1969 DATSUN 610 fuel cap

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

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

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

Accelerator

pump

Piston
diameter

Pump
discharge

Outer
hole

position

Middle
hole

position

Inner
hole

position

Pump
nozzle
diameter

Main
nozzle

diameter

Primary

Secondary
14
0
mm
0
551
in

0
2
cc

per
stroke

0

4
cc

per
stroke

0
6
cc

per
stroke

0

5
mm
0
020

in

2
3
mm
0
0906
in

2
8
mm
0
110
in

Throttle

valve

fully
closed

angle

Primary
10

degrees

Secondary
20

degrees

Idling
opening
5

degrees
approx

Choke
valve

fully
closed

angle
10

degrees

Throttle

opening
at
full
choke
13
5

degrees

FUEL
PUMP

Type

Delivery
Electric

1400
cc
in
one
minute
Emission

control

system

Air

pump
bracket
to

cylinder

head
nut

Adjusting
bar
to
bracket
bolt

Air

pump
to

bracket
bolt

Air

pump
to

adjusting
bar

nut

Anti
backfrre
bracket
to

rocker

cover
0
4Q
0
65

kgm
2
94
7
lb
ft

Anti
backfire
valve
to

bracket
0
4Q
O
65

kgm
2
94

7
lb
ft

Sensing
hose

clamp
to
rocker

cover
0
4Q
0
65

kgm
2
M
7
Ib
ft

Air

gallery
to
exhaust
manifold

plug
5
Q
6

0

kgm
36
243
4lb
ft

Check

valve
to
air

gallery
9

0
10
5

kgm
65

1
75
9Ib
ft
1
6
2
4

kgm
I
1
6
17
4Ib
ft

1
6
2
4

kgm
I
1
6
17
4Ib
ft

1
6
2
4

kgm
I
1
6
17
4
lb
ft

1
6

2
4

kgm
11
6
17
4Ib
ft

Front

SuspensIon
SteerIng

Description

Steering
Maintenance

Wheel
hub
and

bearing

Stabilizer

Spring
and
strut

assembly

Transverse
link
and
lower
ball

joint

Suspension
member

Front
wheel

alignment

Steering
wheel
and
column

Rack
and

pinion
and
tie
rod

Collapsible
steering

DESCRIPTION

The
front

suspension
is
of
the
strut

type
with

the
coil

spring
and

hydraulic

damper
units
mounted
on
the
crossmember

and
transverse
link

assembly
See

Fig
C
I
Vertical
movement

of
the

suspension
is
controlled

by
the
strut

assembly
Forward

and
rearward
movement
is
absorbed

by
compression
rods
6

and
side
movement
controlled

by
the
transverse
links
Front

suspension
servicing
procedures
are
similar
to
those

given
for

vehicle
fitted
with
L14
Ll6
and
LIB

engines
and
can

be
carried

out

by
reference
to

the
instructions

given
in
the

appropriate

section
Camber
and
castor

angles
are

preset
and
cannot

be

adjusted
and
a

check
must

be
made
for

signs
of

damage
to

the

suspension
system
if
the

angles
do
not
confonn
to
the

figures

given
in
Technical
Data

The

steering
is
of
the
direct

acting
rack
and

pinion

type

See

Fig
C
2
A
rubber

coupling
which
absorbs
vibration
and

two
universal

join
ts
are

incorpora
ted
between
the

steering
wheel

and

gear
assembly
The

collapsible
type
of

steering
column

assembly

Fig
C3
is
an

optional
fitting
A
full

description
of
this

type
of

assembly
i

given
in
the

Steering
section
for
L14

L16
and
L18

engines

STEERING
Maintenance

The

steering
system
should
be
lubricated

every
two

years

or
50
000
km
30
000
miles
whichever
comes

fIrst

A
lithium
base

multipurpose
grease
must
be
used
for
the

rack
and

pinion
and
rack
and
tie
rod

joints
The

plug
on
the

steering
gear
housing
should
be
removed
and
a

grease
nipple

fitted
so
that
the
recommended

quantity
of
10
to

15

gram

0
35
to

0
53
oz
of

grease
can
be

injected
Remove
the

grease

nipple
and

replace
the
plug
when
lubrication
is

completed

The

grease
reservoir
on
the
tube
side
should
be

replenished
when

the
level
of

grease
falls
to

approximately
one
third
ofits

capacity

WHEEL
HUB
AND
BEARING
Removal
and
Installation

Wheel
hub
and

bearing
servicing
procedures
are
similar
to

those

previously
given
for
vehicles
fitted
with
L14
LI6
and
LIB

engines

S23

MO

MI
1224
D
I

KM

f
fMn
n

r
A
A
JP
I
I
T
I
I

I

Drain
ill

Changeelemenl
I
42

Cleantlement
3
I

II
r

I

Check
il
topup
4
I

Chinnloil

511
1

11
41

Gle

nelern
n
Ii

I
Orainlluid
7
I
I
I
I

Clunertmtn
81
1

I
I
I
I

I
27

Check

ailltop
up

Jf71

r

I
JIO
WI

28

Change
il

I
ill

limittdSlip
DiHlranti
1
Clleck

ilftopup
1J
I
I

I
Changelil
11
i

ill

ShdmgJolntt
Df
YlShlft
Check

11IIOpup
n
II
I

I

ChangeDl1
1
I
I

I
I

SHOCKASSORBERS
Check
Il

topup
5

PROP
DRIVESHAFTISI
lubncate
Hi

1

GREASE
GUN
POINTS

lubnCIl

it
PEOAlSHAFT

Sj
Lubrlc

te
18

HANDBHAKE
lubnc
1t

I
I

r
1
t

R
IINKAl
iF
luhncll
2u
I
I
i

I

ARlUWIORED
WHEELS
FREE

1m
I
I

i

1121

wHEE
L
tll

AHINli
ronl

HepitCk

211

t
f
WHEEl

BEARINGS
Rur
Repack
77

U
I

BRAKE
FLUID
R
nfWfbletd
1
I
lf
13

117
I

t
I
AH
UUWI
f
t1UN

11Itl
ih1tl

1
i

lcl
Check
oillevtl
B
l

r1i
BI1I1I1
r

Cap
Cleen

1ifj
j

I
Air
Cluner

Service
el
m

nt
l

J7
4

Replace
element
l
l
B

L
5

Cteenfilter

1
C

l
I
I

I

4

Clun
va

vellllR
I

I1

I
I

I
Repl
cH
lve
1

I
I
I

I

Cleen

jets
bOM
R

t
I

Top
liP

pisl
dempe

l

I
r

L

LlIbncatelinkages
I

I
L

Ctean

replace
5
j

I

Ch

ckoill
ve1
Ei
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

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