1969 DATSUN 610 oil

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

carrying
out

extensive
tests

with
the

necessary
equipment
The

hoses
and
connectors
can
of
course
be
checked
for

signs
of

leakage
and
corrected
as

necessary
Also
the
tension
of
the
air

pump
belt

IGNITION
TIMING
AND
IDLING
SPEED

Emission
control

system

The

ignition
timing
should

be
set
and
the

idling
speed

mixture

adjusted
in
the

folloWing
manner

Run
the

engine
until
it
reaches
its
normal

operating
tem

perature
Connect
an

ignition
tachometer
and

timing
light
observ

ing
the
manufacturers
instructions

NOTE
If
the
vehicle
is

equipped
with
automatic
transmission

make
sure
that
the

dashpot
does
not

prevent
the
throttle
from

closing
Turn

the
throttle
shaft
arm

adjusting
screw
anti
clock

wise
so
that
the

tip
of
the
screw

is
clear
of
the
throttle
shaft

arm
see

Fig
A

26

Turn
the
throttle

adjusting
screw
to
set
the

idling
speed
to

700
r

p
m
650

rpm
for

automatic
transmission

Adjust
the

ignition
timing
to
5
A

T
D
C
Refererence
should
be
made
to

the
instructions

given
in
the
section
IGNITION
SYSTEM
for

the
L14
L16
and
LI8

engines
for

ignition
timing
details

Turn
the

idling
adjustment
screw
and

throttle
adjusting
screw

until
the

engine
runs

smoothly
a
t
the
correct

idling
speed
Turn

the

idling
adjustment
screw
clockwise
until
the

engine
speed

starts
to

drop
as
a
weaker
mix
ture
is

obtained
Now
turn

the

idling
adjustment
screw
anti
clockwise

by
one
turn
one
and
a

half
turns
for
automatic

transmission
to
obtain
a
richer
mix

ture

Adjust
the

idling
speed
to
700

rpm
650

rpm
for

automatic

transmission

by
turning
the
throttle

adjusting
screw
Make
sure

that
the
ignition
timing
remains
at
50
A
T
D

C

Turn
the
throttle
shaft
ann

adjusting
screw
clockwise
until

the

tip
of
the
screw

just
contacts

the
throttle
shaft
ann
The

screw
must
not
exert

pressure
on
the
throttle
shaft
arm

EMISSION
CONTROL
SYSTEM
Maintenance

The

system
should
be

inspected
and
serviced

every
I
2

months
or
20
000
km

12
000
miles
whichever
comes
fIrst
to

make
sure
that
the
exhaust
emissions
are
maintained
at
the

minimum
level

Check
the
carburettor
choke

setting
and

adjust
as
described

in
the
section
FUEL

SYSTEM

Check
the
carburettor

idling
speed
mixture

and

adjust
if
necessary
as
described
under
the

heading
IGNITION

TIMING
AND
IDLING
SPEED

in
this
section

2
Check

the
distributor
earn

dwell

angle
and
also
the
condi

tion
of
the
contact
breaker

points
Check
the

ignition

timing
and

adjust
if

necessary
The

distributor
dwell

angle

should
be

adjusted
to
49
55

degrees
and
the

points
gap
to

0
45

0
55
mm
0
0177
0
0217
in

3
Remove

and
clean
the

sparking
plugs
Renew

any
plug
with

badly
worn
electrodes
Set
the

plug

gaps
to
0

80
0
90
mm

0
0315
0
0355
in

by
adjusting
the
earth
electrode

IGNITION
SYSTEM

The

maintenance
and

servicing
procedures
for

the

compo

nents
of
the

ignition
system
on

vehicles
fitted

with
the
GIS

engine
are

basically
similar
to

the
instructions

previously
given

for
the
Ll4
LI6
and
LIS

engines
The
distributor
is
however

of

a
different

type
Either
an
Hitachi
0416
57
distributor

being

fitted
or
an

Hitachi
0423
53
if

the
vehicle
is

equipped
with
an

emission

control

system
The
distributors
have
different

advance

curve
characteristics
as
shown

in
Technical
Data

IGNITION
TIMING

Check
the

ignition

timing
with
a

timing
light
as

previously

described

for
the
LI4
L16
and
L

8

engines
Disconnect

the

distributor
vacuum
line

and
run

engine
at

idling
speed
or

slightly
below
The

timing
should

be
set
at
8

BTDCj600

rpm

for
the
D416

57
distributor
or
at
5

ATDCj600

rpm
for

the

D423
53
distributor
fItted
to

engines
with
emission
control

systems

IGNITION
DISTRIBUTOR

Maintenance

Maintenance
instructions
are

similar
to
those

given
for

the
L14
LI6
and
L18

engines
Set
the
contact
breaker

points

gap
to
0
45
0
55
mm
0
0177

0
0217
in
as

previously

described

SPARKING
PLUGS

The

sparking
plugs
should
be

inspected
and
cleaned
at

regular
intervals
and
renewed
at

approximately
20
000
kIn

12
000
miles
Clean
the

plugs
thoroughly
and
make
sure

they

are
of

the
same

type
and
heat

range
File

the
centre

electrode

nat
before

adjusting
the

gap
Set
the

gap
to

0
8
0
9mm
0
031

0
035
in
if
the

engine
is
fItted
with
emission
control

system

or
to

0
7
0
8
mm
0
028

0
031
in
if
emission
control
is
not

fitted

Adjustment
must

always
be
made

by
bending
the
earth

electrode

TechnIcal

Data

GENERAL
SPECIFICATION
GI8

Engine

Cylinders

Bore
and
stroke

Displacemen
t

Valve

arrangemen
t

Firing
order

Engine
idler

speed

Compression
ratio

Oil

pressure
at

3000
r

p
m
4
in
line

85x80
mm

3
346x3
150

in

1
815
cc

110
8
cu
in

OHC

134
2

600

r

p
m
STD

8
3
I

4
7
to
5
5

kgjsq
cm
66
8

to
78
2

Ibjsq
in
LIQUID
PACKING

APPLICATION

Cylinder
block

2

Cylinder
head

Oil

gallery
blind

plug

Expansion

plug

Gas
breather

guide

Rear

bearing

cap
fitting

surface

Rear

bearing

cap
side
seal

both
ends
Expansion
plug

Rubber

plug
Rea

Manifold
heat

pipe

3
Chain
cover

gasket
both
sides

S13

4

Cylinder
head

gasket

Cylinder
block
side
6
Oil

pump

5
Intake
manifold
Block

installing
surface

near
to

oil
exit

Control
valve

Angle
tube
connector
7
Rocker
cover

Tapping
screw
of
bume

plate
installing

SPECIFICATION

a
Valve

mechanism

Valve
clearance
cold
In
0
25
mm
0
0098
in

Ex
0
25
mm
0
0098
in

Hot
Reference
value
0
0098
in

In
0
28
mm
0
011
in

Ex
0
28
mm
0
011
in

Valve
head
diameter
In
42mm
1
654
in

Ex
35mm
1
378
in

Valve
stem
diameter
In
Ex
8mm
0
3150

in

Valve

length
In
116
4
mm
4
58
in

Ex
117
2
mm
4

61
in

Valve
lift
9
0mm
0
354
in

Valve

spring
free

length
Outer
42
5
mm
1
673
in

Inner
414mm
1
630

in

Valve

spring
loaded

length
Outer
29
0
mm
I
142
in

Inner
26
0
mm
1
024

in

Valve

spring
assembling
height
Outer
37
0mm
I
457

in

Inner
34
0
mm
1
339
in

Valve

spring
effective
wind
number
Outer
4
5mm
0
1772
in

Inner
6
25
mm
0
2461
in

Valve

spring
wire
diameter
Outer
4
2mm
0
1654
in

Inner
29mm
0
1142
in

Valve

spring
coil
diameter
Outer
27
5
mm
1
083
in

Inner
19
9mm
0
733

in

Valve

guide
length
In
48mm
1
890
in

Ex
60mm
2
362
in

Valve

guide
height
from
cylinder
head
In
Ex
16
7mm
0
657
in

Valve

guide
inner
diameter
In
Ex
7mm
0
2756
in

Valve

guide
outer

diameter
In
Ex
14
2mm
0
559
in

Valve

guide
to
stem
clearance
In
0
025
0
055

mm

0
0010
0
0022
in

Ex
0
04
0
077
mm

0
0016
0
0030
in

Valve

guide
interference
fit
In
Ex
0
040
0
069
mm

0
0016
0
0027
in

Max
tolerance
of
above
clearance
In
Ex
0

1
mm
0
0049
in

Valve
seat
width
In
Ex
2
05
2
33mm

0
0807
0
0917
in

Valve
seat

angle
In
Ex
900

b
Camshaft
and

timing
chain

Camshaft
end

play
0
07
0
148
mm

0
0028
0
0058
in

Cam

height
36
53
mm
1
438
in

Camshaft

journal
diameter
37
45
37
475
mm

1
474

1
475
in

S14

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

Fan

coupling

Pulley
ratio
fan
and
water

pump

Tuning
data

Basic

timing

Idling
speed

Distributor
dwell

angle

Spark
plug
gap

Choke

setting

CO

percent
setting
Fan

rpm
water

pump
rpm
3
300

4
000

120
103
Ll71

50
A
T
D
C

700

rpm
650

rpm
automatic

490
550
at
0
02
in
breaker

gap

0
8IJ
0
90
mm

0
03

I
5
0
0355

in

Manual

6
0
I
0
5
air

supply
hose

disconnected

Air

pump
drive
belt

tensioning

Permissible
slackness
of
8
0
12
0

mm
0
3

15
0
4
72
in
under
a

load
of7
1O

kg
1
54
2
20
lb

IGNITION
SYSTEM

DISTRIBUTOR

Type

Firing
order

Rotation

Igntion

timing

Without
emission
control

With
emission
control

Dwell

angle

Condenser

capacity

Advance
characteristics

D416
57
distributor
Hitachi
D416
57

Hitachi
D423
53
with
emission

control

system

134
2

Anti
clockwise

80
B
T
D
C
at
600

rpm

50
A

T
D
C
at
600
r

p
m

49
to
55

degreos

0
20
0

24
1
F
Centrifugal

Start

Maximum

degree
r

p
m

Vacuum

Start

Maximum
degree
r

p
m

Advance
characteristics

D423
53
distributor

Centrifugal

Start

Maximum
degree
r

p
m

Vacuum

Start

Maximum

degree
r

p
m

IGNITION
COIL

Type

Primary
voltage

Spark
gap

Primary
resistance

Secondary
resistance

SPARKING
PLUGS

Type

Gap

Fuel

Systenl

DESCRIPTION

FUEL
PUMP

Testing

FUEL
PUMP

Removing
and

Dismantling

CARBURETTOR

Idling
adjustment

FUEL
LEVEL

Adjusting

STARTING
INTERLOCK
VALVE
OPENING

THROTTLE
VALVE
INTERLOCK
OPENING

CARBURETIOR

Removing
and

Dismantling

DESCRIPTION

A
dual
barrel
down

draught
type
carburettor
is
fitted
to

vehicles
with
the
G
18

engine
A
Stromberg

type
D3034C

carburet

tor
is
installed
on

engines
with
exhaust
emission
controL
and
a

Solex

type
DAK340
carburettor
on

engines
not

equipped
with

this

type
of

system
Both

types
of
carburettors

incorporate
a
550
r

p
m

01
50
at
I
400
16
50
at
2
800

80

mmHg

6
50
at
200

r
p
m

475
r

p
m

01
50
at
1
000
23
50
at
2
600

80
mm

Hg

30
at
120
r

p
m
go
at
400
r

p
m

Hanshin
HM
12F
or

HP5
I
OE

with
emission
control

system

12
volts

more
than
6
mm
0
2362

in

3
8
ohms
at
200C

I
1
2

I
6
8
ohms
at
200
C

NGK
BP

6E

0
7
0
8
mm
0
028
0
031
in
or

0
80
9
mm
0
031
0
035
in

with
emission
control

system

primary
system
for
normal

running
and
a

secondary

system

for
full
load

running
a
float

assembly
which

supplies
fuel
to

both

primary
and
secondary
systems
a
starting
mechanism
and

accelerator

pump
which

provides
a
richer
mixture
on
accelera

tion

SI7

1

D
1

1
I

i
l

I

1
j
j

w
n

I

UJ
1

j

e

tOll
i

j25z
t2JZ2
21

1
S
Mizin
nozzk

2
S
SmtzJJ
v
nturi

3
S
Main

air
bleed

4
S

Slow
jet

5
S

Slow
air
bleed

6
Needle
WIlve

7
Float

8
S
Emulsion
tube

9

S

Mainjd

10

S

Jly
paD
hol

11
S
Throttle

alve

12

Chob
I1tzhe

13
P
Main
air
bleed
14
P
Afuin
nozzle

15
Economizer
bleed

16
P
Slow

jet

17
Slow
onomiur

18
P
Slow
air
bleed

19
Airl
e
nt

20
Lnel

gauge

21

PMainjel

22
Idle

limitler

23
1dl

24
P

Jly

pa
hol

2S
P
Throttle
vahe

Fig
B
l
Sectional
view
of
the
DAK340
carburettor

Coil

Piiton

Strainer

v

cero

Fig
S
3
Electrical
fuel

pump

SI8
A
It
I

IL

o
l

Cfd

rj
1

l
o

j

11
111

r
J

l
l

b

I
1

1
F700
t
vahle

2
Vacuum

piJton

3
P

Slow
air
bleed

4
Slow

jtt

5
Slow

onomUt
T

6
P
Slow
air
bleM

7

Air
Fent

8
P
Main
air
bl
d

9
P
MiJin
nozzle

10
P
SmaU
venturi

1
J
Ozokt
valPe

12

Pumpnozzk

13

Pump
wd6h1

14

Discharft
check
valve

15
S

SnwU
venturi

17
S
Main
air
bleed

18

Step
air
bleed

19

Pump
arm

Fig
B
2
Sectional
view
of
the
D3034C
carburet
tor

fitted
to

engines
with
emiss
ion
control

5Y5tem
20

Step
jet

21

Pump
plunger

22
Inlet
c1r
k
l
aIve

23
S
Mizin

jet

24

lRtzp
uaun

25

lRtzplrragm

26

Step
port

27
Idle

port

28
P
T1vottk
valve

29
Idk

port

30
S
Dw

port

31

Idkadjust
screw

32
P
MiIin

jet

33
Po
NU

jet

34
Float

I

Ul

l

2

1
Fibre
mat

Nvlon
6

Fig
B
4
Fuel

strainer
Fig
Ii

s

Removing
the
fuel

pump
cover

1

The

type
D3034C
carburettor
has
certain
additional

features

These
include
a

power
valve
mechanism
to

improve
the

performance

at

high
speed
a
fuel
cut
off
valve
which
cuts
the
fuel

supply

when
the

ignition
key
is
turned
to
the
off
position
and
an

idling

limiter
to

maintain
the

emissions
below
a

certain
level

Sectional
views
of
the
two

types
of

pumps
are
shown
in

Figs
8
1
and
B
2
An
EP
3
electrical
fuel

pump
is

located
in
the

centre

of
the
spare
wheel

housing
in
the
boot

Fig
B
3
shows
a

sectional
view
of
the

pump
with
its
contact

the
pump
mechanisms

solenoid

relay
and
built
in
filter

The
air
cleaner
uses
a

viscous

paper
type
element
which

should
be

replaced
every
40
000
km
24
000
miles

Cleaning

is
not

required
and
should
not
be

attempted

The

cartridge
type
fuel
strainer

incorporates
a
fibre
clement

which
should
be
renewed
at
inervals
not

exceeding
40
000
km

24
000
miles
Fit
B
4
shows
a
sectional
view
of

the
assembly

The
fuel
lines
should
not
be
disconnected
from
the
strainer
when

the
fuel
tank
is
full

unless
absolutely
necessary
as
the
strainer

is
below
the
fuel
level

FUEL
PUMP

Testing

Disconnect
the
fuel
hose
from
the

pump
outlet
Connect

a
hose
with

an
inner
diameter
of
approximately
6
mm
0
024

in
to

the

pump
outlet
and

place
a

container
under
the
end
of

the

pipe
Note
that
the
inner

diameter
of
the

pipe
must
not
be

too

small
or

the
pipe
will
be

incapable
of

delivering
the
correct

quantity
of
fuel
when

testing
Hold
the
end
of
the
hose
above
the

level
of
the

pump
and

operate
the

pump
for
more
than
IS

seconds
to
check
the

delivery
capacity
The

capacity
should
be

I
400
cc

3
24
U
S

pts
in
one
minute
or
less
The

pump
must

be
removed
from
the
vehicle
if
it
does
not

operate
or
if
a

reduced

quantity
of
fuel
flows
from
the
end
of
the
hose
Remove

the
pump
from
the
vehicle
and
test
as
follows

Connect
the

pump
to
a

fully
charged
battery
If
the

pump

now

operates
and

discharges
fuel

correctly
the
fault
does
not

lie
in
the

pump
but

may
be
attributed
to

any
of
the

following

causes

Battery
voltage
drop

poor
battery
earth
loose

wiring

loose
connections
blocked
hoses
or
a

faulty
carburettor

If
the

pump
does
not

operate
and

discharge
fuel
when

connected
to
the

battery
then
the

pump
itself
is

faulty
and

must
be
checked
as
follows

First
make
sure
that
current
is

flowing
This
will
be
indica

ted

by
sparking
at

the
tenninals
If
current
flows
the
trouble
is

caused

by
a

sticking

pump
plunger
or

piston
The

pump
must

be
dismantled
in

this
case
and
the

parts
thoroughly
cleaned
in

petrol

If

the
current
does
not
flow
a
coil
or
lead
wire
is
broken

and
the

pump
must

be
renewed
A

reduced
fuel
flow
is
caused

by
a

faulty
pump
inlet
or

discharged
valve
or
blocked
filter

mesh
The

pump
must

of
course

be
dismantled
and
serviced
as

necessary

FUEL
PUMP

Removing
and

Dismantling

Remove
the
bolts

attaching
the
fuel

pump
cover
to

the

floor

panel
see

Fig
B
S
Remove
the
bolts

attaching
the

pump
to
the
cover

2
Disconnect
the
cable
and
fuel
hoses
Withdraw

the

pump
Dismantle
as
follows

Slacken
the

locking
band
screws
and

remove
the
strainer

strainer

spring
filter
strainer
seal
and

locking
band

Remove
the

snap
ring
Withdraw
the
four
screws
from
the

yoke
and
remove

the
electromagnetic
ulJ
it
Press
the

plunger
down
and
withdraw
the
inlet
vaive

the

packing

and
the
cylinder
and

plunger
assembly

A
defective
eledrical
unit

cannot
be
dismantled
as

it
is

sealed
and
must

be
renewed
as
a

complete
unit

FUEL
PUMP

Inspection
and

Assembly

Wash
the
strainer
filter
and

gasket
in

petrol
and

dry
using

compressed
air
Renew
the
filter
and

gasket
if

necessary
Note

that
the
filter
should
be
cleaned
every
40
000

km
24
000

miles
Wash
the

plunger
piston
and
inlet
valve
in

petrol
and

make
sure
the

piston
moves

smoothly
in
the

cylinder
Replace

the

parts
if
found
to
be
defective

Insert
the

plunger
assembly
into
the

cylinder
of
the
electri

cal
unit
and
move

the

assembly
up
and
down
to

make
sure
tha
t

the
contacts
are

operated
If
the
contacts
do
not

operate
the

electrical
unit
is

faulty
and
must

be
renewed

Assembly
is
a
reversal
of

the
dismantling
procedures
tak

ing
care
to
renew
the

gaskets
as

necessary

CARBURETIOR

Idling
Adjustment

The
D3034C
carburettor
fitted
to

engines
equipped
with

an
emission
control

system
must
be

adjusted
as
described
under

the

heading
IGNITION
TIMING
AND
IDLING
SPEED
in
the

section
EMISSION
CONTROL
SYSTEM

Reference
should
be
made
to
carburettor

idling
adjustment

procedures
for
the
L14
L16

and
LI8

engines
when

adjusting

the
type
DAK
340
carburettor
fitted
to
the
G
18

engine
A
smooth

engine
speed
of

approximately
550

rpm
should
be
attained
in

this
case

FUEL
lEVEL

Adjustment
DAK
340earburettor

A
constant
fuellevcl
in
the
float
chamber
is
maintained

by

the
float
and
needle
valve
See

Fig
8
6
If

the
fuel
level
does
not

correspond
with
the
level

gauge
line
it
will
be

necessary
to

care

fully
bend
the
float
seat
until
the
float

upper
position
is

correctly

set

The
clearance
H
between
valve
stem
and
float
seat

should

be
I
5
mm
0
0059
in
with
the
float

fully
lifted

Adjustment

can
be
carried
out

by
carefully
bending
the
float
stopper
3

FUEL
lEVEL

Adjustment
D3034Ccarburettnr

The
fuel
level
should

correspond
with
the
level

gauge
line

Adjustment
can

be
carried
out
if

necessary
by
changing
the

gaskets
between
the
float
chamber

body
and
needle
valve
seat

The
gaskets
are
shown
as
item
4
in

Fig
B
7
When

correctly

adjusted
there
should
be
a

clearance
of

approximately
7
mm

0
027
in
between
float
and
chamber
as
indicated

STARTING

INTERLOCK
VALVE
OPENING

The

choke
valve
at
its

fully
closed
position
automatically

opens
the
throttle
valve
to
an

optimum
angle
of
14

degrees
on

the

type
DAK
340
carburettor
and
13
5

degrees
on
the
D3034C

carburettor
With
the
choke
valve

fully
closed
the
clearance

G

I
in

Fig
8
should
be
1

I
mm
0
0433

in
This
clearance

S19

inter
M
j

@W

J

1

i
I

r

p

@
2
1
Strut
mounting
inzulDtor

Thruu
b

aring

J
Coil

prins

4
rubber

j
Sl1ut

mbly

6
Compression
rod

Z
Bal

joint

8
T
1ink

9
Stabi
iur

10
ODS

rnt
r
i

L
St

Ting
wheel

2
Steering
column
maft

J
Rubb
rCOfl
linK

4

Sturing
lower
joint

5

St
rinuotlr
IwusUr8

6
Sid
rod

XlI

Fig
C
1
Front

suspension
assembly
Fig
C
2
The
steering

gear

iQ

r
y
y

v

I
Ii

1
1

Fig
C
3

Collapsible

steering

Fig
C
4

Disconnecting
the
brake
hose

I

f41
I
I
t

h
I

t
t

Il
t

k
I

Fig
C
5

Removing
the
front
hub
and
brake

disc
Fig
C
6

Detaching
the
brake
disc

522