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
air
cleaner
remoye
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
SIde
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
the
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
wlucheveiI
is
i
and
Sl
thde
the
the
linkage
the
mle
the
plpe
the
out
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transmlsslqi1n
le
shIft
of
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and
I
2
I
I
I
l
I
j
r
l
t
j
t
y
e
r
d
f
l
If
TO
CHECK
Wash
1
wIth
dry
or
to
2
Check
damage
3
Check
vot
contact
p
4
Wear
compressed
components
correspondmg
TO
REMOVE
Disconnect
J
ventIlatIOn
cleaner
Smgle
by
pass
Disconnect
Disconnect
Disconnect
lever
Remove
off
the
Twm
carburettor
hose
thermostatic
2
Remove
3
Remove
applicatIon
hose
the
the
the
the
carburettor
apphcatlOn
all
components
an
rocker
the
the
rocker
surfaces
or
damage
will
necessitate
Pivotorrocker
AND
INSTAL
the
and
where
au
the
air
the
carburettor
dISconnect
where
fitted
dlStnbutor
choke
control
throttle
carburettor
remove
Engine
arm
arm
for
to
bleed
cleaner
vacuum
hnkage
to
Rocker
In
Pivot
to
wear
one
arm
rocker
fitted the
hose
assembly
s
the
cable
at
marufold
the
Cover
cleanmg
head
cam
and
or
damage
of
the
the
as
the
cover
mlet
as
follows
fuel
feed
pipe
the
carburettor
retammg
mlet
Removed
solvent
surface
the
above
renewal
case
to
mamfold
mlet
elbows
rocker
mentIOned
may
4
an
pipe
nuts
Showing
and
blow
for
wear
arm
the
of
be
CYLINDER
cleaner
to
air
and
fuel
throttle
and
lift
the
fJ
2m
Val e
TO
INSTAL
InstallatIon
attentIon
Assemble
to
ensure
Adjust
LASH
Clean
rocker
cover
HEAD
Disconnect
Disconnect
Remove
Disconnect
Detach
Unbolt
mamfold
radiator
5
6
cyhnder
7
and
IgmtlOn
remove
8
mamfold
Rocker
to
lubncatlOn
section
cover
the
the
and
4
Dram
bottom
DIsconnect
Disconnect
head
Detach the
the
Disconnect
vent
Arm
the
the
the
valve
the
gasket
Use
fuel
thS
the
choke
fuel
the
throttle
dlstnbutor
remove
the
tank
cou
With
cap
lahon
P
and
IS
a
reversal
followmg
rocker
for InitIal
clearance
surfaces
a
new
mlet
control
overflow
vacuum
each
coohng
and
and
the
high
tower
leads
and
hose
vOt
Layout
arm
gasket
pipes
pipes
hnkage
the
remove
heater
tensIOn
unchp
remove
of
the
components
start
See
on
when
cables
from
feed
carburettor
system
m
plug
the
hose
leads
the
removal
up
TO
ADJUST
the
cyhnder
mstalhngilhe
t
the
float
pipe
Via
the
the
cyhnder
radiator
top
the
at
at
dlstnbutor
the
crankcase
J
procedure
With
1
iiI
chambers
from
tap
hose
rear
the
spark
engme
head
the
block
cap
to
VALVE
rocker
mlet
on
of
plug
Inlet
With
ou
and
the
the
and
15
C
7
1
w
I
p
r
I
J
f
I
I
Engine
9
remove
the
10
umt
11
the
fuel
pump
II2
tlie
cylmder
msulator
13
nuts
flange
14
manifold
mlet
mamfold
15
mamfold
exha
st
gaskefA
16
the
getach
mlet
Detach
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Remove
head
the
mamfold
the
and
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block
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and
detach
Progressively
to
cylinder
Progressively
to
cylinder
malufold
Remove
rocker
cover
retammg
the
the
the
head
head
DIscard
1
the
water
wire
fuel
two
Withdraw
exhaust
the
exhaust
slacken
attachmg
slacken
attachmg
rocker
Discard
from
nuts
the
clip
pIpe
mlet
secunng
the
mamfold
and
Inlet
cover
the
and
the
and
fuel
pipe
and
nuts
nuts
and
rocker
iIJ
then
disconnect
temperature
outlet
the
fuel
pump
to
exhaust
from
the
remove
and
remove
and
exhaust
securIng
cover
pIpes
gasket
11ft
the
lift
1
sender
pump
mamfold
the
away
exhaust
away
mamfold
boIts
gasket
III
and
from
and
pipe
mlet
the
the
and
14
to
DImenSIons
when
NOTE
Adhered
cylmder
Under
hand
to
tools
pme
17
protruded
coyer
18
the
on
mark
cham
dimple
19
stamped
elther
a I
N
been
prevIOusly
These
adjacent
For
found
IS
the2number
camshaft
camshaft
20
SUItable
Remove
21
between
on
cham
hmmg
sUitable
I1lustra
the
The
crankshaft
tenslOner
cham
tlon
of
Camshaft
head
by
10
between
Remove
front
Rotate
IS
on
The
adjacent
or
2
numbers
to
the
example
be
to
on
sprocket
dowel
Usmg
bar
unscrew
the
bolt
Instal
tracks
the
tens
support
piece
Wooden
rocker
bumping
circumstances
the
porhon
the
alIgned
the
camshaft
sprocket
to
3
dependIng
readjusted
are
camshaft
a
If
aligned
the
a correct
and
the
special
of
sprocket
plunger
lOner
tool
of
wood
6
Wedge
and
Cylinder
wvers
fmnly
the
alumlll
external
two
the
of
crankshaft
and
clearly
sprocket
hmmg
the
mark
due
also
staIJiped
dowellqcatmg
2
number
With
the
sprocket
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locatmg
fittmg
the
camshaft
uel
the
limmg
the
hmIng
and
from
bore
can
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to
the
for
can
use
um
Holding
Head
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with
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and
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With
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mark
number
be
dimple
whether
to
I
on
limmg
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pump
also
wIll
the
stretchmg
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cham
wIll
hole
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actuatmg
cham
cham
to
tlmmg
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sprocket
holes
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adjacent
and
socket
retalmng
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to
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prevent
found
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spanner
cam
becommg dislodged
readily
dimenSIOns
fabncated
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Chain
from
of
or
Similar
secure
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hmmg
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to
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to
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tool
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from
IIT
I
the
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IS
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the
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a
the
Correct
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cham
valve
and
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t111l1ng
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If
dropped
22 With
remoYe
23
tool
disconnect
In
support
camshaft
and
progresslyely
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IS
lostItWill
wver
Withdraw
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the
loosen
unforeseen
the
off
to
readjust
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tumng
sprocket
reverse
and
crankshaft
be
the
the
order
remove
necessary
the
cham
tumng
cm
valve
camshaft
cham
of
the
the
umstances
sproLket
to
t1mmg
firmly
sprocket
from
tlghtemng
cylinder
remove
wedged
the
head
the
and
the
from
sprocket
sequence
t1mmg
correct
sump
by
secunng
the
the
bolts
PosItIon
of
Support
Sprocket
Tool
to
WIthdraw
Camshaft
far
the
Lift
enough
cylinder
to
clear
head
the
upwards
tlmmg
from
cham
the
and
cylinder
support
block
tool
16
I
t
I
1
Ii
Ensure
to
facing
6
the
press
7
In
the
connectmg
handle
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crankpm
8
beanng
lower
cap
9
tighten
0
J
connecting
freeness
that
the
the
front
a
USing
piston
assembly
001
Apply
the
tap
Instal
rod
pIston
and
the
wIth the
correspondmg
Instal
the
the
nuts
to
Rotate
rod
assembly
of
rIng
to
rod
upper
bIg
numbers
bIg
the
the
F
front
the
engine
compressor
down
the
crankpln
and
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down
beanng
end
end
speclfied
crankshaft
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marking
Into
a
the
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both
on
beanng
torque
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to
the
and
plece
cylmder
shell
cap
after
Installed
on
compress
cyhnder
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of
wood
bore
seat
correctly
and
cap
connectmg
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see
SpecIficatIOns
each
the
pIston
to
the
bore
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or
untol
lower
check
pIston
hammer
on
rod
nuts
rmgs
shell
half
and
the
the
and
and
for
E
J
IS
with
water
12
the
13
leak
the
FIll
specIfied
Run
the
coohng
grade
engine
GRADING
and
system
quantIty
and
MARKING
with
check
of
water
engme
for
and
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engme
the
sump
and
on
If
If
lJ
J
1
1
NOTE
the
small
groove
Beanngs
See
reground
II
timing
manual
TO
CHECK
NOTE
II
wear
assemblzes
accurate
actual
ovallly
clean
with
1
or
sconng
When
fitteng
on
tang
en
the
connecteng
must
SpeCIficatIOns
crankshafts
Instal
the
cover
as
descnbed
CYLINDER
To
accurately
IS
essentlal
removed
be
measurmg
cylmder
The
cylmder
a
clean
VIsually
check
new
each
not
cyhnder
that all
eqUIpment
bore
rag
before
end
big
beareng
rod
or
cap
be
adjustedbyfilIng
for
undefSlze
head
In
the
u
BORES
check
cylmder
pistons
the
from
overall
bores
be
wear
should
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available
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the
bores
for
beareng
fits
ento
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relevant
bore
and
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cracks
shells
the
or
scrapmg
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sectIOns
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condllIon
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block
to
determene
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ensure
mat
hilled
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of
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and
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Markmgs
IIOHSA
2
and
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3
unseIVIceable
llTImed13te
fitted
NOTE
the
t
vlmder
pistons
See
SpecificatIOns
Engines
on
IndIcate
n
Check
Cyhnder
oversIze
illS
If
are
to
that
PIston
P
O
each
See
cyhnder
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bores
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and
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wllh
the
be
used
for
have been
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ston
S
rebored
that
most
Bore
available
FRONT
and
Gradmg
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for
that
upon
and
new oversIze
the
tylmders
wear
to
all
cylmdersTio
bored
Gudgeon
and
for
cylmder
checking
determIne
ove
rslze
to
fhelr
MARKING
Front
wear
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r
mcludmg
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j
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Pm
prove
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bor
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ang
ing
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rmgs
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t
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iJ
l
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fder
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Block
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3
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23
3
Engine
be
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DEGLAZING
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ongmal
with
andunder
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usmg
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up
cross
the
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strokes
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CA
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soap
components
can
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prevenf
CHECKING
NOTE
the
measured
feeler
t
clearance
nght
down
approximately
thIckness
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pIston
if
with
outer
on
with
Cylmder
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PosItion
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entenng
2
Deglazmg
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cyhnder
3
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down
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cross
hatch
When
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of
size
and
4
Use
or
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5
After
thoroughly
UTJON
after
and
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The
cylmder
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Smear
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appropnate
for
Strlp
IS
Measure
I
angles
from
The
piston
2
Select
and
should
cylmder
diameters
sleeves
CYLINDER
bores
but
plenty
each
cyhnder
the
crankcase
of
surfacmg
to
should
the
cyhnder
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p
angle
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the
zmg
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the
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Increase
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Do
not
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Be
sure
thqt
Ironmg
be
thoroughly
bores
Withawhite
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th oores
PISTON
that
overSIZe
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and
spnng
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to
the
gudgeon
the
gudgeon
temperature
200e 680F
a
feeler
approximately
be
long
which
sleeves
New
pistons
BORES
that
are
fit
re
reqUire
rmgmg
of
clean
bore
area
the
cyhnder
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carned
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walls
ne
fien
h
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most
satIsfactory
It
IS
lmportan
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made
ExceSSIve
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01
whIchISavaolable
engine
It
IS
necessary
to
remove
all
abraSives
It
recommended
IS
used
with
dned
an
be
consldered
with
engm
have
CLEARANCE
been
SKIRT
pistons
m
tned
the
scale
to
t
dIameter
o
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pm
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pm
when
strIp
12
to
rpough
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rag
to
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fast
marks
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or
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Jha
all
traces
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brush
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cloth
4V
rebdred
should
ItS
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ensure
s
and186
004
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Intersect
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t
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ttthe
of
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that
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and
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after
l
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I
of
the
measunng
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50
In
the
full
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the
crankshaft
be
wIth
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at
the
only
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Will
from
011
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abraSive
d
a
solutlq
the
cle
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when
cloth
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each
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t40
piston
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00016
In
Width
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m
three
with
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achIeve
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correct
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mcrease
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block
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n
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remams
l
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732
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of
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eral
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The
the
Invert
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the
90
degrees
end
parallel
the
readIng
should
the
readIng
check
measure
fit
the
select
bore
cyhnder
of
the
be
the
ongInal
thepston
and
remaInIng
a
may
wall
to
feeler
to
on
Within
IS
check
set
the
the
the
the
not
of
be
a
3
the
pIston
feeler
stnp
the full
and
gudgeon
4
and
stnp
lIne
centre
scale
spnng
5
andI5
02
WIthIn
measurements
skIrt
for
another
6
pIstons
FIT
TO
i
piston
Insert
and
IS
pIn
Attach
Withdraw
of
The
these
hIgh
piston
Follow
as
required
NEW
With
nngs
the
feeler
pOSitIOn
located
length
axiS
a
spnng
the
the
cyhnder
correct
kg044
speCifications
the
of
If
spots
obtain
to
the
PISTON
the
cylinder
standard
Into
stnp
It
Into
lengthWise
of
the
piston
scale
feeler
stnp
bore
scale
spnng
and330
and
pIston
necessary
the
reqUIred
same
procedure
RINGS
bore
or
ovefSlze
the
between
the
to
notmg
lbs
then
bore
select
measured
the
cyhnder
cyhnder
at
top
In
a
plane
readIng
If
check
also
fit
to
wluchever
apphcable
2
PosItion
of
portIOn
the
cyhnder
alignItsquarely
accomphshed
and
pushmg
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bore
3
WIth
nng
gap
by
the
where
Withdraw
feeler
fihng
by
the
each
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down
nng
wear
the
gauges
to
the dimenSions
bore
the
IS
at
pIston
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nng
to
cyhnder
an
the
a
found
which
mverted
bore
mmnnum
and
necessary
In
to
measure
the
ItISto
wall
pIston
a lower
as
relatIVely
be
ThiS
from
posItion
the
gap
adjust
gIVen
fi
unworn
tted
can
the
m
and
above
m
end
the
the
be
of
r
SpeCIficatIons
Treat
each
ensure
that
cyhnder
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bore
the
check
4
Each
of
mark
to
y
to
upon
eIther
gap
valve
dIrectly
a
With
cyhnder
top
at
NOTE
boss
be
nngs
I
NOTE
replaced
denote
mstallatlOn
way
up
5
PosItIon
In
the
m
the
at
the
6Lubncate
lengJiie
7
Insert
bore
the
race
of
Enrur
IS
facmg
Use
8
and
Instal
Conne
m
dlsman
mg
top
cyhnder
011
towards
a
the
24
and
nng
are
assembled
m
the
compressIOn
Thesemrks
top
The
the
nng
compressIOn
piston
e
tl
the
plstQn
a1lowmg
cyhnder
that
the
the
SUItable
the
piston
rod
tmg
qlmders
cyhnder
whIch
oJ control
gaps
head
thrust
pIston
the
block
F
front
front
nng
mto
and
from
to
they
nngs
should
180
nng
AVOId
and
gudgeon
asse
concerned
011
control
markmg
the
of
compressor
Its
piston
vhlch
bore
the
respectIve
were
fItted
are
nng
degrees
away
fittIng
and
bly
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engine
respectIve
assemblies
they
lndlvldually
for
proVIded
be
facmg
can
be
apart
from
the
the
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pm
cyhnder
Into
ItS
contact
to
on
the
piston
to
compress
cyhnder
were
removed
pIston
end
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upwards
Installed
WIth
exhaust
rmg
pomts
correct
bore
must
and
for
gap
a
the
gaps
wall
the
pm
the
be
on
I
I
NOTE
groovzng
be
necessary
crankcase
portIOn
8
beanng
9
makmg
If
of
Tap
cap
Instal
sure
where
This
the
the
to
crankshaft
the
and
crankcase
the
that
crankshaft
the
seal
Instal
allow
Will
Side
new
flywheel
IS
It
has
a
shun
the
flange
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seatmg
rear
been
seal
down
to
squarely
flange
prevIOusly
between
to
lip
between
the
rear
shows
the
ron
of
on
ronning
seal
on an
the
the
the
eVidence
and
unworn
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crankshaft
crankshaft
E
of
It
may
the
mam
21
flange
FIt
10
new
lock
On
nve
retammg
See
11
the
crankpm
engtne
correspondmg
end
bIg
I2
procedure
SPROCKETS
TO
REMOVE
1
both
front
2
radIator
3
4
disconnect
radiator tank
dIrt
5
lator
d
ra
6
the
alternator
7
fan
and
1
8
Hose
and
9
remove
bracket
r
I
assembly
NOTE
not
Will
10
and
washers
automatic
with
plate
bolts
to
SpeCIfications
Draw
each
Instal
oil
Ensure
numbers
beanng
Raise
cap
Further
See
sectIOn
the
fenders
Dram the
bottom
Dlsconnetttfe
On
Remove
tank
vehlloles
the
torque
lug
rr
JSlacken
adJustmg
Remove
from
pulley
Detach
Loqsen
the
to
On
be
thermostatic
the
two
the
engines
necessary
Remove
the
mlet
tighten
to
remforcmg
the
that
TIMING
the
the
the
the
bolts
leads
the
speCIfied
transnusslOn
speCIfied
for
connectmg
the
the
on
retammg
InstallatIOn
for
valve
I
O
engme
coohng
and
lupper
fitted
converter
the
pipes
radIator
alternator
bracket
four
the
water
rocker
alf
which
mamfold
fitted
t6
remove
the
dlstnbutor
the
torque
bIg
cap
the
CHAIN
TIMING
bonnet
t
le
retaml
au
clea
with
flywheel
torque
fit
plate
torque
setting
rod
end
bearmg
numbers
connectmg
nuts
IS
a
tlmmg
and
syytem
m
plug
lower
and
WIth
coohng
and
umons
retauung
mountmg
and
g
pump
to
c
over
bleed
ass
secure
an
I
tWin
thl
secunng
the
fit
and
down
are
the
to
reversal
TENSIONER
procedure
fit
VIa
the
cyhnder
radiator
automatic
plp
to
bolts
fan
belt
bolts
and
at
cleaner
hose
mbly
e
remove
type
Sf
illr
c
ean
7
t
t
cap
bolts
and
tighten
mto
posItion
With
caps
alIgned
rods
Tighten
speCified
the
of
converter
With
torque
removal
torque
CHAIN
J
r
felfder
covers
tap
on
the
block
hoses
ri
tr
the
S
at
and
entry
hft
out
an
d
remove
ch
de
v
ntIlatlon
fitted
prevent
bolts
where
ihumb
er
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cle
l
at
t
the
atr
ci1rburdttorsh
er
assembly
wlth
h1gh
v
If
wIth
the
on
clean
the
ther
AND
I
f
I
TENSICtNER
J
to
th
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lmyer
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the
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pe
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screw
e
m
b
y
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oft
J
J
r
1
1
Centre
detach
engme
TO
releva1Jt
cran
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anCl
cran
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gasket
cover
I
f
from
27
Main
BeanrigTo
I
ANn
II
Remove
the
rocker
P
RaJse
chas
S
sta
lds
13
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I1
14
emqye
REMOYB
l5tREmlOve
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16
el1
17
R
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n
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19
j
d
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fr
Ont
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t
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ve
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e
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SPROCKETS
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and
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el
INSTA
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e
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t
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ter
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arate
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oved
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and
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Flimged
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ip
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el
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r
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r
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NOTE
to
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and
and
from
TIMNGMARKS
CAMSHAFT
Engine
Care
cover
gasket
If
necessary
the
t1mmg
brepkmg
23
Wlthd
the
frontofthe
24
Check
I
TIMING
SPROCKET
BOSS
must
Is
ON
gasket
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run
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aw
MARKS
tiiken
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to
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CRANKSHAFl
ensure
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p
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Strip
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and
SPROCKET
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sprockets
PERIPHERY
J
the
the
head
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gasket
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drIve
gear
for
markmgs
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hnks
The
See
1IIustratlOn
25
ltable
sl
Remove
26
VISIble
are
marks
numbers
the
three
The
sprocket
stretchmg
27
thrust
camshaft
Illustratoon
marked
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mark
I
wIth
the
28
o
Both
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marks
unscrew
bolt
WIll
the
wIth
for
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be
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also
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As
plate
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are
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rear
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to
occurs
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penpheryISalIgned
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