clutch DATSUN 610 1969 Owner's Manual

inter
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FIg
M
7

Over
unning
clutch

assembly
1

m
ILE

COMMUTATOR

0
5
to
0
8
mrtl

ROUND

O
0197
to
0
0315
nl

SEGMENT

MICA

CORRECr
INCORRECT

Fig
M
9

Undercutting
the
commutator
insulation

Fig
M
11

Testing
the
field
coils
for
continuity

5

y
SERIES
COIL

5

r
SHUNT
COIL

Fig
M
13

Testing
the
solenoid
witch

10
J

Fig
M
8

Checking
the
brush

pring
tension

Fig
M
lO

Checking
the
armature
shaft
for
run
out

J

I

I
J

I

L
j
J

j

Fig
M

12
Testing
the
field
coils
for

earthing

1

rl

wr

v
E
L
DIMENSION

131
7

to
32
3mm
1
248
to
1
272
in

I

Adjus
llUt

2
PluJlKeradjuster

F
8
M
14

Measuring
the

gap
between

pinion

and

pinion
stop

I

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

Clutch
MIPTOOlS
Trouble
Shootmg
Steering
IYMmlMS

mDING
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ITIBJJNG
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STEEIUNG
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WHEEL
SHIIlOlY

CAR
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ONE
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POOR
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OF
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WHEEL
10
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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

ENGINE

Dismantling

Remove

the

engine
from
the
vehicle
as

previously
described

and

carefully
clean
the
exterior

surfaces
The
alternator

distribu

tor

and
starter
motor
should
be
removed
before

washing
Plug

the
carhurettor

air
horn
to

prevent
the

ingress
of

foreign
matter

Place
the

engine
and
transmission
on

the
engine
carrier
ST4797

0000
if

available
and
dismantle
as
follows

Remove
the

gearbox
from
the

engine
Disconnect
the
intake

manifold

water
hose
the
vacuum

hose
and
the
intake
manifold

to
oil

separator
hose
Remove
the
intake
manifold
with
the

carburettor
Fit
the

engine
attachment
ST3720OG18
to
the

cylin

der
block
and

place
tre

engine
on
the
stand
ST371
00000

Remove
the
clutch

@
Ssembly
as
described
in
the
section

CLUTCH
Remove
the
exhaust
manifold
and
heat
baffle

plate

Take
off
the
fan
blades
and
remove
the
water

pump
pulley
and

fan
belt
Remove
the
rocker
cover
hose
manifold
heat
hose
and

by
pass
hoses

Remove
the

generator
bracket
and
the
oil
fIlter
Extract
the

engine
breather

assembly
from
above
Note
that
the
breather

is
fitted
to
the

guide
and
is
installed
with
a
O

ring
which
is

pressed
into
the

cylinder
block

Flatten
the
10ckwasher
and
unscrew
the
crankshaft
pulley

nut
Withdraw
the

pulley
with
the

puller
ST44820000
if
available

but
do
not
hook
it
in
the
V

groove
of
the

pulley

Remove
the
rocker
cover
and
take
off
the
rubber

plug

located
on
the
front
of
the
cylinder
head

Straighten
the
lock

ing
washer
and
remove
the
bolt

securing
the

distributor
drive

gear
and
camshaft

sprocket
to
the
camshaft
Remove
the
drive

gear
and
take
off
the

sprocket
See

Fig
A
3

Remove
the

cylinder
head
bolts
in
reverse

order
to
the

tightening

sequence
sOOwn
in

Fig
A
18
and
lift
off
the

cylinder

head
as
an

assembly
See

Fig
A
4
Note

that
in
addition
to
the

ten

cylinder
head
bolts
there
are
also
two
bolts

securing
the

chain
cover
to

the
head
Invert
the

engine
and
remove
the
oil

sump
Remove
the
chain
cover
and
oil

flinger
Take
off
the
nut

securing
the
oil

pump
sprocket
and
withdraw
the

sprocket
with

the
chain
in

position
as
shown
in

Fig
A5
Remove
the
oil

pump

and
stramer
Note

that
two
of
the

pump
mounting
bolts
are

pipe
guides

Remove
the

timing
chain
crankshaft

sprocket
chain
ten

sioner
and
chain

stop

Remove
the

connecting
rod

caps
and

push
the

piston
and

connecting
rod
assemblies

through
the
tops
of
the
bores

Keep

all

parts
in
order
so

they
can
be
assembled
in
their

original
posi

tions

Take

out
the

flywheel
retaining
bolts
and
withdraw
the

flywheel
Remove
the
main

bearing

caps
but
take
care
not
to

damage
the

pipe
guides
Lift
out

the
crankshaft
and
main
bear

ings
noting
that
the

bearings
must
be
reassembled
in
their

original

positions
Remove
the

piston
rings
with
a
suitable

expander
and

take
off
the

gudgeon
pin
clips
The

piston
should
be
heated
to

a

temperature
of
50
to
600
122
to
1400F
before

extracting

the

gudgeon
pin
Keep
the
dismantled

parts
in
order
so

they

can
be
reassembled
in
their

original
positions

Remove
the
camshaft
rocker
ann
shaft
and
rocker
ann

assemblies
from
the

head

by
taking
off
the
cam

bracket

clamp

ing
nuts
It
is
advisable
to
insert
disused
bolts
in
the
No
1

and

No
5
bracket
holes
as
the
cam
bracket
will
fall
from
the
rocker

ann
shaft
when

it
is
removed
Remove

the
valve

cotters

using

the

special
tool
ST47450000

and
dismantle
the
valve
assemblies
Keep
the

parts
together
so

they
can
be
installed
in
their

original

order

ENGINE

Inspection
and
Overhaul

Cylinder
head
and
valves

Inspection
and
overhaul

procedures
can

be
carried
out

by

following
the
instructions

previously
given
for
the
L14
LI6

and
LIB

engines
noting
the

following
points

Measure
the

joint
face
of
the

cylinder
head

using
a

straight

edge
and
feeler

gauge
The

permissible
amount
of
distortion
is

0
03
mm
0
0012
in
or
less
The
surface
of
the
head
must
be

reground
if
the
maximum
limit
of
0

1
mm

0
0039
in
is

exceeded

Oean
each
valve

by
washing
in
petrol
then

carefully
examine

the
stems
and
heads
Discard

any
valves
with
worn

or

damaged

stems
Use
a

micrometer
to
check
the
diameter
of
the
stems

which
should
be
8
0
mm
0
315
in
for
both
intake
and
exhaust

valves
If

the
seating
face
of
the
valve
is

excessively
burned

damaged
or
distorted
the
valve
must
be
discarded
The
valve

seating
face
and
valve

tip
can
be
refaced
if

necessary
but

only

the
minimum
amount
of
metal
should
be
removed
Check
the

free

length
and
tension
of
each
valve

spring
and

compare
the

figures
obtained
with
those

given
in
Technical
Data
at
the
end

of
this
section
Use
a

square
to
check
the

springs
for
deformation

and

replace
any
spring
with
a
deflection
of
1
6
mm
0
0630
in

or
more

Valve

guides

Measure
the
clearance
between
the
valve

guide
and
valve

stern
The
stem
to

guide
clearance
should

be
0
025
0
055
mm

0
0010
0
0022
in
for
the
intake
valves
and
0
04
0
077
mm

0
0016
0
0030
in
for
the
exhaust
valves
The
maximum
clear

ance

limit
is
0
1
mm
0
0039
in
The
valve

guides
are
held
in

position
with
an
interference
fit
of
0
040
0
069
mm
0
0016

0
0027
in
and
can
be
removed

using
a

press
and
valve

guide

replacer
set
ST49730000
under
2
ton

pressure
This

operation

can

be
carried
out
at
room

temperature
but
will
be
more
effec

tively

performed
at
a

higher
temperature
Valve

guides
are

available
with
oversize
diameters
of
0
2
mm
0
0079
in
The

cylinder
head
guide
bore
must
be
reamed
out
at

normal
room

temperature
and
the
new

guides
pressed
in
after

heating
the

cylinder
head
to
a

temperature
of

approximately
800
C
1760F

The
standard
valve

guide
requires
a
bore
of
14
0
14
018
mm

0
551
0
552

in
and
the
oversize
valve

guide
a
bore
of
14
2

14
218
mm
0
559
0
560
in
Ream
out
the
bore
of
the

guides

to
obtain
the
desired
finish
and
clearance
Use
the
reamer
set

ST49710000
to

ream
the
bore
to
8
000
8
015
mm
0
3150

0
3156
in
The
valve
seat

surface
must

be
concentric
with
the

guide
bore
and
must
be
corrected
if

necessary
using
the
new

valve

guide
as
axis

Valve
seat
inserts

Check
the
valve
seat

inserts
for

signs
of

pitting
The

inserts

cannot
be

replaced
but

may
be
corrected
if

necessary
using
a

valve
seat
cutter

ST49720000

Scrape
the
seat

with
the
450

cutter
then

reduce
the
width
of
the

contacting
faces

using
the

150
and
600
cutters
for
the
intake
valve
inserts
and
150
cutter

for
the
exhaust
valve
inserts
Seat
correction
dimensions
are

shown
in
millimeters
in

Fig
A
6

Lap
each
valve
into
its
seat
after

correcting
the
seat
inserts

Place
a
small

quantity
of
fme

grinding
paste
on

the

seating
face

of
the
valve

and
lap
in
as

previously
described
for
the
Ll4
LI6

and
L
18

engines

S5

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

MO

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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

1968

I

l

t
l

f
t

B
I

J

TECHNICAL

NOTES

ENGINE

DATA
DATSUN

WJ
G
N

B1
B1
l1

3
1

L

Pi

I
il

iUJ

4

RltiFtIn
GMrtlax
Diftel
ll
rti

earner

ry
20
1DI
KII
II2
ooo
M

17

Stlfring
Linklgt
Sell
Joints

IG
Gun
1

fittin
a
1

Stltrillg
SwiwI
II
Jointl
G

Gun
4

fittinlJLl

23
DISC
8RAKES

only
DRUM

BRAKES
chin
ry
4O
IJ
I
KM

24
DOJ
MI
n

o
badClrbumtorewery

40
lXI
KIIJ24
D1111

4
lII
ifold

11
Abo
IdIIr

Box
27

Umhlntlement

28
VlXCUI
element

16A
DRIVE
SHAFT

BAll
SPLINES
rlpe

ry
SO
OlXI
KM

30
OOO
MI

Saloon

Illy

UIWlt
Ht
ION

I
VALVE
Lt
l

tiMI
t

I
IDLING
SPEED

IspARK
PLUG

GAPIDISTR
POINT
GN

I
OWEn
ANGLE

I
STATIC

IGN
TlMING
STROB

twcm2
psi

INLET
mm
in
hot

hllcold
c
OUTlET
m

mm
incbll
mmJinc
r
dIgreer

BIDC
dIar
BTDC

n
m

RMer
to
Technical

Data

lYRES

I
STANDARD
SIZE

IFRDNT
PRESSUREI
REAR

PflESSUm

I
OPTIONAl51ZE

I
FRONT
PRESSURE

I
REAlI
l
lIESSUIE

I
BRAKES

PrwaulWkWem2
p
si
Ilarmlll
full
narltlll
full

normalJfull

nonnlllfull
W1NIIIUIII

TlUCKNEA

SHOE
mm
in
PAD

Ref
to
Technical
Data

TEST
lOAD

I
TOI
IN

iIlDUTlo

l

kO
lbl
front
mm

in
CAIll
BER

delftlllmin
CASTOR

I
KING
PU
INClNJ
TOE
lNliliOUTlo

I
dIon
min
min
I

rI
nmfin
CAMBEll

I
TOE
oIII

TURIIIS

I

rmin
d
It

laCK
sss

STEERING

GEOMETRY

U10

UtOS

WAGON

TORQUE

VALUES

mlD
b
h

TBA
R
ter
to
T
anal
Data

8D

I
V

BELT
TENSION

RAtJ
AP

PRES8

1
CLUTCH

PLAY

mmJinches
cm2

tIIi
mmJinct

4

5
5

5132
5
39

10
15
4
8
0
9
12

@
me

5
SOll13
4Pfl
12V
4QAh

NGKBP6E
FRAM

PH
2850
FRAM

CAGS1

5
60513
4Pfl

12V
50Ah

12V
60Ah

ImDIImI

t11
C

u
toIlho
AUTOSERVICE
DATA

CHART

I

Part
NanleH
and
AlternatlyeS

Certain

parts
of
motor
cars
are

known

by
other
names
in
different

areas

and
countries
A

list
c
f
the
common
alternatives
is

given
below

ENGINE
ELECTRICA
L

Gudgeon
pin
Piston

pin
small
end

pin
Wrist
Generator

Dynamo

pin
Control
box
Cut

out
Voltage

regulator
Volt

Inlet
valve

Intake
valve

age
control
Circuit
breaker

Piston
oil
control

ring
Piston

scraper
ring

Capacitor
Condenser

Induction
manifold

Inlet
manifold
intake
manifold

Interior

light
Dome

lamp

Oil

sump
Oil

pan
Oil
reservoir

Sump
tray

Core

Plug
Expansion

plug
Welch

plug
Lens
Glass

Sealing
disc

Head

lamp
ring
Headlamp
surround

Headlamp

Dipstick
Oil

dipper
rod
Oil
level

gauge
mouldin

rod
Dillevel
indicator
Direction
indicators

Signal
lamps
Flashers

Silencer
Muffler

expansion
box
diffuser

Micrometer

adjustment
Octane
selector

Tappets
Valve

lifter

push
rods
Rear

lamps
Tail

lamps

Reversing
light
Back
u

pUgh
t

FUEL

Carburettor
choke
Carburettor

venturi
STEERING

Slow

running
jet
Low

speed
jet
Idler

jet

Drop
arm
Pitman
ann

Volume
control
screw

Idling
mixture
screw

Rocker
shaft
Pitman
shaft

Drop
ann
shaft

Fuel

pump
Petrol

pump
Fuel
lift

pump
Swivel

pin
Pivot

pin
King
pin
Steering
pin

Air
cleaner
Air
silencer
Muffler

Stub
axle
Swivel
axle

Fuel
lank

Petrol
Tank
Track

rod
Cross
tube

Tie
rod

Accelerator
Throttle

Drag
link
Side
tube

Steering
connecting

rod

CLUTCH

Steering
column

Steering
gear
shaft

Clutch
release

bearing
Throwout

bearing
Thrust

bearing
Steering
column

bearing
Mast

jacket
bearing

Clutch

lining
Disc

facing
Friction

ring
Steering
arm

Steering
knuckle
ann

Spigot
bearing
Clutch

pilot
bearing
Stator
tube
Control
tube

Clutch

housing
Bell

housing
Steering
joints
Steering
knuckles

GEARBOX
BRAKES

Gearbox
Transmission
Master

cylinder
Main

cylinder

Gear
lever

Change
speed
lever
Gearshift
Brake
shoe

lining
Brake
shoe

facing

lever

BODY

Selector
fork

Change
speed
fork
Shift
fork

Input
shaft
Constant

motion
shaft
First
gannet

Hood

motion
shaft
drive

gear
First

Luggage
locker
Boot

Luggage

compartment

reduction

pinion
Main
drive

pin

Luggage
locker
lid
Boot
lid
Rear
deck

ion

Clutch
shaft
Clutch
gear

Mudguards
Quarter
panels
Fenders
Mud

Countershaft

Layshaft
wings

Synchro
cone

Synchronizing
ring
Roof

Canopy

Reverse
Idler

gear
Reverse

pinion
Nave

plate
Wheel
disc
Hub

cap

Finishing

strip
Moulding
Chrome
strip

REAR
AXLE
Windscreen
Windshield

Rear
Axle
Final

drive
unit
Rear
window
Rear
windscreen
Rear
windshield

Crown
wheel

Ring
gear
Final
drive

gear

Spiral
Backlight

drive
gear
Quarter
ven
t
N
D
V

No

draught
ventilator

Bevel

pinion
Small

pinion
spiral
drive

pinion
Bumpers
Fenders

Loom
Harness

U
bolts

Spring

clips

Odometer

Trip
recorder

Axle
shaft
Half

shaft
Hub

driving
shaft
Jack

Bonnet
catch
Hood
latch

driving
shaft

Kerosene
Paraffin

Differential

gear
Sun
wheel

Boot
Trunk

Differential

pinion
Planet
wheel