Datsun 1200 1971 Operating instructions

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DATSUN 1200
RANGE
1971 1973
MAINTENANCE REPAIR
BY DRAKE AUTOMOTIVE EDITORS
Quick
Referencelodel
MAINTENANCE TUNE
UP 5
STEERING
89
ENGINEERING
13 REAR DRIVE
ELECTRICAL
SYSTEM
35
SUSPENSION
93
IGNITION
SYSTEM
43
CLUTCH 99
FUEL
SYSTEM
49
TRANSMISSION
103
COOLING SYSTEM
63
BODY WORK
111
BRAKES
67
SPECIFICATIONS
129
FRONT
SUSPENSION
83
The
purpose of
this manual IS to
provide
the automobile owner and mechanic with
a reference
source
with which
he can
perform
normal service
operations
We endeavor to
lOcorporate
the
latest manufacturing
design
changes
and up
to date
specifications
at
the
time
of publication
While every effort IS made to attain accuracy
the Publisher cannot be held
responsible
for
manufacturing changes typographical
errors or
omiSSions
Upon
compIling
the information
contained
herein we have tried to be brief and
Simple relvlng
on
the
combination of
photographs
Illustrations and text to
make thIS manual a
useful tool
DRAKE
PUBLISHERS
INC
361
PARK AVENUE SOUTH
NEW
YORK NY 10016

ISBN 0 87 749 309 X
Pubhshed III 1973
by
DRAKE PUBLISHERS INC
381 Park
Avenue South
New York
N Y10016
@Drake Pubhshers
Inc 1973
Prmted m the
Umted States of Amenca

able of
Contents
MAINTENANCE TUNE
UP DIsassembly
32
InspectIOn RepaIr
33
VALVE
CLEARANCES 6
AdJustmg Regulator
33
ENGINE
OIL
6
Assembly
33
OIL FILTER
7
COOLANT 7
COMPRESSION 7
ELECTRICAL SYSTEM
BATTERY
8
IGNITION TIMING
8 STARTER
36
DIstributor
Breaker
Pomt
9 Removal
37
Condenser
9
InstallatIOn 37
Spark
Plugs
9 Trouble
Shootmg
37
Carburetor
9
ALTERNATOR
36
Idle
LImIter
Cap
10
Removal
37
Dash
Pot automatic transmISSIOn
11 InstallatIOn
37
model
only
11 REGULATOR
39
Carburetor
Return
Sprmg
11
DeSCriptIOn 39
Fuel Filter 11
Trouble
Shootmg
40
ENGINE
IGNITION SYSTEM
DESCRIPTION
14
DISTRIBUTOR 44
REMOVAL 14
ConstructIOn
44
INSTALLATION 14
Checkmg
and
Adjustment
44
CLEANING INSPECTION 14
SP ARK PLUGS
46
DISASSEMBL
Y14
DeSCriptIOn 46
INSPECTION
REPAIR
18
InspectIOn 46
PreparatIOn
18
Cleamng Regap
47
Cyltnder
Head
18
Valve
Assembly
18
Valve
Spnng
19
Valve Rocker Shaft
Rocker Arm
19
FUEL
SYSTEM
Valve LIfter Push Rod
20
Camshaft Camshaft
Bearmg 20
FUEL FILTER
50
Valve
Tlmmg
20
DESCRIPTION 50
Cyltnder
Block
21 REMOVAL
50
PIston Piston Pm
Plsto LRmg
21
INSTALLATION
50
Connectmg
Rod
23 FUEL
PUMP
50
Crankshaft
24
DeSCriptIOn 50
Bushmg Bearing 24
Testmg 51
Crankshaft
Sprocket Removal
DIsassembly 52
Camshaft
Sprocket 25
InspectIOn 52
Flywheel 25
Assembly 52
ASSEMBL
Y
25
CARBURETOR
52
PrecautIOn
25
DeSCription 52
Cyltnder
Head
25
Adjustment 53
PIston
ConnectIng
Rod
26
Removal
58
Engme 26
DIsassembly 58
OIL PUMP
32
Cleanmg
InspectIOn 59
Removal
Engme
m
vehicle 32
Assembly
InstallatIOn
60
I

labl8 of
Contents
Jets 60
FRONT SUSPENSION
TlOuble
Shooting
60
f
DESCRIPTION
RECOMMENDATIONS
TROUBLE
SHOOTING
I
85
COOLING
SYSTEM
DESCRIPTION 64
STEERING
WATER
PUMP 64
Hemoval 65
DESCRIPTION 90
InstallatIOn 65
RECOMMENDATIONS
90
THERMOSTAT
65
TROUBLE SHOOTING 91
Removal
65
InspectIOn
65
REAR DRIVE
Installation
65
RADIATOR
66
SUSPENSION
Hemovdl
66
InspectIOn
66
REAR AXLE 94
InstallatIOn
66
DIFFERENTIAL
94
REAR SUSPENSION 95
REAR SHOCK ABSORBER
96
Replacement
96
BRAKES
InspectIOn
97
RECOMMENDATIONS
97
FRONT DISC BRAKE
68
BRAKE
PAD
68
Replacement
68 CLUTCH
InspectIOn
68
ReinstallatIOn
68
DESCRIPTION
CALIPER
70
CLUTCH PEDAL
Removal
70
Removal
Disassembly
71
InspectIOn
InspectIOn Repmr
71 ReinstallatIOn
Reassembly
72
Adjustment
ReinstallatIOn 74 CLUTCH MASTER CYLINDER
REAR BRAKE
74
Removal
Hemoval
Dlsdssembly
74
DIsassembly
InspectIOn
75
InspectIOn
Reassembly
ReinstallatIOn
75
Reassembly
HAND BRAKE
75
RemstallatlOn
Removal
75
BLEEDING CLUTCH
SYSTEM
InspectIOn
76
RemstallatlOn 77
ADJUSTMENT 78
TRANSMISSION
Front DI
c
Brake
78
Rear Brake
78 4 SPEED TRANSMISSION
Brake Pedal
HeIght
78 3 SPEED TRANSMISSION
Hand Brake
79 TROUBLE SHOOTING
BLEEPIN
HYD
AULIC SYs r M 79
i UIQM
ATJ
C
TRANSMJSSIQ
TROUBLE
SHOOTING
80
RECOMMENDATIONS
2

fable of Contents
BODY
WORK
SPECIFICATIONS
I
HOOD
112
SERVICE
DATA
130
Removal
112
ENGINE
134
InstallatIOn
112
General SpeCificatIOn
134
HOOD LOCK
112
Tlghtemng
Torque
134
Removal
112
SpeCIficatIOn
135
Adjustment
112
Coohng System
139
LubncatlOn
114
Fuel
System
140
TRUNK LID
LOCK
116
Starter
142
Removal
116
Alternator
143
Adjustment
116
Regulator
144
TRUNK
LID TORSION BAR
116
Dlstnbutor
145
DOOR CONSTRUCTION
117
IgnItIOn
Cot
145
WIRING DIAGRAMS 118
CLUTCH
146
BULB SPECIFICATIONS
120
NOTES
174
HEADLAMP
121
THERMOMETER AND
FUEL METER 122
OIL PRESSURE AND IGNITION
WARNINGLAMPS 126
I
I
t
I
3

aintenIDce
TUDe
up
Ii

ainteDaDee
TUDe
up
VAL VE CLEARANCES
Valve
clearance
adjustment
should be made
while
engme
IS
stationary
To
adjust proceed
as
follows
Start
engme
and run It until It IS heated
to
operatIng temperature
or
at
least more than
17S
of
engIne
011
temperature
then
stop
engIne
Rotate crankshaft to
bnng
No 1
cylInder
In
top
dead
center
on
ItS compressIOn stroke
Remove valve rocker
cover
to
gaIn
access
to
valve
operatIng
mechamsm
Adjust
valve
clearance at
follOWing
four
pOints
while engIne IS still hot
1
Exhaust valve of No
1
cylinder
2 Intake valve of No
1
cylinder
3
Intake
valve
of
No 2
cylinder
5 Exham t valve of No 3
cylInder
ote
Numbers in
parenthesis agree
with
those
10
accompanY1Og
sketch
AgaIn
rotate crankshaft
one
turn
so
that No
4
piston
IS In
top
dead center
on
ItS
com
pressIOn
stroke
Adjust follOWIng
valves
4 Exhaust valve of No
2
cylinder
6 Intake valve of No 3
cylinder
7 Intake valve of No 4
cylInder
8 Exhaust valve of No
4
cylinder
Rg
1
AdJustmg
valve clearance
8
Adjustment
should ue made whIle
engIne
IS
hot After all valves have been
adjusted
correctly tighten
lock nut
firmly
to secure
the
adjustment
Checking
and
adjusting
drive belt
Check for a cracked
or
damaged
V belt
Replace
If
defective
Adjust
the belt tenSIOn If
necessary
Belt
deflectIOn when thumb
pressure
of 220 Ib IS
applied midway
between
pulleys
0394 to
o 590
In
ENGINE OIL
011
capacity
of
engIne
IncludIng
011 filter
Capacity
MaXimum VB US
gal Imp gal
MInimum 5IB US
gal
III
Imp gal
Make sure that
engIne
011 IS
not detenorated
With
cooling
water
or
gasolIne
DraIn and
refill the 011 lf
necessary
Notes
a
A
m1lky
011 indlcates
presence
of
cooling
water
Valve clearance
Hot
Intake
0014
In
Exhaust
Fig
2
AdJustmg
dnve belt tension

aintenIDce
une
up
Find the cause
for
necessary
corrective
action
b Oil with
extremely
low
viscosity
in
dicates dllutton
with
gasoline
Check 011 level If found
below L
mark refill
to H mark on
gauge
OIL
FILTER
The 011 filter
IS
of
a
cartndge
type
Check for 011 leaks
through
gasketed flange
If
any
leakage
IS
found
retIghten
shghtly
If
nece
sary replaLe
filter
as
an
assembly
When
mstalhng
an
011 filter
tIghten by
hand
Note
Do not
overtighten
011
fIlter
or
oil
leakage
may
result
I
I
Fig
3
Checking engine
011 level
Oc OF
I
0 121
20141
30
21
401401
5015BI
I
EGOQl
I
10 20
Fig
4
Protection concentration
COOLANT
LL
C
IS
al ethylene glycol
base
product
con
tammg
chemical
mhlbltors to
protect
the
coohng
system
from
rustmg
and corrosIOn
The
L
I C does not con tam
any glycerme
ethyl
or
methyl
alcohol It
wIll not
evaporate
or
bOll
away
and can
be
used
wIth either
high
or low
temperature
thermostat It
flows
freely
transfers heat
effiCiently
and
will not
clog
the
passages
m
the
coohng
system
The LL C
must not be
mIxed wIth other
products
ThiS
coolant can
be used
throughout
the seasons
of
the
year
Whenever
any
coolant IS
changed
the
coohng
system
should be flushed
and
refilled
wIth
a
new
coolant
Check
the
level
COMPRESSION
Compression pressure
test
Note To
test
cylinder
compression
remove
all
spark plugs
and
hold
tester
fit
Percent
BOllIng pomt
concen
09
kg
cm2
Freeze
tra
lion
Sea level
coolmg
sys
protectIon
tern
pressure
30
2210F 2550F
50f
50
2280 F 2610F 31oF
ETO 104
Fig
5
Testing compressIon
pressure
7

aiDtenaDce
TUDe
up
ting tightly
m
spark
plug
hole
of a
cylin
der
The tester is used to determme whether
cylinder
can hold
compression
or
whether
there IS excessive
leakage
past
rings
etc
Test
compressIOn
wIth engme warm
all
spark
plugs
removed and throttle and choke valve
opened
No
cyhnder
compressIOn
should be
less than 80 of
highest cyhnder
s Excessive
variatIOn between
cyhnders accompamed by
low
speed
missing
of the
cyllndel usually
10
dlcates
a valve
not
properly seating
or a
blOken
pIston ring
Low
preSsures
even
though
umform
may
indIcate
worn
rings
ThIs
may
be
accompamed by
excessive 011
consumptIOn
Test Conclusion
If
one or more
cyhnders
read
low
Inject
about
one
tablespoon
of
engine
011
on
top
of the
plstons
In
low
readmg cyhnders through
spark
plug
hole
Repeat
compressIOn
check
on
these
cy
II nders
If
compressIOn Improves
conSiderably piston
rings
are defectIve
If
compressIOn
does not
Improve
valves
are
stIcking
or
seatIng Improperly
If two
adjacent cyhnders
mdlcate
low com
pressIOn
and
mjectmg
011
on
pistons
does not
Increase
compreSSIOn
the cause
may
be a
cylInder
head
gasket
leak between
the
cyhn
ders
Engine
011 and coolant In
cylInder
could
result from this
problem
CompressIOn pressure
178 to 206
pSI
at 350
rpm
BATIERY
Check
electrolyte
level 10 each
battery
cell
Unscrew
each filler
cap
and
Inspect
flUId
level If flUId level
IS low add
dIstilled
water
to
bring
level
up
to
approximately
03937 to
07874 In above
plates
Do not
overfill
Mea
ure
P illL gravlty
of
pattery
el
c
trolyte
8
Clean
top
of
battery
and terminals With a
solutIOn of
baking
soda and water Rinse
off
and
dry
WIth
compressed
atr
The
top
of
bat
tery
must be clean to
prevent
current
leakage
between
terminals and from
poSItive
termlndl
to hold down
clamp
In additIOn
to
current
leakage prolonged
ac
cumulatIon of aCId and dirt
on
the
top
of bat
tery
may
cause
bhstenng
of the material
covering
connector
straps
and corrOSIOn of
straps
After
tightening
terminals coat them
With
petrolatum
vasehnel to
protect
them
from
corrosIOn
IGNITION TIMING
Check
spark
plugs
and dIstributor breaker
pOints
for conditIon
I
I
Thoroughly
wipe
off dIrt and dust
from tlmmg
j
marks
on
crank
pulley
and front
cover
Warm
up engine
suffiClently
PermIssIble Full
charge
value
value at 68OF
Fngld
chmates Over
1 22
128
TropIcal
chmates Over
I
18
123
Other
clunates Over
1
20 126
j
J
I
ET002
Flg
S
Gheckmg
the
speCific gravity
of
baltery
elec
trolyte
f

l
aiDteDaDce
UDe
up
Install
a
timing lIght
on No
1
cyhnder spark
plug
WIre and Install
a tachometer
Set
Idhng ipeed
to
approximately
800 rpm
Check
19mtlOn tImmg
If
It
IS 50BTDC
Before
Top
of Dead Center
by
the use
of
tlmmg
hght
If
necessary adjust
It as
follows
Loosen
iet
screw
to such an
extent that
dlstnbutor can be
moved
by
hand
AdJu it IgmtlOn tIming
to 50BTDC
Lock dlstnbutor
set screw
and make sure
that tlmmg
IS correct
IgnitIOn tImmg degreel
50 BT DC
Distributor Breaker Point
Check
dlstnbutor breaker
pomts
for abnormal
pItting
and wear
Replace
If
necessary
Make
wre
they
are
In correct
ahgnment
for full con
tact and that
pOint
dwell and gap
are correct
Clean
and
apply
dlstnbutor
grease
to cam and
WIck
Note Do
not
apply grease
excessively
Dl tI IbutOl
POint
gap
0 018 to 0
022 In
Dwell
angle
49 to
55
degrees
Condenser
Clean outlet
of condenser lead
WIre and check
for loose
set screw
RetIghten
If
necessary
Check
condenber
capacIty
With
a
capacity
meter
Fig
7
Checking Igmllon timing
Condenser msulatlOn
resistance
may
be also
checked
usmg
a
tester
by
adjusting
ItS
range
to measure
large
resIstance value When con
denser IS normal the tester
pomter swmgs
largely
and
rapidly
and
moves
gradually
back
to
the Infimte SIde When the
pomter
does not
stay
still or It
pomts
zero
m reSIstance
replacement
IS
necessary
Condenser
capacIty
022
J
F MIcro
Farad
Condenser InsulatIOn
resIstance
5
Mn
Mega
ohms
Spark Plugs
Remove and clean
plugs
In a sand blast
cleaner
Inspect
each
spark plug
Make iure
that
they
are of the
specified
heat
range
In
ipect
msulator for cracks
and
chIps
Check
both center and
ground
electrodes If
they
are
excessIVely
worn
replace
WIth new
spark
plugs
File center electrode flat
Set the
gap to
0031 to 0035
m
USIng
the
proper adjustIng
tool
Tighten plugs
to
11 0 to
150
ft Ib
torque
CARBURETOR
Idle
mixture
adjustment
requIres
the use of
a
CO meter
When
preparIng
to
adjust
Idle
mixture
It
IS essential
to
have
the meter
thoroughly
warmed
and cahbrated
Warm
up
the
engme suffiCiently
ContInue
engIne operatIOn
for one
mmute
un
der
ldhng speed
I
i
I
I
I
I
I
I
ETOQ4
Fig
8 Checking
dlstnbutor
POint
gap

aiDteDaDce
UDe
up
Adjust
throttle
adjusting
screw so
that
engme
speed
1S 800
rpm
m N
positIOn
for
automatic transmIssIOn
Check
IgnitIOn tlmmg
If
necessary adjust
1t to
the
specIficatIOns
IgnitIOn
timing
50 800
rpm
Adjust
Idle
adjusting
screw so that CO
percen
tage
IS
1 5 t0 5ff
Repeat
the
adjustments
as desctlbed
In
steps
3
above
so
that CO
percentage
IS
15 t0 5ff at
800
rpm
Cautions a On automatic transmission
equipped
model check must be done in
the D
position
Be
sure
to
apply parking
brake and
to
lock both front and rear
wheels wIth wheel chocks
b Hold brake
pedal
while
stepping
down
on accelerator
pedal
Otherwise
car
will
rush out
dangerously
On automatic
transmISSIOn
eqUIpped
model
make sure that the
adjustment
has been made
wIth the selector lever In N
posItion
And then check the
specificatIOns
with the
lever In D
posItion
Insure that CO
percent
and Idle
speed
are as follows
Idle
rpm
650 Idle Limiter
Cap
CO
percentage
Do
not
remove this Idle hm1ter
cap
unless
necessary
If this Unit
IS
removed It
IS
I
with lever
In
D
PoSitIOn
1
5 t 0 5k
necessary
to re
adJust
It at the time of In
If
necessary adjust by progIesslvely turmng
stallatlon To
adjust proceed
as
follows
throttle
adJustlng
screw
and
Idle
adJustmg Make
sure that the
percentage
oLCO
contents
screw until
correct
adjustments
are made satisfies the
specifications
I
I
I
I
J
Fig 9 Checking spark plug
gap
10
Throttle
sdJustlnl
screw
Idle
adjust
Inlscrew
Idle Itmlttc
r
cap
4
Stopper
Fig
10 Throttle
adjusting
screw and Idle
adjusting
screw
CARB
STOPPER
Fig
11
Setting Idle limiter cap
Notes a Do
not
attempt
to
screw
down
the idle
adjusting
screw
completely
to
JI
avoid
damage
to
the
tip
which will tend
to
cause malfunctions
b After idle
adjustment
has
been
made
I
shift the level to N
or
P
position
for
automatic
transmission
c Remove
wheel chocks before
startmg
the car

aiDtenuce
TUDe
up
Fig
12
Fuel strainer
Install
Idle hmlter
cap
m
posItion makmg
sure that the
adJustmg
screw can further turn
rotatIOn m
the CO RICH
d1rectlOn
Dash
Pot
Automatic
Transmission Model
Only
Check
operation
of dash
pot
It
should not be
cracked or bound
It IS also essenttal to check
r
w
be
certam
that
It IS
m
correct
adjustment
Check to be sure
that
dash
pot
contacts
stop
per
lever
when
engme speed
reaches 1
900
to
2
000
rpm
Engme
should
be
slowed
down
from 3 000
to
1
000
rpm
within
a
few
seconds
Readjust
dash
pot
or
replace
It
with a new
one
lflt
falls
to
meet the
above
condItions
Carburetor Return
Spring
Check throttle return
sprmg
for sign
of
damage
wear
or
squareness
Discard
spring
If
found wIth
any
of above
excessIvely beyond
use
Fuel
Filter
Check
for a
contammatlOn
element
water
depoSIt
and defection
All
engmes
use a
cartridge type
strainer If 1t
IS
found
to be
defective
replace
as an
assembly
u

IQgiDe
DESCRIPTION
The A12
engme
IS a
715
cu m In I me over
head
valve four
cyltnder engine
with
2874
m
bore
and 2 765 m stroke It feature
full
opened wedge shaped
combustIOn cham
ber alummum heads and
fully
balanced
5
bearmg
crankshaft to turn out smooth
dependable power
REMOVAL
Removmg
hood
Open
the hood
remove four mstallatlOn bolts
and remove the hood
Disconnect the
battery
cable from the ter
mmal
Removmg
radIator
Dram water from the radiator disconnect two
radIator hoses
remove four
radIator m
stallatlOn bolts and
remove
the radiator
Removmg
cables and hoses
Disconnect the
followmg
cables hoses and
wires
High voltage
cable between
Igmtton
COlI and
distributor
Cable to the thermal transmitter
Cable to the 011
pressure
sW1tch
Cable to the
primary
Side of the distributor
Cable
to the
startmg
motor
Fuel hose
Cable to the
alternator
Heater hose for model With heater
only
I
Fig
13 Sectional view of A
12 Engine
It

Bngine
WIres for accelerator
and
choke The
operatIOn
Will be carned
out more
easily
by
removing
the
a1r
cleaner
Lift
up
the
engine
toward the front
INST ALLA TION
Install the
engine
In
reverse
sequence
of
removal
Disconnecting
clutch
wire on
nght
hand dnve
model
On
left
hand dnve model
disconnect
hydraulIc
line
from the clutch slave
cylInder
DIsconnect
the clutch WIre at the
JXlrtlOn
of the
wIthdrawal lever
Remove
the exhaust front tube
Disconnect the
the cable to the back
up
lamp
SWItch
D1sconnect
the
speedometer
cable
Remove the
propeller
shaft
Remove
four bolts
used In the differential
carner
SIde and Withdraw
the
propeller
shaft
Remove the shift lever
Model With remote control shIft lever
Disconnect
the remote control rod
at the
JXlr
tlOn of transmiSSIOn outer lever
and remove
the
remote control rod
Model With
floor Sh1ft lever
Remove
the boot WIthdraw the
lock
pin
and
remove
the lever The
operatIOn
IS
carned out
In the
passenger compartment
Model With
automatic transmiSSIOn
Remove
pinS
from both ends of the cross shaft
and
remove
the shIft rod
Suspend
the
engine With
wire
Remove the
front
engine
mounting
installation
nuts
Remove the rear
engine
mounting
installation
nuts
When
removing
the
engine mounting
in
stallation
nuts be sure
to
apply
a
Jack
beneath
the transmiSSIOn
CLEANING AND
INSPECTION
Clean the
engine
thoroughly
before disassem
bly
Before
cleaning
the
engine
remove the
l
electncal
parts
and
plug
up
the carburetor
air
horn to aVOid intrusIOn
of
foreign
matter
The
engine
extenor
Check
the covers and
boltsfor
breakage
rust
damage
and loss
CylInder
block Check
thoroughly
the water
Jacket
for cracks and
breakage
Clutch
hOUSing
Check for
cracks
011
pan
Check for excessive
rust
DISASSEMBLY
Mount
engine
assembly
on
engine
stand
Remove the
engine mounting
bracket R H
Side
Install the
engine
attachment
Mount the
engine
on
the stand
Fig
14011
pump
removal
Fig
15 Thermostat
hOUSing
removal
II

Bngine
Remove the altel nator and
engine
mounting
bracket
L
H slde
Remove the crankshaft
pulley
Remove
the
011
pump together
With the 011
filtel
Remove the
high
tensIOn cable
wIth the
dlstnbutor
cap
on
Remove the
spark plugs
Remove the dlstllbutor
assembly
Remove the carburetor
Remove the rocker cover
Remove the thermo itat
houslllg
Remove the manifolds
Remove the water
pump
Remove the fuel
pump
Fig
16 Manifolds removal
Fig
17 Water pump removal
18
Remove the rocker shaft
assembly
and
push
rods
Remove the
cylInder
head
assembly
Invert the
engine
Fig
18
Rocker shaft
assembly
removal
7
1
l
I
h
Y r
I w
L 1
Fig 19 Cylinder
head bolts removal sequence
o
Fig
20 011 strainer removal
j

Bneine
Remove
the
011
pan
and 011 straIner
Remove
the
tImIng
chaIn
cover and the chaIn
tenSlOner
Remove the
crankshaft and camshaft
sprockets
together
WIth the
timing
chaIn
Fig
21
Tlmmg
cham cover
removal
I
FIg
22 PIston and
connectmg
rod
assembly removal
Fig
23 Rear
011 seal removal
Rotate
the
engIne
a
quarter
turn and
remove
the
piston
and
connectIng
rod
assembly
Take
off the
connectIng
rod
beatings
at the
same
tIme and
keep
them
In
order
Rotate the
engIne a
quarter
turn and remove
the
flywheel
Remove
the maIn
bearIng cap
and
the rear 011
seal
Remove the crankshaft
Remove
the baffie
plate
and
the crank case
net
Remove
the camshaft
after
takIng
off
the cam
shaft
plate
Remove
the valve tfter
Remove the
piston rIngs
With a
tlng
remover
Press out the
piston
pIn
With
a
piston pin
remover and
an
arbor
press
Remove
the valves
USIng
a valve tfter
Be careful not to
lose
valve
sprIng
seat
011 seal
valve collet and valve rocker
sprIng
FIg
24 Baffle
plate
and
net removal
Fig
25 Camshaft
plate
removal
17

Bogioe
0
WAI
CI
o
o
WAIl
Cl
I
Fig
26 Valve
components
FIg
27
Cylinder head
Cyhnder
head surface flatness
Standard
MaxImum
m
m
Al2
Engme
less than
o0020 o
0039
INSPECTIONAND REPAIR
Preparation
Check the
cyhnder
head and
cylinder
block
for
traces
of water leaks before
cleaning
Clean all
parts
to remove 011 stains carbon
depoSits
fur and other
foreIgn
matters
com
pletely
M
kslr
1at
all o hol
Lare
clear
Blow
air
Into
them If
reqUIred
18
Fig
28
Checking
the
cylinder
head
surface
Fig
29
CheckIng
valve stem dIameter
Secure
proper assembly carefully
Cylinder
Head
Checking cylinder
head
mating
face
VIsually
check for cracks and flaws
Measure the surface of the
cyhnder
head on
the
cyhnder
block SIde for warping If
It ex
ceeds the hmlt indIcated below
regrind afTec
ted surface wIth a surface
grinder
Valve
Assembly
Check each
of the Intake and exhause valve
assembhes
for
worn
damaged
or
deformed
valve
caps
and stems Correct
or
replace
the
valve If
reqUIred
The valve face
or
valve stem end surface
should be refaced
by
usmg
a valve
gtlnder
Notes
a
Deflection of seat surface
against
axis should be
0
0012 in
or
less
b
o rr ctnes
f
right angle
and
out of round should be
0 0004
in
or less

IBglne
Note When the valve head
has been
reduced to 0 0197 in or
less in thickness
replace
the valve
Grinding
allowance for the valve
stem
end surface is 0
0197
in or less
Valve
spring
Measure
the free
length
and the
tensIOn of
each
spnng
If the measured
value exceeds
the
specIfied
hmlt
replace
the
sprlllg
Check each
spnng
for deformatIOn
with
a
square
Any
sprmgs
w1th deflectIOn
of
0
0630
III or
more
must be
replaced
Valve Rocker Shaft
and Rocker Arm
Check the valve rocker
shaft and rocker arm
1
N
in
00
9E
22
N
o
NO
I
I
I
I
1
I I
Ll
gE
N
cno
CX
co
00
r
o
171M
OtM Be 22
Bo
l
N
11 lit
l
o
cnM
l
Q
1
45 30
290 to 29 2 die
1142
to
1 1501
N
I
350
to 35 2dla
1
378 to
1386
INTAKE EXHAUST
UNIT mm
lnl
Fig
30
The Intake and exhaust valves
Fig
31 Valve
grinder
for
seizure
and
wear
and
repair
or
replace
as
required
Valve
rocker arm to
shaft 011 clearance
o 0008
to 0 0020 III
Spnng specIficatIOns
Free
length
1 831 In
Valve closed
1
524 In at 52
7 Ib
Valve
open
I 19 III at
1291b
EM J
Fig
32 Valve
spring
test
Fig
33
Valve rocker shaft
lB

Bn
in1l
If
camshaft
bearmg
clearance IS exceSS1ve
replace
the camshaft
bearmgs
with service
parts
When
valve contact surface of the valve
rocker
arm IS worn
excessively
m
step repair
by
means
of
a
valve
grinder
or
replace
Grinding
allowance for valve contact surface
of the valve rocker
arm IS 0 0197
In
or
less
Valve Lifter and Push Rod
Check the valve hfter for
wear seizure
and
bevel
edge
contact and
repair
or
replace
as
reqUIred
Measure clearance between the hfter hole on
the
cyhnder
block and valve hfter and
replace
the valve hfter when clearance ex
ceeds the hmlt
Check the
push
rod for
bendmg
and
damage
and
repair
or
replace
as
reqUIred
Camshaft and Camshaft
Bearing
Measure
mner
dIameter of the camshaft
bearing
and outer diameter of the camshaft
Journal
Standard MaxlIDum
m m
Valve hfter
hfter hole
o 0059
o0008 to 00020
clearance
limit
0151010 00059
m
Standard
003
to 0071010
00012
to 00027
m
Fig
34
Camshaft
bearing
check
20
Valve
Timing
If the camshaft has no
apparent
damage
although
some
valve troubles have been
detec
Standard
Wear
hm1t
1st
00015luOO024
2nd
00011 to
00020
Ot
3rd
clearance
00016 to 00025 o 0059
In
4th
00011 to 00020
5th
00015 toO 0024
1st
1 7257 to I
7261
Inner
2nd
1 7050
to
1
7060
diameter
of
camshaft
3rd
beanng
1
6865 to
1
6868
m
4th
I
6663 to
I
6667
5th
1
6243 to
1
6247
TDC
DIRECTION
OF
ROTATION
EXHAUST INTAKE
BDC
Fig
35 Valve
timing diagram