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INTER EUROPE WORKSHOP MANUALS


Titles available NOW

f
1

121 122 123 124 125 126 127 128 129 130 131

132
133 134 135 136 141 144 146 150 159

d r
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f7
1

VOLKSWAGEN 1200 VOLKSWAGEN 1200 1200 A VOLKSWAGEN 1300 1300 A 1500 RENAULT R8 TOYOTA CROWN TOYOTA CORONA FORD ESCORT FORD CORTINA MK II 1300 1500 ENGINES VOLVO 140 SERIES FORD CORTINA 1300 GT 1600 1600E ENGINES VAUXHALL VIVA HB HOLDEN HB TORANA OPEL KADETT RALL YE KADETT ALFA ROMEO RANGE ROOTES IMP RANGE MERCEDES BENZ 230 250 MODELS FORD CAPRI 1300 1600 etc RENAULT R16 16TS 16TA FORD 17 20M TOYOTA COROLLA 1100 1200 PEUGEOT 403 404 SAAB 99

1964 1964 1967 to 1967 to 1967 to 1968 1963 1968 1968 1969 1967 to 1969 1968 1967 1962 1959 1963 1965

1969 1968 1968 1969 1968

From 1965
to 1969 Since Introduction

Up

1968 1970

i
b

WORKSHOP MANUAL for DATSUN Saloon 1300


c c

Estate
c c

1600

COMPILED AND WRITIEN BY PETER R D RUSSEK

PUBLISHED BY

INTEREUROPE

LIMITED

AUTODATA DIVISION 2 4 QUEENS DRIVE LONDON W 3 ENGLAND

Copyright IC
lb
11

IntIInlUrope LIlDtIld AulJllt 1970 110 IYIIIIbIe in Spanish


av

Pnntlld Lan
W ey

England

1Ib1e thRlUllh

SA MexICO City

2nd edition

January

1971

Type Identification
SALOON MODELS E n9108
L13

Model designation
510 U L510 PL510 PL510 T PL510 UT

Type

Gearbox
Three speed remote control
Three

P510 U P510 UT P510 510

Deluxe
L16

UA

PL510 A
S

PL510 UA
L13 Standard L16

speed remote control speed floor shIft AutomatIc three speed


Four Three Three Four

SU

L510

speed

remote

control

P510 SU P510 SUT

PL510 S
PL510 ST

speed remote control speed floor shIft


speed floor sluft

P510 UTK

PL510 TK

SSS

L16 WIth SU tWIn

carb

Four

ESTATE CAR MODELS


I

WP510 U
WP510 UT WPL510 WP510

WPL510 WPL510 T Deluxe UT WPL510 A L16

Three Four

speed

remote

control

speed

floor shIft

UA

WPL510

UA

AutomatIc three spl ed

DIMENSIONS AND TYRf PRESSURES

Length

overall 4 070 4 145


mm

Standard Saloon De Luxe SSS Saloon Estate Car Width overall

1602

10

4 120mm
mm mm

162210 163210 61 410 551 56 5 953 74 64 504 50 2 50 4 496


In In In

1 560

Height overall
Saloon Estate Car Wheel base MIO ground clearance Saloon Estate Car Front track Saloon Estate Car Rear track Saloon Estate Car 1 280 1 275 1 280 1 260 24 pSI 28 pSI 24 psi 28 pSI
mm mm In In

1400mm 1 435
mm mm

420 2

190 165

mm mm

In In

mm mm

In In

Tyre

pressures Front Rear

1 7 kg sq em Normal ltlon corn 20 kg sq em High speed driVing 1 7 kg sq em Normal condition 20 kg sq


em

High speed driVing

FILLING CAPACITIES

Engine
Max MIn

011 4 0 htres

uiG

US

3 0 htres 0 79 US

gal gal

0 88 Imp gal 0 66 Imp gal

Gearbox 011 Autom transmission Differential 011 Saloon Estate Car

7 htres 7 39 US qts

1 7 htres l 79 US qts 3 Imp pts 123 Imp pts 1 4

08 htres 084 US qts

SJeerlng

aL 9e

1 0 htre 1 05 US qts 1 76 032 htres 10 33 US qts 0 56

Imp pts Imp pts Imp Pts

INDEX
lYPE IDENTIFICATION ENGINE LUBRICATION SYSTEM COOLING SYSTEM IGNITION SYSTEM FUEL SYSTEM CLUTCH GEARBOX REAR AXLE REAR SUSPENSION FRONT SUSPENSION STEERING BRAKES ELECTRICAL 4 6 18 20 22 26 36 44 S3 62 68 74 78

EQUIPMENT

86 98 100 101 102

WIRING DIAGRAMS ENGINE 1 JNING DATA

TIGHTENING TORQUES
CONVERSION TABLE

Introduction
This Workshop Manual was WrItten wIth the IntentIon of providIng the owner of a Datsun 1300 or 1600 and the non franchised garage with detdlls of dllthe maIntenance and repalf operatIOns that they are hkely Instructions have been to encounter Much InformatIOn from the manufacturer s ongInal selVlce and repalf condensed and Incorporated m the manual In a form which will enable the reader to qUickly become fanfihar with the IdlOsynchrasles and techmcahtles pecuhar to the Datsun range of cars The manual descnbes the 1300 and 1600 c c engmes fitted to the Standard De Luxe and SSS Saloon models and the range of Estate Cars A complete hst of engme tumng data for all models with smgle or tWIn of rear carburettors IS Included m the manual There are also separate secltons covenng the different types Car Models Sdloon and Estate axles and rear suspenSIOns used for the tool In certaIn cases It Will be necessary for the reparrer to make use of speCial tools and the appropnate refered numbers and thelf methods of use are either descnbed In the text or can be taken from Illustraltons
to
m

the chapter

most of the major menlton should be made of the fact that a fault findmg sechon IS annexed to m sechons thus slmphfymg the some tunes difficult task of diagnOSIS The measurement conversIOns gIVen to mches have been converted as closely as pOSSIble from the ongInal mtlhmetre SIZes but It IS preferable and we adhere to the metnc dunenslons whenever pOSSible A conversion table IS mcluded In the manual adVise the reader to crossreference With the table when deahng With cnhcal dlffienslons

SpeCial

Tills We have tned to make thiS manual as bnef as pOSSible tllustratmg rather than detailing the operahons the be able to out the reader whether he Will carry Iffimedlately WIll save valuable tnne and WIll also show car manufacturers work or not Expenence m prodUCIng hundreds of techmcal pubhcatIons for the motor for 15 years has and the expenence gamed by the author who hunself was a skilled motor mechamc for of thiS nature tills IS the best a that pubhcatlOn proven way

Happy motonng

I and the fewer tnnes you have to refer to tills book the better for you

The author would like to thank for the help and 3SSIStance gtven to bun by Mr John Haley 5

inter

llil

p @

Fog A 1

Removal Of the

nslave cluu

cyhllller

Fog

2 The removal of the A

engll

trel Jb
i
n

1t
r

fd
f7
or
0

if1
L161 engIne

flUBd

10

f g A6

FIlI A 5 Removal

of

the manifold assembly

eket

FIIA7 Removal of the cyhnder h8I

g 8 Removal of the oil straaner A

Engine
INTRODUCTION The 1300 c c and 1600 c c engines are 4 cylinder in line engines with a single overhead camshaft and a five beanng crankshaft The 1300 and 1600 c c engines differ only In size The 1600 c c engine IS available In two versions one of which IS eqUIpped with twin S U carburettors with different cylinder head manifolds pistons and compression ratio whereas the other has
a

Remove the cylinder head assembly Fig A 7 wrench ST49010000 for removing the cylinder

USing

special

llJd bolts h

Turn the engine

over and remove the sump and the Internal 011 strainer Fig A 8 timing chain cover chain tensloner and timing chain Remove the 011 thrower the crankshaft wonn gear

and the chain dnve sprocket

FIg A 9

single twin choke

carburettor

Remove the big end beanng caps pistons and connecting rod assemblies keeping them In sets In the correct assembly order Remove the flywheel and the main beanng caps uSing a special tool ST44630000 for the rear main beanng cap

ENGINE

Removal

Fig

A 11

Drain the coolant engine and gearbox 011 and remove or disconnect the follOWing parts Battery bonnet air cleaner and rocker box breather hose radiator gnll upper and lower radiator hoses radiator torque converter cooling hoses from radiator automatic models only COIling fan and pulley fuel pipe heater hoses If fitted accelerator

Remove the rear 011 seal and 11ft out the crankshaft baffle plate and the cylinder block net F Ig A 11

Remove tne

and the

Remove the piston nngs With a SUitable piston nng expander gudgeon pin With a SUitable mandrel the outer diameter
a

linkage

choke cable

wiring from starter motor alternator Unit and temperature sender Unit Remove the clutch slave Remove or disconnect

COil

011 pressure sender

of which should not exceed the diameter of the piston pin and handpress There IS also special tool ST4484000D

cylinder Fig

A 1

and ItS return spnng

Remove the valve rocker springs loosen the rocker piVOt lock nuts and remove the rocker anns by presSing down the valve spnngs Remove the camshaft taking care not to score the camshaft bushes Remove the valves With a conventional valve lifter Fig A 12

Speedometer

cable

flat connector from reversing

light
the

SWitch

gearchange linkage front exhaust pipe from manifold then the


front pipe first Silencer and centre pipe shaft at the front Jack up the gearbox slightly and bracket the mounting handbrake cable clamps

assembly

propeller
ENGINE

Inspection

and Overhaul

remove

the

rear

mounting

crossmember

engine and the

Thoroughly
inspection

clean all and

before

parts of dirt 011 and water scale before attempting to carry out overhaul

operations Blowout all passages With compressed air Remove carbon depOSits from the top of the pistons combustion
chambers

Remove the bolts secunng the front engine mounting brackets the crossmember Fit a lifting hook to the engine hangers and carefully 11ft the engine and gearbox In a tilted poSition e g
to

cylinder head from any of the parts

and valves

but do not remove metal

forwards and upwards

uSing

SUitable

crane or hOIst

FIg A 2

I nspect and overhaul the parts

as

follows head

Cylinder
ENGINE Remove the

Dismantling

Check

gearbox and the starter motor Mark the clutch and the flywheel SUitably With a centre punch and remove the clutch cover together With the clutch dnven plate
cover

cylinder head for cracks and the mating faces for burrs or uneveness and replace If necessary note that different cylinder heads are used for the Single and twin carburettor verSions of
the 1600
means c c Check the mating surface for flatness by engine of a straight edge placed across the head and checking the clearance With a feeler gauge F g A 13 If the clearance exceeds 1 0 mm 0 0039 In regrind the cylinder head to block face

Remove the

follOWing parts
filter
water

mountings

011

Mount the engine In a ST37200510 attachment Flg A3

engine 011 pressure SWitch SUitable stand If available Special Tool drain

Alternator and bracket

plug

and

Stand

ST37100000

See

Check the valve seats for


In

damage

or wear

accordance With the dimenSions given

and If necessary reface In Fig A 14 and A 15

Remove the d IStnbutor cap together With the spark plug leads unscrew the spark plugs and remove the dlstnbutor Remove the thermostat

hOUSIng

F Ig A 4

If necessary replace valve Inserts To replace the Inserts bore out the old Insert and select the correct Insert Fig A 16 and fit by heating the cylinder head to 150 200oC 300 3900F Valve

Remove the inlet and exhaust manifolds Flg A 5


Remove the crankshaft pulley Remove the fan pulley and the water pump rocker cover fuel pump and

guides

the tolerance micrometers Internal and external che between the valve stems and the valve gUides ThiS clearance

USing

Remove the fuel pump drive FlgA 6

cam

and the crankshaft

sprocket

must

0 073

for Inlet valves and not exceed 0048 mm 00019 In mm 00029 In for exhaust valves An easy way of
the clearance IS to Insert the valve stem Into the gu

checking

inter

E2C0

@F 0

FillA 9
rocket

Removal

of the crankshaft challl

S
o

cf
FillA
11 Removal of

the baffle plata and

FI

12

cyhrder block net

Inlet

Exhal51

Standard valve gUIde hole


diameter

FIllA 13 forfl

Checlul19 the cyhnder heud

rt

Ll3 and Ll6 L16 WIth


twin

carb

With

SIngle

cub U3 and L16 S Ll6 TWlD cub

gle

cub

Inl

F
r

OtA J

Almm

Inl

DIA

41016 410

45 016 450

Azmm
57 DIA 0 37 016 37 O 37 016

DIA

Dlmm
37 DIA 6 37 8 41 6 41 8

Exheult

r
II
IlIt

1
I
La
IlIA HU1

D2mm
ExheuU DIA 326 324 326 324

Llmm
t 2mm

1 1

4 1

1 8 20 16

20

inwt FIlIA 14 St8nd8nI valve Il 8

FIllA 15 VeIve

to

i nte f

bi G D er

r
8

rrt l
I
r T

1 0 I
051

J r
D

010

FI9A 16 Ch c1ung the camshaft beanng


Inner

17

V rettD

far

L13

and L16

wrth

IingIo

lm I 11

0011

II
11

l
5144

51 031

CII

IM

l11

Fig A 18 Valves C81bunmon

far

L16

wIth Ill

twIn

A 19 FIlI
squ

CheckIng

the

valve

IIInng

for

F A 21 MlI8SUnng the of 8 doallllU98

cyl

bore

by

Fig 2 A 2 The
bora

nne

JIlIIII18 of the cyllncllr

by

The nng of the pilllln of 8 mlcrom8lar

B ImII

26 CheckIng the ade cl Fog A pISton Flngs

ence

of

the

FIg A 24 CheckIng the pIston runnIng clearan ce In the bore cyhnd

FtgA Xl
bends or

CheckIng
twIsts

the

connectIng rod for

Fill A 28 CheckIng the crankshaft end float

FI9A 29 CheckIng the running clearance for


the maIn beaFlngs

for FogA 30 Checlllllg the crenkshaft sprocklJt FUIHlllt

A31 The camshaft drIVe mechanam Fog

10

and
10m

move

It

from left to
10

nght

If thiS movement exceeds 0 2


10

0 0079

1 the guide needs replacmg When replacmg valve


the 150
new

out the old gUide and press the cylinder head has been heated to JOOF 3 Valve gUides are available 10

gUides press

gUide after
300

10m gauge and a spring scale With a feeler gauge of 004 00016 10 1 thickness the pullmg force on the spnng scale 3307 Ibs 1 should be 0 2 15 kg 0441

2000C

00079
the between

10

valve

of 02 10m 1 Fmally ream the valve gUide to the dimenSion of stem observmg the specified running clearance
oversize

If the

cyhnder

bores

are worn

beyond

the maximum oversize

there are cyhnder hners available


Pistons

gUide and

stem

gudgeon

pins and piston rmgs

Valves Check the valve face for pitS grooves scores and other damage Check the stem for distortion and wear When mspectmg the valve heads check 10 particular for burrs cracks and corrosion If the valve head edge IS worn down to 0 20 10 0 5 10m replace the valve If necessary gnnd the valve on a valve gnndlng machine taking off only enough matenal to remove pitS and grooves The valve dimenSions
are

Check for wear scratches and seiZing and If necessary replace Check the Side clearance of the piston nngs 10 the grooves of the piston as shown 10 FIg A 25 The correct specificatIOns are given In section TECHNICAL DATA under the same head 109 Place the piston piston nng gap nngs mto the cyhnder bore and measure the Fig A 261 The nng gaps should be as follows nng 0 15 o 0381010 023 00150 00091 In 1 030mm 00059 00118101 030 15
mm

shown

In

Fig

A 17 and A 18

Upper compression
Second compres 011 nng Wear limit

ring

Valve sprmgs Measure the free length of the valve springs and replace If less than speCified Also test the valve sprong pressure Check the valve sprongs for distortion by plaCing a steel square on to a surface plate PosItion the spnng against the square edge and the spring The clearance between the top of the sprmg and the edge should not exceed 1 6 10m 0063 10 Fig A 191 The valve spnng specifications are given In section

0011810 00059 1 0
mm

0 0394

In

slowly

rotate

Measure the gudgeon prn hole and the gudgeon pm diameter and compare the measured results 10 accordance With the dimenSions In section TECHNICAL DATA under the relevant

TECHNICAL DATA Camshaft Measu


re

heading The gudgeon pin should have a finger press fit In the the piston and a tight press fit In the connecting rod at room The fit of the gudgeon pin to temperature erence Interf
connecting
In

rod should be 0015

0033

10m

00006

00013

the InSide diameter of the camshaft

bearings

and the found The Check

Connecting rods
the connecting rods for bends or twistS uSing a connecting rod aligning tool FI A 27 For each 100 10m 394 I In length a permiSSible bend or twist of 0 03 mm 0 0012 In
IS

outside diameter of the camshaft


wear

inSide the blackets replace the limit IS C 1 10m 00039 In 1

Journals cylinder

and If

wear IS

head assembly

Check the camshaft for wear and damage and If these exceed the limits given In sectIOn TECHNICAL DATA replace the camshaft The camshaft
out run on can

allowed

A limit of 005

10m

00020

In

should not be

exceeded Fit the connecting rod to the crankshaft and check the clearance which should be 02 03 mm 00079 00118 In 1 and should not exceed 0 30 10m 0011810 1 Crankshaft Check for the for
wear

be checked

as

shown

In

Fig

A 20 The Indication
10m

the dial gauge should not exceed

005

0002010

Cylmder block Visually check the block for flaws and cracks Check the mating surface the same way as the cylinder head and If the deViation
exceeds 0 1
mm

ovahty and general


The limitS
out run

scores cracks are

and

run out In

0 0039

In

regnnd the block


bore

Journals and crankplns ovallty and taper The


10m

0 03

10m

00012

hmlt

IS a

total deViation of

Cylinder

o 05

0 002

In

Check the cylinder bores for excessive wear FlgA 21 1 The measunng pOInts for the shown
10

ovallty and taper cylinder bores are


remove

Check the crankshaft end float at the centre beanng float exceeds 03 10m 00118
In

If the end

replace the
0 15
10

centre

Fig

A 22

If the bores

are

Within the limits

speCified
In

end float

IS

between 005

mm

shims The 0002 00059

the carbon depOSit ridge at the top of the cylinder bore USing a SUitable The tool specifications are given 10 section TECHNICAL DATA

1 Check the end float as shown


Crankshaft

Fig

A 28

Journals
and

and

big end bearings beanngs should be


carned

Rebormg cyhnders
When

The

checking
follows

of the

maIO

bl end l

out as

rebonng all bores must be done at the same time As a speclahsed workshop IS dealing With operations of thiS nature It IS necessary to mfonn the workshop of thiS procedure Five
piston sets are available and are hsted 10 section TECHNICAL DATA To obtain the fmlshed bore Size measure the piston across Its skirt as shown 10 FlgA 23 and add the
oversize

Check the conditions of the bearings and clean the bearings Place a piece of Plastlgage on the beanng over Its full Width In

parallel
cap Main lhtemng tl

With the crankshaft and fit the bolts to the

together the bearing follOWing torques


4 5 5 5

and Its

average value of the piston to When the

cylinder

clearance honed check the A 24 usmg a feeler

beanngs

kgm

32 5

39 8 Ib ft
23 9lb ft 1

81g cyhnder bores piston cyhnder clearance


have
as

end bean ngs

27 33 kgm

195

been finish
In

shown

Fig

Then remove the cap and check the Width of the

Plastlgage

11

inter

erlLJ @ Pl

FIlIA 32

InstallatIon of the vaJves

FI9A connectIng rod

34

ded Expl

VI8W

of

ooo
pISton
and

FillA 37 InstallatIOn

of

the sKle oil seal

the crankshaft A36 Chedung 19

end float

38 InstallatIOn of the flywheel A FIlI

FillA 39 InstallatIOn of pISton end conllllCtmg rodaay

12

mter

i l

jlJ @

E
ih
FogA 40
caps

t
I

l
s

InstallatIOn

of

the bill end beerll18 FillA 41 Checking the side play of the bill end

Fill A 42 InstallatIOn of the cylinder head

FogA 43 V 1fW of the crankshaft sprocket end

Fill A 44
1 2

The

tIming chain
earn

dIStributor drive geer

Fuelpump dflve Cham guide


nSlone

3 Cham 4 5

Cntnkshm sprocket Camshaft IProcbt

6 Cham guttie

I
FillA 46 AdjUsting the valve clearance

45 FIttIng drIVing slIaft

FlgA

pOSItIon of the dIStrIbutor

13

stnp on the beanng Journal FIQ A 29 If the clearance exceeds the wear limit of 0 10 mm 00039 In for the main beanngs and and for the fit undersize bearings and regrind the crankshaft to SUit the undersize bearings Undersize bearings are available In 1 1000 mm 25 50 75 100 for main bearings and 6 12 25 50 75 and 100 for the big end bearings

big

end

beanngs

rings ensure that the piston ring gaps are opposite each other and neither parallel to or at nght angles to the gudgeon pin Fit the connecting rods With the numbers on the same Side

throughout Fig A 40

and

tighten

to

2 8

3 4

kgm

20 2

24 6 lb ft

the end clearance of the big end bearings which should be 0 20 030 mm 00079 00118 In I Fit the cylinder head spreading JOinting compound either Side of the gasket Tighten the cylinder head borts In the order shown In Fig A 42 to a tightening torque of 5 0 60 kgm 36 2 43 4 Ib ft
In

Check

Crankshaft and camshaft timing gears Check the sprockets and the tlmll19 chain for wear and replace where necessary Check the runout of the camshaft sprocket as shown In Fig A 30 The run out should not exceed the limit of o 1
mm

Note there
came

are

0 043

In

the hole It

out

of

3 types of bolts and each should go Use special tool ST49010000 to

Check

the chain

tenslOner

replace If necessary

Fig

and the chain gu Ide for wear and A 31

tlQhten the cylinder


Fit the crankshaft thrower Fig A 43

head bolts

Flywheel
Check the clutch contact area of the flywheel for damage and wear and If necessary re alr or replace the flywheel Check the

timing marks

on

and distributor drive and fit the 011 Install the timing chain Fig A 44 With the the crankshaft and camshaft timing sprockets

sprocket

to the right hand Side COinCident With the timing marks chain There must be 42 chain links between the marks chain

on on

the

the

flywheel for
worn or

uSing dial gauge and replace the flywheel If the limit of 0 1 mm 0043 In IS exceeded If the ring gear IS
run out a

the gear ring by heating It to about 150 2000 C 300 3900F and tapping It off Sometimes It might be necessary to split the ring gear With a chisel In thiS case take care not to damage the flywheel Refit the new ring

damaged

remove

Fit the chain gUide to the cylinder block and and Install the chain tensloner FIt a new 011 seal In the front cover ThiS seal should any

always

be

replaced

when the front


a

reason

I nstall the lower front

gear

In reverse

order and cool at normal

air

temperature

cover In

that order With

gasket

removed for and the upper front between cover and cylinder
cover IS cover

ENGINE

Assembly

The gasket should be coated With JOinting compound When fitting the upper cover check that It does not Interfere With the cylinder head gasket Then check the height difference block between the upper faces of the cylinder block and the upper cover The difference should be less than 0 15 mm 0059 In Fit the crankshaft pulley and the water pump Set the engine at T D C position on the No 1 cylinder In Its compressIOn stroke Install the 011 pump and dlstnbutor drive so that the offset slot
IS In

Apply engine 011 to all sliding or rotating parts of the engine I e cylinder walls pistons bearings gears etc and renew all seals gaskets and lock plates
Place the valve spring seat In poSition and fit the valve gUide With the 011 seal Assemble the valves In the follOWing and outer valve springs spring retainer valve cotter halves and valve rocker gUide Compress the valves With a suitable valve compressor Fig A 32 when fitting the cotter halves order Valve
Inner

the position shown fuel

In

Fig A 45

pump water Inlet elbow thennostat hOUSing thennostat and water outlet elbow Refit the 011 strainer to the bottom of the cylinder block and enclose the engine interior by refIning the 011 sump coating the new gasket Fit the engine

slinger

Fit the rocker holders


are

arms and the valve rocker springs combined With the rocker pivot bushes

The Spring

With JOinting Fit the

compound

on

both Sides

pistons gudgeon pinS piston rings and connecting cylinder Fig A 34 and A 35 and place the bearing shells Into the main bearing hOUSings and caps and the connecting rods and caps Lift the crankshaft In the bearings Tighten down the main bearing cap bolts to 4 5 55 kgm 325 39 8 lb ft Arrange the arrow mark on the bearing cap to face the front of the engine The bearing caps shou ld be tightened In gradual steps In three or four stages starting at the centre and working towards the outside Check the crankshaft end playas 015 mm 0002 shown In Fig A 36 which should be 005
Assemble the rods for each 00061n Install the Side 011 seals Into the bearing cap In Fig A 37 Fit the rear 011 seal uSing special tool ST49370000
rear main as

rear engine slinger manifolds and valve tappets Fig A 46 to 020 mm AdjUst 0008 In for the Inlet valve cold and 025 mm 0010 In cold and fit the rocker cover uSing for the exhaust valve

distributor
s

carburettor

JOinting compound

on

the gasket

Fit the clutch and gearbox part of the engine and the

assembly the fuel hose to the front high tenSion lead to the distributor

Remove the engine from the mounting stand and fit the alternator bracket alternator engine mountings Ignition COil 011 filter 011 pressure SWitch 011 level dipstick and the water drain

plug

shown ENGINE The installation Installation in reverse order to the removal be noted

Original crankshaft IS used and the contact face for the 011 shows slgns of wear Install a shim In order to shift the contact face FIt the rear end plate
If the seal Fit the flywheel USing lock washers and tighten the bolts to 95 105 kgm 68 7 75 9Ib ft I Flg A 38 Install the piston and connecting rod assembly into the correct cylinder from the

IS

carned

out

procedure but
Do not

the

follOWing points should

tlQhten the nuts and bolts completely until the engine IS resting flnnly on Its mountings Then tlQhten the nuts Fill the
g engine With engine 011 and coolant water o with th recommended lubricant
or

top of the cylinder block as shown In Fig A 39 with the F mark faCing the front of the e gi le Wh en lnsertlng the piston

anti

freeze and the

14

Technical Data
GENERAL SPECIFICATION

Engine model
Number of

L13 4 In line 1296 c 51 02 830 of valves

L16 4 In line
c cu In

cylinders

Arrangement of cylinders
Cubic capacity Bore
x

1595 c 62 80
mm

c cu In

stroke

59 9

830

73 7

mm

Arrangement
Max B H P

3 2677 x 2 3583 In Overhead camshaft 77 at 6000 rpm

32677 x 2 9016 In Overhead camshaft 96 at 5600 rpm 109 at 6000 rpm 13 8

carburettor TWin carbu rettors Max torque

Single

Single

carburettor

11 1 kgm at 3600 rpm 80 3 Ib ft

TWin carburettors

kgm at 3600 rpm 110 0 Ib ft 143 kgm at 4000 rpm 1030Ibft


1 3 4 2

Flnng

order carburettor

Engine Idling speed

Single

600 rpm

TWin carburettors

600 rpm 650 rpm 85 95 38 54 1 1 4 2 60 Ib

Compression

ratio

Single

carburettor

85 38

TWin carburettors 011 pressure 4 2 kg sq 54 60 Ib Isq


cm In

kglsq Isq

cm In

VALVE GEAR Valve clearance Inlet Exhaust Valve clearance Inlet Exhaust Valve head diameter L 13 and L 16 w SC Inlet Exhaust 38mm 150 33 mm 1 30 42 1 65 33mm 130
mm In In

hot
025 030 cold 020
mm mm mm

Valve spnng fitted length L13 L 16 outer

400 389 35

mm mm mm

30 7 kg 29 0 kg 12 3

1 57 1 53 1 38

In In In

0010 In
0012
In

L 16

Inner

kg

167 7 Ib 163 9 Ib 271 Ib

Valve spnng COIl diameter L13 0008


In In

34 9 24 9

mm

1 37 1 31 0 98

In In In

L 16 L 16

outer
Inner

332mm
mm

025mm 0010

Valve gu Ide length Inlet Exhaust

59 0 59 0

mm mm

2 32 2 32

In In

L16wrrC
Inlet Exhaust Valve stem dla Valve length Inlet Exhaust Valve 11ft L13 and L16 L16 wrrc Valve spnng free 1 13 L 16 L16
outer
Inner w In In

Valve gu Ide protrusIOn from head face L13 L16 104 106mm Valve gUide Inlet Exhaust diameter 800 800 8018 8018
mm mm

041

0421n

Inner

Inl

Exh

80mm 031

In

0315
0315

03154 03154

In In

1159mm 1160mm

456In 4571n

Valve gUide outer diameter Inlet 11 985 Exhaust 11 985

11 996 11 996

mm mm

0472 0472

04723 04623

In In

SC

100mm

040

In In

105mm 0413

Valve guide to stem clearance Inlet 0015 Exhaust 0040

0045 0070

mm mm

00006 00016

00018 00028

In In

length
4812mm 189In
52 0 44 85
mm mm

2 05 1 77

In In

Valve seat Width Inlet Exhaust

1 4 1 6

18 mm 0055 2 0
mm

0071 9 079

In In

0 063

15

Valve seat

angle

Inl

Exh

J 4
PISTONS

Valve seat Insert Interference fit Inlet 008 0 11 Exhaust 006 0 10 Valve

mm mm

00031 00024

00043 00039

In In

Matenal

Cast aluminium Slipper sklrt type

Type
Piston diameters

gUide

Interference fit 0027 0049 mm 00011 00019


mm

Inlet

Standard
1 st O S 2nd O S 3rt

8299 83 22 8347 83 72 83 97 8447

8304

mm mm mm mm mm mm

3267
3 276

3 269 3 288 3 298 3 308 3328

In

83 27
8352 83 77 84 02 8452

3 278 In
In In In In

CAMSHAFT AND TIMING GEAR Camshaft end play Camshaft lobe lift L13 L16 w SC L16 TC w o 0838
mm

3286
3 296 3 305 3326

OS

00031 0 0151n

4th O S 5th O S Width of nng grooves Top second 011 control Piston running clearance

665

mm mm

0 261

In In

7 00

0 275

2 0 mm 0 08 40 mm 0 16 o 025 045
mm

In In

Camshaft Journals diameter All 47949 47962 vm 8877 1 8883 Max camshaft
run out

In

0001 0002

In

005

mm

0002

In

PISTON PIN Camshaft Journal to clearance

beanng
0038 0076
mm

00015

00026

In

Pin diameter Pin length

20995 72 00

21 000 72 25

mm mm

08266
2 8346

0 8268 2 8445

In In

Camshaft bearing
diameter

Inner

48 SC

48 000

016

mm

1 8898 1 8904

In

Single

carburettor

TC

TWin carburettors

Pin running clearance In piston 0008 Pin Interference fIt In small end bush 0015

0010 0033

mm

00003 00006

00004 00013

In

mm

In

CONNECTING RODS PISTON RINGS Distance from centre to


centre

13297133 03 mm 5235 5237

In

8eanng
Side

shell thickness 1 498 ends 1 506 mm 020 030 mm 0059 0008 0593 0012
In In

Piston nng heIght Top second 011 control Side clearance


In

20

mm 008 40 mm 0 16

In In

Standard

play of big
rod

Top Connecting
clearance

grooves 0040 0073 0045 0030 0025

mm

00016

00029

In

L 13

bearing
or

running 0014 0056 per 100


mm

00018 0078mm
0 063
vm

mm

00006

00022

In

Second
011 control

000311n L16 00012 0 0025 In 0001 00025


In

Connecting
twist

rod bend 003

0063

mm

mm

00012

In

per 3 937

In

Piston ring gaps

Top
CRANKSHAFT AND MAIN BEARINGS

023

038mm 030

00091 0006

001501n 0012
In

Second
011 control

015 015

mm

030mm 0006

00121n

Crankshaft matenal
Number of

Special forged steel


5
In In In In In

beanngs

Main Journal dla Max Journal taper

54 942 54 955 mm 2 1631 2 1636 003 mm 00012 Max Journal of round out 003 mm 00012 Crankshaft end play o 05015 mm 0 002 0059 Wear limit 03 mm 0012 49 961 Crankpln Journal dla Max crankpln taper Max crankpln of out round Thickness of main beanng 49 975 mm

CYLINDER HEAD Matenal Distortion of sealing face Max distortion Valve seat Insert matenal Inlet Exhaust Fit 003 Aluminium
mm mm

alloy
In In

00012 0004

o 1

1 967 1 9675 In 003mm 00121n o 03


mm

Aluminium bronze

0 012 00722 0 0024

In

Special

cast

Hot pressed

shells
Main

1 827 running

1 835

mm

0072

In

beanng

clearance 0 020 Max main bearing running clearance Crankshaft bend limlt

o 062 mm 0 0008

In

CAMSHAFT DRIVE
Dnve From crankshaft Double roller type and 011 pressure control

o 12mm 00047 005 mm 0002

In In

Chain
Chain tensloner

Spnng

16

Trouble
SYMPTOMS
I

Shooting
ACTIOtJ TO BE TAKEN

PROBABLE CAUSE

Lack of power

Poor compresSion

Incorrect valve clearance Intake valves leaking Sticking valves Valve springs broken Piston rings broken

Adjust valve clearance Lap valve seats Replace valve and gu Ides Replace valve spring Replace piston rings
Overhaul engine

Rings

or

cylinders

worn

Ignition Improperly

set

Incorrect Ignition limIng DefectIve spark plugs Contact breakers defective

Re

set re or

Clean Clean

set

or renew

replace adjust gap

Lack of fuel Clean carburetor Clean fuel pipe Clean fuel tank Check fuel pump Clean or replace element

Clogged carburetor Jet

Clogged

fuel pipe Dirty fuel tank Faulty fuel pump Fuel filter clogged

Overheating

Insufficient coolant Loo e fan belt Fan belt worn or damaged Inoperative thermostat Defective water pump

Top up radiator Adjust fan belt Replace fan belt Replace thermostat Repair or replace
Clean system Re set timing

Clogged cooling system


Incorrect Ignition liming Incorrect valve clearance Incorrect 011 used Radiator finS clogged Oil leaks DefectIve piston rings worn Piston rings grooves Piston or cylinder Valve stem
or

Adjust clearance
Refill With correct oil grade Clean readlator finS F nd 011 leak and rectify

ExceSSive oil consumptIon

or

sticking

In

Replace piston rings Replace Piston rll1gs Replace piston or bore cylinder Replace as necessary Change to proper VISCOSity Charge or replace battery Clean and tighten connections Adjust Ignition check plugs Repair Or replace valves
Overhaul enqlne

worn worn

gUide

D fficult starting

Improper 0 1 Discharged or defective battery


Loose connections Defective Ignition system Burnt valves PIstons piston nngs
worn or

cylinders badly

Engine nOIsy

Crankshaft beanngs

or

Journals
worn

worn

Connecting

rod bearings

Replace bearings and grind crankshaft replace crankshaft Replace bearings and gnnd crankshaft or replace crankshaft
or or replace rod Check and replace parts

ConnectIng rod be
l

Stralgten

Piston piston nngs and pinS damaged

as

necessary

mterCE

lliJ

Plcel @

FIg B 1 system

General

layout

of

tho

lubricatIOn

Fig B 4 SectIOn through the

rehef valvo

Frg B 3 Tho oil pump components

18

Lubrication System
DESCRIPTION The

lubricating system IS a pressurefeed system ronslstlng of a rotor type 011 pump Inoorpotating a regulator valve and driven by the distributor drive shaft and a full flow 011 filter A strainer IS fined to the bonom of the front cover and serves the purpose
to

surfaces for wear Also check the spring for weakness or as necessary The rehef valve F Ig B 4 dImenSIons are as follows

damage Replace
Free length Fitted length

Opening

pressure

38

57 mm 2 24 In 39 mm 1 54 In 42 kg 54 597 Ib

filter the 011 before It can reach the

beanng

locations

OIL PUMP

Removal and InstallatIOn the front 011 pump IS held 111 The

OIL PUMP of the

Assembly

Remove the distributor drain the engll1e Oil


engine bearer and the splash body together With the dnve poSition by four bolts The II1stallatlon

remove

guard and remove the spindle The 011 pump

pump IS a reversal of the dlsmanthng the pump cover gasket IS properly fitted Tighten the 011 pressure rehef valve cap nut to a torque reading of 3 0 3 5 kgm 21 7 25 3 Ib ft

assembly

procedure Make

sure

carned out In reverse order to the removal the 011 pump set the engine so that No 1 cylinder IS at T 0 C position In ItS compression stroke and then fIt the 011 pump and the drive spindle In the front cover With the punched mark on the spindle facing the front of the
IS

procedure

When

replaCing

OIL FILTER The 011 filter


IS

of the

removed from and

replaceable cartridge type and can be replaced on the cylinder block by hand

Check the engagement of the drive vIa the distributor fining hole Refit the distributor and fill the engine with the recommended engine 011 Tighten the mounting bolts to 1 5 21kgm 108 1521bft SeealsoFlgA2 I engine

When refitting the filter element do not overtighten and under no circumstances use any tools The filter body With the element should be replaced every 6000 miles 10 000 km The location of the filter
IS

shown

In

Fig

B 5

OIL PUMP

Dismantling

Separate

the body cover from the pump body by unscrewing the Single securrng bolt and take out the pump drrve and driven gears from the pump body Fig B 3

OIL PUMP Clean all


Items
a

InspectIOn and Overhaul

parts In

SUitable solvent and check the

follOWing

Technical Data
Type Pump type
Drive Pressu re feed system Rotor pump From distributor shaft
Inner

Check the

Worn bearrng faces pump body result In pressure losses If necessary replace the body
0 wear

for

Check the clearance between the lobes of the

and outer rotors The maximum clearance must not exceed 005 0 12 mm 0002 0005 In If the clearance IS found to be greater a new seat of rotors should be fined
Inner

Clearance between
outer rotor

and 0 05

012mmI0 020005111
0 12mm 0005 In I

Clearance between
3 Check the clearance betWeen the outer rotor and the pump ThiS play must not exceed 0 15 021 mm 10006 If thiS clearance IS excessive a new set of rotors 0008 111

rotor

tipS
Celarance between outer rotor 015 and body 011 pressure rehef valve spring

body

021

mm

0006 0008

In

or a new

pump

body

must be fined

Check the end float of the rotors by placing a straight across the Joint face of the body and measuring clearance between the rotor ends and the

edge
the

Free length Fitted length

75 mm 224 In

straight edge by carefully lapped

Opening

pressure

8 4 2 kg sq 3

cm

54

ii f 3 i m 1 54 60 Ib sq

In In

inserting
In

feeler gauge IMust not exceed 0 13 mm 0005

on

If necessary the pump flat surface

body

can

be

011 pressure at

idhng
1 0 1 2

speed
Oil pressure at
scores

kgsq

cm

14 2

17 1 Ib

sq ln

Check the rotor drive shaft for excessive wear or


necessary
renew

If

2000 rpm lhot

38 42 kg sq

cm

54

60 Ib sq in

the rotor set


1I aACI tile IidIng for proper f t sprlll

Cheek

fllJief IiIWe the

19

mter

j M

Pl @

Fill C
OY

General arrangement of the cooling

OperatIon plate

Dust

cover

Drum

SpIder assembly

linnl9

FIlI

C 3

Exploded

of

the fan

h c1u1l

V V
00

o
Fill C 5
parts
V fIW of the radiator and

o
c 4 DlSIllantllng of FIlI
thefan clu1dl

J
component

20
It

Cooling System
DESCRIPTION The cooling system is
radiator

closed pressunsed system It consists of fan clutch thermostat and the water Jackets in cylinder head and block
a

water pump

83 50C 177 182oF The maximum hft of the thermosm valve should be 8 0 mm 0315 In at a temperature
of 80 of

950C 1203oF

WATER PUMP
To remove the system
unsaew

Removal pump drain the cooling belt fan and pulley and

THERMOSTAT

Instellatlon

centrifugal type water completely and remow the fan

the water pump from the front cover Fig C 2 It IS recommended that the water pump is not dismantled due to Its design and manufacture If the water pump IS supected of

The installation of the thermostat is carned out In reverse order to the removal procedure Use a SUitable sealing compound to
seal off both Sides of the

gasket

malfunction

an

exchange

water pump should be fitted To

RADIATOR
remove

Removal and Installation

Replace
vanes or

the water pump If It has eXce5Slvely rusted or corroded If there IS excessIVe wear In the beanngs or
IS

squeaking
of
8n NIS

With the engine running cooling system protector

To prevent squeak the recommended

use

the radiator shown In Fig C S drain the cooling and disconnect the top and bottom radiator hoses Remove the radiator after unscrewing the four radiator system bolts Check radiator for water leaks and cracks and repair or replace as necessary The installation of the radiator s earned out In reverse order to the removal procedure

attaching

The pump should be cleaned WIth Nlssan COOling system cleaner


before It
IS

refitted to the front cover

FAN CLUTCH In the models With air conditIOning a fan clutch IS fitted to the effiCiency of the coohng system and reduce power losses ThiS clutch IS thermostatically controlled by the air
IIlCrease

temperature of the engine compartment If the air temperature In the engine compartment Increases the thermostat beginS to
operate and the fan clutch Will engage

Technical Data
Type
Closed pressunsed system Radiator

FAN CLUTCH

Inspection

Fully warm up the engine Check the operation of the clutch at engine speed of 2500 rpm The clutch should begin to operate at a temperatu re of 61 690C 141 159s o F and shoo Id SWItch automatically off at 50 580C 121 1380F
The temperature should be checked near the clutch and thIS be done several times as there IS a time lag In the operation of the thermostat should To check the operation of the fan clutch thermostat remove the operating plate see Fig C 3 and C 4 and submerge It In hot water 700C for 2 or 3 minutes to check Its operation

13 78 In I 20 24 In Thickness 32 mm 1 26 In 26 IItres 0 7 U S gall 057 Imp gall I Capacity 09 kgsq cm 128 pSI Cap opeOlng pressure
mm mm

Herght

350 514

Width

Thermostat Valve opening Max valve 11ft

80 5

83 SOC 11 7 Morethen 8 mm 0 315 In at

1lF 18
at

950C

2 3 0F

THERMOSTAT

R8IllOVlII

Drain the cooling system remove the radiator hose and the water outlet elbow and 11ft out the thermostat To check the thermostat place It in a container filled with water and gradually heat up tha water Immerse a thermometer into the water and observe the Indication Taka C8I 8 that the
thermostllt or the thermometer cannot touch the bottom or the sides of the contalller oth ise false nIlIdinga will be

obtained The thermostat should start

to

open at

temperature
21

inter e

Ql @

A
I
D2 Fia
Remof

r
FI9 D 1 Explod
YI

the

contact beI8 plaia

of

1118 ognrtlOn dlltnbutor

v
FIQ
D 5

The
F

bly of 1118 flyweight mecherlillll


It tg 2
nd ond Oftronco for at IfInltlOll lranctl MI IIe Hook

FI9 D 3 Removal of 1IIe dIstrIbutor drMlllllllr


1111I1Inln9 pin

FItI D 4 Removal

of 1IIe dlllnbutar drive Iheft

4 5 6 1 8

ght rprll1l Flywo


Dtltrrburor cam pkrte ywetg ltpm F
H

Flyweight rprlnt
RotorpoI

donm

fin

Fig
D 6 Checlull9 1IIe contact FI9 RI IlfP

8 AdJUlling 1118 cantBCt D

er

gap

D FIg

View of 1118 distrillutar

wIth

22

Ignition System
DESCRIPTION The 1300
are

CONTACT BREAKER GAP With the distributor


turn

Adjultment

and the 1600 c c engines With Single carburettors c c fitted With the Ignition distributor model D41058 whilst the 1600 c c engine With twin carburettors has model D40054 The outside appearance of both distributor models IS alike

in reverse order to the removal the engine until the fibre pad of the contact breaker ann IS at the highest POint of the distributor Slacken the clamping screw at the fixed contact pOint and earn turn the adjuster screw With a screwdriver until a contact gap of fitted

procedure

over

IGNITION DISTRIBUTOR Disconnect the

Removal

high tension cables from the spark plugs and the Ignition coli and detach the primary wire from the distributor Remove the vacuum pipe from the distributor connection slacken the distributor clamp bolt and withdraw the distributor

0012 0022 In IS obtained Retighten the and uSing a feeler gauge rlH heck the contact breaker gap to ensure that the fixed contact breaker plate has not moved while the clamping screw was tightened 045 055
mm

clamping

screw

The contact breaker POints can be cleaned by uSing a contact file or an 011 stone The raised areas on the contact should be filed off but do not attempt to remove the crater In the other After cleaning the contacts they should be placed opposite each other meeting over a Wide area If the contacts only meet partially It IS pOSSible that overheating burning and sparking could develop A View of the contact breaker assembly
contact
IS

IGNITION DISTRIBUTOR

Dlsmanthng

Remove the distributor cap and pull off the rotor Loosen the vacuum Unit securing screws and 11ft off the Unit Unscrew the fixed contact POint set screw and 11ft off the pOint Take off
two

shown Fig D8

In

Fig D 7 The adjustment of the pOints

IS

shown

In

the spring clip from the piVOt post of the moveable contact breaker pOint and remove the contact arm From the Side of the distributor body remove the two spring clips and remove the Take care not to loose contact breaker base plate see Fig D 2 the steel balls between the breaker spring and the breaker plate and those between the breaker plates

IGNITION TIMING Remove the distributor

Adjultment
With

vacuum

the engine running at Idle speed proceed

line and start the engine as follows

SUitably support the distributor shaft from


a

underneath and

SUitable punch drive out the drive gear retaining pin uSing Remove the gear and the sI1Ims after marking the Fig D 3 relation of the shaft and the gear and Withdraw the distributor shaft from the other Side Fig D 4 From the InSide of the distributor
cam

USing a stroboscopIC tlml ng light connected In accordance With the instructIOns of the manufacturer check that the timing case pOinter IS In line With the timing mark on the crankshaft which Will be made statIOnary by the effect of the timing IIgt Each of the marks on the crankshaft pulley represents 50 of the
crank angle The tlml ng setting 1300 1600 1600
c c c c c c IS as

remove

the set

Carefully unhook the flyweight deforming them

and pull off the cam springs Without stretching or


screw

follows T DC 1600 rpm

engine SC

TC w

1008
TC w

100 8 T D C 1600 rpm 1408TDC 650rpm


TWin carburettor

IGNITION DISTRIBUTOR

Assembly wlSC

Single

carburettor

Thoroughly clean all parts and examine the distributor cap for cracks carbon tracking and burnt or corroded terminals Check
defective With
an

the carbon brush for excessive wear and If necessary remove Check the contact breaker gaps for pitting parts replaCing them If badly marked Light damage can be smoothed 011 stone
wear or

CHECKING THE CENTRIFUGAL ADVANCE Disconnect the vaaJum pipe from the distributor hOUSing paint white line on the crankshaft pulley and start the engine Direct the flash of the stroboscopiC timing light on the

Check the shaft for condensor for short Check

the vacuum mechamsm for freedom of movement

and proper fIt In the body Check the open circuits and replace If necessary Unit for operation and the flyweight

and observe the movement of the white line engine speed IS slowly Increased The distance between the IgnitIOn timing pOinter on the timing gear cover and the white line should Increase noticeably Incheatlng a satisfactory operation of the centrifugal advance mechanism If crankshaft whilst

pulley

the

The assembly is a reversal of the removal procedure Refer to Fig D 5 when assembling thJ flyweight mechamsm When the distributor isassembled connect a spring scale on the end of the contact arm and slowly pull the spring scale lIWay from the Read off the indication at the moment fixed contact POint when the arm is lust lifting from the fixed POint See FIg D 61 The correct value IS 0 50 0 65 kg 1 10 1 43 Ib Adjust the con1llct breaker gap as described below

the paint marks appears to move back and forth In an Irregular manner It may be that the flyweights are sticking If necessary lubricate the distributor to free off the weights CHECKING THE VACUUM ADVANCE MECHANISM 1500 rpm until the Increase the engine speed to about 1200 throttle disc valve uncovers the vacuum drllhng With the 8Q8IIIll running dISCOnnect the vacuum pipe from the distributor

housing

and re connect

in turn Observe the white paint hne on

23

the
connectlOg re

crank

pulley
of the
vacuum

With

each

disconnecting

and

pIpe the line should move back and forth If the line remalOs stationary It IS possible that the pipe IS obstructed or the vacuum unit is damaged

Technical Data
DISTRIBUTOR Contact gap Contact spring pressu re Shaft diameter lower part Shaft diameter upper part 045 055 050
mm

SPARK PLUGS

Removal Inspection

0012

002210

and Installation Remove the spark plug cables from the plug ends and unscrew the spark plugs only uSlOg a spark plug spanner No make sluft tools should be used for thIS purpose Check the plugs for cracks and chips on the IOsulators and check the electrodes for wear If the carbon depOSIt IS excessive thIS IS an Indication of bummg englOe Oil so Install a hotter plug If the plug faces are excesslvle whIte or rapid electrode noted fit a colder plug Clean the plugs With a sand blast cleaner or carefully WIth a Wire brush and adjust the electrode
wear IS

065 kg 1 1 1 43 Ib 1245 mm 0490210 80mm 03151O 1245


In

HouslOg

lOner diameter

0490210 0001510 0 003


10 10

Clearance between shaft Clearance Cam


wear lOner

housmg and
001 0038
mm

00004 0 08

limit

mm

diameter 0 029

80 mm 0315 00002 00011 50 mm 0197 50


mm mm

Clearance between shaft and cam 0 005

mm

In In 10

Flyweight piVOt dla


PIVot hole dla Clearance between pIVOt and piVOt hole 001 046

0 197 00018

O8 0 9 mm 0 03 0 035 ln When tighten them to 1 5 2 0 kgm 11 15 Ib ft to gapS

flttmg the plugs

00004

10

IGNITION COIL Model 1300 1600 1600


c c c c

wlSC

wrrc

C14 51 C6R 50 12 volts

Primary voltage Primary resistance


1300 1600
c c

1600

c c

SC

3 2

4 1 ohms

wrrc
resistance

Secondary wlSC

2 1 2 7 ohms 11 2 168 ohms

SlOgle

carburettor

wrrc

TwlO carburettor

IGNITION TIMING AND IGNITION ADVANCE

Fully detailed
Data

IOformatlon are gIven under See Index for page number

EnglOe TUOlng

24

II

Trouble
SYMPTOMS
Starter turns but engine will not start Weak battery Excessive mOisture

Shooting
ACTION TO BE TAKEN

PROBABLE CAUSE

Recharge battery
on

spark plugs

or

high

tension or

wires

Remove moisture and dlStnbutor cap


or

dry

Cracked

leaky

Replace

cap or rotor

rotor
Broken wire In pnmary CircUit Burned or Improperly adjusted points Defective condenser

Repair or replace wire Adjust or replace points Replace condenser adjUst or replace plugs Replace breaker points Tighten or repair
Clean

Difficult starting

Defective spark plugs Defective breaker points Loose connection


In

pnmary CircUit

Defective condenser Defective Ignition COil Defective rotor or dlstnbutor cap

Replace condenser Replace Ignition coil

Replace
Clean

cap

or

rotor

Engine misfires

Dirty

or

faulty spark plugs


Ignition
wire

Loose

or

faulty

adjUst or replace plugs Tighten repair or replace Wires Replace cap AdjUst breaker points AdjUst
contact

Insulation Cracked dlstnbutor cap Breaker


not

points

correctly adjusted
contact

Ignition CirCUit Interrupted voltage drop In pnmary CircUit

and

Burnt

or

Incorrectly adjusted
loose

breaker gap

breaker gap Defective leads


connections

or

dirty

Check leads clean connections Check Check

Ignition SWitch defective Ignition COil defective Secondary


current circuit

or or

replace SWItch replace IgnitIOn adjust


or

COil

Interrupted

and

no

Spark plugs

wet

worn

or

inCOrrect

Clean and

replace plugs

gap Defective condenser Defective broken Ignition cable between COil distributor cap
or

Replace condenser Replace ignition cable


Clean and check parts or Check
or

Tracking
and rotor Defective

replace

Ignition COil

replace

COIl

interceM j

@ ce p

J
L

ill

il

T
1

f
A

I a

f 4
Fog
2 E General L 16

r
o

IJ
the
twin

f
c

of

the twm

choke

Fill E 1 General Cllburettor

of

choke

cartJuret1D

englnel

12

1314 IS 16

FJgE 3 V

of the tWin choke cartJurettor for


ilJtomatlC transnllSSlOft

cars fittedWith

FIg E 4

SectIon L 16

through

the

twin

choke

carburetlllr

englnel
c t 15

2Small
3

MIl dach venturi

IHUnmng Slof

MamllJrble J Jet
bleed

SiChatfpl Mamd zer bleed Econor 16 runmng SIow Jet 17 SJoVN unnmg econonuzs
18 Slowrunning BIf bIet1d 19 AN vent 2Q Fue let1el g JiUgt 21 Mam Jet 22 runnmg SJow flW KJlumtllCl 2 24

5 SlowrunnmglII G N tI aM 7 FI 8 Emublon tubtJ

9 M lnJflf 10 s 110 77 Throttle aIwl 12 13


rok C MII w a

SIoMNllnmng
11010 8 Throttle aWe

25

bltJed

FIlI E 5 c a rburetlllr

SectIOll

L13 1

through 1

the

A rWllltptplt

SmsJIWNlbm 5 MatndlS C 6 Mam air bleed a bleed 7 SlorH1lnnmg II bleed IS runnlnfl SIow fIl 19 Vacuum prsfon 20 Power aIw 21 et Ifam

2 Small venturI 1MlJmd


M
m

lTbJeed

5 6
7

tunnlllf Slow
runnm6 SIow

f1t

8 F 9 Emulston rubll 14 M m jet ho 8y 12 Throm 13 ChoIc

obo
00
FIQ E The dlStll8nt1ed throttle vaJve

22 Maml 23 l ldl 24 8 25

hole W Throttle

26

Fuel System
DESCRIPTION The fuel system consists basically of fuel tank fuel pump fuel strainer air cleaner and carburettor The Datsun 1300 IS fitted with a two barrel carbu rettor whereas the Datsun 1600 has either
a

Check

the

throttle

and

choke

valve

shafts

and

bores

for

eccentriCity Check the slow running Jet needles for burrs and parts as necessary Check

two

barrel

downdraught

carburettor

or

twin

SU type

ndges Replace

carburettors

CARBURETTOR

Single

tWin choke

Removal

choke tube clusters for wear or slackness and If necesssary replace the cluster Check all linkages for excessive wear and the filter screen for blockage and distortion Check the operation of the accelerator pump and the chamber for damage to the diaphragm and air leaks replace any defective components

The single carburettor versions are fitted to the Datsun 1300 Type designation DCK306 and the Datsun 1600 Type

diaphragm
Repair
or

deSignation
carburettor and the

OAF

328

See

Fig

E 2

take off the

vacuum

choke cable nuts and washers

air cleaner pipe from the carburettor end and detach the Remove the throttle linkage and undo the four

To remove the disconnect the fuel pipe

E 3

CARBURETTOR The assembly


IS

securing the carburettor to the manifold Lift carned out


In

Assembly

off the carburettor

reverse

procedure
brittle CARBURETTOR The
or

Special care should hard gaskets are used

order to the dismantling taken that no defective Where these are found they be be careful

Dismantling

main Jets slow runnlhg Jets and the needle valves for the pnmary and secondary stage are accessible from the outside of the carburettor body Remove the Jets and needles Fig E 4 E 5

should be replaced When connecting the linkages not to bend or deform any of the components

CARBURETTOR

Adjustments

Float level upper body can be removed by removing the choke connecting rod pp connecting rod return spring stop pin and the four secunng screws Figs E 6 E 7 and E 8 The Mam the gauge line the float IS correctly set If If the fuel level thiS IS not the case hold the float level In ItS chamber and check that the gap between the float seat and the stem of the float
IS

at

needle valve

IS

about 1 0

mm

0039

In

body

mm

059
as

Remove the pnmary and secondary emulSion tubes by removing main air bleeds Fig E 10 Remove the cylinder cover and take out the accelerator pump F Ig E 11 Separate the float the chamber from the throttle butterfly block by removing the rod linking the diaphragm to the secondary throttle valve and the Remove the float chamber four securing screws Fig E 12
cover

seat

for the L 16 engine shown In Fig E 18


In

Fig E 17

for the L 13 and 1 5 Bend the float

Interlock startJng system With the choke valve fu lIy closed there should be a clearance of 1 3 mm 00512 In between the pnmary throttle valve and the carburettor body In the ase of the OAF 328 carburettor and a
In the case of the DCK 306 clearance of 072 mm 0028 In carburettor Fig E 19 and Fig E 20

and the float

Fig

E 13
screws screws

Dismantle the

diaphragm diaphragm
The fuel

diaphragm by removing three chamber and then removing three chamber cover Fig E 14
system
shown
In

holding the

holding

the

Interlock opemng of prunary and throttle valves

secondary

E 15 should not be dismantled If not abolutely necessary When dismantling take care not to damage the bimetal spring
return

Fig

When the pnmary throttle valve IS opened to the speCified degree 590 for OAF 328 or 560 for DCK 306 there should be a clearance of 9 10 mm 03583 In In case of the OAF 328 carburettor and the and A
or

Dash pot This mechanISm With


automatic
IS

Inner

damper

Fig
on

fltteto thecarburettor Fig E 16 on vehicles transmission and IS linked to the pnmary

E 23 the adjustment

between the throttle valve 6 40 mm 0 252 In wall of the throttle chamber See also Figs E 22 To adjUst the clearance bend the pOint marked

plate roORing adjustment


IS obtained by adjusting the and the slow running volume control

Slow The slow running throttle valve stop

throttle vale

linkage

adjustment
screw

CARBURETTOR

Inspection

screw

clean all parts In a su Itable solvent and blowout all Jets and passages With compressed air Check all parts for wear and damage With special attention to the follOWing parts

Thoroughly

Check the float needle and the seat for wear If worn the assembly

replace

the slow runnlng volume control screw and back off three turns Then screw In the throttle stop Unscrew the throttle stop screw screw and start the engine until the engine beginS to rotate unevenly when the englfle Screw
In

by approximately

speed

Will

gradually drop
screw

volume control

until

Now screw In the slow running the engine runs smoothly at the

inter

i D

j1 @

4 4 7 B alh throttle

FIlIE

valves relllDved

FIlI E B The carburettor top

caver removed

ll
li

il 4
0

It

u
Fill E 9 The choke
c hamber

F
I

relllDvecI

FIlI E 10 The pnmary end tubes removell

lOCO ndary

emu

q
o

FIlI E 12 The lower and upper carburetlDr separa18d bod

1 l O Jo
FIg E 13 tor body
The float

reIIICJII8II from the

ret

28

ImmIIII

1J
F

flp fuoIlpul

4
o 0 o F gE 14 The

FIQ E 15 The fuel


Valve 2 3 if

return

sys1em

Body PIPe
SImtlttJl

component

parts

of

the

dl8phragm

a
L

i
J

Ll1
1

f i
r L
4
2 4 DAH OCK AnZl Omm
00

1
I

D au

Fill E 17 The flollllevel adJullment


5 6 Float SlHt 2 FIo t 3 FINt ltop 4 7 2 JIII Ne van

FIQ E 18 Adlusanent of the float 18111

I E 16 FI

The dashpot mechBlllsm

Locknut Jblearm Chok cl 3 OGhpot


ThlO 0 5

Throttle 6 Throm l

ch btK aIw

I E 19 FI
2 rL r

tlng AdJuotment of slllI

Interloca opemng

Choke bell rod 2 Choke connctlllfl rod 3 S11Irtlng Ie 4

Choke vain

5 Choke ItNer 6 Fat dIB connectIng IeYer 1 Throttle chamber 8 Throttle valw

i
r

fr J
L

JhaJi

FIQ

20 MeaRltlng the clearance of the start E

ng Interlock valve Opel1l11l1

29

highest speed engine speed Repeat


thiS

adjust Re

the throttle stop

screw

to

reduce the

adjusting nut and check again If the second check produces a sharper click than the first repeat the centnng Refit the parts
that have been removed pour thin 011 Into the hollow rod of the piston damper to Within 0 5 In 12 7 mml of the top of the rod

until an engine speed of 550 rpm has been obtained Care should be taken not to screw In the slow running volume control screw to tightly as otherwise the tip of the screw might be damaged

adjustment

CARBURETTOR ThiS Datsum 1600 fitted transmission With the engine at operating temperature check that the throttle lever Will touch the dashpot stem when the 2000 rpm There engine IS running With 1800 should be no load on the engine Fig E 161 If thiS IS not the
IS

adjustment

Dashpot adjustment only necessary on the

Adjustments
IS

The proper

adjustment

of the two carburettors

extremely

With

automatic

Important In obtaining peak vehicle performance and redUCing fuel consumption


Carburettor Remove the
air

synchromzsnon

and

idhng adjustment

slacken the dash pot locknuts and turn the dash pot to the nght or left until the throttle lever touches the dash pot stem at the specified engine speed In thiS condition the clearance
case

cleaner when the engine has reached ItS operating temperature and slacken the throttle adjusting screws The heads of the adjusting screws must not contact the throttle lever
not

between the throttle valve and the throttle chamber wall should be 08 mm 0071 In I corresponding to a throttle valve angle of lO

Also make sure that the front and

rear

throttle shafts

are

connected Tighten the Idling adjusting nuts of the front and rear carburettor by one turn towards the top of the carburettors and gradually back them off After the nuts have been turned approximately half a turn the nuts Will contact the needle heads Back off the nuts from thiS pOSition by approx one and a half turn Make sure that the Idling adjusting nuts of both carburettors are In the same pOSition The dimenSion A

SU TYPE TWIN CARBURETTORS

Dismantling

Unscrew the plug and Withdraw the piston damper Take out the two suction chamber secunng screws 11ft off the suction chamber and Withdraw the piston and Jet needle Disconnect the rod from the bottom of the Jet and the nylon feed tube from the base of the float chamber Unscrew the Jet

adjustment descnbed later between the Jet bndge and the needle head should then be approx 1 5 mm 0591 In I
Screw
In the throttle adjustment screws of the front and rear carburettors and start the engine The engine should retain Its operation temperature before carrying out the next step

adjusting

nut

and the spnng Unscrew the Jet

beanng locking

nut

the float

Remove the float chamber cover secunng bolts and Withdraw Screw out the needle valve assembly The dismantling
are

stages

shown

In

Figs

E 24 E 25 and E 26

Now turn the throttle

adjusting

screw

of both carburettors to

CARBURETTOR

InspectIon

reduce the engine speed to approx 600 700 rpm The engine should turn over smoothly and consistent If a flow meter IS available apply the Instrument to the front carburettor flange and turn the adjustment screw on the flow meter so that the upper end of the float In the glass tube IS In line With the scale Llft off the flow meter and re apply It to the rear carburettor Without altering the setting of the flow meter adjusting screw If the pOSItion of the float rear carburettor throttle the mark on the scale
IS

Note the condition of the needle valve and the seating Fit a new needle valve and seating If necessary If the Jet needle IS
or otherwise damaged Withdraw the locking Push the needle piston and fit a new needle shoulder IS flush With the lower face of the piston

bent

screw In In

the

until the Fig A 271 rod

not

In

line With the scale


screw

adjusting

to

align

adjUst the the float With

Clean and

dry

the piston

assembly

Lubncate the piston

WIth thin 011 With the carburettor flow correctly adjusted adjusting nuts of both carburettors by approx CARBURETTOR Reverse the

tighten
1 8 of

the
a

Idling
and

turn

Assembly
and centre the Jet

stop the adjusting of the nuts at a pOint where the engine speed IS fastest and smoothest Without If thiS missing or hunting
be detenmned bnng the nuts back to their positions and unscrewthem from thiS pOSition until the engine runs fastest und smoothest

dlamantllng procedure Centnng

point

cannot

onglnal
the Jet Screw the Jet adjusting nut up as far as poSSible 11ft the piston With the lifting pin and allow It to drop It should drop freely the bndge With a soft metallic click Repeat wltn adjusting nut screwed fully down If the piston does not freely In either of the tests proceed as follows
onto

the fall

Then slacken the throttle adjusting screws of the front and rear carburettors and adjUst the engine speed to the specified value of 650 rpm for standard engines or 700 rpm for models With 011 cooler Make sure that the air flow of both the carburettors remains unchanged Screw In the throttle adjusting screws until their heads contact the throttle connecting lever Connect up the front and rear throttle shaft Without changing the Idling

Disconnect the rod from the bottom of the Jet and the feed tube from the base of the float chamber Pull out the Jet and the tube Unscrew and remove the Jet adjusting nut and the spnng Refit the
as

speed setting
Move engine

up as far

adjusting pOSSible

nut Without the spnng and screw It

Slacken the Jet bearing lock nut until the beanng can be turned With the fingers Remove the piston damper and press the piston down onto the bndge Tighten the lock nut

Idling

interconnecting shaft and accelerate the few times When the engine IS settled once more In Its speed check that the speed IS unchanged Recheck also
a

the throttle

the connection

tift lhe pjS on

and nQ 1l

whetlliij

IS

falls

freely

fully 19w ir

the

of the interconnecting shaft Then turn tha Interconnecting shaft adjusting screw to Increase the engine speed to 800 1000 rpm Check y means of the flow meter Jf the Idling air flOW IS the both carburettors If necessary tor same

30

mterc rlOU @@ce


c

@0 f J
I I

1
I

I
2

I
i I

Ju

Fill E 21

opelung of pnmary ary throttle valves L16 eng ne


4 5

IlltIIrlock

Fill E 22 Interlock op ung of pr mary lIlCondary throttle valves L 13 eng ne


1 2

Fill E 23

throttle valve ConnectIng IrHr Return plate


3 4 Throttle chlmbtK Throttle v Jve

Checlung the body

clearance

between

1 ConntJCttn9 mvu 2 RftUm plate 3

Throttlfl Throttle

nbtN ch

1I1v6

Adjuster pllltrJ

OIL CAP NUT

SUCTION

CHAMBER

SUCTION

PISTON

FUEL PIPE

A
tJ

II
o 0

e
0

SUCTION SPRING

Yo
v

NOZZLE
JET

SLEEVE

SET SCREW

NEEDLE

IDLE ADJUST SPRING IDLE ADJUST NUT NOZZLE Fill E 25

Fill E

Exploded BOO suction piston

24

of

Rlol on

chamber

Exploded

VIew

of nozzle

assembly

0
0

0 0

O
Fill E 28 Exploded
of the float cIIMIber

Fill E Xl Installation of the lat needle

31

the length of the throttle connectmg rod Fmally back off the mterconnectmg shaft adJustmg screws and decrease the engme speed Agam check with the flow meter to confirm that the float settmgs are even ReadJust If neceesary by means of

adjust

FUEL PUMP Disconnect the


connection

Removal

mlet and
remove

outlet hoses from the fuel pump

the throttle cleaner

adJustmg

screws

Stop

the engme and refit the

air

and

the two mounting nuts

Adjustment

of Jet needle Refer to

FUEL PUMP

Dismantling

Remove the suction chamber and the suction piston and turn the Idling adJustmg nut Usmg a depth gauge check that the dimension A between the Jet bndge and the top of the needle head
re IS 05 mm 00197 m When this dimension IS obtamed mstall the suction piston and the suction chamber and check the smooth operation of the suction piston The Jet needle IS

Fig E 37 Remove the screws secunng the upper to the lower body and 11ft off the upper bOdy
Remove the
retainer

valve

retamer

secunng

screws

and 11ft out the


screws

and 11ft

packmg Remove the cover retammg off the cover together With the gasket

valves and

now set

basic position Float level

On the lower body half press down the diaphragm and unhook the diaphragm rod from the rocker ann link Lift out the

disconnect the fuel pipe and remove the sleeve nut If a fuel level connect gauge IS avallable the gauge to the fuel pipe connection on the carburettor re connect the fuel pipe and start the engine The fuel level m the glass tube of the level gauge should be b tween 22 and 24

Remove the float chamber

clip

diaphragm

Remove the spnng 011 seal retamer 01 seal packing To remove the rocker ann assembly dnve out the piVOt pm towards the serration and 11ft off the individual parts

FUEL PUMP

Inspection

from the top of the float chamber If level gauge IS available proceed as follows
mm m

0866

0945

no

Thorouqhly clean all parts and check as follows


The

Remove the float chamber


cover

cover

after

screws

and

11ft

off the

cover

undOing together

the four with the

body and diaphragm for

cover

wear

for cracks defective threads or wear The and tear and a worn pull rod The sealmg
corrOSion

attached float lever Hold the Side IS faCing upwards 2

cover so

that the float lever

faces of the valves and the spnng for weakness and The rocker mechanism for wear

Lift the float lever with the tip of the fmger and then lower It until the float lever seat Just contacts the valve needle stem If the dimenSion H m Fig E 33 IS between 14 to
correct

FUEL PUMP Insert the rocker


arm and

Assembly
m

15

mm

0551

to

05901

the float
as

the link

the lower

I f necessary bend the float lever Illustration

level IS shown m the

body

and hold

place

while

the pin

the piVOt pin from the Install the rocker arm spnng

fitting

non

serrated Side of

StartIng
To

mterlock opemng

Install the 011 seal and the seal washer and the diaphragm to the lower

body

half Press down the Fit the


cover

diaphragm
to

the startmg mterlock opening bend the connectmg rod 4 m Fig E 34 with a suitable pair of pliers The opening IS mcreased by lengthening the connectmg rod and reduced by

adjust

the rocker Install the

arm link

the upper

and engage It With body half

the rod The length of the connectmg rod IS correct If the clearance between the throttle valve and the throttle chamber dimenSion 8 m Fig E 34 IS 0 6 08 mm 00234

shortenmg

00315

I with the

starter

lever

pulled

out

completely

packing and the valves correctly mto the upper body half and secure the valves With the valve retamer and the screws POSition the upper body onto the lower body and msert the screws Make sure the screws pass through the diaphragm Without teanng the matenal Tighten the screws evenly and
securely

Hydraulic damper
The 011 should be checked approx every 3000 miles or To check the 011 level remove the 011 cap nut every 3 months as shown m Fig E 35 and check the level markmg on the two grooves on the lower Ime fill

damper

FUEL PUMP Reverse the removal for fuel leaks

Installation Start up the engine and check

procedure

plunger

rod

If the level has

dropped

below the

m SAE 20 engme 011 Use an 011 can and fill m the 011 until the level has reached the upper line When msertlng the cap nut take care not to bend or damage the plunger rod Tighten the nut suffiCiently by hand

FUEL PUMP

Testing

Remove the carburettor fuel pipe and connect a pressure gauge to the fuel pump outlet fitting Run the engme and check the fuel pump pressure which should be 0 18 024 kg sq cm
on

FUEL FILTER The fuel filter IS of the throw away cartridge type and should be changed every 40 000 km 24 000 miles To remove the fuel filter disconnect the mlet and outlet PipeS and remove the filter Fig E 36 The mstallatlon of the filter IS a reversal of the removal

256

34 pSI I the
a

If the pressure

readmg

IS

below the settmg

replace

diaphragm sprmg
flow check
a

Conduct

the outlet pipe m at 1000 rpm for delivered should

by connectmg the mlet pipe and msertmg SUitable contamer Start the engine and run one mmute The mmlmum quantity of fuel
be 1000
c c

procedure

If not

malfunction and the fuel


restnctlons are

lines for

blockages

check the pump for If blocking or

suspected

blowout the lines With

Compressed

the fuel lines remove the pump and air Repeat the flow test

32

ImmIIII

3B
4
r o

16 17 Screw 1 e 2 Sprmg wash r 3 Fuelpump co 4 Cover gasket 5 VaM1 seel 6 VaJw

eel
I

19

S 6 7

FIg E 36 Removal of the fuel folter

Valve retainer 8 R8tamer screw 9 D hragm 0 Pullrod Selll washer 13 Seal 14 Lock washer 15 Nut 16 Connection Screw
8 Lock washer 19 ConnectIon 20 Rocker arm sprmg 21 pscer 22 Heat Insulator 23 Fuel pump gask8t 24 25 26 12

DIaPhragm

flng

he fuel tank of Saloon Cars

Rocker arm Rockerarm pivot pm Spacer


20 24

12

FIg E 41 Exploded

of the aIF cleaner


13

FIg E 39 The fuel tank f ller tube


22 23

Exploded

VIew of

the fuel pump

Fog E 42 Removal of the with SIngle carbunrtlDrl

aIF

cleamr

33

after

re

assembly
POSITIVE CRANKCASE VENTILATION SYSTEM FUE L TANK Removal

The l 13 engme has


the
aIr

cleaner

Fig

ventilation pipe from the rocker box to 43 whilst the l16 engme uses a

Saloon
seat

Remove the

rear

seat

back trim

Open

the

the board flmsher board


wire

and the seat back and take off the luggage compartment lid and remove Fig E 38 Disconnect the fuel gauge

combmatlon system Fig E 44 which IS Similar to the one used for the l 13 engme but IS fItted addItionally With a tube With a variable Orifice valve fr the crankcase to the mlet vamfold

F g E 39 and the tank filler tube Remove the tank securing bolts and disconnect the fuel outlet pipe and the fuel return Ime lIft out the tank wagon Carry out the same operations as described above With the exception that the fuel tank securmg screws are acceSSible from under the rear floor panel Estate
car

InspectIon Every 12 000 miles 20 000 km remove the hoses and blowout With compressed air If the hose IS blocked or collapsed replace It Check that the crankcase breather valve only allows one way passage of gas mto the mlet manifold Replace the valve If It IS
leakmg
10

statIon

FIg E 40
The mstallatlon of the fuel tank IS removal procedure
10

011 filler cap both


cases a

the opposite dIrection Clean all connections and the which IS sealed and has no connection to the

reversal of the

atmosphere
dIsconnect the To check the operation of the system ventIlation hose from the rocker cover With the engme runmng at Idlmg speed and check that a hlssmg sound can be heard as the aIr passes through the valve A strong vacuum should be felt when
must
a

FUel LINES Examme the fuel hnes for damage and kInks and replace If necessary If dirt IS found 10 the carburettor float chamber or 10 the fuel pump stramer dIsconnect the pipes and blowout WIth com ressed aIr It might be recommendable In thiS connection
remove and clean the fuel tank as depOSits are empty Without doubt 10 the fuel tank whIch would lead to the same fault after a short tIme

fmger

IS

placed

over

the valve

mlet A

damaged

valve

always be replaced

to

AIR CLEANER The air cleaner IS of the VISCOUS paper type and cannot be cleaned but must be replaced every 24 000 mIles 40 000 km ThIS operation IS shown 10 FIg E 41 and IS self explamtory

Technical Data
TWIN CHOKE CARBURETTORS

Engme Model

l16

1600c

l13

1300cc

Primary
Outlet diameter Venturi diameter Main Jet Main air bleed Slow runnmg Jet EconomIzer Jet Economizer bleed Power Jet Float level Fuel pressure 280101 240101 115 240 48 18 1 8

Secondary
32mm 28
x

Primary
26mnt 21 96 80 43
x

Secondary
300101 27x12mm 150 90 180

9 0101

0101

155 120 180

40 23ct 101m 0905 ct 004 024 235 112 109 107 104 101
to

23ct 101m

0905
024

ct

004

to

Weight
Altitude settIng main Jet 100001 3300 ft 2000
01

kg kg

sq em 341 pSI 5 17 Ib

kg 255 kg
94 92

sq cm 341 pSI 5 61 Ib

6600 ft 13 300 ft I 16 600 ft

300001 10 000 ft
400001 5000
01

89
87 85

34

SU TYPE TWIN CARBURETTORS Bore diameter 38mm 28 2 0

FUEL PUMP

Weight
Needle Float needle valve Jet need Ie Suction spring Float level Fuel pressure 024

kg

6 16 Ib B 0 08 In t M 61 N023

Delivery Delivery Type

pressure amount

018

024kg
1000

sqcm
c c

256
at

341psl

Diaphragm

1000 rpm pump driven from camshaft

Imln

mm

23f 1

mm

kg

sq

cm

341 pSI

Trouble Shooting
SYMPTOMS PROBABLE CAUSE ACTION TO BE TAKEN

CARBURETOR

Improper seating or damaged needle valve or seat Incorrect float level


Fuel pump has
excessive

float

Check and replace parts

as

necessary

Adjust float level


Check fuel pump
I

Flooding
ExceSSIve fuel consumption

pressure

Float level too hIgh Loose plug or Jet DefectIve gasket Fuel leaks at pipes or connectIons Choke valves operates Improperly Obstructed air bleed Main Jet obstructed I ncorrect throttle opening Slow running adjustment Incorrect Slow running fuel Jet blocked I ncorrect float level DefectIve accelerator pump Float level too low Incorrect throttle opening Defective accelerator linkage Blocked pump Jet Lean mIxture

Adjust float level

TIghten
Replace gaskets
Trace leak and rectIfy Check choke valve Check and clear

Stalling

Clean

main

Jet

Adjust throttle Adjust slow running


Clean Jet Adjust float level Overhaul pump Adjust float level

Poor acceleratIon

Adjust throttle Adjust accelerator linkage


Clean pump Jet Clean and adjust carburetor Clean carburetor Clean
or

SpItting

Dirty carburetor
fuel pIpes Manifold draws secondary

Clogged

air

TIghten

or

replace pIpes replace gasket

InsuffiCient fuel supply

Clogged carburetor Clogged fuel pIpe


Dirty fuel
Air
In fuel system DefectIve fuel pump Clogged fuel filter

Dismantle and clean carburetor Clean fuel pipe Clean fuel tank Check connections and tighten Repair or replace fuel pump Clean
e or

replace fIlter

FUEL PUMP Loss of fuel delivery

Slotted body screws loo DIaphragm cracked

Loose fuel pipe connections DefectIve valves Cracked fuel pipes Loose pump mounting Worn or defectIve rocker arm Broken rocker
arm

NOISY pump

spring

Tighten mounting bolts Replace rocker arm Replace spring

35

I nter

O C 1

J
0
o 0
c

r
II
o
starter

of the Fog E 28 Exploded v left and the throttle lever roght

lever

tl

Fog E 33 Adjustment of thefloat level


7 2 Floatlever Bend hrre
to

adjust

Jht ht1l

FI90E 30 The throttle valve IKlJUltlng screw

Fig E 34 Adjustment of the startIng


Interlock opening FanIdle 2
4 5 lever pl m Imk rod

Fig E 35 Checkong the hydraulIC damper 001

Fog E

32

The

IKIJustment of the In1erconnec

tlng shaft

Connecting
Connecting

Connecting
St1Irter
Th

lever Jve ttler

36

Clutch
Chttch dnven

plate

DESCRIPTION
coil spring type clutch st fitted In the case of the diaphragm type clutch the clutch cover and the pressure plate are combined by nine spring setting bolts The diaphragm has nine release fingers which apply pressure to the pressure plate to hold the latter In constant contact With the Either
a

diaphragm type

or

out run between the centres Check the clutch driven plate for of a lathe and replace or straighten the plate If the indicated value exceeds 05 mm 002 In Fig F 8 at a distance of 95

from the centre of the plate If the rivet heads are In below the clutch faCings or there IS abnormal wear or rivets m sslng replace the driven plate or the
mm In

3 74

less then 03 mm 0012 clutch factogs

clutch driven plate and thereby With the flywheel The Call sprlng type clutch consists of the clutch cover and the pressure plate combined by nine pressure springs Three release levers retained by eye bolts and nuts serve to release the clutch mechanism

Check the splines In the clutch driven plate hub for rotational backlash by plaCing the plate on the gearbox clutch shaft and rocking It to and fro If It IS felt that the clearance exceeds 0 4 0016 to replace the complete plate It IS also pOSSible to replace the hub only but thiS IS a Job for the more skilled person and should only be carned out If the necessary
mm

CLUTCH Remove the gearbox When a diaphragm


as

Removal
In

deSCribed
IS

section Insert

GEARBOX

eqUIpment

IS

available

clutch

fitted

speCial

tool

ST49090000 clutch aligning tool or a spare clutch shaft Into the splines of the driven plate In order to support the clutch Remove the
SIX

diagonal

manner

clutch cover bolts by loosening and 11ft off the clutch cover

gradually

If the clutch factogs are SOiled With 011 or grease clean off With SUitable solvent and dress up With a wore brush If pOSSible If the OIling up IS exceSSive the clutch factogs or the complete
a

In a

plate

must be

renewed Pressure plate

I n the case of the COIl spring type Insert SUitable hooks under the release levers to restrain the clutch spring tension and remove the clutch cover bolts as descrobed above for the

diaphragm type clutch

such as dents and Check the pressure plate for damage scratches and lall smooth If necessary Remove the mtolmum of metal necessary to restore the surface UStog a surface plate check that the pressure plate IS not distorted To do th s place the pressure plate on to the surface plate press down the plate and Insert feeler gauges to determine the gallS between the pressure plate and the surface plate If thiS exceeds 0 1 mm 0004 In I repaor or replace pressure plate The pressure plate
can can

CLUTCH

Dismantling

The only dismantling recommended IS the Diaphragm clutch replacement of the clutch cover If the clutch IS damaged to a further extent replace the complete assembly Cod spring clutch A clutch assembly tool Similar as Illustrated In Fig F 3 should be used to dismantle the clutch The parts Illustrated are 1 Base plate 2 Centre SpigOt 3 Distance pieces 4 Height gauge 5 Operating lever 6 Securong bolts The speCial Datsun Tool has the number ST47990000 Included With thiS tool IS a chart giVing the parts to be used for every

be skimmed off but the be removed


IS

maximum In

amount

of metal that

1 0

mm

0004 D

Clutch spring

aphragm

clutch

particular type of clutch


In order to dismantle the clutch place the distance spacers on the base plate and arrange the clutch cover so on the base plate that the
cover

With the diaphragm sprong assembled to the pressure plate Inspect the assembly height and the sprong load To do thiS place distance pieces of 78 mm 0307 to height on to the base plate and bolt down the clutch cover Measure the height The release B In Fig F 9 at a diameter of 44 mm 1 732 In

fingers should be between 43 45 mm 1 693 1 772 the base plate If thiS IS not the case replace the sprong
With
a

In

from

holes COinCide With the threaded holes


cover

In

the base

plate Bolt down the

to

the plate

Fig

F 10

plate placed on the clutch press down the clutch by 78 mm 0307 to or until the clutch droven

plate hub
Mark clutch cover the pressure plate lugs and the release levers Remove the restraining hooks previously pushed under the ends of the clutch release levers and unscrew the three nuts from the

IS flush With the edge of the clutch cover mounting face when the applied load should be 350 kg 770 Ibs If less replace the diaphragm spring Do not press the clutch spring down by more than 9 mm 035 In as the spring might break

eyebolts Slowly release the pressure on the clutch COil springs by unscrewing the cover bolts gradually In a diagonal pattern
Lift off the clutch the pressure
cover

Clutch spnngs

Cot spong clutch

spring caps springs spring seats and

plate
CLUTCH INSPECTION

If the load on the assembled clutch IS reduced by more then 15 or the free length of the Call springs has altered by more or the deflection between A and B than 1 5 mm 006 In
In In

Fig
It

F 11

IS more

than

mm

becomes necessary to

replace

per 100 mm 02 In per 394 the clutch springs as a set

Clean all parts With the exception of the clutch release bearing k the indiVidual parts as and the clutch driven plate and che follows

Release

beanng
wear IS exceSSive or a

Replace the release bearing If the


much

play

or

there

IS

roughness

causing too step formed or If the

37

inter eM

f@ CE p

11

Fog F 1
clutch
1

Exploded

v ew

of the doaphragm sprong

Clutch

driven plBte
cover

BNI7ngslllflW bNrmg

2 Clutrh 4 5

Pressure pla Clutch ICunng

bolt

se Ies 9 Clutch 10 Rtlf8tnmg dip 11 Dust cover

Spring Wil3htlr
ner

12
13

Return
llWB Wlthdf

6 Clutch WlthdrawW lever


7 R spnng

nng 11IWIt

pusher

14 Locknut

11

II

Fog F 2
clutch

Exploded

of

the

cod sprong

tlJ l
OIA 257

CIlrtch drltIon 2 Outrh y b 3 Clutch CD c Clutch PlWSUfe pine


5 7

13 ng rpnng Roroln 14 Bolt If 15 Spring m I 16


IT mmr R spring

Eyebolt

6 EYlIlxJ1t pwot pm
Pnmu rlng q 8 Spnng cop lwet 9 R 10 R

Locknut 12 Release IftltJT wpport

18 Boaring re 9 Clutch 1 lwBrlng 2Q Rfltammg rpnng clIp 21 Oust COIffll U Return IPrlng 3 Locknut

F4

Wthdrwwallwer

pulh

mm

DIA 240 mm

FIg F 3 Specull toolset for dutch overhaul

1J
IA 216 DIA

J m
nun

235mm

D Fig F 4 dmphragm clutch

men

diamsJam

for

the

38

clutch cover to inside diameter clearance IS more then 0 5 mm 0 2 In If excessive grease has leaked from the beanng It should be replaced To remove the beanng use a conventional arm two puller as shown In Fig F 12 be pressed on uSing a force of 400 kg 880 When pressing on the bearing for the diaphragm spnng In race as shown type excert the pressure on the outer F 13 In the case of the coil spnng type the pressure must Fig be excerted on the Inner race as In Flg F 14 After assembly The Ibs

to rubber Clean all parts and check for wear With special note bush and lever Replace parts as pedal parts return spring clutch pedal IS a reversal of installation of the The necessary

the removal

procedure

bearing should

CLUTCH PEDAL

Adjustment

check the bearing for smooth rotation

With the pedal stop bracket free adjust the pedal height to 183 mm 7 205 In for R H D models and 208 mm 8 189 In for H 0 models L by adjusting the length of the master cylinder push rod Then tightening the pedal stop bracket obtain a pedal for R H D models or 207 mm of 182 mm 7 165 In

height

CLUTCH

Assembly Call spring type

8 150

In

for L H 0 models and lock the stop bracket

Press the pin Into the eyebolt and through the pressure plate lug Place three distance pieces on the surface of the base plate and arrange pressure plate pressure spnngs and retainers on the plate Set the retracting springs on to the cover and fit the release levers through the springs Place the clutch cover over the pressure springs
are

assist spnng push rod to 203 mm for for R H D models and 183 mm 7205 In fitted models the rod only L H 0 by rotating push adjuster With COil Spring type clutch

AdjUst the length of the


7992
In

tighten

the

plate and the springs observing that the pressure not dislodged and not hable to distortion Then In a cover bolts gradually diagonal pattern to

CLUTCH MASTER CYLINDER

Removal

compress the pressure spnngs Place the release levers over the eyebolts and screw on the nuts after nuts Lock the eyebolt adjustment secunng deSCribed below Push retaining hooks under the release levers and remove the clutch assembly from the base plate slackening the bolts In a diagonal pattern to avOid distortion

Remove the push rod cleVIS Pin disconnect the clutch hose and dram the flUid Remove the cyhnder secunng bolts and hft out the

cyhnder
CLUTCH MASTER CYLINDER Dlsmanthng

Fig Empty
cover

F 18

CLUTCH

Adjustment

Call spring type

the flUid from the reservoir pull back the rubber dust and remove the clrchp Withdraw the push rod together With the retaining nng Unscrew the piston stop screw and The piston can be remove the complete piston assembly dismantled by lifting the spnng seat over the piston shoulder Clean all parts In brake flUid Any damaged or abnormally worn clearance parts should be replaced The maximum permissible between piston and cyhnder must not exceed 0 13 mm 0005 m and as a matter of pohcy the piston cup should be replaced every time them If the piston sprmg
or

USing the height gauge on the centre pillar loosen or tighten the eyebolt nuts so that the tops of the release levers are JUst touching the tip of the gauge Fig F 15 When all three levers In the are correctly adjusted remove the centre pillar and screw F Ig F 16 actuating lever Operate the clutch mechanism
the release lever setting as near to the edge as poSSible If the deViation IS more than 04 mm 0016 In re adJust the levers as necessary Finally secure the eyebolt nuts by peening over the matenal several times and
re check

valve spnng

IS

weak

replace

CLUTCH MASTER CYLINDER ThiS

Assembly

CLUTCH With the

Installation

long chamfered end of the clutch dnven plate sphnes gearbox place the clutch on to the flywheel Use a the spare clutch shaft ahgn the clutch dnven plate by Inserting of the and Into the the dnven pilot shaft through beanng plate flywheel crankshaft Turn the clutch cover In order to bnng In facing
the hne the holes for the clutch bolts In the cover With the threaded holes In the flywheel and tighten the bolts In a diagonal manner 174 188 Ib ft 26 kgm to a torque of 24 Remove the dummy shaft Do not forget to remove the clutch spring restnllmng hooks from under the release leversl Fit the release bearing and the bell hOUSing

IS a reversal of the dlsmanthng procedure All moving parts should be lubncated With brake flUid The piston cup should be soaked In brake flUid pnor to assembly

CLUTCH MASTER CYLINDER

Installation

The installation of the master cyhnder IS a reversal of the removal procedure Take care that the threads of the clutch hose are not damaged Check the pedal height and adjUst If necessary
as

descnbed

earher

on

Finally

bleed the clutch

gradually

hydraulic system
CLUTCH SLAVE CYLINDER
Removal

Fig

F 19

CLUTCH PEDAL

Removal 8IId Installation

Disconnect the flUid line from the slave cylinder and the push rod from the clutch withdrawal lever Remove the two cylinder

Remove the cleviS pin from the end of the push rod and disconnect the push rod end Remove the return spnng the push rod and the push rod adjuster If fitted Remove the pedal lever securing bolt loosen the handbrake bracket secUring bolts and 11ft out the pedal

mounting bolts and hft

outthe

cyhnder Dismantling

CLUTCH SLAVE CYLINDER

After removal of the rubber dust cover and the clrclip all parts of the slave cyhnder can be eaSily removed Check all parts for

39

mt e refJJ cQ P f

dla

255

mm

3 3

Fill F 5 Y

of the

hragrn clutch

Fill F 6 clutch

1Iel1SlOn O

dlllgralll for the coil

ng

Fig F 7

W YIf

of the cod spring clutch F 8


out run

Fig

Checking the clutch

dren

plate

to

the diaphragm

Fig F 9 Checking the release finger height of dutch

Checking the load of the diaphragm

Inspecting the Fill F 11 distOrtIOn

dutch spnngs for

F U F 12 Removal of the clutch

tel

bearIng

Fill F 13
1ng bl

InstallatIOn of the dutch diaphragm dutch

F 14 InstaJlatlOn of the dutch bearing coillPrlng dutch

FIlI

40

mter

Q1 O

@ ce l

12L
Fill F 15 AdJuSbng the release I heIght

FIg F 16

ActuatIng the clutch

to

settle

mechanism

i23

ghtemng torque

35

to

4 0

kg

rn

19

13

15 16

14

CiI

11 JI17J
SectIOn

FIg F 18 cyhnder
2

through the clutch master

Cylmder body
R turn r cup

AdJust

by adjust
pedal pedal

screw

of

master

cyt

1 Piston 4 5 ondaTy 5 PISton


6 1 8

LubricatIon Clutch Clutch full troke 140 4


1m mm

cup t Valve Va stem Valve mng q

free stroke 2S

9 Sprmg 28t 10 Valin st em fop t 7 Stop pMctt 12 Gasket WIIwr 13 Push rod 14 Pudl rod C 15 Nut 16 Locknut

Fill F 17 The clutch pedal adjustment

VIS

17 P stOn fop 18 Abutment wahar 19 Rubber boot 20 Flutd rtnelVOlf 21 22 23

Clip
IINVOlr Rft

ClIP

Cap

INJI

Fill F
Fog F 19 cylinder Exploded
of

20

withdrawal

the clutch slave

lever

41

wear

especially

the piston cup and

replace

If worn or damaged

NOTE

The correct

adjustment

of the clearance is essential as

CLUTCH SLAVE CYLINDER The


to

Aaembly 1nI1nsta11atJon

assembly of the slave cylinder IS carned out in reverse order All moving parts should be the dismantling procedure lubricated With brake flu Id and the piston cup soaked In brake
flUid pnor to assembly

inSUffiCient free travel between release bearing and clutch can failure to cause the clutch to slip Excessive free travel can cause the clutch It IS also Important that the clutch dnven disengage plate IS not worn by more than 20 mm 008 In In thickness
from the
new

dimenSion of 7 8

mm

0 307

In

CLUTCH SYSTEM

Bleeding

The installation IS a reversal of the removal procedure Bleed the hydraulic clutch system and adjUst the free play of the clutch withdrawal lever as descnbed below

Remove the rubber dust cap from the bleeder screw on the slalle cylinder and attach a clear plastiC bleeder hose to the screw a Jar partially filled Immersing the free end of the hose Into With clean brake flUid Open the bleeder screw by 3 4 turn Fill the flUid
reservoir

CLUTCH WITHDRAWAL LEVER Fig F 20 Loosen

With

Adjustment

the recommended

flUid

and

pump

clutch pedal slowly indicated by a solid flow of has left the system Into the Jar tighten the bleeder screw on a downstroke of the pedal Remove the bleeder hose replace the dust cap and replenish the flUid reservOir When all brake
air

the locknut screw the push rod fully home whilst turning the adjustment nut and then unscrew by 1 3 4 turns to 2 3 mm 0079 009 In on the give an end play of 20 Withdrawal lever giVing a clearance of about 1 3 mm 0 051 In bet
en

flUid

te t

release levers

the release bearing and the diaphragm spnng fingers depending which type of clutch IS fitted

or

Technical Data
Clutch pressu Free length
re

springs 52 3 292 5
mm mm mm

Clutch release levers 2 059


In

Fitted length load Side distortion spring force Clutch driven

44

per 100

mm

1 15 In 97 Ib 02 In per 3 94 In

kg

Clearance between release bearing and 1 2 1 4 release levers

mm

0047

0055

In

PermiSSible deterioration of 15

Height diaphragm flywheel Height between release levers and 505t flywheel
Clutch Pedal

between

spnng and 1 44

mm

1 732 to 039 002 1988

In

005mm

In

plate
200 mm 7 87 In 13Omm 5 121n 35vm 0 141n 362 sq
em

Outer diameter Inner diameter Thickness of facings Total fnctlon area Thickness of clutch Free

pedal height In

rest

poSition

182

mm

7 17

In

RHO

56 11 sq

In

plate
86 90 765 795
mm mm

Free stroke of Pedal effort

pedal

207 mm 8 15 In LHD 25 mm 0 984 In 15 kg 33lb

Compressed

03386 03012

03543 03130

In In

Number of torsion springs PermiSSible mln depth from nvet head to facing PermiSSible
out run

6 03

Mastwr

cylinder
1587
mm

Diameter
mm

5 8

In In

0012

In

Max piston clearance

o 13mm 0005

of clutch 05
on mm

plate
PermiSSible free play

020 In
0016 In

splines

04 mm

Pressure plate Perm ISSlble refaclng

1 0 mm

0 394

In

42

Trouble
Troubles Possible InsuffIcient Improper
lever end all
or causes

Shooting
RemedIes free

Shppmg

clutch pedal
of

travel

Adjust pedal free travel

adjustment play
on

withdrawal

Adjust

end

play

grease

lmmgs
burned sprmg
or

Remove

cause

of lcakage

and

re

ptal c Immg
DISC

if necessary

tmmg

worn or

RepLace Imlngs and pres Replace sprmgs

Clutch
sure 1

dIaphragm plate

springs weak
or

broken
worn

Pressure InsuffICIent clutch

flywheel

Reface

or

replace

Excessive free travel of Exce


lve

dutch pedal

Adjust correctly

release

play

of WIthdrawal lever

Adjust correctly
Replace Pllot bCarlllg

PIlot bushmg stH kmg Splme of clutch diSC hub Clutch dIsc arped
orn

Replacl dutch diSC assembly


Sct Ie vcl of clutch dISc
or

replace

dutch diSC

aSbcmbly

LcakIng

from

master

cylmdel

cup cup

Replace cyLinder cup Replace cup Bleed out completely

Leakmg from operatmg cylmder


Air lme

mflLtratIons

Into

the

hydrauhc

Roughncsb

on

Immgs

Rub

hmngs

WIth

metal brush

or re

place them
Low flmd level
In

011

reserVOIr or

Top up With brake flUid


Install
new

Grabbmg

a l

on

facmg

or

burn cd

glazed

diSc

assembly

faCIngs
Loose dISC

lmmgs

due

to poor

rIvet

Rcplat c

defective rIvets

or

replace

tlghteness
Pressure
or

lmmgs
plate
or

flywheel

arped

Replace

them

cracked

Improper lever

adjustment

of

release

Adjust release

er le

Loose engme Wear


sian or

mountmgs
of clutch dIbe tor

Tighten Replace

or

replace mountmgs

damage

dISC

assembly

sprmg

NOISY

Worn

release bearmg

Replace bearmg Replace Replace


dISC diSC

Cracked clutch dlSC plate


Wear
sian or

assembly assembly

damage

of

clutch diSC tor

sprlng

Loose clutch diSC hub

Replace

diSC

assembly

43

inter

ilj

p @

JG 1 FI

Removar of the propeller shaft

Daconnectll19 the

remote

control

Fig G 6 RelMVill of the extensIOn housmg

J
I

l
I

Cw
I

I 1
I
c

9
0

fIr
f

i FI9 G 7 Removal of the crosHhafts For anno1atlons see text

gear

JG FI

10

iifih8

iine idler gear

F19 G 12
trail

Withdrawal of the mall1Shaft gear

44

Gea rbox
sPEED THREE
GEARBOX Removal Check the gearbox casmg for cracks and indentations Where the surface IS machmed check for burrs and remove where Jack up the vehicle and support on suitable stands Disconnect the handbrake cable at the equahzer bracket loosen two exhaust pipe centre clips and turn the centre section of the Disconnect the exhaust to the left Fig G 1

pOSSible
Clean all bearings and blow dry With compressed air Without 011 spmnmg the bearings Lubricate the bear lOgs With light Check for wear SCOring or plttmg Check the needle roller bearings for wear As wear on needle rollers IS hard to ascertam them after a substantial mileage has been driven Check

assembly

at the rear end by removmg the flange bolts from the rear axle drive flange and wlthdrawmg the shaft to the rear Seal off the gearbox extension housing to prevent loss of 011 Disconnect the speedometer drive cable Fig G 2

propeller shaft

replace

shafts for burrs Check

or scores

Dlsconnectthe lower shift rods from the shift levers and remove F Ig G 3 the crossshaft assembly from the gearbox casmg Remove the clutch slave cylinder Fig G 4 Support the engme not under the dram on a Jack placing the Jack under the sump plug With a wooden block between the Jack and the sump and remove the bolts securrng the rear engine mounting to the

all gearwheel teeth and other machined parts of the the gearwheels for scoring scuffing and plttmg Check that on the shaft sphnes With minimum hubs shde synchronizer
out run Check the ma In shaft for usmg V blocks as out run shown 10 Fig G 18 Replace the malnshaft If the exceeds 015 mm 0006 10

clearance

Support the gearbox on a Jack and remove the crossmember Now lower the Jack under the engme to tilt the engine 10 a rearward direction and remove the starter motor and the gearbox to engme mountmg bolts Lower the Jack and
crossmember
remove

the gearbox

10 a

rearward direction

Check the synchronizer rings for wear and replace If necessary Place the synchrOnizer rmg on the cone of the respective gearwheel and push the two parts together Check that the gap The between the gear teeth IS greater than 0 8 mm 00315 10 0063 In See 1 6 mm 0047 correct value IS between 1 2

THREE Dram the

SPEED GEARBOX

Dlsmanthng

diagram Fig
Place the

G 19 selector rods
on a

011 Remove the dust cover release the sprrng and remove the clutch Withdrawal lever complete Remove the bottom cover With release bear 109 Fig G 5 speedometer driven pmlOn assembly and the rear extension

gearbox

flat

surface

to

check

for

retainer

straightness Check locking pms and mterlocklng balls for damage or wear The standard clearance between the selector
forks and the operatmg sleeve groove 0012 n Check 011 seals for have been checked
wear or IS

0 15

0 30

mm

0 006

hOUSing

Fig
Item

G 6 5

Remove and
remove

the

cross

shaft

retaining rings

the operatmg lever lock pms Usmg a drift knock the pins out of poSition and remove both cross shafts Fig G 8

Fig

G 7

the nuts

holding

damage Replace any 0 rmgs that


G 20 shows the 011 seals
to

removed

Fig

be

front cover and Withdraw the countershaft Lift out the countershaft gear cluster together With the needle roller bearings and spacers Fig G 9 Remove the reverse Idler gear shaft lock bolt and remove the shaft followed Remove

the

Iayshaft

THREE SPEED GEARBOX Press the

Assembly

bearing

on

to

the

maIO

the Idler gear Fig G 10 Drive out the pms holding the selector forks to the selector rods unscrew the Interlocking plug and remove the spring and the detent ball as shown 10 Fig G 11

by

fit the spacer Select a clrchp so the bearmg and the clrchp There are 7 sizes of clrchps ranging 10 size from 1 52 mm 0 06 10 to 1 89 mm 0 075 In

drive shaft clutch shaft and that there IS no play between

remove the selector rod for frrst reverse 2nd 3rd speed and hft out the two selector forks

Then

speed

and

Withdraw the maIO shaft assembly from the rear and the drive shaft assembly from the front of the gearbox case Fig G 12 To dismantle the mamshaft remove the clrchp from and G 13 the front of

assembling the synchronizer untl take care that the msert pressure springs are of different size for the 1st reverse and 2nd 3rd speed synchronizers The spring for the reverse l st speed Unit has three Call springs whereas the other uses two
When

expand 109 type springs


To assemble the reverse 1st

synchronizer second speed the speedometer drive wonn and remove the worm gear FIg G 17 Press out the together With the ball and spacer mamshaft bearing under a press Holdmg the shaft With the
ma

mamshaft and remove the fig G 14 Unit for the 2nd and 3rd speed Fig G 15 and the gearwheel Fig G 16 Remove the clrchp securing

the

speed synchronizer Unit msert the clrclips mto the hub as shown 10 Fig G 22 followed by the reflttmg of the shdlng inserts and synchronizer Springs F It the hub complete With Inserts IOta the operatmg sleeve Fig G 23 and G 24 slidmg
msert

mshaft

releaSing gearwheel

reverse gear tap the shaft With a piece of wood so the reverse gear assembly together With the 1 st speed

To assemble the 2nd3rd speed synchronizer fit together With hub and the operating sleeve ensuring that the sleeve shdes

freely
ring THREE SPEED GEARBOX

on

on

the hnes Fit the three Shifting each side of the hub Frg G 25

keys and

frt

SPring

InsplKltlon
as

Thoroughly clean all parts and mspect repairing any defective parts

follows

replacmg

or

To assemble the mamshaft start from the front end of the shaft and slide the 2nd speed gearwheel on to the shaft With the cone facmg forward Fit the correspondmg baulk ring Place the 2nd 3rd speed synchronizer assembly on the front end of the 0 20 haft and IR With a Clrollp giving an end play of 0 6 45

y
i
Removal of the maIn drove shaft FIg G 13 clutch shaft

Fig G 14

Removal of the securIng e the2nd and 3 speed synchronoser hub

hp for Fig G 15 Removal of the 2nd and sychronlser


3

speed

1f
r

I II

f
FIg G 16 Removal of the 2nd speed gearw

Ii

VJ
FIg G 19
wear

lV
rIngs for
FRONT COVER

CD
REAR EXTENSION
on

CheckIng the synchron

CROSS SHAFT

Fog G 20 The oil seals ulOd

the geaTbox

F gG 22
e

ns1allatoon of the

In

Fog G

23

Insortlng the shtftll1ll keys

ehp

Fog G 24 FittIng the synchronaer hub operating sleeve

on

to the

46

mm

0002

0009

In

Clrcllps
0071m

are

available

5 Slles from FOUR SPEED GEARBOX Removal and Installation


I

160

180mm

0063

Fit the 1 st speed gear and baulk ring on the rear of the shaft wIth the COnical end facmg the rear F It the first speed

synchronlser and the

reverse

gear assembly

on

the shaft

Follow the mstructlons for the three speed gearbox except that s a floor mounted gearlever whIch the four speed gearbox should be removed at the control lever bracket FOUR SPEED GEARBOX NOTE There
In

Fit the spacer and press the mamshaft bearing and retamer on the shaft FIt spacer ball and speedometer drive worm uSing a S JItable Clrcllp to secure the drive worm With an end float of 0009 m 005 022 mm 0 002 Clrcllps are avaIlable m 8
sizes

DIsmantling
used
m

gearbox
deSCribed

Borg

from 1 30

1 70

mm

0051

0067

thickness
m

two types of Warner and Servo Three speed gearbox


are

synchromesh

thiS
IS

The Borg Warner type

Check the end float of the whIch should be as follows 1 st speed gearwheel 2nd speed gearwheel Fit the
mam

gearwheels

as

shown

Fig G 26

005 o 1

022 022

mm mm

0002 0004

0009 0009

m m

Dram the gearbox 011 Remove the dust cover the retainer spring Withdrawal lever and clutch release bearing ove the Rem cleVIS pin holdmg the strlkmg rod to the control lever F Ig G 311 speedometer driven p In Ion assembly rear extension housmg dlsengagmg strlkmg rod from the selector rod gates
see

Fig G 32 and

unscrew the

top and bottom

covers

and the mamshaft drive gear clutch shaft assembly mto the gearbox casmg Fit selector rods and selector forks as follows Turn the casmg so that the detent ball hole IS uppermost Fit the spring and the ball m the bottom hole Fig G 27 Hold the ball With a dummy shaft and fit the 1 st reverse selector fork

Unscrew the detent ball plugs and remove the springs and detent balls Drive out the selector fork to rod retalnmg pinS and remove the selector rods and forks Engage the second and fourth gear by pushing the operatmg sleeve of the correspon dmg synchronizer unit to the given gear pOSItions and slacken the main shaft nut Remove the countershaft and the gear cluster together With the needle roller bearings and the spacers Remove the reverse gear clrcllp and remove the reverse Idler gears and the shaft
two

pushmg the dummy shaft out F It the Interlocking plunger 2nd 3rd speed selector fork and rod and Insert the ball and the spring Screw down the mterlockmg plug coatmg the thread With sealing compound Secure the selector forks to the
and the rod rods With the retalnmg pins Fit the
reverse

Fig
secure

G 33

Idler gear and shaft and


an are m

plate F It the countergear cluster and the shaft usmg


thrust washer to obtarn 00047
mm In

With lock bolt and a SUitable 0 12


mm

and

Remove the four bolts holding the malnshaft bearing retamer remove the retamer Fig G 341 Withdraw the mamshaft
as

end float of 0 04 available


rn

00016 403

assembly
shaft

shown

In

Fig G 35 and the

main

drive shaft

clutch

0 151

Washers 0159 In

sizes

from 383

thickness dismantle the malnshaft Fig G 36 release the 3rd 4th synchrOnizer Unit clrcllp and pull off the hub complete With the operating sleeve Remove the third speed gearwheel and the needle roller bearing Remove the mam shaft nut and the locking plate and the speedometer drive worm With the retamlng ball Then WIthdraw the mamshaft reverse gearwheel and the hub and press off the ma Inshaft bearing retainer and the bearing To the thrust washer and the first speed gearwheel With the needle roller bearing taking care not to loose the small thrust washer locating ball Slide off the first speed Next
remove

Fit the cross shafts 11 Fig G 7 thrust washers 2 and operatmg levers 3 Secure cross shafts With retammg rings 5 and lock the operatmg levers to the shafts With the pms 4
extension casmg to the gearbox case and tIghten the 30 kgm 16 22 Ib ft Fit the torque of 22 speedometer driven piniOn set bolt and lockrng plate Check
rear a

Fit the

bolts to

the gear backlash o 13 mm 0 003

as

shown

rn

Fig

G 28 which should be 008


cover

for all gears FIt the front and tighten the bolts to 1 1 1 7 kgm 8 0 12 2 Ib ft the clutch Withdrawal and release bearmg and the bottom
In

0 005

Refit
cover

together

tlghtenmg
123 Ib ft

the bolts to

torque

readmg

of 1 1

1 7

kgm

80

gearwheel bush

Finally

remove

the second

speed gearwheel

together
THREE SPEED GEARBOX Installation reversal of the removal Follow

With the needle roller bearing

FOUR SPEED GEARBOX the


mstructlons

Inspection
three speed given

The mstallatlon of the gearbox IS procedure Note the follOWing pomts Fill the

for

the

gearbox
m

In

accordance

With

the

speCifications

section

TECHNICAL DATA

gearbox
IS

capacity

With the recommended MP 90 011 The flllmg 1 7 IItres 045 U S gall 0 37 Imp gall AdjUst the

clutch slave

cylinder push
mm

rod to obtain

withdrawal lever free

FOUR SPEED GEARBOX

Assembly

play of

2 2

0087

The assembly IS carried out m Similar manner as deSCribed for the three speed gearbox except for the followmg pomts When

mstalllng

the

mam

drive shaft

clutch shaft
are m

select

SUitable clrcllp to eliminate any end float Clrcllps m 5 Slles from 1 52 1 77 mm 006 007 m

available

thickness

47

inter

M @

1i

FI9

2S Flttlll9 the SPring rongs FI9 G 26 Chedung the end float of the gea eels

FI9 G 28 backla

gear

FI9

G 29

and release

Greasing beanng

POlllts for

withdrawal lever

J f
z

J
I

Fog

G 31

VISW

of the gearchange contrOl

arm

F G

33 Removal of the

ne

ler geara

Po

pOlello t
I
FigG 38 Exploded
tram
v

of the mamshaft goer

FIg

34

Fog

35

a1 of the

r rete

malllshaft

ly

48

ImmIIII
4t1l 3rd Rod

Spring Plug
Plunger

Plunger
FIg n Dlllnm of tile G
Idler FOr

FI9 G 38 Assembly of tile selector fol1 s

FIg G 39 SectIOn through tile gearbox


the Interlodung system

to

show

ll G 40 Removal of the steenng wheel F

FIg G 42
bracket

Remoyal

of

the

upper

support

Gnxw naltnd wttmg

01

G 45 Adjustment for neutral setting FIQ


FIQ G 46 View of the selectar

49

The Borg Warner type IS dealt with under the three speed gearbox The instructions therefore apply only to the Servo type synchronIzers The assembly procedure

Synchronizer assembly

and take off the upper support bracket by releaSing the locating bolt and the screw The control rod Insert With bush and return spring
IS now

free to

remove

for all synchronizers but the anchor block thrust block and one brake band of the 1st speed synchronizer dIffer from those of the 2nd 3rd and 4th speed
IS same

the

Remove the clrcllp and gear lever piVOt pin and draw out the gear lever By removing the cotter pin the spring and the plain washer disconnect the shift rods from the gear selector levers

Place gears on flat surface fit the synchronizer ring inside the clutch gear and fIt the thrust block Into positIOn anchor block to each gear and fit the brake bands I nsert a clrcllp Into the groove of each gear When
so

securing the synchronIzer assembly

Fig G 43 Remove the bolts holding the lower support bracket and the clamp and remove the clamp and the gear change lever retainer 2nd 3rd speed selector lever lower support bracket and 1 st and reverse selector lever from the control rod
Withdraw the control rod by removing the cotter pins DIsconnect the gear change rods remove the cross shaft bracket and Withdraw the cross shaft assembly Fig G 44

assembling the malnshaft observe that the end float of the 3rd speed gearwheel should be 005 0 15 mm 0002 0006 In ClrcllPS for adjusting the end float are available In 5 sizes
from 1 40 1 60
mm rear

0055

0063

In

In

thickness

Tighten
65 GEAR CHANGE CONTROL LINKAGE InstallatIon

the locknut at the 79 5 Ib ft To assemble the

end of the malnshaft to 9

11 kgm

reverse Idler gear Fig G 37 place the reverse Idler drive gear 31 14 teeth on the rear end of the Idler shaft 1 with the longest spline and retain with a SUitable Clrcllp 2 Fit the reverse shaft and the gear Into the gearbox casing from the rear with the thrust washer 4 between the gear and the

The installatIOn of the gear change control linkage IS carned out In reverse order to the removal procedure Coat all sliding surfaces With chaSSIS grease prior to assembly

GEAR CHANGE CONTROL LINKAGE

18 teeth 51 and the Idler gear 6 and secure with a SUitable clrcllp 2 The end float of the gear should be 0 1 03 mm 0004 0012 In ThiS can be adjusted by uSing a SUitable clrcllp 2 available In 5 thicknesses between 1 5 mm 0 043 0 06 In 1 1
case

FII the thrust washer

Adjustment

With the linkage assemb led connect change rods With trunnions of the gear change levers Release the adjusting nuts on the shift rods and align the gear change lever With the projection on the head of the lower support bracket F Ig G 45 Check operation of the change levers and lock the adjustment

Adjust
006
In

the countergear end float to 005 015 mm 0002 by uSing thrust washers of SUitable Size which are
In

available
In

5 thicknesses from 2 4

2 6

mm

0 0945

0 102 To
remove

AUTOMATIC TRANSMISSION the gear change control linkage of the automatic follow the removal of the three speed gearbox
as

When

assembling the selector

mechanIsm

Fig G 38

fIt the

transmission

selector forks 1st 2nd 1 and 3rd 4th 2 Into the operating sleeves of the synchronizer Units and Insert the selector fork for the 1 st and 2nd speed 3 Fit an interlocking plunger 4 and the 3rd 4th
IS

linkage

as

for

and including the gear lever

speed

selector

rod

remembering

the

interlocking pin A
mechanism for the

section

through

the selector and

interlocking

given In Fig G 39 Frt an interlocking plunger 6 and assemble the reverse selector fork 8 and the selector fork
same

By removing cotter Pin plain and spring washer disconnect the upper selector rod from the selector lever Remove the speed range pOSition plate the Clrcllp at the lower control rod end and unscrew and remove the lower support bracket Release the locking
screw

gear

9 10

Secure the selector forks to the rods with

the retaining pinS Place

F g G 46 rods and

and remove the selector lever assembly Withdraw the control rod disconnect the selector the
cross

remove

shaft bracket and the

cross

shaft

assembly
a check ball and a spring In each of the holes and screw down the plug to a torque of 1 7 21 kgm 123 15 21b ft after smearing the threads with sealing compound

The

When

fitting the rear extension hOUSing engage the striker rod with the selector rod gates and tIghten the bolts to 2 2 30 16 22 Ib ft FIt the front and bottom covers and kgm tighten the bolts to 1 1 1 7 kgm 18 0 12 3 Ib ft
AUTOMATIC TRANSMISSION

InstallatIOn of the linkage IS a reversal of the removal Set the converter s de lever and the gear lever to the neutral pOSition Fit the upper selector rod to the selector lever and adjust the gear positron plate so that the selector lever stop

procedure

1 0 mm 002 004 In pin to pOSitIon plate clearance IS 0 5 ThiS can be adjusted by turning the selector rod adjusting nut

Finally tighten the

nut

on

each Side of the trunnion

Although
manual
a as

the

automatic transmiSSion

IS

not

covered
IS

In

thiS

Job

inspection and repair far experts the control linkage IS discussed

the maintenance

conSidered

GEAR CHANGE CONTROL LINKAGES Three Remove the

Removal

speed gearbox Steering


switch
In

follOWing
cowl

Items

wheel and

steering

column

indicator

Fig light

G 40 swItch

Fig

G 41 d

Remove the

clrcllp

Fig

G 42 and the washer

50

Technical Data
GENERAL SPECIFICATlor S Gearbox model RSW65L Column F4W63L Floor change Warner 33821 F4C63L Floor change Servo 3 382 1 20131 1312 1 10001 33641 22 27 30 36 39

Gearchange type Synchromesh type


Gear ratios 1 st gear 2nd gear 3rd gear 4th gear Reverse gear Number of teeth mamshaft
on

change

Warner 32631

Borg

Borg

16451 1000 1 33551 19 25 31 34

20131 1 312 1 10001 33641 22 27 30 36 39

Drive gear 3rd speed 2nd speed 1 st speed Reverse speed

Number of teeth countershaft

on

Driven gear 3rd speed 2nd speed 1 st speed Reverse speed

30 24 15 16 16

31 29 21 15 14 18 5
or

31 29 21 15 14 18 5 16

Reverse dler gear

Speedometer

Drive gear Driven gear

5 19

17

16

CLEARANCES AND PLAYS


I

Model Mamshaft end float Max mam shaft end float Cou ntershaft end float Max countershaft end float Reverse Idler gear end float Max Idler gear end float Gearwheel end float 1 st speed gearwheel 2nd speed gearwhee 3rd

R3W6 o 019
mm

F4W63L and F4C63L 0 0008


m

008029 030mm 005 o 20 o 10

mm

0 011 0003 0006 0002

020mm 0008 004 0 12 mm 020 020 o 50 o 05 010 008


mm

0012m
mm In

0005 0002
m

015
mm

0008
mm

040
mm

0008
m

0016

0 008 m 0 30 mm 0 004
m

0012m

0 020

o 50 mm 0 020 0009m 0009m 0005 005 005 005 005 025

0 22 mm 0 002 022 mm 0004 013


mm mm

o 15 mm 0 002 o 15mm 0002 015


mm

0006m 0006m 0006m 0004m

speed gearwheel
0003
m m out n

0002

Gear backlash Max shaft ru

0 10mm 0002
mm

015

0006

0010

51

inter

r1D

p @

FIg H 3 Removal
member

of

FIg H 4 Removal of the SIde drIVe flange

FIg H 5 Removal of dlfferentlallKle cover

t
FIg H 6 Removal of drffarentl8l Clllle Fill H 7 Removal of dlfferentlalllde bearing

FIQG 10 Measunng the clearance between the dJfferentl8l SIde gear and the thnllt washer tapl eel n1rHlut end checkIng the crown ttomL

52

Rear Axle
PROPELLER SHAFT Fig H 1 Release the handbrake Jack up the
the
rear

Removal While of the car and place

DIFFERENTIAL

Dismandlllg
Items

rear end

dismantling check the follOWing

of the vehicle on suitable stands the exhaust

outer section clamps and turn the to the left saloon pre sl lencer only Remove the adjuster nut from the handbrake cable rear adjuster and dlsoonnect the hand left cable Saloon only D soonnect the rear from

Loosen

a suitable mounting stand Special tool ST 37400510 IS available and check the tooth contact pattern uSing a lead OXide at two or three points

Clamp the differentIal In

flange

The backlash between the dnve gear and pmion should be 0 10 20 mm 0 004 0 008 In 0 Also check the out run at the rear of the crown wheel If the backlash or the tooth contact pattern IS found to be out of limit IS 008 mm out run adjustment The 0 003 In The turning torque of the drive pin
on

the rear axle flange and draw the shaft from the gearbox ma Inshaft taking care not to damage the propeller shaft by

accidentally dropping

It

should be 3

15

kgem

PROPELLER SHAFT Clean and

DIsmantling

al components for assembly 10 correct ma rl position Remove four clrcllps from the Journal assembly and Withdraw the needle beanng cap by tapping the yoke With a wooden mallet Clean all partS and check damage has occured The
as

To dismantle the dlfferent al remove the flange clamp bolt and remove the Side flange as shown In Fig H 4 uSing the special tool ST49250000 and a slide hammer or any home made tool Similar
as

shown

In

the Illustration Next

remove

the differential

follows replacing them If

wear or

nght hand Side first as shown In Fig H 5 Mark the beanng camers In order to refit them In their onglnal pOSitIOns The dlfferent al assembly can now be lifted bearing
caps differential from the dIfferentIal
carner

f F Ig H6

spider Journal
In

0006

The standard

spider

seal nngs backlash of the sleeve yoke splu1es to the not exceed 0 5 mm 0002 In

diameter wear should not exceed 0 15 mm size IS 147 mm 0579 In Check the and replace them If necessary The radial

gearbox splines should

Loosen the dnve pinion nut holding the flange With specIal tool or by other SUItable means and pull off the flange Press the drive pinIOn out of the differential carner together With the front and rear beanng Inner races spacers and shims

ST47340000

Place

With the shaft mounted between centres check the runout of the shaft which should not exceed 06 mm 0023 In The shaft can only be straightened With a hydraulic press however
It

SUitable press plate between drive pinIon head and rear and press out the pinion shaft If the correct tooth pattern has been obtained dunng the d smantllng check and pre crown wheel dnve piniOn carner rear beanng shims etc are
a

bearing

not

betng replaced the


the outer
races

recommended that the shaft be replaced Also check that the dynamiC balance does not exceed 15 gnn em 0278 oz 10 at 4000 rpm
IS

remove

drive them out With drift

Inner races are not to be removed o T of the front and rear pinion bearings special tool ST49290000 or any SUitable

PROPELLER SHAFT
Reverse the removal and

Assembly

and Installation

dismantling

To dismantle the differential cage remove the right hand bearing cone as shown In Fig H 7 uSing a SUitable puller Flatten the lock straps and remove the hYPOJd crown wheel slackening the mounting bolts In a diagonal pattern Remove the left hand beanng cone In the same manner as for the other Side Take care not to mile left hand and right hand pans Punch out the differential shaft secUring pin from the crown wheel SIde USing a SUitable drift Great care should be taken when carrying out thiS operation as the pin is caulked Into the hole In the differential cage Remove the differential gears and thrust washers keeping separated front rear left hand and nght hand parts

procedure

fellowing points
Grease the needle
rollers WIth the into the

noting the

wheel bearing grease before placing bearu19 race Lubncate all splines With gear 011 AdjUst Journal radial end float to less than 0 02 mm 0 0008 in with a suitable circllp which are available In 7 SIZes between 2 00 and 2 12 mm 0 079 and 0 0835 In In thickness Check that the marl on the front sleeve aligns With the marl on the
rear

flange yoke

Replacmg of oil
DIFFERENTIAL Saloon Removal Front 011 seal

seals wilh dIfferential titted

Remove the handbrake rear cable propeller and dnve shafts With differential suPPorted on a Jack remove the nuts securing the differential mounting member cross and remove the bolts

holding

the differential to the suspension member Remove the differential and the jack backwards and suppon the SUspension member to avoid straining the parts The removal of the parts to be remoyed Is shown 10 Fig H 2 and H 3

Drain the OIl Jack up and suppan the rear end of the car and remove the propeller shaft from the differential flange and dISCOnnect the hand left rear cable for the handbrake Slacken and remove the dnve pinion nuts holding the dnve flange In suitable manner and remove the flange and the oil seal retainer With a conventional ann two puller as shown In Flg H 8 Remove the 011 seal from the retainer

Replace the

outer diameter or

oil seal into the retainer USing a drift of SUitable special tool ST 49320000 Fill the od seal lips

63

inte r

clJ e

C0LID

6
90H12 F 90H F
I

11

Secbon through the drive pinion


bHn1Id UltJ f

prHoad

Pinion

2 Pmlon dopth
611

lItIJ

ol

Tlf htenlntJ ofpln nut 17 201 11 J 145Ibft 4 fo PtNOtKJ piNon betftntJ without 00 7 IS1 721b ft J 10k 5 Anion bHnng 1IdJU
or

Ii

Amon P8Cf I

lng u IId

90H F

16

Adjsutllll

far

dlff8nntJal

side

cowen

4 Gl

lo

90H F
co

17

The G

maJtuJ18S

of the

dlffwentJal side

FigH 19 ChecIung
wheellDI priOR

the

backof the

54

with grease Fit the oil seal retelllBr end refit the other parts In reverse order to the removel procedure

Also press the outer races of the front and rear pinion into the differential carrier USing a suitable press mandrel cage

beanngs

Side 011 seel


Remove trle drrve shaft from the side flenge of the final dnve assembly and extract the flenge with a slide hemmer and an adaptor screwed to the Side flange as shown in Flg H 9 Remove the oil seal and replace in the same fashion as descrrbed for the front 011 seal

Acljustment
Fit the
Inner

of drive

pmion

load pre

DIFFERENTIAL Clean all parts


as

Inspection
or

follows and

replace

repair

where necessary

Gear teeth for sconng cracklllg and excessIVe wear Note that the dnve pinion and crown wheel should be replaced as a set 2 Gear shaft
excessive

pinion herght adJustlllg washer shlTIS and rear bearrng a dummy shaft as shown In the diagram III Fig H ll Special tool 49300000 If the tooth contact has been satisfactory when It was checked before dismantling use the old washen and shims Then fit the dnve pinion bearing spacer the washer and the special collar ST49310000 and the dnve flange on the dummy shaft and tighten the dnve pinion nut to a torque reading of 17 20 kgm 123 144 5 Ib ft Replace the beanng washer and the spacer with thicker ones If the pinion cannot be turned by hand when the nut IS tightened
rece on

bearrngs

and thrust

washen for

Chipping

or

Measure the drrve pillion bearing preload and select wash en and spacen to give a preload of 7 10 kgcm 972 138 In oz 83 3 In oz for used With new bearrngs or 3 6 kgan 41 7

wear

bearings Flg H 12
between the differential Side 0 008 In IS over 0 2 mm gear and and the

The

preload

should

be

measured

as

shown

In

If the

backlash

differential pinion

AdJustment

of

pinton height depth

of mesh

clearance between the differential Side gear and the thrust washer IS over 0 3 mm 0 012 III replace the thrust washer which are available in three thicknesses 4 Measure the out run of the crown wheel at the rear face USing a dial IIIdlcator The permiSSible value IS 008 mm 0 003 In Replace the crown wheel and drive pinion as a set If thiS value IS exceeded Differential distortion 6 In
carner

dummy

Fit the settlllg gauge ST49300000 Into the houslllg With the pinion Installed and measure the clearance between the head of the dummy shaft and the tiP of the setting gauge by means of a feeler gauge as shown In Fig H 13 Flg H 14 shows for the adjustment The dnve pinion adjusting shim S can be found from the follOWing equation S W T H
x

the tJp set shlckness

0 01

0 20

and differential

cage

for cracks

or

where W Thickness of Inserted washers and shims Measured thickness Figure engraved In pinion head

general replace

all 011 seals

T H S

ReqUired thickness
a

of washers and shims

DIFFERENTIAL

ASIlImbly

and

Adjustment
note

As W T H S

lxample the follOWing might apply


1 20 3 40
mm

to

Assembly is the reversal the follOWing pOlllts Arrange


surfaces the shlTIS

of the

dismantling procedure With

2 20

024mm 2

thoroughly

washen etc and lubrrcate

the space between the Differential cage

sealing lips

order clean all bearings With gear 011 Pack of the 011 seals With grease
In

correct

3AO

0 24

0 01

020

3 46

mm

Fit the shims


Inner race on

reqUired

to

the drive

pillion fit

the rear

bearrng

pinion

Fit the differential Side gear and the bevel gear III the cage using the correct thrust washers Insert the differential shaft so that the hole for the secunng pin III the shaft IS In line With the hole in the dlfferentral cage Measure the clearance between the rear face of the side gear and the cage as shown III Flg H l0 and If necessary mange the thrust washer to obtain a 0 2 mm 0 004 Fit the pinion clearance of 0 1 0008 III shaft lock pin and secure It with a punch by caulking the ITllterlBl of the differential cage Lubricate the gear teeth and check the gear for freedom of rotation

beanng bearing

the drrve pillion and press home Fit the drrve Into the differential carner throat together With the spacer and washer front beanng Inner race and front spacer followed

by

the

beanng

retalller and the 011 seal

Fit the dnve


secure

flange

mange

the parts With the pimon nut 20 kgm 1122 9 144 6Ib ft

and the washer on to the drive pinion and the nut to 17 lhtening tl

Acljustment
If differential
been shims
carTIer

of differential bearing covers

Fit the crown wheel to the differential cage and tighten the bolts to a torque reading of 7 0 80 kgm 50 6 67 8Ib ft Use lock straps
re

replaced adjust

cage side bearings or bearing covers have the side bearing pre load With adjusting The exact thickness of the shims IS obtained by the

following equations
T1

Might

the width of the differential side bearings by placing e of 2 6 leg 6 5 lb on the bearing The nominal width IS

left

A 8

T2

rrghtl

D F

E H

H
x

x 0 01 0 76 0 01 076

00 mm 20

0787 In

Press the

bearfngs

on

to the differential

56

interl

iill

p m

TOE

TOE

TOE

fr
HEEL DRIVE
SIDE

HEEL COAST SIDE FillH2O Tooth contact on heel

HEEL SIDE

DRIVE Tooth co

HEEL COAST SIDE


on toe

HEEL

DRIVE

SIDE F 22 Tooth H
co

21 FIlI H

HEEL COAST SIDE on fImc

TOE

TOE

HEEL COAST HEEL DRIVE SIDE SIDE F H 23 Tooth contact on face

HEEL DRIVE SIDE 24 H C F

HEEL COAST SIDE


tooth contact

56

where A C E B D F The

removal

procedure

figure

The figure

the differential carner on the differential cage


on

Imp pts

08 US qts

and fill the fmal drive With of the recommended 011

08 IItres

1 3

G H Measure

The difference m width of the left hand or nominal width of 20 right hand bearing agamst mm 07874 m gIVen m 11100 mm The figure on the differential bearmg cover

DIFFERENTIAL

Ramoval

Estate Car Stetlon Disconnect the drive

Wagon

Fig H 17
The the
to

figure

etched

In

the crown wheel Side

differential
a

mstrument

placmg
brmg
m

bearmg
F

bearing Width with a suitable on top of the load of 2 5 kg 5 5 Ib under load and determme the value En or

shaft pm Ion flange from the propeller refer to section the axle shafts and remove rear yoke flange Unscrew the differential REAR AXLE for thiS procedure carner from the front of the rear axle and 11ft out

DIFFERENTIAL

Dismantling
shown pinIon

FIt the differential cage assembly mto the differential carner Insert shuns and 0 rmgs mto both differential bearing covers and fit the retamers by screwmg the gUide studs ST49330000 or two other sUItable pilot studs mto the differential carner H 18 Measure the tooth backlash as shown m Fig H 19

Clamp the differential carner Into a SUitable support as m Fig H 26 and Inspect the tooth contact and the drive depth before attempting to dismantle the differential
Remove the

Fig

0008 In and adjust It to 0 10 0 20 mm 0004 backlash IS not sufficient move shim from left to excessive from right to left Check
cover

right

If the If

the drive pinIOn turning torque and adjUst the bearing 3 kgcm shims to give an Increased turning torque of 1 compared with the value obtained when thiS was checked before the differential cage was fitted to the carner If any of the shims must be removed
or additional shims must be fitted It becomes necessary to readjust the backlash

Side bearing caps and the differential cage See left and right hand parts separate assembly Bend Fig H 27 Remove the Side bearings With a SUitable puller back the locking straps for the crown wheel mounting bolts and remove the crown wheel bolts Fig H 28 Now measure the backlash between the differential Side gears and pInions Drive

Keep

out

the lock pin for the differential pInion shaft from left to and the right and remove the pinion shaft piniOnS Side gears thrust washers Measure the turning toque of the drive pinion In the differential carner uSing a SUItable pre load gauge and check the drive mesh depth uSing the special tool set ST46200000 Note pinion the values and write down for later reference

Tooth contact

By applYing Prusslan Blue to 4 or 5 teeth and turning gears evenly back and forward by hand check the crown wheel and drive pinIOn tooth contact pattern and adjust as follows Fig H20 Increase the thickness of the drive pinion shim and the washer to brmg the pin Ion closer to the crown wheel
Heel contact Toe contact Fig H 21 Reduce the drive pinion shim and washer thickness to pinion away from crown wheel Flank contact Fig H 22 ThiS pattern should be treated Face contact Fig H 23 ThiS pattern should be treated

Remove the drive pm Ion nut and the flange and tap out the drive pinion shaft to the rear With a plastiC mallet together With the rear bearing Inner race spacer and adjusting washer out Remove the 011 seal and the front bearing Inner race Draw and rear beanng outer races front uSing speCial tools ST47820000 and ST46310000 as shown In Fig H 30 Also remove the drive pinion rear bearing mner race With the speCial If these tools are not tools ST47120000 and ST46320000 available It

move

might by pOSSible

to

use

other SUitable equipment

as

for toe contact Clean all parts repair


as

DIFFERENTIAL Inspection Fig H 31l

thoroughly

and inSPect

as

follows and

replace

or

necessary

as

for heel contact Cbeck the parts as deSCribed for the Saloon differential With out limit for the crown wheel IS 0 05 the exception that the ru n m the clearance between differential Side gear 0002 and mm and thrust
m

Correct contact Fig H 24 A correct tooth contact IS obtained when the Impression lies within 2 3 to 3 4 of the distance between the tip and the root of the tooth under If shims
or no

load condition have been

available
check the tooth
IS

washer 0 2 mm 0 008 7 different thicknesses

Thrust

washers

are

washers

changed

Also check that the wlthm 008 mm 0003 m


backlash

crown

wheel backlash

stIli

DIFFERENTIAL

Assembly Fig H 33
of the

and

Adjustment

DIFFERENTIAL

Installation

The the

assembly IS a reversal followmg pomts

dismantling procedure notmg

Secure the differential

caITIer mto the rear suspension member Fit the differential mountmg member to the mountmg hole by ITDvmg It forward with a SUitable bar or tyre lever Tighten the 61 5 Ib ft See also nuts to a torque readmg of 85 kgm

Fig

H 25

Fit the

remamlng parts

reverse

order

to

the

Fit the bevel pmlons differential Side gears and thrust washers mto the cage selecting SUitable thrust washers to give a 0 20 mm 0 002 0 008 In between the clearance of 0 05 Side gear and the thrust washer Fit the pinion shaft lock pin

inter

i1 l

PJtE 1D

H 30

I of

tile

pllllOii mv

Ass y

beanng
dlf ereratl al ide

duvt piniOn

31 H F Exploded bly

of d

FigH 32 MeIIsllnng 1he


NIHIUt

crown

wheel

for

58

mte

E illj r

P @

J1ahtenJnc torque lrmo p nu nlDn


14
to

dnn pIJUOD

odj Adj drlnu bearina wttbout

DC

17 k 120

100

to

lb Ct

oD drift hypoid Ie w pat Preload or pinion beannc 10


to

13

cm q

Gear

ratio

TIhrenma
6

torque

dtff bolt

3SP A

TIM TIM TIM

3889

ap 42 to 48 30 to 34 7 ft lb l b

kg m
D

C
4SP 3700 1

FIgH
carr

SectIon

through

the

dofferentl8l

FIg

H 35

CalculetlOn of the

differential side

lbeenng s ums

Fill H 36
IIlIe

Me mng the bearing thockness

entud drtt

Fill H 37 Measunng the crown wheel back

s Me ng the

n dlmen

69

from the nght hand Side and peen the secure the prn 10 posItIon

edges

of the hole to

should be 10 and
a

13 kgcm

138 9

180510

oz

for

new

bearings

FIt the crown wheel to the dIfferentIal cage usrng 8 straps and tIghten the bolts to a torque reading of 4 34 7 39 8 Ib ft
10 a

new

lock

less for used bearings Check the plnton value of 20 40 depth and re adJust If necessary Remove the pInion nut and the flange and press the 011 seal well greased IOta the dIfferentIal carner RefIt the flange washer and the pmlOn nut 130 and tIghten the nut to a torque of 14 17 kgm 101 Ib ft If the holes for the spltt pm WIll not altgn WIth the

5 5

kgm

agonal pattern

the special beanng press mandrel ST49260000 or a dnft wIth SlJttable dimenSIons press 10 the SIde beanngs lOner race Fit the crown wheel adjusting shIms behind the bearings to obtain the correct preload After rnsertlng the correct shIms

USing

specIfIed torque readmg not overtighten the nut

use a

washer of dIfferent thIckness Do

usrng special the dnve plmon rear bearrng or any mandrel WIth SUItable dImenSIOns Also press the plmon front beanng outer race IOta the pmlon housmg and the rear beanng Inner race on to the dnve plmon press
10

outer

race

replacer ST 47820000

FIt the dIfferentIal cage IOta the housmg tapprng Itdown With plastIC mallet as shown m FIg H 34 and fIt the dIfferentIal bearing caps Tighten the cap bolts to 4 2 48 kgm 30 4 34 7
a

Ib ft

shaft

Adjustment
AdJustmg the dnve pinIOn

of d fferentJal

beanng
10

preload

determme the dnve plmon shIm thIckness fIt the drive lOner race and pm Ion Into the housrng and fit the front beanng the flange TIghten the dnve pmlon nut untIl the dnve plmon 1389 1805 10 oz Now 13 kgcm turnmg torque IS 10 rnstall the dnve prnlon settmg gauge and measure the gap between the pinion head and the gauge as shown 10 FIg H 29 The obtained value IS the pinion depth To To determine the exact thIckness of the shIms
use

AdjUst the dIfferentIal bearing pre load followrng formular see Fig H 35
Left Side Tl A

accordance WIth the

Crown wheel SIde C D E 7

RIght SIde DIfferential assembly SIde


T2 where a 0 0 F 6

the

follOWing equatIon
T N H
x

T11T2
A a 0 25 02 C D

Shim thickness

required
on

10

Units

of 1 1000

10

Figure marked

respectIve

differentIal beanng

hOUSing Figure

where T N H The

ElF

required

rear

bearing adJustmg shIm thickness

In

on differentIal cage dIfferentIal beanng differences of thIckness to nommal thIckness of 20 mm 07874 m In Units of 1 100010 under a load of 25 kg 55 Ib

marked

Respective

mllltmetres The gap measured above 10 mllllmetres The figure marked on the dnve prnlon head ThIS eIther
a or a can

FIg
be

H 36

figure

Measure the crown wheel and pinion backlash FIg H 37 and adjUst to 0 15 020 mm 0006 0008 m by movmg the SIde bearing shIms from the left to the right If too small and from

If necessary adjust shIms by removIng the dnve pInion and the and bearing spacer rear bearing outer race FIt the dnve pmlon a torque IOta the pmlon housmg and tIghten the plmon nut to 130 Ib ft Check the pInion pre load by 101 of 14 17

right

to

readmg

ot 4 2

left If too great TIghten 48 kgm 304

bearing

cap bolts to a torque 347 Ib ft Usmg a large

kgm

attach 109 a preload gauge to he prnlon flange and adjust to the bear 109 correct value by selectrng spacers three sIzes and Inner the front 15 sIzes between beanng adJustmg washers 011 seal race and the spacer The Inlt al turnmg torque WIthout 130 Ib ft 17 kgm 101 and drive prnlon nut tightened to 14

or specIal tool ST46380oo0 measure the dImenSIon between the outSIdes of the bearing caps as shown 10 Fig H 38 If 19855 mm 78110 78169 m which should be 1984 less It should be corrected by msertlng shIms of 0 05 mm 0002

micrometer

out run IS less than I on both Sides Check that the dnve gear 005 mm 0002 In I Finally check the tooth contact pattern as described for the Saloon dIfferentIal In

60

Technical Data
PROPELLER SHAFT

Length
Outer dIameter Inner dIameter

1082 mm 426 In Saloon models 1242 mm 48 9 In I Estate car models 635 mm 25 In Saloon models 750
mm

Thickness of pmlon heIght adJustmg washers ThIckness of pinion heIght shims ThIckness of pmlon Saloon Estate
car

2 0 2 2 24 mm From 1 09 1 27
mm

30

In

Estate

car

models

beanng adJustmg washers


From 2 31 257
mm

603 mm 24m Saloon models 71 8 mm 28 In Estate car models 008mm 015


cm

As Saloon

AXIal play of spIder Journal out run Max of shaft Wear limit of spIder diameter Max unbalance 15 gr

00315ml
m In

06 mm 0024
mm

CROWN WHEEL Backlash between gears Saloon Estate


car

0006

0 278

In oz

at

4000 rpm

o 10 015

0 20 020

mm mm

0 004 0006

0 008 0008

m m

FINAL GEAR RATIOS Run out of 1 3 Ittres Saloon models 1 6 lItre engine Saloon With 3 speed box Saloon With automatic Saloon With 4 speed box Estate car WIth 3 speed box Estate Estate With automatIc car With 4 speed box
car crown

wheel Less than 0 08


mm mm

43751 3900 1 39001 37001 38891 38891 37001

Saloon Estate
car

Less than 0 05

0003 0 OOl

In In

DIFFERENTIAL GEARS Thickness of Side gear thrust washers Saloon

DRIVE PINION InitIal turnmg torque Saloon models Estate


car

Estate

car

o 775 0 825 0 875 178 083 088 1 03 1 23

mm mm

without 011 seal 7 10 kgcm 10 13 kgcm

0506 0 723

models

0723 Ib ft I 0940 Ib ft

Clearance between Side gear and washer Saloon 0 10 0 20 Estate car 005 0 20

mm mm

0004

08 00
0008

10 m

0002

Depth from axle


Saloon modesl Estate
car

centre

models

48 5 610

mm mm

1 909 2402

In m

61

ImDIIIII
I

J
8

tt I

i
c

0 f 1 r
i Y

f 1l

IJ

jjJ

jf
YI
II

AiI

0
r

I
FIg I 2 Parts to be removed
t
or

j
dIsconnected for
unit

the removal of the fmal drive

Brake Ime connector 2 Handbr b cable adjuster 3 Rerum spong 4

Propeller thaft flange

Front

O ff

mountmg member

FIg I 3

Removal of the lower

shock absorber

Fig I 4

Removal
as

of

rear

axle

and

rear

mounting

suspenSion

complete

Unit

I nstallatlon
rear

diagram for

suspension

6@

jj

1
l cod ring

Fig I 6
nuts

Removal of the drIVe shaft securing

FIg I 7

Exploded

vIew

of the

rear

FIg I 8 The upper shock absorber mounting

F g 1 11

Removal

of the

rear

wheel

Fig I 10 of
the Or coli sprln9

Removal of the

rear

SIIspel1Slon

ann

bearing

nut

Filii 9

Removal

62

Rea r
DESCRIPTION The Saloon models
semi are

Suspension
COIL SPRINGS Check Installation
rear

fitted WIth
arms

fully Independent
arms

COIl sprrngs traIling suspensIon suspensIOn WIth and telescopIC hydraulic double acting shock absorbers The final drrve Untt IS mounted to the suspension member by four bolts and rubber Insulators The Estate Cars
rear

the sprrng for YIeld deformatIon and cracks Test the and compare the results WIth the information In sprrng TECHNICAL DATA Check the rubber parts for deformatIon
or

damage and replace

If necessary

The installatIon

StatIon

axle WIth seml shock absorbers

floatlng semt Wagons are fItted With a elltptlc leaf sprrngs and telescopiC hydraulic

procedure

IS carried out In reverse order to the removal ensunng that the flat face of the spring IS at the top

REAR SHOCK ABSORBERS

Removal and Installation

REAR AXLE AND SUSPENSION Saloon models

Removal

Remove the boot trrm assembly and the two securrng nuts from Remove the the upper shock absorber mountIng Fig I 8 shock absorber from the lower mountlng bracket and Itft out Test the shock absorber If faCIlitIes the results With the specIfications Check for 011 leaks and
are In

Jack up and support the rear end of the car on Remove the wheels handbrake linkage and return spnngs exhaust tat pipe and Silencer DIsconnect the brake hose from the tube Remove the propeller shaft from the differential The parts to be disconnected from underneath the Refer to

Fig

I 1

SUitable stands

available and compare TECHNICAL DATA check the shaft for


or wear

cracks and

straIghtness Check the rubber bushes for deformatIon and replace If necessary
The mstallatlon
IS a

Jack up the suspension arm and shown In Fig I 2 the shock absorber from the lower arm Fig I 3 and retain the rubber bushes Support the dIfferential unit and the suspensIon With a Jack and remove the suspension member
car are remove

reversal of the removal procedure

REAR SUSPENSION ARMS Jack up the car and place the dlscpnnect the follOWing parts shaft from axle shaft and wheel
rear

Removal

securrng nuts and the nuts secunng the differential mounting Carefully lower the suspensIOn Untt Fig I 4

end on stands Remove or Wheels brake drum drive

SUSPENSION

InspectIon

ExamIne all parts for wear and damage WIth special attention to the rubber bushes In the suspensIon arms and bump rubbers sprrng msulators and rubber Insulators In suspensIon Untt and dIfferentIal mountmg member

handbrake cable from equaltzer bracket lever brake hose from brake line by and the lock WithdraWing through connector spring removing wheel bearrng locknut rear axle shaft wheel bearing and 011 seals and the rear brake assembly Jack up the suspensIon arm and remove the shock absorber from the lower mountmg

cyltnder

Replace

where necessary

Lower rubber

the Jack and Fig 19

remove

the COIl

spnng and the bump

SUSPENSION ThIS

Installation

Remove the suspension arm securing bolts as shown In FIg I 10 11ft out the arm If necessary remove the rubber bushes from the suspensIon arm by pulltng them out With a SUItable and wlthd rawal tool

IS a reversal of the removal procedure noting the follOWing pOints SuspensIon member and dIfferentIal mounting member must be correctly lined up The Insulators should be correctly altgned as shown In FIg I 5 and fItted from the underside of the members Tighten the suspensIOn member mounting nuts to 10

REAR SUSPENSION ARM Check

InstallatIOn

kgm

72 3 Ib ft l the dIfferentIal mounting member to 8 5 kgm 61 6 Ib ft and the lower shock absorber nut to 2 3 kgm 166

Ib ft

the suspensIon arm for dIstortIon or cracks and the rubber bushes for wear damage or separation of the matenals Replace If necessary The installatIon all
IS a

COIL SPRINGS Jack the


rear

Removal

the suspensIon

arm

WIth the wheels

on

reversal of the removal procedure TIghten mounting bolts when thevehlclels resting the ground Replace all self locking nuts

of the vehIcle and support on stands Remove ljP Wheels handbrake Itnkage and or disconnect the follOWing return sprrng drrve shaft flange nuts at the wheel end FIg I 6 and the bump rubber securing nut Jack up the suspensIon and Lower the remove the shock absorber from the lower mountIng

REAR AXLE SHAFTS BEARINGS Removal and

OIL SEALS

Dismantling

Jack FIg

and remove the COIl spring I 7

the seat and the

bump

rubber

Jack up and support the rear of the vehIcle Remove the wheel and brake drum DIsconnect the drive shaft from the axle shaft Remove the wheel bearing locknut hold Ing the flange WIth a SUItable tool FIg 111 WIthdraw the axle shaft as shown In

Fig

I 12

studs

USIng a slide hammer Remove the rear axle dnve

SUitably flange

fIxed

to

the

flange

63

inter

QJ

@LID

00
0
FIg I 12 Removal of thedrIVe axle

t
j

Shock absorber lower mountIng

Bearing hOUSing
mark

Pack With wheel MP2


or MP3

beanng

grease

every overhaul

AXLE HOUSING Fog 115

DISTANCE PIECE for the

The critIcal dane ons mstallatlOn of the RlsponSlOn ann

8 6
6

Fog J 16 Exploded
1 2 3 4 5 6 1 8 9 10

of thedrNe

shaft

shaft Or Orwe maftbafl Ballq eer Orwe Ibaft top rmg Rubber gtl ter

GaJrttrcltp
C IdIP SJtJeve SIewe

yoke yoktl plUf Spider Joomal F yoke

12 0 119 tIbelllJt1g 13 N 4

Clrcltp

Apply grease

In

thIS area

r
1haft

Fig 18 Sec1IOn through the

64

WIth a dnft of suItable SIze dnve out the lOner bearong and the 011 seal Remove the grease catcher and the outer bearmg wIth a conventional beanng puller

The assembly of the drove shaft IS a reversal of the dlsmanthog procedure noting the followmg pOInts Altgn the yokes ensurong balls and spacers are fItted In correct order Select a
to gIve an aXial play of less than 0 02 mm 0 0008 In In Universal JOints Four SIZes avaIlable Apply a SUItable quantIty of multIpurpose grease to the ball groove approx 10 gr 035 oz and addItionally grease the area shown In Fig I 18

clrcltp
the REAR AXLE SHAFTS BEARINGS OIL SEALS

Assembly
Check

and InstallatIon

Replace Replace

the axle shaft for straIghtness cracks damage or wear the 011 seal Check the bearongs for roughness or pIttIng parts
as

necessary

REAR AXLE

Removal

Estate Car Station

Wagon

The assembly and the follOWing mstallatlon IS a reversal of the dlsmantltng and removal procedures notmg the follOWing pOints Clean parts thoroughly The sealed Sides of the wheel bearongs should face to the wheel and the sealed Side of the Inner bearong the dIfferential The arrangement IS shown In all

Jack up the car and support the rear of the vehIcle on SUItable stands Remove or dIsconnect the follOWing parts Wheels brake drums brake hose at the 3 way connector handbrake
rear cable from the equaltzer lever propeller shaft at the dIfferential flange and the shock absorbers from the lower

Fig I 14

When
to

refItting

the bearings the

pressure should be

applted
When

the

lOner race

replaCing the suspensIon arm check that the dIstance less than the hOUSing dimenSIon pIece IS 0 5 mm 0002 In L See FIg I 15 and has the same code mark as the hOUSing In general It should be remembered that the beanng grease should be replaced every 2 years or 30 000 mIles 50 000 km
Pack the bearongs WIth a good wheel bearing grease shown In Fig I 14 and coat the Itp of the 011 seal wheel bearong nut after It has been used tWice Wheel
In

Jack loosen the U bolts and spnng shackles Withdraw the shackles from the sprong eyes Remove the U bolt nuts completely and lower the jack to WIthdraw the axle as shown In Fig I 19
mountmg Support rear axle remove the nuts from the
on a rear

REAR AXLE

Dlsmantltng and Inspection

the spaces Replace the

Disconnect the brake pipe from the slave cylinders and remove the brake pipe and the 3 way connector Remove the cross rod clamp equalizer lever and the cross rod ends from the operatmg levers on the brake backplates Drain rear axle 011 Remove the four nuts holding the brake backplate to the axle housmg and draw off the half shaft and the backplate usmg a sliding hammer Press off or cut the bearing retalmng collar Fig I 20 and
su remove

beanngs

AdJustment

With the nut tIghtened to a torque reading of 25 33 kgm 181 239 Ib ft check the axle shaft end float The end float must be less than 015 have
a mm

the

bearing

WIth

beanng puller

or

by other

0006

In

The

rear

axle shaft should


In oz

turning torque of less than 4 5 kgcm 645 replace the dIstance piece

If not

The backplate IS now free Remove the nuts securing the differential unit to the rear axle and hft out the differential The bearing collars must always be replaced
means

Itable

Check DRIVE SHAFTS Removal and D smantltng

DIsconnect the end flanges and remove the shaft The drove shafts should be dIsmantled every 30 000 mIles 50 000 km or every 2 years to lubrocate the splines Remove the Universal JOint spIder at the differentIal Side In the same manner as dlsmantltng the propeller shaft see approproate the sleeve yoke plug securmg CorcllpS and take out the plug Compress the drove shaft and remove the corcltp 4 10 FIg I 16 and the stopper Disconnect the boot and spltt the shaft tak Ing care to retam all parts
section
remove

the follOWing Items and replace or repair as Half shafts for wear cracks and straightness The necessary half shafts must not be straIghtened by heatIng Check the 011 seal hps for damage or dIstortion and the beanngs for wear or

roughness

REAR AXLE ThiS


IS

Assembly

and InstallatIon and removal procedure

the

reverse

of the pOints

and

dIsmantling

noting the

follOWing

clean all parts FIt a new gasket between dIfferentIal Unit and the axle hOUSing TIghten the nuts

Thoroughly dIagonal

the
m a

DRIVE SHAFT Check the

Inspection Assembly

and Installation

follOWing
shaft
are

the dnve

must

parts and replace If necessary Note that be replaced as a assembly as

FIt grease torque catcher beanng spacer grease packed beanng sealed Side facmg wheel and new bearing collar A 4 5 tons press fIt IS needed for fitting the collar Coat the 011 seal hps WIth wheel bear 109 pattern
to

the

recommended

complete

replacement parts
Check

not

avaIlable

grease proor to fIttIng Check and adjUst the aXIal play between the wheel bearmg and the axle housmg to 0 3 0 5 mm 0012 002 10 See Fig I 21 Fmally fIll the rear axle WIth the recommended 011 and bleed and adjUst the brake system

0 ring Check the wear Check the steel balls and straIghtness damage the sleeve yoke for damage wear or dIstortIon If any fault IS found 10 the Universal jomts replace It as descnbed In the

the boots and the sleeve yoke


or

plug

shaft for

REAR SPRINGS Refer to

Removal and Installation

sectIon

dealtng WIth
sleeve

the propeller shaft

FIg

I 21

support the
Clean the the shaft lubncate WIth 011 and the drove shaft ball grooves and With the drove shaft compressed check that IS less than 01 mm 000410 Fig I 17

rear

Jack up the centre of the rear axle an of the car on stands Remove the wheel and the

yoke

play

shock absorber from the lower mountmg and undo U bolts bump rubber spring seat location plates and seat pads Remove the sprong front bracket securmg bolts and lower the sprong bracket FIg I 22 Remove the upper and lower
rear

shackle

65

ImDBII

Fig I 19 Removal of the


the rear springs

rear

axle

together WIth Fog I 20


WIth
a

CuttIng the bearing

lnlng collar

cold chIsel

Filii 21 Meosunng the axle shaft end float FI91 22 The


rear

rln9 front

hanger

7 8

FillI 23
3

The upper shock absorber mounting

Voew of the axle


as

rear

SIIspenSlon and

rear

frtted

to

models
5 Shock obsorlJor 6 RNr spring front henger
7

Ddfenmtt
2 Rear vie 3 4

C8TTI r

hOUSing

LBet sp mi Bump rubber

HMldbrllktlltnk B ll hO

66

bolts and the front spring eye bolts to separate front spnng The InstallatIon the The the
IS a

hanger and
REAR SHOCK ABSORBER Removal and Instllllatlon

reversal of the removal

procedure

noting

following bump

pOInts

rubber should be fitted WIth the longated flange to Coat the front hanger mounting bolt bushes and shackle pIn WIth a soap solutIon pnor to assembly The front bolt securtng nut and the shock absorber lower mounting nut WIth the car resting on Its wheels Check should be
rear

Jack up and support the rear axle on stands Remove the lower end of the shock absorber from the spring seat Remove the bolts securing the shock absorber upper bracket Fig I 23 and remove the shock absorber and the bracket The installatIon
IS

tIghtened

procedu

re

Tighten the
car

carrted out In reverse order to the removal lower shock absorber mounting nut WIth

that the shackle bush flange

IS

clamped evenly

the wheels of the

resting

on

the ground

Technical Data
COIL SPRINGS Model L510S 510 L510 PL510 W
re

dIameter

142

mm

0559
In In

In

142 306

mm

0559 120

In

142 Same 299

mm

0559 11 8

In

COil dIameter Free length

90 mm 3 543 311 mm 122

Same
mm In

mm

In

The value for the 510 P510 models apply for the R H L H sprtng IS the free length which IS 299 mm 11 8 In I

sprtng The only dIfference for the

HOCIC ABSORBERS Model PIston diameter Stroke Max P L 510 25


mm mm mm

L 510 0984
In In In

25

mm mm mm

0984

In In In

235 578 0 3

9252 22 76

235

9 252 22 76

length
at
m sec

578

DampIng force

ExpanSIon CompressIon

65kg 33 kg

1433Ib 72 8 Ib

50kg 20 kg

1101b 44 Ib

REAR SPRINGS SHOCK ABSORBERS Estate CaB PIston diameter Stroke 25 200 495
at
mm mm

Length
Width 0984 7874 19488
In In In

1200 60 6

mm

47 2 2 362 0 236

In In In

mm mm

Thickness Number of leaves Free camber 24 Laden camber Spring eye bolt diameter Front Rear
mm

4 246 153 mm 6023 In 0938 In at 542 Ib 45 30 1 772 1 181

length Damping force ExpanSion


Max

mm

0 3 mlsec

at

kg

CompressIon

75kg 23 kg

1653Ib 50 7 Ib

mm mm

In In

67

inter

i ill CQllW

J 2 Removal of the wheel hub FIlI

Z I

e
5

tq o
v

O
Frontwheelhub G
I

t 2

FlgJ 1 V
1
enSlon Su

of
umt

the front
Ulator m

spensoon

2
3

Co l Sf rmg
umt 6 embly S crossmem r

SUsptlnSlon 4 SuspensJOlt

StabllMr bar 6 Reaction strut 7 SrnpenSlon ann 8 Steenng lever

Inner WMeI bearing 4 Outer wheel beanng 5 Spmdltl nut

Fog J 3 Exploded

of front wheel hub

J Flg

GreWIth

ated poInts Indoc

J FIlI

5 Removal

of thebrake Pipe J 6 Removal of wheel hub and brake dISC FIg

J7 FIg
l1li8

of the ll1Ibil

bar

For alUlOll1bOnS
an

J 8 Rerniiwal of FIlI
l1li8

the cnon Ilrut

text

tIDltl

68

Front
DESCRIPTION

Suspension
REACTION STRUT Removal and Installation
arm

The front suspensIon IS of the spring strut type 10 which shock absorber and wheel sptndle are combtned to form a sIngle Unit Call spnngs are fItted to the upper ends of the suspensIon Untts

Remove the body fltttng nuts 1 10 FIg J 8 and the suspensIon bolts 21 LIft off the reactIon rod

FRONT WHEEL HUBS

Drum brakes

Removal

Check the rod for distortIon and cracks and rubber parts for damage and fIt by reversIng the remova I tnstructlons
SUSPENSION UNIT Fig J 9 Removal

Jack up the front of the car and support on stands Remove the Remove the hub cap spltt pin wheel and the brake drum beartng nut beartng washer and hub assembly from the spmdle

FIg J 2

Remove the outer cage UStng and outer beartngs


a

beartng
the

bearing cage 011 seals and the Inner sUItable drtft drtve out the outer races of

lOner

Jack up the front of the vehIcle and support on SUItable stands Remove the wheel dIsconnect the brake hose from the connector reaction strut and stablltser bar from the suspensIon
arm Remove the two bolts holdIng the suspension assembly to the SWIvel JOint Fig J 10 Place a Jack under the suspensIon arm and Itft up the suspensIon unIt Remove the mounttng bolts Lower the lack from under the bonnet as shown 10 Fig J 11

clean all parts Replace 011 seals or hub and the grease 10 the bear lOgs

Thoroughly

damaged beartngs

and FRONT WHEEL HUBS The installatIon Installation

remove

the suspension untt

IS a reversal of the removal procedure nottng the followtng polOtS Apply SUItable grease to the parts marked With 10 Fig J 4 and m the hub cap TIghten the beartng nut to a torque of 30 35 kgm 21 7 253 lb ft Turn the hub several times and retighten to the same torque

SUSPENSION UNIT

Dlsmantltng

and Assembly

Unscrew the nut by 900 and tnsert the split ptn Check that the end float of the hub IS zero and the turntng resIstance when checked With a spnng scale hooked to one of the wheel studs IS 7
re

SUitably clamp the suspension unit Into a vice and take off the dust cover the COil clrcllp UStng sprtng compressor ST49100000 slightly compress the sprtng Then remove the self lock109 nut Fig J 12 and take off the mounting msulator thrust beanng spring seat and bump rubber Slacken the sprtng
compressor and remove the sprtng Push down the shock absorber piston and clean the area around the gland packing USing the specIal tool ST49130000 unscrew the gland packing Remove the 0 nng from the pIston rod gUide piston rod and cyltnder assembly by slowly lifting piston Do not separate pIston and cylinder Dram all flUid from the suspension Untt and shock absorber assembly Wash all parts thoroughly In a SUitable WIth the exceptIon of the rubber parts which should be blown dry With compressed aIr JUst solvent

kgcm adJustment 4 kgcm 555


10 OZ

97 2

WIth

new

beanngs

or

10

case

of

10 oz

FRONT WHEEL HUB DISC brakes

Removal

Jack up and support the front of the car remove wheels brake hub cap spltt ptn beartng nut beanng washer pIpe Fig J 5 Remove the bearing collar and 11ft hub and brake dISC FIg J 6
out out the buter races

the outer beartng cage 011 seal lOner beartng cage and drtve Remove the brake dISC from the hub

FRONT WHEEL HUB See descnptlon under drum brake torque setttngs

Installation

Replace the shock absorber flUId gland packtng and 0 nng self lock109 nuts Check the suspension Untt outer casing for deformatIon cracks or damage and the sptndle for cracks at the base or screw portIon Inspect the sprtng rubber parts and
thrust bearing for To assemble
wear

deformatIon and cracks

type nottng the followtng

Calliper

bolts

Brake dISC bolts Baclc plate bolts

7 3 3 9 27

99 kgm 5 3 37

528 28 2 195

71 6 Ib ft 38 3 Ib ft 268 Ib ft

kgm kgm

fIt the outer casing to the adaptor and tnsert rod and pIston cyltnder Into the castng FIll the outer castng With the correct grade of 011 10 accordance WIth the table below
All ledU models P510 UTK

STABILlSER BAR

Removal and Installation J 7

Applied
modeIJ

Ex PSIO

UTK

J 1I

wagon PLSIO TI and LS 105

PLSI0 TI aud LSIO S

model

Remove the securtng bolts on the suspensIon arms 11 In FIg nd the frame bracket bolts 2 and remove the stablltser bar Check for cracks and deformatIon of the bar and

1 0

300 cc

325

cc

290

cc

rubber parts

Reverse the removal procedure 12 3 Ib ft 1 7 kgm 8 7 suspension arm bolts to 1 2 frame bolts to 1 9 25 kgm 137 18 lib ft

damaged tlghtentng the


and the

quanbty

The 011 quantity IS cntlcal and should be accurately measured as It affects the damptng power of the shock absorber Fit the 0 rtng to the top of the pIston rod and uStng the gland paclcmg WIth specIal tool ST49340000 If It has been removed Before the gland packIng Itft the pIston by 90 mm 3 54 lih 65 kgm 43 4 470 kgm Bleed the and then tighten to 6 shock absorber by pumpIng the pIston assembly up and down

tlghtentng

69

ImDIIEI
1
e 8

5 9

Fill J 10 Removal of the SWIvel JOint essembly

e
FIg J 9 Exploded
1 2 3 4 Nut VIew

of the front RlspenSlon umt


6

Clip The upper mounting of the Rlspenslon

Upper mount Gland packmg Upper sprmg eat


cover

7 Coli Pring 8 BumlHf rubber 9

Suspension

Unit

5 Dust

Fig

J 12

Removal of

the self locklng nut With

the suspension

unit compressed

spnng

Fog J 13 Exploded mbly

VIew

of S1Jspenslon

unIt

and

Fig J 14 Exploded

voew

of the shock absorber

Fill J 15 Grease the pOints marked With

70

mmBIIB

Fig

17 The suspension

ann

mounting

nut

FIg J 18 The suspenSIon

arm

bush

JOint on

FIg J 20 The mountmg bolts for the lower ball the RlspenSlon ann

fIiilIII J
I

itJiJ Yf
l

f
Co

p
I

r T
D

fi

L
I

j
F I J 23 the arrowed

Fill J 22 AdjUst
rod
centre

the

In

tube

by turnIng the track

AdjUst the bolt

enng stl

angle bV

means

of

71

untIl the pressure

IS on

both dIrections the

same

LOWER BALL JOINT

Removal and Installation

the assembly by reversong the dlsmantltng procedure The torque settong of the self Iockong nuts IS 6 0 7 5 kgm 434 54 2 Ib ft

Complet e

Jack up and support the front of the car on stands Remove or disconnect the followong reaction rod and stabl Itser bar from suspension arm suspension Unit from SWIvel Joont arm spltt pon from Joont nut ball JOint from SWivel Joont arm and the lower ball JOInt from the suspensIon arm by removIng the bolts 1 on FIg J 20 lower ball

Fig

J 19

SUSPENSION UNIT

Installation
In

Reverse the removal procedure greasing all parts marked FIg J 15 Tighten to the recommended torque values

Replace
06

the

damaged dust
0001 0014

cover

It must be
mm

follOWing
Upper attachment nuts
3 9 6 0 4 9 1 2 5 2 80

replaced complete
on

As the ball Joont IS a sealed UOIt If the end play IS greater than 0 03 I To grease the ball JOInt remove

SuspensIon
Stablltser
to

Unit to

arm

ReactIon rod to
arm

arm

kgm kgm 63 kgm 1 7 kgm

28 2 37 6 Ib ft 434 57 8 Ib ft 35 4 45 6 Ib ft 87 123 Ib ft

the plug and screw In a grease flttong Flush old grease out of the JOint by pumpong on new grease Refit the plug The Installation all bolts and reversal of the removal procedure Tighten to the torque values Itsted under TIGHTENING TORQUES see Index for page number heading Front Suspension
IS a

nuts

SUSPENSION ARM

Removal and InstallatIOn

Jack up and support the front of the car on stands Disconnect the reaction rod 1 and the stablliser bar 2 from the In suspension arm 3 Fig J 16 Remove the lower ball JOint bolts 4 and the nut 1 In Fig J 17 Lift out the suspension
arm

FRONT WHEEL ALIGNMENT

Adjustments

All checks of the front wheels should be carried out With the tyres at correct pressures Camber and castor angles are pre set and cannot
one

Side

Check the suspension arm for damage cracks or distortion and the rubber parts for abraSion If the dimenSions A on FIg J 18
IS

changing

be adjusted To level the vehIcle In the case that more than the other can be accompltshed by the spnngs

hangs

less than 1

mm

004

In

replace the rubber parts


Check the toe
In or

Toe on

The onstallatlon IS a reversal of the removal procedure the bolts to the follOWing torque values

TIghten

by lengthening

by uSing a gauge shown In FIg J 21 and adJust shortening the track rods The standard length

SuspensIon
member Ball JOint

arm

to

cross

of the track rods between the ball JOints and the centre of the SWivel JOintS IS 3095 mm t1219 In Both Sides should be

12 2 19

13 5 kgm

88 2 137

25kgm

97 6 Ib ft 1811bft

adJusted
In

to

equal length

by turning the

centre

tubes

arrowed

FIg

J 22

Steenng angle
With the
car on a In

turn

bolt arrowed

FIg

table adJUst the steerrng J 23 on both SIdes

angle

uSing the

72

Technical Data
FRONT WHEEL ALIGNMENT All Estate Cars Model All Saloon models except L510 S L51 D S

Castor Camber

King
Toe

pIn
In

Inclination

1040 1000 8000


6 9mm 035
In

1040

200
1010

1030
7030
9 12mm 047
In

7050
3 6 n m 024
In

024

035

012

COIL SPRINGS Models L H spring for all models R H sprong for L H 0 models R H spring for all R H D models and and L510 S L H spring for L510 S 12
mm

L Hand R H
air

spring for all models WIth cond Itloner

Except L510 SI
Wire diameter COil diameter Free length F Itled length Fitted load
mm 0472 In 130 mm 5 12 In 3545mm 1394In

12

0472111 I 512 1455 III


III

12

mm

0472

In

130mm 3695 202 243


mm

130mm 3845

51210
In

736lnl 187mm
243 kg 536 Ibs

mm

795

536Ibs

mm 1514 217mm 8541O 243 kg 536 Ib

FROIH SUSPENSION UNITS L510S

All Saloons With drum Models brakes Exc S L51G

Saloons With disc brakes Exc SSS

All Estates With drum brakes

Estate With disc brakes

SSS P510 UTK and

PL510 TKI

Strut outer 50 diameter


mm m

50

50
0

jO

ci

50

50 2 0

2 0

2 0

2 0

2 0

PIston
mm

rod 20 0 787

20 0 787

20 0 787

20 0 787

22 0 866

22 0 866

dIameter
m

hnder

mncr

30 1 181 1

30 181

10 1 181

30 1 181

32 1 260

32 1 260

dIameter
mm
m

Dampmg force
EhpanslOn

at

pIshon speed 0 3 mls 1 08 ft


t 10 67 b7 1 10 147 t 22 7 147 25 55

0 7 22 t 4 8 8 55 147

HO
t 22 7 t4 25 t8 8 1

i t 22 3 147 71 22

kg

Ib

147

t 22 7

CompressIOn kg Ib Shock absorber


inner

251 4 55 t8 8 1

25104
55 t 8 8 1

110
435 17

410
16 1

410
16 1

435
1 17 1

176

25104 40106 t8 8 1 88 2 1 13 2 55
410 16 1

410 16 1

cylinder
mm
tn

length

I
73

interCE QJ

Q @

0 9

I
10

80

Fill
2 3

K 1

Exploded

of the steering I8IIr


StltJrm8 column tube 8St mng column b61Jrmg 9 SttJefmg worm bestlng 70 StHnng nut SttteTmg column Ih6ft
1

FIlI K 2 The column

tIng bolts of the

ng

Smermg gear

lng hou

mg eCtoTdudt Sector sh h ccwer Adu ttng IC W

5 Kbnn

beanng um 0 nng 6 HouSIng cOW

rlll K 4 Removal of the

Nfl

9685

In

jffif
FIlI K 6 Measure me n II1OWI1 to dbne determine If the Nfl illtIlIswvlc8lble Fill K 5 Removal of the WIth nng nut
g

column Nfl

74

Steeri ng
DESCRIPTION
The steering Itnkage IS fItted WIth a torsIon rubber Idler arm whIch absorbs the wheel shock The lubricant of the steenng box should be checked every 6 000 miles 10 000 km at Milch tIme It IS also The column grease

beanng
and

has been

changed
Into

It

should be

packed

WIth

then

cemented

steering

IS

of the

reclrcu

latlng ball type

the worm 0002 003 m adJUst column shaft to 40 6 0

adjusting

steering column By bearing shims 4 SIZes 005 0076 mm the InitIal turning torque of the steering

the

kgcm
ThIS

55 5

833 In

oz

WIthout the

necessary to grease all grease flttmgs of the steering

Itnkage

STEERING GEAR

Removal

Remove the horn ring by depressIng It and turning It to the left the steering wheel nut and uSing the steering wheel puller ST46430000 or any other puller that WIll fIt WIthdraw the

be carrted out by hookIng a scale to one of the steering wheel spokes whIch for thIS spring purpose should be pushed over the steering column shaft Fig K 7 The end clearance of the sector shaft adjusting screw and should be should be 0 01 003 mm 00004 0 0012 In measured as shown In K 8 There are SIX shIms available In
sector

shaft

being

fitted

can

Fig

thicknesses from 1 45

1 57

mm

0057

0062

In

steering wheel

Remove the steering column cowl dIrection IndIcator and light selector SWItch and dIsconnect the gearchange lever steering column change only from the change control rod Remove the two column attaching bolts arrowed the column bottom flange bolts FIg K 3 and FIg K 2 dIsconnect the gearchange rod and the selector rod from the gearchange lever and the selector lever by removing the cotter
In

WIth the ball nut at the centre of travel and the centre tooth of the sector shaft In line WIth the centre tooth space of the ball nut place a new gasket on the sector shah cover and fit the shaft and the cover ensuring that here IS some backlash between the sector shaft and the ball nut teeth 011 the sector shaft pnor to assembly and tIghten the bolts
sector

pin from the trunnion DIsconnect the steering drop arm and the drag link Remove the steering gear mounting bolts and draw the steering gear and the column assembly forward and remove the gear change control

Lock the adjusting screw locknut and turn the sector shaft several times at the drop arm end FIt the drop arm taking care of the alignment marks on the arm and steermg box AdjUst the backlash at the end of the drop arm as shown In Fig K 9 over a radius of 215
mm

Itnkage

as

deSCribed

In

sectIon

GEARBOX

adjusting

screw

at

to less than 01 mm the end of the cover

0004

In

WIth the

FIg

position screw In the adJusting screw lock In pOSItion With the locknut STEERING GEAR

by

From thiS 1 8 to 1 6 turn and

K 10

Dismantling
capacity

Clamp the steering box assembly sUItably Into a Vice and remove the drop arm WIth a SUitable puller or specIal tool ST
011 from the steering box Slacken the and turn the sector shaft adjusting screw several turns antl dockwlse Remove the sector shaft cover and the shaft from the hOUSIng as shown In Fig 4 Remove the steering column tube bolts and WIthdraw the steerrng column as shown 46440000 Drain the

Finally fill the steering box WIth gear 011 90 E P The fllltng IS approx 033 Iltres 0 7 US pts 06 Imp pts
STEERING GEAR In tallatlon

adJustment

nut

The installation IS a reversal of the removal the followmg pOints Check

procedure

noting

Fig K 5 taking care not to let the ball nut run down to eIther end of the steering worm Pull the steenng column out of the column tube Remove the sector shaft 011 seal Note that the sector shaft needle bearings are a press fIt In the hOUSing USing
In a

the front wheel altgnment and the steenng system for of movement The steenng wheel rrm should have a 30 mm 098 1 18 In measured at the free travel of 20 outSide dlll eter of the rim freedom

tube
rear

puller remove the rear beanng Finally remove the bearing


steenng
worm

outer
Inner

race races

from the column of the front and STEERING LINKAGE Refer to Removal end Dismantling

bearmgs and the steering column bearing

STEERING GEAR

Inspection and Assembly

Check the aXial clearance between the ball nut and the balls If the clearance exceeds 008 mm 0003 In the complete Unit should be replaced Inspect the gear teeth for wear or damage Worn or Imperfect bearings should be replaced Examine the steering column shaft for straIghtness and check that the max
In FIg K 6 IS not deflection at points C exceeding 02 mm 0008 IIr when the shaft IS supported at poInts A and B Check the sector shaft and steermg column shaft serratIons for wear

K 11 With the vehIcle resting In stands remove the the castle nuts holding the track rods to the and split pinS from the levers steering levers Remove the track rod ball JOInts by means of a SUitable puller or by holding a large hammer on

FIg

SIde of the lever boss and tapping the opposIte SIde WIth a hammer In the same manner dIsconnect the steenng connecting rod from the drop arm and the Idler assembly and
one

second

the track rod Inner ball JOint from the connecting rod Unscrew the steering Idler from the chaSSIS Side member To dIsmantle the steering linkage slacken the clamp bolts from the ends of the track rods and unscrew the ball JOints Unscrew the Idler arm bracket nut and dismantle the Idler

Replace parts

as

necessary and

reassemble

the steering

gear as follows

assembly

Grease the 011 seal lips and press the seal Into the hOUSing FIt the steering column assembly Into the column tube and fIt the IMIrm bearing shims and the 0 ring Into the hOUSIng TIghten 25 kgm 130 If the the flange bolts to 18 18 1 Ib ft

STEERING LINKAGE

Assembly

and Installation

Check the rubber parts for damage wear or other form of damage and replace If necessary Check all steering rods for

75

mter

f Qp illJ

Fill K 1 Measunng the initial turning torque by


mean

Fill K 8 Checking adjusting ICrewand

the
sector

end shaft

float

between

of

spnng scale

fi jl
I

i
C
l

tJ
y
1
l

q
t
J J

I
4 11
g 8

Ir
J

I i

ri
J
0

7J
0

r r steermg hnkage
seen

TIGHTENING TORQUE 55to76kgm RAD 140rrm SEDAN


145mm

WAGON

FIg K 12 Section through the Klier


1 Nylon bush 2 Dust co r 3 e arm ld

ann

r
I
I

a
TOLERAHa
1

j
47 to 3 47

ANGlE

AFTER TIGHTENING
TME ARM

Fig K 15 Adjustment of Idler bracket and Klier


arm

Clearance 01to05mm Frg K 13


Section

thnlugh the ball JOint IItud

forthe track rod

Frg K 14 SectIOn thnlugh the ball JOint ltud for the connecting rod

76

damage distortion or cracks The ball JOlOts must play due to weak sprlOgs or damage A workIng clearance
o 5 stud
mm IS

have

no

free

of 0 1

0 004
out

pulled

0 02 In 1 should be felt when the ball JOlOt see of Its socket Fig K 13 and K 141

Idler arm bracket coat the rubber bush press In so that It protrudes equally on both SIdes Fit the Idler arm body IOto the bush With the Idler See also arm centre line parallel to the chaSSIS centre Itne When With

assembltng the liqUid soap and

Replace

ball JOInts If necessary

FIg

K 15 for the dImenSion to be obtained


to

The assembly IS a reversal of the dismantling procedure notIng the followlOg pOints TIghten the bolts to the followlOg torque settlOgs Ball stud nut 5 5 7 6 kgm 39 8 55 0 Ib ft 125 140 kgm 90 101 Ib ft 55 7 6 kgm 39 8 550 Ib ft

Bring the track rods


mm

their baSIC length adjustment of 309 5

between the ball stud centres by turnlOg the centre tube 10 the approproate directIon After InstallatIon of the complete steering linkage system check and adJust the wheel 12185
10

Drop
Idler

arm

nut

arm nut

Also as described 10 section Front SuspensIon adjust the toe out 10 turn angle so that the angle of the lOner wheel IS 380 and that of the outer wheel 32 40

alignment

Trouble
SYMPTOMS Hard steenng

Shooting
ACTION TO BE TAKEN Correct pressure Correct alignment Check and replace If neceesary Adjust If necessary

PROBABLE CAUSE

Low tyre pressu re I ncorrect wheel alignment StIff track rod ends

SteerlOg

box needs adJustment

Steenng wheel shimmy

Tyre

pressure Incorrect

I ncorrect wheel altgnment Wheels and tyres need balanclOg Wheel hub nut loose Wheel beanngs damaged Front suspensIon distorted

Correct Correct alignment Balance


as

necessary

Steermg

box needs adJustment

Adjust wheel beanngs Replace wheel beanngs Check repaIr or replace Adjust as necessary

Steenng wheel pulls

to

one

SIde

Uneven tyre pressure Improper wheel alignment Wheel beanngs worn or damaged Brackes Improperly adjusted Sh k absorbers faulty

Correct Correct

SuspensIon dIstorted Steenng box worn


Wheel tramp

Replace and adjust Adjust brakes Check and rectIfy Check and rectIfy Adjust or replace

Over Inflated tyres Unbalanced tyre and wheel Defective shock absorber DefectIve tyre

Correct pressure Check and balance If necessary Check and rectIfy

Repair

or

replace

Abnormal tyre

wear

Incorrect tyre pressure I ncorrect wheel alignment ExcessIVe wheel beanng play

Correct Correct

AdJUst
AVOid sharp turnlOg at hIgh speeds rapId startlOg und braklOg etc

Improper dnvlOg

Tyre

nOIses

tyre IOflatlon I ncorrect wheel altgnment

Improper

Correct Correct

77

inter

MI @

brake system FIg L 1 Layout of thebrake systems wIth thedIsc

on

the left

12 2
3

11

14

WI
r

P 6
f c
17 Ie

11

fA f
1

16

el
Q
19

I
Reservlor tank disc brake for w

Fig L 2 Exploded mbly

2o

FIg L 3 Exploded cyl ncler


t Push rod 2 Dust cover 3 4

of tho master brake

Retalnmg ring Secondary piston cup

t 1 ReseflfOlr 12 ResIHVOlr ClIP 13 Bleeder ICrtlW ClIP 14 15 16


a spnng k vaM Ch tl Gasket ring 18 Paton stop bolt

5 PISton 6 PrImarypiston CliP 7 Inlet aWe 8 p ton return spring 9 10

Bleeder CMck

W SiCffJ

Cylll

derbOOY

9 20

ket Ga

ler was
g Vlllvep1u

l Re rvolr

cltp

fitted to the car Fill L 5 The front drum brake

78

Bra kes
BRAKE PEDAL Removal and Installation Remove the return spring and the push rod cleviS pin and Remove the disconnect the pedal from the master cyltnder See FIg L 2 PIvot pin and 11ft out the pedal Check the
or

and detach the wheel cylinders after disconnecting the bridge pipe between them If the wheel cylinders must be dismantled remove the rubber dust caps and Withdraw the Inner parts Check the brake
mm

pedal

shaft

bushes
or

the

pedal

and other parts for

dIstortIon and replace parts as Install the pedal by necessary reversing the removal procedure Lubncate the shaft bushes and the push rod clevIs pm With brake grease Tighten the PIvot pIn nut to a torque setting of 3 5 40 kgm 25 3 289 Ib ft

damage

excessive

wear

dIameter of 229 6 In Also check the drums for cracks or other damage and replace If necessary If the linings are not seated on In 006 In the shoes properly worn to below 1 5 mm thIckness grease Impregnated Or burnt replace them Check the exceeds 0 05 mm 9040
a maximum

drums for 0002 In to

Qut run

and skim If the

run out

adjusting

cams

for freedom

weakness The standard dimenSions Wire dIameter

of rotation and the springs for are as follows 35mm 77 5


mm

BRAKE MASTER CYLINDER Refer


to

Removal and DIsmantling

Free

length

Remove or disconnect the follOWing Fig L 3 Push rod cleVIS pin at the brake pedal brake pipe at the master cylmder and master cylinder securing nuts from the bulkhead LIft the master cylinder from ItS mounting parts
reservOir and remove the dust cover and piston stop screw from the bott of the cylinder After removIng the piston retaining ring and the abutment washer shake out the piston assembly the piston return spring valve

Number of turns Check brake

215

Drain all flUid from the

the brake backplate for distortion Inspect the wheel cylmder bore for scoring and the pIston surface for corroSion or damage The maximum running clearance of the piston In the cylinder bore must not exceed 0 15 mm 0 05 In It
IS

the

recommended to

renew the

piston cups every time

FRONT DRUIV BRAKE

Assembly and InstallatIOn

cap and check valve

BRAKE MASTER CYLINDER

Assembly and InstallatIon

Reverse the dIsmantling and removal procedures noting the fitted to the Gnnd the new If pOints linings follOWing diameter of the brake drums Take care not to bnng 011 or brake linings LIghtly grease all In contact With the movIng parts adjust the brakes and bleed the brake system grease

Thoroughly clean all parts and check as follows replacmg any defectIve parts Cups and valves shou Id be renewed as a matter
of
course

FRONT DISC BRAKE Check the piston and the cylinder bore for abnormal wear and damage The clearance between the piston and the cylinder wall should not exceed 013 mm 0005 In Springs should be checked

Removal and DIsmantling

Support the vehicle


the brake hose the

damage reservoIr for damage

for

or

weakness

Inspect dust

cover

and

SWivel Remove the hub nut and Withdraw the hub

on stands remove the wheel and disconnect Remove the bolts securing the brake calliper to FIg L 7 JOint flange and remove the calliper

together

With the

brake disc To dismantle the calliper remove the antI rattle clip and remove the brake pads from the callIper Remove the tension spnngs and pull the cylinder out of the callIper Blowout the piston uSing air or hydraulic Itne at the brake hose connection as
In Fig L 8 Remove the rubber seal from the cylinder groove and the retainer and the wiper seal

The assembly of the brake master cylinder IS a reversal of the dismantling procedure noting the follOWing pOints Soak the pIston cup In brake flUid and coat the pIston and the cylinder working surfaces WIth brake flUid prior to assembly After the

complete installatIon adJust the brake pedal height and bleed the hydraultc brake system

shown

BRAKE PIPES plp S or hoses they do not foul any replace the part In question making 1 7 kgm movIng parts Connetors should be tIghtened to 1 5 108 1231bft If any found be due to brake
sure

If for 1

any flUid
wear or

leaks cracks
In

cylinder assembly

It

leakage

IS

to

or defects can be found on the should be replaced Check the brake pads If the pads areworn down to a thIckness of

damage

mm

004

I they

must be

replaced

In

sets

of four

ReplaCing

brake pads causes the brakes to pull to one SIde out run The Check the brake diSC for scoring out of round and run out IS best checked as shown In FIg L 9 w th the hub

only the

worn

FRONT DRUM BRAKE

Removal and InspectIon

mounted to the SWIvel JOint If It IS necessary to re machlne the brake dISC take care that a mln thIckness of 8 4 mm 0331 In IS not exceeded The nominal thIckness of the brake dISC IS 10
mm

Support

the vehIcle

on

stands and remove the brake drum hub

004

In

If the dISC be

IS

cracked
must be

or

damaged

In

any other

cap and hub assembly by removing the spilt pIn and the castle DIsconnect the brake hose nut from the SWIvel JOInt spindle from the wheel brake cylinder Unhook the return springs from the brake shoes and 11ft off the brake shoes From the rear of th brake backplate remove the wheel cyltnder securing screws

way

It cannot

salvaged imd

replaced

79

inter E

@ 1J

55 Y

UBE bu

L H I I c

Fog L 7 Removal of the brake calliper

fR

nIL ILl

F 19 L 4

Exploded

view

of

front

brake

bly

Fill L 8 SSlld comptl

the plSlDn EJectJ


aD

by

means

of

lrJ
1
@ @j
Fill L 9 M88I11nIlg the brake daiC for
7
t run

Fog L 6 Exploded
assembly
I Cylmdor 2 PISton I 3W of RetBtner 6 P 6 a 1 Shim

of

the front dE brake

10 r

MIOn

rpt lfIg

Spl pin
12 13
14 tIenut c

Suppon btlldr
t

8 9

8 cl

I p IpO

pi

15 Hold down pin 16 Pwotpin Ut 17 Mounting brIIc 18 Spnrv

FIg L 10
m 1Mr c

80

rp J

Fig L 13 Removal of thobrake pads

t
Fill L 14 Exploded
YOM

of the rear

brake

jj
I 70
6 M

lM

1I1

Jll
L
1
J

A
I

2
I

J
I

T v
I

lIII lo

I
Fill L 16 posrbon
Tho
In

J Fill L 17
Tho handbnoko cable

foung pOints of Saloon models

the

rear

81

FIg l19 The brake pedal adJustment

FIg L 20 Adjusting the brake hght swItch

FIg

L 22

mode

r 1
J

J
tc

Ji

T F16
1 f
loo t

if

IJ

r7
I

ifi C J

82

the front cable FRONT DISC BRAKE Rinse the

Assembly

and Installation

From
clips

Remove the cable from the handbrake lever underneath the body release the cable from the mounting pull out the lock plates holding the cable retaIner and

cylinder bore thoroughly WIth brake fluid and fIt the piston seal Into the groove as shown In Fig L 10 Fit the wIper seal and Itghtly grease the bore wIth the speclfl grease 91ean the brake dISC and fIt to the hub The hub can now be fitted to
the swIvel JOint fIt the piston Into the cyltnder relteved portIon faCing the PIVOt pin and push In the pIston until It IS almost flush WIth the wiper seal retainer Install the cyltnder Into the calliper plate and secure In posItIon by means of the two torsIon springs FIt the down hold pin spring washer and the nut to the support

Withdraw the cable Pull out the front cable from the car after undotng the outer CllSlng of the cable as shown In F rg L 15 whIch has a pressfIt In the handbrake control bracket

completely

Remove the clevIS pin connecting the lever yoke WIth the lever and the cleVIS ptn connecttng the control Handbreke lever

Carefully

gUIde

and the bracket


IS

The tnstalled lever

shown

LIft out the handbrake lever In FIg L 16

assembly

Rear handbrake cable

Saloon

Remove the adJusttng nut and

bracket and secure the nut With a spltt ptn Assemble the callIper to the mountIng bracket WIth pIVOt pIn WIth spring washer plain washer and castle nut Tighten the nut and secure WIth a Hook the down hold bracket on to the top of the mounting bracket and turn the calltper plate to ensure that It can turn smoothly Then fIt the calltper to the SWivel JOint

dIsconnect the left hand cable from the handbrake adjuster Pull out the lock plates and remove the clevIS pIns securing the See FIg L 17 cables to the rear wheel brake cyltnders Rear handbrake cable the Estate Car
rear

split pin

from both ends of the

cable

by removtng

off pull

Remove the cleVIS ptnS Remove the connecttng rods springs and the cleVIS ptns See

flange
FIt
a

Fig
Inner

L 18

shIm to the

brake pad and msert the

Inner

pad Draw

the callIper towards the chaSSIS Then tnsert the lower cuts on the ends of the pads Into the mountIng bracket and push tn the

HANDBRAKE MECHANISM Check the cables for

Installation

pad untIl

the piston Move the calliper away from the chaSSIS and tnsert the upper cuts Centre the tndentatlons of
It contacts

breakage fraytng
lever

or exceSSive

stretchtng

the outer pad to the callIper plate shown tn FIg L 11

Fit the anti rattle cltp

as

springs for weakness and the ratchet for wear The return and the off pull spnngs should be checked for weakness Also check the equalizer lever and the bushes for wear or damage Replace parts as necessary The tnstallatlon of the removed parts IS a reversal of the removal All slidIng parts should be greased pnor to procedure InstallatIon

Examme the

handbrake

BRAKE PADS The

Replacement

wear of the diSC brake pads should be checked every 3 000 If the pad thIckness IS less than 1 mm 004 miles 5 000 km In change the pads as a complete set of four

BRAKES Take out the antI rattle clip By movIng the calliper plate away from the chaSSIS push the piston mSlde by 3 4 mm 0 12 0 16 In and remove the outer pad Then draw the calliper plate tnwards and remove the lOner pad Clean the Remove the wheel

Adjustments

Brake pedal See Fig L 19 AdjUst the brake pedal by turntng the master cylinder push rod to obtain the heights shown tn the

dIagram

exposed
IS various

surface of the pIston The InstallatIon of the new pads carned out tn reverse order See FIg L 11 12 and 13 for

pedal stop
Now

WIthout dIsturbIng the brake light SWItch must be free TIghten the locknut the brake

The brake

stages of replacement

screw tn IS

light

SWItch untIl the threaded part of

the SWItch REAR BRAKES Removal and Instal ation Fig L 14

touching the front of the stop bracket FIg L 20

tn thIS posItIon Then screw In the stop bolt until the moveable part of the SWItch IS fully pressed tn and lock the stop bolt Check that the brake Itghts come on when the

Lock the SWItch

stands and remove the wheels Release the handbrake and disconnect the connecttng rod from the lever

Support
at

the vehicle

on

pedal

IS

pushed

down

by

1 5

mm

0 06

In

Front brake

the

rear

of the wheel brake

cylinder

Remove the brake

drum Unhook the return spnngs and 11ft off the brake shoes If necessary dIsconnect the brake pipe and remove the brake

Depress the
cams

Jack up the front of the vehicle drum brakesl brake pedal several tImes and then turn the adJuster forward until the wheels are locked From thIS pOSitIon

cyltnder cylinder
I

wheel brake dIsmantled by removtng the corcllp and the rubber dust cover and takIng out the Inner parts Remove the brake adjuster and the brake backplate as descnbed for the removal of the axle dnve shafts
In

dust The

cover

plates

adJusttng shIms cylinder can be

and

then

the

back off the adJuster until the shoes free the brake drum Note that there are two adjusters on each wheel which should be treated NOTE models

completely Independently
The dIsc brakes self adJusttng fItted to the front wheels of some

are

sectIon

Rear Axle and installation


IS

Rear brakes The

assembly

SImilar

as

deSCribed for the

Jack up the released

rear

wheel and WIth the handbrake

front drum brakes

completely

pedal several tImes to settle the mechantsm Turn the adjuster FIg L 22 and L 23 In a clockWise dorectlon untIl the brake shoes are locked to the depress
drum Then back off the the wheel rotates

the brake

HANDBRAKE

Removal

adjuster by

two or three

notches untIl

freely

holdtng

Release the handbrake remove the clevIS pIn Front cable the cable and unscrew the adJusttng nut at the rear of

83

With the handbrake released and the rear brakes HIlA as described above adjust the front and rear handbrake cable to obtain a lever stroke of 85 95 mm 3 346 3 740 In for the saloon Fig L 24 In the case of the estate car adjust at the front adjuster to give e stroke of 110 120 mm 33 4

adjusted

With the master cylinder reservoir completely fIlled remove the ler dust cap from the bleed plug furthest away from the rub

4 724 in

Fig

L 25

cyhnder and connect a bleed hose lD the bleeder valve ImlTllirse the other end of the hose in a Jar containing a httle brake flu id Depress the brake pedal several tImes to the
master air

keep

expel

valve

the 1 3 to

pedal

at its

2 turn 1

BLEEDING THE BRAKE SYSTEM


When any part of the hydraulic system has been disconnected or the presence of air In the system is detected the system must be bled To do this

pumping operation until only brake flUid flows into the glass jar Fit the rubber dust cap and topup the reservoir Repeat the bleeder operations for the other bleed plugs finishing with the bleed plug nearest to the master brake cylinder

and open the bleeder and then close the valve Repeat this

eSt 10Vl

position

proceed as follows

Technical Data
BRAKE PEDAL Brake BRAKE DRUM AND BRAKE DISC Drum inner diameter 187
mm mm

pedal height

Front drum brakes

228 6

mm

900 In

R H D L H D With autom transm Brake pedal height Front diSC brakes R H D L H D With autom transm

187

197 mm

7 362 In 7 362 In 7 756 in

DISC outer dIameter


of Out round of drum Max permissible drum dla Max permissible disc Ut H rul

232 mm 9130 In 0 05 mm 0 002 in max 229 6 mm 9 039 In 0 06 mm 0 0024 in

202

mm 7 953 In 207 mm 8 150 In 197 mm 7 756 In

BRAKE LININGS Drum brakes Width x thick

MASTER BRAKE CYLINDER


Inner diameter Piston running 19 05 mm 3 4 0 13 mm 0 005
In In

length
11 575

4Ox4 5x219mm 0 In x 8 642 in

C8 c1earal

elSC brakes
Front

39 7

9 0

86 0

mm

WHEEL BRAKE CYLINDERS

Rear Total braking area Front drum brake Front diSC brake
Rear brake

1 563 x 0 354 x 3386 In As for drum brake models

Inner diameter Front drum Front diSC


Rear With front drum

22 22 mm

718

In

Rear with front disc Piston running clearance

50 80 mm 2 0 In 22 22 mm 718 in 20 64 mm 11316 in
0 18 mm 0 709 In

351 sq an 54 4 sq in 114 2 sq an 117 7 sq In 351 sq cm 54 4 sq In

84

Trouble
SYMPTOMS Insufflent performance Leak

Shooting
ACTION TO BE TAKEN
worn

PROBABLE CAUSE

In hydraulic system Brake pads or linings excessively Water or 011 on linings

Trace and rectIfy Replace pads or brake shoes Clean or replace linings

Pedal contacts floor

Pads or linIngs No brake flUid

worn

Replace

as necessary Refill and bleed system

Pedal feels spongy

AIr

n system InsuffICIent flUId

In reservoir

Bleed system

Top up flUId system

Pedal

can

be depressed WIthout actIon

Check valve

In

master

cylinder faulty

Valve seat dIrty

Check and repaIr Clean valve seat fIt

new

valve

Brake effort decreases and pedal goes slowly to floor

Brake pipes or hoses leaking

TIghten
In

connections

or

fIt

new

PIpeS

Damaged
brake
or

or defectIve cups wheel cylinders

master

and hoses Overhaul cylinder

In

questIon

Brakes overheat

CompensatIon port

In

master

cylinder

Clean master brake cylinder Fit

blocked Return spring weak Rubber parts swollen due to unSUItable brake flUid

use

of

springs flUId remove all rubber parts and flush system Replace all parts In master brake cylinder Drain

new

Brakes pull to

one

SIde

Loose back plate mounting bolts Oil on Itnlngs or pads Loose

TIghten
Clean
or

damaged wheel beanngs Improper operation of wheel cylinder


or

AdJust Repair

replace replace or replace


or

Improper tyre inflation

Correct tyre pressure

i nter

10

Mil
0 8 04Ii

OG
0 0

C 81

Vl
f

III
81
e II

e
ClO lle

FlgM

t r Exploded vlBW of the h


StoIor 8 Olodo 9L Ia Brush y b I I Slip r IV nd
6

I O pul 2 ThfOugh bolt 30 end brodrn 0

e
M 4 The Fig
COIIl

oo

1l

of the drmt pulley

5 Rotor

II SIIp

IV end

FIg 3 RernlIYaI M

of the drive

pulley nu1

M 6 TIPPing FIII
rotIlr

the dnve

end bndtet off the

6 Remon of the M FII bearing

rotIlr

slip ring end

W
Red
or

Black
on bliwot

figures

Fig8 M

ctenng the temlmal UN

M 7 The FIII

Id

of the dIOdes

88

Electrical
ALTERNATOR Precautumay Service NotllS
IS

Equipment
with a hammer The parts separate as shown In Fig M 2 Hold the drIVe end rotor carefully In a VIce and remove the pulley nut the pulley the fan arid tha spacer from the rotor shaft Fig M 3 and M 4 Tap out the rotor from the drive end bracket uSing
a

The following precautions should be taken when serviCing carned outon vehIcles wIth alternator charging systems
1 Reversed

battery

connections

will

damage

the

dIode
IS

hide mallet
IS

Ensure that the rectifIers connected to earth 2 Never earth the


at
main

battery negatIve
cable
IS

terminal

retainer and

press

out the beartng rotor

FIg M 5 Remove the beartng from the beartng hOUSing The

bearing from the


of conventlonal
IS

removed M6

by

means

of

arm two

puller

deSign

FIg

alternator

when

It

disconnected

the alternator If thiS cable

earthed With and the

the IgnitIon SWItched on the voltage assocIated wlrtng may be damaged 3

regulator

Remove the stator from the dIode 3 negatIVe diodes black fIgures for for pOSitIve dIodes In FIg M6 from care not to overheat the diodes as

end

hOUSing by unsoldering negative diodes red fIgures

Earthing

the

main

WIll damage the alternator and even when the IgnitIon SWItch CirCUIt breakers are used 4 Do not
u nit run

cable or the terminal of the alternator or the alternator CIrcUIt IS SWItched off Since no

damage
stator

Then

unscrew

and
as

the cOIl lead WIres but take thIS WIll lead to Irrepalrable remove the brush cover and
In

unsolder the

termlnai

shown

Fig

M8

Lift

ff the

the alternator WIth the battery dIsconnected and the field WindIngs energlsed otherwIse the control WIll be
not

damaged
to

Remove the heat Sink and the brush holder from the rear cover Dismantle the brush holder and unsolder as shown In Fig M 9 black and also the F black whIte and E the lead wires brush holder wires A dIsmantled View can be seen In Fig M l0

Do

attempt

polartse

the

alternator

It

IS

not to

necessary Any attempt to do so may result In the alternator regulator or associated CirCUItS 6 DIsconnect

damage

charger
charger
first control

to to

the battery cables before uSIng a battery prevent damage to the rectIfIer diodes A boost assIst starting the engine cannot be used WIthout
can

replaCIng they should be pressed out of the replaced USing a SUItable press tool Do not drtve out the damaged dIode as the other stIli servIceable dIodes may be damaged through the Impact and shock
If the diodes need heat Sink and ALTERNATOR Rotor check the rotor COIl for open or short USing CirCUItS Connect the Instrument to the shp rings of the rotor and check the indicatIon on the ohmmeter No reading indicates
an

Inspection

dIsconnectIng the
Unit
wire

control unit be Isolated

voltage regulator by disconnecting

The the ohmmeter

connecting 7 Never lrtven hand


transIstor
use

to

the alternator

an

ohmmeter of the type Incorporating a generator for checking the dIode rectIfIers or

dIsconnected
room

ohms at
to

field co When the readIng IS approx temperature the connectIon IS In order

447

Belt tensIOn
tenSion

aVOid bearing damage when adJustIng belt only on the alternator drtve end leverage apply any other part of the alternator

bracket 9

not on

If arc welding IS carried out on the car disconnect the alternator and control Unit to prevent pOSSIble damage It IS also Important to Inform any welding speclahst of thIS fact as It IS poSSIble that he Will not know that thIS car IS fItted With
an

cbeck the rotor between shp rtng and rotor core If there readIng on the ohmmeter the rotor assembly should be replaced as In thiS case the fIeld COIl or the shp nng must be connected to earth FIg M 11 shows the testIng of the fIeld coil If for conductIVIty top and for earth connectIon bottom
Next
IS
a

there

IS

short

or

open

CirCUIt

then the rotor should be

replaced
Check the rotor for concentnclty Fig M 12 by clamping the at rotor between the centres of a lathe and placing a dIal gauge the outer diameter of the rotor If the eccentricIty exceeds 0 10
mm

alternator chargrng system


or

10

The battery must never be connected dIsconnected while the engine IS running or damage may occur to the devIces conductor seml regulator

0004

In

replace

the rotor Stator

ALTERNATOR

Removal

Disconnect the battery earth cable and dIsconnect the Wires from the alternator Remove the bolt securtng the fan belt tensIoning strut ana hft away the fan belt Remove the

uSing a CIrcuit tester by the neutral wire of the to connectUlg stator The connections are In order If there IS COndUCtiVity If any of the other leads IS connected to the other Side of the tester If thiS IS not the case replace the stator There should be

Check the stator for conductIVity


the lead N

yellow

alternator

retaIning bolts and lift the alternator from the

mounting bracket ALTERNATOR

open CircUit conditIon between the stator M 14 the cOIl leads Fig M 13
an

body

and any of

Diode

Assembly

Dlsmanthng

Fig

M l

Remove the through bolts and remove the diode end hOUSing from the drive end housing by tapping the front bracket hghtly

claSSifIed by the resistance value between the diode holder heat SInk and the diode leads To perform thIS test remove the diode holder from the stator Good
or

defectIVe

diodes

are

f11

inter

cJU

jIJtE @

1
r 1
f

FI9 10 V M 1Ily

of the removed dIode holder

M9 FIlI

holder assembly from

al of 1he heat smIl 811d brush Remo the cover

for Fig M 12 Checking the rotor

out run

for Checking the rotor field cod bottOm and earthIng continurty top

M l1 FI9

FI9 13 Chedung M

1he

wlIldmgs for

con1lnurty

rJl
1he

W1ndlriila

for

M 15 DlOlIe FIlI

test

M 16 DIOlIe test g i F

88

DIode holder posItIve sIde


tester to

Low the diode 1 2

unsteady charge
Check drlvlng belt tension Check for high resistance
CirCUit connectIons at

Connect the posItIve lead of the CirCUIt

holder and the negatIve lead to the diode pin and check the resIstance A good dIode WIll indIcate no resistance Next turn the polarity of the tester and check agaIn If the the diode IS short needle moves In eIther directIon CirCUIted If any of the dIodes IS defectIve It might be advIsable
tester to
renew In

battery termInals and


connectIons

10

particularly earth

VOLTAGE REGULATOR Disconnect the 6 way connector and secUring the regulator to the bulkhead

Removal
remove

shown

the whole assembly FIg M 15

The testing

connections

are

the

screws

2 DIode holder negatIve SIde Check the negative SIde as described above but the CIrCU It tester must be reversed FIg M 16 Broshes Check that the remaining brush length IS 7 5 mm 0 295 In FIg M 17 and check the brush spring pressure by pressmg of the holder The brush down to WIthIn 1 mm 004 10 pressure should be 035 kg mlntmum of 0 2 kg 044 Ib 077 Ib
IS In

VOLTAGE REGULATOR ElectrIcal test

Testing

Connect the CirCUIt as shown In FIg M 22 uSIng a fully charged battery and run the alternator at 5000 rpm The voltage read 109 15 0 volts If the voltage IS not correct adjUst should be 140 the regu lator Mechantcal adJustments The gap values of the constant voltage relay and the pIlot lamp relay must be as follows Gl 09 10mm Constant vo Itage relay

thIS condition but

permissible

ALTERNATOR Install the stator COIl the term mal msulator N

Assembly and Installation


termmal to the brush holder and fit

FIg

M 23 G2 G3

0 035 0 8 1 2

0 039
mm

10

Install the bearing Into the drive end bracket and fIt the bearing WIth the three screws Pack the rear bearing With multI purpose grease If no sealed beanng IS used Then press
retamer

0032 004710 0 4 0 5 mm 0016 0020 In 0 2 0 008


10

the drive end bracket

on

to

the rotor shaft dnve end bearing

PIlot light

relay

G1 G2 G3

mm

The remammg operatIons are carried out 10 reverse order to the dIsmantling procedure Make sure that the dIodes are connected correctly Fig M 18 and M 19 The mstallatlon of the alternator
IS a

08 1 2 mm 0 2 0 024 In 0 4 0 5 mm 0016 02010

reversal of the removal head 109

Observe all procedure pomts gIven under the ALTERNATOR PrecautIonary ServIcIng Notes

Back gap G 1 Clean all contacts With

flOe emery cloth pnor adjustment feeler gauges check the back gap Gl and adjUst If necessary by means of the armature set screw

Usmg

ALTERNATOR Connect the alternator


10 a

Inspection of output
test
ClrCU It as

Air gap
In

G2

shown

FIg M 20

and dnve by means of a SUItable motor With the alternator at 2 amps rest there Will be a negatIve current to the field cool When the alternator IS turnmg at about 1000 rpm there should be
no

aIr gap between the armature and the top of the COli feeler gauge and If necessary adjust by bending the primary contact support Fig M 25 usmg the adJustmg tool

Check the WIth


a

negative current SWItch closed and the load resIstance at


maxImum

WIth the

Pomt gap G3 Check the gap WIth feeler gauges and adjust If necessary by bend 109 the secondary contact support With the adJustong tool Yoke gap gl Use feeler gauges and measure the gap between the armature and the yoke and If necessary adJUst be bending the armature
setscrew

slowly reduce the load reSIstance mcreaslng the alternato speed Read off the current value In relation to the alternator speed and check 10 accordance to the speCIfIcatIons If the deVIation IS small the alternator IS 10 good condItion
ALTERNATOR

Flndmg

of faults

Alternator does not charge the battery 1 Check drlvmg belt tensIon 2 3 4 Field cable broken at control Untt NegatIve cable broken at control unIt POSItive and field cables crossed uncontrolled

Air gap g2 Check the gap With feeler gauges and adJUst by loosenIng the contact set screw and raisIng or lowering the contact set WIth a screwdnver

FIg

M 26

Pomt gap g3 h he gap

Alternator output
1 2 3

y means of a feeler gauge and adjust by the contact po lOt set screw and alsmg or lowerulg the contact set WIth a screwdriver

loosening

POSitive cable broken at control Untt Field and negatIve cables crossed at control unot Field and output connectors touching at alternator

89

IDmZIIIII
1
r
I I I I

jj TBattery
I I I

l
I
I

I
I I I I I I I I I I I I I l I L I J I I I I

F g M 17 The

m nlmum

brush length

Alternator Current flow Current flow


F g M 18

Voltage regulator nng pressure Checking the brush

Red ftgure

lack flgure
M

Diode terminal PILOT LAMP RELAY VOLTAGE

POSItIve dIode

NegatIve diode

REGULATOR

dIodes FIg M t9 The current flow In the

Fill M 21 V prlot lamp relay FI9 M 20


ahemator Test
rcult

of the voltage regulatof and

for

checkIng

the

performance t

t
Back gap G Air gap G2 08 12 Stopper

PrtmafY
contact

support

Voltage corl

SecomlafY
COntact

support
A V

Ammeler V ollago meter FIlIM 23 The voltage reagulator


See text

Woro harneSS foo the voltage regulatOO M22 Test Cllcurt g F

90

mter E itl i j2J CQJ E

Air gap 112

POint gap g3

Sprong

Voltage coIl

M 24 The pilot lamp relay g

See

Fog M 25 Adjusting the regulotor G2 In text

elr

gap of the

voltage

BendIng dIrection

ghten voltage

I Lower voltage

Fog Fog M 26 Adjusting the lemp relay g2 In text


air

27 M

Adjusting the voltage

g Sllttll

gap of the

pilot

cO

5C h
V

12ij0
i Ct

l
Fog M 29
fnIm The tu onn motor body end drIVe end bracket removlKl

1 0

14

IS 16

17

19

ii
the

if 1
g

M 28 ExplodlKl Fog
lINer 10 O

VlOW

of

motor

lnent t Etrpf 2 a 5

pin

rod brocktlt bush Thrun


w r

Sulmg

flntI t

Dr rod brsck 4 Dun protectIOn efMntltwer lI Etrf

12 Slop

C IP

14 Pinion rtap OD
15 Drwe

1er

6 Dud l 7 SoltlnoJd
tbil8 BAnn

tch

16 O 17 Fleldcoll

pimon h nn ngclvtr

IS Sttrter motor body brush 19 brush 20 N 21 Brumllmng 22 Brush dtJr ho 23 BNrtng bush 2tI R co 25 bon lh ThroU

Thnnt

Fog M 30 The moclIanllll1 removed br8ckoL

motu end

nt

from

the

dr

end

91

inter

J I1

1 ID

FI M 31 I

Testmg the f 1d COIl for continuity

I FI

32 CheckIng the brush spring M

te

on

Round

0 5mm O

8mm

Commutator
Ica

Correct

Incorrect

Fig

34 M

uttlng Unden

the mICa Insulators

35 Testing the Innature I M FI Wlndmgs for earth connectIOn

gmtlon swItch

Fill M 36
Circuits

Checkmg

the armature

for

short

IT

Battery

Starter motor

l
M38 FI9
II M ng

the starter

motDr

FI9 37 TesI circuit for M

lenood Mrtd1

l panlOl

92

V ol1age To increase the downwards Fig M 27


to

adjustment

voltage

decrease

bend the stopper upwards or bend It the voltage on the voltage relay

test prod to the commutator and the other one to the armature or shaft If the lamp lights the armature coil IS connected to earth and the armature should be replaced The armature can also be tested by using a Circuit tester as shown In Fig M 35 If the Circuit tester needle moves the coil IS earthed

Check the
VOLTAGE REGULATOR lnstallllt101l order to the removal
armature

armature on

wmdlngs for mternal shorts by placing the

The installation

IS

carrted out

10

reverse

procedure
STARTER MOTOR Removal

the growler and hold a hacksaw blade over the armature while rotatmg It If the hacksaw blade vibrates the wmdlngs are shorting and the armature must be replaced Fig M 36
llts by placmg the Check the armature wmdlngs for open crra armature on the growler and connectIng two commutator

Disconnect the battery earth connectIon and the cables from the starter motor termmals Remove the starter motor mountmg bolts and 11ft the motor forward and out of the
car

segments With the test prods Repeat thiS test for all adJacent segments An mconslstent reading mdlcates an open CIrcuIt
Starter motor clutch the running clutch for damage and Inspect the free wheel actIon 10 one direction and the slipping actIon 10 the opposite directIon Replace If faulty Check
over

STARTER MOTOR

Dismantling

DIsconnect the Wire to the M termmal on the starter motor solenoId swItch remove the solenoid swItch securmg screws and 11ft off the solenoid swItch Remove the two through bolts and take off the brush cover Gently tap off the starter motor body WIth
a

Brush holders the brush holders for earth 109 USIng a CIrcuit tester Place one test prod on the rear cover and the other on the pOSItive brush holder If the tester needle moves It becomes Check necessary to replace the Insulator or the brush holder DrIve end Check the clearance between the
at

wooden

hammer

to

separate the parts

as

shown

10

FIg M 29 Remove the armature assembly and the engagement


lever from the dnve end bracket Fig M 30 From the end of the armature shaft remove the clrcllp and the clutch stop collar and slide off the starter motor clutch Unsolder the brushes from ther connectmg leads and Itft out the brushes

bearing

the dnve
10

end

OOOB STARTER MOTOR

replace

beanng and the armature shaft If the runnmg clearance exceeds 0 2 mm the beanng Press 10 the new beanng and
size

Inspection and Overhaul

ream

out to

the correct 0 10

clearance of 003 FIeld coIls Check the fIeld COIls


one

mm

of the armature to give a runRlng 0004 10 The beanng 0001

Connect

test

prod

for open CirCUIt us 109 a CirCUIt tester on to the field coli lead and the other If the tester needle does not F Ig M 31
an

pressed 10 so that the end of the WIth the end of the dnve end housmg
should be Solenoid switch

beanng

bush

IS flush

prod
move

to

the other fIeld COIl lead

the fIeld Call has

open CirCUIt

the contacts of the solenOid SWitch weldIng of the contacts has occured Check

and see that

no

Check the fIeld COIls for earth Connect one test prod to the field COIl lead and the other prod to the starter motor body If the needle be
moves

the fIeld COlliS connected to earth and should The Brushes

ER MOTOR

Assembly

replaced

assembly of the starter motor IS carried out 10 reverse order to the removal procedure Pack the rear cover with grease and lightly 011 the rear beanng and the dnve pmlon
Solenoid SWItch test With the starter motor assembled connect up a test circuit as shown 10 Fig M 37 With the igRltlon SWItched on check that the dimension between the front edge of the drive plnton and 15 nvn 0012 0059 10 Measure the plRlOn stopper IS 0 3 this dimension
as

Check the length of the brushes and replace them If they are Check the contacts and replace them less than 6 mm 024 10 If loose Check that th brush holders Will hold the brushes down to the commutator Check the spnng tensIon With the aid of a spnng balance as shown 10 Fig M 32 The correct tension IS O B 0 7

kg kg

1 76 1 54 lb

Ib

Ifthe tension IS less than to lift the spnng of the brush

Replace

the

springs

shown in

Fig

M 38 Removal

Armature
Check the armature shaft for distortion as shown In Fig M 33 out run and replace the complete armature if the IS greater then 016 mm 0006 In Check the commutator for roughness burnt or scored surface If necessary skim off the surface 10 a lathe removmg the minimum material necessary to obtam a smooth fiRlsh The round of the commutator should not exceed 0 2 mm of out 0 008 10 Check that the mica inserts areundercut to a depth A mmimum depth of 0 2 mm of 0 5 O B mm 002 0 032 in 0 008 10 must not be exceeded

WINDSCREEN WIPERS

Lift the Wiper arm remove the secunng nut and remove the arm together With the wiper blade Remove the link securing nut Lift the bonnet and remove the screws holding the Wiper

assembly

to

the bulk head

Disconnect the

wiper

motor

Wiring

and remove the

wiper motor and the 1Inkagi

See Fig M 39

WINDSCREEN WIPER
Remove
ended hook

Dismantling

the

linkage and
bolts
from

Check the armature cod for earth usmg

growler Connect

one

IlI8gnetized

case

the bracket the nuts of the the motor case and remove the from the gIl8I case Withdraw the annature

91

i nt e fiE

JI DJ OoJ

l P

1 2 3 4 S

Yoke

16 17

B b Rivet

31 32
retainer

Tapping
Worm
Wheel

lCJ ew

Damper
Armature

wheel
ann

stopper

18 19 20 21 2 23 24 2S 26

Spnng
Gear

33
34 3S 36 y 37 38 39 40

Feltwasbe r

Grommet
case screw us

PlaiD washer

Beanng
Hook
Rivet Felt walber Plate sptmg holt

Hexagon

out

6
7 8 9 10 11 12 13 14 t5

Tapping

Lock washer PlatD wamer C

Brush holder Plate spnng Felt


wa her

type nop

nug

Thtust washer Wave washer

Sprmg
BaU

etamer

Beatlng
Auto Lock

stop

cover aA

41 42

Magnet

ball
au

27 y 28 29 30

plate
erew ass

Beanng Hexagon
Tluwt

nut

Armature

PIa m Imall Gear COVei

43

screw

Commutator Brush spnng

y 4S

Thrust washer Gear shatt


aD

Chp

M FIU

39

Exploded

of the windlcnen wiper motor

3
7

28

43

35

M 40 Removal of the wiper drIVln9 IIl1ndle g

nut

M 42 Removal of the brush h FIg

sr

M 43 Justment for the of the W1P8r blades

Fig

If parlnng

pcIS1tJon

94

Pull the carbon brush

from Its holder and remove the brush

remove It From the gearbox the cover screws and hft off the cover The gear can be removed after loosening the securing nut Remove the circlip from the end of the shaft and remove the shaft

spring

Unsolder the brush and

COYer unscrew

DIRECTION INDICATOR SWITCH

Removal and

Installation

panel WINDSCREEN WIPER MOTOR


Reverse the

Assembly and InstlIlllItJOn

Disconnect the wiring from the connector at the dashboard remove the horn ring and remove the steering wheel Remove the steering column COYer and take off the dIrection indicator SWitch

Apply

dlsmanthng and removal procedures respectIVely grease to the gear and coat the hOUSing and the cover
JOinting bracket Adjust the the stop cover screw and turn
J AI smear

The InstallatIon When

IS the

reversal of the removal procedure


sure

surfaces

With JOInting compound compound between hOUSing and end parklng self the cover switch by
as

fitting

the steering wheel make


to

correct

relation

the

shown

In

loosentng Fig M 43

stralght ahead

posItion

that the spokes are In of the front

wheels

Technical Data
ALTERNATOR Armature shaft dla Maker Nominal output Earth connectIon HITACHI 12 volts 30 amps Max permls shaft out run Bush running clearance Clearance Itmlt Commutator outer dla Wear hmlt Brush 11 0
mm

0433

11 5 003

mm

0453

pinIon SIde rear end 008 mm 004 In


In In

NegatIve
13 500 rpm 1000 rpm 22 amps at 14 volts and 2500 rpm 2251 1 000

Speed
No load
mln

speed
engIne

001 mm OOOl 0004 In 02 mm 0008 In 35 0 mm 1 38 In less 2 0 mm 0 079 In lB5 mm 0728 10 6 0 mm 0236 In o B kg 11 0 11 5


mm

Output current Pulley ratIo to

length

Wear hmlt Brush spring tensIon Drive end bracket bearing bush HITACHI
Inner dIameter Drive end bracket bush bore Inner dIameter

1 76 Ib 0433 0453
In

VOLTAGE REGULATOR Maker

Type
No load

regulating voltage

Constant voltage relay 14 15 volts5000 rpm

mm

In

STARTER MOTOR HITACHI S114 103 12 volts 10kw Less than 480 amps 6 volts 1 1 kgm 8 0 Ib ft Less than 60 amps at 12 volts 7000 rpm Solenoid SWItch 9 120 5 1

LAMPS

Type Voltage Output Starting current Starting voltage


Lock torque No load current Free running speed OperatIon medIum Number of teeth on pinIon Number of teetn on engine

Type 1 Type 2

sealed beam sealed beam

37 5 watts 37 5 50 watts B watts


I

Park 109 lamp Front flasher SIde flasher

lamp lamp

25 watts 6 watts 8 watts 10 watts 25 watts

flywheel ring

gear

Weight

kg

10 4Ib

Engine compartment lamp Interior lamp Rear flasher lamp Tallstop lamp Reversing lamp Number plate lamp IndIcator lamps

25 8 watts 25 watts
8 watts 3 watts

95

Trouble
SYMPTOMS Battery
In

Shooting
ACTION TO BE TAKEN when runntng at about
on

PROBABLE r AUSE

low state of charge shown by

Dynamo
20 mph

not chargIng

lack of power when starting

30 km WIth swItched

lights
Examine charging and field CIrcuIt TIghten loose connectIons or lead Partlcu larly replace broken wiring
examine

Broken

or

loose
or

connectIon

In

dynamo

CirCUIt

regulator

not

functIonIng correctly

battery

connectIons

Examine regulator Commutator greasy


or

dirty

Clean

WIth

soft

rag

mOIstened

In

petrol GIVing low


when
car IS or

running

Intennittent output In top gear

Dynamo belt sli pplng


Loose
or

Adjust belt tensIon


connectIons
In

broken

Examine wiring

charging

and

fIeld

CirCUIt
or

dynamo

CirCUIt

TIghten loose

connectlotl

lead replace broken PartIcularly Inspect battery connections Brushes greasy


or

dirty

Clean

WIth

soft

rag

mOistened

In

petrol
Brushes
worn or

not

fitted correctly

Replace
brushes

worn

bed

brushes oronerlv

See that the

Regulator

not

functlomng correctly
ExamIne regulator

Battery

overcharged

shown very

burnt out bulbs and need for tOpping up

by frequent

Regulator

not

functIoning

tly corre

Examine regulator

Starter does not operate or operates and does not turn the engine

Poor contact of starter swItch contact POints Poor brush contact Burnt commutator Shorted field COIl Shorted armature Poor contact of battery leads Weak battery

Check sWItch and replace If necessary

Replace brushes
Overhau I

or

spnngs
motor
or

starter

clean

commutator

Replace COIl Replace


armature

Clean and tIghten leads

Recharge battery
between starter SWitch Check wlrtng and replace If necessary

Open

CI

rcUlt

and solenOId Poor earth connectIon Check and rectI fy

Starter does
not
seem

motor to

operates
over

but

Drive plnton defectIve

Replace drove pinIon Replace flywheel


gear teeth
or

turn

engine

qUIckly enough

Flywheel ring gear

worn

recondition ring

at

IgnItIon wamlng lamp high rpm

goes

out

only

Generator faulty Regulator fau Ity

Repair generator Replace regulator

IgnItIon warning lamp does not light With Ignition SWItched on

DIscharged battery Defective battery


Bulb burned out Loose or corroded battery terminals Loose or broken cables Defective IgnItion starter SWItch contact between Poor generator brushes and commutator

Charge battery Replace battery Replace bulb Tighten or replace terminals TIghten or replace cables Replace switch Free or replace brushes If necessary replace brush springs Adjust tension or replace belt Replace regulator TIghten connectIon re replace lead Repair generator
Clean commutator

Ignttlon warntng lamp does


fli ckers Increased
or

not

when

engine

go out IS rpm

Loose

or

broken fan belt

Regular defective
POSitIve lead loose or broken Generator de ECt ve Commutator graphlted Brushes worn Brush spring weak or annealed BInding brush levers

turns WIper motor does not operate II too slowly or comes to a standstl

Replace brushes Replace spring


Free brush levers Clean commutator Lubricate all moving pOInts eliminate binding spots Check for voltage drops on
connections

DIrty

commutator
In

ExcesSive frictIon

wiper linkages

Low operating voltage Burnt out armature


motor continues to run after SWItch IS turned off or does not return blades to parking pOSItion

Replace Replace Replace Replace

armature

or

complete

motor

WIper

Contacts In hOUSing damaged Contact spring bent Insulating bracket broken Contacts dl rty Wiper motor cannot be SWItched off Bad connection from wIper SWItch to earth

contacts contacts contacts

Clean contacts Screw SWitch button back slightly bend contacts Check connectIon replace SWItch

Motor squeaks sometimes combined WIth slow operatIon

Wiper linkages
POI
n

bushings

running dry

Grease all moving parts of linkage Bend stop to clear

of

armature

spIndle
of

commutator Side against stop brush holder Incorrect pOSItion of motor cover

RepOSItIOn

cover

Starter motor pinIon does not out of mesh

move

PinIon

or

a rmatu re

shaft

dirty

or

Overhau I starter motor

damaged
SolenOId SWItch defective

Replace solenOId SWItch


Clean plugs and adJust the gaps to the fIgure gIven In the Engine Tuntng Data chart Renew any lead If the Insulatlo shows of deterioration or sIgns Examine the carburettor crackIng

Engine mlsfl res

Remove each sparking plug In turn It on the cylinder head and observe whether a spark occurs at the pOints when the engl ne IS turned Irregular sparking may be due to dirty plugs or defectIve hIgh tenSIon cables If sparking IS regular at all plugs the trouble IS probably due to engine defects
rest

petrol supply

etc

LH

UOHT

R8

J
i R m a

O
0 0

tII
QI 3

nOL
a

O
b

HE

WIRNG

AOIO

DFORIAGRM
DE
o

to
EAfER I

UNIT

r
GW

LUXE
L1GHTlt

eN

eMJI
I

WIPER

Im
0

SW

II
MARK NOTE

SALO N
INCLUDING
T1a 1

l jl

OIL

TS

V 0

IL

up iiill
LIGHT COO
a

OIL E A I R H TERMHIol IGNTO

TAtf
lHT
QO GAI

PADSlRE OIRECT NAl flirtNG


VlMNG
LIGHT
HT U

AIN

VOL
INITRi NENT u
HT

l3EAM

TAGE

PILOT PILOT LIGHT UGHT

REGULATtIl

AL

CMlNATIO
II 1

REAR
TlIjTAIL STOP Br CJ
UP

LIGHT LeEN
L N

PARTS

Jo4 L

111

I
I

Ill

UP
L

STOP T1JIH
L

nOlLH

T 1I

PARTS
fCNAl Cf

REGULATOft
TAGE
VQ

LIN1lQG

LIGHT IGHT LlCOHT LIGKT LNG I UNG LIGHT PILOT PILOT R WA R ENT INSTR BEAM T10N
hI AIN

GAUGE

DIRECTONAL

PRESU EOIm TERMNAL


OIL
1 611

Y jr III Plllr li
I

UNIT

NOTE

MARK YO

Il

TS

OIL

fiRB

II SI I
L

11
W
N i

mE
HEAT R
CLOC

fT
el

SALO N

SSS

rm o
A010

rk
l

HEATRU

FOR

LiGHT

DIAGRM
WIRNG
I

fJ

RELAY
BY

idr
l L1CJ

nu
rr m

HEAD

B B

TI

e 8

RW

B1 e R

if

RTcflv OF
RJi
a

l DUGt

Cb
RH

rv
LH
8L

fMK SIGNAL

HE

AOLGHLH I

AU

IS

ENGLISH

1 2 3 3A 4 5 6 7 6 9 10 11 I1A 12 13 14 IS lSA 158 16 17 16 19 20 21 22

Vear Model

1 2 3 CO
CYlinders

1969no 1300 510

1969no
1000 fLC 510

19ssno

l 2 3 3A

1600 510

HCI

Engine type
EEC Number of

3A
4 4 4

4 42 3 1 1595

Flnng order Capacity


Bore Stroke
cucm mm ratIO preswre 1 pSI P
I

5 6
7

4 3 1 2 1296 83159 9 85 11 170 50 n SAE

342 1 1595 83n3 7 85

5 6 7 8 9

63f73 7
95

CompreSSion Compreulon
011 prnsure ROIted output Fuel
V

8 kg

cm2

9 10
11

9
35 57 40 64

116 171 37 60
42 64 00 3 7

kg cm2

2 4

10 11 llA

HPlrpm
Ltr 100 km DINJ
n

6000

96 SAE 5600

109 SAE 6000

consuFnpllonlmpg
nlet utlet

llA 12 13 0010 0010 3 01110 0012 12 8

w clearance C1earanee opens

mm

25 0
3 0

0 0101025

12

Valve

n mm

0 12

0012 0 30
12 6

13
14 15 15A 158

Inlet valve

oOTOC oATDe

14 IS lSA 158

Outlet valve closes Rood

19

horsepower

Km h rpm gear

auery B

V lty polal

Ah munn

16 17 18 19

I 12V140An
HITACHI OCK 308 600 23

12

iOAh VI

12 V 50 Ah

16 17 18 19 20 21

Svstem

plus

CarburettQt make Carburettor Idllna sperd Fuel


pump pressure type om psl

HITACHI OAF 328 600

HITACHI AJL3fffl 600

20 21 22 23

kg cm2

5117

2 HITACHI 0411 5 o 49 91l21 017 55 58 0 4SO 5 HITACHI o 40ll 9021 0017 55 64 05 045

Dlstnbutor make Distributor type Contact breaker gap


n

HITACHI 0411 57 K 104 49 55

22 23 24 5 26

23 24 25 26
I

mm

24 25 25 27 28 28A 10 650 CP HITACHI 32 41

Dwellangfe
Stmctlmlng

Degrees oaTDC
timing

27 28
I

StroboscopIC Timing Ignition


1ry Pnm

oaTDOrpm
type Ohms
o

10 600 CP HITACHI 15

14 650 CP HITACHI

27 28 28A 288 9 0 31 32 3 34

rk locatIOn

2BA

COil make
stance advanCt

288

288 29 30 3 32 33 34

6 1
800 0

129
30 31 32 33 34

Centnf

starts

rpmE rpmE rpmE


mm nwn

0800

800 0

dlate Interml
intermediate

rpmE o
o o

ends Vacuum advance end


no

ln o ln o

Hg Hg

35 36 37 38

er c Condens ap8C

lty make type

MId

35 36 37

022 024 NGK


8P

22 0
NGK

0 24

022 024 NGK

135
37

Sparking plug Sparlung plug Sparking


St

6E

BP

BE

OP

BE

plug gap make tYpe

n mm

38 3BA

0031 08
HITACHI

0031

8 0

0031

8 0

rter motor

H TACHI

HITACHI

lA
388
ALT

Lockdraw Generator make 40


41

Amps

VolI

388 39 40 HITACHI LT 130


12 30

ALT I 41K

HITACHI LT 12 30 133

AL T

HITACHI

139 I 11

Generator type Generator output AN IrpmG

01

LT 140 4EiK

41

12 30

42 43 44 45 46 47 48 49 50 51

Requlator make
R

42 43
V 44

HITACHI TL1 Z 17

HITACHI TL1 Z 17

HITACHI T1 1 Z 17

ulator type
In

143 145
116

Cut

clO

lnq

voltaQe

c ff voltage Drop Reverse current

V
A

45 46 47 48 49
mln

Open

CirCUit CIrCUit

V
A A V A

Closed

1 148
9 0 1

Current

regulo1tor
egulator

Voltage
NOTES

50 51

52 53

tromchassls from nglOe

um um

52 53

2 3

I Lower shock absorber

TIGHTENING TORQUES
ENGINE

mounting
Drive shaft to differential nuts Drive shaft to 7 0
rear

2 3 8 0 8 0

kgm
SO 6

16 61b ft 57 8 Ib ft

kgm

axle

flange
70 20 8 0

ConnectIng rod nuts Flywheel bolts Main beanng bolts Camshaft sprocket bolt
011 sump 011 pump 011 strainer Crankshaft

27 95 45 50

33 kgm

pulley bolt
nut

Cylinder

head bolts

011 relief valve


Clutch bolts

105kgm 5 5 kgm 32 5 398 Ib ft 60 kgm 36 2 434 Ib ft o 4 0 7 kgm 2 9 5 1 Ib ft 1 5 21 kgm 108 15 21b ft o 8 1 2 kgm 5 8 8 7 Ib ft 160 180kgm 11571300Ibft 5 5 kgm 39 8 Ib ft 3 0 35 kgm 21 7 25 3 Ib ft 24 26kgm 174 18 8Ibft

19 5 23 9Ib ft 687 75 9Ibft

nuts

Bumper

nut

Wheel nuts

kgm 506 57 8 Ib ft 25kgm 145 188Ibft 9 0 kgm 8 65 1 Ib ft 57


10 85

Rear suspension member mounting


nuts

kgm kgm

72 3 Ib ft 61 5Ib ft 72 3Ib ft 43 4 Ib ft 61 6 Ib ft

Differential member mounting


nuts

Suspension arm nuts


DifferentIal to dIfferential member Propeller shaft flange

10

kgm
6 0

57 8

kgm
29

40 85 kgm

FRONT SUSPENSION GEARBOX Front hub nut Rear extension to case Gearbox to engine Bottom cover Front cover Drain 30 73 39
arm

3 5 9 9 5 3

plug

Selector lever bolt


Reverse lamp SWitch Idler shaft screw

Cross shaft lock pIn

Malnshaf

nut

30kgm 160 4 5 5 3 kgm 32 6 1 1 1 7 kgm 8 0 1 7 kgm 80 1 1 3 5 5 0 kgm 25 3 18 21 kgm 130 20 40 kgm 145 07 1 1 kgm 5 1 o 7 1 1 kgm 5 1 90 11 0 kgm 65 1

22

2171bft 38 3 Ib ft 12 3 Ib ft 123 Ib ft 36 2 Ib ft 1521bft 28 91b ft 8 0 Ib ft 8 0 Ib ft 79 5 Ib ft

Brake

calltper bolts

Brake diSC bolts Stablltser bolts suspension SIde Stablltser bolts frame SIde ReactIon rod to frame ReactIon rod to suspension
arm

kgm kgm kgm kgm

21 7 528 28 2 8 7

253 Ib ft 71 6 Ib ft 38 3 Ib ft 12 3 Ib ft

1 2

1 7

1 9 25 kgm 137 18 1 Ib ft 7 2 96 kgm 52 1 9 2 Ib ft 4 9 6 3 5 2

kgm kgm kgm

35 4 282 43 4 2

45 6 Ib ft 37 6 Ib ft 578 Ib ft 97 61b ft

SuspensIon
nuts

Untt

upper 3 9

Steering
FINAL DRIVE shaft flange Drive plnton nut 40 170 140 85 kgm 28 9 61 5 Ib ft 1446Ibft 122 91b ft 57 8 Ib ft 39 8 Ib ft
Untt

lever to suspension 60 80
arm to

SuspensIon Propeller
Saloon
Estate Crown wheel bolts Saloon Estate Saloon models only Side cover bolts Dnve member

suspensIon cross 122 135

kgm 88

200kgm 170 kgm


7 0 4 8

1229 101 2 SO 6 34 7

Lower ball JOInt Lower ball JOInt nut PIston rod nut Gland packing Wheel nuts

1 9 25 kgm 137 18 lib ft 55 76 kgm 398 550 Ib ft 6 0 8 0 7 5 9 0 60 65

80 kgm 5 5

kgm kgm kgm

43 4 434 57 8

47 0 Ib ft 470 Ib ft 65 1 Ib ft

kgm

flange Beanng retainer bolts

bo ts

09 1 2 kgm 6 5 8 7 Ib ft 19 26 kgm 137 18 81b ft 09 1 2 kgm 6 5 8 7 Ib ft

STEERING

Flange mounting bolts


Ball stud nut

1 B 5 5

25 kgm 7 6

130 18 lib ft

Rear cover bolts 1 9 26 Final dnve to final drive mountIng member 60 8 0 Final drive to suspensIon member FInal drive to dnve shafts Final dnve shaft Estate car models only DIfferential carrier to axle Drive 7 0 8 0 8 5

kgm kgm

137 43 4

188 Ib ft 57 8 Ib ft

Drop
Idler

arm arm

nut

nut
screw

AdJustIng
Idler arm

nut

60 kgm 43 4 Ib ft

Steenng gear

mounttng bolts bolts

kgm 39 8 55 0 Ib ft 125 14 0 kgm 90 01010 Ib ft 55 7 6 kgm 39855 0 Ib ft 18 25kgm 130 181Ibft 100 kgm 72 31b ft 44 1 Ib ft 44 6 1 kgm 31 8

kgm kgm

506 289

57 B Ib ft

flange

to

propeller
40 61 5 Ib ft

BRAKES
Brake pedal PIVOt Brake pipeS 145 13 0 15 91b ft Brake diSC bolts 3 5 15 39 1 7 17 7 3 4 0

11 kgm 108
53 kgm 20 kgm 9 0

kgm

25 3 28 9 Ib ft 12 3 Ib ft 282 38 3lb ft

hOUSing flange to propeller


shaft

20 18

22 kgm

Bridge
1591bft

22kgm

pipe Brake hose to Calliper bolts

123 14 51b ft

cylinder

123 20kgm
kgm 52 8

145Ibft 5 1 Ib ft

REAR AXLE AND Rear wheel Brake

REAR

SUSPENSION 25 27 3 33

beanng backplate

nut

kgm 181 239 Ib 7kgm 195 268 Ib


23 kgm

ft ft

Upper shock absorber


mounting
16 61b ft

101

CONVERSION TABLE

mm

lnS

mln

ln

mm

lnS

mm

1m

mm

inS

01 02 03 04 05 06 07 08
09

000394 000787 001181 001575 00 969 002362 002756 003150 003543 003937 004331 004724 005118
0055

020079 020472 020866 021260 021854 022047 022441 022835 023 228 023622 024016 024409 024803 025197 025591 025984 026378 026772 027165 027559 027953 028348 028740 029134 029528 029921 030315 030709 031103 031496 03 890 2 3
4

030370 078740 118110 157480 196850 236220 275590 314960


354330

5 52
53

2 007870 2 047240 2 0866 0 2 125980 2 65350

105 110 15 120 25 130 135 140 145 50 155 60 165 170 175 180 185 190 195 200 210 220 230 240 250 260 270 280 290 300 3
0

4 4 4 4 4

133848 330700 527550 724400 921250

52 53
54

54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69
70

55 56 57 58 59
60

5 6
7

2 204720
2

5 1 81 0 5
5 5 5 3

244090

4950

8 9 10 II 2 13 14 15 16
17

2 283460 2 322830
2

51800 708650 905500

10 1
12 13

393700 433070
472440

362200

61 62 63 64 65 66 67 6B 69 70
71 72 73 74

2 401570 2 440940 2 480310


2

6 102350 6 299200 6 496050 6 692900 6 889750


7 7

511810 551180 590550 629920 669290 708660 748030 787400 826770 866140 905510 944880 984250
1

14 15 16 17 18 19 20 21 22
23 24

519680

005906 006299 006693 0070B7 007480 007874 008268 00866l 009005 009149 009841 010236 010630 011024 011417 011811
0 0 2205

2 559050 2 598420
2

086600 283450

637790

18 19 20 21 22 23 24 25 26
27

2 677160 2 716530 2 755900 2 795270 2 834640


2 2

7 480300 7 677150
7

874000

71 72 73 74 75 76
77

8 267700 8 661400 9 055100 9 448800 9 842600 10 236200 10 629900 11 032600

874010 913380

25 26
27

75 76
71

2 952750 2 992120
3

023620 062990 102360 141730 181100 220470 259840 2992


0

1 1

031490

28 29 30
3

78
79 80

28 29
30

78 79 80 8 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100

3 070860
3 3

110230 149600 188970

11 417300 11 811000

81 82
83 84 85

3 32
33

12 204700 2 598400 12 992100 13 385800 13 779500

32 33
34

2598

032283 032677 033071 033465 033858 034252 034646 035039 035433 035827 036220 036614 037008 037402 037795 038189 038583 038976 039370

3 228340 3 267710 3 307080 3 346450 3 385820 3 425190


3 3

320
330

012992 013386
0

34 35 36 37 38 39 40
41

I 338580 I 377949 I 417319


1

340 350 360 370 380 390


400

35 36 37 38 39
40

3780

014173 014567 014961 015354 015748 016142 016535 016929 017323 017717 018110 018504 018898 019291 019685

86
87 88

14 173200 14 566900 14 960600 15 354300 15 748000 19 685000

456689

I 496050
1

484560 503930

89 90 91 92 93
94

535430

I 574800
1 1 I

3 543300 3 582670
3

41
42

614170 653540 692910

500 600
700

42 43
44 45

622040

23 622000 27 559000 31 496000 35 433000 39 370000 78 740000 118 110000 157 380000

43
44 45

3 661410
3 3

I 732280 I 771650 1 811020 1 850390 I 889760 1 929130

700780 740150

800 900 1000 2000 3000 4000 5000

95 96 97 98 99 Imm

46
47

46 47 48 49 50

3 779520
3

818890

48 49 50

3 858260 3 897630 3 937000

I 968500

196 850000

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CONTAINS
1

DetaIled

descriptIon of ServIce RepaIr and Overhaul OperatIons


shown
m

dearly explamed and

hundreds of illustratIOns

plus
Trouble

Shooting

Tables
l

Tune up Data Tables

WIrIng DIagrams

Exploded

Parts

Diagrams
dentificatlOn

wIth DetaIled Parts

f
r

Q 1T UJ

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