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
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