cooling DATSUN 510 1969 Service Repair Manual
[x] Cancel search | Manufacturer: DATSUN, Model Year: 1969, Model line: 510, Model: DATSUN 510 1969Pages: 171, PDF Size: 10.63 MB
Page 4 of 171
inteN
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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
Page 6 of 171
EngIne
INTRODUCTION
ENGINE
Removal
ENGINE
DismantUng
ENGINE
Inspection
and
Overhaul
VALVES
VALVE
GUIDES
VALVE
SEAT
INSERTS
CAMSHAFT
AND
CAMSHAFT
BEARINGS
Checking
CYliNDER
BLOCK
PtSTONS
AND
CONNECTING
RODS
INTRODUCTION
The
1400
1600
cc
and
1800
cc
engines
are
four
cylinder
in
line
units
with
a
single
overhead
camshaft
and
fully
balanced
five
bearing
crankshaft
The
valves
are
operated
through
rockers
which
are
directly
activated
by
the
earn
mechanism
The
crankshaft
is
a
special
steel
forging
with
the
centre
main
bearing
equipped
with
thrust
washers
to
take
up
the
end
thrust
of
the
crankshaft
The
special
aluminium
pistons
are
of
the
strut
construction
to
control
thermal
expansion
and
have
two
compression
rings
and
one
combined
oil
ring
The
gudgeon
pins
have
special
hollow
steel
shafts
and
are
a
fully
floating
fit
in
the
pistons
and
a
press
fit
in
the
connecting
rods
The
aluminium
alloy
cylinder
head
contains
wedge
type
combustion
chambers
and
is
fitted
with
aluminium
bronze
valve
seats
for
the
intake
valves
and
heat
resistant
steel
valve
seats
for
the
exhaust
valves
The
cast
iron
camshaft
is
driven
by
a
double
row
roller
chain
from
the
crankshaft
pulley
The
engine
is
pressure
lubricated
by
a
rotor
type
oil
pump
which
draws
oil
through
an
oil
strainer
into
the
pump
housing
and
then
forces
it
through
a
full
flow
oil
filter
into
the
main
oil
gallery
ENGINE
Removal
Place
alignment
marks
on
the
bonnet
and
hinges
remove
the
bonnet
from
the
vehicle
2
Drain
the
cooling
system
and
engine
and
transmission
lubricant
Remove
the
radiator
grille
3
Discon
ect
the
battery
cables
and
lift
out
the
battery
4
Detach
the
upper
and
lower
radiator
hoses
remove
the
radiator
mounting
bolts
and
lift
the
radiator
away
from
the
vehicle
The
torque
converter
c
jng
pipes
must
be
disconnected
from
the
radiator
on
vehicles
fitted
with
automatic
transmission
S
Remove
the
COOling
fan
and
pulley
disconnect
the
fuel
pipe
from
the
fuel
pump
and
the
heater
hoses
from
the
engine
attachments
6
Disconnect
the
accelerator
control
linkage
and
the
choke
CRANKSHAFT
AND
MAIN
BEARINGS
CAMSHAFT
AND
SPROCKET
FLYWHEEL
ENGINE
Assembling
VALVE
CLEARANCES
Adjusting
ENGINE
LUBRICATION
SYSTEM
OIL
PUMP
OIL
FILTER
CHANGING
THE
ENGINE
OIL
cable
from
the
carburettor
7
Disconnect
the
wirings
from
the
starter
alternator
ignition
coil
oil
pressure
switch
and
temperature
sender
unit
8
Remove
the
clutch
slave
cylinder
Fig
A
2
and
its
return
spring
9
Disconnect
the
speedometer
cable
and
withdraw
the
plug
connector
from
the
reversing
light
switch
10
Disconnect
the
shift
rods
and
seJector
rods
and
remove
the
cross
shaft
assembly
as
described
in
the
section
Gear
box
II
Disconnect
the
front
exhaust
pipe
from
the
exhaust
manifold
disconnect
the
centre
pipe
from
the
rear
pipe
and
remove
the
front
pipe
pre
muffler
and
centre
pipe
assembly
12
Disconnect
the
propeUer
shaft
flange
from
the
companion
flange
from
the
gear
carrier
13
Jack
up
the
gearbox
slightly
and
remove
the
rear
engine
mounting
bracket
bolts
remove
the
mounting
cross
member
and
handbrake
cable
c1amp
14
Remove
the
bolts
securing
the
front
engine
mounting
brackets
to
the
crossmember
15
Attach
lifting
cable
or
chains
to
the
hooks
installed
at
the
front
and
rear
of
the
cylinder
head
Lower
the
jack
under
the
gearbox
and
carefully
lift
and
tilt
the
engine
and
gearbox
unit
Withdraw
the
engine
and
gearbox
from
the
compartment
making
sure
that
it
is
guided
past
the
accessories
installed
on
the
body
ENGINE
Dismantling
Remove
the
engine
as
previously
described
and
carefully
clean
the
exterior
surfaces
Cbeck
for
signs
of
fuel
oil
or
water
leaks
past
the
cylinder
head
and
block
Remove
the
air
cleaner
alternator
distributor
and
starter
motor
Plug
the
carburettor
air
horn
and
distributor
hole
to
prevent
the
ingress
of
foreign
matter
Remove
the
gearbox
from
the
engine
drain
the
engine
oil
and
coolant
Mount
the
engine
in
a
suitable
stand
the
special
engine
attachment
ST05260001
and
engine
ST0501SOO0
should
be
used
if
available
Fig
A
3
5
Page 18 of 171
h
W
and
connecting
rod
assemblies
Use
a
piston
ring
compressor
to
install
the
pistons
through
the
top
of
the
cylbder
bore
Make
sure
that
the
pistons
and
rings
and
the
cylinder
bores
are
lubricated
with
clean
engine
oil
The
pistons
should
be
arranged
so
that
the
F
mark
faces
to
the
front
and
with
the
piston
ring
gaps
positioned
at
1800
to
each
other
Each
piston
must
be
refitted
into
its
original
bore
NOTE
Single
inlet
valve
springs
are
used
on
the
1400
cc
engine
double
valve
springs
are
used
on
the
1600cc
and
1800
cc
engines
Screw
the
valve
rocker
pivots
with
the
locknuts
into
the
pivot
bushing
Set
the
camshaft
locating
plate
and
install
the
camshaft
in
the
cylinder
head
with
the
groove
in
the
locating
plate
directed
to
the
front
of
the
engine
Install
the
camshaft
sprocket
and
tighten
it
together
with
the
fuel
pump
earn
to
a
torque
reading
of
12
16
kgm
86
116
IbJt
a
eck
that
the
camshaft
end
play
is
within
the
specified
limits
Install
the
rocker
arms
using
a
screwdriver
to
press
down
the
valve
springs
and
fit
the
valve
rocker
springs
Gean
the
joint
faces
of
the
cylinder
block
and
head
thoroughly
before
installing
the
cylinder
head
Turn
the
crank
shaft
until
the
No
1
piston
is
at
T
D
C
on
its
compression
stroke
and
make
sure
that
the
camshaft
sprocket
notch
and
the
oblong
groove
in
the
locating
plate
are
correctly
positioned
Care
should
be
taken
to
ensure
that
the
valves
are
clear
from
the
heads
of
the
pistons
The
crankshaft
and
camshaft
must
not
be
rotated
separately
or
the
valves
will
strike
the
heads
of
the
pistons
Temporarily
tighten
the
two
cylinder
head
bolts
1
and
2
in
Fig
A
37
to
a
torque
reading
of
2
kgm
14
5
lb
ft
Fit
the
crankshaft
sprocket
and
distributor
drive
gear
and
install
the
oil
thrower
Ensure
that
the
mating
marks
on
the
crankshaft
sprocket
face
towards
the
front
Install
the
timing
chain
making
sure
that
the
crankshaft
and
camshaft
keys
are
XJinting
upwards
The
marks
on
the
timing
chain
must
be
aligned
with
the
marks
on
the
right
hand
side
of
the
crankshaft
and
camshaft
sprockets
It
should
be
noted
that
three
location
holes
are
provided
in
the
camshaft
sprocket
See
Fig
A
38
The
camshaft
sprocket
being
set
to
the
No
2
location
hole
by
the
manufacturers
A
stretched
chain
will
however
affect
the
valve
timing
and
if
this
occurs
it
will
be
necessary
to
set
the
camshaft
to
the
No
3
location
hole
in
the
camshaft
sprocket
The
chain
can
be
checked
by
turning
the
engine
until
the
No
1
piston
is
at
T
D
C
on
its
compression
stroke
In
this
position
adjustment
will
be
required
if
the
location
notch
on
the
camshaft
sprocket
is
to
the
left
of
the
groove
on
the
camshaft
locating
plate
as
shown
in
the
illustration
The
correction
is
made
by
setting
the
camshaft
on
the
No
3
location
hole
in
the
camshaft
sprocket
the
No
3
notch
should
then
be
to
the
right
of
the
groove
and
the
valve
timing
will
have
to
be
set
using
the
No
3
timing
mark
Install
the
chain
guide
and
chain
tensioner
when
the
chain
is
located
correctly
There
should
be
no
protrusion
of
the
chain
tensioner
spindle
See
Fig
A
39
A
new
tensioner
must
be
fitted
if
the
spindle
protrudes
Press
a
new
oil
seal
into
the
timing
cover
and
fit
the
cover
into
position
using
a
new
gasket
Apply
sealing
compound
to
the
front
of
the
cylinder
block
and
to
the
gasket
and
to
the
top
of
the
timing
cover
Ensure
that
the
difference
in
height
between
the
top
of
the
timing
cover
and
the
upper
face
of
the
cylinder
block
does
not
exceed
0
15
mm
0
006
in
Two
sizes
of
timing
cover
bolts
are
used
the
size
M8
0
315
in
must
be
tightened
to
a
torque
reading
of
1
0
1
6
kgm
7
2
17
Ib
ft
and
the
size
M6
0
236
in
to
a
torque
reading
of
0
4
0
8
kgm
2
9
81b
ft
Install
the
crankshaft
pulley
and
water
pump
tighten
the
pulley
nut
to
a
torque
reading
of
12
16
kgm
86
8
115
7Ib
ft
then
set
the
No
1
piston
at
T
D
C
on
its
compression
stroke
Finally
tighten
the
cylinder
head
bolts
to
the
specified
torque
reading
in
accordance
with
the
tightening
sequence
shown
in
Fig
A
3
The
bolts
should
be
tightened
in
three
stages
as
follows
First
stage
Second
stage
Third
stage
4
kgm
28
9
lbJt
6
kgm
43
4
IbJ
t
6
5
85
kgm
47
0
61
5lb
ft
The
cylinder
head
bolts
should
be
retightened
if
necessary
after
the
engine
has
been
run
for
several
minutes
Install
the
oil
pump
and
distributor
drive
spindle
into
the
front
cover
as
described
under
Engine
Lubrication
System
r
rf
i
Install
the
fuel
pump
water
inlet
elbow
and
front
engine
slinger
Fit
the
oil
strainer
into
position
coat
the
oil
sump
gasket
with
sealing
compound
and
fit
the
gasket
and
oil
sump
to
the
cylinder
block
Tighten
the
oil
sump
bolts
in
a
diagonal
pattern
to
a
torque
reading
of
0
6
0
9
kgm
4
3
6
5
IbJt
Adjust
the
valve
clearances
to
the
specified
cold
engine
ftgures
following
the
procedures
described
under
the
appropriate
heading
Final
adjustments
will
be
carried
out
after
the
engine
has
been
assembled
completely
and
warmed
up
to
its
nonnal
temperature
Install
the
rear
engine
slinger
exhaust
manifold
and
inlet
manifold
Refit
the
distributor
and
carburettor
assemblies
as
described
in
their
relevant
sections
Install
the
fuel
pipes
and
vacuum
hose
making
sure
that
they
are
securely
cl
ped
Refit
the
thermostat
housing
thermostat
and
water
outlet
together
with
the
gasket
Bond
the
rocker
cover
gasket
to
the
rocker
cover
using
sealant
and
fit
the
rocker
cover
to
the
cylinder
head
Install
the
spark
plugs
and
connect
the
high
tension
leads
Fit
the
left
hand
engine
mounting
bracket
and
install
the
clutch
assembly
using
the
alignment
tool
ST20600000
to
fit
the
clutch
to
the
flywheel
as
described
in
the
section
ClUfCR
Lift
the
engine
away
from
the
mounting
stand
and
into
the
engine
compartment
Install
the
alternator
bracket
adjusting
bar
alternator
fan
pulley
fan
and
fan
belt
in
the
order
given
Check
the
tension
of
the
fan
belt
by
depressing
the
belt
at
a
point
midw
y
between
the
pulleys
The
tension
is
correct
if
the
belt
is
deflected
by
8
12
mm
0
3
0
4
in
under
thumb
pressure
Fit
the
right
hand
engine
mounting
bracket
the
oil
filter
oil
pressure
switch
oil
level
gauge
and
water
drain
plug
Take
care
not
to
overtighten
the
oil
nIter
or
leakage
will
occur
Fill
the
engine
and
gearbox
to
the
correct
levels
with
recommended
lubricant
and
refill
the
cooling
system
Adjust
the
ignition
timing
and
carburettor
as
described
in
the
appro
priate
sections
17
Page 26 of 171
CoolIng
System
GENERAL
FAN
BELT
TENSION
FLUSHING
AND
DRAINING
THE
SYSTEM
THERMOSTAT
Testing
RADlA
TOR
Removal
GENERAL
The
cooling
system
is
pressurised
and
incorporates
a
water
pump
corrugated
fin
type
radiator
fan
and
a
pellet
type
thermostat
The
water
pump
is
of
the
centrifugal
type
and
has
an
aluminium
die
cast
body
The
volute
chamber
is
built
into
the
front
cover
assembly
and
a
high
pressure
sealing
mechanism
prevents
water
leakage
and
noise
The
fan
pulley
is
driven
by
the
V
belt
from
a
pulley
on
the
crankshaft
he
pellct
type
thermostat
enables
the
engine
to
warm
up
rapidlY
and
also
regulates
the
temperature
of
the
coolant
When
the
wax
pellet
in
the
thermostat
is
heated
it
expands
and
exerts
pressure
against
a
rubber
diaphragm
causing
the
valve
to
open
and
allow
the
coolant
to
flow
from
the
cylinder
head
back
to
the
radiator
As
the
pellet
is
cooled
itcontractsand
allows
the
spring
to
close
the
valve
thereby
preventing
coolant
from
leaving
the
cylinder
head
The
rad
ator
is
of
the
down
flow
type
with
an
expansion
tank
The
relIef
valve
in
the
radiator
filler
cap
controls
the
pressure
at
approximately
0
9
kg
sq
cm
l3Ib
sq
in
Always
try
to
avoid
removing
the
filler
cap
when
the
engine
is
hot
as
coolant
may
spray
out
and
cause
scalding
If
the
cap
must
be
removed
in
these
circumstances
use
a
lar
e
pic
c
of
cloth
to
hold
the
cap
and
turn
the
cap
sli
htlY
Walt
until
all
pressure
has
been
released
before
lifting
off
the
cap
F
AN
BELT
TENSION
The
fan
belt
drives
the
water
pump
and
alternator
as
well
as
the
fan
and
its
correct
adjustment
is
most
essential
A
loose
fan
belt
will
sl
ip
and
Y
e
r
and
most
probably
cause
overheating
alternatively
If
the
belt
IS
too
tight
the
pump
and
alternator
bearings
will
be
overloaded
The
belt
is
correctly
tensioned
if
it
can
be
depressed
by
approximately
10
mm
1
2
in
at
a
point
midway
between
the
fan
and
alternator
pulleys
See
Fig
R2
If
adjustment
is
neces
ary
slacken
the
alternator
mounting
and
adjustment
bolts
and
pivot
the
alternator
away
from
the
engine
to
tighten
the
belt
to
towards
the
engine
if
the
belt
is
to
be
slackened
NOTE
Always
apply
leverage
to
the
drive
end
housing
when
pivoting
the
alternator
and
never
to
the
diode
end
housing
or
the
alternator
will
be
damaged
Retighten
the
alternator
bolts
and
make
SUfe
that
the
belt
is
correctly
tensioned
FLUSHING
AND
DRAINING
THE
SYSTEM
The
radiator
and
water
passages
should
be
flushed
out
periodically
to
remove
the
accumulated
scale
or
sediment
Reverse
flushing
equipment
should
be
used
to
carry
out
a
completely
thorough
flushing
operation
but
the
owner
drivef
not
possessing
this
type
of
equipment
can
flush
out
the
system
in
the
following
manner
Drain
the
system
by
removing
the
radiator
filler
cap
and
opening
the
radiator
and
cylinder
block
drain
taps
Close
the
taps
again
and
refill
the
radiator
Run
the
engine
for
a
ShOft
period
and
then
rc
open
the
drain
taps
Continue
this
sequence
until
the
water
flowing
from
the
taps
is
clean
then
close
the
taps
and
refill
the
radiator
An
anti
freeze
mixture
should
always
be
used
in
Winter
time
The
Niss3n
long
life
coolant
L
L
c
is
an
ethylene
glycol
solution
containing
a
corrosion
preventative
which
can
remain
in
the
vehicle
throughout
the
year
but
must
not
be
mixed
with
other
products
It
is
advisable
to
check
the
radiator
and
heater
hoses
when
filling
with
anti
freeze
and
renew
them
if
signs
of
deterioration
are
apparent
WATER
PUMP
Replacement
The
water
pump
must
not
be
dismantled
and
should
be
renewed
if
it
becomes
faulty
The
pump
can
be
removed
in
the
following
manner
Drain
the
cooling
system
2
Take
the
fan
belt
off
the
pulley
3
Remove
the
fan
and
pulley
4
Remove
the
retaining
nuts
and
withdraw
the
water
pump
See
Fig
B
3
lnstallation
of
the
pump
is
a
reversal
of
the
removal
procedures
rERMOST
ATTesting
The
thermostat
is
located
in
the
water
outlet
passage
See
Fig
B
4
To
remove
the
unit
drain
the
cooling
system
remove
the
radiator
hose
and
the
water
outlet
elbow
Take
out
the
thermostat
25
Page 27 of 171
inter
illIl
@
Pl
i
i
n
i
II
L
Vi
It
q
n
lli
J
j
tr
rl
t
lli
3
t
11
1
i
l
Wt
r
till
I
cj
L
f0
co
7
Fig
B
l
The
cooling
system
Fig
8
2
Olecking
the
fan
belt
tension
Fig
B
3
Removing
the
water
pump
Fig
B
4
Removing
the
thermostat
26
Page 28 of 171
The
thermostat
can
be
tested
by
suspending
it
with
a
thermometer
in
a
container
ftlled
with
water
Heat
the
water
gradually
and
stir
it
to
obtain
a
uniform
temperature
Maintain
a
constant
check
of
the
temperature
and
make
sure
that
neither
the
thermostat
or
thermometer
touch
the
sides
of
the
container
or
false
readings
will
be
obtained
The
thermostat
should
begin
to
open
at
a
temperature
of
820C
1
50C
179
60F
2
70Fj
and
should
be
fully
open
with
a
maximum
valve
lift
of
8
mm
0
315
in
at
a
temperature
of
950C
2030F
When
installing
the
thermostat
apply
adhesive
to
both
sides
of
the
gasket
before
refitting
the
water
outlet
elbow
RADIATOR
Removal
Drain
the
cooling
system
as
previously
described
and
remove
the
front
grille
2
Disconnect
the
radiator
upper
hose
lower
hose
and
hose
to
the
reservoir
tank
3
Remove
the
radiator
securing
bolts
and
lift
out
the
radiator
Fig
B
4
It
should
be
noted
that
cars
fitted
with
automatic
transmission
incorporate
a
transmission
oil
cooler
which
must
be
disconnected
Installation
is
a
reversal
of
the
removal
procedure
refill
the
system
as
previously
described
FLUID
COUPLING
The
water
pump
is
equipped
with
a
fluid
coupling
on
vehicles
fitted
with
an
air
conditioner
The
fluid
coupling
Limits
the
maximum
fan
speed
to
approximately
3000
r
p
ro
and
eliminates
noise
and
loss
of
power
at
high
engine
speeds
A
fault
in
the
coupling
may
be
caused
by
the
entry
of
foreign
matter
If
a
fault
developes
the
oupling
must
be
removed
and
dismantled
and
the
interior
cleaned
by
washing
in
solvent
The
condition
of
the
seal
and
bearing
must
be
care
fully
checked
and
the
coupling
replaced
if
the
latter
items
have
become
blackened
If
oil
leaks
occur
it
will
be
necessary
to
replace
the
water
pump
assembly
with
the
coupling
After
cleaning
the
unit
refill
with
11
5
cc
silicon
oil
using
a
suitable
syringe
TechnIcal
Data
Radiator
Radiator
cap
working
pressure
Radiator
core
heightxwidth
x
thickness
1400
and
1600
cc
engines
510
body
1600
and
1800
cc
engines
610
body
Corrugated
fin
type
0
9
kg
sq
cm
13Ib
sq
in
280x488x38mm
I
LOx
19
2x
1
49
in
360x502x32mm
l4
2x19
8x1
26
in
Thermostat
valve
opening
temperature
Standard
B20C
l
BOOF
Cold
climates
880C
1900F
Tropical
climates
76
50C
l700F
Max
valve
lift
Cooling
system
capacity
With
heater
Without
heater
Cooling
system
capacity
With
heater
Above
8
mm
0
31
in
6
8litres
1
75
US
gall
1
5
Imp
gall
6
4litres
1
75
US
gall
1
375
Imp
gall
1600
and
1800
cc
engines
610
body
6
5litres
l
7
US
gall
1
375
Imp
gall
6
0
Iitres
1
625
US
gall
1
375
Imp
gall
Without
heater
27
Page 112 of 171
stopper
to
the
overrunning
clutch
side
and
removing
the
stopper
clip
Remove
the
stopper
and
overrunning
clutch
as
shown
inFig
M
7
Oean
the
dismantled
components
and
check
them
for
wear
or
damage
Cbeck
the
brushes
and
renew
them
if
worn
below
6
5mm
0
257
in
Fit
new
brushes
if
the
brush
contact
is
loose
Cbeck
the
brush
holders
and
spring
clips
and
make
sure
that
they
are
not
bent
or
distorted
The
brushes
should
move
freely
in
their
housings
and
can
be
eased
with
a
file
if
necessary
The
brush
spring
tension
should
be
approximately
0
8kg
1
76Ib
and
can
be
checked
with
a
spring
balance
as
shown
in
Fig
M
S
Armature
assembly
Make
sure
that
the
surface
of
the
commutator
is
not
rough
or
pitted
Oean
and
lightly
polish
with
a
No
500
emery
cloth
if
necessary
If
the
commutator
is
badly
worn
or
pitted
it
should
be
skimmed
in
a
lathe
only
a
light
cut
must
be
taken
to
remove
the
minimum
amount
of
metal
If
the
commutator
diameter
wear
limit
of
0
2mm
0
OS
in
is
exceeded
the
assembly
must
be
renewed
Undercut
the
mica
between
the
commutator
segments
when
the
depth
of
mica
from
the
surface
of
the
segment
is
less
than
0
2mm
0
08
in
The
depth
should
be
between
0
5
0
8mm
0
0197
0
0315
in
as
shown
in
Fig
M
9
The
armature
shaft
should
be
checked
for
straightness
by
mounting
between
the
centres
of
lathe
and
positioning
a
dial
gauge
as
shown
in
Fig
M
I
O
Renew
the
armature
if
the
bend
of
the
shaft
exceeds
0
08mm
0
0031
in
Field
coils
testing
Test
the
field
coils
for
continuity
by
connecting
a
circuit
tester
between
the
positive
terminal
of
the
field
coil
and
the
positive
terminal
of
the
brush
holder
as
shown
in
Fig
M
I
I
If
a
reading
is
not
obtained
the
field
circuit
or
coil
is
open
Cbnnect
the
tester
to
the
yoke
and
field
coil
positive
teoninal
as
shown
in
Fig
M
12
to
check
the
field
coils
for
earthing
Unsolder
the
connected
part
of
each
coil
and
check
the
circuit
for
earthing
in
a
similar
manner
Renew
the
field
coils
if
they
are
open
earthed
or
short
circuited
Outch
assembly
The
overrunning
clutch
must
be
replaced
if
it
is
slipping
or
dragging
Examine
the
pinion
and
sleeve
making
sure
that
the
sleeve
is
able
to
slide
freely
along
the
armature
shaft
spline
Inspect
the
pinion
teeth
for
signs
of
rubbing
and
check
the
fly
wheel
ring
gear
for
damage
or
wear
Bearings
Inspect
the
metal
bearing
bushes
for
wear
and
side
play
The
bushes
must
be
renewed
if
the
clearance
between
the
bearing
bush
and
armature
shaft
is
in
excess
of
0
02mm
0
008
in
New
bearing
bushes
must
be
pressed
in
so
that
they
are
flush
with
the
end
of
the
case
and
reamed
ou
t
to
give
a
clearance
of
0
03
0
10
mm
0
0012
0
0039
in
H
Solenoid
assembly
Inspect
the
solenoid
contact
surface
and
replace
if
showing
signs
of
wear
or
roughness
Replace
the
pinion
sleeve
spring
if
weakened
Check
the
series
coil
by
connecting
an
8
12
volt
supply
between
the
Sand
M
terminals
as
shown
in
Fig
M
13
The
series
coil
is
normal
if
the
plunger
operates
Test
the
shunt
coil
by
connecting
the
S
terminal
the
M
terminal
and
the
solenoid
body
as
shown
in
the
lower
illustration
of
Fig
M
13
Open
the
M
terminal
when
the
plunger
is
operated
the
shunt
coil
is
satisfactory
if
the
plunger
stays
in
the
operated
position
Measure
the
length
L
between
theylonger
adjusting
nut
and
solenoid
cover
Press
the
plunger
against
a
firm
surface
as
shown
in
Fig
M
14
and
check
that
the
dimension
is
within
the
figures
given
Turn
the
adjusting
nut
if
necessary
until
the
required
dimension
is
obtained
STARTER
MOTOR
Assembly
and
Installation
The
assembly
and
installation
procedures
are
a
reversal
of
the
removal
and
dismantling
operations
When
assembling
the
starter
smear
the
armature
shaft
spline
with
grease
and
lightly
oil
the
bearing
bushes
and
pinion
ALTERNATOR
The
alternator
is
driven
by
the
fan
belt
and
has
an
advant
age
over
a
dynamo
in
that
it
provides
current
at
low
engine
speeds
thereby
avoiding
battery
drain
Maintenance
is
not
normally
required
but
the
tension
of
the
fan
belt
should
be
checked
and
adjusted
if
necessary
as
described
in
the
section
COOLING
SYSTEM
Care
must
be
taken
not
to
overtighten
the
fan
belt
or
the
alternator
bearings
will
be
overloaded
The
alternator
output
can
be
checked
with
the
alternator
in
the
vehicle
by
carrying
out
the
following
test
Ensure
that
the
battery
is
fully
charged
Withdraw
the
connectors
from
the
alternator
F
and
N
terminals
and
connect
a
jumper
lead
between
the
F
and
A
terminals
Connect
a
voltmeter
to
the
E
and
A
alternator
terminals
with
the
negative
lead
to
terminal
E
and
the
positive
lead
to
the
terminal
A
as
shown
in
Fig
M
IS
Switch
the
headlamps
on
to
full
beam
and
start
the
engine
Increase
the
engine
speed
gradually
and
note
the
reading
on
the
voltmeter
when
the
engine
reaches
a
speed
of
approximately
lOaD
rpm
The
alternator
is
operating
satisfactorily
if
the
voltmeter
shows
a
reading
above
12
5
volts
If
the
reading
is
below
12
5
volts
the
alternator
is
defective
and
should
be
removed
for
inspection
ALTERNATOR
Removal
Disconnect
the
negative
lead
from
the
battery
and
the
two
lead
wires
and
connector
from
the
alternator
Slacken
the
alter
nator
mounting
bolts
and
take
off
the
fan
belt
Take
out
the
mounting
bolts
and
withdraw
the
alternator
from
the
vehicle
III
Page 142 of 171
pulley
should
be
aligned
with
the
T
mark
on
the
chain
cover
Install
the
cylinder
head
assembly
Coat
the
cylinder
block
side
of
the
head
gasket
with
sealing
agent
Three
Bond
No
4
or
equivalent
but
take
care
that
the
scaling
agent
does
not
enter
the
cylinders
Tighten
the
head
bolts
in
several
stages
to
a
torque
reading
of
8
0
to
9
0
kgrn
58
to
65
lb
ft
Tighten
the
bolts
to
the
sequence
shown
in
Fig
A
IB
Pull
the
timing
chain
out
of
the
chain
cover
and
set
it
on
the
camshaft
sprocket
so
that
the
timing
marks
are
aligned
then
place
the
sprocket
and
chain
on
the
camshaft
Install
the
distributor
drive
gear
on
the
camshaft
and
tighten
the
bolt
to
a
torque
reading
of
4
5
to
5
5
kgrn
32
6
to
39
8
lb
ft
Note
that
the
camshaft
bolt
has
a
left
hand
thread
Adjust
the
valve
clearances
as
described
under
the
appro
priate
heading
Fit
the
rubber
plugs
at
the
front
and
rear
of
the
cylinder
head
taking
care
to
apply
sealing
agent
to
the
rear
plug
Install
the
chain
adjusting
screw
and
adjust
the
tension
of
the
chain
in
the
following
manner
Rotate
the
crankshaft
clockwise
to
establish
the
correct
chain
tension
screw
the
adjusting
screw
fully
home
then
back
it
off
by
half
a
turn
and
secure
with
the
locknut
Install
the
valve
rocker
cover
and
fit
the
water
pump
Note
that
one
of
the
water
pump
mounting
bolts
also
secures
the
generator
adjusting
arm
Install
the
bracket
and
alternator
water
pump
pulley
fan
blades
and
fan
belt
Tighten
the
fan
bolts
and
lock
each
pair
of
bolts
together
using
wire
inserted
through
the
holes
provided
in
the
bolts
Install
the
oil
filter
and
fit
the
rocker
cover
hose
Install
the
distributor
so
that
the
vacuum
control
unit
and
rotor
arc
positioned
as
shown
in
Fig
A
19
Oil
the
distributor
driven
gear
Fit
the
breather
assembly
the
clamp
of
the
pipe
is
tightened
together
with
the
exhaust
manifold
Install
the
spark
plugs
and
connect
the
high
tension
leads
Install
the
exhaust
manifold
Fit
the
head
shield
plate
and
engine
slinger
and
tighten
them
together
Note
that
the
exhaust
manifold
gasket
must
be
fitted
with
the
steel
plate
facing
the
manifold
Install
the
clutch
as
described
in
the
section
CLUTCH
Remove
the
engine
from
the
mounting
stand
and
install
the
gearbox
intake
manifold
and
carburettor
stater
motor
engine
mounting
oil
pressure
warning
switch
etc
Fill
the
engine
and
gearbox
to
the
correct
levels
with
recommended
oils
and
refill
the
cooling
system
Adjust
the
ignition
timing
and
carburettor
as
described
in
the
appropriate
sections
VALVE
CLEARANCES
Adjusting
The
valves
clearances
can
be
adjusted
in
a
similar
manner
to
the
instructions
given
for
the
L14
LI6
L18
engines
Initially
adjust
the
clearances
with
the
engine
switched
off
and
cold
to
0
2
mm
0
0079
in
for
both
intake
and
exhaust
valves
Set
the
final
clearances
to
0
28
mm
0
011
in
for
both
intake
and
exhaust
valves
with
the
engine
warmed
up
to
its
normal
operating
temperature
OIL
PUMP
The
gear
type
oil
pump
is
chain
driven
from
a
sprocket
on
the
crankshaft
The
pump
can
be
removed
in
the
following
manner
1
Remove
the
sump
plug
and
drain
the
engine
oil
Remove
the
distributor
as
described
in
the
section
IGNITION
2
Remove
the
cylinder
head
assembly
fan
belt
crankshaft
pulley
and
oil
sump
3
Take
off
the
chain
cover
with
oil
fl
inger
4
Remove
the
oil
pump
and
crankshaft
sprockets
with
the
drive
chain
then
withdraw
the
pump
after
removing
the
four
mounting
bolts
Separate
the
cover
from
the
body
by
unscrewing
the
four
securing
bolts
and
withdraw
the
drive
and
idler
gear
assemblies
Unscrew
the
threaded
plug
and
take
out
the
relief
valve
and
spring
Clean
the
parts
thoroughly
and
inspect
them
four
signs
of
wear
or
damage
Check
the
following
clearances
Gear
backlash
0
1
to
0
5
mm
0
0039
to
0
0195
in
Side
clearance
between
gear
and
body
0
016
to
0
15
mm
0
0006
to
0
0059
in
Clearance
between
drive
shaft
and
body
0
016
to
0
1
mm
0
0006
to
0
0039
in
Clearance
between
drive
shaft
and
cover
0
02
to
0
1
mm
0
00078
to
0
0039
in
Clearance
between
idler
gear
and
idler
shaft
0
016
to
0
1
mm
0
0006
to
0
0039
in
Assembly
is
a
reversal
of
the
dismantling
procedures
taking
care
to
position
the
gears
so
that
the
dotted
mark
is
towards
the
cover
Install
the
pump
and
adjust
the
tension
of
the
drive
chain
by
ph
otting
the
pump
body
as
shown
in
Fig
A
20
When
the
chain
is
correctly
tensioned
it
should
be
capable
of
a
deflection
of
2
0
to
3
0
mm
0
079
to
0
118
in
as
indicated
OIL
PRESSURE
RELIEF
VALVE
The
pressure
relief
valve
shown
in
Fig
A
21
is
not
adjustable
This
valve
regulates
the
oil
pressure
to
4
55
4
85
kg
sq
cm
64
7
69
0
lb
sq
in
and
when
opened
allows
the
oil
to
by
pass
through
a
passage
in
the
pump
body
and
return
to
the
sump
Check
the
free
length
of
the
spring
which
should
be
64
0
to
66
0
mm
2
51
to
2
60
in
The
compressed
length
should
be
50
mm
at
7
8
to
9
7
kg
1
96
in
at
17
2
to
21
4Ibs
Renew
the
spring
if
necessary
OIL
FILTER
The
oil
filter
is
of
the
full
flow
type
with
a
replaceable
element
and
incorporates
a
by
pass
valve
in
the
cover
Oil
leaks
can
be
corrected
by
replacing
the
body
centre
shaft
or
cover
gaskets
The
body
and
centre
shaft
gaskets
should
always
be
renewed
after
dismantling
the
filter
S
1
Page 147 of 171
Crank
shaf
bend
Less
than
0
02
mm
0
0008
in
e
Piston
Pis
on
diameter
Ellipse
difference
Ring
groove
wid
h
84
968
85
0
mm
3
345
3
346
in
0
4
mm
0
01
7
in
Top
0
05
0
0020
0
0
03
mm
0
0787
0
001
in
Second
I
03
0
0012
2
0
0
01
mm
0
0787
0
0004
in
Oil
0
03
0
0012
4
0
0
01
mm
0
1575
0
0004
in
Piston
ring
side
clearance
0
035
0
55
mm
0
0014
0
0022
in
Top
0
04
0
08
mID
0
0016
0
0031
in
Second
0
02
0
06
mm
0
0008
0
0024
in
Oil
0
02
0
06
mm
0
0008
0
0024
in
Piston
to
bore
clearance
Ring
gap
Top
0
35
0
55
mm
0
0138
0
0217
in
Second
0
3
0
5
mm
0
0118
0
0197
in
Oil
0
35
0
55
mm
0
0138
0
0217
in
Top
0
01
0
0004
2
0
03
mm
0
0787
0
0012
in
Second
0
01
0
0004
2
0
03
mm
0
0787
0
0012
in
Oil
0
Q1
0
0004
4
0
03mm
0
I575
0
0012in
Ring
height
Piston
pin
interferenl
c
fit
of
piston
pin
to
piston
o
0
09
mm
0
0
0035
in
0
003
0
013
mm
0
0001
0
0005
in
Clearance
between
piston
pin
a
connecting
rod
bushing
Piston
pin
outer
diameter
21
991
22
0
mm
0
8658
0
8661
in
Connecting
rod
bushing
inner
diameter
21
995
22
008
mm
0
8659
0
8664
in
EMISSION
CONTROL
Crankcase
emission
con
trol
Closed
type
Exhaust
emiision
control
Nissan
Air
Injec
ion
System
Anti
backIrre
valve
Carburettor
Nihonkikaki
D3034C
Type
Model
Duration
time
Air
by
pass
DV54
1
3
L7
sec
at
500
Hg
9
7
in
Hg
Distribu
or
Hitachi
D423
Spark
plugs
BP
6E
Check
valve
Air
pump
Type
Opening
pressure
AMC
0
15
mAq
5
91
in
Aq
Model
Capacity
Pulley
ratio
ECP
20Q
IA
200
cc
rev
120
120
1
00
Cooling
fan
Type
No
of
blades
Spider
4
S16
Page 168 of 171
MO
MI
1224
D
I
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f
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A
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Drain
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I
42
Cleantlement
3
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Check
il
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4
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511
1
11
41
Gle
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7
I
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81
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27
Check
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Change
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ill
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Check
11IIOpup
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I
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SHOCKASSORBERS
Check
Il
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5
PROP
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GREASE
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Check
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Cleen
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Service
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Replace
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Clun
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Cleen
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Top
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5
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Clun
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38
I
Check
fluid
levll
IlL
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ign
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i
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t
1
l
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CheCk
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y
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Chltk
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Lubrlc
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i
Clleck
top
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L
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Check
topup
4
aJdM
Cllltkspet
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i
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en
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1S
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116
Lubriclt
1il
If
I
II
Clleck
topup
52
1
i
Chtck
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I
I
Gre
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I
1
I
I
I
Clunfiltlr
55
L
I
I
I
Chick
top
up
fluid
I6
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W
e
I
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1
Renewfiltlr
58
I
Check
topupflu
d
i91
i
I
i
Renrwfluid
I
I
I
I
I
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11
I
I
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I
CAR
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E
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j
II
1
I
1
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Ell
Lubrictt
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r
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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
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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
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Clled
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ServiceJndclean
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Adjult
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Check
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PROP
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S
Check
lor
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JJ
Tiglltenbolu
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Check
tor
wear
n
Tiglltenboltl
Clllckbootgeiltrl
Clleckoperltion
Ch
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Tighten
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Clleclbootgaiterl
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Clleck
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Check
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81
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Cleen
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Check
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0
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9
Checkforwp
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192
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Adjultpres
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Check
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I
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Renew
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Check
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114
1
STEERING
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Check
U1L
H
CHECK
FOR
Oil
FUEL
WATER
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LEAKS
1181
I
I
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11
1
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Check
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Adjust
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required
12
DEFECTS
Report
12
EVERY
MOnthl
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1000
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1000
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EngmlMountings
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24
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