Datsun Saloon I300, up to I970, Saloon I600, Estate I300, Estate I600 Workshop Manual

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INTER

Titles

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available

WORKSHOP

NOW

VOLKSWAGEN
VOLKSWAGEN
VOLKSWAGEN

RENAULT
TOYOTA
TOYOTA

FORD

FORD
VOLVO

FORD

ENGINES
VAUXHALL
OPEL

ALFA

ROOTES
MERCEDES BENZ
FORD
RENAULT

FORD

TOYOTA

PEUGEOT

SAAB

CROWN
CORONA

ESCORT

CORTINA

140

CORTINA

KADETT

ROMEO

IMP

CAPRI

17

20M

COROLLA

403

99

R8

SERIES

VIVA

RANGE

1300

R16

MANUALS

1200
1200
1300

MK

1300

RANGE

16TS

404

1200
1300

II

GT

HB

RALL

230

1600

16TA

1100

A
A

1500

1300 1500

1600

HOLDEN

YE

KADETT

250

MODELS

etc

1200

ENGINES

1600E

HB

TORANA

1964
1964 1967

to

1967

to

1967

to

1968
1963 1968
1968 1969
1967

to

1969

1968

1969

1967

1962 1968
1959 1968
1963 1969
1965 1968

From

Up

Since

1968

1965

to

1969

Introduction

1970

r

I

1

f7

I

C

i

E

L

WORKSHOP

MANUAL

for

DATSUN

Saloon

Estate

b

1300

c c

1600 c

c

COMPILED

AND

WRITIEN

BY

PETER

R D

RUSSEK

PUBLISHED

BY

INTEREUROPE

LIMITED

AUTODATA

DIVISION

2

4

QUEENS

DRIVE

LONDON

W

3

ENGLAND

Copyright

IC

IntIInlUrope

LIlDtIld

AulJllt

1970

lb

11

110

IYIIIIbIeinSpanish

av

1Ib1e

thRlUllh

Lan

W

ey

SA

MexICO

City

Pnntlld

n

England

2nd

edition

January

1971

A

r

Type

Identification

SALOON MODELS

Model

designation

Type

E

n9108

Gearbox

510

U

L510

L13

Three

speed

remote

control

P510

U

PL510

Deluxe

Three

speed

remote

control

P510

UT

PL510

T

PL510

UT

L16

Four

speed

floor

shIft

P510

UA

PL510

A

PL510

UA

AutomatIc

three

speed

510 SU

L510

S

L13

Three

speed

remote

control

P510

SU

PL510

S

Standard

L16

Three

speed

remote

control

P510

SUT

PL510

ST

Four

speed

floor

shIft

L16

WIth

SU

P510

UTK PL510

TK

SSS

tWIn

carb

Four

speed

floor

sluft

I

ESTATE

CAR

MODELS

WP510

U

WPL510

Three

speed

remote

control

WP510

UT

WPL510

T

Deluxe

Four

speed

floor

shIft

WPL510

UT

L16

WP510

UA

WPL510

A

AutomatIc

three

spl

ed

WPL510

UA

DIMENSIONS

AND

TYRf

PRESSURES

Length

overall

Standard

Saloon

De

Luxe

SSS

Saloon

Estate

Car

Width

overall

Height

overall

Saloon

Estate

Car

Wheel

base

MIO

ground

clearance

Saloon
Estate

Car

Front

track
Saloon
Estate

Car

Rear

track
Saloon
Estate

Car

Tyre

pressures

Front

4

070

mm

1602

10

I

4

120mm 162210

4

145

mm

163210

1

560

mm

61

410

1400mm

551

In

1

435

mm

56

5

In

2

420

mm

953

In

190

mm

74

In

165

mm

64

In

1

280

mm

504

In

1

275

mm

50

2

In

1

280

mm

50

4

In

I

1

260

mm

496

In

Rear

24

pSI

1

7

kg

sq

em

Normal

cornltlon

28

pSI

20

kg

sq

em

High

speed

driVing

24

psi

1

7

kg

sq

em

Normal

condition

28

pSI

20

kg

sq

em

High

speed

driVing

FILLING

CAPACITIES

Engine

011

Max
MIn

Gearbox

011

Autom

transmission

Differential

011

Saloon
Estate

Car

SJeerlng

9e

aL

40htres

uiG

US

gal

0

88

Imp

gal

30htres079

US

gal

0

66

Imp

gal

17htresl79

US

qts

3

Imp

pts

7

htres739

US

qts

123

Imp

pts

08

htres

084

US

qts

1

4

Imp

pts

10htre105

US

qts

1

76

Imp

pts

032

htres1033

US

qts

0

56

Imp

Pts

4

l

INDEX

lYPE

IDENTIFICATION

ENGINE
LUBRICATION

SYSTEM

COOLING

SYSTEM

IGNITION

SYSTEM

FUEL

SYSTEM

CLUTCH
GEARBOX

REAR

AXLE

REAR

SUSPENSION

FRONT

SUSPENSION
STEERING
BRAKES

ELECTRICAL

EQUIPMENT

WIRING

DIAGRAMS

ENGINE

1

JNING DATA

TIGHTENING

TORQUES

CONVERSION

TABLE

4
6

18
20
22

26
36

44
S3

62
68

74

78
86

98

100
101

102

Introduction

This

Workshop

Manual

was

WrItten

wIth

the

IntentIon

of

providIng

the

owner

ofaDatsun

1300

or

1600

and

the

non

franchised

garage

with

detdlls

of

dllthe

maIntenance

and

repalf

operatIOns

that

they

are

hkely

to

encounter

Much

InformatIOn

from

the

manufacturer

s

ongInal

selVlce

and

repalf

Instructions

have

been

condensed

and

Incorporated

m

the

manual

In

a

form

which

will

enable

the

reader

to

qUickly

become

fanfihar

with

the

IdlOsynchrasles

and

techmcahtles

pecuhar

to

the

Datsun

range

of

cars

The

manual

descnbes

the

1300

and

1600

c c

engmes

fitted

to

the Standard

De

Luxe

and

SSS

Saloon

models

and

the

range

of

Estate

Cars

A

complete

hst

of

engme

tumng

data

for

all

models

with

smgle

or

tWIn

carburettors

IS

Included

m

the

manual

There

are

also

separate

secltons

covenng

the

different

types

of

rear

axles

and

rear

suspenSIOns

used

for

the

Sdloon

and

Estate

Car

Models

In

certaIn

cases

It

Will

be

necessary

for

the

reparrer

to

make

use

of

speCial

tools

and

the

appropnate

tool

numbers

and

thelf

methods

of

use

are

either

descnbed

In

the

text

or

can

be

taken

from

Illustraltons

refered

to

m

the

chapter

SpeCial

menlton

should

be

made

of

the

fact

thatafault

findmg

sechon

IS

annexed

to

most

of

the

major

sechons

thus

slmphfymg

the

some

tunes difficult

task

of

diagnOSIS

The

measurement

conversIOns

gIVen

m

mches

have

been

converted

as

closely

as

pOSSIble

from

the

ongInal

mtlhmetre

SIZes

but

It

IS

preferable

to

adhere

to

the

metnc

dunenslons

whenever

pOSSible

A

conversion

tableISmcluded

In

the

manual

and

we

adVise

the

reader

to

cross

reference

With

the

table

when

deahng

With

cnhcal

dlffienslons

We

have

tned

to

make

thiS

manual

as

bnef

as

pOSSible

tllustratmg

rather

than

detailing

the

operahons

Tills

WIll

save

valuable

tnne

and

WIll

also

show

the

reader

Iffimedlately

whether

he

Will

be

able

to

carry

out

the

work

or

not

Expenence

m

prodUCIng

hundreds

of

techmcal

pubhcatIons

for

the

motor

car

manufacturers

and

the

expenence

gamed

by

the

author

who

hunself

was

a skilled

motor

mechamc

for

15

years

has

proven

that

tillsISthe

best

way

for

a

pubhcatlOn

of

thiS

nature

Happy

motonng

and

the

fewer

tnnes

you

have

to

refertotills

book

the

better

for

you

I

The

author

wouldliketothank

for

the

help

and

3SSIStance

gtven

to

bunbyMr

John

Haley

5

inter

llil

@

p

Fog

A2The

removal

of

the

engll

Fog

A

1

Removal

Of

the

cluu

n

slave

cyhllller

or

L

161

engIne

flUBd

10

1

Jb

trel

t

i

n

fd

r

f7

r

if1

0

FIlI

A5Removal

of

the

manifold

assembly

fgA6
eket

FIIA7

Removalofthe

cyhnder

h8I

F

g

A

8

Removalofthe

oil

straaner

6

Engine

INTRODUCTION

The

1300

c c

and

1600

c c

engines

are

4

cylinder

in

line

engines

with

a

single

overhead

camshaft

andafive

beanng

crankshaft

The

1300

and

1600

c

c

engines

differ

only

In

size

The

1600

c c

engine

IS

available

In two

versions

one

of

which

IS

eqUIpped

with

twin

S U

carburettors

with

different

cylinder

head

manifolds

pistons

and

compression

ratio

whereas

the

other

has

a

single

twin

choke

carburettor

ENGINE

Removal

Drain

the

coolant

engine

and

gearbox

011

and

remove

or

disconnect

the

follOWing

parts

Battery

bonnet

air

cleaner

and

rocker

box

breather

hose

radiator

gnll

upper

and

lower

radiator

hoses

radiator

torque

converter

cooling

hoses

from

radiator

automatic

models

only

COIling

fan

and

pulley

fuel

pipe

heater

hoses

If

fitted

accelerator

linkage

choke

cable

wiring

from

starter

motor

alternator

COil

011

pressure

sender

Unit

and

temperature

sender

Unit

Remove

the

clutch

slave

cylinder

Fig

A1and

ItS

return

spnng

Remove

or

disconnect

Speedometer

cable

flat

connector

from

reversing

light

SWitch

gearchange

linkage

front

exhaust

pipe

from manifold

then

the

front

pipe

first

Silencer

and

centre

pipe

assembly

the

propeller

shaftatthe

front

Jack

up

the

gearbox

slightly

and

remove

the

rear

engine

mounting

bracket

the

mounting

crossmember

and

the

handbrake

cable

clamps

Remove

the bolts

secunng

the

front

engine

mounting

brackets

to

the

crossmember

Fit

a

lifting

hooktothe

engine

hangers

and

carefully

11ft

the

engine

and

gearbox

In

a

tilted

poSition

e

g

forwards

and

upwards

uSing

a

SUitable

crane

or

hOIst

FIgA

2

ENGINE

Dismantling

Remove

the

gearbox

and

the

starter

motor

Mark

the

clutch

cover

and

the

flywheel

SUitably

With

a

centre

punch

and

remove

the

clutch

cover

together

With

the

clutch

dnven

plate

Remove

the

follOWing

parts

Alternator

and

bracket

engine

mountings

011

filter

water

drain

plug

011

pressure

SWitch

Mount

the

engine

In

a

SUitable

stand

If

available

Special

Tool

ST37200510

attachment

and

Stand

ST37100000

See

Flg

A3

Remove

thedIStnbutor

cap

together

With

the

spark

plug

leads

unscrew

the

spark plugs

and

remove

the

dlstnbutor

Remove

the thermostat

hOUSIng

FIgA

4

Remove

the

inlet

and

exhaust

manifolds

Flg

A

5

Remove

the

crankshaft

pulley

Remove

the fan

pulley

and

the

water

pump

fuel

pump

and

rocker

cover

Remove

the

fuel

pump

drive

cam

and

the

crankshaft

sprocket

FlgA

6

Remove

the

cylinder

head

assembly Fig

A

7

USing

special

wrench

ST49010000

for

removing

the

cylinder

h

llJd

bolts

Turn

the

engine

over

and

remove

the

sump

and

the

Internal

011

strainer

Fig

A

8

timing

chain

cover

chain

tensloner

and

timing

chain

Remove

the

011

thrower the

crankshaft

wonn

gear

and

the

chain

dnve

sprocket

FIgA

9

Remove

the

big

end

beanng

caps

pistons

and

connecting

rod

assemblies

keeping

them

In

sets

In

the

correct

assembly

order

Remove

the

flywheel

and

the

main

beanng

caps

uSing

a

special

tool

ST44630000

for

the

rear

main

beanng

cap

Fig

A

11

Remove

the

rear

011

seal

and

11ft

out

the

crankshaft

Remove

tne

baffle

plate

and

the

cylinder

block

net

FIgA

11

Remove

the

piston

nngs

WithaSUitable

piston

nng

expander

and

the

gudgeon

pin

WithaSUitable

mandrel

the

outer

diameter

of

which

should

not

exceed

the

diameter

of

the

piston

pin

and

a

handpress

ThereISalso

special

tool

ST4484000D

Remove

the

valve

rocker

springs

loosen

the rocker

piVOt

lock

nuts

and

remove

the

rocker

anns

by

presSing

down

the

valve

spnngs

Remove

the

camshaft

taking

care

not to

score

the

camshaft

bushes

Remove

the

valves

Withaconventional

valve

lifter

Fig

A

12

ENGINE

Inspection

and

Overhaul

Thoroughly

clean

all

parts

of

dirt

011

and

water

scale

before

inspection

and

before

attempting

to

carry

out

overhaul

operations

Blowout

all

passages

With

compressed

air

Remove

carbon

depOSits

from

the

top

of

the

pistons

combustion

chambers

cylinder

head and

valves

but do

not

remove

metal

from

any

of

the

parts

I

nspect

and

overhaul

the

parts

as

follows

Cylinder

head

Check

cylinder

head

for

cracks

and

the

mating

faces

for

burrs

or

uneveness

and

replace

If

necessary

note

that

different

cylinder

heads

are

used

for

the

Single

and

twin

carburettor

verSions

of

the

1600

c

c

engine

Check

the

mating

surface

for

flatness

by

means

of

a

straight

edge placed

across

the

head and

checking

the

clearance

Withafeeler

gauge

FgA 13

If

the

clearance

exceeds10

mm

0

0039

In

regrind

the

cylinder

headtoblock

face

Check

the

valve

seats

for

damage

or

wear

and

If

necessary

reface

In

accordance

With

the

dimenSions

given

In

Fig

A14andA15

If

necessary

replace

valve

Inserts

To

replace

the

Inserts

bore

out the

old

Insert

and

select

the

correct

Insert

Fig

A

16

and

fit

by

heating

the

cylinder

headto150

200oC

300

3900F

Valve

guides

USing

micrometers

Internal

and

external

che

the

tolerance

between

the

valve

stems

and

the

valve

gUides

ThiS

clearance

must

not

exceed

0048

mm

00019

In

for

Inlet

valves

and

0

073

mm

00029

In

for

exhaust

valves

An

easy

way

of

checking

the

clearance

IS

to

Insert

the

valve

stem

Into

the

gu d

7

r

inter

E2C0

@

0

F

FillA

9

Removal

of

the

crankshaft

challl

rocket

1

1

FillA

11

Removal

of

the

baffle

plata

and

cyhrder

block

net

o

S

0

cf

FI

A

12

Inlet

Exhal51

FIllA

13

Checlul19

the

cyhnder

heud

rt

forfl

Standard

valve

gUIde

hole

diameter

L16

WIth

twin

carb

Ll3

and

Ll6

With

SIngle

cub

U3

and

L16

Ll6

S

gle

cub

TWlD

cub

Almm

410

41016

450

45 016

DIA

Azmm

57

0

37

016

37

O

37 016

DIA

Dlmm

37

6

37 8 41 6

41 8

DIA

D2mm

324

326

DIA

324

326

Llmm

141

8

1 1

8

t

2mm

1620

16

20

FIllA

15

VeIve

to

Inl

t

F

Q

OtA

J

I

Inl

r

i

1

DIA

r

Ex

heult

r

r

1

I

I

IlIt

1

I

ExheuU

La

IlIA

HU

1

FIlIA

14

St8nd8nI

valve

Il8

inwt

8

i

nte

ferbiGD

W

J

r

rrt

l

I

8

r

I

I

r

J

D

I

r

T

010

0

51

01

FI9

A16Ch

c1ung

the

camshaft

beanng

Inner

d

r

F

17

V

far

L

13

andL16

wrth

IingIo

rettD

lm

I

11

0011

II

0

11

5144

031

51

j

l

CII

IM

l11

J

Fig

A

18

Valves

farL16

Ill

wIth

twIn

C81bunmon

FIlIA19

CheckIng

the

valve

IIInng

for

squ

F

A

21

MlI8SUnng

the

cyl

bore

by

of

8

doallllU98

FigA22

The

nne

JIlIIII18

of

the

cyllncllr

bora

F

The

nng

of

the

pilllln

d

by

of8mlcrom8lar

9

ImII

B

FIgA24

CheckIng

the

pIston

runnIng

clearan

ce In

the

cyhnd

bore

FI9A

29

CheckIng

the

running

clearance

for

the

maIn

beaFlngs

FogA

30

Checlllllg

the

crenkshaft

sprocklJt

for

FUIHlllt

10

Fog

A

26

CheckIng

the

ade

cl

ence of

the

pISton

Flngs

Ftg

A

Xl

CheckIng

the

connectIng

rod

for

bends

or

twIsts

FillA28

CheckIng

the

crankshaft

end

float

0

o

FogA31

The

camshaft

drIVe

mechanam

I

and

move

It

from left

to

nght

If

thiS

movement

exceeds

0 2

10m

0

0079

10

1

the

guide

needs

replacmg

When

replacmg

valve

gUides

press

out

the

old

gUide

and

press

10

the

new

gUide

after

the

cylinder

head

has

been

heated

to

150

2000C

300

3

JOOF

Valve

gUides

are

available

10

oversize

of

02

10m

00079

10

1

Fmally

ream

the

valve

gUide

to

the

dimenSion

of

the

valve

stem

observmg

the

specified

running

clearance

between

gUide

and

stem

Valves

Check

the

valve

face

for

pitS

grooves

scores

and

other

damage

Check

the

stem

for

distortion

and

wear

When

mspectmg

the

valve

heads

check

10

particular

for

burrs

cracks

and

corrosion

If

the

valve

head

edge

IS

worn

down

to

0

20 10

0 5

10m

replace

the

valve

If

necessary

gnnd

the

valve

on

a

valve

gnndlng

machine

taking

off

only

enough

matenal

to

remove

pitS

and

grooves

The

valve

dimenSions

are

shown

In

Fig

A17andA18

Valve

sprmgs

Measure

the

free

length

of

the

valve

springs

and

replace

If

less

than

speCified

Also

test

the

valve

sprong

pressure

Check

the

valve

sprongs

for

distortion

by

plaCing

a

steel

square

on

to

a

surface

plate

PosItion

the

spnng

against

the

square

edge

and

slowly

rotate

the

spring

The

clearance

between

the

top

of

the

sprmg

and

the

edge

should

not

exceed16

10m

0063

10

Fig

A

191

The

valve

spnng

specifications

are

given

In

section

TECHNICAL DATA

Camshaft

Measurethe

InSide

diameter

of

the camshaft

bearings

and

the

outside

diameter

of

the

camshaft

Journals

and

If

wear

IS

found

inSide

the

blackets

replace

the

cylinder

head

assembly

The

wear

limitISC

1

10m

00039

In

1

Check

the

camshaft

for

wear

and

damage

andIfthese

exceed

the

limits

given

In

sectIOn

TECHNICAL DATA

replace

the

camshaft

The

camshaft

runout

can

be

checked

as

shown

In

Fig

A 20

The

Indication

on

the

dial

gauge

should

not

exceed

005

10m

0002010

Cylmder

block

Visually

check

the

block

for

flaws

and

cracks

Check

the

mating

surface

the

same

way

as

the

cylinder

head

and

If

the

deViation

exceeds01

mm

0

0039

In

regnnd

the

block

Cylinder

bore

Check

the

cylinder

bores

for

excessive

wear

ovallty

and

taper

FlgA

211The

measunng

pOInts

for

the

cylinder

bores

are

shown

10

Fig

A 22

If

the

bores

are

Within

the

limits

remove

the

carbon

depOSit

ridge

at

the

top

of

the

cylinder

bore

USing

a

SUitable

tool

The

specifications

are

given

10

section

TECHNICAL DATA

Rebormg

cyhnders

When

rebonng

all bores

must

be

done

at

the

same

time

As

a

speclahsed

workshopISdealing

With

operations

of

thiS

nature

It

IS

necessary

to

mfonn

the

workshop

of

thiS

procedure

Five

oversize

piston

sets

are

available

and

are

hsted

10

section

TECHNICAL DATA

To

obtain the

fmlshed

bore

Size

measure

the

piston

across

Its

skirt

as

shown

10

FlgA

23

and

add

the

average

valueofthe

piston

to

cylinder

clearance

When

the

cyhnder

bores

have

been

finish

honed

check

the

piston

cyhnder

clearance

as

shown

In

Fig

A

24

usmg

a

feeler

gauge

and

a

spring

scale

Withafeeler

gauge

of 004

10m

00016

10

1

thickness

the

pullmg

force

on

the

spnng

scale

should

be

0215

kg

0441

3307

Ibs

1

If

the

cyhnder

bores

are

worn

beyond

the

maximum

oversize

there

are

cyhnder

hners

available

Pistons

gudgeon

pins

and

piston

rmgs

Check

for

wear

scratches

and

seiZing

and

If

necessary

replace

Check

the

Side

clearance

of

the

piston

nngs

10 the

grooves

of

the

piston

as

shown

10

FIgA 25

The

correct

specificatIOns

are

given

In

section

TECHNICAL DATA

under

the

same

head

109

Place

the

piston

nngs

mto

the

cyhnder

bore

and

measure

the

piston

nng

gap

Fig

A

261

The

nng

gaps

should

beasfollows

Upper

compression

nng

Second

compres

ring

011

nng

Wear

limit

023

0381010

0009100150

In

1

0 15

030mm

00059

00118101

o15030

mm

00059

0011810

1

0

mm

0

0394

In

Measure

the

gudgeon

prn

hole

and

the

gudgeon

pm

diameter

and

compare

the

measured

results

10

accordance

With

the

dimenSions

In

section

TECHNICAL

DATA

under

the

relevant

heading

The

gudgeon

pin

should

have

a

finger

press

fit In

the

the

piston

and

a

tight

press

fit In

the

connecting

rod

at

room

temperature

The

Interf

erence

fit

of

the

gudgeon

pin

to

connecting

rod

should

be

0015 0033

10m

00006

00013

In

Connecting

rods

Check

the

connecting

rods

for

bends

or

twistS

uSing

a

connecting

rod

aligning

tool

FI

I

A 27

For

each

100

10m

394

In

length

a

permiSSible

bend

or

twist

of003

mm

0

0012

In

IS

allowed

A

limit

of

005

10m

00020

In

should

not

be

exceeded

Fit

the

connecting

rod

to

the

crankshaft

and

check

the

clearance

which

should

be

02

03

mm

00079

00118

In

1

and

should

not

exceed030

10m

0011810

1

Crankshaft

Check

for

wear

ovahty

and

general

scores

cracks

and

run

out

the

Journals

and

crankplns

The

limitS

are

0

03

10m

00012

In

for

ovallty

and

taper

The

runout

hmlt

IS

a

total

deViation

of

o

05

10m

0

002

In

Check

the

crankshaft

end

floatatthe

centre

beanng

If

the

end

float

exceeds

03

10m

00118

In

replace

the

centre

shims The

speCified

end

float

IS

between

005

0 15

mm

0002

00059

In

1

Check

the

end

floatasshown

10

Fig

A

28

Crankshaft

Journals

and

big

end

bearings

The

checking

of

the

maIO

and

bl

l

end

beanngs

should

be

carned

out

as

follows

Check

the

conditions

of

the

bearings

and

clean

the

bearings

Place

a

piece

of

Plastlgage

on

the

beanng

over

Its

full

Width

In

parallel

With

the

crankshaft

and

fit

together

the

bearing

and

Its

cap

tl

lhtemng

the

bolts

to

the

follOWing

torques

Main

beanngs

81g

end

bean

ngs

4 5 5 5

kgm

32

5

39

8Ibft

27

33

kgm

195

23

9lb

ft

1

Then

remove

the

cap

and

check

the

Width

of

the

Plastlgage

11

inter

erlLJ

@

Pl

FIlIA

32

InstallatIonofthe

vaJves

ooo

FI9A

34

Expl

ded

VI8W

of

pISton

and

connectIng

rod

FillA

37

InstallatIOn

of

the

sKle

oil

seal

F

19

A

36

Chedung

the

crankshaft

end

float

FIlI

A

38

InstallatIOn

of

the

flywheel

FillA

39

InstallatIOn

of

pISton

end

conllllCtmg

rodaay

12

FogA

40

InstallatIOn

of

the

bill

end

beerll18

caps

mter

l

i

@

jlJ

E

t

I

l

ih

s

c

Fill

A

42

InstallatIOn

of

the

cylinder

head

Fill

A44The

tIming

chain

1

Fuel

pump

dflve

earn

2

Cham

guide

3

Cham

nSlone

4

Cntnkshm

sprocket

5

Camshaft

IProcbt

6

Cham

guttie

FillA

41

Checking

the

side

play

of

the

bill

end

FogA

43

V

1fW

of

the

crankshaft

sprocket

end

dIStributor

drive

geer

FillA46AdjUsting

the

valve

clearance

I

FlgA

45

FIttIng

pOSItIon

of

the

dIStrIbutor

drIVing

slIaft

13

stnp

on

the

beanng

Journal

FIQ

A 29

If

the

clearance

exceeds

the

wear

limit

of010

mm

00039

In

for

the

main

beanngs

and and

for

the

big

end

beanngs

fit

undersize

bearings

and

regrind

the

crankshaft

to

SUit

the

undersize

bearings

Undersize

bearings

are

available

In

1

1000

mm

25 50 75

100

for

main

bearings

and

6 12

25

5075and 100

for

the

big

end

bearings

Crankshaft

and

camshaft

timing

gears

Check

the

sprockets

and

the

tlmll19

chain for

wear

and

replace

where

necessary

Check

the

run

out

of

the

camshaft

sprocket

as

shown

In

Fig

A

30 The

run

out

should

not

exceed

the

limit

of

o

1

mm

0

043

In

Check

the

chain

tenslOner

and

the

chain

gu

Ide

for

wear

and

replace

If

necessary

Fig

A

31

Flywheel

Check

the

clutch

contact

area

of

the

flywheel

for

damage

and

wear

and

If

necessary

re

alr

or

replace

the

flywheel

Check

the

flywheel

for

run

out

uSing

a

dial

gauge

and

replace

the

flywheel

If

the

limit

of01

mm

0043

In

IS

exceeded

If

the

ring

gear

IS

worn

or

damaged

remove

the

gear

ring

by

heating

It

to

about

150

2000

C

300

3900F

and

tapping

It

off

Sometimes

It

might

be

necessary

to

split

the

ring

gear

Withachisel

In

thiS

case

take

care

notto

damage

the

flywheel

Refit the

new

ring

gear

In reverse

order

and

coolatnormal

air

temperature

ENGINE

Assembly

Apply

engine

011toall

sliding

or

rotating

parts

of

the

engine

I

e

cylinder

walls

pistons

bearings

gears

etc

and

renew

all

seals

gaskets

and

lock

plates

Place

the

valve

spring

seat

In

poSition

and

fit

the

valve

gUide

With

the

011

seal

Assemble

the

valves

In

the

follOWing

order

Valve

Inner

and

outer

valve

springs

spring

retainer

valve

cotter

halves

and

valve

rocker

gUide

Compress

the

valves

With

a

suitable

valve

compressor

Fig

A 32

when

fitting

the

cotter

ha

lves

Fit

the rocker

arms

and

the

valve

rocker

springs

The

Spring

holders

are

combined

With

the rocker

pivot

bushes

Assemble

the

pistons

gudgeon

pinS

piston

rings

and

connecting

rods

for

each

cylinder

Fig

A 34

and

A 35

and

place

the

bearing

shells

Into

the

main

bearing

hOUSings

and

caps

and

the

connecting

rods

and

caps

Lift

the

crankshaft

In

the

bearings

Tighten

down the

main

bearing

cap

bolts

to

4 5

55

kgm

325

39

8

lb

ft

Arrange

the

arrow

mark

on

the

bearing

cap

to

face

the

front

of

the

engine

The

bearing

caps

shouldbe

tightened

In

gradual

steps

In

three

or

four

stages

starting

at

the

centre

and

working

towards

the

outside

Check

the

crankshaft

end

playas

shown

In

Fig

A 36

which

should

be

005 015

mm

0002

00061n

Install

the

Side

011

seals

Into

the

rear

main

bearing

cap

as

shown

In

Fig

A 37

Fit

the

rear

011

seal

uSing

special

tool

ST49370000

If

the

Original

crankshaft

IS

used

and

the

contact

face

for

the

011

seal

shows

slgns

of

wear

Installashim

In

order

to

shift

the

contact

face

FItthe

rear

end

plate

Fit

the

flywheel

USing

lock

washers

and

tighten

the

bolts

to

95

105

kgm

68

7

75

9Ib

ft

I

Flg

A

38

Install

the

piston

and

connecting

rod

assembly

into

the

correct

cylinder

from the

top

of

the

cylinder

block

as

shown

In

Fig

A39with

the

F

mark

faCing

the

front

of

the

e

gi

le

W

h

en

lnsertlng

the

piston

14

rings

ensure

that the

piston

ring

gaps

are

opposite

each

other

and

neither

parallel

toorat

nght

angles

to

the

gudgeon

pin

Fit

the

connecting

rods

With

the

numbers

on

the

same

Side

throughout

and

tighten

to

2 8 3 4

kgm

20

2

246lb

ft

Fig

A

40

Check

the

end

clearance

of

the

big

end

bearings

which

should

be 0

20

030

mm

00079

00118

In

I

Fit

the

cylinder

head

spreading

JOinting

compound

either

Side

of

the

gasket

Tighten

the

cylinder

head

borts

In

the

order

shown

In

Fig

A 42

to

a

tightening

torque

of

5 0

60

kgm

36

2

434Ib

ft

Note

there

are

3

types

of

bolts

and

each

should

go

In

the

hole

It

came

out

of

Use

special

tool

ST49010000

to

tlQhten

the

cylinder

head

bolts

Fit

the

crankshaft

sprocket

and

distributor

drive

and

fit

the

011

thrower

Fig

A 43

Install

the

timing

chain

Fig

A 44

With

the

timing

marks

on

the

crankshaft

and

camshaft

timing

sprockets

to

the

right

hand

Side

COinCident

With

the

timing

marks

on

the

chain

There

must

be42chain

links

between

the

marks

on

the

chain

Fit

the

chain

gUide

to

the

cylinder

block

and and

Install

the

chain

tensloner

FIt

a

new

011

sealInthe

front

cover

ThiS

seal

should

alwaysbereplaced

when

the

front

cover

IS

removed

for

any

reason

I

nstall

the

lower

front

cover

and

the

upper

front

cover

In

that

order

With

a

gasket

between

cover

and

cylinder

block

The

gasket

should

be

coated

With

JOinting

compound

When

fitting

the

upper

cover

check

that

It

does

not

Interfere

With

the

cylinder

head

gasket

Then

check

the

height

difference

between

the

upper

faces

of

the

cylinder

block

and

the

upper

cover

The

difference

should

be

less

than

0 15

mm

0059

In

Fit

the

crankshaft

pulley

and

the

water

pump

Set

the

engine

at

TDC

position

on

the

No

1

cylinder

In

Its

compressIOn

stroke

Install

the

011

pump

and

dlstnbutor

drivesothat the offset

slot

IS

In

the

position

shown

In

Fig

A 45

Fit

the

fuel

pump

water

Inlet

elbow thennostat

hOUSing

engine

slinger

thennostat

and

water

outlet

elbow

Refit the

011

strainer

to

the

bottom

of

the

cylinder

block

and

enclose

the

engine

interior

by

refIning

the

011

sump

coating

the

new

gasket

With

JOinting

compound

on

both

Sides

Fit

the

distributor

rear

engine

slinger

manifolds

and

carburettor

s

AdjUst

valve

tappets

Fig

A 46

to

020

mm

0008

In

for

the

Inlet

valve

cold

and

025

mm

0010

In

for

the

exhaust

valve

cold

and

fit

the rocker

cover

uSing

JOinting

compound

on

the

gasket

Fit

the

clutch

and

gearbox

assembly

the

fuel

hosetothe front

part

of

the

engine

and

the

high

tenSion

leadtothe

distributor

Remove

the

engine

from the

mounting

stand

and

fit

the

alternator

bracket

alternator

engine

mountings

Ignition

COil

011

filter

011

pressure

SWitch

011

level

dipstick

and

the

water

drain

plug

ENGINE

Installation

The

installation

IS

carned

out

in

reverse

order

to

the

removal

procedure

but

the

follOWing

points

should

be

noted

Do

not

tlQhten

the

nuts

and

bolts

completely

until

the

engine

IS

resting

flnnly

on

Its

mountings

Then

tlQhten

the

nuts

Fill

the

engine

With

engine

011

and

coolant

water

or

anti

freeze

and

the

g

o

with

th

recommended

lubricant

Valve

clearance

hot

Inlet
Exhaust

Valve

clearance

cold
Inlet
Exhaust

Valve

head

diameter

L13and

L16wSC
Inlet
Exhaust

L16wrrC

Inlet

Exhaust

Valve

stem

dla

Inl

Exh

Valve

length

Inlet
Exhaust

Valve

11ft

L13

and

L16wSC

L16

wrrc

Valve

spnng

free

length

113
L16

outer

L16

Inner

Technical

Data

GENERAL

SPECIFICATION

Engine

model

L13

L16

Number

of

cylinders

4

4

Arrangement

of

cylinders

In

line

In

line

Cubic

capacity

1296

c c

1595

c c

51

02

cu In

62 80

cu In

Borexstroke

830x59

9

mm

830

x 737mm

3

2677x2

3583

In

32677

x

2

9016

In

Arrangement

of

valves

Overhead

camshaft

Overhead

camshaft

MaxBH

P

Single

carburettor

77at6000

rpm

96at5600

rpm

TWin

carbu

rettors

109

at

6000

rpm

Max

torque

Single

carburettor

11

1

kgm

at

3600

rpm

13 8

kgm

at

3600

rpm

803Ib

ft

1100Ib

ft

TWin

carburettors

143

kgm

at

4000

rpm

1030Ibft

Flnng

order

1

3

4 2

1

3 4 2

Engine

Idling

speed

Single

carburettor

600

rpm

600

rpm

TWin

carburettors

650

rpm

Compression

ratio

Single

carburettor

85

1

85

1

TWin

carburettors

95

1

011

pressure

3842

kg

sq

cm

38

4 2

kglsq

cm

54 60

Ib

Isq

In

54 60

Ib

Isq

In

VALVE

GEAR

Valve

spnng

fitted

length

L13
L

16

outer

L16

Inner

400

mm

30

7

kg

1

57

In

167

7

Ib

389

mm

29

0

kg

1

53

In

163

9

Ib

35

mm

12 3

kg

1

38

In

271

Ib

025

mm

0010

In

030

mm

0012

In

020

mm

0008

In

025mm

0010

In

Valve

spnng

COIl

diameter

L13
L16

outer

L16

Inner

34

9

mm

1

37

In

332mm

1

31

In

24

9

mm

0

98

In

38mm

150

In

33

mm

1

30

In

ValveguIde

length

Inlet
Exhaust

59

0

mm

2

32

In

59

0

mm

2

32

In

42

mm

1

65

In

33mm

130

In

80mm

031

In

ValveguIde

protrusIOn

from

head

face

L13 L16

104

106mm

041

0421n

Valve

gUide

Inner

diameter

Inlet

800

8018

mm

0315

03154

In

Exhaust

800

8018

mm

0315

03154

In

1159mm

456In

1160mm

4571n

Valve

gUide

outer

diameter

Inlet

11

985

11

996

mm

0472

04723

In

Exhaust

11

985

11

996

mm

0472

04623

In

100mm

040

In

105mm

0413

In

Valve

guide

to

stem

clearance

Inlet

0015

Exhaust

0040

0045

mm

00006

00018

In

0070

mm

00016

00028

In

4812mm

189In

52

0

mm

2

05

In

44

85

mm

1

77

In

Valve

seat

Width

Inlet
Exhaust

1418

mm

0055

0071

In

1

6 2 0

mm

0

0639079

In

15

r

Valve

seat

angle

Inl

Exh

4J

Valve

seat

Insert

Interference

fit

Inlet

008

0

11

mm

00031

00043

In

Exhaust

006

0 10

mm

00024

00039

In

Valve

gUide

Interference

fit

Inlet

0027

0049

mm

00011

00019

mm

CAMSHAFT

AND

TIMING

GEAR

Camshaft

end

play

o

0838

mm

00031

0

0151n

Camshaft

lobe

lift

L13

L16wSC

L16

w

TC

665

mm

0

261

In

7

00

mm

0

275

In

Camshaft

Journals

diameter

All

47949

47962

vm

887718883

In

Max

camshaft

run

out

005

mm

0002

In

Camshaft

Journal

to

beanng

clearance

0038 0076

mm

00015

00026

In

Camshaft

bearing

Inner

diameter

48

00048016

mm

1

8898

1

8904

In

SC

Single

carburettor

TC

TWin

carburettors

CONNECTING

RODS

Distance

from

centre

to

centre

13297133

03

mm

5235 5237

In

8eanng

shell

thickness

Standard

Side

playofbig

ends

1

498

1

506

mm

0059

0593

In

020 030

mm

0008 0012

In

Connecting

rod

bearing

running

clearance

0014

0056

mm

00006 00022

In

Connecting

rod

bend

or

twist

003

mm

per

100

mm

00012

In

per

3

937

In

CRANKSHAFT

AND

MAIN

BEARINGS

Crankshaft

matenal

Number

of

beanngs

Main

Journal

dla

Max

Journal

taper

Max

Journal

out

of

round

Crankshaft

end

play

Wear

limit

Crankpln

Journal

dla

Max

crankpln

taper

Max

crankpln

out

of

round

Thickness

of

main

beanng

shells

1

827

Main

beanng

running

clearance

0

020

Max

main

bearing

running

clearance

Crankshaft

bend

limlt

Special

forged

steel

5

54

942

54

955

mm

2

1631

2

1636

In

003

mm

00012

In

003

mm

00012

In

o

05015

mm

0

002

0059

In

03

mm

0012

In

49

96149975

mm

1

967

1

9675

In

003mm

00121n

o

03

mm

0

012

In

1

835

mm

0072

00722

In

o

062

mm

0

0008

0

0024

In

o

12mm

00047

In

005

mm

0002

In

16

Matenal

Type

Piston

diameters

Standard

1

st

O

S

2ndOS
3rt

OS

4th O

S

5th O

S

Width

of

nng

grooves

Top

second

011

control

Piston

running

clearance

Pin

diameter

Pin

length

PISTONS

Cast

aluminium

Slipper

sklrt

type

8299

8304

mm

3267

3

269

In

83 22

83

27

mm

3

276

3

278

In

8347

8352

mm

3286

3

288

In

83

72

83

77

mm

3

296

3

298

In

83 97 84

02

mm

3

305

3

308

In

8447

8452

mm

3326

3328

In

2 0

mm

0

08

In

40

mm

0 16

In

o

025045

mm

0001

0002

In

PISTON

PIN

20995

21

000

mm

08266

0

8268

In

72 00 72 25

mm

2

8346

2

8445

In

Pin

running

clearance

In

piston

0008

0010

mm

00003

00004

In

Pin

Interference

fIt

In

small

end bush

0015

0033

mm

00006

00013

In

Piston

nng

heIght

Top

second

011

control

PISTON

RINGS

20

mm

008

In

40

mm

0 16

In

Side

clearance

In

grooves

Top

0040

0073

mm

00016 00029

In

L13

0045

0078mm

00018

000311n

L16

Second

0030

0

063

vm

00012

0

0025

In

011

control

0025

0063

mm

0001

00025

In

Piston

ring

gaps

Top

Second

011

control

Matenal
Distortion

of

sealing

face

Max

distortion

Valve

seat

Insert

matenal

Inlet
Exhaust
Fit

Dnve

Chain

Chain

tensloner

023

038mm

00091 001501n

015

030

mm

0006 0012

In

015

030mm

0006

00121n

CYLINDER

HEAD

Aluminium

alloy

003

mm

00012

In

o

1

mm

0004

In

Aluminium

bronze

Special

cast

Hot

pressed

CAMSHAFT

DRIVE

From

crankshaft

Double

roller

type

Spnng

and

011

pressure

control

Trouble

Shooting

SYMPTOMS

PROBABLE

CAUSE

ACTIOtJ

TO

BE

TAKEN

I

Lack

of

power

1

Poor

compresSion

Incorrect

valve

clearance Adjust

valve

clearance

Intake

valves

leaking

Lap

valve

seats

Sticking

valves

Replace

valve

andguIdes

Valve

springs

broken

Replace

valve

spring

Piston

rings

broken

Replace

piston

rings

Ringsorcylinders

worn

Overhaul

engine

2

Ignition

Improperly

set

Incorrect

Ignition

limIng

Re

set

DefectIve

spark

plugs

Clean

re

set

or

renew

Contact

breakers

defective

Clean

or

replace

adjust

gap

3

Lackoffuel

Clogged

carburetor

Jet

Clean

carburetor

Clogged

fuel

pipe

Clean

fuel

pipe

Dirty

fuel

tank

Clean

fuel

tank

Faulty

fuel

pump

Check

fuel

pump

Fuel

filter

clogged

Clean

or

replace

element

Overheating

Insufficient

coolant

Top

up

radiator

Looefan

belt

Adjust

fan

belt

Fan

belt

worn

or

damaged

Replace

fan

belt

Inoperative

thermostat

Replace

thermostat

Defective

water pump

Repairorreplace

Clogged

cooling

system

Clean

system

Incorrect

Ignition

liming

Re

set

timing

Incorrect

valve

clearance Adjust

clearance

Incorrect

011

used

Refill

With

correct

oil

grade

Radiator

finS

clogged

Clean

readlator

finS

ExceSSive

oil

consumptIon

Oil

leaks

Fnd011

leak

and

rectify

DefectIve

piston

rings

Replace

piston

rings

Piston

rings

worn

or

sticking

In

Replace

Piston

rll1gs

grooves
Piston

or

cylinder

worn

Replace

piston

or

bore

cylinder

Valve

stem

or

gUide

worn

Replace

as

necessary

D

fficult

starting

Improper

0

1

Change

to

proper

VISCOSity

Discharged

or

defective

battery

Chargeorreplace

battery

Loose

connections

Clean

and

tighten

connections

Defective

Ignition

system Adjust

Ignition

check

plugs

Burnt

valves

RepairOrreplace

valves

PIstons

piston

nngs

or

cylinders

badly

Overhaul

enqlne

worn

Engine

nOIsy

Crankshaft

beanngs

or

Journals

worn

Replace

bearings

and

grind

crankshaft

or

replace

crankshaft

Connecting

rod

bearings

worn

I

Replace

bearings

and

gnnd

crankshaft

or

replace

crankshaft

ConnectIng

rod

be

l

Stralgten

or

replace

rod

Piston

piston

nngs

and

pinS

damaged

Check

and

replace

parts

as

necessary

mterCE

lliJ

@

Plcel

FIg

B1General

layout

of

tho

lubricatIOn

system

o

Fig

B

4

SectIOn

through

the0rehefvalvo

Frg

B3Tho

oil

pump

components

18

Lubrication

System

DESCRIPTION

The

lubricating

system

IS

a

pressure

feed

system

ronslstlng

of

a

rotor

type

011

pump

Inoorpotating

a

regulator

valve

and

driven

by

the

distributor

drive shaft

andafull

flow

011

filter

A

strainer

IS

fined

to

the

bonom

of

the

front

cover

and

serves

the

purpose

to

filter

the

011

before

It

can

reach

the

beanng

locations

OIL

PUMP

Removal

and

InstallatIOn

Remove

the

distributor

drain

the

engll1e

Oil

remove

the

front

engine

bearer

and

the

splash

guard

and

remove

the

011

pump

body

together

With

the

dnve

spindle

The

011

pump

IS

held

111

poSition

by

four

bolts

The

II1stallatlon

IS

carned

out In

reverse

order

to

the

removal

procedure

When

replaCing

the

011

pump

set

the

engine

so

that

No

1

cylinder

IS

at

T 0

C

position

In

ItS

compression

stroke

and

then

fIt

the

011

pump

and

the

drive

spindle

In

the

front

cover

With

the

punched

mark

on

the

spindle

facing

the

front

of

the

engine

Check

the

engagement

of

the

drive

vIa

the

distributor

fining

hole

Refit the

distributor

and

fill

the

engine

with

the

recommended

engine

011

Tighten

the

mounting

bolts

to

1

5

21kgm

108

1521bft

SeealsoFlgA2

I

OIL

PUMP

Dismantling

Separate

the

body

cover

from the

pump

body

by

unscrewing

the

Single

securrng

bolt

and

take

out

the

pump

drrve

and

driven

gears

from the

pump

body

Fig

B

3

OIL

PUMP

InspectIOn

and

Overhaul

Clean

all

parts

In

a

SUitable

solvent

and

check

the

follOWing

Items

2

Check

the

0

pump

body

for

wear

Worn

bearrng

faces

result

In

pressure

losses

If

necessary

replace

the

body

Check

the

clearance

between

the

lobes

of

the

Inner

and

outer

rotors

The

maximum

clearance

must

not

exceed

005

0

12

mm

0002 0005

In

If

the

clearance

IS

found

to

be

greater

a

new

seat

of

rotors

should

be

fined

3

Check

the

clearance

betWeen

the

outer

rotor

and

the

pump

body

ThiS

play

must

not

exceed

0

15

021

mm

10

006

0008

111

If

thiS

clearance

IS

excessive

a

new

setofrotors

oranew

pump

body

must

be

fined

4

Check

the

end

float

of

the

rotors

by

placingastraight

edge

across

the

Joint

face

of

the

body

and

measuring

the

clearance

between

the

rotor

ends and

the

straight

edge

by

inserting

a

feeler

gauge

IMust

not

exceed

0

13

mm

0005

In If

necessary

the

pump

body

can

be

carefully

lapped

on

a

flat

surface

5

Check

the

rotor

drive

shaft

for

excessive

wear

or

scores

If

necessary

renew

the

rotor

set

6

Cheek

the

fllJief

IiIWe

sprlll

t

for

proper

f

1I

aACI

tile

IidIng

surfaces

for

wear

Also

check

the

spring

for

weakness

or

damage

Replace

as

necessary

FIgB

4

The

rehef

valve

dImenSIons

are

as

follows

Free

length

Fitted

length

Opening

pressure

38

57

mm

2

24

In

39

mm

1

54

In

42

kg

54

597

Ib

OIL

PUMP

Assembly

The

assembly

of

the

0

pump

IS

a

reversal

of

the

dlsmanthng

procedure

Make

sure

the

pump

cover

gasket

IS

properly

fitted

Tighten

the

011

pressure

rehef

valve

cap

nut

to

a

torque

reading

of

3 0 3 5

kgm

21 7

253Ib

ft

OIL

FILTER

The

011

filter

IS

of

the

replaceable

cartridge

type

and

can

be

removed

from

and

replaced

on

the

cylinder

block

by

hand

When

refitting

the

filter

element

do

not

overtighten

and

under

no

circumstances

use

any

tools

The

filter

body

With

the

element

should

be

replaced

every

6000 miles

10

000

km

The

location

of

the

filterISshown

In

Fig

B

5

Technical

Data

Type
Pump

type

Drive

Clearance

between

Inner

and

outer

rotor

0

05

Clearance

between

rotor

tipS

Celarance

between

outer

rotor

and

body

015

Pressurefeed

system

Rotor

pump

From

distributor

shaft

012mmI0

020005111

0

12mm

0005

In

I

021

mm

0006 0008

In

I

011

pressure

rehef

valve

spring

Free

length

Fitted

length

Opening

pressure

38

75

mm

224

In

3fiii

m

1

54

In

4 2

kg

sq

cm

54

60

Ib

sq

In

011

pressure

at

idhng

speed

101

2

kg

sq

cm

14

2 171Ib

sq

ln

Oil

pressure

at

2000

rpm

lhot

38 42

kg

sq

cm

54

60

Ibsqin

19

mter

M

j

@

Pl

Fill

C

1

General

arrangement

of

the

cooling

OY

OperatIon

plate

Dust

cover

Drum

SpIder

assembly

linnl9

FIlI

C

3

Exploded

v

of

the

fan

c1u1l

h

o

V V

00

o

J

FIlI

c4DlSIllantllng

of

thefan

clu1dl

Fill

C 5

V

fIW

of

the

radiator

and

component

parts

20

It

Cooling

System

DESCRIPTION

The

cooling

system

is

a

closed

pressunsed

system

It

consists

of

radiator

water

pump

fan

clutch

thermostat

and

the

water

Jacketsincylinder

head

and

block

WATER

PUMP

Removal

To

remove

the

centrifugal

type

water

pump

drain

the

cooling

system

completely

and

remow

the fan

belt

fan

and

pulley

and

unsaew

the

water

pump

from

the

front

cover

Fig

C2It IS

recommended

that the

water

pump

is

not

dismantled

due

to

Its

design

and

manufacture

If

the

water

pump

IS

supected

of

malfunction

an

exchange

water

pump

should

be

fitted

Replace

the

water

pump

If

It

has

eXce5Slvely

rusted

or

corroded

vanes

or

If

there

IS

excessIVe

wear

In

the

beanngs

or

squeaking

With

the

engine

running

To

prevent

squeak

the

use

of

NIS

8n

cooling

system

protector

IS

recommended

The

pump

should

be cleaned WIth

Nlssan

COOling

system

cleaner

before

It

IS

refitted

to

the

front

cover

FAN

CLUTCH

In

the

models

With

air

conditIOning

a

fan

clutch

IS

fitted

to

IIlCrease

the

effiCiency

of

the

coohng

system

and

reduce

power

losses

ThiS

clutch

IS

thermostatically

controlled

by

the

air

temperature

of

the

engine

compartment

If

the

air

temperature

In

the

engine

compartment

Increases

the

thermostat

beginS

to

operate

and

the

fan

clutch

Will

engage

FAN

CLUTCH

Inspection

Fully

warm

up

the

engine

Check

the

operation

of

the

clutch

at

engine

speed

of

2500

rpm

The

clutch

should

begin

to

operate

at

a

temperatu

re

of

61

690C

141

159soF

and shoo

Id

SWItch

automatically

offat50

580C

121

1380F

The

temperature

should

be

checked

near

the

clutch

and

thIS

should

be

done

several

times

as

there

IS

a

time

lag

In

the

operation

of

the

thermostat

To

check

the

operation

of

the fan

clutch thermostat

remove

the

operating

plate

see

Fig

C3andC4

and

submerge

It

In hot

water

700C

for

2or3

minutes

to

check

Its

operation

THERMOSTAT

R8IllOVlII

Drain

the

cooling

system

remove

the radiator

hose

and

the

water

outlet

elbow

and

11ft

out the

thermostat

To

check

the thermostat

place

It

in a

container

filled

with

water

and

gradually

heat

up

tha

water

Immerseathermometer

into

the

water

and

observe

the

Indication

Taka

C8I

8

that

the

thermostllt

or

the

thermometer

cannot

touch

the

bottom

or

the

sides

of

the

contalller

oth

ise

false

nIlIdinga

will

be

obtained

The

thermostat

should

start

to

open

at

a

temperature

of

80

83

50C

177

182oF

The

maximum

hft

of

the

thermosm

valve

should

be

80

mm

0315

In

at

a

temperature

of

950C

1203oF

THERMOSTAT

Instellatlon

The

installation

of

the thermostat

is

carned

out

In

reverse

order

to

the

removal

procedure

UseaSUitable

sealing

compound

to

seal

off

both

Sides

of

the

gasket

RADIATOR

Removal

and

Installation

To

remove

the

radiator

shown

In

Fig

C

S

drain

the

cooling

system

and

disconnect

the

top

and

bottom

radiator

hoses

Remove

the radiator

after

unscrewing

the

four

radiator

attaching

bolts

Check

radiator

for

water

leaks

and

cracks

and

repair

or

replace

as

necessary

The

installation

of

the

radiator

s

earned

out

In

reverse

ordertothe

removal

procedure

Technical

Data

Type

Closed

pressunsed

system

Radiator

Herght

Width

Thickness

Capacity
Cap

opeOlng

pressure

350

mm

13

78

In

I

514

mm

20

24

In

32

mm

1

26

In

26

IItres

0

7

U

S

gall

057

Imp

gall

I

09

kg

sq

cm

128

pSI

Thermostat

Valve

opening

Max

valve

11ft

80583

SOC

11

7

18

1lF

Morethen

8

mm

at

950C

0

315

In

at

2

30

F

21

inter

e

l

@Ql

0

0

A

r

FI9

D

1

Explod

YI

of

1118

ognrtlOn

dlltnbutor

v

FI9

D

3

Removal

of

1IIe

dIstrIbutor

drMlllllllr

1111I1Inln9

pin

FItI

D

4

Removal

of

1IIe

dlllnbutar

drive

Iheft

FI9

D

6

Checlull9

1IIe

contact

IlfP

RI

FIg

D

7

Viewof1118

distrillutar

wIth

22

I

FiaD2

Rem

of

the

contact

beI8

plaia

7

FIQ

D

5

The

blyof1118

flyweight

mecherlillll

F

tg

It

2

Oftronco

for

nd

ond

at

IfInltlOll

lranctl

MIIIe

3

Hook

4

Flywo

ght

rprll1l

5

Dtltrrburor

cam

pkrte

6

F

ywetg

lt

pm

1

H

8

Flyweight

rprlnt

9

Rotor

poI

donm

fin

Fig

D

8

AdJUlling

1118

cantBCt

b er

gap

Ignition

System

DESCRIPTION

The

1300

c

c

and

the

1600

c c

engines

With

Single

carburettors

are

fitted

With

the

Ignition

distributor

model

D410

58

whilst

the

1600

c c

engine

With

twin

carburettors

has

model

D400

54

The

outside

appearance

of

both

distributor

models

IS

alike

IGNITION

DISTRIBUTOR

Removal

Disconnect

the

high

tension

cables

from

the

spark

plugs

and

the

Ignition

coli

and

detach

the

primary

wire

from the

distributor

Remove

the

vacuum

pipe

from the

distributor

connection

slacken

the

distributor

clamp

bolt

and

withdraw

the

distributor

IGNITION

DISTRIBUTOR

Dlsmanthng

Remove

the

distributor

cap

and

pull

off

the

rotor

Loosen

the

two

vacuum

Unit

securing

screws

and

11ft

off

the

Unit

Unscrew

the

fixed

contact

POint

set

screw

and

11ft

off

the

pOint

Take

off

the

spring

clip

from the

piVOt

post

of

the

moveable

contact

breaker

pOint

and

remove

the

contact

arm

From

the

Sideofthe

distributor

body

remove

the

two

spring

clips

and

remove

the

contact

breaker

base

plate

see

Fig

D2Take

care

not

to

loose

the

steel

balls

between

the

breaker

spring

and

the

breaker

plate

and

those

between

the

breaker

plates

SUitably

support

the

distributor

shaft

from

underneath

and

drive

out

the

drive

gear

retaining

pin

uSing

a

SUitable

punch

Fig

D

3

Remove

the

gear

and

the

sI1Ims

after

marking

the

relation

of

the

shaft

and

the

gear

and

Withdraw

the

distributor

shaft

from the

other

Side

Fig

D4From

the

InSideofthe

distributor

cam

remove

the

set

screw

and

pull

off

the

cam

Carefully

unhook

the

flyweight

springs

Without

stretching

or

deforming

them

IGNITION

DISTRIBUTOR

Assembly

Thoroughly

clean

all

parts

and

examine

the

distributor

cap

for

cracks

carbon

tracking

and

burnt

or

corroded

terminals

Check

the

carbon

brush

for

excessive

wear

and

If

necessary

remove

defective

parts

Check

the

contact

breaker

gaps

for

pitting

replaCing

them

If

badly

marked

Light

damage

can

be

smoothed

Withan011

stone

Check

the

shaft

for

wear

and

proper

f

It

In

the

body

Check

the

condensor

for

short

or

open

circuits

and

replace

If

necessary

Check

the

vacuum

Unit

for

operation

and

the

flyweight

mechamsm

for

freedom of

movement

The

assembly

isareversal

of

the

removal

procedure

Refer

to

Fig

D5when

assembling

thJ

flyweight

mechamsm

When

the

distributor

isassembled

connect

a

spring

scaleonthe

endofthe

contact

arm

and

slowly

pull

the

spring

scale

lIWay

from the

fixed

contact

POint

Read

off

the

indication

at

the

moment

when

the

arm

is

lust

lifting

from the

fixed

POint

See

FIgD

61

The

correct

valueIS0

50065

kg

1

10143

Ib

Adjust

the

con1llct

breaker

gap

as

described

below

CONTACT

BREAKER

GAP

Adjultment

With

the

distributor fitted

in

reverse

order

to

the

removal

procedure

turn

over

the

engine

until

the

fibre

pad

of

the

contact

breaker

ann

IS

at

the

highest

POint

of

the

distributor

earn

Slacken

the

clamping

screw

at

the

fixed

contact

pOint

and

turn

the

adjuster

screw

Withascrewdriver

untilacontact

gap

of

045 055

mm

0012

0022

In

IS

obtained

Retighten

the

clamping

screw

and

uSing

a

feeler

gauge

rlH

heck

the

contact

breaker

gap

to

ensure

that the

fixed

contact

breaker

plate

has

not

moved

while

the

clamping

screw

was

tightened

The

contact

breaker

POints

can

be

cleaned

by

uSing

a

contact

file

or

an

011

stone

The

raised

areas

on

the

contact

should

be

filed

off

but do

not

attempt

to

remove

the

crater

In

the

other

contact

After

cleaning

the

contacts

they

should

be

placed

opposite

each

other

meeting

over

a

Wide

area

If

the

contacts

only

meet

partially

It

IS

pOSSible

that

overheating

burning

and

sparking

could

develop

A

View

of

the

contact

breaker

assembly

IS

shown

In

Fig

D7The

adjustment

of

the

pOints

IS

shown

In

Fig

D8

IGNITION

TIMING

Adjultment

Remove

the

distributor

vacuum

line

and

start

the

engine

With

the

engine

running

at

Idle

speed

proceed

as

follows

USing

a

stroboscopIC

tlml

ng

light

connected

In

accordance

With

the

instructIOns

of

the

manufacturer

check

that the

timing

case

pOinter

IS

In

line With

the

timing

mark

on

the

crankshaft

which

Will

be made

statIOnary

by

the effect

of

the

timing

IIgt

Each

of

the marks

on

the

crankshaft

pulley

represents

50

of

the

crank

angle

The

tlml

ng

setting

IS

as

follows

1300

c c

engine

1600

c c

w

SC

1600

c c

w

TC

1008

T

DC

1600

rpm

100

8TD C

1600

rpm

1408TDC

650rpm

wlSC

Single

carburettor

w

TC

TWin

carburettor

CHECKING

THE

CENTRIFUGAL

ADVANCE

Disconnect

the

vaaJum

pipe

from the

distributor

hOUSing

paint

a white

line

on

the

crankshaft

pulley

and

start

the

engine

Direct

the

flash

of

the

stroboscopiC

timing

light

on

the

crankshaft

pulley

and

observe

the

movement

of

the white

line

whilst

the

engine

speed

IS

slowly

Increased

The distance

between

the

IgnitIOn

timing

pOinter

on

the

timing

gear

cover

and

the

white

line

should

Increase

noticeably

Incheatlng

a

satisfactory

operation

of

the

centrifugal

advance

mechanism

If

the

paint

marks

appears

to

move

back

and

forth

In

an

Irregular

manner

It

may

be

that the

flyweights

are

sticking

If

necessary

lubricate the

distributor

to

free

off

the

weights

CHECKING

THE

VACUUM

ADVANCE

MECHANISM

Increase

the

engine

speed

to

about

1200 1500

rpm

until

the

throttle

disc

valve

uncovers

the

vacuum

drllhng

With the

8Q8IIIll

running

dISCOnnect

the

vacuum

pipe

from the

distributor

housing

and

re

connect

in

turn

Observe

the white

paint

hne

on

23

the

crank

pulley

With

each

disconnecting

and

re

connectlOg

of

the

vacuum

pIpe

the

line

should

move

back

and

forth

If

the

line

remalOs

stationary

It

IS

possible

that the

pipe

IS

obstructed

or

the

vacuum

unit

is

damaged

SPARK

PLUGS

Removal

Inspection

and

Installation

Remove

the

spark

plug

cables

from the

plug

ends and

unscrew

the

spark

plugs

only

uSlOg

a

spark

plug

spanner

No

make

sluft

tools

should

be

used

for

thIS

purpose

Check

the

plugs

for

cracks

and

chips

on

the

IOsulators

and

check

the

electrodes

for

wear

If

the

carbon

depOSIt

IS

excessive

thIS

IS

an

Indication

of

bummg

englOe

Oil

so

Installahotter

plug

If

the

plug

faces

are

excesslvle

whIte

or

rapid

electrode

wear

IS

noted

fitacolder

plug

Clean

the

plugs

Withasand

blast

cleaner

or

carefully

WIth

a

Wire

brush

and

adjust

the

electrode

gapS

to

O80

9

mm

0

030035

ln

When

flttmg

the

plugs

tighten

them

to

1

5 2

0

kgm

11

15Ibft

24

II

Technical

Data

DISTRIBUTOR

045

055

mm

0012

002210

050 065

kg

1 1 143Ib

1245

mm

0490210

80mm

03151O

1245

In

0490210

Contact

gap

Contact

spring

pressu

re

Shaft

diameter

lowerpart

Shaft

diameter

upper

part

HouslOg

lOner

diameter

Clearance

between

housmg

and

shaft

001

0038

mm

00004

0001510

Clearance

wear

limit

0

08

mm

0

003

10

Cam

lOner

diameter

80

mm

0315

10

Clearance

between

shaft

and

cam

0

005

Flyweight

piVOt

dla

PIVot

hole

dla

Clearance

between

pIVOt

and

piVOt

hole

001

046

mm

00004 00018

10

0

029

mm

00002

00011

In

50

mm

0197

In

50

mm

0

197

10

IGNITION

COIL

Model

1300 1600

c

c

wlSC

1600

c c

wrrc

Primary

voltage

Primary

resistance

1300 1600

c c

w

SC

1600

c c

wrrc

Secondary

resistance

wlSC

SlOgle

carburettor

C14

51

C6R

50

12

volts

3 2 41ohms
212 7

ohms

112168

ohms

wrrc

TwlO

carburettor

IGNITION

TIMING

AND

IGNITION

ADVANCE

Fully

detailed

IOformatlon

are

gIven

under

EnglOe

TUOlng

Data

See

Index

for

page

number

Trouble

Shooting

SYMPTOMS

PROBABLE

CAUSE

ACTION

TO

BE

TAKEN

Starter

turns

but

engine

will

not

start

Weak

battery

Recharge

battery

Excessive

mOisture

on

spark plugs

or

high

tension

wires

Remove

moisture

and

dry

Cracked

or

leaky

dlStnbutor

cap

or

Replace

cap

or

rotor

rotor

Broken

wire

In

pnmary

CircUit

Repairorreplace

wire

Burned

or

Improperly

adjusted

points

Adjustorreplace

points

Defective

condenser

Replace

condenser

Difficult

starting

Defective

spark

plugs

Clean

adjUstorreplace

plugs

Defective

breaker

points

Replace

breaker

points

Loose

connection

In

pnmary

CircUit

Tighten

or

repair

Defective

condenser

Replace

condenser

Defective

Ignition

COil

Replace

Ignition

coil

Defective

rotor

or

dlstnbutor

cap

Replace

cap

or

rotor

Engine

misfires

Dirty

or

faulty

spark

plugs

Clean

adjUst

or

replace

plugs

Loose

Ignition

wire

or

faulty

Tighten

repair

or

replace

Wires

Insulation
Cracked

dlstnbutor

cap

Replace

cap

Breaker

points

not

correctly

adjusted

AdjUst

breaker

points

Ignition

CirCUit

Interrupted

and

Burnt

or

Incorrectly

adjusted

contact

AdjUst

contact

breaker

gap

voltage

drop

In

pnmary

CircUit

breaker

gap

Defective

leads

loose

or

dirty

Check leads clean

connections

connections

Ignition

SWitch

defective

Check

or

replace

SWItch

Ignition

COil

defective

Check

or

replace

IgnitIOn

COil

Secondary

circuit

Interrupted

and

no

Spark

plugs

wet

worn

or

inCOrrect

Clean and

adjustorreplace

plugs

current

gap

Defective

condenser

Replace

condenser

Defective

or

broken

Ignition

cable

Replace

ignition

cable

Tracking

between

COil

distributor

cap

Clean and

check

parts

or

replace

and

rotor

Defective

Ignition

COil

Check

or

replace

COIl

interceM

j

@

p

ce

L

ill

il

0

7

i

l

f

I

IJ

f

A

a

r

o

Fill

E1General

of

the

twin

choke

Cllburettor

FJg

E3V

of

the

tWin

choke

cartJurettor

for

cars

fitted

With

ilJtomatlC

transnllSSlOft

6

7

FIlI

E5SectIOll

through

the

c

arburetlllr

L

13

1

1

A

rWllltptplt

2

Small

venturI

1MlJmd

MmlTbJeed

5

Slow

tunnlllf

a

bleed

6 SIow

runnm6

f1t

7

8

F

9

Emulston

rubll

14

M

m

jet

8y

ho

12

Throm

13

ChoIc

SmsJIWNlbm

5

MatndlS

C

6

Mam

air

bleed

7

SlorH1lnnmg

II

bleed

IS

SIow

runnlnfl

fIl

19

Vacuum

prsfon

20

Power

aIw

21

Ifam

et

22

Maml

23

ldl

l

24

8

hole

25

Throttle

W

26

J

T

t

1

4

f

c

Fog

E2General

of

the

twm

choke

cartJuret1D

L

16

englnel

12

1314

IS

16

FIg

E4SectIon

through

the

twin

choke

carburetlllr

L

16

englnel

MIl

dach

2

Small

venturi

3

MamllJrble

J

4

Slof

IHUnmng

Jet

5

Slow

runnmg

lII

bleed

G

N

tI

aM

7

FI

8

Emublon

tubtJ

9

M

lnJflf

10

s

110

77

Throttle

aIwl

12

C

rok

aw

13

MII

bltJed

t

c

Mamd

SiChatfpl

15

Econor

zer

bleed

16

SIow

runmng

Jet

17 SJoVN

unnmg

econonuzs

18

Slow

running

BIf

bIet1d

19

AN

vent

2Q

Fue

let1el

g

JiUgt

21

Mam

Jet

22

SJow

runnmg

KJlumtllCl

flW

2

SIoMNllnmng

24

8

11010

25

Throttle

aWe

obo

00

FIQEThe

dlStll8nt1ed

throttle

vaJve

Fuel

System

DESCRIPTION

The

fuel

system

consists

basically

of

fuel

tank

fuel

pump

fuel

strainer

air

cleaner

and

carburettor

The

Datsun

1300ISfitted

with

a

two

barrel

carbu

rettor

whereas

the

Datsun1600

has

either

a

two

barrel

downdraught

carburettor

or

twin

SU

type

carburettors

CARBURETTOR

Single

tWin

choke

Removal

The

single

carburettor

versions

are

fitted

to

the

Datsun

1300

Type

designation

DCK306

and

the

Datsun

1600

Type

deSignation

OAF

328

See

Fig

E

2

E

3

To

remove

the

carburettor

take

off

the

air

cleaner disconnect

the

fuel

pipe

and

the

vacuum

pipe

from the

carburettor

end and

detach

the

choke

cable

Remove

the

throttle

linkage

and

undo

the

four

nuts

and

washers

securing

the

carburettor

to

the manifold

Lift

off

the

carburettor

CARBURETTOR

Dismantling

The

main

Jets

slow

runnlhg

Jets

and

the

needle

valves

for

the

pnmary

and

secondary

stage

are

accessible

from the

outside

of

the

carburettor

body

Remove

the

Jets

and

needles

Fig

E

4

E

5

The

upper

body

can

be

removed

by

removing

the choke

connecting

rod

pp

connecting

rod

return

spring

stop

pin

and

the

four

secunng

screws

Figs

E6E 7

andE8

Mam

body

Remove

the

pnmary

and

secondary

emulSion

tubes

by

removing

the

main air

bleeds

Fig

E

10

Remove

the

cylinder

cover

and

take

out

the

accelerator

pump

F

Ig

E

11

Separate

the

float

chamber

from the

throttle

butterfly

block

by

removing

the

rod

linking

the

diaphragm

to

the

secondary

throttle

valve

and

the

four

securing

screws

Fig

E

12

Remove

the

float

chamber

cover

and

the

float

Fig

E

13

Dismantle

the

diaphragm

by

removing

three

screws

holding

the

diaphragm

chamber

and

then

removing

three

screws

holding

the

diaphragm

chamber

cover

Fig

E

14

The

fuel

return

system

shown

In

Fig

E

15

should

not

be

dismantled

If

not

abolutely

necessary

When

dismantling

take

care

not

to

damage

the

bimetal

spring

Dash

pot

damper

This

mechanISm

IS

fltteto

thecarburettor

Fig

E

16onvehicles

With

automatic

transmission

and

IS

linked

to

the

pnmary

throttle

vale

linkage

CARBURETTOR

Inspection

Thoroughly

clean

all

parts

Inasu

Itable solvent

and

blowout

all

Jets

and

passages

With

compressed

air

Check

all

parts

for

wear

and

damage

With

special

attention

to

the

follOWing

parts

Check

the

float

needle

and

the

seat

for

wear

If

worn

replace

the

assembly

Check

the

throttle

and

choke

valve

shafts

and

bores

for

eccentriCity

Check

the

slow

running

Jet

needles

for

burrs

and

ndges

Replace

parts

as

necessary

Check

choke

tube

clusters

for

wear

or

slackness

and

If

necesssary

replace

the

cluster

Check

all

linkages

for

excessive

wear

and

the

filter

screen

for

blockage

and

distortion

Check

the

operation

of

the

accelerator

pump

and

the

diaphragm

chamber

for

damage

to

the

diaphragm

and

air

leaks

Repair

or

replace

any

defective

components

CARBURETTOR

Assembly

The

assembly

IS

carned

outIn

reverse

order

to

the

dismantling

procedure

Special

care

should

be

taken that

no

defective

brittle

or

hard

gaskets

are

used

Where

these

are

found

they

should

be

replaced

When

connecting

the

linkages

be

careful

not

to

bendordeform

any

of

the

components

CARBURETTOR

Adjustments

Float

level

If

the

fuel

level

IS

at the

gauge

line

the

float

IS

correctly

set If

thiS

IS

not

the

case

hold

the

float

level

In

ItS

chamber

and

check

that the

gap

between

the

float

seat

and

the

stem

of

the

float

needle

valveISabout10

mm

0039

In

for

the

L13

and15

mm

059

In

for

the

L16

engine

Fig

E

17

Bend

the

float

seat

as

shown

In

Fig

E

18

Interlock

startJng

system

With

the

choke

valve

fu

lIy

closed

there

should

be

a

clearance

of

1

3

mm

00512

In

between

the

pnmary

throttle

valve

and

the

carburettor

body

In

the

ase

of

the

OAF

328

carburettor

and

a

clearance

of 072

mm

0028

In In

the

case

of

the

DCK

306

carburettor

Fig

E19and

Fig

E

20

Interlock

opemng

of

prunary

and

secondary

throttle

valves

When

the

pnmary

throttle

valve

IS

opened

to

the

speCified

degree

590

for

OAF

328

or

560

for

DCK

306

there

should

be

a

clearance

of

9 10

mm

03583

In In

case

of

the

OAF

328

carburettor

or

6

40

mm

0

252

In

between

the

throttle

valve

and

the

Inner

wall

of

the

throttle

chamber

See

also

Figs

E

22

and

Fig

E

23

To

adjUst

the

clearance

bend

the

pOint

marked

A

on

the

adjustment

plate

Slow

roORing

adjustment

The

slow

running

adjustment

IS

obtained

by

adjusting

the

throttle

valve

stop

screw

and

the

slow

running

volume

control

screw

Screw

In

the

slow

runnlng

volume

control

screw

and

back

off

by approximately

three

turns

Then

screw

In

the

throttle

stop

screw

and

start

the

engine

Unscrew

the

throttle

stop

screw

until

the

engine

beginS

to

rotate

unevenly

when

the

englfle

speed

Will

gradually

drop

Now

screw

In

the

slow

running

volume

control

screw

until

the

engine

runs

smoothly

at

the

D

inter

D

i

@

j1

4

4

alh

throttle

valves

relllDved

FIlIE

7

B

removed

carburettor

top

caver

FIlI

E B

The

O

l

1

Jo

u

0

ll

li

il

4

I

f

It

F

I

0

D

j

hamber

relllDvecI

9

The

choke

c

Fill

E

ndary

emu

end

lOCO

10

The

pnmary

FIlI

E

ell

tubes

remov

q

o

i

0 0 0

carburetlDr

The

lower

and

upper

FIlI

E

12

bod

separa18d

ret

from

the

reIIICJII8II

FIg

E

13

The

float

tor

body

28

4

o

o

0

ImmIIII

3

1J

F

fuoIlpul

flp

FIQ

E

15

The fuel

return

sys1em

Valve

2

Body

3

PIPe

if

SImtlttJl

FgE

14

The

component

parts

of

the

dl8phragm

r

r

a

i

L

J

I

Ll1

1

f

i

r

L

4

5 6

FI

I

E

16

The

dashpot

mechBlllsm

7

Locknut

2

Chok

cl

Jblearm

3

OGhpot

ThlO

0

5

Throttle ch

btK

6

Throm

l

aIw

2

r

rL

i

r

L

fr

J

L

J

JhaJi

DAH42AnZl
OCK

00

1

I

OmmDau

I

Fill

E17The

flollllevel

adJullment

Float

SlHt

2

FIo

t

3

FINt

ltop

4 NeJIII

van

FIQE18

Adlusanent

of

the

float

18111

FI

I

E

19

AdJuotment

of

slllI

tlng

Interloca

opemng

Choke

bell

rod

2

Choke

connctlllfl

rod

3

S11Irtlng

Ie

4

Choke

vain

5

Choke

ItNer

6

Fat

dIB

connectIng

IeYer

1

Throttle

chamber

8

Throttle

valw

FIQE20

MeaRltlng

the

clearance

of

the

start

ng

Interlock

valve

Opel1l11l1

29

highest

speed

Re

adjust

the

throttle

stop

screw

to

reduce

the

engine speed
Repeat

thiS

adjustment

until

an

engine

speed

of

550

rpm

has

been

obtained

Care

should

be

taken

not

to

screw

In

the

slow

running

volume

control

screw

to

tightly

as

otherwise

the

tip

of

the

screw

mightbedamaged

Dashpot

adjustment

ThiS

adjustmentISonly

necessary

on

the

Datsum

1600

fitted

With

automatic

transmission

With the

engine

at

operating

temperature

check

that

the

throttle

lever

Will

touch the

dashpot

stem

when

the

engineISrunning

With

1800

2000

rpm

There

should

be

no

load

on

the

engine

Fig

E

161

If

thiS

IS

not

the

case

slacken

the

dash

pot

locknuts

and

turn

the

dash

pot

to

the

nght

or

left

until

the

throttle

lever touches

the

dash

pot

stem

at

the

specified

engine

speed

In

thiS

condition the

clearance

between

the

throttle

valve

and

the

throttle

chamber

wall

should

be

08

mm

0071

In

I

corresponding

to

a

throttle

valve

angle

of

lO

SU

TYPE TWIN

CARBURETTORS

Dismantling

Unscrew

the

plug

and

Withdraw

the

piston

damper

Take

out

the

two

suction

chamber

secunng

screws

11ft

off

the

suction

chamber

and

Withdraw

the

piston

and

Jet

needle

Disconnect

the

rod from the

bottom

of

the

Jet

and

the

nylon

feed

tube

from the

base

of

the

float

chamber

Unscrew

the

Jet

adjusting

nut

and

the

spnng

Unscrew

the

Jet

beanng

locking

nut

Remove

the

float

chamber

cover

secunng

bolts

and

Withdraw

the

float

Screw

out

the

needle

valve

assembly

The

dismantling

stages

are

shown

In

Figs

E24E25andE26

CARBURETTOR

InspectIon

Note the condition

of

the

needle

valve

and

the

seating

Fit

a

new

needle

valve

and

seating

If

necessary

If

the

Jet

needle

IS

bent

or

otherwise

damaged

Withdraw

the

locking

screw

In

the

piston

and

fit

a

new

needle

Push

the

needle

In

until

the

shoulder

IS

flush

With

the

lower

face

of

the

piston

Fig

A

271

Clean

and

dry

the

piston

assembly

Lubncate the

piston

rod

WIth

thin

011

CARBURETTOR

Assembly

Reverse

the

dlamantllng

procedure

and

centre

the

Jet

Centnng

the

Jet

Screw

the

Jet

adjusting

nut

up

as

far

as

poSSible

11ft

the

piston

With

the

lifting

pin

and

allow

It

to

drop

It

should

drop

freely

onto

the

bndge

With

a

soft

metallic

click

Repeat

wltn

the

adjusting

nut

screwed

fully

down

If

the

piston

does

not

fall

freely

In

either

of

the

tests

proceed

as

follows

Disconnect

the rod from the

bottom

of

the

Jet

and

the

feed

tube

from the

base

of

the

float

chamber

Pull

out

the

Jet

and

the

tube

Unscrew

and

remove

the

Jet

adjusting

nut

and

the

spnng

Refit the

adjusting

nut

Without the

spnng

and

screw

It

up

as

far

as

pOSSible

Slacken

the

Jet

bearing

lock

nut

until

the

beanng

can

be

turned

With

the

fingers

Remove

the

piston

damper

and

press

the

piston

down

onto

the

bndge

Tighten

the

lock

nut

tift

lhe

pjS

on

and

nQ

1l

whetlliij

IS

falls

freely

fully

19w

ir

the

30

adjusting

nut

and

check

again

If

the

second

check

produces

a

sharper

click than

the

first

repeat

the

centnng

Refit the

parts

that

have

been

removed

pour

thin

011

Into

the

hollow

rod

of

the

piston

damper

to

Within05

In

12

7

mml

of

the

top

of

the

rod

CARBURETTOR

Adjustments

The

proper

adjustment

of

the

two

carburettors

IS

extremely

Important

In

obtaining

peak

vehicle

performance

and

redUCing

fuel

consumption

Carburettor

synchromzsnon

and

idhng

adjustment

Remove

the

air

cleaner when

the

engine

has reached ItS

operating temperature

and

slacken

the

throttle

adjusting

screws

The

headsofthe

adjusting

screws

must

not

contact

the

throttle

lever

Also

make

sure

that

the

front

and

rear

throttle

shafts

are

not

connected

Tighten

the

Idling

adjusting

nuts

of

the

front

and

rear

carburettor

by

one

turn

towards

the

top

of

the

carburettors

and

gradually

back

them

off

After

the

nuts

have

been

turned

approximately

half

a

turn

the

nuts

Will

contact

the

needle

heads

Back

off

the

nuts

from

thiS

pOSition

by

approx

one

andahalf

turn

Make

sure

that the

Idling

adjusting

nuts

of

both

carburettors

are

In

the

same

pOSition

The

dimenSion

A

adjustment

descnbed

later

between

the

Jet

bndge

and

the

needle

head

should

then

be

approx

1

5

mm

0591

In

I

Screw

In

the

throttle

adjustment

screws

of

the

front

and

rear

carburettors

and

start

the

engine

The

engine

should

retain

Its

operation

temperature

before

carrying

out

the

next

step

Now

turn

the

throttle

adjusting

screw

of

both

carburettors

to

reduce

the

engine

speed

to

approx

600 700

rpm

The

engine

should

turn

over

smoothly

and

consistent

Ifaflow

meter

IS

available

apply

the

Instrument

to

the

front

carburettor

flange

and

turn

the

adjustment

screw

on

the

flow

meter so

that the

upper

end

of

the

float

In

the

glass

tube

IS

In

line

With

the

scale

Llft

off

the

flow

meter

and

re

apply

It

to

the

rear

carburettor

Without

altering

the

setting

of

the

flow

meter

adjusting

screw

If

the

pOSItion

of

the

float

IS

not In

line

With

the

scale

adjUst

the

rear

carburettor

throttle

adjusting

screw

to

align

the

float

With

the

mark

on

the

scale

With

the

carburettor

flow

correctly

adjusted

tighten

the

Idling

adjusting

nuts

of

both

carburettors

by

approx

18of

a

turn

and

stop

the

adjusting

of

the

nuts

at a

pOint

where

the

engine

speed

IS

fastest

and

smoothest

Without

missing

or

hunting

If

thiS

point

cannot

be

detenmned

bnng

the

nuts

back

to

their

onglnal

positions

and

unscrew

them

from

thiS

pOSition

until

the

engine

runs

fastest

und

smoothest

Then

slacken

the

throttle

adjusting

screws of

the

front

and

rear

carburettors

and

adjUst

the

engine

speed

to

the

specified

value

of

650

rpm

for

standard

engines

or

700

rpm

for

models

With

011

cooler

Make

sure

that the

air

flow

of

both

the

carburettors

remains

unchanged

Screw

In

the

throttle

adjusting

screws

until

their

heads

contact

the

throttle

connecting

lever

Connect

up

the

front

and

rear

throttle

shaft

Without

changing

the

Idling

speed

setting

Move

the

throttle

interconnecting

shaft

and

accelerate

the

engine

a

few

times

When

the

engine

IS

settled

once

more

In

Its

Idling

speed

check

that the

speedISunchanged

Re

check

also

the

connection

of

the

interconnecting

shaft

Then

turn

tha

Interconnecting

shaft

adjusting

screw

to

Increase

the

engine

speed

to

800

1000

rpm

Check

y

means

of

the

flow

meter

Jf

the

Idling

air

flOW

IS

the

same

tor

both

carburettors

If

necessary