1968 DATSUN 510 clutch

28

CHAPTER
FIVE

011

gallery
supphes
011
to
the
crankshaft
mam

beanngs
Dnlled

passages
m
the
crankshaft

direct
oil
from
the

mam

bearings
to
the

con

nectmg
rod

beanngs
011

mJected
from

jet
holes

in
the

connectIng
rods

IS
directed

to
the

cylmder

walls
and

piston
pins
0U
dlstnbuted
from
the

mam

gallery
enters
the
cham
tensioner
The

pad

IS
held

against
the
cham

by
011

pressure
and

spnng
tension
The

tmung
chain
receives
011

through
the

Jet
located
near
It

LubncatIon
IS

supphed
to
the

cyhnder
head

mam
011

gallery
through
the
crankshaft
center

beanngs
Camshaft

beanngs
on
the

cyhnder

head

are
fed

directly
from
the

cyhnder
head

mam

gallery
The
rocker

arms
and
valves
are

lubncated

intermittently

by
the
camshaft
011

gallery
and
the

small
channel
at
the
base
CIrcle

portIon
of
each
cam
OllIS

supphed
to
the
cam

shaft
011

gallery
through
the
No
2
and
No
3

camshaft

bearings

OIL
PUMP

The
011

pump
IS
mstalled
m
the
bottom
of

the

front
cover
as
shown
in
2
The

pump
is

held
m

place
by
four
bolts
to
the
front
cover
It

IS
a
rotor

type
dnven

by
the
011

pump
spmdle

whIch
IS
dnven
off
of
the
crankshaft
Pressure
IS

regulated
by
a
valve
shown

m

Figure
3
A
slot

at
the

top
of
the
dnve
rotor

engages
a

dog
clutch

at
the
lower
end
of
the
distnbutor
dnve
shaft

assembly
The

011

pressure
rehef
valve

IS
not

adjustable
In
the
released

pOSition
the
valve

pernnts
011
to
be

by
passed
through
a

passage
on

the

pump
cover
to
the
mlet
Side
of

the

pump

CD
CD

Oil

Pump
Removal

1
Remove
the
dIStnbutor
from
the

top
of
the

front

cover
Make
certam
to
mark
the

posItIon

of
the

dtstnbutor
relative
to
the

front
cover
so

that

It
can
be

replaced
m
the

same

posItIon

2
Drain
the

engme
od

3
Remove
the
front
stabIhzer
from
the
bottom

front
of
the

engme
compartment

4
Remove
the
front

splash
shIeld
from
the
bot

tom
front
of
the

engine
compartment

5
Remove
the
bolts

holdmg
the
oil

pump
to

the

front
cover
Remove
011

pump
and
drive

gear

spmdle
from
the
front
cover

Disassembly
Inspection
Repair
and

Assembly

Figure
4
IS
an

exploded
VIew
of
the
011

pump

assembly
Refer
to
the

figure
and
the

accom

panymg
index

1

Separate
the

body
cover
from
the

011

pump

body
by

unscreWIng
the

secunng
bolt

2
Remove
the

pump
dnve
mechamsm
and

dnver

gear
from
the

pump
body
Clean
the
dIS

assembled

parts
m
a
suitable
solvent

3

Inspect
for

Signs
of
wear
or

damage
Reparr

or

replace
as

necessary

4

Inspect
the
drive
rotor
shaft
for

excessive

wear
or

sconng
Check
the

followmg
clearances

a
Side

clearance
between
mner
and
outer

rotor
00020
to
00047
m
005
to

0
12mm

b

Tip
clearance
0
0492

m
0
12mm

c
elearance
between

outer
rotor
and

body

00059

to
0
0083
in
015
to
0
21mm

5
Check
the
relief
valve

spring
dtmenslOn
to

ensure
that
It
has
not
lost
tension

Free

length

should
be
2
24

m
57mm

Compressed

length

I
Piston
with
pin

2
Piston
nng
set

3
Piston
nng
set

4
Connecting
rod

5
Connecting
rod
bolt

6
Connecting
rod
nut

7
Connecting
rod
bushing

8
Crankshaft

9
011
gallery
plug

10
Bushing

11
Woodruff
key

12
Crank
gear

13
011
pump
gear

14
OJlthrower

15
Pulley
washer

16
Crank
pulley
bolt

17
Crank
pulley
shaft

18
Crank
bushing
set

19
Flywheel
assembly

20
Flywheel
nng
gear

21
Flywheel
to
clutch
dowel

22
Flywheel
bolt
4

23
Converter
pilot

24
Dnve
plate

25
Crankshaft
plate

26
Dnve
plate
bolt
13
I

14

17

15
2
3

l
L
4
8
9
6
19
1
J
21

2
24
8
ICD
I

For
automatic
transmission
W

lit

38

CHAPTER
SIX

EMISSION

CONTROL
DEVICES

All

Datsuns
have
a
sealed

type
of
crankcase

emISSion
control
device
and
an
exhaust
emISsion

control
deVice
Models
sold

m
Cahfornla

smce

1970
also
have
an

evaporative
emisSion

control

deVice
An

rmportant
part
of
the

exhaust
control

device
is
the
air

pump
located

at
the

bottom
left

hand
side
of
the

engme
It

IS
dnven

by
a
belt
off

of
the
crankshaft

pulley
and

supphes
air
to
the

exhaust

system
In
1972

an
electric
blower
in

corporated
m
the

air
cleaner

replaced
the

mechanical

pumI

ENGINE
REMOVAL

Expenence
has

shown
It
IS
easier

to
remove

the

engine
and

the
transmission

as
a

smgle
UnIt

than

to
remove
the

engme
alone
Once

the
en

gine
and

transmiSSIon
are

out
of

the
vehIcle
the

tranSmIssion
can
be

detached
from
the

engme

To
remove
the

engme
transmISsion

proceed

as
follows

1
Scribe

ahgnment
marks
on
the
hood

around

the

hmges
ThIS

will
make
remstallatlon

eaSIer

2
Remove
the

two
bolts
that
secure

each

hInge

and

remove
the
hood

It
is

not

necessary
to
re

move
the
hood

support
from

the

engme
firewall

3

DISconnect
the
lower

radIator
hose

from
the

right
hand
SIde
of
the

engine
and
at
the
bottom

of
the
radIator
ThIS
will

pernnt
coolant
to
dram

from
the

engme
and
the

radIator

4

Remove
the
draIn

plugs
from
the

engine

pan

and
translIDSsIon

and

completely
dram
lubn

cants
Into
suitable

contamers

5
DISconnect

the

battery
cables
from

the
bat

tery
loosen

the
two
hold
down

clamps
and

re

move

the

battery

NOTE

The
location
and

number

of

hoses

to
be
removed

from
the
air

cleaner
varies

from
model
to

model

It
IS

normally
easier
to
remove

the

hoses

from
the
sources
rather

than

try

to

dISconnect

them

from

yndemeath

the

air

cleaner
The
1972
model

Will

requlre
dlsconnectlOn

of
the
electrica1

cirCUit

In
the
air

cleaner

system
wing
nut
from
the

top
of
the
air
cleaner
and

remove
the

aIr
cleaner

7
DIsconnect
the

upper
radiator
hose
from
the

radiator
and
the
thermostat

housmg
Remove

the
hose

8
Disconnect
the
two
heater

hoses
from

the

nght
hand
side
of
the

engme
TIe
these
bac
so

they
won
t
interfere
with

removal
of
the

engme

9
Remove
the
radIator

grille

by
unscrewing
all

mountmg
screws

10
Remove
the
four

mounting
screws

holding

the
fan
shield
to
the
backside

of
the

radiator

11
Remove
the
four

mountmg
bolts

holdIng
the

radiator

In

place
In
automatic
tranSmISsion

models
dISconnect

the
two
transnnsslOn
oIl

cooler

lInes
from

the
bottom
of
the
radiator

Pull
the

radiator

straight
up
to
remove
Remove

the
fan

shield

12
Loosen

the

adjustment
and

mounting
bolts

from

the

retamIng
brackets
on
the
alternator

and

air

pump
If
so

eqwpped
The

alternator
is
lo

cated
at
the
bottom

nght
hand
Side
of
the

engme

and
the
air

pump
on
the

lower
left
hand
Side

13
Loosen
tenSIon

on
the

two
dnve
belts

re

move
the
belts
from

the
alternator
and
air

pump

and
then
from
the

fan

pulleys

14
Remove
the
bolts

holdIng
the
fan
and

pulley

to
the
water

pump
assembly
and
remove
the

fan
and

pulley

15

DISconnect
the
fuel
hne
from
the
fuel

pump

16
DIsco

ect
accelerator

control

linkage
and

choke

WIre
at
the
carburetor

17
Disconnect

the

wiring
from

the
starter

motor
alternator

Ignition
coIl
oIl

pressure

switch

and

temperature

transmItting
unit

NOTE
The

following

steps
are

per

formed

from
under
the
car
lack

up

the

front
of
the

car
and

position

stands
under

the

front
support

points

to

proVide

working
room

under

the

vehicle

WARNING

Never

climb
under
a
vehicle
that
is

supported
by
the

lack
only
If
stands

are

not
avflllable

sturdy
wooden

blocks
can

be
U3ed

6
Disconnect
all
hoses

that
lead
to
the

air

cleaner

remove
two

bolts
that
hold
the
air

cleaner
to

its

mountmg
bracket

unscrew
the
18
Remove
two
bolts

holdIng
the
clutch

operat

Ing
cylInder
to
the

flywheel
hOUSIng
shown

m

ENGINE
39

Figure
11
Remove
the
clutch
return

spnng
from

Its

holdmg
bracket
and
the
clutch

operatmg

cylmder
from
the
clutch
withdrawal
lever

19
Disconnect
the

speedometer
cable
from
the

side
of
the
transnnsslOn
as
shown
m

Figure
12

20
Disconnect
the
flat

attachmg
plug
connector

from
the
reverse

lamp
sWitch
on
the

translDlSSlon

housing

21
At
the
transnnsslOn

housmg
disconnect
the

shIft

and
the
select
rods
Remove
the
cross
shaft

assembly
by
remOVIng
Its
bracket
from
the
Side

member

22
DISconnect
the
front
exhaust

pipe
from
the

exhaust
manIfold

by
remoVing
the
two
connect

mg
bolts

23
Disconnect
the
center
exhaust

pipe
from
the

rear
exhaust

pipe

24
Remove
the
front
exhaust

pipe
the

pre
muffler
and
the
center
exhaust

pipe
from
the

vehicle

25
Disconnect
the
dnve
shaft
from
the

matIng

flange
of
the

gear
carner

26
Insert
a

Jack
under
the
transmiSSIOn
and

jack
It

up
Just
a
little
to
remove
some
of
the

tension
from
the
rear
motor
mounts

CAUTION

Use
care
m
the

placement
of
the

lack

head
to

prevent
transmiSSIOn

housmg

damage
A
block

of
wood
can
be
m

serted

between
the

Jack
head
and

transmISSIOn

for

protection
The
block

of
wood
should
be

long
enough
to

span
the
transmiSSion

housmg

27
Remove
the
rear

engine
mountIng
cross

member

by
remoVing
the
bolts

holdmg
the
en

gine
mountIng
msulator
the

mountIng
cross

member
and
the
handbrake

clamp

28
Remove
the
bolts

secunng
the
front

engine

mountmg
msulators
to
the
front
cross
member

NOTE
At
thiS
time
all
Wires
hoses

and

lmkages
should
have
been
dIScon

nected

from
the

engme
and
transmIS

sIOn

Recheck
thiS
and

make
sure
that

no
loose

ends
Will

hamper
actual
en

gme
removal

29

RIg
a
cham

or
cable
hOist
to
the

lifting
eyes

stnngers
located

on
the

nght
front
and
left

rear

of
the

cylmder
head
Take

up
slack
m
the
hOist

30

Figure
13
shows
the

engme
bemg
lifted
Re

move
the

engine
slowly
by
lowenng
the

jack

beneath
the
transnnssion

gradually
until
It
can

@

40
CHAPTER
SIX

be
removed
Hoist
the

engme
off

Its
mounts
and

adjust
the
cham
or
cable
to
tIlt
the

engme
as

shown
in
the
illustration
ContInue
to

raIse

gradually

31
Once
the

engine
and
transmission
are
clear

of
the
vehIcle
lower
them
to
a
swtable

support

or
stand
and
dIsconnect
the
hOISt

32
The
transmISSIon
can
now
be
freed

by
re

movmg
the
bolts

holdIng
the
clutch

assembly
to

the

flywheel
housing
and

movmg
the
clutch

assembly
back
to

dIsengage
the
dnve
shaft

splmes

33
Witlltlie

engIne
removed

carefiillyinspect

the

mountIng
Insulators
for

SIgnS
of

damage
or

detenoratIon

Replace
them
1f

necessary

ENGINE
DISASSEMBLY

ThIS
sectIon
covers

dIsassembly
of
the

engine

once
It
has
been

removed
from
the
vehIcle
All

steps
would
be
followed
for
a

complete
engme

overhaul
But
smce

many
of
the

procedures
can

be
done
WIthout

removing
the

engIne
from
the

velucle
a

complete
course
of
actIon
should
be

decided
on
before
needless
removal
and
ms

assembly

Mount
the

engme
on
a
stand
or
other
sUItable

work
surface
before

msassembly
Thoroughly

clean
the
extenor
WIth
steam
or
solvent

CAUTION

Remove

the
alternator
starter
motor

carburetor
and
dIStributor

from
the

engine
before

cleaning
to

prevent

damage

Once
clean

mspect
the

engme
for

SIgnS
of

damage
or

mlssmg
parts
cracks
or
accumulated

rust
on
the
block

especIally
around
the
soft

plugs
cracks
In
the
clutch

housing
and
dents

or
cracks

In
the
oil

pan

DISassemble
as
follows

Alternator
Removal

1

Figure
14
shows
the

positIon
of
the
alternator

on
the

engme
and
a
VIew
of
the
alternator

mountIng
parts
Remove
the
two

bolts
lock

washers
and
shmls

holding
the
alternator
to
the

adjustIng
bar
and
the

adjustIng
bar
to
the

engme

block

2
Remove
the
two
bolts
and
lockwashers

hold
ing
the
alternator
to
lower

mounting
bracket

3
Remove
the
alternator
and

mountmg
brack

ets

Starter
Motor
Removal

1
Remove
two

mountIng
bolts
and
lockwashers

holdmg
starter
motor
to
clutch

housmg

2
Pull
starter

assembly
toward
front
of

engme

and

remove

Distributor
Removal

1
Scnbe

ahgnment
marks
on
the
mstrlbutor

shaft
tl
ie

ihsthDutor
mountmg
oracket
anihlfe

front
cover
so
that
the
dIStnbutor
can
be
re

placed
accurately
later

2
Remove
two
bolts
and
lockwashers

holdIng

the
dlstnbutor

mountmg
housmg
to
the

front

cover

3
Pull

up
on
the
dlstnbutor
and
remove
it

as

a
unit

Carburetor
Removal

1
Remove
the
four
nuts
and
lockwashers

join

mg
the
carburetor
and
mtake
manifold
then

remove
carburetor

Oil

Pump
Removal

1
Remove
the
four

mountIng
bolts
and
lock

washers

2
WIthdraw
the
011

pump
assembly
from
tht

front
cover
as
shown
m

Figure
15

@

Air

Pump
Removal

1
Remove
the
bolt

passmg
through
the
slot
on

ENGINE
53

the
mam

beanng
cap
and
the

cyhnder
block

beanng
recess
and

tighten
the

cap
bolts
to
the

proper
torque
WIth
a

torque
wrench

Tig
temng

torque

Main

bearings
506
to
57
8
It
Ib

70to80kg
m

195
to
23
9
It
Ib

27
to3
3

kg
m
Rod

beanngs

9
Loosen
the

cap
bolt
on
one
Side
and
measure

the
clearance

Figure
53
between
the

cap
and

block
Side
Clearance
should
be
WIthm
the
fol

lowmg
specmcatIons
Mam

beanngs
0

through

o

0024
m
0
to
0
06mm
rod

beanngs
00012

through
0
0032
m
0
030
to
0
0024mm

Weight
@

10
If

beanng
crush
IS
not
m
tolerance

replace

the

beanngs

Crankshaft
and
Camshaft

Sprockets

1
Check
for

damaged
teeth

Replace
sprocket

1f

necessary

2
Install
the

camshaft

sprocket
and
check
for

runout
as
shown
m

Figure
54
If
over
0
04331

m
0
Imm

replace
the

sprocket
Check
for

thrust
deViation
at
the
same
tIme
Thrust
deVia

tIOn

should
be
between
0
0031
and
0
0150
m

008
to
0
38mm

3
Check
the
chain
for

damage
severe
wear

and
stretch
at
the
roller
hnks

Replace
the
cham

1f
defects
or
exceSSIve
stretch
IS
found

4
Check
the
cham
tenslOner
and
the
cham

gwdes
for
wear
and

damage

Flywheel

1
Check
the
clutch
disc
contact
surface
of
the

flywheel
for
wear
and

damage
@

2

Measure
deviation
of
the
clutch
disc
contact

surface

usmg
a
dial

gauge
If
deVIation
exceeds

004331
m
O
lmm

replace
the

flywheel

3
Check

flywheel
teeth
for

damage
Consult
a

dealer

Or
machIne

shop
1f
m
doubt

ENGINE
ASSEMBLY

This
section
covers

assembly
of
the

engme

after
corrective
mamtenance
has
been
com

pleted
SpecificatIons
and

torque
informatIon

are

given
at
the
end
of
the
sectIon
The

followmg

general
precautions
should
be
followed
m

assembhng
the

engme

1
Make
certam

all

parts
are

thoroughly
clean

and
that
all
011
and
water

passages
are
free
from

foreign
matenal

2
All

parts
that

slIde
mto
or

through
other

parts

should
be
coated
With
a
thm
film
of
new

engme

011
before

assembly

3
Don
t
reuse

gaskets
packIng
and
011
seals

Complete
lats
are
aVlUlable
for
the
entire

engme

and
for
the

cyhnder
head
and
block
assemblIes

4

Keep
tools
and
work
benches
clean
to
aVOid

contammatlon
of
delIcate

parts

5
Be

sure
to
follow

specmed
torque
tIghtenmg

values
and
order

of

tlghtenmg
where

given

6

Unless

complete
rebwld

of
the

engme
has

been
done
valves
and
associated

parts
bear

ings
pistons
and

connectIng
rods
should
be

remstalled
where

they
were
taken
from

CYLINDER

HEAD

Valve
and
Valve

Spring
Assembly

1
Insert
valve
from
bottom
of
block

ENGINE
59

2
Coat

the

pan
gasket
on
both
sides
With

gasket

compound
and
attach
the

oil

pan
to
the

cyhnder

block

Torque
as

specIfied

Manifold
and
Carburetor
Installation

1
Install
the
mtake
and
exhaust
manIfolds
WIth

associated

gasket
to
the

cylmder
head

2
Mount
the
carburetor
and

gasket
to
the
mtake

manIfold

2

Adjust
all
mtake
and
exhaust
valves
to
the

specIfied
clearance
for
a
cold

engme

Clutch

Assembly
Installation

CAUTION

Take

extreme
care
not
to

get
grease

or
011
on
the

clutch
or

flywheel
frlc

hon
contact

surfaces

1
Place
the
clutch
disc

assembly
on
the

flywheel

With
the

longer
chamfered

splmed
end
of
the
dISC

toward
the
transmISSion

2

Visually
align
or
use
a

dummy

splmed
dnve

shaft
to

ahgn
the
diSC

assembly
With
the

flywheel

pilot
beanng

3
Install
and

tighten
the
SIX
bolts

holdmg
the

clutch
cover

assembly
to
the

flywheel
Tighten

the
bolts
a
turn
each
tune

by
diagonal
pattern

until

they
are

tight
Tlghtenmg
torque
should
be

174

to
188ft
lbs
24
to
2
6

kg
m

NOTE
There
are
two
dowels
on

the

flywheel
to

locate
the
clutch
cover

4
Remove

dummy
shaft
If
used

after
the

above
bolts
are

fully
tightened

5
Refit
the
release

bearing
and
translI11Ssion

case
Miscellaneous
Installation

1
Connect
the
fuel
hose

on
the
front

part
of
the

engme
to
the
fuel

pump
and
to
the
carburetor

2

Gap
the

spark
plugs
and
mstall
them

usmg

new

gaskets

3
Coat
the
rocker
arm
cover

gasket
With
sealer

and

position
It
on
the

cylmder
head

4
Install
the
rocker
arm
cover
and

tighten
the

two
thumb

screws
that
hold
it

m

place

5
Install
distrIbutor

makmg
certam
that
the

notch

on
the
distributor
shaft

assembly
mates

With
the
drive

spmdle
Ahgn
the
location
marks

made

dunng
disassembly
so
that
the
distrIbutor

is

positioned
as
before

6

Install
and

tighten
the
bolts
which
hold
the

dIStributor

to
the
front

cover

7
Install

pomts
condenser
and
rotor

8

Replace
distrIbutor

cap
and
attach

spark
plug

Wires
m
the
correct

sequence
Make
certain
that

all
wires
are

firmly
seated
m
the
distrIbutor

cap

and
attached

securely
to
the

spark
plugs

9
HOISt
the

engme
assembly
from
the
work

stand

10
Install
the
alternator
bracket
alternator

and

engme
mounts
to
the
block

11
Install
the

IgnItIon
coil
oil
filter
oil

pressure

SWitch

dipstick
and

water
drain

plug

12
Connect
the

vacuum
Ime
between
the
dis

trIbutor
and
carburetor

13
Connect
the
transIDlSSlOn
to
the

engine
prior

to
mstallatIon
m
the
vehicle

Engine
Installation

Installation
is
the

reverse
of
the

procedures

followed
m

removal
Be
certaIn
thatlall

battery

connections
are
made

that
water
hoses

are
se

cured

wmng
IS
connected

properly
and
that
all

required
bolts
and
mounts
are
mstalled
and

tightened
Replace
the
radiator
fan
belts
and

radiator
shroud
Fill
the

engme
With
the

proper

grade
of
oil
and
the
radiator
With

recommended

coolant
Install
the
hood

to
the

hInges
according

to
the
marks
made

dUrIng
removal

SERVICE
DATA
AND
SPECIFICATIONS

Table
1
covers
servIce
data
and

engme
Speci

fications

COOLING
SYSTEM
8S

and

In
those
with
exhaust
and

evaporatIve
emIS

sion
control
devIces
a
fan
clutch
IS
combIned

WIth
the
thermostat
to
detect

temperature
m
the

engme
compartlnent
When
the

temperature

nses
the
thermostat
detects
the

change
an
the

fan
clutch

engages
thereby
helpmg
to
cool
the

engme

WATER
PUMP

Figure
2

page
86
IS
an

exploded
drawmg
of

the
water

pump
and
fan

assembly
for
1970
to

1971
The

top
half
of
the
IllustratIon

applIes
to

those
models
WIth
exhaust
and

evaporatIve

emiSSIOn
control

systems
The
bottom
half
covers

models
WIth
a
crankcase

emiSSIon
control
deVIce

only

Figure
3

page
87

IS
an

exploded
drawmg
of

the
water

pump
and
fan

assembly
for
1968

models
Without
exhaust

or

evaporatIve
controls

Figure
4

page
88
shows
the
1968
model
With

emISSIon
control
deVIce
As

can
be
seen
from
the

illustratIons
most
dIfferences
eXISt
withIn
the

fan
clutch

assembly

Water

Pump
Removal

1
Remove

upper
and

lower
radIator
hoses
from

the
thermostat

housmg
and

cylmder
block
re

spectIvely
Dram
coolant
from
rad1ator
and

cylInder
block

2
Loosen
the
alternator

mountlng
bolt
and
the

adjustIng
bolt
on
the
alternator

mountIng

bracket

3
Move
the
alternator
toward
the

cylinder

block
untIl
slack
IS
eVIdent
10

the
fan
belt
Re

move
fa
belt
fro
alternator
water

pump
and

crankshaft

pulley

4
It
IS
difficult
to
remove
the
water

pump
from

the
front

housmg
With
the
radiator
and

top

shroud
10

place
so
remove
them

5
Remove
the
bolts

holdmg
the
fan

assembly

to
the
water

pump
and
remove
the
fan

assembly

6
Remove
the
bolts

holdmg
the
water

pump
to

the
front

housmg
as
shown
In

Figure
S

Water

Pump
Disassembly
Repair
and

Assembly

Disassembly
or

attempted
repaIr
of
the
water

pump
assembly
IS
not
recommended
If
the

pump
assembly
IS
corroded
the

vanes
are
dam
aged
or
the

bearmgs
are

nOISY

replace
the

entIre
umt

1

Inspect
the
water

pump
assembly
and

replace

If

reqUIred

2

If
the
water

pump
assembly
IS
stIll
serVIce

able
clean
It

thoroughly
before
mstallatIon

3
Assemble
the
water

pump
assembly
m
the

front
cover
10
the
reverse
order
for

disassembly

Do
not
reuse
old

gaskets

4

Replace
the
fan

assembly
on
the

water

pump

and
mstall
the
radiator
and

top
shroud

5

Inspect
the

fan
belt

carefully
for

SIgnS
of

wear

or
cracks
DIscard

It
If
10
doubt

6
Install
the
fan
belt
around
the
crankshaft

pulley
water

pump
pulley
and
the
alternator

pulley

7

Adjust
the
alternator
on
Its
bracket

so
there

IS
no
more
than
0
5
10

deflection
of
the
fan

belt
when

pushed
10

by
thumb

pressure

8

TIghten
alternator
bracket

adjustIng
bolt
and

alternator

mountmg
bolt

securely

9
Install
the

upper
and
lower
rad1ator
hoses

and

tIghten
securely

10
Refill
the
radIator
and

coolmg
system
With

approved
coolant

or
water

NOTE
Because

of
the

many
aluml

num

parts
In
the

engine
a

hIgh
qualIty

antI

freeze

compound
should
be
used

In
the

cooling
system

11
Start
the

engme
and
run
untIl

operatIng

temperature
IS
reached
or
untIl

you
re
sure
the

thermostat
has

opened
and
coolant
IS

CIrCulatIng

throughout
the
entIre

coolIng
system
Top
up

radIator
as

reqUIred