Datsun 1000 Instruction manual

SCIENTIFIC PUBLICATIONS
WORKSHOP MANUAL
SE
IES No 87
rl
WITH SPECIFICATIONS
REPAIR AND
MAINTENANCE
DATA
COVERING
AIO
AI2 ENGINE
STATION
WAGON
SEDAN
PICKUP
1000
Z
1
1
r
ProCarManuals.com

SCIENTIFIC
PU
LICATIONS
WORKSHOP
MANUAL
SERIES No
87
DATSI
TN
14M
O
1 00
I
ProCarManuals.com

c
seIE IFIe PUBLICATIONS
WORKSHOP MANUAL SERIES No 87
DATSUN
1000 1200
SERIES OIO
0110
SEDAN
WAGON PICK UP
AUTOMATIC
and
MANtJAL TRANSMISSIONS
With
Speelfieations
Repair
and
Maintenanee Data
SCIIL C PUBUCADONS S MELBOURNE
ProCarManuals.com

Published
by
Scientific Publications
Ply
Ltd
142 Oarence Street
Sydney
2000 New South
Wales
Printed
by
Kenmure Press
Ply
Ltd
New
South Wales
Copyright
by
Scientific Publications
Pty
Ltd
Registered
at GPO
Sydney
for transmission
by post
as a
book
First
Edition
January
1972
National
Library
of
Australia
Registry
Number
SBN 85566 038 4
CK
OWLt UC
E
IE
T
Scientific Publications
wishes to
thank
Nissan
Motor
Corp
USA
and
Borg
Warner
Lid
Fairfield for
help
in
aspects
of
preparing
this manual
J
ProCarManuals.com

EXGIXE
COOLING SYSTEM
FUEL SYSTEM
CLUTCH
MANUAL
TRANS1UISSION
AUTOMATIC
TIlANSMISSION
REAR AXLE
STEERING
FRONT SUSPENSION
RE R SUSPENSION
BRAKES
ELECTRIC
L
SYSTE
BODY
WHEEL AXD TYRES
LUHIUCATION AND MAINTENANCE
EMISSIOX CONTROL
SYSTI MS
IXDEX
GLOSSARY OF
TERMS
ROAD TEST
7
28
14
47
57
73
85
103
I ll
126
131
148
184
195
200
20 1
211
lIlt
217
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OTHER
TITLES IN THE
SCIENTIFIC
PUBUCATIONS
B NUAI
SERIES
Bool
Pag
s
IDo
Price Book Pages
Dlu s Price
Car No of Text Indiom
Aus
t
Car
No of Text trntiollS
AusLt
Austin A40 Devon 00 106
89 1 20
Lawn
Mowers
Vieta 2 Stroke
Austin A40 Somerset 1
99 84 2 30
Kirby
4 Stroke
100 80 89 1 40
A utoServ I 50 294
48 7 00 Morris Minor
MM II 23 142
161 2 30
Complete
BMC
Mini
Morris
Minor
1000
24 96 96 3 50
1100 1800 7L 431 315
9 00
Morris Austin Mini
Datsun
1000 1200
87
224
208 6
25
Cooper
and S
Datsun 510 1300
Mini 1100 Moke 64 236 187
6 25
1400
1600
88 256 241
6 50
Morris Austin 1100 65 145 106 5
75
Dodge
ASM 106
6 464 517 2 80
Morris Austin 1800
Ford
Capri
1600
Mk
I
66 138 95 5
75
and 1600 GT 82
173 108 5 75
Morris Austin 1800
Ford
Consul
Zephyr
Mk I Mk II
66a 224 174 6
25
Mk I
1951
55 7 153 85 1
20
MG
Midget
Series TO
29 90 106 2 30
Ford
ConsulZephyr
MG Series TC TD
Mk II 1956
62 8 184 124
3 50
TF MGA MGB 70
304 204 7 00
Ford Cortina 1200
Peugeot
403 404 31 121 171 3
75
1500 1600
68 288 192 6
25
Renault
750f760
33 79 98 1 00
Ford Customline
Renault
Dauphine
34 133 158
4 00
Custom 1949 54 10 166 193
1 20
Renault R8 and RIO
74 164 97 5 75
Ford Customline OHV 9
121 107 3 50
Rootes
Group
Hillman
Ford Escort I 100
Humber
Husky
Cob
BOO 1300 GT 81 184 172 5 75
1958
66 36 390
399 7
00
Ford Falcon XK to
Simca Aronde
Elysee
XW 6
cyl
62 290 188 7 00
Ford Falcon XR to
1200 1300
37 113
121 3
75
XW V8 63 238 155
6 25
Standard 8 14
Ford V8 and
1939
46 40
81 51 1
00
Mercury
1932 48 11 122 132 3
50
Standard 10 1955 58 41
147 134
1 75
Hillman Hunler
Standard
Space
Arrow HB HC 79 188 121 5 75
master
Series 11 42 125 105
3 00
Holden 1948 53 FJ
Standard
Vanguard
III 43
184 149
5 75
FE FC FB EK
Toyota
Corolla 11 00 73
176
107 5 75
EH EJ HD HR
67 286
128 7 00
Toyota
Corolla 1200
93
Holden FE FC FB 16 80 82 1
85
Toyota
Corona 83
224 175 6
00
Holden
HI
Series
Triumph
TR2
3
4 44 167
130 5 25
V8 and 6
cyt
75 287 197 7 00
Valiant
AP 6 VC
Holden HK HT HG
VE VF V8
Engine
69 174
95 6 25
V8
Engine
85 272 215
7 00
Valiant R S
AP5
Holden HK HT HG
AP6 VC VE
6
cyl Engine
86
224
188 6
25
VF 6
cy
Engine
78
279 145 6
25
Holden Torana S SL
Vauxhall Viva HA
1969 Brabham 72 191 120 6 25
HB 90
76
200 140 5
75
HC Trucks AR AL 17 437 657 3 50
Volkswagen
1500
IHC
Trucks AS line 18 173 245
1 40
1600
47
224 160 6
25
IHC Trucks AA line 19 595 1040 3 50
Volkswagen
1100
1200
Jaguar
Mks VII VIII
1200A 1300
1500 46
224 204
6 25
IX XK 20 140
Volkswagen
150
21 274
237 7 00 Transporter
48
256 202 6
25
Jaguar
24 34 Mks I
Wolseley
1500
49 100
66 1 00
and II 3 8 Mk II 22 274 281 7
00
In
Production
Jaguar
3 8 4 2 E 77 202 124 6 25
t Recommended
retail
price
in Australia
OVERSF AS REPRESENTATIVES
South
Africa
Central
News
Agency
Ltd
Laub Street New Centre
Johannesburg
10799
United
Kingdom
Alltech Distributors 15
High
St
Hampton
Middlesex
North America Autobooks 2900
W
Magnolia
Blvd
Burbank California
91503
Repco
Auto
Parts
Doylestown
Penn
I
os
Angeles
Calif Toronto
Ontario Vancouver Be
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Type
Bore
Stroke
AIO
engine
A
12
engine
Capacity
A I
0
engine
A 12
engine
Compression
ratio
AIO
engine
A
12
engine
Bhp
Maximum
AIO
engine
A 12
engine
Maximum
torque
A I 0
engine
A 12
engine
Firing
order
Idling
speed
CYLINDER
HEAD
Type
Gasket face
distortion
limit
Valve seat material
Inlet
Exhaust
Valve seat
insert recess diameter
in head
Inlet standard
insert
Inlet
replacement
insert
Exhaust
standard insert
Exhaust
replacement
insert
Cylinder
head bore diameter
for valve
guide
tandard
guide
ENGINE
SPECIFIC TIO S
4
cylinder
in
line OHV
73mm
2 874 in
59mm
2 323
in
70mm
2 756 in
988 cm3
60
3 in3
1171 em
71 5 in3
8 5 I
90 1
56 at 6000
rpm
68
at 6000
rpm
8 50
kg
m
@
4000
rpm
61 5
ft lb
@4000
rpm
9
70
kg
m
@ 3600
rpm
70
1
ft lb
@ 3600
rpm
1 3 4 2
600
rp
Aluminium
alloy
O IOmm
0
004
in
Aluminium
bronze
Cast
iron
37
016
37 00
mm
14573 14567
in
37 516 37
50 mm
14770
14763
in
33 016
33
00
mm
1
2998
1 2992
in
33
516 3350 mm
1 3195
1 3190
in
12 011
12 00
mm
0 4728 0 4724
in
Replacement guide
12
211 12 200 mm
0 4807 0 4800 in
450
Valve seat
angle
Valve seat
width
Inlet 1 30
mm
0
0512
in
1 80mm
0
p709
in
Exhaust
Valve seat insert outer diameter
standard
Inlet
37 080 37
096 mm
I
459 1
460
iri
33 080 33 096 mm
1 302 1 303
in
Exhaust
Valve seat insert inner
diameter
Inlet
Exhaust
30
to
1O mm
1181
to
004in
26mm
1 023 in
6 0 5 90 mm
0
2362 0 2323 in
0 064
0 096
mm
0 0025
0 0038 in
V ALVES
GUIDES
AND
SPRINGS
Valve
seat
insert
depth
Inlet
and
exhaust
Insert interference fit in head
Valves
Head
diameter inlet 35mm
1 378 in
29mm
0
142
in
8 70
8
69 mm
0 3426 0 3430
in
103
5 104 1 mm
4
0750
40984 in
0
015 0 045 mm
0 0006 0 0018
in
0
040 0 070 mm
0 0016 0 0028
in
exhaust
Stem
diameter
Overall
length
Stem
to
guide
clearance
Inlet
Exhaust
Valve lift
A10
engine 7
80 mm
0 3071 in
7 50
mm
0 2953
in
A 12
engine
Valve
guide
Inner
diameter 8 015
8
000 mm
0 3155 0 3150
in
12 044 12 033
mm
0 4740
0 4737
in
0
022
0
044
mm
00009 0
0017
in
53mm
2 087
in
Outside diameter
Interference
fit in head
Length
7
ProCarManuals.com

2 Engine
Fitted
height
above
spring
seat
Valve
spring
Free
length
Fitted
length
and
load
Number of
effective coils
Wire diameter
Coil diameter
Rocker arm to valve
stem clearance
Hot
18mm
0
709
in
45 7 mm
I 7992 in
38 5 mm
@ 30 0
kg
1 516 in
@66
llb
4 5
4
276 mm
0
1693
in
26 224 mm
0 0324
in
03 5 mm
0 0138
in
0
25 mm
0
0098
in
PISTONS
PISTON RINGS AND GUDGEON
PINS
Cold
Pistons
Type
Piston
fit
Skirt diameter standard
It oversize 25 mm
2nd oversize 50
mm
3rd
oversize 75 mm
4th
oversize 100 nun
5
th oversize
125 mm
6th
oversize
150 nun
Piston to
cylinder
bore
clearance
Piston
rings
Width
compression
oil con trol
Side clea ance
in
grpove
Ung
gap
GUDGEON PIN
Gudgeon
pin
Diame er
Slipper
skirt
cast
aluqlinium
alloy
Selective
72 967 73 0
7
nun
2 8727
2
8747
in
73
217 73 267 nun
2 8826
2
8845 in
73
467
73 517 mm
2 8924
2
8944
in
73 717
73 767 nun
2 9022
2
9042
in
73 967 74 017 riun
2 9121 2 9140
in
74
217 74
297
nun
2
92 19 2 9239
in
74 467
74
517 nun
2
9318
2 9337 in
0
023 0 043 nun
00009 0 0017 in
2
00
mm
0 0787
in
4
00 mm
0
1575
in
0 04
0 07 mm
0 0016 0 0027
in
0 20 0 30 mm
0
0079 0 0ll8
in
17447 17452mm
0
6869 0 6871
in
Clearance
in
piston
0 006 0 008
mm
10
0002 0 0003 in
Interference fit in
connecting
rod
0 017 0 034 mm
0 0007 0 00
13
in
Length
65 23 6548 mm
2 5681
2
5779 in
With
pistolJ
at a
temperature
of 200C
680F
CRAN SHAFT
AND
MAIN
BEARINGS
Crankshaft
Main
journal
diamet r 49 964 49 957 mm
I
9671
1 9668 in
0 03
mm
0 0012
in
0 020
0 062
nun
0
0008
0
0024
in
0 5mm
0 0059
in
0 015
0 050
nun
10
0006
0
0020 in
0
05
0 15
mm
0
0020 0 0059
in
0 30 mm
0 0118
in
1
835 1 827
mm
0 0722 00719
in
44
974
44
961 mm
I 7706
1
7701
in
0
03
mm
0 0012 in
CONNECTING ROD
AND BIG END BEARING
Journal
taper
or
ovality
wear limit
Main
be
ring
clear ce
Clearance wear l
it
CrankShaft
run
out
End float
End float
wear
limit
Main
bearing
thickness
rankpin
diameter
Crankpin taper
or ovality
wear
limit
Connecting
rod
Lergth
A 10
engine
116
97
117 3
mm
4
9051
4 6188
in
121
47 121
53
mm
4 7822 4 7846
in
1 500
1
508 mm
0
0591
0 0594
in
0
20
0 30 mm
0 0079 0 0012
in
0 40 mm
0 016
in
0
020 0
050 mm
0 0008 0 0020
in
0 05 010 mrn
0 0020
0 0039 in
CAMSHAFT AND BEARINGS
AI2
engine
Big
end
bearing
thickness
Big
end end
float
End float wear
limit
Big
end
bearing
clearance
on
crankpin
Connec
ing
rod bent
or
misalignment
Camshaft
bearing journal
diameter
No
43 793 43
806 mm
I
7241 1 7246
in
43 283
43 296 mm
1 7040
1 7046
in
No 2
8
ProCarManuals.com

No
3
No
4
No
5
Camshaft
run
out
Journal
to
bearing
clearance
Bearing
inner
diameter
No
1
No 2
No 3
No 4
No 5
LUBRICATION
Type
Oil
pump type
Filter
type
Oil
pump
Side
clearance
inner
and
outer
rotors
Clearance outer rotor
and
body
Clearance rotor to
end
cover
Relief valve
spring
Free
leilgth
Fitted
length
Relief
pressure
42 783 42 796
mm
1
6844
1 6849 IiI
42 283
42 296 rom
I
6647 1
6652
in
41 218
41 231 mm
1 6228 1
6233 in
0 61 0
IOmm
0 0004 0
0039 in
0 024
0
065
mm
0 0009
0
0026
in
43
843 43
833
mm
17261 17257
in
43 333 43 323 mm
I
7060 1
7050 in
42 846
42 836 mm
1
6868
1
6865
in
42 333 42 323
nim
1
6667
1 6663 in
41 268
41 258 mm
1 6247
1 6243 in
Full
pressure
Eccentric motor
trochoid
Full
flow
065 0 12
mm
0 0020 0
6047
in
0 15 0 21 mm
0
0059
0 0083 in
0 12mm
0
0492
in
4349 mm
I
71 in
3030
mm
I
19 in
3
80
4 26 kg cm2
54 0 59 70
psi
Engine 3
Capacity
With
new
filter
3 20 litre
2
75
Imp qts
3 37 US qts
2 70 litre
2 37
Imp qts
2 87 US qts
Less
filter
TORQUE
WRENCH SETTING
MAXIMUM
Comiecting
rod
nuts
3 6
kg
m
26
ft lb
Cylinder
head
bolts
4 80
kg
m
34
70
ft lb
Flywheel
bolts
A10
engine 3
00
kg
in
7
50
ft
lb
Al2
engine 7
50
kg
m
5420
tt
lb
Main
bearing
cap
bolts
5 30 kg
m
3830
ft lb
Camshaft
sprocket
bolt
4 50
kg
m
32 50
ft
lb
Camshaft
locating
plate
bolts
0 50
kg
m
3 60 ft lb
Sump
bol
ts
0 60
kg
in
4 30 ft lb
Oil
pump attachment
bolis
1 50
kg
m
I0
80 ft
lb
Oil
strainer bolts
1 40
kg
in
10
10
ft
tb
Crankshaft
pulley
bolt 16kg
m
116
ft
lb
Timing
chain
tensioner
bolts
0
80
klilm
5
80
ft lb
Rocker
pedestal
bolts
2 50
kg
m
I
8 10 ft
lb
Mainfolct
bolts
1 40
kg
ni
10
10
ft lb
Pump
release
valve
plug
5 00
kg
in
36 20
ft lb
t
I DES RIP i lON
The four
cylinder
overhead valve
engine
has a cast iron the
comi
cting
rod and this
is the
only
means
of
retaining
the
alloy cylinder
block and
crankcase The
cylinder
head is
of
gudgeon pin
in the
assembly
cast aluminium
alloy
with
replaceable
valve
guides
Each
The crankshaft
is
counter
balanced and funs
in three
valve has its individual
port
and
is
operated
by
a
tappet push
AIO or five
AI2
steel
backed
copper
lead
split
shell
rod and rocker
arm
from
the camshaft
main
bearings
Crankshaft end float
is
taken at
the centre
main
bearing
Connectirig
rod
big
end
bearings
are
split steel
backed
copper
lead
replaceable
shells
Pistons are marked on
the crown
with
a
code
number of
the
cylinder
bore size which
must
be to
the
front of the
engine
Pistons
are
slipper
skirt aluminium
alloy type
with two
compression rings
and orie
oil
ring
The
lower
compression
ring
is
taper
faced and t eoil
ring
comprises
an
upper
and
lower chrome faced
steel
segment
with a
spacer
in
between
The
gudgeon pin
is
an
interference fit in the smail
end
of
9
ProCarManuals.com

4l
Engine
I
Driven Side View of 1000 Series
Engine
and Automatic Transmission
Typical
Also of 1200 Series
Connecting
rods
and
big
end
bearing caps
are numbered
The
big
ends
of the
connecting
rods are bored wi
th an
oil
squirt
hole
on the thrust
side
The
oil
pump
is
the trocoid
gear
or internal rotor
type
and
is driven
by
the
camshaft to
provide
full
pressure
to
the
engine
Oil
passes
through
a
drilling
to the centre rocker
pedestal
to
provide
lubrication
to
the
rocker armS and shaft
Oil
pressure
is maintained
at a
pre
detennined
maximum
by
a
spring
loaded relief valve situated
within
the
pump
body
The
lubricating
oil
passes
through
a
full flow
oil filter
moun
ted
externally
on the oil
pump
TO
REMOVE AND INSTAL
2 E mNE AND TRANSMISSION
1
Drain the
cooling system
and the
gearbox
2
Disconnect the
battery leads
at
the
battery
and
remove the battery
and
battery
Hay
3 Release the
retaining clips
and remove the
upper
and
lower radiator
hoses Remove the air cleaner
4 Where fitted release the
retaining
clips
and
disconnect the
heater hoses at the
engine
5
Disconnect
the
high
and low
tension
leads at the
coil
and
distributor
6
Disconnect
the
alternator leads
at the
alternator and
the
starter leads at the starter solenoid
7
Disconnect the
oil
gauge
and
temperature gauge
wires
at
the
eng
ne
8
Disconnect
the choke
and
throttle con
rrollinkage
at
the carburettor
9
Disconnect
the fuel inlet
pipe
at the fuel
pump
10
Remove the
flange
nuts and
disconnect
the exhaust
outlet
pipe
at the
manifold
11
Raise the
car
sufficiently
take
out
the
split pins
and
disconnect the gear
change
links at the levers
on
the
side
of
the
gearbox
12
Unscrew the ferrule
and
disconnect
the
speedometer
drive cable
assembly
at the
gearbox
rear
extension
13
Disconnect the earth
strap
at
the
starter motor
mounting
bolt
14 Disconnect
the
handbrake
rod
support
on the
gearbox
15
Take out the
four bolts disconnect
the rear
universal
joint flange
from
the
pinion
flange
at
the rear and
withuraw
the
pC0peller
shaft
from the
rear
ufthc
gearbox
t
16 1000 model Slacken the lock
nut at the
adjuster
end
of
the clutch
control cable and unscrew
the cable
adjuster
bolt
from
the
end of
the
cable 1200 model
Slacken
the
adjustment
at the
upper
end
ofth
cable
case
and unhook
the
lower end of the
cable off the clutch release throwout
lever
17
Remove clutch cable
casing
bracket
attaching
bolt
and withdraw the
cable and bracket clear of the
engine
and
gearbox
assembly
18
On models
with
hvdraulic
clutch
operation
10
ProCarManuals.com

disconnect
the flexible hose at the
slave
cylinder
and
plug
both the
hose
and
the
cylinder
connection
to
prevent entry
of
dirt
19
Take
out
the
four
securing
bolts and remove
the
radiator
20
Using
suitable
lifting
tackle attached
to
the
lifting
brackets
on the
engine tighten
the
lifting gear
to take the
weight
of
the
engine
assembly
21 Remove the nuts
securing
the
front
engine
mountings
take
out the
two
bolts
attaching
the rear
engine
mounting
to the rear
extension
housing
take out
the two
Engine 5
bolts
attaching
the
mounting
bracket
to the underframe
and
remove the
rear
mounting
assemble
22 Raise
the
engine
tilting
it
upwards sharplv
at the
front and lift
it from
the car
through
the
bonnet opening
Installation
is a reversal of
the removal
procedure
with
attention to
the following points
AIl Ow
the
weight
of
the
engine
to settle on
the
front
engine mounting
before
tightening
the
mounting
n1 1ts
Fill
the
gearbox
with
the correct
grade
and
quantity
of
oil
frEnsure
that
there
are
no
water
leaks
TO
REMOVE
AND DISMANTLE
1 ROCKER i nMS AND
SHAFI
I
1
Remove the air cleaner
and
the
pipe
from the
air
cleaner
to the
rocker cover
2
Take out
the
screws and
lift off the rocker cover and
remove
the
cork
gasket
3 Unscrew the five
rocker
pedestal
bolts
progressively
loosening
eacn
bolt
a
few turns at a
time until
they
are all free
and lift off the rocker
assembly
4 Remove the bolts from the rocker
pedestals starting
at the rear and withdraw the rear
pedestal
rocker arm
spring
rocker arm
pedestal
in
that order
noting
any
spacer
washers
interposed
between the rocker arms
and the
adjacent
pedestaL
NOTE
Keep
each
component
in the order
of dismantling
so
that
it
can be assembled in the
original position
This is
important
as the rocker
arms
are
offset
with the
adjusting
screw end
towards
the
adjacen
t
pedestal
TO ASSEMBLE AND
INSTAL
1
Check
each rocker
arm and the
rocker
shaft for
wear
Check that the oil
holes and
passages
in the rocker
arms
are
clean
and
free
of
any sludge
or scale
2
Position
the
front
rocker
pedestal
on the
front
end
of the
shaft and
insert the
pedestal
bol
t to hold
it in
position
3
Instal
a
spacer
washer
if fitted
followed
by
the
front rocker ann
spring
rocker ann washer
and
the second
pedestal
push
the
pedestal
along
the
shaft
compressing
the
spring
unttl
the
pedestal
bolt can
be inserted
to
hold the
assembly
in
position
t
V i
i
4
Continue
to reassemble
the
remaining components
ii tilthe
rear
pedestal
has
been installed
and retained
in
position by inserting
the
securing
bolt
NOTE If
the
rocker
shaft
is
correctly
assembled
each
rocker
arm v fiu be
offset
with
the
adjuster
screw end
of
the
rocker
towards the
adjacent pedestal
5 Place
the rocker
assembly
on the
cylinder
head and
screw the
securing
bolts into
the head until
they
are finger
tight
Ensure
that the
ball end of
each rocker
adjusting
screw
is seated
correctly
in
the socket
end
ofits
push
rod
6
Using
a
suitable
spanner tighten
each
pedestal
securing
bolt
progressively
a
few turns ach
until the five
pedestals
are
seating securely
on the
cytlnder
head Use
care
to
ensure that the centre
pedestal
is located
correctly
on
the
oil
passage
in the
cylinder
head
7 Tighten
the rocker
pedestal securing
bolts
to the
specified torque
8 Check
the rocker
arm to
valve
stem clearance
and
adjust
if
necessary
as
described
in TO ADJUST VALVE
CLEARANCE
9
Using
a new
gasket place
the
rocker cover
on
the
cylinder
head
with the oil
filler
cap
to
the front
instal
the six
securing
screws
firmly
but do
not over
tighten
or the
cover
flange
will
become
distorted
10
Position
the air cleaner
on the carbureltor
and
secure
with
clamp
and
wing
nut
Using
suitable
pliers
to
expand
the
clips
connect the
pipe
between the air cleaner and
the
rocker
cover
r
U
Rocker and
Shaft
Assembly
Note Offset
of Rocker Screws
11
ProCarManuals.com

6 Engine
4Cl
LI
DER
UK
D
TO REMOVE
I
Remove
the air
cleaner
and the
pipe
from
the air
cleaner to the
rocker
cover
2
Drain
the
cooling
system
at the two drain cocks one
on the rear of the lower
radiator tank and
the
other on the
left
hand
side of
the
engine
towards
the
rear
NOTE
If
anti
freeze
mixture is
being
used drain into a dean
container
to
be used
again
3
Disconnect
the earth
cable
at
the battery
tenninal
4
Slacken both
hose
clips
and
remove
the
upper
radiator hose
between
the
radiator and the thermostat
housing
5
Disconnect
the
fuel feed
pipe
at the
carburettor
and
the fuel
pump
release the fuel
pipe
from
the
steady
clip
on
the front
of
the
cylinder
head and remove the
pipe
from
the
engine
6 Disconnect
the
vacuum
advance
pipe
from
the
RINGSE U
A
COTTERS
b
COTTERS
9
SPRING eN
A
INLET VALVE
SEAL
I
O sEAT
WASHERS
q
4HLET VALVE
I
1
EXHAUST VALVE
Valve
and
Valve
Spring Companenu
carburettor and distributor and remove
from the
engine
7
Disconnect the
high
tension
leads
at the
spark
plugs
and coil and remove the distributor
cap
and leads
Remove
the
spark
plugs
from the
cylinder
head
8
Disconnect
the
temperature
gauge
wire
at
the
connection on
the
front of the
cylinder
head
9
rake
out the
six
securing
screws and remove
the
rocker cover
and
gasket
from
the
cylinder
head
10
Progressively
loosen
the rocker
pedestal
securing
bolts a
few
turns
at a time
until
they
can
be
fully
unscrewed
with
the
fingers
Do not remove
the
bolts from
the
pedestals
and shaft
as they
will serve to
retain the
rocker components
on
the shaft Remove the rocker
and
shaft
assembly
from
the
cylinder
head
II
Withdraw
the
push
rods
keeping
them in order of
removal
to
ensure
installation
in the
original positions
12
Remove the
nuts and
washe and remove the
inlet
and exhaust manifold
assembly
Remove and discard
the
manifold
gasket
13 Unscrew and
remove
the
cylinder
head bolts
in the
reverse
order of
tightening
see illustration Note that
the
cylinder
head bolt removed from
the
centre hole
on the
right
hand
side is marked with a T on the
bolt head
14
Lift off
the
cylinder
head
and
gasket
Discard
the
gasket
TO
DISMANTLE
1
Place the
cylinder
head on
its
edge
on
a
bench
and
using
a
suitable
valve
spring compressor compress
each valve
spring
in turn
remove
the
O
ring
seal and
split retaining
wllets
2 Release the
spring compressor
and remove
the
valve
spring retaining cap spring
and
spring
seat washer if fitted
3 Check the end of the valves
for bur and
upsetting
caused
by
slack
adjustment
and
if
necessary
clean
up
with a
smooth
file
4 Withdraw
the
valves
keeping
them
in
order so that
EXHAUST VALVES
LLJI
J JL
INLET
VALVES
Combustion Chamber Side of
Cylinder
Head
12
ProCarManuals.com

Engine
7
7
e
Sequence
f r
Tightening Cylinder
Head
Its Loosen in Reverse Order
they
can be reassembled
in
the
original positions
Jlt
surface ground
to
bring
the head back
to a serviceable
5 Pull the shroud
type neoprene
seal
off the
end of the
condition
inlet valve
guide
and
discard
if
they
have
been
in service for a
7
With
a
valve
spring
tester
check the valve
spring
considerable time
Note that the shroud
type
seal is retained
tensions
and
lengths
see
Specifications
If
a valve
spring
on
the
end of
the
guide by
a
spring ring
tester
is unavailable
then the test can
be made
by comparing
the used
springs
with a
new
spring
Also
check
the valve
springs
for
squareness
TO CHECK
AND
INSPECT
I
Clean
the valves
thoroughly
of
carbon
deposit
and
discard
any
valve
that is
cracked
or
burnt
2
Reface each
valve face to
the
recommended
angle
as
shown
in the
specifications
and each
valve
stem
flat
and true
on
a suitable valve
eefacing
machine Discard
any
valve tha
t
proves
to
be
excessively
bent
If a valve head
has
been reduced
to 0
50
mm
0
020 in or
less after
the
grinding
operation
then
the valve
concerned
should
be renewed
Valve
stem ends
may only
be
reduced
up
to
0 50
mm
0 020 in
3 Measure the valve stem outer diameter
and
the valve
guide
inner diameter to calculate the actual valve
stem to
guide
clearance If clearance
is in
excess
of the limit of
0 1
mm
0 004
in then the
valve
guides
and
or valves should be
renewed
4 Remove
the
carbon
deposits
from the
cylinder
head
face and
the
valve
throats
and
check the
conditions of the
valve se ts
If
necessary
recut the
seats
with
a
valve seat
cutter to
the
recommended
angle
and wid tho
NOTE If
the
seats in
the head
are
worn or
recessed
excessively
then new inserts will
have to
be installed It is
recommended
that
the
installation
of
new valve inserts
and or
valve
guides
if necessary
be
entmsted
to an
automotive
engine
reconditioner
who
has
the
necessarv
specialised equipment
to
carry
out these
operations
5
Lap
the valves to the
valve seats with
a
lapping
compound
Apply
a
smear
of
Pruss ion blue to
the valves after
lapping
and check the valves
on
their respective
seats to
ens ure that
a true and concentric
seating
has
been
gained
6 With a steel
straight edge
and feeler
gauge
check the
cylinder
head face for
warping
If
the
cylinder
head is
found
to
be
warped
in excess of the limit
specified
see
Specifications
then it
will
be
necessary
to
have the head
TO
RENEW
V ALVEGUIDES
I Using
asuitable
pilot
drift
drive
the
worn
valve
guides
out of
the
cylinder
head towards the combustion
chamber
2 Clean
the
area in
and around
the
guide
position
in
the
cylinder
head
and
wipe
clean
3 Warm the
cylinder
head
up
to
a
temperature
of
2000C 3920F
lightly
oil
the
lower
end of
the
new
guide
and
using
the
shouldered
drift drive
the
new
guide
into
position
so
that it
stands
proud
of
the valve
spring
seat
by
the
specified
amount
See
Specifications
NOTE
The internal
bore
of
the exhaust valve
guide
is
counter bored
at its
combustion
chamber
end
Ensure that
this end
of
the
guide
enters the cvlinder
head
first
4
Check
the fit of
the
valve
in the new valve
guide
and
if
necessary
ream
the
guide
to
the
specified
diamete
r
5 After the
new
guide
has been fitted and if
necessary
reamed to size reface
the
valve
seat
using
a
vibro centric or
suitable tool
to
ensure
that the
valve
seat
is
true and
concentric with bore
axis of the valve
guide
This is
most
important
to ensure
that the valve
seats
correctly
TO CHECK VALVE SPRING
I
Check
the valve
spring
free
length
and
length
under
load
2
Check
that the
springs
arenot
bent or
distorted
from
heat
If
a
spring
tester
is not available
check
the
springs
by
comparison
with
new
springs
This
can
be done
by using
a
surface
plate
and
straight
edge
for
checking
free
length
and
by
using
a
new
spring
and a
used
spring
loaded
in a vice end on
end with
a
plate
in
between
Measure from
the
plate
to the
vice
jaw
adjacent
to both
the new
and used
springs
13
ProCarManuals.com

s
Engine
A used
spring
is serviceable
if1t does
not
show
collapse
in
excess aftive
percent
when
subjected
to
this
comparison
test
TO ASSEMBLE
1 Before
assembling
the
cylinder
head
ensUre that all
traces
of
emery
dust
or
grinding
paste
are
removed from the
valv
seats
and
ports
and
apply
a
light
coating
of oil to
the
seats and
the
valve
guides
2 Oil the valve items and instal
all
eight
valves
ensuring
that each
valve is
installed
in the
position
from
which it
was
remQved
3
On
inlet valves instal
a
new shroud
type
seal on
each valve stem and secure on the valve
guide
upper
end
by
fitting
the
spring ring
4 Instal a valve
spring
seat washer valve
spring
and
spri g retaining
cap
5
Using
a suitable
spring compressor
compress
the
spritig
and
fit
the
split retaining
collets
in
the recess
in
the
end of
the
valve stem Hold
the collets in
position
and
carefully
release
and remove
the
spring compressor
Ensure
that the collets are
correctly
seated
in the
spring
retaining
cap y
tapping
on
the
end
of the valve stem
with
the end of
a hammer handle
6 Oil
a
new
O
ring
seal
and instal it in
the
receSS
in
the
spring
retaining
cap
above
the
split
collets Assemble
the
remaining
valves
in
a similar
manner
TO
INSTAL
I
Ensure that
the
gasket
faces of
the
cylinder
block
and the
cylinder
head are
perfectly
clean
and free
of
any
burrs or
pieces
of the old
gasket
2 Place the new
gasket
in
position
on the cylinder
block face
and ensure that all bolt and water
circulation
holes
register
If available screw a
guide pin
into
one
of the
hold down bolts holes
at
each end
of
the cylinder
block
face
NOTE
The
cylinder
head
gasket
is
marked TOP to
acilftate
co
ect
assembly
3
Lower the
cylinder
head into position
and
instal
seve
al
of
the
cylinder
head bolts
finger
tight
4 Remove
the two
guide pins
if used
and
instal
the
remmnder
of
the cylinder
head bolts
finger
tight
NOTE One
of
rhe cylinder head bolts is marked
wirh a
r on
the
bolt head
This
bolt
must be installed
at
the
centre
hole
position
on the
right
hand side
of
rhe
engine
5
Using
a suitable
torque
wrench
tighten
the
cyli
det
head bolts
evenly
and
progressively
to
the
specified
tightening
figure
See
Specifications
in
the
order shown
in the illustration
6
Instal
the
push
rods
ensuring
that
each
is
replaced
in the location from which
it was
removed
and that each
rod
seats
correctly
in its
tappet
7
Position
the rocker shaft and
tocker
ann
assembly
on the cylinder
head
and
instal the rocker
pedestal securing
bolts
finger tight
8
Tighten
the
rocker
pedestal
bolts
a
few
turns at a
time
evenly
and
progressively
to the
specified torque
see
Specifications
9 Turn the
engine
crankshaft
in
the direction
of
normal totation
until each valve
tappet
is
exactly
on
the
heel
of its
cam
and
adjust
the clearance
between
the tocket
arm and
the valve stem See
Specifications
This
is a
starting point
for valve
adjustment
and the c1eatance
should
be
ch
cked
wheQ
the
engine
is at normal
opetating
temperature
10
Refit
the
inlet and exhaust
manifolds
using
a new
manifold
gasket
and
temporarily
fit the r ket cover and
gasket
11
Connect
the fuel
delivery
pipe
between
the
catbureltot
and
the
fuel
pump
and
the vacuum advance
pipe
between the
distributot
and the catbureltor
12
Clean
adjust
and instal
the
spark
plugs
fit
the
distributor
cap
and
connect
the
high
tension leads to the
spark plugs
and the
ignition
coil
13
Connect
the wire to
the
tempetature
gauge
sender
unit
on
the front of
the cylinder
head
14
Instal
the
upper
tadiator hose and
secure with the
two hose
clips
15
Fill the
cooling system
with
clean
water if
necessary using
the water
and anti freeze
mixture drained
from
the
engine previously
I6
Connect the
earth lead to the
battery
tenninal
start
the
engine
and
bring
it to nonnal
operating
temperature
switch off
the
engine
remove the rocker cover
and
check
and
if
necessary
adjust
the rocker
to
valve stem
cleatance see
Specifications
17
Re
instal
the
rocker
cover
and
tighten
the
six
screws securely
18 Inst
the
ait
cleaner and
pipe
from the cleaner
to
the rocker cover start
the
engine
and run to check
for oil
leaks
TO ADJUST VALVE
CLEARANCE
I
Run
the
engine
at
a
fast idle
speed
until
it has
attained
the normal
operating
temperature
2 Remove
the air cleaner
and
rocker covet
3
Turn the crankshaft in the normal direction
of
rotation until No
I
cylinder
is
at
tde on
the
compression
stroke
and
adjust
both rocker
anns to
give
the
specified
rocker
to valve stem clearance
4
Using
the same
procedure
fot
the
remaining
three
cylinders adjust
the other
six
tockers
5 To
check the
adjustment
turn the crankshaft until
one
valve is
fully
open
then turn a
fUtther one
complete
turn
and
check the clearance
for
this
valve Check the
remaining
valves
in the
same manner
6 Refit
the
rocker cover and
air cleaner
14
ProCarManuals.com

Engin
9
TO
REMOVE AND
INSTAL
d ENGINE
SUMP
I
With the
engine
removed
from
the vehicle
remove
the drain
plug
and drain
the oil into a suitable
container
Replace
and
tighten
the
plug
2
Progressively
loosen
and remove all
the
bolts and
spring
washers
securing
the
slimp
to the crankcase
3 Remove
the
sump
lifting
it clear of the
oil intake
strainer Remove the side
gasket
and the
end
seals around
the rear
bearing cap
and
the
lower
edge
of the
timing
cover
and discard
J
4 Clean the
sump
thoroughly ensuring
that all traces
of
the
old
gasket
are
removed
5 Clean the
gasket
face of
the crankcase
and
the end
seals
ensuring
that all traces o
the old
gasket
are
removed
6
Using
a small
quaniity
of suitable
sealing
compound position
a
new
gasket
on
the crankcase
face of
the
cylinder
block
NOTE
With
new cork
gaskets
that
appear
to be too small
or have shrunk a
few
minutes immersed
in water will
restore
them to their norma
length
7 Place
the
end seals in
position
and
ensure that the
ends of the seals
mate with the ends of the side
gasket
to
form
an
oil
tight joint
8
Carefully place
the
sump
in
position
on
the
gaskets
and
instal
two or
three
sump
retaining
bolts
to
hold
it in
position
9
Instal the
remainder of
the
bolts and
tighten
finger
tight
10
Using
a
suitable sockei
wrench
tighten
the bolts
evenly
and
progressively
a few
tums each
to
pull
the
sump
up firmly against
the
gasket
Do not over
tighten
the
bolts
or
the
flange
on the
sump
will be
distorted
Ensure that the
drain
plug
is
tight
before
filling
with oil
TO
REMOVE
6 TIMiNG HAIN AND
ieUV K
1 vlith the
engine
rerrloved
from the vehicle remove
the water
pump
and fan
assembly
2
Take out
the
retaining
bolt
and
washer
and
withdraw the
crankshaft
pulley
3 Remove ihe
sump
drain
plug
drain
the
oil
into a
suitable
container and
remove the
sump
Timing
Cover
showing Timing
Chain
Damper
Pad
4 Remove the
remaining
bol
ts and
washers
and
withdra
the
timing
chain cover from
the
front
of the
engine
Remove the oil
slinger
if fitted from
the
front
end
of
the
crankshafi
5 Unscrew the two bolts
securing
the
chain
tensioner
to the front
of the
cylinder
block and remove
the chain
tehsioner
B
NOTE
Use
care
when
removing
the tensioneras
the
pad
and
stem will be
forced
out
of
the tensioner
body
by the
spring
when the bolts
are moved
6 Rotate
the
crankshaft
until the
sprocket
key
is at
4
o
clock
and the
timing
mark
on
the
crankshaft
sprocket
is
adjacent
to
the
marked
link
plate
on the
chain The other
marked link
plate
on
the chain will be at
approximately
12
15 clock and
adjacent
to
the
timing
mark
dimple on
the camshaft
sprocket
7 Remove the
camshaft
sprocket
retaining
bolt and
washers
and
using
a suitable lever
prise
the
sprocket
off
the camshaft from
the
top
and remove the
sprocket
and
chain
disengaging
the chain from around
ihe crankshaft
sprocket
TO INSTAL
1
Clean all
components
and
remove all
traces
of the
old
gasket
from
the
timing
cover
waier
pump body
and
sump
2 Check
and if
necessary
rotate
the
camshaft until
the
sprocket
locating
dowel
is at
the
4 0 clock
position
in
relation to the centre of the camshaft
3 Check
and if
necessary
rotate
the crankshaft until
the
sprocket
drive key
in
the shaft
is at 4 0
clock
position
15
ProCarManuals.com

lQ
Engine
Showing
Wear
Limit for
Timing
Chain Stretch and
Tensioner Pad Wear
in relation
to the centre
of
the crankshaft
4 With the
camshaft and crankshaft
positioned
as
in
i and 3 above
a
line drawn
through
the centre of
each
shaft will also
pass
through
the centre of
the
camshaft
dowei and
the crankshaft
key
5
uy
the camshaft
sprocket
flat on a bench
with
the
timing
mark
dimple
to the
top
arid
facing up
The
locating
dowel hole
will be at
4
0 clock
6
Loop
the
timing
chain on the
camshaft
sprocket
so
that one of
the two marked
link
plates
of the
chain
engages
the
sprocket
adjacen
t to the
sprocket
timing
mark
dimple
The second
marked chain
link
plate
must
be
to
the
right
on
the short chain run
SPROCKET
RETAINING
WASHER
BOLT
t
4
RETAIDlER
PLATE
1
SPRING
WASHER
TIMING CHAIN
TENSIONER
BODY
fE NSIONER SPRING
0
SUPPER
HEAD
WASHER
Camshaft and Timing
Chain
Components
NOTE
The
liming
clwill
lillk
plale
marks
circles are rell
plates apart
on the shortest chain run This includes
the
marked
plates
7
Grasp
the camshaft
sprocker engaged
in the chain
and
position
it on
the
camshaft
looping
the chain around
the crankshaft
sprocket
so
that the
second mark circle
on
the chain link
is
adjacent
to the
timing
mark
dimple
on
the crankshaft
sprocket
see
illustration
8
Push the
camshaft
sprocket
on
to
fully
engage
the
locating
dowel
lnstal the
securing
bolt
and
washers and
tighten
to the
specified
torque
see
Specifications
9 Check
that
both
sprocket
and chain
timing
minks
register
for correct
valve
timing
10
Instal the chairi
tensioner on the front face of the
cylinder
block
ensuring
that
the
long
end
of the
slipper
pad
is to the camshaft
sprocket
II
Check
that
the
side tensioner
pad
in the
timing
cover
is serviceable and
renew
if
excessively
worn
12
Instal a new
oil seal in the
timing
cover with the
lipped
face
of the seal towards the
timing
sprocket
Instal
the oil
slinger
if fitted with the concave face
towards the
crankshaft
pulley
i
3 Further installation
is
a reversal
of
the removal
procedure
with
attention
to
the
following
Fit new
gaskets
where
necessary
Do not
over
tighten
the
sump retaining
bolts
7
C AMSHAFT
ND TAI PETS
2
Evenly
and
progressively
loosen
the rocker
pedestal
securing
bolts and remove
the
rocker
arm and shaft
assembly
3
Take
out
the
retaining
bolt and withdraw
the
crankshaft
pulley
TO REMOVE
I
With
the
engine
removed from
the
vehicle
remove
the water
pump
and
fan
assembly
and
take
off
the rocker
cover
16
ProCarManuals.com

r
Checking
Camshaft End Float
4
Drain the
engine
oil
and remove the sump
5 Take oui the
remaining
bolts
and withdraw the
timing
chain
cover from
the
front of
the
engine
Remove
tlie
oil
Slinger
from
the
front
end
of
the
crankshaft
6 Unscrew
the two
bolts
securing
the chain tensioner
to
the
front of
the
cylinder
block
and remove
the
chain
tensioner
NOTE
Use
care
when
removing
the
tensioner as the
pad
and stem
will be
forced
out
ofthe
tensioner bodv bv the
spring
when the bolts are removed
7 Remove the
eamshaft
sprocket retaining
bolt
and
washers and
using
a suitable lever
prise
the
sprocket
off
the
camshaft from the
top
and remove
the
sprocket
and
chain
disengaging
the chain from around the crankshaft
sprocket
8
Turn
the
engine
so
that the
crankshaft
is
Engine
ll
uppermost
and
press
each
tappet
down well
clear of the
camshaft
9 Disconnect
the
fuel
delivery pipe
at
the fuel
pump
take out
the two bolts and remove the fuel
pump
from the
right
hand side
of
the
engine
10
Remove
the
distributor
cap
and
high
tension
leads
disconnect the vacuum
pipe
at the vacuum advance
unit
II
Unscrew
and
remove the iwo
bolts from
the
oistributor retaining plate
and
withdraw the
distributor
from the
cylinder
block
12
Remove
the
oil
pump
and tilter
as
an
assembly by
unscrewing
the
three
bolts
and
withdrawing
the
assembly
from
the crankcase
13
Remove the two
retaining
bolts
and
washers
and
slide the camshaft
retaining
plate
clear of
the
groove
in
the
camshaft
and
remove
the
plate
14
Withdraw the
camshaft from
the
cylinder
block
using
care not to
damage
the camshaft
bearings
with
the
sharp
sides
of the
cams
Remove
the
tappets keeping
them
in
their
correct order
for
reassembly
5 Check the
camshaft
bearings
and
if worn
to
excess
using
a
special
screw
press
remove the
worn
bearings
and
press
ne
bearings
into
position
Line bore the
new
bearing
to
the cor ect size and fit
a new
expansion
plug using
a small
quantity
of
sealing compound
in the
end of
the rear
camshaft
bearing
bore
TIMING MARKS
A
9
tr
r
l
CAMSHAFT SPROCKET
J
e i
O
j
wf 1
17
ProCarManuals.com

12
Engine
TO
INSTAL
t Check
tha t the
bearings
are clean and if new
bearings
have
been installed
check that the oil holes
register
wi th the oil
passages
in the
block
casing
2 Biow out all
oil
ways
to remove
any
dirt
or
metal
cuttings
Apply engine
oil
to the tappets and fit
them
in
their cortect
positions
3
Apply engine
oil to
the
bearing
bores
and
the
cainshaft
jOlJ
rnals
and insert the
camshaft into
position
taking
care not to
damage
the
bearings
with the
edges
of
the
cams
4
Che k the camshaft
retaining
plate
for
wear and if
serviceable
apply
a
coating
of oil and
position
it in
the
groove
in the
camshaft line
up
the holes and instal tlie
two
securing
bolts
and
tighten firmly
If a
small lubrication
hole
is
preSent
in
the camshaft
retaining
plate
it should
be
to
the
right
of the
engine
when
the
plate
is
correctly
installed
5
Rotate
the
camshaft
until the
sprocket
locating
d owel is
at
the
4 u clock
position
in
relation
io the centre
of
the camsHaft
6 Rotate the crankshaft until
the
sprocket
drive
key
ii1
tl
e
shaft is
at
4 o clock
position
in
relation
to
the centre
of
the crankshaft
7
Witli die camshafi
aM
crankShaft
positioned
as in
5
and
6
above a line drawn
ihrOligh
the
centre
of
eac
shaft will also
pass
through
the centres of the
camshaft
dowel
and the crankshaft
key
8
Lay
the
cainsh ft
sprocket
flat
on
a
bench
With
the
timing
mark
dimple
to
the
top
and
facing
up
The
locating
dowel hole
will be
at 4
0 clock
9
Loop
the
timing
chain
on the
camshaft
sprocket
so
that one of the two
marked link
plates engages
tlce
sprocket
adjacent
to the
sprocket timing
mark
dimple
The
second
marked link
plate
must be to
the
right
on the
short chain
run
NOTE The
timing
chain link
plate
maries
circles
are
ten
plates
apart
on
the shortest
chain
roll This
includes
the
marked
plates
10
Grasp
the
camshaft
sprocket
engaged
in
the
chairi
and
position
it on
the camshaft
looping
ine chain
around
the crankshaft
sprocket
so
that the
secdnd mark on the
chain
link
circle is
adjacent
io ihe
timing
mark
dimple
on
the crankshaft
sprocket
See illustration
11
Push the
camshaft
sprocket
on
to
fully engage
the
locating
dowel instal
the
securing
bolt and
washers and
tighten
io
the
specified
torque
see
Specifications
t
2
Check
that
both
sprocket
and chain
timing
marks
register
for correct valve
timi1Jg
13 Instlil
the chain tensioner
ensuring
that ille
long
end of
the
slipper pad
is
to
the
camshaft
sprocket
14 Check
the
side tensioner in
the
timing
cover is
serviceable and renew if
excessively
worn
15 Instal
a new
oil seal in the
timing
cover with the
lipped
face
of
the
seal towards
the
timing
sprocket
Instal
the oil
slinger
if
fitted with the
concave face towards the
crankshaft
pulley
16
Further installation is a
reversal
of
the
removal
procedure
with attention to the
following
Fit n w
gaskets
where
ne
essary
Instal the distributor and time the
ignition as
described
in
DISTRIBUTOR ELECTRICAL
SYSTEM
Ensure that the
push
rods are
installed in the
positions
from which
they were
removed and
adjust
the
valve
clea
ance
after the
engine
has
been
brought to
operating
temperature
TO
REMOVE AND
DISMANTLE
8
PISTONS
AND
CONNECTING
RODS
lJ
With
the
engine
removed from ihe vehiCle
drain
the
engine
oil
aridJemove
the
sump
2 Remove
the
cylinder
pead
as
previously described
3j
Turn the cr mkstf ift ntil iwd
of the
pistons
are at
the
top
of
theicylinder
bores
The two other
connecting
rods will be
ai the
lo
esipoinls
ih
the
engine
4
Check that
the
big
end
bearing
caps
and
connecting
rods
are numbered with the
number of
the
corresponding
cylinder
bore
and
note
the
side of the
engine adjacen
t to
the
numbers
5
Release and remove
the
big
end
bearing
nuts
on
one of the
connecting
rods
and withdraw the
big
end
bearing cap
and
lower half shell
bearing
NOTE
If
the
piston iings are
to be reneWed it is
good
policy
to
remove
any
ridge
around the
upper
end
of
the
cylinder bore
using
a suitable ridge
removing
tool
before
removing
the
piston
and
connecting
rod assemblies
from
the
cvlinder bore
This will
prevent
the
metal
shavings
from getting
into the
crankcase area
of
the
enginc
6 Push
the
connecting
rod and
piston up
the bore of
the
cylinder
and remove from
the
top
of
the
engine
Remove the other
piston
and
connecting
rod
assemblies
in a
like manner
7
Replace
the
big
eno
liearing
shells and
cap
in each
assembly
as
it is
removed arid instal
the
retaining
nuts
8
If new
piston rings
are
being
installed
remove
the
old
piston rings
from
the
pistons
using
care
not to
damage
the
piston
skirt
or
ring
lands
9 Clean all carbon
deposits
from the bottoms
of the
ring
grooves taking
care not to
damage
the sides of
the
lands
or base
of
the
grooves
A
broken
piston
ring
of the
Correct section width used
carefully
makes a
satisfactory
scraper
10
Remove the carbon
deposits
from the
piston
crown
using
care not to score the
top
of the
piston
II Do not
press
the
gudgeon
pin
out of the
piston
18
ProCarManuals.com

and
small end
of
the
connecting
rod unless
one or other
of
the
components
are to
be renewed
NOTE
The
gudgeon pin
is an
interference fit
in the small
end
of
the
connecting
rod
and this is the
sole means
of
retaining
the
assembly
together
The
gudgeon pin
is a
thumb
push fit
in
the
piston
at normal
room
temperature
TO FIT
NEW PISTON RINGS
1
Wipe
the
cylinder
bores clean
and
ensure
that there
are
no
traces of carbon
or other
foreign
matter
present
2 Place
a new
piston ring
in the
bore of
the
cylinder
and
using
the
piston
inverted
push
the
piston ring
down
to
a
relatively
unworn
part
of
the
cylinder
bore
3
Using
a
feeler
gauge
of the correct thickness
check
the
gap
If
necessary
adjust
the
gap by filing
to
increase
the
gap
width
If
the
gap
is
too wide
select another
ring
from
the set If the
rings
are a matched set
adjustment
will
not
be
necessary
4 Treat
all
piston rings
in the same manner
and
ensure
that
the
ring
side
clearance
in the
piston groove
is
within the
specified
limits
and
that the
rings
are installed on
the
piston
for the
cylinder
to
which the
rings
have been
fitted
NOTE USe a
ring expanding
tool to
fit
the
rings
on
the
pistons
Fit the
rings from
the
top of
the
piston
never
over
the skirt
f
Lubricate the
piston
and
ring
assemblies
with
engine
oil
before
fitting
in
the
cylinder
bores
6
If the
compression rings
are
taper
faced
they
will
be
marked
Top
and this mark must
be
uppermost
when ihe
rings
are
installed on
the
pistons
TO
REASSEMBLE
AND INSTAL
1
With the
rings
fi
tted to
the
pistons
and the
piston
and
connecting
rod
assembly
adequately
lubricated with
clean
engine
oil
arrange
the
piston rings
so that the
top
ring
gap
will
be to
the side of the
piston directly away
from the
exhaust
valve
position
2
Fit
the second
compression ring
with
the
gap
at
1800
to the
top ring gap
3
Fit the
oil
ring spacer
with the
gap
to the
right
side
of
the
engine
and the
upper
and
lower oil
ring segments
with their
gaps
1200
either
side of
the
spacer
gap
4
Insert the
connecting
rod into
the
cylinder
bore
from which
the
assembly
was
originally
removed and
using
a suitable
ring
compressor
to
compress
the
rings tap the
assembly
iilto
the bore
using
a
clean hammer
handle until
the
ring
compressor
is
free The
size
code number
and
the
letter F if
shown should
be
to
iheTront
5
Oil the
upper
half of the
big
end
bearing
shell and
ensure
that
it
is
correctly
seated in
the
connecting
rod
with
tang
oUhe
bearing
shell
locating
with
the recess in
the rod
6
Pull
the
connecting
rod and
piston
assembly
down
Engine
13
TOP
RING
o
SECOND RING
O
OIL RING SEGMENT
O
OIL RING EXPANOER
OIL RING SEGMENT
0
PISTON
CONNECTING ROD
1
BOLT
J
BEARING CAP
NUT
Piston and
Connecting
Rod
Components
the
bore until the
big
end
of
the
connecting
rod
engages
squarely
with the
crankpin
7
Oil the lower
half
bearing
shell and
bearing
cap
and
fit it to the
connecting
rod
Instal
the
big
end nuts
finger
tight
NOTE Ensure that
the
number of
the
bearing
cap
is
adjacent
to
the
number on the
connecting
rod and that
the
squirt
hole
in the
big
end ofthe
connecting
rod
is to the
right
hand
side
of
the
engine
8 Instal the other
piston
and
connecting
rod
assemblies
using
the
same
procedure
9
J Tighten
the
big
end
bearing
nuts to the
specified
torque
See
Specifications
19
ProCarManuals.com

14
Engine
TO CHECK
CYLINDER
BORES
9
LlNDER BOllES
AND PISTONS
DEGlAZING
CYLINDER BORES
NOTE To
accurately
check cvUnder
bore
condition alld
wear
it is essential that all
pistons
and
connecting
rod
assemblies be
removed
from
the
cylinder
block
also that
accurate
measuring equipment
be available to determine the
actual
cvlinder bore overall wear
including taper
and
ovality
The
cylinder
boTf s should be
wiped thoroughly
clean
with
a clean
rag before
checking
I
Visually
check the
bores for
cracks
flaws
scuffing
or
scoring
2
Check each
cylinder
bore for
wear
including
taper
and
ovality
3
Cylinder
bores that
upon
checking prove
to
be
unserviceable should be
rebored and honed to
the
smallest
immediate oversize and new
oversize
pistons
and
rings
filted
NOTE
Ifit
is
found
that the
cylinders
leed
boring
select
the
cylinder
with the
most
wear
to
detennine what
oversize
pistons
aTe to
be
used
Bore all
cylinders
to that oversize
See
Specifications for
available
oversize
pistons
Engines
that have been bored to their extreme limit can
be filted
with
cylinder
sleeves which are available
in
three
sizes
on outer
diameter
New
pistons
and
rings
should still
be filted with sleeves
NOTE
Cl li lder bores
that
are
fit
for further
service
with
original
pistons
but
require
re
nOnging
should
be
deglazed
with
a
hone
1
Position
plenty of clean
rag
over the crankshaft
and under each
cylinder
bore to
keep
abrasive materials
from
entering
the
crankcase
area
2 De
glazing
of
the
cylinder
walls
may
be done
by
using
a
cylinder
surfacing
hone
equipped
with
280
grit
stones
3Honing
should be carried out
by moving the hone
up
and
down the
cylinder
walls
fast
enough
to achieve
a
cross
hatch
pattern
When hone marks
inter
ect
at
60
deg
the Cross hatch
angle
is
most
satisfactory
for
the correct
seating
of
piston rings
NOTE
When
deglazing
it is
important
t wt
only
enough
strokes
of
the
hone are made to
eliminate the
glazing
condition
of
the
cylinder Excessive
honing
will increase
bore size and thus
increasepiston skirt
clearance
4
Use
honing
oil which is
available from all
major
distributors Do
not use
engine
or transmission oil mineral
spirits
or kerosene
5 After
honing
it is
necessary
that
the
cylinder
block
be
thoroughly
cleaned to remove all traces of
abrasive
Piston and
Cylinder
Grade Numbers
Stamped
on Pistons and
Top
of
Cylinder
Block
20
ProCarManuals.com