1969 DATSUN 610 automatic transmission

BRAKE
PEDAL
ADJUSTMENT

The

brake
pedal
height
and
free

play
can
be

adjusted
in

the

following
manner
1400
and
1600
CC
models

Adjust
the

length
of

the
master

cylinder
push
rod
until
the

height
of
the

pedal
pad
is
187
mm
7
36
in

for
manual

gear

boxes
and
202
mm
7
95in
for

automatic
transmission
vehicles

without
brake

light
switch

Fig
L

31

Retighten
the
locknut

Screw
in

the
brake
light
switch
until
the
screwed

part
of
the

switch
is

against
the
front
of
the

stopper
bracket
then

tighten

the
locknut

Screw
in
the

stopper
bolt
until
the
moveable

part
of
the

switch
is

completely
pushed
in

by
the

pedal
and

tighten
the

locknut
in
this

position
Make
sure

that
the

lamp
is
00

when
the

pedal
is

pushed
down

by
1
5mm
0
06
in

1800cc
models

Adjust
the
bolt
of
the
brake

lamp
switch
until
its
end
face

is
flush
with
the
locknut
then

tighten
the
locknut

securely

See

Fig
L
32

Adjust
the

pedal
stopper
until

the

pedal
pad
is

positioned
at
a

height
of
185
mrn

7
28
in
from
the
floor

then

tighten
the

stopper
with
the
locknut

Adjust
the

length

of

the
master

cylinder

push
rod
until
a

pedal
free

play
of
I
5mm

0
04
D
2in
is
obtained
then

retighten
the
locknut

Depress
the
brake

pedal
several
times
to
make
sure
that
a

full
travel
of
145mm
5
7
in
is
available
and
that

the
pedal

moves

freely
and
without
noise

Technical
Data

BRAKE
PEDAL

Pedal

height

1400
and
1600cc
models
I
87mm

7
362in
manual

gearbox

202mm
7
953in
auto

matic

185mm

7
28in

145mm
5
71
in
1800cc
models

Full
stroke

MASTER
CYUNDER

Inner
diameter

Piston

running
clearance
19
05mm
0
75
in

0
15mm
0
006
in

WHEEL
BRAKE
CYLINDERS

Inner
diameter

1400
and
1600cc

Front
drum

Front
disc

Rear
with
front
drum

Rear
with
front
disc
22
22mm
7
8in

50
8mm

2
0

in

22
22mm

7
8in

20

64mm
13
16
in

Inner
diameter
I
BOOcc

Front
drum

20
6mm

13
16in
Front

disc

Rear
50
8mm
2

0in

22
2mm
7
8
in

BRAKE
DRUM
AND
BRAKE
DISC

Drum
inner
diameter

Drum
outer
diameter

Out
of
round
maximum

Repair
limit
of
drum

Maximum
disc
run
out

Repair
limit
of
disc
228
6mm
9
0in

232mm
9
13in

0
05mm
0
002

in

230mm
9
055
in

0
06mm
0
0024
in

8
4mm
0
331
in

BRAKE
UNINGS

Drum
brakes

Width
x

thickness
x

length
40
x
4
5
x
219
5mm

1
575
x
1
772
x
8
642in

Disc
brakes
39
7
x
9
x
86mm

1
563
x
0
354
x

3
386in

Total

braking
area

Front
drum
brake

Front
disc
brake

Rear
351

sq
cn
54
4

sq
in

114
2

sq
cm

17
7

sq
in

351

sq
cm
54
4

sq
in

107

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

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