Nissan Bluebird 1977 User Manual

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PUBLISHED
BY
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ENGINE
COOLING
FUEL
CLUTCH
MANUAL
SYSTEM
SYSTEM
TRANSIUISSION
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AUTOMATIC
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FRONT
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STEERING
BRAKES
ELECTRICAL
ROAD
BODY
WHEELS
LUBRICATION
EMISSION
INDEX
GLOSSARY
TRANSMISSION
AXLE
SUSPENSION
SUSPENSION
SYSTEM
TEST
AND
CONTROL
OF
TYRES
AND
TERMS
MAINTENANCE
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n
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m
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DESCRIPTION
almost
stroke
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The
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type
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to
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2
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380ft
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220ftlb
3
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kg
23
0
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7
kg
120
on
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crankshaft
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controlled
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on
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a
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The
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the
turn
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lb
m
m
ft
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m
ft
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crankshaft
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the
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press
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pressure
face
fitted
gudgeon
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haveaflat
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Left
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View
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1600
l
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12
and
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Assembly
t
5
I
t
r
t
v
Hand
RIght
TO
REMOVE
Raise
I
both
front
2
Mark
bonnet
wIth
replacement
3
Remove
vra
system
4
Remove
drain
the
lubricant
5
Disconnect
remove
cover
radiator
6
and
7
8
the
Disconnect
remove
Disconnect hoses Unscrew
grille
9
On disconnect radiator tank
dirt
Remove
10
radiator
the
Slacken
II
the
fan
belt
water
the
temperature
12
pump
Disconnect
SIde
fenders
and
the
battery
vehicles
the
Remove
sender
V
AND
the
around
a
remove
drain
and
torque
plug
soft
the
the
the
the
the
ew
INSTAL
engine
tap
sump
from
the
from
the
and
the
the
the
umt
of
1600
bonnet
the lead
the
radiator
on
the
and
both
leadsatthe
the ventilatIOn
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cleaner
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heater
fixing
fitted
converter
pipes
radiator
alternator
the
four
the
wlfes
coil
Engone
and
bonnet
pencil
bonnet
cap
lower radiator
transmission
assemblies
engine
assembly
hoses
bolts
and
wIth
cooling
umons
and
retaining
mountlllg
boIts
at
and
alternator
and
TransmiSSion
2
fit
fender
hinge
plates
to
facilitate
and
drain
drain
battery
compartment
hose
from
the
upper
where
apphcable
detach
automatic
pipes
to
prevent
bolts
boIts
fan
and
the
011
pressure
ENGINE
covers
the
tank
plugs
terminals
theIrocker
and
the
radiator
transmiSSIOn at
the
entry
and
and
pulley
0
Assembly
to
on
the
correct
coohng
and
and
lower
lower
of
hft
out
remove
from
switch
ASSE
choke
ti
ue
from
the
support
spring
posItion
inhibitor
apphcable
the
the
remove
select member
assembly
hnkage
bracket
cross
13
14
1
pump
IS
the
engine
16 17
18
19 20
vehicle
self
On
On
BL
control
safely
Tie
on
the
manual
and
shaft
21
Y
Disconnect
wIre
Disconnect
Remove
exhaust
assembly
Raise
Remove
the
the
Disconnect
and
either
for
Disconnect On
manual
remove
locking
lever
shift
retaining
automatic
the
at
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to
bracket
Remove
at
the
mamfold
the
on
Jour
the
cylinder
underbody
reverSing
manual
the
nut
column
rods
bolts
transmiSSIOn
cross
member
assembly
the
the
throttle
the
carburettor
the
fuel
nuts
TIe
and
front
sUitable
clutch
to
the
reversing
hght
the
speedometer
floor
shift
gaiter
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from
un
0
Shdlft
and
shaft
retaining
four
pipe
and
detach
the
rear
chaSSIS
actuating
a
cO
lYement
sWitch
or
automatic
transmISsion
from
lower
transmISsIOn
the
cross
remove
bracket
bolts
control
from
exhaust
hght
the
the
disconnect
bolts
of
stands
cyhnder
plug
ca
gear
end
shaft
undo
and
t
i
the
t
exhaust
vehicle
the
disconnect
bracket
shaft
the
nuts
S
v
away
and
of
from
lever
lever
the
cross
remove
from
and
of
e
fj
ret
the
9
J
inSide
to
bracket
selector
l
PIP
frifp
and
way
i
undo
shaff
the
Jl1
n
h
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i
and
Sl
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the
the
linkage
the
mle
the
plpe
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out
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le
shIft
of
cross
and
I
2
I
I
I
l
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j
r
l
t
j
t
y
e
r
d
t
R
bracket
0
assembly
e
NOTE
not
and
pomt
propeller
transmISSion
NOTE
to
disconnect
the
rear
22
the
at
transmission
23
to
mountmg
24
transmiSSIOn engme
25
transmISSIOn
the
crossmember
26
hooks
which
engme the
weight
TO
REMOVE
I
hose
and
2
remove
be
necessafY
3
carefully
away
shaft
rear
To
remove
the
see
tlOn
of
Detach
Remove
secunng
Interpose
and
and
transmISSIOn
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crossmember
InstalasUitable
are
of
the
thermostatIc
two
the
engines
from
head
the
the
mlet
the
tIe
cylmder
Detach
Loosen
the
to
On
Detach
flange
the
rear
the
propeller
the
handbrake
rear
the
bolts
a
a
Jack
the
posItIoned
and
engme
rocker
the
au
bolts
whIch
manIfold
fitted
to
remove
hIgh
the
hIgh
rocker
the
and
propeller
handbrake
crossmember
two
transmISSIOn
wooden and
take
assembly
four
bolts
the
to
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at
the
With
assembly
cover
au
bleed
cleaner
secure
and
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twm
the
arr
tensIOn
tensIOn
cover
WIthdraw
shaft
cable
shaft
cable
block
the
which
underbody
cable
front
sUitable
to
hose
assembly
the
remove
SU
cleaner
leads
leads
It
where
from
weight
or
cham and
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I
atr
cleaner
where
atr
carburettors
at
the
may
rear
ROCKER
shaft
from
be
necessary
It
runs
ItS
retammg
crossmember
between
of
the
attach
the
the
and
remove
to
the
rear
tackle
ventIlatIOn
fitted
thumb
cleaner
the
screw
assembly
au
cleaner
ssembly
the
spark
ataconvement
under
clIp
the
rear
rear
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of
the
take
It
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plugs
the
AR
27
Remove
crossmember
28
assembly
and
also
29
upwards
the
transmiSSIOn
be
lIfted
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to
ensure
that
all
Gradually
to
clear
clearofthe
InstallatIon
attentIon
securely
weIght
vanous
antI
Ensure
IS
components
FIll freeze
FIll
to
the
the
to
that
all
taken
If
the
radiator
necessary
crankcase
recommended
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and
operatmg temperature
f
ND
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IVOTS
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order
pOSItIons
head ends
replacement
removmg
8
to
9
and
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arm
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ensure
m
the
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remove
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to
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taIse
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on
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vehicle
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a
reversal
followmg
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engme
mountmgs
the
by
to
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of
grade
run
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rocker
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pomts
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water
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S
M
engme
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rocker
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out
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engme
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at
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ou
engine
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m
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co
rf
kss
rack
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engme
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sprmg
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ongmal
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can
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m
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each
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7
Withascrewdnver
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and
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el
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at
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m
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remove
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possible
manoeuvre
take
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cover
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push
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gasket
small
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l
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of
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arms
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steady
locknuts
cylInder
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out
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valve
valve
ensure
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leads
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each
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adjacent
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Method
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14
J
t
t
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1t
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l
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TO
CHECK
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to
2
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damage
3
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p
4
Wear
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TO
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Disconnect
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ventIlatIOn cleaner
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pass
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hose
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the
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remove
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arm
arm
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to
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assembly
s
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marufold
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cam
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or
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fuel
feed
pipe
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carburettor
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mamfold
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pipe
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and
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arm
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be
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air
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fuel
throttle
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lift
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fJ
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TO
INSTAL
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attentIon
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to
ensure
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LASH
Clean
rocker
cover
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mamfold
radiator
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cyhnder
7
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8
mamfold
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cover
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head
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gasket
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remove
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and
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vacuum
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pipes
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remove
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remove
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start
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m
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t
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at
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procedure
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block
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of
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ou
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and
15
C
7
1
w
I
p r
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f
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I
Engine
9
remove
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10
umt
11
the
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pump
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tlie
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msulator
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nuts
flange
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manifold
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15
mamfold
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st
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the
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head
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block
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and
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rocker
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head
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water
wire
fuel
two
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slacken
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slacken
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clip
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pipe
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nuts
nuts
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pump
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remove
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gasket
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lift
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away
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gasket
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pipe
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14
to
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when
NOTE
Adhered
cylmder
Under
hand
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tools
pme
17
protruded
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the
on
mark
cham
dimple
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stamped
elther
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N
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found
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20
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between
on
cham
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on
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bolt
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alIgned
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uel
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um
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on
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of
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IIT
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remoYe
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tool
16
I
t
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1
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ongmal
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to
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e
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Installed
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p
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24
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c
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h
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Li3
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engine
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NOTE
cam
1
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of
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Check
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Idling
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Remove
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as descnbed
2
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manoeuvre
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and
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sectIOn
adjust
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m
TO
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water
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ace
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small
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take
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arm
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o
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to
mixture
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each
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valve
91
fl
ensure
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17
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12
Engine
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ro
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SPRING
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I
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SEATS
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NG
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rack
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Installed
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camshaft
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9
Q
Components
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ensure
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t
18
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to
l
r
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l
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remove
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r
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order
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i
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dl
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Exploded
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rm
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posIl
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Unsc
and
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7
Re
caii1s
i
e
8
Carefully
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head
9
USIng
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It
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ons
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ove
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n
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the
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remove
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turn
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a
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CHECK
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2
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proves
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12
them
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Clean
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Reface
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to
damaged place
ongInal
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discard
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true
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concerned
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gUIde
I
o should
head the
the
NOTE
excessively
recommended and
automotive
spepallsed
c01J1p
to
ensure
should
Valve
stem
3
Measure
Inner
gUide
clearance
mm
0004
be
renewed
4
Remove
face
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valve seats
If
necessary
recommended
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then
or
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gaIned
6
With a
the
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SpecificatIons
surface
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7
Withavalve
and
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unavatlable
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Also
check
SpeCificatIons
upon
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burrs
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file
to
ensure
In
AND
the
a
when
the
valves
the
rack
INSPECT
Valves
are
valves
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they
reassem
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thatIScrackedorburnt
each
the
specIficatIons
valve
be
excessIvely
head
has
the
be
ends
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If
In
the
valve
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seats
new
that
guides
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een
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may
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clearance
then
carbo
l
throatsandcheck
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m
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the
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If
necessary
wIdth
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carry
W
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Apply
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steel
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lengths
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valves
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check the
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the
squareness
to
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to
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and
straight
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In
excess of
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see
SpeCificatIons
then
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valve
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unserYlceable
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bhng
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be
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calcull
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he
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out
valve
prusslon
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be
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tester
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hmIt
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the
can
the
I
the
J
tr
reduced
outer
te
Cdep
oslts
are
have
who
these
on
and
If
the
back
check
test
the
of
to
of
be
spnng for
valve
stem
valve
gUIdes
cyhnder
be
Installed
cyhnder
carbon
recommended
valve
stem
Discard
0
50
mm
then
up
d13meter
actual
the
of
and
guides
the
from
the
condltIons
seat
worn
to
be
mstalled
new
valve
entrusted
has
the
operdllons
with
seats
blue
to
theu
respectIve
seatmg
feeler
gauge
the
cyhnder
hmlt
speCified
to
have
a
to
the
valve
If
a
yalve
can
be
squareness
Renew
spnngs
ends
are
head
In
head
depOSIt
flat
any
0
020
the
to
050
and
valvy
hrillt
the
or
valves
cyhnder
cutter
or
recesseq
mserts
to
necessary
a
lappIng
the
valves
has
check
head
the
serYlceable
spnng
spnng
made
with
no
and
theu
and
angle
and
valve
In
valve
mm
the
stem
of
of
to
It
an
seats
been
IS
see
head
by
See
that
i
I
I
t
f
F
1
1
IS
f
j
10
I
1
L
A
1
Il
i
1
arm
and
piVOt
cam
lighten
of
exhaust
measured
between
With
at
norrnal
V
e
13
for
head
with
the
untrl
heel
valves
has
the
fast
ordei
hot
the
1
1
l
Engine
camshaft
TO
ASSEMBLE
IS
a
Assembly
with
Lubncate all
before
atte
ntlOn
asserrtbly
the
to
component
reversal
following
to
ensure
starting
The
Installed
special
below
posllioned
care
Use
Ensure
the
TO
ADJUST
Valve
the
cylinder
wrll
be
With
the
If
to
recheck
any
necessary
clearances
NOTE
the
with
I
to
valve
found
cylinder
the
It
engme
Rotate
damage
In
compressor
t
flared
the
over
the
when
the
seals
that the
stem
VALVE
clearance
has
head
more
head
valve
clearance
the
clearance
readjustments
hot
for
IS
not
praGtlcable
runnmg
the
I
f
spnng
ends
compressing
valve
grooves
CLEARANCE
may
been
convement
sitting
or
cold
camshaft
type
the
of
retamlng
be
removed
IS
when
whichever
the
of
wear
adequate
valve
retamers
valve
the
before
adjusted
to
adjust
on
the
adjusted
the
See
to
adJust
unlil
d
smanthng procedure
surfaces
with
engine
lubncalion
stem
seals
should
with
the
flared
gUides
yalve
are
collets
releasmg
either
the
from
the
work
bench
It
cold
engme
SpecificatIOns
IS
apphcable
the
the
heel
spnngs
fully
hot
vehicle
valve
IS
sttll
S
hot
valve
of
to
the
or
clearance
adVIsable
and
for
clearance
the
when
end
avoid
seatmg
spnng
cold
then
make
valve
No
orl
be
If It
I
on
carn
No
NOTE
cam
I
exhaust
Will
the
In
this
be
assembly
Q
Back
the
correct
heel the
feeler
and
the
the
rocker
m
turn
ItS
carn
Valve
cyhnder
NOTE
between the
rocker
engme
operatmg temperature
Idle
to
Carry
already
en
ne
b
INLET
of
3
4
m
Exhaus
5
obtain
the
gauge
rocker
When
piVOt
Adjust
ensunng
the
localion
head
t
IS
It
the
arm
If
the
hot
out
outlined
thickness
cam
nle
camshaft
ensure
heel
valve
pOSitIOn
pomtmg
off
the
and
IS
a
arm
the
deSlfed
lock
the
clearance
that
posllion
IS
follows
as
nlel
Important
and
valve
valve
the correct
the
usmg
IS
adjacent
the
lobe
vertical
arm
rocker feeler
gauge
the
rocker
sliding
light
adjustment
and
each
exhaust
and
stems
If
recheck
on
valye
as
prevIOusly
that
rocker
necessary
exhaust
valve
engme
nut
commencing
clearance
that the
tclnperature1
adjustment
the
appropn
the
to
the
of
from
piVOt
positIOned
arm
adjust
fit
between
the
the
remalnmg
that
IS
from
clearana
arm
S
be
to
ls
ru
proced
i
valve
rocker
abovementIOned
the
cylmder
lock
nut
the
the
IS
obtamed
adjustment
being
explamed
the
front
mlet
mlet
and
NOT
k
s
dJ
mHactl
t
2
t
sJt
ngs
1
1 1
ll
t
I
between
seven
adjusted
IS
ed
1
m
frthe
TO
both
tank
the
Ji
REMpVE
I
Raise
fenders
front
2
Dram
Disconnect
3
hoses
heater
AND
the
the
INSTAL
engine
coohng
where
the
upper
apphcable
bonnet
system
and
and
lower
r
il
II
1
t1
b
tJt
t
y
Water
from
throttle
Corcula
fuel
and
pipe
the
Face
5
Head
ENGINE
covers
Cylinder
fit
fender
Showong
to
fuel
SUMP
Valve
4
Disconnect
pump
and
Arra
gement
the
detach
the
hnkage
Inlet
lon
Holes
Sideofthe
from
the
carburettor
with
an
automatrc
coohng
umons
the
at
radiator
radiator
hoses
bottom
and
5
dISconnect
radiator
On
tank
vehicles
the
torque
plug
the
fitted
converter
pipes
pipes
to
prevent
transnf
at
t
e
dut
19
A
Y1
l4
Engine
6
the
exhaust
7
on
safely
8
9
clutch
automatIc
housmg
10
Idler
arm
the
sump
II
12
a
and
Jack
13
crossmember
14
two
blocks
1
Remove
RaIse
four Unscrew Remove
Djsconnect and
Remove
Interpose
Remove
RaIse
mamfold
the
sUItable
transmISSIOn
steenng
take
the
secunng
the
of
wood
the
front
the
the
or
the
a
weIght
the
front
nuts
and
detach
rear
and
ChasSIS
stands
sump
cover
torque
IS
the box
engine
wooden
front
and
plug
plate
converter
fitted
steenng connectIng
and
lower
front
block
the
of
engine
engIne
bolts
of
the
of
SUItable
the
of
the
draIn
from
the
splash
between
engme
dunensIOns
exhaust
velucle
the
the
hOUSIng
lInkage
tray
assembly
mountmg
assembly
and
englj
front
rod
away
the
between
pIpe
support
e
sump
to
and
6
from
011 of
where
at
from
front
Insert
the
the
and
the
OIL
engine
and
Jack
engine
15
engine clear
of
InstallatIon
attentIon
Scrape
old
gasket
With
of
carbon
Apply
sump
crankcase
Instal
progressIVely
PITMP
mountmgs
allow
assembly
Remove
crankcase
the
engIne
to
the
the
cleamng
or
sludge
JOIntmg
gasket
the
and
and
the
blocks
and
IS
a
follOWIng
sump
solvent
attach
and
sump
evenly
the
of
the
screws
tunmg
reversal
pOInts
and
cylInder
wash
depOSits
compound
the
and
front
wood
secunng
cover
of
the
to
gasket
tIghten
crossmember
take
to
and
manoeuvre
removal
block
the
mSldeofthe
both
In
the
the
weight
the
sump
procedure
faces
SIdes
pOSItIon
secunng
Lower
of
to
the
sump
freeofthe
sump
the
of
on
screws
the
the
the
WIth
free
new
the
TO
REMOVE
I
both
front
2
crankshaft
tunIng
cover
compreSSIOn
the
the
used
The extreme engine
hand
for
3
and
4
NOTE
on
of nght
are
plugs rllstnbutor
t
and
filrimg
6
mountmg
WIthdraw
7
dnve
gear
cover
tunIng
WIth
the
t
the
e
18
stands
SlS
t
DraIn
9
10
I
I
RaIse
the
engine
fenders
Rotate
the
pulleyISalIgned
With
stroke
tdc
mark
left
of
compartment
Side
the
of
IgmtlOn
Disconnect
cod
and
remove
DIsconnect
vacuum
the
advance
Scnbeamark
cover
to
faclljtate
Remove
the
racJset
the
aSsembly
To
facIlItate
to
dlstnbii
dnvmg
the
the
scnbe
dog
front
engine
the
spIndle
offset
dnvmg
Ralse
DIsconnect Remove
bonnet
crankshaft
with I
No
the
on
crankshaft
the
pulley
The
tdc
mark
timing
purposes
the
hIgh
the
dlstnbutor
hose
o
the
correct
two
bolts
assembly
from
correct
tor
dog
IS
and
engine
the
a
pencll
assembly
on
offset
of
011
fron
and
fit
untIl
the
the
pomter
piston
on
looking
graduated
In
5
are
deg
only
tensIOn
dlstnbutor
dlstnbutor
low
leads
tensIOn
replacement
secunng
to
the
cover
tImIng
replacement
or
crayon
mountIng
dnve
the
towards
the
velucle
the
front
remo
ve
t
splash
fender
tdc
on
the
pulley
In
from
marks
Increments
and
cap
mountmg
the
dlstnbutor
tunmg
of
mark
gear
spmdle
the
and
stabllIser
tray
mark
the
top
IS
at
the
leads
lead
over
the
across
flange
front
support
covers
t
the
the
and
bracket
OIl
on
engine
of
front
on
spark
pump
m
of
bar
mark
and
Note
the
the
the
and
and
the
lIne
the
Remove
12
INSTAL
Check
I
crankshaft
If
the
removed
operatIOn
2
Instal
cover
dog
mark before
Ensure
the
engme
bolts
To
the
of
Jomtmg
3
With
mountmg
cover
removal
The
dlStnbutor
the
oll
be
untI
the
engme
on
that
mlnlmlse
pump
necessary
engagement
WIthdraw
to
ItS
TO
at
the
been removal
tImmg
offset
crayon
of
mountmg
NOTE Sides
approved
and
tunIng
before
WIth
It
may
2for
1LFurther
on
procedure
Ensure
amount
Check
that
andgrde
for
OIl
to
then
the
With
the
new
a
new
bracket
and
oll
the
the
the
011
pump
together
ensure
that
pulley
has
been
realIgn
oil
pump
a
new
gasket
gear
spIndleISaligned
removal
offset
Instal
and
the
chance
Oil
pump
compound
gasket
assembly
mountIng
offset
dnve
gear
to
rotate
these
of
nstallatIOn
sump
of
engme
leaks
WIth
pump
WIth
the tdc
4
rotated
the tdc
and
dnve
so
smce
marks
that
dogISfacmg
securely
of
mounting
Instal
and
allgnmg
bracket
dnve
tongue
spmdle dog
the
dlStnbutor
component
reversal
Is
a
IS
replemshed
oll
the
engine
secunng
the
marks
Oil
secure
runnmg
dnve
are
the
as
descnbed
gear
when
WIth
towards
tIghten
leakage
gasket
the
r
the
wluch
Will
m
one
takes
of
With
bolts
gear
st1l1
011
pump
spIndle
mstalled
the
pencil
the
the
coat
dlStnbutor
marks
were
only
posItIon
shaft
place
t
the
at
operatmg
spIndle
alIgned
m
to
front
pump
both
with
on
made
engage
by
removal
correct
and
has
the
the the
the
but
th
or
an
i
I
I
temperature
20
7
TO
DISMANTLE
2
and
detach
3
that
It
4
outer
5
end
cover
CHECK
TO
I
solvent
2
the
pump
between should
3
rotor
these
pomts
4
and
check
Clearance
5
6
pump
7
I
Withdraw Remove
the
Clean
can
be
Withdraw
from
rotor
Unscrew
and
AND
Wash
and
blow
Temporanly
body
the
not
exceed
Check
and
the
should
a
Lay
the
should
Check
Check
housmg
Check
the
cover
the
mstalled
the
the
Withdraw
INSPECT
all
pump
dry
and
outer
0
the shoulders
straight
end
not
the
pump
the
the
the
dnve
small
and
gasket
face
of
correctly
the
mner
pump
relief
the
components
With
compressed
assemble
Withafeeler
rotor
and
21
mm
clearance
of
exceed
not
edge
clearance
exceed
end
mner
rotor
pressure
gear
bolt
the
body
valve spnng
0
between
the
across
of
0 12
cover
rehef
from
the
rotor
assembly
with
cap
and
from
the
pump
bolt
valve
pump
and
drive shaft
from
spmdle
from
outer
on
rotor
thoroughlymcleanmg
au
the
the
009
0 12
dnve shaft
mner
gauge
outer
the
the
mm
valve
m
for
pump
mm
mner
end
check
the
rotor
0
wear
for
and
0
005
outer
body
tips
005
faceofthe
and
m
or
for
free
the
011
end
body
mark
the
rotors
the
clearance
Clearance
of
the
Clearance
m
outer
sconng
wear
fittmg
pump
cover
pump
mner
pump rotor
m
m
It
and
the
Its
bore
and
the
rehef
valve
spnng
for
Enginel
weakness
or
broKen
c01ls
8
Renew
that
prove
should
be
so
TO
ASSEMBLE
1
HaVIng
replacements
engme pump
rotor
on
to
hghtly ugh
fit
order
at
the
wlthm the
011
housmg
2
PositIOn
and
dlsmanthng
3
Instal
smeared
the
ten
4
Lubncate
the
valve
IOta
5
Instal
spmdle
be
to
renewed
as
and
mstal
cover
spnng
the
pump
the
gently
011
pump
all
components
unsemceable
If
cleaned
necessary
msert
the
It
mto
facmg
the
pump
With
retammg
the rellef
end
dnve
t1l
Ul
one
IS
found
all
llght1y
the
mner
outer
the
pump
uppermost
end
omtlng
bolts
valve
copper
cover
gear
the
spmdle
of
Both
unserviceable
components
rotor
rotor
body
cover
compound
bore
waslier
spmdle
ml
the
to
dnve
rotors
the
mesh
With
With
With
and
to
011
pump of
components
and
shaft
With the
a
and
engme
cap
the
pump
tongue
the
and
bolt
the
mark
new
mstal
IS
assembly
Oil
pump
effected
With
the
mto
mner
made
gasket
and
011
and
m
that
rotatmg
engaged
fP
t
Exploded
Q
remove
TIMlNG
VIewof011
1
Dram
the
2
cyhnder
Remove
the
the
CHA1N TENSIONER
3
Remove
the
Pump
engme
headand
tllmpg
two
bolts
OIL STRAINER
Assembly
ad
and
sump
cover
AND
which
BODY
PUMP
coolIng
as
prevIOusly
and
tlmmg
SPROCKETS
sec
re
the
system
descnbed
chun
section
011
pick
and
See
ROTOR
INNER
J
1
J
up
iitiSW
b
r
V
1
i
16
NOTE
cylinder
remove
the
block
each
nngs
Engine
If
bore
the
piston
7
Replace
respectiVe
If
8
over
9
With
there
rzdge
assemblzes
the
piston
the
top
a
IS
an
orIfnew
a
with
the
big
assembly
nngs
of
the
broken
UPPER
COMPRESSION RING
a
exceSSiVe
nngs
suitable
are
end
as
piston
piece
are
rzdge
wIthdrawn
beanng
IS
removed
It
are
to
and
of
ndge
be
discard
piston
at
to
be
removing
from
cap
removed
the
top
Installed then
tool
the
cylinder
shell
and
from
the
remove
remove
nng
of
before
nuts
engine
the
the
carbon
must
and
on
NOTE
all
be
sidesofthe
10
the
piston
a
press
pressed
be
will
therefore
depOSit
With
from
Pressing
assemblIes
the
piston
Gudgeon
available
are
The
new
new
pIston
the
connecting
from
exercised
nng
If
wear
and
connectmg
the
the
In
the
VICinIty
recommended
be
only
and
gudgeon
pms
only
gudgeon
at
room
rod
is
special
piston
force
the
when
grooves
apparent
pressmg
and
needed
dIsmantled
pin
a
are
selective
as
assemblzes
should
pinS
temperature
small
bottom
scraping
of
that
end
to
not
are
at
the
rod
w1l1
tools
connectmg
to remove
from
the
piston
when
assemblzes
fit
wIth
beahand
of
the
ensure
scored
gudgeon
havetobe
and
rod
one
to
and
It
IS
the
In
their
and
a
nng
that
the
the
three
connecting
necessary
piston
mated
push
tight
grooves
bottom
the
pm
assembly
supported
gudgeon
gudgeon
tons
to
bosses
p
mto
fit
fit
press
Care
renew
stons
It
Into
m
pm
pin
IS
rod
and
the
front
hole
nght
dnving
the
that
Installed
and
mto
pm
the
rod
If
new
of tool
fitted
bee
gap
compressIOn
the
Posil1on
top
gudgeon
Liberally
to
AND
the
the
to
w1l1
m
the
hand
posil1on
gudgeon
the
piston
to
lubncate
the
the
assembly
piston
each
Instal
that
In
correctly
The
piston
the
compresslOn
fittmg
coat
itS
contact
TO
ASSEMBLE
Assemble
PISTON
when
I
mstalled
denotmg
011
SqUllt
toward
from
I
J
NOTE
Important
and
of
a
the
then
2
the
As
Lightly
press
gudgeon
the
Both
way
gap
valve
thrust
and
msertitmto
control
3
up
4
m
5
mto mg
Ensure
rmg
fittings
on
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