ESP DATSUN 510 1968 Service Repair Manual
[x] Cancel search | Manufacturer: DATSUN, Model Year: 1968, Model line: 510, Model: DATSUN 510 1968Pages: 252, PDF Size: 12.2 MB
Page 20 of 252
TROUBLESHOOTING
15
5
Stumbling
when
acceleratmg
from
Idle
Check
accelerator
pump
diaphragm
and
Idle
speed
adjustment
6
Engine
mISses
at
hIgh
speed
or
lacks
power
This
mdlcates
pOSSible
fuel
starvatIon
Check
fuel
pump
pressure
and
capacIty
Clean
main
Jet
and
float
needle
valve
7
Black
exhaust
smoke
Black
exhaust
smoke
means
a
badly
ovemch
nuxture
Check
Idle
mIXture
and
Idle
speed
ad
Justment
Check
for
excessive
fuel
pump
pres
sure
or
blocked
return
hne
from
carburetor
to
fuel
tank
Check
for
leaky
float
or
worn
needle
valve
8
ExceSSIve
fuel
consumptIOn
ThIS
may
be
another
mdIcatIon
of
an
ovemch
fuel
mixture
Check
that
automatIc
choke
oper
ates
If
so
eqUIpped
or
that
the
manual
choke
contraIlS
not
being
left
out
Check
Idle
mIXture
and
Idle
speed
Check
for
excessIve
fuel
pump
pressure
leaky
float
or
worn
needle
valve
Make
certam
that
jets
are
the
proper
SIZe
Fuel
Pump
Pressure
Testing
1
Install
a
T
fittmg
m
the
fuel
hue
close
to
the
carburetor
2
Connect
a
fuel
pressure
gauge
to
the
fittmg
WIth
a
short
tube
3
Check
fuel
pump
pressure
as
described
in
the
Fuel
System
chapter
EXHAUST
EMISSION
CONTROL
The
followmg
symptoms
as
ume
you
have
ad
justed
the
Ignition
and
carburetor
to
specdicatIon
and
that
you
have
checked
the
results
on
an
accurate
exhaust
gas
anajyzer
1
CO
content
too
low
Make
sure
Idle
speed
IS
not
too
low
Check
Idle
mIXture
adjustment
too
lean
Check
carbu
retor
Jets
and
channels
Clean
and
or
replace
as
necessary
Check
engme
condition
With
a
com
pressIOn
and
vacuum
test
2
CO
content
too
hIgh
Check
Idle
mixture
adjustment
too
nch
Check
for
dIrty
air
cleaner
and
defectIve
automatIc
choke
If
so
equipped
Check
carburetor
Jets
and
channels
Clean
and
or
replace
as
necessary
Check
engme
condItIon
WIth
compression
and
vacuum
test
3
Hydrocarbon
level
too
hIgh
Check
that
Idle
speed
and
mIXture
adjustments
are
to
specIfication
Check
spark
plug
condItIon
and
gap
Check
breaker
pomts
Check
IgnItIon
tnumg
too
early
Check
mtake
mamfold
for
leaks
Check
valve
clearance
too
small
Check
condItIon
of
valves
With
compressIOn
test
MANUAL
CLUTCH
1
SlIppage
ThiS
is
most
noticeable
when
acceleratIng
m
a
hIgh
gear
at
relatIvely
slow
speed
To
check
slip
page
park
the
car
on
a
level
surface
WIth
the
handbrake
set
ShIft
to
2nd
gear
and
release
the
clutch
as
If
drlVing
off
If
the
clutch
is
good
the
engme
will
slow
and
stall
If
the
clutch
shps
con
tInued
engme
speed
will
gIve
It
away
CAUTION
ThIS
IS
a
severe
test
Perform
only
when
slippage
IS
suspected
not
penodlcally
Shppage
results
from
IDSufliclent
clutch
pedal
free
play
all
or
grease
on
the
clutch
disc
worn
pressure
plate
or
weak
sprmgs
Also
check
for
bIndIng
m
the
clutch
cable
and
lever
arm
which
may
prevent
full
engagement
2
Drag
or
failure
to
release
ThIS
problem
usually
causes
dIfficult
shIftIng
and
gear
clash
espeCially
when
downshIftmg
The
causes
may
be
excessive
clutch
pedal
free
play
warped
or
bent
pressure
plate
or
clutch
dISC
ex
cessive
clutch
cable
guide
sag
and
broken
or
loose
clutch
lmings
Check
conditIOn
of
mam
shaft
splines
3
Chatter
or
grabbing
A
number
of
thmgs
can
cause
tIns
Check
cable
gUIde
sag
and
tIghtness
of
transnusslOn
to
frame
and
engme
to
transmlSslon
mountIng
bolts
Check
for
worn
or
mISaligned
pressure
plate
and
misalIgned
release
plate
4
Other
nOIses
NOISe
usually
mdlcates
a
dry
or
defective
release
bearIng
Check
the
beanng
and
replace
If
neces
Page 30 of 252
ENGINE
AND
IGNITION
TUNE
UP
4
25
block
the
throttle
and
choke
m
the
WIde
open
position
3
Remove
all
four
spark
plugs
4
Sequentially
press
a
compressIOn
test
gauge
mto
each
of
the
spark
plug
holes
and
crank
the
engme
for
at
least
four
strokes
Record
the
com
pressIOn
readmg
for
each
cylmder
Standard
compressIOn
readmg
IS
171
Ibs
m
12
0
kg
cm
Mmlmum
acceptable
readmg
IS
159
lbs
m
2
11
5
kg
cm
5
No
readmg
should
be
less
than
80
of
the
highest
cylmder
reading
ExceSSive
vanatiC
ns
between
cylmders
accompanied
by
low
speed
mlssmg
of
the
cyhnder
or
cylmders
that
read
low
usually
mdlcates
a
valve
not
properly
seat
mg
or
a
broken
piston
ring
Low
pressures
even
though
uniform
may
mdicate
worn
nngs
ThIS
IS
especlall
true
1f
ex
cessive
011
cQIlsumptlon
has
been
noticed
If
one
or
more
cylmders
read
low
or
uneven
inject
about
a
tablespoon
of
engine
ail
on
top
of
the
piston
of
that
cylinder
and
crank
the
engine
several
tlmes
noting
the
compressIOn
reading
If
compressIOn
has
nsen
the
piston
nngs
or
cylmders
are
worn
and
should
befserviced
If
compressIOn
has
not
unproved
after
addmg
oil
the
valves
are
Stlcking
or
are
not
seating
prop
erly
If
two
adjacent
cylmders
have
low
compres
sion
and
mjectmg
01
9es
not
increas
the
read
mg
the
head
gasket
between
the
cylmders
IS
probably
leaking
VALVE
CLEARANCE
ADJUSTMENT
Valve
adjustment
should
be
done
in
two
steps
first
With
the
engme
cold
and
then
at
operatmg
temperature
Refer
to
Figure
6
and
proceed
as
follows
1
Remove
arr
liter
2
Remove
rocker
arm
cover
Take
care
not
to
damage
the
gasket
3
Remove
the
spark
plugs
and
rotate
the
en
gine
unt1l
number
1
cylinder
IS
at
top
dead
center
o
l
the
compressIOn
stroke
This
can
be
de
tepnmed
w
hen
the
top
dead
center
mark
on
the
crankshaft
pulley
is
m
alignment
With
the
statIOnary
pomter
and
both
valves
for
number
1
cylmder
are
closed
I
4
Counting
from
the
front
of
the
engme
ad
Just
valves
1
2
3
and
5
as
follows
Loosen
the
pivot
lockmg
nut
and
turn
the
pivot
screw
unt1l
clearance
between
the
pivot
screw
and
the
rock
er
ann
IS
0
0079
m
0
200mm
for
the
mtake
valves
and
0
0098
in
0
25mm
for
the
exhaust
valves
Check
clearances
With
a
feeler
gauge
as
shawn
When
correct
tlghten
the
pivot
locking
nut
l
1
5
Rotate
the
crankshaft
unt1l
the
number
4
pISton
IS
at
top
dead
center
an
the
compressIOn
stroke
This
IS
one
complete
revolution
of
the
crankshaft
Agam
the
0
degree
mark
should
align
With
the
pomter
and
both
valves
on
num
ber
4
cylinder
should
be
closed
6
Adjust
valves
4
6
7
and
8
as
above
i
I
7
Replace
spark
plugs
Ignition
WIres
r
ick
r
1
arm
cover
gasket
and
air
filter
8
Start
engine
and
run
it
unt1l
operating
tem
perature
IS
reached
9
Remove
rocker
ann
cover
and
repeava
iius
ment
Clearances
should
be
0
0098
m
0
25fumj
for
the
mtake
valves
and
00Il8
m
0
30mi
for
the
exhaust
valves
Check
clearances
before
loosening
the
pivot
lockmg
nuts
as
they
may
already
be
properly
set
If
not
adjust
as
re
quir
l
ADDmONAL
CHECKS
l
Qunng
tune
ups
check
the
followmg
Ite
far
SignS
of
defects
or
excessive
wear
I
i
1
Inspect
the
carburetor
for
buildup
of
foreign
matenal
Pay
Special
attention
to
the
throat
and
linkages
Clean
or
overhaul
as
required
Det8
1ls
for
carburetor
mamtenance
are
given
in
Chapter
seven
Page 45 of 252
40
CHAPTER
SIX
be
removed
Hoist
the
engme
off
Its
mounts
and
adjust
the
cham
or
cable
to
tIlt
the
engme
as
shown
in
the
illustration
ContInue
to
raIse
gradually
31
Once
the
engine
and
transmission
are
clear
of
the
vehIcle
lower
them
to
a
swtable
support
or
stand
and
dIsconnect
the
hOISt
32
The
transmISSIon
can
now
be
freed
by
re
movmg
the
bolts
holdIng
the
clutch
assembly
to
the
flywheel
housing
and
movmg
the
clutch
assembly
back
to
dIsengage
the
dnve
shaft
splmes
33
Witlltlie
engIne
removed
carefiillyinspect
the
mountIng
Insulators
for
SIgnS
of
damage
or
detenoratIon
Replace
them
1f
necessary
ENGINE
DISASSEMBLY
ThIS
sectIon
covers
dIsassembly
of
the
engine
once
It
has
been
removed
from
the
vehIcle
All
steps
would
be
followed
for
a
complete
engme
overhaul
But
smce
many
of
the
procedures
can
be
done
WIthout
removing
the
engIne
from
the
velucle
a
complete
course
of
actIon
should
be
decided
on
before
needless
removal
and
ms
assembly
Mount
the
engme
on
a
stand
or
other
sUItable
work
surface
before
msassembly
Thoroughly
clean
the
extenor
WIth
steam
or
solvent
CAUTION
Remove
the
alternator
starter
motor
carburetor
and
dIStributor
from
the
engine
before
cleaning
to
prevent
damage
Once
clean
mspect
the
engme
for
SIgnS
of
damage
or
mlssmg
parts
cracks
or
accumulated
rust
on
the
block
especIally
around
the
soft
plugs
cracks
In
the
clutch
housing
and
dents
or
cracks
In
the
oil
pan
DISassemble
as
follows
Alternator
Removal
1
Figure
14
shows
the
positIon
of
the
alternator
on
the
engme
and
a
VIew
of
the
alternator
mountIng
parts
Remove
the
two
bolts
lock
washers
and
shmls
holding
the
alternator
to
the
adjustIng
bar
and
the
adjustIng
bar
to
the
engme
block
2
Remove
the
two
bolts
and
lockwashers
hold
ing
the
alternator
to
lower
mounting
bracket
3
Remove
the
alternator
and
mountmg
brack
ets
Starter
Motor
Removal
1
Remove
two
mountIng
bolts
and
lockwashers
holdmg
starter
motor
to
clutch
housmg
2
Pull
starter
assembly
toward
front
of
engme
and
remove
Distributor
Removal
1
Scnbe
ahgnment
marks
on
the
mstrlbutor
shaft
tl
ie
ihsthDutor
mountmg
oracket
anihlfe
front
cover
so
that
the
dIStnbutor
can
be
re
placed
accurately
later
2
Remove
two
bolts
and
lockwashers
holdIng
the
dlstnbutor
mountmg
housmg
to
the
front
cover
3
Pull
up
on
the
dlstnbutor
and
remove
it
as
a
unit
Carburetor
Removal
1
Remove
the
four
nuts
and
lockwashers
join
mg
the
carburetor
and
mtake
manifold
then
remove
carburetor
Oil
Pump
Removal
1
Remove
the
four
mountIng
bolts
and
lock
washers
2
WIthdraw
the
011
pump
assembly
from
tht
front
cover
as
shown
m
Figure
15
@
Air
Pump
Removal
1
Remove
the
bolt
passmg
through
the
slot
on
Page 52 of 252
ENGINE
47
allowable
warpage
IS
0
0039
in
0
I
mm
Standard
should
be
less
than
0
0012
in
O
03mm
In
the
event
the
measurements
are
out
of
tolerance
the
cylmder
head
surface
should
be
milled
or
resurfaced
3
Verify
that
all
water
and
011
passages
are
free
of
foreign
matena
Use
compressed
aIr
to
clean
passages
after
scraping
4
Note
the
condition
of
all
studs
in
the
cylinder
head
Replace
damaged
ones
Valve
Assembly
I
Check
intake
and
exhaust
valve
assembhes
for
worn
damaged
or
deformed
valve
caps
and
stems
Correct
or
replace
the
valve
If
excessive
defects
exist
2
Measure
valve
stem
diameter
WIth
a
micro
meter
as
shown
in
Fignre
36
Figure
37
gives
cnncal
drmensions
@
@
Y
lm
1
0
515
r
3
Reface
the
valve
face
and
valve
stem
using
a
valve
grinder
as
18
shown
in
Fignre
38
NOTE
When
the
valve
head
1uzs
been
reduced
to
00197
in
0
Smm
or
less
In
thIckness
replace
the
valve
Grinding
allowance
for
the
valve
stem
end
surface
is
00197
In
0
Smm
or
less
4
Measure
the
free
length
and
tension
of
each
valve
spring
If
the
measured
values
exceed
the
hnuts
specified
below
replace
the
spring
SPRING
SPECIFICATIONS
Free
Length
Outel
Spring
Inner
Spring
Outer
Spring
2
0472
10
52
Omm
1
765710
44
85mm
153m
at6393
331Ib
389mm
at290
15kg
138m
at
2712
154lb
35mm
at12
3
0
7
kg
121
10
at
105
38
5
29
Ib
30
7mm
at
47
8
2
4
kg
09610
at5621
2871b
245mm
at
25
5
13
kg
Valve
Closed
I
nner
Spring
Outer
Spnng
Valve
Open
Inner
Spnng
5
Check
the
deformation
of
each
spnng
with
a
square
Replace
any
spnng
WIth
a
deflection
of
o
063
in
I
611lID
or
more
6
Check
all
workmg
surfaces
of
the
rocker
arms
for
damage
or
wear
If
defects
or
apparent
ex
cessIve
wear
are
found
replace
them
A
defective
PIvot
reqwres
It
S
replacement
along
WIth
the
correspondIng
rocker
ann
7
Measure
the
clearance
between
the
valve
gwde
and
the
valve
stem
If
the
clearance
ex
ceeds
hnuts
replace
the
worn
parts
or
both
Page 59 of 252
54
CHAP1ER
SIX
2
Set
the
valve
spnng
seat
m
position
on
the
top
of
the
block
and
over
the
valve
stem
3
Place
the
oil
seal
over
the
valve
stem
4
Place
the
mner
and
outer
valve
spnngs
over
the
valve
stem
S
Place
the
spnng
retamer
over
the
springs
compress
spnngs
With
spring
compressor
Figure
55
and
mstall
valve
collets
around
valve
stem
so
that
they
lock
onto
stem
6
Release
spnng
compressor
If
collets
are
firm
ly
locked
onto
the
groove
m
the
valve
stem
assembly
IS
complete
7
Install
the
rocker
guIde
on
top
of
the
valve
stem
when
assemblmg
the
rocker
pivot
assembly
VaIve
Rocker
Pivot
Assembly
1
Thread
lock
nut
onto
valve
rocker
pivOt
and
place
rocker
retaIner
over
the
valve
rocker
pivOt
2
Thread
the
above
assembly
mto
the
rocker
bushIng
protrudIng
from
the
head
Camshaft
Assembly
1
Mount
the
locatIng
plate
on
the
front
of
the
head
as
shown
m
FJgIlI
1
56
2
From
the
back
of
the
head
carefully
InSert
the
camshaft
through
the
four
camshaft
beanngs
being
ca
efu1
not
to
move
or
damage
the
bear
ings
NOTE
Install
the
CQJ7IShaft
sprocket
onto
the
camshaft
so
that
the
three
locating
holes
are
at
the
top
left
and
bottom
h
1
3
Install
the
camshaft
sprocket
and
fuel
pump
cam
onto
the
front
of
the
camshaft
and
torque
to
specificatIon
4
Check
the
camshaft
for
end
play
using
a
feeler
gauge
as
preViously
described
Rocker
Pivot
Assembly
1
Push
down
on
valve
spnng
with
screwdriver
and
insert
rocker
piVOt
arm
between
camshaft
and
valve
stem
Insert
rocker
valve
guide
onto
top
of
valve
stem
at
this
time
2
Install
valve
rocker
springs
over
top
of
rocker
pivot
arm
Piston
and
Connecting
Rod
Assembly
1
Assemble
the
four
pistons
pms
and
connect
mg
rods
Secure
piston
pm
The
connecting
rod
IS
press
fitted
onto
the
pISton
pin
With
from
1
to
3
tons
of
force
NOTE
The
pistons
are
marked
with
an
F
which
should
point
toward
the
front
of
the
engine
The
connecting
rods
must
be
installed
so
that
the
011
Jet
In
the
large
end
IS
positioned
to
ward
the
right
Side
of
the
tnglne
The
center
of
the
piston
pin
IS
oD
set
In
relation
to
the
center
of
the
piston
so
correct
assembly
is
cntical
2
Use
a
nng
expander
to
install
the
rings
onto
the
pistons
Install
the
top
and
rmddle
nngs
with
the
marks
up
3
Lubncate
the
rod
bearings
hghtly
and
mstall
them
into
their
respective
connectIng
rods
and
rod
caps
Page 76 of 252
FUEL
SYSTEM
71
Dash
Pot
Adjustment
The
adjustment
of
the
dash
pot
IS
done
by
warmmg
up
the
engme
properly
and
checkIng
If
the
throttle
lever
touches
th
dash
pot
stem
as
the
engine
reaches
1
800
and
2
000
rpm
under
no
load
conditIons
Proper
contact
between
the
throttle
lever
and
the
dash
pot
stem
produces
a
normal
dash
pot
performance
Should
a
normal
mcrease
m
engme
speed
not
occur
adjust
the
dash
pot
as
follows
1
Loosen
the
dash
pot
locknuts
2
Rotate
the
dash
pot
nght
and
then
left
3
Adjust
the
dash
pot
so
that
the
throttle
lever
hIts
the
stem
between
1
800
and
2
000
rpm
4
Fasten
the
lock
nuts
securely
5
The
clearance
between
the
throttle
valve
and
the
throttle
chamber
wall
should
be
0
0709
m
0
8mm
or
10
degrees
In
throttle
valve
angle
MAJOR
CARBURETOR
SERVICE
PROCEDURES
A
carburetor
m
good
operatIng
condition
will
delIver
the
pr
per
gasolme
and
aIr
ratIos
for
all
engme
runnmg
speeds
A
gradual
declme
In
smoothness
response
and
power
Will
occur
as
the
carburetor
slIps
from
adjustment
and
Its
delI
cate
parts
become
dirty
and
worn
Overhaul
should
only
be
attempted
by
an
expenenced
mechanic
Accurate
calIbratIon
of
passages
and
dIS
charge
hole
reqUIre
that
extreme
care
be
taken
In
dISassembly
cleanmg
and
reassembly
Use
only
a
hIgh
grade
carburetor
cleaner
and
com
pressed
arr
to
clean
parts
and
passages
Never
use
wire
or
other
pOInted
Instruments
for
clean
ing
CalIbratIon
of
the
carburetor
will
be
af
fected
The
procedures
below
are
generally
true
for
all
models
As
an
aId
Figures
13
and
14
are
typIcal
examples
of
the
carburetors
used
Carburetor
Removal
1
Remove
the
au
cleaner
by
dIsconnectIng
all
hoses
attached
to
It
remoVmg
the
two
bolts
holdmg
the
aIr
cleaner
to
the
support
and
loos
enmg
the
band
bolt
at
the
base
of
the
aIr
cleaner
2
DIsconnect
fuellme
vacuum
Ime
and
choke
wire
u
eqUIpped
from
the
carburetor
3
Remove
the
throttle
lever
4
Remove
four
nuts
and
washers
holdmg
car
buretor
to
manIfold
5
Lift
carburetor
off
of
manuold
6
Remove
and
dIscard
carburetor
to
manuold
gasket
7
Place
carburetor
on
clean
workbench
Carburetor
Disassembly
1
The
maIn
Jets
slow
Jets
and
needle
valves
on
both
the
pnmary
and
secondary
systenIS
are
accessIble
from
outsIde
the
carburetor
Refer
to
FIgures
13
and
14
for
locatI
n
2
The
choke
chamber
can
be
detached
by
re
mOVIng
the
connectIng
rod
pump
connectIng
rod
return
sprmg
stop
pm
and
the
set
screws
I
that
hold
It
in
place
3
The
pnmary
and
secondary
emulSIon
tubes
can
be
disassembled
by
remOVIng
the
mam
air
bleeds
on
the
respectIve
SIdes
4
To
check
the
accelerator
pump
remove
the
cylInder
cover
Be
careful
not
to
lose
the
return
spnng
and
Inlet
valve
at
the
lower
part
of
the
pIston
durmg
dIsassembly
5
Detach
the
throttle
chamber
from
the
float
chamber
by
remOVIng
the
rod
lInkIng
the
dia
phragm
WIth
the
secondary
throttle
valve
and
the
four
screws
that
hold
It
However
It
IS
preferable
to
leave
the
throttle
valve
mtact
unless
absolutely
reqUired
If
It
IS
necessary
to
dlS
assemble
the
valve
It
should
be
Installed
so
that
the
secondary
throttle
valve
will
be
gap
free
OtherwIse
stable
Idle
and
good
slow
speed
performance
will
suffer
is
To
check
the
float
the
float
chamber
cover
must
be
removed
I
7
The
dIaphragm
IS
dIsassembled
by
removing
the
set
screws
holdmg
the
dIaphragm
chamber
cover
In
reassemblIng
the
diaphragm
be
careful
not
to
turn
the
edge
of
the
dIaphragm
up
8
In
dlsassemblmg
and
reassembling
the
mter
lockIng
lInks
take
care
so
that
each
lInkage
has
a
smooth
actIon
and
that
parts
are
not
forced
mto
pOSItIon
9
For
vehIcles
equipped
With
an
automatIc
choke
remove
the
brmetal
case
by
releasmg
the
set
screws
The
bimetal
1l
extremely
senSItIve
Page 80 of 252
FUEL
SYSTEM
75
s
E
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c
DO
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c
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e
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oeQ
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g
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Q
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2
en
e
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9
E
en
J
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s
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ctI
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01
1
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lC
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rr
r
tr
P
t
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l
m
u
m
bOt
J
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co
en
bel
3
J
ca
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tt
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3
j
31b031
31
c
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ca
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t
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Q
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ClOClOClOClOClOClOClOOlOlOlOlOl
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DO
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ClOOlO
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ClOOlO
N
1
11
1
I
1
1
l
l
l
l
l
l
lC
lC
lC
l
and
delIcate
Therefore
do
not
attempt
to
force
It
Improper
handlmg
WIll
cau
e
dIstortIOn
10
In
assemblIng
the
bImetal
place
the
ther
mostat
cover
gaSket
gently
In
place
and
mstall
the
thermostat
cover
after
makmg
sure
that
the
lever
on
which
the
bImetal
hangs
moves
smoothly
11
After
ughtenmg
completely
bend
and
ad
Just
the
bImetal
rod
so
that
the
upSIde
of
the
bImetal
case
IS
level
withm
0
02
m
O
5mm
of
the
slIt
on
the
bImetal
rod
Be
sure
the
bImetal
rod
operates
smoothly
12
Adjust
the
choke
valve
opening
to
00709
m
1
8mm
by
bendIng
the
connecting
rod
Carburetor
Cleaning
and
Inpection
Dirt
gum
water
or
carbon
contammation
of
cntIcal
parts
IS
often
responsIble
for
unsatlsfac
tory
carburetor
performance
Careful
cleanmg
and
InspectIon
IS
therefore
essential
1
After
disassembly
submerge
all
parts
In
a
specIal
carburetor
cleaner
Be
certam
to
follow
the
mmufacrurer
s
instructions
In
usmg
the
cleaner
2
After
cleanmg
blow
all
passages
and
cast
mgs
With
compressed
aIr
Make
certam
all
parts
are
completely
dry
3
Carefully
mspect
parts
for
SIgnS
of
wear
VISIble
wear
IS
suffiCIent
cause
to
replace
a
part
4
Pay
speCIal
attentIon
to
condItIon
of
the
float
seat
and
needle
the
throttle
and
choke
shaft
bores
In
the
throttle
body
and
cover
castIngs
and
to
the
Idle
adjustIng
needles
5
Inspect
all
gaskets
to
see
IT
they
are
hard
or
bnttle
or
IT
the
edges
are
tom
or
dIstorted
It
IS
sound
practIce
to
replace
them
whenever
the
carburetor
is
dIsassembled
6
Check
the
filter
screen
for
dIrt
or
lint
If
after
cleanmg
It
IS
not
completely
clean
replace
It
7
Check
all
lInkages
for
smooth
operatIon
Correct
as
reqUIred
8
Check
operation
of
the
acceleration
pump
by
puttIng
gas
m
the
float
chamber
and
operatIng
the
throttle
lever
by
hand
Fuel
should
be
pumped
from
the
acceleration
nozzle
IT
the
unIt
IS
satlsfactory
9
Carefully
InSpect
the
dIaphragm
for
holes
or
leaks
Replace
IT
defective
il
Page 110 of 252
ENGINE
ELECTRICAL
SYSTEM
105
VOLTAGE
REGULATOR
REMOVAL
To
remove
the
voltage
regulator
dISconnect
the
6
way
multIple
electrIcal
COlInector
and
the
screws
holdmg
the
regulator
to
the
SIde
wall
lJ
R
ftl5
C
Wt
Str
Ii
DISTRIBUTOR
W
I
vE
Dlstnbutors
used
on
models
covered
m
this
manual
are
SImilar
except
that
some
have
a
dual
contact
pomt
system
rather
than
a
single
contact
system
The
dual
pomt
system
applies
to
1970
and
newer
models
eqUIpped
With
the
exhaust
and
evaporatIve
ermsslOn
control
deVIce
The
pomts
are
placed
m
parallel
In
the
circuIt
so
that
there
IS
a
pqase
dIfference
In
their
opera
tIon
Phase
dlfference
IS
5
degrees
on
1970
19
71
models
and
31h
degrees
on
1972
models
This
can
be
adjusted
With
the
adjustIng
screw
on
what
IS
called
the
retarded
breaker
Figure
51
shows
the
dual
point
distributor
FunctIonally
the
dIStnbutor
consists
of
the
hIgh
voltage
electrical
system
the
ignitIon
switch
the
centrifugal
advance
mechanISm
a
vacuum
ad
vance
mechanIsm
and
a
mechanIcal
driving
mechanISm
Figure
52
next
page
IS
an
ignItion
diagram
that
shows
parts
of
the
IgnItIon
CIrCUIt
The
dIstributor
shown
IS
typIcal
of
the
single
contact
pomt
system
CONSTRUCTION
Figure
53
shows
a
typical
distributor
used
and
Figure
54
shows
the
dIStnbutor
in
an
exploded
VIeW
Figures
55
page
107
and
56
page
108
provide
detaIled
exploded
VIews
of
the
lugh
tenSIon
cable
system
and
the
single
point
contact
system
Figure
57
page
109
covers
dIStrIbutors
With
the
dual
pOInt
system
The
descnptions
given
below
for
dIsassembly
and
repair
apply
espeCIally
to
the
smgle
pOInt
system
but
are
generally
true
for
the
dual
point
system
@
@
ADVANCED
BREAKER
PHASE
DIFFERENCE
5
DEGREES
Page 137 of 252
132
CHAPTER
ELEVEN
CD
NAnCO
22
20
21
r
i
T
l
C
r
Jl
i
i
18
Clutch
operating
cylinder
19
Piston
cup
20
PIston
21
Dust
cover
22
Push
rod
23
Bleeder
screw
24
Bleeder
cap
22
I
should
be
8
150
m
207mm
for
the
sedan
and
wagon
Pedal
heIght
should
be
591
m
150mm
for
the
pick
up
3
Apply
multI
purpose
grease
to
all
PIvot
pOInts
4
Bleed
all
aIr
out
of
the
sy
tem
as
dIscussed
below
OPERATING
CYLINDER
Operating
CyHnder
Removal
1
Remove
retum
spring
2
Disconnect
clutch
line
from
operating
cyl
inder
18
Ii
TOKICO
21
I
LL
18
23
24
I
I
3
Disconnect
pushrod
from
wIthdrawal
lever
4
Release
two
bolts
holdmg
operating
cylInder
to
clutch
hOUSIng
5
Remove
operating
cymder
from
clutch
hous
mg
Operating
CyHnder
Disassembly
1
Remove
dust
cover
2
Remove
snap
ring
All
other
parts
can
now
be
removed
See
Figure
10
Operating
CyHnder
Inspection
Check
all
parts
especIally
the
pIston
cup
for
wear
and
damage
Replace
if
defects
are
found
Page 202 of 252
BRAKES
IV
197
I
Ensure
that
the
brake
flUid
reservOir
at
the
master
cylmder
IS
full
and
that
the
vent
m
the
cap
is
open
2
Connect
a
plastIc
or
rubber
tube
to
the
bleeder
valve
on
the
nght
rear
wheel
Suspend
the
other
end
of
the
tube
m
a
Jar
or
bottle
filled
With
a
few
Inches
of
clean
brake
flwd
During
the
remaInIng
steps
keep
thiS
end
submerged
at
all
times
and
never
let
the
level
in
the
brake
flUid
reservoir
drop
below
full
3
Open
the
bleeder
valve
on
the
nght
rear
wheel
about
one
turn
Have
an
asSistant
depress
the
brake
pedal
slowly
As
soon
as
the
pedal
is
all
the
way
down
close
the
bleeder
valve
and
let
the
pedal
up
Repeat
thiS
step
as
many
tImes
as
necessary
until
pure
flUid
WithOUt
au
bubbles
comes
from
the
tube
4
Bleed
the
remammg
wheels
m
the
followmg
order
left
rear
nght
front
and
left
front
Keep
checkmg
the
brake
flUid
reservoir
to
make
cer
tam
It
doesn
t
TWl
out
of
flUId
5
When
all
wheels
are
bled
fill
the
reservOIr
to
the
full
level
Never
reuse
the
brake
flwd
bled
from
the
system
or
any
that
has
been
lymg
around
Start
With
a
fresh
contaIner
HANDBRAKE
Figures
19
next
page
and
20
page
199
are
exploded
views
of
the
handbrake
system
used
on
the
sedan
and
statIon
wagon
respectively
F1gDre
21
page
200
shows
the
pick
up
handbrake
system
Front
Cable
Removal
Sedan
and
Wagon
I
Release
handbrake
completely
Disconnect
the
front
cable
by
removmg
the
cleVIS
pm
that
connects
to
the
handbrake
control
stem
2
Screw
out
the
adJusting
nut
from
the
rear
end
of
the
front
cable
Disconnect
the
cable
from
the
center
lever
4
Remove
the
hand
brake
cable
clamp
from
under
the
verucle
Pull
out
the
lock
plate
fixmg
the
front
cable
to
the
front
cable
retamer
Ex
tract
the
front
cable
5
Unfasten
the
front
cable
outer
casing
from
the
bracket
Remove
the
cable
Front
Cable
Removal
Pick
up
I
Loosen
handbrake
2
Remove
cleVIS
pm
and
separate
cable
from
outer
lever
See
Figure
22
p
3
Remove
cleVIS
pm
and
eparate
cable
from
front
lever
Removecable
4
Remove
center
cable
from
control
levers
by
removmg
cleViS
pms
Rear
Cable
Removal
Sedan
I
Remove
adJusting
nut
from
adJuster
DIScon
nect
left
hand
rear
cable
from
handbrake
ad
Juster
2
Pull
out
lock
plates
see
Figure
23
and
re
move
cleVIS
pms
that
connect
rear
cable
With
rear
wheel
cylJnder
levers
Remove
cable
Rear
Cable
Removal
Wagon
1
Remove
both
cleVIS
pins
at
the
ends
of
the
rear
cable
2
Remove
cable