

checked

usingastrip

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

thatitis

clearofthe

oil

hole

Install

the

bearing

caps

and

tighten

the

bearing

cap

bolts

to

a

torque

reading

of

4

5

5 5

kgm

33

40Ibft

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

clearanceis0

0200062

mm

0

0008

0

0024

in

with

a

wear

limit

of01

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

and100

mm

0

0098

0

019700295

and00394

in

Connecting

rod

bearing

clearance

The

connecting

rod

bearing

clearances

should

be

checked

in a

similar

manner

to

the

main

bearing

clearances

The

standard

clearanceis0

0250055

mm

0

001000022

in

with

a

wear

limit

of01

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

of06012

0 25 0 50 0 75

and

1

00

mm

0

0236

0

004700098

0

019700295

and00394

in

Fitting

the

crankshaft

bearings

Cb

eck

the

fitofthe

bearing

shellsinthe

following

manner

Install

the

shellsonthe

main

bearing

caps

and

cylinder

block

bearing

recess

and

tighten

the

cap

boltstothe

specified

torque

13

inter

Q1I

f

Q

I

ll

oJ

Fig

A

27

Olecking

the

big

end

play

Fig

A

28

Checking

the

crankshaft

for

runout

Weight

Fig

A

29

Checking

the

bearing

crush

Fig

A

30

Checking

the

camshaft

sprocket

for

runout

Fig

A

31

OIecking

the

camshaft

end

float

Fig

A

32

Installing

he

valves

14

reading

Slacken

one

of

the

cap

bolts

and

check

the

clearance

between

the

cap

and

cylinder

block

with a

feeler

gauge

See

Fig

A

29

The

bearing

crush

nip

should

be

between

00

03mm

00

0012

inifthis

is

not

the

case

then

the

bearing

must

be

replaced

beck

the

connecting

rod

bearings

in a

similar

manner

after

tightening

the

caps

to

the

specified

torque

readings

The

bearing

clearance

shouldbebetween0150045

mm

0

0006

0

0018

in

CAMSIIAFf

AND

SPROCKET

Inspect

the

camshaftjoumals

for

signs

of

wear

or

damage

and

check

the

camshaft

for

run

out

using

a

dial

gauge

in a

similar

manner

to

that

previously

described

for

the

crankshaft

The

bending

limitof0 02

mm

0

0007

in

must

not

be

exceeded

Install

the camshaft

sprocket

mount

the

assembly

in

V

blocksasshown

in

Fig

A

30

and

check

that

the

runout

of

the

sprocket

does

not

exceed01

mOl

0

04331

in

O1eck

the

timing

chain

and

sprocket

to

ensure

that

the

chain

is

not

stretched

or

damaged

or

the

teethofthe

sprocket

damaged

or

distorted

A

timing

chain

which

has

become

stretched

will

affect

the

valve

timing

and

be

noisyinoperation

Check

the

chain

tensioner

and

chain

guides

for

wear

and

damage

replacing

the

parts

if

necessary

Replace

the

sprocket

if

the

runout

is

exceeded

or

if

the

teethofthe

sprocket

are

worn

or

damaged

in

any

way

The

camshaft

end

play

should

be

within

0 08038

mm

0

0031OoI50

inIfthe

clearance

limitof0

1

mm

0

0039

inisexceededitwill

be

necessary

to

replace

the

cam

shaft

locating

plate

See

Fig

A

3l

FLYWHEEL

Inspecting

Ensure

that

the

clutch

disc

contact

face

of

the

flywheel

is

not

worn

or

damaged

The

runout

of

the

flywheel

contact

face

should

not

exceed02

mOl

0

008inwhen

measured

with

a

dial

gauge

The

flywheel

ring

gear

can

be

replaced

if

the

teeth

are

damaged

or

worn

This

operation

will

entail

splitting

the

ring

gear

to

remove

itAhacksaw

should

be

used

to

cut

between

the

teeth

followed

by

splitting

withacold

chisel

When

replacing

the

ring

gear

it

must

be

heated

to

a

temperature

of

approximately

1800 2000Fbefore

fitting

and

then

allowed

to

cool

slowly

ENGINE

Assembling

Before

starting

to

assemble

the

engine

make

sure

that

all

components

are

perfectly

cleanItis

always

advisable

to

pay

particular

attention

to

the

following

points

when

assembling

an

engine

Keep

the

work

bench

and

tools

clean

and

make

sure

that

the

tools

are

to

hand

Ensure

that

all

engine

oil

ways

are

clear

of

foreign

matter

fit

new

gaskets

and

oil

seals

throughout

All

sliding

parts

such

as

bearing

shells

must

be

smeared

with

engine

oil

before

installing

B

Ensure

that

the

specified

tightening

torque

readings

are

strictly

followed

A

mbling

the

cylinder

Head

To

install

the

valves

and

valve

springs

place

the

valve

spring

seats

into

position

and

fit

the

valve

guides

and

oil

lip

seals

Assemble

in

the following

order

valve

springs

spring

retainers

valve

collets

and

valve

rocker

guides

Use

the

special

compressor

ST

12070000

as

shown

in

Fig

A

32

to

compress

the

valve

springs

Piston

and

connecting

rods

The

piston piston

pins

and

connectiJ1

rods

must

be

assembled

in

accordance

with

the

cylinder

numbers

The

gudgeon

pin

is

press

fitted

to

the

connecting

rod

and

requiresafitting

force

from

05to1

5

tons

This

operation

will

require

the

use

of

the

special

tool

ST

1303000

as

shown

in

Fig

A

33

Apply

engine

oil to

the

gudgeon

pin

and

connecting

rod

before

fitting

It

should

be noted

that

the

oil

jet

of

the

connecting

rod

big

end

must

face

towards

the

right

hand

sideofthe

cylinder

block

See

Fig

A

34

Fit

the

piston

rings

the

oil

control

ring

in

the

bottom

groove

followed

by

the centre

and

top

compression

rings

which

must

be

installed

with

the

marks

facing

upwards

Install

the

connecting

rod

bearings

and

caps

making

sure

that

the

markings

coincide

Ensure

that

the

backsofthe

bearing

shells

are

perfectly

clean

otherwise

they

will

be

damaged

when

tightened

Assembling

the

engine

Fit

the

baffle

plate

and

cylinder

block

net

Install

the

crankcase halvesofthe

main

bearing

shells

the

flanged

shell

is

fitted

to

the

centre

bearing

Smear

the

bearing

surfaces

with

engine

oil

and

carefully

lower

the

crankshaft

into

position

Install

the

main

bearing

caps

with

their

shells

making

sure

that

the

arrow

on

the

caps

facestothe

front

of

the

engine

Rotate

the

crankshaft

to

settle

the

caps

and

tighten

the

bearing

cap

bolts

gradually

in

two

or

three

separate

stages

Work

out

wards

from

the

centre

bearing

and

finally

tighten

to

the

specified

torque

reading

of45 5 5

kgm

3240

Ib

ft

in

the

sequence

shown

in

Fig

A35Ensure

that

the

crankshaft

rotates

freely

after

finally

tightening

the

cap

bolts

Check

the

crankshaft

end

float

which

should

be

between

0 05 0

18

mm

0

002

0

0071

in

see

Fig

A

36

Smear

the

side

oil

seals

with

sealant

and

fit

them

into

the

rear

main

bearing

cap

Install

the

rear

oil

seal

using

a

suitable

drift

and

grease

the

lip

of

the

seal

Place

the

flywheel

in

position

and

install

the

lock

washers

and

retaining

baits

Tighten

the

bolts

evenly

to a

torque

reading

of

14 16

kgm

101

106Ib

ft

Rotate

the

engine

by

a

quarter

turn

and

install

the

piston

15

inter

Q1

jX

E

Fig

A

33

Installing

the

piston

pins

Fig

A

34

Piston

and

connecting

rod

cD

I

E

103470t

O

L

I

1

I

riC

J

lt

I

t

1
1

C

j

I

If

I

r

Fig

A

35

Bearing

cap

bolts

tightening

sequence

Fig

A

36

Installing

the

piston

and

connecting

rod

assembly

J

0

k2

CD

1 1

r

1

P

l

b

S

LM

J

Jr

T9T

J

I

J

@@@C@@

I

3

TimJn

mark

Lt

j

Location

hole

Oblonl

groon

I

I

Afteradju5tment

1

i

Before

adjustment

At

TDCor

No

I

piston

Fig

A

37

Cylinder

head

bolts

tightening

sequence

Fig

A

38

Adjusting

the camshaft

sprocket

Fig

A

39

Fitting

the

chain

tensioner

Fig

A40Valve

clearance

adjusting

16

h

W

and

connecting

rod

assemblies

Use

a

piston

ring

compressor

to

install

the

pistons

through

the

top

of

the

cylbder

bore

Make

sure

that

the

pistons

and

rings

and

the

cylinder

bores

are

lubricated

with

clean

engine

oil

The

pistons

should

be

arranged

so

that

the

F

mark

faces

to

the

front

and

with

the

piston

ring

gaps

positioned

at

1800toeach

other

Each

piston

must

be

refitted

into

its

original

bore

NOTE

Single

inlet

valve

springs

are

usedonthe

1400

cc

engine

double

valve

springs

are

usedonthe

1600cc

and 1800

cc

engines

Screw

the

valve

rocker

pivots

with

the

locknuts

into

the

pivot

bushing

Set

the

camshaft

locating

plate

and

install

the

camshaft

in

the

cylinder

head

with

the

groove

in

the

locating

plate

directed

to

the

frontofthe

engine

Install

the

camshaft

sprocket

and

tightenittogether

with

the

fuel

pump

earn

to

a

torque

reading

of

12 16

kgm

86

116

IbJt

a

eck

that

the

camshaft

end

play is

within

the

specified

limits

Install

the

rocker

arms

using

a

screwdriver

to

press

down

the

valve

springs

and

fit

the

valve

rocker

springs

Gean

the

joint

facesofthe

cylinder

block

and

head

thoroughly

before

installing

the

cylinder

head

Turn

the

crank

shaft

until

the

No

1

piston

is

at

T

D Conits

compression

stroke

and

make

sure

that

the

camshaft

sprocket

notch

and

the

oblong

groove

in

the

locating

plate

are

correctly

positioned

Care

should

be

taken

to

ensure

that

the

valves

are

clear

from

the

headsofthe

pistons

The

crankshaft

and

camshaft

must

not

be

rotated

separately

or

the

valves

will

strike

the

headsofthe

pistons

Temporarily

tighten

the

two

cylinder

head

bolts1and

2

in

Fig

A

37

to

a

torque

reading

of

2

kgm145

lb

ft

Fit

the

crankshaft

sprocket

and

distributor

drive

gear

and

install

the

oil

thrower

Ensure

that

the

mating

marksonthe

crankshaft

sprocket

face

towards

the

front

Install

the

timing

chain

making

sure

that

the

crankshaft

and

camshaft

keys

are

XJinting

upwards

The

marks

on

the

timing

chain

must

be

aligned

with

the

marksonthe

right

hand

sideofthe

crankshaft

and

camshaft

sprockets

It

should

be

noted that

three

location

holes

are

provided

in

the

camshaft

sprocket

See

Fig

A38The

camshaft

sprocket

being

set

to

theNo2

location

holebythe

manufacturers

A

stretched

chain

will

however

affect

the

valve

timing

andifthis

occurs

it

will

be

necessary

to

set

the

camshaft

to

theNo3

location

holeinthe

camshaft

sprocket

The

chain

can

be

checked

by

turning

the

engine

until

the

No

1

piston

is

at

TDConits

compression

stroke

In

this

position

adjustment

will

be

required

if

the

location

notch

on

the

camshaft

sprocket

istothe

leftofthe

groove

on

the

camshaft

locating

plate

as

showninthe

illustration

The

correction

is

made

by

setting

the

camshaft

on

the

No3location

holeinthe

camshaft

sprocket

theNo3

notch

should

then

betothe

right

of

the

groove

and

the

valve

timing

will

havetobe

set

using

theNo3

timing

mark

Install

the

chain

guide

and

chain

tensioner

when

the

chain

is

located

correctly

There

should

be

no

protrusion

of

the

chain

tensioner

spindle

See

Fig

A39A

new

tensioner

must

be

fittedifthe

spindle

protrudes

Press

a

new

oil

seal

into

the

timing

cover

and

fit

the

cover

into

position

using

a

new

gasket

Apply

sealing

compound

to

the

front

of

the

cylinder

block

andtothe

gasket

andtothe

top

of

the

timing

cover

Ensure

that

the

difference

in

height

between

the

top

of

the

timing

cover

and

the

upper

faceofthe

cylinder

block

does

not

exceed

0

15

mm

0

006

in

Two

sizes

of

timing

cover

bolts

are

used

the

size

M80315

in

must

be

tightened

to

a

torque

reading

of1016

kgm

7

217Ibftand

the

size

M60236

in to

a

torque

reading

of

0 4 0

8

kgm

2 9

81b

ft

Install

the

crankshaft

pulley

and

water

pump

tighten

the

pulley

nut

to

a

torque

reading

of

12 16

kgm

868115

7Ib

ft

then

set

the

No

1

piston

at

TDConits

compression

stroke

Finally

tighten

the

cylinder

head

bolts

to

the

specified

torque

reading

in

accordance

with

the

tightening

sequence

shown

in

Fig

A3The

bolts

should

be

tightened

in

three

stages

as

follows

First

stage

Second

stage

Third

stage

4

kgm

28

9

lbJt

6

kgm

434IbJ

t

6 5

85

kgm

47 0615lb

ft

The

cylinder

head

bolts

should

be

retightened

if

necessary

after

the

engine

has

been

run

for

several

minutes

Install

the

oil

pump

and

distributor

drive

spindle

into

the

front

cover

as

described

under

Engine

Lubrication

System

r

rf

i

Install

the

fuel

pump

water

inlet

elbow

and

front

engine

slinger

Fit

the

oil

strainer

into

position

coat

the

oil

sump

gasket

with

sealing

compound

and

fit

the

gasket

and

oil

sump

to

the

cylinder

block

Tighten

the

oil

sump

bolts

in a

diagonal

pattern

to

a

torque

reading

of06

0 9

kgm

43 65

IbJt

Adjust

the

valve

clearances

to

the

specified

cold

engine

ftgures

following

the

procedures

described

under

the

appropriate

heading

Final

adjustments

willbecarried

out

after

the

engine

has

been

assembled

completely

and

warmed

up

to

its

nonnal

temperature

Install

the

rear

engine

slinger

exhaust

manifold

and

inlet

manifold

Refit

the

distributor

and

carburettor

assemblies

as

described

in

their

relevant

sections

Install

the

fuel

pipes

and

vacuum

hose

making

sure

that

they

are

securely

cl

ped

Refit

the

thermostat

housing

thermostat

and

water

outlet

together

with

the

gasket

Bond

the

rocker

cover

gasket

to

the

rocker

cover

using

sealant

and

fit

the

rocker

cover

to

the

cylinder

head

Install

the

spark

plugs

and

connect

the

high

tension

leads

Fit

the

left

hand

engine

mounting

bracket

and

install

the

clutch

assembly

using

the

alignment

tool

ST20600000

to fit

the

clutch

to

the

flywheel

as

described

in

the

section

ClUfCR

Lift

the

engine

away

from

the

mounting

stand

and

into

the

engine

compartment

Install

the

alternator

bracket

adjusting

bar

alternator

fan

pulley

fan

and

fan

beltinthe

order

given

Check

the

tension

of

the fan

belt

by

depressing

the

belt

at a

point

midwybetween

the

pulleys

The

tension

is

correct

if

the

belt

is

deflected

by

8

12

mm

03

0 4inunder

thumb

pressure

Fit

the

right

hand

engine

mounting

bracket

the

oil

filter

oil

pressure

switch

oil level

gauge

and

water

drain

plug

Take

care

not

to

overtighten

the

oil

nIter

or

leakage

will

occur

Fill

the

engine

and

gearbox

to

the

correct

levels

with

recommended

lubricant

and

refill

the

cooling

system

Adjust

the

ignition timing

and

carburettor

as

described

in

the

appro

priate

sections

17

inter

lmi

@

jl

Fig

A

41

Engine

lubrication

circuit

i

Punch

rmrk

Oil

hole

L

Fig

A

44

Aligning

the

oil

pump

spindle

18

II

l

o

CD

I

Fig

A

42

Component

parts

of

the

oil

pump

L

Pump

body

2

Inner

rotor

and

wft

3

OutO

rotor

4

Pump

coper

5

Reliefvalve

6

Relief

valve

Jpring

7

Washer

8

S

alp

9

ConT

613ut

I

Sideclruance

2

TIp

clearance

3

Guier

10

00

body

clearance

t

4

Rotor

to

bottom

cover

cleatance

Fig

A

43

Checking

the

rotor

clearance

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

resultinloss

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

A40Slacken

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

untilitreaches

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

and030

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

signsofdamage

or

wear

Useafeeler

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

usingastraight

edge

as

shown

in

Fig

A

43

OIL

PUMP

Assembly

and

Installation

Assembly

is

a

reversalofthe

dismantling

procedure

Before

installing

the

oil

pump

in

the

engine

it

will

be

necessary

to

rotate

the

engine

until

the

No

1

piston

isatT

D Conits

compression

stroke

Fill

the

pump

housing

with

engine

oil

and

align

the

punch

markonthe

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

11 15

kgm

81Ilb

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

istothe

H

mark

on

the

dipstick

19

Engine

model

Number

of

cylinders

Arrangement

of

cylinders

Cubic

capaci

ty

Borexstroke

Arrangemen

t

of

valves

MaxBH

P

Max

torque

Firing

order

eidlingspeed

Compression

ratio

Oil

pressure

Valve clearance

hot

Inlet
Exhaust

Valve

clearance

cold

Inlet
Exhaust

Valve

head

diameter
Inlet
Exhaust

Valve

stem

diameter
Inlet
Exhaust

Valve

lift

Valve

spring

free

length

Valve

spring

fitted

length

Valve

spring

coil

diameter

Valve

guide

length

Inlet
Exhaust

Valve

guide

protrusion

rreclll11cal

ata

L

lJEngine

LI3

4

In

line

1296
83 0x59

9

3

2677

x

3583

in

Overhead

camshaft

77at6000

rpm

II

1

kgm

at

3600

rpm

I

342

600

rpm

8 5

1

3 842

kg

sq

em

54

60Ib

sq

in

VALVES

0 25

mm

0

010

in

0 30

mm

0

01

in

0

20

mm

0

008

in

0 25

mm

O

OIJ

in

38

mm

150in

33

mm

1

30

in

8

0

mm

0

31

in

8

0

mm

031in

10 0

mm

040in

48

12

mm

1

89

in

40

0

mm

30

7

kg

1

57

in

67

7

lb

34

9

mm

1

37 in

59 0

mm

2

32

in

59 0

mm

232in

10410 6

mm

041042in

Valve

guide

inner

diameter

Inlet

8008l8

mm

0

31503154

in

Exhaust

8008

018

mm

0

31503154

in

Valve

guide

outer

diameter

Inlet

Exhaust

Valve

guide

to

stem

clearance

Inlet

Exhaust

20

1198511996

mm

0

47204723

in

11

98511996

mm

0

4172

0

4723

in

0

0150045

mm

0

000600018

in
0

0400070

mm

0

001600028

in

Valve

seat

width

Inlet

Exhaust

V

lve

seat

angle

Valve

seat

insert

interference
fit
Inlet

Exhaust

Valve

guide

interference

fit

Inlet

141

8

mm

0

0550071

in

162

0

mm

0

0630079

in

450

0080

11

mm

0

003100043

in

0060

10

mm

0

002400039

in

0

0270049

mm

0

001100019

in

CAMSHAFT

AND

TIMING

GEAR

Camshaft

end

play

Camshaft lobe

lift

Camshaft

journal

diameter

Max

camshaft

runout

Camshaft

bearingtojournal

clearance

Camshaft

bearing

inner

diameter

0080

38

mm

0

0011

0

0019

in

6 65

mm

0

261

in

47

94947962

mm

fI

8877

1

8883

in

0 05

mm

0

002

in

0

0380076

mm

0

001500026

in

48 000

48

016

mm

1

8898

1

8904

in

CONNECTING

RODS

Distance

from

centre

to

centre

13297133

03

mm

5

235

5

237

in

Bearing

shell

thickness

Standard

Big

end

side

play

Connecting

rod

bearing

running

clearance

Connecting

rod

rend

or

twist

1

4981506

mm

0

0590593

in

0200

30

mm

0

0080012

in

0

0140056

mm

0

000600022

in

0 03

mm

per

100

mm

0

0012

in

per

3

937

in

CRANKSHAFT

AND

MAIN

BEARINGS

Crankshaft

material

Number

of

bearings

Main

journal

diameter

Max

journal

taper

Max

journal

out

of round

Crankshaft

end

play

Special

forged

steel

5
54

94254955

mm

2

1631

2

1636

in

0 03

mm

0

0012

in

0 03

mm

0

0012

in

0

050015

mm

0

00200059

in

Wear

limit

Crank

pin

journal

diameter

Max

crankpin

taper

Max

crankpin

out

of round

Thickness

of

main

bearing

shells

0

3

mm

0

012

in

49

96149975

mm

1

967

1

9675

in
0 03

mm

0

012

in

0 03

mm

0

012

in

1

8271835

mm

0

07200722

in

Main

bearing

running

clearance

0

0200062

mm

0

0008

0

0024

in

Max

main

bearing

running

clearance
Crankshaft

bend

limit

Material

Type

Piston

diameters

Standard

Istoversize

2nd

oversize

3rd

oversize

4th

oversize

5th

oversize

Width of

ring

grooves

Top

and

second

Oil

control

Piston

running

clearance

0

12

mm

0

0047

in

0 05

mm

0

002

in

PISTONS

Cast

aluminium

Slipper

skirt

82 99 83

04

mm

3

2673269

in

83 228327

mm

3

276

3

278

in

8347

83 52

mm

3

286

3

288

in
83 72 83 77

mm

3

296

3

298

in
83 97 84 02

mm

3

3053308

in
84 47 84 52

mm

3

3263328

in

2

0

mm

0 08

in

4 0

mm

0 16

in

0

0250045

mm

0

0010002

in

PISTON

PIN

Pin

diameter

20

99521000

mm

0

8266

0

8268

in

Pin

length

720072 25

mm

2

8346

2

8445

in

Pin

running

clearance

in

piston

0

0080010

mm

0

000300004

in

Pin

interference

fit

in

small

end

bush

0

0150033

mm

0

000600013

in

Piston

ring

height

Top

and

second

Oil

control

Side

clearance

in

grooves

Top

PISTON RINGS

2

0

mm

0

08 in

4 0

mm

0 16

in

0

0400073

mm

0

001600029

in

Second

Oil

control

Piston

ring

gaps

Top

Second

Oil

control

Material
Distortion

of

sealing

face

Max

distortion

Valve

seat

insert

material

Inlet
Exhaust
Fit

Drive
Chain
Chain

tensioner

0

0300063

mm

0

001200025

in
0

0250063

mm

0

00100025

in

0 23 0 38

mm

0

0091

0

0150

in

0150 30

mm

0

0060012

in
0150

30

mm

0

0060012

in

CYLINDER HEAD

Aluminium

alloy

0

03

mm

0

0012

in

0

1

mm

0

004

in

Aluminium

bronze

Special

cast

Hot

pressed

CAMSHAFT

DRIVE

From

crankshaft

double

roller

type

Spring

and

oil

pressure

control

Engine

model

lWIN

CHOKE

CARBURE

ITOR

Outlet

diameter

Venturi

diameter

Main

jet

Main

air

bleed

Slow

running

jet

Power

jet

Float

level

Fuel

pressure

Weight

Altitude

setting

main

jet

1000

m

3300

ft

94

2000

m

6600

ft

92

3000

m

10

000

ft

89

4000

m

13

300

ft

87

5000

m

16

600

ft

85

PRIMARY

L13

SECONDARY

30mm
27x

12mm

150

90

180

26

mm

21

x8mm

96

80

43
40

23

I

mm

0

905

0 04

in

0 24

kg

sq

em

3

41b

sq

in

2

55kg561lb

1

21

TechnIcal

Data

L

14 16

and

18

Engine

GENERAL

SPECIFICATIONS

Cylinders

Displacement

L14

L16
L18

Bore

and

stroke

L14
L16

Ll8

Compression

ratio

L14
L16

single

carburettor

L16

SU

twin

carburettor

L18

single

carburettor

Ll8

SU

twin

carburettor

Valve

arrangement

Firing

order

e

idling

speed

Engine

idling

speed

with

automatic

transmission

Oil

pressure

Hotat2000

rpm

Valve

clearance

Hot

Intake
Exhaust

0 25

mm

0

0098

in

0 25

mm

0

0098

in

Valve

clearance

Cold

Intake
Exhaust

Va

head

diameter

L14

Intake

Exhaust

Vahoe

head

diameter

L16

Intake
Exhaust

0 20

mm

0

0079

in

0 20

mm

0

0079

in

38

mm

1

5361

in

33

mm

1

2992

in

42

mm

1

6535

in

33

rom

1

2992

in

Valve

head

diameter

L18

Intake

Exhaust

42

mm

1

6535

in

35

mm

1

3780

in

Valve

stem

diameter

Intake

7

9657980

mm

0

3136

0

3142

in

Exhaust

7

9457960

mm

0

312803134

in

Valve

length

L14

Intake

Exhaust

115

6

115

9mm

4

551

4

562in

1157116

0

mm

4

5554567

in

Valve

length

L16

LIB

Intake

114

9

115

2

mm

4

5244535

in

Exhaust

1157116

0

mm

4

5554567

in

22

4inline

1428

cc

87

1cuin

1595

cc

973cu

in

1770

cc

108

0cuin

83x66

mm

3

27x260in

83

x

73

7

mm

3

27x290in

85x7B

mm

3

35x307in

9 0
8 5

9

5

8 5
9 5

Overhead

valve

I

34

600

rpm

single

carburettor

650

rpm

twin

carburettor

650

rpm

single

carburettor

700

rpm

twin

carburettor

354 0

kg

sq

cm

50

57Ib

sq

in

VALVES

Valve

lift

Single

carburettor

Valve

lift

Twin

carburettor

10

0

mm

0

3946

in

10

5

mm

0

413

in

Valve

spring

free

length

LI4

Ll4

Intake

Ll4

Exhaust

outer

L14

Exhaust

inner

Valve

sprin8

free

length

L16

LIB

Outer
Inner

49 0

mm

1

929

in

49 98

mm

1

968

in

44 85

mm

1

766

in

49 98

mm

1

968

in

44 85

mm

1

766

in

59 0

mm

2

393

in

10

6

mm

0

417

in

Valve

guide

length

Valve

guide

height

from

head

surface

Valve

guide

diameter

inner

Intake

8

018

Exhaust

8

018

Valve

guide

diameter

outer

Intake

12

034

Exhaust

12

034

Valve

guide

to

stem

clearance

Intake
Exhaust

Valve

seat

width

L14

Intake
Exhaust

Valve

seat

width

L16

LIB

Intake
Exhaust

8

000

mm

0

3154

0

3150

in

clia

8

000

mm

0

3154

0

3150

in

clia

12

023

mm

0

4738

0

4733

in

clia

12

023

mm

0

473804733

in

clia

1

8

mm

1

1024

in

I 7

mm

1

0630

in

I

4

mm

0

0551

in

1

3

mm

0

0512

in

0

0200053

mm

0

000800021

in

0

0400073

mm

0

001600029

in

Valve

seat

angle

Intake

Exhaust

Valve

seat

interference

fit

450
450

Valve

guide

interference

fit

Intake

0

0270049

mm

0

01100019

in

Exhaust

0

0270049

mm

0

01100019

in

Intake

Exhaust

0

0810113

mm

0

003200044

in

0

0640096

mm

0

002500038

in

CAMSHAFT

AND

TIMING

CHAIN

Camshaft

end

play

0 08038

mm

0

0031

0

0150

in

Camshaft

lobe

lift

L14
Ll6

LIB

intake

with

single

carburettor

Ll6

LIB

Intake

with

twin

carburettor

L16

L18

Exhaust

6

65

mm

0

2618

in

6

65

mm

0

2618

in

7

00

mm

0

2753

in

7

00

mm

0

2753

in

47

949

47

962

mm

1

8877

1

8883

in

0 02

mm

0

0007

in

0

0380067

mm

0

0015

0

0026

in

Camshaft

journal

diameters

Camshaft

bend

Camshaft

journaltobearing

clearance

Rocker

arm

lever

ratio

L14
L16

L18

15

1

45

CONNECTING

RODS

Connecting

rod

centres

L14
L16

L18

136

6

mm

535In

133

0

mm

5

24

in

130

35

mm

5

132

in

I

4931506

mm

0

0588

0

0593

in

0 20030

mm

0

0079

0

0118

in

0

0250055

mm

0

0010

0

0022

in

less

than0025

mm

0

001

in

per

100

mm

2

937

in

Bearing

thickness

Big

end

play

Connecting

ro

d

bearing

clearance

Connecting

rod

bendortwist

CRANKSHAFI

AND

MAIN

BEARINGS

Journal

diameter

Journal

taper

and

out

of

round

Crankshaft

free end

play

Wear

limit

Crank

pin

diameter

Crankpin

taper

and

out

of

round

Thickness

of

main

bearing

shells

Main

bearing

clearance

Wear

limitofclearance

Crankshaft

bend

limit

54

942

54

955

mm

2

163121636

in

less

than

0 0

I

mm

0

0004

in

0 05018

mm

0

0020

0

0071

in

0

3

mm

0

0118

in

49

961

49

974

mm

1

967019675

in

less

than001

mm

0

0004

in

1

8221835

mm

0

0717

0

0722

in

0

0200062

mm

0

0008

0

0024

in

0

12

mm

0

0047

in

0 05

mm

0

0019

in

PISTONS

Piston

diameter

L14

Piston

diameter

L14 L16

82

985

83

035

mm

3

2671

32691 in

84

985

85

035

mm

3

345933478

in

LI4andLl6

1stoversize
2nd

oversize

3rd

oversize

4th

oversize

5th

oversize

0

25

mm

0

0098

in

0 50

mm

0

0197

in

0

75

mm

0

0295

in

1

00

mm

0

0394

in

1

25

mm

0

0492

in

23

liB

Oversizes

Ring

groove

width

Top

ring

Second

ring

Oil

ring

Pistontobore

clearanl

e

Pin

diameter

I

ength
Ll4

Ll6

Ll8

Pin

to

piston

clearance

Pin

interference

fitinsmall

end

bush

Piston

ring

height

Top

Second
Side

clearance

Ll4 Ll6

Top

ring

LI8

Top

ring

Second

ring

Ring

gap

U4

Top

ring

U4

Second

ring

Ll6

Top

ring

L16Second

ring

U8

Top

ring

U8

Second

ring

Oil

ring

Oil

pump

Oearance

between

inner

and

outer

rotor

Rotor

tip

clearance

Oearance

between

outer

rotor

and

body

Rotor

to

bottom

cover

clearance

Oil

pressure

at

idling

Oil

pressure

relief

valve

spring

Free

length

Fitted

length

Relief

valve

opening

pressure

24

85465485

515

mm

3

648 667

ill

86

06586015

mm

13

3844

33864 in

0

mm

CO

0787

in

0

mm

0

0787

in

4

0

mm

01qc

in

0

0250045

mm

0

0010

0

0018

in

PISTON

PIN

20

995

1

000

mm

0

8266

0

8168

in

72

00

72 25

0

001

0

Dl5

72 25

mm

2

834628445

in

73 00

mm

2

844528740

in

0

013

mm

0

00004

0

00051

in

0

033

mm

0

000600013

in

PISTON

RING

1

977

mm

0

0778

in

1

977

mm

0

0778

in

0

0400080

mm

0

001600031

in

0

0450080

mm

0

001800031

in

0

0300070

mm

0

0012

0

0028

in

0

23

0 38

mm

0

009100150

in

0

15030

mm

0

005900118

in

0

25040

mm

0

009800157

in

0

15

0 30

mm

0

005900118

in

0

35 0

55

mm

0

013800217

in

0

30 0

50mm

0

011800197

in

0

30 0

90

mm

0

011800354

in

LUBRICATION

SYSTEM

Rotor

Pump

0 05 0

12

mm

0

0020

0

0047

in

less

than012

mm

0

0047

in

0150

21

mm

0

005900083

in

0

03 0

13

mm

0

001200051

in

0 8 2 8

kg

sq

cm

1140

Ib

sq

ln

52

5

mm

2

067

in

34

8

mm

1

370

in

3 5 5

0

kg

sq

cm

50

71

Ib

sq

ln

CoolIng

System

GENERAL

FAN

BELT

TENSION

FLUSHING

AND

DRAINING

THE

SYSTEM

THERMOSTAT

Testing

RADlA

TOR

Removal

GENERAL

The

cooling

system

is

pressurised

and

incorporates

a

water

pump

corrugated

fin

type

radiator

fan

and

a

pellet

type

thermostat

The

water

pump

isofthe

centrifugal

type

and

has

an

aluminium

die

cast

body

The

volute

chamberisbuilt

into

the

front

cover

assembly

and

a

high

pressure

sealing

mechanism

prevents

water

leakage

and

noise

The

fan

pulley

is

driven

by

the

V

belt

from

a

pulley

on

the

crankshaft

he

pellct

type

thermostat

enables

the

engine

to

warm

up

rapidlY

and

also

regulates

the

temperature

of

the

coolant

When

the

wax

pellet

in

the

thermostat

is

heated

it

expands

and

exerts

pressure

against

a

rubber

diaphragm

causing

the

valve

to

open

and

allow

the

coolant

to

flow

from

the

cylinder

head

back

to

the

radiator

As

the

pellet

is

cooled

itcontractsand

allows

the

spring

to

close

the

valve

thereby

preventing

coolant

from

leaving

the

cylinder

head

The

rad

ator

is

of

the

down

flow

type

with

an

expansion

tank

The

relIef

valveinthe

radiator

filler

cap

controls

the

pressure

at

approximately

0

9

kg

sq

cm

l3Ib

sqinAlways

try

to

avoid

removing

the

filler

cap

when

the

engine

is

hot as

coolant

may

spray

out

and

cause

scalding

If

the

cap

must

be

removed

in

these

circumstances

use

a

lar

e

pic

c

of

cloth to

hold

the

cap

and

turn

the cap

sli

htlY

Walt

until

all

pressure

has

been

released

before

lifting

off

the

cap

FANBELT

TENSION

The

fan

belt

drives

the

water

pump

and

alternator

as

well

as

the

fan

and

its

correct

adjustment

is

most

essential

A

loose

fan

belt

will

sl

ip

and

Y

e

r

and

most

probably

cause

overheating

alternatively

If

the

belt

IS

too

tight

the

pump

and

alternator

bearings

willbeoverloaded

The

belt

is

correctly

tensioned

if

it

can

be

depressed

by

approximately

10

mm

1

2

in at a

point

midway

between

the

fan

and

alternator

pulleys

See

Fig

R2

If

adjustment

is

neces

ary

slacken

the

alternator

mounting

and

adjustment

bolts

and

pivot

the

alternator

away

from

the

enginetotighten

the

belt

to

towards

the

engine

if

the

belt

is

to

be

slackened

NOTE

Always apply

leverage

to

the

drive end

housing

when

pivoting

the

alternator

and

never

to

the

diode

end

housing

or

the

alternator

will

be

damaged

Retighten

the

alternator

bolts

and

make

SUfe

that

the

belt

is

correctly

tensioned

FLUSHING

AND

DRAINING

THE

SYSTEM

The

radiator

and

water

passages

should

be

flushed

out

periodically

to

remove

the

accumulated

scaleorsediment

Reverse

flushing

equipment

should

be

used

to

carry

out

a

completely

thorough

flushing operation

but

the

owner

drivef

not

possessing

this

type

of

equipment

can

flush

out

the

system

in

the

following

manner

Drain

the

system

by

removing

the

radiator

filler

cap

and

opening

the

radiator

and

cylinder

block

drain

taps

Close

the

taps

again

and

refill

the

radiator

Run

the

engine

foraShOft

period

and

then

rc

open

the

drain

taps

Continue

this

sequence

until

the

water

flowing

from

the

taps

is

clean

then

close

the

taps

and

refill

the

radiator

An

anti

freeze

mixture

should

always

be

used

in

Winter

time

The

Niss3n

long

life

coolant

LL

c

is

an

ethylene

glycol

solution

containing

a

corrosion

preventative

which

can

remain

in

the

vehicle

throughout

the

year

but

must

not

be

mixed

with

other

products

Itisadvisable

to

check

the

radiator

and

heater

hoses

when

filling

with

anti

freeze

and

renew

them

if

signs

of

deterioration

are

apparent

WATER

PUMP

Replacement

The

water pump

must

not

be

dismantled

and

should

be

renewed

ifitbecomes

faulty

The

pump

can

be

removed

in

the

following

manner

Drain

the

cooling

system

2

Take

the fan

belt

off

the

pulley

3

Remove

the

fan

and

pulley

4

Remove

the

retaining

nuts

and

withdraw

the

water

pump

See

Fig

B 3

lnstallation

of

the

pump

isareversalofthe

removal

procedures

rERMOST

ATTesting

The

thermostat

is

located

in

the

water

outlet

passage

See

Fig

B

4

To

remove

the

unit

drain

the

cooling

system

remove

the

radiator

hose

and

the

water

outlet

elbow

Take

out

the

thermostat

25

inter

illIl

@

Pl

i

i

n

i

II

L

Vi

It

q

n

lli

J

j

tr

rl

t

lli

3

t

11

1

i

l

Wt

r

till

I

cj

L

f0

co

7

Fig

B

l

The

cooling

system

Fig

8

2

Olecking

the

fan

belt

tension

Fig

B

3

Removing

the

water

pump

Fig

B

4

Removing

the

thermostat

26

The

thermostat

can

be

tested

by suspending

it

with a

thermometer

in a

container

ftlled

with

water

Heat

the

water

gradually

and

stir

ittoobtainauniform

temperature

Maintain

a

constant

checkofthe

temperature

and

make

sure

that

neither

the

thermostat

or

thermometer

touch

the

sidesofthe

container

or

false

readings

willbeobtained

The

thermostat

should

begin

to

open

at a

temperature

of

820C

1

50C

179

60F

2

70Fj

and

should

be

fully

open

with a

maximum

valve

liftof8

mm

0

315

in at a

temperature

of

950C

2030F

When

installing

the

thermostat

apply

adhesive

to

both

sides

of

the

gasket

before

refitting

the

water

outlet

elbow

RADIATOR

Removal

Drain

the

cooling

systemaspreviously

described

and

remove

the

front

grille

2

Disconnect

the

radiator

upper

hose

lower

hose

and

hose

to

the

reservoir

tank

3

Remove

the

radiator

securing

bolts

and

lift

out

the

radiator

Fig

B

4

It

should

be

noted

that

cars

fitted

with

automatic

transmission

incorporate

a

transmission

oil

cooler

which

must

be

disconnected

Installation

isareversalofthe

removal

procedure

refill

the

system

as

previously

described

FLUID

COUPLING

The

water

pump

is

equipped

withafluid

coupling

on

vehicles

fitted

with

an

air

conditioner

The

fluid

coupling

Limits

the

maximum

fan

speedtoapproximately

3000

rpro

and

eliminates

noise

and

loss

of

power

at

high

engine

speeds

A

faultinthe

coupling

may

be

causedbythe

entry

of

foreign

matter

Ifafault

developes

the

oupling

must

be

removed

and

dismantled

and

the

interior

cleaned

by

washing

in

solvent

The

condition

of

the

seal

and

bearing

must

be

care

fully

checked

and

the

coupling

replaced

if

the

latter

items

have

become

blackened

If

oil

leaks

occur

it

will

be

necessary

to

replace

the

water

pump

assembly

with

the

coupling

After

cleaning

the

unit

refill

with

11 5ccsilicon

oil

using

a

suitable

syringe

TechnIcal

Data

Radiator
Radiator

cap

working

pressure

Radiator

core

heightxwidth

x

thickness

1400

and

1600

cc

engines

510

body

1600 and

1800

cc

engines

610

body

Corrugated

fin

type

0

9

kg

sq

cm

13Ib

sq

in

280x488x38mm

I

LOx192x149

in

360x502x32mm

l4

2x19

8x1

26

in

Thermostat

valve

opening

temperature

Standard

B20ClBOOF

Cold

climates

880C

1900F

Tropical

climates

76

50C

l700F

Max

valve

lift

Cooling

system

capacity

With

heater

Without

heater

Cooling

system

capacity

With

heater

Above

8

mm

031in

6

8litres

175US

gall

15

Imp

gall

6

4litres

1

75

US

gall

1

375

Imp

gall

1600

and

1800

cc

engines

610

body

6

5litres

l

7

US

gall

1

375

Imp

gall

6 0

Iitres1625

US

gall

1

375

Imp

gall

Without

heater

27

inter

lW

j

@lPX

TT

Y

Gw

PRIMARY

COIL

RESISTOR

I

I

l1@

l

I

IGNITION

U

SECONDARY

COIL COIL

IS

AK

R

POIN

i

1

1

DISTRISUTOR

I

1

J

ISI

V

nl

N

I

TO

STARTER

l

1

ROTOR

HEAD

r

SPARK

PLUG

Fig

C

t

Ignition

sys

em

circuit

diagram

i

II

@

1

1

@

J

i

9

28

l

I

i

1

I

I

@

@

G

N

7

FigC2lgnition

distributor

1

Shaft

assembly

2

Collar

assembly

3

Cam

assembly

4

Governor

weights

5

Governor

spring

6

Rowr

head

7

Breaker

plate

8

Contact

set

9

Tennirtal

assembly

10

Vacuum

control

J

1

Condenser

12

Distributor

cap

13

Carbon

point

14

Plate

15

CIilmp

IgnItIon

System

DESCRII

TION

IGNITION

TIMING

IGNITION

DISTRIBUTOR

Maintenance

ADJUSTING THE

CONTACT

BREAKER

GAP

CENTRIFUGAL

ADVANCE

MECHANISM

VACUUM

ADVANCE

MECHANISM

IGNITION

DISTRIBUTOR

Removal

and

Dismantling

IGNITION

DISTRIBUTOR

Assembling

and

Installation

SPARKING

PLUGS

DESCRII

TION

The

ignition

circuit

comprises

the

distributor

ignition

coil

ignition

switch

spark

plugs

high

tension

lead

and

the

battery

See

Fig

C

1

The

Hitachi

distributor

is

shown

in

exploded

form

in

Fig

C

2

19niton

timing

is

automatically

regulated

by

the

distributor

centrifugal

advance

mechanism

or

vacuum

advance

mechanism

depending

upon

the

demand

made

on

the

engine

The

vacuum

advance

mechanism

operates

under part

throttle

only

and

uses

intake

manifold

depression

to

advance

the

ignition

timing

When

the

engine

speed

is

increased

the

vacuum

is

inoperative

and

ignition timingisregulated

by

the

centrifugal

advance

mechanism

The

centrifugal

advance

mechanism

uses

a

system

of

governor

weights

and

springs

which

turn

the

carn

assembly

in

on

anti

clockwise

direction

to

advance

the

ignition

timing

As

the

engine

speed

is

decreased

the

weights

move

back

and

allow

the

cam

to

return

thereby

retarding

the

ignition timing

The

ignition

coil

isanoil

filled

unit

comprising

a

coil

around

whichiswound

the

secondary

and

primary

windings

The

number of

turns

in

the

primary winding

provideahigh

secondary

voltage

throughout

the

speed

range

The

resistor

is automatically

by

passed

at

the

moment

of

starting

and

allows

the

ignition

coiltobe

directly

connected

to

the

battery

This

applies

the

full

battery

voltage

to

the

coil

to

give

the

necessary

staTting

boost

When

the

starter

switchisreleased

the

current

flows

through

the

resistor

and

the

voltage

through

the

coil

is

dropped

for

normal

running

purposes

IGNITION

TIMING

The

ignition timing

can

be

accurately

checked

using

a

stroboscopic

timing

light

which

should

be

connected

in

accor

dance

with

the

manufacturers

instructions

Make

sure

that

the

timing

marks

on

the

crankshaft

pulley

are

visible

if

they

are not

visible

mark

them

with

chalk

or

white

paint

Each

mark

represents

a

50

division

of

the

crank

angle

Disconnect

the

distributor

vacuum

line

start

the

engine

and

allow

it

to

run

at

normal

idling

speedorslightly

below

Point

the

timing

light

at

the

timing

pointer

on

the

front

cover

Fig

C3The

crankshaft

pulley

groove

should

appear

to

be

stationery

and

aligned

with

the

pointer

on

the

front

cover

The

top

dead

centre

markislocated

at

the

extreme

right

as

showninthe

illustration

If

the

setting

requires

adjustment

the

distributor

flange

bolts

must

be

slackened

and

the

distributor

body

turned

clockwise

to

advance

or

anti

clockwise

to

retard

the

timing

See

Technical

Data

for

timing

settings

After

adjusting

the

timing

tighten

the

distributor

flange

bolts

and

recheck

the

timing

IGNITION

DISTRIBUTOR

Maintenance

Remove

the

distributor

cap

by

easing

away

the

two

clamps

and

examine

the

points

for

signsofburningorpitting

The

points

can

be

cleaned

if

necessary

using

a

fine

grade

of

oilstone

or

file

The

faces

of

the

points

must

be

completely

flat

and

parallel

and

all

abrasive

dust

removed

with

compressed

air

If

the

points

are

excessively

pitted

they

must

be

renewed

and

grease

applied

to

the

moving

contact

pivot

and

the

surface

of

the

cam

Ensure

that

the

distributor

cap

is

thoroughly

clean

both

inside

and

outside

A

contaminated

cap

will

promote

tracking

indicated

by

black

lines

and

causedbyelectrical

leakage

between

the

segments

on

the

insideofthe

cap

Make

sure

that

the

carbon

button

is

not

worn

Both

the

distributor

cap

and

rotor

must

be

renewed

if

they

are

cracked

or

damaged

IGNITION

DISTRIBUTOR

Adjusting

the

contact

breaker

gap

To

adjust

the

contact

breaker

points

remove

the

distributor

cap

and

pull

the

rotor

off

the

cam

spindle

Turn

the

engine

until

the

heelofthe

contact

breaker

arm

is

positioned

on

the

cam

lobe

the

contact

breaker

gap

is

set

to

the

maximum

in

this

position

Slacken

the

adjusting

screw

Fig

CA

insertafeeler

gauge

between

the

points

and

adjust

the

breaker

plate

until

the

re

quired

gap

of045 0

55

mm

0

017700217

in

is

obtained

Tighten

the

adjusting

screw

and

recheck

the

setting

After

the

contact

breaker

gap

has

been

adjusted

check

the

ignition

timing

as

previously

described

The

tension

of

the

contact

breaker should

be 050 65

kg

I

II4

lb

Measure

the

tension

with

a

gauge

andat900

to

the

contact

breaker

arm

29