air suspension DATSUN 610 1969 Workshop Manual

inteN
j

@IP
B

Index

ENGINE

COOLING
SYSTE
l

IGNITION
SYSTE
I

FUEL
SYSTBl

CLUTCH

GEARUOX

PROPELLER
SHAFT
Id
DIFFERENTIAL

REAR
AXLE
nd
REAR
SUSPENSION

FRONT
SUSPENSION

STEERING

BRAKING
SYSTEM

ELECTRICAL

EQUIP
JENT

WIRING
JAGRA
IS

TROUBLE
SHOOTING

TIGHTENING

TORQUES

SERIES
C
30
MODEL
SUPPLEMENT

AUTOSERVlCE
DATA
CHART

PART
NA
ES
nd
ALTERNATIVES

CONVERSION

TABLES
S

15

2S

33

43

51

62

7S

83

91

9S

lOB

liB

I2S

129

51

End
of
manuir

IntroductIon

OUf
intention
in

writing
this
Manual
is
to

provide
the

reader
with

all
the
data
and
in

formation

required
to
maintain
and

repair
the
vehicle
However
it
must
be
realised
that

special
equipment
and
skills
arc

required
in
some
caseS
to

carry
out
the

work
detailed

in
the
text
and
we

do
not

recommend
that
such
work
be

attempted
unless
the
reader

possesses
the

necessary
skill

and

equipment
It
would
be
better
to

have
an

AUTHQRISED

DEALER
to

carry
out
the

work

using
the

special
tools
and

equipment
available
to

his
trained
staff
He
will
also
be
in

possession
of
the

genuine
spare
parts
which
may
be

needed
for

replacement

The
information
in
the
Manual
has
been
checked

against
that
provided
by
the
vehicle

manufacturer
and
any

peculiarities
have
been
mentioned
if

they
depart
rom
usual

work

shop
practice

A
fault

finding
and
trouble

shooting
chart
has
been
inserted
at

the
end
of
the
Manual
to

enable
the
reader
to

pin
point
faults
and
so
save

time
As
it
is

impossible
to
include

every

malfunction

only
the
more
usual
ones
have
been
included

A

composite
conversion
table
has
also
been
included
at

the
end
of
the
manual
and
we

would
recommend
that
wherever

possible
for

greater
accuracy
the
metric
system
units

are
used

Brevity
and

simplicity
have
been
our
aim
in

compiling
this
Manual

relying
on

the
number

ous
illustrations
and
clear
text

to
inform
and
instruct
the
reader
At
the

request
of
the

many
users
of
our
Manuals
we
have
slanted
the
book
towards

repair
and
overhaul
rather

than
maintenance

Although
every
care
has
been

taken
to
ensure

that
the
information
and
data
are

correct

WE
CANNOT
ACCEPT

ANY
LIABILITY
FOR
INACCURACIES
OR
OMISSIONS

OR
FOR
DAMAGE
OR
MALFUNCTIONS
ARISING
FROM
THE
USE
OF
THIS
BOOK

NO
MATTER
HOW
CAUSED

I

3

BRAKE
WARNING
UGHT
SWITCH

A

hydraulically
operated
warning
light
switch
is
located

in
the

engine

compartment
Fig
LA

The
front
and
rear
brake

systems
of
the
dual
circuit
are

connected
to

the
switch
which

provides
a

warning
via
the

warning
light
on
the
instrument

panel
when
a

pressure
difference

of
13
17

kg

sq
cm
185
242Ib

sq
in
occurs
between
the

front
and
rear
brake

systems
The

switch
cannot
be

repaired

and
must

be
renewed
if

faulty

FRONT
DRUM
BRAKE
Removal

1
Jack

up
the
front
of

the
vehicle

and

support
it
on
stands

2
Remove
the
brake
drum
and
the
hub

cap
and
hub

assembly

3
Disconnect
the
brake

pipe
at
the
bracket
on
the
front

suspension
strut
as

previously
described
in
the
section

FRONT
SUSPENSION

4
Unhook
the
two
return

springs
shown
in

Fig
L
5
and

remove

the
brake
shoes

5
Disconnect
the

bridge
pipe
3
in

Fig
L
6
and
remove

the

two
wheel

cylinders

6
Take
out

the
installation
bolts
and
withdraw
the
brake

backplate
from
the

spindle

FRONT
DRUM

BRAKE

Inspection
and
Overhaul

Examine
the
brake
drums
for

scoring
and
out
of
round

The
maximum

permissible
inner
diameter
of
the

drums
must

not
exceed
228
6mm
9
00
in
and
out

of
round
should
be

below
0
02mm
0
0008in

The
brake
shoe

linings
must
re
renewed
when
worn
down

to
a
thickness
of
1
5mm
0
06

in
or
below
Renew
the

linings
if

they
are
contaminated
in

any
way
or

incorrectly

seated
The

complete
set

of

linings
must

be

replaced
if
any

single
lining
is

unsatisfactory

O1eck

the
shoe
return

springs
and
if

they
have
become

weakened

replace
them

Withdraw
the

pistons
and

springs
from
the
wheel

cylinders

and

inspect
the
bore
of
the

cylinders
for

signs
of

wear

corrosion
or

damage

Renew
the

cylinder
and
the

piston
if
the
clearance
between

the
two

exceeds
O
15mm

0
006

in
Renew
the
rubber
boots

and

cups

FRONT
DRUM
BRAKE

Assembly
and
Installation

Assembly
and
installation
is
a
reversal
of
the
removal
and

dismantling
procedure
noting
the

fOllowing
points

Apply
a
thin

layer
of

special
grease
to

the
piston

cup
and

other
rubber

parts
when

assembling
the
wheel

cylinder
The

internal

components
of
the

cylinder
should
be

dipped
in
brake

fluid
and
assembled
whilst
still
wet
Install
the
wheel

cylinders
on
the
brake

backplate
and

smear
the

cylinder
backplate
and

cylinder
lever
fulcrum
with

grease
Fig
L
8

Tighten
the

backplate
mounting
bolts
to
a

torque
reading

of
2
7
3
7

kgm
19
5
26
71b
ft

Adjust
the
brake
shoes
and
bleed
the

hydraulic
system
as

described
under
the

appropriate
headings

REAR
DRUM
BRAKE
REMOVAL

Fig
L
IO

Jack

up
the
vehicle
at
the
rear
and

support
it
on

stands

Remove
the
road
wheel

2
Release
the
handbrake
remove
the
clevis

pin
3
from
the

rear
wheel

cylinder
lever
4
see

Fig
L
9
Disconnect
the

handbrake
cable
2
and
remove

the
return

spring
I

3
Remove
the
brake
drum
Remove
the
shoe
retainers
the

return

springs
and
brake
shoes

Fig
L
II

4
Disconnect
the
fluid
line
from
the
wheel

cylinders
and

plug

the
opened
end
to

prevent
to
loss
of
fluid

5
Remove
the
dust
cover

adjusting
shims
and

plates
then

remove
the
wheel

cylinder
from
the

backplate

6
The
brake

backplate
and
axle
shaft

assembly
can
be
with

drawn
if

necessary
by
taking
out
the
four

flange
bolts

and

removing
the

assembly
as
described
in
the
section

REAR
AXLE
AND
REAR
SUSPENSION

REAR
DRUM
BRAKE

Inspection
and
Overhaul

The

inspection
and
overhaul

procedures
fpr
the
rear

drum

brakes
are
similar
to

those

previously
described
for
the
front

drum
brakes

Tighten
the
brake

backplate
mounting
bolts
to
a

torque

reading
of

3
9
5
3

kgm
28
38Ib
ft

FRONT
DRUM
BRAKE

Adjusting

Jack

up
the
vehicle
and

pump
the
brake

pedal
several
times

With
the
brake
drum
installed
turn
one
of

the
adjusting
cams

clockwise
until

the
brake
shoe
is
in
contact
with
the
drum

This

operation
is
carried
out
from
the
rear
of

the
backplate

When
the
brake
shoe
contacts
the
drum
turn
the
cam
in

the

opposite
direction
until
the
shoe
is

just
clear
and
the
brake

drum
can
be
rotated

freely
by
hand

Repeat
the

operation
on
the
other

adjusting
cam
and
then

depress
the
brake

pedal
to
make
sure
that
the
brakes
are

working

correctly
The

adjusters
must
be
released

slightly
if
the
brake

drum
binds
when
turned

by
hand

Fig
L
12
shows
the

adjusting

cams

REAR
DRUM
BRAKE

Adjusting

Jack

up
the
vehicle
at

the
rear
and

pump
the
brake

pedal

several
times
Turn
the
brake
shoe

adjuster
Fig
L
13
until
the

101

HAND
BRAKE
Removal

The
mechanical
handbrake

linkages
are
shown
in

Figs
L
21

1
22
and

1
23

1400
and
1600cc
models

Front
cable

Release
the
hand
brake
and
disconnect
the
front
cable

by

removing
the
clevis

pin
from
the
lever
Unscrew
the

adjusting

nut
from
the
rear
of
the
front
cable

Fig
L
24
Remove
the

cable
from

the
hand
brake
lever

Remove
the

clamp
holding
the
cable
to
the
under
body

Pull
out
the
lock

plate
holding
the
front
cable
to
the
retainer

and
completely
withdraw
the
cable
Withdraw
the
cable

by

unfastening
the
outer

casing
which
is

pressed
into
the
handbrake

control
bracket

Handbrake
lever

Fig
1

25

Remove
the
clevis

pin
connecting
the
lever

yoke
and
lever

Remove
the
clevis
pin
connecting
the
control

guide
and
the

control
bracket
Lift
out
the
handbrake

assembly

Rear
cable
Saloons

Remove
the

adjusting
nut

from
the

adjuster
Fig
L
26

and
disconnect
the
left
hand
rear
cable
from
the
handbrake

adjuster
Pull
out
the
lock

plates
and
remove
the
clevis

pin

connecting
the
cables
to
the
levers
of
the
rear
wheel

cylinders

Rear
cable
Estate
car
and

rigid
axle
saloon

Remove
the
clevis

pin
from
both
ends
of

the
rear
cable

Remove
the
connecting
rods

by
extracting
the

puU
off
springs

and
clevis

pins

1800cc
models

Handbrake
lever

Disconnect
the
terminal
from
the
hand
brake

warning

switch
Remove
the
nuts

securing
the
control
bracket
to

the

dashboard
Pull
out

the
lock
pin
and
cotter

pin
and
withdraw

the
handbrake
lever

assembly

Front
cable

Remove
the
return

spring
and
loosen
the

adjuster
10cknuL

Detach
the
front
cable
from
the
handbrake
lever
Remove
the

nuts

securing
the
cable
to
the
dashboard

Fig
L
27
and
with

draw
the
cable
towards
the

engine

Rear
cable
Saloon

Disconnect
the

cable
at
the

adjuster
and
detach
the
return

spring
from
the
centre
lever

See
Fig
L
28
Remove
the
cable

lock

plates
from
the
rear

suspension
Remove
the
clevis

pin

attaching
the
cable
at
the
rear

wheel

cylinder

Rear
cable
Estate
car

and
Van

Unfasten
the

pull
spring
and
remove
the
clevis

pins
at
the

balance
lever
and
wheel

sides

Fig
L
29
Detach

the

connecting

rod
Remove
the
nut

securing
the

connecting
rod
balance
lever

and
the
lever
from
the
rear
axle

housing
HANDBRAKE
Installation

Check
the
cables
for

signs
of
deterioration

fraying
etc

Examine
the
handbrake
lever
and
ratchet
for
wear
and
renew

as

necessry

Check
the

springs
for
evidence
of
weakness
and
make
sure

that
the
balance
lever
and
bushes
are

satisfactory

Installation
is
a
reversal
of
the
removal
procedure
Make

sure

that
all
sliding

parts
are

greased

Adjust
the
hand
brake
in
the

following
manner

Release
the
hand
brake
and

adjust
the
rear
brake
shoes
as

previously
described

The
1400
and
1600cc
Saloon
handbrake
is

adjusted
to

give
a
lever
stroke
of
85
95mm
3
34
3
74
in

by
setting

the

adjusting
nuts

Fig
L
24
The
lever
stroke
on
the
estate

car
should
be

adjusted
to
50
75mm
2
0
3
0
in

by
turning

the

adjuster
shown
in
Fig
L
30

Adjust
the
1800cc
models
to

give
a
handbrake
lever
stroke

of

90
100
mm
3
5
3
9in

by
turning
the

adjuster
2
in

Fig
L

28

Retighten
the
locknut
after

adjusting

BLEEDING
THE
HYDRAULIC
SYSTEM

The
hydraulic
system
must
be
bled
if
the
circuit
has
been

opened
at

any
point
or
if

the
level
of
the
fluid
in
the
master

cylinder
reservoir
has
fallen
too

low
allowing
air
to
enter

the

system

Bleeding
is

usually
a
two
man

operation
as
assistance
will

be

required
to
work
the
brake

pedal
The
master

cylinder

reservoir
must
be

topped

up
constantly
throughout
the

operation

whilst
a
check
is
carried
out
on

the
fluid

expelled

Bleeding
should
be
carried
out
at
the
master

cylinder
nrst

then
from
the
brake
furthest

away
from
the
master

cylinder

and

working
round

finally
to

the
brake
nearest
to
the
master

cylinder
Bleeding
should
therefore
be
carried
out

in
the
follow

ing
order
Rear
left
wheel
rear

right
wheel
front
left
wheel

front

right
wheel

Oean
the
area
round
the
master

cylinder
cover
take
off

the
cover

and

top
up
the
reservoir
if

necessary
Clean
the
rele

vant

air
bleed
screw
and
take
off
the

cap

Attach
a
suitable
hose
to
the
bleed
screw
and

place
the

free
end
of

the
hose
in
a

glass
jar
containing
brake
fluid

Open
the
bleed
screw
and

depress
the
brake

pedal
to
allow

the
fluid
to
enter
the

glass
container

Tighten
the
bleed
screw

when
the

pedal
is
fully
depressed
and
allow
the

pedal
to
return

Repeat
the

procedure
until
the
fluid
is

completely
free

from
air
bubbles
then

carry
out
the
same
operation
on
the

other
three
wheels

Top
up
the
fluid
in
the
reservoir
to
the
correct
level
but

do
not
re
use
the
fluid

previously
withdrawn
from
the

system

105

GIS

DESCRIYfION

ENGINE
Removal
and
Installation

ENGINE
MOUNTING

INSULATORS

ENGINE

Dismantling
Inspection
and
Overhaul

CHAMSHAFT

AND
CAMSHAFT
BEARINGS

CYLINDER
BLOCK

PISTONS

CONNECTING

RODS

CRANKSHAFT

ENGINE

Assembling

VALVE
CLEARANCE

Adjusting

DESCRIYfION

The
G
18

engine
is
a
short

stroke
unit
with
a

displacement

of
1
815
ce
The
aluminium

alloy
cylinder
head
has
cross
flow

ports
and
a
V

shaped
valve

layout
The

single
overhead
camshaft

is
driven
from
the
crankshaft

by
a
double
row
roller
chain
at
a

reduction

ratio
of
2
I

The
crankshaft
is
a

carbon
steel

forging
and
is

provided

with
five
main

bearings
and
four

balancing
weights
Aluminium

thrust

bearings
are
located
at

the
No
2

journal

The
cast
aluminium

alloy
pistons
have
two

comp
ression

rings
and
one
oil

ring
Gudgeon

pins
are

fully
floating
in
the

piston
bores
and
are

equipped
with

circlips
at

each
end
to
limit

the
amount

of
their
travel
The

forged
steel

connecting
rods

have
weight
adjusting
bosses
at
both

large
and
small
ends
to

insure
that
the
rods
are

correctly
balanced

during
operation

The

lubricating
system
is
of

the

pressure
feed

type
with

the
oil

pump
driven

by
a

gear
on
the
crankshaft
Oil
is
delivered

to
the
main

gallery
via
a
full
flow
ftlter

ENGINE
Removal
and
Installation

Although
the

engine
can
be
removed
as
a

single
unit
it

will

prove
an
easier

operation
to
remove

the

engine
with
the

transmission
Proceed
as
follows

Fit
the
engine
slingers
ST49760000
to
the

engine

Disconnect
the
battery
cables
and
lift
out

the

battery

Drain
the
coolant
and

engine
oil

2
Place

alignment
marks
on
the
bonnet
and

hinges
remove

the
bonnet
from
the
vehicle

3
Remove
the
blow

by
hose
from
the
rocker
cover
and
take

off
the
air
cleaner

4
Disconnect
the
accelerator

linkage
and
choke
cable
from

the
carburettor

S
Detach
the

upper
and
lower

radiator
hoses
remove
the

two
brackets
from
the
core

support
and
lift
the
radia
tor

away
from
the
vehicle
The

torque
convertor

oil

pipes
must

be
disconnected
from
the
oil
cooler
if
the
vehicle
is

equip

ped
with
automatic
transmission
Detach
the
fuel

pipe
if

fitted
from
the
engine
and

heater
hose

6
Disconnect
the
electrical

wires
from
the
alternator
thennal
EngIne

OIL
PUMP

OIL
PRESSURE
RELIEF
VALVE

OIL
FILTER

EMISSION
CONTROL
SYSTEM

IGNITION

TIMING
AND
IDLING
SPEED

Emission

control

system

EMISSION
CONTROL
SYSTEM
Maintenance

IGNITION
SYSTEM

IGNITION
TIMING

IGNITION
DISTRIBUTOR
Maintenance

SPARKING
PLUGS

transmitter
the

primary
side
of
the
distributor
oil

pressure

switch
starter

motor
and
reverse

light
switch

7

Remove
the
clutch
slave

cylinder
and
its
return

spring
from

the
transmission
as
described
in
the
section
CLUTCH

8
Disconnect
the
shift
rods
and
selector
rods
then
remove

the
cross
shaft

assembly
by
detaching
the
bracket
from

the
side
member
See
GEARBOX
section

9
Disconnect
the

speedometer
cable
and
detach
the
front

exhaust

pipe
from
the
exhaust
manifold

10
Disconnect
the

propeller
shaft
and

plug
the

gearbox
rear

extension
to

prevent
the
loss
of
oil

11
Jack

up
the

gearbox
slightly
and
remove
the
rear

engine

mounting
support
Take
out

the
bolts
which
secure
the

front

mounting
insulators
to
the
cross
member

12
Attach
chains
or
wire

rope
to
the

engine
Gradually
lower

the

jack
under
the

gearbox
and
carefully
lift
and
tilt
the

engine
and
gear
box
to
clear
the

compartment
Withdraw

the
unit

making
sure

that
it
does
not
foul
the
accessories

Installation
is
a
reversal
of
the
removal

procedure
RefIll

with
the
correct

quantities
of
oil
and
coolant
when
the

engine
is
installed

ENGINE
MOUNTING
INSULATORS

Replacing

The

front
and
rear

mounting
insulators
should
be
checked

with
the

engine
installed
to
make
sure
that
the
dimensions

conform
with
those

given
in

Figs
A
I
and
A
2

To
remove
the
front
insulator

proceed
as
follows

Position
a

jack
under
the
oil

sump
Make
sure
that
the

jack
is
clear
of
the
drain

plug
and
insert
a
wooden
block
between

the
jack
and

sump
to

prevent
the

sump
from

being
damaged

Remove
the
bolts

securing
the
insulator
to
the
front

suspension

member
and
the
nut

attaching
the
insulator
to
the

engine

mounting
bracket
Raise
the

jack
slightly
and
remove
the

insulator
To
remove
the
rear

mounting
insulator

proceed
as

follows

Position
a

jack
to
take
the

weight
of
the

gearbox
and
take

out

the
bolts

connecting
the
insulator
to

the
transmission
rear

extension

housing
Remove
the
bolts

attaching
the
cross
member

to

the
underside
of
the

body
and
withdraw
the
insulator

Installation

of
both
insulators

is
a
reversal
of
the

removal

procedures

S3

Accelerator

pump

Piston
diameter

Pump
discharge

Outer
hole

position

Middle
hole

position

Inner
hole

position

Pump
nozzle
diameter

Main
nozzle

diameter

Primary

Secondary
14
0
mm
0
551
in

0
2
cc

per
stroke

0

4
cc

per
stroke

0
6
cc

per
stroke

0

5
mm
0
020

in

2
3
mm
0
0906
in

2
8
mm
0
110
in

Throttle

valve

fully
closed

angle

Primary
10

degrees

Secondary
20

degrees

Idling
opening
5

degrees
approx

Choke
valve

fully
closed

angle
10

degrees

Throttle

opening
at
full
choke
13
5

degrees

FUEL
PUMP

Type

Delivery
Electric

1400
cc
in
one
minute
Emission

control

system

Air

pump
bracket
to

cylinder

head
nut

Adjusting
bar
to
bracket
bolt

Air

pump
to

bracket
bolt

Air

pump
to

adjusting
bar

nut

Anti
backfrre
bracket
to

rocker

cover
0
4Q
0
65

kgm
2
94
7
lb
ft

Anti
backfire
valve
to

bracket
0
4Q
O
65

kgm
2
94

7
lb
ft

Sensing
hose

clamp
to
rocker

cover
0
4Q
0
65

kgm
2
M
7
Ib
ft

Air

gallery
to
exhaust
manifold

plug
5
Q
6

0

kgm
36
243
4lb
ft

Check

valve
to
air

gallery
9

0
10
5

kgm
65

1
75
9Ib
ft
1
6
2
4

kgm
I
1
6
17
4Ib
ft

1
6
2
4

kgm
I
1
6
17
4Ib
ft

1
6
2
4

kgm
I
1
6
17
4
lb
ft

1
6

2
4

kgm
11
6
17
4Ib
ft

Front

SuspensIon
SteerIng

Description

Steering
Maintenance

Wheel
hub
and

bearing

Stabilizer

Spring
and
strut

assembly

Transverse
link
and
lower
ball

joint

Suspension
member

Front
wheel

alignment

Steering
wheel
and
column

Rack
and

pinion
and
tie
rod

Collapsible
steering

DESCRIPTION

The
front

suspension
is
of
the
strut

type
with

the
coil

spring
and

hydraulic

damper
units
mounted
on
the
crossmember

and
transverse
link

assembly
See

Fig
C
I
Vertical
movement

of
the

suspension
is
controlled

by
the
strut

assembly
Forward

and
rearward
movement
is
absorbed

by
compression
rods
6

and
side
movement
controlled

by
the
transverse
links
Front

suspension
servicing
procedures
are
similar
to
those

given
for

vehicle
fitted
with
L14
Ll6
and
LIB

engines
and
can

be
carried

out

by
reference
to

the
instructions

given
in
the

appropriate

section
Camber
and
castor

angles
are

preset
and
cannot

be

adjusted
and
a

check
must

be
made
for

signs
of

damage
to

the

suspension
system
if
the

angles
do
not
confonn
to
the

figures

given
in
Technical
Data

The

steering
is
of
the
direct

acting
rack
and

pinion

type

See

Fig
C
2
A
rubber

coupling
which
absorbs
vibration
and

two
universal

join
ts
are

incorpora
ted
between
the

steering
wheel

and

gear
assembly
The

collapsible
type
of

steering
column

assembly

Fig
C3
is
an

optional
fitting
A
full

description
of
this

type
of

assembly
i

given
in
the

Steering
section
for
L14

L16
and
L18

engines

STEERING
Maintenance

The

steering
system
should
be
lubricated

every
two

years

or
50
000
km
30
000
miles
whichever
comes

fIrst

A
lithium
base

multipurpose
grease
must
be
used
for
the

rack
and

pinion
and
rack
and
tie
rod

joints
The

plug
on
the

steering
gear
housing
should
be
removed
and
a

grease
nipple

fitted
so
that
the
recommended

quantity
of
10
to

15

gram

0
35
to

0
53
oz
of

grease
can
be

injected
Remove
the

grease

nipple
and

replace
the
plug
when
lubrication
is

completed

The

grease
reservoir
on
the
tube
side
should
be

replenished
when

the
level
of

grease
falls
to

approximately
one
third
ofits

capacity

WHEEL
HUB
AND
BEARING
Removal
and
Installation

Wheel
hub
and

bearing
servicing
procedures
are
similar
to

those

previously
given
for
vehicles
fitted
with
L14
LI6
and
LIB

engines

S23

MO

MI
1224
D
I

KM

f
fMn
n

r
A
A
JP
I
I
T
I
I

I

Drain
ill

Changeelemenl
I
42

Cleantlement
3
I

II
r

I

Check
il
topup
4
I

Chinnloil

511
1

11
41

Gle

nelern
n
Ii

I
Orainlluid
7
I
I
I
I

Clunertmtn
81
1

I
I
I
I

I
27

Check

ailltop
up

Jf71

r

I
JIO
WI

28

Change
il

I
ill

limittdSlip
DiHlranti
1
Clleck

ilftopup
1J
I
I

I
Changelil
11
i

ill

ShdmgJolntt
Df
YlShlft
Check

11IIOpup
n
II
I

I

ChangeDl1
1
I
I

I
I

SHOCKASSORBERS
Check
Il

topup
5

PROP
DRIVESHAFTISI
lubncate
Hi

1

GREASE
GUN
POINTS

lubnCIl

it
PEOAlSHAFT

Sj
Lubrlc

te
18

HANDBHAKE
lubnc
1t

I
I

r
1
t

R
IINKAl
iF
luhncll
2u
I
I
i

I

ARlUWIORED
WHEELS
FREE

1m
I
I

i

1121

wHEE
L
tll

AHINli
ronl

HepitCk

211

t
f
WHEEl

BEARINGS
Rur
Repack
77

U
I

BRAKE
FLUID
R
nfWfbletd
1
I
lf
13

117
I

t
I
AH
UUWI
f
t1UN

11Itl
ih1tl

1
i

lcl
Check
oillevtl
B
l

r1i
BI1I1I1
r

Cap
Cleen

1ifj
j

I
Air
Cluner

Service
el
m

nt
l

J7
4

Replace
element
l
l
B

L
5

Cteenfilter

1
C

l
I
I

I

4

Clun
va

vellllR
I

I1

I
I

I
Repl
cH
lve
1

I
I
I

I

Cleen

jets
bOM
R

t
I

Top
liP

pisl
dempe

l

I
r

L

LlIbncatelinkages
I

I
L

Ctean

replace
5
j

I

Ch

ckoill
ve1
Ei
l
j

16

Clun
replac
n

11

R
fill
witll

fluid
38
I

Check
fluid
levll

IlL

t

I

CI
ign
toil

t

i
I
t

1
l
9

CheCk
top
u

p
10

Flulhryst
m

y

Cllecksolullon
44

Chltk
45

Lubrlc
tt

46
i

Clleck

top
up
L

L
Check
topup
4
aJdM

Cllltkspet

gl1vity
i

CI
en

gr
1S

liD

116
Lubriclt

1il

If
I

II
Clleck

topup
52

1
i

Chtck

topuplluid
3

I
I

Gre
rlm

4
I
1
I
I
I

Clunfiltlr
55

L
I

I

I
Chick
top

up
fluid

I6
w
W

e
I

ofi

Ldtir
1
Renewfiltlr
58

I

Check
topupflu
d

i91
i
I

i

Renrwfluid
I
I

I
I

I

ilinlil1r

11
I
I
I
I
I
I

CAR

DOWN
E

TERNAL
j

II
1
I
1

lOCKS
HINGES
Ell
Lubrictt

S21
r
1

el
L
Door
Dram

Hol
l

Clun
f
J

I
I
WIPER
SPINDLES
lubrictt
64
W
I
I

En

in
Dil
Filwr

GttrbOK
1968

Lubricate
and
Clean

ENGINE

Filt
r

GEARBOX

Dvttdrivt
Filt
r

AUTOMATIC
TRANSM

Filt
r

DIFFERENTIAL

PCV

Syllem

rburettor

s

FUll
Bowl

Filter
S1

Fu

llnjectionPump

Fittll
ll

AUTOMATIC
TRANSM

DISTRIBUTOR

Spindl
Ctm

COOLING
SYSTEM

CorrDlionlnllibitor

Anti
Frltl

W
t

rPump

CREENWASHER

ArrERY

Connections

3ENERATOR

STEERING

POMrStlering

CLUTCH
BRAKE

BRAKE
SERVO

HYDR

SUSPENSION

CAPACITIES

LUBRICANTS
Il
D
P
LUSClu
Service
Check

Adjust

CAR
UP

I

l
lletksumpbulttortM
1

Clled

rque
i6

ServiceJndclean
J1

Adjult
brake
bandl

tB

RtnMsumpgal
tt

fiS

Check
llJmpbnlttort

PROP
lOAIVE
SHAFT
S
Check
lor
wear

JJ

Tiglltenbolu
Jl

Check
tor
wear

n

Tiglltenboltl

Clllckbootgeiltrl

Clleckoperltion

Ch
CQmpon
l
welr

Tighten
bolts

Clleclbootgaiterl

Checktorqu

Gheck
edjult

Clllck
ljust

CIIRCk

adjult

Clleck

tighltnbolts

W

M

KSI

1
t

heCklMliiili
86

Check

ldjust
81

Overllllulcompl
rvll

Cleen

chltkwtlr
R9

Check
for
wear
0

Check

9

Checkforwp

lr
192

Il1Ipecttyrel
1IJ

Illte
II
blIl1nCl

Adjultpres
lure

Cllecktorul

liON

ET
OPE

l

heckcompression

Checktorqul

AdjUltclttr
nc

CheckoptTltion

Check
lIljLllt

AdjUlI

Clleck
alIj
tension

adj
t
nsion

I

Clun

selpp
jt1

Renew

Chetk

tPoint
tp

Renew

pointl

Check

6djult
110

J

Check

edjult
ill
i
ii

j
Tiglltenhoseclips
112

R

plece
lIastl

ill

PreSSIJ
test
114

1

STEERING
Clleek

play
adjust
ill
j
i

itl

e
Ti9htenboltl
ill

ii
Geometry
Check
U1L

H
CHECK
FOR
Oil
FUEL

WATER
etc
LEAKS
1181

I
I
R
DOWN
FXIE
HNA

11

1
1
lIGHTS

If
isfHUMt
NTS

Check
flll
C
lOn
f

3

Headlights
Checkllhgnmlnt
112Cr

WIPERS

Checkbladu

11111
J

TS

r
h
kIl

CII

I
Jrl7

iI

An
UH
OVNAUOMFTER
I
ST
I

BRAKES
CheCkemCienCY

1
I

AUTOMATIC
TRANSM

Clleek

op
rttioQ

T

ENGINE
Adjust
if

required
12

DEFECTS
Report
12
EVERY
MOnthl

Miles

1000

KMs
1000
lIBt
wtJichewl

ENGINE

EngmlMountings

Engine
Film
Trap

AUTOMATIC
TRANSM

24

2

30
SUSP
FRONT
REAR

Shock

Ablorb
rs

STEERING

1
21

5
1

c
e
U
80lTS

HANDBRAKE

CLUTCH

GEAR

LINKAGE

EXHAUST
SYSTEM

f

HFf
K
FOR
Oil

FllE
1

CAH

LUWI
RI
If

WHEEL
BEARINGS

BRAKES

UningsJDruml

Plds

Discl

Selhdj
Meclleni5l11

Cylinders
Hosel

ROAD
WHEELS

3S
Whe
1

Nun

AHllIIWN

ENGINE

Cyllnd
r
Held

Vllyes

Clloke

MiKtulli

ldling

linkagel

Timing
Ch
in

16
V

Belt

Is

SPARK
PLUGS

OISTRIBUTOR

Owell

Angle

Ignition
Timing

COOLING

SYSTEM

8

X

Automatic
Diffrrrntill

ICoolinginc
Ht
lltel

AntilrH1f

Ltr
lmoP
Ugo
IL
dmo

PII
U

Ou
HydrJBrak

Fluid

4

7
1
21
81
7
ULlma

II

USP
ULlmD
USP
L

L
tmoP

USQu

127

2
4
4

SAE
3O
2OW
411

SAE
lfrN
2fJ

IOWI3O

SAE1OW

IOW
30
320C

JOe

o
e
SAE80
EP

SAE90EP

SAE
140
EP

mmDIIIII

Ifn
c
ID

WIthDv
1

LI
obWt7
3
LtrJ
PtLUSPtL

3
2
0
75
T
3
1
8
B
8

WAGON

1
1
72
1

TYPE
A

SUFFIX
A
SAE80
EP

SAE90EP

SAE
140EP
0

aSoC
BFl

AUTOSERVICE
DATA

CHART
DATSUI

D

FurlT
nk

n
tln
G
0

Slltring

Re
I

lm
r
JSGI
11
1
No

4S

8
9
11
9
11
17
18

19
20
41
82
84

52

SSS
95
SAElll

SAE

80
c

14O