Datsun 510 series Instruction manual

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S IENTI
IC I
UBLI ATIONS
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VORKSIIOI IUANIJAL
SERIES No 88
DATStIN
1600 1300
SIfRIE
S 510
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AIJTOMATI
and
MANIJAL TRANSMISSIONS
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LI4
Specifications
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With
Specifications
Repair
and
Maintenance Data
1
SCIENTIFIC PUBLICA
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SYDNEY DURHAM
BRISBANE
LONDON
MELBOURNE
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PUBLISHED BY SCIENTIFIC
PUBLICATIONS PTY L TO
J
j
AustrahaJ
89 97 Jones Stre t
ULTIMO
N
S
W
2007
PhO
21T6I1
j
England
Umt4
Hetton
Lyons
Industnal Estate
HETION LE
HOLE
TYNE AND WEAR DHS ORH
Phone Hetton Ie Hole 2443
Pnnted
by
Tjmes Pnnters
Sdn Bhd
Smgapore
@
Copynght
by
SCIentIfIc PubhcatIons Pty
Ltd
RegIstered
at GPO
Sydney
for
transnussJOn by post
as a
book
FlfSt
EdItIon December 1971
Reprmted May
1972
Repnnted
December 1973
Repnnted
November
1975
Repnnted
June
1977
ISBN
85566 039 2
4
t 1
The
informatIOn
In thiS
manual IS deTlved
from
the latest models
available
for
our
workshop
research and
from
other available
sources
at
the tlme
of wTltmg
Any
subsequent
modificatIOns
will
need
to be taken mto consideratIOn
by
the
operator
While
every precaution
IS taken to ensure the accuracy
of the
contests onus can not be
accepted
for any miSinterpretatIOn ofthe
descTlbed
repalT operations
or
for any
errors
or omiSSIOns inad
vertently
made
n N owum F N
T
Sclentlfic PubhcatlOns WIshes to thank NlSSan
Motor
Corp
USA and
Borg
Warner
Ltd
FaIrfield for
help
ill
aspects
of
preparIng
thIS
manual
Il
J
l
o
v OVERSE S REPRES ENT A TIVES
Canada
Repco
Auto
Parts Canada Ltd 325 West 6th Avenue Vancouver
IOBC
New Zealand
M E
P
Bookshop
82 TaranakI St
WellIngton
Pubhshers ServIces 13
Eden
St
Newmarket Auckland
J
E Slme
anll
Co 82
Tory
St
Welhngton
and
140
Target
Rd Glenfield Auckland
SouthAfrica Austrahan Industnes
Export Pty
Ltd PO Box 2016
Johannesburg
United
Kingdom
AIItech Distnbutors 15
HIgh
St
Hampton
MIddlesex
Fredenck
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Ltd
Vlctona Works
Edgware
Road London
SCjentIfic
PublIcations
Urnt
4
Hetton
Lyons
Industnal
Estate
HETION LE
HOLE TYNE and WEAR DH5 ORH
IJ
fJ
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ENGINE
COOLING SYSTEM
FUEL SYSTEM
CLUTCH
MANUAL TRANSIUISSION
AUTOMATIC
TRANSMISSION
REAR
AXLE
FRONT SUSPENSION
RRotR SUSPENSION
STEERING
d
BRAKES
ELECTRICAL
SYSTEM
ROAD TEST
BODY
WHEELS AND TYRES
LUBRICATION AND MAINTENANCE
EMISSION CONTROL SYSTEMS
INDEX
GLOSSARY OF TERMS
v
J
7
40
46
I35
143
150
167
216
217
226
231
233
252
4
255
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f
MOTOR VEIDCLFS
Austin
AustIn lillO
1300
AustIn
Met 1
Allegro OHV
lillO 1300 1973
76
Allegro
OHC
1500 1750
1973
76
it
1
1
ChrysIer
MrtsuInslu
Galant GA GB Colt
1300 1600 1971 74
Galant
GCGD Colt
600
1774 77
Dalslm
1000
1200
510
1300 1400 1600
1968
72
180B
16OB
Sunny
120Y
r
i
Ford
Capn
Mk
I
Consul
Zephyr
Mk II
1956
62
CortlDa
1200
1500
1600
Mk
I II
1964
71
Cortma
Mk III
1600
2000
1971 74
Cortma
Mk III
6
cyl
1972
74
Excort Mk
I
Escort Mk II
Falcon
XK to XW
l
6
cyl
1960 70
t b
t
Rican XY
to
XB
I
J
1
6
yl 1970 76
Falcon
XR
to XY
t
V8
1966 71
Falcon
XA
and XB
V8 1971
76
1
If
i
H
lnuUl
Avenger
Hunter
New Hunter
j1 t
c
Holden
GerolDl
FX
FJ FE FC FB
EK EJ
EH
HD
HR
1948 i8
HK HT HG
V8
1968 71
HK HT
HG
6
cyl
1968
71
HQ
HI 6
eyl
HQ
HJ
V8
Torana
LC
U 6
cyl
1969
74
Torana
LH LX 6
cyl
1974 76
T
orana HB
Torana
LC LJ
TA
4
cyl
1969
75
ohv
Torana LC
U TA
4
cyl 1969
75 ohc
Torana LH LX
4
cyl
1974
76
Honda
ElVIe HondamatIc
CIVIC
Manual
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SCIENTD1C PUBLICATIONS MANUAL
SERIES
Bool
Pagea
m
Bool
PaIfS
I h
No
tre 1
No tretioDS
I
1
1 11
148
149 192
298
25
51
192
37 7
r
I
200
129
05
192 202
17
87
88
110
III
224
208
256
241
224 208
224 278
82
08
173 108
184
124
68
60
59
81
20
62
155
154
156
288
192
240
239
176
135
192 172
192 240
290 188
272 226
272 190
240
327
80
79
37
176 267
188 121
113 160
215
67
85
86
146
147
84
58
72
56
145
16
286
128
272
215
224
188
208 194
256
240
192 172
192 200
192 120
196
287
196
295
180
197
139
140
176
350
176
339
Leyland
Allegro
OHV
lillO
1300
1973
76 25
Allegro
OHC
1500
1750
1973
76 51
Manna I 3 I 8
1971 75 142
Manna 1500 1750 03
P76 V8 04
P76
6
cyl 141
BL
1100 1300
148
Mazda
Capella
616 1600
1970
73
89
1500 1800 90
RX2 R I 00 Rotanes 91
1000 1300 92
MG
TC
to
MGB Mk
I
70
Moms
MlDor 1000 24
Manna
see
Leyland
MIDI
1961
72 64
MmJ 1971
76 02
1100
65
1800 Mk
I
Mk
II
66a
Peugeot
403
404 31
Renaalt
12
32
DauphIne
34
R8
and
RIO
74
Toyota
Corolla 1100 73
Corolla 1200
122
Corona
2R 83
Corona 2000
16R
18R
120
Corona
12R
RT80 81 123
Vabant
AP6 VC VE VF
V8 1965 70 69
R
S AP5 AP6
VC
VE
VF 6
cyl
1962
70
78
Heml
VG VH
6
eyl 1970
74
52
Galant see
under
Chrysler
Veuxhall
VIva HA
HB
90 76
Viva
HC OHV
57
Chevette
1256 ce
114
Volkswagen
Super bug 1302S 1600
1971
73 45
Beetle 1100
1200
1200A 1300 1500
1954 71
46
Fastback
Type
3
1600
47
Transporter 1954
72
48
Type
2
1700
1800 2000 151
Passat
1300
1500
1600 152
Golf 1500 1600 153
192
277
160 291
180
274
180
324
160 134
212 196
200
199
160
305
320
204
96
96
236
187
224
276
146 106
224 174
122 171
160 317 J
134 158
164
97
176
107
240 217
224
186
176 256
160 220
174
95
280
145
224 183
200 140
160 239
224
1 88
260
240
232
167
272
205
168
240
168 235
Bool
Pagea
m
No
treb
Volvo
Senes
140
WIth Carb es
With
Fuel
Inject
HARD
TO GET
AND
VINTAGE MANUALS
Austm
A40
Devon
Dorset
A40 Somerset
Jagoar
Mks
VII VIII IX
XK
120
140
150
Mk
I II
2
4
3
4
3 8
E
Type
3 8
4 2
1962
69
Staodanl
8 14
1939 46
Ten
1955
58
Spa
aster
II
TR2
TR3 TR4
MOWERS AND
SMALL ENGINFS
Rover Senes to 1977
Small
EngInes
V
lcta Series
to
1977
Scott
Bonnar 1976
77
MOTOR CYCLFS
53 212
54
196
00 106
01 100
21 274
22
274
77
202
40 82
41
148
42 126
44
168
99
112
160
103
128
97
Honda
QA50 MmJblke 129
64
SL70 Cf90
130 128
CIS
50 65
70 131
96
StreetTfrad
175 132 112
125
Vert
eal
TWIn
133 112
250 350
134 128
100
125
VertIcal
SmgIe
135 112
OUTBOARDS
EnnrudeJoImson
34
hp
1964
72
105
64
5
6hp
1965
74
106 96
9
hp
1964 73
107 80
18
20
25
hp 1960
73 108 112
18
20
25
hp 1960 73 108
112
3340
hp
1965
74
109
128
40
hp
Lark 1965
74
104 112
MANUALS
IN
PRODUCfION
Austm
1100
1300
148
Hillman New
Hunter
37
Vahant VJ VK 157
Golf
1500
1600 153
Rovers Mowers 99
Scott Bonnar
Mowers
97
l
172
147
89
84
237
281
124
51
134
105
130
231
138
95
224
182
341
346
376
374
f
92
177
198
260
260
300
250
WWW.PlanDeGraissage.Org

Engllle type
Engllle
models
Fmng
order
CompressIOn
ratio
L13 16
slllgle
carb
L14
L16 tWill carb
Bore
Stroke
L13
L14
L16
CapacIties
L13
L14
L16
Brake
horsepower
L13
L14
L16
slllgle
carb
L16 twill carb
Maximum
torque
L13
L14
L16
single
carb
L16 tWin
carb
Standard
compressIOn pressure
@ 350
rpm
L13
L14 L16
single
carb
L16 tWin
carb
Minimum
compressIOn pressure
@
350
rpm
ENGINE
l
SPECIFICA TIO
S
4
cyl
OHC
L13
L14
L16
1 34 2
85
90
95
J
83mm
3
2677
Ill
59 9 mm
2358 Ill
660mm
2598
In
73 7 mm
2901 In
1296
cc
79 086
cu
In
1428
cc
87 141 cu In
1595
cc
97331
cu In
77
@ 6000
rpm
85 @ 6000
rpm
96
@ 5600
rpm
109
@6000
rpm
III
kg
m
@ 3600
rpm
803
ft
lb
@ 3600
rpm
119
kg
m
@ 3600
rpm
86
0
ft lb
@ 3600
rpm
13 8kg
m
@ 3600
rpm
99 8 ft lb
@
3600
rpm
143
kg
m
@
4000
rpm
1034
ft lb
@ 4000
rpm
120
kg cm2
171 pSI
125
kg cm2
178
pSI
II
5
kg cm2
159 pSI
EngIne
IdlIng
speed
I
L13 L14 L16
single
carb
L16
tWIn
carb
I
Igmtlon
tIming
InItIal
settIng
at
IdlIng speed
LJ3 LJ4 LJ6
single
carb
LJ6 tWin carb
600
rpm
650
rpm
10
deg
btd
14
deg
btdc
Type
CYLINDER BLOCK
Bore dIameter standard
Bore
wear
lImit
Bore
measunng pOInts
depth
from block face
Fust
J
Second
Thud
CylInder
block
face
warp IInut
O
S
pistons
avaIlable
FIrSt O S
Second O
S
l
ThIrd O S
r
FourtJi
O S
t
FIfth O
S
4
cyl
In
lIne
Integral
WIth
crankcase
83000
83
050
mm
3 2677
3 2697 In
o 20 mm
0008 on
1
w
r
J
20mm
i
0787
In
60mm
J
2 362 In
7
100mm
39371
910mm
0004 In
CYtINDER HEAD
Type
Matenal
Valve Eeat
Width In
t c
cylInder
head
l
Inlet
t
Exhaust
t
i
7
1J
K
i
J
C
4
o
250 mm
0010 on
approx
o 500 mm
0
020 In
approx
0750 mm
0030 on
approx
I
000 mm
0040 In
approx
I
500
mm
f
0060
In
approx
iL
Wt
t Fr
One
piece
AlumInIUm
Alloy
fe
to
Y
I 40
I 80 mm
0055
0071 In
160 200mm
0063
o 079
In
t
I
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2
Engine
Valye
seat
angle
Inlet and
exhaust
Valve seat msert mterference
fit
m
cyhnder
head
Inlet
Exhaust
Cyhnder
head
tempera
ture
for
fittmg
valve seat mserts
Valve
gUide
mterference
fit m
cylmder
head
Inlet and exhaust
1
Cylulder
iiead face
warp hmlt
j45
deg
J
008 0 II mm
00031
00043 m
006 01Omm
00024
00039
m
150
200
deg
C
302
392
deg
F
o 027
o 049 mm
00011
00019
m
o 10mm
0
004 m
CR
ANKSHAFT AND
MAIN BEARINGS
Type
rJ i
Matenal
jIl
Number of
mam
Journals
End thrust taken at
Thrust clearance
Thrust clearance IUTIlt
y
Mam
beanngJournal
diameter standard
Mam
beanng
Journal
taper
and
ovahty
hmlt
VIS
beanng
avaIlable for
VIS
Journals
Fust
VIS
Second
VIS
Third
VIS
yl
i ffi
Fourth
VIS
c
Counter balanced
Forged
steel
5
No
3 mam
beanng
o 05 0 15 mm
0002
0006
m
03mm
0012
m
54 942
54955 mm
21631
2
1636 on
003 mm
00012m
o
250 mm
OOIOm
approx
o
500
mm
0020
m
approx
0750 mm
0 O JO m
approx
I
I
00
mm
I
0040
ur
T
approx
1
Ot r
tt
A
Ii
I
t
r
t
l
J1tJ
d
J
Maon
beanng
oIl clearance
L13
L14
o 020
0062 mm
00008
o 0024 m
o
020
0072 mm
00008
o
0028
m
L16
Mam
beanng
oIl
clearance
hmlt
L13 LI4
L16 o IOmm
00039
m
49961
49
975
mm
I
9670
I
9675
m
003 mm
00012 on
CONNECTING
RODS
AND
BEARINGS
Crankpon
diameter standard
Crankpon taper
and
ovahty
hmlt
Connectmg
rod
type
Matenal
Length
centre to centre
L13
H
sectIOn
Forged
steel
139 87
139 93 mm
5507
5
509
m
1366
mm
5371 m
13297
133 03 mm
5235
5
237
m
L14
L16
Connectmg
rod bend or tWIst
maxnnum lumt
per
100 mm
394 m 005
mm
00020 m
Replaceable
Big
end
beanng
type
BIg
end
beanng
011
clearance
L13 L14 0014
0056mm
00006
00022 m
0014
o
066 mm
00006
00026
m
o IOmm
00039
m
L16
Big
end
bearmg
oIl
clearance hmlt
L13 L14 L16
VIS
beanngs
avaIlable
for
VIS
crankpms
FITSt VIS o
060
mm
0
002 m
approx
o 120
mm
0004
on
approx
Second
VIS
8
WWW.PlanDeGraissage.Org

Thud
U S
o
250 mm
0010
In
approx
Fourth
UIS
o
500
mm
0
020
In
approx
FIfth
U S
0750 mm
0030
In
approx
SIxth
U S 100mm
0040
In
approx
GUDGEON PINS
Type
Interference fit
In rod
20995
21 000 mm
0
8266
08268
In
72 00
72
25 mOl
2
8346
28445
In
o 008
0010
mm
00003
00004
In
0015
0033 mm
00006
00013 In
DIameter
Length
Clearance In
pIston
Interference
fit In rod
PISTONS
Type
L13 L14 Flat
top
Invar
strut
slipper
skut
Concave
top
Invar
strut
slipper
skIrt
Cast alumInIUm
Top
of
cylinder
82
99
83
04
mm
3 267
3
269
In
L16
Matenal
Removal
DIameter standard
DIameters
O S
FIrSt O S
83 22
83
27
mm
3
276
3
278
In
8347
83 52 mm
3 286
3288
In
Second
O S
83
72
83 77
mm
3
296
3
298
m
83 97
84 02
mm
3 305
3
308 In
8447
84 52 mm
3
326
3 328m
18 6
mm
9
732
In
o 025
o
045
mm
0001
00018 In
o 950
1
050 mm
t
li
003740 J
004134
In
DIstance
below
centre
lIne
of
gudgeon
pm
Thud O
S
Fourth O S
FIfth O S
PIston
measunng
pOInt
Skut
clearance In
bore
Gudgeon
pIn
bore offset
PISTON
RINGS
LocatIOn
i
Number
Width
Upper
compressIOn
Lower
compressIOn
011
control
Clearance
10
grooves
Upper
compressIOn
L13 L14
L16
Lower
compressIOn
L13 L14 L16
i
011 control
L13
L14 L16
9
Engine
3
r
0
4
It
l
11
r
J i
r
4
f
k
1
I
t
V
gudgeon
pin
3
20mm
0078
In
20mm
007810
40mm
015610
e
f
0040
0073 mm
00016
00029
10
o 045
0078
mm
00018
00031
10
j
0030
o
063 mm
00012
o 0025
10
o
025
0 063 mm
0001
00025m
WWW.PlanDeGraissage.Org

Engine
Rmg
gap
Upper
compressIOn
Lower
compressIOn
k
t
iff
011 control
VALVES
II
it
Ji
if
Head
dIameter
mlet
i1
tC
l
13 LI4 LI6
sIngle
carb
J
J
t
i lt
6tWIn carb
fl
o I
f y
Head
dIameter exhaust
t
Stem dIameter
Inlet
and
exhaust
Clearance
In
gUide
bore
Inlet
Exhaust
r
I
Valve
length
Inlet
Exhaust
d
J
l
VaJve
hft
Inlet and exhaust
LI3 LI4
LI6
smgle
carb
itr
Ll6
twm
carb
Valve face
angle
Inlet and
exhaust
Valve
clearance
Hot
Inlet
5Jt i
l if
lj
Exhaust
Cold
Inlet
Exhaust
oj
o
023
o
38
mm
00091
0015
m
015 030mm
00059
00118 In
o 15
0 30
mm
0
0059
00118
m
38
00 mm
1
50 In
42
0
mm
I 65 m
33mm
1
30 In
8mm
0 31
m
0015
0045
mm
00006
00018 In
0040
o
070
mm
00016
00028
m
1159mm
456 m
1160mm
457
In
100mrl
03937
m
10 5
mm
04l24m
45
deg
30 mm
o
25 mm
0010 In
o 30 mm
0012
m
o 20
mm
0008
m
o
25
mm
OOIOm
VALVE
SPRINGS
Type
Free
length
Outer
LI3
Ll4
Ll6
Inner
LI6
Length
at load valve
closed
Outer
LI3 Ll4
Ll6
Inner
Ll6
Length
at
load valve
open
OUJer
Ll3 Ll4
LI6
Inner
LI6
10
Valve
spnng squar
eness
hmlt
r
3
1 r
t
Hehcal
48
12 mm
I
89
m
52
00 mm
20472
m
44
85 mm
1
7657
m
400mm
@ 29 2
322 k
g
1
57
m
@ 64 39
71011b
38
9 mm
@ 27 5
30 5 kg
1
53 In
@ 60 62
67241b
35mm
@116
13 0 k
g
1
38 m
@
25 58
28661b
30 0 mm
@ 67 7
74 7
kg
118m
@ 149 19
164611b
30 7 mm
@
45
4
50
2k
g
307m
@10009
11667Ib
245
mm
6
@ 24
2
j
26 8
k
tl
eb
96
Ini
y
5i31f
59
Olf
lb
I
6 Inm
0063 m
J
t
1
J
1f
4
t
t
J
4
i
j
r
fJ
r
t
f
J
r
A
l
r
t
I
I i
l
t
1
w
i
f
1
ft
l
j
WWW.PlanDeGraissage.Org

4
C
t
VALVE GUIDES
Type
Length
Inner
diameter
Ou ter
diameter
Fitted
height
above
cyhnder
head
q
GUide to
yalve stem
clearance
Inlet
Exhaust
j
1ft
ll
CAMSHAFT
Type
Number of
beanngs
Camshaft
Journal
diameter
aj
CamshaWJournal
wear hmlt
Camshaft
bearmg
diameter
Camshaft lobe hft
L13
Ll4
Ll9 smgle
carb
L16 twm carb
Camshaft
Journal
to
beanng
clearance
Beanng
clearance hmlt
M
CfiTshaft
nd float
f
11
dJ
1
P lmshaft
bend I1I1 t l
J
qr
r
0
Cf
r
t
J
L
J t
t
yr
r
u
t
J t i h I
Camshaft
sprocket
Fit on camshaft
Method
of
secunng
ctankshaft
sprocket
Fit
on crankshaft
Method
of
secunng
Renewable
59
0 mm
232111
8000
8 018 mm
03150
03154
m
11 985
11 996 mrn
04718
04723111
104 106mm
0
409
0417111
p
0015
o 045 mm
00006
00018 m
0040
0070
mm
00016
00028
m
Overhead
4
47949
47962 mrn
1 8877
1 8883 m
o10
mm
00039 m
48
000
48016 mrn
1 8898
1 8904
m
6 65 mm
0261
m
7 00
mm
0275
m
o
038
0076
mm
00015
00026
m
o 10mm
0 0039 m
008
0
38 mrn
00031
00150m
005 mm
0
002 m
It
f
i
1 i
CAMSHAFf
DRIVE
Engine 5
Type
Sprocket
and
cham
Light
fit
One bolt and
peg
Light
fit
Key
LUBRICA nON
Pump type
Outer
rotor to
pump
body
clearance max
Eccentnc
rotor
021
mm
0 009
lOW
Inner rotor
tIp
clearance
max o 12mm
0005 11
J
Inner and outer rotor end
clearance
JTlax
Ou
pressure
at Idle
012mm
0005
m
I
0
I
2
kg
cm2
142 171
pSI
Rehef
valve
spnng
Free
length
57mm
2 24 m
39mm
I
540 m
38
42
kg
cm2
l54
00
59 7
pSI
il
Length
at
load
Rehef
valve
opemng
pressure
Ou
capacity
Sump
Without
filter
J
111
Sump mcludmg
filter
TORQUE
WRENCH SETTINGS
Cylmder
head bolts
t
Mam
beanng cap
bolts
Big
end
beanng
nuts
Camshaft
sprocket
bolt
11
If
Y l
fl f
t
ra
l
k
J1
1h
w
o4
0
WWW.PlanDeGraissage.Org

6
Engine
Sump
bolts o 7
kg
m Rear
crossmember to
body
bolts
5 2
kg
m
50 ft
lb
38
0
ft lb
011
pump
bolts 2 1
kg
m
Front
engme mountmg
IS
0
ft lb bracket to
engme
bolts
30
kg
m
Flywheel
bolts 105
kg
m
220 ft lb
76
0 ft
lb
Front
engme
mountmg
Rear
engme mountmg
to bracket bolts 32
kg
m
to transmISSIOn bolts
32
kg
m
23 0
ft lb
23
0
ft
lb
Front
engme mountmg
Rear
engme
mountmg
to crossmember 1
7kg
m
to crossmember
bolts
1
6
kg
m
120
ft lb
120 ft lb
I
DESCRIPTION
The
L13 and L16 overhead camshaft
engmes
are almost
IdentIcal m
deSIgn
The
L16
engrne
wIth
ItS
longer
stroke
and thus
mcreased
capacIty develops
more
horsepower
DImenSIOns of some
components
m the L16
engme
haye
b n
mcreased to
take the
load of
the
hIgher output
The
L16
engme
IS also
avaIlable
m a
sports
type versIOn
and
utlhzes
twm carburettors
and
hIgher compressIOn
ratIo
to
mcrease
power by
13
bhp
over
that of the L16 standard
versIon
of the
engme
The
engInes
have
a cast Iron
deep
slmt
deSIgn cyhnder
block The
five
mam
bearIngs
whIch
are
used to
support
the
crankshaft aH of the
precIsIon
msert
replaceable type
The
mam bearIn m
al1
engInes
must
l
ot
be
adjusted
by
filmg
or
by scrapmg
The
cran
1t
end
float
IS
control1ed
by
thrust faces
which are
mtegraJ
With the
centre mam
bearIng
half
shel1s
011 leaks from
the front and
rear
of
the
crankshaft are
Jf
Itt
t
y
il
J
ff
4
J
1
Yi
t
tir
t
1
ll
l
l 10
tJ
li
f
t I
t
prevented
by
seals whIch are mstal1ed m the
tlmmg
coyer
and
rear
mam
beanng
The front
seal
runs
on
the
crankshaft
pul1ey
hub and the
rear
seal
runs
on the
crankshaft
flange
The
cyLmder
head IS constructed of alummlUm
al10y
SpecIal
alurmrnum bronze
valve seats
are used
for the mlet
valves
and
specIal
cast seats are mstalled for
the
exhaust
valves
Both mlet and
exhaust valve seats
are a hot
press
fit
mto the
cyhnder
head The
camshaft
IS
supported
over the
top
of the
cyhnder
head
by
four alummlUm
alloy
brackets
A
long
double row
roller
cham
drIves the camshaft from the
crankshaft
sprocket
Cham tensIon
IS
controlled
by
a
tenslOner
whIch
IS
operated by
a
sprmg
and OIL
pressure
A
shoe
type Neoprene pad
whIch IS bolted on the face of
the
crankcase
keeps
cham VIbration
down
to
a
mmlmum
Connectmg
rods
are H
section
forgmgs
fitted WIth
replaceable
bIg
end
preCISIon
msert
bearIngs
The
gudgeon
pms
are a hollow
type bemg fully floatmg
m
the
pIston
and
a
press
fit m the
connectmg
rod
The
hght
weIght shpper
skIrt
type pIstons
have a flat
top
m the L13
engIne
and a
concave
top
m
the L16
engIne
The 011
pump
IS
a
bl rotor
type
and IS drIven
by
the
dIstrIbutor
dnve
shaft asse
mbly
whIch
m
turn
IS
drIven
by
a
gear
whIch
IS
keyed
to
the front of the
crankshaft
Left Hand Side View of 1600
Engone
and Transmission
Assembly
12
WWW.PlanDeGraissage.Org

RIght
Hand SIde V
ew of 1600
Engone
and TransmiSSion Assembly
2 ENGINE
ASSE BL Y
TO
REMOVE
AND INSTAL
I
Raise the
engine
bonnet and
fit
fender
covers
to
both front fenders
2 Mark around the
bonnet
hinge
plates
on the
bonnet wIth
a
soft
lead
pencil
to facilitate correct
replacement
and remove
the bonnet
3 Remove the radiator
cap
and
drain
the
coohng
system
vra the drain
tap
on
the
lower radiator tank
4
Remove
the
sump
and
transmission drain
plugs
and
drain the lubricant from both
assemblies
5
Disconnect the
leads
at
the
battery
terminals and
remove the
battery
from the
engine
compartment
6 Disconnect
the
ventilatIOn hose from
the
I
rocker
cover
and
remove
the air cleaner
assembly
7 Disconnect
and remoye
the
upper and
lower
radiator
hoses
and the heater
hoses where
apphcable
8
Unscrew
the
fixing
bolts and detach
the
radiator
grille
9 On
vehicles
fitted wIth
automatic
transmiSSIOn
disconnect the
torque
converter
cooling
pipes
at the lower
radiator tank
plug
the
pipes and
umons to
prevent
entry
of
dirt
10
Remove the radiator
retaining
bolts and
hft
out
the
radiator
II
Slacken
the alternator
mountlllg
boIts and remove
the fan belt Remove the four boIts fan and
pulley from
the
water
pump
0
12
Disconnect the
wlfes at the 011
pressure
switch
temperature
sender umt coil and alternator
5
I
t
r t v
i
tI
2
13
Disconnect the
throttle control
linkage
and
the
I
choke
control
wIre
at
the
carburettor
I
14
Disconnect the
fuel
pipe
from
the
mle
t S
e
of the
ti
1
v
ue
pump
l lI
IS
Remove
the
nuts
and detach the exhaust
PIP
I
from the
exhaust
mamfold TIe
the
exhaust
plpe
away
frifp
j
the
engine assembly
Jl1
16
Raise the front
and
rear of
the
vehicle
and
support
safely
on Jour
sUitable
chaSSIS
stands fj
17
Remove the clutch
actuating cyhnder
and ret n
spring
Tie
the
cylinder
to
a
cO lYement
out of
the
way
posItion
on the
underbody
r
18
Disconnect
the reversing
hght
sWltctplug
9
h
inhibitor and
reverSing
hght
sWitch
plug
wlucheveiI is
t
Ji
i
l
apphcable
for
either manual
or
automatic
transmlsslqi1n
19
Disconnect
the
speedometer
ca
le y
j t
20
On manual floor shift transmISsion
from
inSide
the vehicle remove
the
gaiter
from
the
gear
shIft
lever undo
the self
locking
nut from
the lower end of the
lever and
remove the lever
On manual column
Shdlft
transmISsIOn
disconnect
thde
select
and shift rods
un 0 the cross shaft bracket to
Sl e
member
retaining
bolts
and
remove
the
cross shaft bracket
assembly
On
automatic transmiSSIOn
disconnect the selector
hnkage
at
the cross shaft bracket undo
the cross shaff
bracket to
SIde
member
retaining
bolts and
remove the
cross shaft bracket
assembly
21
Remove
the four bolts and
nuts from
the
d
r
WWW.PlanDeGraissage.Org

I ROCKER
AR f ND I IVOTS
relevant arm
before
attemptmg
to
co rf kss
the valve
sprmg
and
removmg
the
arm
8
Place
the rocker arms m a
rack
or
lay
them out
m
order to ensure
that
they
wIll be mstalled m
theu
ongmal
pOSItIons
m the
cylInder
head
9
Unscrew the
rocker
arm
PIvOtS
from
the
cylInder
head
and
remove the
rocker
guides
from the yalve stem
ends
Lay
these Items also out m
order to ensure correct
replacement
to
cylmder
head
propeller
shaft rear
flange
and
WIthdraw
the
shaft from
the
transmISSion
NOTE
To
remove the
propeller
shaft
It
may
be
necessary
to
disconnect the rear handbrake
cable where
It
runs under
the rear
see tlOn
ofthe
propeller shaft
22 Detach the handbrake
cable from ItS
retammg clIp
at
the
transmission rear
crossmember
23
Remove the two transmISSIOn rear
crossmember
to
mountmg
secunng
bolts
24
Interpose
a
wooden block between
the
transmiSSIOn
and
a
Jack
and take the
weight
of the rear
engme
and
transmISSIOn
assembly
25
Remove the four bolts which attach
the rear
transmISSIOn
crossmember to
the
underbody
and
remove
the crossmember
26
Instal a sUitable
IIftmg
cable
or
cham
to the
IIftmg
hooks which
are
posItIoned
at the front
and
the rear of the
engme
cylmder
head and With
sUitable
IIftmg
tackle take
the
weight
of the engme
assembly
TO
REMOVE
I
Detach the rocker
cover to
atr
cleaner
ventIlatIOn
hose
and
the
thermostatIc au
bleed hose where fitted
R
2 Loosen
the au cleaner
assembly
thumb screw
remove
the
two bolts whIch secure the
atr cleaner
assembly
0
bracket
to the
mlet
manIfold and remove the au
cleaner
assembly
t
e
NOTE On
engines fitted
With twm
SU
carburettors It Will
not be
necessafY
to remove the arr
cleaner
ssembly
3 Detach the
hIgh
tensIOn leads at
the
spark plugs
and
carefully
tIe the
hIgh
tensIOn leads at a convement
pomt away
from
the
rocker cover
NOTE
Carbon
filled
high
tensIOn leads
should
be
handled
carefully at all
times
Mlshandlmg
of
leads Will
cause a
breakdown m
lead
wntmUlty
J
4
Remove
the rocker
cover
secunng
bolts
and detach
the rocker
cover and rocker cover
gasket
5UnclIp
and
remove the
small
steady spnng
from
each
rocker
arm
6
Back off
the
rocker
pivOt
locknuts and screw the
PIvOtS
down
as far
as
possible
mto the
cylInder
head
7
With
a
screwdnver
push
down on
each
valve
spnng
l
see IllustratIon
and
manoeuvre out each
rocker
arm
Dunng
this
operatIon
take care that the valve rocker
gUides
which
are located
on
the end of
the valve
stems are
not
dIslodged
and
lost
NOTE
When
removlIIg
rocker
arms ensure
that the
cam
el
for
the
rocker arm
bel1lg
removed IS
adjacent
to Its
tt
1t
27
Remove the
front
engme
mountmg
to front
crossmember
secunng
bolts
28
Check
around
the
engme
and transmISSIOn
assembly
to ensure
that
notlung
will
foul on the
assembly
and also
that
all
relevant Items have been disconnected
29
Gradually
taIse
the engme WIth the front
tuted
upwards
to clear
the
body
and at
the
same tune
lowenng
the
transmiSSIOn on
the
jack
untu
the
engme
assembly
can
be lIfted clear of the vehicle
InstallatIon IS a reversal
of the removal
procedure
With
attentIon to the
followmg
pomts
Ensure that the
engme assembly
IS
mstalled
and bolted
securely
to all
mountmgs
and that
the full
engme assembly
weIght
IS
taken
by
the
mountmgs
before
connectmg up
the
vanous
components
to the
engine
and transmission
FIll the
radiator With water and add condItIoner
and or
antI freeze If
necessary
FIll
the
crankcase
With the correct amount
of
the
recommended
grade
of
M
S
engine
ou
Start and
run the engme un tu
It reaches
normal
operatmg temperature
and
check for
ou
and
water leaks
Method of
RemOVing
Valve Rocker
Arms
14
J
1
WWW.PlanDeGraissage.Org

f
If
l
TO CHECK
Engine
Rocker Cover Removed
Showing
Val e Rocker Arm
and
P vOt
Layout
TO
INSTAL
J
1
Wash
all
components
In
cleanmg
solvent
and blow
dry
wIth
compressed
an
2
Check the
rocker
arm
Pivot
head
surface for wear
or
damage
3
Check the
rocker arm to cam and the rocker
arm
to
p
vot
contact
surfaces for wear
or
damage
4
Wear
or
damage
to one of the above
mentIOned
components
will
necessitate the renewal of
the
correspondmg
Pivot
or
rocker
arm
as the case
may
be
InstallatIon IS a reversal of the removal
procedure
With
attentIon to
the
followmg
Assemble the
rocker arm
components
With
engme
ou
to ensure lubncatlOn for InitIal start
up
Adjust
the
valve
clearance
See TO ADJUST
VALVE
LASH
section
Clean the
gasket
surfaces
on
the
cyhnder
head and
rocker
cover Use
a
new
gasket
when
mstalhngilhe
rocker
cover
t
1 iiI
TO REMOVE AND INSTAL
4 CYLINDER HEAD
J
Disconnect the
rocker cover to
an
cleaner
ventIlatIOn hose and where fitted the mlet
mamfold to air
cleaner thermostatic au bleed
hose
2
Remove
the air cleaner
assembly
3
Remove the carburettor
s as follows
Smgle applicatIon
dISconnect the fuel mlet
pipe
and fuel
by pass
hose
where fitted
Disconnect the dlStnbutor
vacuum
feed
pipe
Disconnect the choke
control
cable
Disconnect the
throttle
hnkage
at
the carburettor
throttle
lever
Remove
the
carburettor to marufold
retammg
nuts
and lift
off the
carburettor
Twm
apphcatlOn
remove
the
mlet elbows
fJ 2m
the
carburettor
Disconnect
thS
fuel
mlet
pipes
Disconnect
the choke control cables
Remove the fuel overflow
pipes
from the float
chambers
Disconnect
the
throttle
hnkage
Detach the dlstnbutor vacuum feed
pipe
Unbolt and remove
each
carburettor
from the
mlet
mamfold
4
Dram the
coohng system
Via
the
tap
on the
radiator bottom
tank and the
plug
m the
cyhnder
block
5
DIsconnect and remove the
top
radiator
hose
6
Disconnect the
heater hose
at
the
rear
of
the
cyhnder
head
7
Detach the
high
tensIOn leads at the
spark
plug
and
IgmtlOn
cou tower
unchp
the dlstnbutor
cap
and
remove the
cap
With leads
8
Disconnect and remove the
crankcase to Inlet
mamfold
vent lahon hose
15
C
7
1
w
I
WWW.PlanDeGraissage.Org

iIJ
1
III
Engine
p
9
Remove
the
retammg
clip
and
then disconnect
and
r
remove the
mlet mamfold water
pIpe
10 Detach
the wire from the
temperature
sender
I
umt
11 Disconnect the fuel mlet and
outlet pIpes from
the fuel
pump
II2
Remove
the
two nuts
secunng
the fuel
pump
to
tlie
cylmder
head and Withdraw the
fuel
pump gasket
and
msulator
block
13
Remove the
exhaust
mamfold to exhaust
pipe
flange
nuts and detach
the
exhaust pipe
from the
mamfold
14 Progressively
slacken and remove
the mlet
J
manifold to
cylinder
head
attachmg
nuts and
11ft
away
the
mlet mamfold
15
Progressively
slacken and remove the exhaust
mamfold to
cylinder
head
attachmg
nuts and lift
away
the
exha st malufold
DIscard the
Inlet
and exhaust
mamfold
gaskefA
1
16
Remove the rocker
cover
securIng
boIts and
getach
the rocker cover
Discard
the rocker cover
gasket
f
I
I
Correct PosItIon of
Support
Tool to WIthdraw Camshaft
Sprocket
t
14
6
DImenSIons
of
Wooden
Wedge
for
Holding TIming
Chain
when Camshaft and
Cylinder
Head are
Removed
I
NOTE
Adhered rocker
wvers can be dislodged from
the
cylmder
head
by bumping fmnly
with
the
palm
of
the
hand
Under
10
circumstances use
screwdrivers or
Similar
tools
to
pme
between the
alumlll um
cover
and
head
17
Remove the
two
external bolts which secure the
protruded
front
porhon
of
the
cylinder
head to the
hmIng
coyer
18
Rotate
the crankshaft unlil the 0
tunIng lark
on
the cham
IS
alIgned
and
clearly
VISible
With
the
hmmg
mark
dimple
on the
camshaft
sprocket penphery
19
The
sprocket hmmg
mark number which
IS
stamped adjacent
to
the mark
dimple
wIll
be
found to be
elther aI 2
or 3
dependIng
whether
the
tlmmg
cham
has
N
been
prevIOusly readjusted
due to
stretchmg
These numbers are also
staIJiped
on
the
sprocket
boss
I
adjacent
to the camshaft
dowellqcatmg
holes
For
example
If
a 2
number on
the
sprocket penphery
IS
found
to
be
aligned
With
the limmg
cham
0 mark then
the 2 number
on
the
sprocket
boss wIll
be
adjacent
to
the
camshaft
sprocket
dowel
locatmg
hole and also
the
camshaft dowel
20
Usmg
acorrect
fittmg
metnc
socket spanner and
SUItable bar unscrew
the
camshaft
sprocket
retalmng
bolt
Remove
the
bolt
and
the
uel
pump
actuatmg
cam
21
Instal the
special limmg
cham
support
tool down
between the
tracks of
the
hmIng
cham
to retam
the
cham
on
the
crankshaft
sprocket
and
also
to
prevent
the
hmmg
cham
tenslOner
plunger
from
becommg dislodged
from
the
hmmg
cham tens lOner
bore
The
support
tool can be
readily
fabncated
from a
sUitable
piece
of wood to the
dimenSIOns shOWn
IIT the
I1lustra tlon
NOTE If through unforeseen
cm
umstances the
t1mmg
cham IS
dropped off
the
crankshaft sproLket
and correct
valve
t111l1ng
IS
lost It Will be
necessary
to remove
the
sump
and
t1mmg
wver
to
readjust
the
valve t1mmg
22 With
the
tumng
cham
firmly wedged
by
the
support
tool Withdraw the camshaft
sprocket
from
the
camshaft disconnect
the
tumng
cham from the
sprocket
and remoYe
the
sprocket
23 In
the reverse
order
of
the
tlghtemng
sequence
progresslyely
loosen and remove
the
cylinder
head
secunng
bolts
Lift
the
cylinder
head
upwards
from the
cylinder
block
far
enough
to clear
the
tlmmg
cham and
support
tool
16
I
Ii
I
1
WWW.PlanDeGraissage.Org

Section of
Cylinder
Head
Showing
Exhaust and Inlet Valve
and Rocker
PivOt and Seat
Assembly
Removed
before
movmg
It forward and out of
the
engme
compartment
NOTE
For
both Li3 and Li6
engl les
It wLll be
necessary
to use Tool
No
ST490i
0000 to remove the
special
headed
c vlmder
head
sewrmg
bolts
24 Remove
and discard
the
cylmder
hedd
gasket
NOTE
Do not
rotate
the
crankshaft
while
the
timing
cham
IS
wedged by
the
support
tool
InstallatIOn
IS a reversal of
the removal
procedure
with
particular
attention to
the
folloWIng
pOInts
Use new
gaskets throughout
Smear both
sides
of
the
cylinder
head
gasket
With an
approved grade
of
JomtIng
compound
before
mstaltIng
the
oylmd hd
1
7
EJ
IMPORTANT
it IS
essentzal when
installing
the c
head to make sure
that
the
valves
are clear
of
the
p
crowns
If
the
cylznder
head
IS
mstalled
with
the
camshaft
In Its
ongmal
positIOn
I e when the cham
sprocket
was removed
pnor
to
head
removal
then
the
posslbllzty
of
the
val
contactmg
the
pistons
will
be ellmmated
Do
not rotate
the
camshaft
untzl the
tzmmg
cham and
sprocket
have been Installed
on the
camshaft
and thecham
support
tool removed
Use
gUIde
studs
screwed
mto
dIagonal
holes at
opposite
ends of
the block face
to
pOSll1on
both
the
cylinder
head
and
gasket
Instal
and
tighten
the
cylInder
head
bolts
evenly
and
progressIVely
In the order as shown In
the
IllustratIOn to
the
specified torque
see
Speclfical1ons
Check
and
adjust
the
rocker
arm
to
valve
stem
slearance
as
outlined m
TO
ADJUST VALVE
CLEARANCE sectIOn
Check and
adjust
the
cl1rburettor
Idling
mixture
and
engme Idling speed
as
necessary
Check for
engIne
011 or water leaks
TO
DISMANTLE
I
Remove the
cylinder
head
assembly
from
the
engine
as descnbed earlier
and
pJ
ace
on a
SUitable bench
2
Unclip
and
remove the
small
steady spnng
from
each rocker arm
3 Back
off
the
rocker
piVOt
locknuts and screw
the
piVOtS
down as
far
as
pOSSible
mto the
cylinder
head
10
4 With a screwdnver
push
down
on each valv s
ru1g
and
manoeuvre
each rocker arm from
the
cylmder
he iid I
Dunng
thiS
operation
take
care
that
the valve16
gke
If
guides
which
are located on
the
end of
the valve s e s
ar8 1
not
dislodged
and lost
91
fl
NOTE When
removmg
the rocker arms
ensure that
the
cam
heel
fof1he
rocker
arm
bemg
removed IS
adJ
e
to
ItS
r
o
J
I j
U
ii
1
to
r 1
tu t
i
4Y
1 r
L
jf
11
t
1
1 I7
t
J
i
r s
t7
t
17
o
WWW.PlanDeGraissage.Org

12
Engine
ro m
SPRING
RETAINERS
A
A
OIL SEALS
I
J OUTER SPR
NG
9
INNER
SPRING SEATS
0
Q
Il
J OIhiRlsPRING
SEATS
It
to l
r
V
INLET VALVE
l
EXHAUST VALVE
l
Exploded
View
of Valve
and
Spring
Components
1
relevant
a rm
before attemptmg
to
compress
the
valve and
remove
the
iirm
f
f place
the rocker arms In a
rack
or
lay
them out
In
order to ensure
that
they
will be
Installed back
In theu
iigmal posIl
ons
4
6 Unsc
w
the
rocker arm
pivots
from
the
cyhnder
head and remove
the
rocker
gUIdes
from the valve
stem
f
ends
Lay
tliese
components
also out In order to
ensure
r
cofrec
eplacement
7 Re
ove the two camshaft thrust
plates
to
caii1s i
1fro n
kbeanng
secunng
bolts and detach
the
thrust
plat
e
f
8
Carefully
withdraw
the
camshaft from the
cyhnder
head
ensurIng
that the camshaft
Journals
or
lobes
do not
dama
e
the camshaft
bearings
IMPORTANT Do
not
remove tHe
camshaft
bearmg
bracket
j
i
l s or
brackets
from
the
cylmder
head
assembly
If
i
bracket bolts
or
brackets are
removed
beanng misalignment 1 f
I
dl
result
which will
neceSSItate
the
renewal
of the
J
J
gylmder
head
assembly
v
9
USIng
a
sUItable
valve
spnng compressor compress
t
each valve
spnng
In
turn and remove
the
valve
retaInIng
coHets
IO
Remove
the
compressor
and hft off
the
spnng
retaIner valve
spnng
s valve stem 011 seal and
spnng
seat s DIscard
the
011 seals
4
l
J
I
I
I
Remove
any
burrs from
the
valve stem ends with
a
wardIng
file
to ensure that the valve
gUIdes
are
no
damaged
when the
valves
are
withdrawn
12 WIthdraw the
valves from the
cyhnder
head and
place
them In a
rack so
they
can be Installed In theu
ongInal pOSitIOns
when
reassem
bhng
the
cyhnder
head
i
TO
CHECK
AND
INSPECT
I
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
refacIng
machIne
Discard
any
valve
that
proves to
be
excessIvely
bent
tr
J
If a valve head has
een 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 050 mm
I
3
Measure
the valve stem outer d13meter and
the t
valve
gUide
Inner
dIameter to
calcull
te the
actual
valvy
stem
f
to
gUIde
clearance
If clearance IS
In
excess
of
the
hrillt
of
o
I mm
0004 In then
he valve
guides
and or
valves
should be renewed
4
Remove
the
carbo l
Cdep oslts
from
the
cyhnder
head face
and the
valve
throats a ndcheck the
condltIons of
the valve seats
If
necessary
recut
the
seats wItlf a valve seat cutter to
the recommended
a
gre
and wIdth
I
F
1
1
NOTE
If
the
seats m the head
are worn
or
recesseq
excessively
then new
mserts
will have
to be
mstalled
It IS
recommended
that
the
mstallatlOn
of
new
valve mserts
and
or valve
guides If necessary
be
entrusted to
an
automotive
engmetrecondlllOner
who
has the necessary
spepallsed
equIPfrfe
W
carry
out these
operdllons
5
Lap
the valves to
the
valve seats
with
a
lappIng
c01J1p
mnd
Apply
a smear
of
prusslon
blue to the
valves
Jafter IappIng and
check the
valves
on theu
respectIve
seats
to ensure
that
atrue
and concentnc
seatmg
has
been
gaIned
6 With a
steel
straight edge
and feeler
gauge
check
the
cyhnder
head
face for
warpmg
If the
cyhnder
head IS
found
to be
warped
In
excess of the hmlt
speCified
see
SpecificatIons
then It Will be
necessary
to have
the head
surface
ground
to
bnng
the head
back
to
a
serYlceable
condItIOn
7
With
a
valve
spnng
tester check the
valve
spnng
tensIOns and
lengths
see
SpeCificatIons
If
a yalve
spnng
tester IS unavatlable
then
the test can be made
by
companng
the
used
spnngs
with
a new
spnng
Also check
the valve spnngs for
squareness
See
SpeCificatIons
for
squareness
hmIt Renew
spnngs
that
upon testIng prove to
be unserYlceable
f
j
10
I
1
Il
A
L
1
18
WWW.PlanDeGraissage.Org

1
i
TO ASSEMBLE
Assembly
IS a
reversal of
the d
smanthng procedure
with
atte ntlOn
to
the
following
Lubncate all
component
wear surfaces
with
engine
orl
before
asserrtbly
to ensure
adequate
lubncalion when
starting
The
special
flared
type
valve
stem seals should
be
Installed below the
spnng
retamers
with the
flared end
posllioned
over the ends of
the
valve
gUides
Use
care
when
compressing
the yalve
spnngs
to avoid
damage
to
the
seals
Ensure that the
valve
retamlng
collets
are
fully seatmg
In the valve stem
grooves
before
releasmg
the
spnng
compressor
TO
ADJUST
VALVE CLEARANCE
Valve clearance
may
be
adjusted
either
hot
or cold
If
the
cylinder
head
has been
removed from
the
vehicle then
It
wrll be
found more convement
to
adjust
the
valve
clearance
With the
cylinder
head
sitting
on
the
work bench
If
the valve clearance
IS
adjusted
cold
It IS sttll adVIsable
to recheck
the clearance when
the
engme
S hot and make
any necessary
readjustments
See
SpecificatIOns
for
valve
clearances
for
hot or cold
whichever IS
apphcable
t
NOTE
It IS not
praGtlcable
to
adJust
the
valve
clearance
with
the
engme runnmg
I
Rotate
the
camshaft
unlil
the
heel of
the No I
I
f
Ji
Engine
13
carn
on
the
camshaft IS
adjacent
to
the valve rocker
arm
for
No I exhaust valve
NOTE
In
this
pOSitIOn
the lobe
of
the abovementIOned
cam
Will be
pomtmg
vertical
from
the
cylmder
head
assembly
Q Back
off the
rocker
arm
piVOt
lock nut
and with
the correct
thickness
feeler
gauge
positIOned
between
the
heel of
the
cam and
the rocker
arm
adjust
the
piVOt
untrl
the feeler
gauge
IS
a
light
sliding
fit between the
cam
heel
and
the
rocker
arm
3
When the deSlfed
adjustment
IS
obtamed
lighten
the
rocker
piVOt
lock
nut
and recheck the
adjustment
4
Adjust
the
clearance
on the
remalnmg
seven valves
m turn
ensunng
that
each
valye
that IS
being
adjusted
has
ItS carn
m the
heel
posllion
as
prevIOusly explamed
Valve localion
commencing
from
the front of the
cyhnder
head
IS
as
follows
Exhaus
t nle nlel exhaust exhaust mlet mlet
exhaust
1
NOTE
It
IS
Important
that valve
clearana IS
measured
between
the
camshaft
and
rocker
arm and NOT
between
the rocker arm
and
valve
stems
k
5 If the
valve
clearance
S
to
be
dJ
s
ed
With
the
engme
hot ensure that the
engme
ls
mHactl
at norrnal
operatmg temperature
If
necessary
ru
t 2
1
V
fast
Idle
to obtain
the correct
tclnperature1
Carry
out
the
adjustment proced
m e ordei
already
outlined
usmg
the appropn i sJt
t
ngs
f
r
the
hot
1 1 1
en ne
ll
b t
INLET
1
l
I
r
il
II
1
tJt
t1 b t
y
Cylinder
Head
Face
Showong
Valve Arra
gement
and Water
Corcula lon Holes
TO
REMpVE
AND
INSTAL
5 ENGINE SUMP
I Raise
the
engine
bonnet and fit fender covers
to
both front
fenders
2 Dram the
coohng
system
at
the
radiator
bottom
tank
3
Disconnect the
upper
and lower
radiator
hoses and
the heater
hoses where
apphcable
A
4 Disconnect
the fuel
pipe
from the Inlet
Side
of
the
fuel
pump
and detach
the
throttle
hnkage
from the
carburettor
5
On
vehicles fitted
with automatrc transnf
dISconnect the
torque
converter
coohng pipes
at t
radiator tank
plug
the
pipes
an umons
to
prevent
e
dut
19
WWW.PlanDeGraissage.Org

Y1
l4
Engine
6 Remove the
nuts and detach the exhaust
pIpe
from
the exhaust mamfold
7
RaIse the front
and
rear
of the velucle and
support
safely
on four sUItable
ChasSIS stands
8 Unscrew
the
sump plug
and draIn the
englj
e
011
9
Remove the
cover
plate
from the front
of the
clutch
housmg
or
torque
converter
hOUSIng
where
automatIc transmISSIOn
IS
fitted
10 Djsconnect
the
steenng connectIng
rod
at the
Idler
arm and
steenng
box
and
lower the
lInkage away
from
the
sump
II
Remove the
engine
front
splash tray
12
Interpose
a
wooden block
between the
sump
and
a
Jack
and
take the
weIght
of
the
engine assembly
13
Remove
the
front
engIne
mountmg
to front
crossmember
secunng
bolts
14
RaIse
the
front of
the
engme assembly
and
Insert
two blocks
of wood of
SUItable dunensIOns
between the
1
engine mountmgs
and
the
front
crossmember Lower
the
Jack
and allow the blocks of wood
to
take
the
weight
of the
engine
assembly
15
Remove
the
screws
secunng
the
sump
to the
engine
crankcase
and
tunmg
cover and
manoeuvre the
sump
clear of
the
engIne
InstallatIon
IS
a reversal of the
removal
procedure
WIth
attentIon to the
follOWIng pOInts
Scrape
the
sump
and
cylInder
block faces free of the
old
gasket
With
cleamng
solvent
wash
the
mSlde of the
sump
free
of carbon or
sludge depOSits
Apply JOIntmg
compound
to both SIdes of
the
new
sump
gasket
and
attach
the
gasket
In
pOSItIon
on
the
crankcase
Instal
the
sump
and
tIghten
the
secunng
screws
progressIVely
and
evenly
6 OIL PITMP
TO REMOVE
I
RaIse the
engine
bonnet
and
fit fender covers to
both front fenders
2
Rotate
the
crankshaft
untIl
the
tdc mark
on
the
crankshaft
pulley
IS
alIgned
with the
pomter
on the
engine
tunIng
cover With No
I
piston
on
the
top
of
ItS
compreSSIOn
stroke
t
NOTE
The tdc mark
on
the
crankshaft
pulley
IS the mark
on the
extreme
left of
the
pulley
looking
In
from
the
front
of
the
engine compartment
The
graduated
marks
on the
nght
hand
Side
of
the tdc mark
are
In 5
deg Increments
and
are
used
for
IgmtlOn timing purposes
only
3
Disconnect the
hIgh
tensIOn leads at the
spark
plugs
and
cod and
remove the dlstnbutor
cap
and leads
4
DIsconnect the
dlstnbutor low tensIOn lead and the
rllstnbutor
vacuum advance
hose
t
Scnbe
a
mark o the
dlstnbutor
mountmg
bracket
and
filrimg
cover to faclljtate
correct
replacement
6 Remove
the
two bolts
secunng
the dlstnbutor
and
mountmg
racJset
assembly
to the
tunmg over
and
WIthdraw
the
aSsembly
from
the
tImIng
cover
7 To
facIlItate correct
replacement
of the
OIl
pump
dnve
gear
spIndle
scnbe
a
pencll
or
crayon mark across
the
tunIng
cover to dlstnbii tor
assembly
mountIng
flange
m
lIne
WIth the
offset
dnvmg dog
on
the
dnve
gear spmdle
Note
t the
dnvmg dog
IS offset towards
the front of the
e
18 Ralse the front of
the velucle and
support
on
SlS
stands
t
9
DraIn
the
engine
011
10 DIsconnect
and
remo ve
the front stabllIser bar
I
I Remove the
engine
fron t
splash tray
12
Remove the 011
pump
secunng
bolts
and
WIthdraw
the
OIl
pump together
WIth the
dnve
gear
spIndle
TO
INSTAL
I
Check to
ensure that the tdc
marks
are st1l1
alIgned
at the crankshaft
pulley
4
If the
engme
has been rotated
smce the 011
pump
has
been
removed then
realIgn
the tdc
marks as descnbed
m
the
removal
operatIOn
2
Instal the oil
pump
and
dnve
gear
spIndle
to
the
tImmg
cover
With
a
new
gasket
so
that
when
mstalled
the
offset
dog
on the
gear
spIndle
IS
aligned
WIth
the
pencil
or
crayon
mark before removal
Ensure
that
the offset
dog
IS
facmg
towards the front
of
the
engme
Instal
and
securely tIghten
the
pump
mountmg
bolts
NOTE To
mlnlmlse the
chance
of
Oil
leakage
coat both
Sides
of the
new
Oil
pump mounting gasket
with
an
approved Jomtmg
compound
3
With
a new
gasket
Instal
and secure the dlStnbutor
r
and
mountmg
bracket
assembly allgnmg
the marks
on
the
tunIng
cover and
mountIng
bracket wluch were
made
before removal
The dlStnbutor offset
dnve
tongue
Will
only
engage
WIth the oll
pump
dnve
gear
spmdle dog
m one
posItIon
but
i
It
may
be
necessary
to rotate the dlStnbutor shaft
by
th
I
2for
untI
engagement
of
these
component
takes
place
I
1LFurther
nstallatIOn Is a
reversal
of t
removal
procedure
Ensure that the
sump
IS
replemshed
With
the correct
amount and
gr
de of
engme
oll
Check for oll leaks WIth the
engine
runnmg
at
operatmg
temperature
20
7
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