Nissan Sunny 1969 1973 User Manual
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DATSUN
MAINTENANCE
RANGE
BY
DRAKE
1971
AUTOMOTIVE
1200
1973
REPAIR
EDITORS
MAINTENANCE
ENGINEERING
ELECTRICAL
IGNITION
FUEL
COOLING
BRAKES
FRONT
SYSTEM
SYSTEM
SYSTEM
SUSPENSION
Quick
TUNE
SYSTEM
The
purpose
a
reference
We
endeavor
specifications
the
Publisher
errors
Upon
Simple
make
or
omiSSions
compIling
relvlng
thIS
manual
source
UP
of
to
at
cannot
on
Referencelodel
this
manual
with
lOcorporate
time
the
the
information
the
a
useful
which
be
combination
of
held
ISto
he
the
publication
responsible
tool
13
35
43
49
63
67
83
provide
can
latest
contained
5
perform
of
STEERING
REAR
SUSPENSION
CLUTCH
TRANSMISSION
BODY
SPECIFICATIONS
the
automobile
normal
service
manufacturing
While
for
manufacturing
herein
photographs
design
every
effort
we
Illustrations and
have
DRIVE
WORK
owner
operations
changes
IS
madetoattain
changes
tried
and
to
mechanic
and
up
typographical
be
brief
text
to
to
accuracy
and
89
93
99
103
111
129
with
date
DRAKE
PUBLISHERS
PARK
361
NEW
AVENUE
YORK
INC
SOUTH
NY
10016
ISBN
087749
309
X
Pubhshed
DRAKE
381
New
@Drake
Prmtedmthe
PUBLISHERS
Park
York
Pubhshers
III
1973
Avenue
N
Umted
by
South
Y
10016
INC
Inc
1973
StatesofAmenca
able
of
Contents
MAINTENANCE
VALVE
ENGINE
OIL
COOLANT
COMPRESSION
BATTERY
IGNITION
DIstributor
Condenser
Spark
Carburetor
Idle
Dash
model
Carburetor
Fuel
DESCRIPTION
REMOVAL
INSTALLATION
CLEANING
DISASSEMBL
INSPECTION
PreparatIOn
Cyltnder
Valve
Valve
Valve
Valve
Camshaft
Valve
Cyltnder
PIston
Connectmg
Crankshaft
Bushmg
Crankshaft
Flywheel
ASSEMBL
PrecautIOn
Cyltnder
PIston
Engme
OIL
Removal
CLEARANCES
OIL
FILTER
Plugs
LImIter
Pot
only
Filter
Assembly
Spnng
Rocker
LIfter
Tlmmg
Piston
Camshaft
PUMP
Engme
TUNE
TIMING
Breaker
Pomt
Cap
automatic
Return
transmISSIOn
Sprmg
ENGINE
INSPECTION
Y 14
REPAIR
Head
Shaft
Push
Camshaft
Block
Pm
Rod
Bearing
Sprocket
Sprocket
Y
Head
ConnectIng
m
Rocker
Rod
Bearmg
Rod
vehicle
Plsto
LRmg
Arm
UP
DIsassembly
6
6
7
7
7
8
8
9
9
9
9
10
11
11
11
11
14
14
14
14
18
18
18
18
19
19
20
20
20
21
21
23
24
24
25
25
25
25
25
26
26
32
32
AdJustmg
Assembly
ELECTRICAL
STARTER
Removal
InstallatIOn
Trouble
ALTERNATOR
Removal
InstallatIOn
REGULATOR
DeSCriptIOn
Trouble
DISTRIBUTOR
ConstructIOn
Checkmg
SP
ARK
PLUGS
DeSCriptIOn
InspectIOn
Cleamng
FUEL
DESCRIPTION
REMOVAL
INSTALLATION
FUEL
CARBURETOR
FILTER
PUMP
DeSCriptIOn
Testmg
Removal
InspectIOn
Assembly
DeSCription
Adjustment
Removal
DIsassembly
Cleanmg
Assembly
InspectIOn
RepaIr
Regulator
Shootmg
Shootmg
IGNITION
and
Adjustment
Regap
FUEL
DIsassembly
InspectIOn
InstallatIOn
SYSTEM
SYSTEM
SYSTEM
32
33
33
33
36
37
37
37
36
37
37
39
39
40
44
44
44
46
46
46
47
50
50
50
50
50
50
51
52
52
52
52
52
53
58
58
59
60
I
labl8
of
Contents
Jets
TlOuble
DESCRIPTION
WATER
Hemoval
InstallatIOn
THERMOSTAT
Removal
InspectIOn
Installation
RADIATOR
Hemovdl
InspectIOn
InstallatIOn
Shooting
COOLING
PUMP
BRAKES
SYSTEM
60
60
DESCRIPTION
RECOMMENDATIONS
TROUBLE
64
64
65
65
65
65
65
65
66
66
66
66
DESCRIPTION
RECOMMENDATIONS
TROUBLE
REAR
DIFFERENTIAL
REAR
REAR
RECOMMENDATIONS
FRONT
AXLE
SUSPENSION
SHOCK
Replacement
InspectIOn
SUSPENSION
SHOOTING
STEERING
SHOOTING
REAR
SUSPENSION
DRIVE
ABSORBER
f
I
85
90
90
91
94
94
95
96
96
97
97
FRONT
BRAKE
DISC
Replacement
InspectIOn
ReinstallatIOn
CALIPER
Removal
Disassembly
InspectIOn
Reassembly
ReinstallatIOn
REAR
BRAKE
Hemoval
InspectIOn
Reassembly
HAND
BRAKE
Removal
InspectIOn
RemstallatlOn
ADJUSTMENT
Front
DIcBrake
Rear
Brake
Brake
Hand
Pedal
Brake
BLEEPIN
TROUBLE
PAD
Dlsdssembly
HYD
SHOOTING
BRAKE
Repmr
ReinstallatIOn
HeIght
AULIC
SYsrM
78
79
79
80
68
68
68
68
68
70
70
71
71
72
74
74
74
75
75
75
75
76
77
78
78
78
DESCRIPTION
CLUTCH
Removal
InspectIOn
ReinstallatIOn
Adjustment
CLUTCH
Removal
DIsassembly
InspectIOn
Reassembly
RemstallatlOn
BLEEDING
4
SPEED
3
SPEED
TROUBLE
i
UIQM
RECOMMENDATIONS
ATJ
CLUTCH
PEDAL
MASTER
CLUTCH
CYLINDER
SYSTEM
TRANSMISSION
TRANSMISSION
TRANSMISSION
SHOOTING
C
TRANSMJSSIQ
2
fable
of
Contents
HOOD
I
Removal
InstallatIOn
HOOD LOCK
Removal
Adjustment
LubncatlOn
TRUNK
Removal
Adjustment
TRUNK
DOOR
WIRING
BULB
HEADLAMP
THERMOMETER
OIL
BODY
LOCK
LID
LID
TORSION BAR
CONSTRUCTION
DIAGRAMS
SPECIFICATIONS
FUEL
PRESSURE
WARNINGLAMPS
METER
AND
WORK
AND
IGNITION
112
112
112
112
112
112
114
116
116
116
116
117
118
120
121
122
126
SERVICE
ENGINE
General
Tlghtemng
SpeCIficatIOn
Coohng
Fuel
System
Starter
Alternator
Regulator
Dlstnbutor
IgnItIOn
CLUTCH
NOTES
SPECIFICATIONS
DATA
SpeCificatIOn
Torque
System
Cot
130
134
134
134
135
139
140
142
143
144
145
145
146
174
I
t
I
I
3
aintenIDce
TUDe
up
Ii
ainteDaDee
VAL
VE
CLEARANCES
adjust
dead
Exhaust
Intake
Intake
Exham
ote
piston
Exhaust
Intake
Intake
Exhaust
clearance
engme
proceed
engme
temperature
of
engIne
crankshaft
center
valve
operatIng
valve
while
valve
valve
valve
t
valve
Numbers
10
accompanY1Og
rotate
IS
stroke
valve
valve
valve
valve
IS
stationary
and
on
rocker
mechamsm
clearance
engIne
of
of
of
of
crankshaft
In
top
Adjust
of
of
of
of
adjustment
follows
as
run
011
temperature
to
bnng
ItS
compressIOn
cover
IS
still
No
1
No
No
2
No
in
parenthesis
dead
No
No
3
No
4
No
Valve
while
To
Start
operatIng
17S
engIne
Rotate
top
Remove
valve
Adjust
pOints
1
2
3
5
those
AgaIn
4
pressIOn
4
6
7
8
It
until
at
or
No
to
at
hot
1
cylinder
cylinder
cylinder
3
cylInder
sketch
one
center
follOWIng
2
cylinder
cylinder
cylInder
4
cylinder
TUDe
should
least
turn
be
It
IS
heated
more
then
1
cylInder
stroke
access
gaIn
follOWing
agree
that
so
ItS
on
valves
made
with
com
than
stop
four
No
up
Adjustment
hot
After
correctly
should
all
tighten
adjustment
for
the
In
and
a
If
defective
when
midway
of
belt
to
Check
Replace
Adjust
deflectIOn
Checking
In
to
applied
o
590
011
capacity
Capacity
MaXimum
MInimum
Make
With
refill
Notes
presence
Valve
sure
cooling
the
011
a
clearance
Hot
VB
5IB
that
of
US
US
lf
A
cooling
valves
lock
adjusting
cracked
tenSIOn
thumb
between
ENGINE
engIne
gal
gal
engIne
water
necessary
m1lky
Intake
Exhaust
ue
made
nut
pressure
IncludIng
Imp
III
Imp
011
or
water
whIle
have
firmly
drive
or
damaged
If
necessary
pulleys
OIL
gal
gal
not
IS
gasolIne
011
indlcates
been
to
belt
of
011
detenorated
0014
engIne
adjusted
secure
220
0394 to
filter
DraIn
In
IS
the
V
belt
Belt
Ib
IS
and
8
Rg1AdJustmg
valve clearance
Fig
2
AdJustmg
dnve
belt
tension
aintenIDce
une
up
Find
action
b
Oil
dicates
Check
to
H
The
011
Check
any
nece
When
Note
leakage
the
with
dllutton
011
level
mark
filter
for
leakage
sary
mstalhng
Do
may
cause
on
ISofa
011
leaks
IS
replaLe
not
for
extremely
with
If
found
gauge
FILTER
OIL
cartndge
through
found
filter
011
an
overtighten
result
necessary
low
gasoline
below
gasketed
retIghten
as
an
filter
viscosity
L
type
assembly
tIghten
fIlter
011
corrective
mark
flange
shghtly
by
refill
hand
or
COOLANT
rustmg
con
It
used
IS
level
base
tam
wIll
wIth
will
and
system
other
changed
and
product
protect
and
any
not
either
flows
It
not
The
products
the
the
refilled
L
C
in
L
tammg
coohng
The
ethyl
or
or
transfers
passages
If
If
oil
must
coolant
the
Whenever
system
new
L
or
bOll
low
not
year
coolant
IS
al
ethylene
chemical
system
I
C
does
methyl
and
away
temperature
heat
m
the
mIxed
be
be
can
any
should
Check
mhlbltors to
from
not
alcohol
can
thermostat
effiCiently
coohng
wIth
used
throughout
coolant
be
flushed
the
glycol
be
con
corrosIOn
glycerme
evaporate
high
freely
clog
LL
ThiS
seasons
coohng
wIth
the
the
C
of
a
COMPRESSION
cylinder
plugs
test
and
compression
hold
tester
fit
Compression
Note
remove
To
all
pressure
test
spark
Fig3Checking
I
I
I
Fig
4
Protection
Oc
0
20141
30
401401
5015BI
engine
OF
121
21
011
10 20
concentration
level
EGOQl
Sea
2210F
2280
BOllIng
level
F
Percent
concen
lion
tra
30
50
I
I
Fig5Testing
ETO
104
compressIon
pomt
09
coolmg
tern
pressure
cm2
kg
pressure
2550F
2610F
sys
Freeze
protectIon
50f
31oF
7
aiDtenaDce
TUDe
up
ting
tightly
der
The
tester
cylinder
whether
plugs
etc
compressIOn
removed
rings
Test
opened
less
than
variatIOn
low
speed
dlcates
blOken
though
ThIs
may
consumptIOn
Test
Conclusion
If
one
or
one
tablespoon
plstons
spark
plug
thesecyII
can
there
No
80
between
missing
a
valve
pIston
umform
more
In
hole
nders
m
spark
is
used
IS
wIth
and
cyhnder
of
highest
ring
be
accompamed
cyhnders
of
low
readmg
Repeat
to
hold
excessive
engme
throttle
compressIOn
cyhnders
of
the
not
properly
may
engine
hole
plug
determme
compression
and
cyhnder
cyllndel
Low
indIcate
by
read
011
cyhnders
compressIOn
of
a
whether
leakage
choke
should
s
all
Excessive
warm
accompamed
usually
seating
preSsures
worn
excessive
low
Inject
on
top
through
check
cylin
past
spark
valve
or a
even
rings
about
of
the
or
be
by
10
011
on
Clean
solutIOn
and
tery
between
to
In
cumulatIon
tery
covering
straps
With
from
Check
pOints
dry
must
hold
additIOn
may
petrolatum
corrosIOn
for conditIon
top
down
After
spark
Thoroughly
marks
Warm
on
up
of
of
baking
WIth
be
terminals
clamp
to
of
cause
connector
IGNITION
wipe
crank
engine
battery
soda
compressed
clean
to
and
current
aCId
and
bhstenng
straps
tightening
vasehnel
plugs
and
off
dIrt
pulley
suffiClently
and
and
prevent
from
leakage
dirt
terminals
TIMING
and
and
terminals
water
The
atr
current
poSItive
on
of
and
to
dIstributor
dust
front
Rinse
top
termlndl
prolonged
the
top
the
material
corrOSIOn
coat
protect
from
cover
With
bat
of
leakage
of
bat
them
them
breaker
tlmmg
a
off
ac
of
I
I
j
If
compressIOn
are
rings
If
compressIOn
stIcking
If
two
pressIOn
Increase
cylInder
ders
result
defectIve
or
adjacent
and
compreSSIOn
head
Engine
from
CompressIOn
178to206
Check
Unscrew
level
to
07874
Mea
If
bring
ure
electrolyte
flUId
level
In
trolyte
seatIng
this
pSI
each
above
P
Improves
does
cyhnders
mjectmg
gasket
011
and coolant
problem
pressure
at
350
BATIERY
filler
level
up
plates
illL
not
Improperly
011
the
leak
rpm
level
10
cap
IS
low
to
approximately
Do
gravlty
conSiderably
Improve
mdlcate
on
pistons
cause
between
In
cylInder
each
battery
and
Inspect
add
dIstilled
not
overfill
of
pattery
valves
low
does
may
the
03937
piston
cell
water
are
com
not
be
cyhn
could
flUId
el
PermIssIble
value
1
chmates
Fngld
TropIcal
Other
a
chmates
clunates
22
Over
OverI18
Over120
Full
charge
at
68OF
128
123
126
value
j
J
I
to
ET002
c
FlgSGheckmg
trolyte
the
speCific
gravity
of
baltery
elec
f
8
l
Install
WIre
plug
Set
Idhng
Check
of
Top
hght
If
necessary
Loosen
dlstnbutor
AdJu
it
Lock
dlstnbutor
that
tlmmg
IgnitIOn
Distributor
Check
pItting
wre
they
tact
and
and
Clean
WIck
Note
Do
DltIIbutOl
POint
gap
Dwell
angle
Condenser
Clean
outlet
for
loose
Check
meter
a
timing
and
ipeed
19mtlOn
Dead
iet
can
IgmtlOn
tImmg
dlstnbutor
and
are
that
apply
not
0
set
condenber
lIght
Install
to
tImmg
Center
adjust
screw
be
tIming
IS
correct
degreel
Breaker
wear
In
correct
pOint
dlstnbutor
apply
018to0
49
to
of
condenser
screw
on
No
a
tachometer
approximately
It
If
IS
the
by
follows
It
as
to
such
moved
set
breaker
to
screw
Point
Replace
by
50BTDC
50
pomts
If
ahgnment
dwell
and
grease
022
In
55
degrees
lead
RetIghten
capacIty
1
cyhnder
800
50BTDC
use
extent
an
hand
and
make
BT
DC
for
necessary
for
are
gap
grease
to
excessively
WIre
If
necessary
a
With
spark
rpm
Before
of
tlmmg
abnormal
Make
full
correct
cam
and
check
capacity
that
sure
con
and
aiDteDaDce
tester
resIstance
the
and
When
pomts
resIstance
each
the
specified
for
cracks
ground
replace
electrode
USIng
to
essential
and
suffiCiently
operatIOn
resistance
by
plugs
spark
110to
preparIng
Condenser
checked
to
measure
denser
largely
to
stay
the
IS
and
Infimte
still
replacement
Condenser
022JF
Condenser
Mn
5
Spark
Remove
cleaner
that
ipect
both
Mega
Plugs
they
msulator
center
excessIVely
File
plugs
0031
to 0035
tool
Tighten
mixture
Idle
CO
meter
mixture
thoroughly
Warm
ContInue
der
up
ldhng
msulatlOn
usmg
large
normal
rapidly
or
IS
capacIty
MIcro
InsulatIOn
ohms
and
Inspect
are
and
worn
center
It
warmed
the
engIne
speed
a
SIde
It
necessary
Farad
clean
of
m
plugs
CARBURETOR
adjustment
When
IS
engme
adjusting
value
tester
moves
the
zero
In
and
electrodes
WIth
flat
the
requIres
to
cahbrated
for
may
pomter
gradually
pomter
m
a
plug
heat
chIps
Set
proper
ft
150
to
have
one
UDe
ItS
When
does
reSIstance
sand
Make
range
If
they
new
the
adjustIng
Ib
torque
the
use
adjust
the
mmute
be
range
swmgs
blast
Check
spark
gap
meter
also
con
back
iure
are
of
up
not
In
to
a
Idle
un
Fig7Checking
Igmllon timing
Fig
8
Checking
dlstnbutor
POint
gap
ETOQ4
I
i
I
I
I
I
I
I
aiDteDaDce
UDe
I
I
I
up
Fig9Checking
Adjust
speed
automatic
Check
the
IgnitIOn
Adjust
tage
Repeat
3
800
Cautions
throttle
1S
IgnitIOn
specIficatIOns
timing
Idle
15t0
IS
the
above
so
rpm
equipped
the
D
position
brake
wheels
b
on
rush
On
make
wIth
And
lever
and Idle
Idle
CO
with
If
throttle
screw
and
wIth
Hold
accelerator
out
automatic
sure
the
then
In
rpm
percentage
lever
necessary
until
brake
selector
speed
650
adJustlng
spark plug
adjusting
800
rpm
transmIssIOn
tlmmg
50
adjusting
5ff
adjustments
that
CO
a
On
model
to
lock
wheel
pedal
pedal
dangerously
transmISSIOn
that
the
lever
check
D
In
posItion
are
D
the
PoSitIOn
adjust
correct
gap
screw
m
If
necessary
800
rpm
screw
as
percentage
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so
that
Connectmg
or
or
tOrsIon
3
per
94
m
the
pm
pm
Rod
pitted
large
bend
If
or
weight
rod
length
pm
fittmg
hole
pressed
rnust
rod
rod
on
end
or
bend
replace
the
difference
0
bend
100
mm
of
to
such
at
be
shows
both
correct
torsIOn
or
the
connectmg
18
oz
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bend
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the
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tight
any
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usmg
torsIOn
connectmg
m
umt
piston
extent
an
press
scratch
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rod
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weIght
o
o 0028
pm
that
temperature
fitted
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of
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thrust
replace
a
connectmg
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rod
select
new
MaXimum
0020
I
mto
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score
It
the
the
and
o
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PIston
clearance
Interference
pm
FIg43Connecting
pm
to
connectmg
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fit
piston
of
piston
rod
rod
ahgner
00002
00079
check
Standard
to
0
0118
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end
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play
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end
play
MaXImum
I
U0157
23
BogiDe
1910to1940 1910to19 40
45
Crankshaft
Fig
Taper
of
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crank
pm
Crankshaft
Install
the
corresponding
thrust
ceeds
the
Crankshaft
Check
for
scars
replace
Check
ceeds
the
Note
gauge
27
0752
to
49951to49 964
11
ALL
JOURNALS
out
of
Journal
bend
m
connecting
clearance
hmlt
the
crankshaft
biased
as
reqUired
the
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hmlt
When
00to27 05
07641
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MAIN
round
and
replace
replace
me
9671
BEARING
rods
crank
If
wear
8
sJlring
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0752to0
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44 961to44
1
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ALL
S
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the
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Journal
and
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bend
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crankshaft
jJncldtSe
7641
34 97
1
377
CRANK
UNIT
bearings
and
measure
and
If
the
to
3503
to
1
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7706
PINS
mm
MaXimum
00012
MaxJmum
value
crank
Repair
bend
3791
m
0020
on
rod
the
pin
ex
dial
Llmtl
00118
EM141
Crankshaft
play
free
Standard
end
0
m
o0020
0059
to
Fig46Plasllgage
extent
wear
turned
to
block
It
ob
Its
to
un
of
at
and
Bend
tamed
once
center
After
the
derSize
reqUIred
Install
and
to
ex
Check
the
value
when
with
journal
regrInding
necessary
bearing
the
measure
the
rear
repair
end
isahalf
the
size
crankshaft
th
main
of
the
dial
the
by
according
the
thruht
drIve
the
crankshaft
of
crankshaft
gauge
crankshaft
uSing
In
clearance
shaft
the
the
an
to
pilot
readmg
is
applied
fimsh
adequate
the
cyhnder
beating
for
damage
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1f
Replace
all
scar
bushings
off
bushing
the
main
and
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and
011
Bushing
or
Check
melt
Rgj
Jlace
Wipe
the
Set
defects
any
Bearing
burr
and
bearing
If
dust
and
any
on
detected
are
bushings
defects
especially
the
cap
are
block
for
detected
the
seIzure
rear
of
14
Cut
and
gettmg
Install
1
them
Tlghtentng
36to43ftlb
Note
when
Remove
plastlgage
printed
Crankshaft
Sprocket
Check
Replace
a
plastIgage
place
clear
the
together
Be
the
the
tn
tooth
defective
It
m
parallel
of
the
on
cap
with
torque
sure
not
plastIgage
cap
at
Its
the
plastIgage
Sprocket
surfaces
to
the
011
hole
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the
to
is
and
widest
sprocket
wIdth
with
assembly
specified
turn
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measure
part
envelope
and
for
flaws
the
of
the
torque
wIdth
wIth
the
bearing
crank
and
tighten
crankshaft
the
Camshaft
and
of
wears
pm
the
scale
Install
check
for
replace
Check
deViated
Check
and
If
the
the
stretch
defective
Flywheel
Check
the
flywheel
replace
Measure
surface
IfItexceeds
Check
and
with
tooth
wear
Replace
Note
to
392
Replace
F
the
camshaft
run
the
camshaft
camshaft
replace
cham
clutch
for
If
necessary
deVtat10n
If
necessary
out
at
ItS
damage
a
dial
0
0079
surfaces
the
the
for
roller
diSC
gauge
sprocket
If
sprocket
thrust
camshaft
damage
the
of
m
replace
of
ring
It
Imks
contact
and
the
gear
exceeds
deViatIOn
wear
clutch
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ring
m
posItion
00039
locatmg
excessive
Replace
surface
Repair
dISC
gear
at
about
Ingine
and
tn
If
It
IS
plate
wear
cham
of
the
or
contact
for
flaw
356
Fig
Fig
47
48
Camshaft
Clearance
Standard
1
Check
sprocket
locatmg
limit
0
0
02
0008
plate
t
0
to
thrust
runout
1
0
to
mm
check
08mm
0
0031
clearance
00039
ASSEMBLY
EM148
m
m
PrecautIOn
Use
thoroughly
make
matter
When
bearings
Use
new
tools
Keep
Keep
hand
Be
sure
and
orders
Cylinder
Assembly
the
Set
the
valve
sure
mstalltng
packmgs
the
to
Head
valve
gUIde
that
be
sure
and
necessary
follow
of
valve
work
sprmg
with
cleaned
011
holes
sltdmg
to
apply
and
benches
specified
and
the
011
seals
parts
valve
seat
011hpseal
parts
are
cleal
parts
engme
clean
and
tIghtemng
sprmg
m
poSItIon
PartIcularly
of
foreign
such
011tothem
tools
near
torque
and
as
at
fit
21
BDgiDe
Note
clear
Make
from
sure
foreign
that
matters
the
valve
face
is
Fig
Fig
Piston
Assemble
rod
every
Notes
connectmg
from
speCIal
49
Valve
installatIon
When
necting
and
b
oil
directed
cylinder
STl
303001
InstallIng
Install
pOSItIOns
EM156
FIX
connecting
Piston
50
pin
installation
Note
and
assorted
cylInder
1
pressmg
the
Arrange
of
Jet
bearings
Clean
a
to
tool
small
the
pIston
P1ston
3
rod
the
toward
block
piston
so
rod
Connecting
piston
accordmg
pin
rod
tightly
tons
must
the
apply
end
the
connecting
connecting
rmgs
and
top
that
the
on
the
cap
the
back
Rod
to
is
and
When
be
used
piston pin
engine
of
the
the
right
second
marks
connecting
side
and
pm
cyhnder
press
fitted
fitting
fitting
into
oil
connecting
rod
rod
large
side
rings
are
faced
of
connecting
number
piston
to
so
upward
rod
the
to
force
pin
the
con
the
rod
that
end
of
In
nght
and
bearmg
for
the
is
pin
the
is
the
the
carefully
28
51
FIg
Assemble
spnng
gUIde
Piston
retamer
and
the
connecting
parts
valve collet
rod
assembly
In
order valve
and
sprmg
valverocker
Engine
the
Set
WIth
Install
and
Locate
ft
Fig52Installing
cyhnder
the
engine
the
retain
plate
lb
valve
by
tightemng
camshaft
block
bottom
hfters
the
on
faced
camshaft
locate
the
Install
torque
plate
workmg
upSIde
the
locate
IS
camshaft
2 9
stand
plate
to
3 6
Bogine
Note
LOWER
tom
side
Set
the
the
cylinder
Notes
bearmg
b
Two
of
the
c
The
as
type
d
All
are
interchangeable
lower
Apply
on
bearings
engIne
both
Set
maIn
a
is
lOner
same
front
the
bearings
sIdes
the
mark
bearIngR
block
The
a
flanged
bearmgs
type
bearmg
rear
OIltothe
of
the
locate
comes
center
bearmg
except
cyltnder
on
type
No2and
No
between
mam
plate
to
theIr
bearmg
for
No
for
bearIng
block
the
1
thrust
IS
5
No
so as
engine
posItIOns
No
No
the
I
bearing
upper
surfaces
and
cap
force
4
same
bot
are
and
the
Install
Install
bolts
on
Tlghtemng
3
36to43ftIb
Notes
arrow
toward
b
bolts
posItIon
axial
c
in
wardly
d
ascertam
easily
Make
correct
the
the
with
a
mark
Prior
place
direction
Tighten
separatmg
After
rotated
sure
crankshaft
mam
specified
torque
Arrange
the
to
by
the
from
securing
that
on
front
tightening
the
shlftmg
bearmg
two
the
that
bearmg
torque
the
the
of
the
bearing
to
center
the
the
the
crankshaft
cap
parts
bearing
engine
the
cap
three
bearing
bearing
crankshaft
and
cap
the
cap
crankshaft
bolts
stages
tighten
so
that
bearing
at
a
gradually
and
cap
end
IS
proper
can
play
faced
in
bolts
the
the
cap
the
out
be
IS
Fig
Fig
53
54
Mam
Crankshaft
bearing
end
caps
play
check
Crankshaft end
0020
nstalI
to
the
0
rear
the
and
o
I
Install
washers
torque
Tlghtemng
47to54ftIb
piston
the
rod
a
Rotate
the
Notes
corresponding
b
c
on
Apply
Arrange
the
engine
piston
engine
d
Install
avoIdIng
aXial
pIn
piston
to
directIOns
0059
011
flywheel
tighten
torque
engine
assembly
Insert
pistons
IS
fit
them
play
In
seal
securely
a
quarter
the
cyhnders
oil
to
so
faced
rings
In
the
parts
at18Y
the
that
to
bolts
turn
pistons
as
the
thrust
USIng
with
required
the
front
to
and
F
each
and
the
lock
specIfied
mstall
in
the
mark
of
the
other
pIston
27
Bagine
Fig55ApplYing
adhesive
Note
Arrange
necting
bers
are
Install the
Tlghtenmg
1
to
23
Make
large
Big
00079
Install
end
275ft
sure
end
play
to
the
temporarily
by
usmg
Install the
sprocket
Camshaft
29to35
rod
caps
faced
connectmg
torque
lb
that
correct
IS
0
0118
camshaft
for
adJustmg
tlmmg
sprocket
ft
lb
connecting
so
that
toward
rod
end
play
and
adjustment
washers
cham
tlghtemng
the
the
same
cap
of
the
crankshaft
of
rods
cylinder
direction
connectmg
the
tooth
and
torque
and
con
num
sprockets
height
camshaft
rod
L
and
installation
connecting
rod
assembly
0
installation
FIg58Connecting
59
Big
Fig
end
play
rod
check
cap
installation
FIg56Flywheel
c
57
Piston
FIg
281
dIfference
HeIght
AdJustmg
tluckness
washer
Bogine
that
the
and
located
of
camshaft
crankshaft
both
its
mating
crankshaft
and
tighten
of
43
down
at
to
the
the
58
Notes
less
III
than00197
sprocket
sprocket
dowel
m
0006
ward
b
marks
sprocket
right
Install
the
ft
Install
Set
Ib
a
hole
the
hand
the
tenslOner
the
Check
key
timing
meet
and
tlmmg
crankshaft
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Make
dowel
side
temloner
and
with
bolts
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are
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to
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sprocket
tenslOner
torque
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projection
60
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Fig
e
8
Fig61Settmg
r
f
0
Wear
limit
sprocket
tooth
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Spindle
projection
t
a
IT
Match
mark
Tlsnaft
1
hol
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cham
0
k
Matohma
0
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Key
groove
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63
Carn
sprocket
gear
mstallatlon
Fig
tt
f
I
I
l
r
I
4
Cham
62
tensloner
Installation
Fig
64
Checkmg
the
tension
spindle
projection
21
BDgiDe
Install
front
the
Install
agent
front
cover
to
the
the
both
cover
new
011
front
011
seal
disassembled
IS
surfaces
seal
cover
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should
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be
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cover
replaced
the
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when
seahng
The
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and
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on
cyhnder
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for
the
head
bolt
center
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one
IS for
uses
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nght
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center
the
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all
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posItIOns
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a
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of
in
SIde
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mark
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Side
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heet
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to51
36
Install
the
gasket
Apply
seahng
gasket
tlOns
of
011
pan
2 9
to
4 3
Invert
head
assembly
Note
cylinder
It
on
gasket
Tighten
peclfied
torque
ft
lb
the
ot
especIally
the
011
pan
tlghtemng
ft
lb
the
engine
Apply
block surface
and
apply
top
the
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strainer
agent
on
torque
and
gasket
sealing
cylinder
Sealmg
on
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and
sealing
and
agent
both
front
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agent
Place
head
the
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surfaces
and
the
overall
agent
bolts
not
pan
rear
the
required
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of
the
por
cyhnder
the
gasket
to
the
to
the
v
Bolt
number
j
lor
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u
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CD
65
Head
FIg
Fig66Tlghtenmg
bolt
O
segment
sequence
rmg
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L
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tl
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30
Cylinder
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sheet
Remarks
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Be
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because
WIth
WIthout
thIS
sealing
J
applymg
not
SIde
agent
to
has
damage
sealing
the
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push
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head
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gasket
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be
mto
hole
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