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Руководство по ремонту, эксплуатации и техническому обслуживанию Nissan Datsun

  — полные технические характеристик

 -особенности эксплуатации

 — устранение неисправностей Nissan Datsun

  — цветные электросхемы Nissan Datsun
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Руководство по эксплуатации Nissan Datsun
— полные технические характеристики Nissan Datsun
— особенности эксплуатации

— устранение неисправностей

— цветные электросхемы
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Руководство по ремонту Nissan Datsun в фотографиях
— полные технические характеристики

— особенности эксплуатации Nissan Datsun
— устранение неисправностей
 в фотографиях своими руками
— более 1980 фотографий процесса ремонта
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Каталог деталей и сборочных единиц Nissan Datsun
— таблица взаимозаменяемости деталей автомобилей

— предназначен для работников СТО и владельцев автомобилей Nissan Datsun
— каталог деталей Nissan Datsun
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Подробная электросхема Nissan Datsun
— полное описание электрооборудования Nissan Datsun , подробная интерактивная электрическая схема Nissan Datsun
— подробно описан алгоритм поиска неисправностей электрооборудования (стартер, генератор, система зажигания, впрыск, инжектор)
— подробная схема электрооборудования ( электро схема ) Nissan Datsun
— распиновка разъемов электрических, распиновка электро проводки Nissan Datsun
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Руководство по ремонту двигателя Nissan Datsun
— полные технические характеристики двигателя Nissan Datsun
— особенности конструкции и ремонта двигателя Nissan Datsun
— подробное описание процессов разборки, дефектовки и сборки двигателя с фотографиями, ГРМ
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Руководство по ремонту коробок передач Nissan Datsun
— полные технические характеристики КПП
— особенности конструкции и ремонта КПП Nissan Datsun
— устранение неисправностей КПП трансмиссия, валы, шестерни, ШРУС
— подробное описание процессов разборки, дефектовки и сборки КПП  с фотографиями
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а вот здесь можно заработать на новую машину, и тогда старую не придется ремонтировать!!!

Nissan Datsun

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• Aet tO

  DATSUN TRUCK

  MODEL 320

  SfRVICE MANUAL

  NISSAN

  yNI55AN MOTOR CO LTD

  OTEMACHI BLDG OTEMACHI CHIYODA KU

  TOKYO JAPAN

  CAlLI ADDRISS I NISMO TOKTO

  HONU I 211 5281

  c

  fi 11t

  lJ

  l

  E

  t

  Book Sale

• MODEL 1IO U

  NEW MODEL 1IO U

  I

  i

• INTRODUCTION

  ThIS manual has been comphes for purpose

  of asslstmg DATSUN dIstnbutors and dealers

  for effectIve serVIce and mamtenance of the

  Model P L 320 U Each assembly of the major

  components IS descnbed 10 detaIl In addItIOn

  comprehenSIve mstructlOns are gIven for com

  pIete dlsmanthng assembImg and mspectlOn of

  these assembltes

  It IS emphasIsed that only genuine DATSUN

  Spare Parts should be used as replacements

  l

  cfi4

• CONTENTS

  SPEClFICA TION

  ENGINE

  1 6

  1

  1

  3

  1015

  203435

  38

  3943444954

  General SpecIftcatlOnsCOOLING SYSTEM

  Lubncatlon

  ServIce OperatIOns wIth EngIne In PosItionRocker Mechamsm

  Removmg RefittIngOperatIOn WIth the Engme Removed

  FUEL SYSTEM

  The GasolIne TankFuel StrainerFuel PumpAdjustment and Inspection
  of EngIneCarburetor

  BRAKER POINT AND IGNITION TIMING ADJUSTMENT

  DlstnbutorAdjustIng the Igmtlon TImIngCheckIng the Spark
  Plugs

  CLUTCH

  Clutch

  Descnptlon of Clutch Control

  TRANSMISSION

  TransmIssIOn

  DIsassemblIng the CaseAssembhng the TransmISSIOnSelector Inner
  Operatmg Lever Cross Shaft

  PROPELLER SHAFT UNIVERSAL JOINT

  Propeller Shaft Umversal jomts

  STEERING

  FRONT AXLE

  Front Axle

  Settmg of TenSIon Rex

  Page

  59

  596165

  qit0 t

  1

  66

  67

  68

  76

  77818791

  93

  U1IJJ

  l

  rt

  i1

  94

  97

  106t

  106 l114

• uc

  Page

  REAR AXLE 117

  Rear Axle 118AssemblIng Adjustment 122

  BRAKE 138

  IGNIfI0N SYSFEM 147

  ELECTRICAL SYSTEM 150

  Starter Motor 164

  Battery 171

  t

  v

• SPECIFICA TIONS

  For Model 320 U

  VEHICLE DIMENSIONS

  Length overall approxWIdth overall approx

  HeIght overall approxWheelbaseTread Front

  Rear

  Mm road clearance

  CARGO SPACE DIMENSIONS

  Intenor lengthlntenor wIdthlntenor height

  WEIGHTS

  Dry vehIcle weIght emptySeating capacItyMax cargo weIght

  Model 320 UModel 320 UN

  Model 320 UP

  PERFORMANCE

  Max speedGrade ablhty Sm 6Mm turnmg radIUs

  ENGINE

  NameKmd

  Cyhnder No and arrdngementCyclevalve arrangementBore x
  StrokeTotal piston dIsplacementCompressIOn ratioMax powerMax
  torque

  FInng order

  4 185 mm 164 8 m1 515 mm 59 6 m1 50S mm 59 3 m2 470 mm 97 2 InI
  170 mm 46 1 In1 187 mm 46 7 m

  177 mm 7 0 In

  I 850 mm 72 8 m1 427 mm 56 2 In

  406 mm 16 0 In r

  945 kg 2 080 lbs 12

  225 kg 500 lbs500 kg 1 000 lbs910 kg 2 000 lbs

  J

  120 KPH 75 MPH

  t385 2 m 17 ft

  Model E 1

  Gasohne engme4 cvls m lme

  4 cycleValve m head

  73x7l mm 2 875 m x 2 796 m1 189 cc 72 5 cu m

  8 2

  60 HP at 5 000 r P m SAE

  9 3 kg m 673ft lb at 3 600 r p m1 3 4 2

  ir f

• rValve tlmmgInlet opemngInlet closmgExhaust opemngExhaust
  closmg

  Valve clearance Both m1et and exhaust Hot

  IGNITION SYSTEM

  19mtlon tlmmgSpark plugsSpark plug gap

  FUEL SYSTEM

  CarburetorThrottle valve dlaVentlro dlaMam Jet dla

  t Slow Jet dla

  PQwer Jet dlaSlo economlzerSlow aIr FIrstSlow atr Second

  Float levelFuel tanJlcapaclty

  Llj RICA TION SYSTEM

  OIl pan capacity

  COOLING SYSTEMt

  r

  Coolmg water capacIty

  BATTERY

  TypeVoltage

  Capacity

  Termmal grounded

  JGENERATOR

  CapacityVoltage current regulator

  2

  14 deg B T C50 deg A B C52 deg B B C

  12 deg A T C0 35 mm 0 014 m

  10 deg B T C 600 rpmNGK Model B 6E 14 mm

  0 7 0 8 mm

  Pnmary28 mm

  21 8 mm

  9848

  4Q145

  100220

  Secondary30mm25 14 7 mm

  11540

  19mm35 htres 9 3 U S gal

  3 1 htres 0 86 U S gal

  5 4 htres 1 4 U S gal

  CF3 12K 14M2 M39 1212 volts2 SMS

  40 amp hr 20 hr50 amp hr 20 hr

  posltlve sIde

  0 2 KWCarbon ptie type

• STARTER MOTOR

  Voltage and power 12 volts 14 hp

  CLUTCH

  TypeOperating systemMaster cyhnder mSlde dlaOperatmg cy1mder
  mSlde dza

  Dry smgle plate typeHydrauhc

  15 85 mm 5 8 m19 05mm 3 410

  TRANSMISSION

  Type Four forward speeds and one reverseSynchromesh on 2nd 3rd
  and top gears

  For 320U320 UN For 320UP

  3 94 4 942 40 3 01149 1731 00 1 005 16 6 46

  2 0 lures 0 53 U S gal

  Gear ratIOs

  1st speed2nd speed3rcl speed4th speedReverse

  all capacIty

  REAR AXLE

  TypeGear ratIo

  all capacIty

  Semi floatIng4 875 39T 8T for 320 U 320 UN 5 143 36T 7T for 320
  UP

  for other 320 senes as potIonalO 85 htres 0 22 U S gal

  STEERING SYSTEM

  Gear mechamsm

  Gear ratIO

  Warm and roller

  17 3 I

  FRONT AXLE

  Toe mCamberCaster

  Kmg pm mchnatIon

  2 3 mm1 deg 30 mm4 deg 15 min6 deg

  c

  BRAKE SYSTEM

  Type Foot brake FrontRear

  Hydrauhc umservo typeHydrauhc duoservo type

  Mechanical rear wheels brakedHand brake

  3

• Brake drum dla front and rearMaster cylmder boreWheel cyhnder
  bore

  Front wheelsRear wheels

  254 rom 10 1019 05 mm 0 77 10

  19 05 mm 0 77 lD19 05 mm 0 77 lD

  SUSPENSWN SYSTEM

  Front suspensIOnFront spnngsDimensIOn Ola x LengthRear
  spnngs111lckness number

  Wishbone type Independent suspensionTorsIOn bar spnng

  20 5 x 604 5 mmParallel semlelltptic leaf spnng

  7 mm x 2f 320 U

  6 mm x 1or

  6mm 412 mm 1

  6mm

  215 mm 212 mm 1for 320 UN

  for 320 UP With

  helper rubber

  Shock absorbers FrontRear

  smgle actionsmgle action

  TIRES

  Model Front Rear

  320 U 5 60 14 6PL T 24 lb 5 60 14 6PL T 30 lb

  320 UN 5 50 14 6PL T 22 lb 5 50 i4 6PL T 36 lb320 UP 6 00 14 6PL
  T 22 lb 6 00 14 8PL T 60 lb

  I

  4

• FOT

  RUNCH SEDAN U320 Double Seat 2 DOOR ST WAGON V320N320 Single
  Seat

  VEHICLE DIMENSIONS

  U320 V320 N320

  Length overall 4 285 mm 4 155 mm 4 155 mmapprox 168 7 m 163 6 m
  163 6 m

  WIdth overall 1 497 mm 1 497 mm 1 497 mm

  approx 58 9 10 58 9 m 58 9 m

  HeIght overall 1 520 mm 1 515 mm 1 530 mmapprox 59 8 m 59 6 m 60
  3 m

  Wheel base 2 470 mm 2 470 mm 2 470 mm97 2 10 97 2 m 97 2 m

  CARGO SPACE DIMENSIONS

  Intenor length 880 mm 2 1 555 mm 1 560 mm34 6 m 61 2 m 61 6 m
  F

  Intenor wIdth 1 245 mm 5940 mm 1 254 mm49 m 1 180 10 49 4 m

  tIntenor heIght 420 mm 905mm 430 mm

  16 5 m 35 6 m 16 9 m

  WEIGHTS

  VehIcle weIght 1 000 kg 1 020 kg 955 kg2 200 lbs 2 255 lbs 2 100
  lbs

  Seatmg and loadmgcapacIty 5 400 kg 2 SOO kg 2 500 kg

  880 lbs 1 100 Ibs 1 100 1bs5 300 kg

  660 lbs

  TRANSMISSION

  Gear tram HIgh gear 4 forward1 reverse

  Gear ratIO Low 3 94 2nd 2 40 3rd 1 49 Low 3 94 2nd 2 40

  hIgh 100 reverse 5 16 3rd 1 49 4th 1 000Reverse 5 16

  5

• FINAL GEAR

  Gear ratIO 5 143 36T 7T 4 875 39T 8T

  SUSPENSION

  Front Wishbone type IndependentsuspensIOn wIth torsIOn bar

  Rear thickness andnumber of spnngleaves 6 mm 4

  12 mm I6 mm I12 mm 1

  Supplemental Sp 108 mm 80 mm

  Shock absorbers Front Single actingRear Single acting

  Optional

  Single actionSingle action

  TIRE SIZE AND PRESSURE

  Front

  Rear5 50 l4 6PL T 22 lb5 50 14 6PL T 46 lb

  5 50 14 6PL5 50 14 6PL

  1 PERFORMANCE

  iT Max speedGrade abilityMin turning

  radIus

  110 KPH 70 MPH0 30

  120 KPH 74 6 MPH0 30

  5 2 m 17 ft 5 2 m 17 ft

  NOTE Other speclftcatlOns are same as Model 320 U

  6

• ENGINE

  I

  c

  1

  l

  I

  I

• ENGINE

  The engme IS of monobloc construction and IS fitted with
  overheadvalves

  operated by rockers and push rods from the camshaft 011 seals
  are fItted to thevalves Three steel backed beanngs support the
  camshaft whIch IS cham dnven

  The OIl pump and dlstnbutor are dnven from the camshatt each
  component

  havmg Its own dnve shaftThe pIstons are each htted with two
  compressIOn rmgs and a slotted

  011

  control nng Beanngs of the thm shell preformed type are fitted
  to the connect109 rod bIg ends and to the malO beanngs A counter
  blanced crankshaft IS fittedThe end thrust on this component IS
  taken by specIal washers at the center malO

  beanng The centnfugal water pump and coolmg fan are dnven by the
  dynamobelt

  GENERAL SPECIFICATIONS

  No of Cyhnder 4

  Bore 73 025 mm 2 875 m

  Stroke 71 mm 2 796 m

  Volume 1 189 cc

  Max brake horse power 60 HP at 5000 r p m

  Torque 9 3 kg m at 3600 r p m

  Flnngorder 1 3 4 2

  Valve arrangement Overhead valve push rod type

  CompressIOn pressure 163 lbs per sq m 11 5 kg cmat 350 r p m

  CompressIOn ratio 8 2 1

  1

• 1Engine Rightside

  Engine Leftside

  2

• COOLING SYSTEM

  An effIcIent coohng system IS of major Importance to ensure the
  satisfactoryrunmng of the engIne and It IS therefore necessary to
  pay patlcular attention toIts maIntance

  DescriptionThe coohng system IS maIntaIned by water pump
  CIrculation combIned wIth

  an effIcient fan cooled radIator and thermostat

  The system IS pressunsed and the rehef valve Incorporated 10 the
  radIatorfIller cap controls the pressure at approxImately O 4 kg
  per sq cm Do notremove the ftller cap If the temperature of the
  coolant IS above IXJhng poInt or

  If the engIne IS runmng ToppIng up should only be requIred
  occasIOnally to replace water lost through the overflow pIpe Top up
  when the engIne IS cold andIf pOSSIble use clean soft water

  lij

  l

  Fig 1 Rmliator

  FIll to wIthIn 1 2 of the bottom of the fIller plug well
  OverfIlhng when the

  engIne IS cold may cause water to flow through the overflow pIpe
  The capacItyof the system IS approxImately 5 2 htres

  3

• In order to ensure maxImum effIcIency It IS essential to keep
  the engineoperating temperatures within certain hmlts To assist
  this a bellows typethermostat IS fttted being located In the water
  outlet at the front of the cyhnderhead The deVIce consIsts of
  metalhc bellows fIlled WIth a volatile hqUledwhIch controls a
  mushroom valve When the engine IS cold thIS valve IS closedand on
  starting the engine the flow of water to the radiator IS temporanly
  restncted

  Due to thiS the temperature of the water In the cyhnder head and
  cyhnderJackets wIll qUIckly nse thus ensunng rapid warnllng up The
  heat so generatedwill gradually expand the bellows so opening the
  valve and ultlmatelly permittinga full flow of water to the
  radIator

  The thermostat Itself IS detachabletherefore should the occasIOn
  anse Itcan be removed from ItS housmg and thehose reconnected to
  aVOId laYing up thecar Should the thermostat be tightthere are two
  tapped holes on the topwhIch may be utlhzed to ease It from

  casting When the system has been com

  pletely emptied It IS essential to allowaIr to escape through
  the thermostatvalve and then fmally top up The thermostat opening
  IS set by the manufacturerand cannot be altered It open at a
  tem

  perature of 71 5 74 5 C Dunng decarbomslng It IS pohcy to test
  thiS openlng by Immersing the thermostat In waterraIsed to the
  reqUIsite temperature The

  t lQ valve should open under these conditIOnsAr but If It fads
  to open a new umt should befitted Fig 2

  Therm ostat

  Overheating

  r lt ffr i itl

  J

  J II

  t

  4Y 2Jr

  0

  J tc

  J

  nlustTahng the Removelof the Thermostat fromits Housing

  Overheating may be caused by a slack fan belt excessIve carbon
  depoSItIn the cyhnders runmng WIth the Igmtlon too far retarded
  Incorrect carburetoradjustment falhre of the water to CIrculate or
  loss of water

  Fan Belt Adjustment

  The fan IS dnven from the crankshaft by a V belt thIS also
  dnvlng thedynamo

  A New belt can be fitted by ftrst loosemng the clamp bolts FIg 3
  whIchhold the dynamo m posltJon llld moving the dynamo towards the
  engine Shdethe belt over the fan and onto the fan pulley

  4

• Adjustment IS then made by bnngmg thedynamo away from the engme
  The belt shouldbe sufftclently tight to prevent shp yet thebelt
  should have 15 to 20 rnm 5 8 3 4 slack

  between the generator and crankshaft pulleywhen the mIdspan IS
  pushed ftrmly

  As the dnve IS taken on the V of the

  pulleys It IS not necessary to have the fan belttight to do so
  may cause excessIve wear tothe dynamo and water pump beanngs
  Afterthe correct tensIOn has been obtamed securelylock the dynamo m
  pOSItiOn agam

  FIg 3 Fan Belt AdjustmentI Generator hmge bolt2 AdJustmg lmk
  bolt

  Frost Precautions 0

  Freezmg may occur ftrst at the bottom of the radIator or m the
  lower hose

  connectionsIce m the hose wIll stop water cIrculation and may
  cause bOllmg A muff

  can be used to advantage but care must be taken not to run wIth
  the muff fullyclosed or bOlhng wIll result When frost IS expected
  or when the car IS to beused m a very low temperature make sure
  that the strength of the solution ISm fact up to the strength
  adVIsed by the manufacturers The strength of thesolution must be
  mamtamed by toppmg up WIth anti freeze solution as
  necessaryExcessIve toppmg up with water reduces the degree of
  protection affordedSolution must be made up m accordance WIth
  mstructlons supphed WIth the

  contamerRelations of freezmg temperatures of alchol water and
  glycenne mIxtures

  ratIO

  co

  5

  10

  15

  lDIS

  31

  35

  III

  45

  1

  co

  5

  10

  i5

  ID

  15

  JOJ5

  41

  45

  1

  1

  10 lOYJ 4Q 50 601lI a1 10 20 30 40 50 60 70 80

  Glycenne Water mIxture roAlcohol Water ro

  5

• Top up when the system IS coldIf the coolmg system has to be
  dramed run the mIxture mto a clear contamer

  and use agam

  Protection by Draining

  On cars where antI freeze IS not used the followmg precautions
  must betaken dunng frosty weather to obvIate any damage due to
  freezmg of the coohngsystem

  When heavy frost IS Immment the coohng system must be completely
  dramedIt IS not suffIcient merely to cover the radiator and engme
  wIth rugs and musksThere are two dram cocks one on the left hand
  SIde of the cyhnder block and theother at the base of the radiator
  block Both taps must be opened to dram the system and the car must
  be on level ground while drammg

  The dram taps should be tested at frequent mtervals by lOsertlng
  a pIece ofwIre to ensure that they are cleare Tlus should be done
  immedIately the tapsare opened so that any obstruction freed by the
  wIre may be flushed out by thewater The drammg should be carned out
  when the engme IS hot

  When completely dramed the engme should be run for a tImed mmute
  to ensurethat all water has been cleaned from the system

  A SUItable notice should be then affIxed to the radIator
  mdIcatlng that thewater has been dramed

  I Flushing the Radiator

  To ensure effICIent CIrculatIon of the coolant and to reduce the
  fonnatIon of

  scale and sedIment m the radIator the system should be
  pencxhcally flushed Withclear runnmg water preferably before puttmg
  m antI freeze m the wlOter andagam when takmg It out m the spnng
  The water should be allowed to run throughuntIl It comes out clear
  from the dralO taps At mtervals a stIff pIece ofWireshould be
  mserted mto the taps durmg drammg to ensure that they are not
  becommgclogged with sedIment

  Tlus rnethod of radiator flushmg may serve well but m cases
  where the fur

  rlOg up is excessIve the operator Will find it more effiCIent
  practIce to removethe radIator completely and flush m the reverse
  way to the flow turn the radIatorupSIde down and let the water flow
  m through the bottom hose connectIon and out ofthe top
  connectIon

  WATER PUMP

  After drammg the water from the radIator remove the pump unIt
  from thecylInder block by takmg off the fan belt and releasmg the
  setbolts WIth spnnpwashers and hmge bolts to dynamo

  4

  6

• WATER PUMP

  Removing the Pump Shaft Assembly

  DIsconnect the fan blades pulley and coverThe shaft and ball
  beanngs IS combmed with one umtPut the pulley hub on the benchFIrst
  press or knock the shaft

  end WIth a dnft hard bar and drawout the pulley hub on the U
  typebench

  Take out the set pm from thesht whIch locked the shaft
  assemblyto the pump body See Fig 1

  Next turn the body upsIde downand press out the shaft
  assemblyfrom the vane SIde on the U typebench

  ji

  7

• The shaft and ball beanng assembly can be drewout from the
  bodyThus take out the vane floatmg seal and seal whIch remamed the
  pump body

  Reassem bly

  The reassembhng of the pump IS a reversal of the disassembly
  procedurebut a care should be taken to ensure that the shaft
  assembly IS fItted correctlyfor a slIt a hole of set nng wIth a
  groove of shaft so as to msert and set the saId

  nng correctly

  Pulley

  Pulley hub

  Set bol t

  Shaft WJ thbearIngs

  21035 OOO

  Set rlDg plD

  SPrIng washer

  Body

  Washer

  Cover

  Fig 1 Sectional View of the Water Pump

  8

• Adjusting the Clearance the Vane End and BodyFIrst press down
  the shaft fIttmg wIth a groove lme to msert the set pmInsertmg
  thIckness gauge fhlckness O 4 0 5 mm between the vane end on

  the U block bench Take out the thickness gauge and fmd out good
  condmonScrew up wIth the cover and cork washer

  sere

  Shaft bear1llgsassembly

  Set p1ll 0Yf VaneFloatl llg seal

  Insert herethlckness

  gauge0 40 5 mm

  9

• LUBRICATION

  Circulation

  Pressure lubncatlon IS used throughout the umt and IS provIded
  by gear 011pump The 011 pump IS bolted mto the left hand sIde of
  the crankcase and IS dnven from the camshaft gear by a short
  vertical shaft

  OllIS drawn mto the pump vIa the filter and IS dehvered through
  mternal 011way The rehef valve dIrectly IS situated m the 011
  filter body

  From the rehef valve the 011 passes Into the mam 011 way If
  caused the elementfml to pass rhe 011 The flow then passes vIa
  connectmg 011 ways to the mam bIgend and cam shaft beanngs through
  dnllmgs m the crankshaft The connectmg rodends are dnlhng m the
  cyhnder block and the rear rocker shaft bracket to lubncate the
  rockers and then drams back Into the engme sump vIa the push rod
  apertures all from the center camshaft beanng enters a gallery on
  the left handsIde of the engme and lubncates the tappets through
  mdlvldual dnlhngs As thecamshaft rotates two grooves m the front
  Journal regIster WIth a small hole mthe camshaft thrust plate thus
  allowmga small amount of 011 to pass mto the

  tlmmg case tWIce dunng case revolution of the camshaft to
  provIdelubncatlOn for the tlmmg cham andgears From the tlmmg case
  the011 returns VIa a dram hole back to

  the engme sump The ftlter therefore forms part of the mam oJ

  gallery and as such IS fIlled withoJ under pressure

  The full of 011 enters the element through holes m the casmgand
  passes through the element mtothe annular space round the
  center

  boltThIs space IS sealed top and

  bottom so that the 011 can only escape through the hole mto the
  hollow center bolt and from thIS pomtback Into the mlet passage
  throughthe element

  Flg 1 Checkmg the Oil FlUt

  10

• Draining the Sump Oil Pan

  The sump IS a metal pressmg with the dram plugOne new and
  reconditiOned engmes the sump must be dramed and refilled with

  new 011 after the first 1000 km and subsequently atmtervals of
  5000 km

  Dram the 011 when the engme IS hot smce warm Oil flows freely
  and takeswith It any sludge or sediment whIch may have
  accumulatted

  Never use petrol or paraffm for flushmg purposes Such cleamng
  medlUmsare never completely dIspersed from the engme lubncatiOn
  system and wIll remam to contammate any fresh Oll ThIs may cause
  premature beanng faIlure

  Oil Pressure

  The normal operatmg OIl pressure IS 60 lb per sq m

  The warmng lIght whIch IS emboclted 10 the mstrument panel hght
  If the Oilpressure drops below 8 lbs sq m under these cIrcumstances
  do not attemptto run the engme or serIOus damage may result

  Refillig

  When refllltng the sump do not pour the OIl m too qUIckly as It
  may overflowfrom the fIller orifIce and mIslead the operator as to
  the quantity of lubricant 10

  the engmeBefore testing the level of the Oil ensure that the
  vehIcle IS as near level

  as pOSSIble Always WIpe the dIp stick clean wIth a non fluffy
  cloth before talangthe readmg It should be remembered that time
  must be allowed for new 011 toreach to sump before readmg the
  dIpstick

  Check for Low Oil Pressure

  Check the level of OIl m the engme sump by means of the dip
  stIck and topup If nece sal v If the warnmg Itgiit IS still on
  after reftllmg the sump switchoff and ascertam that the gauge
  stramer m the ump IS clean and not choked

  with sludge ale that no aIr leakage eXIsts at the strainer uniOn
  on the suctionSide of the Oil pump bemg defectIve remove the umt
  and rectify the fault

  11

• Removing the Filter

  A new hlter element should be fitted every 6 000 km

  The fIlter forms part of the mam 011 gallery of the engme To
  remove thehlter It IS only necessary to unscrew the center bolt
  when the bowl can be removedfrom the cylinder block complete wIth
  the element For full flow type E1 engmeIt IS neceE sary to cover
  wIth some of rugs to prevent from flow 011 on the generatorwhen
  remove the body Take care not to lose the rubber seahng nng Remove
  theelement and note the assembly of the components

  Wash out the bowl WIth pettol so that It IS clean It IS
  Important to thoroughlydry the bowl to obVIate any contammatIon of
  the lubncatmg 011

  rr

  J

  Flg 3 Components of Oil Rlter

  Replacing the Filter4

  Put the element WIth seat of It on the bracket Cover with the
  filter body after

  puttmg the element retamer spnng andthe gasket 10 posltlon
  Insert the center

  shaft mto posltlon and screw up Itwith ughtmg torque 2 2 5 kg m
  and secure mto

  posttJon by means of the center bolt

  12

• Removing the Oil Pan0

  The sump capacIty IS 3 1 htres Dram the 011 and replace the dram
  plugRemove the set screw bolts whIch are mserted from the undersIde
  of the se

  cunng flange and the lower bolts from the bottom edge of the
  bell housmg Lowerthe OIl pan from the engme takmg care not to
  damage the Jomt washers m theprocess

  moviDg the StrainerJ

  i

  l t

  WIth the sump lowered It IS possIble to remove the OIl stramer
  through whIch011 IS drawn mto the 011 pump To remove the stramer
  unto the umon connectingthe 011 pIck up to the pump and unscrew the
  secunng bolts

  The stramer may be dIsmantled for cleamng purpose by removing
  the dehvery pipe flange bolts

  Notice that there are the dowel pinS to the cover whICh must be
  posItIOnedcorrectly when reftttmg

  Removing the Oil Pump

  Remove the 011 pan and pIck up strainer Three of the ftve bolts
  secunng theOIl pump bottom cover are long enough to secure the pump
  to the crankcaseFIg 4 Illustrates the pump In explosed form Unscrew
  the long bolts and removethe pump with ItS dnve shaft

  Dismantling the Oil PumpRemove the setscrews and spnng washers
  whIch secure the cover to the b6dy

  and take off the cover On tlltmg the body upSide down the Inner
  rotor with ItSdnve shaft and the outer rotor wIth shde out

  Refitting the Sump

  Clean out the sump by washing It In paraffin the care to remove
  any tracesof the paraffm before reflttmg the OIl pan to the engme
  Pay patlcular attentIOnto the 011 pan and crank case JOint faces
  and remove any traces of old Jomtlngmatenal Examme the JOint washer
  and renew It If necessary The old JOintwasher can be used again If
  It IS sound but It IS adVIsable to ftt a new one

  Smear the faces of the JOint WIth grease and ftt the JOint
  washer Lift the OIl panInto positIOn and Insert the setscrews Into
  the flange tlghtlng them up evenly

  Reassembling the Oil Pump

  The outer rotor FIg 4 has a chamfered edge It IS of great
  Importance that

  tills chamfer be towards the base of the body ftlure to assemble
  In thIS way Willresult In the cover IS tightened down Insert the
  slotted end of the dnve shaft Intothe body and brmg the rotors Into
  mesh

  13

• Oil strainer ass y

  Oil pump dnve spmdle 01l pump plalnwasher

  Lock washer

  Oil pump bolt

  Oil pump gearshaft

  ass y

  I

  eJV Dowel pinl Oil pump

  Dcover

  f

  f i

  Fig 4 Oil Pump

  14

  a

• SERVICE OPERATIONSENGINE IN

  WITHPOSITION

  Removing Starting Nut and PulleyRemove the radIator Slacken the
  dynamo attachment bolts and remove the

  fan beltBend back the tab on the startmg dog nut lockmg washer
  Unscrew the start

  mg dog nut by usmg Heavy duty Shock type spannerA few sharp
  blows m an ant1 clockwlse d1reCtIOn WIll slacken the nutPull off
  the crankshaft pulley

  Removing the Timing Cover

  The tImmg cover IS secured by set screw bolts each havmg
  ashakeproofwasher and a special plam washer Note that the specIal
  washer IS of elongatedshape and IS f1tted next to the tImmg cover
  flange

  The spnng washers are Imme

  dIately below the bolt headsTake out the set screw bolts

  remove the cover and Its Jomt twasher Care should be taken notto
  damage the washer when breakmgthe Jomt If damage does occur fita
  new washer cleanmg of the facesof the JOint surfaces beforehand

  Fag 1 Heavy Duty Shock TypeSpanner

  Removing the Timing GearJI

  The tImmg cham IS endless and It 1S necessary to remove both the
  crankshaft and camshaft gears together Before domg thIS notIce the
  tImmg markson both gears and theIr relatIonshIp to each other

  Draw off both the gears a httle at a t1me hrst removmg the
  crankshaft gearretaining nut

  As the gears are w1thdrawn care must be taken not to lose the
  packmgwashers from behind the crankshaft gear Between the camshaft
  gear teeth IS arubber nng Wh1Ch acts as a tenslOner and ensures
  SIlent operatIon of the chamdnve Examme the felt washer and renew
  It If 011 has been lost be seepage

  Refitting the Timing Gear

  ReplaCing the components of the tlmmg gear 1S largely a reversal
  of the dISmantlmg process but spec1al attentlon should be pa1d to
  the follOWing pomts

  15

• FIt the crankshaft and camshaft gears mto theIr respective
  shafts Ensurethe tlmmg marks are opposIte and mime

  Turn the engme crankshaft until the keyway IS at T D C and the
  camshaftWIth Its keyway m approximately the one 0 clock
  posJtJon

  Place the gears mto pOSitIOn ensunng that the keys are present m
  keywayson the shafts Ensure that the tJmmg marks on the gears are
  opposite to eachother and mime Dnve the gears home

  The same number of packmg washers taken from behmd the
  crankshaft gearmust be replaced unless a new crank or camshaft has
  been fitted In thIs case thealIgnment of the gear faces and
  measuremg the alIgnment wIth a feeler gauge Toadjust the alIgnment
  It Will be necessary to vary the number of packmg washers

  FIt the 011 thrower behmd the crankshaft gear so that Its
  concave face It towards the front of the car and check that the
  felt washer IS In posJtJon

  Valve Rocker Cover Removal

  Remove the aIr cleaner Unscrew the cap nuts secunng the engme
  IIftmgbrackets Remove the rocker cover and the cork Jomt washer

  Removing the Rocker Assembly

  Dram the coolmg system If anti freeze IS m use use a clean
  contamerfor the flUId If It IS to be used agam

  It IS necessary to dram the system and slacken the cylmder head
  nutsbecause four of the rocker shaft ftxmg nuts also secure the
  cylmder head

  If the cylmder head nuts are not slackened dlstonatlOn may
  result and allowwater to find ItS way from the coolmg system mto
  the cylmders and pump

  Notice that under the nght hand rear rocker stud nut IS a
  speCIal lockmgplate Completely unscrew the rocker shaft blacket
  nuts and remove the rockerassembly Complete with brackets and
  rockers

  Dismantling the AssemblyTo dIsmantle the rocker shaft assembly
  ftrst remove the grub screw and

  lockmg plate from the rear rocker bracketRemove the split pms
  flat washers and spnng washers from each end of the

  shaft SlIde the rockers brackets and spnngs from the shaft
  Unscrew the plugfrom the end of the shaft and clean out the OIl
  way

  The two end rockers may be dIsmantled without the whole rocker
  assemblybemg drawn out ThIS may be achlved by turmng the engme by
  hand untIl No Ipush rod reacher Its lowest pOSItIOn

  Unlock the tappet adJustmg screw and screw It back as far as It
  WIll goWithdraw the split pm flat and spnng washers and slide the
  rocker off the

  shaftSometimes the valve spnng WIll have to be slIghtly
  compressed by levenng

  a screwdnvel under No 2 rocker thus allOWing the end rocker to
  slIde off theshaft eaSily Repeat the procedure for No 8 rocker

  16

• Frg 2 Rear Locking Plate 1 Plate 2 Locatmg Stud

  Reassembling the Rocker

  On reassembly tIghten the pedestal bracket secunng nuts a httle
  at a timeworkmg dIagonally from nut to nut left nut of No 1
  pedestal bracket nght nutof No 2 left of No 3 and so on returmng
  from the left nut of No 4 bracket and

  repeating the process until they are all tight If the rocker
  assembly has beencompletely stnpped down and rebushed the OIl holes
  wIll have to be rednlledand the bushes reamed down to sIze before
  assembly on the shaft

  The rockers and spnng must be replaced m theIr ongmal pOSJtJon
  on theends of the shaft Remember to replace the rocker shaft
  locating screw andlock plate

  Replace the spnng and flat washers wIth the spht pms on the ends
  of theshaft Replace the rocker cover and gasket The vent pIpe
  should be at thefront of the engme Secure the cover by means of the
  two cap nuts ensunngthat the rubber bushed and engme hftlng plates
  are m positIOn If the rockercover gasket or the rubber bushes are
  found to be faulty they must be renewedotherwIse OIl leaks will
  result

  Push Rod Removal

  If the valve rocker assembly has already been removed all that
  remamsIS for the push rods to be hfted out They may on the other
  hand be taken outWIthout detaclung the rocker assembly

  Remove the aIr cleaner and rocker cover

  Slacken all the tappet adJustmg screws to their full extent then
  usmg ascrewdnver with the rocker shaft as a fulcrum depress the
  valve sprmg

  17

• sltde the rocker sIde ways and Itft out the push rodAll but the
  end push rods can be withdrawn In thIs way These wIll have to
  be

  withdrawn after the removal of the two end rockers from the
  shaft When replacingpush rods ensure that the ball ends regIster In
  the tappet cups From here onwards reassembly IS a straIght forward
  reversal of the dIsmantling process

  Adjusting Valve Rocker Cltarances

  Remove the aIr cleaner and rocker coverThere should be a
  clearance of O 014 In 0 3S mm fbetween the face of the

  rocker and the base of the valve stem Whtlst checking the
  clearances It IS lmportant to maintain pressure wIth a screw dnver
  on the tappet adjusting screw todIsperse the fIlm of 011 from the
  push rod cup Fallure to follow thIs procedureWIll result In a wrong
  reading being taken

  Turn the engine over by hand Starting handle untll the push rod
  stops fallingthe valve IS fully closed

  Fig 3 Adjusting the Rocker Clearance

  18

• To adjust FIg 3 msert a screwdnver m the adJustmg screw slot and
  slakenthe lock nut Then msert 014 m feeler gauge between the face
  of the rocker and

  the valve stem RaIse or lower the adJustmg screw until the
  correct clearanceIS obtamed

  TIghten the lock nut and recheck the clearanceIt IS Important to
  note that whIle the clearance IS bemg set the tappet of the

  valve bemg adjusted must be on the back of the cam opposite to
  ItS peak

  I

  19

• ROCKER MECHANISM

  Rocker shaft

  LengthOuter dIameter

  Rocker arm bush

  TypeOuter dIameter before

  mountmgInner dIameter Reamer

  flntshed dImensIOn after

  mountIngThIckness before reamer

  fmlshmgClearance

  Rocker arm

  Bore

  Lever ratIo

  355 63 mm 14 1 32 m15 850 15 875 mm 0 624 0 625 m

  WhIte metal wIth steel hnmg

  19075 19 101 mm 0 751 0 752 m

  15 888 15 901 mm 0 625 1 2 0 626m

  1 644 1 727 mm 0 065 1 2 0 068 m0 013 0 051 mm 0 0001 2 0 002
  m

  19012 19 037 mm 0 7481 2

  0 749 1 2 In25 003 to 35 719 mm

  63 64 to 1 13 32 m

  CYLINDER HEAD

  Removing the Cylinder HeadDram the coohng system by openmg the
  radIator and cylmder block dram

  tapsOne IS sItuated mlet tube at the backSIde of the radIator
  and other at the

  rear nght hand SIde of the engme If antI freeze mIxture IS m use
  It should bedramed mto a SUItable contamer and retamed for future
  use

  DIsconnect the negatIve cable from the battery be extractmg the
  termmalscrew and removmg the lug from the battery term mal post

  Slacken both the retammg chps on the hose connectIng the
  radIator to thethermostat housmg and remove the hose

  Extract the termostat housmg securmg nuts and remove the housmg
  andthermostat

  Remove the alrcleaner carburetor rocker cover and the mlet and
  exhaustmamfo1ds

  Detach the Iugh tensIOn cables and remove the sparklOg plugs
  also dISconnect the water temperature gauge connectIon from the
  thermostat housmg

  Take off the rocker assembly not forgettmg to slacken the
  external cyhnderhead nuts at the same tIme

  Withdraw the push rods keepmg them m the order of removal

  I

  i

  20

• The cylinder head can now be lifted off the cylinder block To
  facIlitatebreadmg the cylmder head omt tap each sIde of the head
  wIth a hammer usmga pIece of wood mterposed to take the blow Do not
  use excessIve force Whenlifting the head a dIrect pull should be
  gIven so that the head IS pulled evenly upthe studs Remove the
  cylinder head gasket

  Remove the cylmder head WIth the valves still m posJtJon remove
  thecarbon from the combustion chambers and the valve faces Leavmg
  the valvesm positIOn for thIs operation ensures that damage cannot
  be caused to the seatsby the wIre brush whIch should be used for
  the removal of carbon

  If the exhaust valve heads are coated with a very hard deposit
  thIs may beremoved by usmg a chIsel shaped pIece of hardwood

  Remove the valves and usmg the wIre brush clean out the carbon
  from the

  mlet and exhaust portsBlowout all traces of carbon dust with
  compressed aIr or type pump and

  fmally clean the ports with gasolme and dry them out The carbon
  should nowbe removed from the pIston crowns Rotate the engme until
  the pIston to be

  worked on IS at T D C Protect the other cylinder bore from the
  entry ofcarbon particles by pushmg a non fluffy rag mto them

  Usmg a chIsel shaped pIece of hardwood Carefully remove the
  carbon fromthe pIston crowns A nng of carbon should be left round
  the penphery of eachpIston and the deposIt round the top of the
  cylinder bore should not be touchedAn mdlcatlon as to when
  decarbomsatlOn IS requIred IS generally gIven by an allround loss
  of power Cars used mamly on short runs WIll reqUIre thIS
  attentIOnmore often than those used for longruns

  Decarbonising

  Removal and Replacementof a Valve

  WhIlst the cylmder head ISremoved the valves can be taken

  out To do thIS compress thevalve sprmg WIth the specIal
  valvespnng compressor as shown m

  FIg 4

  Removal

  Remove the two cap retammgcollets Release the valve sprmgthe
  valve spnng cap valve 011 seal

  Inlet valve only and ItS retamerWIthdraw the valve from the
  gUIde

  Keep the valves m theIr relative posJtJons when removed from

  the engme to ensure replacementm theIr ongmal valve guIdes

  r 1

  1

  p t4T l

  l

  y

  irlAf 1h

  C

  t

  i

  1 h

  tJ

  n

  oyt t 5 r jL I r i4ldl

  Fig 4 Valve pring Compressor

  21

• ReplacementNote that the dIameter of the exhaust valve heads are
  smaller than the mlet

  valve To replace the valves msert each valve mto Its gUIde and
  replace thesprmg OIl seal and retamer FIt 011 seal chamfered sIde
  down wards The 011seals are more easIly fItted If they have been
  soaked m engme 011 for a shortpenod before use The 011 seal IS used
  for the mtake valve only

  Replace the valve spnng and compress the valve spnngRefIt the
  cap retamers and secure them by means of the valve cotters

  Remove the compressor

  Free length mmLength m use and loaded

  mm kgTurnmng Nos of COIlEffectlve turn of COliDIa of COli
  wireDIameter of COlI

  Inner Sp50mm

  Outer Sp52mm

  36 9 13 1 t O 78 56 55 6 tO 2 mm24mm

  38 9 29 t1 56 54 58 510 2 mm33 7 mm

  VALVE SPRING

  f

  i x0

  I

  r1

  i

  r

  A

  O132j4 0 IOO

  10N EH

  00 I1320 o Jcj1 t f r

  Fig 5 Valve Spring Valve Ass y

  22

• Valve GrindingBefore replacement of the cyhnder head the valves
  and theIr seats should be

  exammed for SIgnS of pitting or burnt patches and dIstortionIf
  these condItIOns are present the valve seats must be recut before
  attempt

  109 to gnnd m the valves whtlst dIstorted valve heads should be
  trued or the valverenewed Only the mmlmum amount of metal should be
  removed 10 the turmngprocess

  When gnndmg a valve onto Its seahng the valve face should be
  smeared hghtly WIth gnndmg paste and then lapped 10 WIth a suction
  type gnndmg tool Thevalve must be ground to ItS seat WIth a semI
  rotary motlron A ltght COIl spnngmterposed between the valve head
  and the port WIll assIst consIderably when ltftmgthe valve m order
  to rotate the face to a dIfferent posJtJon ThIs should be done

  frequently to spread the gnndmg compound evenlyIt IS necessary
  to contmue the gnndmg process until an even matt surface IS

  produced on the seatmg and the valve faceOn completion the valve
  seats and ports should be throughly cleaned WIth

  gasoltne soaked rag and dned and the subjected to a compressed
  aIr blast Thevalves should be washed 10 gasoltne and all traces of
  gnndmg compound removed

  VALVESJ

  Valve head dIameter

  Intake valveExhaust valve

  Valve seat WIdth

  Valve stem outer dIameter

  both mtake and ex

  Overall lengthIntake valveEx valve

  34 7911 34 935 mm 1 370 1 375 m30 023 30 150 mm 1 182 1 187
  m

  1 6310 015 mm

  8 6805 8 6932 mm 0 341 3 4

  0 342 1 4 m

  109 54 mm 4 5 16 m108 74 mm 4 9 32 m

  VAL VE GUIDE

  f r

  Length Intake valveExhaust valve

  Outer dIameter both mtakeand exhaust

  Inner dIameter both mtakeand exhaust

  Inner dIameter at guIdemlet to msert both mtakeand exhaust

  Clearance of valve stemand guIde both mtake andexhaust

  47 63 mm 1 7 8 1057 94 mm 2 9 32 m

  14 313 14 440 mm 0 5635 0 5685 m

  8 733 8 860 mm 0 3438 0 3443m

  14 3 mm 0 5634 m

  0 0394 0 0648 mm 0 0015 0 0025m

  I

  23

• Refitting the Cylinder Head

  Ensure that the cyhnder head and cylInder block Jomt faces are
  cleanThe cylInder head gasket IS marked Top so that It wIll be
  placed head

  m correctly Place the gasket mto posltJon and lower the cyhnder
  head mto placeFit the cylInder head securing nuts fmger tIght

  Insert the push rods replacmg them m the posltJons from whIch
  they weretaken

  Screw back all the tappet adJustmg screws Replace the rocker
  assemblyand screw down the securing nuts finger tIght Evenly
  tIghten the eleven cyhnderhead nuts a lIttle at a tIme m the order
  gIven m FIg 6 fmally pullmg them downwith a torque wrench set to 45
  Ibs 1ft

  5 7

  oooo

  o

  D 10

  8 4 2 6

  Fig 6 The Order of Tighting the Cylinder Heag Nuts

  1

  Reset the valve clearances and fmally check them when the engme
  IS nothot or cold The cyhnder head nuts may pull down shghtly more
  after the engmehas attamea Its normal workmg temperature 10 whIch
  case the valve clearances

  t will have to be checked agam and reset If necessaryRefit the
  mlet and exhaust mamfoldsFIt the craburetor and reconnect the
  control hnkage Reftt the IgmtIon advance

  suctIon pIpe to the connectIon on the carburetter but do not at
  thIs stage refit theair cleaner or It WIll have to be removed later
  to check the valve clearances Re

  place the rocker cover takmg care to ftt the cork gasket
  correctlyPlace the thermostat and Its housmg m posltJon and secure
  wIth the three nuts

  Reconnect the water temperature gauge wIre and fIt the radIator
  hose to the thermostat housmg Connect the cables to the battery
  Ensure that the radiator andcyhnder block dram tapes are closed and
  reftll the radIator

  Clean and adjust the sparkmg plugs and reftt them chppmg on the
  hlghtenslOnleads The flnng order of the engme IS 1 3 4 2 Replace
  the chp wluch secures parr of the electrical whlnng harness to the
  SIde of the head

  The IgnltJon can now be switched on and the engme started When
  the normal

  operatmg temperature has been reached sWItch off and remove the
  rocker coverso that the valve clearances may be rechecked Replace
  the rocker cover and fitthe atr cleaner when the fmal check has
  been made

  Whilst the engifie IS runmng check that the water hose
  connectIOns and fuelline umons do not leak TIghten them If
  necessary

  24

• Removing and Refitting Valve Guides

  Remove the cyhnder headRemove the appropnate valve and

  spnngRest the ylmder head with Its

  machmed face downwards on a cleansurface and dnve the gUIde
  downwardmto the combustion space wIth a dnft

  ThIS should take the form of a hardened steel punch See Fig
  8

  When fIttmg new valve guides theseshould be dnven m from the top
  of the

  cyhnder head

  0

  Fig 8 Hardened Steel Punch

  Renewing a Valve Spring in Position

  Fig 7 Renewmg a Valve Glade

  In an emergency a new valve spnng can be fitted wIthout removmg
  the cyhnderhead When domg thIS the apphcable pIston must be brought
  to ItS T D C posltJonto ehmmate any posslblhty of the valve falhng
  mto the cylmder

  Remove the spark plug from the cyhnder concerned Hold the valve
  onto Itsseahng WIth the aId of a sUItable tool such as a bent
  screwdnver WhICh WIll passthrough the sparkmg plug onftce and
  locate on the valve head By usmg the rockershaft as a fulcrum pomt
  the spnng can be compressed WIth two screwdnvers or afork ended
  bar

  WlthClraw the valve cotters and renew the valve spnng

  25

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  GEAR

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  00Or

  e

  Frg 9 Cylinder Head

  I Engine slln2 011 fIll

  g brdcket

  1 Valver cap

  4 was eercover

  over JOint

  n Thermostat6 JOint washer7 Cylmder head

  ff

  27

  JA

  rr

  evh

  I

  rq

  w

  fcr

  l

• Jrit

  Removing and Replacing the Tappets

  Remove the carrWetor and therocker cover then tak off
  themamfolds

  DIsconnect the hIgh tensIOnleads from the sprkmg plugsremove the
  rocker assembly andwIthdraw the push rods keepmgthem m theIr
  respective pOSItIOnsso that they wIll be replaced ontothe same
  tappets

  Remove the tappet covers andhft out the tappets also keepmgthem
  m same locations FIg 10

  New tappet should be fitted byselective assembly so that they
  fallmto the gUJds under theIr ownwdlght when luorlcated

  Assembly IS a reversal of theabove procedure but car should
  betaken to see that tappet cover JOIntSare 011 tight and that the
  rockersare adjusted to gIve the correctvalve clearance Fig 10
  Removing a Tappet

  7

  Piston and Connecting Rod Removal

  Dram the coohng water from the engme and radIator Dram and
  removethe sump from the engme then dIsconnect and remove the od
  strainer Takeout the set screws and rock washers from the bIg ends
  and WIthdraw the capsIt WIll be noted that the caps are off set
  When used parts are replaced afterdlsmantlmg It IS essential they
  are fItted mto theIr ongmal posltJons To ensure Qorrect refIttmg
  mark the caps and connectmg rods on the SIdes to Identify them
  together The pIston and connecting rods must be WIth drawn upwards
  through the cyhnder bores

  Release the connecting rod from the crankshaft and slowly push
  the pIstonand rod upwards through the cyhnder bore

  NOTE

  It may be necessary to remove the nng of carbon or hp from the
  topof the cyhnder bore WIth a hand scraper to aVOId risk of pIston
  nngbreakage

  Remove the assembly from the top of the cyhnder blockCheck the
  crankpms for ovahty WIth a paIr of mIcro meter caltpers

  and examme the beanng surface for scoring eIther defect WIll
  necesSItate the removal of the crankshaft for regnndmg

  28

• CONNECTING ROD

  pl

  DIstance between center of

  large end and small end

  Large end beanng

  Type

  Overall lengthThICkness

  Outer dIameterWidth of large endEnd play of large end

  Fmlshmg dimensIOn of mnerdIameter of small end bush

  Standard

  1441 0 03 mm

  Coppensh metal with steel llnmg upperSIde

  WhIte metal with steel lmmg lowerSIde

  25 273 25 527 mm 0 995 0 005 mI 8288 1 8352 mm 0 072 0 0725 m51
  346 mm 2 015 m26 8 mm 1055 m

  o 203 0 305 mm 0 008 0 012 m

  17 450 17 462 mm 0 6870 0 6875 m

  CRANKSHAFT

  Clearance of beanng penphery to cyhnder block hole

  Matenal

  Clearance of beanng mnerdtameter and crank Journal

  DIameter of mam Journal

  End play of crankshaftCrank pm dIameter

  Standard

  DIfference of crank pmdIameter

  End play when flywheel wasmstalled

  0 013 0 050 mm

  Forged steell

  o 0127 0 0508 mm 0 0005 0 0020 m i

  50 183 50 825 mm 2 0005 2 001 m

  o 051 0 076 mm 0 002 0 003 m

  47 640 47 652 mm 1 875 1 876 m

  Less than 0 012 mm 0 00048 m

  Less than O 05 mm 0 002 m

  The shell beanng are removable by hand The beanngs are reqUIre
  no

  beddmg m It IS bemg only necessary to ensure that the hOlsmgs
  are scrupulously clean and dry and to place the beanngs mto
  posltJon with the tangs locatedm theIr correspondmg slots Always
  renew beanngs If they are scored or dam

  aged m any way or followmg the regnndmg of the crankshaft beanng
  surfacesIn the latter case underSIze beanngs Will be requIred and
  the bnds of sIzes avaIlable are 0 010 0 020 0 030 and 0 040 etc

  29

• ri II

  h

  J

  q

  l

  l

  ol

  ilIdA5r

  I Ir

  t

  I

  Jc t

  i t

  J

  7 8Jr1t

  y

  I

  ConnectingrodasSY

  tit

  Dowelo

  t

  f

  Crankshaftkey

  lowerilo

  PlSTONCRANK

  SHAFT

• ILI J

  Fig 11 Crank Shaft

  1f

  PI STON

  Replacing Pistons and Connecting Rods

  Insert each pIston and connecting rod assembly Into the cyhnder
  from whIch Itwas taken It IS essential that the splIt In the skIrt
  of the pIston IS pObltJOned towards the camshaft

  Compress the piston rings WIth inserting pIston uSing tool FIg
  12 and gentlytap the crown of the pIston With the wooden end of

  a hammer handle until the pIstonIS clear of the pIston nng
  clamp

  I

  Fig 12 PIston Adapter

  if

  l

  t 1itJf J

  l31

• Now push the piston down the cylmder block until the big end of
  the connectmgrod Just protrudes through the bottom of the cylmder
  bore then posItIOn upper halfbeanng shells

  NOTE Each upper lower beanng has two OIl holes there by
  ensunngsuffIcient and It IS of the greatest Importance that the
  correspondmg 011 hole m thebeanng shell regIsters with the 011 way
  to provide an unobstructed passage

  Pull the connecting rod onto the crankpm takmg care not to
  injure the beanngsurface Insert the shell mto the connecting rod
  cap posltlon the cap and the lockmg washers Insert the setscrews
  and tighten with a torque wrench to 21 7 24 6lbs ft

  Fmally knock back the lock washersCheck the connectmg rod bIg
  end for side clearance 1 1000 m and see that

  the shell beanngs are not bmdmg on the crankpm when rotatmg the
  crankshaftIf It IS dIffIcult to turn undo the bIg end and examme
  the shell and seat for dIrtor grit

  Before reassembhng always apply a httle clean Oil to the pIston
  surfaces andmto the cyhnder bore Never ftle the connectmg rod caps
  or theIr matmg surfacesas thiS creates ovallty m the beanng

  Removing a Piston

  Remove the clampmg bolt from the small end of the connectmg rod
  and push outthe gudgeon pm The gudgeon pm IS a push ftt m pIston at
  70 F 21 1 C

  When reassembhng ensure the gadgeon pm IS posItIoned m the
  connectmg rodso that ItS groove IS mime with the clamp screw hole
  Check that the spnng washerfttted under the head of the pitch bolt
  IS not damaged

  Cf

  PISTON PIN

  DIameter

  10 1000 m

  17 447 17 452mm0 6869 0 6871 m

  17 574 17 579 mm0 6919 0 6921 m

  17 701 17 706 mm0 6969 0 6971 m

  17 828 17 833 mm0 7019 0 7021 In

  64 20 64 45 mm2 568 2 578 m

  Degree to be able to push It byfmger at 200C

  o 003 0 010 mrn0 0001 0 0004 m

  Over SIze 5 1000 m

  2tt 15 1000 m

  Length

  Clearance of pm and pm hole

  Clearance of pm and connectmgrod bush hole

  32

• PISTON AND BORES

  There should be a clearance of O 0010 0 0016 m 0 025 0 040
  mm

  PISTON RINGS

  The pIston nng gap should be O 008 0 013 10 0 203 0 330 mm when
  checked10 the cyhnder bore The clearance of tne compressJOn rlOgs
  10 theIr groovesshould amount to 0 0015 0 0035 m 0 038 0 089 mm and
  the 011 control nngo 0016 0 003610 0 041 0 092 mm

  Hecause the pIston nngs do nor travel to the end of the cyhnder
  bores a hpIS eventually formed due to wear

  ThIs may be checked wIth a dIal gauge and must be removed If
  thIs IS notdone there wIll be a tendency to nOIsy operation or a
  fractured nng caused bythe top pIston nng stnklOg the hp

  PIston and nngs are avatlable 10 0 OlD 10 0 254 mm 0 020 10 0
  508 mm0 030 10 0 762 mm and 0 04010 1 016 mm overslzes The pIston
  nngs

  should always be htted from the crown of the pIston and never
  pushed upwardsover the skIrt Before httmg the nngs remove any
  carbon deposit from thegrooves 10 the pIston When httIng note that
  the second compressIOn IS taperedtype and 011 control nng IS slat
  type processed by chromIUm platIng

  33

• Jt REMOVING REFITTING

  Experience has shown that It IS much easIer to remove the engine
  and transmISSIOn as a smgle umt than to detach the engme by
  Itself

  To remove the engme and transmISSIOn upwards proceed as
  followsCompletely dram the coolmg system and the transmIsSIOn
  dIsconnect and

  remove the battery and ItS supportmg trayRemove the upper and
  lower radIator hoses by undonng the retammg clIpSDIsconnect the
  capacitor lead at the dlstnbutor also the hIgh tenSIOn and

  switch wIres at the COIlTake off the dynamo lead and dIsconnect
  the starter motor cable at the motor

  end

  Remove the 011 gauge and water temperature gauge leads from
  theIr termmalson the engme

  Engine Transmtsswn Assembly bemg ltfled from ChasSlS

  The throttle and choke controls must be dIsconnected from the
  carburetorDIsconnect the fuel pIpe from the fuel pump

  Next remove the exhaust pipe from the mamfoldFrom below the
  vehIcle remove the gear change selector rod from the lever

  on the transmISSIOn casmgDIsconnect the earth strap from the
  starter motor Remove the hand brake

  control rod supporting from transmISSIOnDIsconnect the speed
  meter cable from the transmISSIOn Uncouple the pro

  peller shaft pmIOn franges at rear axle and draw the shaft out
  of the transmIssIonTo allow the engme and transmISSIOn to be drawn
  forward the radIator must

  be removed by undomg the four secunng bolts

  34

• OPERA TION WITH THE ENGINE REMOVED

  The followmg operations are best performed wIth the engme
  removed fromthe car

  Although Itmay be found possIble to carry out cerram attentlons
  wIth theengme m posItIOn It IS more convement to do the work on the
  bench

  Withdrawing Camshaft

  The camshaft IS pOSJtJoned by a locatmg plate held by three
  screws andshakeproof washers Note the posJtJon of the small
  lubncatlng 011 hole m the

  locating plate when replacmg should be to the nght of the
  engmeEnd play of O 003 0 007 m 0 076 0 178 mm IS controlled by the
  thIckness

  of the locating plate and can be checked WIth a dIal mdlcator
  set agamst the camshaft gear

  Before wlthdrawmg the camshaft the dlstnbutor and ItS dnvmg
  spmdle pushrods and tappet WIll have to be removed Remove the 011
  pump and ItS dnve

  shaft and take off the tlmmg cover and gears The engme front
  mountmg plateIS now accessIble and may be removed by wlthdrawmg the
  setscrew and lockmgplates The dynamo swmgmg Itnk must be
  removed

  Take out the setscrews secunng the camshaft locatmg plate when
  the camshaft can be WIthdrawn from the cyltnder block

  CAMSHAFT BEARINGS

  Wlute metal beanngs with steel lmmg are used for the camshaft
  They canbe taken out renewed when necessary It bemg usual to do
  thIS when the cyltnderblock IS bemg recondJtJoned

  The beanngs can be removed by dnftmg them out of theIr
  hosmgsWhen fitting new beanngs care must be taken to lme up the 011
  holes WIth the

  correspondmg holes m the cylmder blockTap the new beanngs mto
  pOSItIOn and ream them to gIve a runmng clearance

  of O 001 0 002 m 0 025 0 051 mm

  Refitting the Camshaft

  Tlus IS a reversal of the lOtroductlons for removal Care should
  be taken

  however to ahgn and engage the dnve pm m the rear end of the
  camshaft WIth

  the slot m the 011 pump dnve shaft

  35

• Main Bearing Caps

  Remove the flywheel and clutchTake off the tJmmg cham the sump
  and stramer and the engme rear mount

  mg plate Unlock and remove the bolts secunng the mam beanng caps
  to thecyhnder block also the two bolts secunng the front cap to the
  engme front bearerplate

  Note that a thrust washer IS fitted on each sIde of the centre
  mam beanng totake the crankshaft end thrust These thrust washers
  each consIst of two semIcIrcular valves one half havmg a lug whIch
  IS located m a recess m the detachable half of the beanng the other
  bemg plam

  When flttmg new beanngs no scrapmg IS reqUIred as they are
  machmed togIVe the correct runmng clearance of 0 0005 0 002 m 0
  0127 0 0508 nn

  Ensure that the locating tangs are properly engaged m theIr
  recessesHandle the new beanngs carefully so as not to damage the
  fme surface ftmshRemove all traces of dIrt and 011 from the housmgs
  and throughly dry them

  WIth a non fluffy rag Make sure that the Oil ways are clear When
  flttmg thebearmg caps ensure that they are replaced the nght way
  round Each cap IS punchmarked and the marks should face the
  camshaft SIde of the engme

  fJ

  I

  Engine Rear Slde

  36

• CautionNever file the beanng caps to take up excessIve playas
  thIs wIll cause

  ovalttyAlways cover the beanng surfaces wIth engine OIl when
  they are replacedThe main beanng caps are held In posJt1on by set
  screws and lock washers

  Pull the set screws up tight WIth a torque wrench set to a
  loading of 75 80Ibs ft10 36 11 05 kgm

  When refItting the mam beanng caps tIghten the center one ftrst
  after eachcap IS tighten rotate the crankshaft to ascertam that It
  revalues freely

  If It IS tight remove the last cap tightened and examme the
  beanng and ItSseating for foreIgn matter

  Check the crankshaft end play by means of a dIal gauge ThIS
  should be 0 002m 0 051 mm

  If a beanng has run It IS essential to clean out all OIl ways m
  the crankshaft and block Wash out the engme sump and the
  stramer

  The OIl pump sho lld be dIsmantled and cleaned Ensure that no
  particles ofbeanng metal are left wlthm the engme lubncatlon
  system

  FIg 15 Remarmlg a Mcnn Bearing Cap Extractor

  37

• FUEL SYSTEM

  38

  1627508100

  16119 08100

• The fuel tank has a capacIty of 31 0 Ittres and IS sItuated at
  the rear of the

  luggage compartmentThe fuel pump operated off the camshaft draws
  fuel from the tank and forces

  It mto the carburetor float chamber A large and effIcIent air
  cleaner fIlters theaIr supply to the carburetor

  THE GASOLINE TANK

  Drainin the Tank and Fuel Gauge

  The fuel tank IS dramed by tummg the wrench operated dram
  cock

  Fuel Tank Gauge Unit

  Fig 1 Fuel Tank Securing

  SItuated on the top face of the tank IS the gauge unIt To remove
  wIthrawthe set screws whIch secure the Unit to the tank not
  forgettmg to dIsconnect theelectncallead beforehand Care must be
  taken not to stram or bend the float

  lever as thIS may serously effect subsequent gauge readmgs
  Remember thISalso appltes when eftttmg the Unit

  Examme the Jomt washer to ensure that It IS m pOSItion and
  undamageThIs IS essential as the JOInt between the tank and gauge
  Unit must be fuel tight

  39

• o2

  11

  o1

  i coOg

  sl

  S

  0

• Troubles and Repairs of Gasoline Tank

  A When Fuel Leaks from Gasoline Tank

  When a crack dIstortion or damage IS found In the tank repaIr or
  replace ItTo make repaIrs put marks with chalk at the leakIng
  pOInts and even after

  the fuel In the tank has been draIned out blow with compressed
  aIr through thetank to force out stagnant gasolIne vapor completely
  RepaIrs should be done onlywhen the tank IS completely dry

  Leakage IS ordInanly mended by soldenng When weldIng IS
  necessary theabove precaution must be stnctly observed OtherWIse
  there WIll be danger ofexploslOn

  B When Gasoline Fails to Reach Gasoline Strainer

  If the fuel fatls to reach the gasohne strainer when there IS
  some fuel left Inthe gasoline tank and the operation of fuel pump
  IS known to be satisfactory checkthe follOWIng pOints

  When It IS dlfftcult to confIrm the dehvery of fuel at the
  strainer loosen theconnector at the fuel Intake of the
  carburetor

  1 Check to see If gasohne pIpe ISclogged with dust and dIrt ThIS
  canbe eastly checked by dIsconnectingthe connector of the pIpe and
  blow

  Ing WIth compressed aIr toward thedIrection of the tank Then
  from thetank end blow the pipe again andclean the pIpe

  In many cases the tip of gasohneIntake pIpe of tank umt IS
  cloggedwith dust and water

  Therefore together with cleaningof the pIpe the Intenor of the
  tank

  should be cleaned by removmg thedrain plug at the bottom of the
  tank

  Check to see If the gasohne pIpeof the tank umt IS so bent as to
  fall

  to reach the fuel surfaceThe standard posJtJon of the bottom

  end of pIpe IS about 3 4 m apart from

  the bottom m order to prevent ItS

  suckIng up sedIments on the tank bottom

  If not normal remove tank umtand adjust the bend of the pIpe

  Check too seelf the vent hole of the

  ftller cap IS clogged WIth dust and dIrtnot supplymg aIr to the
  tank

  AccordIng to the degree of vacuumwlthm the tank fuel cannot be
  drawn

  up even by the operatlOn of fuel pump

  j

  Fig 2 Wtring of Fuel Gauge1 Umt Gauge 4 19mtlon Switch2 Fuse 5
  Ammeter3 Fuel Gauge 6 Battery

  41

• So be sure to clean the aIr vent of the capIf you should lose
  the cap and substitute a wooden plug for It a measure

  whIch is sometimes wirnessed the condItIOn mSIde of the tank
  becomes the sameas though It were sealed up Always use only the
  standard cap

  Operation and Repairs of Fuel GaugeAs shown m FIg 2 the fuel
  gauge consIsts of the dash Unit and tank UnitThe dash Unit whIch is
  mstalled on the mstrument panel has two cotls that

  cross each other at nght angles whose magnetic forces control
  the movementof a keeper iron pIece with a hand mdlcator

  On the tank Unit a contact arm shdes over a resIstance m
  response to thefloat level

  As shown m FIg 2 If the IgnJtJon switch IS turned on when the
  tank IS emptyelectnc current WIll flow from the battery through the
  ammeter mto COIl A andthen through the contact arm to the
  ground

  Cotl A IS then magnetized attracts the Iron pIece and the
  mdlcator pomtsto E

  As the float IS raIsed and the contact arrn moves tank unit
  mcreases resIstance m the CIrcuit and thus the current wluch
  traveled through COIl A then flowsthIs time both contact arm and
  COIl B and fmally to the ground

  As both A and B cils are so wound as to have theIr magnetic
  poles m the samedIreCtiOn the iron pIece wtll rotate to the
  directIOn where the magnetic power ofthe two COIls can be balanced
  WIth the mdlcator deflectmg m the dlrecnon of F

  That IS this IS a gauge of electnc resIstance control type E
  sIgnifIesEmpty level and F Full level

  Troubles with Fuel Gauge and their Remedies

  When somethmg IS wrong with the readmgs of the fuel gauge fIrst
  diSconnect the wlnng at the Unit and turnm on the IgnitIOn SWItch
  ground and unground the termmal end of the saId wlnng to the body
  of the car

  If the mdIcator of the dash Unit swmgs acnvely between E and F
  the wIrmgbetween the dash Unit and the saId termmal end IS m good
  condltJon WIth the defect eXlstmg either m tank Unit Itself or m
  poor ground of thIS Unit

  In the test mentIOned m the preceedmg secnon If the mdlcator
  does not swmgbut Itmoves moves to E when the dash UDlt end of the
  wlnng from the tank UnitIS grounded the wlnng between the dash Unit
  and tank Unit IS def ctJve

  Therefore rewlnng or repalrmg is reqUIredIf when mdlcator flals
  to swmg but sparkmg is observed when the wlnng

  connectmg the battery with the termmal on the dash Unit IS
  dIsconnected at thedash Unit end and grounded It proves the wlrmg
  IS satisfactory and the troubleIS m the dash Unit Itself

  If sparkmg does not occur the wlrmg whIch IS thus mdlcated to be
  out oforder should be repaIred or replaced

  Incorrect readmgs of the mdlcator probably means that the heIght
  of the floatof the tank Unit is m error

  In thIS case adJust the heIght of the float by bendmg the
  rodTroubles with the Unit are dIffIcult to repaIr so it should be
  replaced by a new

  Unit

  42

• In checlang the tank Untt be sure to Insert a fuel gauge In the
  CIrcuitbetween the battery and the unit

  FUEL STRAINER

  Instruction for Disassembly

  To remove the bowl from the body loosen the strainer nut and
  remove the

  wIre to a SIde Take off the bolt nut and washer from the wIre
  and remove bowl

  gasket and screenThe strainer body IS made of aluminum alloy
  Take good care not to break

  threads of each connectIOn

  Pay attention not to tighten the strainer nut so excessIvely
  that the gasket andbowl are broken

  When mstalhng the stramer assembly the strainer bracket should
  be cleaned

  suffICIently Dust and dIrt on the bracket surface prevent plug
  from keeping aIr

  tight1Il I

  1511tl

  a

  IN071l2lO

  lUOl 5GOOO

  1N03SOODO

  Fuel stromer Assembly

  43

• FUELCOMPONENTS

  PUMPOF FUEL PUMP

  Hand pnmerlever rod

  i Cap boltcap screw washer

  Fuel pump capFuel pump cap gasket

  Angle connector

  Rocker arm

  slde spacer

  Rockerarm pln

  Lower body gasket sheet

  Rocker arm slde spacel

  rRocker [email protected] ass yRocker arm plnRocker arm slde spacer

  44

• FUEL PUMP

  TypeMethod dnven

  DIaphragm spnngFree legnthLength m use and tenslOn

  Rocker arm spnng

  Free lengthValve spnng

  Free length

  ThIckness of valve

  Performance

  Max quantIty dIscharged

  Max pressure dIschargedMax degree of suctlOn

  vacuum

  Hand pnmer quanty

  dIscharged

  DIaphragm purnp

  Dnven by camshaft

  36 5 O 1 mm

  18 mm 1 6 O 1 kg

  30mm

  95mm

  1 6mm

  1300 cu cm per mmute at 1000 r p m

  of cam 500 mm m suction heIght110 130 mm m mercury column

  More than 400 mm m mercury column

  80 cu cm at 20 strokes

  The fuel pump whIch IS of the dIaphragm type IS mechanIcally
  dnven bythe

  eccentnc part of the camshaft of the engmeIt draws gasohne from
  the tank and dehvers It under pressure to the carbure

  tor

  Even when the engme IS not runnmg fuel can be dehveredunder
  pressure by

  movmg the hand pnmer up and down

  By the rotation of camshaft rocker arm IS pushed and pullrod of
  dIaphragm

  IS pulled downAt the same time dIaphragm goes down agamst
  dIaphragm spnng and then IS

  pushed up agam by ItS spnngBy the movements of the dIaphragm and
  functIonmg of the valves at

  the mlet

  and outlet of the pump chamber gasohne IS drawn up from the tank
  to the carburetor

  If the float chamber of the carburetor contams enough gasolme
  and the needlevalve IS closed gasohne IS not allowed mto the
  carburetor

  Thus gasolme IS stored m the pump chamber and due to ItS
  pressurethe

  dIaphragm IS kept down and cannot returnUnder thIs condltlOn the
  rocker arm works m vam as the rod

  remams low

  The rocker arm spnng serves to prevent nOIse keepmgthe rocker
  arm

  pushed agamst the eccentnc of the camshaft

  45

• Disassembling Inspection

  Checkmg wIth fuel pump mstalled on engmeSwitch off and stop the
  engme Disconnect the fuel pIpe at the mlet umon of

  the carburetor and then turn the engme with the crank handle

  Now the gasohne should be ejected vlgorounsly from the tip of
  the pIpe onceevery two rotations of the crankshaft

  To test the functIOn of the pump alone operation of the hand
  pnmer and

  checkmg the fuel ejection IS enough

  Removal from engmeFuel pump can be easIly removed by
  disconnecting the mlet and outlet umons

  and loosenmg the 2 attachment nuts

  Inspection pnor to dlsassembhngPnor to dlsassembhng of the
  removed pump measure the distance between

  the rocker arm and flange of the lower body by means of a scale
  and see If therocker arm rocker lmk and pms are worn

  Method of dlsassembhngfirst wipe dIrt off the outer surface of
  the pump and put marks on both the

  upper and lower bodies to make their reassemblmg easyIt IS
  eaSIly separated mto two when the fIve screws around the upper
  body

  are loosened

  Take great carenot to damage the diaphragm dunng thiS
  disassembly

  Checking Repaires of Parts

  Wash the dIsassembled parts well m gasohne then mspect
  themIReplace the dIaphragm If any damage ImpregnatIOn by
  gasohneReplace a valve assembly If any wear or faulty operation IS
  detectedEven If repaIrs are unavoIdably reqUIred the hmlt for
  repaIrs of warp or

  wear of the valve IS 0 001 In

  When the surface of the valve seat or valve IS found Irregular
  remove thevalve seat of the outlet and dress the surface with a fme
  oIlstone

  In case of Irregulanty of the seat surface of the mlet valve
  which cannotbe taken off from the body recondItion ItwIth a cutter
  and gnndmg tool

  When the surface of the valve IS faulty place some very fme
  gnndmg corn

  pound on the surface of a flat pIece of glass plate and gnnd
  Ithghtly wIth the tipof a finger The standard thIckness of tbe
  valve IS 1 6 mm

  The hole of the jomt parts of diaphragm shaft and lmk may be
  worn to someextent ThIS IS not senous but when senous eccentnc wear
  crack or break

  age IS found the part must be replacedAs a remedIal measure such
  wear can be compensated for at the time of

  dlsmanthng and reassembhng of the body by msertmg a packmg made
  of thIck

  paper between the lower body and diaphragm to raise the relative
  pOSition of

  dIaphragm shaft WIth respect to the lower bodyThe rocker arm
  should be replace when ItS contact face WIth the cam and

  that WIth the hnk and ItS pm hole are senously worn1

  46

• When ItS re employment by recondmomng IS unavoIdable add matenal
  tothe rocker arm and lmk by weldmg and flmsh them wIth a file but
  thIs cannotlast long and IS no more than a temporary measure

  Renew the arm pm when It IS found worn excessivelyThe dIaphragm
  spnng arm spnng seldom become faulty but when weakened

  replace them always with standard onesIf the dIaphragm spnng IS
  too stron It results 10 overflow of the float cham

  ber of the carburetorThe tensIOn of the spnng must not be
  strengthened or weakened arbltranly

  by handCheck to see If there IS any warp on the Jomt surfaces of
  the cap and body

  and after dlsassembltng IS over renew the gasket to keep Its alr
  tlghteness

  Reassembling Installing

  Employ standard spnngs for the vanous uses as stated
  beforeInstall valves preCIsely for close contact wIth theIr
  respective seatsIn screwmg 10 of upper and lower bodIes and
  dIaphragm fit them together

  accordmg to the marks WhClh were put before the dlsassemblmg and
  altgn onescrewmg hole to Its mate and then screw 10 at the
  positIOn

  where the dIaphragmIS fully pulled down with the rocker arm
  pushed towards the SIde of the body byand pressure

  Do not screw 10 tight one by one smce It causes warpmg Instead
  clamp allthe screws ruund loosely and umformly

  Then tighten them dIagonally and lastly re tlghten all of them
  10 order to makesure

  As a general rule gaskets should be replaced by new
  onesInstallation on the engme IS done 10 the reverse order to

  that for dIsassemblyBe sure to set the rocker arm so that It IS
  contacting the eccentnc of camshaft

  properly not the rear SIde or to one SIde Replace the gasket
  between the cyltnderblock and pump with a new standard one

  Checking Function

  When repaIrs of the pump IS over or before It IS mstalledon the
  engme

  make a check to see

  When a vacuum gauge IS connected to the pump mlet portand the
  pump IS

  mounted on a tester the rocker arm IS activated by the eccentnc
  of the camshaft

  revolvmg at 1000 rpm Then the gauge pressure should nse to
  hIgher than 400mm of mercury column and even If operation IS
  dlscontmued

  thIS condItion

  should remain for more than 3 secondsWhen a gauge or tester IS
  not avatlable test

  10 the followmg wayClost the mlet port and outlet port wIth
  ftnger tips Then after operating

  the rocker arm several times suddenly release the ftngers The
  pump IS 10 goodcondltlons If 3 to 5 seconds thence there can be
  heard strong mlet

  and outlet

  nOIse respectivelyThe pump IS mechamcally fIt for use when by
  connectmg a hose to the mlet

  port It IS able to draw up gasoltne from a heIght of more than O
  5 m After

  mstallmg the pump test Its functlons dunng operatlon

  47

• A Connect the gasohne pIpe on the mlet post sIde only Leave that
  on theoutlet port sIde as It IS and turn the engIne 6 to 7
  rotatIOns by means of the crankhandle and make sure that there IS
  sure outflow of gasohne from the outlet port

  8 Connect the gasohne pIpe to the outlet port sIde and tighten
  all the plpmgomts Then turn the engme agam several times to see If
  there IS any leakage

  of aIr or gasohne from each connection

  48

• ADJUSTMENT AND INSPECTION OF ENGINE

  The engme must always be operated m the best possIble condItIon
  and forthIS purpose pencxhc mspectlon and adjustment must be
  mamtamed m a certamorder whIle m use as well as after overhaul

  Order of Inspection and Adjustment of Engine1 Check the coolmg
  water water level and extent of ftlthmess2 Inspect the battery all
  connections level of electrolyte speclftc gravItyof electrolyte and
  voltage3 Inspect the 011 amount fIlthmess clasSIfICation and
  vIscosIty4 Cleaning of spark plugs and adjustment of theIr gaps5
  Measurement of compressslOn pressure of cyhnders The standard
  com

  pressIOn pressure of the engme IS approx 163 lbs per sq m at 350
  r p mMeasurement of pressure IS made m the followmg manner see FIg
  1 Firstwarm up the engme temperature of coolmg water 70 80 C Then
  remove allspark plugs and pull out the throTtle knob all the way
  that IS m the carburetortne throttle valve and choke valveare fully
  opened press a compresSIOn gauge agamst each spark plughole and
  runmng the startermotor with a fully charged batteryread the
  maxImum pressure obtamed wIthm 5 8 rotations of xhemotor ThIS
  measurement mustbe made as qUIckly as pOSSIble

  It the compressIOn pressureof anyone cyhnder differs by 10lb jsq
  In or more from that ofanother the cause must be m

  vestlgated6 Check and adjust the dlstn

  butorIf the breaker contact pomts

  have defective contact surfacesdress them and adjust the gapto O
  45 0 55 mm

  Also turn the cam of the dlstnbutor clockwIse and check tosee If
  the governor can carry out advancmg functIOn7 Adjust IgnItIOn tlmmg
  correctly

  By utJhzmg a power tlmmg hght the function of the governor can
  be checkedtogether WIth the IgnitIOn tlmmg tilummatlon of carnk
  pulley Will enable to mspect the condItIons of runnmg and advancmg
  of the tlmmg B T D C 208 Inspection of fuel pump and gasohne
  stramer9 Adjust the slow settmg of carburetor

  Fig Compression Gauge1

  49

• 10 Checkmg operatIOn of generatorCheck the generating conditIOn
  and functlonmg of the cut out relay by means

  of mdlCatlOnS of the ammeter11 Adjustment of slack m fan
  belt

  12 Adjustment of valve tappet clearance13 Road test

  WhIle dnvmg m 3rd speed at about 25 km hr suddenly step on
  theaccelerator If only a sltght knockmg results the IgnItion tlmmg
  IS correctSlow speed adjustment IS made so that the speed IS about
  15 km hr whendnvmg m 3rd speed

  Diagnosing of Engine by means of VacuumGauge and Combustion
  Tester

  In dlagnosmg the engme the condmon of eachcyltnder can be
  assumed by measunng ItS compressIOn

  For employment of a vacuum gauge connectIt to the engme mtake
  manIfold and refer to FIg2

  The use of a master motor tester as shownm FIg 2 IS
  convenIent

  When a combustion tester IS used mstall a

  speCIal mtake pIck up m the exhaust tube andafter the engme has
  been started analyze bymeans of a speclal gauge the combustIOn
  gaswhIch flows through the connectmg hose mto thetester and Judge
  the combustion condmon accordmg to the mIxture ratio of fuel and
  aIrWhen measurement IS to be made m ramyor coldweather use an
  auxlltary condenser between thepIck up and the meter otherWIse the
  excessIvemOIsture m the exhaust gas WIll damage the functlonmg of
  the meter If permitted to enter It

  Fg 2 Motor Master TesterAva lable for 4 6 and 8
  CylmderEngrne

  When a SUN tester IS to be used make adjustments accordmg to the
  followmgtable

  Condmons Without load SUItable WeIght RatIO of MIxture

  Low Speed RunnIng 70 t 2600 r p m

  HIgh Speed Runnmg 5852 000 r p m 2

  50

• Engine Trouble Shooting

  FIg 3 IS mtended to be of assIstance m the systematic analysIs
  and IsolatIOn of symptoms of engme troubles so that the defective
  pomts may be accuratelytraced and economIcally repaIred

  1

  Normal condItIOn

  Settles between 18 20 In

  2

  Normal condItiOn

  When IndIcator fluctuates

  between a range of 0 251D

  as engme IS raced rings

  and valves are In good

  condltlODs

  3

  Even If Indicator settles

  If read mg IS low rmgs or

  011 arc ID faulty condition

  4

  When above 3 condItIon

  eXists Indicator Will sWing

  to 0 In 1f engIne IS raced

  5

  When Indicator sometimes

  drops by 4 In or so valve

  sticking eXists

  51

  6

  When mdlcator drops by

  several Inches at certalOtime alves are burnt

  7

  When Indicator drops Jy

  about 2 m valves leak

  Faulty sllatmg of valves

  8

  When IndIcator OSCIllates

  actIvely between 14 and18 In valve stem gutde ISworD out

  9

  When wIth a shght speedIng up mdlcator movesbetween 10 22 m
  andwIth Increase of speed the

  range becomes largervalve sprIngs are weak

  10

  When mdlcator remamsstIll between 8 15 m It15 because either
  valve

  timIng IS retarded or valveclearances are notcorrect

  J

• Io

  iiw

  11

  When indIcator settles bet

  ween 14 7 In IgnItion

  tIming s retarded

  12

  When IndIcator moves

  slowly between 14 16 mIt s because eIther electrode gaps of
  plugs are toonarrow or breaker pOIntIS defectIve

  13

  When md cator polOts to5 m or below there IS

  leakage at mtake manlfoldor gasket of carburetor

  Faulty clampmg of gasket

  14

  When indIcator oscIllates

  regularlybet een 5 19 Inthere IS leakage at cy lInder head
  gasket Faultyclamping of gasket

  15

  When indIcator first rises

  hIgh drops down to zeroand then returns to 16 In

  muffler IS clogged

  16

  When IndIcator moves

  slowly between 13 17 In

  carburetor IS poorly ad

  Justed

  FIg 3 IAagnosmg Engme by means of a Vacuum Gauge

  No gasolme In carburetor

  Batter dlschaq ed or connections poor

  Tlmmg poorl adjustedIrbemg sucked In

  lPlugspark Plug sparking weak

  il Sparking at termlnalS Tr

  gdlorrect

  Immg mcorrect

  U

  PI dShort m CirCUIt

  ugs 0t3 not spark

  LIgmtlOD COil or condenser defective

  No sparkIng at ter contact pOint dirtymmals Breaker POtnt
  contact poordefectIve

  Break r arm m ulatlOn defective

  Rotor shorted

  asohne to tunk

  Stramer defective

  PIpe cloggedFloat vah e stiCkmgNo aIr can enter tanh

  Fuel pump not operatmg

  52

• tl

  80

  S

  d

  0d

  0

  c

  cbO

  lo

  Plugsspark

  Plugs donot spark

  10 ga olIne or ga olm supply stopped

  Carburetor EEngmeseIzed

  free of Lubrication msuffiClenttrouble

  Compres AII bemg sucked InSlon good Jet or pipe clogged

  Carburetor Float sunkdefective Float m hIgh positIOn will not
  descend

  Carburetor attachment not secure

  EPlstonf1ng or vahe sticky

  Piston or connectmg rod broken

  alve seatmg poorBreaker arm sprmg defectIve

  No spark

  reontaetpomt poor

  mg from Rotor shortedcOli hne

  Breaker Igmtlon coil or condenser defectivearm good Dlstnbutor
  wet

  Cap insulatIOn defective

  Cord shorted or connectIOn poor

  CVlnng shorted or cut

  Sparkmg form coil hne Plugs dirt orbroken

  ompreSSlOn poor

  A Trouble Shootmg Chart

  Compression weak

  Valve clearance Incorrect

  Valve spring weakValve deformed

  Muffler cloggedContinuous

  lack of power Valve tlmmg Incorrect

  lgOltlOn retarded too much

  Carburetor adjustment poorGasolIne supphed InsuffiCIentlyarbon
  deposits exceSSive

  Gasolme of poor grade

  Intermittent carburetor defective

  lack of power Valves slickIngPre Ignition

  gives off abnormal nOIse I verheatlngBearIng wornPlugs dirty

  Sparkmg Breaker pOint defectIveIrregular Intermittent
  shortmg

  Mlsfirmg Mixture too rtch

  Insuffielent gasolIne supply to carburetorSparkmg normal Water
  In gasoline

  Nozzle clogged

  Power weak

  Engine operatIOndefective darmg

  runningEngme

  B Trouble Shoohng Chart

  53

• CARBURETOR

  SPECIFICATlONS

  20 30C Type Pnmary Secondary

  Bore dIameter 28mm 30mm

  Ventun dIameter 21 8 mm 25 14 7 mm

  Mam Jet 98 115

  Mam aIr breed 60 60

  Slow Jet 48 48

  Slow AIr FIrst 100 160

  Slow AIr Second 220

  Slow EconomIzer 145

  Power Jet 40

  Power valve Begms to open when the pnmary throttlevalve IS at 48
  openmg

  Float level 19 mm below the upper surface of thefloat chamber
  body

  t

  The carburetor has the functIOn of atomIzmg the fuel mlxmg It m
  sUItableratio to aIr mId supplymg the mIxture to the engme

  It IS therefore an Important parr whIch can mfluence the
  performance of theengm

  The Model 2D 3OC carburetor IS a hIghly effIcIent carburetor of
  two barreltwo step and down draft type havmg the followmg specIal
  features

  j

  ll Construction and Operation

  @

  54

• Secondary SIde Pnmary SIde Seconcary SIde

  I Ikxlv a embly2 VenturI

  rloat chamberI Throttle shaft5 MaID Jet6 MaID Jet carrier

  7 Float chamber clver8 Float9 Ma ID aJ r bleed

  Ill AIr bent pipeII Choke valve

  12 Choke control 11l1k

  11 Conneclng rod11 Choke wIre blacket

  15 Throttle Wlre blacker

  16 Lower body

  17 AUX 1l Y throttle valve

  18 Throttle valve19 Bv pass hule20 Iow Jet21 VentUri22 Auxlharv
  valve hdft21 MaID Jet24 MaID aIr bleed

  25 Pump IDJecler20 Out let valve27 Inlet check valve28 Power
  valve

  29 Pump pl ton10 AIr vent hole

  11 Pump pl ton return pnng12 Connecl ng rod

  55

• Main Carburetting SystemThe fuel flowing out of the passage at
  the bottom of the float chamber passes

  through the pnmary main Jet and then mIxed WIth the aIr commlng
  from the mainaIr bleed to be minute drops and inJect Into the
  ventun through the main nozzle

  When the throttle valve IS WIdely open and the engine reqUIres
  dense mIxturegas the acceletlng pump opens ItS power valve from
  where the fuel also flowsInto the main system

  The power valve beginS to operate when the throttle valve opens
  48 fromfull closed posJtJon

  Slow Speed SystemPassing through the main Jet the fuel passage
  separate from main line and

  flows through the slow Jet slow aIr bleed fIrst slow economIzer
  slow aIrbleed second and Inject from the by pass holes and Idle
  holes

  Accelerating SystemMechamcal accelerating pump synchromzed WIth
  the throttle valve IS adapted

  When throttle valve IS open the pIston rod IS pushed up with the
  hnkage wluchpushed up the pIston through the dumper spring When the
  pIston IS commlngdown the Inlet check valve closes the out let
  check valve opens and the fuel within

  the pump IS blown out from the pump Jet by the compressed dumper
  spnng andhIts against the SIde wall of the small ventun to be
  minute drops compensatingtranclent sparseness of the fuel A Jetting
  amount of the fuel can be vaned WIththe two holes provIded on the
  pump arm that IS the inserting posmons of theconnectIng rod

  r Starting Systemhe choke valve IS provIded with the spnng and
  Installed eccentncally on the

  normal carburetting deVIce and synchromzed with the throttle
  valve When thechoke IS fully closed the throttle valve opens about
  14 from a full close ThIsIS the best condItIOn to start operation
  The synchromzatlon of the choke valveand the throttle valve can be
  exactly maintained often the engine has started fIrIng

  S6

• 12 Choke conrrol lmkI3 Connectmg rod14 Choke wIre blacket15
  Throttle WIre blacket33 Sta rung con rod34 AUXIliary lever35 Stanmg
  throttle lever36 Sprmg37 Throttle adJustmg screw38 Con rod

  39 Throtrle wIre clamp40 Throtrle lever

  41 Scale42 Idle adjust screw

  0 0

  000 6

  POWER CARBURETTING FUNCTION

  Main Carburetting SystemSame as the normal carburettIng function
  the fuel flowmg out of the passage

  at the bottom of the float chamber passes through the secondary
  mam Jet and become mmute drops mlxmg with the aIr commg from the
  mam aIr bleed and ISblown mto the ventun through the mam nozzle

  Fig 12 Carburetor

  1 Float level2 Float

  Model NJkkt 2D 30C

  3 Needle valve4 Needle valve carner

  When the throttle valve of the normal carburetor IS WIdely
  opened and theengme produces hIgh power the throttle valve of the
  power carburetor begmsto open by the sunchromzed Itnkage

  However at the top of the power carburetor throttle valve IS an
  auxlltaryvalve whIch IS not open at a slow speed with a heavy load
  due to the load of the

  57

• counter weIght connected to the valve shaft even when the
  throttle valve IS openWhen the engine change to sull hIgher
  revoluuons the auxlhary valve openagainst the loat of the counter
  weIght and the power carburetor stans operauonfor high power When
  the normal carburetor throttle valve IS In a full open thepower
  craburetor throttle valve IS also to be In a full open

  Float Chamber

  The float chamber IS provIded cover of whIch IS made of glass of
  faCilitatefor inspecting inSide condItIon through the marked line
  of cover of It Adjustmentof the float level can be done from
  outSide by adding or subtracting the needle valvecarner gasket
  after removing the float needle valve Installed at the Inlet
  connector

  As venulatlon within the float chamber IS of a aIr vent method
  and pressurewltlun the ventun and the float chamber IS always
  constant no matter how sucuonal

  reglstance of the aIr cleaner vanes fuel consumption can be
  always economIcallymaintained

  @

  Float Chamber

  Adjusting Fuel Level

  3 Pump armFloat valve sheet gasket

  45 Float yalve sheet6 UnIOn bolt

  7 BanjO Union48 Needle vdlve49 Spnng retdmerSO Needle valve
  spnng51 Choke wIre clamp

  Float level IS shown on the float chamber cover With the hne 19
  mm belowthe body top to whIch fuel IS to be adjusted Adjusting the
  float level IS done byadding or subtracting the gasket of float
  valve seat needle valve carner

  AddJt10n or subtraction of 2 numbers gasket make the float level
  up ordown about I mm

  58

• BRAKER POINT AND IGNITIONTIMING ADJUSTMENT

  DISTRIBUTOR

  Type

  19mtlon timing standard

  Apparatus of automatic advance

  Advance starting vacuum pressure

  Advance angle by vacuumpressure of 340 mm HgNumber of revolution
  at the

  start of advance angleMax advance angle at crankshaft

  Rotating dIrection of cam

  Flnng orderPOint gap

  Dowel angleContact arm spnng pressure

  Condenser capacity

  HItachI 0406 01

  10 before top dead centerat 600 r p m

  Governor type

  100 120 mm Hg

  120 18 Crankshaft6 9 DIstnbutor

  450 r p m

  11 15 at 2400 r p m

  CounterclockwIse

  1 3 4 2

  0 45 0 55 mm 0 018 0 022 In

  50 55

  O 5 O 65 kgO 20 O 24 mfd

  InsIde the dlstnbutor IS a braker pOint as shown In FIg ThIS
  braker makesand brakes contact several thousand times In one minute
  Each time thIS brakerbrakes contact a spark IS generated In one of
  the spark plugs Therefore themaintenance of thIS braker must not be
  treated Itghtly Also because the timedunng whIch the IgnItlon COIl
  current flows vanes with the gap between thesebraker pOints see
  that thIS gap IS maintained at the standard value WhICh IS 0 45mm 0
  018 to 0 022 In

  The braker pOints must be kept free of grease and 011 If the
  pOints shouldbecome burnt or blackened they are cleaned With a fine
  honing stone or croucuscloth after WhICh they should be wIped clean
  WIth a pIece of cloth whIch has beendampened WIth gasoltne

  If the pOints are badly burnt they must be replaced Braker
  points mustalways be replaced as sets

  Adjusting the Braker Points

  To adJust the braker pOints turn the engine crankshaft with the
  crank handleuntil the braker IS fully open Then loosen the braker
  pOint ftxlng screw Nextby turning the adjusting screw move the
  plate until a feeler gauge of O 45 to 0 55

  59

• DISTRIBUTOR

  60

  1tr

• mm 0 018 to 0 022 ms thIckness shdes easily between the braker
  pomtsThen tighten the Flxmg screw securely

  fmally check the gap once more then remstall the rotor The
  Intenor andextenor of the cap IS wIped clean with a soft dry piece
  of cloth extra attentionbemg paId to the areas between the termmals
  Clean the center electrode on themSlde of the cap also

  Whether or not the