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MODEL 411 SERIES

DATSUN
MODEL 411 SERIES

SERVICE
MANUAL

INISSANI

NISSAN MOTOR CO LTD

OTEMACHI BLDG OTEMACHI CHIYODA KU

TOKYO JAPAN

CABLE ADDRESS llNISMOll TOKYO

PHONES 216 2311
INTR ODUCTION

for of assisting
This manual has been complies purpose
DATSUN distributors and dealers for effective service and

maintenance of the Model P L 411 Each assembly of the

is described in detaiL In addition

major components
for complete dismantl
comprehensive instructions are given
assembling and inspection of these assemblies
ing
DATSUN Spare Parts
It is emphasised that only genuine
should be used as replacements

DATSUN MODEL 1 411 U

CONTENTS

Page

MAJOR SPECIFICATIONS
ENGINE 1

Cooling System 3

Lubrication 8

SERVICE OPERATIONS 11

Rocker Mechanism 12

REMOVING REFITTING 25

Operation with the Engine Removed 26

IGNITION TIMING 31

Distributor 31

Adjusting the Ignition Timing 31

FUEL SYSTEM 34

Carburetor 34

The Gasoline Tank 37

Fuel Strainer 40

Adjustment and Inspection of Engine 43

CLUTCH 48

TRANSMISSION 57

Cover of Transmission Case 58

Transmission Case 59

Extension of TransmiBBion Case 65

Transmission Case Stage Floor Shift 72
DiBaBSembly the For 4

CHASSIS 85

FRONT AXLE 85

DiBaBSembling the Front Hub 86

Indipendent Front Suspension 88

REAR AXLE 98

STEERING 112

BRAKE 119

Front Brake 120

Rear Brake 123

Hand Brake 126

ELECTRICAL SYSTEM 129

Alternator 130
Generator 132

Regulator 139

14 ItemB on Handling 142

Trouble Shooting List 143

Starter Motor 144

 MA
JOR SPECIFICATION OF
MODEL 41 1 SERIES

MODEL P L 411 U WP L 411 U

ITEM P L 4 1 1 oUT WP L 411 UT

Overall Length 3 995 mm 157 3 in 3 995 mm 157 3 in

Overall Width 1 490 mm 58 7 in 1 490 mm 58 7 in

Overall Height 1 440 56 7 in 1 56 3 in

mm 430 mm

Wheel Base 2 380 mm 93 7 in 2 380 mm 93 7 in

L 1 710 mm 67 3 in 1 704 mm 67 1 in

Room Space Inner Width 1 240 mm 48 8 in 1 240 mm 48 8 in

Inner Height 1 130 mm 44 5 in 1 130 mm 44 5 in

1 206 mm 47 5 in 1 206 mm 47 5 in

A
Tread

rront
Rear 1 198 mm 47 2 in 1 198 mm 47 2 in

Min Road Clearance 175 mm 6 9 in 175 mm 6 9 in

Overhang to the Front End

605 mm 23 8 in 605 mm 23 8 in
without bumper

Overhang to the Rear End

950 mm 37 4 in 947 mm 37 3 in
without bumper

Vehicle Weight 885 kg 1951 Ib 960 kg 2116 lb

Front 505 1113 lb 500 kg 1102 Ib

kg
Distribution
Rear 380 kg 838 lb 460 kg 1014 lb

Vehicle Gross Weight 1 160 kg 2557 lb 1 235 kg 2723 lb

Front 600 kg 1323 lb 595 kg 1312 Ib

I Distribution
9 Rear 560 kg 1234 lb 640 kg 1411 lb

Height of Gravity Center 580 mm 22 8 in 580 mm 22 8 in

Proportion of Front Tire

51 7 48 2
with load

Max Inclination Right 46 46

Angle Left 46 46

I
r
DATSUN

MODEl P l 411 U WP l U
411
ITEM P l UT
411 WP l UT
411

Max Speed 140 km H 87 MPH 140 km H 87 MPH

l

Fuel Consumption 18 5 P
km 18 5 km t

p Grade Ability sinO 0 375 0 417 UT o 334 o 391 UT

0
r
p Min Turning Radius 5 0 m 164ft 5 0 m 164ft
l
Po
Brake Stopping Distance 50 h
km 135m 44 3 ft 135m 443ft

Model J

Make NISSAN MOTOR CO LTD

Classification GASOLINE ENGINE

Cooling System WATER FORCED CIRCULATION

No of Cylinder Arrang 4 IN LINE

Cycle 4

Combustion Chamer BATHTUB TYPE

Valve Arrangement OVER HEAD VALVE

Bore x Stroke 73 x 77 6 mm 2 874 x 3 055 in

DiBplacement 1299 c c 7927cu in

l Compression Ratio 8 2

as
Compression PreBsure kg cm2
lE 11 5 350 r p m
l

Max Exploding PresBure 48 3600 kg cm2 r p m

Max Mean Effective PreBB 9 7 28000 kg cm2 r p m

Max H P
B SAE 67 5200 HP r p m

Max Torque SAE 76 7 2800 ft Ib r p m 10 6 2800 kg m r p m

Length x Width x Height 597 x 575 x 690 mm 23 1 x 22 6x26 5 in

Weight 139 kg 306 Ib

PiBton Type SPLIT SKIRT TYPE

PiBton Material LO EX

2
 MAJOR SPECIFICATION

MODEL P L 411 U WP L 411 U

ITEM P L 411 UT WP L 411 UT

2
No of PreBsure
PiBton Ring 011
1

Inlet Open 14 B T D C

50 A B D C
Inlet Close
riI
Valve Timing
I
i 52 B B D C
Exh Open
@
f
riI

12 A T D C
Exh CloBe

0 35 mm 0 014 in
Intake
Valve
Clearance
ExhauBt 0 35 mm 0 014 in

Starting Method MAGNETIC STARTING SYSTEM

N41 14MZ N50 2SMB 1 each

Type
p
riI
Eo 12V
Voltage

40 50 A H
Capacity

Ground Polarity NEGATIVE

AC300 12WR
Type

Make MITSUBISHI

p
ALTERNATOR
0 Generating Method
Eo

p 12V
Voltage
riI
Z
riI
300 W
Capacity

Voltage Regulator RL 2Bl

S114 92
p Type
riI

Make HITACHI

Eo
on Power 12 1 4V HP
Voltage

I BATTERY COIL TYPE

Ignition Method
t

8 600 B T D C r p m
l
z Ignition Timing
9
1 4 2
3
Zl Firing Order
l

3
r

DATSUN

MODEL P l 411 U WP l U
411
ITEM P l UT
411 WP l UT
411

Type C1Z 18
Ignition Coil
Make HITACHI

Type 0411 53

Distributor
Make HITACHI

Ign Timing
Distributor VACUUM AND GOVERNOR
Advance System

Type B 6E

Make NGK
Spark Plug
Thread 14 mm 0 551 in

Gap 0 7 08 mm 00275 0 0315 in

l Type D2630A 5A
0

Make NllIONKIKAKI
Q
Throttle P S
iII
Eo Valve Bore 26 mm 30mm

Z Venturi Size 20mm 27 mm

0

E Carburetor Main Jet 192 1140

Z
0
Slow Jet 148 I 48

Pump Jet 145

Power Jet 140

Air Draught DOWN

Type No PAPER TYPE 1 each

Air Cleaner
Make TSUCHIYA

Type DIAPHRAGM
Fuel Pump
Make SHOWA KYOSAN

Capacity of Fuel Tank 41f r 10 8 U S gal

z
0
Lubrication Method FORCED PRESSURE TYPE
9t2E

4
 MAJOR SPECIFICATION

MODEL p L 411 U WP L 4 1 1 U

a
ITE P L 411 UT WP L 411 UT

C Oil Pump Type TROCHOID TYPE

E
0
Oil Filter FULL FLOW TYPE CARTRIDGE TYPE
l
f
p
Q
I
Oil Pan Capacity 2 9 fr 0 76 U S gal
H

Type WATER CUULING CLOSED TYPE

l
riI
E Radiator CORRUGATED FIN AND TUBE TYPE

5 4 fr S
l
t Cooling Water Capacity 1 43 U gal
as
H CENTRIFUGAL TYPE
Water Pump Type
0
0
U
Thermostat PELLET TYPE

Type SINGLE DRY DISC HYDRAULIC OPERATION

No of Plate 1 FACING 2

Out dia x In dia x Thickness 200 x 130 x 3 5 mm 7 87 x 5 12 x 0 138 in

U
E

Total Friction Area 181 x 2 cm2 28 06 x 2 sq in

H
U

dia of 19 05 mm 3 4 in
In Operating Cylinder

In dia of Master Cylinder 15 87 mm 5 8 in

3 FORWARD 1 REVERSE 4 FOREARD 1 REVERSE

Type ALL SYNCHROMESHED SYNCHROMESHED ON

ON FORWARD GEARS 2ND 3RD 4TH

Gear Shift Method REMOTE CONTROL FLOOR SHIFT

Z
2 2 0 58 U S
9 Oil Capacity 1 7 fO 45 U S gal gal
f
l
l 1st 3 197 3 945

2nd 1 725 2 402

p
E 000 1 490
Gear Ratio 3rd 1

4th 1 000

Reverse 4 125 5 159

I 1st Length Out

x dia x In dia 1222 x 71 x 67 8 mm

0
0 of Universal Joint SPICER TYPE
Type
0
Gear Type HYPOID
5
o

5
r

DATSUN

MODEL P L 411 U WP L 411 U

ITEM P L UT
411 WP L UT
411

0 P L 41l U P L 41l UT
Gear Ratio 4 375 4 111 OP 3889
i WP L 41l U WP L 411 UT
1

1
Housing Type BANJO
J
r

Type No of Gear STRAIGHT BEVEL PINION 2 each

Oil Capacity 1 fO 26 U S gal

is

Type RECIRCULATING BALL TYPE

Gear Ratio 15 0
Eo

360
Steering
ES
I
Angle
r Out 280 36

Eo Steering Wheel Dia 405 mm 15 95 in

Oil Capacity 0 33 f 0 087 UoS gal

Wheel Arrangement 2 FRONT 2 REAR

Front Axle Type WISHBONE BALL JOINT TYPE

Toe in 3 mm

Camber 1 45

ES Caster 0

D
p Inclination Angle of King Pin 6 15

Rear Axle SEMI FLOATING TYPE

Type

Type FRONT 2 LEADING REAR LEADING AND TRAILING

Lining Dimension 40 x 4 5 x 215 mm 1 575 x 0 177 x 8 465 in

Thickness
Width x

x Length 40 x 4 5 x 215 mm 1 575 x 0 177 x 8 465 in

Eo p 351 cm2 54 4 in2

l
Total Braking Area
U 351 cm2 54 4 in2
j
f
p
p F
l 228 6 mm 9 0 in
In dia of Brake
Drum
R 228 6 mm 9 o in

6
 MAJOR SPECIFICATION

MODEL P L 411 U WP L 411 U

ITEM P L 411 UT WP L 411 UT

In dla of Master
I
r 22 22 mm 0 8748 in
Cylinder
II j
Q
I F 25 40 mm 1 000 In
II In dla of Wheel
r
I
Q
I
0 Cylinder R 23 81 mm 0
H 9374 In
I
r II 0
I
r
n Max Oil PreSBure 115 kg cm2 1636 Ib ln2

I
r I
r Type MECHANICAL FOR REAR WHEEL

II II 40 x 4 5x215mm 1 575xO 177 x 8 465 In

Q
I Q
I Lining Dimension
t
Total Braking Area 351 cm2 54 4 sq in

II
In dla of Drum 228 6 mm 9 0 In
Po

Front Suspension Type INDEPENDENT SUSPENTION WITH COIL SPRING

R H CAR L H CAR
Coil Wire dia x Coil dla x
336 R
Free Length No of Coils 14 2 x 94 x 8 5 14 2 x 94 x 325 8 5
325 L

Z
Rear Suspension Type LONGITUDINAL SEMI ELLIPTING SPRING
9
Z
Size Width 6 2 6 3
I
r Spring Length x x
1200
1200 x 60 x x 60 x
Po 5 2 5 2
Thickness No
P

ShOck Absorber F TELESCOPIC DOUBLE ACTION

Shock Absorber R TELESCOPIC DOUBLE ACTION

Stabilizer F TORSION BAR TYPE

F 5 60 13 4P
Tire Size
R 5 60 13 4P
e

Head Lamp Sealed beam 12V 37 5 50W x 2

Width Indicators 12V 8Wx2

Tail Lamps 12V 8W x2

LlcenBe Plate LampB 12V 8W x2

Po

12V 25W x 2
Stop Lamps
H

12V 25W xl
Reverse LampB

Room 12V 5W x 1
Lamps

7
r

DATSUN

MODEL P L U
411 WP L 411 U
ITEM P l UT
411 WP L UT
411

12V 35W x 2
Fog Lamps

Inspection Lamps 12V 8Wx 1

12V 8Wx4
Parking Lamps

Turn Signal Lamps 12V 25W x 4

Dash LampB 12V 3W x 4

p
Reflection 32 50 x 2

l
Warning Lamps

Turn Signal 12V 15W x 2

Main Beam 12V l 5W xl

12V 1 5W xl
Ignition

Oil Pres sure 12V l 5W xl

8
 EJ
oc l 0f
o lc zor0E z8 g

11 10 9 8 7 300 200 100

CENGI E URVE 40
m
p

102
x

PERFOMANC
A

SPE D
MODEL W
ENGIE
U

70 60 SO 10

0 0 Oc

I I I I I I

I
1 S d t r 0

I
SO O 40 0 30 0 20 0
357 rn 160
p
sin8
O
m le ISO
l
8
280 T p
0
5
0
3
140
382 kg
52o r 130
CURVE
35
kg m
lanD
O
375 197 725 000 160 287 6rn 120
4 3 1 1 1 O 10 67HP 5

110
U
100

PMODEL ERFOMANC
1
3
411 30 90
weight abilty radius SAE
h

80 Ian
L

ratio ratio ratio ratio ratio SAE

spe d spe d vehicle grade ef ctive torque
P
70
40
geal spe d spe d BHP 60 SPE O
Final 1st 2nd 3td 4th Gron Max Tire Max Max 50
CAR

RUNIG
40

600 SOO 400 300 200 100

f
bii I
u VI Z 1il

2
I

tIici
r t5

417 m SO O 40 U 30 0 J2000 10 0
P
sinO
O m foo
280 r P
lSO
4S9
CURVE 52o r
kg 40
kg m
0
111 945 403 490 000 160 287 6m
UT
4 3 2 1 1 1 tan O 10 67HP
102 31
PMODEL ERFOMANC
411
Pil

Final
P

1st 2nd 3rd 4th

weight radius SAE SAE
ratio ratio ratio ratio ratio abil ty
gear eed spe d spe d spe d vetlc1e rade ef ctive torque BHP
Crol
p

Max Tire Max Max

SO
45
40
joo
90

80
70

60
h

kg

RUNIG 1st
s
sil

3040
21
Spe d
Car

10
I

I
o

soo 400 3oo 200

S u l S
0 j

391 m jIi 0 zOI01 r

p
O
dn8

280 r
m
P 50 0 40 0 30 0 20 0
425 160
g
m
kg
520 1 ISO
287 6m
111 945 403 490
1000 tan8 10 67HP
CURVE
4 3 2 1 O

UT

ratio ratio tio

ratio ratio
weight abilty radius SAE SAE 102 3 4
PERFOMANC
411 ra 100
L gear spe d spe d spe d
cd
spl vehicle llde
gt
ef ctive torque BHP 90

WP Final 1st 2nd 3rd 4th Gros Max Tire IMaxMu 80

h

70
45
DEL SO 60
km

MO Spe d
RUNIG
50

40
Car
30

lat 20
10

600 100
f 0 II5 n
J

I
 ENGINE

ENGINE

ENGINE
The is of monobloc construction and aluminum alloy and carry two compression
engine
and a slotted oil control ring
the valve are set in line in the cylinder head and rings
bolted in connecting
are operated by rockers and push rods from the The piston pins are

camshaft in the left hand side of the engine rods which have steel backed lead and copper

The camshaftrunning in three steel backed alloy changeable big end bearings
is chain driven and has a A counter balanced crankshaft is fitted The
whitemetal bearings
rubber chain tenssioner end on this component is taken by special
ust
thr
the main The
The distributor and oil pump are driven washers at center bearing
centrifugal water and cooling fan are
from the camshaft pump

The pistons are the split skirt type of driven by the generator belt

GENERAL SPECIFICA TlONS

J
Engine type type
4
No of Cylinder
Bore mm 73 mm

77 6 mm
Stroke
1 299
Volume
Max 67 HP at 5200 r p m
brake horse power
10 6 kg m at 2800 r p m
Torque
1 3 4 2
Firing order
Valve arrangement Overhead valve push rod type
Compression pressure 163 lbs per sq in 11 5 kg cm2 at 350 r p m

ratio 821
Compression
DATSUN

j
f

St
J

ENGINE RIGHT SIDE

ENGINE LEFT SIDE

2
 ENGINE

COOLING SYSTEM

f I
I

An efficient cooling BYBtem is of major

importance to enBure the satisfactory running

of the engine and it iB therefore necessary to

pay particular attention to its maintenance

Description
The cooling system iB maintained by water
pump circulation combined with an efficient fan
cooled radiator and thermostat
The system is pressurised and the relief
valve incorporated in the radiator filler cap
controls the pressure at approximately 0 4 kg

per sq cm Do not remove the filler cap if

the temperature of the coolant is above boiling Fig 1 Radiator
point or if the engine iB running Topping up

should be required occasionally to replace Fill to within 1 2 of the bottom of the filler
only
water lost through the overflow pipe Top up plug well Overfilling when the engine is cold

when the is cold and if possible may cause water to flow through the overflow
engine use

clean soft water pipe The capacity of the system is approxi

5 2 litres
mately

3
DATSUN

Thermostat from housing and the hose reconnected to

its

avoid laying up the car

In order to ensure maximum The thennostat opening is set by the
efficiency it

is essential to keep the engine operating manufacturer and can not be altered

temperatures within certain limit To assist During decabonising it is policy to test this
this a pellet tyep thermostat is fitted being opening by immersing the thennostat in water
located in the water outlet at front of the raised to requisite temperature The valve

cylinder head should open under these conditions but if it

Pellet type thermostat works by the principle fails to open a new unit should be fitted
of rapid variation of solution of wax

Overheating
Overheating may be caused by a slack fan
belt excessive carbon deposit in the cylinders

the too far retarded

running with ignition
incorrect carburetor adjustment failure of the

water to circulate or loss of water

Fan Belt Adjustment

The fan is driven from the crankshaft by
a V belt this also driving the alternator
A new belt can be fitted by first loosening
the clamp bolts Fig 3 which hold the dynamo

in position and moving the dynamo towards the

engine Slide the belt over the fan and onto the
Fig 2 Pellet Type Thermostat fan pulley

The devise consists of metalic pellet filled

with the wax which controls a mash room valve
by solution of wax

When the engine is cold this valve is closed

and the
on starting engine the flow of water to

the radiator is temporarily restricted

Due this the temperature of the water in the

cylinder head and

cylinder jackets will quickly
rise thus ensuring rapid warming up
The heat so generated will gradually press

up the piston by shrinkage of synthetic rubber

sleeve so opening the valve and ultimately
pennitting a full flow of water to the radiator
The thennostat itself is detachable therefore
should be occasion arise it can be removed

Fig 3 Fall Belt AdjustmeTlt

Part No Rated Temperature

Open at 76 5 t1
C 5 C
Standard 21200 61001
Open fully at t1
90 5 C

Open at 82 t1
C 5 C
Optional for cold district 21200 61001
Open fully at 95 t 1 5 C

4
 ENGINE

Adjustment is then made

by bringing the When completely drained the engine should
alternator away from
engine the
The belt be run for a timed minute to ensure that all
Bhould be sufficiently tight to prevent slip yet water has been cleaned from the system
the belt should have 10 to 15 slack between
mm A suitable notice should be then affixed to
the generator and crankshaft when the the radiator that the water has been
pulley indicating
midspan is pushed firmly drained
After the correct tension has been obtained

securely lock it in position again

Flushing the Radiator
To ensure efficient circulation of the coolant
Frost Precautions and to reduce the formation of scale and
Freezing may occur first at the bottom of sediment in the radiator the
system should be
the radiator or in the lower hOBe connections periodically flushed with clear running water
Ice in the hose will stop water circulation preferably before putting in anti freeze in the

and may cause boiling A muff can be used to winter and again when taking it out in the spring

advantage but care must be taken not to run The water should be allowed to run through until
with the muff closed boiling will result clear from the drain taps At
fully or it comes out

When frost is expected or when the car is to be intervals a stiff piece of wire should be inserted
used in a very low temperature make sure that into the taps during draining to ensure that they
the strength of the solution is in fact up to the are not becoming clogged with sediment
strength advised by the manufacturers The This method of radiator flushing may serve
strength of the solution must be maintained by well but in cases where the urring up is
topping up with anti freeze solution as neces excessive the operator will find it more efficient
Excessive
sary topping up with water reduces practice to remove the radiator completely and
the degree of protection afforded Solution must flush in the wayreverse to the
flow turn the
be made up in accordance with instructions radiator upside down and let the water flow in
supplied with the container through the bottom hose connection and out of

Top up when the system is cold the top connection

If the cooling system has to be drained run

the mixture into a clear container and use again

Water Pump
Protection by Draining After draining the water from the radiator
On cars where anti freeze is not used the the pump unit from the block
remove cylinder
following precautions mUBt be taken during by taking off the fan belt and releasing the
frosty weather to obviate any damage due to setbolts with washers
spring and hinge bolts
freezing of the cooling system to dynamo
When heavy frost is imminent the cooling
system must be completely drained It is not
sufficient merely to cover the radiator and
engine with rugs and masks There are two

drian cocks one on the left hand side of the

cylinder block and the other at the base of the
radiator block Both taps must be opened to

drain the system and the car must be on level

ground while draining
The drain taps should be tested at frequent
intervals by inserting a piece of wire to enBure

that they are clear This should be done

immediately the taps are opened so that any

obstruction freed by the wire may be flushed out

by the water The draining should be carried

out when the engine is hot

5
r

DATSUN

Seat set

v n

h
Sn r
Boh

twi j
1lj
db
Pulley 21051 10600 131 m m

143 dla
21051 10800 m m

Beanng
k

WA
lL
Bolt long

I
L
Hub for fan
pump pullf v

Gasket

FOlD belt
Screw
21067 10600

21067 10800
Used for 2MB type battery

Fig 4 Water Pump

Removing the Pump Shaft Assembly

one

drift
Disconnect the fan blades
The shaft and ball

unit

Put the
First

hard bar
the U type bench
pulley bub
bearings

on the bench

press or knock the shaft end

and draw out the
pulley and
is combined with

pulley
cover

with
hub on
a

Fig
5Jtj
5 Example of the Bench for
Pump Body

Take out the set pin from the slit which

locked the shaft assembly to the pump body The shaft and ball bearing be
aBsembly can

See Fig 6
drew out from the body
Next turn the body upside down and press Thus take out the vane floating seal and seal
out the shaft assembly from the vane side on the which remained the pump body
U type bench

6
 ENGINE

Reassembly The reassembling of the pump is a reversal

of the disassembly procedure but a care should

905 0 2 taken to ensure
be that the shaft assembly is
21 O 3
Front
fitted correctly for a slit a hole of set ring with

Set screw
a groove of shaft so as to insert and set the said

ring correctly

Shaft with
bearings Adjusting Clearnace the Van
End and Body
First press down the shaft fitting with a

groove line to insert the set pin

0 4 mm O 5 mm

Inserting thiclmess gauge Thiclmess 0 4

Clearance
o 5 mm between the vane end on the U block
Set pin
Insert here Take out the thiclmess
bench gauge and find
a thickness
gauge
out good condition Screw up with the cover and
cork washer

Fig 6

7
r

DATSUN

LUBRICATION

Circulatiol

Pressure lubrication is used throughout the The full of the oil enters the element through
and passes through the
unit and is provided by an ecentric non draining holes in the cartridge
oil pump The oil pump is bolted into the left element into the annular space round the center
hand side of the crankcase and is driven from pipe
the camshaft gear by a short vertical shaft This space is sealed top and bottom so that
The oil is drawn into the pump via the filter the oil can only escape through a small hole into

and is delivered through internal oilways to the the hollow center pipe and from this point back
relief valve which is situated at the cover of into the oil pan

oil pump

Draining the Oil

The oil on new and reconditioned engines
must be drained and then filled with new oil
after first 2000 mileB 3000 Lan and at intervals
of every 3000 miles 5000 Lan The drain plug
is at the oil pan The oil should be drained
when the is hot as the oil will flow more
engine
readilY
Before filling the oil pan with new oil dis
connect and change the oil cartridge

Oil Pressure
The oil pressure should not drop below 30
lb sq in 2 1 kg cm2 on the gauge at normal
Fig 1
road speeds whilst approximately 10 lb sq in
From the relief valve the oil passes into the 0 7 kg cm2 should be shown when the engine is
main oil the right hand side of the
gallery on idling New engines with new oil will
give
engine The flow then passes via connecting considerably higher readings at low speeds
oilways to the main big end and camshaft should there be a noticeable drop in pressure
bearings through drillings in the crankshaft the following points should be checked
The connecting ends in the
are drilling cylinder a That there is a good supply of the correct
block and the rocker shaft bracket to in the oil pan
rear grade of oil
lubricate the rockers and then drains back into b That the strainer in the oil pan is clean and
the oil pan via the push rod apertures The oil not choked with sludge
from the center camshaft bearing enters a c That the bearings to which oil is fed under

gallery the left hand side of the engine and

on
pressure have the correct working clear
lubricates the tappets through individual drill ances excessive the oil will escape more

ings As the camshaft rotates two grooves in from the sides of the
readily bearings
the front journalregister with a small hole in particularly when the oil is warm and

the camshaft thrust plate thus allowing a small becomes more fluid
amount of oil to pass into the timing twice This will in preBsure on the
case cause a drop
during case revolution of the camshaft to provide as compared with that shown when the
gauge
lubric ation for the timing chain and gears bearings are in good order The relief valve in
From the timing case the oil returns via a drain the lubrication system deals with any excessive
hole back to the oil pan The filter therefore oil pressure when starting from cold When hot
forms part of the main oil gallery and as such is the pressure drops as the oil becomes more

filled with oil under pressure fluid

8
 ENGINE

Check for Low Oil Pressure resistance of the oil filter element is large
caused by its choke up the relief valve will be
Check the level of oil in the engine sump by
means of the dip stick and top up if necessary opened with pressure difference to bypass oil

If the warning light is still on after refilling the

sump switch off and ascertain that the gauge

Removing the Oil Pan
strainer in the sump is clean and not chocked
with sludge sale that no air leakage existB at The sump capacity is 3 1 litres Drain the

the strainer union on the suction side of the oil oil and replace the drain plug

defective the unit and Remove the set screw bolts which are
pump being remove

the fault inserted from the underside of the securing

rectify
flange and the lower bolts from the bottom edge
of the bell housing Lower the oil pan from the

the Filter taking not to damage the joint

Removing engine care

A new filter cartridge should be changed washers in the process

after first 2000 miles 3000 kIn and then every

10 000 km after this

Removing the Strainer
The forms part of the main oil gallery of

the engine The element of oil filter is sealed With the snup lowered it iB pOBsible to

removed the oil strainer through which oil is

in the container as a unit it can easily remove

Take not to lose the rubber drawn into the oil pump To remove the strainer
by hand care

sealing ring unto the union connecting the oil pick up to the

The filtered oil in the element of filter pump and unscrew the Becuring bolts
cartridge is sent to the oil paasage in the The Btrainer may be dismantled for cleaning

block delivered to all the lubrication purpose by removing the delivery pipe flange
cylinder
system crankshaft journal crank pin cylinder bolts
bore locker arm camshaft journal and chain Notice that there are the dowel pins to the

tensioner and finally returned to the oil pan cover which must be positioned correctly when
The oil filter is provided with a relief valve refitting
If the temperature of lublicant oil is low at

starting oil viscosity is high or if the filtration

Element
embly
oil filter
idge
Flemfilt

To blode
Cyl

Relief alve I

Fig 2 Oil Filter

9
r

DATsUN

Removing the Oil Pump the cover On tilting the body upside down the

Remove the oil and pick up strainer

pan inner rotor with its drive shaft and the outer
Three of the five bolts securing the oil pump rotor with slide out
bottom cover are long enough to Becure the
pump to the crankcaBe 3 illustrates the
Fig
pump in explosed form Unscrew the bolts
Refitting the Pump
long
and remove the pump With its drive Bhaft Clean out the sump by washing it in paraffin
the care to remove
any traces of the paraffin
before refitting the oil pan to the engine Pay
particular attention to the oil pan and crankcase
joint faces and remove any traces nf oil jointing
material Examine the joint washer and renew

it if The oil joint washer can be

necessary
used again if it is sound but it iB advisable to

fit a new one Smear the faces of the joint With

grease and fit the joint washer Lift the oil pan
into position and insert the setscrews into the
flange tighting them up evenly

Reassembling the Oil Pump

The outer rotor haB a chamfered
edge It is

Fig 3 of great important that this chamber be towards

the base of the body failure to assemble in this
way will result in the cover is tightened down
Dismantling the Oil Pump Insert the slotted end of the drive Bhatt into the
Remove the setscrews and washers
spring body and bring the rotors into meBh
which secure the cover to the and take off
body

I r I
n i
f

j11 j
1
o Jl

Fig 4 Oil Pump

10
 ENGINE

SERVICE OPERATION WITH

ENGINE IN POSITION
The
Removing Starting Nut and Pulley spring washers are
immediately below
the bolt heads
Remove the radiator Slacken the dynamo Take out the set screw bolts remove the
attachment bolts and remove the fan belt cover and its joint washer Care should be taken
1 Bend back the tab on the starting dog nut not to the
damage washer when breaking the
locking washer Unscrew the starting dog nut joint If damage does occur fit a new washer
by using Heavy duty Shock type spanner cleaning of the faces of the joint surfaces
A few sharp blows in an anti clockwise beforehand
direction will slackent the nut
Pull off the crankshaft pulley Timing
Removing the Gear

Fig 1 3
Fig
The chain is endless and it is
timing
Removing the Timing Cover
necessary to remove bOth the crankshaft and
The timing cover is secured by set screw
camshaft gears together Before doing this
bolts each shakeproof and
having a washer a
notice the timing marks on both gears and their
special plain washer Note that the special relationship to each other
washer is of elongated shape and is fitted next Draw off boththe gears a little at a time
to the timing cover flange first removing the crankshaft gear retaining nut
As the gears are withdrawn care must be

taken not to lose the packing washers from

J
behind the crankshaft gear Between the cam

shaft gear teeth is a rubber ring which acts as

a tensioner and ensures silent operation of the

chain drive Examine the felt washer and
renew it if oil has been lost be seepage

Refitting the Timing Gear

Replacing the componentB of the timing gear

is largely a reversal of the dismantling process
but special attention should be paid to the

Fig 2
following points

11
DATSUN

Fit the crankshaft and camshaft gears into It is necessary to drain the system and
slacken the cylinder head nuts because four of
their respective shafts Ensure the timing
rocker shaft fixing nuts also secure the
marks are opposite and in line the

Turn the engine crankshaft until the keyway cylinder head

and the camshaft with its If the cylinder head nust are not siackened
is at T D C keyway
the one o clock poBition distonation may result and allow water to find
in approximately
Place the gears into position ensuring that its way from the cooling Bystem into the
the present in keyways the shafts cylinders and pump
keys are on

Ensure that the timing marks the gears are on Notice that under the righi hand rear rocker

opposite to each other and in line Drive the stud nut is a special locking plate Completely
unscrew the rocker shaft blacket nuts and
gears home
The Bame number of packing washers taken remove the rocker assembly Complete with
from behind the crankshaft gear must be brackets and rockers

replaced unless a new crank or camshaft has

of the Dismantling the Rocker Shaft
been fitted In this caBe the alignment
gear faces and measuring the alignment with a Assembly
the alignment it will To dismantle the rocker shaft assembly
feeler gauge To adjust
be neceBsary to vary the number of packing first remove the grob screw and locking plate
wash from the rear rocker bracket

Fit the oil thrower behind the crankshaft

gear so that its Concave face it towards the

front of the car and check that the felt waBher

is in pOBition

ROCKER MECHANISM

Valve Rocker Cover Removal

Remove the air cleaner Unscrew the cap

securing the engine lifting brackets

nuts

Remove the rocker cover and the cork joint

washer

Removing the Rocker Assembly Fig 5 Cylinder Head

Drain the cooling sYBtem If anti freeze is

in use UBe clean container for the fluid Remove the Bplit pins flat washers and

spring washers from each end of the shaft

Slide the rockers brackets and Bprings from

the shaft Unscrew the plug from the end of the
shaft and clean out the oil way
The two end rockers may be dismantled
without the whole rocker assembly being drawn
out This may be achived by turning the engine

by hand until No 1 push rod reacher its lowest

pos ition
Unlock the tappet adjuBting screw and screw

it back as far as it will go

Withdraw the Bplit pin flat and Bpring

waBher and slide the rocker off the shaft

Sometimes the valve spring will have to be

slightly compressed by levering a Bcrewdriver

Fig 4 the end rocker
underNo 2 rocker thus allowing

12
 ENGINE

to slide off the shaft easily Repeat the screw and lock plate
procedure for No 8 rocker Replace the spring and flat washers with the
split pins on the ends of the shaft Replace the
Reassembling the Rocker rocker cover and gasket

o s

Fig 6 Fig 8 Reassembling the Cylinder Head

On the bracket The vent should be at the front of the

reassembly tighten pedestal pipe
little time working engine Secure the of the two
securing nuts a at a cover by means

diagonally from nut to nut left nut of No 1 cap nuts ensuring that the rubber bushed and
pedestal bracket right nut of No 2 left of engine lifting plates are in position If the
No 3 and so on returning from the left nut of rocker cover gasket or the rubber bushes are
No 4 bracket and repeating the process until found to be faulty they must be renewed other

they are all tight If the rocker has wise oil leaks will result
assembly
been stripped down and rebushed
completely
the oil holes will have to be redrilled and the
bushes reamed down to size before assembly
on the shaft

Push Rod Removal

If the valve rocker assembly has already

been removed all that remainB iB for the push
rods to be lifted out They may on the other

hand be taken out without detaching the rocker

aBsembly
Remove the air cleaner and rocker cover

Slacken all the tappet adjusting screws to

their full extent then using a screwdriver with

the rocker shaft as a fulcrum depress the valve

spring slide the rocker side ways and lift out

the push rod
All but the end push rods can be withdrawn
in this way These will have to be withdrawn
after the removal of the two end rockerB from
Fig 7
the shaft When replacing push rodB ensure that

The rockers and spring must be replaced in the ball ends register in the tappet cups From

their original pOBition on the ends of the shaft here onwards reassembly is a straight forward
Remember to replace the Ocker
l shaft locating reversal of the dismantling process

13
DATSUN

Adjusting Valve Rocker Clearances

Remove the air cleaner and rocker cover To adjust Fig 9 insert a screw driver in

There should be a clearance of 0 014 in the adjusting screw slot and slaken the lock nut
0 35 mm between the face of the rocker and Then insert 0 014 in feeler gauge between the

the base of the valve stem Whilst checking the face of the rocker and the valve Btem Raise

clearances it is important to maintain pressure or lower the adjusting screw until the correct

with a screw driver on tappet adjusting

the clearance is obtained
the lock nut and recheck the
screw to disperse the film of oil from the push Tighten
rod cup Failure to follow this procedure will clearance

result in awrong reading being taken

It important to note that while the
is

Turn the engine over by hand starting clearance is being set the tappet of the valve

handle until the push rod StopB falling the being adjusted must be on the back of the cam

valve is fully closed opposite to itB peak

Fig 9 Adjusting the Rocker Clearance

CYLINDER HEAD

Rocker shaft the Cylinder

Removing Head
356 4
Length Drain water from the cooling sYBtem by
OUter diameter 15 85 15 88 mm
opening the radiator and cylinder hlock drain
Rocker inn bush cocks
Outer diameter One is situated inlet tube at the backside of
19 01 19 04 mmo
before mounting the radiator and other at the rear right hand
Inner diameter side of the engine If anti freeze mixture is in
Reamer finished use it should be drained into a suitable container
15 89 15 90 mmo
dimension after and retained for future use

Disconnect the
negative cahle from the
mounting
Clearance o 01 0 05 mm battery he extracting the tenninal screw and
removing the lug from the hattery terminal post
Rocker arm
Slacken both the retaining clips on the hose
Bore 19 012 19 037 mm
connecting the radiator to the thennostat hous
Lever ratio 1 43
ing and remove the hose

14
 ENGINE

Extract the thermostat housing securing will require this attention more often than those

nuts and the and thermostat used for long

remove housing runs

Remove the aircleaner carburetor rocker

cover and the inlet and exhaust manifolds

Removal and Replacement of the Valves
Detach the high tension cables and remove

the sparking plugs also disconnect the water Whilst the cylinder head is removed tbe

connection from the valves can be taken out To do this compress

temperature gauge
thermostat the vaive spring with the special valve spring
housing
Take off the rocker assembly not forgetting compressor as shown in Fig 1
slacken the external head nuts at the
to cylinder
same time

Withdraw the push rods keeping them in the

order of removal
The cylinder head can now be lifted off the

block facilitate breading the

cylinder To

head joint tap each side of the head

cylinder
with a hammer using a piece of wood interposed
to take the blow Do not use excessive force

When lifting the head a direct puil should be

given so that the head is puiled evenly up the

studs Remove the cylinder head gasket

Decarbonising
Remove the cylinder head With the valves Fig i Valve spring Compressor
still in position remove the carbon from the
combustion chambers and the valve faces
Removal
Leaving the valves in position for this operation
ensures that damage cannot be caused to the Remove the two cap retaining coilets
be used Release the valve spring the valve spring cap
seats by the wire brush which should
valve oil seal Inlet valve only and its retainer
for the removal of carbon
Withdraw the valve from the guide
If the exhaust valve heads are coated with a

very hard deposit this may be removed by using Keep the valves in their relative positions
a chisel shaped piece of hardwood when removed from the enigne to ensure

Remove the valves and using the wire replacement in their original valve guides
brush clean out the carbon from the inlet and
exhaust ports
Blowout all traces of carbon dust with
Replacement
compressed air or type pump and finally clean
them out The Note that the diameter of the exhaust valve
the ports with gasoline and dry
be removed from the heads smailer than the inlet valve To
carbon should now piston are

crowns Rotate the engine until the piston to be replace the valves insert each valve into its

worked on is at T D C Protect the other guide and replace the spring oil seal and
retainer Fit oil seal charrifered side down
cylinder bore from the entry of carbon particles
by pushing fluffy rag into them
a non wards The oil seals are more easily fitted if

Using a chisel shaped piece of hardwood they have been soaked in engine oil for a short
Carefuily remove the carbon from the piston period before use The oil seal is used for the
intake valve
crowns ring of carbon should be left round
A only
Replace the valve spring and compress the
the periphery of each piston and the deposit
round the top of the cylinder bore should not be valve spring
touched An indication as to when decarbonisa Refit the cap retainers and secure them by

an ail round of the valve cotters Remove the

tion is require is generally given by means

loss of power Cars used mainly on short runs compressor

15
r

DATSUN

Inner Sp Outer Sp Valve Grinding

Free length mm 50mm 52mm Before replacement of the head the
cylinder
Length in use and 36 9 13 1 38 9 29 valves and their seats should be examined for
loaded
mill kg t0 7 i1 5 signs of pitting or burnt patches and distortion
Turning Nos of coil 8 5 6 5 If these conditions are present the valve
Effective turn of coil 6 5 4 5 seats mUBt be recut before attemoting to grind
Dia of coil wire 28 mml
i i
4mml in the valves whilst distorted valve heads
Diameter of coil 24 l
mm 25 2 i
mml should be trued the valve renewed
or Only
the mimmum amount of metal should be
removed in the turning process
When grinding a valve onto its sealing the
valve face should be smeared lightly with
grinding paste and then lapped in with a suction

type grinding tool The valve must be ground

to its seat with a semi A
rotary motiron light
coil spring interposed between the valve head
and the port will assist considerably when lifting
the valve in order to rotate the face to a different

position This should be done frequently to

spread the grinding compound evenly

It is necessary to continue the grinding
process until an even matt surface is produced
on the seating and the valve face
On completion the valve seats and ports
should be throughly cleaned with gasoline soaked

rag and dried and the subjected to a compressed

air blast The valves should be washed in

gasoline and all traces of grinding compound

removed

Fig 2 Checking Spring Tension

tJ20 OI KI
l

Oi
U
J

tRl
bU1
lOO
g
l
Fig 3 Valve Spring Valve Ass y Fig 4 Turning the Value Seating

16
 ENGINE

VAL VES

Valve head diameter

Intake valve 34 9 mm

Exhaust valve 30 mm

Valve seat width I 63 t0 015 mm

Valve stem outer diameter 8 7 mm0

and 0 01 0 02
both intake ex

Overall length
Intake valve 109 54 mm

Ex valve 108 74 mm

Fig 5 Cylinder Head Distortion

Measurement

o
Dimensions Place the into and lower the
gasket position
A 40 mmq head into place Fit the cylinder head
cylinder
B 34 5 mmdl
Intake securing nuts finger tight
c 32 2 mmth in the
Insert the push rods replacing them
DO 2 O 4 mm

positions from which they were taken

A 3S mmq
Screw back all the tappet adjusting screws
B 29 4 mmq
Exhaust Replace the rocker assembly and screw down
C 26 8 mmq
D1 1 2mm
the securing nuts finger tight Evenly tighten
0
the eleven cylinder head nuts a little at a time

in the order given in Fig 6 finally pulling them

down with a torque wrench set to 45 lbs 1ft
VALVE GUIDE
9 5 1 3 7

47 6 mm
Length Intake valve
Exhaust valve 56 mm

Outer diameter both intake

14 31 14 33 mm 10
and exhaust
Inner diameter both intake
8 74 8 76 mm
and exhaust
Inner diameter at guide 8 4 2 6

inlet to insert both intake 14 3 mm

and exhaust Fig 6 The Order ot Tightening

Clearance of valve stem the Cylinder Head Nuts
and guide both intake and 004 007 mm

exhaust check
Reset the valve clearances and finally
Height of valve guide from them when the is not hot or cold The
15 5 15 9 mm engine
face of the spring seat
cylinder head nuts may pull down slightly more
after the engine has attained its normal working
temperature in which case the valve clearances

Refitting the Cylinder Head will have to be checked again and reset if

Ensure that the cylinder head and cylinder necessary

block joint faces are clean Refit the inlet and exhaust manifolds
Fit the craburetor and reconnect the control
The cylinder head gasket is marked Top
head in correctly linkage Refit the ignition advance suction pipe
BO that it will be placed

17
 JN
DATSl

to the connection on the carburetter but do not

at this stage refit the air cleaner or it will have

to be removed later to check the valve clear

ances Replace the rocker cover taking care to

fit the cork gasket correctly

Place the thermostat and its housing in

position and secure with the three nuts

Reconnect the water temperature gauge wire

and fit the radiator hose to the thermostat hous

ing Connect the cables to the battery Ensure

that the radiator and cylinder block drain tapes

are closed and refill the radiator
Clean and adjust the sparking plugs and refit
them the hightension leads The
clipping on

firing order of the engine is 1 4 2

3 Replace
the clip which secures part of the electrical Fig 9 Location of Valve Guide
wiring harness to the side of the head to be Fixed
The ignition can now be switched on and the

engine started When the normal operating Remove the cylinder head

has been reached switch off and Remove the appropriate valve and spring
temperature
remove the rocker cover so that the valve Rest the cylinder head with its machined face
downwards clean surface and drive the
may be rechecked Replace the
clearances on a

rocker cover and fit the air cleaner when the gnide downward into the combustion space with

final check has been made a drift

Whilst the engine is running check that the This should take the from of hardened steel
punch See Fig 8
water hose connections and fuel line unions do
valve these should
not leak Tighten them if necessary When fitting new guides
be driven in from the top of the cylinder head

Removing and Refitting Valve Guides

Removing a Valve Spring in Position

Fig 7 Fitting Position of a Valve Guide

o l

Fig 8 Hardened Steel Punch 10 Tension

Fig Checking Spring

8
 ENGINE

In an emergency a new valve spring can be driver which will pass through the sparking plug

fitted without removing the cylinder head When orifice and locate on the valve head By using
doing this the applic able piston must be brought the rocker shaft fulcrum point the spring
as a

its T D C to eliminate can be compressed with two screwdrivers or a

to position any
of the valve falling into the cylinder fork ended bar
possibility
the cylinder Withdraw the valve cotters and renew the
Remove the spark plug from
concerned Hold the valve onto its sealing with valve spring
the aid of a suitable tool such as a bent screw

Nut Cotter Pin

VVaSher

tr VVasher

Adjust screw nut

Locating Spdng
plate out j
d
C@l
s
Valve rocker

Valve rocker shaft

Bush I i
11 tJ
smcke
Valve

Valve rocker shaft

Rocker shaft bracket

COllet
8
Spring etainer G
Tappet adjwting screw

dng
Rubb II Push od

Outer spring II G Inner spring

tension
Intake valve Valve hfter

jChaiD
Bolt
Exhaust valve
Lock w hec

e earn maft

Locating plate

lock washer

Bolt

Timing Chain

11 Camshaft Valve Gear

Fig

19
r

DATSUN

Oil iller
i Screw

is Washer

to fix Nut i
outlet elbow
sherI e

Cover valve rocker

I
I nCgaver
Jorntwash
p
r
at
Thennost
@ Nut

waSher bolt i Washer

Heater outlet
Cover plate
I rear

Cy J3Slinger Guide ex valve

6
a
j Q
Stud
@
Nut
Q Guide in valve

I
1
I I

I
Ilil
Stud exh CyI head
manioHd
Slinger froIit
Washer
e
e oo

Nut

Gasket
t ey head

Fig 12 Cylinder Head

Removing and Replacing the Tappets

Remove the carburetor and the rocker
cover then take off the manifolds
Disconnect the high tension leads from the

sprking plugs the rocker assembly and

remove

withdraw the push rods keeping them in their

respective positions so that they will be replaced
onto the same tappets

Remove the and lift out the

tappet covers

tappets also keeping them in same locations

jFig 13
New should be fitted Belective
tappet by
assembly so that they fall into the guides under
their own weigbt when lubricated
Assembly is a reversal of the above pro
cedure but car sbould be taken to see that
tappet cover joints are oil tight and that the Fig 13 Removing a
Tappet

20
 ENGINE

rockers to the correct valve CONNECTING ROD

are adjusted give
clearance
Dia of tappet 22 48 22 49 i
mm
Distance between center of
Dia of cyl side hole 22 50 22 52 i
mm t0
150 03 mm
large end and small end
Clearance of the hole 0 01 0 04 mm
Large end bearing
Clevite F500
Type
Piston and Connecting Rod Removal Overall width 22 0
t 1 mm

Drain the cooling water from the engine Thickness 1 87 2 34 mm

and radiator Drain and remove the sump from Outer diameter 51 35 mm

and the oil

the engine then disconnect remove Width of large end 31 mm

and rock 20 0 31
strainer Take out the setscrews End play of large end o mm

washers the big ends and withdraw the

from
Finishing dimension of
caps It will be noted that the caps are off set
inner diameter of 17 450 17 462 mm
When used parts are replaced after dismantling small end bush Standard
it is essential they are fitted into their original
To ensure correct refitting mark the
positions
caps and connecting rods on the sides to identify CRANKSHAFT
them together The piston and connecting rods
must be with drawn upwards through the cylinder
bores Clearance of bearing
0 013 0 050 mm
peripbery to cylinder
block hole
Material White metal

Block side
Clevit metal
Cap side
Clearance of bearing
inner diameter and o 0127 0 0508 mm

crank journal
Diameter of main 50 813 50 825 mm
t
journal
End play of crankshaft o 051 0 076 mm

Crank pin diameter

Standard 47 640 47 652 mm

Difference of crank pin

Less than 0 012 mm
diameter
Rod
Fig 14 Removing Connecting End play flywheel is
Less than 0 05 mm
with Pis ton installed
Release the connecting rod from the crank
shaft and slowly push the piston and rod upwards

through the cylinder hore

NOTE Theshell bearing are removable by hand

It may be necessary to remove the ring of The bearings are require no bedding in it is
carbon or lip from the top of the cylinder bore being only necessary to ensure that the housings
are scrupulously clean and dry and to place tbe
with a hand scraper to avoid risk of piston ring
bre akage bearings into position with the tangs located in
Remove the assembly from the top of the their corresponding slots Always renew bear

cylinder block ings if they are scored or damaged in any way

oval with a or following the regrinding of the crankshaft
Check the crankpins for pair
bearing surfaces In tbe latter case undersize
of micro meter calipers and examine the bear

ing surface for scoring either defect will bearings will be required and the kinds of sizes
8 12 25 50 75 and 100
necessitate the removal of the crankshaft for available are

with punched mark

regrindin
g

21
f

DATSUN

P
on

ton
og

et
f

1
Bol

Key

Packing
Thrower
oil
1
nut
Starting
Bushing 1st
motion shaft

Budling Fly wheel

4
Jrgl
i
assembly

C nk shaft
wNut Pal nut

Fig 15 Piston Crankshaft

Fig 16 Crankshaft

PISTON

Replacing Pistons and Connecting Rods

Insert each piston and rod

connecting
assembly into the cylinder from which it was

taken it is essential that the split in the skirt of

the piston is positioned towards the camshaft
Fig 17 Inserting the Piston
Compress the piston rings with inserting
piston using tool Fig 18 and gently tap the
crown of the piston with the wooden end of a
hammer handle untt the piston is clear of the
piston ring clamp Fig 18 Piston Adapter

22
 ENGINE

The is a in
Now push the piston down the cylinder block gudgeon pin gudgeon pin push fit
at 700 F 21 1 C
until big end of the connecting rod just
the piston
protrudes through the bottom of the cylinder Whenreassembling ensure the gudgeon pin
bore then position upper half bearing shells is positioned in the connecting rod so that its
groove is in line with the clamp screw hole
NOTE the
Check that the spring washer fitted under
Each upper lower bearing has two oil head of the pitch bolt is not damaged
holes by ensuring sufficient and it is of
there

the greatest importance that the corresponding

oil hole in the bearing shell registers with the

oilway to provide an unobstructed passage
Pull the connecting rod onto the crankpin

taking care not to injure the bearing surface

Insert the shell intoconnecting rod cap
the

position the cap and the locking washers

Insert the setscrews and tighten with a torque
wrench t 21 7 24 6lbs 1ft

Fig 20 Re assembling Pistons and

Connecting Rods

PISTON PIN

Diameter 17 41 mmli
Over size 1 o 125

2 o 250

3 o 375

19 Thrust Clearance 65 3 mm
Fig Measuring Length
of Connecting Rod Clearance of pin and Degree to he able to

pin hole push it by finger at

200 C
Finally knock back the lock washers
Clearance of pin and
Check the connecting rod hig end for side o 01 mm
connecting rod bush
clearance 7 1000 in and see that the shell
hole
bearings are not binding on the crankpin when
rotating the crankshaft If it is difficult to

turn undo the big end and examine the shell and
seat for dirt or grit Piston and Bores
Before reassembling always apply a little
Insert Feeler 0 04 mm thick
clean oil to the piston surfaces and into the gauge
file the connecting rod between cylinder bore and piston and measure
cylinder bore Never

or their mating surfaces as this creates at the lower portion of the cylinder bore at right
caps
angle to the piston pin
oval in the bearing
There should be a clearance of 0 015 0 030

mm

Removing a Piston Pull out with feeler gauge by the spring

Remove the clamping bolt from the small scale and then inspect if the reading is within
0 5 1 5 kg or not
end of the connecting rod and push out the regulations

23
DATSUN

Because the piston rings do not travel to the

end of the cylinder bores a 1ip is eventually
formed due to wear

This may be checked with a dial gauge and

must be removed If this is not done there will

tendency or a fractured
be a to noisy operation
ring caused by the top piston ring striking the

lip
available in 0 010 in
Piston and rings are

0 254 mm 0 020 in 0 508 mm 0 030 in

0 762 mm and 0 040 in 1 016 mm over

sizes piston rings should always be fitted

The

from the crown of the piston and never pushed

upwards over the skirt Before fitting the

rings remove any carbon deposit from the

grooves in the piston When fitting note that
Fig 21 Removing Piston Ring the second compression is tapered type and oil
control ring is slat type processed by chromium
plating
Piston Rings
The piston ring gap should be 0 008 0 013 in
0 203 0 330 mm when checked in the cylinder
bore The clearance of the compression rings
in their grooves should amount to 0 0015 0 0035
in 0 038 0 089 mm and the oil control ring
o 0016 0 0036 in 0 041 0 092 mm

22 Clearance Between Ring Fig 23 Measuring Clearance of

Fig
and Groove Ring Joint

24
 ENGINE

TROUBLES REMEDIES

Excessive Oil Consumption Lack of Engine Power

Burning oil Ignition system improperly adjusted

1 Rings not correctly seated to cylinder wall 1 Spark plug faulty

Give Bufficient time for rings to seat Replace or clean adjust and seat Bpark

Replace if neceBsary plugs

2 Piston rings worn excessively or stuck in 2 Distributor points not set correctly
Set distributor points and timing engine
ring grooves
Replace ring 3 Ignition not properly timed
3 Excessive clearance between piston and Set ignition by the instruction under
wall due to improper correct Bpecification of engine
cylinder wear or

fitting
Fit new pistons Lack of fuel

4 Cylinder walls scored tapered or out of 1 Gas line partly plugged

round Clean gas lineB
Recondition cylinders and fit new pistons 2 Dirt or water in carburetor

5 Piston ring oil return holes clogged with Clean carburetor and fuel pump

carbon
3 Dirt in gasoline tank
Replace rings Clean the tank

6 Pistonrings broken 4 Air leaks in gasoline line

Replace ring S Check gasoline lines and tighten

7 Valve stem oil seals missing or leaking 5 Fuel pump not functioning properly
Replace seals check for sealing
Replace or repair fuel pump

Leaking oil
Carburetor air inlet restricted
1 Rocker arm cover gasket or tightening
tappet cover damaged or loose 1 Air cleaner dirty

Tighten covers or replace gasket Clean air cleaner

2 Oil pan drain plug loose 2 Carburetor choke partly closed

Tighten drain plug Adjust or replace choke mechanism

3 Oil pan retainer boltB loose

Over heat
Tighten oil pan bolts
1 Lack of water
4 Oil pan gasket damaged Refill BYBtem
Replace gasket
2 Fan belt loose
5 Timing gear cover loose or gasket damaged
Adj ust or replace
Tighten cover bolts or replace gasket
3 Fan belt worn or oil soaked
6 Fuel pump loose or gasket damaged
Replace belt
Tighten fuel pump bolts or replace gasket
4 Water pump inoperative
7 Rear main bearing leaking oil into clutch
Replace water pump
housing or flywheel housing
Adjust or replace main bearing or main 5 Thermostat sticking closed

bearing oil seal Replace thermostat

24
r

DATSUN

6 Cooling system clogged 4 codes loose and corroded in

Spark plug
Clean and reverse flush distributor cap
Clean code and cap terminals
7 Incorrect ignition or valve timing
Retime engine 5 Loose connections in primary circult

8 Tighten all connections in primary circuit

Improper grade and viscosity oil being
used 6 Series resistance in condenser circuit

Change to correct oil Clean all connectiOnB in condenser circuit

9 Fuel mixture too lean Low

7 capacity condenser
Overhaul or adjust carburetor Install proper condenBer

10 Valve improperly adjusted

Engine condition
Adjust valves
1 Valves burned
11 ExhanBt system partly restricted
Grind valveB or change
Clean or replace
2 ValveB holding open
Over cooling Adjust valves

Thermostat holding open 3 Leaking manifold gasket

Replace thermostat Tighten manifold bolts or replace gasket

4 Loose carburetor mounting

Hard Tighten carburetor mounting boltB
Starting
5 Faulty pistonB ringB or cylinderB
Slow cranking See Lack of power

1 Heavy engine oil

Carburetion
Change to lighter oil
1 Choke not working properly
2 Partially diBcharged battery
AdjuBt or repair choke mechaniBm
Change battery
2 Throttle not Bet properly
3 Faulty or
undercapacity battery Set throttle
Replace battery
3 Carburetor dirty and passageB restricted
4 Poor battery connections
Overhaul carburetor
Clean and tighten or replace connections

5 Faulty starter switch

Spitting and Detonation
Replace switch

6 Faulty starting motor or starting switch Ignition trouble

1 LooBe wiring connectionB

Tighten all code connections
Ignition troubles
2 Faulty wiring
1 Distributor points burned or corroded
Replace faulty wiring
Clean or replace points

2
3 Faulty Bpark plugs
Points improperly adjusted
Clean or replace and adjust plug gap
Readjust points correctly
3 Spark plugs improperly gapped
Set plug gap correctly

07 08 mm 00275 0 0315 in

24 2
rl
ENGINE

REMOVING REFITTING

has shown iliat it is much easier The throttle and choke controls must be
Experience
to remove the engine and transmission as a disconnected from the carburetor Disconnect
unit than to detach the engine by itself the fuel pipe from the fuel pump
single
and transmission Next the exhaust from the
To remove the engine remove pipe
upwards proceed as follows manifold
the cooling system and the From below the vehicle the gear
Completely drain remove

transmission disconnect and remove the change selector rod from the lever on the

battery and its supporting tray transmission casing

Disconnect the earth strap from the starter
Remove the upper and lower radiator hoses
motor Remove the hand brake control rod
by undoing the retaining clips
Disconnect the capacitor lead at the dis supporting from transmission
tributor also the high tension and switch wires Disconnect the speed meter cable from the
at the coil transmission Uncouple the propeller shaft
at rear axle and draw the shaft
Take off the dynamo lead and disconnect the pinion franges
starter motor cable at the motor end out of the transmission

Remove the oil gauge and water temper To allow the engine and transmission to be
ature gauge leads from their terminals on the drawn forward the radiator must be removed

engine by undoing the four securing bolts

Fig 1

i
t

Fig 2

25

f
r

DATSUN

OPERA nON WITH THE ENGINE

REMOVED

L a Iosulator engme

@ mounting Front
Bolt
I W
Bolt

I
J
InRUib I6fl
Washe

Nut self
Washer
rfj lock

l
Bolt
Nut Nut
1 118 I Bolt fllii
lo
f
Washer
Washer
Bolt

R H Insulator engine

r Bushing
f
f fNut self lock
i he ri
mounting F ont

spacer

rW
Bolt Washer
Cross member engine bushing Bolt
mounting rear

Fig 3 Engine Mounting

The following operations are best performed out certain attentions with the engine in position
with the engine removed from the car it is more convenient to do the work on the

Although it may be found possible to carry bench

Fig 4 Removing Crank Gear Carn

Gear and Chain Fig 5 Checking Thrust Clearance

26
 ENGINE

Withdrawing Camshaft

The camshaft is positioned by a locating mounting plate is now accessible and may be
plate held by three screws and shakeproof removed by withdrawing the setscrew and lock
washers position of the small lubricat
Note the ing plates The dynamo swinging link must be

ing oil hole in the locating plate when replacing removed

should be to the right of the engine Take out the setscrews securing the cam

End of 0 003 0 007 in 0 076 0 178 shaft locating plate when the camshaft can be
play
mm is controlled by the thickness of the locating withdrawn from the cylinder block

plate and can be checked with a dial indicator

set against the camshaft gear

Camshaft Bearings
Before withdrawing the camshaft the dis
trihutor and its driving spindle push rods and White metal bearings with steel lining are

tappet will have to be removed Remove the used for the camshafL They can be taken out
oil pump and its drive shaft and take off the renewed when necessary it being usual to do this
and The front when the cylinder block is being reconditioned
timing cover gears engine
The bearings can be removed by drifting

them out of their housings

When fitting new bearings care must be taken
to line up the oil holes with the corresponding
holes in the cylinder block

Tap the new bearings into position and ream

them to give a running clearance of 0 001 0 002

in 0 025 0 015 mm

Refitting the Camshaft

This is a reversal of the introductions for
removal Care should be taken however to

align and engage the drive pin in the rear end of

the camshaft with the slot in the oil pump drive

6 out Camshaft shafL
Fig Pulling

27
r

DATSUN

fix gear xm
bo
QUIlting plate
1

I
II1I

I
Au Y pan it
Ass y tube

ap breather

Stud to fix fuel pump

to lnk
cr care

7 Cylinder Block A
Fig

Adapter it p cDUre switch

An bI ock cylinder
Wl th plug

Plug welch
cylinder

6 block

Au y
Washer Jock gauge
oil level
Bolt

Plug chain
tI r ensione oil
Q eed br us

Cock drain

if
l
Y

Bearing crank Ih aft

half tand rd e

Washer t st hI met a 1 upper

m2in b frent
Cap eanng

Waiher thrust bl metal l ower

Seal il
I
frant bearing cap

to fiJ bearing
kSeal iI
bunngo side
rear

Fig 8 Cylinder Block B

28
 ENGINE

Main Bearing Caps

Remove the flywheel and clutch
Take off the timing chain the sump and
strainer and the engine rearmounting plate
Unlock and remove the bolts securing the main
bearing caps to the cylinder block also the two

holts securing the front cap to the engine front

bearer plate
Note that a thrust washer is fitted on each

side of the centre main bearing to take the

crankshaft end thrust These thrust washers

each consist of two semicircular valves one half

having a lug which is located in a recess in the

detachable half of the bearing the other being

plain
When fitting
new bearings no scraping is
required Fig 10 Removing Main Bearing Cap
they are machined to give the
as

correct running clearance of 0 0005 0 002 in

0 0127 0 0508 mm

Ensure that the locating tangs are properly

engaged in their recesses

Handle the new bearings carefully so as not

to damage the fine surface finish

Remove all traces of dirt and oil from the

housings and them
throughly dry with a non
Make sure that
fluffy rag the oilways are

clear When fitting the

bearing caps ensure
that they are replaced the right way round

Each cap is punch marked and the marks should

the camshaft side of the

race engine

Fig 11 Removing Crankshaft

ii
r JL
0

0 0
fJ
0
0 O

L
l

0
j 10 0
r01
Or
0

Wheel 12 Engine Rear Side

Fig 9 Removing Fly Fig

29
r

DATSUN

Check the crankshaft end play by means of a

dial gauge This should be 0 002 in 0 051

I mm

If
If bearing has it is essential to
l a run

in the
I
clean out all oilwayB crankBhaft and

I L

1
block Wash out the engine sump and the

I 1 strainer

q The oil pump should be dism antled and

1
l cleaned Ensure that no particles of bearing
II
I
a

metal are left within the engine lubrication

I
I system

I i
J

Fig 13 Measuring Bend of Crankshaft

Fig 15 Measuring End Plav of Crankshaft

Pin
Fig 14 Measuring Crankshaft
and Journal

Caution

Never file the bearing caps to take up

excessive this will ovality
playas cause

Always cover the bearing surfaces with

engine oil when they are replaced
The main bearing caps are held in position

by setscrews and lock washers Pull the set

tight with a wrench set to a

screws up torque
loading of 75 80 lb 1ft 10 36 11 05 kgm
When the main
refitting bearing caps tighten
the center one firBt after each cap iB tighten
rotate the crankBhaft to BBcertain that it re

volveB freely
If it is tight the last cap
remove tightened
and examine the bearing and its seating for
foreign matter
Fig 16 Removilzg Crankshaft

30
 ENGINE

IGNITION TIMING

DISTRIBUTOR
Adjusting the Braker Points

Hitachi D411 53 To adjust the braker points turn the engine

Type
So before top dead crankshaft with the crank handle until the braker
Ignition timing standard
center at 600 r p m is fully open Then loosen the braker point

Apparatus of automatic Governor type fixing screw Next by turning adjusting

the

advance screw move the plate until a feeler gauge of

100 120 H o 45 to 0 55 mm 0 01S to 0 022 ins thickness
Advance starting mm

slides easily between the braker points Then

vacuum pressure
Advance angle by 120 is Cranksbaft tighten the Fixing screw Becurely
check the gap once then
vacuum Finally more

60 90 Distributor reinstall the rotor The interior and exterior

pressure of 340 mm
of the cap is wiped clean with a soft dry piece
Hg
450 r pm of cloth extra attention being paid to the areas
Number of revolution
the terminals Clean the center
at the start of between

advance angle electrode on the inside of the cap also

Max advance angle at 11 15 at Whether or not the vacuum type timing

2400 r p m advancer is
functioning properly can be
crankshaft
Counterclockwise determined the inspection painter located at
by
Rotating direction of cam

1 3 4 2 the diaphragm if as the engine is being run

Firing order
Point gap o 45 0 55 mm this painter moves when the engine speed is
0 01S 0 022 in suddenly changed the advancer is satisfactory
Dowel angle 500 55

Contact o 5 0 65 kg
arm spring
pressure

Condenser capacity o 20 0 24 mfd

Inside the distributor is a braker point as

shown in Fig 1 This braker makes and brakes

contact several thousand times in one minute
Each time this braker brakes contact a spark
is generated in one of the spark plugs There
fore tbe maintenance of this braker must not be

treated lightly Also because the time during

which the ignition coil current flows varies with
the gap between these braker points see that
Fig 1 Adjusting the Point Gap
this is maintained at the standard value
gap
which is 0 45 mm 0 01S to 0 022 in ADJUSTING THE IGNITION
The braker points must be kept free of TIMING
and oil If the points should become The ignition timing is adjusted to 10 degrees
grease
burnt or blackened they are cleaned with a fine before top dead center with the engine stopped

stone or croucus cloth after which they as shown in Fig 2 With this adjustment the
honing
should be wiped clean with a piece of cloth which automatic timing advancer of the distributor
has been dampened with gasoline advances the ignition timing even further at the

If the points are badly burnt they must be time the engine starts to rotate and the timing
Braker must always be is maintained constantly at valveB suitable for
replaced points
sets the rotational Bpeed
replaced as

31
DATSUN

With engine stopped adjust so that the

the slot of the distributor drive of the upper end of
the shaft somewhat to the left as shown in Fig
distributor breaker point just breaks when the
4 At this time the smaller of the semicircle
piston of the No 1 cylinder is in its 10 degrees
is placed toward the front
before top dead center position for compression
If a timing lamp is used the standard ignition

timing is 15 degreBs before top dead center at

idling 600 rpm speed

In the case of marks which are not evenly
spaced pointers indicate 10 deg 15 deg and
20 deg before top dead center
positions
Adjustment is made by the following procedure

1 First distributor to the correct

adjust the

gap as described previously

2 Turn the crankshaft gradually until the top

dead center mark Fig 2 on the pulley
perifery coincides with the mark for 10 deg
before top dead center on the timing gear
cover as the crankshaft approaches i tB
somewhat before that corresponding Fig 3 Setting of Timing Gear Mark
positions
to the end of the compression stroke of the
in
No 1 piston Stop the crankshaft this
The of the 4 Adjusting the direction of the rotor so that it
position compression stroke
No 1 piston can be determined if the spark the drive shaft slot mount the
engages
plug of the No 1 cylinder is removed the distributor to the engine During this

hole plugged with a finger and the crankshaft assembly the directions of the distributor

turned With the crankshaft in the previously and rotor must be as shown in Fig 4 At the

mentioned position the No 1 is in its time the breaker must be in its position
piston same

before top dead center of when it is just begining to open If these

position of 10 deg
compression conditions do not coincide they are made to
do so by slightly turning the distributor body
only
To determine the position when the breaker
turn on the
point is just begining to open
ignition key hold the end of the No 1 spark
cord about 1 4 inch away from the cylinder
head and turn the body until spark jumpB
across the gap

The off set slot position of the drive shaft

when the No I piston is in its compression top
dead center position is shown here

5 Next cap on and clamp it

put the distributor
securely with the clip

2 Checking the Ignition Timing To the No l connect the cord from

Fig 6 spark plug
the terminal to which the arm of the rotor is
3 Next inserting the driving shaft of the pointing Thereafter connect the terminal
to plugs in the counter
distributor at an angle to the engine engage cords their spark
clockwise order to obtain a 1 3 4 2
the gear on its lower and with the gear on the so as

camshaft During this assembly place the firing order

32
 iINE
EN

7 Upon completion of the wlrmg cover the

distributor with a rubber cap The engine

should now start properly

Ordinarily the pointer of the octane selector

is set at its zero reading during the ignition
timing adjustment If the octane number of the
fuel being used is low and the engine knocks
the pointer is adjusted to the right R to the
optimum advance angle
if the octane number is high the
Conversely
to the left A One unit of
pointer is adjusted
calibration of the selector corresponds to 2 deg
of the distributor angle and to 4 deg of the

crankshaft angle
When a timing lamp is used the standard

setting is 15 dge before top dead center with Fig 4 Assembly Angle of Orive Shaft
the engine idling 600 620 In any case the

optimum adjustment is that in which a slight

knocking is heard when with the car running at CD Distributor shaft

low speed in HIGH

TOP gear acceleration 2 Distributor drive shaft

is applied suddenly @ Distributor fixing plate

33
DA UN

FUEL SYSTEM

I
CARBURETOR
Starting con

SP ECIFICA TlONS

D2630A 5A Primary Secondary

Bore diameter 26 mm 30 mm

Venturi diameter Pump planger

kit
large 20mm 27 mm Pump valve
Pump strainer
small 8 8 Small venturi

Main jet 1192 11140

Throttle shaft arm
Main air bleed 1160 1160
Slow jet 1148 1148 Fig 1
Slow air bleed first 100 11120
Slow air bleed second 11240
Emulsion hole 1160 x 12 1160 x 20
low economizer 11145 Body gasket
Power jet 1140
Power valve Begins to open whe

the primary throttle

valve is at 48 opening
Float level 21 5 mm below the
upper Burface of the
float chamber body

The carburetor has the function of automizing

the fuel mixing it in suitable ratio to air and

supplying the mixture to the

engine Flange gasket
It is therefore
important part which
an can Secondary Bide
Primary side
influence the performance of the engine
The carburetor is a highly efficient one of
two barrel two step and down draft type having
the following special features

Construction and Operation

Main air bleed

Pum p valve

1
Small venturi
l55embly Power jet sheet
gasket
Power Jet

Secondary side

Fig 2

34
 ENGINE

amount of the fuel can be varied with the two

holes provided on the pump arm that is the

inserting pOBitions of the Connecting rod

Starting System
The choke valve is provided with the spring
and installed eccentrically on the normal

carburetting device and synchronized with the

throttle valve When the choke is fully closed
the throttle valve opens about 140 from a full
close This is the best condition to start

operation The synchronization of the choke

Idle adjust screw
valve and the throttle valve be
can exactly
maintained often the engine has started firing
Fig 3

Main Carburetting System

The fuel flowing out of the passage at the Slow jet
embly
bottom of the float chamber passes through the

primary main jet and then mixed with the air

coming from the main air bleed to be minute

drops and inject into the venturi through the

main nozzle
Throttle
When the throttle valve is and
widely open adjust
screw
the engine requires dense mixture the
gas
acceleting pump opens its power valve from
where the fuel also flows into the main system
The power valve beings to operate when the

throttle valveopens480from full closed position Con rod spring

Slow Speed System

Passing through the main jet the fuel
passage separate from main line and flows
through the
slow jet slow air bleed first slow
economizer slow air bleed second and inject
from the by pass holes and idle holes

Accelerating System
Mechanical accelerating pump synchronized
with the throttle valve is adapted When throttle
valve is open the piston rod is pushed up with
ihe linkage which pUBhed up the piston through
the dumper spring When the piston is coming
down the inlet check valve closes the out let
I
check valve opens and the fuel within the pump is
blown out from the pump jet by the compressed Throttle lever assembly
dumper spring and hits against the side wall of
the small venturi to be minute drops compensat

ing trancient sparseness of the fuel A jetting Fig 4

35
f

DATSUN

Float Chamber
4
Adjustment of the float level can be done
from outside by adding subtracting the needle
or

valve carrier gasket after removing the float

4 needle valve installed at the inlet connector

As ventilation within the float chamber is of

a air vent method and pressure within the
Fig 5
venturi and the float chamber is constant
always
no matter how suctional registance of the air
cleaner varies fuel consumption can be always

econmically maintained
Main Carburetting System
Same as the normal carbUretting function
Adjusting Fuel Level
the fuel flowing out of the passage at the bottom

of the float chamber passes through the 1 Take off the cover of float chamber
secondary main jet and become minute drops 2 Raise the float slowly until its hanger lip
mixing with the air coming from the main air contact with the valve retainer
bleed and is blown into the venturi through the 3 At this stage the float upper surface must
Il ain nozzle be level and parallel with the chamber top
4 Adjusting the float level is done by adding or
subtracting the gasket of float valve seat
g
J needle valve carrier

JI L
i1 U
J
u
cl
ll
5 Addition or subtraction of 2 numbers gasket
make the float level up down about 1
1
or mm

jll ffi p
jAYd
is thickness 0 5 mm
one gasket

Lc IJr r
J

c U l
Adjustment of accelerator
v i71
IIi
J
fT
q

fl fl The accelerator must be

adjusting plate at
so

the carburetor side that the

adjusted by the

11 throttle valve may be full open with full pedal

and of slight gap with pedal off
this tighten up surely the nuts of the
After adjusting
adjusting
on

Fig 6 Nikki Carburetor

plate

When the throttle valve of the normal

carburetor is widely opened and the engine
produces high power the throttle valve of the c
1
power carburetor begins
chronized linkage
to open by the syn

5 p i1 l I
1
J
c
However at the top of the power carburetor
01
throttle valve
open at a slow
is an auxiliary
speed with aheavy load due to the
load of the counter weight connected to the valve
valve which is not

l
I
J

0
J
shaft when the throttle valve t y
even is open Z
When the to still higher revolu
engine change
tions the valve open against the loat
auxiliary
of the counter weight and the power carburetor
starts operation for high power When the
normal carburetor throttle valve is in a full 0

open the power carburetor throttle valve is also

to be in a full open Fig 7

36
 ENGINE

Fig 8

Dimensions of D is adjusted to 86 5 mm by THE GASOLINE TANK

rod and adjusting plate
The nut must tighten surly after fixing the The fuel tank has 41 Olitres
a capacity of
dimension of D and is situated at the rear of the luggage
compartment
The fuel pump operated off the camshaft

draws fuel from the tank and forces it into the

carburetor float chamber A large and efficient
air cleaner fillers the air supply to the
carburetor

Draining the Fuel

The fuel tank is drained by turning the

wrench operated drain cock

Fuel Tank Gauge Unit

Situated on the top face of the tank is the

To remove withdraw the set screws
gauge unit
9 which secure the unit to the tank not forgetting
Fig
to disconnect the electrical lead beforehand
Care must be taken not to strain or bend the

CD Rod float lever as this may serously effect subsequent

o Adjusting plate gauge readings Remember this also applies
@Nut when refitting the unit

37
r
DATSUN

Examine the joint washer to ensure that it

is in position and undamage This is essential

the between the tank and gauge unit
as joint I j

must be fuel tight

J
J r
r
Fig 1 Fuel Tank Securing i

I
1
Ii

C
J
capass y

Filler lube

Clamp Fuel tank

for sedan

Breather

tube

Band ear

Grommet

For SEDAN
Tube to S crew
strainer
washer
Ventilation
Gauge tube E

Gas
ket

Bolt1
j
Washer

Fue tank

for wagon

For WAGON

Fig 2 Fuel Tank Mounting

38
 E
E Gl

3
S
l

40
 ENGINE

FUEL PUMP

By the rotation of camshaft rocker arm is

pushed and pull rod of diaphragm is pulled down
At the same time diaphragm goes down
against diaphragm spring and then is pushed up
again by its spring
diaphragm and
By the movements of the

functioning of the valves at the inlet and outlet of

the pump chamber gasoline is drawn up from

the tank to the carburetor

If the float chamber of the carburetor

contains enough gasoline and the needle valve is

closed gasoline is not allowed into the
carburetor

Thus gasoline is stored in the pump chamber

and due to its pressure the diaphragm is kept

down and cannot return
Under this condition the rocker arm works

Fig 5 in vain as the rod remains Io

The rocker arm spring serves to prevent
FUEL PUMP

noise keeping the rocker arm pushed against

Type Diaphragm pump
the eccentric of the camshaft
Method driven Driven by camshaft
IDiaghragm spring Disassembling Inspection
Free legnth 36 5 0 1 mm
installed
in use and 18 mm l 6 0 1 Checking with fuel pump
Length kg on
tension
engine
Switch off and stop the engine Disconnect
Rocker arm spring
Free 30 mm the fuel pipe at the inlet union of the carburetor
length
Valve spring and then turn the engine with the crank handle
Free length 95 mm N ow the gasoline should be ejected vigorously

Thickness of valve 1 6 mm rom the tip of the pipe once very two rotations
Performance of the crankshaft

the function of the alone

Max quantity dis 1300 cu cm per minute To test pump

charged at 1000 I p m of cam operation of the hand primer and checking the
500 mm in suction height fuel ejection is enough
Max pressure 110 130 mm in
Removal from engine
discharged I ercury column
Max degree of More than 400 mm in Fuel pump can be easily removed by dis

suction vacuum mercury column connecting the inlet and outlet unions and loosen
Hand primer quanty 80 cu cm at 20 strokes ing the 2 attachment nuts

di scharged Inspection prior to disassembling

Prior to disassembling of the removed

The fuel pump which is of the diaphragm pump measure the distance between the rocker

and flange of the lower body by means of a

type is mechanically driven by the eccentric arm

scale and see if the rocker arm rocker link

part of the camshaft of the engine
It draws gasoline from the tank and delivers and pins are worn

it under pressure to the carburetor

Even when the engine is not running fuel can

be delivered under pressure by moving the hand
primer up and down

41
DATSUN

Method of disassembling Checking Repaires of Parts

First wipe dirt off the outer surface of the Wasbthe disassembled parts weU in gasoline
pump and put marks on both the upper and lower then inspect them
oodies to make their reassembling easy Replace diaphragm if any damage
the
It is easily separated into two when the five impregnation by gasoline
screws around the upper body are loosened Replace a valve assembly if any wear or
Take great care notto damage the diaphragm faulty operation is detected

during this disassembly Even if repairs are unavoidably required

the limit for repairs of warp or wear of the
valve is 0 001 in
When the Burface of th valve Beat or valve
is found irregular remove the valve Beat of the
outlet and dress the surface with a fine oilBtone
In case of irregularity of the seat surface of
the inlet valve which cannot be taken off from
the recondition it with cutter and grind
body a

ing tool
When the surface of the valve is faulty place
some very fine grinding compound on the surface

of a flat piece of glass plate and grind it lightly

with the tip of a finger The standard thickness
of the valve is 1 6 mm
The hole ofthe joint parts of diaphragm shaft
and link may be worn to some extent This is
Fig 6
not serious but when serious eccentric wear

crack or breakage is found the part must be

replaced
As a remedial measure such wear can be

compensated for at the time of dismantling and

reassembling of the body by inBerting a packing

made of thick paper between the lower body and

diaphragm to raise the relative position of
diaphragm shaft with respect to the lower body
The rocker arm should be replace when its

contact face with the carn and that with the link
and its pin hole are seriously worn

When its is
employment
re by reconditioning
Fig 7 unavidable add material to the rocker arm and

link by welding and finish them with a file but

this cannot last long and is no more than a

temporary measure

is found worn
Renew the arm pin when It
excessively
The diaphragm spring arm spring seldom

become faulty but when weakened replace them

always with standard ones

o If the diaphragm spring is to strong it

results in overflow of the float chamber of the

carburetor
The tension of the spring must not be

strengthened or weakened arbitrarily by hand

Fig 8

42
 ENGINE

Check to see if there is any warp on the joint The pump is in good conditions if 3 to 5 seconds

and thence there can be heard strong inlet and outlet

surfaces of the cap and body after

disassembling is over renew the gasket to keep noise respectively

The pump is mechanically fit for use when

its air tighteness
by connecting a hose to the inlet port it is able

to draw up gasoline from a height of more than

o 5 m After installing the pump test its

Reassembling Installing
functions during operation
for the various
Employ standard springs
A Connect the gasoline pipe on the inlet post
uses as stated before
Install valves precisely for close contact side only Leave that on the outlet port side

as it is and turn the engine 6 to 7 rotations

with their respective seats
means of the crank handle and make
screwing in of upper and lower bodies and by
In sure

that there is outflow of gasoline from

diaphragm fit them together according to the sure

the outlet port

marks which were put before the disassembling
hole to its mate and then B Connect the gasoline pipe to the outlet port
and align screwing
one

side and tighten all the piping joints Then

screw position where the diaphragm is
in at the

fully pulled down with the rocker arm pushed turn the eI gineagain several timeB to Bee if
the body by and pressure of air or from
towards the side of there iB any leakage gasoline
Do not screw in tight one by one since it each connection

causes warping Instead clamp all the screws

round loosely and uniformly ADJUSTMENT AND

Then tighten them diagonally and lastly re INSPECTION OF ENGINE
tighten all of them in order to make sure

As rule should be re must always be operated in the

The engine
a general gaskets
placed by new ones best possible condition and for this purpose
Installation on the engine is done in the periodic inspection and adjuBtment must be
reverse order to that for disassembly maintained in a certain order while in use as

Be sure to set the rocker arm so that it is well as after overhaul

contacting the eccentric of camshaft properly

not the rear side or to one side Replace the Order of Inspection and Adjustment
block and pump with of Engine
gasket between the cylinder
a new standard one 1 Check the cooling water water level and
extent of fillthiness

2 InBpect battery all connections level of

the

Checking Function
electrolyte specific gravity of electrolyte
When repairs of the pump is over or before and voltage
it is installed on the engine make a check to 3 Inspect the oil amount filthiness classifi

see cation and

viscosity
4 Cleaning of spark plugs and adjustment of
When a vacuum gauge is connected to the their gaps

pump inlet port and the pump is mounted on a 5 Measurement of compression pressure of
rocker arm is activated by the The standard compression
tester the cylinder
of the is 163 lbs
eccentric of the camshaft revolving at 1000 rpm pressure engine approx
Then the gauge pressure should rise to higher per sq in at 350 r p m Measurement of

than 400 mm of mercury column and even if pressure is made in the follOWing manner

is discontinued this condition should see Fig 1 First warm up the engine
operation
remain for more than 3 seconds temperature of cooling water 70 80oC then

all plugs and pull out the

When a gauge or tester is not available test remove spark
in the throttleknob all the way that is in the
following way
Close the inlet port and outlet port with carburetor the throttle valve and choke valve

finger tips Then after operating the rocker are fully opened press a compression gauge

arm several times suddenly release the fingers against each spark plug hole and running

43
 RUN
DA

of
the starter motor with a fully charged battery Diagnosing of Engine by means
Vacuum Gauge and Combustion Tester
read the maximum pressure obtained within

This measure In diagnosing the engine the condition of

5 8 rotations of the motor
each be assumed by measuring its
ment must be made as quickly as possible cylinder call
It the
compression pressure of any one compression
For employment of a vacuum gauge connect
cylinder differs by 10 lb Isq in or more

must it to the engine intake manifold and refer to Fig

form that of another the cause be
2

The use of a master motor tester as shown

in Fig 2 is convenient

When a combustion tester is used install a

special intake pick up in the exhaust tube and

after the engine has been started analyze by
means of a
special gauge the combustion gas
which flows through the connecting hose into the
tester and judge the combustion condition

according to the mixture ratio of fuel and air

When measurement is to be made in rainy or

cold weather use an auxiliary condenser between

the pick up and the meter otherwise the

excessive moisture in the exhaust gas will

Compression Gauge damage the functioning of the meter if permitted

Fig 1
to enter it

6 Check and the distributor

adjust
If the breaker contact points have defective
contact surfaces dress them and adjust the

gap to 0 45 0 55 mm

Also turn the cam of the distributor clockwise

and check to see if the governor can carry
out advancing function
7 Adjust ignition timing correctly
By utilizing a power timing light the function
of the governor can be checked together with
the ignition timing illumination of crank

pulley will enable to inspect the conditions of

B T
running and advancing of the timing
DC 200
8 Inspection of fuel pump and gasoline strainer

9
Adjust the slow setting of carburetor
of
10 Cbecking operation generator
Check the generating condition and functioning
of the cut out relay by means of indications
of the ammeter

11 Adjustment of slack in fan belt

12 Adjustment of valve tappet clearance

13 Road test
While driving in 3rd speed at about 25 lanl
hr suddenly step on the accelerator If
the ignition
only a slight knocking results
timing is correct Slow speed adjustment is
made so that the speed is about 15 Ian hr Fig 2 Motor Master Tester Available for
when driving in 3rd speed 4 6 and 8 Cylinder Engine

44
 ENGINE

When a tester is to be used make adjust

ments 5 When indicator some
according to the following table
times drops by 4 in
conditions Without Suitable Weight Ratio or so valve sticking
load of Mixture exists

Low Speed Running

12
70
600 r pm

IEligh Speed Running

1
85
5

2 000 r p m 2 6 When indicator drops

by several inches at

certain time valve are

Engine Trouble Shooting
burnt
Fig 3 is intended to be of assistance in the
systematic analysis and isolation of symptoms
of engine troubles so that the defective points
be accurately traced and
may economically
repaired

1 Normal Condition 7 When indicator drops

Settles between 18 by about 2 in valve
20 in leak Faulty seating of
valves

2 Normal condition 8 When indicator oscil

When indicator fluct lates actively between

uates between a range 14 and 18 in valve

of 0 25 in as engine stem guide is worn

is raced and out

rings
valves are in good
conditions

3 Even if indicator set 9 When with a slight

tles if reading is low speeding up indicator
in between 10 22
rings or oil are moves

faulty condition in and with increase

of s peed the range
becomes larger valve
springs are weak

4 When above 3 con 10 When indicator re

dition exists indicator mains still between

will swing to 0 in if 8 15 in it is be
either
engine is reaced cause valve

timing is retarded or

valve clearances are

not correct

45
DATSUN

11 When indicator set 14 When indicator oscil

tles between 14 17 lates regularly between

is 5 19 in there is
in ignition timing
retarded leakage at cylinder
head gasket Faulty
clamping of gasket

When indicator moves 15 When indicator first

12

slowly between 14 16 rises bigh drops down

in it is because to zero and then re

either electrode gaps turns to 16 in muffler

of plugs are too nar is clogged

row or breaker point
is defective

13 When indicator points 16 Whenindicator moves

to 5 in or below slowly between 13

there is leakage at 17 in carburetor is

intake manifold or poorly adjusted

gasket of carburetor

Faulty clamping of

gas ket

Fig 3 Diagnosing Engine bv Means of a Vacuum Gauge

Battery discharged or connections poor

Timing poorly adjusted

Air being sucked in

Plug spark Plug sparking weak

Wiring incorrect
Plugs dirty
Sparking at terminals
Timing incorrect

5 B Plugs do Short in circuit

not spark Ignition coil or condenser defective
g
o
Q No sparking Contact point dirty
c Breaker
at terminals Point contact poor
defective
Breaker arm insulation defective
1 Rotor shorted
c
6D No in tank
c
gasoline
Strainer defective
Pipe clogged
Float valve sticking
in carburetor
No gasoline No air can enter tank

Fuel pump not operating

46
 ENGINE

No gasoline or gasoline supply stopped

carbureto Engine seized
free of Lubrication insufficient
Compression Air
trouble being sucked in
a good Jet or pipe clogged

r
a
o
Carburetor Float sunk
Plugs
defective Float in high poSition will not descend
spark
t Carburetor attachment not secure

Piston ring or valve sticky

l
r
Compression poor
E Piston or connecting rod broken

Valve seating poor

Breaker arm spring defective

No spark Contact point poor

ing from Rotor shorted

coil line Breaker Ignition coil or condenser defective
Plugs do
foe arm good Distributor wet
not spark
o
Cap insulation defective
5
Cord shorted or connection poor

Wiring shorted or cut

S parki ng form COI 11 me
PIugs dlrty or broIre n

A Trouble Shooting Chart

Compression weak
Valve clearance incorrect
Valve spring weak
Valve deformed
Muffler clogged
Continuous lack
Valve timing incorrect
of power
Ignition retarded too much
Carburetor adjustment poor
Power weak Gasoline supplied insufficiently
Carbon deposits excessive
Gasoline of poor grade

Engine operation
Intermittent

lack of power t Carburetor defective

Valves sticking

defective during Pre ignition

renning Engine gives off abnormal noise

f Overheating
Bearing worn

Plugs dirty
Sparking Breaker point defective

irregular Intermittent shorting

MIS fIrIng
Mixture too rich
Insufficient gasoline to carburetor
supply
Sparking normal Water in gasoline
Nozzle clogged

B Trouble Shooting Chart

47
r

DATSUN

CLUTCH

GENERAL DATA DISASSEBLY OF CLUTCH SIDFT

LEVER

Single dis Clutch Housing

Type ry i
pl
Construction of disc With coil spring
Outer dia of facing 200 mm

Inner dia of facing 130 mm

Thickness of facing 3 5 mm

Gross friction area 363 cm2

Thickness of disc ass y 86 9 1 mm

when releasing
7 3 8 1 mm

when depressing
Disc run out Less than 0 5 mm

Backlash at splines part o 05 0 15 mm

0 002 0 006 in

Operating method Oil pressure

Inner dia of master 15 85 mm 5 8 in

cylinder
Inner dia
Fig 1
of operating 19 05 mm 3 4 in

cylinder
Operating liquid
d
Genuine super
brake oil
Return spring with
drawal wire dia
16 mm
3 j r
Free length 87 mm
J
Length in used tension 136 5
rmn kg
tI

PRESSURE SPRING X

Free length 49 mmct 1 5

L
c
ompreBsed length Less than 25 mm

urn numbers 7 8

ower of comp in full About 300 kg Fig 2

ire diameter 33 mm

ength in used and load 29 2 37 t2

5 kg

RELEASE BEARING

Construction Ball bearing type

Height of release plate From flywheel face
to rear end of plate
50 10 2
5 mm

elease plate run out Less than 0 03

0 0012 in

If use master disc 7 8 mm I 05 rom

height height of release lever is 50 t0 2

5 mm Fig 3

48
 CLUTCH

Driver Plate Assembly Removing the Clutch

To gain access to the clutch it is first
This is the flexible type in which the splined
hub is indirectly attached to a disc which necessary to remove the transmission complete
the power and the over run from the engine
transmi ts through a

number of coil springs held in position by Once the transmission unit is free a turn at

retaining wires a time by diagonal selection until the spring

Two friction riveted to the disc pressing is relived
linings are

Then remove the screws and lift

completely
the clutch assembly away from the flywheel
Cover Assembly Finally remove the driven plate assembly
The release levers set
The cover assembly consists of pressed steel are correctly on

cover and a cast iron pressure plate located by assembly Interference with this setting unless
throw
six pressure springs new parts have to be fitted will the

Mounted on the pressure plate are three pressure plate out causing judder
release levers

Adjusting nuts are screwed on the bolts of

pressure plate Retainers of pressure spring
insert to the clutch cover holes and anti rattle

springB load release levers

Dismantling Assembling Gauging
By using service tool the clutch can be
Release Bearing quickly dismantled reassembled and adjusted to

a high degree of accuracy

The release bearing consists of a carbon

bearing shrunk into a bearing cup the cup The tool comprises the following parts base
bearing located by the operating fork and the plate centre pillar spacing washers distance
release bearing retainer spring pieces hight finger actuating mechaniBm Bet
screws speed brace and metal box As thiB
tool is universal a chart indicating the

Running Adjustment particular parts to be used for particular types

of clutch will be found on the inside of the lid of
Owing to the hydraulic design of the clutch the box
controls no adjustment is necessary to the
clutch pedal

IF

o 0 0

Fig 4
Fig 5

49
r

DAmUN

Ey bolt

Clutch caver

Pin with drawa 1

Preuure spring
etalner

Sleeve bearing

Clutch release
bearing

cav

i Tnmnicm

Nut lock bush red

Dutch disc
assembly part No 30100 10600
Cover assembly Part No 30209 10600
Pressure
@ F S37kg
spring

I
I
Lock washer
Bolt

Fig 6 Clutch

Dismantling
Place the clutch cover
aBsembly on the three time by diagonal selection until the cover is

spring so that the holes In the cover coincide attached to the base plate at all possible
firmly
with the tapped holes in the plate insert the set This IB
pointB mOBt important if the best
screws prOVided and tighten them a little at a reBults are to be achieved

Mark the cover pressure plate lugs and

release leverB with a centre punch so that the
CD parts can

In
be reassembled
order to maintain the
in their relative
balance of
position
the clutch
Detach the release lever plate from the eye
boltsand remove the three lock nuts and

adjusting nutB

@
e
r
f
I
l
0
or L b
r

N o

50
 OLUTOH

@
@
8

e
fa

j
@

@
I

7 Disassembling
Fig

5
r

DATSUN

Slowly release the pressure on the springs Place the pressure plate on the base plate

unscrewing by diagonal selection the set with the pressure springs in poSition on the
screws securing the coyer to the base plate plate and the
pressure put preBsure spring
The clutch can then be lifted to expose all retainers on it Cover and set the clutch cover

components for inspection assembly on the base plate

The release levers man should sprlngB
sprin c omp
Bsthe
El sBure
pr screwing
examined for wear and diatorsion Renew these down the cover to the base plate by using fhe
parts if necessary bearing in mind that the special set screw placed through each hole In
pressure springs must only be renewed in sets the cove r

Clean all parts and lubricate the bearing Tighten the screw a little at a time by
surfaces of the levers sparingly with grease diagonal Belection to prevent distortion to the
cover Set the release lever on the eye bolt
with lock nuts inserting for lug at the edge of
s1mm
G
qB pressure plate

nfn 7j8mm
E

CD
Fig 8

Assembling
Press the pin into the eye bolt hole through
the lug on the pressure plate as shown

@
I

Fig 9

52
 O U OH
I

10
Fig

53
r

DATSUN

Gauging Refitting the Clutch

Screw the nuts into the boltB and proceed as Place the driven plate on the flywheel with
follows Screw the centre
pillar base into the the longer chamfered splined end of the driven
plate and slip the distance piece over the pillar plate hub towards the transmission
followed by the camshaped height finger Adjust The driven plate Bhould be centralished by a
the height or the release levers by screwing or dummy drive shaft which fits the spi ined bore of
unscrewing the bolt nuts until the height finger the driven plate hub and the pilot bearing of the
when roted just contact the heighest point on flywheel
the tip of the release leverB

Replace the height finger and pillar by the

clutch actuating mechanism S e insert Fig 5
and actuate the clutch several times by operating
the handle
This will enable the partB to settle down on

their knife edges

Replace the height finger and distance piece
and readjust the height of the release levers
checked for out the
run as near edge as

possible as if the error is more than 0 02 in

press over the high spots until it is true within

this figure It is important to keep friction

facings free from oil or grease
Finally repeat the procedure to make quite
sure the release levers are seating properly
and gauge again Secure the lock nuts and fix
the release lever
Release the setscrews and remove the Fig 11

clutch assembly from the base plate

the Driven Plate The clutch cover

sembly can now be
Refacing
secured to the flywheel by means of the holding
If a new complete clutch driven plate is not
screws tightening them a turn at a time by
available new linings may be fitted to the old
diagonal selection
driven plate in the following manner
There two dowels in the
are flywheel to
Each rivet Bhould be removed by using drill
locate in the clutch cover Remove a dummy
The rivets should not be punched out Rivet
shaft after these screws are fully tightened
one new facing in positiOn then if the correct
35 Ibs ft 4 84 kg m
tool is not available use a bluntended center
Refit the release bearing and transmission
punch to roll the rivet shanks securely against
case The weight avoid strain on the drive shaft
the plate The second facing should then be
and diBtortion of the driven plate assembly
riveted on the opposite side of the plate with the
clear holes over the heads already formed in
fitting the first facing The plate should then
be mounted on a mandrel between centers and
Description of Clutch Control
checked for run out as near the edge as

possible if the wabbing is more than 0 02 in The clutch is operated from a master

press over high spots until it Is true within thiB cylinder by means of
suspended pedal
a

figure It IB important to keep friction facings A cylinder mounted on the clutch bell houBing
free from oil or is coupled to the clutch operating shaft
grease

54
 CLUTCH

Pull back the rubber boot and remove the stopper

ring with a pair of long nosed pliers The push

rod and ring can then be removed and unscrew

the release pin

When the push rod has been removed the
piston with caps attached will be exposed
remove the piston assembly complete
The assemblycan be separated by lifting the

spring Beatedge over the shouldered end of the

piston Depress the piston return spring
allowing the valve assembly to slide through the
elongated hole of the spring seat thus releasing
the tension on the Bpring

Fig 12 Components of the Master Examine all parts especially

gasket the

Cylinder cylinder bore and piston cups for wear or

distortion and replace the new parts where
1 Push rod assembly @ Let in valve spring necessary
@ Master cylinder @ Return spring se at
rubber boots @ Piston return spring
@ Stopper ring @ Clutch master cyl
Assembling
@ Piston secondary inder body ass y Smear the assembly well with the recom

cup ring @ Let in valve release mended brake fluid and insert the assembly
@ Secondary cup pin into the bore of the cylinder end first easing
@ Primary cup @ Ring the piston cups lips in the bore

Z Master cylinder @ Gasket Replace the push rod with the secondary
piston @ Filler cap gasket cup ring into the cylinder followed by the

@Let in valve @ Cap stopper ring which engages into the groove

assembly @I End plug gasket machined In the cylinder body

@ End plug Replace the rubber boot and secure the unit

by meanB of the two bolts on the flange and refit

When pressure to the clutch pedal is applied the pressure pipe union into the cylinder
the piston of the master cylinder displaces the
fluid in the cylinder and via a pipe line in turn
The Operating Cylinder
moves the piston of the cylinder pushing against
the lever of the clutch shaft This cylinder is of simple construction

consisting of the body piston piston with cup

the
spring and bleed screw open end of the
The Master Cylinder rubber dust
cylinder being protected by a cover

mounted under side of the

The master cylinder consists of an alloy The cylinder is

with polished finish bore and reservoir starting motor

body a

with cap The inner assembly is made up of the

push rod ring

stopper ring piston cups

spring spring valve and valve spring

seat

The end of cylinder is protected by a rubber

boot

Dismantling the Clutch Master Cylinder

Disconnect the pressure pipe union from the

cylinder and remove the securing bolts then o

the and be withdrawn
master cylinder may
complete from the car

Remove the filler cap and drain out the fluid Fig 13

55
r

DATSUN

Dismantling
Remove the rubber dust cap from the bleed stem smear well with the recommended fluid
screw attach a bleed tube open the bleed screw and insert into the cylinder Replace the dust
three quarters of a turn and pump the clutch and mount the cylinder in
cover position making
pedal until all the fluid has been drained into a the
Bure puBh rod enterB the hole in the ruhber
clean container boot Secure the cylinder with the bolt and
Unscrew the flexible pipe union and Bcrew in the pipe union Adjust
the pUBh rod hy
adjustable push rod The operating cylinder the screw driver at top of withdrawal level with
can now be removed Removed the rubber the adjustable rod of operating cylinder to give
cover and if compressed air line is available the end play 2 5 3 0 mm
blowout the piston from the side union
Examine all parts especially the seal and the Clutch System
Bleading
replace if worn or damaged

Fig 14 16
Fig

Assembling Remove the bleed dust at

Bcrew cap the
Place the seal into the stem of the piston operating cylinder open the bleed screw

with the back of the Beal against the piston approximately three quaterB of a turn and attach
replace the springs with the small end on the a immersing the open end into a clean
tube
receptacle containing a Bmall amount of brake
fluid Fill the master cylinder reservoir with
I the recommended fluid and by using slow full
I Btrokes pump the clutch pedal until the fluid

v
II

entering the container is free from air bubbles

On a down stroke of the pedal screw up the

bleed screw remove the bleed tube and replace
the dust cap
When the clutch pedal is depressed the
force is transmitted to the ball bearing and the
surface pushed the release plate Effectual

p
i
a

i1 stroke of the pedal is 128 mm

leaving 30 mm
o

c
surplus in stroke 95 mm until the clutch
disengages When there is undue Burplus or

shorness Instroke readjust the pedal position

Fig 15 with the shim
adjust

56
 o
ob

ntkg places
2

10602 tOrque
0

0870
4

32 0 v

46520
S

ces
46123
Tightenig
3

pl
2
place46485
2
1

3QO O 0410 1

46482 46460
J
Vlc

Pe
stOP

uteh up
Brake Cl
lock the
pad of

the mark point

with lon
adjustmen arm
pedal
of
dimeuS
stop er lodung nut tandhe
the
sa1d
the
contaced pedal
at

height Adjust Stop er After end

ce
pl
The without the

2
places
2
1

25 32
1
GJ

0870 1

stroke stroke
j
0410 465W
345
U

9 pedal pedal
4648 Clutch Brake
kg ntm ntm
M4
lb 9

95 1
32
kt mtn 3

m1ll nun
ce
18 4

t7
145 05mIl 45
v kg kg
58

143 120
pl
place place 1

kl
28 16 3
15 17

14 14 side Y
foot fun

30614 304
5
to bl

strOKe
OL
sUlt

15215 1 145 h2
h

plateslower
end hy
prdS1ng
strokee1lcestopendl top Ces pushedped3for1 n stroke
of
9 9 2 ting 3
iert ke
trC
at
e

eacn up er
l
1
r dl I

the 1y
iu oke
uu uU sb
8t 5t
level
strength kg
6t full Ilt

height
h d r a w l e v r
0
60
pedal stroKe pedal pedal pedalBu uM
t 0
1

ed l

t e n c e pedal
46182760 Clutch Withdrawl Clutch presing
U
27260
ped 27260 rele tull Brake
e

ndQtd St
461 7 461 9
k
C l u t c h For
t
Wi

a
DATSUN

56 2
 TRANSMISSION

TRANSMISSION

Fig 1

Model 3 stage for forward 1 4

stage stage for forward synchro
for
f
reverse mesh on for speed
Remote control
Full synchromesh on forward
gears

t Type of ge ar Synchro
type
meshed helical gear 2nd 3rd 4th gear

Ratio 1 3 197 3 94
Ratio 2 1 725 2 40
Ratio 3 1 000 1 49
Ratio 4 1 00
ReverBe 4 125 5 159

57
r

DATSUN

COVER OF TRANSMISSION
DlSASSEBL Y COURSE
CASE

Drain out the gear oil from the case Hold

the cover in position are 14 set Front Bearing Retainer
ing nuts all of
which must be removed when cover can be taken Release the front bearing retainer situated
off within the clutch housing by removing the nuts

Fig 1 1
Fig

Ii
u
p iV
j
1

i
f

Fig 2 Bottom Cover Fig 2

Fig 3 View of Inside of Transmission 3

Fig

58
 TRANSMISSION

TRANSMISSION CASE

IL SEAL CROSS SHAFT

I
GJ G l1
101 r n
3
1
Q
1 1
1

1
Fig 4 Fig

Plug Cross Shaft

PLUG CROSS SHAFT

5 Fig 2
Fig

fIIIIIIM
1
SPRING CHACK BALL

PLUG INTER LOOK HOLE CRACK BALL

3
Fig 6 Fig

59
DATSUN

o
n 1
i
J I 1 Ii
C

j l
I
Ii
I

co
1
f
ul f
f
C
c

c
L

tS
G D f
8 7
t
it I i
i k
I
1 1
i I
b r

Fig 6
Fig 4 Press out the pin from fork shaft
Disassembly Insert the pin and
tap into the shaft and hole fork
setting hole

Take out the cross shaft from the case

j
6
J
r

n
Q 1 3

II
I
0
J

I
I I Fig 7

rf I I
1 CO 4
j

S
I
H
iI
1 III H
ii
j
ot
I I Ii
I L i
t
J

Ii N
1
I
il
d
U
c

Fig 5
Fig 8 Take off the Pin Nut of Cross Shaft

60
 TRANSMISSION

9 Pull out the Cross Shaft Fig 12

Fig

Fork Shaft

LF
R 1V J
J

O O lO O

i
J I I I
I 0
II 1 I

llh 0

t I
r4
1 J
1
1

111 I
1 i h
I

r
u zt I

Detach the Fork the Gear

Fig 10 Fig 13 from

11 Fig 14 Take out the Fork Shaft

Fig

61
r

DATSUN

front and small one at the rear then place the

cluster gears in the case

Fig 17 Assembly Course

Fig 15 Pull out the Shaft

J
I I
Counter Shaft Gear J I
J t
1
I
u
bc j s ja

j
I

J
v
I
I1 r

c
J
0 3 r

Fig 18 Disassemblv Course

D r

j
it
THFW r
T
FRON
9 ER Ii M
E 3IfI
J I
c
iJ o

16
Fig

Disassembly
Using a soft and long metal drift pushing
out the counter shaft forward When the counter
gear cluster and two thrust washer will drop in
the case

Assembling
First locate the two washers to the counter

gearB ensuring that the larger washer is at the 19

Fig
62
 TRANSMISSION

Main Shaft

Pull out the bearing and the speed gear

rear

sleeve by the bearing puller from the main shaft

rear side

20
Fig

Fig 23 Removalof Main Shaft

Assembly

trmIC I
I
l
lJ J

I ffJ
C
E
Fig 21 Pull Out the Reverse Gear Shaft 8 t
0

Main Drive Shaft

I
4

1
r 0

24 Take olll the Main Drive

Fig
Gear

Fig 22

63
DATSUN

Caver fcoat
tnmmhl10ll

Glldu tfront
covel

o fi1

ft

Oil

Aa y breather

l IlIion

G
Plug d

PlugCI
OQ go
ri

AD y enelJlilXl rear

Caver
botoom x bottom
fi cover
An y plug
d

Fig 25 Transmission Case Rear Extension

Aa y 5
AI Y hev
pinion
speedomete speedometer
OD
in

Sleeve
Gear 3 rd
coupling speed
Per Piece
tfvun 6
washer din pee
for peg
Spring
i CeardrivinS
eedometer

Gear reverst
mailld1aft

r I

w mg
1
Gm count
ring
It C ft
Washer
CCIWlter
duwt

counter frOUt
An y gear
n

Sbaft erseidler

I
Bushing fevet1 t gUf
Walber lock
1 0 fix revent shaft
Jd
Scre

Fig 26 Components of Transmission Gear

64
 TRANSMISSION

Reverse Gear

Alug which iB an integral part of the main

casting locateB the forward end of the reverse
gear Bhaft To Becure the Bhaft in pOBition a
set pin is screwed through the lug locating in the

shaft The Bet key is locked out side of the rl I

F I l

case
r
Ilr

remove
Release the set pin
the reverBe gear
then tap forward and
shaft Lift out the
f r

1 1 J
reverse gear I
R2
i
Rear Oil Seal If li
J
I
ThiB oil seal is situated in the end of the
C
rear bearing retainer

dismantled unleBs suspected of leaking

and should not be
It is
L
almoBt impossible
it
to take off the seal without Q
damage consequently a new oil seal should be
fitted if the old one has been removed

This can removed by uBing a punch and

hammer

Main Shaft

Counter cluster gear in the case Insert the

Fig 2 Detatchment of Rear Extension
first gear to the main shaft together with second
and third gear assembly from rear hole and fit
the first and reverse fork shifter over the first

gear
Fit the shift fork of the second and third

gears assembly on the hub of synchronizer

DepreBs the main shaft bearing to the end of
the case

Change the dummy shaft to counter gear with

the B aid shaft

EXTENSION OF
TRANSMISSION CASE

r
r r
oJ
l 5

Fig 3

II I c

L
1
0
0

1
Fig 1 Speedometer Pinion Gear

65
r

QATSUN

Fig 4
Fig 5

1ever
change
2nd 1
3

to fix
cha ver

Fork 2nd 3rd

Fork 1st
Roo frok
10
Rod fork reverse
2nd 1
3

I Lever change
1st
2pd
Shaft ClOSS

at reverse

Ball
Spring
PI checking
DDg
inter lock Spring checking
Pin Leve

Was r
NU
Ball

6
I
tJ
1G
Jm
ball

Lever
Pm D
loC k operating ta
operatmg
lever to Washer lock r
Nut
maft

Fig 6 Transmission Fork Rod

66
 TRANSMISSION

i
I

e
I

0
n

01
trf
0

T
CD

IJ
ell u@

Transmission
Fig 7 Components of

WaSher lock

Bolt location e
upper support
bracket
co

S J
Pin pivot
control lever

Fig 8 Remote Control

6
DATSUN

e o
o o
11
MAIN SHAFT

Fig 9 Assembling order through the Main Shaft

Disassembly of Main Shaft Front Side

Fig 10 Main Shaft ComPlete Assembly

Disassembling Course
1

Fig 11 Taking out by the Sliap Ring Plier Fig 13

68
 TRANSMISSION

of Main Shafti
Disassembly

16 Take out
15 Fig
Fig 14 Fig the Spacer

@
@ 3

20
19 Fig
17 Press out the Fig 18 Tapping Fig
Fig
Shaft Bearing out
Main
Retainer

69
S
l
k tUng
the Bau
ing
setnb

nO
Qoo
21
Fig

22
Fig
j

24
Fig

23
Fig 10
 TRANSMISSION

25 Fig 29
Fig

26 Fig 30
Fig

Fig 31
Fig 27

Jo
I
Jli
f

Fig 32 Oil Seal F Ollt COlier

Fig 28

1
r

DATSlffl

Insulator
gearshiftrod

Ass y lever Truman gear

2nd 3M shift rod
change speed
Washer
asher
W
Nut

Tn
spechtl
Wa
r
J
i
Pin
cotter
j e@
@ Washer plain 1 6t
Washer plain 2 Ot I we t
f
lone

S
a cJD
il Bolt t
n

l Wa h
rOd
lock
tf

Ass y bracket
supPort low er
Seat
change speed
lever upper
Retainer lower
Ch nge
Clamp
support bracket
syeed
lever

Rod shift 1st reverse

gear

Fig 33 Remote Control Linkage For Left Handle

DISASSEMBLE THE
TRANSMISSION CASE Counter Shaft Gear
For 4 Stage Floor Shift Using soft metal drift drive out the counter
shaft forward and out of case when the counter
Removal of Control Lever
gear cluster and two thrust washers will drop to
Twist the cap on the lower portion of the the bottom of the case
control lever counterclockwise with a slight These be lifted from
gears can only the
downward pressure casing when the main and drive shafts together
with their respective gears have been removed
To remove the needle roller bearing within
Removal of Shift Rod Shift Fork
the counter gear cluster itis necessary to break
Remove the cover from the transmission by the retaining circlips before driving out the
detaching six bolts bearing with a suitable piece of metal tubing

Reverse Gear Main Shaft

A
lug which is an integral part of the main The main shaft can now be withdrawn from
casing locates the forward end of the reverse the transmission casing To remove the gears
gear shaft To secure the shaft in position a from the main shaft first slide off the third and
setting screw is locked by a tab washer forth speed synchronizer assembly then with a
Straighten the tab washer release the setting piece of wire inserted through the hole in the
screw then tap forward and remove the reverse
gear cone deprese the small spring loaded
gear shaft Set out the reverse gear
plunger which locates the splined washer at the

72
 TRANSMISSION

forward end of the main shaft turning the

Reverse Gear
washer into line with the splines The third
Refit the into the gear case
and second speed constant mesh gears together reverse gear
with their common phosphor bronze sleeve can with the large gear to the rear

now be pulled over the steel plunger and so Oil the reverse gear shaft before inserting
and the shift with locating and
clear of the main shaft As the phosphor bronze secure screw

sleeves and their common driving washer are lock washer

tight fit on the shaft the shaft should be

immersed in warm oil in order to expand the
Counter Shaft Gears
sleeves so that they will slide off the shaft when
First put the two thrust washers to the
the second speed gear can be removed
Take out the steel plunger and spring counter gears ensuring that the larger washer
the is at the front and then place the gear cluster
Next splined washer separating
remove

in the gear case

the second speed constant mesh gear assembly
from the first gear unit and then slide the first Check that there is end play for the cluster
between 0 04 mm and 0 12 mm 0 0015
gear assembly free of the main shaft gears
release the wheel from the o 0046 and remedy if necessary by fitting a
To speedometer
main the tab washer and thicker or thinner rear washer
shaft straighten
unscrew its securing nut then slide the speedo
meter wheel off the shaft Thickness of front thrust washer
Do not lose the key Take off the distance
and the main shaft bearing can be Part No Thic knes s
piece
its after the nut has
separated from housing
32224 26760 3 91 3 96T
been prised from the shaft
If it is desired to dismantle the fourth and

or the first speed Thickness of rear thrust washer

third speed coupling sleeve

gear these can be pressed clear of their splined

but must be taken to Part No Thickness
synchronizers care

retrieve the three balls and springs in each

Take out the main shaft front needle 32226 26760 3 9T
assembly
roller bearings from the end of the drive gear 32227 26760 40T
32228 26760 4 1T
shaft
32229 26760 4 2T

Replace the counter shaft with a thin

Rear Oil Seal
temporary rod which will permit the gear cluster
This oil seal is situated in the end of the to remain out of mesh with the main and drive

rear cover and should not be dismantled unless shaft gears

suspected of leaking It is almost impossible

to take off the seal without damaging It
Drive Gear Shaft
consequently a new oil seal should be fitted if
the old one has been moved It will be seen The ball journal bearing should now be

position drifted on to the shaft with its spring ring away

that the oil seal housing is pinched into

be removed punch and from the geared end Position the geared end
This can by using a

hammer of the drive shaft in dummy 3rd and 4th speed

a

coupling sleeve put the washer over the bearing

tighten the nut and lock it in position
Smear grease in the end of the shaft where
Assembling the Transmission the main shaft locates then load the needle

The 2nd speed gear the 3rd and 4th speed rollers so that they adhere in pOSition by means

sleeves each p aired with their of the grease Turn the gear casing to ensure
coupling are

the counter teeth are below the drive shaft

respective synchronizers Only mated pairs of that

these parts should therefore fitted bearing housing

3
DATSUN

Refit the thrus t washer to the shaft

Failure to do this will result in damage to on

and drive shaft followed by the baulking ring The phosphor

both the counter gear geared
ends bronze sleeve which carries the second speed

drive shaft be drifted into is a tight fit on the shaft there it must be first
The can now

position from the clutch housing end immersed in warm oil and then slid into position

Ensure that the spring ring resisters on the shaft Fit second speed wheel over the

in the rece on the gear case sleeve driving washer and the second
then the
properly
bronze sleeve which carries the third speed
wheel The two sleeves are locked together by
Main Shaft
the driving washer Now position the third gear
Press th main shaft center bearing over its sleeve

complete with housing on to the shaft from the Place thespring and plunger into the hole in
rear the main shaft and sUde the spUned washer
wire
The bearing must be pressed firmly against Depress the plunger with a piece of through
the shoulder of the center splined portion of the the hole in the third speed and the slide spUned
shaft smear oil the shaft forward of washer over the plunger Then turn the washer
Lightly
the bearing and refit the first speed wheel for the plunger to engage with a groove in the
assembly with the synchronizer pointing washer
forward The gear are now assembled on the main

shaft

4
 TRANSMISSION

l
22

7 25

t 5
2i 2i
lO b

fl
16

11 13

f1 fIT
26
8910
s
ff
CD Case transmission @ Stud

Ass y extension rear @ Washer lock to fix front cover

@ Bushing rear extension @ Nut

@ Seal oil rear extension @ Bolt

@ Bushing speedometer pinion @ Bolt

@ Ass y breather @ Wa8her lock to fix transmission case

Gasket rear extension @ Nut

@ Washer lock Ass y pinion speedometer 18T

@ Washer plain to fix rear extension Ass y pinion speedometer 15T

@ Bolt @ Ass y sleeve speedometer pinion

@ Bolt rubber @ Ring 0 speedometer pinion

Bracket spring return @ Retainer O ring

Spring return @ Ring Oft pinion sleeve

@Ass y stick oil level dip @ Plug speedometer pinion

@Ass y plug drain Screw set

1
to fIx reverse shaft

@Cover front transmission case Washer lock

@Gasket front cover @ Gasket cover transmission case

@ Bolt

@ Washer lock

Transmission Case 4 Speed

5
DATSUN

29
28
t

14

15

8 9

Ass y cover transmission @ Wire lock

Ass ycover transmission @ checking
Ball

Cover transmission @ Spring poppet shift rod

Ring O shift rod @ Pin interlock

Pin control lever pivot @ Ball interlock

@ Rod fork 1st 2nd speed @ Plug weld
@ Fork 1st 2nd speed @ Plug weld
@ Bracket rod 1st 2nd @ Plate dust
Rod fork reverse @ Washer lock
@ Fork reverse @ Bolt
@ Bracket rod reverse @ Plug
@ Pin fork reverse @ Ass y Iever control
Boot control lever
@ Pin cotter

@ Spring pin reverse fork @ Knob control lever

lever
@ Rod fork 3rd 4th speed @ Spring control

t3 Fork 3rd 4th speed @ Cap cover transmission case

speed @ Boot rubber

@ Bracket rod 3rd 4th
Ball checking @ Seat lever spring

Spring poppet pin Screw stop reverse fork

@ Screw set Nut plain

Transmission Fork Rod 4 SpeedJ

6
 TRANSMISSION

16

13 12
34 3S

38 33373639 0

1c
JL IS
d l
S

ll I
l

Gear main shaft

CD Ass y gear reverse @
@ Bushing reverse gear @ Ring baulk 2nd speed

Shaft reverse gear @ Washer thrust main shaft rear

Screw set reverse gear @ Gear 2nd speed

Washer lock @ Bushing 2nd speed gear

8 Gear counter @ Washer thrust main shaft

@ Shaft counter @ Bushing 3rd speed gear

@ Roller needle @ Gear 3rd speed

Counter shaft spacer @ Washer thrust main shaft front 3 9T

@ needle roller Washer thrust main shaft front 4 OT

Ring retainer
Washer thrust main shaft front 4 1T
@ Washer thrust counter front

@I Washer thrust counter rear 3 9T @ Peg locking

Washer thrust counter rear 4 OT @J Spring locking peg
Washer thrust counter rear 4 1T @ Hub synchro 3rd 4th speed
4th
Washer thrust counter rear 4 2T @ Ring baulk 3rd speed
Gear main drive @ Sleeve synchro 3rd 4th speed
@
main shaft
@ Bearing main drive gear @ Bearing
main shaft
@ Spacer bearing 1 6T @ Ass y retainer bearing
@ Ring snap main drive gear 1 6T @ Peg locking
Ring snap main drive gear 1 65T @ Gear drive speedometer 5T
Ring snap main drive gear 1 74T @ Gear drive speedometer 4T
Ring snap main drive gear 1 77T @ Piece distance main shaft

@ Shaft main @ Key woodruff

@ Hub synchronizer @ Washer lock
Nut main shaft
@ Spring synchronizer hub @
@ Ball synchronizer hub @ Bearing main shaft pilot

Transmission Gear 4 Speed for 1200 cc Engine

n
 ii

with
seal 4T
oil
mficently 32 64 267 0
spedomtr 0720
of

control smal 26761

3posible 2647
lip mm No 9

lever 08 0 greas
the 12 as 6

on
O
part
32841
l

drive 0

the
Gear 32701
y C

Ass Smear NCS 0

by

26761
Dime on play
End Adjurt B play s
end No
26762 6

Dimenso Selct part

by

Engine
cc
by
32 64 32 64
No

120 Adjust Part

play
for end 26761
lit le 26762 32 64
6

m
NCS before
Transmio water 32 64
A as 0

gre
here
Dimenso pOSlibe aplay djuster spring
No 5

the 1
the
As by Pa tight
Pack and rod return
Adjust Bearing push fit ing
by

I
em
kg
grease 3010 280
240
brake 4 0 3
the No T

Smear Part

J ex
 TRANSMISSION

Transmission 4 forward
type
i

Ii

Fig 1
Fig 3

2 Rear extension
Gear ratio

Floor shift rod setting through the rear

New Former
extension is set in rear extension

1 3 657 3 945

2 2 177 2 402

3 1 419 1 490

4 1 000 1 000

Rev 3 638 5 159

1 Transmission case

The cover of transmission is attached to the

bottom of case

Fig 4

oo

ro 0

QO

Fig 2 Fig 5

9
DATSUN

sleeve
3 Reverse lamp switch
4 Speedometer pinion

It is placed at the side of rear extension and

shift fork
directly operated reverse

7
Fig
SW TCH
LAMP

6
Fig

@ Revene Lamp Switch

80
 TRANSMISSION

81
DATSUN

SECTIONAL VIEWS OF TRANSMISSION

I
I
SECTION A A
SECTION B B
SECTION C C

IE
3F

T 2
I IAkg m

T 9 11 kg m

A B C
i

J DIMENSION
SELECT AND ADJUST THE END PLAY OF
REVERSE GEAR IDLER SO AS TO FIT
J 2 3 4
0 05 0 15 mm BY PART No 32285 14600 1
H DIMENSION
ADJUST THE END PLAY OF COUNTER GEAR
SO AS TO FIT 0 05 0 15 mm BY PART No
352
32225 14600 1 2 3 4
665

HZ
 TRANSMISSION

II

i F

SEer ON D D

1ST
N 2ND
17lo REV
45 IllS
D
4

T 27 37 kg m

GEAR RATIO
1ST 7
2ND 2177
9
4TH
Tol7 23 kg m

SECTION E E

83
S
l
A

84
 CHASSIS

ASSIS
CFI

FRONT AXLE

Fig 1

85
r

DATSUN

NUT
10
lock
e
NUT o

UTj
ASHER
fJv
JSpecial ASS Y
BUSHING LT
outer MEMBER
rubber shock o
front
PAD
ASHER absorber rubber suspension
special o
oi ront
inner 10600
466
V54
ear S44b7 1060
Z
o

g
li NUT
WASHER

@special
e outer
USHING SEA T ru hb er
ruhber BUSHING
8hock WASHER iront 54468 10600 l
lii
l
tfi t
rubber
ab SOl ber
specla I ear 54469 10600 or front
outer
suspension member
WASHER special mounting
SEA T front 54464 10600
BAR
u er front
54465 10600
iPring rea r tens n front

p stab1l1zer
NUT

o
WAHER
@ special outer

BUSHING
rubber

SPACER
BUSHING front
rubber WASHER stabilizer
tabilizer pecia I C
t
BRACKET Inner

tabili er llSl BUSHING

mountIng rubber
WASHER
WASHER lock specia
outer
BUSHING
WASHER
e
I BOLT
WASHER
rubber
plain
ClrWASHER lock special
uutter

BO LT
OD connecting
front stabilizer
C
EAT lower
front spring

Fig 2 Front Suspension Member Shock Absorber

DISASSEMBLING THE FRONT HUB

of the front hub first jack the and tapping the out bearing clear of the hub
Dismantling
car until the wheel is clear of the
ground and The inner bearing and oil seal can then be

then place blocks under independent suspension removed by inseriing the drift from the opposite

spring plate Lower the car on to the blocks side of the hub
Remove the wheel and the screw If the drum When assembling the hub the inner bearing
appears to bind on the brake shoes The shoe race should first be inserted into the hub Pack

adjusters should be slackened the hub with recommended grease Replace the
Lever off the hub cap and then extract the hub oil seal over the inner bearing Renew the

split pin from the spindle nut seal if it is damaged any way

Using a box spanner remove the spindle nut The hub can now be replaced on the spindle
and ease flat washer under the nut clear of the Gently tap the hub into position until the inner
axle thread by carefully using a narrow rod into race bear against the shoulder on the spindle

small boles in turn in each side of the spindle Place the spindle flat washer into position
and tapping the lightly
race With the hub and screw the nut down finger tight Spin the
removed outer bearing can be dismantled and wheel l
Ild examine the resistance Tighten the
by inserting a drift through the inner bearing nut

86
 CHASSIS

A slightly increased resistance to the is fully home before this sc rews is tightened and
spinning of the wheel will then be noticed The if necessary the drum should be pressed in

bearings are now preloaded and the split pin position by tightening two wheel nut Refit the
should be inserted to lock the nut Tap the hub wheel and nuts are
finally tightened when
best
cap to the hub after packing the cap with grease the car is off the backing blocks but readjust
Replace the brake drum and secure with the brake shoes if necessary before the car is

machine screws It is important that the drum lowered to the ground

NUT knuckle
CQLLAR
runt
pindle

WASHER ASS V
front wheel
WHEEL
Learing 0

Fig 1 Front Hub Drum

n NIP PL E
T 8
O NUT
ASS Y 4Jt r 1
BUS HING Hl 04101
rr in SHIM cabe 2 0

Ul
154
5 04101
NIP SS Y T b lI
10 JOI pp
fro pennon

lr
1
opp

J b n

JOin
BOLT
front UT
upper
on
pe
LJl
CLAMP

ri
o

CO ER
ASS Y
dUll up
STOPPER
Ji o
bnuId
bdl

11 2 i 3 BOLT WASHER DIll

NUT

PIN colte

Nlf
SS
tr
BUSHING
10 link
SEAL dua
lowe hnk
J aOLT

buoh

SPINDLE
I
lInke
NUT

Fig 2 Front Suspension Link

8
DATSUN

INDEPENDENT FRONT SUSPENSION

The dependent front suspension is known as

Fig 1
the wishbone type since the
top upper and lower
bottom linkages roughly conform to the shape of
CD Front suspension CD Oil pan
a wishbone
upper link
Between these two wishbones is the coil @ Exhaust front tube

@ Front coil spring

spring held under compression between the @ Front swpension
upper and lower which is secured to the lower @ Front suspension memb r

lower link
suspension member by four bolts Ai the Lower link
@ spindle
swivel axle end the upper and lower linkages Outch operating Stabilizer
jointed by the ball The upper spindle cylinder @
are joints
bracket is bolted to the front suspension member @ Cross rod
@Speedometer cable
with caster shims and the lower spindle is

connected to the lower bracket of the suspension

@Trommhsion
member

the number of Shims Camber Caster

Change

Adjust for Front side Back side

1 0001 0029
1 0016 0 31
Both Camber Caster
1 0002 0 31

1 0 04 0029

1 1 0 15

2 2 0 Zl
Camber only
1 1 0 15

2 2 0 Zl

88
 CHASSIS

a thickness of each shim 1 m m

Camber adjusting shims

Parts No 54542 04100 1 mm

54543 04100 2mm

54544 04100 4mm

Standard adjustment Camber 1 30 R L difference within 40

Caster 1 30 R L difference within 40

BALL JOINTS BUSHES OF THE

SWIVEL AXLE

Wear if the swivel ball of the movement be detected between the upper
joint or wear can

screw bushes of links or both may be checked and lower swivel joints and the swivel axle
by jacking the front of the car and
endeavouring assembly the ball joints or the screw bushed
to rock the wheel by grasping opposite points of are worn and must be stripped for examination
the tyre in horizontal If any
a position

Front Coil Spring

UPPER LINK
SPiNDLE
1J
l PER
BALL
rOINT
CeJ 0
0
It
t

UPPER LINK

I a
J

o
LOWER
LOWER LINK LINK
I SPINDLE

Fig 2

Between the upper and lower links is the coil Through the center of coil the
spring
held under
spring compression of it which is telescorp type shock absorber whcih is connected

secured by nuts of the lower and upper ball to the top spring seat and lower link with nuts of

joints the lower and upper

89
r

DATSUN

Fig 3

FRONT SUSPENSION

Fig 4

The rubber bearing bushes or screw bushes The screwed bushes or the ball joints may
may in time deteriorate and need develop free
renewing excess play due to wear of either
Excessive side ways movement in either of of these parts This assembly can best be
these bearings would denote softening of the checked when the suspension has been
robber bushes or screw bushes dismantled

90
 CHASSIS

METHOD A
Disassembling Order of
Front Suspension 1 Unscrew nut of the shock absorber at the
top
and take out if from down side after unscrew
1 Remove shock absorber lower of it from lower link
flange
2 Compress the coil spring by tool Fit the serVice tool and screw up the spring
3 Disconnect lower ball joint and rebound compressor nut
bumper from lower link In the absence of the service tool a suitable
4 Release the coil spring by loosing the nut of tool will be required to release the
too compression from the coil spring
5 When tbe coil spring is extended take
fully Compressing the coil spring unscrew the 3
out it nuts of lower ball joint which located under

6 Disconnect upper link spindle from suspen the edge of lower link
sion member if need to inspect for Remove these nuts and release the
compres
sion from the coil
spring by loosing of nut
Removing the Coil Spring too

When the coil Spring is fully extended take

out it

Fig 5

FrontSuspension
Assembly

Fig 6 Detachmellt of Shock 7 Detachment Absorber

Fig of Shock
Absorber from Suspension from Suspension

91
DATSUN

8 Remove Shock Absorber 9 Detachment of Rebound

Fig Fig
Bumper

Assembling
Tightening torque
4 04 5 kgm

10 the Nuts of Lower Ball JOillts

Fig Releasillg

92
 CHASSIS

METHOD B

Unscrew the four bolts of lower spindle

which is secured to the suspension member

Remove these bolts and release the compression

from the coil spring When the lower link with

spindle can be driven out

Refitting the Coil Spring

Use the coil compressor or jack against the

lower link Screw up the screw bolts of the

lower link spindle to the front suspension

member and then secure the bolts of the lower
spindle Release the compression by loosing
the compressor nut or the
jack screw down
Set up the shock absorber by the double nut
Fig 11 of upper side and the bolts of lower side

METHOD C

Replacing Order of Upper Link

@
1 Prepare to remove front wheel

2 Jack up and support front suspension lower

link

3 Remove wheel

4 Disconnect ball and rebound

upper joint
bumper from upper link

5 Detach upper link and spindle from suspension

member

6 Disassemble upper link spindle from upper

Fig 12 link by unscrewing link bushings

7 Reassemble upper link spindle and bushings

to upper link of replacing reinforced part
@ carefully following undermentioned instruc
tion

8 Reassemble whole parts back to

again
complete unit

9 Check and adjust fron wheel alignment

Instruction

1 Don t hold spindle tight against link when

screwing in bushings Because the pitch of

threads of spindle inner and outer screw of

bushing and link sleeve are all same

Fig 13

93
r

DATSUN

2 Assemble the
Apply sufficiently grease on to the inner upper and lower link to the
screw of bushing and spindle knuckle spindle

careful Tightening torque for ball joint nut

3 Pay attension not to damage the
thread when screwing in the bushing Upper 6 7 kgm

Lower 9 5 12 5 kgm
Tighten up bushing against link sleeve by the
to ue of 19 20 kg m 137 145 ft
ibs Connect with upper link to the suspension
member by tightening torque 4 7 5 0 kg m
4 Friction resistance torque between spindle
Do not forget to insert the adjusting shims
and bushing should be within 0 5 kg m 3 6
of chamber
ft 1bs when assembled

5 the reiative
Adjust position of spindle and
link as shown in the figure by turning the
spindle so as to the link and the spindle to
bave dimension of it

6 Align the direction of grease nipples as

shown in the figure

7 Lubricate bushings with grease completely

until the grease will come out from dust seal

Center of ball joint

Center of
ball joint

S5
sj
5

Fig 15
Assembling of Lower Link

til0
Front Wheel Alignment
rS4 sS
189
Toe in 3 mm 1 8 in

14 Link Caster
Fig Assembling of Upper r30
Camber 1 30

Tightening Torque King pin inclination angle 6030

Nuts ball
fixing upper joint and rebound Adjust camber with adjusting shim at upper
bumper to the upper link 2 4 2 6 kgm bush spindle fixing portion
174 188Ib ft Adjust caster with the same shim or by turn
Bolt fixing upper link spindle 4 7 5 0 kgm ing upper link spindle only 1 2 one turn
34 36 2 Ib ft

Nut lower link spindle 4 0

fixing 4 5 kgm Turning of upper spindle
29 32 5Ib ft
360 One turn 0032
Prior to install the screw bush sufficient Caster 180 turn 0018
Half
grease shall be applied in the inside of the bush Only 180 0013
and screw threads of the spindle 360 027
Pay carefull attension not to damage the
threads when screwing in the bushing Tighten
up bushing against link sleeve by the torque of Clockwise See fro n back side
24 25 kgm
Counterclockwise See from back side

94
 CHASSIS

CJ 0

or1 I
D

o r

i 1f 1J
I

I I I

i
J J

0
1U013

O
oq U 3
n
11

A
Front suspension
95
DATSUN

c
0
C

r
rl di
II

0
C

I
JJ
Q

ji i

0
2

0
C
I lC
C
c

Q
l C I
41 It

U 2

@ @
@ 0

I
Q

Front Suspension B

96
 o ww w

body
of

line torque
BaISe
Tightenig
T

N
0

C0

0 1g
0
lu
of

of limo spIndle
HJ
r ente
spIndle Bue up er
C
up er

spindle
of
lower
front of

line
SIde
embl
r condit loading Center
M under
Tight standr

cs 1 5

l
r

DATSUN

REAR AXLE

I Rear spring seat 6 Hand brake swing arm 11 Rear trunk drain hole

2 Muffler 7 Hand brake cable 12 Rear shock absorber

3 Pre muller 8 Rear spring U bolt 13 Rear axle case

4 Side rod 9 Hand brake balance lever 14 Exhaust tube

5 shaft 10 Rear spring shackle pin IS Rear spring

Propeller

Plu per axle

43010 10600
43010 10800
Camp case ia1
aXI
Camp case axle

Stud gear carrier

Ass y plug drai

Ass y breather

Drum brake

43235 04101 Ass y catcher L H

I
grease
43234 04101 Ass y catcher grease R H

Fig 1 Rear Axle Case

Shaft

98
 CHASSIS

r8 D UK91ft

Smear grease a little

on the surface of shaft

Fill up grease suffieiently

the surface of
on
bearing
raCe excpet other space

Press this collar by

pressure 3 v 5 tons
T Tightening torque
metric

The collar is required

to change new one when

disassembled

Fig 2 Component of Rear Axle

Axle Shaft Removal

Choke all the wheels not being operated upon brake is release slack off the brake shoe
jack up the car few notches
adjuster a

Lower the axle on to the blocks and remove Take off the fix bolts of the brake disc and
the wheelusing a screw driver unscrew the remove the axle shaft as shown Fig Tap with
drum locating screws release the hand brake swing hammer the wheel studs bolt with
holding
and tap the drum off with the mallet If the the rear axle shaft stand draw out the shaft and
brake linings should hold the drum when the hand disc assembly by gripping it outside of the disc

99
DATSUN

Order of Rear Axle Shaft Brake

Disc Assembl
The axle bearing with the brake disc
rear

assemblv is
replaceable in one operation by
pressing into place When fitting the axle shaft
it should be compressed inlo the shoulder of the

case end after inserting the end shim between

its flange and hub Part No 43036 04100
The following points must be taken into
consideration

1 Nominated Hypoid gear oil No MP90 must be

used In warner district than 32 C use

o
oo MPII 140

2 It is to use any other kinds of gear

prohibited
oil or any oil of different viscocity The
same brand must always be selected

The standard
capacity of oil is about oil
o 93 L
The method of feeding oil should be
done by taking off the feeler plug at the rear
cover of the bousing and fill in full up to the

feeding hole

Dismounting Disassembling of
Differential Gear Carrier
1 Take off and drain oul the gear oU

2 At the ti me of
3 dismounting the gear
Fig Remolle of Axle Shaft and
carrier pull out the both left and
Disc Assemblv right
axle shaft with the disc of the brake
assembly
3 Take off the joint flange from the side of

propeller shaft

G 4

5
Pull off the nuts

mount forward the carrier ass y

Take

and
of the housing

off the side bearing cap of carrier

and dis

4 pry with a lever the differential gear

Fig case and the bearing
DT 4679 DT 4678
6 Dismount the differential
side bearing
Special Stand Swing Hammer
As illustratedFig 5 with the aid of
in

side bearing puller pull oul the bearing

The puller should be handled wilh care in

Disassembly and Assembly of catching the hedge of bearing inner lace

Axle Shaft which is hard to hook Both the left and

right should be
When bearing arranged
replacing the differential axle shaft do
separately
not forget the adjusting washer between the top
of the axle flange and the brake disc assembly
7 Dismount the differential drive gear
so as to keep the end
play of the axle shafts the 8
Ring gear by loosening fixing

100
 CHASSIS

the differential gear and As illustrated No drive

screws on case 11 in Fig 6 the

spreading out the lock washer pinion bearing

rear inner race replace and

Loosen them in adiagonal line considering the adapter should be employed in this

to keep from the gear bending case The adapter in the round form is

for and the other for off It

fixing taking
is easy to handle with the vice fixing one

end of replacer

12 Taking out the rear bearing outer race of

gear carrier
The drive pinion bearing outer race

replacer as illustrated in Fig 6 should be

employed in this case In other upon the

stud so as to make the screw at the center

of carrier and set the adapter at the

lower frim of the race

Supporting the tommy bar 1 and screw

up till the corn 7 closely touches the

adapter then screw the wing nut to take

out the rear outer race

5 Using of Side Bearing Puller
Fig
DT 4686

8 Take out the differential pinion as well as

the side gear Tbe mate shaft

pinion
should first be pulled out by striking out
the pinion mate shaft locking pin which is

fixed on the differential case from left

side from theside of ring gear fixed to
the right before pulling out the pinion
side gear and the thrust washer The gear

as well as the thrust washer should be

arranged separately as left and right
front and rear

9 After taking out the nut of the carrier pull

out the companion flange The drIve
pinion flange wrench should be employed Tool No DT4782 DT4631 DT4689

setting its four points in the holes of Pull out the Race
Fig 6 Bearing
flange to keep it from moving take off the
nuts with the box wrench

10 Take out the drive pinion of gear carrier

by striking out lightly to the backwards the

front end at the side of companion flange

of drive pinion with the drift of soft metal
Thus the pinion would be taken out

together with the inner lace of rear bear

ing and roller distance piece and the

adjusting shim and the oil seal outer lace

and pinion of front and rear bearing as

well the shim left

as pinion adjusting in

the carrier

11 Pull out the inner race of the

rear bearing
drive pinion

101
r
j

UN
DAT

13 To When the drive pin

pull out lhe front hearing outer race Drive pinion nut

from
ion nut is tightened
the gear carrier set the tool body Tightening torque
with torque 14 17
3 as illustrated in Fig 7 pull it out with 14 t7 kg m
without the oil
kg m

in the way of rear race 100 120 ft lbs

adapter B al of hypoid drive
gear adjust the irk
tion of rotation so

the torque is to be
M

7 19 kg em
by the
0
adjust washer of drive
C
0 pinion bearing and
pacer

Fig 7 Drive Pinion Front and Rear Tightening torque

4 2 4 8 kg m

Bearing Outer Race Replacer 30 35 ft lb

Fig 9 Section of Differential Case

Fig 8 Inner Race Replacer

Fig 10

102
 CHASSIS

38440 04100
Gear drive

38101 04101
137Tl
38120 04100

38189 027

38210 25660

INSPECTION REPAIRING OF
DISASSEMBLED PARTS

locking condition defacement or any defects

Every parts after they are disassembled be re
on the surface to see if they can
should be cleaned and cleaned by the compressed standard
used In case of insufficient
air before making an inspection and adjustment
back lash deformation or damage found
1 Each bearing should be inspected in replacement is necessary

every unit of ass y regard with the defect Specially the drive pinion and drive gear
and defacement before deciding to re use should be replaced in a set whenever the
them locking condition gets worse and the
be
defacement is already in progress
2 The axle should be inspected in respect of noise in later
cause it would cause the
the crack and the defacement of spline be difficult to adjust
operation and even

measuring the shake with the gauge by is made

with proper adjustment
houlding the both end The difference

0 4 mm should be with 0 8
over adjusted Theperfect driving condition at the surface
m m or replaced
of drivepinion gear should be about from 2 3 to
The clearance between the end of rear
3 4 mm in unloaded driving while the gear
axle case and brake disc should be
surface should start to touch from tip to full
adjusted with the adjusting end shim
surface in an ordinary loaded driving
Part No 43036 04100
The inspection of this condition can be made

to the it is
3 Every gear should be inspected as as

103
r

DATSUN

If it is hard to
inspect them as it is do Strike in the pinion shaft locking pin from
otherwise by cleaning the both surface with the the right side of the case opposite side of
rugs before disassembling and paint thinly and drive gear and must be fixed by setting
evenly with the mixed wi th thin oil on the gear well the striking hole of it after putting it
surface drive side then turn the pinion with to lhe required piston so as the pin should
hand to print the track of it on the gear Which not loosen
shows the situations of considerably worn out

gear 2 Fix the drive gear Ring gear with the

In case of unloaded test it is perfect that differential case

the gears contact for about three quarter at the The drive gear as well as the drive pinion
center of 1 4
of whole gear from tooth should be well inspected to they must be
length
interior tip end of the gear on the Pitch line replaced as a set whenever the replace
ment is required
4 Lock the side gear with pinion together Otherwise they would not properly lock
with respective thrust in the gear case after assembling is complected
In case of the back lash over 0 2 mm and In mounting in the case the fitting surface
the clearance between the side gear and must specially be cleaned and fixed with 8
thrust washer exceeds 0 5 mm replace the set screws as well as lock washer bend the
thrust washer washer with sureness after the drive gear
The else worn out parts should also be shake is adjusted In tightening up the
replaced screw it should be set and supported by
The contact when ring gear is too close to vice or any other setting tools so as not to
pinion center in case of back lash should damage it and screw up in a diagonal line
be adjusted closely or it gives much noise with a wrench which fit correctly with the

head of the screws The standard screw

5 Put the drive gear ring gear on the buoy ing torque for this is 25 it lbs to 30 ft lbs
block as it is fixed in the differential gear Screw in for sure striking lightly the head
case and with the dial indicator of
measure screw by one quarter pound hammer
Revolve the drive gear to turn around the
differential gear case as the bearing do 3 Mount the side bearing in the differential
not move on the buoy block Measure the case

shake at the rear side of gear by the scale Press in the both side of the bearing by
and the shake should be within 0 5 mm the drift
In mounting the gear clean well the fitting It is important in this case to assemble by
face and rear face measured face of it side bearing
putting the adjusting shim to
and fix correctly then there should not be give the bearing preload
a proper in fixing
any shaking with the carrier

ASSEMBLING ADJUSTMENT

Asseinbling Differential Gear

1 Assemble the pinion and side gear in the

differential case

Every parts should be cleaned and oiled

with new gear oil then the pinion mate
side gear and the thrust washer should be
assembled by the mentioned inspection
and selection before pushing in the pinion
mate to shaft Inspection should be made
again in the clearance of between the
washer or the back lash Adjustment must
be made in case
any abnormal Is found Fig 12

104
 CHASSIS

ASSEMBLING ADJUSTMENT BY
GEAR CARRIER ASS Y

It is to decide the assembling adjustment They show the manufacturing error

of gear which is very important in an rear axle in a figure at the unit of 0 001 in
ass y and should be carried in accordance with 0 025 mm to decide the thickness of

by the manufacturer adjusting shim for of

the exact sample shown adjustment
The construction and mechanism must well standard position The standard
be comprehended referring to Fig 19 21 and pinion height is 51 0 mm from axle

repairing according to center shown in Fig 13 17

the adjustment exactly as

the condition of practical use based on the If the figure is difficult to discriminate

exact calculation due to the corrosion off the

adjustment by scrape
oxidize substance on the surface by a

A The for the

some what narrow grind stone with
Preparation Mounting
care not to scrape off even the mark
Drive Pinion in the Gear Carrier
Adjust to the direction of on arrow in

1 If the drive gear drive pinion and accordance with the Pinion mark

bearing are to the reused as they are

as a result of disassembling and 3 The thickness of drive pinion adjusting
shim are
inspection they should be assembled arranged as following
in on order of disassembling at the The use of the adjusting shim will be

previous condition of adjusting shim explained in the following paragraph

In case any item should be replaced of adjustment Supposing the drive
or required to reuse even if any item gear and the drive pinion were re
is worn Qut prepare the various shim placed as a new set and the height of
as mentioned later because the drive pinion previously used was
position of drive pinion to be fixed right prepare the shim of thickness

with carrier must be the which equals to the difference of

adjusted by
adjusting shim between the carrier figures on the new and this pinion
and pinion Deduct the previously used shim in
rear bearing outer race

case it is plus increase in case of

2 There are few numbers with 0 or minus and have the general idea of
besides set number marked by an required thickness of the shim for
electric pen on the tip head surface of assembling to prepare
drive pinion Standard
Part No Thickness
Leaf No

Drive pinion 0 75 mm 1 0
38153 25660
shim 0 030 in 1 0
adjusting
O 25 mm

3815425660 2
0 010 in

O 125 rnm

3815525660 2 1
0 005 in

0 075 mm

38156 25660 2 1
0 003 in

It is convenient inspect the condi

to

tion before disassembling in a way as

mentioned later in the measurement
of pinion height Besides the condi
tion of defacement on the carrier the

pinion bearing must be taken into

consideration though it will be

13 Pinion explained in detail later
Fig Adjustment of Height

105

e
r

DATSUN

B Fixing and Adjustment of

Drive Pinion
1 Drive pinion rear bearing outer race

should be mounted in the carrier in

this case after inserting the properly

selected adjusting shim as previously
mentioned between the carrier and
bearing race mount the outer race

by the
special tool of drive pinion
front rear bearing outer race

replacer
For of
adjustment previously
mentioned pinion height the shim at
the rear side of this outer race is
increased or decreased and the race

also must be taken offln each time for 14

Fig
this adjustment therefore the tools
must be handled properly to avoid This might as well be done In pressing
such a situation as to make the bear in the ofa certain drift
by use

ing hole of carrier in on oval

Referring to Fig 8 for handling 4 Mount the drive pinion in the carrier
method of tool set the adaptor ring and adjust by measuring the position
on the corn to guide the body of 1001 at The pinion height must be adjusted as

the small hole of carrier put the rear mentioned in the previous paragraph
outer race on the corn as the bearing by mounting temporarily the pinion in
surfaces inside at the tip end of screw the carrier and the bearing be given
and put the split adaptor inside race a regular preload On the other hand
At the same lime supporting it by the the bearing of drive pinion should be
bar lwist up the corn till the adaptor newly oiled after the pinion is inserted
and race come 10 the setted position from the inside of the carrier the
then screw up the wing so as the race inserted end of pinion should be locked
be housed properly at the setted with front bearing corn and tightened

position up by the pinion nut fixing with the

companion flange till the regular
2 Mounl the front bearing outer race in revolving torque is required As this
the carrier is not at the final
yet assembling the
For mounting the fronl ouler race bearing spacer distance piece bear
take off at first the adapter from Ihe ing adjusting shim and oil seal are
front end of the carrier and fix the not mounted
1001 at the side of stud in opposite At the time of
inserting the front
side tighten the screw to be the bearing
as pushing in the inner race
as

center of shown Fig

carrier 14
as
by pulling out the drive pinion from

then mount itby using adaptor as in a the rear side of the carrier
way of mounting the rear outer race Put the rear side of the carrier down
ward and set the tool under it then
3 Mount the bearing inner
rear race supporting the end surface of drive
and roller to the drive pinion By pinion press in the bearing by using
using the round adapter attached to the drift The operation would be
the drive pinion rear bearing inner easier by using the drive pinion front
race replacer which was employed at bearing inner race inserter as shown
disassembling press in the drive in

pinion Tighten up the pinion nut by turning it

106
 CHASSIS

slowly with hands with the use of The preload supportedly the bearing
preload Fig 15 to the degree
gauge as in this case is different according to
that support the bearing preload at the condition of the bearing adjusting
7 10 shim inserted
kg cm

When the drive pinion is mounted in

the previously mentioned condition it
is necessary to measure the height of
rear surface of the pinion whether in
is higher or lower than the standard

Make use of the special drive pinion

arrangement gauge
The standard height of the pinion is

51 0 mm from the bottom of the side

bearing fixed with the carrier

The fixing position can be measured

by setting an arc of circle on both

sides of arrangement guage at the

position of side bearing and insert the

thickness in the clearance
gauge
between the tip of gauge bar and the
pinion such as to push in by scraping Fig 16

of the carrier in diagonal otherwise

preload and the pinion height of the The more of the shim inserted much

bearing would come out of order and the play of pinion to the direction of
tend to cause an unexpected trouble in axle is increased
fulure The less of the shim inserted the

more the bearing tightened by the

previously mentioned nuts and cause

it to be burned if left and turned as it

is Therefore for readjustment of

the bearing preload in this case it
must be adjusted by increasing or
decreasing the number of four kinds
of adjusting shim as shown in the

following list and measuring with the

use ofthe drive pinion bearing preload

as Fig 15 so as to make the
gauge

Fig 15

of the drive
5 The formal adjustment
pinion bearing and preload After
the fixing position of drive pinion is
decided as mentioned in the previous

paragraph take off the pinion nut

companion flange to mount again the

drive pinion bearing spacer distance

piece and nut

Tighten up the nut as

Fig 16 by using the torque wrench at

the regular torque of 100 120 ft per
lbs Fig 17

IO
DATSUN

revolving torque of kg practical use give it an

pinion at 7 10 so as not to

cm if there should not by any error in over preload

the pinion with the head mark at 0 and

the clearance should be sealed at 0 2 6 When the former adjustment of pre

mm 0 008 in by the feeler gauge load of the bearing is completed as in

thus pinion is regarded as at the the previous paragraph inspect the

correct position because lhe height of pinion height again Unless any thing
the gauge is made shorter for 0 2 mm wrong is found loosen the pinion nut
than the standard size 51 0 mm take off the flange insert the new oil

seal in the rear of the carrier and

Remarks formerly fix the flange washer and
pinion nut The nut should be tightened
When measuring the height of the pLnLOn
up at the standard torque In case the
head set the semi circular side portions of the
cotter pin hole fitted the adjustment
on the side bearing seats insert a feeler
gauge
should be made not by tightening the
gauge into the clearance between the tip of the
nut but by filling the washer
gauge center rod and the pinion head and adjust
the pinion The guage rod is made 0 2 mm 8
CMounting the Differential
1000 In shorter than the standard measurement
51 mm Gear Ass y in Carrier

Therefore adjustment Is made by selectlug 1 Mount the complete unit of differential

a feeler gauge in accordance with the plus or gear in the carrier and fix the bearing
minus valve marked on the pinion head cap There is a engrayed mark on
the side of cap which should be fitted
If it is necessary to adjust the pinion with mark on the leg of bearing hous
height take off the drive pinion as ing when mounting It is important

well as pinion rear bearing outer race to note that the fixing part of the cap

form the carrier to adjust by increas of each bearing housing is machinerly

ing or decreaSing the number of the finished up

adjusting shim In other words read The differential gear case is inserted

the mark on the head of the drive by the bearing adjusting shim with the

pinion before adjusting by increasing side bearing as explained in 3 of A

or decreasing the number of drive and by housing in the
bearing housing
of carrier the bearing must be given
pinion adjusting shim 110 50936 to

insert the feeler

gauge is which the regular preload The screwing
deducted for the number of mark from torque of the fixing nut of the side
o 008 in in case of minus side added bearing cap is at 35 40 fi lbs and
for the number of mark to 0 008 in should be equally locked with fixing
in case of plus cotter pin
For instance the mark shows 2 So far only the differential unit is

adjust the position of drive pinion by mounted and the drive gear is locked
the number of shim so as to with the drive pinion therefore the
deducting
make the clearance at 0 008 in follOWing adjustment must be made to
o 002 in 0 001 in It is necessary acquire the regular side bearing pre
to give the bearing a right preload load the gear back lash
At the time of pushing the outer race
into the carrier it must be done in a 2 Adjustment of side bearing preload
right way otherwise back lash

Specially when the old bearing is to To give the right preload on the side
be used again in assembling the bearing of differential gear case and

adjustment should be made at the in pressing the bearing in the

lower torque than standard in differential case adjust hy inserting
accordance with the conditions of inside the bearing adjusting shim of

108
 CHASSIS

thickness calculated in accordance 0 004 0 008 If it is much move to left by

with the following method of taking off the right shim for adjustment

computation
There is a marked numberal of Thickness of Shim of Thickness of shim on

adjusting basis on the bearing housing Left Side Right Side

of the gear carrier and differential Ring gear side Pinion mate side

The numberal is the Left Side T 1 A C D Right Side T2 B F 6

case

erro in a unit of 1 1000 E 7

manufacturing
in against each standard measure
Example of calculation
ment of A B C D in Fig 18
A 1 E 8 0 2 mm O 025 mm 8
To measure the width of the side
B 2 F 10 0 25 mm O 025 mm 10
left and the
bearing on right use

standard guage 18 5 mm thickness Left T A C D E 7 0 025 mm x 20 0 5 mm

1
and dial gauge on a flat board In this 1 1 3 8 7

load the B D F 6 0 025 mm x 15 0 375mm

case place the on bearing Right T2
with the aid of weight block for about 2 3 10 6

2 5 kg to the steady figures

acquire A D O 07 E
C B D 0 006 F
Calculate the error on minus side T2
0 001 0 002 0 002 0 003
against the each standard measure
006 0
o 002 0 007 o 010
ment of 18 5 mm on the unit basis of
o 008 0 016 0 015
1 1000 and assume each of them as E
Thickness of left Thickness of right
F Take the left side bearing for
side shim side shim
example When the measured width

is 18 3 mm it is 0 2 mm 0 008 in The numeral marked by the electric pen on

the side of the drive shows that of the

against the standard measurement and gear
the E is by excluding the minus sign recommended back lash besided the set number

o 008 in For example b 6 means the back lash of 0 006

in 0 025 mm x 6 0 15 mm
The thickness of the shim is
acquired by
applying the numerals to the following method
of computation
It may as well be assembled by using the
shim of thickness which is in accordance with

above method of computation The left and right

otherwise the
bearing must be well pressed in

preload changes
Measure the back lash of the drive pinion
Fig 20 by using the dial indicator
ring gear as

to make sure that it is within 0 1 mm O 2 mm

Fig Fig 19

109
DATSUN

After the Operation

JJ

Fig 20 Measurement of Back Lash for the

Drive Pinion Ring Gear
at
If it is necessary to use the bearing again
of each shim
the time of repairing the thickness
001
of left right must be reducted for 0
o 003 on the basis of 80 against
or 60

preload in accordance with the practical

standard
becuase over preload is given
condition of use
to the bearing with the shim of thickness Fig 21 Using the Differential Side

calculated from above method of computation Bearing Cap Gauge

110
 CHASSIS

3 11 DJ4 1

l Wl
Jl OJ4 J

JO J

JI3IDH

Jill OJ4
JIm Ok

Select from UJ4 bJ4 1J

J J QJ411D

J IJ IIHOII
7 D94M

J8 J8 M4011 3 10
15132

IJ 1 1
40 38166131011

J81 O MOO
O 3 167 IJ2
3 1410
400

J6153 1001
to
Impact chassis grease 361541061

361551U6UI
the lip of oil al
161561001

Adjust the hack lash O 19 O 18 36157 10 I

shims
in good mesh by adjusting
of drive and bearing cap
pinion

H
38 03 11
32

Ca1culwes 38101 0 1
0

Thickness of shim for preload ide hearings

Left side Tl A C D E 0 025 0 175

Right side TZ 8 D F x 0 025 O 150

To tight this head of bolt

tapping slightly with
1 4 pound 0 1 kg hammer
Tightening torque 3 5 4 2 klOm
25 30 ft lhs

JIJIJ 13700

Contact wide of tooth

3B453 10500
must he more than three forth 3BJj S410
t fS51050
n
Back lash O 1 O 2
Refer ential Q J 384561050Q
3 457 050
dirnension IT3Sf

Give preload for side berings

with adjusting him gained
by alculuses

22 Carrier
Fig

Mounting the Gear Carrier Ass y on

the Rear Axle Housing

Thus the adjustment completed
is By way
of precaution measure with michrometer of the Interior of the axle housing should be cleaned

large size the L measurement which is within well

173 40 173 55 mm as Fig 21 Service No tool The carrier packing should also be replaced
DT 4685 If it is insufficient add an additional with new one

shim of 0 002 in 0 05 mm
right In left and Mountthe gear carrier ass y withoutmistak

this case the said michrometer Fig 21 or ing its upper side with down side and through 8
studs then fix with the lock washer nut The
special gauge should be employed for scaling
nut must be in a diagonal line so as not
Tbe shake of the back of drive gear which tightened
has been fixed with the carrier should be to cause the oil leaks

measured dial indicator to confirm that is When it is mounted on the vehicle feed the
by
within 0 05 mm gear oilimmediately The oil of the designated
hypoid gear oil No 90 should be feed
Feed the oil till it comes up to the down side

of the feeding hole

III
I

DATSUN

STEERING

48400 10600 Ass

y wheel steering black
48420 10600 Ass
y iug horn black
48420 11500 Ass
y ing born yellow

48327 10651 Set shell 48422 10610

Pad horn ring
rteering black black
48327 11550 Set shell
48422 11510
steering yellow Pad horn
48327 10851 Set shell ring
steering black Plate yellow
clamp
Bushing horn

l4
f
jthionbwhing
A y contact horn

Bushing
horn at

3 10610 1 Screw
to fix shell

3 30614 1 Screw
to fix turn signal

switch to shell

Fig 1 Steering Wheel

Type Recirculating ball type connected to the rocker shaft is a steering is a

Gear 15 0 steering side cross rod lever that links up with
Rotational numbers 2 96 the steering linkage The is of the
steering
Distance between three cross rod connecting the side and cross
sector shaft worm rod lever to the gear arm the
on idler shaft
shaft 45 mm Two shorter side rod one on either side
0ear oil capacity o 3L connect the steering gear arm to the steering
gear and idler arms respectively
Steering system consist of the recirculating
ball type robust structure and gives light handl

ing and stable functioning The worm gear

supported with and lower
upper angular contact
ball bearings to the housing is meshed with the
sector arm through the circulating steel ball and
ball nut This assembly is enclosed in an oil
tight casing which carries two ball bearings at
either end of the earn

When the steering wheel is turned the tube

revolves the earn which in turn causes the
taper peg to remove over a predetermined arc

thus giving the rocker shaft its desired motion

112
 CHASSIS

Side Cross Rods Gear Removal

Steering Housing
The side and rods held in position
cross are Removing the horn ring assembly from the
by a castllated nut and split pin at each end steering wheel unscrew the column lock then
To remove the rod withdraw the split pin disconnect higher up the column jacket from the
and release the nut at each end of the rod and housing
then carefully tap the rods clear of the levers to First disconnect ball stud nut and draw out
which they are connected from the end of steering gear arm
Unscrew the bolts secured to front suspen
sion member Thus the steering gear housing
Removing the Steering Gear Arm
assembly should be removed from its position
These are secured to the steering gear
rocker shaft and idler shaft respectively by a STEERING GEAR
nut and split pin each Normally these levers
not be removed for any mainte
need general
screw
The casion their Adjuster
nance only o requiring
removal would be when damage has occurred
under which circumstances the steering box or
idler should also be remove for inspection when

the arm concerned can be withdrawn once the

steering gear box or idler has been removed to

the work bench

The gear arm should be with drawn from the

shaft concerned using a suitable extractor The Recirculating
ball nut

gear arm must not be hammered from its shaft

Removing the Idler

Referential Figure of
Recirculating Ball Type

Ball Nut Assembly

After the side and cross rods disconnected

idler be detached from the It is
the can body
secured by two bolts to the front suspention
member

Holding the idler body on the bench and take

off rubber cover Slip the nut over the worm with the ball guide
Unscrew the idler shaft out of the body holes up and the shallow end of the rack teeth

113
DATSUN

Align the grooves in the worm and nut by sight Assemble the ball guide clamp to the nut

ing through the ball guide holes being sure to use a lock washer under the clamp
Count 58 balls into a suitable container screw then tighten the screw securely Check
This is the proper number of balls for this ball the assembly by rotating the nut on the worm to

nut see that it moves freely

into each of two holes on the same
Drop balls
side of nut this operation may be perfonned
from either side of nut but two holes on the

same side must be used not two holes on same

end Shake the nut gradually away from hole

being filled Continue until all 42 balls are
installed
Place remaining 16 balls in ball guides 8

in each of two halves

o
9

ASSEMBLING

1 Fix the completed gear housing with needle

roller beearings and oil on the vice

2 Set the main column unit to the gear

0
shims and
housing with @ the wonn adjust
@ o ring

3 Insert correctly @ the bearing to the

housing
Push the guides into the guide holes of the
nut If the guides do not push all the way down
4 Tight 0 temporarily the bolts with CD
easily tap lightly into place washer after finding correct position

5 the bOlts
Retighten 0 surely witli tighten
ing torque 1 8 2 5 kg m 13 18 lbs feet

6 To carry on the adjustment of main column

after for the bearing by
oiling wonn rotation
of steering wheel

7 Motive be
power should adjusted by @
shims 2 3 4 with 200 450 grams at 20
cm R on the circumference of steering handle

ADJUSTING

a Adjust for rotation of steering gear after

fixing the main column and coltJ inh gasket

114
 CHASSIS

c2 Roller shaft adjust shim 48130 71200

@ C ing 1 550 1 575 mm

@ Bearing
c3 Roller shaft 1 48131 71200
adjust shim
1 525 1 550 mm

@801t c4 Roller shaft adjust shim 48132 71200

iWasher 1 500 1 525 mm

d Sector shaft gasket 1 48204 16500

e Sector shaft cover 1 48201 16500
f Bolt 5 16 24 x 18 3 1 24518

g Lock washer 5 16 3 9 15115

h Lock nut 3 8 24 1 9 11346

Filler plug 1 48064 16500

Part No No s

48029 71200 1 o 762

48030 71200 2 o 254

48031 71200 1 o 127

48032 71200 1 o 050

Signs Parts Name Q ty Part No

a Steering column 1 48024 16500

assembly
bl Worm bearing shim 1 48029 71200

b2 Worm bearing shim 2 48030 71200

b3 Worm bearing shim 1 48031 81200

b4 Worm bearing shim 1 48032 71200

c 0 ring 1 48035 71200

d Steering worm 1 48025 16500

bearing
e Bolt 3 1 24520
f Lock washer 3 9 15115

b Insert the sector shaft and then attach hous CD

@
ing cover

Signs

a
Part Name

Steering sector shaft

Q ty

1
Part No

48103 16500 @CD

y
Arm sector shaft

for RH
1 48502 16500
I
Arm sector shaft 1 48502 1 Set with the selected 4 numbers shims Cl C2

b
for LH
Roller shaft screw 1
170001
48135 32200
C3 C4
o
after fitting
the sector shaft
E the adjusting screw to

Gap at screw to the direction of shaft

cl Roller shaft adjust shim 48129 71200 adjust
1 575r l 600 mm
1 should be 0 01 0 03 mm

liS
r

DATSUN

ADJUSTING

2 Correct the position of ball nut to the center 1 Attach with

temporary sector gear arm
and insert oiled sector shaft to the housing Rotating slowly the sector shaft find and
adjust meshed point of the clearance 0 at
3 Stick the gasket on the housing with sealing center of

cover

2 Fix lock nut

@the
4 Fitting with @ adjust screw screw up

temporarily the bolt and washer with G

l the 3 Make sure smooth rotation of gears

housing cover

4 The k lash of gear arm should be

bi adjusted
5 Pull the sector shaft 2 3 to the the 0 0
up mm
by screw 1 mm at the neutral
direction of cover retighten the bolts of position
housing cover with the torque 1 8 2 5 kg
13 18 lbs ft After rotate the gears
m 5 finishing adjustment
repeatedly then lock @ the nut surely after
retightening adjust screw more 1 8 1 6 up

9 11246 2 5kg
Tightening torque m

Select and adjust with the shim by

part No 48129 30 31 3271200 so

48204 16500
as to the clearance is to be 0 01 0 03

Type
Distance between 4Smm

Gear ratio sector 15 0

and column

Locking angle 450

Ge oil MP90 0 33L

45

IX

tl

Impact Grease NCS 17112

at assem
bling 1
I

Tightening torque l4kg m 9 1l252

116
 CHASSIS

0
49

19
r
18 17

CD Steering gear housing ass y @ Steering worm bearing

2 Needle bearing complete @ Steering column assembly

0 Expantion plug @ Steering sector shaft

G Secter shaft oil seal @ Secter shaft adjusting screw

@ Secter shaft cover @ Secter shaft adjusting shim

@ Secter shaft cover gasket @J Lock nut

J Plug @ Bolt

@ Bolt @ Lock washer

@ Lock washer @ Nut

Worm
@ bearing shim @ Washer

@ 0 ring @ Steering gear arm

@ Steering column jacket complete @ Lock washer

@ Steering column bearing assembly @ Nut

2 Components of steering Gears

Fig

II
 D TSUN
i

Bolt to fix idler

Nut to body

Nut

to lock ball
to bar
joint

Ass y Ass y socket ide

rod inner R H
Ass y socket ride

rod inner R H

Ass y rod side t H

s1y
As rod side R H

Fig 3 Steering Linkage

Steering Faults
Loose steering is invariably attributed end already mentioned To check for this end play
of the worm gear
play through steering column disconnect ball joint stud at the end of cross rod
which can be rectified by the removal of shimes from gear arm and turn the steering partly to
located behind the gear housing front cover as the right or left lock

118
 CHASSIS

BRAKE

GENERAL DA TA

2 shoes for 4 wheels

Type Foot brake Hydraulic expansion
Hand brake Mechanical internal expansion rear 2 wheels braked

Lining
40 x 4 5 215 mm Same for Front Rear
Width x Thickness x Length x

Rear
Area of surface cm2 35 Front

Brake drum dia Front Rear 228 6 cm2 Same for Front Rear

Master cylinder bore

22 22 mm
Inner dia

Wheel cylinder bore

Inner dia Front wheels 25 40 mm

Rear wheels 23 81 mm

Fig 1 Front Brake Flange

Brake Disc

119
DATSUN

00

o
i
B

o y
f
on
o
lI
P

ll
Fig 2 Front Brake Out Side

the pistons out wards which in

The brake on all four wheels are hydrauli This moves

cally operated by foot pedal application directly turn expand the brake shoe thus producing
coupled to a cylinder
master in which the automatic equalisation and efficiency in direct

hydraulic pressure of the brake operating fluid proportion to the effort supplied at the pedal
is originated As supply tank cast integrally When the pedal is released the brake shoe

with the master cylinder provides a reservoir spring return the shoe which then return the

by which the fluid is replenished and a pipe wheel cylinder pistons and therefore the fluid

line consisting of tube flexible hose and union back into

the pipe and master cylinder
lines

inter connected the master cylinder and wheel An independent mechanical linkage actuated by a
hand brake mounted drivers seat side This is
cylinders
The pressuregenerated in the master positioned on the right hand side of seat if the
cylinder by application with the foot pedal is car has right hand steering and on the left
transmitted with the equal and undiminished hand side if it has left hand steering
force to all wheel cylinders simultaneously Operated the rear wheels by mechanical
expanders attached to rear wheel cylinder bodies

FRONT BRAKE

The front brakes are constrocted by the two over the lining ensuring high efficiency the
area

leading system with each two wheel cylinder brake disc caused by adjuster housing against
The shoes are allowed to slide and centralize the friction of the brake linings of front and rear

automatically druing the actual braking operation shoes and even lining wear

which distributes the braking force strongly

120
 CHASSIS

55 Y TUBE
f oftt I It
J

O
BL
NG ao i
ft

BCOl
r t l

tI

p
S T
I
A
RET INER
l
plln
h
CYLlND
H I H
S Y

Fig 3 Frollt Brake L H

4 Adjusting of Front Brake

Fig

for the front brake shoes is by direction until the shoe becomes locked on the
Adjustment
the shoe
means of the bolts of adjuster which located at brake dru then turn back it until
the lower and upper position of the out side of becomes just free form the brake drum

the brake disc Turn adjusting bolt to the left

III
SuN
l
IA

o
o

pll

L B
5 Front Brake
Fig
l22
 ELECTffiCAL SYSTEM

REAR BRAKES

The rear hrake shoe are not fixed but are hydraulically operated by wheel cylinder and

allowed to slide and centralize with the same independent hand brake mechanism
effect as in the front hrake They are

WASHER
nylon

ASS Y

lSPR1rtaiNnGer
BRACKET
hand brake
control

WASHER loe k
to fix hand brake bracket
WASHER BOLT
nylon

PIN cl
hand brake control

SPRING nail
COMP STEM
hand brake
hand brake control
control

NAIL ratchet
hand brake
control
I

WASHER nylon

PIN
clevis

YOKE
hand brake WASHER
control nylon

Fig 6 Halld Brake COlltrol

Adjustment for the rear brake shoes is by

means of the screw bolt which located at the

outside of brake disc This precaution should

0

be taken to eliminate the possibility of brake

shoe drag due to mis adjusted parking brakes
I n
I Turn the bolt to screw direction tightly and then
I r

i
0 turn back screw 2 3 notches until the wheel
fl JJ
drum turns just free from the shoe
I
If IJ
II
I

J
A

ttt J
Brake Shoe
Fig 7 Adjusting

123
DATSUN

o 0 Section

Dl

ci

44060 10500

Upper side
Sett1l
g jl 4 Isio
4407 JOOO
of
44118 JOOO I
Feq eCt10I
Fq
A 44 00 10600

Jrle 21 5

f
o

I 41128 JOOOI
j
41129 JOOOI

B B Section
LI055 Adjustment of brake shoe

This precaution should be

taken to eliminate
thepossibility of brake shoe drag due to
mis adjusted parking brakes Turn the
bolt to Screw direction
tightly and then turn back
screw 2 3 notches until the wheel drum turns
Fig 8 Rear Brake No 1
just free from the shoe

124
 CHASSIS

85

A A Section 44118 30001

Fitting Df wheel cyl
44030 10600ML H
44020 10600 R H

4414131700
44142 31700

4414931700
44144 31700
I
J
44145 31700

44205 10500

44081 04100
S
c 44084 30000
C SectiDn

8 Rear Brake No 2
Fig

125
DATSUN

55 iDER
CYLl htel

dust B TOKICO
COVER PL TE TOKlCO
A SS Y LEVER tTOKICO COVER duH 8 S BCO
PLHE A8CO

5 LEVER
S
SABCO i
SHIM 8 TOKlCO SHlM adJuumg
adJuuln
SHIM B NASCa J
oa adjatlng A TOKICO
SHIM NASCO
adjuulng

SCREW bl d
fOle SPRING bralshoe
ASS Y SHOE bral
e return e

yhnder Ide
CAP bleeder

I COVER dun COVER du

A TOK S BCO
A

LIISG brake

CUP p
u

r
RI G

TOKICO
snap
PISTON

RING snap
NASCa
cylinder
heel TOKICO
PISTO
l
wheel
cyhnder
ABCO

ASS Y HOUSIN G
bra shoe
e adjuster

WSHER locl
TAPPET adJuulU

SUT

J
TAPPET adjuSI r

LINING bral WEDGE adjuster

ASS V
SPRING rerun bral hoe
e SHOE
bral after
e

adJu ung de

Fig 9 Rear Brake L H

HAND BRAKE

The hand brake operates on the rear wheels

l
only and is applied by a pull up type of lever r
tk
j
situated along side the driver s seat The cable I

from the control is attached to the toggle lever

c
connected with the brake disc
brake linkage is set when
rear The hand
5 i
leaving the works and
should not require any attention under normal r

Jf
maintenance Only when a complete overhaul
is necessary should the hand brake linkage
require resetting
When this is correct the rear shoes should t J

f
0

be locked to the drums the hand brake control

just slightly applied and the wire rope set with
the slackness just removed by means of a nut
at the center rod of the equalizer drag link
Fig 10 Adjusting Nut

126
 CHASSIS

MASTER CYLINDER

This is consists of an alloy body with a filler cap and drain out fluid Pull back the

polished finished bore and reservoir with cap rubber boot and remove the stopper ring with a
The inner assembly is made of the push rod pair of long nosed pliers The push rod

stoper plate ring piston secondery cap return assembly can then be removed When the push

let out valve and check valve seat rod has been removed the piston with the
spring
The open end of the cylinder protected by
is secondary cap will be
xposed therefore remove
a rubber boot as shown Fig disassembling the the piston assembly complete
Brake Master Cylinder The assembly can be separated by taking out

Disconnect the pressure pipe union from the other small parts

cylinder and remove the securing bolts when Examine all parts especially the rubber

the master cylinder and fluid reservoir may primary cap for wear of distortion and replace

withdrawn complete from the ar Remove the with new parts where necessary

GASKET filler
SET CAP ap
s
fille

s
r
SPRING eturn brake pedal SPACER piston up
1

1
PISTON brake
AS Y VALVE

1sterj
l i
aJP piston secondary s
f
s

NUJASHER T
orWASHER NUT
IOCk

lJ J
COVER dos SPRING
ASS y ROD P
ru
I alve SEAT I
n alve BOLT

i i

RING soap
NUT
BUSHING 1
pedal PIN fulcrum
fulcrum
PlN SLEEVE pedal shaft
STOPPER clevis
brake pedal brake master cyl

ASS Y PEDAL
brake

11 Brake Master Cylinder

Fig
Bleeding the Hydraulic System
the is of air
Bleeding is necessary any time a portion of entering jar completely free
Then downstroke of
the hydraulic system has been disconnected or bubbles during a the
if the level of the brake fluid has been allowed to brake pedal tighten the bleed screw cap

fall so low that air has entered the master sufficiently to seat remove bleed tube

cylinder This process must now be repeated for each

With all the hydraulic connections secure of the other wheel cylinder
and the supply tank topped up with the fluid Always keep a careful check on the supply
remove the cap from the bleed valve and fit the tank during bleeding since it is most important

bleed tube over the bleed valve immersing the that a full level is maintained

free end of the tube in a clean jar containing a Should air reach the master cylinder from
the tank the whole of the bleeding opera
liltle brake fluid supply
Unscrew the bleed valve cap about three tion must be repeated
the brake bieeding top up the supply tank to its
quarters of a turn and then operate After
pedal with a slow full stroke until the fluid correct level of approximately three quarters
full

l2
r

DATSUN

Never use fluid that has been bleed from a the air bubbles in the fluid lime to disperse
brake system for topping up the supply tank as Great cleanliness is essencial when dealing with
this brake fluid may be to some extent aerated any part of the hydraulic system and especially
Such fluid must be allowed to stand for at least so where the brake fluid is concerned

one day before it is used again This well allow Dirly fluid must never be added to the

system

to fix a
l
rn to llg
l
ASS Y acket
CABLE front
RE TAINER spring SPRING pull
I PIN de
brak
U od

j
ARM PIN tH
0

h nr
f ASS i 6q t cleVis
CABLE PIN den c
0 N1PPLE A II

f
hand to hx If grease If d
brake ablepIN e 0
b a1 ance clevis
after v
lever LEVEK tI
Eo RING
1
0
FERRULE balance 1I
felt
cross
T
PLATE LU ck
PIN clevlS BOLT
TO handk
ra e PIN
o

co

Gl plaln er

CI

adjustlllg NltT
TRUNNION pIn lock ROD cross
NUT BRACKET
hand brake hand brake hand brake
hanger
cable to lever short

to hx
cable rSCRE i
W 1oss rod

brackeUWASHER PIN
to fa rod
cottoc to balance lever
e
SPRING pull
FELT
off TOSS rod BRACKET@ PIN
hanger
ng
rosa cotter CARRIER
to fix rod f
PIN
clevis
NU djll
rod
tofix
balanct lever
to flXbracket COMP SUPPORT
to wheel cylinder Nul cable to

leverl PIN
cotter
ROD cross
hand brake
balance
leverl
balance lever

long
WASHER lac k

Fig 12 Hand Brake Linkage

128
 tr1ttr1 o el o rD tr1

IrP
P IoI u oJ r J JIP
I3

ComblfOt
Il

lamp
Combhun lamp

lamp lamp lamp lamp

I
g

lamp pilot pilol warm

O

l1ll b
r

lompv
u Left Ilgnal beam
womlng
1 Sid RighI itch
lW InJl1me TUrn Mom Ignitu prul
unit 1

0 Door Lamp IL TS Wi3 IG OIL

auQe itc

i
Tank I

r urn nUl n col ur

d

OIo
n 2 DIm er tM
lamp or B
0
th

line Block Whu Red Gr Yelow Blu

OJ
I
L
swi Hl Combuled c

Elet
B w R G Y l

1
igniton llr k
GII
toc
wneh witch

ICSJ
r

C l
lIghting Wiper
i

1k
r

twitc ll ll 10mp
l
j
lamp
SlOp
1I l
Bt
lH
b
lff C

1 molar
Aldrm nlLJJ
r

rt F
I
C

Wiper Speak AI

100
111

t plug 1
COnCl
Spark
H

I
Bolery
ij
lo
Hight
linn
HClrn Horn
1Irl t

lo

Conectd
r

i
u

Igmp
llp
lol
J turn lomp
Fog
IF
alall
lp
OO

Head
Porhng ligtIC omp
H
hl
Onel Right
RightlParun
l ft

ight
R
ft
L

12t t o to

ND
DATSUN

1 SCREW

BRUSH cove
TI
WASHER

COVER

d
BEARING
over

DIODE

W
set 1 WASHER

BEARING ball

ASHERl
WASHERl
BEARING

WASHER
l BEARING washer

Fig 1 Alternator Mitsubishi

AL TERNA TOR

Altemator Mitsubishi Denki Co Secondary

Primary side
Model AC300 12WR side
Nominal output 12V 300W
valve 14 14 15V
Constant Successive
djust 15V

Pole side ground Dynamo

4 OOOr p m 4 000r p m
Constant revolution 2 500 r m revolution
p
No load minimum 1 000 r p m down
Battery resisting
revolution 14V normal temp Load Battery
load 21 5A approx
Output current 2 500 r p m 14V
24 5A up normal temp
2 500 r p m 14V
21 5A up high temp Note Use battery charged in full

Pulley ratio 1 1 73

Regulator Mitsubishi Denki Co

Pilot lamp relay 3 contact point type
23500 12200

Model RL 2BI

Type Tirrill type leaf spring

Put off voltage Put
Element Constant voltage
on voltage
relay
Pilot lamp relay
4 5 5 2V o 5 3V
Constant voltage relay 3 contact point type

130
 ELECTRICAL SYSTEM

MAJOR COMPONENTS OF
AL TERNA TOR FOR 41 1

0
0 11
10 9
12 14
2
3 0
19 lf0
0
Il

ljG 1700
@ j
L I 181716
13 1817

Fig 1 Major Components

ey Key
Part No Part Name Q ty Part No Part Name Q ty
No
No

21 23159 14610 Grommet 1

23100 14600 As s y alternator 1
1
Mitsubishi 12V 300W 23233 14610 Clip
22 23118 14610 Ass y cover front 1
23100 14602 Ass y alternator
23121 14610 Washer seal 1
Mitsubishi 12V 300W 23

Bearing ball 1
1 23108 14610 Ass y rotor 1 24 23120 14611
Retainer 1
2 23116 14610 Washer seal 1 25 23123 14610 bearing
26 23352 12210 Screw 3
3 23120 14610 Bearing ball 1
27 22203 32210 Wasber spring 3
4 23102 14610 Ass y stator 1
Ass y puUey 1
5 23131 14610 Bolt through 4 28 23151 14610
1 29 23152 12210 Wasber spring 1
6 23127 14610 Ass Iy cover rear

30 23162 12210 Wasber plain 1

7 23230 14610 Ass y diode set 1
Nut 1
8 23133 14610 Ass y holder brusb 1 31 23153 35010
23139 12900 Bolt to 1
9 23135 14610 Ass y brush 2 32

fltema
to bracket 1
Cover 1 33 9 15115 1 Washer lock
10 23107 14610 brush
fix
34 9 11245 1 Nut 1
11 23352 09160 Screw 4 ti X 10 2

12 22156 01302 Washer 2

spring
13 23156 14610 Ass y teminal 1

14 23158 14610 Screw 1

Insulator 1 Part No Part Name Remarks

15 23161 14610
16 23157 14610 Insulator 1
The con
17 22213 71311 Washer 1 23500 14602 Regulator ass y

23100 14602 Alternator ass nectar was

18 22203 22210 Washer spring 1 y

19 23139 12210 Bolt terminal E 1 24299 14801 Connector regulator enlarged

Connector alternator in this type
20 22203 32210 Washer spring 1 24299 14800

l31
r

DATSUN

GENERA TOR

Construction and Feature

Different from the DC

generator the AC current and rectifies all waves with the silicon

generator turns the magnetic pole and fixes diode each three that are built within

armature making it generates 3 phase alternate and takes out as direct current

tn A Tenn
S T i l
Ito bolt ra k

cet
l lon
It n

ulot
tn 8ail 8 IocoW
11
bn h A N 10
o
a p M e

0 n

It Au
l l U

Fig 2 1 1 Sectional View of Dynamo

r r

The sealed ball bearing @ @ are used to

support the rotor Clearance between the brush
and brush holder is also made so as to prevent
it from dust Thus the AC generator will
I
increase milage without maintenance Each 3

diodes are pressed in the rear cover and the I

diode base respectively

@ @
Fig 2 1 3 Magnetic Circuit

f sw
Relay
C i r

R I

0
CD Field core I s
o
o

0 e
Field segment

I
h

Field coil
2 1 2 Sectional
Fig

The
View of
clip ring pressed
Rotor
o Shaft
in tbe shaft is soldered
I I
I
L
s

at both ends of the field coil to pass magnetic

Fig 2 1 4 Connection within Dynamo
current
The pole of rotor makes out the magnetic
circuit as shown in
Fig 1 3 and all the
poles The armature is of a three Y connection
phase
are magnetized by doughnut coil type and the silicon diode rectifies all waves

132
 ELECTRICAL SYSTEM

It pulls out the neutral point and adds voltage Disassembly and Assembly
having conducted 3 phase half wave rectification
in the circuit of relay and controls the voltage A
Disassembly
coil of the pilot lamp relay
The dynamo is disassembled in the following
order
r r

I
I a
0
l
E
i
SC j 1l
o O
U t
9 i
Hi

lePl
FC

Dynamo I

Fig 2 1 5 Charging System

Regulator 2 2
Fig 1

The completed

rhe parenthesized is the part number for

SP311

1 0 ji 1 I
I f
r
I I

Charge pilot lamp

Fig 2 1 6 Outside Connection

When

battery
the

current
ignition
flows
switch

in the
is

arrow
put on

marked
the a t
direction passing through the dynamo E termInal

brush slip ring field coil slip ring brush Fig 2 2 2

dynamo F terminal relay F terminal and IG
Remove the brush cover and pull off the
terminal and completes the field circuit It in
brush 2 ea
difficult for the dynamo to stand up only by
residual magnetism of the field core so that c

magnetization is necessary until voltage rises to

suit charging after the engine has started 1
This is because the diode is used and when
the voltage to add to it is low large
proportional resistance shows
so

up and current
r
0
t
does not flow through the field coil unless the c f
0
dynamo

the
makes very high revolution
This is because the diode is used and when

voltage to add to it is so low large

t 0
0
j
1

proportional resistance shows up and current

does not flow through the field coil unless the

dynamo makes very high revolution 2 2 3

Fig

133
DATSUN

Remove the cover of bearing and take off Remove the bearing from the front
ball
the hex bol t of shaft cover Remove the bolt
or tightening the

bearing plate and or pull off the bearing

d
with such as a hand press
Slacken N terminal bolt on the rear cover

side and remove the clip terminal then

the rear cover and the stator can be

separated

oQ
2 2 4
Fig
Remove the hex pulley and pull off
nut of

the pulley and the half moon key Be

careful not to injure the fan when the nut

is removed

e
Fig 2 2 7

Remove the rear cover and stator

Separate the silicon diode 3 ea from the

stator coil lead wire 3 ea by melting

soldering with an electric iron
I
Slacken N terminal bolt on the rear cover

side and remove the clip terminal then

the rear cover and the stator can be
P 0

separated

NOTE When temperature within diode gear

up over 150 C the diode will lose
Fig 2 2 5
functioning so that use the electric
Remove the through holt tightening bolt iron 100 200W for around 2

front cover and rear cover pull off the seconds at the soldered portions
front cover and rotor
Use a hammer of wood or plastic if

necessary

f h

i A
y

6 2 2 8
Fig 2 2 Fig

134
 ELECTRICAL SYSTEM

Remove the diode set and brush holder Installation

from the rear cover

When be careful not to lose small parts the heat sink or end
Support frame with a
such as screws washers and bushings suitable tool and then press the diode in the heat
sink and end frame by using the tool shaped @
B
Assembly which fits over the outer diode edge A portion
Press down perfectly the diode in the mount
Assembly is done in the reverse sequence of
ing bore of C portion to the lower edge of B
disassembly portion of the diode
Always make sure the of alternator
polarity Checking the replaced diodes
or regulator before replacing the diode either I I

positive or negative The polarity of alternator @

i
or regulator is usually marked on the name plate j
ff i
lable which is attached to each model I
or i

the
In case

positive
the

ground
alternator
the red
or regulator
coloured
shows

diode
l
AI nJ
should be mounted in the frame of slip ring end
and the black coloured diode in the heat sink

Red mk

Black m k

Red or Black mark

Fig 2 2 9

Fig 2 2 12

Inspection of Troubles

A Inspection of Output

For inspection of output remove the dynamo

from the vehicle and connect wiring as shown in
Diode 3 1 and drive it with motor
Fig
of of
View
For
inspection output dynamo without
Fig 2 2 10 ExPloded
removing it from the vehicle refer to Inspection
Removal of AC to be published later
generator

To remove a diode use a suitable tool to lAe

support the end of the frame or heat sink and Ammeter l
Q

I le
push the diode out by using an arbor press as
Volt II
s own the below meter

Fig 2 3 1

NOTE Use the battery charged in full up to

the normal
Press out so not to
capacity

injure the mounting

bore of the frame
Through the wiring shown in Fig 3 1
the heat sink
magnetic current flows from the battery to the

field coil of In this state raise

dynamo
2 2 11 revolution of dynamo slowly up to the speed
Fig

135
DATSUN

flow 2 A approx at both terminals

where there is no reverse to alternately
the field coil and read the revolution Correct When one low resistance and the
shows

revolution is approx 1000 rpm Without load other shows pretty high resistance the 3
Next increase load resistance to the 3 diodes in the diode set are all right

maximum and almost stop flowing of load

current and put off the switch Then raising

the load current increase revolution of
slowly
dynamo Observe thus increasing output current
as revolution of dynamo increases U there is

no large difference from the specification it is

correct

No matter bow the battery is over charged

if the charging current is small
or discbarged
first make either the the
sure dynamo or relay
is in disorder See the charging current by

inserting the ammeter between A terminal of

rei ay and the battery 2 3 3

F
Fig
Disconnect Wire passing from the dynamo
terminal to the F terminal at the relay F Check between the terminals A E same
relay
terminal and make the removed lead wire short as above

A terminal when if the When the same result is obtained 3diodes

circuits relay
at the
charging current highly increases the relay is are also all right

in disorder
However when there is no disorder found

in this simple test and the dynamo output

B Short Circuits on Diode Side 2
is somewhat lower than the standard 1

diodes are often in opening when one by

It can be judged as the pilot lamp does not
one checking will be necessary
flare even if the key switch is turned on

trouble such diode open is very b Separate Inspection

Actually a as

rare and short circuits at the polar line are

also rare Ordinarily there are

many caseS

of side short circuits

C Inspection of Diode with Tester

a Simple Inspection

Fig 2 3 4

Fig 2 3 2

Check between the terminals A N as

shown in Fig 3 2 Set the dial of tester

for conductivity and put the tester needles Fig 2 3 5

136
 ELECTRICAL SYSTEM

Check resistance with the tester between When one side shows low resistance and
the diode base commonly used for 2 diodes the other shows high resistance there is

and lead wire on the rear cover 2 times no disorder If both sides are low there

changing the poles will be short circuit and both sides are

high there will be open

D lnspectioll of Diode with Lamp

a Simple Inspection

Check pOSitive diodes Check negative diodes

Test Lamp Method Test Lamp Method

Test Test
Method Method
Connection Lamp Result Connection Result
Lamp

Should be Connect EEl Light Good Should be Light Good

conductive to@ and 8 non con
Connect 8 to
@ and to @
@ to @ to@ No Light Defective ductive @ No Light Defective
to@

Should be Connect 8 Should be

No Light Good Light Defective
non con to @ and con duc Connect8 to
ductive 8 to @ tive @ to @andEjjto@
Light Defective No Light Good
@to@ @

The soldering for the lead wires should be excessive heat may damage the diodes

performed in less than 20 seconds as the

I C

I o

rii
i 1
l

Fig 2 3 6

Check between the terminals A N as alternately On one side the lamp flares
shown in Fig 3 6 and on the other the lamp is off when 3

Connect with the lamp 12V in straight diodes of the diode set are all right
and put both ends at A and N terminals

l3
DATSUN

Fig 2 3 9

Check between the lead wire and lhe diode

set common wilh lhe olher 2 diodes or lhe

rear cover with lhe lamp and battery It

is all right if one side flares and the olher

is off If bolh sides flare lhere is short

circuit and bolh sides are off lhere is

open

E Inspection Field Coil

Fig 2 3 7

The same step is taken between lhe

terminals N E When lhe same result

is obtained 3 diodes pressed in lhe cover

are all right However if lhe simple test

is all right but when the is
dynamo output
lower lhan lhe standard 1 2 diodes may

often be opening so that one by one check

will be necessary

b Separate Inspection

2 3 10
Fig
As shown in Fig 3 10 put lhe tester be
tween the slip ring of rotor and if lhere are
2 3 8
Fig 7 j all Make there is
6 it is right sure no

conduction between lhe rotor slip ring and lhe

shaft

138
 ELECTRICAL SYSTEM

F Ball Connect the tester cord to IOOV wire put

Bearing
the stator on the test stand and make the
Both sides sealed ball bearing is used so tester one turn reading the ammeter If
lubrication is not there is short circuit on the coil
necessary swings
G stator Armature of the ammeter abruptly increase and if
Inspection of
there is no trouble there will be no
a Conduction Test
change

If the terminal connected to the diode is

not conductive with the stator core that H Inspection of Brush
is all right
Wipe with clean cloth when oil or dust is on

the contact surface of the brush and slip ring

Same as in case of DC generator replace the

brush when wear of it reaoohed to the wear limit

REGULA TOR

L Construction and Operation

1 Construction

Fig
2 3 11

Fig
2 3 12

If each terminal of the coil and the Fig 3 1 1

terminal connected to N terminal are not
2 Operation of Constant Voltage Relay
conductive that is all right

r
b Layer Test
I
0
I
e
III
R
Isc o c T
II

J O
I

s S
I

LEecril
Fe c

a
I
o
I
I E
Dynamo J

Fig 3 1 2
current from
When the ignition switch is on

E
the battery passes through the dynamo
Fig contact and
terminal field coil points P2 PI
2 3 13 the dynamo is magnetized

139
DATSUN

While it alBa flowB the regulator E terminai iB kept evenly and continueB charging
contact pOints and the lamp flares
PS P4
r

I r
r

I I
I
j
c I 0

I
I
a l I t
I ISC o
sc t I gr
I 8 aT
Cl U
I
II

n
1 I
II tl J I I

re
Fe S I I

I I I

r
I I I
I I
I I o
I I
I l
I I I
I
I
l
L J RegulatornJ
lbn
I
Dynamo I
Regulator
L J In n

Fig 3 1 5
3 1 3
Fig
When the engine Btarts and the iB When the still higher
dynamo dynamo revolutiongetB
driven three phaBe alternate current generates the movable piece iB drawn and the movable
the stator coil pas Bing through the three contact point BtickB to that current
on
Pz P3 BO

phase all wave rectifier diode and changeB to almOBt does not flow the field and the generated
direct current between the terminal A E for voltage of dynamo goeB down AB the reBult
charging the contact point P2 BeparateB from P3 and the
At the N terminal voltage half of that current from through the dynamo E terminal
between A E generates and through the field coil F terminal reBiBtance and
pasBes RI voltage
circuit N terminal VCI coil E terminal and goes up again At such a high speed with open
with action of the VC coil the movable contact and close of the contact pilints
P2 and the
P3
point Ps leaves from P 4 and makeB contact With dynamo terminal voltage is always kept evenly
P6 BO that the lamp iB off and it paBBeB through
the circuit E terminal contact pointB PS P6 r

reBistance coil and A terminal then I

RZ VCZ I
I
the
VCZ coil animated and prepares to vibrate I
I

the movable contact point Pz of the conBtant

lsc
voltage relay I

When the
dynamo revolution getB higher the Fe

contactpoint Pz BeparateB from PI With electric I

I

magnetiBm of the VCZ coil and the field current I

I
I
from the circuit of the E terminal field I
dynamo I Regulator
Dynamo
coil F terminal and reBiBtance and when the J L J
HI

r
Fig 3 1 6

I
I u The operation of this time is called a high
IL
I R
t
ISC
I
c Bpeed operation and the adjuBt voltage iB called
0 tl

I Fe S
a secondary voltage

Jr
I When the dynamo revolution goeB down and

charging capacity reduces the voltage between

N the terminalB N E alBo lowers
namo
Dy
magnetiBm of
J
As the result the electric
and the contact point fixed
Fig 3 1 4 VCI coil weakep s
Ps
with the movable piece can not continue contact
With and changes to P side and lights the
contact point
Pz contactB With PI the current P6 4
flows through the circuit of dynamo E terminal lamp indicating non generation
field coil F terminal contact pointB When the ignition SWitch is turned off to stop
Pz PI
ThiB iB repeated vibration of the the engine the lamp goes out and the current to
according to
contact point Pz and the dynamo terminal voltage the field coil is Buspended

140
 ELECTRICAL SYSTEM

3 Operation of Pilot Lamp Relay

As shown in Fig 3 1 2 this is made up First put on the lamp with connection as

with the contact points P4 P5 and The

P6 shown in Fig 2 2 and read the voltage
betweel
contact point is the movable side and N by putting off the lamp moving the volt split
E
P5 on

usually makes contact with P Between the point of the rubbing resistance This is a put
4
terminals N E the movable piece is drawn off voltage
when voltage half of the battery is added and From this state the rubbing resistance
P5 move

fixed to the movable piece separates from P volt split point and lower the voltage and read
4
and makes contact to When the voltage the when the
P6 voltage lamp flares
between N E terminals is conspicuously reduced This is a put on voltage If the put off
makes contact with P is 4 2 5 2V
P5 4 again voltage and the put on voltage is

The voltage between N E terminals neces o 5 0 3V it is all right

to make contact with is
sary for P5 P6 Put off
voltage and that P5 changes from P6 to is 3 Adjustment of Gap Constant Voltage
P4
Put on voltage Pilot Lamp Relay

2
Thevoltage adjust values of the constant
Adjustment
voltage relay and the pilot lamp relay must be
Check Value of Constant Voltage as shown in Fig 2 3
1 Adjust
Relny

Gap
0

1 g
Gl G2 G3
u
J Constant
0 8 1 0 0 7 0 9 o 3 0 4
Voltage Relay
Fig 3 2 1

Pilot Lamp
Connect the battery almost charged in full as o 8 1 2 o 8 1 1 o 8 1 1

shown and make the revolution with

Relay
dynamo
4000 rpm
When the voltage of this time is 14 15V it

is all right

2 Check Voltage of Put off Put on Pilot Auxiliary

leaf
spring
Lamp Relay
r

I
L I
I

I
I
I

Thrusting J I
I
esistance I I
I I
I Fig 3 2 3
N I
r
I
l p
I
1 p I
I
p
I 4 Adjustment of Voltage
I
E I Put off voltage of the constant voltage relay
VC2 R2 I
and pilot lamp
I I relay
I I
I I Adjust the voltage by bending the stopper up
E
L

adjust value
n

and donw Bend upward to heighten

and bend downward to lower adjust value
Fig 3 2 2

141
r

DATSUN

14 ITEMS ON HANDLING

Prohibition Reason

1 When mounting on vehicle polish the contact pOints

on both sides removing point rust or oil

2 Make the
sure engine side pitch and dynamo side
pitch of the front cover are well fitted together

3 Be attentive to the belt tension

4 Regulator is sealed with lead If the seal is

removed the claim period the claim will

during
invalid

5 If the earth is not correctly set the value

adjust
will change

6 Connect the and battery with full attention

dynamo When the battery poles are connected in
reverse large current flows from

battery to dynamo resulting in dam

ages of diode or lead wire

7 Make sure the whole circuit is completely com

posed

8 Change wiring with full attention When after the engine started the
dynamo is magnetized from the ignition
switch so that incorrect wiring will
result in hampering magnetization and
then generation

I 9 Do not use the high voltage tester such as megger I As diode is built in the diode will be
damaged with high voltage

10 must be in the condition of stand

Engine room kept Because there is diode which will
ard usage deteriorate or be damaged with temper
ature higher than the normal

11 Do not separate the battery terminal dynamo Separation ofthe terminal causes serge
terminal during driving vehicle voltage within battery and dam ages
diode

12 When cleaning with steam cleaner do not expose If the diode is moistened the perfor
dynamo to steam directly When washing with mance will be lowered
water dynamo must be free from reckless pour of
water

13 When the is
battery quicklv charged with the quick Serge voltage of the quick charger will
charger the lead wire or regulator A terminal also damage diode
dynamo A terminal should be disconnected

14 Put the key switch off when the engine in a stop When the
key switch is on magnetic
except when particularly needed current always flows on the field coil
and might damage the dynamo and often
causes over discharge of
battery

142
 ELECTRICAL SYSTEM

TROUBLE SHOOTING LIST

Trouble Cause Remedy

5 1 Over discharge of battery

1 Slackness of fan belt

Adjust
2 Earth or breakage of stator coil Repair or replace
3 Breakage of rotor coil Replace
4 Mal contact of brush and slip ring Replace blUsh clean holder
5 Mal function of diode Replace as a set
6 of constant voltage relay is low
Adjust voltage Readjust
7 Mal contact of low speed side contact point of
constant voltage relay Polish contact point
8 Adherence of high speed side contact point Replace
9 Shortage unfitness of electrolyte
or Add distilled water check S G
10 Mal function of battery pole short circuit Replace or repair
11 Mal contact of battery terminal Clean retighten terminal
12 Mal contact or breakage between ignition switch
and relay IG terminal Repair
13 Mal contact breakage between F
or regulator
terminal and dynamo F terminal Repair
14 Excessive electric load Check power consumed

5 2 Over charge of battery

1 Constant voltage relay adjust voltage is too high Readjust

2 Constant voltage relay coil breakage or rare

short Replace
3 Constant voltage relay coil straight resistance
breakage Replace
4 Constant voltage relay low speed side contact

point adherence Replace

5 Constant voltage relay high speed side contact

point mal contact Polish contact point

6 Breakage or rare short of pilot lamp relay Replace
7 Mal contact of pilot lamp relay contact point Polish contact point
8 Mal function of regulator earth
Adjust
9 Mal contact or breakage between regulator N
terminal and N terminal
dynamo Repair

5 3 Noises of Dynamo

1 Mal function of bearing Replace

2 Mal function of diode Replace diode as a set

3 Earth or rare short of stator coil Replace

143
r

DATSUN

STARTER MOTOR

with the ignition switch By turning switch to

the right direction the relay on the magnetic

switch move to permit current to flow to the

starter and cause the armature to start turning

suddenly
CONTACTOR

ARMATURE

BRUSH

Fig 1 Magnetic Shift Type

Type S1l4 92 Starting Motor

Make Hitachi After about

advancing 14 mm the pmlOn
Weight 4 6 kg completes the
meshing into the ring gear and
drives it with a powerful torque The direction

in whicll the pinion moves is from the end of the

Type S114 92
shaft towards the starter bracket thus reducting
Rated Output V Kw 12 1 0
the bending torque After the engine starts and
Meshing Device Magnetic its speed becomes greater than the no load
No Load Current V A Under 12 60
speed of the starter the pinion is kicked back to
No Load Rev rpm Above 7 000
unmesh and return to its former position
Brush Normal Height mm 14

Brush Wear Limig mm 4 5 CONTACTOR

STARTING SWITCH
Brush Spring Tension kg o 8

Commutator Dia rom 33

Commutator Wear
Limig Dia rom 2

Pinion Operating
Voltage V Under 8
PinionGap mm 3 5

RING GEAR
PINION SLEEVE SPRING 1

Construction and Operation PINION SLEEVE SPRING 2

The starter motor is 1 0

a horsepower
sliding inertia type electric motor for use in Fig 2 A View of Starter System
starting The motor when mounted on the engine
is on the front right side of the transmission
with its pinion gear directly opposite to the ring
The construction of the starter motor is
gear
similar to that of the Operational Precautions
generator but differs only
in that its armature shaft extends out backwards
The instructions to be observed when
with starting
a pinion group installed on the end as show
the engine are as follows
in Fig 1 2

The connection diagram for the starter is

shown in Fig 3 1 The starter should be mounted

securely on
The starter switch is a combined
key type the engine and should not show any looseness

144
 ELECTRICAL SYSTEM

PIN cotter ASSrY switch magnetic

I
ASS y lever pinion shift

PIN lever shift

ASS y case

gear

n
o

SCREW set pole core

3 starter Motor Hitachi

Fig

Checking While in Operation

2 The starter switch should be operated 1 With a fully charged battery and with the
properly and should be release immediately lamps lighted the
starter switch is used
when the engine starts If the
lamps become dim especially when the

Excepting in extremely cold weather the engine does not start the current is flowing
engine should normally start within 10 through the starter motor coil but for some
seconds reason the armature is not turning Careful

check should be made since the starter

3 The starter switch should not be operated pinion may be locked in the flywheel ring
when the is If the engine and unable to return
engine running gear a trouble usually
fails to start allow time for the pinion to caused by turning on the starter while the
come to rest before turning the starter engine is still running
switch again
2 When the starter switch is turned up and the
4 When the engine fails to start after starter motor fails to turn
turning although the lights
the starter key for over 10 seconds do not remain bright the switch should first be
continue turning the key lime after time but checked If the switch is in satisfactory
try to save the In this case check
battery condition then the condilion of all the
for the cause of the trouble and correct so terminal and ground connections of the
that the engine will start battery starter switch and starter are

145
r

DATSUN

checked If the starter motor runs but its taken when inspecting to also check the
movement is sluggish it indicates either a flywheel and take remedial measures if the
high resistance due to loose connection in ring gear is found worn or damaged When
the the
starter circuit or a badly discharged pinion is found defective replaced the

battery entire pinion group

3 If after the above troubles are corrected and 2 When the armature check the
inspecting
the starter fails to operate occasionally and armature to core gap shaft to bushing
shows defective performance it is due to clearance bending in shaft etc in the

internal defects so that in this case it should same manner as that for the generator and
be dismantled and checked are corrected to the specified limits or the

armature is replaced Special attention

should be given to the clearance between the

Dismantling and Disassembling armature and the core to see that they are

1 The starter can be dismantled easily by not contacting and corrosion found on the
removing the two stud nuts the outside surface of the armature or the inner
mounting
starter on the engine surface of the core should be removed by
polishing and the surfaces painted with rost
2 The two stay bolls on the starter rear cover preventive oil
front end when mounted on the engine are
removed 3 The armature is inspected and repaired in

accordance with the procedures outlined for

3 After removing the band cover the broshes the generator Especially to improve or

and lead wires are removed correct the brosh contacting condition the

broshes are reseated At the same time

4 By properly and holding the the brush checked and
protecting spring are are

starter body the armature shaft is pulled corrected or replaced

out

4 The insulation the wires

on are carefully
5 The armature and the front cover are taken inspected and wires found with weak or

out together damaged insulation should be replaced

6 To the from the An found with

remove pinIOn group 5 armature one part especially
armature shaft the cotter pin on the end of damaged by buring should be strictly tested
the shaft is pulled out and by removing the by the insulation test

pinion nut the pinion group is removed

ADJUSTMENT
Inspection and Repairing Parts

The same procedure that for lhe Meshed Pinion Position by Magnetic Switch
as generator a

parts is followed the parts being cleaned and

inspected after which determinations are made The correct clearance between the pinion
as to whether they can be reused or if repairs stopper and pushed out pinion which is shown by
or replacements are necessary L dimension in Fig 4 must be following L 0 3
1 5 mm

1 The is
pinion inspected for defects and if the In case that the Ldimension is incorrect adjust
tooth face isworn or the tooth edge is plunger gap of the magnetic switch by following
damaged the pinion should be replaced paragraph b Pay attention that theLdimension
Worn or broken teeth will not make the be measured when the pinion is
only must atmostly
gear mesh poorly but will hasten the wear on pushed out by the shift lever of the plunger and
the opposing gear and also the back lash ofthe
poorly meshing pinion is eliminated by pUSh
gears will cause bending in the armature ing gear inward with finger as Fig 3 shows
shaft For this last reason care should be If the L dimension is incorrect It wll1 be the

146
 ELECTRICAL SYSTEM

possible of large meshing

cause noises or early
wear and damage of the pinion and ring gear

7
Y I

10

1O 3 1 Slltllt

Fig 6 Measurement of Plunger Cap

Fig 4 Checking Dimension

l
1

t 1
Battery
r CH

J r

I
i t

Fig 5 Cable Connection of I

I
Dimension Adjust
00
b Adjustment of Plunger Gap of Magnetic r T
Switch o o

The L dimension when the plunger gap is

to 0 be
Fig a
Removing Magnetic Switch
compressed must following in Fig 6
L 31 7 32 3 mm

This adjustment is carried out at the adjuster

and the adjusting nut

DISASSEMBLING AND ASSEMBLY

OPERATION

5 1 Disassembling the Armature Gear Case

and Pinion

Disassembling order is shown by Fig a to

Fig c
o 0
Q 0

Disassembly operated is
by removing I
magnetic switch fixing bolts through bolts and
the armature shaft clip Before disassembling
main body remove brushes by unscrewing brush Fig b Drawing out Brushes
fixing screws as Fig 6
After removing fixing screw

14
rj

DATSUN

ARMATURE

PINION
STOPPER

o o

Fig c
Drawing Out Yoke Fig f Disassembling Armature

GEAR CASE

SHIFT LEVER

Fig d Disassembling Armature and

Fig g Removing Pinion Clip
Gear Case

SL
EEVE

PINION SLEEVE
SPRINC3
PINION STOPPER
CLIP

seREVV DRIVER
Id
Fig e
Removing Pinion Stopper Fig h Disassembling Pinion
Subassembly

148
 ELECTRICAL SYSTEM

0
L
oo 8

01 o 0 1
o

0
r

e
r M
OIV Q

MJJ
Fig i
DisPlay of all Component

Disassembling Pinion the current falls to pass through the

magnetic circuit most of the trouble is

Disassembling is carried out by removing due to broken soldered connection between

pinion clip as Fig g the magnetic coil wire add the magnetic
switch terminal and defective ground
Assembling will be done in reverse

of connection from the coil wire to the

sequence disassembling operation At

magnetic switch
assembly check each dimension and major body
specification standard
B Defective contact in main circuit 8
When the magnetic circuit is satisfactory
Assembling and Testing Starter
and 82 is closing but only a small current
R oassembling is performed by following the flowing due to high contact resistance and
reverse procedure for disassembling All the of switch
opposite case
81 opening but
frictional parts are lubricated with mobile oil remaines closed In either case the
82
8AE 30 while the bearings are coated with in the of the
a trouble lies faulty moving
small amount of grease circuit in the magnetic core or roughness ofthe contacting point
switch and causes the main circuit in the 82 surface Therefore polished the surface
magnetic circuit to close Releasing the starter well then the operation will become
switch opens the magnetic circuit which also satisfactory
opens 82 Causes for mechnical troubles
Failure to operate is caused in many
1 Causes for magnetic switch failing to cases by the guide shaft on the moving
operate can be divided into electrical and core of the magnetic switch main clrcuit
mechanical sources hole
82 sticking against the cover

Causes for electrical troubles Correction can be made in this case by

loosening the cover screws 4 pieces and
A Current failure in magnetic circuit
retightening them so that the shaft moves

When the starter switch in pressed and freely

149
DATSUN

Construction of Magnetic Switch

2 Precaution
and Instructions

In removing nuts from the magnetic switch magnetic switch is

The an apparatus when
main circuit terminals when installing or the engine is being started by shift lever serves

removing cables the lower nul of the double to close the circuit between the battery and the

nuts should be kept in a tightened state while starter motor and permits a large current to
If the lower nut is loose the flow and actuate the starter motor
unscrewing After
terminal bolt may turn together and ground starting or when the engine is stopped the

the terminal to the cover and cause damage switch serves to keep the circuit open The

principles of operation can be seen from Fig 7

Then Causes and Closing the starter switch 81 allows the current
Starter Troubles
to flow through the magnetic
Remedies

The following is a list of troubles which can

be determined from the state the starter is

installed on the IGNITION SWITCH

engine

1 Starter fails to turn

CONNECT TO
OlHERS
m
The engine is checked to see if it can be
cranked by hand
If it cannot be cranked the engine is at fault
and should be checked If it can be cranked
BATTERY
the starter including the wiring
easily
should be checked and correclion made

accordingly
Is the battery down Check the specific Starter Circuit
run
Fig 8 Magnetic
gravity of the battery fluid to see if it is

over 1 240 and recharge or replace the

battery as found necessary If there is trouble in the magnelic circuit it

All loose battery and ground cables should be should be corrected

starter broshed
cleaned and properly tightened For improperly contacting
the broshes together with the armature should
Magneto grease or Gargoyle BRB No 1
All cord connections are carefully tightened be checked and corrections or replacement
and special attention given to the condition made as found necessary

of insulation The assembly check is made

If all of the above checks with their
by testing the starter as a single unit using
a fully charged battery Tests are made corresponding repairs have been made and the
with a starter motor tester or with the starter still fails to operate the trouble can be
assumed to be in the starter itself so that it
apparatus shown in Fig 4 by which braking
torque is measured In this case the should be removed from the engine and checked
rare wt care should be
normal value should be 0 9 m kg This is exceedingly
taken to see that the starter pinion is not locked
into the flywheel ring gear Cases like this are
Starter whe l
usually caused by badly worn gears meshing
mot 15v
improperly and if the defect is not too severe it

7ffiVolt
ce Gl
Bai be remedied by placing the gear shift lever
I
Ammeter 500A can
dynamometer back and
Battory 12v into fourth speed and rocking the car

Startu motor forth to free the gears If this trouble is

frequently repeated the starter should be

dismantled from the engine for checking and

Fig 7 Torque Testing Apparatus repairs

150
 ELEOTRIOAL SYSTEM

1 Starter turns but its turning power is weak The flywheel ring gear is checked and if the
and fails to start the teeth deformed
engine are they should be repaired
If the trouble is due to a run down battery or the gear replaced
loose terminals troubles in magnetic shift Rattling noise caused by loose starter

switch worn and sticking brushes dirty and mounting bolts are corrected by retightening
damaged commutator etc the checking the bolts
and repairs are made in the same manner as Noise caused by brushes improperly contact
described in the preceding chapters ing the armature
required correcting as this
If the outer surface of the armature is condition not only produces noise but will

rubbing against the core the starter should hasten wear on both parts
be dismantled disassembled and repaired Noises made by the armature rubbing against
Besides the above there is the case of the the core while in operation is caused by too
pinion meshing improperly If the trouble large a clearance between the armature shaft
is due to the gear teeth being badly worn and the bushing so the worn
parts should be
the gears should be replaced but if it is due replaced Wear
between the shaft and
to the guide on the pinion shaft being
screw bushing is due to lack of oil so that attention
dirty and not allowing the pinion to advance should be given to proper lubrication
smoothly and causing improper meshing the Lubricate once every half year using good
shaft should be cleaned and oiled of machine or mobile oil and lubricate
grade
the parts through the oil nipples The

amount of oil required is about 0 5 cc for

2 Starter exceeding noisy when operation each bracket

151
r

DATSUN

BODY
DISMOUNTING ASSEMBLING

Body Parts Mechanism of the Hood Lock

Hood Bonnet top Disassembling

Tocompletely remove the hood Bonnet top Detach the grill of radiator from the front of
is simply a matter of detatching the bolts of the body
hood and hinge at each side visible when the Disconnect the relurn spring of the hood lock
hood is remove after disconnecting the support lever from back of the radi r top frame
of it

Assemhling of the hood is a reversal of

dismantling process

Hood Lock

To adjust the position of the hood lock bolt

for the hole of the radiator top frame

To remove up or down way

By removing the nut at the top of the center

bolt of the spring unit the spring center bolt
etc can be separli d from the hracket to the
bonnet top

To remove left or side way

right
By removing the position of the hood and Disconnect the Return Spring
hood hinge bolts can he adjusted the direction
to left or right side Remove the hood lock lever clamp from its
lever
Adjusting the Hood Lock Lever
Detach the assemhly of female from the front
In the event of the hook working loose through panel
the lever the hood lock cannot he hold the hood

tightly
Adjust by removing the position of the hood
lock lever as showing the figure

Disconnect the Hood Lock Male

Adjust the Position of Hood Lock Lever
Assembly from the Hood

152
 BODY

is a Front Fender
Assembling of the hood lock system
reversal of disassembling routine
Detatch the front bumper
Jack up the front wheels and take out the
tire
Disassemble the head lamps and
parking
lamps from front the body
Remove the antena assembly

Detatch the fender milar and side emblem

Disconnect the bolts and screws as showing
the figures

Disconnect the Hood Lock Female

Adjusting the Position for Upper

or Lower Direction

153
r

DATSUN

moulds inside and out must be removed also the

door glass must be removed from the door
upwards through the main aperature

Front Dopr

Front door trim panel

1 Take out the door inside handle and wind

regurator handle as shown the figure

I I
T3 lO
I
J

T3 261

2 Take out the inside

moulding garnish
Assembling of the front fender is a reversal of
the disassembly routine

Front Door Window

To change a front door window first remove

the door trim then lower the window Extract

the drive screws that secure the window rear

channel to the door frame

Rear Door Window

The same routine for removing a rear door

window is adopted as that outlined for a front
door window namely removal of trim in this

instance front window channel window stop

bracket and regulator In addion the window

154
 BODY

Remove the front door finish as showing in Remove the fixing bolts and screws as show
the figure ing figure

Door Trim Door Shell Remove the Front Door Ventirator

Springing Clips from
Assembling of the front door is a reversal of
the disassembling routine

Front Door Glass

Take out the panel of front door trim and

strip the vinyl cover on the operation hole
Loosing the screws remove the door

regulator

Unscrew the Bolts Screws

Detaching Door Regulator

T3 245

Remove the Velltilator Glass Frame

155
r

DATSUN

The door be removed from the

glass must

door upwards through the main aperture

1 Remove the nut of pivot pin and the spring

Remove the Door Glass

2 Detach the

lator window
rivet and then

3 Take off the lock of ventilator

remove the venti

I
4 Change the glass as same as the method of
Removing the front door glass from the
the front glass replacement
bezel of channel

Door Lock Mechanism

1 Remove the of channel
glass by tapping
slightly with wooden hammer
Removing
1 Detach the front door trim panel from the

body and strip the vinyl cover of the operation

hole

2 Take off the 2 numbers set screws and detach

out side handle from the door

tt J
i

0
r v
7I
I
J

I 8 i
I

To fixing for the channel insert the glass

2J
with the weather strip in the bezel and tap
with wooden hammer slightly
b 18
r
Detaching Outer Handle

156
 BODY

Loosing the screws detach the assembling

of front door lock remote control as the shown
in the figures

e
i

T3 257

Remollal the Retaining Plate

3 Remove the retaining plate of the door lock

cylinder and detach the cylinder assembly

Front door

1 Removing the pin of the door check linkage

detash the check link

l3 56

Extract the Door Lock Cylinder

2 Detach the bolts of door hinge at the front

pillar take off the door assembly

Wind Shield Glass

Removing the wind glass

1 Extract the wipper arms

2 Detach the shield if used

molding
3 Strip out contact portion between the weather
Unscrew the Front Door Lock strip and the body with a spatula

IS
DATSUN

4 Detach the front wind glass with the weather

strip carefully as
showing the figure

4 Offer the window to the aperture frame of the

car from the outside and whilst one operator
5 Remove the weather the detached maintains pressure
strip from on the glass the operator
wind glass assembly on the inside of the car should peel out the
cord of the inner lip which fits the ap
over

Fixing the wind glass assembly erture frame The outside operator then
arrange the outer edge which will bring the
1 the weather strip with the sealing
Assembling outer rubber the scuttle
lip over side and
material cemendine 366E to the wind sheild
top window frame
glass insert the strong cotton cord to the
of the weather strip inside around of
Finally peel out the cord so that the rubber
gloove
it
lip settles over the fascia side fillets and
headlining Pushing or tapping the front
2 Then insert the above the prepared wind wind ghl sS assembly from the outside of it
sheild Iass assembly to the frame of the assemble the glass as pulling out the cotton
front body where the bezel is to fit string to a right angle slowly

3 To assemble to fix for the frame

Two operators are essential when fitting the
5 the material cemendine
wind glass Filling up sealing
366E between the weather strip and body
First the rubber must be sprung over the
6 Clean and wipe off the
glass which fits into the deep square groove
excess sealing
material around the weather strip by a
whilst the large portion of the bead bulges to

the inside of the curvature spatula

Fixing the rear wind glass is a same method
Next insert sealing compound between glass
of the front glass fixing
and bead on the outside face

158
m