fuel cap 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 9 of 252
4
CHAPTER
ONE
chassIs
number
Write
the
numbers
down
and
carry
them
ill
your
wallet
Service
Hints
Throughout
thIs
manual
keep
two
conven
bons
ill
mmd
Front
refers
to
the
front
of
the
vehicle
The
left
and
nght
sides
of
the
ve
hicle
refer
to
a
person
sittIng
ill
the
car
facing
forward
For
example
the
steenng
wheelIS
on
the
left
hand
Side
All
dimensIOns
and
capacities
are
expressed
ill
units
fanuhar
to
a
Umted
States
mechaniC
such
as
illches
and
pounds
Metric
measurements
are
also
given
Metnc
tools
are
reqUITed
to
work
on
the
Datsun
CD
DATSUN
IENGINE
CAPACITY
IMAX
HP
RPM
IWHEELBASE
IENGINE
NUMBER
FAR
NO
NlSSAN
MOTOR
co
LTD
YOKOHAMA
JAPAN
TYPEI
510
1595
cc
961P
6600
rpm
mm
L
1
00988
P61
l
O
1
l
M
Table
1
MAIN
SPECIFICATIONS
AND
DIMENSIONS
r
ITEM
Sedan
Wagon
Plm
up
EnglDe
Type
L16
L16
L16
Valve
Arrangement
Overhead
Cam
Overhead
Cam
Overhead
Cam
Bore
3
26n
ID
83mm
3
2677
ID
83mm
3
2677
ID
83mm
Stroke
2902
ID
73
7mm
2
902
ID
73
7mm
2
902
In
73
7mm
Displacement
97
3
cu
ID
l595cc
97
3
cu
In
l595cc
97
3
cu
ID
1595cc
CompressIOn
Ratio
851
851
851
MaXimum
SAE
Hompower
96
@
5
600
rpm
96
@
5
600
rpm
96
@
5
600
rpm
MaXimum
SAE
Torque
998ft
Ib
138
kg
m
998ft
Ib
138
kg
m
9911
ft
Ib
138
kg
m
Fuel
Octane
85
85
85
Lengtb
1622
ID
4
12Omm
163
2
ID
4
I45mm
168
9
ID
4
290mm
Width
61
4
ID
l
560mm
61
4
ID
1
560mm
62
8
In
Cl
595mm
Height
55
lID
1
400mm
565
ID
Cl
435mm
60
8
ID
Cl
545mm
Wheelbase
95
3
ID
2
42Omm
95
3
ID
2
420mm
99
6
In
2
530mm
Room
Space
Inner
Length
63
3
In
1
61Omm
673
ID
1
710mm
72
8
ID
1
850mm
Inner
Width
499
ID
1
27Omm
507
ID
1
29Omm
563
In
1
430mm
Inner
Height
44
4
In
1
130mm
44
61D
1
135mm
15
7
ID
399mm
Tread
Front
50
4
ID
28Omm
502
In
1
275mm
492
In
1
250mm
Rear
504
In
1
280mm
496
In
Cl
260mm
499
ID
1
267mm
Road
Clearance
741n
l88mm
64
ID
l63mm
787
ID
200mm
Weight
4
Speed
2
0611b
935
kg
2
138
Ib
970
kg
2
127
Ib
965
kg
Automatic
2
114Ib
959
kg
2
182
Ib
990
kg
Minimum
Turning
RadiUS
157ft
48m
157ft
48m
171
ft
52m
Seating
Capaaty
5
5
2
Battery
Volt
12
12
12
Capacity
400rSOAH
400r50AH
40
or
60
AH
Connection
Negative
ground
Negative
ground
Negative
ground
Fuel
Tank
Capaaty
11
9
gal
45
liter
11
9
gal
45
liter
108
gal
41J
r
011
Pan
Capacity
42
qts
40
liter
4
2
qb
40
liter
1
06
gal
40
Iller
011
Filter
Capaaty
74
ql
07
liter
74
ql
0
7
liter
1
48
Pint
0
7
liter
Transmission
Capaaty
1
8
ql
1
7
liter
18
ql
1
7
Iller
2
11
qt
20
Iller
Dlflerenbal
Capaaty
85
ql
80
liter
11
ql
1
0
liter
87
ql
0
83
lIter
Coolant
Capaaty
7
2
ql
6
8
liter
7
2
ql
6
8
lIter
7
2
qt
6
8
Iller
Clutch
Type
Dry
Single
diSC
Dry
slDgle
diSC
Dry
slDgle
diSC
Draphragm
spnng
Diaphragm
spnng
Diaphragm
spnng
l
Page 12 of 252
PERIODIC
MAINTENANCE
7
Table
1
ENGINE
LUBRICATION
AND
MAINTENANCE
FREQUENCY
EVERY
E
E
E
E
E
E
E
Eo
00
00
00
00
00
00
00
gq
00
00
00
NO
t
r61li
0
CD
Check
engine
011
level
top
up
If
required
X
Change
engine
011
X
Lubricate
carburetor
hnkage
X
Lubricate
distributor
rotor
shaft
and
ann
shaft
X
Apply
grease
to
distributor
cam
heel
X
Check
radiator
coolant
level
X
Change
radIator
coolant
X
Change
radiator
coolant
additive
X
Check
battery
electrolyte
level
X
Check
specific
gravity
of
battery
X
Check
engine
starting
exhaust
color
X
Tighten
cyhnder
head
manifolds
and
pipe
flanges
X
Adjust
valve
clearance
X
Check
Ignition
timing
X
Tighten
carburetor
fittings
X
Check
fan
belt
tension
X
Check
for
011
pan
leakage
X
Tighten
engine
mounts
X
Check
fuel
strainer
X
Replace
fuel
strainer
X
Check
for
fuel
leaks
X
Replace
011
filter
X
Check
spark
plugs
X
Replace
spark
plugs
X
Check
dlstnbutor
cap
rotor
and
POints
X
Adjust
engine
Idle
speed
X
Check
air
cleaner
fittings
X
Clean
011
filler
cap
X
Clean
battery
cables
and
terminals
X
Check
alternator
and
voltage
regulator
function
X
Check
starter
motor
function
X
Replace
aIr
cleaner
element
X
Check
fuel
pump
function
X
Check
cyhnder
compressIon
X
Clean
carburetor
Jets
and
float
chamber
X
Check
dlstnbutor
condenser
X
Check
crankcase
ventilation
control
valve
X
Page 15 of 252
10
CHAPTER
THREE
pressure
bUllt
up
In
each
cylInder
The
readIngs
when
properly
Interpreted
IndIcate
general
cyl
Inder
and
valve
condltlOn
Vacuum
Gauge
The
vacuum
gauge
IS
easy
to
use
but
dIfficult
for
an
Inexpenenced
mechanIC
to
Interpret
The
results
when
conSIdered
WIth
other
findIngs
can
prOVIde
valuable
clues
to
pOSSIble
trouble
Connect
the
vacuum
gauge
WIth
a
T
connec
tIon
In
the
hose
from
the
carburetor
to
the
vacuum
advance
on
the
dIstnbutor
Start
the
engme
and
let
It
warm
up
thoroughly
Vacuum
readIng
should
be
steady
at
18
22
Inches
NOTE
Subtract
1
Inch
from
reading
for
every
1000
feet
of
altitude
Figure
1
shows
numerous
tYPical
readIngs
WIth
InterpretatIons
Results
are
not
conclusive
WIthout
companng
to
other
tests
such
as
com
preSSIOn
readIngs
Fuel
Pressure
Gauge
ThIS
Instrument
IS
VItal
for
evaluatIng
fuel
pump
performance
Often
a
vacuum
gauge
and
fuel
pressure
gauge
are
combIned
Dwell
Meter
A
dwell
meter
measures
the
dIstance
In
de
grees
of
cam
rotatIon
that
the
breaker
pOInts
remaIn
closed
while
the
engme
IS
runnIng
SInce
thIS
angle
IS
determmed
by
breaker
pOInt
gap
the
dwell
angle
IS
an
accurate
IndIcatIon
of
pOInt
gap
Many
tachometers
Intended
for
tunIng
and
testIng
Incorporate
a
dwell
meter
as
well
Follow
the
manufacturer
s
InstructIon
to
measure
dwell
on
the
Datsun
Tachometer
A
tachometer
IS
essential
for
tunIng
Datsuns
WIth
exhaust
emission
control
deVices
IgmtIOn
turung
and
carburetor
adjustments
must
be
per
formed
at
the
specified
Idle
speed
The
best
In
strument
for
thIS
purpose
IS
one
WIth
a
range
of
0
1
000
or
0
2
000
rpm
Extended
range
0
6
000
or
8
000
Instruments
lack
accuracy
at
lower
speeds
The
InStrument
should
be
capable
of
detecting
changes
of
25
rpm
Stroboscopic
Timing
Light
ThIS
Instrument
pernuts
accurate
IgnitIon
tImIng
By
f1ashmg
a
bght
at
the
preCISe
Instant
cylInder
No
1
fires
the
posItIon
of
the
crank
shaft
pulley
at
that
Instant
can
be
seen
Marks
on
the
pulley
bne
up
With
a
reference
pOInter
on
the
block
dunng
the
tIming
procedure
SUltable
bghts
are
neon
bulb
types
and
xenon
strobe
hghts
Neon
tunmg
bghts
are
ddticult
to
see
and
must
be
used
in
dImly
bt
areas
Xenon
strobe
bghts
can
be
used
In
bnght
sunbght
Use
the
bght
accordIng
to
the
manufacturer
s
InStruC
tIons
Exhaust
Analyzer
Of
all
Instruments
descnbed
here
this
IS
the
least
bkely
to
be
owned
by
a
home
mechanic
One
Instrument
samples
the
exhaust
gases
from
the
taIlpIpe
and
measures
the
thermal
conduc
tIVIty
of
the
exhaust
gas
SInce
different
gases
conduct
heat
at
varYIng
rates
thermal
conduc
tIVIty
of
the
exhaust
IS
a
good
IndIcatIon
of
gases
present
This
Instrument
IS
VItal
for
accurately
checkIng
the
effectIveness
of
exhaust
emIssion
control
adjustments
but
IS
too
expenSIve
for
an
amateur
mechanIC
to
conSIder
buying
STARTER
Starter
system
troubles
are
relatIvely
easy
to
ISolate
The
followmg
are
common
symptoms
and
cures
1
Engme
cranks
very
slowly
or
not
at
all
Turn
on
the
headhghts
If
the
bghts
are
very
dun
most
likely
the
battery
or
the
connecting
WireS
are
at
fault
Check
the
battery
using
the
pro
cedures
descnbed
in
the
Tune
up
chapter
Check
wmmgfur
e
s
wom
andd
connectIom
H
the
battery
and
connectIng
WIres
check
good
turn
the
headlIghts
on
and
try
to
crank
the
engIne
H
the
lIghts
dIDl
drastIcally
the
starter
is
probably
shorted
to
ground
Remove
the
starter
and
test
it
usmg
the
procedures
gIven
in
Chapter
NIne
If
the
lights
remain
bnght
or
dun
slIghtly
when
crankIng
the
engme
the
trouble
may
be
in
the
starter
solenOId
or
wmng
To
ISolate
the
trouble
short
the
two
large
solenoid
ternunals
together
not
to
ground
if
the
starter
cranks
normally
check
the
solenoid
and
wmng
up
to
the
Page 18 of 252
TROUBLESHOOTING
13
trouble
may
also
be
worn
bearings
Remove
the
alternator
and
repair
ENGINE
These
procedures
assume
the
starter
cranks
the
engme
over
normally
If
not
refer
to
Starter
section
m
this
chapter
1
Engme
won
t
start
Could
be
caused
by
the
IgOltlon
or
fuel
problems
First
determine
If
high
voltage
to
spark
plug
occurs
To
do
thiS
dISconnect
one
of
the
spark
plug
wires
Hold
the
exposed
wrre
termlOal
y
to
Y2
lOch
from
ground
any
metal
in
engine
com
partment
With
an
msulated
screwdriver
Crank
the
engme
over
If
sparks
do
not
Jump
to
ground
or
the
sparks
are
very
weak
the
trouble
may
be
10
the
IgnitIOn
system
See
Ignition
System
Trou
bleshootmg
to
further
check
If
sparks
occur
properly
the
trouble
may
be
10
the
fuel
system
See
Fuel
System
Troubleshootmg
2
Engme
misses
steadily
Remove
one
spark
plug
wrre
at
a
tune
and
ground
the
wrre
If
engme
mISs
increases
that
cyhnder
was
work
109
properly
Reconnect
the
wire
and
check
the
others
When
a
wire
IS
dIs
connected
and
engme
miss
remams
the
same
that
cylinder
IS
not
finng
Check
spark
as
descnbed
10
Step
1
If
no
spark
occurs
for
one
cyhnder
only
check
dlStnbutor
cap
wrre
and
spark
plug
If
spark
occurs
prop
erly
check
compressIOn
and
mtake
maOlfold
vacuum
to
ISolate
the
trouble
3
Engme
misses
erratlcally
at
all
speeds
Interrmttent
trouble
can
be
difficult
to
find
It
could
be
ill
the
Ignition
system
exhaust
system
or
fuel
system
Follow
troubleshooting
proce
dures
for
these
systems
carefully
to
isolate
the
trouble
4
Engme
misses
at
Idle
only
Trouble
could
exist
anywhere
ill
IgOltlon
system
Follow
Ignition
TroubleshootlOg
procedure
care
fully
Trouble
could
also
eXist
10
the
carburetor
Idle
crrcult
Check
Idle
mIXture
adjustment
and
check
for
restnctions
m
the
idle
crrcUlt
5
Engme
misses
at
high
speed
only
Problems
could
be
ill
the
fuel
or
IgOltlon
systems
heck
accelerator
pump
operation
fuel
pump
dehvery
fuel
hnes
etc
as
descnbed
under
Fuel
System
Troubleshootillg
Also
check
spark
plugs
and
wrres
6
Low
performance
at
all
speeds
poor
acceleratIOn
Trouble
usually
ill
IgOltlon
or
fuel
system
Check
each
With
the
appropnate
troubleshooting
pro
cedure
7
ExceSSive
fuel
consumptIOn
Could
be
caused
by
a
Wide
variety
of
seemmgly
unrelated
factors
Check
for
clutch
shppage
brake
drag
defective
wheel
beanngs
or
poor
front
end
alignment
Check
IgOltlOn
system
and
fuel
system
8
011
pressure
lamp
does
not
light
when
IgmtlOn
switch
IS
on
Check
the
alternator
warning
lamp
If
it
ISn
t
on
either
go
to
Step
1
Chargmg
System
Trouble
shootlOg
If
only
the
oil
pressure
lamp
IS
off
open
the
englOe
compartment
hd
and
locate
the
oil
pressure
sender
on
the
block
near
the
oil
filter
Make
sure
the
wrre
is
connected
to
the
sender
and
makmg
good
contact
Pull
the
wrre
off
and
ground
it
If
the
lamp
hghts
replace
the
sender
If
the
lamp
does
not
light
replace
the
lamp
9
011
pressure
lamp
lights
or
flickers
when
engme
IS
runmng
Indicates
low
or
complete
loss
of
oil
pressure
Stop
the
englOe
unmedmtely
coast
to
a
stop
With
the
clutch
dISengaged
Tlus
may
simply
be
caused
by
a
low
oil
level
or
an
overheatmg
en
glOe
Check
the
oil
level
and
fan
belt
tensIOn
Check
for
a
shorted
oil
pressure
sender
with
an
ohmmeter
or
a
contlOulty
tester
Remove
and
clean
the
oil
dipstick
and
check
oil
level
and
condition
RepleOlsh
or
replace
the
oil
as
re
qurred
Listen
for
unusual
nOISes
mdlcatmg
dam
aged
beanngs
etc
Do
not
re
start
the
engine
until
you
know
why
the
hght
went
on
and
are
sure
that
the
problem
has
been
corrected
IGNITION
SYSTEM
This
procedure
assumes
the
battery
IS
ill
good
enough
condition
to
crank
the
engme
at
a
normal
rate
Page 19 of 252
14
CHAPTER
THREE
I
No
spark
to
one
plug
The
only
possible
causes
are
a
defective
dlStri
butor
cap
or
spark
plug
wrre
Examme
the
dis
tnbutor
cap
for
mOisture
drrt
or
carbon
track
ing
caused
by
flashover
cracks
etc
2
No
spark
to
any
plug
ThlS
could
mdicate
trouble
in
the
prImary
or
secondary
Circuits
Frrst
remove
the
coil
wire
from
the
center
post
of
the
dlStributor
Hold
the
Wire
end
about
1
1
mch
from
ground
With
an
msulated
screwdrIver
Crank
the
engme
H
sparks
are
produced
the
trouble
is
m
the
rotor
or
distributor
cap
Remove
the
cap
and
check
for
burns
mOisture
dirt
carbon
trackmg
cracks
etc
Check
the
rotor
for
excessive
burn
mg
pittmg
or
cracks
Replace
both
rr
necessary
H
the
cod
does
not
produce
any
spark
check
the
secondary
Wire
for
opens
H
the
wrre
is
good
turn
the
engme
over
so
the
breaker
pomts
are
open
Examme
the
points
for
excessIVe
gap
burmng
pittmg
and
looseness
Replace
and
ad
Just
rr
necessary
With
the
points
open
check
voltage
to
ground
at
the
cod
with
a
voltmeter
or
test
lamp
If
voltage
is
present
the
cOlllS
prob
ably
bad
Have
it
checked
or
substitute
a
known
good
one
If
voltage
is
not
present
check
wrre
connec
tions
to
cOll
and
distrIbutor
Temporanly
dIs
connect
the
Wire
from
the
distrIbutor
to
the
cOll
and
measure
from
the
coli
to
ground
If
voltage
is
present
the
distnbutor
lS
shorted
Examme
the
breaker
pomts
and
connecting
WIres
care
fully
If
voltage
is
still
not
present
check
the
other
coli
termmal
for
ground
Voltage
at
thiS
termmal
but
not
at
the
other
mdicates
a
defecnve
cOll
No
voltage
at
tlus
termmal
mdicates
an
open
Wire
between
the
termmal
and
the
battery
3
Weak
spark
If
the
spark
lS
so
small
it
cannot
Jump
from
the
wrre
to
ground
check
battery
condinon
Other
causes
are
bad
breaker
points
condenser
m
correct
breaker
pomt
gap
dirty
or
loose
con
necnons
m
the
pnmary
crrcuit
or
dirty
or
burned
rotor
or
distnbutor
Also
check
for
worn
dis
tnbutor
cam
lobes
4
Mlssmg
ThiS
is
usually
caused
by
fouled
or
damaged
plugs
plugs
of
the
wrong
heat
range
or
mcorrect
plug
gap
Clean
and
regap
the
spark
plugs
flus
trouble
can
also
be
caused
by
weak
spark
see
symptom
3
or
mcorrect
igmnon
tlIDing
5
Spark
polarity
Less
voltage
is
requrred
to
cause
electron
flow
from
a
relatively
hot
electrode
to
a
cooler
elec
trode
Smce
the
center
electrode
is
hottest
this
electrode
should
be
negative
Electron
flow
lS
then
from
the
center
electrode
to
the
outer
elec
trode
From
20
to
40
percent
more
voltage
is
requrred
to
cause
electron
flow
from
the
outside
electrode
to
the
hotter
center
electrode
This
occurs
when
the
spark
voltage
is
positive
The
cOll
wrres
must
be
connected
correctly
FUEL
SYSTEM
Fuel
system
troubles
must
be
iSolated
at
the
carburetor
fuel
pump
or
fuellrnes
These
pro
cedures
assume
that
the
igmtlon
system
has
been
checked
and
properly
adjusted
I
Engme
Will
not
start
Frrst
detenmne
that
fuellS
reachIng
the
carbu
retor
Remove
the
au
cleaner
look
into
the
carburetor
throat
and
depress
the
accelerator
several
tlIDes
There
should
be
a
stream
of
fuel
from
the
discharge
tube
each
time
the
accelerator
lS
depressed
If
not
the
fuel
pump
lS
not
dehver
mg
fuel
to
the
carburetor
or
the
float
system
m
the
carburetor
lS
not
workmg
Make
certam
there
is
fuel
m
the
fuel
tank
Check
the
automatic
choke
rr
so
equipped
to
make
certain
it
is
not
stuck
If
necessary
rebudd
the
fuel
pump
or
overhaul
the
carburetor
whichever
lS
determmed
to
be
faulty
2
Engme
runs
at
fast
Idle
Usually
thiS
is
caused
by
misadJustment
of
the
carburetor
idle
setting
Readjust
as
required
3
Rough
Idle
or
engme
miss
with
frequent
stallmg
Check
idle
miXture
and
idle
speed
adjustments
Inspect
the
overall
conchtlOn
of
the
carburetor
for
foreign
material
and
clean
or
overhaul
as
required
4
Engme
diesels
contmues
to
run
after
engme
IS
turned
off
Check
idle
IDlXture
and
idle
speed
adjustments
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 27 of 252
22
CHAPTER
FOUR
CD
Normal
plug
appearance
noted
by
the
brown
to
graYish
tan
deposits
and
slight
electrode
wear
This
plug
rndlcates
the
correct
plug
heat
range
and
proper
air
fuel
ratio
f
j
l
Carbon
fouling
dlstrngUlshed
by
dry
fluffy
black
carbon
deposits
which
may
be
caused
by
an
over
nch
alr
fuel
mixture
excessIVe
hand
chokrng
clogged
air
filter
or
excessive
Idling
lJ
6
1
4i
Z
011
fouling
rndlcated
by
wet
OIly
depOSits
caused
by
011
pumprng
past
worn
rrngs
or
down
the
rntake
valve
gUides
A
hotter
plug
temporanly
reduces
011
depOSits
but
a
plug
that
IS
too
hot
leads
to
pre
IgmtlOn
and
possible
engrne
damage
Red
brown
yellow
and
white
coatrngs
caused
by
fuel
and
011
additives
These
depOSits
are
not
harm
ful
If
they
remarn
rn
a
powdery
form
C
I
Shrny
yellow
glaze
on
rnsulator
cone
IS
caused
when
the
powdery
depOSits
from
fuel
and
011
additives
melt
Meltrng
occurs
dunng
hard
acceleration
after
prolonged
Idling
This
glaze
conducts
electnclty
and
shorts
out
the
plug
Overheated
plug
rndlcated
by
burned
or
blistered
rnsulator
tip
and
badly
worn
electrodes
This
condl
bon
may
be
caused
by
pre
Igmtlon
cooling
system
defects
lean
air
fuel
ratiOS
low
octane
fuel
or
over
advanced
Igmbon
bmrng
Spark
plug
condition
photos
courtesy
of
At
Spark
Plug
DIvision
General
Motors
Corporation
The
procedures
given
below
would
generally
apply
to
eIther
type
In
the
dual
pomt
system
one
set
of
pomts
IS
known
as
the
advance
set
and
the
other
the
retard
set
Complete
details
are
given
m
Chapter
Nme
Figure
4
IS
a
detaIl
of
the
dual
pomt
system
1
Remove
dIStnutor
cap
Clean
It
carefully
to
remove
grease
or
dIrt
2
Examme
the
mSIde
of
the
cap
for
d1rt
or
ex
ceSSIve
wear
Look
for
SIgns
of
carbon
tracks
arcmg
from
contact
to
contact
mSIde
the
dIS
trIbutor
cap
Carbon
tracks
mdlcate
defects
or
cracks
and
If
found
the
cap
should
be
replaced
3
Remove
the
rotor
and
mspect
for
exceSSIve
wear
around
the
top
metal
contact
wiper
surface
If
defectlve
replace
As
a
matter
of
good
prac
nce
the
rotor
should
be
replaced
whenever
the
contact
pomts
are
replaced
4
Use
a
screwdriver
to
gently
open
the
contact
pomts
If
they
show
wear
or
plttmg
remove
the
I
7
r
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 64 of 252
ENGINE
59
2
Coat
the
pan
gasket
on
both
sides
With
gasket
compound
and
attach
the
oil
pan
to
the
cyhnder
block
Torque
as
specIfied
Manifold
and
Carburetor
Installation
1
Install
the
mtake
and
exhaust
manIfolds
WIth
associated
gasket
to
the
cylmder
head
2
Mount
the
carburetor
and
gasket
to
the
mtake
manIfold
2
Adjust
all
mtake
and
exhaust
valves
to
the
specIfied
clearance
for
a
cold
engme
Clutch
Assembly
Installation
CAUTION
Take
extreme
care
not
to
get
grease
or
011
on
the
clutch
or
flywheel
frlc
hon
contact
surfaces
1
Place
the
clutch
disc
assembly
on
the
flywheel
With
the
longer
chamfered
splmed
end
of
the
dISC
toward
the
transmISSion
2
Visually
align
or
use
a
dummy
splmed
dnve
shaft
to
ahgn
the
diSC
assembly
With
the
flywheel
pilot
beanng
3
Install
and
tighten
the
SIX
bolts
holdmg
the
clutch
cover
assembly
to
the
flywheel
Tighten
the
bolts
a
turn
each
tune
by
diagonal
pattern
until
they
are
tight
Tlghtenmg
torque
should
be
174
to
188ft
lbs
24
to
2
6
kg
m
NOTE
There
are
two
dowels
on
the
flywheel
to
locate
the
clutch
cover
4
Remove
dummy
shaft
If
used
after
the
above
bolts
are
fully
tightened
5
Refit
the
release
bearing
and
translI11Ssion
case
Miscellaneous
Installation
1
Connect
the
fuel
hose
on
the
front
part
of
the
engme
to
the
fuel
pump
and
to
the
carburetor
2
Gap
the
spark
plugs
and
mstall
them
usmg
new
gaskets
3
Coat
the
rocker
arm
cover
gasket
With
sealer
and
position
It
on
the
cylmder
head
4
Install
the
rocker
arm
cover
and
tighten
the
two
thumb
screws
that
hold
it
m
place
5
Install
distrIbutor
makmg
certam
that
the
notch
on
the
distributor
shaft
assembly
mates
With
the
drive
spmdle
Ahgn
the
location
marks
made
dunng
disassembly
so
that
the
distrIbutor
is
positioned
as
before
6
Install
and
tighten
the
bolts
which
hold
the
dIStributor
to
the
front
cover
7
Install
pomts
condenser
and
rotor
8
Replace
distrIbutor
cap
and
attach
spark
plug
Wires
m
the
correct
sequence
Make
certain
that
all
wires
are
firmly
seated
m
the
distrIbutor
cap
and
attached
securely
to
the
spark
plugs
9
HOISt
the
engme
assembly
from
the
work
stand
10
Install
the
alternator
bracket
alternator
and
engme
mounts
to
the
block
11
Install
the
IgnItIon
coil
oil
filter
oil
pressure
SWitch
dipstick
and
water
drain
plug
12
Connect
the
vacuum
Ime
between
the
dis
trIbutor
and
carburetor
13
Connect
the
transIDlSSlOn
to
the
engine
prior
to
mstallatIon
m
the
vehicle
Engine
Installation
Installation
is
the
reverse
of
the
procedures
followed
m
removal
Be
certaIn
thatlall
battery
connections
are
made
that
water
hoses
are
se
cured
wmng
IS
connected
properly
and
that
all
required
bolts
and
mounts
are
mstalled
and
tightened
Replace
the
radiator
fan
belts
and
radiator
shroud
Fill
the
engme
With
the
proper
grade
of
oil
and
the
radiator
With
recommended
coolant
Install
the
hood
to
the
hInges
according
to
the
marks
made
dUrIng
removal
SERVICE
DATA
AND
SPECIFICATIONS
Table
1
covers
servIce
data
and
engme
Speci
fications
Page 70 of 252
FUEL
SYSTEM
6S
CD
2
Remove
the
fuel
stramer
from
Its
mountlng
clIp
3
Replace
the
fuel
stramer
as
reqUIred
4
Reconnect
the
mtake
and
outlet
fuellmes
FUEL
PUMP
The
fuel
pump
conSISts
of
a
body
rocker
arm
and
lmk
assembly
dIaphragm
dIaphragm
spring
seal
and
mlet
and
outlet
valves
The
l
r
t
1
9
l
F
r
fl
rocker
arm
IS
dnven
by
a
pump
cam
mounted
on
the
catnShaft
In
the
front
part
of
the
rocker
arm
front
cover
assembly
Figure
S
shows
the
fuel
pump
for
all
models
through
1970
Figure
6
illustrates
the
fuel
pump
for
1971
and
later
models
Fuel
pump
Testing
Fuel
pump
pressure
and
fuel
pump
capacity
testlng
are
performed
m
tests
descnbed
below
Both
tests
are
performed
With
the
fuel
pump
mounted
to
the
engme
Static
Pressure
Test
1
DIsconnect
the
carburetor
fuel
lme
at
the
carburetor
2
Install
an
adapter
and
a
tee
fittmg
to
the
fuel
lIne
and
attach
a
SUItable
pressure
gauge
3
Connect
adapter
to
carburetor
4
Start
and
run
engine
at
varymg
speeds
5
The
gauge
reading
IS
static
fuel
pressure
It
should
remam
between
256
and
341
Ib
m
2
018
to
0
24
kg
cm2
Pressure
below
thelower
lImIt
mdlcates
extreme
wear
on
one
part
or
gen
eral
wear
on
several
pump
parts
Pressure
above
the
upper
hrmt
indIcates
an
excessIvely
strong
diaphragm
spnng
or
a
dIaphragm
that
is
too
tIght
Both
condItIons
require
the
removal
of
the
fuel
pump
for
necessary
repaIr
or
replacement