Datsun 510 series Instruction manual

i
WORKSHOP
MANUAL
for
510
series
DATSUN
130014001600
610 series
I l
A
160B 180B
COMPILED
AND WRlTTEN
av
C R Newton
SBN
901610 13
5
PUBUSHED
BY
OOEREUROPE
AUTODA TA DIVISION
NICHOLSON HOUSE
MAIDENHEAD
BERKSHIRE
ENGLAND
C Copyrirt lnt eurupe
Cktoblr 1972
WSM 137
Printed
Engl w

i
I
inter
llil j
@ W
E
Hu tol
and
Type
Identl ficatlOn
YOUR MANUFACTURER
The Nissan Motor
Company
was founded
in
1933
under the
name
of Jidosha Seizo Co Ltd
In 1934
the present title was
adoptedand during
1966 the
company merged
with
Prin
c
Motors builders of
the Skyline and Gloria ars
With the head office
and six main factories near
Tokyo Japan
other sister
plants
ace
also
in
production
in various countries
throughout
the world
YOUR VEHICLE
In the
early days
of
the company
s
history
vehicles constructed were
given
the trade name
DA TSDN which means SON of DAT the initials of three of
the financial backers
forming
the
syllable
DA T To avoid confusion with a similar
Japanese
word the name was
eventually
changed
to DATSUN
The various
models covered in this Manual
together
with alternative namt s used for the
world markets are listed below
MODELS COVERED
MODEL ALTERNATIVE
IDENT
510 SERIES Datsun
1300
510
SERIES Datsun
1400
510
SERIES
Datsun 1600
610 SERIES Bluebird 160 B
610 SERIES Bluebird 180 B
00 SERIES DATSUN ISoo
ENGINE FITTED
1300 c c L l3
1400
c
LI4
1600 c
c
LI6
1600
c
LI6
1800 c c L 18
181S GIS
WUUUU
I
fl
I
lfI
r
7
I
i
I
1 11
lii
Identification
plate
location
Engine
serial and model number
2
REMARKS
Superseded by
1400 c
c
model with L 14
engine
Similar to 1300 c c car
Similar to 1300 1400
e c car
In some markets identified
as 1600 SSS 1800 SSS
J
S
1
HI
I
Car serial
number location

inteN
j
@IP
B
Index
ENGINE
COOLING SYSTE
l
IGNITION SYSTE I
FUEL
SYSTBl
CLUTCH
GEARUOX
PROPELLER SHAFT Id DIFFERENTIAL
REAR
AXLE nd REAR SUSPENSION
FRONT
SUSPENSION
STEERING
BRAKING SYSTEM
ELECTRICAL
EQUIP
JENT
WIRING JAGRA IS
TROUBLE SHOOTING
TIGHTENING
TORQUES
SERIES C 30 MODEL SUPPLEMENT
AUTOSERVlCE DATA CHART
PART
NA ES nd ALTERNATIVES
CONVERSION TABLES
S
15
2S
33
43
51
62
7S
83
91
9S
lOB
liB
I2S
129
51
End of
manuir
IntroductIon
OUf intention
in
writing
this
Manual is to
provide
the
reader
with
all the data
and in
formation
required
to maintain and
repair
the vehicle
However it must be realised that
special equipment
and skills arc
required
in some caseS to
carry
out the work
detailed
in the text and
we
do
not
recommend
that such work be
attempted
unless the reader
possesses
the
necessary
skill
and
equipment
It would be better
to
have
an
AUTHQRISED
DEALER to
carry
out the work
using
the
special
tools and
equipment
available to
his trained
staff He will also be in
possession
of
the
genuine spare parts
which may
be
needed for
replacement
The information in the Manual has been checked
against
that provided by
the vehicle
manufacturer and any
peculiarities
have been
mentioned if
they depart
rom
usual
work
shop
practice
A fault
finding
and trouble
shooting
chart has been inserted
at
the end of the Manual
to
enable the reader
to
pin point
faults and
so save
time As
it is
impossible
to include
every
malfunction
only the
more usual ones have been included
A
composite
conversion table has also been included
at
the end
of the manual and we
would
recommend that wherever
possible
for
greater
accuracy
the metric system
units
are used
Brevity
and
simplicity
have been our aim in
compiling
this Manual
relying
on
the number
ous illustrations and clear
text
to inform and instruct the reader
At the
request
of the
many
users of our Manuals we have slanted the book towards
repair
and overhaul rather
than maintenance
Although every
care has been
taken
to ensure
that the information and data are
correct
WE CANNOT
ACCEPT
ANY LIABILITY FOR INACCURACIES OR OMISSIONS
OR FOR DAMAGE OR MALFUNCTIONS ARISING FROM THE USE OF THIS BOOK
NO MATTER HOW CAUSED
I
3

t
r
Engine
type
Ovendi
cngth
1300
L
13
Overall
width
Oyerall
height
Turning
circle
din
metres
tfeet
Supen eded
by
Track
font
rear
1400
c
c
car
Ground
dearance
Olin
Weight
dry
I
820
808
I
Fuel
tClflk
capacity
35
29
6
150
93
Fuel
consumption
aximum
peed
Technical
Data
BLUEBIRD
400
1600
1600
U4
U6
0
4
120
162
20
1 560
6142
410
55
51
420
55
91
10
2
33
5
270
50
0
2
420
95
281
215
8
5
885
1
950
210
8
27
930
2
050
10
1
12
33
2
27
7
50
931
28
2123
5
60
99
L
16
4
215
165
941
1
600
62
99
405
55
3
Ii
0
6
34
8
290
5079
1
300
51
18
2
500
9843
185
7
281
955
2
1061
12
14
5
28
2
23 5
60
991
BLUEBIRD
1800
L
18
3
0
5
57
320
5
971
000
2
2051
165103
BLUEBIRD
1800
ESTATE
U8
4
280
168
501
4
5
557
330
52
361
1
065
2
348

EngIne
INTRODUCTION
ENGINE
Removal
ENGINE
DismantUng
ENGINE
Inspection
and Overhaul
VALVES VALVE GUIDES VALVE SEAT INSERTS
CAMSHAFT AND CAMSHAFT
BEARINGS
Checking
CYliNDER
BLOCK
PtSTONS
AND CONNECTING RODS
INTRODUCTION
The 1400 1600 cc
and 1800 cc
engines
are four
cylinder
in line units with
a
single
overhead camshaft
and
fully
balanced
five
bearing
crankshaft
The valves are
operated through rockers
which are
directly
activated
by
the
earn mechanism
The crankshaft is a
special
steel
forging
with the centre
main
bearing
equipped
with thrust washers
to
take
up the end
thrust of
the crankshaft The
special
aluminium
pistons
are of
the
strut
construction to
control thermal
expansion
and
have
two
compression rings
and one combined oil
ring
The
gudgeon pins have
special
hollow steel shafts
and
are
a
fully
floating
fitin
the
pistons
and a
press
fit
in the
connecting
rods
The aluminium
alloy cylinder head contains
wedge type
combustion chambers and
is fitted with aluminium
bronze valve
seats
for the intake valves
and heat resistant steel valve seats
for the exhaust
valves
The cast
iron camshaft is driven
by a double row roller
chain from the crankshaft
pulley
The
engine
is
pressure
lubricated
by
a rotor
type
oil
pump
which draws oil
through
an
oil strainer into the
pump
housing
and
then forces
it
through
a full flow
oil
filter
into the main oil
gallery
ENGINE Removal
Place
alignment marks on the bonnet
and
hinges
remove
the bonnet from the vehicle
2
Drain the
cooling system and engine and transmission
lubricant Remove
the radiator
grille
3 Discon ect the
battery cables and lift out the
battery
4 Detach the
upper
and lower radiator
hoses remove
the
radiator
mounting
bolts and lift the radiator
away
from
the vehicle
The
torque
converter
c
jng pipes
must
be
disconnected from the radiator on vehicles
fitted with
automatic transmission
S Remove
the
COOling
fan and
pulley
disconnect
the fuel
pipe
from the fuel
pump
and
the heater hoses from
the
engine
attachments
6 Disconnect the accelerator
control
linkage
and the
choke
CRANKSHAFT AND MAIN BEARINGS
CAMSHAFT AND SPROCKET
FLYWHEEL
ENGINE
Assembling
VALVE CLEARANCES
Adjusting
ENGINE
LUBRICATION SYSTEM
OIL PUMP
OIL FILTER
CHANGING THE ENGINE
OIL
cable from the
carburettor
7 Disconnect the
wirings
from
the starter alternator
ignition
coil oil
pressure
switch
and
temperature
sender
unit
8 Remove
the clutch slave
cylinder Fig
A 2
and its
return
spring
9 Disconnect the
speedometer
cable and withdraw
the
plug
connector from the
reversing light
switch
10
Disconnect the
shift rods and seJector
rods and remove
the cross shaft
assembly
as described
in the section Gear
box
II Disconnect the
front exhaust
pipe
from the
exhaust
manifold disconnect the centre
pipe
from
the rear
pipe
and
remove
the
front
pipe pre
muffler and centre
pipe
assembly
12 Disconnect the
propeUer shaft
flange
from the
companion
flange from the
gear
carrier
13 Jack
up
the
gearbox slightly and remove the
rear
engine
mounting
bracket bolts remove the
mounting
cross
member and handbrake
cable
c1amp
14 Remove the bolts
securing
the front
engine mounting
brackets to the crossmember
15
Attach
lifting
cable or
chains to the hooks installed at
the front and rear of the
cylinder
head
Lower the
jack
under
the
gearbox
and
carefully
lift and tilt the
engine
and
gearbox
unit Withdraw the
engine and
gearbox
from the
compartment
making
sure that it is
guided
past
the
accessories installed on the
body
ENGINE
Dismantling
Remove the
engine
as
previously
described and
carefully
clean
the exterior
surfaces
Cbeck for
signs
of fuel oil or
water leaks
past
the
cylinder head and block Remove the air
cleaner
alternator
distributor and starter motor
Plug
the
carburettor air horn
and distributor hole to
prevent
the
ingress
of
foreign
matter
Remove the
gearbox
from
the
engine
drain the
engine
oil
and coolant Mount the
engine
in a suitable
stand the
special
engine attachment ST05260001 and
engine
ST0501SOO0 should
be used if available
Fig A
3
5

engine
600
tb
tllroogh
Section
S
O
sef1
es
ofenll
A o
ne l
Right
S
0
61
ttor
bure
n
car
l
tWI
thS
hi
4
t
V
ne
of
engJ
vie
lJlt
side
Gene
ol
Engine
FIS
to

fl
J
J
f
1
ST052fiOOOl
Fig
A 2
Removing
the
clutch slave
cylinder
Fig
A 3
Mounting
the
engine
STI 0
120000
CI
@j91 7
m I3L
I T
IC
t
J
i1
C
J 6 i
11
j 1
j
4
I
U O J
I Ll
LJJ
1r9i
V
@
1
EM092
Fig
AA
Removing
the
camshaft
sprocket
Fig
A 5
Cylinder
head
bolt removal
sequence
t
J1
I
J
1
1
i
I
G
qt
7
r
J
O
I
IS
Fig
A 6
Removing
the chain tensioner and
timing
chain
Fig
A 7Removing the drive
sprocket
7

inter lliJ j
@I IJ
I
7
4
i
ll
W
f
l
rr
er
j
il
Fig
A 9
Removing
the
flywheel
Fig
A S
Removing
the
pistons
and connecting
rods
Fig
A II Removing
the baffle
plate
and net
c
11i
t1
I
c2
r
Id f
tij
Fig
A
IO
Removing
the
Tear main
bearing
cap
Fig
A 12
Removing
the
piston
pin
Fig
A 13
Removing
the valves
Fig
Al4
OIecking
the cylinder
head
joinlface
Fig
A I 5
Reaming
the
valve
guide
8

Remove the
fan
and pulley
the
right
hand
engine mounting
and oil filter Remove the oil
pressure
switch
Remove the
following
items
oil level
gauge
spark plugs
thermostat
housing
rocker cover carburettor and inlet and
exhaust manifolds
Remove the
clutch
assembly
as described in the section
CLUTCH Remove the
left hand
engine mounting
crankshaft
pulley
water
pump
fuel
pump
fuel
pump
drive
earn and cam
shaft
sprocket
See
Fig
A 4
Remove the
cylinder
head
bolts
in the
sequence
shown in
Fig
A
5 and lift
off the
cylinder
head Invert the engine
and remove the oil
sump
and oil
strainer oil pump and drive
spindle
assembly
front cover and
chain tensioner
Remove the
timing
chain oil thrower
crank
shaft worm
gear
and chain
drive
sprocket
See
Fig
A 6 andA 7
Remove the
connecting
rod caps and
push
the
pistons
and
connecting
rods through
the
top
of the bores as shown
in
Fig
A B
Keep
the
connecting
rod
caps
with their respective
rods to
ensure
that
they
are assembled in their
original positions
Remove the flywheel retaining
bolts and withdraw the
fly
wheel
Fig
A 9 Remove the main
bearing caps using
the
special puller
ST 1651 SOOO
to withdraw the centre and rear main
bearing caps as
shown in
Fig
A
l O Remove the rear oil seal
and
lift out the crankshaft remove the
baffie
plate
and cylinder
block net
Fig
A II Remove
the
piston rings
with
a
suitable
expander
and
press
out the
gudgeon pins
under
an
arbor
press
using
the
special
stand
STl300001 as shown in
Fig
A
12
Keep
the
dismantled
parts
in order so that
they
can
be
reassembled
in their
original positions
Slacken
the
valve rocker
pivot
lock
nut and remove the rocker arms
by pressing
down
the valve
springs
Remove the
camshaft
taking
carenot to
damage
the
bearings
and earn lobes Withdraw the
valves
using
the valve
lifter STl2070000 as shown in
Fig
A 13
ENGINE
Inspection
and Overhaul
Cylinder
Head and
Valves
Clean all
parts
thoroughly
and
remove carbon
deposits
with
a
blunt
scraper
Remove
any
rust which has accumulated in
the
water
passages
and blow
through
the oil holes
with
compres
sed air to make
sure
that
they
are
clear
Measure the
joint
face of the
cylinder
head
for out of true
as shown in
Fig
A 14
The
surface should be checked at various
positions using
a
straight edge
and feeler
gauge
The permissible
amount of distortion is 0 05 mm 0
0020 in or less If the
surface is
out of true
by
more than the limit of 0 1 mm
0
0039
in it
will be
necessary
to
regrind
the head
Clean each
valve
by washing
in
petrol
and
carefully
examine
the stems and heads
If the stem is worn
damaged
or
not
straight
the
valve must
be
discarded Check
the
diameter
of the stem with amicro
meter
The diameter
of
the
inlet valves should be 7 965
7 980 mm 0 3136 0 3142 in and the diameter
of
the
exhaust
valves 7 945
7 960 mm 0 3128 0 3134 in
If
the seating
face of the valve is
excessively
burned
damaged
or distorted it must
be discarded A
badly pitted
seating
face should be refaced on a valve
grinding
machine
removing only
the minimum
amount of metal
Renew the valve
if the thickness
of
the
valve head has
been
reduced
by
0 5 mm 0 0197 in
see Technical Data
for
valve dimensions
The
valve
stem
tip
may
be refaced
if
necessary
the maxi
mum allowance however is
0 5 mm 0 0197 in
The valves can be
ground
in to
their
seats when
completely
satisfactory
The valve
seats and valve
guides
should
be
in
good
condition and must be checked as
described in the
following
paragraphs
VALVE GUIDES
Replacement
The valve stem to valve
guide
clearance can be checked
by
inserting
a new valve into
the
guide
The
stem to
guide
clearance
should be 0 020 0 053 mm 0
0008 0 0021 in for the inlet
valves and 0 040 0 073
mm 0 0016 0 0029
in for the exhaust
valves If the clearance
exceeds 0 1 mm
0 0039 in for the
inlet valves and the exhaust valves
then new
guides
should be
fitted
The valve
guides
are held in
position
with
an interference
fit
of 0 027 0 049 mm 0 0011 0
0019 in and can be removed
by
means of a
press
and
drift 2 ton
pressure
This operation
can be carried
out at room
temperature
but will
be
more
effectively performed
at a higher temperature
Valve
guides
are available with
oversize diameters
of 0 2 mm
0 0079
in
if required
The standard valve
guide
requires
a bore
in the
cylinder
head of 11
985 11 996 mm dia 0 4719
0 4723 in
dia and the oversize valve
guide
a bore of 12 185
12 196 mm dia
0 4797 0 4802 in
dial
The
cylinder
head
guide
bore
must be reamed
out at
normal room
temperature
Heat the
cylinder
head to a
temperature
of 150 2000e
302
3920F before
pressing
in the
new valve
guides
Ream
out the bore of the
guides
to obtain the desired
fInish and
clearance Fig
A IS The
special
valve
guid
reamer ST 1103
SOOO should be used
if available Valve
guide
inner diameters
are
specified
in Technical Data
at
the
end of this section The
valve seat surface
must
be
concentric with the
guide
bore
and
can be
corrected with the
facing
tool
STll670000
Fig
A 16
using
the new valve
guide
as
the axis
VALVE
SEAT INSERTS
Replacing
The valve seat inserts should be replaced
if
they
show
signs
of
pitting
and excessive
wear
The inserts
can be removed
by boring
out to a
depth
which
will cause them
to
collapse
although
care must be taken
not
to bore beyond
the bottom face of the
recess
in
the
cylinder
head
Select the valve
seat
inserts
and check the
outer
diameters
Machine the
recess in the
cylinder
head
to
the following
dimensions at room
temperature
9

it
r
inter
iJ i
@ Pl
Fig
A 16
Correcting
the valve seats
Li4
lnlakt
t1
c
r
I I 37 8
1 4882
di
410
6142
dia
Unit rnrn
in
L14
and
L16
Exhaust
Ct
rill
I II
ill
300 1Bll du
l
32 6
1 2835 dia
37
1
4561
dia
Unll
In
Llb thtwin
1 13
Ut
WiTh
Ie
ro
rLl
Incak
h
C 1
q
J
j
Exhaust
Fig
A I Standard valve seat dimensions
U
l
and liS
11tJ
1l
ioo
l
j
14 u
055i1
r
m
JA
9bIJUI4
l9
611
559lldi
a
4L80 6457
dlll
45 J 1717
liS
311
fJ
90o
LJ
13 0 0512
r
1
II
I
i
30
n
Il i1
I tlla
32
60 2835
di L
34 6 1 3622 dla
37
1
4561lia
Fig
A
IS Valve at
grinding
dimensions
10

CYUNDER HEAD RECESS DIAMETER
Standard inoerts
Engine
L14
Ll6
and
Ll8
Inlet
41 000 41 016 1 6142 1 6148 in
45 000 45 016 mm 1 77l7
1 77231n
Engine
Ll4
Ll6 and Ll8
Exhaust
37
000 37 016mm
1
4567 1 4573 in
37 000 37
016mm l
4567 1 4573 in
CYLINDER HEAD RECESS DIAMETER
Oversize inserts
Engine
Ll4
Ll6andLl8
Inlet
41
500 41
516mm l
6339 1 6345in
45 S00 45 516mm I 7913 1 7920in
Engine
L14
Ll6andLl8
Exhaust
37 500 37 516mm 1 4764 14770in
37
500 37
516mm
1 4764 l4770in
Dimensions for the standard valve inserts
are
shown
in
Fig A 17
Heat the
cylinder
head to a
temperature
of ISO 20DOC
302 3920F and drive in the inserts
making
sure
that they
bed down correctly
The inserts should be caulked at more than
four
positions
and then cuf or
ground
to
the
specified
dimensions shown in Fig
A IS
Place a small
amount
of fine
grinding
compound
on the
seating
face of
the
valve and insert the valve into the valve
guide
Lap
the valve
against
its seat
by rotating
it backwards and
forwards
approximately
half a revolution in each direction
until a continous
seating
has been obtained Remove the valve
and clean all
traces of
the
grinding
compound
from valve and
seat
VALVE SPRINGS
The valve
springs
can be checked for
squareness using
a
steel
square
and
surface
plate
If the
spring
is out of
square
by
more
than 1 6mm 0 063 in it
must
be
replaced
Check the
free
length
and the load
required
to deflect the
spring
to
its
assembled
height Compare
the figures
obtained with those
given
in
Technical Data
and replace
the
spring
if the
specified
limits are exceeded
CAMSHAFT AND CAMSHAFT BEARINGS
Checking
Measure the
clearance between the inner diameter of the
camshaft
bearing
and the outer diameter of the
camshaft
journal
If the wear limit
for the
bearing
clearance exceeds
O lmm 0 0039 in it will be
necessary
to
replace
the
cylinder
block assembly See
Technical Data for all diameters
Check the
camshaft and camshaft
journals
for
signs
of
wear
or
damage
ace the camshaft in V
Blocks as shown in
Fig
A 19 and
position
the
dial
gauge
to the
journal
The runout of the cam
shaft must not exceed 0 05 mm 0 0020in It should be noted
that
the actual run out will be
half
the the
value indicated
on the
dial
gauge
When the camshaft
is turned one full revolution
with the dial
gauge positioned
against
the
second and third
journals
CYLINDER BLOCK
Inspection
and
Overhaul
Ensure that the
cylinder
block is thoroughly clean
and
check it for cracks and flaws
Check the
joint
face of the block for
distortion
using
a
straight edge
and feeler
gauge
as shown in
Fig
A 20 The
surface
must
be
reground
if the maximum
tolerance of O lmm
0 0039 in is exceeded
Examine the
cylinder
bores
for out of round or
taper
using
a
bore
gauge
as
shown
in
Fig
A 21 The readings
must
be
taken at the
Top
middle and bottom positions
indicated
in
Fig
A 22
The
standard bore diameters
are
83 000 83
050 rom
3 2677 3 3697 in for the 1400
and 1600cc
engines
and 85 000
85 050 mm
3 3465 3 3484
in
for the 1800
cc
engine
with
a
wear limit of 0 2mm 0 0079 in
Out of round and taper
must not exceed 0 15mm
0 0006 in If the bores
are within the
specified
limits
remove
the carbon ridge
at the
top
of the
cylinder
bores wring
a
suitable
ridge
reamer
If
any
of the bores are in
excess of the
specified
limits
then all the bores
must be rebored
at
the same time Pistons
are
available
in five oversizes See
Technical Data and can be
selected in accordance with the
amount of wear
of
the cylinder
When the oversize
of
the
pistons
has been decided it will
be necessary
to measure the
piston
at the
piston
skirt
Fig
A 23
and add
to
this dimension the
specified
piston
to
cylinder
bore
clearance to determine the final honed measurement
of the
cylinder
Machine the
cylinder
bores in
gradual stages
taking only
a 0 5mm 0
002
in
cut each time The bores
must
be brought
to the final size
by honing
and the
block
thoroughly cleaned
to remove all
traces of metal
Measure the
finished
bore
and check the clearance between
each
piston
and its
cylinder
The clearance
can
be
checked as
shown in
Fig
A 24 with the aid
of a feeler
gauge
and
spring
scale The
standard clearance is 0 023 0 043 mm
0 0009
0
0017 in
NOTE Cylinder
liners can be fitted
if
the cylinder
bores
are
worn
beyond
the
maximum
limit
The liners
are an interference fit in the
block and
must be bored to the
correct
inner
diameter
after
fitting
Three
undersize liners
are available
in the following
sizes
11

y
t
interCE
MI
D liPl
E
r
i
J
r i
1
4
1
r l
I
I I
I
QJJ
I
ki
g
the camshaft for run out
Fig
A 19 Chec
n
I
I
I
y
Ii der
bores
Fig
A 2Measuring
lbe
cy
n
1
I
1l
or
r
i
r
mO
1874
r
I
abllUI O
I
I
Q
k
t
diameters
h
pistons tr
F A 23
Measunng
t e
g
the
piston
ring
side
fi
A 25
Measurmg
g
clearance
12
k oint face I der bloc
J
ki
gthecym
A20Chec n
FIg
1
7
rb
I
tinder ositions for the
cy
A 22
Measunng
p
F
g
bores
the
piston
ring gap
A 26
Measunng
F
g

OUTER DIAMETER
4 0mm 0 1575 in
Undersize
4 5mm 0 1772 in Undersize
5 Omm 0
1969 in Undersize
87 000 87 05mm 3 4252 3 4272
in
8750 87 55mm 3 4449 3 4468 in
88 00 88 05mm 3 4646 3
4665 in
PISTONS
Checking
Check each
piston
for
signs
of
seizure
and wear Renew
BIlY
piston
which is unsatisfactory
Remove all carbon deposits
from the
grooves
and
piston
rings
Measure the side clearance of each
piston ring
and
groove
with a feeler
gauge
as
shown in
Fig
A 25 If the side clearance is
excessive new
rings
should be fitted The clearance
required
for
new
pistons
a
piston
rings
can be found in Technical Data
Check the
piston ring gap
by placing
the
ring
in the
cylinder
bore as shown in
Fig
A 26 The
ring
can
be
squared
in
the
bore
by pushing
it into
position
with the
piston
Measure the
ring gaps
with a feeler
gauge
and
compare
the dimensions with the infor
mation
given
in Technical Data
NOTE Ifnew
piston rings
are to
be
fitted and the
cylinder
has not been rebafed check the
piston ring gap
with
the
ring
positioned
at the bottom of the
cylinder
This being
the
position
with the least
amount of wear
O1eck the
clearance between
gudgeon pin
and
piston
If
the
specified
limit is exceeded it will be
necessary
to
replace
both
piston
and
pin
It should be
possible
to
press
the
gudgeon
pin
into the
piston by
hand at a
room
temperature
of 200C
680F The
pin
should be a tight
press
fit in the
connecting
rod
CONNECTING RODS
O1ecking
Cleck the
connecting
rods for bends
or
twists
using
a
guitable
connecting
rod
aligner
The
maximum deviation should
not exceed
0
05
mm 0 0020 in
per
100 mm 3 94 in
length
of rod
Straighten
or
replace
any
rod
which does not
comply
with the
specified
limit
When
replacing
the connecting
rod it is essential
to ensure
that the
weight
difference between
new and old rods is within
5
gr
0 18 oz for the 1400 cc
engine
and 7
gr
0 25
oz for
the 1600 and 1800
cc
engines
Install the connecting
rods with
bearings
to
the
correspond
ing
crank
pins
and measure the end
play
of the
big
ends s e
Fig
A 27 The end play
should be between 0 2 0 3 mm
0
0079 0 0118 in fthe maximum
limit of 0 6 mm 0 Ql18
in is exceeded the connecting
rod
must
be
replaced
CRANKSHAFT
Inspection
and Overhaul
aean the
crankshaft
thoroughly
before
checking
the shaft
for distortion and
cracks
Measure thejournals
and crankpins for our of round If
the
journals
and
pins
are found to be oval
or
if the
wear
limit
exceeds the
specified fUnning
clearance it
will
be necessary
to
re llrind
the crankshaft
to
the
required
undersize See Technical
I
INNER DIAMETER
82 45 82
60mm 3 24613 2520 in
82 4S 82 60mm 3
24613 2520 in
82 4S 82 60mm
3 24613 2520 in
Data
Place the
crankshaft in V blocks as shown in Fig A
28
and check with
the aid of a dial
gauge
that
the shaft
bending
limit of 0 05 mm 0 002 in is
not exceeded With the
dial
gauge
positioned against
the centre
journal
the
crankshaft should be
rotated
by
one turn The actual bend
value will be a half of the
reading
obtained
on the
gauge
If the
specified
limit is
exceeded
it
will be
necessary
to
replace
the
crankshaft
Install the crankshaft in the cylinder
block and check the
crankshaft end float which should be be J
Yieen 0 05 0 18 mm
0 0020 0 0071 in Make
sure that the main drive shaft pilot
bushing
at the rear of the
crankshaft is not worn or
damaged
in
any way Replace
the
bushing
if
necessary
using
the
special
puller
STl 66 1000 I
Thoroughly
clean the bushing
hole before
installing
and
press
in the new
bushing
without
oiling
so that its
height
above the
flange
end is 4 5 5 0 mm 0 18 0 20 in
Main
bearing
clearance
The main bearing
clearances
can be checked
using
a
strip
of
plastigage
Set the main bearings
on the
caps
Cut
the
plasti
gage
to the width
of the
bearing
and
place
it
along
the
crankpin
making
sure that it is clear
of
the
oil hole Install the bearing
caps
and
tighten
the bearing
cap
bolts to
a
torque reading
of 4
5
5 5
kgm
33 40 Ib ft DO NOT
turn the crankshaft when
the
plastigage
is inserted
Remove the main
bearing cap
and take
out the
plastigage
which should be
measured at its widest
po
t
with the
scale
printed
in the plastigage envelope
The
standard
clearance is 0 020 0 062
mm 0 0008 0
0024 in with a wear
limit of 0 1
mm 0 0039 in If the
specified
limit is
exceeded
an undersize
bearing
must
be
used and the crankshaft journal
ground
accordingly
See Technical Data
Bearings
are available
in four
undersize of 0 25 0 50 0 75
and 1 00 mm 0
0098
0 0197 0 0295 and
0 0394 in
Connecting
rod
bearing
clearance
The
connecting
rod
bearing
clearances should be
checked
in a
similar manner
to
the main
bearing
clearances The standard
clearance is 0
025 0 055 mm 0 0010 0 0022 in
with a wear
limit
of 0 1 mm 0 0039 in Undersize bearings
must be fitted
and the
crankpins
reground
if the
specified
wear limit is
ex
ceeded See
Technical Data
Bearings
are
available in six under
sizes
of 0 6 0 12 0 25 0 50 0 75 and 1
00 mm 0 0236
0 0047 0 0098 0
0197 0 0295 and 0 0394 in
Fitting
the crankshaft
bearings
Cb eck the
fit of the
bearing
shells in the following
manner
Install the shells on the main
bearing caps
and
cylinder
block
bearing
recess
and
tighten
the
cap
bolts to the
specified
torque
13

inter
Q1I f Q
I ll
oJ
Fig
A 27
Olecking
the
big
end
play
Fig
A
28
Checking
the crankshaft for
runout
Weight
Fig
A 29
Checking
the
bearing
crush
Fig
A 30
Checking
the camshaft
sprocket
for
runout
Fig
A 31
OIecking
the camshaft
end
float
Fig
A
32 Installing
he valves
14

reading
Slacken one of the
cap
bolts and check the
clearance
between the
cap
and
cylinder
block with a feeler
gauge
See
Fig
A
29
The
bearing
crush
nip
should be between 00 03mm
00 0012 in if this is
not
the
case
then the
bearing
must
be
replaced
beck the
connecting
rod
bearings
in a similar manner
after
tightening
the
caps
to the
specified
torque
readings
The
bearing
clearance should be between 0 15 0 045 mm 0 0006
0 0018 in
CAMSIIAFf AND SPROCKET
Inspect
the
camshaftjoumals
for
signs
of wear or
damage
and check the camshaft for run
out
using
a dial
gauge
in a
similar
manner to that
previously
described for the crankshaft
The
bending
limit of 0 02 mm 0 0007 in must not be
exceeded
Install the camshaft
sprocket
mount
the
assembly
in V
blocks as shown
in Fig A
30 and check that the runout of
the
sprocket
does
not
exceed 0 1 mOl 0 04331 in O1eck the
timing
chain and
sprocket
to ensure that the chain is not
stretched or
damaged
or the teeth of the
sprocket damaged
or
distorted A
timing
chain which has become stretched will
affect the valve
timing
and be
noisy
in
operation
Check the
chain tensioner and chain
guides
for wear and
damage replacing
the
parts
if
necessary
Replace
the
sprocket
if the runout is exceeded or if the
teeth
of
the
sprocket
are worn or
damaged
in
any way
The camshaft end
play
should be within 0 08 0 38 mm
0 0031 O oI50 in If the clearance limit of 0 1 mm
0 0039 in is exceeded it will be
necessary
to
replace
the cam
shaft
locating plate
See
Fig
A 3l
FLYWHEEL
Inspecting
Ensure that the clutch disc
contact face of
the flywheel is
not worn or
damaged
The runout of the
flywheel
contact face
should not exceed 0 2 mOl 0 008 in when measured with a
dial
gauge
The
flywheel ring gear
can be
replaced
if the teeth
are
damaged
or worn This
operation
will
entail
splitting
the
ring
gear
to remove it A hacksaw should be used to cut between the
teeth followed
by splitting
with a cold
chisel
When
replacing
the
ring
gear
it must be heated
to a
temperature
of
approximately
1800 2000 F before
fitting
and then allowed
to
cool
slowly
ENGINE
Assembling
Before
starting
to
assemble the
engine
make sure that all
components
are
perfectly
clean It is
always
advisable to
pay
particular
attention to the
following points
when
assembling
an
engine Keep
the work bench and tools clean and make
sure
that the
tools are to hand Ensure that all
engine
oil
ways
are
clear of
foreign
matter fit
new
gaskets
and oil seals
throughout
All
sliding
parts
such as
bearing
shells must be smeared with
engine
oil before
installing
B
Ensure that the
specified
tightening
torque
readings
are
strictly
followed
A
mbling
the
cylinder
Head
To
install the valves and valve
springs place
the valve
spring
seats into
position and
fit
the
valve
guides
and oil
lip
seals
Assemble in the following
order valve
springs spring
retainers valve collets and valve rocker
guides
Use the
special compressor
ST 12070000
as
shown
in
Fig
A 32
to
compress
the valve springs
Piston and
connecting
rods
The
piston piston pins
and
connectiJ1
rods must be
assembled
in
accordance with the
cylinder
numbers
The gudgeon pin
is
press
fitted to the
connecting
rod and
requires
a
fitting
force from 05
to
1 5
tons This
operation
will
require
the use of the
special
tool ST 1303000 as shown in
Fig
A 33
Apply
engine
oil to the gudgeon
pin
and
connecting
rod
before
fitting
It should be noted that the oil
jet
of the
connecting
rod
big
end
must face
towards
the
right
hand side of the
cylinder
block
See
Fig
A 34
Fit the
piston rings
the
oil control
ring
in the bottom
groove
followed
by
the centre and
top compression rings
which
must
be installed with
the marks
facing upwards
Install the
connecting
rod bearings
and
caps
making
sure
that
the
markings
coincide Ensure that the backs
of
the bearing
shells are
perfectly
clean otherwise
they
will be damaged
when
tightened
Assembling
the
engine
Fit the
baffle
plate
and
cylinder
block net Install the
crankcase halves of the main
bearing
shells the
flanged
shell
is
fitted to
the
centre
bearing
Smear the bearing
surfaces with
engine
oil and
carefully
lower the crankshaft into
position
Install the main
bearing
caps
with their shells
making
sure
that the arrow on the
caps
faces
to
the front
of
the
engine
Rotate
the crankshaft to settle the
caps
and
tighten
the
bearing
cap
bolts
gradually
in two or three
separate stages
Work
out
wards from the
centre
bearing and finally tighten
to the
specified
torque
reading
of 4 5 5 5
kgm
3240 Ib
ft
in
the
sequence
shown in
Fig
A 35 Ensure that the crankshaft
rotates
freely
after
finally tightening
the
cap
bolts
Check the crankshaft
end float which should be between 0 05 0 18 mm 0 002
0 0071 in see
Fig
A
36 Smear
the side
oil seals with sealant
and fit them into the rear main
bearing cap Install
the rear
oil
seal
using
a suitable
drift
and
grease
the lip
of the seal
Place the
flywheel
in
position and
install the lock
washers
and
retaining
baits Tighten the
bolts
evenly
to a
torque
reading
of 14 16
kgm 101
106Ib ft
Rotate the
engine by
a
quarter
turn and install the
piston
15

inter
Q1 jX
E
Fig
A
33
Installing
the
piston
pins Fig
A 34
Piston and
connecting
rod
cD
I
E
103470t
O
L
I
1
I
riC
J
lt I
t
1
1
C
j
I
If
I
r
Fig
A 35 Bearing
cap
bolts tighteningsequence
Fig
A
36
Installing
the
piston
and
connecting
rod
assembly
J
0
k2
CD
1 1
r
1
P
l
b S
LM
J
Jr
T9T
J
I J
@@@C@@
I 3 TimJn mark
Lt j
Location hole
Oblonl groon
I
I
Afteradju5tment
1
i
Before
adjustment
AtTD
C or
No I
piston
Fig
A 37
Cylinder
head bolts
tightening
sequence
Fig
A 38
Adjusting
the camshaft
sprocket
Fig
A 39
Fitting
the chain tensioner
Fig
A 40 Valve clearance
adjusting
16

hW
and
connecting
rod assemblies Use
a
piston
ring
compressor
to
install the
pistons
through
the top of
the
cylbder
bore Make
sure that the
pistons
and
rings
and the cylinder bores
are
lubricated with clean
engine
oil The
pistons
should be
arranged
so that the
F
mark
faces to
the
front and with the
piston
ring
gaps
positioned
at 1800 to each other Each piston
must
be refitted
into
its
original
bore
NOTE
Single
inlet valve
springs
are used
on
the
1400 cc
engine
double
valve springs
are used on the 1600cc
and 1800
cc
engines
Screw the valve rocker
pivots
with the
locknuts into the
pivot bushing
Set the camshaft
locating plate
and install the
camshaft in the cylinder
head with the
groove
in the
locating
plate
directed
to
the front of the
engine
Install the
camshaft
sprocket
and tighten
it
together
with the fuel
pump
earn to
a
torque reading
of 12 16
kgm
86 116 IbJt a eck that the
camshaft end play is
within
the specified
limits Install the
rocker arms
using
a screwdriver to
press
down the valve
springs
and fit the valve rocker
springs
Gean the
joint
faces of the
cylinder
block and head
thoroughly
before
installing the cylinder
head Turn the crank
shaft until the No 1
piston
is
at T D C on its
compression
stroke
and make sure that the
camshaft
sprocket
notch and the
oblong
groove
in the locating plate
are
correctly positioned
Care
should be taken to ensure that the valves
are
clear from the
heads of the
pistons
The crankshaft and camshaft must not be
rotated
separately
or the valves will strike the heads of the
pistons Temporarily
tighten the
two
cylinder
head bolts 1 and
2 in
Fig
A 37 to a
torque reading
of 2
kgm 14 5
lb ft
Fit the crankshaft
sprocket
and distributor drive
gear
and
install the oil thrower Ensure that the
mating
marks on the
crankshaft
sprocket
face towards the front Install the
timing
chain
making
sure that the crankshaft and camshaft
keys
are
XJinting upwards
The marks
on the
timing
chain must be
aligned
with the marks on the
right
hand side of the crankshaft
and camshaft
sprockets
It should be noted that three location
holes
are
provided
in the
camshaft
sprocket
See
Fig
A 38 The
camshaft
sprocket being
set to the No 2 location hole
by
the
manufacturers A stretched chain will however affect
the
valve
timing
and if this occurs it will be
necessary
to set the camshaft
to the No 3 location hole in the camshaft
sprocket
The chain
can
be checked
by turning
the
engine
until
the
No 1 piston
is
at T D C on its
compression
stroke In this
position adjustment
will be
required
if the location notch
on
the
camshaft
sprocket
is to the left of the
groove
on the camshaft
locating plate
as
shown in the illustration The correction is made
by
setting the
camshaft on
the
No 3 location hole in the camshaft
sprocket
the No 3 notch should then be to the
right
of the
groove
and
the valve
timing
will have
to
be
set
using
the No 3
timing
mark
Install the chain
guide
and chain tensioner when the chain
is located
correctly
There should be
no
protrusion
of the chain
tensioner
spindle
See
Fig
A 39 A new tensioner must be
fitted if the
spindle
protrudes
Press a new oil seal into the
timing
cover and fit the cover
into
position using
a new
gasket Apply
sealing compound
to
the front of the
cylinder
block and to the
gasket
and to the
top
of
the
timing
cover
Ensure that
the difference in
height
between
the
top
of the
timing
cover and the
upper
face of the
cylinder
block does
not
exceed
0 15 mm 0 006 in Two sizes of
timing
cover bolts
are
used the size M8 0 315 in
must
be tightened
to
a
torque reading
of 1 0 1 6
kgm 7
2 17 Ib ft and the
size M6 0 236 in to
a
torque
reading
of 0 4 0 8
kgm
2 9 81b ft
Install the
crankshaft
pulley
and water
pump
tighten
the
pulley
nut to a
torque reading
of
12 16
kgm
86 8 115 7Ib ft
then
set
the
No 1
piston
at T D C on its
compression
stroke
Finally tighten
the
cylinder
head bolts
to the
specified
torque
reading
in accordance with the
tightening sequence
shown
in
Fig
A 3 The bolts
should be
tightened
in three
stages
as
follows
First
stage
Second stage
Third
stage
4
kgm
28 9
lbJt
6
kgm
43 4 IbJ t
6 5
85
kgm
47 0 61 5lb ft
The
cylinder
head bolts should
be
retightened
if
necessary
after the
engine
has been run for several minutes
Install
the oil
pump
and distributor drive
spindle
into the
front cover as described under
Engine
Lubrication
System
r rf
i
Install the fuel
pump
water inlet elbow and front
engine
slinger
Fit the oil strainer into position
coat the oil
sump
gasket
with sealing compound
and fit the
gasket
and oil sump
to the
cylinder
block
Tighten
the oil
sump
bolts in a
diagonal
pattern
to
a
torque
reading
of 0 6 0 9
kgm
43 65 IbJt
Adjust
the valve clearances
to the
specified
cold
engine
ftgures following
the
procedures
described under the
appropriate
heading
Final
adjustments
will
be carried
out after the
engine
has
been assembled
completely
and warmed up
to
its
nonnal
temperature
Install the rear
engine slinger
exhaust manifold and inlet
manifold Refit
the
distributor and carburettor assemblies
as
described in their relevant
sections
Install the
fuel
pipes
and
vacuum hose
making
sure that
they
are
securely
cl
ped
Refit
the thermostat
housing
thermostat
and water outlet
together
with the
gasket
Bond the rocker cover
gasket
to the
rocker
cover
using
sealant and fit the rocker
cover to the
cylinder
head
Install the spark plugs
and connect the
high
tension leads
Fit the left hand
engine mounting
bracket
and install the clutch
assembly using
the
alignment
tool ST20600000 to fit the clutch
to the
flywheel
as described in the section ClUfCR
Lift
the engine away
from the
mounting
stand and into
the
engine
compartment
Install the alternator bracket adjusting
bar alternator
fan
pulley
fan and fan belt in the order
given
Check the tension of the fan belt
by depressing
the belt
at a
point
midw
y
between the
pulleys
The
tension
is correct if
the belt is
deflected
by
8 12 mm 03 0 4 in under thumb
pressure
Fit the
right
hand engine mounting
bracket the oil filter
oil
pressure
switch oil level
gauge
and
water
drain plug
Take
carenot
to
overtighten
the oil
nIter or
leakage
will occur
Fill the
engine
and
gearbox
to the correct levels with
recommended
lubricant
and
refill the
cooling system
Adjust
the
ignition timing
and carburettor
as described in the
appro
priate
sections
17

inter lmi
@ jl
Fig
A 41 Engine lubrication circuit
i
Punch rmrk
Oil hole
L
Fig
A 44
Aligning
the oil pump
spindle
18
II
l
o
CD
I
Fig
A 42
Component parts
of the oil
pump
L
Pump
body
2 Inner rotor and
wft
3 OutO rotor
4
Pump
coper
5
Reliefvalve
6
Relief
valve
Jpring
7 Washer
8
S
alp
9 ConT
613ut
I
Sideclruance
2
TIp
clearance
3
Guier
10
00 body
clearance
t 4 Rotor
to bottom
cover cleatance
Fig
A 43
Checking
the rotor
clearance

VALVE
CLEARANCES
Adjusting
Incorrect
valve clearance will affect the
performance
of
the
engine
and
may damage
the valves
and valve seats Insuf
ficient valve clearance will result in loss of
power
and
may
prevent
the valve from
seating properly
Excessive clearance
causes the valve
to seat and reduces the
amount of
valve
lift
This will result
in
noisy operation
with
damage
to the valves
and
seats
Adjustment
is made with the
engine
switched
off
and should be carried
out
initially
with
the
engine
cold to
allow the
engine
to run Final
adjustments
are
made after
wanning
up
the
engine
to
its Donnal
operating temperature
The
engine
can be rotated
by removing
the
sparking plugs
to release
the cylinder compressions
then
selecting
top
gear
and
pushing
the vehicle backwards and
forwards
The
cold valve clearances should be
set to 0 20 mm
0 0079 in for the
inlet valves and 0 25
mm 0 0098 in for
the exhaust valves Check the
clearance between the valve and
rocker
using
a feeler
gauge
as shown in
Fig
A 40 Slacken the
locknut and turn the adjusting
screw until the
specified
clearance
is obtained
then
tighten
the locknut and
recheck the clearance
The feeler
gauge
should
just
be free to move between the rocker
and valve
When the cold valve clearances have been
set run the
engine
until it reaches its
normal
operating temperature
then
switch off and
adjust
the
valve clearances with
the
engine
warm
to
0 25
mm 0 0098 in for the inlet
valves and 0 30 mm
0 0118 in for the
exhaust valves
ENGINE LUBRICATION SYSTEM Fig
A 41
OIL
PUMP Removal and
Dismantling
The
rotor
type
oil
pump
is
mounted at the bottom of the
front
timing
cover and driven
by
the distributor drive shaft
assembly
Overhaul of the
pump
will
require
careful measurement
of
the various clearances
to determine the
amount
of
wear
which
has taken
place
If
any part
is found to be worn it may be
neces
sary
to
replace
the entire oil pump
assembly
To
remove the oil
pump
from the
engine
proceed
as follows
1 Remove
the distributor
assembly
as described in the
section IGNITION
SYSTEM Remove the oil
sump
drain
plug
and drain off the
engine
oil See under the heading
CHANGING
THE ENGINE OIL
2 Remove the front stabiliser and the splash
shield board
3 Withdraw the
securing
bolts and
detach the oil
pump
body together
with the drive
gear
spindle
Take out the bolts securing
the
pump
cover to the
pump
body
and withdraw the
rotors and drive shaft See Fig
A 42
The
pin securing
the driven
shaft and inner rotor
must not
00 taken
out as the shaft
is
press
fitted to the rotor
and the
pin
is caulked
Unscrew the
threaded
plug
and withdraw the regulator
valve
and
spring
Oean each
part
thoroughly
and examine
for
signs
of
damage
or
wear Use a feeler
gauge
to check
the
side
clearances
between the
outer
and inner
rotors the clearances
at the
tips
of the rotors
and the clearance between
the outer
rotor and the
pump
body
See
Technical Data for the relevant
clearances The clearances
can
be
checked
using
a
straight
edge
as
shown
in
Fig
A 43
OIL PUMP
Assembly
and Installation
Assembly
is
a reversal of the
dismantling
procedure
Before
installing
the oil pump in the
engine
it will be
necessary
to
rotate
the
engine
until the No 1
piston
is
at
T D C
on
its
compression
stroke
Fill the
pump housing
with
engine
oil and
align
the
punch
mark on the
spindle
with the hole
in the oil pump as shown
in
Fig A
44
Install the
pump
with a new
gasket
and
tighten
the
securing
bolts to a
torque reading
of 11 15 kgm
8 1 Ilb ft
Replace
the
splash
shield board and the front stabiliser
refill
the
engine
with
the
specified
amount
of
engine
oil
OIL
FILTER
The
cartridge
type
oil filter can be removed with the
special
tool ST 19320000 or a suitable filter
remover Interior
cleaning
is not
necessary
but the
ftIter
body
and element
must
be
repiaced
every
10 000 km 6000 miles Be
care ul not to
overtighten
the filter when
replacing
or
oil leakage
may
occur
CHANGING
THE ENGINE OIL
After the fIrst oil
change
which
should take
place
at 1000
km 600 miles the
oil should be
changed regularly
at 5000 km
3000
miles intervals
Draining
is
more
easily accomplished
after
a
lengthy
run
when the oil
being thoroughly
warm will flow
quite freely
Stand the vehicle on
level
ground
and
place
a suitable
container
under the drain
plug
Remove the
drain
plug carefully
as the hot oil
may spurt
out with considerable force
When
refIlling
the
engine
make
sure
that the
oil is to the H mark on
the
dipstick
19