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d
1
I
INTER
Titles
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
141
144
146
150
159
EUROPE
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
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140
CORTINA
KADETT
ROMEO
IMP
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17
20M
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403
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1200
1200
1300
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230
1600
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A
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1500
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1600
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KADETT
250
MODELS
etc
1200
ENGINES
1600E
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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
1965
to
Up
Since
1968
1969
Introduction
1970
r
I
1
f7
I
INDEX
l
This
Workshop
and
the
to
encounter
condensed
fanfihar
The
manual
models
carburettors
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LUBRICATION
COOLING
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FUEL
CLUTCH
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IDENTIFICATION
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AXLE
REAR
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SUSPENSION
FRONT
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STEERING
BRAKES
ELECTRICAL
WIRING
ENGINE
TIGHTENING
CONVERSION
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Introduction
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Inlet
on
the
gearbox
the
from the
alternator
SWitch
ENGINE
carned
nuts
mountings
and
011
to
2 8 3 4
mm
the
are
3
of
bolts
and
the
cylinder
011
when
a
gasket
be
cover
of
and
1
dlstnbutor
Fig
and
the
the
on
both
valve
cold
gasket
assembly
high
out
points
and
coolant
ring
nght
the
clearance
cylinder
types
Use
timing
sealInthe
front
coated
check
Then
the
be
the
cylinder
A 45
Inlet
water
011
engine
tappets
and
engine
011
bolts
are
gaps
angles
numbers
00079
JOinting
torque
special
distributor
and
With
links
the
cylinder
less
water
elbow thennostat
cylinder
sump
Sides
cold
tenSion
mounting
opposite
to
the
on
20
kgm
of
the
00118
compound
head
borts
of
5 0
of
bolts
and
tool
drive
chain
Fig
camshaft
the
timing
between
and and
block
front
front
cover
cover
and
between
check
drivesothat the offset
fit
With
that
than
pump
In
Its
outlet
block
coating
slinger
Fig
and
the rocker
the
leadtothe
cover
JOinting
does
It
the
block
0 15
compressIOn
elbow
A 46
025
fuel
stand
mountings
level
dipstick
Installation
in
reverse
should
order
be
completely
Then
tlQhten
water
or
anti
lubricant
each
gudgeon
2
big
ST49010000
timing
the
cover
the
the
In
60
each
and
A 44
IS
same
246lb
end
I
either
In
kgm
marks
marks
Install
removed
upper
and
pin
bearings
the
should
fit
the
With
sprockets
on
on
ThiS
cylinder
compound
Interfere
not
difference
height
and
the
mm
0059
Set
the
engine
stroke
hOUSing
Refit the
and
enclose
new
the
manifolds
to
020
mm
0010
cover
hosetothe front
distributor
and
fit
Ignition
and
the
to
the
nuts
freeze
the
removal
engine
Fill
and
noted
until
the
other
Fit
Side
ft
Side
order
36
go
to
011
the
the
the
the
seal
for
front
upper
In
slot
011
the
gasket
and
mm
In
uSing
the
COil
water
the
the
2
at
IS
14
Trouble
Shooting
Lack
of
Overheating
ExceSSive
D
fficult
nOIsy
Engine
power
oil
starting
SYMPTOMS
consumptIon
PROBABLE
I
1
Poor
compresSion
Incorrect
Intake
Sticking
Valve
Piston
valves
valves
springs
rings
valve
broken
Ringsorcylinders
2
Ignition
Incorrect
DefectIve
Contact
3
Lackoffuel
Clogged
Clogged
Dirty
Faulty
Fuel
Insufficient
Looefan
Fan
Inoperative
Defective
Clogged
Incorrect
Incorrect
Incorrect
Radiator
Oil
DefectIve
Piston
grooves
Piston
Valve
Improper
Discharged
Loose
Defective
Burnt
PIstons
worn
Crankshaft
Connecting
ConnectIng
Piston
filter
belt
leaks
Ignition
spark
breakers
carburetor
fuel
fuel
tank
fuel
clogged
belt
worn
water pump
cooling
Ignition
valve
011
finS
piston
rings
or
cylinder
stem
0
connections
Ignition
valves
piston
piston
Improperly
pipe
pump
coolant
thermostat
used
or
1
or
beanngs
rod
rod
CAUSE
clearance Adjust
leaking
broken
worn
set
limIng
plugs
defective
Jet
or
damaged
system
liming
clearance Adjust
Clean
Clean
clogged
rings
worn
gUide
worn
worn
or
sticking
In
Replace
Replace
Change
defective
battery
system Adjust
Chargeorreplace
Clean
RepairOrreplace
nngs
bearings
be
nngs
or
or
l
and
cylinders
Journals
worn
pinS
badly
worn
damaged
Overhaul
Replace
or
Replace
I
or
Stralgten
Check
ACTIOtJ
valve
clearance
Lap
valve
seats
set
up
valve
valve
piston
engine
re
set
or
replace
carburetor
fuel
pipe
fuel
tank
fuel
or
replace
radiator
fan
fan
thermostat
or
pump
belt
belt
Replace
Replace
Replace
Overhaul
Re
Clean
Clean
Clean
Check
Clean
Top
Adjust
Replace
Replace
Repairorreplace
Clean
system
Re
set
timing
clearance
Refill
With
readlator
leak
piston
Piston
piston
as
to
and
Ignition
enqlne
correct
and
necessary
proper
tighten
Clean
Fnd011
Replace
Replace
bearings
crankshaft
replace
bearings
crankshaft
replace
or
replace
and
replace
TOBETAKEN
andguIdes
spring
rings
renew
adjust
element
oil
grade
finS
rectify
rings
rll1gs
or
bore
VISCOSity
battery
connections
check
plugs
valves
and
grind
and
gnnd
rod
parts
gap
cylinder
as
crankshaft
crankshaft
necessary
Ignition
System
The
1300
are
fitted
the
1600
The
outside
Disconnect
Ignition
Remove
slacken
Remove
vacuum
two
fixed
the
the
spring
breaker
distributor
contact
the
steel
and
those
SUitably
drive
out
D
3
Fig
relation
shaft
from the
distributor
Carefully
deforming
Thoroughly
cracks
carbon
the
carbon
defective
replaCing
an
With
Check
the
condensor
Check
mechamsm
The
assembly
D5when
Fig
distributor
contact
fixed
contact
when
the
The
correct
con1llct
c
c
With
c c
appearance
IGNITION
the
coli
the
distributor
the
IGNITION
the
contact
clip
pOint
body
breaker
balls
between
support
the
Remove
of
the
cam
unhook
them
IGNITION
clean
parts
them
stone
011
shaft
for
the
for
isassembled
arm
arm
valueIS0
breaker
and
the
the
engine
high
and
detach
vacuum
distributor
Unit
securing
POint
from the
remove
and
remove
base
between
the
drive
shaft
other
remove
all
tracking
brush
Check
If
badly
for
short
vacuum
freedom of
isareversal
assembling
and
slowly
POint
is
lust
gap
DESCRIPTION
1600
Ignition
With
of
DISTRIBUTOR
tension
pipe
clamp
DISTRIBUTOR
set
plate
the
breaker
the
distributor
gear
the
gear
and
Side
the
flyweight
DISTRIBUTOR
parts
and
for
excessive
marked
wear
or
Unit
connect
Read
lifting
50065
described
as
twin
both
the
cap
screws
screw
piVOt
the
the
retaining
the
the
and
the
and
open
movement
thJ
pull
c c
engines
distributor
carburettors
distributor
cables
primary
from the
bolt
and
contact
two
see
Fig
breaker
plates
and
gear
Fig
set
examine
burnt
contact
proper
circuits
for
operation
of
the
flyweight
a
the
off
the
from the
below
from
wire
and
withdraw
off
pull
and
11ft
and
11ft
of
post
arm
spring
D2Take
spring
shaft
pin
the
sI1Ims
and
Withdraw
D4From
screw
springs
or
corroded
wear
and
breaker
Light
damage
f
It
and
removal
spring
spring
indication
fixed
10143
kg
1
With
Single
D410
model
has
model
modelsISalike
Removal
the
spark
from the
distributor
Dlsmanthng
the
rotor
off
the
off
the
moveable
the
From
and
clips
care
and
the
underneath
from
a
uSing
after
the
and
pull
Without
Assembly
the
distributor
terminals
If
necessary
gaps
can
In
the
body
replace
and
procedure
mechamsm
scaleonthe
scale
at
POint
carburettors
58
D400
plugs
distributor
connection
the
distributor
Loosen
Unit
Unscrew
Take
pOint
the
Sideofthe
remove
not
to
breaker
SUitable
marking
the
distributor
InSideofthe
off
the
stretching
for
smoothed
be
Check
If
necessary
the
flyweight
Refer
When
endofthe
from the
lIWay
the
moment
See
FIgD
Ib
Adjust
whilst
and
contact
punch
cap
Check
remove
pitting
loose
plate
and
cam
54
the
the
the
the
the
off
the
the
CONTACT
With
the
distributor fitted
procedure
contact
earn
turn
045 055
clamping
breaker
not
moved
The
file
filed
contact
opposite
only
sparking
IS
shown
D8
Fig
Remove
the
engine
USing
the
pOinter
Will
of
the marks
crank
or
for
to
1300
1600
1600
wlSC
Disconnect
a white
Direct
crankshaft
whilst
between
and
satisfactory
the
manner
lubricate the
breaker
Slacken
the
adjuster
screw
gap
contact
or
an
off
but do
After
each
meet
could
In
the
a
stroboscopIC
instructIOns
IS
be made
angle
c c
engine
c c
w
c c
Single
CHECKING
line
the
the
the
white
the
marks
paint
It
CHECKING
turn
the
mm
to
while
breaker
011
partially
Fig
distributor
running
In
line With
The
SC
w
TC
the
flash
pulley
engine
operation
may
distributor
over
ann
clamping
screw
0012
and
ensure
the
stone
not
cleaning
other
develop
D7The
IGNITION
of
statIOnary
on
tlml
carburettor
vaaJum
on
the
IgnitIOn
line
appears
be
THE
BREAKER
the
IS
at
Withascrewdriver
uSing
that the
clamping
POints
The
attempt
the
meeting
It
IS
pOSSible
A
vacuum
at
Idle
tlml
ng
manufacturer
the
the
the
crankshaft
ng
setting
THE
pipe
crankshaft
of
the
and
observe
speed
timing
should
of
to
that the
to
VACUUM
GAP
in
reverse
engine
the
highest
at
screw
In
0022
a
feeler
fixed
screw
can
be
raised
areas
remove
to
contacts
over
that
View
of
adjustment
TIMING
line
proceed
speed
connected
light
mark
timing
the effect
by
IS
as
w
TC
CENTRIFUGAL
from the
stroboscopiC
the
IS
slowly
pOinter
Increase
the
centrifugal
move
flyweights
off
free
ADVANCE
Adjultment
order
until
the
POint
the
fixed
IS
obtained
gauge
contact
was
tightened
cleaned
on
the
the
they
a
Wide
overheating
contact
the
of
the
Adjultment
and
start
as
check
on
of
pulley
follows
100
1008
1408TDC
TWin
distributor
and
pulley
movement
Increased
on
the
noticeably
advance
back
and
are
the
weights
the
to
fibre
pad
of
the
contact
untilacontact
Retighten
rlH
heck
the
breaker
by
uSing
contact
crater
In
should
area
If
the
burning
breaker
pOints
the
In
accordance
that the
crankshaft
the
timing
T
8TD C
ADVANCE
engine
DC
follows
the
represents
carburettor
hOUSing
start
timing
light
of
the white
The distance
timing
Incheatlng
mechanism
forth
In
sticking
If
MECHANISM
removal
distributor
pOint
contact
plate
a
contact
should
the
be
contacts
assembly
IS
shown
timing
IIgt
50
1600
1600
650rpm
the
on
gear
an
Irregular
necessary
of
and
gap
other
placed
With
With
case
which
Each
of
rpm
rpm
paint
engine
cover
the
of
the
has
be
and
In
the
the
line
a
If
61
Increase
throttle
running
housing
the
engine
disc
valve
dISCOnnect
and
re
connect
speed
uncovers
the
1200 1500
about
to
the
vacuum
vacuum
in
turn
pipe
Observe
drllhng
from the
the white
rpm
With the
distributor
paint
until
8Q8IIIll
hne
the
on
23
Trouble
Shooting
Starter
Difficult
Engine
Ignition
voltage
turns
starting
misfires
drop
SYMPTOMS
but
CirCUit
In
pnmary
engine
Interrupted
will
CircUit
ACTION
battery
moisture
cap
or
on
spark plugs
dlStnbutor
CAUSE
cap
or
or
Recharge
Remove
Replace
PROBABLE
not
start
Weak
Excessive
tension
high
Cracked
battery
mOisture
or
wires
leaky
rotor
TO
and
BE
dry
TAKEN
rotor
and
Broken
Burned
Defective
Defective
Defective
Loose
Defective
Defective
Defective
Dirty
Loose
Insulation
Cracked
Breaker
Burnt
breaker
Defective
connections
Ignition
Ignition
wire
or
spark
breaker
connection
condenser
Ignition
rotor
or
faulty
Ignition
dlstnbutor
points
or
Incorrectly
gap
SWitch
COil
In
pnmary
Improperly
condenser
plugs
or
spark
not
leads
defective
defective
points
In
COil
dlstnbutor
plugs
wire
cap
correctly
adjusted
loose
CircUit
adjusted
pnmary
or
points
CircUit
cap
faulty
adjusted
contact
or
dirty
Repairorreplace
Adjustorreplace
Replace
Clean
Replace
Tighten
Replace
Replace
Replace
Clean
Tighten
Replace
AdjUst
AdjUst
Check leads clean
Check
Check
condenser
adjUstorreplace
breaker
or
condenser
Ignition
cap
adjUst
repair
cap
breaker
contact
or
or
repair
or
or
replace
replace
wire
points
points
coil
rotor
replace
or
replace
points
breaker
SWItch
IgnitIOn
plugs
plugs
Wires
gap
connections
COil
Secondary
current
circuit
Interrupted
and
no
Spark
gap
Defective
Defective
Tracking
and
rotor
Defective
plugs
condenser
or
between
Ignition
wet
broken
worn
COil
COil
Ignition
distributor
or
inCOrrect
cable
cap
Clean and
Replace
Replace
Clean and
Check
adjustorreplace
condenser
ignition
or
check
replace
cable
parts
COIl
or
plugs
replace
The
fuel
strainer
with
a
two
either
a
carburettors
CARBURETTOR
The
single
Type
designation
deSignation
carburettor
and
the
choke
cable
nuts
and
off
the
carburettor
The
main
pnmary
the
carburettor
E
5
The
upper
connecting
the
four
Remove
the
main air
take
out
chamber
the
linking
four
securing
cover
and
Dismantle
diaphragm
diaphragm
The
fuel
dismantled
care
not
This
mechanISm
With
automatic
throttle
vale
Thoroughly
and
Jets
and
damage
Check
the
the
assembly
system
air
cleaner
barrel
two
carburettor
OAF
take
vacuum
washers
Jets
and
secondary
body
rod
secunng
the
pnmary
bleeds
the
from the
diaphragm
the
the
chamber
chamber
return
If
to
damage
linkage
clean
passages
With
float
consists
and
carbu
barrel
downdraught
DCK306
328
off
pipe
Remove
securing
CARBURETTOR
slow
runnlhg
body
can
connecting
pp
screws
and
Fig
accelerator
throttle
screws
float
Fig
diaphragm
and
cover
system
not
abolutely
the
IS
fltteto
transmission
CARBURETTOR
all
parts
With
special
needle
DESCRIPTION
basically
carburettor
rettor
Single
versions
See
the
air
cleaner disconnect
from the
the
throttle
the
Jets
are
stage
Remove
removed
be
E6E 7
Figs
Mam
secondary
10
E
pump
butterfly
to
the
E
12
Fig
E
13
by
removing
then
removing
Fig
shown
necessary
bimetal
Dash
pot
thecarburettor
Inasu
compressed
attention
the
and
of
fuel
The
whereas
carburettor
choke
tWin
are
fitted
the
and
E
2
Fig
carburettor
linkage
carburettor
Dismantling
and
accessible
the
Jets
rod
return
body
emulSion
Remove
E
F
Ig
block
secondary
Remove
E
14
In
spring
damper
IS
and
Inspection
Itable solvent
air
to
the
seat
for
tank
Datsun
the
Datsun
E3To
to
the
needle
and
by
removing
andE8
the
11
throttle
three
three
E15should
Fig
When
Fig
linked
Check
follOWing
wear
Fuel
fuel
1300ISfitted
Datsun1600
or
twin
Removal
to
the
the
end and
and
undo
the manifold
valves
from the
needles
spring
tubes
cylinder
Separate
by
removing
valve
the
float
screws
screws
dismantling
E
16
to
and
all
parts
If
worn
pump
SU
Datsun
1600
remove
fuel
detach
the
outside
Fig
the choke
stop
removing
by
cover
the
chamber
holding
holding
on
the
blowout
for
parts
fuel
type
1300
Type
pipe
four
for
E
4
pin
float
the
and
not
take
vehicles
pnmary
wear
replace
System
Check
eccentriCity
has
the
the
Lift
the
of
and
and
rod
the
the
the
be
all
Check
parts
Check
necesssary
wear
Check
chamber
replace
The
procedure
brittle
should
not
to
If
the
thiS
that the
needle
mm
seat
With
1
3
carburettor
clearance
carburettor
When
degree
a
clearance
carburettor
and
and
A
The
throttle
screw
Screw
by approximately
screw
until
speed
volume
throttle
the
the
slow
as
choke
running
necessary
tube
replace
the
any
the
operation
for
defective
filter
damage
CARBURETTOR
IS
carned
and
assembly
Special
or
hard
replaced
level
the
gap
In
choke
00512
gaskets
CARBURETTOR
IS
case
between
for
In
valve
be
bendordeform
fuel
IS
not
valveISabout10
059
as
shown
the
mm
body
of 072
Fig
Interlock
the
pnmary
for
of
or
Inner
23
E
adjustment
running
valve
the
start
engine
gradually
control
OAF
9 10
6
wall
To
stop
slow
the
Fig
on
590
the
slow
In
and
the
Will
and
clusters
the
screen
of
to
components
care
When
at the
hold
the
E
Fig
Interlock
fu
In
between
In
the
mm
E19and
opemng
throttle
328
mm
40
mm
of
adjUst
Slow
adjustment
screw
runnlng
three
the
engine
beginS
screw
Jet
cluster
for
the
the
outIn
should
are
any
gauge
the
the
L16
18
lIy
ase
0028
throttle
or
the
the
plate
roORing
turns
to
drop
until
choke
needles
for
Check
blockage
accelerator
diaphragm
reverse
used
connecting
of
the
Float
float
float
mm
engine
startJng
closed
the
of
the
In In
E
Fig
of
prunary
valve
560
03583
252
0
throttle
clearance
and
the
volume
Then
Unscrew
rotate
Now
the
valve
for
burrs
wear
all
and
pump
Assembly
order
be
taken that
Where
components
Adjustments
level
line
the
In
level
and
seat
0039
In
Fig
system
there
pnmary
OAF
the
20
valves
IS
opened
for
DCK
In In
In
between
chamber
adjustment
IS
obtained
slow
control
screw
unevenly
screw
engine
shafts
or
linkages
and
these
the
float
ItS
E
should
328
case
and
bend
running
the
runs
and
slackness
distortion
and
air
leaks
to
the
are
linkages
IS
correctly
chamber
the
stem
for
the
17
be
throttle
carburettor
of
secondary
to
306
there
case
of
the
See
the
by
screw
In
the
throttle
when
In
the
smoothly
and
ndges
for
the
diaphragm
dismantling
no
found
of
L13
Bend
a
clearance
valve
the
the
the
throttle
also
pOint
adjusting
volume
and
throttle
stop
the
slow
bores
Replace
and
excessive
Repair
defective
be
careful
set If
and
check
the
and15
the
and
and
DCK
speCified
should
OAF
Figs
marked
control
back
screw
englfle
running
at
they
float
float
the
306
328
valve
E
stop
for
If
or
of
a
be
22
the
off
the
D