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Workshop Manual Datsun 1300 1400 1600 18 PDF
Workshop Manual Datsun 1300 1400 1600 18 PDF
WORKSHOP MANUAL
for
510 series
130014001600
DATSUN
610 series
160B 180B
I l
A
av
C R Newton
SBN 901610 13 5
PUBUSHED BY
OOEREUROPE
AUTODAT A DIVISION
NICHOLSON HOUSE
MAIDENHEAD
BERKSHIRE
ENGLAND
Printed
WSM 137 w
Engl
C Copyrirt eurupe Cktoblr 1972
lnt
i
I inter j
llil @E
W
YOUR MANUFACTURER
The Nissan Motor Company was founded in 1933 under the name of Jidosha Seizo Co Ltd
In 1934 the present title was adopted and during 1966 the company merged with c
Prin
Motors builders of the Skyline and Gloria ars
With the head office and six main factories near Tokyo Japan other sister plants ace also
in production in various countries throughout the world
YOUR VEHICLE
In the early days of the company s history vehicles constructed were given the trade name
DA TSDN which means SON of DAT the initials of three of the financial backers forming
the syllable DAT To avoid confusion with a similar Japanese word the name was eventually
changed to DATSUN
The various models covered in this Manual together with alternative namts used for the
world markets are listed below
MODELS COVERED
WUUUU I J S 1
7
fl
lfI r
I
I i I
HI
I
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11
1
2
inteN j@IP B
Index
ENGINE S
COOLING l
SYSTE 15
IGNITION SYSTE
I 2S
FUEL SYSTBl 33
CLUTCH 43
GEARUOX 51
FRONT SUSPENSION 83
STEERING 91
BRAKING SYSTEM 9S
ELECTRICAL EQUIP JENT lOB
WIRING JAGRA IS liB
TROUBLE SHOOTING I2S
TIGHTENING 129
TORQUES
SERIES 30
C MODEL SUPPLEMENT 51
AUTOSERVlCE DATA CHART End of manuir
PART NA ES nd ALTERNATIVES
CONVERSION TABLES
IntroductIon
OUf intention in writing this Manual is to provide the reader with all the data and in
formation required to maintain and repair the vehicle However it must be realised that
special equipment and skills arc required in some caseS to carry out the work detailed
in the text and we do not recommend that such work be attempted unless the reader
possesses the necessary skill and equipment It would be better to have an AUTHQRISED
DEALER to carry out the work using the special tools and equipment available to
his trained staff He will also be in possession of the genuine spare parts which may be
needed for replacement
The information in the Manual has been checked against that provided by the vehicle
manufacturer and any peculiarities have been mentioned if they depart rom usual work
shop practice
A fault finding and trouble shooting chart has been inserted at the end of the Manual to
enable the reader to pin point faults and so save time As it is impossible to include every
malfunction only the more usual ones have been included
A composite conversion table has also been included at the end of the manual and we
would recommend that wherever possible for greater accuracy the metric system units
are used
Brevity and simplicity have been our aim in compiling this Manual relying on the number
ousillustrations and clear text to inform and instruct the reader At the request of the
many users of our Manuals we have slanted the book towards repair and overhaul rather
than maintenance
every care has been taken to ensure that the information and data are correct
Although
WE CANNOT ACCEPT ANY LIABILITY FOR INACCURACIES OR OMISSIONS
OR FOR DAMAGE OR MALFUNCTIONS ARISING FROM THE USE OF THIS BOOK
NO MATTER HOW CAUSED
I
3
361 348
501 2
52
557
ESTA E 168 065
BLUEBIRD 330
5 1
U8 280 4
1800 4
57 971 2051
2
5 5 103
165
18 0 000
320
BLUEBIRD 1800 L 3
5 5
23
941 99
Ii
3
79
50
18 43
98
281 1061 14 991
8 51 7
2 2
55 60
62 34
165 500 185 955 12 28
290 300
BLUEBIRD
16
1600 L
215 600 405
6
0 1
2
Data
1
4
27 050 99
51
55
8 2
2123 60
210 930 28
160 U6 410
Technial
7
281
20 91 5
0
50 95 5 9501
12 27 931
162 6142 55 33
420
8 1
10
2
33
50
2 270 215 885
400 U4 120 560
1
420 10
2
6
93
c 808 29
eded
Supen by
c
car 35 150 0
1300
13 1400 820
I
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r
Olin
circle
tfeet font rear
metr s
dearnce I
dry
tClf k consumption aximu
type
Turni g Track Ground Weight Fuel Fuel
Engine Ovendi Overal Oyeral
t
EngIne
INTRODUCTION CRANKSHAFT AND MAIN BEARINGS
ENGINE Removal CAMSHAFT AND SPROCKET
ENGINE DismantUng FLYWHEEL
ENGINE Inspection and Overhaul ENGINE Assembling
VALVES VALVE GUIDES VALVE SEAT INSERTS VALVE CLEARANCES Adjusting
CAMSHAFT AND CAMSHAFT BEARINGS Checking ENGINE LUBRICATION SYSTEM
CYliNDER BLOCK OIL PUMP
PtSTONS AND CONNECTING RODS OIL FILTER
CHANGING THE ENGINE OIL
The 1400 1600 cc and 1800 cc engines are four cylinder 7 Disconnect the wirings from the starter alternator
in line units with a single overhead camshaft and fully balanced ignition coil oil
pressure switch and temperature sender
five bearing crankshaft The valves are operated through rockers unit
which are directly activated by the earn mechanism
8 Remove the clutch slave cylinder Fig A 2 and its return
The crankshaft is a special steel forging with the centre spring
main bearing equipped with thrust washers to take up the end
thrust of the crankshaft The special aluminium pistons are of 9 Disconnect the speedometer cable and withdraw the plug
the strut construction to control thermal expansion and have connector from the reversing light switch
two compression rings and one combined oil ring
10 Disconnect the shift rods and seJector rods and remove
The gudgeon pins have special hollow steel shafts and are the cross shaft assembly as described in the section Gear
a fully floating fit in the pistons and a press fit in the connecting box
rods
II Disconnect the front exhaust pipe from the exhaust
The aluminium alloy cylinder head contains wedge type manifold disconnect the centre pipe from the rear pipe
combustion chambers and is fitted with aluminium bronze valve and remove the front pipe pre muffler and centre pipe
seats for the intake valves and heat resistant steel valve seats
assembly
for the exhaust valves
3 Discon ect the battery cables and lift out the battery ENGINE Dismantling
4 Detach the upper and lower radiator hoses remove the Remove the engine as previously described and carefully
radiator mounting bolts and lift the radiator away from clean the exterior surfaces Cbeck for signs of fuel oil or
the vehicle The torque converter c jng pipes must be water leaks past the cylinder head and block Remove the air
disconnected from the radiator on vehicles fitted with cleaner alternator distributor and starter motor Plug the
automatic transmission carburettor air horn and distributor hole to prevent the ingress
of foreign matter
S Remove the COOling fan and pulley disconnect the fuel
pipe from the fuel pump and the heater hoses from the Remove the gearbox from the engine drain the engine oil
engine attachments and coolant Mount the engine in a suitable stand the special
engine attachment ST05260001 and engine ST0501SOO0 should
6 Disconnect the accelerator control linkage and the choke be used if available Fig A 3
5
o
A l
ne ofenll
Right S
0
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ttor
carbure
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es
S O sef1
engJ ne
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ol
Gene
Engine
FIS
to
1
f
fl
JJ ST052fiOOOl
Fig A 2 Removing the clutch slave cylinder Fig A 3 Mounting the engine
STI 0 120000
CI @ j 91
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7
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m
IC
J i1 J6
C
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i t1
I UO
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5
A bolt removal sequence
Fig AA Removing the camshaft sprocket Fig Cylinder head
t
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J
1
1
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I
7
qt
J
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7
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lliJ IJ
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Fig A 12 Removing the piston pin
Fig A 13 Removing the valves
I5
A Reaming the valve guide
Fig
Fig l4
A OIecking the cylinder head joinlface
8
Remove the fan and pulley the right hand engine mounting Renew the valve if the thickness of the valve head has
and oil filter Remove the oil pressure switch Remove the been reduced by 0 5 mm 0 0197 in see Technical Data for
valve dimensions
following items oil level gauge spark plugs thermostat housing
rocker cover carburettor and inlet and exhaust manifolds
The valve stem tip may be refaced if necessary the maxi
Remove the clutch assembly as described in the section mum allowance however is 0 5 mm 0 0197 in
CLUTCH Remove the left hand engine mounting crankshaft
The valves be ground in to their seats when completely
pulley water pump fuel pump fuel pump drive earn and cam
can
Remove the cylinder head bolts satisfactory The valveseats and valve guides should be in good
shaft sprocket See Fig 4
A
in the sequence shown in Fig A 5 and lift off the cylinder condition and must be checked as described in the following
head Invert the engine and remove the oil sump and oil paragraphs
strainer oil pump and drive spindle assembly front cover and
chain tensioner Remove the timing chain oil thrower crank
shaft worm gear and chain drive sprocket See Fig A 6 andA 7 VALVE GUIDES Replacement
Remove the connecting rod caps and push the pistons and The valve stem to valve guide clearance can be checked by
a new valve into the guide The stem to guide clearance
connecting rods through the top of the bores as shown in Fig inserting
A B Keep the connecting rod caps with their respective rods to should be 0 020 0 053 mm 0 0008 0 0021 in for the inlet
ensure that they are assembled in their original positions valves and 0 040 0 073 mm 0 0016 0 0029 in for the exhaust
valves If the clearance exceeds 0 1 mm 0 0039 in for the
Remove the flywheel retaining bolts and withdraw the fly inlet valves and the exhaust valves then new guides should be
wheel Fig A 9 Remove the main bearing caps using the fitted
special puller ST 1651 SOOO to withdraw the centre and rear main
A l O Remove the rear oil seal The valve guides are held in position with an interference
bearing caps as shown in Fig
and lift out the crankshaft remove the baffie plate and cylinder fit of 0 027 0 049 mm 0 0011 0 0019 in and can be removed
block net Fig A II Remove the piston rings with a suitable by means of a press and drift 2 ton pressure This operation
can be carried out at room temperature but will be
more
arbor
expander and press out the gudgeon pins under an press
using the special stand STl300001 as shown in Fig A 12 Keep effectively performed at a higher temperature
the dismantled parts in order so that they can be reassembled
in their original positions Slacken the valve rocker pivot lock Valve guides are available with oversize diameters of 0 2 mm
nut and remove the rocker arms by pressing down the valve 0 0079 in if required The standard valve guide requires a bore
in the cylinder head of 11985 11996 mm dia 4719
0
springs
4723
0 in dia and the oversize valve guide a bore of 12 185
12 196 mm dia 4797
0 40
802 in dial
Remove the camshaft taking care not to damage the
bearings and earn lobes Withdraw the valves using the valve
lifter STl2070000 as shown in Fig A 13 The cylinder head guide bore must be reamed out at
normal room temperature
ENGINE Inspection and Overhaul Heat the cylinder head to a temperature of 150 2000e
Cylinder Head and Valves 302 3920F before pressing in the new valve guides Ream
out the bore of the guides to obtain the desired fInish and
Clean all parts thoroughly and remove carbon deposits with clearance Fig A IS The special valve guid reamer ST 1103
a blunt scraper Remove any rust which has accumulated in SOOO should be used if available Valve guide inner diameters
are specified in Technical Data at the end of this section The
the water passages and blow through the oil holes with compres
sed air to make sure that they are clear valve seat surface must be concentric with the guide bore and
can be corrected with the facing tool STll670000 Fig A 16
new valve guide as the axis
Measure the joint face of the cylinder head for out of true using the
as shown in Fig 14
A The surface should be checked at various
positions using a straight edge and feeler gauge The permissible
amount of distortion is 0 05 mm 0 0020 in or less If the VALVE SEAT INSERTS Replacing
surface is out of true by more than the limit of 0 1 mm
If the stem is worn damaged or not straight the valve must to bore beyond the bottom face of the recess in the cylinder
head
be discarded Check the diameter of the stem with a micro
meter The diameter of the inlet valves should be 7 965
7 980 mm 0 3136 0 3142 in and the diameter of the exhaust Select the valve seat inserts and check the outer diameters
valves 7 945 7 960 mm 0 3128 0 3134 in Machine the recess in the cylinder head to the following
dimensions at room temperature
If the seating face of the valve is excessively burned
damaged or distorted it must be discarded A badly pitted
seating face should be refaced on a valve grinding machine
removing only the minimum amount of metal
9
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13
1 Ut
Llb thtwin Ie
WiTh ro
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Incak
C 1J Exhaust
q j
Fig A 16 Correcting the valve seats Fig A I Standard valve seat dimensions
11tJ
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410 6142 dia
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9 611 559lldi
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32 6 12835 dia 32 60 2835 di L
dia 34 6 1
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Unll In
10
CYUNDER HEAD RECESS DIAMETER that the actual runout will be half the the value indicated on the
Standard inoerts dial gauge When the camshaft is turned one full revolution
with the dial gauge positioned against the second and third
Engine Inlet journals
L14 41 41
000 016 16142 16148 in
Ll6 and Ll8 45 45
000 016 mm 177l7 1 77231n
CYLINDER BLOCK Inspection and Overhaul
Engine Exhaust
Ensure that the cylinder block is thoroughly clean and
Ll4 37 000 37 016mm 1 4567 1 4573 in check it for cracks and flaws
Ll6 and Ll8 37 000 37 016mm 4567 1 4573 in
l
Check the joint face of the block for distortion using a
straight
edge and feeler gauge as shown in Fig A 20 The surface
CYLINDER HEAD RECESS DIAMETER must be reground if the maximum tolerance of O lmm
Oversize inserts 0 0039 in is exceeded
Engine Inlet Examine the cylinder bores for out of round or taper
a bore gauge as shown in Fig A 21 The readings must
Ll4 41 41
500 l 6339 1 6345in
516mm using
45 45
S00 516mm I 7913 1 7920in be taken at the Top middle and bottom positions indicated
Ll6andLl8
in Fig A 22
Engine Exhaust
L14 37 500 516mm
37 1 4764 14770in The standard bore diameters are 83 000 83 050 rom
37 500 37 516mm 1 4764l4770in 3 2677 3697
3 in for the 1400 and 1600cc engines and 85 000
Ll6andLl8
85 050 mm 3 3465 3 3484 in for the 1800 cc engine with a
Dimensions for the standard valve inserts are shown in wear limit of 0 2mm 0 0079 in
302 3920F and drive in the inserts making sure that they Out of round and taper must not exceed 0 15mm
bed down correctly The inserts should be caulked at more than 0 0006 in If the bores are within the specified limits remove
four positions and then cuf or ground to the specified the carbon ridge at the top of the cylinder bores wring a
Place a small amount of fine grinding compound on the If any of the bores are in excess of the specified limits
then all the bores must be rebored at the same time Pistons
seating face of the valve and insert the valve into the valve guide
are available in five oversizes See Technical Data and can be
Lap the valve against its seat by rotating it backwards and
forwards approximately half a revolution in each direction selected in accordance with the amount of wear of the cylinder
until a continous seating has been obtained Remove the valve
and clean all traces of the grinding compound from valve and When the oversize of the pistons has been decided it will
seat be necessary to measure the piston at the piston skirt Fig A 23
and add to this dimension the specified piston to cylinder bore
clearance to determine the final honed measurement of the
Measure the clearance between the inner diameter of the NOTE Cylinder liners can be fitted if the cylinder bores
are worn beyond the maximum limit
camshaft bearing and the outer diameter of the camshaft
The liners are an interference fit in the block and
journal If the wear limit for the bearing clearance exceeds
must be bored to the correct inner diameter
O lmm 0 0039 in it will be necessary to replace the cylinder
after fitting Three undersize liners are available
block assembly See Technical Data for all diameters
in the following sizes
11
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interCE MID
liPl E
i J
i
1 r 1
4
r l I I I
QJJ I I
Fig A 19 Chec ki ng the camshaft for run out
7
I 1 rb
y
F g A 22 Measunng
Fig A 2 p ositions for the cytinder
Measuring lbe cy Ii nder bores
bores
r or r1li
abllUI O O
m 1874 r
I
I
I
Q
Fg A 23 Measunng th e pistons k trt diameters
fi g A 25 Measurmg the piston ring side F g A 26 Measunng the piston ring gap
clearance
12
I
Check each piston for signs of seizure and wear Renew Place the crankshaft in V blocks as shown in Fig A 28
piston which is unsatisfactory and check with the aid of a dial gauge that the shaft bending
BIlY
limit of 0 05 mm 0 002 in is not exceeded With the dial gauge
Remove all carbon deposits from the grooves and piston positioned against the centre journal the crankshaft should be
rotated by one turn The actual bend value will be a half of the
rings Measure the side clearance of each piston ring and groove
with a feeler gauge as shown in Fig A 25 If the side clearance is reading obtained on the gauge If the specified limit is exceeded
excessive new rings should be fitted The clearance required for it will be necessary to replace the crankshaft
new pistons a piston rings can be found in Technical Data
Install the crankshaft in the cylinder block and check the
Check the piston ring gap by placing the ring in the cylinder crankshaft end float which should be be J Yieen 0 05 0 18 mm
bore as shown in Fig A 26 The ring can be squared in the bore 0 0020 0 0071 in Make sure that the main drive shaft pilot
by pushing it into position with the piston Measure the ring gaps bushing at the rear of the crankshaft is not worn or damaged in
the special
with a feeler gauge and compare the dimensions with the infor any way Replace the bushing if necessary using
mation given in Technical Data puller STl 66 1000 I
NOTE If new piston rings are to be fitted and the cylinder Thoroughly clean the bushing hole before installing and
has not been rebafed check the piston ring gap with press in the new bushing without oiling so that its height
the ring positioned at the bottom of the cylinder above the flange end is 4 5 5 0 mm 0 18 0 20 in
This being the position with the least amount of wear
O1eck the clearance between gudgeon pin and piston If Main bearing clearance
the limit is exceeded it will be necessary to replace
specified
both piston and pin It should be possible to press the gudgeon The main bearing clearances can be checked using a strip
pin into the piston by hand at a room temperature of 200C of plastigage Set the main bearings on the caps Cut the plasti
680F The pin should be a tight press fit in the connecting gage to the width of the bearing and place
it along the crankpin
rod
making sure that it is clear of the oil hole Install the bearing
a torque reading of 4 5
caps and tighten the bearing cap bolts to
5 5 kgm 33 40 Ib ft DO NOT turn the crankshaft when
CONNECTING RODS O1ecking the is inserted Remove the main bearing cap and take
plastigage
out the plastigage which should be measured at its widest po t
Cleck the connecting rods for bends or twists using a with the scale printed in the plastigage envelope The standard
guitable connecting rod aligner The maximum deviation should clearance is 0 020 0 062 mm 0 0008 0 0024 in with a wear
not exceed 0 05 mm 0 0020 in per 100 mm 3 94 in length limit of 0 1 mm 0 0039 in If the specified limit is exceeded
of rod Straighten or replace any rod which does not comply an undersize bearing must be used and the crankshaft journal
with the specified limit ground accordingly See Technical Data Bearings are available
in four undersize of 0 25 0 50 0 75 and 100 mm 0 0098
When replacing the connecting rod it is essential to ensure 0 0197 0 0295 and 0 0394 in
that the weight difference between new and old rods is within
5 gr 0 18 oz for the 1400 cc engine and 7 gr 0 25 oz for
the 1600 and 1800 cc engines
Connecting rod bearing clearance
Install the connecting rods with bearings to the correspond
ing crank pins and measure the end play of the big ends s e The connecting rod bearing clearances should be checked
FigA 27 The end play should be between 0 2 0 3 mm in a similar manner to the main bearing clearances The standard
0 0079 0 0118 in fthe maximum limit of 0 6 mm Ql18
0 clearance is 0 025 0 055 mm 0 0010 0 0022 in with a wear
in is exceeded the connecting rod must be replaced limit of 0 1 mm 0 0039 in Undersize bearings must be fitted
and the crankpins reground if the specified wear limit is ex
ceeded See Technical Data Bearings are available in six under
CRANKSHAFT Inspection and Overhaul sizes of 0 6 0 12 0 25 0 50 0 75 and 1 00 mm 0 0236
0 0047 0 0098 0 0197 0 0295 and 0 0394 in
aean the crankshaft thoroughly before checking the shaft
for distortion and cracks
Fitting the crankshaft bearings
rellrind the crankshaft to the required undersize See Technical bearing recess and tighten the cap bolts to the specified torque
13
inter fQ I
Q1I ll
oJ
Weight
Fig 30
A Checking the camshaft sprocket for
A 29 the bearing crush
Fig Checking out
run
Fig 31
A OIecking the camshaft end float A 32 Installing he valves
Fig
14
reading Slacken one of the cap bolts and check the clearance Ensure that the specified tightening torque readings are
between the cap and cylinder block with a feeler gauge See strictly followed
FigA 29 The bearing crush nip should be between 0 03mm
0 0012 in if this is not the case then the bearing must be
replaced A mbling the cylinder Head
beck the connecting rod bearings in a similar manner To install the valves and valve springs place the valve
after tightening the caps to the specified torque readings The spring seats into position and fit the valve guides and oil lip
Inspect the camshaftjoumals for signs of wear or damage Fig A 32 to compress the valve springs
and check the camshaft for run out using a dial gauge in a
similar manner to that previously described for the crankshaft
The bending limit of 0 02 mm 0 0007 in must not be Piston and connecting rods
exceeded
The piston piston pins and connectiJ1 rods must be
Install the camshaft sprocket mount the assembly in V assembled in accordance with the cylinder numbers
blocks as shown in Fig A 30 and check that the out
run of
the sprocket does not exceed 0 1 mOl 0 04331 in O1eck the The gudgeon pin is press fitted to the connecting rod and
timing chain and sprocket to ensure that the chain is not requires a fitting force from 05 to 1 5 tons This operation
stretched or damaged or the teeth of the sprocket damaged or will require the use of the special tool ST 1303000 as shown in
distorted A timing chain which has become stretched will Fig A 33 Apply engine oil to the gudgeon pin and connecting
affect the valve timing and be noisy in operation Check the rod before fitting
chain tensioner and chain guides for wear and damage replacing
the parts if necessary It should be noted that the oil jet of the connecting rod big
end must face towards the right hand side of the cylinder block
Replace the sprocket if the out
run is exceeded or if the See Fig A 34
teeth of the sprocket are worn or damaged in any way
Fit the piston rings the oil control ring in the bottom
The camshaft end play should be within 0 08 38 mm
0 groove followed by the centre and top compression rings which
0 0031 oI50
O in If the clearance limit of 0 1 mm must be installed with the marks facing upwards
dial gauge Fit the baffle plate and cylinder block net Install the
crankcase halves of the main bearing shells the flanged shell
The flywheel ring gear can be replaced if the teeth are is fitted to the centre bearing Smear the bearing surfaces with
damaged or worn This operation will entail splitting the ring engine oil and carefully lower the crankshaft into position
gear to remove it A hacksaw should be used to cut between the
teeth followed by splitting with a cold chisel Install the main bearing caps with their shells making sure
that the arrow on the caps faces to the front of the engine
When replacing the ring gear it must be heated to a Rotate the crankshaft to settle the caps and tighten the bearing
temperature of approximately 1800 2000 F before fitting cap bolts gradually in two or three separate stages Work out
and then allowed to cool slowly wards from the centre bearing and finally tighten to the
specified torque reading of 4 5 5 5 kgm 40
32 ft
Ib in the
sequence shown in Fig 35
A Ensure that the crankshaft rotates
ENGINE Assembling freely after finally tightening the cap bolts Check the crankshaft
end float which should be between 0 05 0 18 mm 0 002
Before starting to assemble the engine make sure that all 0 0071 in see Fig A 36 Smear the side oil seals with sealant
components are perfectly clean It is always advisable to pay and fit them into the rear main bearing Instal
cap the rear oil
particular attention to the following points when assembling seal using a suitable drift and grease the lip of the seal
an engine Keep the work bench and tools clean and make sure
that the tools are to hand Ensure that all engine oil ways are Place the flywheel in position and install the lock washers
clear of foreign matter fit new gaskets and oil seals throughout and retaining baits Tighten the bolts evenly to a torque
reading of 14 16 kgm 101 106Ib ft
All sliding parts such as bearing shells must be smeared with
engine oil before installing Rotate the engine by a quarter turn and install the piston
15
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@@@C@@ At T D C or
No I Afteradju5tment Before adjustment
piston
Fig 37
A Cylinder head bolts tightening sequence
Fig 38
A Adjusting the camshaft sprocket
Fig 40
A Valve clearance adjusting
16
W
h
and connecting rod assemblies Use a piston ring compressor to size M6 0 236 in to a
torque reading of 0 4 0 8 kgm
install the pistons through the top of the cylbder bore Make 2 9 81b ft
sure that the pistons and rings and the cylinder bores are
lubricated with clean engine oil The pistons should be arranged Install the crankshaft pulley and water pump tighten the
so that the F mark faces to the front and with the piston pulley nut to a torque reading of 12 16 kgm 86 8 115 7Ib ft
ring gaps positioned at 1800 to each other Each piston must then set the No 1 piston at TD C on its compression stroke
be refitted into its original bore
Finally tighten the cylinder head bolts to the specified
NOTE Single inlet valve springs are used on the 1400 cc torque reading in accordance with the tightening sequence shown
engine double valve springs are used on the 1600cc in Fig 3
A The bolts should be tightened in three stages as
and 1800 cc engines follows
Screw the valve rocker pivots with the locknuts into the First stage 4 kgm 28 9 lbJt
pivot bushing Set the camshaft locating plate and install the Second stage 6 kgm 4 IbJ t
43
camshaft in the cylinder head with the groove in the locating Third stage 6 5 85 kgm 47 0 5lb
61 ft
thoroughly before installing the cylinder head Turn the crank slinger Fit the oil strainer into position coat the oil sump
shaft until the No 1 piston is at T D C on its compression stroke gasket with sealing compound and fit the gasket and oil sump
and make sure that the camshaft sprocket notch and the oblong to the cylinder block Tighten the oil sump bolts in a diagonal
5 IbJt
groove in the locating plate are correctly positioned Care pattern to a torque reading of 0 6 0 9 kgm 3
4 6
should be taken to ensure that the valves are clear from the
heads of the pistons The crankshaft and camshaft must not be Adjust the valve clearances to the specified cold engine
rotated separately or the valves will strike the heads of the ftgures following the procedures described under the appropriate
pistons Temporarily tighten the two cylinder head bolts 1 and heading Final adjustments will be carried out after the engine
2 in Fig A 37 to a torque reading of 2 kgm 5 lb ft
14 has been assembled completely and warmed up to its nonnal
temperature
Fit the crankshaft sprocket and distributor drive gear and
install the oil thrower Ensure that the mating marks on the Install the rear engine slinger exhaust manifold and inlet
crankshaft sprocket face towards the front Install the timing manifold Refit the distributor and carburettor assemblies as
chain making sure that the crankshaft and camshaft keys are described in their relevant sections Install the fuel pipes and
XJinting upwards The marks on the timing chain must be vacuum hose making sure that they are securely cl ped Refit
aligned with the marks on the right hand side of the crankshaft the thermostat housing thermostat and water outlet together
and camshaft sprockets It should be noted that three location with the gasket Bond the rocker cover gasket to the rocker
holes are provided in the camshaft sprocket See Fig 38
A The cover using sealant and fit the rocker cover to the cylinder
camshaft sprocket being set to the No 2 location hole by the head
manufacturers A stretched chain will however affect the valve
timing and if this occurs it will be necessary to set the camshaft Install the spark plugs and connect the high tension leads
to the 3 location hole in the camshaft sprocket The chain
No Fit the left hand engine mounting bracket and install the clutch
can be checked by turning the engine until the No 1 piston is assembly using the alignment tool ST20600000 to fit the clutch
at T D C on its compression stroke In this position adjustment to the flywheel as described in the section ClUfCR
will be required if the location notch on the camshaft sprocket
is to the left of the groove on the camshaft locating plate as Lift the engine away from the mounting stand and into
shown in the illustration The correction is made by setting the the engine compartment Install the alternator bracket adjusting
camshaft on the 3 location hole in the camshaft sprocket
No bar alternator fan pulley fan and fan belt in the order given
the 3 notch should then be to the right of the groove and
No Check the tension of the fan belt by depressing the belt at a
the valve timing will have to be set using the 3 timing mark
No point midw y between the pulleys The tension is correct if
the belt is deflected by 8 12 mm 3
0 0 4 in under thumb
Install the chain guide
and chain tensioner when the chain pressure
is located correctly There should be no protrusion of the chain
tensioner spindle See Fig 39
A A new tensioner must be Fit the right hand engine mounting bracket the oil filter
fitted if the spindle oil pressure switch oil level gauge and water drain plug Take
protrudes
care not to overtighten the oil nIter or leakage will occur
Press a new oil seal into the timing cover and fit the cover
into position using a new gasket Apply sealing compound to Fill the engine and gearbox to the correct levels with
the front of the cylinder block and to the gasket and to the top recommended lubricant and refill the cooling system Adjust
of the timing cover Ensure that the difference in height between the ignition timing and carburettor as described in the appro
the top of the timing cover and the upper face of the cylinder priate sections
block does not exceed 0 15 mm 0 006 in Two sizes of timing
cover bolts are used the size M8 315
0 in must be tightened
to a torque reading of 10 16 kgm 7 2 17 Ib ft and the
17
inter lmi
@jl
II
l o
CD I
Fig 41
A Engine lubrication circuit Fig 42
A Component parts of the oil pump
I Sideclruance
2 TIp clearance
3 Guier 10
00 body clearance
t 4 Rotor to bottom
cover cleatance
Punch rmrk
i Oil hole
18
VALVE CLEARANCES Adjusting
rotor must not
pin securing the driven shaft and inner
Incorrect valve clearance will affect the performance of 00 taken out as the shaft is press fitted to the rotor and the pin
the engine and may damage the valves and valve seats Insuf is caulked
ficient valve clearance will result in loss of power and may
prevent the valve from seating properly Excessive clearance Unscrew the threaded plug and withdraw the regulator
causes the valve to seat and reduces the amount of valve lift valve and spring Oean each part thoroughly and examine for
This will result in noisy operation with damage to the valves signs of damage or wear Use a feeler gauge to check the side
and seats Adjustment is made with the engine switched off clearances between the outer and inner rotors the clearances
and should be carried out initially with the engine cold to at the tips of the rotors and the clearance between the outer
allow the engine to run Final adjustments are made after rotor and the pump body See Technical Data for the relevant
wanning up the engine to its Donnal operating temperature The clearances The clearances can be checked using a straight edge
engine can be rotated by removing the sparking plugs to release as shown in Fig 43
A
the cylinder compressions then selecting top gear and pushing
the vehicle backwards and forwards
OIL PUMP Assembly and Installation
The
The cold valve clearances should be set to 0 20 mm
0 0079 in for the inlet valves and 0 25 mm 0 0098 in for Assembly is a reversal of the dismantling procedure Before
the exhaust valves Check the clearance between the valve and installing the oil pump in the engine it will be necessary to
rocker using a feeler gauge as shown in Fig 40
A Slacken the rotate the engine until the No 1 piston is at T D C on its
locknut and turn the adjusting screw until the specified clearance compression stroke
is obtained then tighten the locknut and recheck the clearance
The feeler gauge should just be free to move between the rocker Fill the pump housing with engine oil and align the punch
and valve When the cold valve clearances have been set run the mark on the spindle with the hole in the oil pump as shown
in Fig A 44
engine until it reaches its normal operating temperature then
switch off and adjust the valve clearances with the engine warm
Install the pump with a new gasket and tighten the
to0 25 mm 0 0098 in for the inlet valves and 30
0 mm
1 Remove the distributor assembly as described in the After the fIrst oil change which should take place at 1000
section IGNITION SYSTEM Remove the oil sump drain km 600 miles the oil should be changed regularly at 5000 km
plug and drain off the engine oil See under the heading 3000 miles intervals
CHANGING THE ENGINE OIL
3 Withdraw the securing bolts and detach the oil pump Stand the vehicle on level ground and place a suitable
body together with the drive gear spindle container under the drain plug Remove the drain plug carefully
as the hot oil may spurt out with considerable force When
Take out the bolts securing the pump cover to the pump body refIlling the engine make sure that the oil is to the H mark on
and withdraw the rotors and drive shaft See Fig A 42 the dipstick
19
rreclll11cal ata L lJEngine
Valve lift 10 0 mm 40
0 in Distance from centre to centre 132 97 133 03 mm 5 235
Valve spring free length 48 12 mm 1 89 in 5 237 in
Valve spring fitted length 40 0 mm 30 7 kg
1 57 in67 7 lb Bearing shell thickness
Valve spring coil diameter 34 9 mm 37
1 in Standard 1 498 1506 mm 0 059 0 593
in
Valve guide length Big end side play 0 20030 mm 0 0 012 in
008
Inlet 59 0 mm 2 32 in
Exhaust 59 0 mm 2 32 in Connecting rod bearing
running clearance 0 0 056
014 mm 0 0 0022
0006
Valve guide protrusion 4
10 10 6 mm 41
0 42
0 in in
in in per 3 937 in
Exhaust 8 008 018 mm 0 315 0 3154
in
CRANKSHAFT AND MAIN
Valve guide outer diameter BEARINGS
Inlet 11 985 11996 mm 472
0 0 4723
in Crankshaft material Special forged steel
Exhaust 11985 11996 mm 0 4172 4723
0 Number of bearings 5
in Main journal diameter 54 942 54 955 mm 2 1631
1636
2 in
Valve guide to stem clearance Max journal taper 0 03 mm 0 0012 in
Inlet 0 015 0 045 mm 0 00060 0018 Max journal out of round 0 03 mm 0 0012 in
in Crankshaft end play 0 0 015
05 mm 0 0 0059
002
Exhaust 0 040 0 070 mm 0 00160 0028 in
in
20
0 3 mm 0 012 in Second 0 030 0 063 mm 0 0012 0 0025
Wear limit
Crank pin journal diameter 49 961 49 975 mm 1 967 1 9675 in
in Oil control 0 0 063
025 mm 0 001 0 0025
0 15 0 30 mm 0 0 012
006
Main bearing running clearance Second
0 0200 062 mm 0 0008 0 0024 in
in Oil control 0 030 mm 0
15 0 012 in
006
L13
Width of ring grooves Engine model
Top and second 2 0 mm 0 08 in
PRIMARY SECONDARY
Oil control 4 0 mm 0 16 in
PISTON RINGS
Oil control 4 0 mm 0 16 in
21
TechnIcal Data L 14 16 and 18 Engine
GENERAL SPECIFICATIONS
Cylinders 4 in line
Displacement
L14 1428 cc 87 1 cu
in
L16 1595 cc 3
97 in
cu
L18 1770 cc 108 0 in
cu
Compression ratio
L14 9 0
L16 single carburettor 8 5
L16 SU twin carburettor 9 5
L18 single carburettor 8 5
Ll8 SU twin carburettor 9 5
Firing order I 4
3
idling speed
e 600 r p m single carburettor 650 r p m twin carburettor
Engine idling speed with automatic transmission 650 r pm single carburettor
700 rp m twin carburettor
Oil pressure Hot at 2000 r m 3 5 4 0 kg sq cm 5057Ib sq in
p
VALVES
Intake 115 6 115 9mm 4 551 4 562in Valve seat width L14
Exhaust 115 7 116 0 mm 4 555 4 567 in
Intake I 4 mm 0 0551 in
Exhaust 13 mm 0 0512 in
Valve length L16 LIB
Valve seat width L16 LIB
Intake 114 9 115 2 mm 4 524 4 535 in
Exhaust Intake 0 020 0 053 mm 0 0008 0 0021 in
115 7 116 0 mm 4 555 4 567 in
Exhaust 0 040 0 073 mm 0 0016 0 0029 in
22
Valve seat angle Valve guide interference fit
L14 1
5
L16 L18 45
1
CONNECTING RODS
L14 136 6 mm 5 35 In
L16 133 0 mm 5 24 in
L18 130 35 mm 5 132 in
PISTONS
23
liB Oversizes 85465485 515 mm 3 648 667 ill
86 065 86 015 mm 13 3844 33864 in
Piston to bore e
clearanl 0 025 0 045 mm 0 0010 0 0018 in
PISTON PIN
eI
ngth
Ll4 Ll6 7200 72 25 mm 2 8346 2 8445 in
Ll8 72 25 73 00 mm 2 8445 2 8740 in
Pin to piston clearance 0 001 0 013 mm 0 00004 0 00051 in
Pin interference fit in small end bush Dl5
0 0 033 mm 0 0006 0 0013 in
PISTON RING
Side clearance
Ring gap
U4 Top ring 0 23 0 38 mm 0 0091 0 0150 in
U4 Second ring 0 15 0 30 mm 0 0059 0 0118 in
Ll6 Top ring 0 25 0 40 mm 0 0098 0 0157 in
L 16 Second ring 0 15 0 30 mm 0 0059 0 0118 in
U8 Top ring 0 35 0 55 mm 0 0138 0 0217 in
U8 Second ring 0 30 0 50mm 0 0118 0 0197 in
Oil ring 0 30 0 90 mm 0 0118 0 0354 in
LUBRICATION SYSTEM
24
CoolIng System
GENERAL
FAN BELT TENSION
FLUSHING AND DRAINING THE SYSTEM
THERMOSTAT Testing
RADlA TOR Removal
Retighten the alternator bolts and make SUfe that the belt
GENERAL
is correctly tensioned
The cooling system is pressurised and incorporates a
water pump corrugated fin type radiator fan and a pellet type FLUSHING AND DRAINING THE SYSTEM
thermostat
the crankshaft
Drain the system by removing the radiator filler cap and
opening the radiator and cylinder block drain taps Close the
he pellct type thermostat enables the engine to warm up
taps again and refill the radiator Run the engine for a ShOft
rapidlY and also regulates the temperature of the coolant When the drain taps Continue this sequence
period and then rc open
the wax pellet in the thermostat is heated it expands and exerts
until the water flowing from the taps is clean then close the taps
pressure against a rubber diaphragm causing the valve to open
and refill the radiator
and allow the coolant to flow from the cylinder head back to
the radiator
An anti freeze mixture should always be used in Winter
time The Niss3n long life coolant L L c is an ethylene glycol
As the pellet is cooled itcontractsand allows the spring to
solution containing a corrosion preventative which can remain
close the valve thereby preventing coolant from leaving the
in the vehicle throughout the year but must not be mixed with
cylinder head other products
25
inter illIl Pl
@
i n
L
i II
Vi
q n
It J j
rl
l llii
l
tr
3
tWt11 r
t
till 1
i
I
f0 co
cj L
7
Fig B l The cooling system
Fig 4
B Removing the thermostat
26
The thermostat can be tested by suspending it with a
Heat the water gradually and stir it to obtain a uniform transmission oil cooler which must be disconnected
incorporate a
TechnIcal Data
Radiator Corrugated fin type
Radiator cap working pressure 0 9 kg sq cm 13Ib sqin
27
inter j@lPX
lW
J
V
ISI
PRIMARY COIL
TT Y Gw
RESISTOR
nl N
I
II TO STARTER
l1@
l
IGNITION
U
I
SECONDARY
COIL COIL
l
AK R POIN
IS i ROTOR HEAD
1 1 1
DISTRISUTOR I SPARK PLUG
r
1
circuit diagram
Fig C t Ignition sys em
II
@ 1
i
i
@
1 i
J
1 9
@
7
GN
8 Contact set
1 Shaft assembly
2 Collar assembly Tennirtal assembly
9
28
l
I
IgnItIon System
TION
DESCRII
IGNITION TIMING
IGNITION DISTRIBUTOR Maintenance
ADJUSTING THE CONTACT BREAKER GAP
CENTRIFUGAL ADVANCE MECHANISM
VACUUM ADVANCE MECHANISM
IGNITION DISTRIBUTOR Removal and Dismantling
IGNITION DISTRIBUTOR Assembling and Installation
SPARKING PLUGS
TION
DESCRII cover Fig C 3 The crankshaft pulley groove should appear
be stationery and aligned with the pointer on the front cover
to
The Hitachi distributor is shown in exploded form in Fig the timing See Technical Data for timing settings
C 2 19niton timing is automatically regulated by the distributor
centrifugal advance mechanism or vacuum advance mechanism After adjusting the timing tighten the distributor flange
depending upon the demand made on the engine bolts and recheck the timing
governor weights and springs which turn the carn assembly in on parallel and all abrasive dust removed with compressed air If
clockwise
anti direction to advance the ignition timing As the the points are excessively pitted they must be renewed and grease
engine speed is decreased the weights move back and allow the applied to the moving contact pivot and the surface of the cam
cam to return thereby retarding the ignition timing Ensure that the distributor cap is thoroughly clean both inside
and outside A contaminated cap will promote tracking
The ignition coil is an oil filled unit comprising a coil indicated by black lines and caused by electrical leakage between
around which is wound the secondary and primary windings The the segments on the inside of the cap Make sure that the
number of turns in the primary winding provide a high secondary carbon button is not worn Both the distributor cap and rotor
voltage throughout the speed range The resistor is automatically must be renewed if they are cracked or damaged
by passed at the moment of starting and allows the ignition
coil to be directly connected to the battery This applies the
full battery voltage to the coil to give the necessary staTting IGNITION DISTRIBUTOR
boost Adjusting the contact breaker gap
When the starter switch is released the current flows through To adjust the contact breaker points remove the distributor
the resistor and the voltage through the coil is dropped for cap and pull the rotor off the cam spindle
normal running purposes
Turn the engine until the heel of the contact breaker arm
ispositioned on the cam lobe the contact breaker gap is set to
IGNITION TIMING the maximum in this position
The ignition timing can be accurately checked using a Slacken the adjusting screw Fig CA insert a feeler gauge
stroboscopic timing light which should be connected in accor between the points and adjust the breaker plate until the re
dance with the manufacturers instructions quired gap of 045 0 55 mm 0 0177 0 0217 in is obtained
Make sure that the timing marks on the crankshaft pulley Tighten the adjusting screw and recheck the setting After
are visible if they are not visible mark them with chalk or the contact breaker gap has been adjusted check the ignition
white paint Each mark represents a 50 division of the crank timing as previously described
angle
The tension of the contact breaker should be 0 5 0 65 kg
Disconnect the distributor vacuum line start the engine II I 4 lb Measure the tension with a gauge and at 900 to
and allow it to run at normal idling speed or slightly below the contact breaker arm
29
inter Dj
i 2l
@ J
J EARTH
LEAD
WIRE
SET
SCREW
OAmER
L
2
1
1 Governor weight
2 Oearance for start and
nd ofadvanc angle
7
V
1 Hook
J 4 GOllernor spring B
1 J 5 Com plate
6 F7YWt ight pin
7 Hook
I @ 8 Goverrwrspring A
9 Rotor positioning tip
30
Remove the two screws and lift out the contact breaker
CENTRIFUGAL ADVANCE MECHANISM plate detach the clamp the terminal and the lead
Lift off the distributor cap and turn the rotor clock
anti
wise When the rotor is released is should return to the fully and Installing
IGNITION DISTRIBUTOR Assembling
retarded position without sticking If it does not return to the
fully retarded position it will be necessary to check for dirt
Assembly is a reversal of the dismantling procedure
and weak springs
Lubricate the moving contact pivot and smear the lobes of the
cam with multi purpose grease
It should be noted that any wear in the mechanism or
lose of spring tension will upset the advance characteristics and If the centrifugal advance mechanism has been dismantled
cause unsatisfactory engine running performance over the speed
the governor springs and cams must be refitted as shown in
range
Fig e 8 The governor weight pin 6 should be fitted into the
longer of the two slots leaving a certain amount of clearance
for the start and end of the centrifugal advance movement
VACUUM ADVANCE MECHANISM
Also make sure that the vacuum inlet pipe is not blocked The sparking plugs should be inspected and cleaned at
or leaking and is securely tightened regular intervals not exceeding every 10 000 km 6000 miles
New sparking plugs should be fitted at approximately 20 000
flange mounting bolts and withdraw the distributor loose plugs low fuel pump pressure or incorrect grade of fuel
Colder sparking plugs should be fitted
To dismantle the distributor proceed as follows
The plugs should be cleaned on a blasting machine and
Take off the distributor cap and remove the rotor Slacken tested Dress the electrodes with a small file so that the surfaces
the two set screws holding the contact breaker upper plate of both electrodes are flat and parallel Adjust the spark plug
Remove the primary cable terminals and withdraw the contact gap to 0 8 0 9 mm 0 031 0 035 in by bending the earth
set from the distributor Fig C S Remove the vacuum control electrode Refit the plugs and tighten them to a torque reading
of 1
5 2 5 kgm II ft
15Ib
unit
31
c
TechnIcal Data
IGNITION DISTRIBUTOR
Type
L16 ll8 with single carbl Hitachi D411 58K
L16 L18 with twin arb Hitachi D409 54 K
L14 Hitachi 0411 63
order I 3 4 2
Firing
Rotation anticlockwise
0411 63 80 at 600 r pm
Condenser capacity 0 22 44
0 F
IGNITION COil
32
Fuel System
DESCRIPTION CARBURETIOR Removal and Overhaul
FUEL TANK FLOAT LEVEL Adjustment
FUEL PUMP SU TWIN CARBURmORS Adjustments
CARBURETTOR IDLING ADJUSTMENT SU TWIN CARBURmORS Dismantling
FAST IDLE OPENING ADJUSTMENT SU TWIN CARBURETTORS Inspection
THROTTLE VALVES INTERLOCK OPENING STARTING INTERLOCK VALVE OPENING
DASHPOT HYDRAULIC DAMPER
The diaphragm type fuel pump shown in Fig D 1 feeds A viscous paper type air cleaner element is fitted which
fuel from the tank to the carburettor in a regulated supply does not require cleaning and should be repl ced every 40 000 km
according to the needs of the engine A cartridge type fuel 24 000 miles The air cleaner fitted on the single carburettor
strainer prevents any dirt from reaching the pump inlet valve is equipped with an idling compensator to prevent the mixture
from becoming too rich at high idling temperatures Additional
Thecarburettor fitted to the engine is either a down fresh air is introduced into the inlet manifold by the action of
draught twobarrel type equipped with a throttle operated a bimettalic strip located in the air cleaner When the temperature
acceleration pump and power valve mechanism See Fig D 2 under the bonnet is high the bimetal is heated by the hot inlet
or a twin SU carburettor of the type shown in Fig 3 In the
D air and lifts to allow the valve to open The idling compensator
two barrel type carburettor fuel flows from the passage at the valve partially opens at 550 I310F and is fully open at 650C
bottom of the float chamber passes through the primary main l490F The unit cannot be dismantled as it is pre sealed and
jet and mixes with air introduced through the main air bleed correctly adjusted for valve timing Fig D 6 shows the layout
screw The petrol and air mixture is injected into the venturi of the idling compensator piping
Referring to Fig D 5 the suction chamber is mounted above FUEL PUMP Testing
the venturi The suction piston slides vertically within the
chamber and changes the venturi opening area The piston is Pressure and capacity tests can be carried out with the
operated by a difference between the upper vacuum pressure pump installed in the following manner
suction piston to rise or fall under the intluence of the engine between carburettor and fuel pump Start the engine and run it
suction The pozzle opening therefore changes and provides an at varying speeds
optimum air fuel mixture at all engine speeds
The reading the gauge should be 0 18 0 24 kg sq
on
The cartridge type fuel strainer utilizes a fibre strainer cm 2 6 34 Ib If the pressure is below the specified
sqin
element which should be replaced every 20 000 km 12 000 figure then either one part of the pump has worn excessively
miles Removal of the fuel strainer is a simple operation but as or general wear has occured to all the working parts The faults
it cannot be drained the strainer should not be removed when may include a ruptured diaphragm worn and warped valves
33
inter 1 jQ I
JJtE
u
G 40
j
t
1
fE SV
11
If
T
C1l
@
51
lID
t
l ID
I
I 9J
1 Float valve
I
2 Float lJi
3 C1roke aU l
34
and seats or a weak diaphragm return spring Assembly is a reversal of the dismantling procedure
noting the following points
A be due to
pressure above the specified figure may an
FUEL PUMP Removing and Dismantling Idling adjustment is carried out with the throttle stop
screw in conjunction with the idling adjustment screw See
Before removing the pump take off the petrol tank cap Fig D 8
and disconnect the pump inlet and outlet pipes Blow through
the pipes with compressed air to make sure that they are not Run the engine until it attains its normal operating
clogged temperature and then switch off
Remove the pump retaining nuts withdraw the pump and Starting from the fully closed position unscrew the
dismantle it in the following order idling adjustment screw by approximately three turns
Referring to Fig D l Screw the throttle stop screw in by two or tftr e turns and
start th engine
Take out the screws holding the two body halves together
and scparate the upper body from the lower body Unscrew the throttle stop screw until the engine commences
to run unevenly then screw in the idling adjustment screw so
2 Remove the cap and cap gasket that the engine runs smoothly at the highest speed
3 Unscrew the eI bow and connector Readjust the throttle stop screw to drop the engine speed
of approximately 600 r p m is obtained
4 Take off the valve retainer and remove the two valves
WARNING Do not attempt to screw the idling adjustment
To the diaphragm diaphragm spring and lower screw down completely or the tip of the screw
5 remove
body sealing washer press the diaphragm down against may be damaged
the force of the spring and tilt the diaphragm at the same
time so that the pull rod can be unhooked from the rocker
FAST IDLE OPENING ADJUSTMENT
arm link Fig D 7
The rocker arm pin can be driven out with a suitable The choke valve is synchronized with the throttle valve
drift and connected to it by levers as shown in Fig D 9 The fast
idle opening can be check by fully closing the choke valve and
measuring the clearance between the primary throttle valve and
FUEL PUMP Inspection and Assembly the wall of the throttle chamber This clearance being shown
as A in the illustration The clearance for the carburettor
Check the uppcr and lower body halves for cracks Inspect types is as follows
the valve and valve spring assembly for signs of wear and make
sure that the diaphragm is not holed or cracked also make sure
that the rocker arm is not worn at the point of contact with the Carburettor type Throttle opening Dimension A
camshaft angle
213304 361 180 1 55mm 0 06lin
The rocker oil leakage if and 4
13304 I 180 1 55mm 0 06Iin
arm pin may cause worn
35
inter ill j pl
@
T 5 i
J6 6
12
J Pump injuror
2 Weight
2 Outklvolve
B
4 Piston
5 Damper spring
6 Piston return spring
Fig D 3 View of the SU twin type carburettors 7 Clip
8 Strainu
1 Throttle r 9 Inlet lmlJe
2 JaJana crew
4 AuxiliDry shoft
I
5 Ftnt idle selling lCnW
1
6 Throttle shaft
l illi I
lit
m D 6
9 Fig Idling compensator
Fig 5 Section
D through the SU twin carbureUor
21
J 1 Float Iel cr
Idling adjustment nut
36
Carburettor type Throttle opening Dimension A these are accessible from the exterior of the carburettor
angle
213282 341 190 3mm
l 0 051 in Remove the choke connecting rod pump lever return
213282 221 200 I 4mm 0 056in spring and set screws and take off the choke chamber
If adjustment is required the choke connecting rod can be The primary and secondary emulsion tubes can be with
carefully bent until the required clearance is obtained drawn after removing the main air bleed screws
Open the primary throttle valve 500 from the fully closed
position as shown in Fig D I O At this angle the connecting Separate the throttle chamber from the float chamber by
link 2 should be at the extreme right of the groove in the removing the retaining screws leave the throttle valve intact
primary throttle arm The linkage between the primary and unless otherwise required
the secondary throttles is operating correctly if the clearance
C between the primary throttle valve and the wall of the All parts of the carburettor must be ctifefully cleaned and
chamber is as follows sediment gum or other deposits removed
Carburettor type Dimension C Clean the jets by blowing through them with compressed
213304 361 6 3 mm 0 248 in air Never push wire through the j ts or passages or the orifices
213304 421 6 3 mm 0 248 in will be enlarged and the calibration affected
213282 331 74 mm 0 291 in
213282 341 74 mm 0 291 in Check all parts for signs of wear and exchange them if
necessary
not hard
This adjustment is only required on carburettors fitted to Inspect the gaskets to make sure that they are
vehicles with automatic transmission Correct contact must be and brittle or distorted
made between the throttle lever and the dashpot stem See
Fig D II Adjustment can be carried out if necessary by Oean the filter screen if it is clogged or change it if it
2 and then rotating the dashpot in is otherwist unsatisfactory
slackening the locknut
either direction so that the throttle ann touches the stem at a
throttle valve opening angle of 110 At this angle the clearance Check the operation of the accelerator pump by pouring
B between the throttle valve and the wall of the chamber petrol into the float chamber and operating the throttle lever
should be as follows Petrol should spurt from the pump discharge jet if the pump is
working correctly If petrol cannot be ejected from the jet
Carburettor type Dimension B when the lever is actuated clean the discharge jet by blowing
213304 421 0 780mm 90 0307 in through it with compressed air
213282 341 0 586mm 0 0231 in
Retighten the locknut after completing the adjustment CARBURETTOR Assembly and Installation
2 Disconnect the fuel and vacuum pipes and the choke wire The performance of the carburettor will depend on the
from the carburettor condition of the jets and air bleeds As previously stated these
pacts should be cleaned using petrol and compressed air only
3 Remove the throttle lever and take off the nuts and Replacement jets or air bleed screws can be used to provide
washers securing the carburettor to the manifold greater economy or to increase output whatever the require
ment When the carburettor is installed adjust the idling speed
4 Lift the carburettor away from the manifold and discard as previously described
the gasket
37
inter
t
L
t l
c
cl
0
rfC
1 i
SID jID
v I
i
L
s
I Choke lever
Crank rod
1 aok arm
J Throttle valve
7 Throttle lYl J1e
2
Connecling kv r
3 Throttle ann
4 Rocking ann
5
Secondary throttle ann
6 Return pring
38
FLOAT LEVEL Adjustment that the air flow for both carburettors is correctly matched If
the air flow is uneven it will be necessary to readjust the balance
A constant fuel level in the float chamber is maintained by screw
the float and ball valve Fig D 12 If the fuel level is not in
accordance with the level gauge line it will be necessary to care Finally back off the fast idle setting screw Fig D 16
fully bend the float seat until the float upper position is correctly and decrease the engine speed Apply the flow meter to the
set FigD 13 carburettors to confirm that the float positions are even Re
adjust if necessary by means of the throttle adjusting screws
The clearance H between the valve stem and float seat Stop the engine and fit the air cleaner
should be 1 0 mm 0 039 in with the float fully lifted as shown
Adjustment can be carried out by carefully bending the float
stopper Fig D 14 until the required clearance is obtained SU TWIN CARBURETTOR Dismantling
Piston and suction chamber Dismantling
SU TWIN CARBURETTORS Adjustments Unscrew the plug and withdraw the piston damper Fig D
17 Remove the four set screws and lift out the suction
It is essential that the two carburettors are correctly adjusted chamber withdraw the spring nylon washer and the piston
if peak m3l1ce and economical fuel consumption is to be Take care not the damage the jet needle and the interior of the
realized Incorrect carburettor a ljustment will have an adverse suction chamber
affect during idling and on acceleration etc
Do not remove the jet needle from the piston unless
Carburettor synchronization and idling adjustment absolutely necessary If a replacement is to be fitted ensure that
the shoulder of the needle is flush with the lower face of the
Run the engine until it reaches its normal operating piston This operation can be accomplished by holding a strai
temperature remove the air cleaner and slacken the front and edge over the shoulder of the needle and then tightening the
rear throttle adjusting screws the balance screw and the fast set screw as shown in Fig D 18
idling setting screw Make sure that the front and rear throttle
shafts are not connected Fully tighten the idling adjustment Wash the suction chamber and piston with dean solvent
nuts of the front and rear carburettors Fig 15
D the back and dry with compressed air Lubricate the piston rod with a
off each nut by an equal amount and by one and a half to two light oil Do NOT lubricate the large end of the piston or the
tUrns interior of the suction chamber
few turns and start the engine Allow the engine to reach its NOZZLE Dismantling
normal operating temperature before proceding to the next
stage The nozzle See Fig D 19 can be removed quite easily
but should not be dismantled unless absolutely necessary as
Adjust the front and rear throttle adjusting screws until reassembly of the nozzle sleeve washer and nozzle sleeve
the engine speed is reduced to approximately 600 700 r p m set screw is an extremely intricate operation
The engine should turn over smoothly and consistently Apply
a flow meter to the front carburettor air cleaner flange and turn To remove the nozzle detach the connecting plate from
the adjustment screw on the flow meter so that the upper end the nozzle head pulling lightly on the starter lever to ease the
of the float in the glass tube is in line with the scale Uft off the operation Loosen the retaining clip take off the fuel line and
flow meter and apply it to the rear carburettor air cleaner flange remove the nozzle Be careful not to damage either the jet
without altering the setting of the flow meter adjusting screw needle oc the nozzle Remove the idle adjusting nut and spring
If the position of the flow meter float is not aligned with the The nozzle sleeve can be removed if necessary by taking out
scale adjust the rear carburettor throttle adjusting screw to the set screw but as previously stated should not be dismantled
align the float with the mark on the scale unless absolutely necessary
Both nuts must be turned by amount Assemble the piston assembly into position but do not
an equal
fill with damper oil
Back off the front and rear throttle adjusting screws and
adjust the engine speed to the specified value of 650 r p m for Assemble the nozzle sleeve washec and set screw by
the standard engine or 700 r p m with vehicles fitted with temporarily tightening the Set the piston to its fully
set screw
automatic transmission Make sure that the air flow of both closed position and insert the nozzle until it contacts the nozzle
carburettors remains unchanged Screw in the balance screw sleeve When the nozzle jet contacts the jet needle the nozzle
until the screw head contacts the throttle shafts without sleeve must be slightly adjusted so that it is at right angles to the
changing the idling speed setting centre axis and positioned to leave the nozzle jet clear of the
jet needle Raise the piston without disturbing the setting and
Move the throttle connecting shaft and accelerate the allow it to drop The piston should drop smoothly until the
engine a few times then check that the idling speed is unchanged stop pin strikes the venturi with a liaht metallic click See below
under Centering the jet Tighten the nozzle sleeve set screw
Turn the fast idle setting screw to increase the engine speed remove the nozzle install the idle adjustinJ spring and adjusting
to approximately 1500 r p m and recheck with the flow meter nut on the nozzle sleeve and refit the nozzle
39
inter j Q
nJ E
i2l
n
I
r i 11
g c
Ir
l
ID
i J
oJ
f It
Ln J
L
2 Locknut
3 lJaJItpot
4 Throttle lever
15
D Fig D 16 Adjusting the fast idle setting SU
Frg Id1ing adjustment SU twin
cuburettors twin carburettors
40
inteN lliiD U
I
i
n
2
1
3
1 Jet n edle
j I 2 Set screw
1
r
Oil cap nut
Fig D 18 Installing the jet needle
2 Suction chomber
3 Suction piston
4 Litingpin
S Stop pin
6 Oil dDmper L
7 Plunger
1 Nozzle sleeve
2 sher
Wa
J
c
3 Nozz V
det d W
C1e
4 u ting him
Ad
5 dlingadjustment spring
6 Idling adjustment nut
Z Nozz l9
D the nozzle assembly
Fig Dismantling
STlq O OO
twin carburettors r
I Float lever
J
iT
1 Conn
ctingrod
2 Wiguard
3 Choke lever
J 4 Connecting plate
S Thrott adjusting Tt
SCW
7
6 Fast id lever
9 cletlran B
Throttlevalv
41
Connect the fuel line from the float chamber to the nozzle Take out the float chamber coveT securing screws and
nipple and tighten the retaining clip Pull out the choke lever lift off the cover and attached float lever Hold the cover so that
and place the connecting plaie betw n the washer and sleeve the float lev r is facing upwards Lift the float lever and then
collar Screw the plate to the nozzle head and check that the lower it until the float lever seat just contacts the valve stem
collar is installed in the hole in the plate by ing the choke
mo The dimension uH in Fig D 1 should be 11 12 mm 43
0
lever as necessary 47 in and can be corrected by bending the float lever at the
0
point indicated
Recheck the piston to make sure that it falls freely without
binding
SU TWIN CARBURETTOR
SU TWIN CARBURETTOR Centering the jet
Starting interlock valve opening adjustment
Remove the damper oil cap nut and gradually raise the
To adjust the starting interlock opening the connecting
lifter pin 4 in Fig D 17
rod 4 in Fig D 22 1 must be bent using a suitable pair of
Continue to raise the lifter pin until the head of the pin pliers The throttle opening can be increased by lengthening
the connecting rod or reduced by shortening the rod
raises the piston by approximately 8 mm 0 31 in When the
lifter pin is released the piston should drop freely and strike
The throttle opening is correctly adjusted when the
the venturi with a light metallic click If the ston
pi does not
fall freely it will be necessary to dismantle the carburettor in clearance 8 between the throttle valve and throttle chamber
is set to 0 6 mm 0 023 in with the choke lever half completely
the manner previously described
out
SU TWIN CARBURETTOR
HYDRAULIC DAMPER
FLOAT LEVEL Inspection and Adjustment
The fuel level in the float chamber can be checked using The damper oil should be checked approximately every
the special gauge ST 19200000 Remove the float chamber 5000 km 3000 miles To check the oil level remove the oil
drain plug and install the special gauge as shown in Fig D 20 cap nut as shown in Fig D 23 and check the level of oil against
the two grooves on the plunger rod Top up with SAE 20
Start the engine and allow it to run at idling speed The engine oil if the oil level is below the lower of the two grooves
fuel level is conect if it is indicated on the glass tu be at a Take care not to bend the plunger rod when
removing and
distance of 22 24 mm 0 866 0 945 in below the top of the replacing the oil cap nut and make sure that the nut is
float chamber sufficiently tightened by hand
TechnIcal Data
Engine Model Ll4 I400cc Ll6 1600cc Ll8 l80Occ
Primary Secondary Primary Secondary Primary Secondary
Outlet diameter 28mm 32mm 28mm 32mm 30mm 34mm
Venturi diameter 21x7mrn 28xlOmm 22x7mm 29xlOmm 23x14x7mm 30xlOmm
Main jet 96 165 102 165 102 170
Main air bleed 60 60 60 60 60 60
1 st slow air bleed I Omm 10mm IOmm
2nd slow air bleed 220 100 180 100 210 100
Economizer 16 16 16
Power jet 55 55 55
Float level 22mm 22mm 22m
Fuel pressure 0 24 kg sq cm 3 41b sqin
Main nozzle 2 2mm 2 Smm 2 3mm 2 5mm 3mm
2 2 8mm
Type IUL 38 W6
Bore diameter 38mm 1 4961 in
FUEL PUMP
Piston lift 29mm 1417 in
Jet needle M 76
Type Mechanical
Nozzle jet diameter 324 mm 0 0921 in
Delivery amount 1000cc minute at 1000
Suction spring No 23 rp m
Delivery pressure 0 0 24 kg sq cm
18
Float needle valve
2 5 41b
3 sqin
inner diameter 15mm 0 059 in Drive from eccentric on cam
Float level 23mm 0 9055 in shaft
42
Clutch
DESCRIPTION CLUTCH PEDAL Adjusting
CLUTCH Removal and Dismantling CLUTCH MASTER CYLINDER
CLUTCH Inspection and Adjustment CLUTCH SLAVE CYLINDER
CLUTCH Installation CLUTCH WITHDRAWAL LEVER Adjusting
CLUTCH PEDAL Removal and Installation CLUTCH SYSTEM Bleeding
Either a diaphragm spring or coil spring type clutch is Coil spring clutch
fitted to the vehicle The component parts of the diaphragm
spring clutch are shown in Fig E l and the component parts A special tool No ST200S0000 is available to ensure that
of the coil spring clutch are shown in Fig E 2 the clutch can be dismantled and accurately reassembled The
tool shown in Fig E 3 consists of a Base plate I Centre
The clutch is of the single dry plate type consisting of spigot 2 Distance pieces 3 Height gauge 4 Operating lever
the drive plate clutch coveT and pressure plate and release 5 Securing bolts 6
bearing
A chart is included to indicate the various parts to be used
The driven plate comprises a flexible disc and splined hub for each type of clutch
which slides on the clutch shaft Friction linings are rivetted to
both sides of the disc To dismantle the clutch place the distance pieces on the
base plate as shown and arrange the clutch cover on the base
The clutch cover and pressure plate are combined by nine plate so that the cover holes coincide with the threaded holes
in the base plate Insert the securing bolts provided in the kit
spring setting bolts The diaphragm is dished to maintain a
constant pressure on the pressure plate which in turn holds and tighten them gradually and evenly in a diagonal pattern
the driven plate in contact with the flywheel The release bearing until the cover is firmly attached to the base plate Mark the
is a sealed type ball bearing mounted on a bearing sleeve Both clutch cover the pressure plate lugs and the release levers with
centre punch that they can be reassembled in their original
bearing and sleeve are operated by the withdrawalleveT when
a so
The clutch pedal actuates a master cylinder which transmits Remove the restraining hooks from the release levers and
fluid under pressure to a slave cylinder The movement of the unscrew the three nuts from the eye bolts Slowly release the
bolts
slave cylinder piston operates the clutch withdrawal lever via pressure on the clutch coil springs by unscrewing the
a push rod See Fig E 14 securing the cover to the base plate and lift off the cover springs
and pressure plate
gearbox can be found in the section GEARBOX exception of the disc linings and the release bearing
If a diaphragm clutch is fitted insert a spare clutch shaft Check the clutch cover diaphragm spring and pressure
or a special alignment tool ST20600000 into the splines of plate assembly for wear or damage and renew the complete
the driven plate So that the dutch is supported Slacken the assembly if necessary The pressure plate on the coil spring
six bolts securing the clutch cover to the flywheel by a single clutch can be lapped if necessary as described below Ensure
turn at a time and in a diagonal pattern until the spring pressure that the disc rivets are not loosened and inspect the linings for
contamination Grease or oil should be removed and the linings
is relieved Remove the bolts completely and lift away the
dressed using a wire brush
clutch assembly
When removing the coil spring type clutch it will be Check the disc for run ut using a dial gauge as shown in
insert suitable hooks under the release levers to Fig 4 Position the dial gauge at a point approximately 9Smm
E
necessary to
restrain the tension of the clutch spring before removing the 3 74 in from the centre of the disc and check that the run
clutch cover lx
llts out does not exceed the permissible limit of 0 5 mm 0 02in
be dismantled and must be replaced if wear or damage has if grease is leaking from it or if it is noisy when turned
occurred Make sure that the friction face of the pressure plate
43
inter i
llD
p1
@
81
r
3 8011
4 Lock washer
5 Withdrawal lacr
6 Retainer spring
7
BeaMI ve
u
8 Relmsf bearing
9 Beving s vc holder spring
10 Dust co r
11 l 1
14 l 11
44
The coil spring clutch pressure plate can be lapped with a CLUTCH Assembly
surface grinder to remove dents or scratches only the minimum Coil spring type
amount of metal should be removed to restore the surface
Press the pin into the eyebolt and through the lug on the
Check the plate for distortion by placing it on a surface pressure plate Place the three distance pieces on the surface
plate with the friction face towards the surface plate Press of the base plate of the special tool ST20050000 and position
the pressure plate down and insert a feeler gauge of 1 0mm the pressure plate pressure springs and retainers on the plate
0 0039 in between the pressure plate and surface plate If it
is possible to insert the feeler gauge then the pressure plate must Set the retracting springs on the cover and insert the
be repaired or replaced The plate can be skimmed but the release levers through the spring Place the clutch cover over
maximum amount of metal that can be removed is 1 0mm the pressure plate and springs making sure that the retracting
0 0039in springs do not become dislodged or distorted
With the diaphragm spring assembled to the pressure plate release levers on the eye bolts and screw OR the securing nuts
inspect the spring height and load in the following manner Place retaining hooks under the release levers and remove the
Place distance pieces of 7 8 mm 0 307 in on the base plate as clutch assembly from the base plate slackening the set bolts in
shown in Fig E 3 and bolt down the clutch cover using the a diagonal pattern
special bolts provided with the kit Jre
Meas the height B in
Fig E 5 at a diameter of 44mm 1 732 in The release fingers
should not exceed a height of 43 45 mm 1 693 1 772 in COIL SPRING CLUTCH Adjusting
from the base plate Replace the spring if the height is in excess
of the figures quoted Screw the centre pillar into the base plate and place the
high finger over the pillar The height of the release levers must
Press the dutch down as shown in Fig E 6 to a depth of be adjusted by turning the eye bolt nuts until the tops of the
7 8mm 307
0 in or until the clutch driven plate upper surface release levers are just touching the tip of the gauge See Fig E
lines up with the clutch cover mounting face If the load applied 11 Remove the centre pillar when the release levers are
is less than 350 kg 770 lbs it will be necessary to renew the correctly adjusted and screw in the actuating lever Fig E 12
diaphragm spring Do not press the clutch disc down by more Turn the actuating mechanism several times to bed down the
than 9mm 35 in or the diaphragm spring may be broken
0 parts and then recheck the height of the release levers Check
for out
run as near to the edge as possible and readjust if the
The clutch springs must be replaced as a set if any of the CLUTCH InsWlation
springs are found to be defective Specifications for the springs
are given in Technical Data at the end of this section Generally Ensure that the friction faces are free from oil and grease
a
spring may be considered faulty if when assembled the load is and place the driven plate on the flywheel The longer chamfered
reduced by more than 15 or if the free length has altered by splined end of the assembly should face the gearbox Use a
more than 15mm 0 0590 in or if the deflection B to A spare drive shaft to align the driven plate The shaft must be
in Fig E 7 exceeds 5mm per 100mm 0 2 in per 3 94 in inserted through the splined hub of the driven plate and into
the pilot bearing of the flywheel
Release Bearing Place the clutch cover into position on the flywheel and
tighten the dutch bolts gradually in a diagonal pattern to a
The release bearing should be renewed if excessively worn ft
16Ib
torque reading of 1 5 2 2 kgm 11 Remove the
orif roughness can be felt when the bearing is turned by hand dummy shaft and the restraining hooks from the release levers
The bearing should also be renewed if the grease has leaked Refit the release bearing and the bell housing
away or if the clearance between the clutch cover and inner
diameter of the sleeve is more than 0 5 mm 0 0197 in
CLUTCH PEDAL Removal and Installation
The bearing can be removed using a conventional puller
as shown in Fig E 8 Two types of release bearings are available Remove the clevis pin from the end of the master
and care must be taken when fitting onto the bearing sleeve cylinder pushrod and disconnect the pushrod Remove the
The release bearing should be pressed into place on the diaphragm return spring Remove the pushrod after slackening the pushrod
spring type of clutch with a force of 400 kg 880 lbs applied adjuster Coil spring clutch only Remove the pedal lever
at the outer race as shown in Fig E 9 On the coil spring clutch securing bolt slacken the handbrake bracket bolts and lift out
the same force must be applied at the inner race as shown in the pedal
Fig E IO It should be possible to turn the bearing freely and
smoothly when it is pressed into place Clean all parts thoroughly and check them for wear or
damage paying particular attention to the rubber parts return
spring and pedal lever bush
45
r
ft I
J
Ie
T
I Baseplate
2 Czn epiUfU @i
3 Distance preces
y
P
4 height iPuge
5 Actuilting mechanl
6 Set bolt
sQ
I e
Fig E 3 autch assembly tool Fig E 4 Checking the driven plate for out
run
81
r
A
if
I I 4 J J
jI
1111
1 11I 11111111111
the load of the dt
Fig E 6 Olecking b
I
I
I
A
8
I 1 j 1 I
l i y
l 0
p
I 0
W ihm 17
Illmi 9
I0 Installing the
E lease bearing coil
FiB E 9 Installing the leabearing diaphragm FiB
spring spring
46
CLUTCH PEDAL Adjusting 3 Disconnect the push rod from the clutch withdrawal lever
400 and 1600 cc models
4 Take out the mounting bolts and withdraw the slave
Adjust the pedal height to 209 mm 8 22 in with the pedal cylinder from the clutch housing
stop slackened off by altering the length of the master cylinder
push rod See Fig E 13 Tighten the pedal stop and obtain To dismantle the slave cylinder remove the dust cover and
from the cylinder
a pedal height of 207 ffim 8 15 in for Left Hand drive models snap ring and withdraw the remaining parts
or 182 mID 7 I7 in for Right Hand drive models Secure the
stop by tightening the locknut and make sure that the points Oean all components carefully and check them for signs
illustrated are correctly greased of damage or wear renew any part found to be defective and
fit a new piston seal
Adjust the pedal height to 175 mm 6 89 in by adjusting Reassembly is a reversal of the dismantling procedure
the pedal stop See Fig E 13 then retighten the locknut A Ensure that the parts are dipped in brake flu d before assembling
to a torque reading of 0 79 1 07 kgm 6 8Ib ft Turn the and that the piston seal is correctly installed
master cylinder push rod to obtain a play between 1 Smm
0 04 0 2 in at the clevis pin then tighten the locknut B When the slave cylinder is installed in the vehicle bleed
to torque reading of 0 79 1 07 kgm 6 8 Ib ft
a Ensure when the hydraulic system by following the procedures given under
adjusting the play that the port on the master cylinder is not the heading CLlTfCH SYSTEM Bleeding
blocked too small a play at the clevis pin may block the port
Bend the clevis pin over completely The push rod must be adjusted so that the withdrawal
lever has an end play of 2 0 2 3 mm 0 078 0 091 in details
of this operation are given below
CLlTfCH MASTER CYLINDER Removal and Dismantling
Disconnect the push rod from the clevis Fig E 14 CLlTfCH WITHDRAWAL LEVER Adjusting
Detach the fluid line from the master cylinder and pump The correct adjustment of the clutch withdrawal lever is
the fluid into a suitable container most essential as insufficient clearance between the clutch
release bearing and the diaphragm will cause the clutch to slip
3 Withdraw the retaining bolts and remove the master On the other hand an excessive clearance will prevent the clutch
To dismantle the master cylinder remove the filler cap and drain The clearance between the release bearing and diaphragm
away the fluid or release levers can be adjusted in the following manner
push rod piston assembly and return spring fully home with the adjusting nut Return the adjusting nut
I 3 4 turns to adjust the play at the end of the clutch withdrawal
Oean the components in brake fluid and check them for wear lever to 2 0 2 3 mm 0 078 0 091 in This will give a clear
or damage ance of approximately 1 3 mm 0 051 in between the release
bearing and the diaphragm spring or release levers
Renew the cylinder and piston if uneven wear has taken place
the clearance between the cylinder and piston must not exceed NOTE When adjusting clutch pedal free travel at the withdrawal
0 13 mm 0 005 in lever it is essential to check that the clutch driven plate
has not worn by more than 2mm 0 08 in otherwise
Renew the dust cover oil reservoir filler cap and fluid line if the clutch will slip even if it is correctly adjusted See
Technical Data for the relevant clutch driven plate
necessary
thickness
Reassembly of the master cylinder is a reversal of the dismantling
procedure take care to soak the components in brake fluid and
assemble them while still wet CLUTCH SYSTEM Bleeding
When the master cylinder is installed in the vehicle make sure The clutch system must be bled after it has been dismantled
that the pedal height is adjusted as previously described and orif any part of the circuit has been opened This operation
bleed the hydraulic system by following the procedures given should also be carried out if the fluid level in the reservoir has
under the heading CLlTfCH SYSTEM Bleeding been allowed to fall and pennit air to enter the system
47
D
inter J
1D7
T T
J I
aj
1
W T
7
f T
n e
35 to 4 0kltm
Tightening torque 125 to 29 h lb
Rs
I
@
8J
1 3
fP I
l
A
l
I I
Pedal
Lock
Lock
height
ul
A
Bn
175 mm 6 89 nl
I Pcdalfullstrokc b 135mm
Jt 5 JI n
01
@ l Lubricatic
140 4 5 51 0 16
Clutch dal full trek mm
610 series
510 series
48
inter j
lliJ flDlJ
l
Jl
iO
L
cxB I
n
of t hl
9 q 615 1
o
I
lii
r
r
i
8t
I Q
L L
a
ID
1 Cylinder
2 Return spring
C1
3 Piston
4 seat
Spring
5 Push rod
6 Nut
7 Stopper ring
8 Stopper
9 Dust cover
10 on reservoir
1J Reservoir balld
12 Reservoir cap
cylinder
Adjusting nut
49
other end of the tube into a clean container partly filled with
required when
brake fluid It should be noted that assistance will be
out bleeding operations as not only must the fluid
carrying
also the clutch
Top up the master cylinder reservoir with recommended entering the glass container be watched but
three quarters be operated and the reservoir topped up frequently
fluid and open the bleed screw approximately pedal has to
Depress the clutch pedal slowly and hold it completely When the fluid is completely free from air bubbles the
of the pedal
down retighten the bleed screw and allow the pedal to return bleed screw should be retightened on a down stroke
slowly
Finally remove the bleed tube and replace the dust cap
Repeat the operation until the fluid emerging from the
tube is free from air bubbles
TechnIcal Data
Outch type Diaphragm spring or coil spring
Pressure spring
Free length 52 3mm 2 059 in
Permissible deterioration
of spring force 15
Master cylinder
Diameter 15 87mm 0 625in
Pressure plate
Permissible refacing limit Imm 0 0394in
50
Gearbox
GEARBOX Removal
GEARBOX Dismantling
GEARBOX Inspection and Overhaul
GEARBOX Assembling
THREE SPEED GEARBOX GEARCHANGE CONTROL Removal and Adjusting
AUTOMATIC TRANSMISSION Gearchange control linkage
Three types of transmission are available for the Datsun Drain the gearbox oil Remove the dust cover release
models covered by this manual Either a three speed gearbox the retainer spring and remove the withdrawal lever complete
a four speed gearbox or three speed automatic transmission with release bearing from the clutch housing See section
can be fitted CLUTCH
The three and four speed gearboxes are equipped with
nchromesh on all forward gears with the three speed gearbox Remove the gearbox bottom cover the speedometer drive
operated by a steering column gearchange system and the four pinion assembly and the rear extension housing Take out the
floor mounted gear lever crossshaft retaining rings and unscrew the nuts securing the
speed gearbox by a
by a synchrcrring on the servo gearbox gear shaft lock bolt and remove the shaft and the idler gear
Fig F B Drive out the pins securing the selector forks to the
selector rods
THREE SPEED GEARBOX Removal
Unscrew the interlock plug and remove the detent ball
I Jack up the vehicle and support it on stands and spring Fig F 9 Remove the first reverse speed and second
third speed selector rods and lift out the selector forks
2 Disconnect the hand brake cable at the equalizer bracket
Slacken the two exhaust pipe centre clamps and turn the Withdraw the main shaft assembly and the drive shaft
centre section of the exhaust assembly to the left as shown assembly from the gearbox See Fig F 1O and F 11
in Fig F 2
To dismantle the mainshaft release the circlip from the
3 Disconnect the propeller shaft from the rear axle drive front of the mainshaft as shown in Fig F 12 and remove the
flange by removing the four securing bolts Seal off the second and third speed synchronizer hub and second speed
gearwheel Fig F 13 Remove the circlip securing the speedo
gearbox extension housing to prevent the loss of oil and
withdraw the shaft to the rear meter drive gear and withdraw the gear together with the ball
6 Support the engine with ajack positioned underneath the and extension housing for cracks
oil sump making sure that the jack does not foul the drain
If the joint faces are burred or pitted it may be necessary
plug A block of wood should be placed between the sump
and jack to avoid damaging the sump to replace the units if repair cannot be carried out satisfactorily
Remove any adhesive which remains on the faces
51
VP
lip J
F rr
l I I ii
iI
a
It J 4
j C
f
e
V
tJ
J
52
inteN I j D p
c jiii
Fig F7 the countershaft gear
Removing
Fig F6 Removing the shaft
ero
tT
JO
8 F I0
F Withdrawing the mainshaft gear assembly Fig lI
F Removing the main drive shaft
Ii
ii jjf
vr
O
Fig F 12 Removing the 2nd and 3rd speed F 13
Fig Removins the 2nd and 3rd speed hub
syndlroniur hub circlup and 2nd speed gearwheel
S3
i nte r IJ jJ
DW
J
F 15 the IIlJIDlShofllor ol
ron F I7 the insert snap
Fill Checking Fig Installing ring
baulk
Fill F 16 Checking the clearance between
ring and gear
Fig F 18 InsWlins the shifting inserlll Fig F 19 Fitting the synchronizer hub to the
coupling sleeve
54
to ascertain the amount of wear that has taken place Install the spacer ball and speedometer drive pinion
Select a snap ring which will give an end float of 0 05 0 22mm
Check the teeth of the gearwheels and the machined surfaces 0 002 0 009 in on the mainshaft first gear Snap rings are
for signs of wear scoring pitting and burrs Ensure that the available in eight thicknesses from 30mrn
1 0 0512 in to
synchronizer hubs slide freely on the splines of the main shaft 1 70mm 0 0669 in
with minimum clearance Check the mainshaft for out
run
using V blocks and a dial gauge as shown in Fig F 15 Renew Secure the drive gear with the selected snap ring and check
the mainshaft if the out
run exceeds 0 15mm 0 0059 in the end float of the gearwheels as shown in Fig F 21 The correct
end float should be as follows
Check the synchronizer rings for wear and renew them if
I st speed gearwheel 0 2o 3mm
necessary Place the rings in position on their respective gear
wheel cones and check the gap between the end of the ring and 0 008 0 012 in
2nd speed gearwheel 0 2 0 3mm
the front face of the teeth Fig F 16 The correct gap should
be within 1 2 16mm 0 047 0 063 in Renew the synchronizer 0 008 0 012 in
Make sure that the oil seals are satisfactory and discard position Insert the interlocking plunger and fit the second third
the Orings speed selector fork and rod Insert the steel ball and spring and
refit the interlocking plug after coating the threads of the plug
with sealing compound See Fig F 22 Secure the selector forks
THREE SPEED GEARBOX to the rods by inserting the retaining pins
Assembly
Press the main drive gear bearing onto the main drive shaft Fit the reverse idler gear and shaft and secure the shaft
with the lock bolt and plate Insert the counter gear cluster and
and fit the spacer Select a snap ring of suitable thickness so
that all play is eliminated between the bearing and snap ring shaft using a suitable thrust washer to obtain an end float of
Seven sizes of snap rings are available and vary in thickness from 0 04 0 12 mm 0 0016 0 0047 in Thrust washers are available
1 52mm 0 0598 in to 189mm 0 0747in in five sizes from 3 85 4 05 mm 0 1516 0 1594 in thickness
in increments of 0 05 mm 0 002 in
The synchromesh unit consists of a coupling sleeve baulk
Fit the crossshafts 1 in Fig F 23 the thrust washers 2
ring spring synchronizer hub and insert When assembling the
and the operating levers 3 Secure the shafts
cross with the
unit make sure that the correct insert pressure springs are fitted
to the relevant speed unit The first reverse gear synchronizer retaining rings 5 and lock the operating levers to the shafts with
should be fitted with the three coil spring type and the second the pins 4
third gear synchronizer with the two expanding springs
Locate the rear extension housing on the gearbox case
To assemble the fiI3t speed synchronizer insert the sliding and tighten the bolts to a torque reading of 2 8 4 kgm
20 32 ft
Ib Insert the speedometer drive pinion and retain it
insert snap ring onto the synchronizer hub as shown in Fig F 17
Fit the sliding inserts Fig F 18 and the synchronizer springs with the set bolt and lock plate Check the backlash of all the
on the synchronizer hub and assemble the synchronizer hub gears using a dial gauge as shown in Fig F 24 The backlash
should be between 0 05 0 20 mm 0 002 0 008 in Fit the
complete with inserts into the coupling sleeve Fig F 19
gearbox front cover and tighten the fixing bolts to a torque
Assemble the second third gear synchronizer hub and reading of 1 I 1 7 kgm 8 0 12 3 ft
lb taking care not to
coupling sleeve making sure that the sleeve slides freely on the damage the oil seal Fit the clutch release bearing and with
hub splines Fit the three shifting inserts and install a spring ring drawallever Fig F 25 Replace the bottom cover and tighten
on each side of the hub Fig F 20 the bolts to a torque reading of 1 I 1 7 kgm 8 0 12 31b ft
Fit the first speed gear and baulk ring on the rear of the Adjust the clutch slave cylinder push rod as described in
the section CLUTCH to provide a free play of 2 2 mm 0 087in
shaft so that the tapered cone faces to the rear Assemble the
first speed synchronizer and reverse gear on the shaft Fit the at the withdrawal lever
55
inter iillu@U
1 crossshil t
2 l
hnut washers
3 OperatirJ8levm
4 Lock pim
5 Retaining rings
y
hk 9
0
Ll
7
1 i l
I
A
rmJ t 0
f
II
56
FOUR SPEED GEARBOX Removal and Installation When assembling the main drive gear bearing on the shaft
insiall the spacer and select a new snap ring to eliminate all end
The removal and installation procedures for the four speed float between bearing and snap ring Snap rings are available in
gearbox are similar to those previously described for the three five thicknesses from 1 52 1 77mm 0 06 0 07 in
speed gearbox However the floor mounted gear lever must be
removed from the controllevef bracket in addition to the The assembly procedures for the Warner type synchronizers
operations already detailed aresimilar to the instructions previously described for the three
speed gearbox Refer to THREE SPEED GEARBOX Assembly
for further details
FOUR SPEED GEARBOX Dismantling
To assemble the Servo F4C63 type synchronizers proceed
Drain the oil from the gearbox Remove the dust coveT and as follows
release the spring securing the clutch withdrawal lever Remove
a clean flat surface and install the
the withdrawal lever and release bearing from the clutch housing Place the gear on
asdescribed in the section CLurCH Remove the clevis pin synchronizer ring the inner side of theclutch gear Fit the
on
securing the striking rod to the control lever thrust block into place as shown in Fig 31
F Place the anchor
block and brake band into position and fit the circlip into the
Remove the speedometer drive pinion assembly and with groove in the gear to secure the synchromesh assembly
draw the rear extension housing Disengage the striking rod from
the selector rod gates Remove the gearbox covers See Figs F 26 When assembling the mainshaft select a snap ring which
and F 27 will give an end float between 0 05 0 15 mm 0 002 0 006in
to the third speed gearwheel Snap rings are available in five
Unscrew the three detent ball plugs and remove the spriags sizes from 1 40 mm 0 0551 in to 160 mm 0 0630 in thick
and detent balls Drive out the pins securing the selector forks ness Tighten the locknut at the rear of the mainshaft to a
to the rods and withdraw the forks and rods Lock the main torque reading of 7 1 kgm 51 87Ib ft
shaft by moving the first second and third fourth coupling sleeve
into gear at the same time and release the ffiainshaft nut Assemble the reverse idler gear as shown in Fig 32
F The
reverse idler driven gear 3 should be placed on the end of the
Remove the countershaft and the gear cluster together reverse shaft 1 with the longest spline and retained with a
with the two needle roller bearings and spacers Remove the suitable snap ring 2 Install the reverse shaft and gear assembly
snap ring holding the e idler gear and withdraw the reverse
revep into the gearbox case from the rear with the thrust washer 4
idler gears and shaft Fig F 28 between the gear and the case Fit the thrust washer 5 and
idler gear 6 18 teeth and secure with a suitable snap ring
Take off the bolts securing the mainshaft bearing retainer 2 The end float of the gear should be checked and adjusted
tothe gearbox case Fig F 29 Withdraw the mainshaft to 0 1 3mm
O 0 004 0 012 in by selecting a suitable snap
assembly Fig F30 and the main drive shaft ring 2 Five thicknesses of snap rings are available from I lmm
0 043in to 1 5mm 0 06in See Technical Data for F4W63
The mainshaft can be dismantled in the following manner and F4C63 gearboxes Adjust the counter gear end float to
Release the third fourth synchronizer unit snap ring and with 0 05 0 15 mm 0 002 0 006in by selecting a thrust washer
draw the hub complete with coupling sleeve Remove the third of the required thickness Thrust washers are available in five
speed gearwheel and the needle roller bearing from the main thicknesses from 40
2 2 60 mm 0 094 0 102 in
shaft Take off the mainshaft nut and locking plate Remove the
fit
speedometer drive gear with the retaining ball Withdraw the When assembling the selector mechanisms Fig 33
F
mainshaft reverse gear and the hub Press off the mainshaft the first second selector forks I and the third fourth selector
bearing complete with the bearing retainer forks 2 onto the coupling sleeves and insert the first second
fork rod 3
Remove the thrust washer and the first speed gear together
with the needle roller bearing taking care not to lose the small Fit an interlock plunger 4 and the third fourth speed
baU used to locate the thrust washer Slide off the first speed selector rod 5 Do not forget the interlock pin 7 A section
gearwheel bush Withdraw the first second synchronizer and through the selector and interlock mechanism is given in Fig
hub Remove the second speed gearwheel and needle roller F 34 Install an interlock plunger 6 and assemble the reverse
bearing selector fork 8 and fork rod 9 Secure the selector forks to
the rods with the retaining pins 10
FOUR SPEED GEARBOX Installation Place a check ball and spring into each of the holes and
57
inter llir@
8 F 29 Removing the
F mainshaft bearing Fig F 30 Withdrawing the mainshaft assembly
retainer
0
6
I r
CD 1 Q 7
1ib 1 Hv
l
d
L
9
II n j2
@
1 17uu t
c
block
@
I
4 Anchor block 1 R
r
nt shaft
JJ I
1
1
v
1l ij07
ISland 2nd selector fork
1
5 Fork rod
u
2 md bruke 5 Circlip SntJpring 2 3rd and 4th selector fork 6 Inter ock phmgtr
3Synchro rint 6 Band b ke 3 R idler driving geor UT 3 Fork rod 7 Intulock pin
4 Thrust washer 4 Interlock plunger 8 Revene selLetor fork
8 F 31
F Syncbromesh assembly 5 1
hnat washer 9 Fori rod
6 Idlergeor 18T 10 Retaining pin
4th
3rd Rod
58
THREE SPEED GEARBOX
GEARCHANGE CONTROL LINKAGE Acijusting
Fig F 35 Set the gear lever to the neutral position and temporarily
connect the trunnion on the lower support bracket to each rod
As previously described the three speed gearbox is Fig F41
equipped with a steering column gearchange linkage system
which incorporates a collapsible control rod when combined Set the rod on the lever so that the neutral adjustment
with the collapsible type of steering column assembly grooves on the upper surface of the lower support bracket are
and the washer then remove the upper support bracket by Gearchange control linkage
releasing the locating bolt and screw The control rod insert with
bush and return spring can now be removed Remove the snap The automatic transmission gear change control linkage
a similar manner to the three speed gearbox
and gear lever pivot pin and withdraw the gearlever can be removed in
linkage Carry out the operations previously described under
Remove the cotter pin plain washer and spring washer and the relevant heading as far as the removal of the gear lever and
disconnect the shift rods from the gear selector levers Fig F 39 proceed as follows
Unscrew the bolts securing the lower support bracket and the
clamp Remove the clamp and gear change lever retainer Disconnect the upper selector rod from the selector lever
by removing the cotter pin plain washer and lock washer See
Remove the second third speed selector lever the lower Fig F 42 Remove the speed range position plate the snap ring
support bracket and the first reverse selector lever from the at the lower end of the control rod and unscrew and remove
control rod Withdraw the control rod Disconnect the gear the lower support bracket Release the locking screw and with
change rods by removing the cotter pins and remove the cross draw the selector lever assembly Withdraw the control rod
shaft bracket from the side member Withdraw the cross shaft disconnect the selector rods and remove the cross shaft bracket
assembly Fig F 40 and crossshaft assembly Clean all parts and repair or renew
any part which is worn or damaged Installation is a reversal of
Examine the components for signs of wear and damage the removal procedure noting the following points
and replace if necessary
Coat all the sliding surfaces with chassis grease prior to
Installation is a reversal of the removal procedure noting assembling
the following points
Set the converter side lever and the gear lever in the neutral
Take not to strike apply load to the collapsible
care or a
position Install the upper selector rod to the selector lever and
type of control rod or the rod may be damaged adjust the gear position plate to give a clearance of 0 5 I Omm
0 02 0 04 in between the selector lever stop pin and the
The rod should not be slack in the axial direction when position plate The adjustment can be obtained by turning the
installed and must be removed if slackness is detected Coat selector rod adjusting nuts Finally tighten the nuts on each
the sliding surfaces with grease before assembling them side of the trunnion
S9
inter j@
IUI lce
Steerin
6
id rod
m r
mb Control
T 1 0 4 k m
7 2 10 1 h b
Lowe ket
bra
eros shalt
Upper
k
bracket
ft lb
er i
12 kl1 m So
T Change J
P dl lu Reverle
s Neutral
1
od
T S
2 0 kg m
2nd 3
i14 5ft lb
d
Trunnion Reve e
k
R b hifirod Neutral
C
H dl
Steering gear
I
n
T 0 35 0 5 kg m 2 3 6 ft lb
S
3
i S
3 d hh 1m
Note
f
1 7fOC
Tightening torque
L v 1 T
Rev lhift le er
Rev lst 2
@ Chauis grease
Apply grease the points shown by
to
@
when recnsembling
Fig 39
F Removing the lower bracket
lO br
Gr fOf
il
trllllett
ll
Ch
Fig
lwer
F 41 Neutral setting
1
adjustment
i Fig F 42 View of the selector lever
60
Technical Data
GENERAL SPECIFICATIONS
R3W65 L F4C63
Gearbox mode
F4W63L 3N71B
Num ber of
teeth on
mainshaft Drive gear 19 22
3rd speed 27
2nd speed 25 30
1st speed 31 36
Reverse 34 39
Num ber of
teeth on
counter
shaft Driven gear 30 31
29
3rd speed
2nd speed 24 21
1st speed 15 15
Reverse 16 14
Reverse
idler
16 18
gear
Speedometer Drive gear 5
Driven gear 19 or 17 16
Max countershaft end float 0 05 0 15mm 0 002 0 0059 in 0 04 0 12mm 0 0016 0 0047 in
0 20 40mm
0 0 0079 0 0157 in
Reverse idler gear end float 0 05 0 15mm 0 002 0 0059 in
61
E
inter j
lill
jIl
lll
1 3 I
I t
An
i I
1r
1 ll 2
L O I
i
JII
i
I
1 5
11 85 l OIlU 3
39
378
1
1 Sleeve voke arsembh
4 Snap ring
Unit in
5 iPreopre shaft tube assl mblv mm
6 flan oke
Fig G I Section through the propeller shaft
selecting 2 and 3
j Pinio bearing adjusting spacer
@ 4 PInion height adiustinx MUS1m
c 5 Lock strap
6 Ring gear bolts T 70 to 80 kgm
50 6 ro 578 bIt
@ TIghten by tapping bolt head with
I I Jj41b3 hamTMr
7 Lock pin
i
8 Rear cover
9 Ring gmr
10 Diff mounting member
1 J Bolt diff to diff mounting member
@ T 6 0 to 80kKm 4 0 78
43 ft
b
12 ShIlf pinion m1te
13 Thnl lWlJIJer
@ 14 Pinion mate
15 17vust washer
mm
00039 0 0 0079 bv 16
16 Side ar
19 Side flange
cJi
20 Side retainer
y
21 Bolt side retainer T 09 to 2 kgm
1
65 to 8 71b
22 ring
j 23 Side bearing
24 Diff Gear case
30 Oil seal
3J CompanionfliInge
rID 32 Dri pinion nut T 17 to 20 Jwn
@
122 9 0144 fI
6Ib
62
Propeller Shaft and DIfferentIaJ
DESCRIPTION
PROPELLER SHAFT
DIFFERENTIAL Removal and Dismantling
DIFFERENTIAL Assembly and Adj Jstment
DIFFERENTIAL Installation
DIFFERENTIAL Estate car and van
TOOTH CONTACT PATTERN Checking
wagon and van has a three section shaft in contrast to the two Check that the dynamic balance of the shaft does not
piece shaft used on the other models covered by this manual exceed 15 grm cm 0 208 in
oz at 4000 rp m
3 Remove the adjuster nut from the handbrake cable rear DIFFERENTIAL Removal
adjuster and disconnect the left hand cable Saloon only Saloons with independent rear suspension
Remove the bolts securing the centre bearing bracket
1800 cc stati n wagon Remove the hand brake rear cable remove the propeller
shaft and drive shafts as described in their relevant sections
4 Disconnect the fearflange from the rear axle flange With
draw the propeller shaft to the rear away from the gear 2 Support the differential with ajack and remove the nuts
box mainshaft Take care that the shaft is not dropped securing the differential mounting crossmember Fig G 3
during removal or the balance of the shaft may be altered
3 Remove the bolts holding the differential to the suspension
5 Plug the gearbox rear extension to prevent the loss of oil member Withdraw the differential and jack to the rear
0 15mm 0 006 in the standard size of a new journal is 14 7mm impression of the tooth contact
pattern Check the backlash
0 579 in Check the spider seal rings and replace them if between the teeth of the crownwheel and pinion using a dial
necessary The radial backlash of the sleeve yoke splines to gauge The backlash should be within 0 10 0 20mm 0 004
gearbox splines should not exceed 0 5mm 0 002 in Renew 0 008 in
the sleeve yoke if the figures are in excess of the specified value
63
E
inteN j
Il1l @QI
tJ
v
r
f
snl530000
Fig G 9 Removing the drive flange G IO Removing the gear canier side flange
FIg
64
l
and the shims Place a press plate between the drive pinion head Check the gear teeth for scores cracks or excessive wear
and rear bearing and press out the pinion shaft Check the tooth contact pattern of the crownwheel and
pinion for correct meshing depth The crownwheel and
The inner races need not be removed if the tooth contact pinion are supplied as a set and should either part be
to the complete set
pattern is correct and the crownwheel drive pinion carrier damaged it will be necessary renew
rear bearing and shims etc are to be re used The front and
rear outer races of the pinion bearings can be removed with the 2 Check the pinion shaft and gear mating faces for scores or
wear Inspect the inner faces of the side gears and their
special tool ST 30610000 or with a suitable drift
seating faces on the differential cage
To dismantle the differential cage remove the right hand
bearingcone as shown in Fig G 8 The special puller ST 3306 3 Any small defects on the faces of the thrust washers can
0000 and adaptor ST 33052000 should be used for this pur be corrected using emery cloth The thrust washers must
pose taking care not to damage the edge of the bearing innec be replaced however if the backlash between the side gear
race Flatten the lock straps slacken the crownwheel bolts in and pinion exceeds 0 2mm 0 008 in and the clearance
a
diagonal pattern and remove the crownwheeL between the side gear and thrust washer exceeds 3mm
O
0 012 in Three sizes of washers are available and the
Remove the left hand bearing cone in a similar manner to thicknesses are detailed in Technical Data at the end of
the right hand bearing cone Make sure that the parts do not this section
become mixed and can be assembled in their original positions
Punch out the differential shaft lock pin from the crownwheel 4 Measure the out
run of the crownwheel at the rear with a
side using a suitable drift Great care must be taken when dial gauge Replace the crownwheel and drive pinion as a
carrying out this operation as the pin is caulked into the hole set if the out
run exceeds the permissible value of O 08mm
in the differential cage 0 003 in
Remove the shaftthe differential pinion gears and the side 5 Examine the differential carrier and cage for cracks or
gearsand thrust washers Separate the left and right hand gears distortion Renew any part found to be defective It is
and washers so that they can be reassembled in their original advisable to renew all oil seals
positions
Drain the oil from the differential unit and jack up the
vehicle at the rear Remove the propeller shaft from the Differential cage
differential flange Disconnect the handbrake left hand rear
cable Slacken and remove the drive pinion nuts whilst holding Fit the differential side gear and bevel gear in the cage
the drive flange with a suitable wrench or special tool ST using the correct thrust washers Insert the pinion shaft so that
31530000 Withdraw the drive flange with a conventional two the lock pin hole corresponds with the hole in the differential
65
inter j
M jJ
@
5c
J
t i
t
3
jp r 4
1 7 i
72 3 lbjl
3 Tightening torque of nut dril e 10 kgt1L 5a 6 to
lbr ril
s lJ i
Ilc d I V r IHei t
giluge
0
lST31210c
l
@ 1 I
l iF C l
B I
Q 0QJ
DUrnmYPinlOn
collar L
Drive pinion lST3121QOCX 1
f r
IST315000001 Dummvspacer
Fig G t3 Drive pinion markings ST318500001
bb
o
T 0 24 mm
and check the gear for freedom of rotation
H
S 340 0 24 2 x 0 01
Install the crown wheel in the differential cage and insert
0 20 46
3 mm
the bolts with new lock straps Tap the head of each bolt lightly
and tighten the bolts in a diagonal pattern to a torque reading
of 7 0 8 0 kgm 51 58Ib ft Measure the width of the side An adjusting washer rrlust be selected which is nearest in
bearings before installing them Place a weight of 2 5 kg 5 51b thickness to the value of 3 46mm Adjusting washers are available
onthe bearings and check the nominal width which should be in thicknesses of 3 09mm 0 01217 in to 3 66m 0 1441 in
20mm 0 787 in Press the side bearings into the differential for the l800cc models and in thicknesses of O 2 and 2 4mm
cage 0 787 0 866 and 0 945 in for the 1400 and 1600 cc models
Adjustment of drive pinion preload pinion and press on the rear bearing inner race Install the drive
pinion into the differential carrier together with the bearing
and the front
This adjustment is carried out without fitting the oil seal spacer and washer the front bearing inner race
Press the front and rear bearing outer races into the gear carrier bearing pilot spacer
and fit the pinion height adjusting washer Fig G 12 the
shims and the rear bearing inner race onto a dummy shaft Fit the drive flange and washer on the drive pinion and
special tool ST 31 The old washers and shims can
120000 secure them with the pinion nut Tighten the nut to a torque
be re used if the tooth contact pattern was found to be correct reading of 17 20 kgm 123 145Ib ft
on the pre dismantling check Fit the drive pinion bearing spacer
the washer ans special collar 5T 312140000 or 5T 31500000
and the drive flange on to the dummy shaft Tighten the drive SIDE BEARING SHIMS Selecting
pinion nut to a torque reading of 17 20 kgm 123 145 Ib ft
Measure the drive pinion bearing pre load and select washers and The side bearing pre load must be adjusted with selected
Adjusting spacers are available in lengths of 56 2 57 2 mm The required thickness of the shims can be obtained using
2 2126 2520 in and adjusting washers in thicknesses of
2 the following formula and referring to Fig G l 5
59 2 31 mm 0 1020 0 0909 in
T1 left side bearing A C GI D E H x 0 01
0 76
Adjustment of pinion height
B D G2 F H 0 01 0 76
T2 right side bearing x
this tokrance is accompanied by a or sign to show the bearings against the nominal width of 20 0mm
deviation from the nominal dimension Thc plus sign indicates 0 7874 in given in units of 1 100 mm
The pinion height can be adjusted using the original The A B C D G and H figures indicate the dimensional
washer and shims between the rear bearing cone and variations in units of 1 100 mm Jm
fr the standard measurement
adjusting
the drive pinion Install the setting gauge 5T 31210000 on the An example of the calculations to decide the thickness of shim
carrier with the dummy pinion installed Sce Fig G 14 required is given below
I 3 1 2 x 0 01 0 76 0 01 0 8mm
S W T H x 0 01 0 20
Right side bearing
Where W thickness of inserted shims and washers
Measured thickness T2 B D G2 H x 0 01 0 76 F
T
2 I I 2 0 01 0 76 0 02 0 8mm
H Figure engraved on pinion head x
67
inter lJIi pl
@
J
Y
rI
e c J
sr s
t
i J
Jr
A
c
G
I fo
t
L
l
Ir i f1 s
u
r
h
f r 1 i vf r P
ST06J60000
0 i J 5T0631110UO
estate car
I van Fig G 20 Removing the side bearing
J Fig G 19 Mounting the differential carriers
1
fl4j P
tj l
ff
P
j
Fig C 21 Removing the crownwheel bolts
f
l
I
tf ST23510000
S
1
Fig C 23 Removing the drive pinion nut
t
1
I l u
L
ti i
3 3S6
Ice
F idth lction
1
Ol Ibvr
1
68
The standard width of the side bearings is 20 0mm forwards to check that the backlash is Io ithin thL
speL ified limits
0 7874 this width must be measured before attempting to Shims and adjusting washers must bL altered if the tooth con
calculate the thickness of the adjusting shims Use a dial gauge tact pattern and backlash is L the neL cssary details for
incorre
and surface plate to ohtain the measurement Place a weight of these operations can be found towards the end of this section
approximately 2 5 kg 5 5 lb on the bearing to obtain steady under the appropriate Jdjn
he s Fil1JJly mark the bearing caps
readings with a hammer and punch to ensure correct t1ignment on re
assembly
Install the differential cage assembly in the carrier Fit the
sckcted shims and O rings into both differential side bearing Remove the bearing caps nd withdraw the differ ntial
covers and install the covers in the carrier
using the special tool cage make a note of the left and right hand positions so Jt
h
ST 33720000 Fig G 16 l Make sure that the side bearing the bearing caps and outer race can be re assembled in their
outer races are not damaged
by the roller Measure the backlash original positions
between the teeth of the crown wheel and drive pinion with a
dial gauge as shown in Fig G I Sct the dial gauge to 0 10 O Withdraw the side beJrings with the s cjal puller as shown
f
mm 0 004 0 008 in I If the backlash is less than the specifIed in Fig G 20 taking care not to catch the edge of the bearing
value move he left side adjusting shim to the right side and vice inner races
Secure the differential carrier on the rear suspension Tap the drive pinion assembly to the rear with a plastic
mem
mallet and withdraw it together with the rear bearing inner race
ber using the four bolts and washers Fit the differential
bearing spacer and adjusting washer
mounting member thc mounting holes by pushing it forwards
to
with a suitable lever Fig G 18 Tighten the nuts to a torque Remove and discard the oil seal and withdraw thc front
reading of 8 5 kgm 61 5 Ib ft Tighten the bolts attaching the
gear carrier to the suspension member to a
bearing inner race Drive out the outer races of the front and
torque reading of rear bearings with a suitable drift
6 7 Fig G 25
kg 36 5Ilb ft t
The drive pinion rear bearing inncr race can be removed
The rcmainder of the installation operations are a reversal
with the special tool ST 300310000 as shown in Fig G 24
of thc removal
procedure Fill the differential with the correct
quantity of recommended oil
DIFFE
lENTlAL Inspection
DIFFERENTIAL CARRIER Removal and Dismantling Clean all components thoroughly and examine for signs
Estate car alld Vanl
of wear or damage
To the differential carrier disconnect and remove
remove
Check the teeth of the crownwhcel and pinion for scoring
rhe propeller shaft as previously described and remove the two
rear axle shafts as described in the section REAR AXLL With
and hipping Ii should be noted that the crownwhecl and
draw the nuts securing the differential and remove the carrier pinion are supplied as a matched set and if either part is damaged
the complete set must be replaced
from the rear axle
Examine the inner faces of the side gears and seats on the
Mount the unit on the special attachment as shown in
differential case Inspect the bearing races and rollers and replace
Fig G 19 and carry out a preliminary check before dismantling
them if necessary
69
Check the out
run of the crownwheel as shown in Fig G 15 be ring and dummy shafr and place the Ippropriatt ettil1g
rear
Position the dial gauge to the rear of the crownwheel and check gauge on the carrier See Fig C 2S l The fOllowing setting
that the run out does not ceed 0 0 mm 0 0020 10 I It the gaUges and dUlllmy houlJ bt llsed for th various modds
shaft
run out limit is exceeded replace the crownwheel and pinion
t
as a
I OO and Estate
1600 c r Setting g3uge ST 1941000
Dummy shaftST 31942000
Inspect the differenti l L arrier nd case for cracks or
distortion and replace them if necessary ISOOce Estate car Setting gauge ST 31141000
Dummy shaftST 1941000
SIDE GEAR THRUST WASHERS Whe rc T The required thickness of adjusting shim mrn
0 0467 in
N 0 30mm H 1 D I S O
1800 cc
Van 0 75 0 80 mm 0 80 0 85 mm
T 0 30 2 0
1 x 0 01 0 28 0 59 mm
0 85 0 90 mm 0 90 mm0 95
0 0295 0 0315 in 0 0315
Shims are available in thicknesses of 0 050 0 070 0 10
f 0 0335 in 0 0335 in 0 0354 in
0 20 and 0 50 mID 0 0019 0 0027 0 0039 0 0078 and
0 0354 0 0374 in
0 0196 in for the Estate cars and in thicknesses of 2 37 2 97mm
Drive in the differential pinion lock pin from the right hand
0 0933 0 1169 in for the 1800cc Van
side of the case and peen the rim of the hole to prevent the pin
from working loose
Take off the drive pinion and the rear bearing outer race
and adjust the position of the drive pinion by installing shims
Fit the crownwheel to the differential cage and install the
of selected thicknesses Fit the drive pinion and bearing spacer
bolts and new lock plates Tap the head of each bolt lightly
in the
and tighten the bolts in a diagonal pattern to the specified pinion housing and tighten the drive pinion nut to a
torque reading of 14 17 kgm 101 130 Ib fl for the Estate
torque readings
cars or 13 20 kgm 94 145Ib
ft for the 1800 cc Van
70
greased Install the flange washer and pinion nut Tighten the Fig G 31 The following formulae can now be used to deter
nut to torque reading of 14 17 kgm 101 130
a fL
Ib If mine the required shim s for both side
thicknessl bearings
the cotter pin hole is not correctly aligned a suitable washer
should be fitted Do NOT adjust by overtightening the pinion I OOcc Estate car
nul Left side bearing TI A C D H x 0 01 0 100 E
Van
I800cc Van
Left side bearingTI A C D H xO OI 0 175 E
Lubricate the front bearing with oil and place it in the
Right side bcaringT2 8 D H x 0 01 0 150 F
carrier Grease the lip of the oil seal and install it to the final
drive housing Install the drive pinion the new collapsible spacer As an example where A 1 B C 2 D 3 E 0 02mm
and the drive flange H I The formula for the left side bearing is T I I 1 3 1
x 0 01 0 175 0 02 0 205mm
Fit the drive pinion nut and tighten temporarily until all
slackness is eliminated from the front and rear of the drive 1400 and 1600cc Estate car
pinion The required thickness of shim can be found using the following
formula in a similar manner to that previously described for
NOTE Ensure that oil and grease have been completely
the 1800cc models
removed from the threads of the pinion gear the pinion
nut and the washer
Left side bearing T I A C D E 7
on the right side bearing housing of the gear carrier and on the TOOTH CONTACT PATTERN Checking
differential case These variations are marked in units of l lOOmm
and are used for the f rmula to calculate t1H thickness of the The final check on reassembly is an inspection of the tooth
adjusting shims in the following manner contact markings of the crownwhed and pinion
71
inter Q1Ju@
j1l J
Ikli l1t
J T
1
II ill 1
77
o
LU
4
I
r
uc J
N
0 L
I l lllL m h
l
Il lJr
I I
Dm hJtl
I wrllJ
l
O O 1 U
mu J
u
1iJ
Y
Fig JO
G Measuring the width of the side bearing
under load
Fig G 28 Location of the dummy shaft and
drive pinion setting gauge
Af
HEEL DRIVE
SIDE
HEEL COAST
SIDE
AHEEL
SlOE
DRIVE HEEL
SIDE
COAST
A
HEEL
SIDE
DRIVE HEEL
SIDE
COAST
TOE
TOE
A
HEEL DRIVE
SIDE
HEEL
SIDE
COAST
A
HEEL DRIVE
SIDE
HEEL
SIDE
COAST
72
increase the thickness of the drive pinion adjusting shim pattern showing the impressioll
A correct contact ithill
and washer to move the drive pinion closer to the crown wheel a of 2 3 to 4 of the distance bct h tip lllU till
l en t
range
root of the teeth under no load
Toe contact Fig 34
G
Technical Data
PROPELLER SHAFT
DRIVE PINION
sea
InitiJI turning torque without oil
Saloon modds 7 10 kg em 0 506 0 ftb
723I
Estate CJr models 10 13 kg em 0 723 0 940Ib
ft
73
J
CROWNWHEEL
out
Run at rear of crownwheel
DIFFERENTIAL GEARS
74
Rear Axle Rear SuspensIon
DESCRIPTION REAR AXLE SHAFTS BEARINGS AND SEALS Saloons
REAR AXLE AND SUSPENSION Removal Saloons DRNE SHAFTS
COIL SPRINGS Saloons REAR AXLE Removal Estate cars and Vans
REAR SHOCK ABSORBERS Saloons REAR SPRING Estate cars and Vans
REAR SUSPENSION ARM Saloons REAR SHOCK ABSORBERS Estate cars and Vans
with semi trailing armssuspension arms coil springs and Installation is a reversal of the removal procedures noting
the following points
telescopic hydraulic double acting shock absorbers The differ
ential gear carrier and suspension member is mounted directly
onto the body structure via rubber mountings See Fig H I Ensure that the suspension member and differential mount
are correctly aligned as shown in Fig 5 and insert
U
ing member
Estate cars and 1800 ce Vans are fitted with a semi floating the rubber insulators from the underside of the vehicle
rear axle with elliptic
semi leaf springs and telescopic hydraulic
shock absorbers mounted on rubrer bushes See Fig H 2 Tighten the differential mounting member the suspension
member and lower shock absorber nuts to the specified tighten
ing torques
REAR AXLE AND SUSPENSION Removal
Saloon models
COIL SPRINGS Removal
I Jack up the rear of the vehicle and support it on stands Saloons
2 Remove the road wheels disconnect the hand brake linkage Jack up the rear of the vehicle and support it on stands
4 Disconnect the brake hoses and plug the openings to prevent 3 Remove the drive shaft flange nuts at the wheel side Fig
the ingress of dirt H6 and the bump rubber securing nuts
5 Remove the propeller shaft assembly as described in the 4 Place ajack under the suspension ann and remove the
relevant section after marking the propeller rear flange shock absorber from the lower mounting bracket Carefully
and differential pinion flange lower the jack and remove the coil spring spring scat and
bump rubber Fig H7
6 Jack up the suspension ann and remove the shock absorber
lower mountings taking care not to lose the rubber
COIL SPRINGS Installation
bushings
Saloons
Examine all parts for wear and damage paying particular REAR SHOCK ABSORBERS Removal and Installation
attention to the rubber bushes in the suspension arms and the Saloons
75
inter T r
if
II 10 4 9
I
I w
I
s
A tf4
i I
7
J r
y
1Sl
2 8wpmsion arm
f
n1 I lilJ11
J 3 MountinK buuJDror
0
t J
I
4 DiffomtiDJ OIl1rtlnt insulaior
J CoU PinI
6 Bump rubber
7 Sf1TinI mzt
j
11 71
Iii I
8 S1tock absorber
9 I
Jmtlrtifi
3
I V 1
1
1
10 Differentli1l nlf
mount ober
II Differentitzl CtUTio
H I rear suspension Saloons A
Fig Independent
FJ8 4
H OIecking the mounting insulators
1DiffomtiDJ CtUTio
2 I1
R eazu
u I 1
3 L
l l Sf11inI
4 Shock abJOriJer
T 110 to lS m
Oq
l
0 80 to 108 lb J
ft
5
06 t iO iI
1Vt i
wn
t
T 1
j
1
u
a c 1 Front
J3 J
20mm
1200
1
111 mm
O 787 n
041 2
Q in1 T 7 0 to 10 0 m
q
i
CD 51 to 72 ft lb
n f I T 20 0 to 30 0 kg m
I J
0 1
J
145 to 217 fHb j
I I
410mm Di
I 16 1 n member
Om
T 7 0 to 10 q m
T 5lI072 ft Ib
Tilhtening torque
76
inter nDG O jlI
060001
sn
0 I
l
4
J
To
jY
l H 13 Removing the rear axle shaft H 14 the oil seaJ and inner
FI Fig Removing bearing
77
inter j @IP
Bearing housing
mark
u
1 Gmu
Dinancc piece mart
j
L2
fig l6
H Installing the suspension ann lee text
Fig H 15 Section the wheel hub
through
@
@ iW
jJ
I @ 8
iJ 1
I r
mrG
1JJNf
Apply in thi Fig H20 lhe rear axle shaft
grease Removing
Estate cars
JL I m
Fig B 21 Removing the locknuts and U Bolts
78
factory parts 6 Remove the grease retainer and withdraw the outer
bearing with a conventional puller DO NOT reuse this
Installation is a reversal of the removal procedure outer bearing
REAR SUSPENSION ARM Removal and Installation REAR AXLE SHAFTS BEARINGS AND SEALS Saloon
Saloon Assembly and Installation
I J ad up the car at the rear and support it on stands Oleck the axle shaft for straightness make sure that it is
not cracked or damaged in any way 00 NOT heat the shaft
2 Remove the road wheel and brake drum as described in if attempting to straighten
re Make sure that the lip of the oil
the section BRAKES seal is not damaged or distorted Check the bearing for excessive
wear and damage
The rubber bushes can be drawn out of the suspension arm Tighten the locknut to the specified torque reading of
if necessary using the special tool ST 38280000 Fig H Il 25 33 kgm 181 239 lb ft and check that the rear axle shaft
end play does not exceed 0 15 mm 0 006 in with a turning
O1eck the suspension arm for distortion or cracks and torque of less than 7 kg em 6 in
11b for the 1400 and 1600cc
inspect the rubber bushes for signs of wear or damage Renew models 510 series or 4 5 kg em 3 91b in for the 1800cc
any part which is unsatisfactory 610 series
Installation is a reversal of the removal procedure Tighten If the correct end play or turning torque cannot be
all the suspension arm mounting bolts with the weight of the obtained it will be necessary to change the distance piece See
vehicle resting on the rear wheels The self locking nuts must above
be renewed at each overhaul
body member
Remove the universal joint spider at the differential side
2 Remove the road wheel and brake drum Refer to the
propeller shaft section Remove the snap ring
securiilg the sleeve yoke plug and take out the plug Compress
3 Disconnect the drive shaft from the axle shaft and remove the drive shaft and remove the snap ring and stopper Fig H 17
the wheel bearing locknut The special wrench ST 38060001 Disconnect the boot and split the shaft Make sure that the
can be used to hold the flange as shownin Fig H 12 balls and spacers are retained
79
F
I lf ii
s
JlJJ
1J fi I
e
J c
a co
fo
Q
I
O 9 II EJl
00
c9 D j
H 23 Removing the shock absorb
Fig 10
attaclunent
R 0
tJ
j
fT 8 1Jo
jJ J
fI
fJ
o
SO
80
the steel balls and the sleeve yoke for damage or wear Renew REAR AXLE Assembly and Installation
the boots and the sleeve yoke plug 0 ring if necessary Renew Assembly is a reversal of the removal procedure noting the
the universal joint jf faulty following points
Check the play in the drive shaft using a dial gauge as
Thoroughly clean all parts and fit a new gasket between
shown in Fig H 18 The measurement taken with the le
dri the axle case and
gear carrier Tighten the nuts in a diagonal
shaft fully compressed should not exceed O lmm 0 004 in
pattern and to the specified torque readings
Renew the drive shaft as embly if the specified value is not
obtained Fit the grease catcher bearing spacer bearing and new
Oean the old grease from the sleeve yoke and the drive
bearing collar onto the axle shaft A load of 4 5 tons will be
shaft ball grooves and lubricate with oil required to press the bearing onto the shaft Insert the wheel
Asse bly of the drive shaft is a reversal of the dismantling bearing with the seal side facing the wheel and ensure that the
procedure noting the following points oil seal lips are coated with wheel bearing grease prior to fitting
Align the yokes and make sure that the steel balls and Check and adjust the axial play between the wheel bearing
spacers are fitted in the correct order Select a snap ring which and the axle housing using a dial gauge as shown in Fig H 22
will adjust the axial play of the universaIjoints to within 0 02mm The axial play should be adjusted to within 0 3 0 5mm
0 0008 in Snap rings are available in four thicknesses of 0 0118 0 0197 in on the 1400 and 1600cc models and to
149 152 1 55 and 1
58 mm 0 0587 0 0598 0 0610 within O lmm 0 0039 in on the 1800cc models
0 0622 in
Fill the rear axle with the specified amount of oil and
Apply a generous quantity of multi purpose grease to the
bleed and adjust the brake system as described in the appropriate
ball groove and the areashown in Fig H 19
section
REAR AXLE Removal See Fig H 2 REAR SPRING Removal and Inspection
Estate car and Van Estate cars aud Vans
I Jack up the vehicle at the rear and support it stands
on The rear springs can be removed in the following manner
4 Disconnect the handbrake rear cable from the balance Disconnect the shock absorber from the spring seat
lever assembly Fig H 21a and support the rear axle housing with ajack
5 Disconnect the propeller shaft from the differential flange
Release the lower shock absorber self locking nuts and 3 Take off the locknuts and remove the U bolts shown
slide the mounting eyes of the shock absorber from the arrowed in Fig H 2t the spring seat location plates and
rear spring seat pivot seat pads
6 Support the rear axle with ajack loosen the U bolts and
4 Remove the nuts securing the front bracket to the body
remove the nuts from the rear spring shackles Withdraw
remove the bracket from the spring eye and car body and
the shackles from the spring eyes
withdraw the rear spring
7 Remove the V bolt lock nuts completely and lower the
to withdraw the rear axle assembly
jack 5 Remove the upper and lower rear shackle nuts Fig H 23
REAR AXLE Dismailtling and Inspection and remove the rear spring from the vehicle
Remove both cross rod ends from the wheel cylinder lever
Check the front pin shackle U boIts and spring seat for
assembly
signs of
wear cracks and damaged threads Renew the
Unscrew the oil drain plug and drain the oil from the axle components as required
case into a clean container The oil may be re used if it is in REAR SPRING Installation
good condition Installation of thespring is a reversal of the removal
rear
81
REAR SHOCK ABSORBERS Replacing Check the shock absorber for leakage or cracks and make
Estate cars and Vans sure the shaft is straight Inspect the rubber bushings for
that
the spring seat Fig H 23 NOTE The weight of the vehicle must be resting on the fear
wheels when tightening the lower mounting to damp the rubber
Remove the shock absorber upper attachment nuts and bushes in an unloaded position
withdraw the shock absorber The upper attachment nuts are
located behind the Tear seat backrest as shown in Fig H 24
TechnICal Data
Type Independent suspension with trall I1g
semi arms or semi 1800cc Estate cars
35 mm1
3 78 in 584 lb
Piston diameter
40 mm 1 575 in
Piston diameter Hard suspension Spring eye bolt diameter
Stroke 206 mm 8 110 in Front 45 mm I 772 in
568 mm 362
22 in Rear 30 U81 in
Max length mm
SHOCK ABSORBERS
REAR AXLE SHAFT
Estate cars and Vans
less than 4 5 kg cm 3 91b
1400 and 1600cc estate cars and rigid axle sedan Turning torque
in
Piston diameter 2S mm 0 984 in
End play less than 0 1 S mm 0 006 in
Stroke 205 mm 8 071 in
Max length 518 mm 39 in
20 DRIVE SHAFT AND JOURNAL
Damping force at 0 3 in see
Sliding resistance 1400 and
Estate cars
1600 cc 0 15 kg 033 lib
Expansion 90 kg 4 lb
198
Sliding resistance 1800cc less than 20 kg 44 lb
Compression 50 kg 110 3 lb
82
Front SuspensIon
DESCRIPTION SPRING AND STRUT ASSEMBLY
WHEEL HUBS TRANSVERSE LINK AND LOWER BALL JOINT
WHEEL BEARINGS Adjusting FRONT WHEEL ALIGNMENT
FRONT AXLE AND SUSPENSION ASSEMBLY ADJUSTING THE STEERING ANGLE
DESCRIPTION nutwith grease and assemble the parts onto the wheel spindle
Make sure that dirt and foreign matter does not adhere to the
The front suspension is of the strut type with the coil greased surfaces
spring and hydraulic damper units mounted on the suspension
member and transverse link assembly See FigJ 1 Adjust the wheel bearings as described under the following
heading
Vertical movement of the suspension is controlled by
the strut assembly the tension rod absorbs the forward and
backward movement of the transverse links whilst side move WHEEL BEARINGS Adjusting
ment of the body is controlled by the stabilizer rod which is
attached to the body and transverse links The wheel bearings can be adjusted with the road wheel
the hub cap and the bearing locknut cotterpin removed as
previously described
WHEEL HUBS Removal
Tighten the wheel bearing locknut to a torque reading of
1 Jack up the vehicle remove the road wheel and disconnect 3 0 3 5 kgm 21 7 3lb
25 ft Turn the hub several times in
the brake hose at the strut outer casing bracket as each direction to settle the bearing and then retighten the
described under the previous heading Plug the opened end bearing locknut to the specified torque reading
of the hose to prevent loss of fluid
Slacken the bearing locknut to an angle between 40 to 700
2 Remove the brake calliper assembly or the brake drum a ayfrom the previously tightened position and align the cotter
as described in the section BRAKES pin hole with the hole in the spindle Turn the wheel hub a few
times in each direction and then measure the torque required
3 Remove the grease cap from the hub by tapping lightly at to cause the hub to turlI A spring balance should be used as
the joint using a screwdriver and hammer shown mRig J p make sure that the brake pads are not binding
on the disc type of brake unit and check that the force required
4 Withdraw the cotter pin from the wheel bearing locknut to turn the hub is within the following fIgures
and remove the nut Remove the wheel hub together with
the wheel bearing and washer Fig J 2
Wheel bearing rotation starting torque
On fitted with disc brakes the hub is removed complete
cars 1800ce With new bearing 7 0 kg cm 97 in oz
5 The wheel bearing outer race can be removed from the hub
using a drift as shown in Fig I
3 Starting torque at the hub bolt
The wheel bearing outer race can be refitted with a suitable Remove the road wheels and the splash board
drift or special tool ST 35310000
3 Disconnect the front brake hoses and remove the brake hose
Fill the wheel hub and the hub cap to the positions shown
locking springs Withdraw the plates and remove the hoses
in J 5 with multi purpose grease
Fig from the strut assembly Plug the ends of the hoses to
prevent the ingress of dirt and loss of fluid
Fill the spaces between the bearing rollers and the lip of
the grease seal with the same type of grease Lightly smear the 4 Remove the cotter pin from the tie rod ball joint remove
spindle shaft and threads the bearing washer and bearing lock
83
i1 W
u@
inter
CD
P
h
J
9 1
race
@ 1 Outerrace
ler
lW
@ @ 3 Small collm
4 Co 1m surface
5 nnu race
fitted 1UTfa
6 Inner surfaarace
@ I W
A
7
9
Outer race fitted surfacr
8 Outer race
l 1a Inner
Q
Jer olJing
Ro
ruTfa
surface
race
w Fig J 5 Front wheel hub greasing points
IJ wrgecolltu
@
12 Supporter
j
18 J 4 the wheel
Checking bearing assemblies
84
nter i
a 8
Fig
bolts
J l0 SuspensIOn cross member mounting
t
7
1
Fig J 12 View of the front suspension unit
9 Strut assembly
the strut
4 Upper s
7ing setJt
85
inteN j
GD @fPJ
2
l i
VDJ U
I
I
if
i
i Fig J 17 Removing the link bush
r
FiB J 16 Removing the transverse link
AI 0 1 O 039
mm n
I
r1 J
11
r
0
e f
86
the castle nut and detach the tie rod from the knuckle arm SPRING AND STRUT ASSEMBLY
Dismantling and Assembly
5 Remove the tension rod securing nuts Fig J 7 remove
the bolts and withdraw the tension rod Withdraw the nut Care must be taken when dismantling the assembly to
shown arrowed in FigJ 8 and remove the stabilizer ensurethat aU parts are maintained in a clean condition
6 Support the engine with suitable lifting tackle so that the Clamp the suspension strut assembly in a vice and fit the
specialattachment ST 2770000 I to the lower end of the strut
engine mounting bolts can be removed and the suspension
crossmember detached from the engine FigJ 9 Prise off the dust cover snap ring Use the coil spring compressor
ST 35650001 to slightly compress the spring Remove the self
7 Place ajack under the crossmember Remove the bolts locking nut and take off the mounting insulator thrust bearing
indicated in Fig J IO and separate the crossmember from spring seat and bump rubber Slacken the spring compressor and
the body remove the spring Push down the shock absorber piston until it
bottoms and remove the gland packing with the special tool
8 Remove the strut assembly upper attachment self locking ST 35500001 Fig J 14 Remove the O ring from the piston
nuts at both sides Fig Jll and lower the front suspension rod guide and lift out the piston rod and cy linder assembly
assembly to remove it from the vehicle 00 NOT separate the piston and cylinder which are serviced
as a complete assembly Drain all fluid from the suspension unit
and shock absorber assembly Wash all parts thoroughly not
FRONT AXLE AND SUSPENSION ASSEMBLY Installation rubber parts in petrol or a suitable solvent
Installation is a reversal of the removal procedure noting The gland packing and 0 ring must be renewed at each
the following points overhaul Always refill with the correct grade of fresh oil in
accordance with the information in the table below
Make sure that all rubber parts are free from wear and
deterioration Any part of the suspension assembly which has
ATSUGI KAYABA
been damaged or distorted must be replaced The front wheel
alignment should be checked after completing the installation Part No
a brief description is given at the end of this section Camber 54302 UO 100
and castor angles are preset and cannot be adjusted UOl10 325 cc 332 cc
54302 3 U0500 1
Jack up the front of the vehicle and support it on stands Position the coil spring bump rubber spring seat and dust
cover on the top of the piston rod The piston rod must be in
2 Disconnect the brake hose from the strut assembly bracket the fully extended position Compress the spring fit the strut
as previously described under the heading FRONT AXLE
mounting insulator and bearing assembly Tighten the self
and SUSPENSION ASSEMBLY Removal locking nut to a torque reading of 6 7 5 kgm 43 541b ft
3 Remove the stabilizer bar and tension rod from the trans
verse links Loosen and remove the knuckle arm fixing SPRING AND STRUT ASSEMBLY Installation
bolts Fig J 9 And separate the strut assembly from the
ball joints reversal of the removal
Installation is a procedure
Thoroughly grease the parts marked in Fig J
15 Tighten the
4 Remove the strut assembly upper attachment self locking
fixing bolts to the torque readings given in TIGHfENING
nuts Fig J 11 and withdraw the strut assembly from the TORQUES
body Fig J 13
Installation is a reversal of the removal procedure Ensure TRANSVERSE LINK AND LOWER BALL JOINT Removal
that the bolts are tightened to the specified torque readings
given under TIGHTENING TORQUES The transverse link with rubber bushing is connected to
the suspension crosSlTIember by a mounting bolt as shown in
Fig J 11 and to the strut assembly via the lower ball joint
87
Removal from the vehicle can be carried out in the following
manner
Install the lower ball joint on the transverse link and
tighten the installation bolt to a torque reading of 1 9 5kgm
Jack up the front of the vehicle and support it on stands
14 ft
18Ib
Lower the vehicle and remove the jack Tighten the trans
TRANSVERSE LINK AND LOWER BALL JOINT Inspection verse link mounting bolts to a torque reading of 9 0 10 0 kgm
65 72 Ib ft with the vehicle unladen
The transverse link bushing is shown in Fig J 18 If the
rubber and inner tube joints are melted or cracked the complete
transverse link assembly must be replaced
Fit the bushing into the transverse link using the special when the adjustment is completed
88
TechnICal Data
FRONT WHEEL ALIGNMENT
L R Drive exc
I for U S A Canada
2 Optional parts
89
COIL SPRINGS
Fitted height
Left side spring 185 mm
270 kg 7 29 in 560 lb
f
Right side spring 200 mm
270 kg 7 87 in560 lb
Parts No Items 54302 UO 100 54302 3 U0500 54302 UOI10 54302 3 U051O 54302 N 1200
Expansion kg Ib 40 88 2 176
80 4 40 88 2
Compression kg Ob 25 55 1 40 88 2 25 55 1
Stroke mm in 178 7 01
90
SteerIng
DEsn IPTION STEERING GEAR Assembly and Adjustment
S i EERlNG MaintenaDce COLLAPSIBLE STEERING
STEERING WHEEL AND STEERING GEAR COLLAPSIBLE STEERING Removal and Inspection
Removal and Installation COLLAPSIBLE STEERING Installation
STEERING GEAR Dismantling STEERING LINKAGE
STEERING GEAR Inspection and Adjustment
A collapsible steering column assembly can be fitted to the Installation is a reversal of the removal procedure When
vehicle to protect the driver from injury in a head on collision the installation has been completed make sure that the steering
Details of this type of assembly are given under the appropriate wheel can be turned smoothly and is correctly aligned The
free travel of the steering wheel should be between 2S 30mm
heading
0 9B 1 18 in Tighten the steering wheel locknut to a torque
reading of 4 0 5 0 kgm 29 36Ib ft and the steering column
upper clamp and plate bolts to a torque reading
STEERING Maintenance of 1
3 1 8 kgm
94 3 Ib ft
1
O1eck the oil level in the steering box every 10 000 km
6 000 miles and top up with recommended lubricant if Ensure that the steering box is topped up to the correct
level with recommended lubricant
necessary
Slacken the adjusting screw nut and turn the sector shaft
STEERING WHEEL AND STEERING GEAR Removal screw a few turns in the clockwise
anti direction
adjusting
1 Take out the retaining bolts and remove the horn ring Remove the sector shaft cover retaining bolts and pull the
remove the steering wheel nut Fig 3
K and pull off the sector shaft cover and sector shaft from the gear housing Fig
wheel The special tool ST 27180000 should be K 7
steering
used if available
Remove the bolts securing the column jacket to the gear
2 Disconnect the battery leads remove the steering column housing and carefully withdraw the main column jacket assembly
shell covers and the turn signal and lighting switch assembly from the gear housing Fig K B
3 On vehicles fitted with steering column gear change NOTE The ball must not be allowed to run to either end of
assemblies the gear lever must be removed from the the worm or the ends of the ball guides will be damaged
5 If the vehicle is fitted with steering column gear change worm bearings
remove the cotterpin from the trunnion and detach the
Remove the column shaft bearing
gearchange rod and selector rod from the change lever and
selector lever
91
inte rlliIl
E Pl
@
r
ill y AA
11
N @
l
E
@ @I
J Drop Urn
2 Centre rod
tie
1 K
Steeri whl fit
i J Outer tierod
2 Column clamp 4 Tie rod outer ocket
3 Steerinx column @ 5 Ti rod inner rocket
4 LoWfTmoun ins f
Jurge @ @ 6 ldkr arm
auembly
5 Rubber coupling
6 St
Fig K 2 The steering linkage component
ring galf
7 Drop arm
8 Centre tie rod
@
9 Outer tie rod
10 Idler ann Fig K l The steering system components
Fig K 3 Removing the steering wheel nut Fig KA Steering column upper attachment
bolts
FIg K S Steering column cover plate Fig K 6 Removing the steering gear mounting
bolts
92
STEERING GEAR Inspection and Adjustment STEERING GEAR Assembly and Adjustment
Thoroughly clean all parts and examine them for signs Grease the lip of the oil seal and press it into the housing
of wear ordamage Replace any comIK nent found to be un
satisfactory Insert the column assembly into the column jacket and fit
the worm bearing shims to the gear housing Install the flange
It is advisable to renew the assemblies if the steering column securing bolts and tighten them to a torque reading of 1 8
or ball nut assembly is defective as the adjustment procedures 2 5 kgm 13 18lb ft If a new column bearing assembly is
required to overhaul the units are rather involved fitted it must be filled with bearing grease and cemented to the
column
The dismantling and adjustment procedures for the ball
nut assembly can be carried out in the following manner if it is The preload of the worm bearing can be adjusted by
decided that overhaul procedures are to be carried out altering the thickness of the worm bearing shim Four shim
are available in sizes of 0 76 0 254 0 127 0 050mm
thicknesses
0 0300 0 100 0 005 in 0 002 in
Ball nut
This adjustment check is carried out without the sector
Remove the ball guide tube clamp withdraw the guide shaft fitted and with the worm bearings oiled
tubes from the ball nut and collect the steel balls
Install the steering wheel as shown in Fig K 9 use a spring
Turn the nut upside down and rotate the steering column balance as indicated to check that the force required to turn
the wheel is between 4 0 8 0 kg cm 56 l120z
inch
backwards and forwards until all 36 steel balls have dropped
out of the ball nut Pull the ball nut from the column Select a suitable shim from the sizes given
Inspect the ball guide tubes and make sure that they are Assemble the selector shaft adjuster with a shim into the
not damaged Pay particular attention to the ends of the tubes sector shaft Measure the end clearance of the adjuster with a
that pick up the balls from the helical path Renew the tubes if feeler gauge as shown in Fig K 1 O
they are unsatisfactory Check the steel balls and the ball nut
The correct clearance is 0 01 0 03mm 0 0004 O 0012in
for wear and replace the complete unit if necessary
and canbe adjusted by varying the thickness of shim Four
Assemble the ball nut on the worm with the ball guide thicknesses of shim are available as follows
holes upwards Drop 18 balls into each of the two holes on the
same side of the ball nut until all 36 balls are installed The 1 57 mm 0 0618 in
column should be gradually turned away from the hole being 155 mm 0 0610 in
filled and if the balls are stopped by the end of the column hold 1 52 mm 0 0598 in
down those already installed with a clean rod or punch while 1 50 mm 0 0591 in
Push the guide tubes into the ball nut guide holes and Temporarily lock the adjusting screw with the locknut
assemble the guide tube clamp Move the sector shaft several times from the pitman arm side
to make sure that it turns smoothly
Oteck the axial clearance between the ball nut and the
balls If the clearance exceeds 0 08 mrn 0 003 in the complete Adjust the backlash with the steering in the central
unit must be replaced Inspect the gear teeth of the sector position using a dial gauge as shown in Fig K II Turn the
shaft forwear or damage Replace any worn or imperfect adjusting screw with a screwdriver until the amount of free
movement at the top of the pitman arm is within O lmm
bearings Examine the steering column shaft for straightness
and check that the maximum deflection does not exceed 0 2mm 0 0039 in at a radius of 127 mm 5 0 in Lock the adjusting
0008 in at point C in Fig K 9 when the shaft is supported screw with the locknut Fig K 12 and recheck the free move
at points A and B Check the sector shaft and steering ment
93
ru If@fjV
inter
mtl
mm
ch 1 9685 in
fOJf f
1
8 K 13 The
F coUapsible steering assembly
1 Upper bmrins 7 Lower jacket tube
Fig K 12 Adjusting the steering gear h
baclda
2 UPIX jacket shaft 8 Lower jacket tu flange
3 Steeringpost clamp 9 Lower aring
4 Upper jacket tube J0 Rubber coupling B
5 Sled ball II blumn dU31 cover
6 1
LoWf jacket shaft
l7
2
h
6 5
I
J r
e j 1 i
I I Column cbmp
L1lI11L
T1
J II
tL L D DCr
111lllJl Block
L l
8 3
Fl K 14 The column clamp
94
the system operates smoothly 3 Remove the steering wheel nut using the special puller
ST 27180000 Eig K 15 Remove the column shell covers
Fig K 16 and the turn signal switch assembly
COLLAPSIBLE STEERING
Column shaft
The collapsible steering column is designed so that
compression occurs when the vehicle is involved in a on
head 4 Remove the cotter pin and detach the shift rod Automatic
collision See Fig K 13 Transmission Remove the bolt securing the worm shaft
and coupling Fig K 17
Two forces can be considered when a collision of this
type takes place These being the primary force in which the 5 Take out the bolts securing the column tube flange to the
forward motion of the car is suddenly halted and the secondary dash panel and the bolts securing the column clamp With
force as the driver continues in a forward direction onto the draw the steering column shaft towards the car interior
gear change levers dropping or leaning on the assembly can Take care not to damage the bearing Remove the plain
cause the column jacket to bend particularly at the bellows washer and spring from the upper shaft
part which absorbs the shock
Check the column bearings for damage and lack of smooth
The steering movement is transmitted by the lower shaft ness Apply multi purpose grease to the bearing if necessary
and upper tube The lower shaft exterior and upper tube Inspect the jacket tubes for signs of deformation renew the
interior are tightly fitted together with four plastic pins com tubes if necessary Check the dimension A in Fig K 1B to
pletely eliminating any gap make SUfe that the jacket has not been crushed Check the
dimension B Fig K 14
When a collision occurs the plastic pins shear and the lower
shaft enters the upper tube this action will cause the shaft end
to spread and the lower shaft cannot then be withdrawn unless COLLAPSffiLE STEERING Assembly and Installation
an extremely high load is applied
I Disconnect the battery earth cable Jack up the front of the vehicle and support it on stands
2 Disconnect the horn wiring and remove the horn pad 2 Remove the cotterpins and castle nuts fastening the tie rod
ball joints to the knuckle arms
95
inter imj rD f
1
r
1 j
A iJI1i
j
I
I I
Ii
K 16 Removing the column sheD covers
Fig
s
i
Fig l7
K Removing the rubber coupling
securing bolt
FIg K 15 Removing the steering wheel
I
I
1 Rubbt r coupling
2 column
Steen t
3 Worm 1
4 Dash ptmd
5 ColUmrl 3hDf
V c 6 Colliclamp
7 Lowtr jacket flangt
96
3 Free the ball studs from the knuckle arms by placing a
hammer behind the boss and striking the opposite side STEERING LINKAGE Assembly and Installation
with another hammer
Assembly is a reversal of the removal procedure noting
4 Remove the centre tie rod ball studs in a similar manner the following points
to that described above and remove the centre tie rod and
outer tie rods as an assembly To assembly the idler arm assembly coat the outer dia
meter of the bushing with soapy water and press the bushing
5 Remove the idler assembly from the side member by with into the idler arm until the bushing protrudes equally at both
drawing the retaining bolts sides
Fit the idler arm body in the rubber bushing Ensure that
SfEERING LINKAGE Dismantling the centre line of the idler arm is parallel with the centre line
of the chassis
Disconnect the tie rods from the centre rod Loosen the
clamp bolts unscrew the socket assembly and remove the Installation is
a reversal of the removal procedure The
socket from the tie rods Remove the idler arm nut and dismantle outer tie rods must be set so that the lengths between the ball
the idler assembly stud centres are 309 5 mm 12 18 in for the 1400 and 1600cc
models and 313 2 mm 33 in for the 1800cc models
12
Check the idler arm rubber bushing for signs of damage
or play and replace the bushing if
necessary Oteck the
wear
Tighten the ball stud nut to
torque reading of 5 5 7 6
a
centre and outer tie rod for damage or bending 39 8 55Ib ft the idler 5 7 6 kgm
kgm nut to
ann
TechnIcal Data
Steering type Worm and recirculating ball
Gear ratio 15 0 I
Steering angle
Inner wheel l800cc 370 380
Outer wheel 1800 cc 30040 32040
wheel
97
inter G @lfi
OIl
ll
V
1 Re rvoir azp
I
I Ji
A
f
tf
A1
r
Fig L 4 Section through the brake warning
light switch Fl L 5 View of the front drum brake
98
BrakIng System
DESCRIPTION REAR DRUM BRAKE Adjusting
MASTER CYLINDER Removal dismantling and Overhaul FRONT DISC BRAKE Friction pads
BRAKE LINES Replacing FRONT DISC BRAKE Removal and Dismantling
BRAKE WARNING LIGHT SWITCH FRONT DISC BRAKE Assembly and Installation
FRONT DRUM BRAKE Removal inspection and Overhaul HANDBRAKE Removal and Installation
REAR DRUM BRAKE Removal inspection and Overhaul BLEEDING THE HYDRAULIC SYSTEM
FRONT DRUM BRAKE Adjusting BRAKE PEDAL ADJUSTMENT
All brakes are hydraulically operated from the brake pedal Assembly of the master cylinder is a reversal of the
with the rear brakes additionally operated by a mechanical dismantling procedure noting the following points
handbrake and linkage system Either a single or a tandem
master cylinder can be fitted The tandem master cylinder Wet the cylinder bore and piston etc with brake fluid
provides a dual braking circuit in which the front and rear before assembling Care must be taken to prevent dust and
brakes are separately supplied If ODe circuit fails the other foreign matter entering the cylinder and reservoir Ensure that
circuit will still operate and provide a reduced but efficient cups and soals are not damaged when locating them
braking action
After the master cylinder is reinstalled the system must
The brake pipes are double wall steel tubes and are be bled and the pedal height adjusted as described under the
galvanized at the sections beneath the vehicle floor to prevent appropriate headings
corrosion
1 Remove the clevis pin and separate the brake pedal from Thoroughly clean the pipe or hose after removing from
the master cylinder push rod the vehicle and check for collapsing cracking or rusting of the
pipe and for signs of expansion and weakening of the hose
2 Disconnect the brake tubes from the master cylinder Any pipe or hose which is not in a satisfactory condition must
be renewed Remove any dust from the brake clip and replace
3 Remove the master cylinder mounting bolts withdraw the clip if the vinyl coating is torn
the shims and take out the master cylinder assembly
Installation is a reversal of the removal procedure Make
sure that the brake pipes cannot vibrate against any part of
MASfER CYLINDER Dismantling and Overhaul the vehicle and the brake hoses are not twisted and rubbing
against the tyres or suspension units If the brake hose is
Drain the brake fluid from the cylinder and remove the disconnected from the threeway connector on the rear axle
stopper bolt Remove the dust cover the snap ring the stopper housing it will be necessary to fit a new copper sealing washer
ring and the pusbrod assembly
Do not overtighten the installation flare nuts the correct
Take out the primary piston and secondary piston tightening torques are as follows
assemblies and the piston spring
Three way connector master cylinder and brake hoses
Remove the valve cap and take out the valve assembly 5 18 kgm II
1 ft
13Ib
Oean all the components with brake fluid and check them Fill the master cylinder with recommended fluid and bleed
for damage Make sure that the cylinder bore and
wear or the system as described under the appropriate heading Make
are not damaged or unevenly worn The clearance sure that fluid is notleaking from any part of the system by
piston
between cylinder and piston must not exceed 0 15mm 0 006 fully depressing the brake pedal for several seconds Check the
in pipes and connections and replace any defective part
99
inter Il IT Q
J
1 Brd be
2 Wllul cylinder bolts
J BridI pip
1 tzrc
ckp
BllIke 8 Return sprins
9 Air
2 RthUn spring JCrew
bleed
3 Brate 10 Lockp
orc
JlSkr
ad
4 Front brake h 11 tzrc
Lockp
5 12 Lockplizte
rottk
Anti pin
6 Lever 13 Dust cover
14 brake droe
Fig L9 Removing the rear wheel cylinder 7 Wheel cylinder t1T
Rt
1 BnrIce pip
2 Handblllke cable
J CIMJ pin
4 Lnu
5 1
DustCI1ft
3 Retum
11 L 12 The front brake shoe adjusting
4 A ntHuttle pin cams
100
BRAKE WARNING UGHT SWITCH Install the wheel cylinders on the brake backplate and
smear the cylinder backplate and cylinder lever fulcrum with
A hydraulically operated warning light switch is located grease Fig L8
in the engine compartment Fig LA
Tighten the backplate mounting bolts to a torque reading
The front and rear brake systems of the dual circuit are of 2 7 3 7 kgm 19 5 26 ft
71b
connected to the switch which provides a warning via the
warning light on the instrument panel when a pressure difference Adjust the brake shoes and bleed the hydraulic system as
of 13 17 kg sq cm 185 242Ib sq in occurs between the described under the appropriate headings
front and rear brake systems The switch cannot be repaired
and must be renewed if faulty
REAR DRUM BRAKE REMOVAL Fig L IO
FRONT DRUM BRAKE Removal Jack up the vehicle at the rear and support it on stands
Remove the road wheel
1 Jack up the front of the vehicle and support it on stands
2 Release the handbrake remove the clevis pin 3 from the
2 Remove the brake drum and the hub cap and hub assembly rearwheel cylinder lever 4 see Fig L 9 Disconnect the
handbrake cable 2 and remove the return spring I
3 Disconnect the brake pipe at the bracket on the front
suspension strut as previously described in the section 3 Remove the brake drum Remove the shoe retainers the
FRONT SUSPENSION springs and brake shoes Fig L II
return
4 Unhook the two return springs shown in Fig L5 and 4 Disconnect the fluid line from the wheel cylinders and plug
removethe brake shoes the opened end to prevent to loss of fluid
5 Disconnect the bridge pipe 3 in Fig L 6 and remove the 5 Remove the dust cover adjusting shims and plates then
two wheel cylinders removethe wheel cylinder from the backplate
6 Take out the installation bolts and withdraw the brake 6 The brake backplate and axle shaft assembly can be with
backplate from the spindle drawn if necessary by taking out the four flange bolts
and removing the assembly as described in the section
REAR AXLE AND REAR SUSPENSION
FRONT DRUM BRAKE Inspection and Overhaul
Examine the brake drums for scoring and out of round REAR DRUM BRAKE Inspection and Overhaul
The maximum permissible inner diameter of the drums must
not exceed 228 6mm 9 00 in and out of round should be The inspection and overhaul procedures fpr the rear drum
below 0 02mm 0 0008in brakes are similar to those previously described for the front
drum brakes
The brake shoe linings must re renewed when worn down
to thickness of 1 5mm 0 06 in or below Renew the
a Tighten the brake backplate mounting bolts to a torque
linings if they are contaminated in any way or incorrectly reading of 3 9 5 3 kgm 28 38Ib ft
seated The complete set of linings must be replaced if any
single lining is unsatisfactory
FRONT DRUM BRAKE Adjusting
O1eck the shoe return springs and if they have become
weakened replace them Jack up the vehicle and pump the brake pedal several times
With the brake drum installed turn one of the adjusting cams
Withdraw the pistons and springs from the wheel cylinders clockwise until the brake shoe is in contact with the drum
and inspect the bore of the cylinders for signs of wear This operation is carried out from the rear of the backplate
corrosion or damage
When the brake shoe contacts the drum turn the cam in
Renew the cylinder and the piston if the clearance between the opposite direction until the shoe is just clear and the brake
the two exceeds O 15mm 0 006 in Renew the rubber boots drum can be rotated freely by hand
and cups
Repeat the operation on the other adjusting cam and then
depress the brake pedal to make sure that the brakes are working
FRONT DRUM BRAKE Assembly and Installation correctly The adjusters must be released slightly if the brake
drum binds when turned by hand Fig L 12 shows the adjusting
Assembly and installation is a reversal of the removal and cams
Apply a thin layer of special grease to the piston cup and REAR DRUM BRAKE Adjusting
other rubber parts when assembling the wheel cylinder The
internal components of the cylinder should be dipped in brake Jack up the vehicle at the rear and pump the brake pedal
fluid and assembled whilst still wet several times Turn the brake shoe adjuster Fig L 13 until the
101
inter JiJ I
E
Al g
b5m
tt
s
td
t @
4 PiJton 11 Cylinder
5 Hold down pin 12 Tension spring
6S 13 Brake pad
7 Support bracket 14 MountinK bmcket
5
1 lOtpin
Pi
Top Saloons
Fig t6
L Moving the piston
FIg L 15 Removing the anti attle clip
J I
h
t
FJB LI7 Removing the brake pad Fig L IS Removing the brake calliper
102
brake shoe is in contact with the drum The adjuster must be 3 Remove the bolts securing the brake calliper to the
turned from the rear of the backplate and the drum turned by knuckle flange and remove the calliper assembly Fig L IS
hand
4 Remove the hub nut and withdraw the hub and disc
When the shoe contacts the drum turn the adjuster in
the opposite direction until the shoe is just clear and the drum To dismantle the calliper remove the anti rattle clip and
can be rotated freely by hand withdraw the brake pads Remove the tension springs and pull
the cylinder out of the calliper out
Blow the piston with com
Depress the brake pedal and make sure that the brakes pressed air applied at the brake hose connection
operate correctly The adjusters must be released slightly if the
brake shoe binds Oean the components in brake fluid and examine them
for signs of wear or damage
FRONT DISC BRAKE Friction pads Fig L 14 The cylinder walls can be carefully polished with fine
emery cloth if they are rusted or contaminated If the parts
The disc brakes are self adjusting but the friction pads are excessively corroded they should be renewed
To replace the friction pads proceed as follows Siphon Check the thickness of the friction pads as previously
out some of the fluid in the master cylinder reservoir Jack up described and replace them if necessary Renew the piston seals
the front of the vehicle and remove the road wheel and the dust covers
Remove the anti rattle clip from the calliper plate Fig L lS O1eck the brake disc for scoring and outof round The
standard disc thickness is 10 Omm 0 0394 in and must not
Unhook the hanger spring and withdraw the brake pads be reground below 8 4mm 0 3307 in
and shims Fig L 17
Check the disc run out with a dial gauge as shown in Fig
It should be noted that the friction pads must be replaced L 19 Position the gauge near the outer diameter and check that
as a set and renewed at both sides of the vehicle otherwise the the run out does not exceed 0 06mm 0 0024 in
braking action will be uneven
Oean the calliper and pad at their installation positions FRONT BRAKE DISC Assembly and Installation
Press the pistons into the calliper bores so that the new friction
can be installed The pistons can be installed by applying Rinse the cylinder bore with brake fluid and fit the piston
Pads
light pressure as shown in Fig L 16 but care must be taken to seal into the cylinder groove Fig L 20 Fit the wiper seal and
avoid pushing them too far or the groove of the piston will lightly grease the bore of the cylinder Clean the brake disc
damage the seal and fit it to the hub Install the hub to the knuckle spindle
If the pistons are pushed down excessively it will be Carefully insert the piston into the cylinder until the face
necessary to dismantle the calliper as described under the of the piston is almost flush with the wiper seal retainer The
appropriate heading relieved part of the piston should face the piston pin
Assemble the anti squeal shims to the friction pads with Fit the cylinder to the calliper plate and secure in position
the arrowmark on the shims pointing in the direction of with the two torsion springs Assemble the hold down pin
forward disc rotation the spring washer and the nut to the support bracket Secure
the nut with a cotter pin
Refit the pads and retaining pins and assemble the coil
spring to the retaining pin furthest away from the air bleed screw Assemble the calliper to the mounting bracket using the
pivot pin washer spring washer and nut Tighten the nut and
After installing the new pads and shims depress the brake secure with a cotter pin Hook the hold down bracket to the
to make
pedal several times to reposition the pistons in the calliper top of the mounting bracket and turn the calliper plate
O1eck the fluid level in the master cylinder reservoir and refill sure that it can slide smoothly Fit the calliper assembly to the
Fit a shim to the inner pad and insert the pad Draw the
FRONT DISC BRAKE Removal and Dismantling calliper towards the chassis and insert the lower cuts on the pad
into the mounting bracket and push the pad in until it contacts
1 Jack up the front of the vehicle remove the road wheel the piston Move the calliper away from the chassis and insert
and take out the friction pads the upper cuts Centre the indentation of the outer pad in the
calliper plate Fit the anti rattle clip Fig L 14
2 Disconnect the brake hose from the brake tube and plug
the opened end to prevent the loss of fluid
103
filll
inter l
@
Au y l ver
R H able
6c 1l
I Equaliler b2nd
Pl te
i b7ke
Iock band buk able I
I I
T @A Adjuster cable
s
SPd wm
oo
pm Odb k
LH able
C
Note
@ Apply bearing grease Fig L 19 Checking the brake disc for out
run
S
@APPIYch
cable frout N
nd brake
Clip
i
1
Saloons v
J
fti
1
I
Pull priDg
1
CltvU
v
Balance leve I
I r
1
l J c
1
I
1 J L
I
I
iL 8 Fig L 20 As
embling the seals and
Note
@ Apply engine oil retainer
piston
S
J
@ I
Rear cable
ti
L Fran able Aj
I r t f 7
n
A
i
J
4
Adjust position
104
Removal HANDBRAKE Installation
HANDBRAKE
The mechanical handbrake linkages are shown in Figs L 21 Check the cables for signs of deterioration fraying etc
1 22 and 1 23 Examine the handbrake lever and ratchet for wear and renew
as necessry
Release the hand brake and disconnect the front cable by that the balance lever and bushes are satisfactory
removing the clevis pin from the lever Unscrew the adjusting
Installation is a reversal of the removal procedure Make
nut from the rear of the front cable Fig L 24 Remove the
cable from the hand brake lever sure that all sliding parts are greased
Remove the clamp holding the cable to the under body Adjust the hand brake in the following manner
Pull out the lock plate holding the front cable to the retainer
Release the hand brake and adjust the rear brake shoes as
and completely withdraw the cable Withdraw the cable by
unfastening the outer casing which is pressed into the handbrake previously described
control bracket
The 1400 and 1600cc Saloon handbrake is adjusted to
the adjusting nuts Fig L24 The lever stroke on the estate
should be adjusted to 50 75mm 2 0 3 0 in by turning
Remove the clevis pin connecting the lever yoke and lever car
dashboard Pull out the lock pin and cotter pin and withdraw cylinder Bleeding should therefore be carried out in the follow
the handbrake lever assembly ing order Rear left wheel rear right wheel front left wheel
front right wheel
Front cable
area round the master cylinder cover take off
Oean the
Remove the return spring and loosen the adjuster 10cknuL the and top up the reservoir if necessary Clean the rele
cover
Detach the front cable from the handbrake lever Remove the vant air bleed screw and take off the cap
Unfasten the pull spring and remove the clevis pins at the Top up the fluid in the reservoir to the correct level but
balance lever and wheel sides Fig L 29 Detach the connecting do not re use the fluid previously withdrawn from the system
rod Remove the nut securing the connecting rod balance lever
and the lever from the rear axle housing
105
inter j iC@
V
J
6iIiIIlli Ii
I
r
Y
f
r
t
r
I 7 ei 7 I
I
1
10
i
L
@ i1 1
1
u
0
e
V V r
I
N
r
1i
clO
c
if1
I
JiY
t a
ll L 2S The handbrake
F mbly t
3
SatOOWl
ll L 28 Rear cable layout 1800 C c
F
ok pedat height H
Brake pedal p P
tJv
I
5 to 15 mm 0 2 to 0 6 ilL
r
y
i
J
f
I
I
I I
of
II
F
J 1400 and 1600 c c
Fig L 31 Brake pedal adjWltment
models
Ll
n
Push rod adjusting
l
scrt
W
2 Ptdlz stop
1
71 3 Brake Iilmp switch
i1
t 4 Clevis pin
Unit mfll
in
800
ll L30 AdjWltins the handbrake cable L 32 Brake models
c c
F Fig pedaladjWltment
Estate ClU1l
106
BRAKE PEDAL ADJUSTMENT
the pedal is pushed down by 15mm 0 06 in
The brake pedal height and free play can be adjusted in
the following manner 1400 and 1600 CC models 1800cc models
Adjust the length of the master cylinder push rod until the Adjust the bolt of the brake lamp switch until its end face
height of the pedal pad is 187 mm 7 36 in for manual gear is flush with the locknut then tighten the locknut securely
boxes and 202 mm 7 95in for automatic transmission vehicles See Fig L32 Adjust the pedal stopper until the pedal pad is
without brake light switch Fig L31 Retighten the locknut positioned at a height of 185 mrn 7 28 in from the floor
Screw in the brake light switch until the screwed part of the then tighten the stopper with the locknut Adjust the length
switch is against the front of the stopper bracket then tighten of the master cylinder push rod until a pedal free play of I 5mm
the locknut 0 04 D 2in is obtained then retighten the locknut
Screw in the stopper bolt until the moveable part of the Depress the brake pedal several times to make sure that a
switch is completely pushed in by the pedal and tighten the full travel of 145mm 5 7 in is available and that the pedal
locknut in this position Make sure that the lamp is 00 when moves freely and without noise
Technical Data
BRAKE PEDAL 2
Front disc 50 8mm 0in
Rear 22 2mm 7 8 in
Pedal height
1400 and 1600cc models I 87mm 7362in manual
gearbox BRAKE DRUM AND BRAKE DISC
202mm 7 953in auto
matic 9 0in
Drum inner diameter 228 6mm
1800cc models 185mm 7 28in
Drum outer diameter 232mm 9 13in
Full stroke 145mm 5 71 in Out of round maximum 0 05mm 0 002 in
Repair limit of drum 230mm 9 055 in
Maximum disc out
run 0 06mm 0 0024 in
MASTER CYUNDER 0 331 in
Repair limit of disc 4mm
8
Drum brakes
WHEEL BRAKE CYLINDERS
Width x thickness x length 40 x 4 5 x 219 5mm
1 575 x 1 772 x 8 642in
Inner diameter 1400 and 1600cc
Front drum 22 22mm 7 8in
Disc brakes 39 7 x 9 x 86mm
Front disc 50 8mm 2 0 in
1 563 x 0 354 x 386in
3
Rear with front drum 22 22mm 7 8in
Rear with front disc 20 64mm 16 in
13 Total braking area
Front drum brake 351 sq cn 4
54 sqin
Inner diameter I BOOcc
Front disc brake 114 2 sq cm 17 7 sqin
Front drum 20 6mm 13 16in Rear 351 sq cm 4
54 sq
in
107
8 j@W 2
interQ
m
tV
r ReJld cop level
th elk
I Thermal u e
Hydrometer
Q
ti iJ
I
II Qy@
I @ @
@
1 uJIner pin
u 13 PirUon srap collar
L
2 Drive mil Nack t 14 Pinion
108
ElectrIcal EquIpment
DESCRIPTION ALTERNATOR Assembly and Installation
BATTERY Maintenance HEADLAMPS Replacing
STARTER MOTOR Removal and Dismantling HORN
STARTER MOTOR Testing INSTRUMENT PANEL Removal
STARTER MOTOR Assembly and Installation WINDSCREEN WIPERS
ALTERNATOR Removal Dismantling and Inspection WINDSCREEN WASHERS
IGNITION SWITCH AND STEERING LOCK
regulator and pilot lamp relay are built in the regulator box temperature below 450C l130F during charging
which nonnally does not give trouble or require attention
Check the specific gravity after charging and if it is above
The starter motor is a brush type series wound motor in 1 260 at 200C 680C add distilled water
which positive meshing of the pinion and ring gear teeth are
secured by means of an overrunning clutch
STARTER MOTOR Removal and Dismantling
BATTERY Maintenance As previously stated the starter motor is brush type series
wound motor in which the positive meshing of the pinion and
The battery should be maintained in a clean and dry ring gear teeth are secured by an overrunning clutch The over
condition at all times or a current leakage may occur between running clutch employs a shift lever to slide the pinion into
the terminals If frequent topping up is required it is an mesh with the flywheel ring gear teeth when the starter is
indication of overcharging or deterioration of the battery operated
When refitting the cables clean them thoroughly and coat their
terminals and the terminal posts with petroleum jelly When the engine starts the lion
pL is permitted to overrun
the clutch and armature but is held in mesh until the shift lever
Check the level of the electrolyte in the battery at frequent is released An exploded view of the starter is shown in Fig M 2
intervals and top up if necessary to the level mark on the
battery case with distilled water A hydrometer test should be
carried out to determine the state of charge of the battery by To remove the starter motor proceed as follows
by 0 0007 when its temperature rises or falls by 10C 1 80F To dismantle the starter motor ftrst remove the brush
and lift out the brushes as shown in Fig 3
M
respectively cover
109
inter 0J
r jl @
@
J
1
FIg M 7 unning clutch assembly
Over Fig M 8 Checking the brush pring tension
m ILE
COMMUTATOR
0 5 to 0 8 mrtl
ROUND
O 0197 to 0 0315 nl SEGMENT
MICA
CORRECr INCORRECT
Fig lO
M Checking the armature shaft for out
run
I I
J
J
j
I L
j
5 1
SERIES COIL
y rl
5
wr
r SHUNT COIL
v
131 7 to
E
32 3mm
L
1
DIMENSION
248 to 1 272 in
10
stopper to the overrunning clutch side and removing the Solenoid assembly
stopper clip Remove the stopper and overrunning clutch as
shown inFig M 7 Inspect the solenoid contact surface and replace if showing
signs of wear or roughness Replace the pinion sleeve spring if
Oean the dismantled components and check them for weakened
wear or damage
Cbeck the brushes and renew them if worn below 6 5mm Check the series coil by connecting an 8 12 volt supply
0 257 in Fit new brushes if the brush contact is loose Cbeck between the Sand M terminals as shown in Fig M 13 The
the brush holders and spring clips and make sure that they are series coil is normal if the plunger operates
not bent or distorted The brushes should move freely in their
housings and can be eased with a file if necessary The brush Test the shunt coil by connecting the S terminal the M
spring tension should be approximately 0 8kg 1 76Ib and terminal and the solenoid body as shown in the lower illustration
can be checked with a spring balance as shown in Fig M S of Fig M 13 Open the M terminal when the plunger is operated
the shunt coil is satisfactory if the plunger stays in the operated
Armature assembly position
Make sure that the surface of the commutator is not Measure the length L between theylonger adjusting nut
rough pitted Oean and lightly polish with a No 500 emery
or and solenoid cover Press the plunger against a firm surface as
cloth if necessary If the commutator is badly worn or pitted shown in Fig M 14 and check that the dimension is within
it should be skimmed in a lathe only a light cut must be taken the figures given Turn the adjusting nut if necessary until the
to the minimum amount of metal If the commutator
remove required dimension is obtained
diameter limit of 0 2mm 0 OS in is exceeded the
wear
Cbnnect the tester to the yoke and field coil positive The alternator output can be checked with the alternator
teoninal as shown in Fig M 12 to check the field coils for in thevehicle by carrying out the following test Ensure that the
Inspect the metal bearing bushes for wear and side play Disconnect the negative lead from the battery and the two
The bushes must be renewed if the clearance between the bearing lead wires and connector from the alternator Slacken the alter
bush and armature shaft is in excess of 0 02mm 0 008 in nator mounting bolts and take off the fan belt Take out the
New bearing bushes must be pressed in so that they are flush mounting bolts and withdraw the alternator from the vehicle
with the end of the case and reamed ou t to give a clearance of
0 03 0 10 mm 0 0012 0 0039 in
III
H
inter E Q G2
I r0
E A
o c
3l
Battery
o
I I I
Voltmeter
@
S
1 PuOey assembly
2 Front CCJVU
3 Front bearing
4 Rotor
5 Rear betrrint
6 Stator
7 RetlTcoPO
8 8 h assembly
9 Diode ph
10 Diode COPO
it4
1ttDr
@
lOa
M lH the front and rear Fig M 19 Removing the rotor from me front
FJ8 Separating
covers cover
112
inteN Il1JIi OJaIlir
J
Pr drp
J
r 1
the diodes
Fig M 25 Inspecting positive
TERMINAL
OPLATE
113
inter 1
ill fl@
@ J
GJ
2mm O 07e7 in
l
r
HORN RELAY
oo
f
fI L IBGIGY
tt
FUS E BOX
20A
I
El Sl
te SWITCH
eATT RY
q
HO N r
M 29 R the headlamp Ied beam
Fig h FUSIBLE LINK IO e5 REO
iER
E
AMM HO to SA
HO N
SWITCH
1
VOLTMETER
I
115 to 2OV
I
114
The stator coil lead wires must be resoldered to the diode
ALTERNATOR Dismantling assembly terminal as quickly as possible or the diodes may be
and take off damaged When installing the diode A tenninal make sure that
Refening to Fig M 16 remove the pulley nut the insulating bushing and tube are correctly fitted
the pulley rim fan and spacer Withdraw the brush
holder
retaining screws and remove the brush holder cover Withdraw
The pulley nut should he tightened to a torque reading of
the holder and brushes as shown in Fig M 17
350 400 kg cm 301 344Ib
in Mount the assembly in a
viceas shown in Fig M 28 and when the pulley is tightened
Slacken and remove the three through bolts and separate
the diode housing from the drive end housing by tapping the make sure that the deflection of the pulley groove does not
exceed O 3mm m o 118 in
front bracket lightly with a wooden mallet Fig M 18
Remove the screws from the bearing retainer and separate the ilEA D LAMPS Replacing
rotor from the front cover Fig M 19 All weather type sealed beam headlamp units are fitted to
the vehicle Each lamp is of the double fIlament type with a
Remove the rear bearing from the rotor assembly with the
full beam filament of 50W and a dipped beam filament of 40W
aid of a puller as shown in Fig M 2D Take off the diode cover
and unsolder the three stator coil lead wires from the diode
The replacement of the sealed beam unit can be carried
terminal
out asfollows
Remove the A terminal nut and diode installation nut and
remove the diode assembly Do not force the diode assembly
Remove the wiring socket from the back of the headlamp
when removing or it may be damaged Remove the stator from
unit On Coupe models withdraw the screws attaching the
the rear cover
front grille to the radiator core support On all other models
ALTERNATOR Inspection remove the three retaining screws and remove the headlamp rim
renewed HORNS
Brushes
The instrument panel holds the various meters and
indicators A printed circuit board is located at the rear of the
Check the movement of the brushes in their holders The
brushes should move freely and can be eased in necessary by panel and the connections to it are multipolres
connect When
the panel is remove the instruments are easily withdrawn for
carefully ming the sides Oean the brush holders before replacing
inspection and servicing
the brushes Renew the brushes if they are worn below a length
of 7mm 0 275 in With the brush projecting approximately
Disconnect the battery negative terminal
2mm 0 08 in from the holder it is possible to measure the
brush spring pressure using a spring balance as shown in Fig M 27
2 Remove the windscreen wiper switch lighting switch and
The pressure of a new brush should be 255 345 grammes choke control knobs by pressing them in and turning
9 0 12 2 oz the pressure will however decrease by approxi
anticlockwise Remove the escutcheon
mately 20 grammes per I amm 0 039 in of wear
ALTERNATOR Assembly and Installation 3 Disconnect the cigarette lighter cable at the rear of the
instrument panel and turn the cigarette lighter outer case
115
inter @IP
FUSIBLE LINK
I
h J 00
IGNITION
VI
II BATTERY 03 Br SWITCH
WASHER MOTOR
FUSE BOX
I ILR IDA
0
rj
W ACC
lity
ILR
l P
X
I 2W
I
9P 111
W
r
LWI
9
t
l LR
j
Fig M 33 Removing the instrument panel
J
Fig M 36 Circuit diagram for the windshield wipers
and washer
Fig 34
M Wiper motor and linkage
1 Wiper arm
2 Pivot
3 Wiper ann
4 Pirot
5 WiTNr motor
116
4 Remove the shell covers from the steering column slacken The wiper arms can be removed quite easily by taking off
the screws securing the meter housing and withdraw the the attachment bolt as shown in Fig M J 5 and then pullin
panel from the facia Fig M 33 the wiper arm from the pivot shaft When installing the wiper
arm make sure that the blade is positioned approximately
5 Pull out the 12 pole round shaped connector and remove 27mm 1 06 in away from the bottom of the windscreen and
the speedometer cable union nut then remove the instru tighten the wiper arm attachment bolt
ment panel completely WINDSCREEN WASHERS
A twospeed wiper motor is fitted The motor has an auto operated by turning the switch in the appropriate direction It
should be pointed out that it is inadvisable to operate the washers
stop mechanism and drives the wiper arms through a link
for more than 30 seconds at a time If the washers are operated
mechanism located behind the instrument panel If the wiper
in short spells of approximately 10 seconds duration their
system does not operate check the fuses connectors control
switch and motor If the wiper speed does not change the working efficiency will remain unimpaired for a considerable
switch must be repaired or replaced If the wiper motor becomes length of time
unserviceable it can be removed from the vehicle in the fOllowing IGNITION SWITCH AND STEERING LOCK
manner
TechnICal Data
Battery 12 volt Oearance between pinion and
Starter motor 0 3 15mm 0 0118
stopper
Type HITACHI S114 87M 0 0591 in
Depth of nuca
Repair limit 0 2mm 0 008 in Slip ring
0 5 0 8mm 0 0197 Outer diameter 31 1 220 in
Repair accuracy mm
117
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SPE D SPE D SPE DS
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CRANK SLOWY OBUTES RBUTUNS
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aNL c y l i n d e r cylinder n
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COMPRESIN
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Faul iEfneoilt ohitck Mechani l Flult SY TEM Flult Clion Air Reltric on Poor Lclk nl Worn Wom Dam ced Incore tly CrI ked Broken
ENGIE ENGI E ENGIE ENGIE PERIODS ENGI E ENGI E ENGIE ENGIE AND ROUGH RUNS lACK PO R LACK EXCSIVE PINK G
In In
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CRANKS STARS MISARE MISflRE5 MISFRE MISAKES FAILS IDLE RUNS POWER TOP empty blocked Pll
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CI
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ENGINE ENGINE PERIODS ENGI E ENGI E ENGI E ENGI E AND ROUGH ENGI E LACK PO R LACK EXCSIVE PINK G BACKFIRE
OF OF leak
Fuel Fu Fuel Air Fuel Wile C Ail Aif
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15
TIghtenIng Torques
ENGINE LIB engines Three speed geabox
Mainshafl
Ll4 and L16 engines Four speed gearbox
Final drive to suspension member 6 7 kgm 43 510
4 ft
Ib
Rearexlension to case bolts 16 2 5 kgm 12 ft
18Ib
Gearbox to engine 2 5 4 0 kgm 18 ft
29Ib Final drive to drive shafls 6 kgm 36 431b ft
5
Final drive flange to propeller shaft 16 2 4 kgm 12 17 Ib ft
Bottnm cnver L1 1 8 kgm 8 13 Ib ft
Fronl cover L1 1 8 kgm 8 13 IbJI Final drive flange to propeller
shaft Eslale 16 4 kgm l2
2 ft
17Ib
Drain plug 3 5 5 0 kgm 25 3 36 2
f
Ib
Reverse lamp switch 2 4 kgm 14 5 28 9IbJt drive flange to propeller
Mainshaft nut 9 11 kgm 65 1 79 ft
5Ib Final
shaft l800cc 610 only 2 0 2 7 kgm
ft
5
14 19 5 lb
129
REAR AXLE AND REAR SUSPENSION
Tension rod to frame 4 5 5 5 kgm 33 40Ib ft
Rear wheel bearing nut 25 33 kgm 181 239 IbJt Tension rod to transverse link 4 9 3 kgm
6 4 45 6
35
Brake backplate 7 3 7 kgm 19 5 26 8 lb Ib ft
ft Strut assembly upper nuts 3 9 5 2 kgm 28 2 37 6
1400 1600 Shock absorber Ib fr
upper mounting 3 kgm l6 61b ft
3 kgm 16 6 Ih ft Steering lever to strut 8 kgm 43
6 581b ft
Shock absorber lower mounting
Ball joint to transverse link 19 5 kgm 14 fL
18Ib
1800cc Shock absorber mountings 16 2 2 kgm 12 ft
161b
Ball joint to knuckle ann 5 5 7 6 kgm 40 55Ib ft
Drive shaft to differential nuts 5 6 kgm 36 2 ft
4341b
Piston rod nut 67 5 kgm 43 54Ib ft
Drive shaft to rear axle flange 6 kgm
5 36 2 4lb
43 ft
Gland packing 7 13 kgm 51 94Ib ft
Bump rubber nuts 2 8
4 0 kgm 2029 Ib ft
Bump rubber nuts 180Occ 1 6 2 2 kgm 12 16 Ib ft
STEERING
Wheel nuts 8 9 kgm 58 651b ft
Rear suspension member
1400 and 1600 CC models
mounting nuts 10 kgm 72 Ib ft
Flange mounting bolts 18 2 5 kgm 13 18Ib ft
Bali stud nut 5 7 6 kgm 40 55Ib ft
Differential member
Gear ann nut 12 5 14 0 kgm 90 101 lb
mounting nuts 8 5 kgm 615Ib ft
ft
Idler ann nut 5 5 7 6 kgm 40 55Ib ft
Suspension arm to
nuts 10 kgm 58 72 Ib ft Adjusting screw nut 18 5 kgm 13
2 18Ib ft
suspension member
Steering gear mounting bolts 10 kgm 72 Ib ft
Idler arm bolts 4 4 6 1 kgm 32 44Ib ft
Differential to differential
member 6 8 kgm 43 581b fl
1800cc models 610 Body
Propeller shaft flange nuts 4 08 5 kgm 62 Ib
29 ft
Gear ann nut 14 kgm lOllb ft
Propeller shaft flange nuts I800cc 2 0 2 7 kgm 14 201b fl
Rear cover bolts L5 2 5 kgm II 18Ib ft
Sector shaft cover 15 2 5 kgm II 18Ib ft
Differential to suspension member 68 kgm 43 58Ib ft
Sector shaft adjusting screw
locknut 2 0 2 5 kgm 5
14 18Ib ft
Steering gear mounting bolts 6 8 kgm 4
43 57 8Ib ft
1800cc Estate car and Van 610 Body
Steering linkage
Shock absorber upper mounting 0 9 1 2 kgm 5 8 7Ih fl
6
Idler arm to frame 4 6 1 kgm 32 44Ib ft
Shock absorber lower mounting 3 5 4 5 kgm 25 33Ib ft
Ball stud nuts 5 7 6 kgm 40 55Ib ft
Rear spring U bolt clip 6 0 5 kgm
6 47 Ib ft
43
Side rod locknuts 44 6 1 kgm 32 44lb ft
Shackle spring 6 0 6 5 kgm 43 47Ib ft
5 kgm 43 47Ib ft
6
Spring front pin 6 0
Column shaft
Brake back plate
Estate car 22 2 7 kgm 16 20IbJt Steering wheel nut 4 5 kgm 29 36 Ib ft
Column clamp 3 18 kgm 9 4 13 0 lb
1
Van L5 2 0 kgm II 14 Ib ft
Differential gear carrier ft
ft
18Ib COll piing worm shaft 4 5 kgm 29 36Ib ft
to axle case 2 0 2 5 kgm 14
Coupling mounting bolts L5 2 2 kgm II 16Ib ft
Propeller shaft flange 20 2 7kgm 14 20Ib ft
130
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Contents
INTRODUCTION SI
G 18 ENGINE S2
FUEL SYSTEM SI7
FRONT SUSPENSION STEERING S22
BRAKING SYSTEM S30
TIGhlGJ u
GTORQUES S36
IntroductIon
This supplement has been added to include Series 30
C
model with the G 18 engine
parent sections
SI
interl lli f@
j
0
11
Engine installation 2 5 mm
0 0787 0 1969 n l
Engine nstatlstion 8 15 mm
0 3150 0 5906
1 i
1 11
Fig A 3 Ying
Remo the canuohaft sprocket
Fig 1
A Front mounting insulator
A J A L
0
I
unted
Ii o o
r
i 1
gf
6 mm 10 2362 1
t
Vi more than if
6 mrn 0 2362 in
m
0
1
r t
t
l I IJ l
o
4
A Removing the cylinder head
Rear mounting insulator Fig
Fig A 2
52
GIS EngIne
DESCRIYfION OIL PUMP
ENGINE Removal and Installation OIL PRESSURE RELIEF VALVE
ENGINE MOUNTING INSULATORS OIL FILTER
ENGINE Dismantling Inspection and Overhaul EMISSION CONTROL SYSTEM
CHAMSHAFT AND CAMSHAFT BEARINGS IGNITION TIMING AND IDLING SPEED
CYLINDER BLOCK Emission control system
PISTONS EMISSION CONTROL SYSTEM Maintenance
CONNECTING RODS IGNITION SYSTEM
CRANKSHAFT IGNITION TIMING
ENGINE IGNITION DISTRIBUTOR Maintenance
Assembling
VALVE CLEARANCE SPARKING PLUGS
Adjusting
the bonnet from the vehicle Position a jack under the oil sump Make sure that the
jack is clear of the drain plug and insert a wooden block between
3 Remove the blow by hose from the rocker cover and take
the jack and sump to prevent the sump from being damaged
off the air cleaner
Remove the bolts securing the insulator to the front suspension
Disconnect the accelerator linkage and choke cable from member and the nut attaching the insulator to the engine
4
the carburettor mounting bracket Raise the jack slightly and remove the
insulator To remove the rear mounting insulator proceed as
S Detach the upper and lower radiator hoses remove the follows
two brackets from the core support and lift the radia tor
Position a jack to take the weight of the gearbox and take
away from the vehicle The torque convertor oil pipes must
out the bolts connecting the insulator to the transmission rear
be disconnected from the oil cooler if the vehicle is equip
extension housing Remove the bolts attaching the cross member
ped with automatic transmission Detach the fuel pipe if
to the underside of the body and withdraw the insulator
fitted from the engine and heater hose
Installation of both insulators is a reversal of the removal
6 Disconnect the electrical wires from the alternator thennal
procedures
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01 v
35 v 0 d
1
3101 1
b 380g 3
3
a
g
340
e 410 8
Fig 5
A Removing the oil pump sprocket
Fig A 6 g the valve seats
Lm
y PILOT BEARING
c
L
x
l
A S
AB10 11 1 I
I
t
1
a n
Fig 7 Measuring the ctankshaft journals and crankpins
A Fig A g Removing the main drive shaft pilot hearing
16mm
0236 in
PILOT BEARING
Apply grease
Fig A 9 Fitting the main drive shaftpilot hearing Fig A 11 Camshaft and camshaft bracket alignment marl
s
IIWI
e No a
ton front r
i
IRScIItIonOlrllole
or tM
rocbr ft
j
kImIII roa lIfIaft oiIl
OIM
1or nshclwn in tM In
fil
54
ENGINE Dismantling Keep the parts together so they can be installed in their original
order
Remove the engine from the vehicle as previously described
and carefully clean the exterior surfaces The alternator distribu ENGINE Inspection and Overhaul
tor and starter motor should be removed before
washing Plug Cylinder head and valves
the carhurettor air horn to prevent the ingress of foreign matter
Place the engine and transmission on the engine carrier ST4797 Inspection and overhaul procedures can be carried out by
0000 if available and dismantle as follows following the instructions previously given for the L14 LI6
and LIB engines noting the following points
Remove the gearbox from the engine Disconnect the intake
manifold water hose the vacuum hose and the intake manifold Measure the joint face of the cylinder head using a straight
tooil separator hose Remove the intake manifold with the edge and feeler gauge The permissible amount of distortion is
carburettor Fit the engine attachment ST3720OG18 to the cylin 0 03 mm 0 0012 in or less The surface of the head must be
der block and place tre engine on the stand ST371 00000 reground if the maximum limit of 0 1 mm 0 0039 in is
exceeded
Remove the clutch @Ssembly as described in the section
CLUTCH Remove the exhaust manifold and heat baffle plate Oean each valve by washing in petrol then carefully examine
Take off the fan blades and remove the water pump pulley and the stems and heads Discard any valves with worn or damaged
fan belt Remove the rocker cover hose manifold heat hose and stems Use a micrometer to check the diameter of the stems
which should be 8 0 mm 315
0 in for both intake and exhaust
by pass hoses
valves If the seating face of the valve is excessively burned
Remove the generator bracket and the oil fIlter Extract the damaged or distorted the valve must be discarded The valve
engine breather assembly from above Note that the breather seating face and valve tipcan be refaced if necessary but only
is fitted to the guide and is installed with a O ring which is the minimum amount of metal should be removed Check the
pressed into the cylinder block free length and tension of each valve spring and compare the
figures obtained with those given in Technical Data at the end
Flatten the 10ckwasher and unscrew the crankshaft pulley
of this section Use a square to check the springs for deformation
nut Withdraw the pulley with the puller ST44820000 if available
and replace any spring with a deflection of 16 mm 0 0630 in
but do not hook it in the V groove of the pulley
or more
Remove the cylinder head bolts in reverse order to the 0 00160 0030 in for the exhaust valves The maximum clear
ance limit is 0 1 mm 0 0039 in The valve guides are held in
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 position with an interference fit of 0 0 069 mm 0 0016
040
0 0027 in and can be removed using a press and valve guide
ten cylinder head bolts there
are also two bolts securing the
can be reassembled in their original positions 150 and 600 cutters for the intake valve inserts and 150 cutter
for the exhaust valve inserts Seat correction dimensions are
Remove the camshaft rocker ann shaft and rocker ann shown in millimeters in Fig A 6
assemblies from the head by taking off the cam bracket clamp
ingnuts It is advisable to insert disused bolts in the No 1 and Lap each valve into its seat after correcting the seat inserts
No 5 bracket holes as the cam bracket will fall from the rocker Place a small quantity of fme grinding paste on the seating face
ann shaft when it is removed Remove the valve cotters using of the valve and lap in as previously described for the Ll4 LI6
the special tool ST47450000 and dismantle the valve assemblies and L 18 engines
S5
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7 5 2 4 10
56
CAMSHAFT AND CAMSHAFT BEARINGS Side clearance in grooves
Check the camshaft bearing and journals for signs of wear Standard
Plastigage should be used to check the clearance between bear Top ring 0 040 08 mm 0 0016
0031 in
ing and journal which should be 0 025 0 075 mm O OOl Second ring 0 02 0 06 mm 0 0008 0 0024 in
0 0030 in The cylinder head assembly must be renewed if the Oil ring 0 02 0 06 mm 0 0008 0 0024 in
wear limit of 0 mm 0 0039 in is exceeded Limit
Top ring LO mm 0 0039 in
Place the camshaft in V blocks and apply a dial gauge
Second ring LO mm 0 0039 in
tothe centre journal to check the amount of camshaft bend
Oil ring LO mm 0 0039 in
The run out of the camshaft must not exceed 0 03 mm 0 0012
in It should be noted that the actual run out will be half the Piston ring gap
value indicated on the dial gauge when the camshaft is turned
one full revolution Check the camshaft end play which should Standard
be within 0 07 0 148 mm 0 0028 0 0058 in Top ring 35
0 55 mm 0 01 38
0 D 021 7 in
Second ring 0
3 5 mm 0 0138 0 0197 in
Check the earn contacting surfaces of the valve rocker and Oil ring 35
0 55 mm oJ38
O 0217 in
the earn heels of the camshaft Slight damage can be corrected
Limit
using a fine oil stone It is advisable at this stage to check the Top ring LO mm 0 0394 in
clearance of the rocker shaft and rocker bushes which should be Second ring LO mm 0 0394 in
0 016 0 052 mm 0 0006 0 0020 in The parts must be renewed
Oil ring LO mm 0 0394 in
if the wear limit of 0 07 mm 0 0028 in is exceeded
is exceeded Check the connecting rods for bends or twists using a suit
able connecting rod aligner The maximum deviation should not
Check the cylinder bores for wear out of round and exceed 0 05 mm 0 0020 in per 100 mm 3 94 in of rod
excessive taper Use a bore gauge to take readings at the top Straighten or replace any rod which does not comply with the
middle and bottom positions of the bore as previously described specified limit When renewing a rod make sure that the weight
The standard bore diameters are 85 000 mm 0 0 mm
035 difference between new and old rods in within 6 gr 212 oz
347
3 0 00140 in with a wear limit of 0 2 mm 0 0079 in
Out of round and taper must not exceed 0 02 mm 0 0008 in Install the connecting rods with bearings to the correspond
If any of the bores are worn or in excess of the specified limit ing crank pins and check that the end play of the big ends is
then all bores must be rebored at the same time between 0 100 246 mm 0 0043 0 0097 in Replace the
appropriate rod if the maximum limit of 0 3 mm 0 0118 in
Pistons are available in five oversizes and should be selected is exceeded
in accordance with the amount of wear of the cylinder Refer
to the instructions given for the Ll4 L16 and L18 engines and CRANKSHAFT Inspection and Overhaul
select pistons from the table below
Clean the crankshaft thoroughly and check the journals
PISTON SIZE OUTER DIAMETER and crankpins for taper and out of round Use a micrometer to
Standard 84 958 84 990 mm 345
3 346
3 in measure the journals and crankpins at the positions shown in
250 5 85 220 85 240 mm 3 355 3356 in Fig A 7 It will be necessary to regrind the crankshaft if the
500 5 470
85 490
85 mm 365
3 366
3 in specified limit of 0 03 mm 0 0012 in is exceeded and then
750 S 85720 85 740 mm 375
3 33
76 in fit the appropriate undersize bearings Place the crankshaft in
1000 S 85 970 85 990 3846
3 3854
3 in V blocks as described for the L14 L16 and LIB
mm engines and
1250 S 86 22086 240 394
3 395
3 in
mm apply a dial gauge to the centre journal to check that the bend
limit of 0 05 mm 0 0020 in is not exceeded The actual bend
Cylinder liners be fitted if the bores areworn beyond
can
value will be half the reading obtained on the gauge Install the
the maximum limit Undersize liners are available with outer crankshaft in the cylinder block and check the crankshaft end
diam ters of 89 091 89 126 mm 3 507 3 509 in and inner float which should be 0 060 0 192 mm 0 00240 0076 in
diameters of 83 5 84 5 mm 3 287 3 327 in The liners are centre shims if the specified figure is exceeded
Replace the
an interference fit in the block and must be rebored after Make sure that the main drive shaft pilot bearing at the rear of
fitting the crankshaft is not worn or damaged in any way Remove the
bearing if necessary using the special tool ST49700000 as
PISTONS shown in Fig A 8 Clean the bearing hole oil the outer side of
Checking
the new bearing and use a drift as shown in Fig A 9 to drive
Oteck the pistons for signs of seizure and wear measure it into the hole Insert 2 grams 0 07 oz of multi purpose grease
the side clearance of the rings in the ring grooves and check the into the hole as illustrated
piston ring gaps as previously described for the L14 Ll6 and
Ll8 engines Compare the figures obtained with those given in Main bearing clearance
the tables opposite
Check the main bearing clearances as described for the
Ll4 Ll6 and Ll8 engines The Plastigage should be placed so
57
inter j
ill j2
@
J
CA SPROCKET
TIMING MARK
AOJUSTING SCREW
CHAIN TENSIONER
OIL JET
CHA N GU DE
CRANK SPROCKET
Fi3 17
A TiminS Jsm
Ai m
Jjr
I
rtIuNtor
c t
1 II
uum
Y
ing Ii
I I Antl b
cktire
I ChedC
58
that it is clear of the oil hole Install the bearing caps and Heat the piston to a temperature of 500 to 600 1220 to
tighten the bolts to a torque reading of 10 01 LO kgm 72 3 1400F and press the gudgeon pin in by hand The pistons and
79 51b ft connecting rods must be assembled as shown in Fig A 12 with
the arrow mark on the head of the piston pointing to the front
The standard main bearing clearance is 0 03 0 06 mm of the engine
0 0012 0 0024 in with a wear limit of 0 1 mm 0 0039 in
If the specified limit is exceeded an undersize bearing must be Fit new clips to both ends of the gudgeon pins as indicated
fitted and the crankshaft journal ground accordingly Bearings in Fig A 13 Fit the piston rings with the marks facing upwards
are available in four undersizes See Technical Data Place the bearings on the connecting rods and caps making sure
that the backs of the bearing shells are perfectly clean
Connecting rod bearing clearance
Assembling the engine
Check the connecting rod bearing clearances in a similar
manner to the main bearing clearances The standard clearance Insert the oilscal into the grooves of the cylinder block
is 0 03 0 06 mm 0 0 0024 in
0012 with a wear limit of 0 1 and rear bearing cap Fit the seal down with the speCial tool
mm 0 0039 in Undersize bearings must be fitted and the ST49750000 if available as shown in Fig A 14 and trim off
crankpins reground if the specified limit is exceeded Bearings the excess with a knife Apply sealing agent to the oil plug and
are available in four undersizes See Technical Data install it in the cylinder block
Fit the main bearings lubricate with clean engine oil and
Fitting the crankshaft bearings
install the crankshaft Fit the bearing caps and tighten the bolts
to a torque reading of 10 0 to I LO kgm 3 to 79 5 Ib ft
72
Check the fit of the bearing shells in the following manner
Install the bearings on the main bearing caps and cylinder block Note that liquid packing should be applied to the rear bear
bearing recess and tighten the cap bolts to the specified torque ing capsurfaces as shown in Fig A 15
reading of 10 0 11 0 kgm 72 3 79 5 Ib ft Slacken one of the
cap baits and check the clearance between the cap and cylinder Fit the thrust washers at both sides of the No 2 bearing
block with a feeler gauge as described for the L14 Ll6 and with the oil channel in the washers facing the thrust face of the
LIS engines The bearing crush should be from 0 to 0 04 mm crankshaft Install the rear bearing cap side seal so that is projects
0 to 0 0016 in 0 2 to 0 6 mm 0 008 to 0 024 in from the lower surface of
the cylind r block then apply liquid packing to the projecting
Replace the bearing if the clearance is not correct
tip
Check the connecting rod bearings in a similar manner Install the engine rear plate Fit the flywheel and tighten
after tightening the rod cap bolts to a torque reading of the bolts to a lorque reading of 10 0 to 11 0 kgm 3 to 79 5
72
5 5 0 kgm 32 636 2 Ib ft
4 ib ft using new lock washers
Install the connecting rod caps o that the marks face the
Install the valve spring seats and valves Fit the oil seal
same way and tighten the bolts to a torque reading of 4 5 to
rings on the valve stems and place the seal ring coversover the
5 0 kgm 32 6 to 36 2 Ib ft Bend the lock washers as shown
oil seal rings Note that a gap of from 0 3 to 0 7 mm 0 0118
in FigA16
to 0 0276 in should be present between the seal ring cover and
spring seat If the gap is less than 0 3 mm 0 0118 in the oil Fit the oil jet to the front of the cylinder block Install
seal ring or the cover must be replaced Assemble the valve the chain tensioner and stopper crankshaft sprocket and timing
springs and retainers Compress the valve springs and install the chain
cotters See instructions for the LI4 U6 and Ll8 engines
Assemble the camshaft brackets valve rockers seats spacers Note that the timing mark on the chain must be aligned
and springs on the rocker shafts in the order shown in Fig A l O with the mark on the sprocket as shown in Fig A 17
Note that the exhaust rocker shaft has identification marks but
Smear the mounting face of the oil pump with sealing agent
the intake rocker shaft has not Make sure that the oil holes
Three Bond No 4 or equivalent install the pump and tempora
point in the direction shown It may be advisable to insert any
convenient bolts into the bolt holes of the front and rear cam rily tighten the mounting bolts Adjust the tension of the oil
shaft brackets to prevent the assembly from being displaced pump chain using the pin as the central point then tighten the
mounting bolts
Mount the camshaft on the head fit the rocker assembly
Install the oil thrower Fit the chain cover into position
and tighten the nuts Make sure that the mark on the flange of after coating the new cover gasket with sealing compound Cut
the camshaft is aligned with the arrow mark on the No I earn
off the projecting parts of the gasket
shaft bracket as shown in Fig A II
Fit the crankshaft pulley and tighten the pulley nut to a
Pistons and connecting rods to 20 0 kgm 108 5 to 144 61b ft Bend
torque reading of 15 0
the lock washer Install the oil strainer and oil pump
Assemble the pistons gudgeon pins and connecting rods
Invert the engine and set the No I piston to T D C of the
in accordance with the cylinder numbers
compression stroke Note that the notch on the crankshaft
S9
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CarbUretor
JJ
ir cleaner
F
I
Control aln
Oil pan Ialiable
orifice alve
DiIIchqe
w
Bal Ifttrkion
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orif
I
510
pulley should be aligned with the T mark on the chain cover OIL PUMP
Install the cylinder head assembly Coat the cylinder block The gear type oil pump is chain driven from a sprocket on
side of the head gasket with sealing agent Three Bond No 4 the crankshaft The pump can be removed in the following manner
or equivalent but take care that the scaling agent does not
enter the cylinders 1 Remove the sump plug and drain the engine oil Remove
the distributor as described in the section IGNITION
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 2 Remove the cylinder head assembly fan belt crankshaft
sequence shown in Fig A IB pulley and oil sump
Pull the timing chain out of the chain cover and set it on 3 Take off the chain cover with oil fl inger
the camshaft sprocket so that the timing marks are aligned then
4 Remove the oil pump and crankshaft sprockets with the
place the sprocket and chain on the camshaft
drive chain then withdraw the pump after removing the
Install the distributor drive gear on the camshaft and four mounting bolts
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 Separate the cover from the body by unscrewing the four
securing bolts and withdraw the drive and idler gear
Adjust the valve clearances as described under the appro assemblies Unscrew the threaded plug and take out the
relief valve and spring
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 Clean the parts thoroughly and inspect them four signs
Install the chain adjusting screw and adjust the tension of wear or damage Check the following clearances
0 0039 in
of bolts together using wire inserted through the holes provided
Clearance between
in the bolts
idler gear and idler shaft 0 016 to 0 1 mm 0 0006 to
Install the oil filter and fit the rocker cover hose Install 0 0039 in
the distributor so that the vacuum control unit and rotor arc
positioned as shown in Fig A 19 Assembly is a reversal of the dismantling procedures taking
care toposition the gears so that the dotted mark is towards the
Oil the distributor driven gear Fit the breather assembly cover
and exhaust valves with the engine warmed up to its normal always be renewed after dismantling the filter
operating temperature
S 1
Renew the ruter element at 10 000 km 6000 miles inter to the exhaust system during the flrstpredetennined period
vals Dismantling is a straight forward operation Remove the of cleration and prevents back firing from occuring
dCl
plug from the cover and withdraw the washer spring and by pass To check valve is located between the air pump and air
valve Check the free length and compressed length of the by pass
injection nozzle and is fitted to prevent a backflow of exhaust
valve spring and renew if necessary The free length of the spring
gases from entering the system The valve doses when the
should be 54 5 to 56 0 mm 2 14 to 2 20 in and the compressed
exhaust manifold pressure exceeds air injection pressure as It
length 49 0 mm 193 in
will at high speed or if the pump drive belt fails
Positive Crankcase Ventilation System The following tests should be carried out to make sure that
the exhaust emission control system is operating correctly The
lbis system returns the blow by gases to the intake mani engine must be at normal operating temperature to perfonn the
fold and the carburettor air cleaner see A 22 Under part
Fig tests Before the system can be tested the engine itself must be
throttle conditions the intake manifold draws the gases through checked to ensure that It is functioning correctly Disconnect
a variable orifice valve Control valve into the combustion the ant backflTe valve sensing hose and insert a plug into the
chambers Ventilating air is then drawn from the carburettor hose to close the passage to the intake manifold Make sure that
air cleaner and passes throygh a tube in to the crankcase
the engine operates normally and then reconnect the parts
the gases flow tluough the tube to the air cleaner in the reverse
direction The gases are therefore retained or burnt to lessen Run the engine until it reaches its nonnal operating tem
the risk of air pollution pemture and check all hoses and connectors for signs of leakage
Servicing and testing Disconnect the air supply hose from the check valve and
check the position of the plate inside the valve body The plate
Once a year or every 20 000 km 12 000 miles the Posi should be lightly positioned against the valve seat and away from
tive Crankcase Ventilation System should be serviced as follows the air distributor manifold Insert a suitable probe into the
valve and depress the plate When released the plate should
Check all hoses and connectors for signs or leakage Discon return to its position against the valve seat
freely
nectthe hoses and blow through them with compressed air to
make sure they are not blocked Fit a new hose if air cannot Leave the hose disconnected and start the engine Slowly
be forced through increase the engine speed to 1500 r p m and examine the valve
to make sure that the exhaust gases are not leaking The valve
The Nissan Air Injection System comprises an air cleaner system does not backfire Further test can be made with the by
pass hose to the air pump suction line disconnected from the
belt driven air injection pump check valve anti backfIre valve
valve
and the related connecting tubes and hoses The sealed pump is
driven by the engine and injects clean mtered air into the exhaust Open and close the throttle valve rapidly Hold a fInger
combines with unbumt gases
port of each cylinder The clean air over the valve outlet and check that air flows for between a
are expelled into the exhaust manifolds and reduces the half and one second If air does not flow or alternatively if it
asthey
emissions to below the permissible level required by air pollution flows continuously for more than two seconds the valve is
laws faulty and must be renewed
A modified carburettor and distributor is fitted with this Disconnect the vacuum sensing hose from the valve Insert
type of system The air injection system is shown in Fig A 23 a suitable plug securely into the hose The valve is not functioning
correctly if the idling speed now differs excessively from the
The anti backfrre valve is controlled by intake manifoLd speed at which the engine operated with the hose connected
vacuum and is fitted to prevent the exhaust system from back
Testing the air pump
fIring during deceleration When decelerating the mixture in
the intake manifold is too rich to bum and ignites as it combines
Special tools are required to test the air pump The vehicle
with air injected by the pump The valve shuts off the air delivered
should therefore be taken to an Approved Agent capable of
SI2
carryingout extensive tests with the necessary equipment The necessary as described under the heading IGNITION
hoses and connectors can of course be checked for signs of TIMING AND IDLING SPEED in this section
leakage and corrected as necessary Also the tension of the air
2 Check the distributor earn dwell angle and also the condi
pump belt
tion of the contact breaker points Check the ignition
IGNITION TIMING AND IDLING SPEED timing and adjust if necessary The distributor dwell angle
Emission control system should be adjusted to 49 55 degrees and the points gap to
45
0 0 55 mm 0 0177 0 0217 in
The ignition timing should be set and the idling speed
3 Remove and clean the sparking plugs Renew any plug with
mixture adjusted in the folloWing manner
badly worn electrodes Set the plug gaps to 0 80
0 90 mm
Run the engine until it reaches its normal operating tem 0 0315 0 0355 in by adjusting the earth electrode
NOTE If the vehicle is equipped with automatic transmission The maintenance and servicing procedures for the compo
make surethat the dashpot does not prevent the throttle from nents of the ignition system on vehicles fitted with the GIS
closing Turn the throttle shaft arm adjusting screw anti clock engine are basically similar to the instructions previously given
wise so that the tip of the screw is clear of the throttle shaft for the Ll4 LI6 and LIS engines The distributor is however
arm see Fig A 26 of a different type Either an Hitachi 041657 distributor being
fitted or an Hitachi 0423 53 if the vehicle is equipped with an
Turn the throttle adjusting screw to set the idling speed to
emission control system The distributors have different advance
700 r p m 650 rpm for automatic transmission Adjust the
curve characteristics as shown in Technical Data
ignition timing to 5 A T D C Refererence should be made to
the instructions given in the section IGNITION SYSTEM for
IGNITION TIMING
the L14 L16 and LI8 engines for ignition timing details
Turn the idling adjustment screw and throttle adjusting screw
Check the ignition timing with a timing light as previously
until the engine runs smoothly a t the correct idling speed Turn
described for the LI4 L16 and L 8 engines Disconnect the
the idling adjustment screw clockwise until the engine speed
distributor vacuum line and run engine at idling speed or
starts todrop as a weaker mix ture is obtained Now turn the
one and a
slightly below The timing should be set at 8 BTDCj600 rpm
idling adjustment screw clockwise
anti by one turn
for the D416 57 distributor or at 5 ATDCj600 rpm for the
half turns for automatic transmission to obtain a richer mix
D423 53 distributor fItted to engines with emission control
ture
systems
Adjust the idling speed to 700 rpm 650 rpm for automatic
transmission by turning the throttle adjusting screw Make sure IGNITION DISTRIBUTOR Maintenance
that the ignition timing remains at 50 A T D C
Maintenance instructions are similar to those given for
Turn the throttle shaft ann clockwise until
adjusting screw the L14 LI6 and L18 engines Set the contact breaker points
the tip of the screw just contacts the throttle shaft ann The gap to 045 0 55 mm 0 0177 0 0217 in as previously
screw must not exert pressure on the throttle shaft arm described
The system should be inspected and serviced every I 2 The sparking plugs should be inspected and cleaned at
months or 20 000 km 12 000 miles whichever comes fIrst to regular intervals and renewed at approximately 20 000 kIn
make sure that the exhaust emissions are maintained at the 12 000 miles Clean the plugs thoroughly and make sure they
minimum level are of the same type and heat range File the centre electrode
nat before adjusting the gap Set the gap to 0 8 0 9mm 0 031
Check the carburettor choke setting and adjust as described 0 035 in if the engine is fItted with emission control system
in the section FUEL SYSTEM to 0 028
or 0 7 0 8 mm 0 031 in if emission control is not
fitted Adjustment must always be made by bending the earth
Check the carburettor idling speed mixture and adjust if
electrode
TechnIcal Data
GENERAL SPECIFICATION GI8 Engine LIQUID PACKING APPLICATION
S13
4 Cylinder head gasket 6 Oil pump
a Valve mechanism
Ex 0 04 0 077 mm
0 0016 0 0030 in
0 0016 0 0027 in
1 474 1 475 in
S14
Camshaft bend 0 1 mm 0 0004 in
c Connecting rod
S T D 485
2 2 505 mm 55 971 55 990 mm
0 0978 0 0986 in 2 2036 2 2043 in
SI5
Crank shaf bend Less than 0 02 mm 0 0008 in
e Piston
0 0016 0 0031 in
Second 0 02 0 06 mm
0 0008 0 0024 in
Oil 0 02 0 06 mm
0 0008 0 0024 in
0 0138 0 0217 in
Second 0 3 0 5 mm
0 0118 0 0197 in
Oil 0 35 0 55 mm
0 0138 0 0217 in
0 8659 0 8664 in
EMISSION CONTROL
S16
Fan coupling Fan rpm water pump rpm 3 300 Centrifugal
4 000
Pulley ratiofan and water Start 550 rp m
DISTRIBUTOR
IGNITION COIL
Type Hitachi D416 57
Hitachi D423 53 with emission
Type Hanshin HM 12F or HP5 I OE
control system
with emission control system
Firing order 134 2
Rotation Anti clockwise
Primary voltage 12 volts
Igntion timing than 6 mm 0 2362 in
80 B T D C at 600 rpm Spark gap more
Without emission control
Primary resistance 3 8 ohms at 200C
With emission control 50 A T D C at 600 rp m
Secondary resistance I1
2 I 6 8 ohms at 200 C
Dwell angle 49 to 55 degreos
Condenser capacity 0 20 0 1 F
24
SPARKING PLUGS
Advance characteristics
D41657 distributor
Type NGK BP 6E
0 7 0 8 mm 0 028 0 031 in or
Gap
0 80 9 mm 0 0 035 in
031
with emission control system
Fuel Systenl
DESCRIPTION
FUEL PUMP Testing
FUEL PUMP Removing and Dismantling
CARBURETTOR Idling adjustment
FUEL LEVEL Adjusting
STARTING INTERLOCK VALVE OPENING
THROTTLE VALVE INTERLOCK OPENING
CARBURETIOR Removing and Dismantling
DESCRIPTION
A dual barrel down draught type carburettor is fitted to primary system for normal running and a secondary system
for full load running a float assembly which supplies fuel to
vehicles with the G 18 engine A Stromberg type D3034C carburet
tor is installed on engines with exhaust emission controL and a both primary and secondary systems a starting mechanism and
Solex type DAK340 carburettor on engines not equipped with accelerator pump which provides a richer mixture on accelera
SI7
I IL
A It l
o
1 l o
Cfd
rj
1 j
111
11
D 1 1 I
l
r J l
b
l
i
1 j
I
j
n
w
I
UJ 1
j
I 1
1 F700 t vahle 20 Step jet
e 2 Vacuum piJton 21 Pump plunger
tOll i t2JZ2
j25z 21
3 P Slow air bleed 22 Inlet k l
c1r aIve
4 Slow jtt 23 S Mizin jet
5 Slow 24
T
onomUt uaun
lRtzp
1 S Mizin nozzk 14 PAfuin nozzle 6 P Slowair bleM 25 lRtzplrragm
2 S SmtzJJ v
nturi 15 Economizer bleed 7 Air Fent 26 Step port
3 S Main air bleed 16 PSlow jet 8 PMain air bl d 27 Idle port
4 S Slow jet 17 Slow onomiur 9 P MiJin nozzle 28 P T1vottk valve
5 S Slow air bleed 18 PSlow air bleed 10 P SmaU venturi 29 Idk port
6 Needle WIlve 19 e
Airlnt 1J Ozokt valPe
30 Dw
S port
7 Float 20 Lnel gauge 12 Pumpnozzk 31 Idkadjust screw
8 S Emulsion tube 21 13
PMainjel Pump wd6h1 32 PMiIin jet
9 S Mainjd 22 Idle limitler valve
14 Discharft check 33 NUjet
Po
10 S hol
JlypaD 23 1dl 15 S SnwU venturi 34 Float
11 S Throttle alve 24 P Jly pa hol 17 S Main air bleed
12 Chob I1tzhe 2S P Throttle vahe 18 Step air bleed
13 P Main air bleed
19 Pump arm
Fig B l Sectional view of the DAK340 carburettor B2 Sectional view of the D3034C carburet tor
Fig
fitted to engines with emission control 5Y5tem
Coil
I
Ul
l
Piiton
2
Strainer
1 Fibre mat
v Nvlon 6
cero
Fig 3
S Electrical fuel pump Fig 4
B Fuel strainer Fig Ii s Removing the fuel pump cover
SI8
The type D3034C carburettor has certain additional features Dismantle as follows
These include a power valve mechanism to improve the performance
Slacken the locking band screws and remove the strainer
at high speed a fuel cut off valve which cuts the fuel supply
strainer spring filter strainer seal and locking band
when the ignition key is turned to the off position and an
idling Remove the snap ring Withdraw the four screws from the
limiter to maintain the emissions below a certain level
yoke and remove the electromagnetic ulJ it Press the
Sectional views of the two types of pumps are shown in plunger down and withdraw the inlet vaive the packing
and the cylinder and plunger assembly
Figs 8 1 and B 2 An EP 3 electrical fuel pump is located in the
centre of the spare wheel housing in the boot Fig 3 shows a
B
A defective eledrical unit cannot be dismantled as it is
sectional view of the pump with its contact the pump mechanisms
sealed and must be renewed as a complete unit
solenoid relay and built in filter
FUEL PUMP Inspection and Assembly
The air cleaner uses a viscous paper type element which
should be replaced every 40 000 km 24 000 miles Cleaning
Wash the strainer filter and gasket in petrol and dry using
is not required and should not be attempted
compressed air Renew the filter and gasket if necessary Note
The cartridge type fuel strainer incorporates a fibre clement that the filter should be cleaned every 40 000 km 24 000
which should be renewed at inervals not exceeding 40 000 km miles Wash the plunger piston and inlet valve in petrol and
24 000 miles Fit B 4 shows a sectional view of the assembly make surethe piston moves smoothly in the cylinder Replace
The fuel lines should not be disconnected from the strainer when the parts if found to be defective
the fuel tank is full unless absolutely necessary as the strainer
is below the fuel level Insert the plunger assembly into the cylinder of the electri
cal unit and move the assembly up and down to make sure that
FUEL PUMP the contacts are operated If the contacts do not operate the
Testing
electrical unit is faulty and must be renewed
quantity of fuel when testing Hold the end of the hose above the The D3034C carburettor fitted to engines equipped with
level of the pump and operate the pump for more than IS
an emission control system must be adjusted as described under
seconds to check the delivery capacity The capacity should be
the heading IGNITION TIMING AND IDLING SPEED in the
I 400 cc 3 24 U S pts in one minute or less The pump must section EMISSION CONTROL SYSTEM
be removed from the vehicle if it does not operate or if a
reduced quantity of fuel flows from the end of the hose Remove Reference should be made to carburettor idling adjustment
the pump from the vehicle and test as follows procedures for the L14 L16 and LI8 engines when adjusting
ted by sparking at the tenninals If current flows the trouble is The clearance H between valve stem and float seat should
caused by a sticking pump plunger or piston The pump must be I 5 mm 0 0059 in with the float fully lifted Adjustment
be dismantled in this case and the parts thoroughly cleaned in can be carried out by carefully bending the float stopper 3
petrol
FUEL lEVEL Adjustment D3034Ccarburettnr
If the current does not flow a coil or lead wire is broken
and the pump must be renewed A reduced fuel flow is caused The fuel level should correspond with the level gauge line
by a faulty pump inlet or discharged valve blocked filter
or Adjustment can be carried out if necessary by changing the
mesh The pump must of course be dismantled and serviced as gaskets between the float chamber body and needle valve seat
necessary The gaskets are shown as item 4 in Fig B 7 When correctly
adjusted there should be a clearance of approximately 7 mm
FUEL PUMP Removing and Dismantling 0 027 in between float and chamber as indicated
Remove the bolts attaching the fuel pump cover to the STARTING INTERLOCK VALVE OPENING
S19
Onter 2
1
J I
I
I
f r
1 F10at
2
1 SelllC
Float Float WJlve ltat
2 F10aI 3 Float valJ1e
3 Ffotzt T
toppt 4 AcJiwtiflK tpsket
4 m
Nudk 5 Stopper
1 11
J Xi I
J
t
I
I
3
J
tf
J
Th
1 Chokemr
r 2 m
Otoke
3 Conn ting rod
LuL 4 Connectinlla o
5 TIuottle lever
l
I
1
L
4 J L 5
520
between primary throttle valve and the wall of the throttle the diaphragm chamber and gasket Take off the float chamber
chamber can be adjusted if necessary by carefully bending the cover and remove the gasket level gauge rubber seal and float
choke connecting rod 3
Remove the screw from the filter and withdraw the nipple
THROTILE VALVE INTERLOCK OPENING and filter Remove the needle valve Take off the cylinder
cover and pump cover and withdraw the piston piston return
With the primary throttle valve of the type DAK340 spring and inlet valve Remove the primary main air bleed the
carburettor opened to 600 as shown in Fig B 9 the adjusting secondary main air bleed and emulsion tube Take off the
plate 3 should contact the connecting lever J This being small venturi and remove the primary and secondary slow jets
the point before the secondary throttle valve is brough into and slow air bleeds Remove the drain plugs and take out the
operation The linkage between primary and secondary throttles primary and secondary main jets
is working correctly if the clearance G between primary throttle
To dismantle the throttle chamber remove the throttle
valve and the wall of the chamber is 738 mm 3937
0 in
adjusting screw and spring and the idling adjusting screw and
Adjust if necessary by carefully bending the adjusting plate at
spring Withdraw the throttle lever spring hanger sleeve
point A until the correct setting is obtained
connecting lever return plate and adjusting plate Withdraw
the primary throttle valve and primary throttle shaft Withdraw
With the primary throttle valve of the type D3034C car
the secondary throttle valve and secondary throttle shaft
burettor opened at an angle of 500 the connecting link 3 in
FigB IO should ge at the extreme left of the slot in the throttle The type D3034C carburettor can be dismantled as follows
ann 4 With the linkage positioned as shown measure the
Detach the starting connecting rod from the choke lever and
clearance between primary throttle valve and the wall of the
accelerator pump connecting rod
chamber as described for the DAK340 carburettor Adjustment
can be made if necessary by bending the connecting link until Remove the air horn pump rod slow jets the primary and
the correct clearance is obtained
secondary small venturies Detach the primary and secondary
linkages Take off the diaphragm chambe cover and take out
CARBURElTOR Removing and Dismantling the spring and diaphragm Remove the diaphragm chamber and
gasket Separate the float chamber from the throttle chamber
The carburettor can be removed by following the instruc take off the float chamber cover and remove the components
tions previously given for carburettor removal on the Ll4 L16 Remove the inlet strainer and float valve seat Remove the main
and LIB engines jets and take off the fuel cut off valve
Dismantle the type DAK340 carburettor as follows CARBURETTOR Assembly and Installation
Remove the primary throttle return spring Take off the
The assembly and installation of the carburettor is a
E ring and remove the pump and connecting rod Remove the
reversal of the dismantling and removal procedures
split pin and choke connecting rod Remove the secondary
throttle return spring Remove the choke wire arm choke valve Clean and inspect all components as described for the
shaft and valve spring Take off the clip and remove the choke
carburettors fitted to the Ll4 Ll6 and LI8 engines
lever and spring To dismantle the float chamber take off the
diaphragm cover and remove the spring and diaphragm Remove
TechnIcal Data
CARBURETIOR Small ven turi
52
inter j
M@W
J
r
i
r p
I
2
J
Steering column maft
rCOfl linK
Rubb
4 Sturing lower joint
5 Strinuotlr IwusUr8
6 Sid rod
@
XlI
y y
v
I Ii
1 1
iQ
I
I
t
th
f41 I
I
t
t
Il
k
the front hub and brake disc Fig C 6 Detaching the brake disc
Fig C 5 Removing
522
Accelerator pump Emission control system
Piston diameter 14 0 mm 0 551 in
Pump discharge Air pump bracket to cylinder
Outer hole position 0 2 cc per stroke head nut 16 2 kgm I1 6 17 4Ib ft
4
0 4 per stroke Adjusting bar to bracket bolt
Middle hole position cc 16 4 kgm I1 6 17 4Ib ft
2
Inner hole position 0 6 cc perstroke Air pump to bracket bolt 16 4 kgm I1 6 17 4 lb ft
2
Pump nozzle diameter 0 5 mm 0 020 in Air pump to adjusting bar
Main nozzle diameter nut 16 4 kgm
2 116 17 4Ib ft
Primary 2
3 mm 0 0906 in Anti backfrre bracket to rocker
Secondary 2 8 mm 110
0 in cover 4Q
0 0 65 kgm 2 7 lb ft
94
Anti backfire valve to bracket 0 4Q 65 kgm
O 2 94 7 lb ft
Throttle valve fully closed angle Sensing hose clamp to rocker
Primary 10 degrees cover 4Q 0 65 kgm 2 M 7 Ib ft
0
Secondary 20 Air gallery to exhaust manifold
degrees
5 degrees approx plug 5 Q6 0 kgm 36 4lb
243 ft
Idling opening
Check valve to air gallery 9 0 5 kgm
10 65 1 75 9Ib ft
Choke valve fully closed angle 10 degrees
Throttle opening at full choke 13 5 degrees
FUEL PUMP
Type Electric
1400 in one minute
Delivery cc
Suspension member
Front wheel alignment
Steering wheel and column
Rack and pinion and tierod
Collapsible steering
The front suspension is of the strut type with the coil STEERING Maintenance
spring and hydraulic damper units mounted on the crossmember
and transverse link assembly See Fig C I Vertical movement The steering system should be lubricated every two years
of the suspension is controlled by the strut assembly Forward or 50 000 km 30 000 miles whichever comes fIrst
and rearward movement is absorbed by compression rods 6
and side movement controlled by the transverse links Front A lithium base multipurpose grease must be used for the
suspension servicing procedures are similar to those given for rack and pinion and rack and tie rod joints The plug on the
vehicle fitted with L14 Ll6 and LIB engines and can be carried steering gear housing should be removed and a grease nipple
out by reference to the instructions given in the appropriate fitted so that the recommended quantity of 10 to 15 gram
section Camber and castor angles are preset and cannot be 35 to 0 53 oz of grease can be injected Remove the grease
0
adjusted and a check must be made for signs of damage to the nipple and replace the plug when lubrication is completed
suspension system if the angles do not confonn to the figures The grease reservoir on the tube side should be replenished when
given in Technical Data the level of grease falls to approximately one third ofits capacity
The steering is of the direct acting rack and pinion type WHEEL HUB AND BEARING Removal and Installation
See C 2 A rubber coupling which absorbs vibration and
Fig
two universal join ts are incorpora ted between the steering wheel Wheel hub and bearing servicing procedures are similar to
and gear assembly The collapsible type of steering column those previously given for vehicles fitted with L14 LI6 and LIB
assembly Fig C3 is an optional fitting A full description of engines
S23
inter lm j1l
@
i
Iii FRONT
l
REAR
il I I I
link bush
strut mounting insulator
524
Remove the road wheel and disconnect the brake hose at A grease nipple must be installed in
place of the ball joint
the connector as shown in Fig C4 of this section plug so that the joint can be lubricated with multi purpose grease
as
previously described
Remove the brake calliper assembly and hub cap Withdraw
the cotter pin and remove the wheel bearing locknut SUSPENSION MEMBER Removing and Installing
Remove the wheel bearing washer and take off the hub
Jack up the vehicle and support it on stands
and brake disc Fig C5 Remove the bearing collar take out
the outer bearing cage and prise out the hub grease seal Remove
2 Remove the splash board Refer to Fig C I 0 and detach
the inner bearing cage and drive out the outer races of the inner the compression rod I the stabilizer 2 from the trans
and outer bearings using the special drift ST49120000 if avail
verse link 3 Detach the steering linkage from the suspen
able sion crossmember 4
Separate the brake disc from the hub by taking out the
3 Take out the nuts attaching the transverse links and remove
retaining bolts as shown in Fig C 6 the links at both sides of the vehicle
Installation is a reversal of the removal procedure Adjust 4 Support the engine with a hoist as shown in FigC II taking
the wheel bearings as previously described taking care to carenot to damage the throttle and remote control linkages
tighten the wheel bearing locknut to the specified torque read and then remove the engine mounting bolts at both sides
ing of 3 0 to 3 5 kgm 21 7 to 3lb
25 ft Turn the hub
several times to settle the bearing then retighten the nut to the 5 Remove the bolts shown arrowed in Fig C 12 and lift the
same figure Slacken the locknut by a quarter turn 900 and suspension member away
insert the cotter pin when the hole in the spindle is aligned
Renew the suspension member if it is cracked or deformed
with the hole in the nut Check that the force required to turn
in any way Installation is a reversal of the removal procedure
the hub is less than 7 0 kg cm 97 2 in oz
Remove the bolts attaching the stabilizer bracket 2 to parts renewed if the angles are incorrect See Technical Data
Installation is a reversal of the removal procedures Tighten be required for this operation
the fixing bolts to a torque reading of 12 to I 7 kgm 8 7 to
12 3 lb ft at the transverse link side and 1 9 to 2 5 kgm 13 7 to STEERING WHEEL AND COLUMN Removal
18 llb ft at the frame bracket
Disconnect the horn wire and remove the horn bar Remove
SPRING AND STRUT ASSEMBLY the steering wheel nut and pull off the steering wheel
5 Remove the steering column upper clamp and take out the
TRANSVERSE LINK AND LOWER BALL JOINT
bolts securing the lower plate
S25
inter l
Il l
@
J
5 4 Z
10 9 8
I
7
i
6
I
3
I I 1 I
I
1
2P
3 St
I
I
Snap ring
antwashor
I
ng column bNring
4 S eerinK column shaft
I I
Windiameler
26 3
26mm
1
al02in
5 nUIx column jacket
Str FfflI ngth 3 mm 1 035 in
J6
6 St riJrg column spring CoillUms 5 5
7 Dust covu Load I ngth JOkg 44 jx
b
8 Rubber coupling I 3
16 mm 0 642 in
9 Rubber coupling f10nre I
10 Strt
rin8lcwer joint mbly FiS C20 Retainer sprins
I 1
I
J
Fig ClS 1be steering column t
lfj
2 ck 11 Locknut Free Ie
3 Oil i6d 12 Sid f1fUtl
rodinmr QU tums
J 9 FiIJd
9
plug
FiJILr p1u
2
9 Fig C 17 Removing the splash board
Cl6 The rack and pinion with tierod
Fig
I
1
t4
o
I
il 1
Ol W
J
y
lr
I
C IS rod
Tie ban stud Fig C 19 Removing the retainer locknut
Fig
526
Gean all parts thoroughly and renew if damaged If the Renew the oil seal Examine the retainer and tierod springs
column shaft or jacket is excessively damaged the steering gear and compare them with the values given in Figs C20 and c n
housing must be checked A damaged bearing must be replaced
together with the column jacket assembly RACK AND PINION AND TIE ROD
3 Remove the bolts from the steering column rubber coupl Grease the pinion teeth end bushing and pinion bearing
ing See Fig C 15 and remove the splash board Fig C 17 Engage the tccth of the pinion with the rack and insert the
pinion Make sure that the bushing does not become damaged
4 Remove the tierod ball stud nut and disconnect the tie
The rack must project from the housing by an equal amount
rod from the knuckle arm Fig C I8
at each side with the groove on the pinion serration facing
5 Lift the engine slightly with suitable tackle but take care upwards
not to damage the accelerator or remote control linkage
Fit the snap ring into the housing groove to hold the
the bearing outer race in position The snap ring must fit tightly
Remove the bolts securing the steering gear housing to
and can be selected from the following oversizes
suspension member Withdraw the rack and pinion
assembly
Snap Ring Thicknesses
Dismantle as follows
LS5 to 1 60 mm 0 0610 to 0 0630 in
Detach the steering lower joint from the rack and pinion 1 60 to 1 65 mm 0 0630 to 0 0650 in
assembly Clamp the unit in a vice taking care not to damage 165 to I 70 mm 0 0650 to 0 0669 in
the steering gear housing 70
1 to I 75 mm 0 0669 to 0 0689 in
Refer to Fig C 16 and take off the dust cover and boot Fit the oil seal Use a dial gauge as shown in FigC22 to
clamps at both sides Slacken the stopper nut remove the tie check the thrust play of the pinion The play should be less
rod inner socket and disconnect the tie rods from the rack than 0 09mm 0 0035 in
Withdraw the spring seat and tie rod spring Take off the Grease the retainer and insert it with the spring Tighten
steering gear boots at both sides Slacken the locknut and the retainer adjusting screw fully then back it off by 20 to
disconnect the tie rod outer socket from the ball 25 degrees Tighten the locknut to a torque reading of 4 0 to
6 0 kgm 28 9 to 4lb
43 ft Coat the locknut with liquid pack
Slacken the locknut remove the retainer adjusting screw
ing Three Bond
and withdraw the steering gear retainer See FigC 19
When the rack and pinion is assembled measure the force
Take off the oil seal remove the snap ring and withdraw
required to rotate the pinion and also the preload of the rack
the pinion Remove the snap ring and withdraw the bearing from
Use a spring balance as shown in Figs C 23 and C24 and check
the pinion Remove the filler plug and take out the rack Remove
that the pinion torque is 8 to 20 kg cm 7 to 17 Ib in and the
the grease reservoir rack preload is from 8 to 18 kg 17 6 to 39 7Ibs Take care
Clcan all parts thoroughly and replace any which show to slide the assembly over the complete range of the stroke
527
inter C7
l
IJ
l
j
Fig C 24 Measuring the rack preload C25 the tierod inner socket stop nut
Fig Tightening
S rod ing
p
I
Spring
Boot I Boot np
cl
Side rod 1
I
t I
Lock n
rt
38 m 1
5n 5115in
Fig C26 Measuring the torque required to swing the tierod Fig C 2 Section through the tierod ball joint
Slila niversatjoint
upper nd of upper
steering shaft
Fig C28 Aligning the universal joint with upper steering shaft
528
Tighten the inner socket until the ball seat is at the rack Installation of the rack and pinion assembly is a reversal
end then back off the socket by 30 to 40 degrees and tighten of the removal procedure
the stop nut to a torque reading of 8 0 to 10 0 kgm 57 8 to
3 Ib ft as shown in Fig C25
72 COLLAPSIBLE STEERING 8 and
Removi Dismantti
8
Remove the grease nipple and fit the plug Fit the boot
Assembly is a reversal of the dismantling procedure Note
Fill the grease reseIVoir with grease and attach it to the rack
that the slot in the universal joint must be aligned with the punch
housing Adjust the length of the tierods at both sides as mark at the top of the upper steering shaft as shown in Fig C 28
desribed under FRONT WHEEL ALIGNMENT
When installing the column make sure that the bellows do not
Assemble the steering lower joint to the rack and pinion become bent of twisted as the clamp and bottom plate bolts
and tighten the lower joint bolt to a torque reading of 4 0 to are tightened
5 0 kgm 29 0 to 36 0 Ib ft
TechnICal Data
Freelenath 36 5 mm 1 4370 in
llJ
CoiltW 3
Load length 25q 551 18mm 0 7087
40
10 Strut outer Ilia 50 8 mm 2 0 in
Cut
m
c Piston rod di
a 20 mm 0 787 in
Kinl pin inclination 8005 Cylinder inner dia 30mm I 181 in
Toein 12 15 mm 47 0
0 59 in Dampinl force at pistonlpeed
In 38024 03 mI 1 08 ft I
Steerinlan
eOut 35036 Expansion 67 I47
IOq 7 221bs
Compression 25 4kl 55 1 8 81bs
Shock absorber inner
cylinderlcngth IOmm 16 1 in
Free in 514 6
371 386 5 15 2 514
371 6
lenJth mm
Installed hei
htload mmq 180 270 200 270 180 270
in lb 7 1 594 79 594 7 1 594
SpriDgCOfl ltant ka mm 45
1 US 45
1
529
1
1
12
i
3
11
4
5
l
a h rod a Sy
Dus ewer
20
Stopper rint 20
condiuy putcm cup
MaJler cylinder puto y
17 l 17
Primmy plJlan cup
tIhe cwy
Inlet l
Jx
1 As 13 Itukin8
retunl SPrin8 bm
y
ke cylinder
1
Jton
Pi mtUtn
18 2 U pbto
y
b A
cylinder body Oil rnenoir ClIp
15 PUlon cup
RtJeTfoir btJnd auy 3 Brake oil 1
turJ1 U
le 15 Ou
Rel6l 4 Oil rnervou hlznd 16 Cylbukr
8 Reservoir cap
ass
5 JCTeW
Dlertler
17 puto
y
Au B
Fig D Components of the single master cylinder Fig D 2 Components of the tandem master cylinder
1A
Sy catft7a
2 Equalizu hmuJ broke
J RB lJ1 cab
Tt
4 AdiU3tt cailk
T rmr
5 1TiIw retum
S
6 LH ntu Ofbk
7 Pirfulcrum hand r
braJcalev
8 Vb1l
aJ front hand bmka
9 TrutUon pin hand bt
rzU ctlbk
10 P
atMock rand IRvke azb1l
10
4
1 L
4 6
lNota
@ Apply 11lI gteall
@ApplychlSSis 1
2
Tandem nmt cylintkr
Two MY COnMC or
3 Brake line e
prtSlf ootch
1 umil16
difftrentiJzl
530
BrakIng System
Description
Front disc brake Friction pads
Front disc brake Removal and Installation
Rear drum brake Removal and Installation
MasterVac Servo Unit
Handbrake cables Removing
Handbrake Adjusting
Brake pedal Adjusting
Rear drum brake Adjusting
DESCRIPTION Check the brake disc for scoring and out of round The
standard diSc thickness is 10 0 mm 394
0 in and must not
The vehicle is fitted with disc brakes for the front wheels be reground below 8 40 mm 0 331 in The run out of the
and leading trailing shoe type drum brakes for the rear wheels disc should be less than 0 06 mm 0 0024 in and can be
checked with a dial gauge positioned near the outer diameter
A conventional single master cylinder is fitted to the of the disc as previously described
Standard and DeLuxe models See Fig D I for details The
DeLuxe models are however additio ally equipped with a
REAR DRUM BRAKE Removal and Installation
Master Vae unit which provides a much higher braking
servo
performance with minimum force required on the brake pedal The reardrum brakes See Fig D 6 can be removed and
A tandem master cylinder and Master Vac servo unit are inspected described in the section BRAKING SYSTEM for
as
when a pressure difference of 13 to 17 kg sq cm IB5 to 242 Check the shoe return springs and replace them if they
lb sq in occurs between the front and rear systems have become weakened Check the bores of the wheel cylinders
for signs of wear damage or corrosion Renew the cylinders
Brake piping layouts of the single and tandem master
and pistons if the clearance between the two parts exceeds to
cylinder systems are shown in Figs 4 and 0 5
D
0 15 mm 0 006 in Renew the c ps when overhauling the
wheel cylinders
FRONT DISC BRAKE Friction pads
Refer to the section BRAKING SYSTEM for the Ll4 L16 3 Take off the retaining nuts and remove the Master Vac and
and LIB engines for full details of the removal and installation spacer then separate the master cylinder from the Master
procedures Vac
Mark the front cylinder shell and the rear shell and stud
Check the thickness of the friction pads as previously
described and replace them if necessary assembly before dismantling the unit then proceed as
follows
S31
inter j IJ ITJJ
4
J Bralee rube A
2 Front COfIMctor
3 Bralee tube B
4 lJ
PreS hOefront RH
5 Brake tube C
6 tubeD
7 Pressure hose front LH
8 2 way connector
9 Brake tube E
10 Rear connector
11 Pressure hose rear R
12 Brake tube F
13 Brake tube G
14 PntruFe h e raIT LH
15 IJ Brake hlbe H
16 Hose lock plate
17 Hose Jock spring
3 6 7
Fig D 4 Layout of brake piping with single master cylinder
6
Fig US Removing the air silencer retainer
e
1 rQtcoper
2 Adiwtint Urim
3 dUe
4 Adiuster
5 Retum springs
6 Anti ttk qJrinp
V 7
2 t
Adiwt
Fig D 6 Rear drom brake components 8 JIJmd bnzke Iner
9 Wh
1 cylinder
10 Lilli
11 Anti rattle pim
1 PIIz ed tl1
st
3 4 2 Push rod
3 urtun
Dittp
4 Rmr Vrdl
Fig D 9 Removing the valve plunger stop key
J Jbwer phton
6 OJlt
VQcwunl
7 01
8 VQcuum wzhe
9 fuppet aucmb1y G
10 Vah body pzrd
JEiID lj
12 II Air mur Fzlter
li
12
t1tintrod
l
V4lveopt
13 Vobe rdunuJNin8
14 lbppet mum Pri
If
15
16
e
AiTvah t
RDut I
17 Valve plunger e I
18 Reaction dUe r
6
19 rrqm mum Pri
lJttp If 6
20 Front s
relJ
IS Fig D 1O Removing the bandbrake front cable
532
J
or C
CI i
c t
7
1
vc
j V
k
f
l
7D
Fig D lt Removing the handbrake front cable
Fig D 13 Removing the rear cable Fig D 14 Adjusting the handbrake cable
Jt
A G
J
L
CD
I
I
I I
I
I Fig D 16 Setting the brake light switch
I
I
I I
1
l
I
lSOt4
831
B
brakes
D S Adjusting the brnke pedal Fig D I7 Adjusting the rear
Fig
S33
Re lf rnble
Clamp the flange and bolt assembly in a vice Push the rear
shell and stud assembly down and turn it anti clockwise
to release Take care not to drop the Remove the nut from the adjuster and disconnect the
body and
valve di
left hand rear cable
phrdgm plate which will be detached at the same time
Remove the retainer and detach the bearing and seal from Disconnect the rear cables from the wheel cylinders Refer
to FigD 13 pull out the lock plates 1 and 2 andremove
the rear shelL A needle can be used to remove the retainer
the clevis pin
Pull the diaphragm from the groove in the diaphragm plate
Remove the valve body guard and the air silencer See Fig HANDBRAKE CABLES Inspection and Installation
0 8 Remove the valve plunger stop key Fig D 9 detach
the valve rod and plunger assembly and the air silencer lnspect the cables and replace them if any of the wires
fllter from the valve body and diaphragm plate Pull out the have broken Cables which have stretched must be renewed as
reaction di c it will no longer be possible to adjust the handbrake correctly
Check the springs and renew them if they have weakened or
To dismantle the front shell and stud assembly first pull
broken
out the push rod then remove the plate and seal and the
check valve
Oteck the centre lever trunnion pin and equalizer and
replace as necessary
MASfER V AC SERVO UNIT Assembling
Installation is a reversal of the removal procedure Grease
inspect the components and replace any which show signs all sliding parts and adjust the handbrake as described below
of wear or damage As previously stated the repair kit contains
a number of items which must be used to replace the original HANDBRAKE Adjusting
parts Assembly is reversal of the dismantling procedure but
a
the following components should be lubricated with silicon Release the handbrake and adjust the rear brake shoes as
Grease the lip and face of the seal the lip of the poppet Adjust the front and rear cables to give a handbrake lever
both faces of the reaction disc Grease the diaphragm edge in stroke of 85 to 95 mm 0 35 to 3 74 in by setting the adjust
contact with the front and rear shell ing nuts shown arrowed in Fig D 14
Grease the face of the plate and seal assembly which con BRAKE PEDAL Adjusting
tacts the front shell and push rod the face of the check valve
in contact with the packing and also the push rod at the point
Adjust the length of the master cylinder push rod until
of contact with the diaphragm plate
the brake pedal pad is set to a height of 187 0 mm 36 in
7
with the brake light switch free from the pedal stopper Lock
Check the clearance between the master cylinder and push
the push rod by tightening the locknut l in Fig D 15 Screw
rod after assembling The clearance should be 4 0 0 5 0 mm
in the brake light switch until the screwed shaft of the switch
ot 575 0 0197 0 in and can be adjusted if necessary by
makes contact with the stopper brJcket bolt then retighten the
altering the length of the push rod Installation of the Master locknut
Vac unit is a reversal of the removal procedure
Adjust the stopper bolt 2 until the brake pedal pad is set
HANDBRAKE CABLES Removing
to height of 183 0 mm 7 2 in
a then retighten the locknut
The full stroke of the brake pedal should now be set to 150 0
The cables of the mechanical handbrake See Fig D 3 can
mm 5 9 in
be removed in the following manner
1 Release the hand brake and disconnect the front cable by Lubricate all sliding parts with bearing grease
removing the clevis pin 1 in Fig D I 0 at the handbrake
equalizer Screw out the adjusting nut 2 to disconnect REAR DRUM BRAKE Adjusting
the cable from the handbrake lever
Jack up the vehicle at the rear and release the handbrake
2 Straighten the cable clamp Iin Fig D II and pullout the
Depress the brake pedal several times and turn the adjuster
the lock plate 2 to extract the cable from the retainer clockwise until the drum is locked See Fig D I Turn the
adjuster in the opposite direction until the shoes arc just dear
3 Detach the cable outer casing from the handbrake control
of the drum and the wheel can be turned freely by hand
bracket then pull out the front cable
Removal of the control stem is a straight forward opera BLEEDING THE HYDRAULIC SYSTEM
tion Refer to FigD 12 and take out the clevis pin I connect
ing the yoke 2 to the lever 3 Remove the clevis pin 4 secur Refer to the section BRAKING SYSTEM for L14 Ll6
ing the guide 5 to the bracket 6 then withdraw the control and LIS engines and follow the instructions given under the
stem
appropriate heading
S34
Technical Data
Brake pedal Drum inside out of roundness below 0 05 mm 0 002 in
Pedal free height 183 mm 7 2 in Limit of reconditioning drum
Full stroke of pedal head 150 4 mm 5 9 0 158 in in dia 229 6 mm 9 039 in
Run out of the rotor below 0 06 mm 0 0024 in
772
1 x 8 642 in
Inner dia of wheel cylinder
Material D233
Front 50 8 mm 2 in
Rear 20 64 mm in Pad width x thickness x
16
13
length 397 x 9 x 86 mm 563
1 x 354
0
Allowablemax clearance
x 386
3 in
between cylinder wall and
piston 18
0 mm 0 0709 in Pad material standard M78S option Sl6D
835
Tlght enlna Torques
ENGINE Lower ball joint to transverse
link fixing nut 19 5 kg m l3 7 18 llb ft
Main bearing cap bolt 10 11 kg m 723 79 5Ib ft Lower bJH joint stud nut 7 6 kgm 139 8 1 0 Ib ft
t Connecting rod bolt 4 5 5 kg m 32 636 2Ib ft Suspension aoss member
19 2 5 kg 13 7 18 1 lb ft
Flywheel bolt 10 11 kg m 723 79 5 Ib fL mounting boils m
S36
1968 DATSUI D
MO MOnthl wtJichewl
Drain ill
I I T I I
I ENGINE
CAR UP I 1
llletksumpbulttortM
Filt Changeelemenl I 42 Clled i6
r
EngmlMountings rque
Cleantlement 3 I II r Engine Film Trap ServiceJndclean J1
GEARBOX Check topup
il 4 I I AUTOMATIC TRANSM Adjult brake bandl tB
Chinnloil 1 RtnMsumpgal tt fiS
Dvttdrivt Filt r
AUTOMATIC TRANSM
Filt r
Gle nelern
Orainlluid
Clunertmtn
n
511
11 Ii
7
81 1 I I
I
I
I
I
I I
I
41
24
2
lOAIVE
PROP SHAFT S Check lor
Tiglltenbolu
l Jmpbnlt ort
Check
wear JJ
Jl
27
DIFFERENTIAL Check ailltop up
Jf71 r JIOWI
ill I 28 30
SUSP FRONT REAR Check tor wear n
limittdSlip DiHlranti 1
ShdmgJolnt YlShlft
Df
Change il
Clleck ilftopup
Changelil
Check 11IIOpup
1J
11
n
i II I
ill
II
I
I
I Shock
Ablorb
STEERING
rs
Tiglltenboltl
Clllckbootgeiltrl
Clleckoperltion
Ch CQmpon l welr
ChangeDl1 1 I I I I
Tighten bolts
SHOCKASSORBERS
PROP DRIVESHAFTISI
Check Il topup
lubncate
5
Hi
I
1
U 80lTS
Clleclbootgaiterl
Checktorqu
GREASE GUN POINTS lubnCIl HANDBRAKE Gheck edjult
it
PEOAlSHAFT Sj Lubrlc te 18 CLUTCH Clllck ljust
HANDBHAKE lubnc 1t I GEAR LINKAGE CIIRCk adjult
I
r 1t R I NKAl
iF luhncll 2u I I i EXHAUST SYSTEM Clleck tighltnbolts
i
1
I FREE I I f HFfK FOR Oil W
ARlUWIORED WHEELS
1121 21
FllE 1
M
1m f
wHEE L tllAHINli ronl HepitCk CAH LUWI RI If
211 t KSI 1
WHEEl BEARINGS Rur Repack 77 U
I
WHEEL BEARINGS t heCklMliiili 86
I 1
5 BRAKES Check ldjust 81
BRAKE FLUID R nfWfbletd I 1 lf 13 117
I AH f UUWI t1UN i Ovrvll
erl lulcompl
t 11Itl ih1tl 1 c e
UningsJDruml Cleen chltkwtlr R9
BI1I1I1 Cap
Air Cluner
PCV Syllem
r
Check
Cleen
oillevtl
Service el m ntl
Replace
Cteenfilter
el
J7
lement l B
Cl I
1
L
l
B
1ifj lclr1i
j
I
I
I 4
5
Plds Discl
Selhdj Meclleni5l11
Cylinders
ROAD WHEELS
Hosel
Check
Check
for wear
Checkforwplr
Il1Ipecttyrel
Illte II blIl1nCl
192
1IJ
0
Clun va vell lR
I I 4 Adjultpres
lure
I1
rburettor s
Repl cH lve
Cleen jets bOM R
1
I I
I I I
r
I I 3S Whe 1 Nun
AHllIIWN liON
Cllecktorul
ET OPE
l heckcompression
It
Top liP pisl dempe l L ENGINE
Cyllnd Held
LlIbncatelinkages I
I L r
Checktorqul
FUll Bowl Ctean replace 5 j Vllyes
Filter
S1 I AdjUltclttr nc
Fu
llnjectionPump Ch ckoill ve1 Ei l j Clloke CheckoptTltion
16
Fit l
ll Clun replac n MiKtulli ldling Check
lIljLllt
11
AUTOMATIC TRANSM R fill witll fluid 38 I
linkagel AdjUlI
Check fluid levll IlL t Timing Ch in Clleck alIj tension
DISTRIBUTOR ign toil I9 16 V Belt Is adj t nsion
I
Spindl Ctm CI t I t 1 l 10
COOLING SYSTEM CheCk top up SPARK PLUGS Clun selpp jt1
Renew
i
Flulhryst m y
CorrDlionlnllibitor Cllecksolullon 44 OISTRIBUTOR Chetk tPoint
tp
Renew pointl
Anti Frltl Chltk 45
i 110
W t
rPump Lubrlc tt 46 Owell Angle Check 6djult J
CREENWASHER Clleck top up L Ignition Timing Check edjult ill i ii
ArrERY topup
Check aJdM
4 L COOLING SYSTEM Tiglltenhoseclips 112
j
Cllltkspet gl1vity i R plece lIastl ill
Connections PreSSIJ test 114
CI en gr 1S liD 1
IfI 1 II 116
3ENERATOR Lubriclt 1il I STEERING Clleek play adjust ill j i itl
STEERING Clleck topup 52 i
Ti9htenboltl ill
POMrStlering Chtck topuplluid 3 I Geometry Check U1L ii
8e
Gre 4 CHECK FOR Oil FUEL WATER etc LEAKS 1181
H
rlm I 1 I I I
11 1
CLUTCH BRAKE Chick top up fluid I6 wW e I lOn
Ldtir
Renewfiltlr 58 II Checkbladu J
HYDR SUSPENSION Check topupflu d i i TS rh kIlCII
I
Jrl711111iI
Renrwfluid i91 I I
I I An UH OVNAUOMFTER I ST I
X
I
ilinlil1r I I I I I I BRAKES CheCkemCienCY 1 I
TRANSM
CAR
DOWN E TERNAL j 1 I 1 AUTOMATIC Clleek op rttioQ T
lOCKS
Door Dram Hol l
WIPER SPINDLES
HINGES Ell Lubrictt
Clun
lubrictt
En in
11S21 f
64
J
Dil Filwr
r II W
1
I I
el L I
GttrbOK
I
ENGINE
DEFECTS
Adjust
Report
if required 12
12
4 7 4 4 1 21 81 7 3 32 0 75 3
T 1 8 8
B 127 2 4S 9
8 9
11 11 17 18 82 84
19 20 41
WAGON 52
1 1 72 1
mmDIIIII
Ifn c ID WIthDv1 LI
obWt7
AUTOSERVICE DATA CHART
1968 DATSUN
N
G
WJ
t
I
tl
l
l1
3 1
I
B B1 B1
L
J
Pi
I il
iUJ
28 VlXCUI element
sss
Ref to Technical Data
STEERING TEST lOAD TOI IN iIlDUTlo CAIll BER CASTOR KING PU INClNJ TOElNilOUTlo
GEOMETRY lbl
kO I mm in
front l delftlllmin dIonmin I min I rI nmfin I CAMBEll
rmin I d
oIII
TOE
It
TURIIIS
laCK I
U10
UtOS ter to T anal Data
R
WAGON
TORQUE 8D V BELT TENSION
I AP PRES8 CLUTCH PLAY
VALUES
mlDb h 4
mmJinches RAtJ cm2 tIIi 1 mmJinct
5 5 51325 39
10 15 4 8 9 12
0
TBA @ me
5 SOll13 4Pfl 12V 4QAh NGKBP6E FRAM PH 2850 FRAM CAGS1
5 60513 4Pfl 12V 50Ah
12V 60Ah
ImDIImI AUTOSERVICE
t11 C toIlho
u
DATA CHART
I
Part NanleH and AlternatlyeS
ENGINE ELECTRICAL
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
STEERING
Carburettor choke Carburettor venturi
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
Stator tube Control tube
Spigot bearing Clutch pilot bearing
Clutch housing Bell housing Steering joints Steering knuckles
BRAKES
GEARBOX
Master cylinder Main cylinder
Gearbox Transmission
Brake shoe lining Brake shoe facing
Gear lever Change speed lever Gearshift
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 window Rear windscreen Rear windshield
Rear Axle Final drive unit
Backlight
Crown wheel Ring gear Final drive gear Spiral
Quarter ven t N D V No draught ventilator
drive gear
Bumpers Fenders
Bevel pinion Small pinion spiral drive pinion
Loom Harness
U bolts Spring clips
Odometer Trip recorder
Axle shaft Half shaft Hub driving shaft Jack
Bonnet catch Hood latch
driving shaft Paraffin
Kerosene
Differential gear Sun wheel
Boot Trunk
Differential pinion Planet wheel
n
E
inter iDJ
M
ConverSIon Tables
UNEAR MEASUREMENT SPEED OR BRAlUNG
U UQUIDS PRESSURES
DISTANCE DISTANCE
ILlIlIIIET Elf IoICHU fO N
INCHES LLllIIETRU
TO INCHES ON ARM DR
iCHES
II INCHES LITRESlpINTS
TO TO
LlTR
TO
GMt
TO
kg em
to ill to
in2 KILOS
TO
1 MILES
TO
GROUND NO
WINO
IDEe
ll
enOl
f AU
I I S PINTS
p ITRE
GALOl UTR Ibs iIl2 k cm
MlLESl KILOS
MEJO Fr
IS I a ooll oIto
OIllJI OOO1 OO
32
1
156Ji1UM
lS1
OJ1 usn oOO2 cL0CI021
000CII 176 057 0 22 4 55 14 2 0 62 161
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661 13 64 42 6
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30140 50160
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