1969 DATSUN 610 alternator belt

h
W

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
4
3
6
5
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
0
3
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

care
not
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

CoolIng
System

GENERAL

FAN
BELT
TENSION

FLUSHING
AND
DRAINING
THE
SYSTEM

THERMOSTAT

Testing

RADlA
TOR
Removal

GENERAL

The

cooling
system
is

pressurised
and

incorporates
a

water

pump
corrugated
fin

type
radiator
fan
and
a

pellet
type

thermostat

The
water

pump
is
of
the
centrifugal
type
and
has
an

aluminium
die
cast

body
The
volute
chamber
is
built
into

the

front
cover

assembly
and
a

high
pressure
sealing
mechanism

prevents
water

leakage
and
noise

The
fan

pulley
is
driven

by
the
V
belt
from
a

pulley
on

the
crankshaft

he

pellct
type
thermostat
enables
the

engine
to
warm

up

rapidlY
and
also

regulates
the

temperature
of
the
coolant
When

the
wax

pellet
in
the
thermostat
is
heated
it

expands
and
exerts

pressure
against
a
rubber

diaphragm
causing
the
valve
to

open

and
allow
the
coolant
to
flow
from
the

cylinder
head
back
to

the
radiator

As
the

pellet
is

cooled
itcontractsand
allows
the

spring
to

close
the
valve

thereby
preventing
coolant
from

leaving
the

cylinder
head

The
rad
ator
is
of
the
down

flow
type
with
an

expansion

tank
The
relIef
valve
in
the
radiator
filler

cap
controls
the

pressure
at

approximately
0
9

kg
sq
cm

l3Ib
sq
in
Always

try
to
avoid

removing
the
filler

cap
when
the

engine
is
hot
as

coolant

may
spray
out
and
cause

scalding

If
the

cap
must
be
removed
in
these
circumstances
use
a

lar
e

pic
c
of
cloth
to
hold
the

cap
and
turn

the
cap
sli

htlY

Walt
until
all

pressure
has

been
released
before

lifting
off
the

cap

F
AN
BELT
TENSION

The
fan
belt
drives
the
water

pump
and
alternator
as

well

as

the
fan
and
its
correct

adjustment
is
most

essential
A
loose

fan

belt
will

sl
ip
and

Y
e
r

and
most

probably
cause

overheating

alternatively
If
the
belt
IS
too

tight
the
pump
and
alternator

bearings
will
be
overloaded

The
belt
is

correctly
tensioned
if
it
can
be
depressed

by

approximately
10
mm

1
2
in
at
a

point
midway
between
the

fan
and
alternator
pulleys
See

Fig
R2

If

adjustment
is
neces

ary
slacken
the
alternator

mounting

and

adjustment
bolts
and

pivot
the
alternator

away
from
the

engine
to

tighten
the
belt
to

towards
the

engine
if

the
belt

is

to
be
slackened

NOTE

Always
apply
leverage
to
the
drive
end

housing
when

pivoting
the
alternator
and
never
to
the
diode
end

housing
or
the
alternator
will
be

damaged
Retighten
the
alternator
bolts
and
make
SUfe

that
the
belt

is

correctly
tensioned

FLUSHING
AND
DRAINING
THE
SYSTEM

The
radiator
and
water

passages
should
be
flushed
out

periodically
to
remove
the
accumulated
scale
or
sediment

Reverse

flushing
equipment
should
be
used
to

carry
out
a

completely
thorough
flushing
operation
but
the
owner
drivef

not

possessing
this

type
of

equipment
can
flush
out
the

system

in

the
following
manner

Drain
the
system
by
removing
the
radiator
filler

cap
and

opening
the
radiator
and

cylinder
block
drain

taps
Close
the

taps
again
and
refill
the
radiator
Run

the
engine
for
a
ShOft

period
and
then
rc
open

the
drain
taps
Continue
this

sequence

until
the
water

flowing
from
the

taps
is
clean
then
close
the

taps

and
refill
the
radiator

An
anti
freeze
mixture
should

always
be
used
in
Winter

time
The
Niss3n

long
life
coolant
L
L
c
is
an

ethylene
glycol

solution

containing
a
corrosion

preventative
which
can
remain

in
the
vehicle

throughout
the
year
but
must
not

be
mixed
with

other

products

It
is
advisable
to
check
the
radiator
and
heater
hoses
when

filling
with
anti
freeze
and
renew

them
if

signs
of
deterioration

are

apparent

WATER
PUMP

Replacement

The
water
pump
must
not
be
dismantled
and
should
be

renewed
if
it
becomes

faulty
The

pump
can
be
removed
in
the

following
manner

Drain
the

cooling
system

2
Take
the
fan
belt
off

the
pulley

3
Remove
the
fan
and

pulley

4
Remove

the
retaining
nuts
and
withdraw
the
water

pump

See

Fig
B
3

lnstallation
of

the

pump
is
a

reversal
of
the
removal

procedures

rERMOST
ATTesting

The
thermostat
is
located
in
the
water
outlet

passage

See

Fig
B
4
To
remove
the
unit
drain
the
cooling

system

remove
the
radiator
hose
and
the
water
outlet
elbow
Take
out

the
thermostat

25

stopper
to

the
overrunning
clutch

side
and
removing
the

stopper
clip
Remove
the

stopper
and

overrunning
clutch
as

shown

inFig
M
7

Oean

the
dismantled

components
and
check
them
for

wear
or

damage

Cbeck
the
brushes
and
renew

them
if
worn
below
6
5mm

0
257
in
Fit
new
brushes
if
the
brush
contact
is
loose
Cbeck

the
brush
holders
and

spring
clips
and
make
sure

that

they
are

not
bent
or
distorted
The
brushes
should
move

freely
in

their

housings
and
can
be
eased
with
a
file
if

necessary
The
brush

spring
tension
should

be
approximately
0

8kg
1
76Ib

and

can
be
checked
with
a

spring
balance
as

shown
in
Fig
M
S

Armature

assembly

Make
sure
that
the
surface
of
the
commutator

is
not

rough
or

pitted
Oean
and

lightly
polish
with
a
No
500

emery

cloth
if

necessary
If
the
commutator
is

badly
worn
or

pitted

it
should
be
skimmed
in
a
lathe

only
a

light
cut
must

be
taken

to
remove

the
minimum
amount

of
metal
If
the
commutator

diameter
wear
limit
of
0
2mm
0
OS
in

is
exceeded
the

assembly
must
be

renewed

Undercut

the
mica
between
the
commutator

segments

when
the

depth
of
mica
from
the
surface
of
the

segment
is

less
than
0
2mm
0
08

in
The

depth
should
be
between

0
5
0
8mm
0
0197
0
0315
in
as
shown
in

Fig
M
9

The
armature
shaft
should
be
checked
for

straightness

by
mounting
between

the
centres
of
lathe
and

positioning

a
dial

gauge
as
shown
in

Fig
M
I
O
Renew

the
armature

if
the

bend
of
the
shaft
exceeds
0
08mm
0
0031
in

Field
coils

testing

Test
the
field
coils
for

continuity
by
connecting
a

circuit

tester
between
the

positive
terminal
of
the
field
coil
and
the

positive
terminal
of
the
brush
holder
as
shown
in

Fig
M

I
I
If

a

reading
is
not

obtained
the
field
circuit
or
coil
is

open

Cbnnect
the
tester
to
the

yoke
and
field
coil

positive

teoninal
as

shown
in

Fig
M
12
to

check
the
field
coils
for

earthing

Unsolder
the
connected

part
of
each
coil
and
check
the

circuit
for

earthing
in
a
similar
manner

Renew
the
field

coils

if

they
are

open
earthed
or
short
circuited

Outch
assembly

The

overrunning
clutch
must
be

replaced
if
it
is

slipping

or

dragging
Examine
the

pinion
and
sleeve

making
sure
that

the

sleeve
is
able
to
slide

freely

along
the
armature
shaft

spline

Inspect
the

pinion
teeth
for

signs
of

rubbing
and
check
the

fly

wheel

ring
gear
for

damage
or
wear

Bearings

Inspect
the
metal

bearing
bushes
for
wear
and
side

play

The
bushes
must

be
renewed
if
the
clearance

between
the

bearing

bush

and
armature
shaft

is
in
excess
of
0
02mm
0
008
in

New

bearing
bushes
must
be

pressed
in
so
that

they
are
flush

with
the
end
of
the
case
and
reamed
ou
t
to

give
a
clearance
of

0
03
0
10
mm
0
0012
0
0039
in

H
Solenoid

assembly

Inspect
the
solenoid
contact
surface
and

replace
if

showing

signs
of

wear
or

roughness
Replace
the

pinion
sleeve

spring
if

weakened

Check
the
series
coil

by
connecting
an

8
12

volt

supply

between
the
Sand
M
terminals
as
shown
in

Fig
M
13
The

series
coil
is
normal
if
the

plunger
operates

Test
the
shunt
coil

by
connecting
the
S
terminal
the
M

terminal
and
the
solenoid

body
as
shown
in
the
lower
illustration

of

Fig
M
13

Open
the
M
terminal
when
the

plunger
is
operated

the
shunt
coil
is

satisfactory
if
the

plunger
stays
in
the

operated

position

Measure
the

length
L
between

theylonger
adjusting
nut

and
solenoid
cover

Press
the

plunger
against
a

firm
surface
as

shown
in

Fig
M
14
and
check
that
the
dimension
is
within

the
figures

given
Turn
the

adjusting
nut
if

necessary
until
the

required
dimension
is
obtained

STARTER
MOTOR

Assembly
and
Installation

The
assembly
and
installation

procedures
are
a
reversal

of
the
removal
and

dismantling
operations
When

assembling

the
starter
smear

the
armature
shaft

spline
with

grease
and

lightly
oil
the

bearing
bushes
and

pinion

ALTERNATOR

The
alternator
is
driven

by
the
fan
belt
and
has
an
advant

age
over
a

dynamo
in
that
it

provides
current
at

low

engine

speeds
thereby
avoiding
battery
drain
Maintenance
is
not

normally
required
but
the
tension
of
the
fan
belt
should
be

checked
and

adjusted
if

necessary
as

described
in
the

section

COOLING
SYSTEM
Care
must
be
taken
not
to

overtighten

the
fan
belt
or

the
alternator

bearings
will
be
overloaded

The
alternator

output
can
be
checked
with
the
alternator

in

the
vehicle

by
carrying
out
the

following
test
Ensure
that
the

battery
is

fully
charged
Withdraw
the
connectors
from
the

alternator
F
and
N
terminals
and
connect
a

jumper
lead
between

the
F
and
A
terminals

Connect
a
voltmeter
to
the
E

and
A
alternator
terminals

with
the

negative
lead
to

terminal
E
and
the

positive
lead
to

the
terminal
A
as
shown
in

Fig
M
IS
Switch
the

headlamps

on
to
full
beam
and
start

the

engine
Increase
the

engine
speed

gradually
and
note

the

reading
on
the
voltmeter
when
the

engine
reaches
a

speed
of

approximately
lOaD

rpm
The

alternator
is

operating

satisfactorily
if
the
voltmeter
shows
a

reading
above
12
5
volts
If

the

reading
is
below
12
5
volts
the

alternator
is
defective
and
should
be
removed
for

inspection

ALTERNATOR
Removal

Disconnect
the

negative
lead
from

the

battery
and
the
two

lead
wires
and
connector
from
the
alternator

Slacken
the
alter

nator

mounting
bolts
and
take
off

the
fan
belt
Take
out

the

mounting
bolts
and
withdraw
the
alternator
from
the
vehicle

III

ENGINE

Dismantling

Remove

the

engine
from
the
vehicle
as

previously
described

and

carefully
clean
the
exterior

surfaces
The
alternator

distribu

tor

and
starter
motor
should
be
removed
before

washing
Plug

the
carhurettor

air
horn
to

prevent
the

ingress
of

foreign
matter

Place
the

engine
and
transmission
on

the
engine
carrier
ST4797

0000
if

available
and
dismantle
as
follows

Remove
the

gearbox
from
the

engine
Disconnect
the
intake

manifold

water
hose
the
vacuum

hose
and
the
intake
manifold

to
oil

separator
hose
Remove
the
intake
manifold
with
the

carburettor
Fit
the

engine
attachment
ST3720OG18
to
the

cylin

der
block
and

place
tre

engine
on
the
stand
ST371
00000

Remove
the
clutch

@
Ssembly
as
described
in
the
section

CLUTCH
Remove
the
exhaust
manifold
and
heat
baffle

plate

Take
off
the
fan
blades
and
remove
the
water

pump
pulley
and

fan
belt
Remove
the
rocker
cover
hose
manifold
heat
hose
and

by
pass
hoses

Remove
the

generator
bracket
and
the
oil
fIlter
Extract
the

engine
breather

assembly
from
above
Note
that
the
breather

is
fitted
to
the

guide
and
is
installed
with
a
O

ring
which
is

pressed
into
the

cylinder
block

Flatten
the
10ckwasher
and
unscrew
the
crankshaft
pulley

nut
Withdraw
the

pulley
with
the

puller
ST44820000
if
available

but
do
not
hook
it
in
the
V

groove
of
the

pulley

Remove
the
rocker
cover
and
take
off
the
rubber

plug

located
on
the
front
of
the
cylinder
head

Straighten
the
lock

ing
washer
and
remove
the
bolt

securing
the

distributor
drive

gear
and
camshaft

sprocket
to
the
camshaft
Remove
the
drive

gear
and
take
off
the

sprocket
See

Fig
A
3

Remove
the

cylinder
head
bolts
in
reverse

order
to
the

tightening

sequence
sOOwn
in

Fig
A
18
and
lift
off
the

cylinder

head
as
an

assembly
See

Fig
A
4
Note

that
in
addition
to
the

ten

cylinder
head
bolts
there
are
also
two
bolts

securing
the

chain
cover
to

the
head
Invert
the

engine
and
remove
the
oil

sump
Remove
the
chain
cover
and
oil

flinger
Take
off
the
nut

securing
the
oil

pump
sprocket
and
withdraw
the

sprocket
with

the
chain
in

position
as
shown
in

Fig
A5
Remove
the
oil

pump

and
stramer
Note

that
two
of
the

pump
mounting
bolts
are

pipe
guides

Remove
the

timing
chain
crankshaft

sprocket
chain
ten

sioner
and
chain

stop

Remove
the

connecting
rod

caps
and

push
the

piston
and

connecting
rod
assemblies

through
the
tops
of
the
bores

Keep

all

parts
in
order
so

they
can
be
assembled
in
their

original
posi

tions

Take

out
the

flywheel
retaining
bolts
and
withdraw
the

flywheel
Remove
the
main

bearing

caps
but
take
care
not
to

damage
the

pipe
guides
Lift
out

the
crankshaft
and
main
bear

ings
noting
that
the

bearings
must
be
reassembled
in
their

original

positions
Remove
the

piston
rings
with
a
suitable

expander
and

take
off
the

gudgeon
pin
clips
The

piston
should
be
heated
to

a

temperature
of
50
to
600
122
to
1400F
before

extracting

the

gudgeon
pin
Keep
the
dismantled

parts
in
order
so

they

can
be
reassembled
in
their

original
positions

Remove
the
camshaft
rocker
ann
shaft
and
rocker
ann

assemblies
from
the

head

by
taking
off
the
cam

bracket

clamp

ing
nuts
It
is
advisable
to
insert
disused
bolts
in
the
No
1

and

No
5
bracket
holes
as
the
cam
bracket
will
fall
from
the
rocker

ann
shaft
when

it
is
removed
Remove

the
valve

cotters

using

the

special
tool
ST47450000

and
dismantle
the
valve
assemblies
Keep
the

parts
together
so

they
can
be
installed
in
their

original

order

ENGINE

Inspection
and
Overhaul

Cylinder
head
and
valves

Inspection
and
overhaul

procedures
can

be
carried
out

by

following
the
instructions

previously
given
for
the
L14
LI6

and
LIB

engines
noting
the

following
points

Measure
the

joint
face
of
the

cylinder
head

using
a

straight

edge
and
feeler

gauge
The

permissible
amount
of
distortion
is

0
03
mm
0
0012
in
or
less
The
surface
of
the
head
must
be

reground
if
the
maximum
limit
of
0

1
mm

0
0039
in
is

exceeded

Oean
each
valve

by
washing
in
petrol
then

carefully
examine

the
stems
and
heads
Discard

any
valves
with
worn

or

damaged

stems
Use
a

micrometer
to
check
the
diameter
of
the
stems

which
should
be
8
0
mm
0
315
in
for
both
intake
and
exhaust

valves
If

the
seating
face
of
the
valve
is

excessively
burned

damaged
or
distorted
the
valve
must
be
discarded
The
valve

seating
face
and
valve

tip
can
be
refaced
if

necessary
but

only

the
minimum
amount
of
metal
should
be
removed
Check
the

free

length
and
tension
of
each
valve

spring
and

compare
the

figures
obtained
with
those

given
in
Technical
Data
at
the
end

of
this
section
Use
a

square
to
check
the

springs
for
deformation

and

replace
any
spring
with
a
deflection
of
1
6
mm
0
0630
in

or
more

Valve

guides

Measure
the
clearance
between
the
valve

guide
and
valve

stern
The
stem
to

guide
clearance
should

be
0
025
0
055
mm

0
0010
0
0022
in
for
the
intake
valves
and
0
04
0
077
mm

0
0016
0
0030
in
for
the
exhaust
valves
The
maximum
clear

ance

limit
is
0
1
mm
0
0039
in
The
valve

guides
are
held
in

position
with
an
interference
fit
of
0
040
0
069
mm
0
0016

0
0027
in
and
can
be
removed

using
a

press
and
valve

guide

replacer
set
ST49730000
under
2
ton

pressure
This

operation

can

be
carried
out
at
room

temperature
but
will
be
more
effec

tively

performed
at
a

higher
temperature
Valve

guides
are

available
with
oversize
diameters
of
0
2
mm
0
0079
in
The

cylinder
head
guide
bore
must
be
reamed
out
at

normal
room

temperature
and
the
new

guides
pressed
in
after

heating
the

cylinder
head
to
a

temperature
of

approximately
800
C
1760F

The
standard
valve

guide
requires
a
bore
of
14
0
14
018
mm

0
551
0
552

in
and
the
oversize
valve

guide
a
bore
of
14
2

14
218
mm
0
559
0
560
in
Ream
out
the
bore
of
the

guides

to
obtain
the
desired
finish
and
clearance
Use
the
reamer
set

ST49710000
to

ream
the
bore
to
8
000
8
015
mm
0
3150

0
3156
in
The
valve
seat

surface
must

be
concentric
with
the

guide
bore
and
must
be
corrected
if

necessary
using
the
new

valve

guide
as
axis

Valve
seat
inserts

Check
the
valve
seat

inserts
for

signs
of

pitting
The

inserts

cannot
be

replaced
but

may
be
corrected
if

necessary
using
a

valve
seat
cutter

ST49720000

Scrape
the
seat

with
the
450

cutter
then

reduce
the
width
of
the

contacting
faces

using
the

150
and
600
cutters
for
the
intake
valve
inserts
and
150
cutter

for
the
exhaust
valve
inserts
Seat
correction
dimensions
are

shown
in
millimeters
in

Fig
A
6

Lap
each
valve
into
its
seat
after

correcting
the
seat
inserts

Place
a
small

quantity
of
fme

grinding
paste
on

the

seating
face

of
the
valve

and
lap
in
as

previously
described
for
the
Ll4
LI6

and
L
18

engines

S5

pulley
should
be

aligned
with
the
T
mark
on
the
chain
cover

Install

the
cylinder
head

assembly
Coat

the

cylinder
block

side
of
the
head

gasket
with

sealing
agent
Three
Bond
No
4

or

equivalent
but
take
care
that

the
scaling
agent
does
not

enter

the

cylinders

Tighten
the
head
bolts
in
several

stages
to
a

torque
reading

of
8

0
to
9

0

kgrn
58
to
65
lb

ft
Tighten
the
bolts
to
the

sequence
shown
in

Fig
A

IB

Pull
the

timing
chain
out
of
the
chain
cover
and
set
it
on

the
camshaft

sprocket
so
that
the

timing
marks
are

aligned
then

place
the

sprocket
and
chain
on

the
camshaft

Install
the
distributor
drive

gear
on
the
camshaft
and

tighten
the
bolt
to
a

torque
reading
of
4
5
to

5
5

kgrn
32
6
to

39
8
lb
ft
Note
that
the
camshaft
bolt
has
a
left
hand
thread

Adjust
the
valve
clearances
as
described
under
the

appro

priate
heading
Fit
the
rubber

plugs
at
the
front
and
rear
of
the

cylinder
head

taking
care
to

apply
sealing
agent
to
the
rear

plug

Install
the
chain

adjusting
screw
and

adjust
the
tension

of
the
chain
in

the

following
manner

Rotate
the
crankshaft
clockwise
to
establish
the
correct

chain
tension
screw
the

adjusting
screw

fully
home
then
back

it
off

by
half
a
turn

and
secure
with
the
locknut

Install
the
valve
rocker
cover
and
fit
the
water

pump
Note

that
one
of
the
water

pump
mounting
bolts
also
secures
the

generator
adjusting
arm

Install
the
bracket
and
alternator
water

pump
pulley
fan

blades
and
fan
belt

Tighten
the
fan
bolts
and
lock
each
pair

of
bolts

together
using
wire
inserted
through
the
holes

provided

in
the
bolts

Install
the
oil
filter
and
fit
the
rocker
cover
hose
Install

the
distributor
so
that
the
vacuum
control
unit

and
rotor

arc

positioned
as
shown
in

Fig
A
19

Oil
the
distributor
driven

gear
Fit
the
breather

assembly

the
clamp
of
the

pipe
is

tightened
together
with
the
exhaust

manifold
Install
the

spark
plugs
and
connect
the

high
tension

leads

Install
the
exhaust
manifold
Fit
the
head
shield

plate
and

engine
slinger
and

tighten
them

together
Note
that
the
exhaust

manifold

gasket
must
be
fitted
with
the
steel

plate
facing
the

manifold
Install
the
clutch
as
described
in
the
section
CLUTCH

Remove
the

engine
from
the

mounting
stand
and
install

the
gearbox
intake
manifold
and
carburettor
stater
motor

engine
mounting
oil

pressure
warning
switch
etc

Fill
the

engine
and

gearbox
to
the
correct
levels
with

recommended
oils
and
refill
the

cooling
system
Adjust
the

ignition

timing
and
carburettor

as
described
in
the

appropriate

sections

VALVE
CLEARANCES

Adjusting

The
valves
clearances
can

be
adjusted
in
a
similar
manner

to
the
instructions

given
for
the
L14
LI6
L18

engines

Initially
adjust
the
clearances
with
the

engine
switched
off
and

cold
to

0
2
mm
0
0079

in
for
both
intake
and
exhaust
valves

Set
the
final
clearances
to
0
28
mm
0
011
in
for
both
intake

and
exhaust
valves
with
the

engine
warmed
up
to
its
normal

operating
temperature
OIL
PUMP

The

gear
type
oil

pump
is

chain
driven
from
a

sprocket
on

the

crankshaft
The

pump
can

be
removed
in
the

following
manner

1
Remove

the

sump
plug
and
drain
the

engine
oil
Remove

the
distributor
as
described
in
the
section
IGNITION

2
Remove
the

cylinder
head

assembly
fan
belt
crankshaft

pulley
and

oil

sump

3
Take
off
the
chain
cover
with

oil
fl

inger

4
Remove
the
oil

pump
and
crankshaft

sprockets
with
the

drive
chain
then
withdraw
the

pump
after

removing
the

four

mounting
bolts

Separate
the
cover
from
the

body
by

unscrewing
the
four

securing
bolts
and
withdraw
the
drive
and
idler

gear

assemblies
Unscrew
the
threaded

plug
and

take
out

the

relief
valve
and

spring

Clean
the

parts
thoroughly
and

inspect
them
four

signs

of
wear
or

damage
Check

the

following
clearances

Gear
backlash
0

1
to

0
5
mm
0
0039
to

0
0195

in

Side
clearance
between

gear
and

body
0
016
to
0
15
mm
0
0006
to

0

0059
in

Clearance
between

drive
shaft
and

body
0
016
to
0
1
mm
0
0006
to

0
0039
in

Clearance
between

drive
shaft
and
cover
0
02
to
0
1
mm
0
00078
to

0
0039
in

Clearance
between

idler

gear
and
idler
shaft
0
016
to

0
1
mm
0

0006
to

0
0039
in

Assembly
is
a
reversal
of
the

dismantling
procedures
taking

care
to

position
the
gears
so

that
the
dotted
mark
is
towards
the

cover

Install
the

pump
and

adjust
the
tension
of
the
drive
chain

by
ph
otting
the
pump

body
as

shown
in
Fig
A
20

When
the

chain
is

correctly
tensioned
it
should
be

capable
of
a
deflection

of
2
0
to

3
0
mm

0
079
to

0
118
in
as

indicated

OIL
PRESSURE
RELIEF
VALVE

The

pressure
relief
valve
shown
in

Fig
A
21
is
not

adjustable

This
valve

regulates
the
oil

pressure
to
4
55
4
85

kg

sq
cm

64
7
69
0
lb

sq
in
and
when

opened
allows
the
oil
to

by
pass

through
a

passage
in
the

pump
body
and
return
to
the

sump

Check
the
free

length
of
the

spring
which
should
be
64
0

to
66
0
mm
2
51
to
2
60
in
The

compressed
length
should

be
50
mm
at

7
8
to

9
7

kg
1
96
in
at
17
2
to
21
4Ibs
Renew

the
spring
if

necessary

OIL
FILTER

The
oil
filter
is
of
the
full
flow

type
with
a

replaceable

element
and

incorporates
a

by
pass
valve
in
the
cover

Oil

leaks
can
be
corrected

by
replacing
the

body
centre

shaft
or
cover

gaskets
The

body
and
centre

shaft

gaskets
should

always
be
renewed
after

dismantling
the
filter

S
1