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Sunny 1972
User Manual
224 pgs15.62 Mb0

Nissan Sunny 1972 User Manual

SCIENTIFIC
PUBLICATIONS
WORKSHOP
WITH
REPAIR
MAINTENANCE
DATA
SPECIFICATIONS
AND
MANUAL
SE
IES
No
87
1000
1
Z
1
COVERING
AIO
STATION
SEDAN
PICKUP
AI2
ENGINE
WAGON
r
SCIENTIFIC
WORKSHOP
DATSI
MANUAL
TN
PU
14M
LICATIONS
SERIES
1
O
00
No
87
I
c
seIE
WORKSHOP
DATSUN
SERIES
AUTOMATIC
SEDAN
I FIe
MANUAL
and
PUBLICATIONS
1000
OIO
WAGON
MANtJAL
SERIES
No
1200
0110
PICK
TRANSMISSIONS
UP
87
Repair
SCIIL C
With
and
PUBUCADONS
Speelfieations
Maintenanee
S
Data
MELBOURNE
Published
142
Oarence
Copyright
Registered
Printed
at GPO
Scientific
by
Street
by
New
by
Sydney
Sydney
Kenmure
South
Scientific
Publications
Publications
for
transmission
2000
Press
Wales
New
Ply
Ply
South Ltd
Pty
by
post
Ltd
Wales
Ltd
book
as
a
National
First
Library
Edition
SBN
Australia
of
85566 038
January
1972
Registry
4
Number
Scientific
Corp
USA
CK
Publications
and
Borg
aspects
OWLt
Warner
of
preparing
wishes
UC
to
Lid
this
E
IE
thank
Fairfield for
manual
T
Nissan
Motor
help
in
J
EXGIXE
7
COOLING
FUEL
CLUTCH
MANUAL
AUTOMATIC
REAR
STEERING
FRONT
RE
R
BRAKES
ELECTRIC
BODY
WHEEL
LUHIUCATION AND
SYSTEM
SYSTEM
TRANS1UISSION
AXLE
SUSPENSION
SUSPENSION
L
AXD
TIlANSMISSION
SYSTE
TYRES
MAINTENANCE
103
126
131
148
184
195
200
28
14
47
57
73
85
I
ll
EMISSIOX
IXDEX
GLOSSARY
ROAD
TEST
CONTROL
TERMS
OF
SYSTI
MS
211
lIlt
217
20
1
Car
Austin Austin
A
Complete
Datsun
Datsun
Dodge
Ford
Ford
Ford
Ford
Ford
Ford Ford
Ford
Ford
Ford
A40 A40
utoServ
1100 1800
1000
510
1400
ASM
Capri
and
1600
Consul
Mk
I
1951
Mk
II
Cortina
1500
Customline
Custom
Customline
EscortI100
BOO 1300
Falcon
XW
6
Falcon
XW
V8
V8
I BMC
1600
1956
1600
and
Mercury
Hillman
Holden
Holden
Holden
Holden
Holden
Holden Torana
HC IHC
IHC
Jaguar
Jaguar Jaguar
North
Arrow
FE EH
V8
V8
6
cyl
1969
Trucks
Trucks Trucks
IX XK
150
and
South
United
Hunler
HB
1948
FC
EJ
FE
HI
and
HK
Engine
HK
Engine
Brabham
Mks
24 34
II
3 842
Africa
Kingdom
America
Devon Somerset
1300
1600
GT
Zephyr
ConsulZephyr
1949
XK
cyl
XR
1932
FB
HD
FC
Series
6
HT
HT
AR
AS
AA
VII 20
3 8
1200
106
1200
GT
HC
53
cyt
Mk
Mini
55
62
54
OHV
to
to
48
FJ
EK
HR
FB
HG
HG
S
SL
AL
line
line VIII
140
Mks
E
Central
Autobooks
Repco
II
Bool
No
I
Alltech
00
1
50
7L
87
88
6
82
7
8
68
10
9
81
62
63
11
79
67 16
75
85
86
72 17 18
19
21
22 77
News
Auto
OTHER
PUBUCATIONS
s
Pag
of
Text
106
99
294
431
224
256 464
173 108
153
184
288
166
121 107
184
290
238
122 132
188
286
80 82
287
272 215
224
191 120
437 657
173 595
274
274 202
Agency
Distributors
2900
Parts
TITLES
IDo
Indiom
89 84
48
315
208
241 517
85
124
192
193
172
188
155
121
128
197
188
245
1040
237
281 124
OVERSF
Ltd
15
W
Magnolia
Doylestown
Laub
High
Price
Aus
1
2
7
9
6
6 2
5
1
6
3
5
7
6
3
5
Penn
IN
THE
B
t
20 30
00
00
25
50
80
75
20
3
50
25
1
20
50
75
00
25
50
75
7
00 85
1
7
00
7
00
25
6
6
25
3
50
1
40
3
50
7
00
00
7 6
25
AS
REPRESENTATIVES
Street
New
St
Hampton
Burbank
Blvd
os
I
SCIENTIFIC
NUAI
Lawn
Kirby
Morris Morris Morris Austin
SERIES
Car
Mowers
4
Minor
Minor
Cooper
Mini
1100
Morris Austin Morris
Morris Austin
MG MG
Peugeot
Renault Renault
Renault Rootes
Standard
Toyota Toyota
Mk
Mk
Midget
Series
TF
Humber
1958
Simca
1200
1939
Standard Standard
master
Standard
Toyota
Austin I
I
Mk
MGA
403 404
750f760
Dauphine
R8
Group
66
Aronde
1300
46 40
Corolla Corolla
Corona
Triumph
VE
AP6
VF
HB
AP
VF
R VC VE
6
cy
90
Valiant
Valiant
Vauxhall Viva
Volkswagen
1600
Volkswagen
1200A 1300
Volkswagen
Transporter
Wolseley
Production
In
t
Recommended
Centre
Angeles
Johannesburg
Middlesex
California
Calif
Vieta2Stroke
Stroke
MM
1000
Mini
and
S
Moke
1100
1800
1800
II
Series
TC TD
MGB
and
Hillman
Husky
Elysee
8
14
10
1955
Space
Series
Vanguard
11
1200
TR2
3
6
VC
V8
Engine
AP5
S
Engine
HA
1500
1100
1500
91503
Toronto
RIO
11
1500
Book
No
100
II
23
24
64
65
66
66a 224
29
TO
70
31 33 79 98
34 74
Cob
36
37
41
58
42
III
43
73
00
93
83
4
44
69
78
76
47
1200
46
48 49
retail
price
10799
Ontario
Pages
of
Text
80
142
96 96
236
145
138
90
304 204
121
133
164
390
113
81 51
147
125
184 176
224 167
174
279
200
224 160
224 204
256 202
100
in Australia
Vancouver
trntiollS
89
161
187
106
95
174
106
171
158
399
121
134
105
149
107
175 130
145
140
Dlu
s
Price
AusLt
1
40
2
30
3
50
6
25 75
5
75
5
25
6 2
30
7
00
75
3
1
00
4
00
97
5
75
00
7
75
3
00
1
1
75
3
00
5
75
5
75
00
6
5
25
95
6
25
25
6
75
5
25
6
6
25
25
6
66
Be
1
00
Type
Bore
Stroke
AIO
engine
A
12
engine
Capacity
A
I
0
engine
A
12
engine
Compression
AIO
engine
A
12
engine
Maximum
Bhp
AIO
engine
A
12
engine
Maximum
AI0
engine
A
12
engine
order
Firing Idling
speed
Type
Gasket
face
Valve
seat
Inlet
Exhaust
Valve
seat
in
head
Inlet
Inlet
Exhaust
Exhaust
Cylinder
guide
tandard
ratio
torque
distortion
material
insert
recess
standard
insert
replacement
standard
replacement
head
bore
guide
CYLINDER
limit
diameter
insert
insert
insert
diameter
ENGINE
SPECIFIC
4
cylinder
line
73mm
2
874
in
OHV
in
59mm
2
323
in
70mm
2
756
in
988
cm3
3
in3
60
1171
em
71
5
in3
85I
90
1
HEAD
56at6000
at
68
8
50
4000
@
61
5
@4000
70
9 @
3600
70
@
3600
134 2
600
Aluminium
O
IOmm
0
004
rpm
6000
rpm
m
kg
rpm
ft
lb
rpm
m
kg
rpm
ft
lb
1
rpm
rp
alloy
in
Aluminium bronze
iron
Cast
37
37
14770
33
33
for
valve
12
37 00
016
14573
516
14567
37
14763
33
016
1
1
3195
1
2998
516
1
3190
12
011
0
472804724
50
00 2992 3350
00
mm
mm
mm
mm
mm
TIO
Valve
Valve
Valve
S
Replacement
seat
angle
width
seat
Inlet
Exhaust
seat
insert
guide
outer
diameter
12
450
0
1
0
1
30
211
0
4807
mm
0512
80mm
p709
12
200
mm
0
4800
in
in
in
standard
37
080
Inlet
I
33
30
Valve
Exhaust
Inlet
seat
insert
inner
diameter
1181
Exhaust
Valve
Inlet
Insert
Valves
Head
seat
and
interference
diameter
exhaust
insert
exhaust
V
ALVES
depth
fitinhead
inlet
GUIDES
AND
26mm
605
0
0
0
SPRINGS
35mm
1
378
29mm
0
diameter
Stem
Overall
Stem
Inlet
Exhaust
Valve
A10
in
in
A
Valve
Inner
in
in
to
guide
lift
engine
12
engine
guide
diameter
Outside
Interference
length
clearance
diameter
fitinhead
Length
in
8
103
4
0
0
0
7
8
12
0
53mm
37
460
459
1
080
33
1
3021303
1O
mm
to
to
1
023
in
90
mm
2362
0
096
064
0
0025
in
142
in
70869
0
342603430
5
104
4 0984
0750
0150045
000600018
0400070
0
001600028
80
mm
0
3071
in
mm
7
50
2953
in
0
0158000
0
315503150
044
12
0
4740
0220044
0009 0
0
in
2
087
096
096
004in
0
0038
mm
0
4737
0017
2323
1
033
mm
iri
mm
in
in
mm
in
in
mm
in
mm
in
mm
in
mm
in
mm
in
mm
in
7
2
Engine
Fitted
Valve
spring
Free
length
Fitted
Number
Wire
Coil diameter
Rocker
Hot
Cold
PISTONS
Pistons
Type
Piston
Skirt
I t
oversize
oversize
2nd
oversize
3rd
oversize
4th
5
th
oversize
oversize
6th
Piston
Piston
Width
oil
Side
clea
Ung
height
length
of
diameter
arm
fit
diameter
to
cylinder
rings
compression
con
trol
ance
gap
above
and
effective
to
valve
PISTON
in
25
50
75
100
125
150
grpove
spring
load
coils
stem
standard
mm
mm
mm
nun
mm
nun
bore
seat
clearance
RINGS
clearance
AND
18mm
0
709
45
7
I
7992
38
5
@300
1
516
@66
4
5
4
276
0
1693
26
224
0 0324
03
5
0
0138
0
25
0
0098
GUDGEON
Slipper
cast
alloy
Selective
72
967
2
872728747
217
73
2
882628845
73
467
2
892428944
73
717
2
902229042
73
967
2
912129140
74
2
92 1929239
74
467
2
9318
0
0230043
0
0009
2
00
0
0787
4
00
0
0
04
0
001600027
0
20030
007900ll8
0
in
mm
in
mm
kg
in
llb
mm
in
mm
in
mm
in
mm
in
PINS
skirt
aluqlinium
73
73
73
73
74
217
74
74
mm
in
mm
in
1575
0
07
2
0
0
267
767
017
9337
0017
mm
mm
517
297
517
nun
6548
mm
0
0003
in
mm
13
0
00
in
mm
in
Clearance
Interference
Length
With
pistolJ
in
at
piston
fit
a
CRAN
SHAFT
in
connecting
temperature
AND
rod
of
MAIN
200C
0
0060008
0002
10
0
0170034
0
0007
23
65
2
568125779
680F
BEARINGS
Crankshaft
taper
ring
be
wear
wear
bearing
diameter
taper
rod
engine
bearing
float
bearing
A
wear
diamet
run
10
float
Main
journal
Journal
Main
Clearance
CrankShaft
End
float
End
float
Main
7
nun
in
nun
in
mm
in
nun
in
riun
in
nun
in
nun
in
in
rankpin
Crankpin
CONNECTING
Connecting
Lergth
AI2
end
Big
end end
Big
End
end
Big crankpin
in
in
Connec
rod bent
ing
CAMSHAFT
or
ovality
clear
l
out
limit
thickness
or
engine
thickness
limit
clearance
r
ce
it
ovality
ROD
or
limit
wear
wear
limit
AND
BIG
on
misalignment
AND
BEARINGS
49
I
0
0
0
0
10
0
44
0
END
964
49
9671
03
mm
in
0
0012
020
0
0
0008
5mm
0
0
1
116
121
1
0
0
0
in
0059
015
0
000600020
0 15
05
0020 0 0059
0
30
mm
in
0
0118
835
1
0
0722
44
974
I
770617701
03
mm
0
0012
in
BEARING
97
4
9051
47
4
782247846
5001508
0591
0
20
0
30
0
007900012
0
40
mm
in
0
016
020
0
0
0008
05
010
0
0020
957
1
9668
062
0
0024
050
mm
827
00719
117
4
6188
121
0 0594
mm
050
0 0020
0
nun
nun
mm
961
3
53
mm
mm
mrn
0039
mm
in
in
in
in
in
mm
in
mm
in
mm
in
in
in
in
in
Gudgeon
Diame
er
pin
GUDGEON PIN
17447
0
6869
17452mm
0
6871
Camshaft
bearing
journal
No
No
2
in
diameter
43
I
43
7241
1
7040
283
793
43
806
mm
in
1
7246
43
296
mm
in
1
7046
8
No
No
No
Camshaft
Journal
Bearing
No
No
No
No
No
Type
Oil
pump
Filter
Oil
pump
Side
rotors
Clearance
Clearance
Relief
Free
Fitted
Relief
3
4
5
run
to
inner
1
2
3
4
5
type
type
clearance
valve
leilgth
length
pressure
out
bearing
diameter
outer
rotor
spring
clearance
LUBRICATION
inner
rotor
end
to
and
and
cover
outer
body
42
78342796
1
6844
42
283
6647
I
41
218
1
6228
0
61
0
0
0004
0
0240065
0
000900026
843
43
17261
43
333
7060
I 42
846
1
6868
42
333
1
6667
41
268
1
6247
Full
pressure
Eccentric
trochoid
Full
flow
65
0
0
0
0020
0
15
0 21
0
0059
0
12mm
0
0492
4349
mm
71
in
I
3030
mm
19
in
I
3
4
80
54 0 59 70
mm
1
6849
42
296
rom
6652
1
41
231
6233
1
IOmm
0039
0
mm
43
833
17257
43
323
7050
1
42
836
6865
1
42
323
1
6663
41
258
1
6243
motor
mm
12
0
6047
mm
0
0083
in
26kgcm2
psi
IiI
in
mm
in
in
in
mm
in
mm
in
mm
in
nim
in
mm
in
in
in
Capacity
With
new
filter
Less
TORQUE
Comiecting
A10
Al2
head
engine
engine
bearing
bol
pump
strainer
chain
pedestal
release
Cylinder
Flywheel
Main
Camshaft
Camshaft
Sump
Oil
Oil
Crankshaft
Timing
Rocker
Mainfolct
Pump
filter
nuts
rod
bolts
bolts
cap
sprocket
locating
ts
attachment
bolts
pulley
tensioner
bolts
valve
WRENCH
bolts
bolt
plate
bolt
bolts
plug
bolis
bolts
bolts
SETTING
t
3
20
litre
2
75
337US qts
270litre
2
37
2
87
MAXIMUM
3
6
kg
ft
26
4
80
kg
34
70
3
00
kg
50ftlb
7
7
50
kg
5420
5
30
kg
3830
4
50
kg
32
50
0
50
kg
3
60ftlb
0
60
kg
430ft
1
50
kg
80
I0
1
40
kg
10fttb
10
16kg
116ftlb
0
80
klilm
5
80
2
50
kg
8
10
I
1
40
kg
10
10
5
00kgin
36
20
Imp
Imp
US
m
lb
ft
m
ft
qts
m
lb
in
m
lb
tt
m
ft
lb
m
ft
m
in
lb
m
ft
in
lb
m
ft
ni
ft
ft
Engine
3
qts
qts
lb
lb
lb
lb
lb
The
four
alloy
cylinder
cast aluminium
valve
has its
rod
and
rocker
Pistons
compression
is
ring
taper
lower
chrome
The
gudgeon
cylinder
block
alloy
individual
arm
are
slipper
rings
faced
faced
overhead
and
with
port
the
from
skirt
and
orie
and
t
steel
isaninterference
pin
crankcase
replaceable
and
camshaft
aluminium
oil
ring
oil
e
ring
segment
valve
The
is
operated
The
comprises
with
engine
cylinder
valve
alloy
lower
a
spacer
fit
in
hasacast
guides
a
by
tappet
type
compression
an
the
smail
I
head
upper
in
is
Each
push
with
between
end
iron
two
and
of
of
DES
9
RIP
i
lON
comi
the
gudgeon
The
AIO main main
Connectirig
copper
Pistons
the
cylinder
engine
cting
pin
crankshaft
or
five
bearings bearing
lead
rod
and
in
the
assembly
AI2
Crankshaft
rod
replaceable
are
marked
bore
size
is
big
this
counter
steel
end
shells
on
which
is
the
balanced
backed
end
floatistaken
bearings
the
crown
must
only
copper
withacode be
means
are
to
and
split
of
lead
the
retaining
funs
split
the
at
steel
number
front
in
centre
backed
of
the
three
shell
of
the
4l
Driven
The
squirt
and
engine
Engine
Side
View
Connecting
ends
big
hole
on
oil
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Withdraw
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ring
cap
in
a
the
that
head
are
the
old
new
ensure
available
holesateach
assembly
the
cylinder
head
the
two
cylinder
rhe
cylinder
head
on
a
suitable
evenly
See
push
if1t
does
this
cylinder
paste
instal
position
a
new
the
valve
seat
compressor
to
are
all
washer
head
coating
eight
shroud
subjected
the
applyalight
and
in
the
instal
on
spring
collets
the
the
seated
the
and
manner
spring
valve
the
faces
collets
in
stem
instal
split
of
clean
Hold
of
seal
above
similar
gasket
perfectly
gasket
gasketinposition
that
all
bolt
and
screw
a
guide
endofthe
head
This
the
gasket
head
bolts
guide
head
head
bolt
right
torque
and
is
into
finger
if
pins
bolts
finger
boltsismarked
must
hand
side
wrench
progressively
Specifications
rods
ensuring
show
not
comparison
ensUre
removed
valves
from
guide
upper
valve
compress
in
the
in
compressor the
spring
with
it
in
collets
the
cylinder
and
on
water
into
pin
cylinder
marked
position
tight
used
tight
be installed
rhe
of
to
in
the
that
each
collapse
from
of
oil
ensuring
which
type
spring
recess
position
retaining
the
the
receSS
Assemble
free
the
circulation
one
and
and
instal
engine
tighten
the
specified
order
is
in
test
that
all
the
the
to
it
was
seal
on
end
by
and
the
in
the
and
Ensure
end
of
in
block
of
any
cylinder
of
the
block
TOP
to
instal
the
wirh
at
the
the
shown
replaced
a
14
in
the
location
seats
rod
on
bolts
time
7
the
8
correctly
Position
cylinder
finger
Tighten
evenly
Specifications
9
Turn
normal heel
arm
starting
be
temperature
manifold
gasket
catbureltot
pipe
distributor
spark
unit
two
necessary
from
start
and cleatance
screws
the
leaks
TO
attained
rotation
stroke rocker
cylinders
one
of
its
and
ch
cked
10
11
between
12
plugs
13
on
14
hose
15
the
I6
the
temperature
check
17
securely
18
rocker
ADJUST
I
2
3
and
to
4
5
valve
turn
and
remaining
6
totation
cam
the
point
Refit
gasket
Connect
Clean
Connect
the
Instal
clips
Fill the
using
engine
Connect
and
see
Re
cover
Run
the
Remove
Turn
until
valve
Using
adjust
To
is
check
valves
Refit
from
in
the
head
tight
the
and
progressively
the
engine
until
and
adjust
valve
for
valve
wheQ
the
inlet
and
the
and
the
the
distributot
adjust
and
cap
and
the
ignition
the
front
of
the
the
upper
cooling
the
previously
the
engine
switch
if
necessary
Specifications
the
instal
the
Inst
ait
start
VALVE
the
engine
normal
operating
the
the
crankshaft
I
No
both
adjust
stem
the
same
the
check
the
fully
open
the
in
the
the
rocker
it
which
its
tappet
rocker shaft
and
instal
rocker
pedestal
crankshaft
each
valve
the
stem
See
adjustment
the
engine
and
exhaust
temporarily
fuel
fuel
pump
and
and
instal
connect
coil
wire
to
cylinder
tadiator
system
and
water
earth
and
bring
off
the
engine
adjust
rocker
cleaner
the
engine
CLEARANCE
at
air
cleaner
cylinder
rocker
clearance
procedure
six
other
adjustment
then
clearance
same
manner
cover
was
removed
and
the
rocker
to
the
tappet
clearance
Specifications
and
is
fit
delivery
and
the
catbureltor
the
the
high
the
tempetature
head
hose
anti
freeze
lead
to
it
to
remove
the
cover
and
pipe
and
a
fast
idle
temperature
and
rocker
in
the
at
is
tde
anns
fot
tockers
turn
turn
a
for
air
and
and
tocker
ann
pedestal
boltsafew
specified
in
the
direction
is
exactly
between
the
c1eatance
at
normal
manifolds
the
r
ket
between
pipe
the
vacuum
plugs
spark
tension
gauge
secure
and
with
clean
mixture
the
battery
nonnal
the
rockertovalve
and
tighten
from
the cleaner
run
to
check
speed
covet
normal
the
on
to
fUtther
this
cleaner
give
the
the
valve
the
remaining
crankshaft
one
that
each
assembly
securing
turns
at
the
This
on
tocket
see
the
is
torque
should
opetating
a
new
using
cover
and
the
advance
the
fit
leadstothe
sender
with the
water
drained
tenninal
operating
rocker
cover
stem
six
the
for
it
until
has
direction
compression
specified
three
until
complete
Check
the
a
of
a
if
to
oil
of
Engin
9
REMOVE
TO
With
I
the
drain
plug
2
3
rear
discard
4
the
washers
old
5
ensuring
6
and
Progressively
Remove
Remove
bearing
Clean
gasket
Clean
Using
Replace
spring
strainer
the and
of
seals
compound
the
cylinder
REMOVE
TO
1
vlith
the
water
pump
2
Take
withdraw
suitable
the
3
container
AND
the
and
tighten
securing
cap
the
the
that
a
position
block
the
and
out
crankshaft
Remove
ihe
INSTAL
engine
drain the
the
the
and
sump
removed
are
gasket
all
small
a
engine
fan
the
and
removed
plug
loosen
the
sump
side
the
thoroughly
traces
new
assembly
pulley
sump
remove
the
oil
and
slimp
lifting
gasket
lower
face
of
o
quaniity
gasket
rerrloved
retaining
drain
the
from
into
remove
to
the
it
and
edge
the
the old
on
from
plug
sump
the
vehicle
a
suitable
all
crankcase
clearofthe
end
the
of
the
ensuring
crankcase
gasket
of
suitable
the
crankcase
6
TIMiNG
the
vehicle
and
bolt
drain
d
the
seals
timing
that
and
are
washer
the
ENGINE
remove
container
bolts
oil intake
around
cover
all
traces
the
removed
sealing
face
remove
into
oil
and
end
of
HAIN
and
J
a
SUMP
NOTE
or
have
restore
7
ends
of
an
form
8
instal
and
position
9
tight
10
evenly
up
firmly
the
or
drain
plugistight
AND
4
engine
the
of
5
to
the
tehsioner
NOTE
stem
and
spring
6
clock
o
adjacent
marked
15
12
the
camshaft
7
washers
the
camshaft
chain
sprocket
With
new
shrunk
them
to
Place
the
the
seals
oil
tight
Carefully
two
Instal
the
Using
and
progressively
against
on
flange
ieUV
Remove
the
timing
withdra
Remove
crankshafi
Unscrew
of
front
Use
care
will
be
when
the
Rotate
and
the the
to
link
plate
clock
and
sprocket
Remove
and
using
from
disengaging
cork
a
their
end
mate
joint
place
three
or
remainder
suitable
a
the
the
before
K
the
the
the
the
when
forced
bolts
the
timing
marked
adjacent
the
crankshaft
on
a
the
gaskets
minutes
few
norma
length
seals
in
with
the
the
sump
sump
sockei
a
few
gasket
will
sump
filling
remaining
chain
cover
oil
slinger
two
bolts
cylinder
removing
out
are
moved
mark
link
the
chain
to
camshaft
suitable lever
the
top
and
chain
that
appear
immersed
position
ends
in
position
retaining
the
of
bolts
wrench
tums
Do
not
be
distorted
with
oil
bol
from
if
fitted
securing
block
and
the
the
tensioner
of
until
the
the
on
on
plate
will
the
timing
sprocket
remove
from around
and
of
the
bolts
and
tighten
to
each
over
tighten
ts
and
the
from
the
remove
tensioneras
sprocket
crankshaft
chain
the be
at mark
retaining
the
prise
the
to
be
too
small
in
water
ensure
that
side
gasket
the
on
gaskets
to
hold
finger
tighten
the
bolts
the
pull
Ensure
the
that
sump
bolts
washers
of
front
the
front
tensioner
chain
the
chain
B
the
by
body
is
key
sprocket
The
other
approximately
dimple
bolt
sprocket
sprocket
ihe
crankshaft
will
the
it
the
and
the
end
pad
the
at
and
and
to
in
4 is
on
off
Timing
Cover
showing
Timing
Chain
Damper
Pad
TO
INSTAL
the
0
the
traces
all
pump
camshaft
clock
crankshaft
clock
0
of
body
position
position
the
and
until
in
until
old
sump
the
relation
the
Clean
1
gasket
2
Check
sprocket
to
3
Check
sprocket
from
the
all
components
the
and
locating
centre
and
drive
if
if
key
timing
necessary
dowel
of
the
necessary
in
cover
is
camshaft
the
and
at
shaft
rotate
the
rotate
remove
waier
4
isat4
15
SPROCKET
lQ
Engine
RETAINING
SPRING
1
WASHER
BOLT
WASHER
t
TIMING
CHAIN
4
RETAIDlER
PLATE
WASHER
Showing
in
relation
4
i
and
shaft
dowei
5
timing
dowel
6
that
one
the
sprocket
The
second
the
short
With
3
will
and
uy
mark
hole
Loop
of
chain
Limit
Wear
to
the
centre
camshaft
the
abovealine
also
pass
the
crankshaft
the
camshaft
dimple
will
be
the
the
two
adjacen
marked
run
Tensioner
through
to
4
at
timing
marked
t
to
chain
for
of
drawn
key
sprocket
the
0
clock
chain
the
Timing
Pad
the
crankshaft
and
the
top
link
sprocket
link
plate
Wear
crankshaft
through
centre
flat
arid
facing
on
the
plates
must
Chain
the
on
camshaft
of
timing
Stretch
positioned
centre
of
the
a
bench
The
up
sprocket
chain
the
mark
betothe
as
each
of
camshaft
with
locating
engages
right
and
the
on
in
so
dimple
NOTE
plates
apart
marked
7
and
position
the
crankshaft
the
chain
the
crankshaft
8
locating tighten
9
register
10
cylinder
is
to
the
II
is
cover
12
lipped
the
oil
crankshaft
3
i
procedure
Fit
Do
TENSIONER
Camshaft and
The
liming
on
the
plates
the
Grasp
it
on
sprocket
is
link
sprocket
Push
the
the
correct
Instal
lnstal
specified
that
the
ensuring
dowel
to
Check
for
block camshaft
that
Check
serviceable
Instal
a
of
face
slinger
the
if
pulley
Further
with
attention
new
gaskets
not
over
tighten
BODY
fE
NSIONER
Timing
clwill
shortest
camshaft
camshaft
the
so
adjacent
camshaft
the
torque
both
valve
chairi
that
sprocket
the
and
renew
oil
new
seal
towards
fitted
installation
where
lillk
that
to
illustration
see
sprocket
securing
sprocket
timing
tensioner
side
seal
with
to
necessary
the
sump
SPRING
SUPPER
Chain
plale
chain
sprocker
looping
the
the
timing
see
Specifications
the
long
tensioner
if
excessively
the
in
the
the
concave
a
is
the
following
retaining
0
HEAD
Components
marks
run
This
engaged
the
second
mark
on
to
and
bolt
and
chain
on
the
end
of
pad
timing
timing
reversal
circles
includes
in
chain
mark
fully
washers
timing
front
the
in
worn
cover
sprocket
towards
face
the
of
bolts
are
the
chain
around
circle
dimple
engage
minks
faceofthe
slipper
the
timing
with
Instal
removal
rell
the
on on
the
and
pad
the
the
TO
the
cover
REMOVE
With
I
water
pump
the
engine
and
fan
removed
assembly
from
and
7
C
AMSHAFT
the take
vehicle
remove
the
off
rocker
ND
securing
assembly
crankshaft
TAI
2
3
PETS
Evenly
bolts
Take
pulley
and
progressively
and
out
the
remove
retaining
the
loosen
rocker
bolt
the
and
rocker
arm
withdraw
pedestal
and
shaft
the
16
r
Checking
4
5
timing
oil
tlie
Slinger
6
the
to
tensioner
NOTE
and
stem
when
spring
7
washers
the
camshaft
chain
sprocket
8
Camshaft
Drain
the
Take
oui
chain
cover
from
Unscrew
front
of
Use
care
will
be
the
Remove
and
using
from
disengaging
the
Turn
engine
the
the
when
forced
bolts
the
End
the
from
the
two
cylinder
are
eamshaft
a
suitable
the
the
engine
Float
and
oil
remaining
the
endofthe
front
bolts
removing
out
removed
and
top
chain
so
remove
bolts
front
of
securing
block
and
the
the
tensioner
of
sprocket
lever
prise
remove
from around
that
the
and
the
engine
crankshaft
the
remove
tensioner
retaining
the
the
the
sump
withdraw
chain
as
bodv
sprocket
sprocket
the
crankshaft
crankshaft
Remove
tensioner
the
the
bv
bolt
the
chain
pad
the
and
and
ll
Engine
clear
of
uppermost
and
press
each
tappet
down
well
the
camshaft
two
of
remove
to
the
order
a
press
to
small
camshaft
bolts the
the
the
block
the
three
the
retaining
damage
cams
the
special
ne
the
the
engine
vacuum
and
plate
oil
bolts
two
the
the
for
camshaft
bearings
cor
quantity
fuel
delivery
and
remove
distributor
remove
and
pump
and
retaining
plate
plate
camshaft
the
Remove
reassembly
screw
ect
size
bearing
pipe
the
withdraw
and
withdrawing
clear
camshaft
the
bearings
press
into
and
of
sealing
bore
9
Disconnect
out
hand
10
disconnect
II
the 12
the crankcase
13
the
14
care
sides
their
correct
5
using
bearing
using
the
of
the
side
Remove
Unscrew
retaining
cylinder
Remove
the
Remove
camshaft
and
Withdraw
not
of
Check
and
a
rear
take
right
leads
unit
oistributor from
unscrewing
from
slide camshaft
using
sharp
in
off
excess
bearings
new
plug
is
end
pipe
the
cap
at
tilter
bolts
from
position
at
fuel
and
the
iwo
as
the
of
the
bearings
tappets
remove
a
fit
compound
the
pump
vacuum
bolts
the
an
and
cylinder
and
new
fuel
from
high
advance
from
distributor
assembly
the
assembly
washers
groove
with
keeping
if
worn
the
Line
bore
expansion
pump
tension
in
block
them
worn
in
the
the
by
and
the
the
to
the
the
CAMSHAFT
TIMING MARKS
SPROCKET
J
A
r
9
tr
e
l
O
i
wf
1
j
17
12
TO
INSTAL
t
bearings
register
2
cuttings
their
cortect
3
cainshaft
taking
the
cams
4
serviceable
groove
securing
is
preSent
the
right
5
d
owel
i satthe
the
camsHaft
6
e
ii1
tl
of
the
7
5
and
shaft
will
dowel
and
8
the
timing
locating
9
that
one
adjacent
Engine
Check
have
withthe
Biow
out
Apply
positions
Apply engine
rnals
jOlJ
care
not
Chekthe
apply
in
the
camshaft
and
bolts
in
the
of
the
Rotate
4
Rotate
shaft
isat4
crankshaft
Witli
die
6
abovealine
also
the
crankshaft
the
Lay
mark
dowel
hole
the
Loop
of
the
two
to
the
sprocket
thatthe
been
oil
passages
all
engine
and
to
damage
camshaft
a
tighten
camshaft
engine
the
u
clock
the
crankshaft
o
camshafi
pass
cainsh
dimple
will
timing
marked
bearings
installed
oil
ways
oil
to
oil
to
insert
coating
line
firmly
retaining
when
camshaft
position
clock
position
aM
drawn
through
key
ft
sprocket
to
be
at
chain
link
timing
check
in
the to
remove
the
the
the
the
bearings
retaining
of
oil
the
up
If
the
plate
until
in
until
crankShaft
ihrOligh
the
centres
the
top
4
0
clock
on
the
plates
mark
are
block
tappets
bearing
camshaft
plate
and
holes
a
small
plate
is
the
relation
the
in
relation
flat
and
camshaft
engages
dimple
clean and
that
the
casing
dirt
any
and
bores
into
with
for
position
and
instal
lubrication
it
should
correctly
sprocket
io
the
sprocket
to
positioned
the
centre
of
the
a
on
bench
facing
tlce
if
oil
or
fit
them
and
position
the
edges
wear
it
in
tlie
installed
locating
centre
drive
the
centre
of
camshaft
up
sprocket
sprocket
The
second
holes
metal
and
hole
be
as
With
new
two
key
The
the
the
marked
run
NOTE
plates
marked
in
and the
of
chain
on
if
locating
tighten
to
of
register
end
serviceable
lipped
the
in
crankshaft
eac
procedure
in
so
from
clea
link
plate
The
timing
on
apart
plates
10
Grasp
position
it
crankshaft
link
circle
the
crankshaft
11
Push
the
dowel
io
the
Check
for
Instlil
the
slipper
Check
and
Instal
face
slinger
specified
correct
renew
the
of
if
2
t
13
of
14
15
oil
pulley
Further
16
with
attention
Fit
n
w
gaskets
Instal
the
distributor
DISTRIBUTOR
Ensure
that
which
ance
they
after
must
chain
the
the
camshaft
on
the
sprocket
is
sprocket
camshaft
instal
that
valve
the
chain
pad
the
a
new
seal
fitted
installation
where
ELECTRICAL
the
push
were
the
engine
be
to
the
link
plate
shortest
chain
sprocket
camshaft
so
that
adjacent
io
See
sprocket
the
securing
torque
both
see
sprocket
timi1Jg
tensioner
is
the
to
camshaft
side tensioner
if
excessively
oil
sealinthe
towards
with
the
is
to
the
ne
essary
and
time
rods
are
removed
has
right
maries
roll
engaged
looping
the
secdnd
ihe
timing
illustration
on
bolt
Specifications
and
ensuring
sprocket
in
the
worn
timing
the
timing
concave
a
reversal
following
the
ignition
SYSTEM
installed
and
been
brought
on
This
ine
to
fully
and
chain
timing
sprocket
face
of
in
adjust
the
circles
includes
in
chain
mark
mark
washers
timing
that
cover
towards
the
as
the
to
short
are
the
around
on
dimple
engage
marks
ille
cover
with
Instal
removal
described
positions
the
operating
chain
ten
the
chairi
the
the
and
long
is
the
the
valve
temperature
TO
REMOVE
lJ
the
engine
2
3j
the
top
rods
will
4
rods
are
cylinder
the
numbers
5
one
of
bearing
NOTE
policy
cylinder
removing
With
Remove
Turn
of
be
Check
numbered
bore
Release
the
cap
If
to
remove
bore
the
AND
the
oil
aridJemove
the
the
theicylinder ai
the
that
and
and
connecting
and
lower
the
piston
using
piston
DISMANTLE
removed
engine
the
cylinder
cr
lo
any
esipoinls
the
big
with
the
note
remove
half
iings
ridge
a
suitable
and
mkstf
ift
bores
end
the
side
rods
shell
are
around
connecting
8
sump
pead
ntil
The
ih
bearing
number
the
and
bearing
to
ridge
PISTONS
from
as
previously
iwd
two
the
engine
of
of
the
end
big
withdraw
be
the
removing
rod
ihe
of
the
other
caps
the
engine
bearing
reneWed
upper
assemblies
AND
vehiCle
described
are
pistons
connecting
and
connecting
corresponding
adjacen
nuts
the
big
it
is
end
of
tool
before
drain
t
end
good
the
from
at
to
on
CONNECTING
the
cvlinder
from
getting
6
the
cylinder
Remove
like
manner
7
assembly
8
old
piston
the
piston
9
ring
grooves
or
lands
Correct
scraper
10
crown
using
II
18
into
Push
the
other
Replace
it
as
If
new
rings
skirt
Clean
base
section
Remove
care
Do
bore
the
the
connecting
and
the
is
removed
piston
from
or
all
carbon
taking
the
of
width
not
not
press
RODS
This
crankcase
remove
piston
big
ring
care
the
to
and
eno
rings
the
lands
grooves
used
carbon
score
the
will
rod
from
connecting
liearing
arid
instal
are
pistons
deposits
not
carefully
the
gudgeon
prevent
area
and
the
the
being
using
from
to
damage
A
broken
deposits
top
of
piston
shells
installed
of
pin
the
top
retaining
makes
the
metal
enginc
up
the
of
rod
assemblies
and
care
not
the bottoms
the
sides
piston
a
satisfactory
from
the
piston
out
of
the
cap
nuts
remove
to
ring
the
the
shavings
bore
engine
in a
in
each
the
damage
of
the
of
the
of
the
piston
piston
of
small
and
the
components
NOTE
end
of
retaining
thumb
TO
FIT
no
are
and
using
a
relatively
the
gap
width
gap
the
set
be
necessary
4
ensure
within the
piston
fitted
end
The the
the
push
NEW
1
Wipe
traces
2 Place
3
Using
If
If
Treat
that
the
of
gudgeon connecting
assembly
in
fit
PISTON
the
of
carbon
a
the
piston
unworn
a
necessary
the
If
the
rings
all
the
specified
the
for
the
are
the
cylinder
new
part
feeler
gap
piston
ring
connecting
to
be
pin
rod
together
piston
RINGS
or
piston
inverted
of
gauge
adjust
is
too
are
a
side
limits
cylinder
renewed
is
an
and
at
bores
other
ring
push
the
cylinder
of
the
wide
matched
rings
clearance
that
and
to
rod
unless
interference
this
is
The
normal
and
clean
matter
foreign
in
the
bore
the
piston
bore
the
correct
gap
by
filing
select
set
adjustment
in
the
in
the
the
rings
which
the
one
fit
the
sole
gudgeon
room
ensure
of
thickness
to
another
same
piston
are
rings
or
other
of
in
the
small
means
of
is
pin
temperature
that
there
present
the
cylinder
down
will
groove
to
check
the
from
not
and
is
on
been
ring
increase
ring
manner
installed
have
13
Engine
RING
TOP
o
SECOND
RING
a
OIL
RING
SEGMENT
O
O
OIL
RING
EXPANOER
OIL
RING
SEGMENT
0
PISTON
CONNECTING ROD
NOTE
pistons
the
skirt
f
engine
6
marked
be
are
rings
TO
REASSEMBLE
1
and
connecting
clean
engine
will
gap
exhaust
2
1800
to
3
the
of
with
their
4
from
which
a
suitable
assembly
the
ring
letterFif
5
ensure
oUhe
tang
6
USe
a
ring
Fit
the
Lubricate
oil
before
If
the
Top
installed
With
the
oil
the
be
to
valve
position
Fit
the
the
top
Fit
the
engine
gaps
Insert
the
ring
iilto
the
compressor
shown should
Oil
the
thatitis
bearing
Pull
the
expanding
rings
from
the
piston
in
fitting
compression
and
this
the
on
AND
fi
rings
rod
assembly
arrange
the
sideofthe
second
ring
gap
oil
ring
spacer
and
the
1200 the
upper
either
connecting
assembly
compressor
bore
using
is
free The
halfofthe
upper
correctly
shell
connecting
tool
the
top
and
the
cylinder
are
rings
mark
must
pistons
INSTAL
tted
the
to
adequately
piston
piston
compression
with
and
side
of
rod
was
originally
to
compress
a
clean
size
be
iheTront
to
seated
in
rod
with
and
locating
to
of
be
pistons
rings
directly
the
lower
the
into
hammer code
big
the
piston
the
fit
the
piston
assemblies
ring
bores
faced
taper
uppermost
and
lubricated
so
that
with
ring
to
gap
oil
spacer
the
removed
the
number
end
bearing
connecting
the
recess
assembly
rings
the
away
the
ring
gap
cylinder
rings
handle
on
never
they
when
the
top
from
the
gap
right
segments
and
tap
and
shell
rod
in
the
the
over
with
will
ihe
piston
with
ring
the
side
bore
using
the
until
the
and
with
rod
down
BOLT
BEARING
CAP
J
NUT
Piston
1
and
at
the
bore
squarely
7
fit
it
until
with
Oil
the
to
the
Connecting
the
big
the
crankpin
lower
connecting
end
half
tight
19
NOTE
adjacent squirt
hand
right
8
assemblies
9
torque
Ensure
hole
Instal
J
Tighten
See
to
the
in the
sideofthe
using
Specifications
that
number
the
the
the
big
same
the
on
end
engine
other
big
Rod
the
of
bearing
rod
Instal
number
the
connecting
the
of
piston
procedure
end
bearing
Components
connecting
shell
and
the
big
the
of
connecting
and
nuts
rod
bearing
end
nuts
bearing
rod
and
rod
connecting
to
the
specified
engages
and
cap
finger
cap
that
the
istothe
rod
is
14
Engine
TO
CHECK
NOTE
wear
To
it
is
assemblies be
accurate
actual
ovality
clean
or
and
with
I
scoring
2
ovality
3
measuring
cvlinder
The
Visually
Check
Cylinder
unserviceable
immediate filted
NOTE
the
pistons
cylinder
See
Specifications
If
aTe
Engines
filted
filted
with
on
outer
with
be
sizes
be
CYLINDER
accurately
essential
removed
cylinder
a
clean
should
oversize
it
is
found
with
to
that
sleeves
equipment
bore
rag
check
each
bores
the
be
used
for
have been
cylinder
BORES
check
that
all
from
overall
boTfsshould
before
the
bores
cylinder
that
be
rebored
and
new
that
the
wear
most
Bore all
available
boredtotheir
sleeves
New
diameter
9
cvUnder
pistons
the
be
wear
bore
and
cylinder
availabletodetermine
including
be
wiped
checking
cracks
for
bore
for
wear
checking
upon
and
honed
oversize
cylinders
to
pistons
leed
detennine
cylinders
oversize
which
pistons
pistons
are
and
LlNDER
condition
connecting
block
flaws
including
to
boring
what
to
that
extreme
available
rings
also
taper
thoroughly
scuffing
prove
the
smallest
and
select
oversize
oversize
limit
in
should
alld
that
and
taper
to
rings
can
three
still
BOllES
rod
the
be
AND
PISTONS
DEGlAZING
NOTE
original
with
and from
a
hone
1
under
entering
2
Cl
pistons
Position
each
De
glazing
li
lder
usingacylinder
stones
3
Honing
and
up
cross
the
Cross
down
hatch
pattern
hatch
seatingofpiston
NOTE strokes
condition bore
distributors
spirits
be
When
of
of
size and
4
Use
or
kerosene
5
After
thoroughly
the
honing
Do
CYLINDER
that
bores
but
requirerenOnging
plenty
cylinder
the
crankcase
the
of
surfacing
should
be
the
cylinder
When
is
angle rings
deglazing
hone
are
the
cylinder Excessive
thus
increase
oil
not
use
it
honing
cleaned
is
to
BORES
are
of
clean
bore
area
cylinder
hone
carried
walls
hone marks
most
it
is
important
made
piston
which
engine
necessary
remove
fit
for
further
over
rag
to
keep
walls
equipped
out
by
fast
enough
satisfactory
to
eliminate
honing
skirt
clearance
is
available
or
transmission
that
all
traces
should
abrasive
may
moving
t
wt
the
of
the
be
with
to
ect
inter
for
only
will
from
cylinder
abrasive
service
be
deglazed
crankshaft
materials
done 280
the
achieve
at
60
the
correct
enough
the
glazing
increase
all
oil
mineral
with
by
grit
hone
a
deg
major
block
Piston
and
Cylinder
Grade
Numbers
Stamped
20
on
Pistons
and
TopofCylinder
Block
Engine
IS
CA
UTlON
engine
after
and
soap components
The
cylinder
can
be
wiped
clean
Smear
prevent
rusting
CHECKING
NOTE
the measured
strip
is
right
down
approximately
appropriate
and
obtained
1
angles
from
The
2
Cylinders
and
spring
Measure
piston temperature
Select
Be
sure
honing
water
thorough
clean
the
PISTON
then
to
the
the
gudgeon
200C 6S0F
a
that
It
be
used
bores
withawhite
bores
SKIRT
that
oversize
tried
scale
the
outside
gudgeon
feeler
all
abrasives
is
recommended
with
y
dried
can
be
with
haye been
pistons
in
its
to
ensure
pin
centres
pin
strip
a
brush and
cf
msidered
cloth
engine
CLEARANCE
rebored and
should
respective
that
correct
diameter
axis
and
when
measuring
0
04
are
and
oil
of
mm
removed that
the
after
have
bore
the
IS
clean
skirt
6
mll
0
a
solution
the
cloth
cleaning
honed
each
with
piston
0016
from
affected
when
remains
to
piston
a
clearance
skirt
0
732
should
in
the
they
take
feeler
in
i
thickness
of
strip
should
and
approximately
be
long
enough
12
to
mm
extend
0
50 in in
the
full
width
length
The
the
of
piston
3
Insert
the
feeler
the
feeler
to
and
gudgeon
strip
centre
spring
2
0
within
measurements
piston
check
at
piston
strip
the
pin
4
Attach
and
lineofthe
scale
5
The
and15
these
skirt
another
Follow
6
and
is
located
full
length
axis
withdraw
correct
kg
for
piston
position
lengthwise
of
a
spring
the
cylinder
spring
044and330
specifications
the
of
high
spots
to
the
same
strip
it into
the
scaletothe
feeler
bore
scale
piston
If
obtain
procedure
into
the
between
piston
strip
noting
reading
Ibs
then
and
necessary
the
the
cylinder
cylinder
at
top
in a
plane
If check
bore
select
required
to
boresothat
the
90
degrees
end
parallel
the
reading
should
the
reading
and
also
fit
the
fit
bore
cylinder
of
the
be
the
check
measure
remaining
Invert
the
wall
the
to
feeler
the
to
the
on
within
is
not
original
the
and
pistonsasrequired
be
in
fi
o
l
r
W
Q
Underside of
TO
REMOVE
1
the
rocker
previously
2
Wi
th
described
Remove
Engine
AND
the
engine
mechanism
the
sprocketsaspreviously
3 4
Remove Release
the
the
I
SPACER
with
INSTAL
sump
described
oil
lock
pick
h
fi
SHIMSfU
Removed
Sump
Crankshaft
lO
removed
manifold
plates
timing
up
from
tube
take
r
@
X
q
eo
i
I
Sprocket
CRANKSHAFT
the
vehicle
and
cylinder
cover
timing
strainer
and
out
the
EP
x
s
Showing
1000
chain
six
I
1
1
Arrow
Series
remove
head
and
securing
I
l
1200
MAIN
5
end
of
correct
cap 6
11
and
and
in
With
on
bearing
the
Push
I
I
J
r
t
H
Intermediate
has
HEAIIINGS
remove
relation
the
bearing
installation
I
five
Main
the
engine
cylinder
cap
the
connecting
l
0
0
If
iiI
j
l
i
II
1ll
on
Front
shown
NU
bolts
position
as
bench
big
half for each
Il
1
t
0
I
Il
Main
Bearings
the
flywheel marking
to
the
crankshaft
inverted
block
nuts
and
shells
Keep
and
note
ff
if
o
7Q
Bearings
top
remove
each
rod
i
I
o
gasket
the
h
flange
and
cap
number
and
and
resting
surface
the
and
piston
caps
Shims
the
shell
on
on
release
the
behind
flywheel
a
clean
and
lower
together
side
assemblies
the
of
21
16
Engine
FLANGE
t
PLATE
INNER
PLATE
down the
crankshaft
of
top
bearing sticking
7
bolts
Torque
the
the
shell
to
On
and
bores
bores
the
lift
Converter
but
has
crankpin
the
off
towards
do
Ensure
remained
AIO
the
not
engine
three
Drive
PlatetoCrankshaft
the
top
push
that
the
in
the
release
main
the
of
the
pistons
upper
connecting
the
bearing
block
half
caps
main
out
of
well
through
each
rod
bearing
Attachment
and
and
lower
clear
big
is
the
end
not
cap
half
SECURING
LOCK
cap
engine
five
each
PLAn
release
main
cap
1000
Series
Automatic
bolts
bearing
shells
and
On
shells
remove
Keep
the
A
12
the
Keep
each
of
bearing reassembly
cap half
131
and
bearing
and
shell
shell
BOLTS
the
161
O
together
main
caps
together
bearing
and
for
lower
for
reassembly
NOTE
already
Number numbered
the
With
main
the
bearing
exception
caps
they
are
rear
not
main
if
the
of
Rear
Main
t
Fii
Bearing
tJ
at
Crankshaft
Centre
1000
on
Checking
float
Oil
Seal
with
Bearing
Cap
Removed
Bearing
22
End
Main
Model
Engine
I
7
8
the
9
them
there
which
Lift
qankcaSe
Remove
bearing bearings
from
keep reassembly
NOTE
side
attention
excessive unserviceable
undersize
TO
anti filter
available
the
The
fake
to
Ins
allation
Journals
REMOVE
1
Grasp
clockwise
is
Take
pump
oil
to
too
to
Installation
attention
pump
Use
to
a
body
Tighten
torque
see
Irtstal
comparatively
Tighten
over
tighten
Ensure
DISMANTLE
TO
1
and
2
Remove
withdraw
the
Unscrew
bolts
Discard
is
must
the
ctankshaft
the
together
centre
crankshaft
is
a
the
following
and
wear
taper
should
shells
and
AND
the
and
tight
the
fit
lower
out
the
the
from
is
a
the
following
new
gasket
and
the
three
the
Specifications
a
new
ne
the
filter
or
leaking
that
gasket
AND
the
gasket
and
an
arrow
point
upper
in
main
bearing
end
reversal
bearing
be
the
journal
INSTAL
oil
upscrew
to
rotate
end
three
right
eversa1
etween
1
and
body
pump
filter
to
may
faces
ASSEMBLE
oil
filter
the
pump
remove
DRI E
aja
RET
Exploded
cast
to
the
directly
half
pairs
thrust
of
points
shells
or
sc
replaced
filter
it
off
by
of
securing
hand
of
points
crankcase
securing
if
the
pump
result
are
assembly
the
GASKET
GEAR
11
iifJ
AINER PIN
in
front
of
with
shells
the
should
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30
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