lock DATSUN 610 1969 Repair Manual

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6iIiIIlli
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r

7
r

Y

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10

1
L

u

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c

I

F
ll
L
2S
The
handbrake

mbly

Fig
L
27
Front
handbrake
cable
attachment

nuts

e7
rl
A

I
r

I
r

J
i

I
f

I
I

I
of

II

J

F

F
ll
L29
Balance
lever
Estate
ClU1l
and
Vans

F
ll
L
30

AdjWltins
the
handbrake
cable

Estate
ClU1l

106
J

ei
Fig
L
26

Removing
the
lock

plates
see
text

I

7
I

i

1

@
i
1

0
1

e

V

O
V

I
r

r

if1
1i

cl

t
Ji
Y

a

t

3

F
ll
L
28
Rear
cable

layout
1800
C
c
SatOOWl

ok

pedat
height
H

87
mm
7

362
in

202
mm

7
953
ill
Jltznual
transmission

AutomItic
transmission

y
Brake

pedal
full
stroke
L

141
0149
mm

5
55
to
5
86
in

Brake

pedal
p
tJv
P

5
to

15
mm

0
2
to
0
6
ilL

Fig
L
31
Brake

pedal
adjWltment
1400
and
1600
c

c

models

l

car

Ll
1
f
1

J

111

I
l
j
u

n

l

71

t
i1

Unit
mfll
in
1
Push
rod

adjusting
scrt

W

2
Ptdlz

stop

3
Brake

Iilmp
switch

4
Clevis

pin

Fig
L
32
Brake

pedaladjWltment
800
c
c

models

BRAKE
PEDAL
ADJUSTMENT

The

brake
pedal
height
and
free

play
can
be

adjusted
in

the

following
manner
1400
and
1600
CC
models

Adjust
the

length
of

the
master

cylinder
push
rod
until
the

height
of
the

pedal
pad
is
187
mm
7
36
in

for
manual

gear

boxes
and
202
mm
7
95in
for

automatic
transmission
vehicles

without
brake

light
switch

Fig
L

31

Retighten
the
locknut

Screw
in

the
brake
light
switch
until
the
screwed

part
of
the

switch
is

against
the
front
of
the

stopper
bracket
then

tighten

the
locknut

Screw
in
the

stopper
bolt
until
the
moveable

part
of
the

switch
is

completely
pushed
in

by
the

pedal
and

tighten
the

locknut
in
this

position
Make
sure

that
the

lamp
is
00

when
the

pedal
is

pushed
down

by
1
5mm
0
06
in

1800cc
models

Adjust
the
bolt
of
the
brake

lamp
switch
until
its
end
face

is
flush
with
the
locknut
then

tighten
the
locknut

securely

See

Fig
L
32

Adjust
the

pedal
stopper
until

the

pedal
pad
is

positioned
at
a

height
of
185
mrn

7
28
in
from
the
floor

then

tighten
the

stopper
with
the
locknut

Adjust
the

length

of

the
master

cylinder

push
rod
until
a

pedal
free

play
of
I
5mm

0
04
D
2in
is
obtained
then

retighten
the
locknut

Depress
the
brake

pedal
several
times
to
make
sure
that
a

full
travel
of
145mm
5
7
in
is
available
and
that

the
pedal

moves

freely
and
without
noise

Technical
Data

BRAKE
PEDAL

Pedal

height

1400
and
1600cc
models
I
87mm

7
362in
manual

gearbox

202mm
7
953in
auto

matic

185mm

7
28in

145mm
5
71
in
1800cc
models

Full
stroke

MASTER
CYUNDER

Inner
diameter

Piston

running
clearance
19
05mm
0
75
in

0
15mm
0
006
in

WHEEL
BRAKE
CYLINDERS

Inner
diameter

1400
and
1600cc

Front
drum

Front
disc

Rear
with
front
drum

Rear
with
front
disc
22
22mm
7
8in

50
8mm

2
0

in

22
22mm

7
8in

20

64mm
13
16
in

Inner
diameter
I
BOOcc

Front
drum

20
6mm

13
16in
Front

disc

Rear
50
8mm
2

0in

22
2mm
7
8
in

BRAKE
DRUM
AND
BRAKE
DISC

Drum
inner
diameter

Drum
outer
diameter

Out
of
round
maximum

Repair
limit
of
drum

Maximum
disc
run
out

Repair
limit
of
disc
228
6mm
9
0in

232mm
9
13in

0
05mm
0
002

in

230mm
9
055
in

0
06mm
0
0024
in

8
4mm
0
331
in

BRAKE
UNINGS

Drum
brakes

Width
x

thickness
x

length
40
x
4
5
x
219
5mm

1
575
x
1
772
x
8
642in

Disc
brakes
39
7
x
9
x
86mm

1
563
x
0
354
x

3
386in

Total

braking
area

Front
drum
brake

Front
disc
brake

Rear
351

sq
cn
54
4

sq
in

114
2

sq
cm

17
7

sq
in

351

sq
cm
54
4

sq
in

107

ElectrIcal

EquIpment

DESCRIPTION

BATTERY
Maintenance

STARTER
MOTOR

Removal
and

Dismantling

STARTER
MOTOR

Testing

STARTER
MOTOR

Assembly
and
Installation

ALTERNATOR
Removal

Dismantling
and

Inspection

DESCRIPTION

A
12
volt

negative
earth
electrical

system
is
used
in
which

the

battery
is

charged
by
an
alternator
In
the
alternator
a

magnetic
field
is

produced
by
the
rotor

which
consists
of
the

alternator
shaft
field
coil

p
le

pieces
and

slip
rings

Output
current
is

generated
in
the
armature
coils
located

in
the
stator
Six
silicon
diodes
are

incorporated
in
the
alternator

caSing
to

rectify
the

alternating
current

supply
A
voltage

regulator
and

pilot
lamp
relay
are
built
in
the

regulator
box

which

nonnally
does
not

give
trouble
or

require
attention

The
starter
motor
is
a

brush

type
series
wound
motor

in

which

positive
meshing
of
the

pinion
and

ring

gear
teeth
are

secured

by
means
of
an

overrunning
clutch

BATTERY
Maintenance

The

battery
should
be
maintained
in
a
clean
and

dry

condition
at
all
times
or
a
current

leakage
may
occur

between

the
terminals
If

frequent
topping

up
is

required
it
is
an

indication
of

overcharging
or
deterioration
of
the

battery

When

refitting
the
cables
clean
them

thoroughly
and
coat

their

terminals
and
the
terminal

posts
with

petroleum
jelly

Check
the
level
of
the

electrolyte
in
the

battery
at

frequent

intervals
and

top
up
if

necessary
to

the
level
mark
on

the

battery
case
with
distilled
water
A

hydrometer
test
should
be

carried
out

to
determine
the
state

of

charge
of

the

battery
by

measuring
the

specific
gravity
of
the

electrolyte
It
should
be

pointed
out

that
the
addition
of

sulphuric
acid
will
not

normally

be

necessary
and
should

only
be
carried
out

by
an

expert
when

required

The

specific
gravity
of
the

electrolyte
should
be
ascertained

with
the

battery

fully
charged
at
an

electrolyte
temperature
of

200C
680F

The

specific
gravity
of
the

electrolyte
decreases
or
increases

by
0
0007
when
its

temperature
rises
or
falls

by
10C
1
80F

respectively

The

temperature
referred

to
is
that
of
the

electrolyte
and

not
the
ambient

temperature
to
correct
a

reading
for
an
air

temperature
it
will
be

necessary
to

add
0
0035
to
the

reading

for

every
50C
above
200C

Conversely
0
0035
must

be
deducted

for

every
SOC
below
200C
Test
each
cell

separately
and
draw

the

liquid
into
the

hydrometer
several
times
if
a
built
in

thermometer
type
is
used

The
correct

specific
gravity
readings
should
be
as
follows
ALTERNATOR

Assembly
and
Installation

HEAD
LAMPS

Replacing

HORN

INSTRUMENT
PANEL
Removal

WINDSCREEN
WIPERS

WINDSCREEN
WASHERS

IGNITION
SWITCH
AND
STEERING
LOCK

Cold
climates

Temperature
climates

Tropical
climates
Permissible

value

Over
1
22

Over
1
20

Over
1
18
Fully
charged
at
200C

680F

1
28

1

26

1
23

The

battery
should
be

recharged
if
a
low

specific
gravity

reading
is
indicated

Always
disconnect
both
terminals
of
the

battery
when

charging
and
clean
the
terminal

posts
with
a

soda

solution
Remove
the
vent

plugs
and

keep
the
electrolyte

temperature
below
450C
l130F
during
charging

Check
the

specific
gravity
after

charging
and
if
it
is
above

1
260
at

200C
680C
add
distilled
water

STARTER
MOTOR
Removal
and
Dismantling

As
previously
stated
the
starter
motor

is
brush

type
series

wound
motor
in
which
the

positive
meshing
of
the

pinion
and

ring
gear
teeth
are
secured

by
an

overrunning
clutch
The
over

running
clutch

employs
a
shift
lever
to
slide
the

pinion
into

mesh
with
the
flywheel
ring

gear
teeth
when
the
starter
is

operated

When
the
engine
starts
the

pL
lion
is

permitted
to
overrun

the
clutch
and
armature

but
is
held
in
mesh
until
the
shift
lever

is
released
An

exploded
view
of
the
starter

is
shown
in

Fig
M
2

To
remove
the
starter

motor

proceed
as
follows

Disconnect
the

battery
earth
cable

2
Disconnect
the
black
and

yellow
wire
from
the
solenoid

terminal
and
the
black
cable
from
the

battery
terminal

3
Remove
the
two
bolts

securing
the
starter
motor
to
the

clutch

housing
Pull
the
starter
motor

assembly
forwards

and
withdraw

it
from
the
v
hicle

To
dismantle
the
starter

motor
ftrst
remove
the
brush

cover
and
lift
out

the
brushes
as
shown
in

Fig
M
3

Loosen
the
nut

securing
the

connecting
plate
to

the

solenoid
M
terminal
Remove
the
solenoid

retaining
screws

take
out

the
cotter

pin
and
withdraw

the
shift
lever

pin
Remove

the
solenoid

assembly
as
shown
in

Fig
M
4

Remove
the
two

through
bolts

and
rear
cover

assembly

then
remove

the
yoke
assembly
by
lightly
tapping
it
with
a

wooden
mallet

Fig
M
S
Withdraw
the
armature
and
shift

lever

Fig
M
6
Remove
the
pinion

stopper
from
the

armature
shaft

by
removing
the

stopper
washer
pushing
the

109

ALTERNATOR
Dismantling

Refening
to

Fig
M
16
remove

the

pulley
nut
and
take
off

the

pulley
rim
fan
and

spacer
Withdraw
the
brush
holder

retaining
screws
and
remove
the
brush
holder
cover
Withdraw

the
holder
and
brushes
as
shown
in
Fig
M
17

Slacken
and
remove
the
three

through
bolts
and

separate

the
diode

housing
from
the
drive
end
housing
by
tapping
the

front
bracket

lightly
with
a
wooden
mallet

Fig
M
18

Remove
the
screws
from
the

bearing
retainer
and

separate
the

rotor
from
the
front
cover

Fig
M
19

Remove
the
rear

bearing
from
the
rotor

assembly
with
the

aid
of
a

puller
as
shown
in

Fig
M
2D
Take
off
the
diode
cover

and
unsolder
the
three
stator
coil
lead
wires

from
the
diode

terminal

Remove
the

A
terminal
nut
and
diode
installation
nut
and

remove
the
diode

assembly
Do
not
force

the
diode

assembly

when

removing
or
it

may
be

damaged
Remove
the
stator
from

the
rear
cover

ALTERNATOR

Inspection

Use
an

ohmmeter
as

shown
in
Fig
M
21
to
test

the
rotor

field
coil

Apply
the
tester
between
the

slip
rings
and
check
that

the
resistance
is

approximately
4
4
ohms
at

normal
ambient

temperature
Check
the

conductivity
between

slip
ring
and
rotor

core
as
shown
in

Fig
M
22
if

conductivity
exists
the
field
coil

or

slip
ring
must
be

earthing
and
the
rotor

assembly
should
be

renewed

Cbeck
the
stator
to
ensure
that
there
is

conductivity

retween
the
individual
stator

coil
terminals
as
shown
in

Fig
M

23
If
there
is
no

conductivity
between
the
individual
terminals

the
stator
is
defective

Check
each
lead
wire

including
the
neutral
wire
as
shown

in

Fig
M
24
If
there
is

conductivity
between

any
wire
and
the

stator
COTe

the
stator
core

is

earthing
and
the
stator
must

be

replaced

Diodes

Three

positive
diodes
are
mounted
on
the
positive
plate

and
three

negative
diodes
are
mounted
on
the

negative
plate

The
diodes
allow

current
to
flow
in
one
direction

only
The

diodes
on
the

positive
plate
only
allow
current
to
flow
from

the
terminal
to
the

positive
plate
whilst
the
diodes
on
the

negative
plate
only
allow
current
to
flow
from
the

negative

plate
to
the
terminal
A
diode
which
allows
current
to
flow

in
ooth
directions
or
does
not

allow
current
to
flow
in
the

correct
direction
is
unserviceable
and
all
six
diodes
must
be

replaced
Use
a
tester
as
shown
in
Figs
M
25
and
M26
to
check

each
diode

Brushes

Check
the
movement
of
the
brushes
in
their
holders
The

brushes
should
move

freely
and
can
be
eased
in
necessary
by

carefully
ming
the
sides
Oean
the
brush
holders
before

replacing

the
brushes
Renew
the
brushes
if

they
are
worn
below
a
length

of
7mm
0
275
in
With
the
brush

projecting
approximately

2mm
0
08
in
from
the
holder
it
is
possible
to
measure
the

brush

spring
pressure
using
a

spring
balance
as
shown
in

Fig
M
27

The

pressure
of
a
new
brush
should
be
255
345

grammes

9
0
12
2
oz
the

pressure
will
however
decrease

by
approxi

mately
20

grammes
per
I
amm
0
039

in
of
wear

ALTERNATOR

Assembly
and
Installation

Asssembly
is
a
reversal
of
the

dismantling
prQcedure
noting

the

following
points
The
stator
coil
lead
wires
must
be
resoldered
to
the
diode

assembly
terminal
as

quickly
as

possible
or

the
diodes

may
be

damaged
When

installing
the
diode
A
tenninal
make
sure

that

the

insulating
bushing
and
tube
are

correctly
fitted

The

pulley
nut
should
he

tightened
to
a

torque
reading
of

350
400

kg
cm
301
344Ib
in
Mount
the

assembly
in
a

vice
as
shown
in

Fig
M
28
and
when
the

pulley
is

tightened

make
sure
that
the
deflection
of
the

pulley
groove
does
not

exceed
O
3mm
m
o
118

in

ilEA
D
LAMPS

Replacing

All
weather

type
sealed
beam

headlamp
units
are
fitted
to

the
vehicle
Each

lamp
is
of
the
double
fIlament

type
with
a

full
beam
filament
of
50W
and
a
dipped
beam
filament
of
40W

The

replacement
of
the
sealed
beam
unit
can

be
carried

out
as
follows

Remove
the

wiring
socket
from
the
back
of
the

headlamp

unit
On

Coupe
models
withdraw
the
screws

attaching
the

front

grille
to
the
radiator
core

support
On
all
other
models

remove

the
three

retaining
screws
and
remove
the

headlamp
rim

Withdraw
the
three

retaining
screws

securing
the

retaining

ring
3
in

Fig
M
29
and
remove

the
sealed
beam
unit

When

installing
a
new
sealed
beam
unit
make
sure
that
the

Top
mark
on
the
ring
is

uppennost
when
fitted

HORNS

The
circuit
for

the
horns
is
shown
in

Fig
M
30
The
horns

can
be
adusted
for
v01ume
and
tone
in

the

following
manner

Remove
the
connector

and
the

retaining
nut
in

the
centre

of
the
horn
withdraw
the
horn
from
the
vehicle
Connect
a

voltmeter
and
ammeter

into
circuit
as
shown
in

Fig
M
3I
Set

the
switch
to
ON
and
check
that
the
voltmeter
shows
a

reading
of
12
to
12
5
volts
The
sound
can
be

regulated
by

turning
the

adjusting
screw

Fig
M
32
A

reading
of

2
5

amps

should
be
obtained
for
the
flat

type
of
horns
or
5
0

amps
for

the

spiral
type
of
horns

Turning
the

adjusting
screw
clockwise
will
increase
the

current

turning
anti
clockwise
decreases
the
current

Install
the
horns
in
the
vehicle
and
check
that
the
correct

sound
can
still
be
obtained
when
the

higher
voltage
of
14
15

volts
is

generated
by
the
alternator
Turn
the

adjusting
slightly

if

necessary
then

tighten
the
locknut

INSTRUMENT
PANEL
Removal

The
instrument

panel
holds
the
various
meters

and

indicators
A
printed
circuit
board
is
located
at
the
rear
of
the

panel
and
the
connections
to
it
are

multiple
connectors
When

the

panel
is
remove

the
instruments
are

easily
withdrawn
for

inspection
and

servicing

Disconnect
the

battery
negative
terminal

2
Remove
the
windscreen

wiper
switch

lighting
switch
and

choke
control
knobs

by
pressing
them
in
and

turning

anticlockwise
Remove
the
escutcheon

3
Disconnect
the

cigarette
lighter
cable
at
the
rear
of
the

instrument

panel
and
turn

the

cigarette
lighter
outer
case

so
that
it
can
be
removed

115

inter

@IP

Fig
M
33

Removing
the
instrument

panel
h
J
I

II
VI

BATTERY
FUSIBLE

LINK

0
3
Br

WASHER
MOTOR

I

ILR

rj

WIPER
MOTO
R

ILR

lity

111
W

J
9P

l
l
0

0

IGNITION

SWITCH

FUSE
BOX

IDA

0

W
ACC

r
WIPER
SWITCH

P
I
2

W

I

X

9

LWI

t

j

LR

Fig
M
36
Circuit

diagram
for

the
windshield

wipers

and
washer

Fig
M
35

Removing
the

wiper
arm

116
Fig
M
34

Wiper
motor

and

linkage

1

Wiper
arm

2
Pivot

3

Wiper
ann

4
Pirot

5

WiTNr
motor

f

Fig
M
37

Steering
lock

installation

1

Steering
lode

cwmp

2

Self
hear

ty
screw

3

Ignition
switch

4

SUmng
lock

4
Remove
the
shell
covers

from
the

steering
column
slacken

the

screws
securing
the
meter

housing
and
withdraw
the

panel
from
the
facia

Fig
M
33

5
Pull

out
the
12

pole
round

shaped
connector
and
remove

the

speedometer
cable
union

nut
then
remove
the
instru

ment

panel
completely

WINDSCREEN
WIPERS

A
two

speed
wiper
motor
is
fitted

The
motor
has
an
auto

stop
mechanism
and
drives
the

wiper
arms

through
a
link

mechanism
located
behind
the
instrument
panel
If
the

wiper

system
does
not

operate
check
the
fuses
connectors
control

switch
and
motor
If
the

wiper
speed
does
not

change
the

switch
must

be
repaired
or

replaced
If

the

wiper
motor
becomes

unserviceable
it
can
be
removed
from
the
vehicle
in
the

fOllowing

manner

I
Remove
the
connector

plug
from

the
motor
See

Fig
M

34

2

Working
from
the

passenger
compartment
side
of
the
dash

panel
remove
the
nut

connecting
the

wiper
motor
worm

wheel
shaft
to
the

connecting
rod

3
Remove
the
three
bolts

securing
the

wiper
motor
to

the

cowl
and
lift
out
the
motor

Battery

Starter
motor

Type

Output

No
load

Terminal

voltage

Current

Revolution

Load

Terminal

voltage

Current

Torque

Brushes

Brush

length

Wear
limit

Spring
tension

Commutator

Standard
outer

diameter

Wear
limit

Depth
of

nuca

Repair
limit

Repair
accuracy

Qearance
between
armature

shaft
and

bushing

Repair
liinit

Repair
accuracy

Armature
shaft
ou
ter

diameter

Pinion
side

Rear
end

Wear
limit

Bend
limit
The

wiper
arms
can
be
removed
quite
easily
by
taking
off

the
attachment
bolt
as
shown
in

Fig
M

J
5
and
then

pullin

the

wiper
arm
from
the

pivot
shaft
When

installing
the

wiper

arm
make
sure
that
the
blade
is

positioned
approximately

27mm
1
06
in
away
from
the

bottom
of
the
windscreen
and

tighten
the

wiper
arm
attachment
bolt

WINDSCREEN
WASHERS

The
windscreen
washer
SWItch
and

wiper
switch
are
com

bined
in
a

single
unit
See

Fig
M
36
the
washers
can
be

operated
by
turning
the
switch
in
the

appropriate
direction
It

should
be
pointed
out
that
it
is
inadvisable
to

operate
the
washers

for
more
than
30
seconds
at
a
time
If
the
washers
are

operated

in
short

spells
of

approximately
10
seconds
duration
their

working
efficiency
will
remain

unimpaired
for
a
considerable

length
of
time

IGNITION
SWITCH
AND
STEERING
LOCK

The

steering
lock
is
built
in

to
the

goition
switch
When

the

key
is
turned
to
the
LOCK

position
and

then
removed

the
steering
system
is

automatically
locked

by
the

steering
lock

spindle
which

engages
in
a
notch
in
the
collar
on
the

steering

shaft

See

Fig
M
37
The
heads
of

the
screws
are
sheared
off

on
installation
so
that
the

steering
lock

system
cannot
be

tampered
with
If

the

steering
lock
is
to

be

replaced
it
will
be

necessary
to
remove
the
two

securing
screws
8
and
then
drill

out

the
self

shearing
screws
7
When

installing
a
new

steering

lock

tighten
the
new
self

shearing
screws
until
the
heads
shear

TechnICal
Data

12
volt

HITACHI
S114
87M

1
0KW

12
volts

Less
than
60

amperes

More

than
7000
r

p
m

6
3

volts

Less
than
420

amperes

More
than
0
9

mkg
6
5
lb

ft

16
mm

0
630
in

6
5mm
0
256
in

0
8

kg
1
8
lb

33mm
1
299
in

2mm

0
078
in

0
2mm
0
008
in

0
5
0
8mm
0
0197

0
0315
in

0
2mm
0
008

in

0
03
O
lmm
0
0012

0
0039
in

13mm
0
512
in

11
5
mm

0
453
in

O
lmm
0
0039

in

0
08

mm
0
0031

in
Oearance
between

pinion
and

stopper
0
3
1
5mm
0
0118

0
0591
in

ALTERNATOR

Type
HITACHI
LTl25
06

HITACHI
LTl33
05
USA

Canada

More
than
18

amps
at

14

volts
2500
r

p
m

More
than
25

amps
at

14

volts
5000
r

p
m
Output
current

LTl25
06

Output
current

LT
133
05

More
than
24

amps
at

14

volts
2500
r

p
m

More
than
33

amps
at
14

volts
5000
r

p
m

Brushes

Lengtb

Wear
limit

Spring
pressure
14
5mm
0
571
In

7mm
0
2756
in

0
25
0
35

kg
0
55
0
771b

Slip
ring

Outer
diameter

Reduction
limit

Repair
limit

Repair
accuracy
31
mm
1
220
in

I
mm

0
039

in

O
3mm
0
0118
in

0
05
mm

0
0197
in

VOLTAGE
REGULATOR

Type

Regulating

voltage
HITACHI
TL
lZ
37

14
3
15
3
volts
at
200C
680F

117

N
Engme
SYMPTOMS
I

Trouble
Shooting
Lubrication
System

SYMPTOMS

bed
t
f
I
h
i
1m
0
p
q
r
I
I
II
bed
t
f
I
h
Ii
I
m
n

ENGINE
WILL
NOT
CRANK

ENGINE
CRANKS
SLOWLY

ENGINE
CRANkS
BUT
OOES
NOT
START

ENGINE
STARTS
BUT
RUNS
FOR
SHORT

PERIODS
aNL
Y

ENGINE
I
tISFIRES
AT
LOW
SPEED

ENGINE
MISFIRES
AT
HIGH
SPEED

ENGINE
MISFIRES
AT
ALL
SPEEDS

ENGINE
MISFIRES
ON
ACCELERATION

AND
FAILS
TO
REV

ROUGH
IDLE

RUNS
ROUGH
AT
HIGH
SPEED

lACK
OF
POWER

POOR
CCElERA
nON

LACK
OF
TOP
SPEED

EXCESSIVE
FUEL
CONSUMmON

EXCESSIVE
OIL
CONSUMmON

PINKING

COMPRESSION
LEAK
PROIABLE
CAUSE

Faull
In
th
e
ltartinll
IYltem
Refer
to
the
ELECTRICAL

EQUIPMENT
leetion
fOI
dilllflOlIll

b
Eft
ineoiltoothick
Stiffenpne

d
Mechanieal
scimre

Flult
In
lhe
IpUlion
I
ltem
Refer
to
the
IGNITION

SYSTEM
IeCtion
for
di
I

f
Flult
the
fuellYlltm
Refer
to
the
FUEL
SYSTEM

Clion
or
di
l
OIII

Incomcl
tllvetlmln

h
ComprellllllIU
IClk

Air
leak
IRlel
JIlIIni
old

j
Reltriction
nhlu5t5ylltm

Ie
Poor
alYe
WIIIIIJ

I
Stick
tnlvall
n

m
Lclklnl
cylinder
held
Illke

Womcamlhlft
lobel

IncolTe
ttappetclurance

p
Worn
dlm
ed
cylinder
born
pUlon5
Ind
or
pll
f1np

q
Wom
nl
fC
paides

Damaced
a1wlttmseal

LeWnloilwaI
pu
e

Incorrectly
installed
apark
plu

CrICked
cylinder

Broken
weakv
w
sprinp
EXCES9lVE
OIL
CONSUMPTION

WW
OIL
ilRESSURE
PROIABLE
CAUSE
REMEDIES

I
Worn
dlmalJl
dcyhnderbon
P
v
lnd
orpulu
nnr
s

b
WorJl
valve
r
uides

C
D
m
led
valve
lIemluls

d
Lnlunr
oil
ul
pillet

e
Flulty
nil
P
uu
IluP
Iwnch
wmn

f
Relief
valve
defecuve

011
pick
up
pipellfline
blocked

h
011
filler
nver
flow
yaJYe
dcffe

WO
n
oil
pump

J
Dlmllfd
om
maUl
Ind
or
bl
nd
b
lnnll

l
lncorreCllndeofentpneoil

l
Oil
level
10

m
Oillevel
tnnhllh

Oillelk
the
preuunled
Ilde
of
the
lubn
IYSfem
p
Tldc

Rel1
f1nd
yllOde1

ne
OVCntZl
nd
nnJ

b
Rcpltte
v
lve
and
Iltd

c
Repl
cc
5c
l

d
Sullu
rt
pl
cp
aI
kCl

e
Trice
Ind
rtClify

f
heel
lod
replace
if
nccess
T

RemoYcblQChJC

h
Chcck
Ind
repllcclfncct
i
ry

i
Repll
e
rump

J
Renew
nnp

k
Rerl
ec
OIl
with

l
Top
up
oil

m
DTllnofllurpIUloil

Tn
ndremedy

Coolmg
System

b
r
h
j
I
m
p
q

d
REMEDIES
SYMI
IOMS

b
Drlm
oiJ
nd
rcpl
ce
with
ot

Add
smlll
quanllty
n
oil
to
the
fuel
Ind

rune
lmeFnd

d
SlfIpenJine
Ind
renew
p
ru
asn
celllry
I
bed
t
f
I
h
I
i
k
I
mn
0

OVERHEATING
ENGINE
FAILS
TO
REAOI

NORMAL
OPERATING
TEMPERAt
lRE

PROIAILE
CAUSE
REMEDIES

I
RetUne
enJine

h
Trace
ndseal

Tr
Ind
seal

j
RemO
f
t
rellnction

k
Relnnd
sel

I
Freelnd
trice
C
UIe

m
Renewguke
Fit
new
clmlhlrt

AdJult
t
appeti

p
bch
ngeenfin

q
Replacevalnluldes
Rtplace
seall

Repllccgukel
Repllcc
plulwlth
correct
Cl
Ie

Renew
cyhndcrblock

Repllce
5prLnp
I
IlIIIIfficien
coolant

b
DriYebellllippinIOfbrobn

c
RldiatOf
fUll
cloq
ed

d
Coo
inlflndefeclln

e
Wit
pl1mpdtfectlve

f
ThelTllOllatj
mmed
Ihul

Thermost
j
mmed
open

r
t
eti
I
kt
r
re
a
q
brake

j
lntel1laJp
se
lheenpne
ndforradi
torbloeked

11
HOItI
blocked

I
Carburetterm
djullmem

m
Excellive
arbon
depolit
in
thecylinden

In
ffici
enpneoil
uae
of
inferior
p1Ide
of
oil

Exce
inrldi
lorlrea
I
Topupradil
v

b
Ti
htenbdtorftnc

I
t
rmify

e
Repl
cwaterpump

f
Rcpll
e
thermoltll

I
Replleclhermolt
t

h
RetimeiaTUlion

i
Unload
ear
check
brl
ktt

j
Trace
ndclu

k
TfI
cdUrblockaae

L
AdjUllcorrc
cth

m
Decarbonise
fO
tne
top
overh
uJ

Top
up
wlth
correct
rade
Dr
inifneceUlry

PUIl
lly
blink
off
in
winter
only

Trouble
Shooting

Ignition
System

SYMnONS
be
d
t
f
I
h

ENGINE
CRANKS
IUT
DOES
NOT
nART

ENGINE
STARTS
BUT
RUNS
FOR
SHORT

PERIODS
ONLY

ENGINE
MISfiRES
AT
LOW
SPEED

ENCINE
WlSflRES
AT
HIGH
SPEED

ENGINE
MISFIRES
AT
ALL
SPEEDS

ENCINE
MISfiRES
ON
ACCELERATION

AND
FAI
TO
REV

ROUGH
IDLE

ENGINE
RUNS
ROUCH
AT
toGH
SPEED

UCK
OF
POWER

POOR
ACCELERAnON

LACK
OF
TOP
SPEED

EXCESSIVE
FUEL
CONSUMmON

PlNKlNC
PROBABLE
CAU5E

t
Bani
dilcharFd
01
defective

b
COJlIllCl
nabr
poinb
nCiCCl
c1Unlftl
renewlna

c
Incorrect
cantlel
ltn
ktr
potftu

d
ConllCt
maker
Iprtn
wuk

Spark
plup
n
d
ch
ntnl
nnewlJIl

r
Jncorrec
llpulpl1llPpI

WronllypeoCap
rtpllllflttad

h
Slltlc
I
lllon
limina
Incorrect

I
Coli
c
plCilor
defC
tl

t
g
o
o
c
o
c
t1o
t
n
h
CllIl
the
toil

H
T
lud

I
Open
cimail
lIlort
nnh
1
conneclion
Ih
spart

m
l
1ulludslnCClfRcllyc
oIIJlCC
tcd

H
T
Ink
coil
dbtribulor
elp
due
oil
din

mol
t
I
o
d
ml

C
ntrlfuplld
anee
not
unetionln
eOll
lctly

p
VKuum
Id
e
not
funclionill
cOIYKtly

q
om
datrlbutw
elm
Or
4iltributor
dldt
bluh

I
UllntWJlOlllpldl
off
ld

L
i
k
I
m
no
p
q
I

b
m
q

f
h
i
j

REMEDIES

I
aceh
tJe
oc
pllce
blHery

b
Clean
01
n

c
Fi
wrrecl
poin

d
Renew
blnker
ll
t

Clea
l
l
ne
plllll

f
Adjull
pt

Fit
cor
c
plu
l

h
aetUne
i
mtlon

I
a
plaCf
I
nece
r

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recury

k
True
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nd
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m
Con
c
cOI
ct1r

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dry
hn
fne
rl

EllImlne
and
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ly

p
Cheek
Ind
rectlly

q
aepllccddectkol
plnl

r
Chlnp
comct
Il
adl
of
fuel
Fuel
System

ENGINE
CRANKS
8lTf
DOES
NOT
START

ENGINE
STARTS
BUT
RUNS
FOR
SHORT

PERIODS
ONLY

ENGINE
MISARES
AT
LOW
SPEED

ENGINE
MISflRE5
AT
HIGH
SPEED

ENGINE
MISFIRES
AT
ALL
SPEEDS

ENGINE
MISAKES
ON
ACCELERA110N

AND
FAILS
TO
REV

ROUGH
IDLE

ENGINE
RUNS
ROUGH
AT
HIGH
SPEED

LACK
OF
POWER

POOR
ACCELERA110N

LACK
OF
TOP
SPEED

EXCESSIVE
flJEL
CONSUMmON

PINKING
BACKFIRE
PROBABLE
CAU5E

Fuel
tank
empty

b
Fu
llinc
blocked

Fuel
pumpd
fectiYe

d
Block
in
cllburene

Air
lock
in
fuel
line

f
Fuel
rut
r
blocked

I
Cuburetter
needle
nlve
jammed

h
Wile
CI
buRlt
r

Errltic
fllel
now
due
blocka

j
IdlinJlpeed
too
low

k
InConectlCtllnlofcttoke
conllol

1
lncorrectcarbuntterfuel
nOltlewl

m
C
muretler
Itlna

Ail
leak
It
Inlet
mlrurold

Incorrect
pade
offuet

p
Carburetter
accelerator
pumpdefect
e

q
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e

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Incorm
t
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Clrburellel
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un
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Wron
cllburenerjetl
Atled
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I
bell
f
1
h
I
j
k
I
m
nOli
I
I
I
0

b
f
h
i
J
k
I
m
REMEDIES
q

FLllllnk

b
Blow
ObSIf1rCllUll
ilh
compl
t
lIed

R
pll
pump

d
RemO
l
e
blockaJe

Trace
Uld
bleed
QUI

r
CIUl1fi1tef

K
Fretne
dle

h
Drlln
d
yout

Removeblockq

J
Adju
throlllelfOl

k
Reset
conllol

1
AdjUSlle
e

m
Wlit
fOI
melt
If
pt
nLS
n
nu

Tlact
lelklndse
a1

Dllu
e
fuel
with
hlah
I
rllln
ubl
ln
blc

p
Trace
fault
and
reeufy

q
AdjuII
correelly

Adju
mutufWconlrol

Clnnnlttr
Retjme
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OdClrbulelle
Repllce
Wllh
Je

Clutch
MIPTOOlS
Trouble
Shootmg
Steering
IYMmlMS

mDING
S1
1FFNESS

ITIBJJNG
IIl
ACJt

STEEIUNG
WANDER

WHEEL
SHIIlOlY

CAR
PUl
U
TO
ONE
IIDE

POOR
RECa
Dy
OF
STEERING

WHEEL
10
CENl1tE

EXCESSIVE
01
ABNORMAL
TYKE
WEAR
It
d
e
f
I
II
J

e
It
b
I
J
k1
D
0
P
41
r

nUTCH
SI
IPPING
WIu
NOT

ENGAGE
PROPERLY
CLUfCHDRAG
WILLNOT

DISENGAGE
PROf
ERL
Yl

a
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Torques

LIB

engines
Three

speed
geabox
ENGINE

2
5
4
0

kgm
18
29
Ib
ft

0
3
0
4

kgm
8
13
IbJI

Ll
1
8

kgm
8
0
12
llbJt

1
6
2

5
kgm
12
18Ib
ft

I
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1
8

kgm
8
0
12
llbJt

0
7
I
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kgm
5
1
8
0

IbJt

17
2

lkgm
l2
15IbJI

7
0
12
0

kgm
51

87IbJI

0
8
1
0

kgm
5
8
7
2
IbJI

0
3
0
4

kgm
2
2
2
9Ib
ft

2
3

kgm
14
22IbJI

J
9
2
2

kgm
14
16IbJI
Gearbox
to

engine

Dust
cover

Front
cover

Rear
extension

Bottom
cover

Reverse
idler
shaft

Detent
ball

plug

Mainshaft
nut

Mainshaft

bearing
retainer

Speedometer
pinion
sleeve

lock

plate

Reverse

lamp
switch

Control
lever
nut
Cylinder
head
bolts

1st

stage

2nd
stage

3rd

slage
4
0

kgm
28
9Ib
ft

6
0

kgm
43
4lb
ft

6
5
8
5

kgm
47
0
61
5

Ib
ft

Connecting
rod

big
end
nuts

Ll4
Ll8

engines

Ll6

engine

Flywheel
bolls

Main

bearing
cap
bolts

Camshaft

sprocket
bolt
4
5
5
5

kgm
33
40
Ib
fl

3
2
3
8

kgm
23
27
lb
ft

14
16

kgm
l01
106Ib
ft

4
5
5
5

kgm
33
40Ib
ft

12
16

kgm
86
8
116IbJt

0
6
0
9

kgm
4
3
6

5IbJt

I
I
1
5

kgm
8
0
10
8

Ib
fl

2
3

kgm
14
5
21
7Ib
ft

5
6

kgm
36
43
Ib
ft

0
6
0
9

kgm
4
3
6
5
Ib

ft

12

16kgm
86
8
115
7

IbJt
LIB

engines
Four

speed
gearbox
Oil

sump
bolts

Oil

pump
bolts

Oil
drain

plug

Rocker

pivot
locknuts

Camshaft

locating
plate
bolts
2
5
4
0

kgm
18
29

IbJt

0
8
1
0

kgm
5
8
7
2Ib
ft

Ll
l

7kgm
8
12IbJt

Ll
I

7kgm
8
12Ib
ft

3
3
44

kgm
24
32IbJI

1
7
2
1

kgm
12
15

IbJt

2
3

kgm
14
22Ib
ft

0
5
0
7

kgm
3
6
5
IlbJI

0
8
I
I

kgm
5
8
8
0Ib
ft

0
8
Ll

kgm
5
8
8
01b
ft

0
8
1
0

kgm
5
8
7
2Ib
ft
Gearbox
to

engine

Dust
cover

Front
cover

Bottom
cover

Rear
extension

Detent
ball

plug

Reverse

lamp
switch

Lower
bracket
bolt

Shift
rod
nut

Cross
shaft
bracket
bolt

Gear

change
lever

mounting
bolt
Crankshaft

pulley
nut

Outch

mounting
bolts

L14
Ll6

Ll8
2
4
2

6kgm
174
18
8

Ib
ft

1
6
2
2

kgm
12
16Ib
fl

PROPELLER
SHAFf
AND
DIFFERENTIAL

GEARBOX

17

20kgm
l22
145IbJI

14
17

kgm
101
123Ib
ft

13
20

kgm
94
145Ib
fI
Drive
pinion
nuts
Saloon

Drive

pinion
nuts

Estate
car

Drive

pinion
nuts
Van
Ll4
and
L16

engines
Three

speed
Gearbox

Rear
extension
to
case

bolts
2
8
4
4

kgm
20
32lb
ft

Gearbox
10

engine
2
5
4
0

kgm
18
29Ib
fI

Bnttom
cover
L1
1
7

kgm
8
0
12
3
lb

ft

Ll
1
7

kgm
8
0
12
3
lb

fl

3
5
5
0

kgm
25
3
36
2

Ib
ft

1
8
2
1

kgm
13
0
15
2

Ib
ft

2
4

kgm
14
5
29
Ib
ft

0
7
L1

kgm
5
1
8
0
lb

ft

0
7
Ll

kgm
5
1
8
0
lb

fl

9
11

kgm
65
1
79

51b
ft
Crown
wheel
bolts

1400
and
1600

cc
Saloon

1400
and
1600
cc
Eslale

1800ce
Saloon

I800cc
Estate

1800cc
Van
7
8

kgm
51
58Ib
ft

4
8
5
5

kgm
35
40
Ib
ft

7
8

kgm
51
58Ib
ft

7
8

kgm
51
58Ib
ft

4
8
5
5

kgm
35
40
Ib
ft

0
9
1
2

kgm
6
5
8
7Ib
ft

1
9
2
6

kgm
13
7
18
8

IbJI

1
9
2
6

kgm
13
7
18
8

Ib
f
Front
cover

Drain

plug

Selector
lever
bolts

Side
retainer
bolts
Saloon

Drive

flange
bolts
Saloon

Reverse

lamp
switch

Idler
shaft

screw

Rear
cover
bolts

Cross
shaft
lock

pin

Final
drive
to

mounting
member

1400
and
1600cc
models
6
8

kgm
43
4
57
8IbJI

1800cc
models
5
7

kgm
36
2
50
6Ib
fI

Final
drive
to

suspension
member
6
7

kgm
43
4
51
0
Ib
ft

Final
drive
to
drive
shafls
5
6

kgm
36
431b
ft

Final
drive

flange
to

propeller
shaft
1
6
2
4

kgm
12
17
Ib
ft

Final
drive

flange
to

propeller

shaft
Eslale
1
6
2
4

kgm
l2
17Ib
ft

Mainshafl
locknut

Ll4
and
L16

engines
Four

speed
gearbox

Rearexlension
to
case

bolts
1
6
2
5

kgm
12
18Ib
ft

Gearbox
to

engine
2
5
4
0

kgm
18
29Ib
ft

Bottnm
cnver

L1
1
8

kgm
8
13
Ib
ft

Fronl
cover
L1
1
8

kgm
8
13
IbJI

Drain

plug
3
5
5
0

kgm
25
3
36
2

Ib
f

2
4

kgm
14
5
28
9IbJt

9
11

kgm
65
1
79
5Ib
ft
Final
drive

flange
to

propeller

shaft

l800cc
610

only
Reverse

lamp
switch

Mainshaft
nut
2
0
2
7

kgm
14
5
19
5
lb

ft

4
6

kgm
29
43
Ib
ft

Oil
drain
and
flller

plug
Saloon

129