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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

I

d r I

f7

I

1

133 134 135 136 141 144 146 150 159

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

C

E

i b

WORKSHOP MANUAL for DATSUN Saloon 1300

1600

c c

L

Estate c c

COMPILED AND WRITIEN BY PETER R

D RUSSEK

PUBLISHED BY

INTEREUROPE

LIMITED

AUTODATA DIVISION 2 4 QUEENS DRIVE LONDON W 3 ENGLAND

lb

Pnntlld

IntIInlUrope LIlDtIld AulJllt 1970

Copyright IC 11

110 IYIIIIbIe in Spanish

av

1Ib1e thRlUllh

Lan

W ey

SA MexICO City

2nd edition

n

January

England

1971

A

r

Type Identification SALOON MODELS

Model designation 510

U

Type

L510

P510 U

L13

P510 UT

PL510 T

PL510

P510

PL510 A

PL510 UA

510

SU

L510

P510 SU

S

speed remote control speed floor shIft AutomatIc three speed Four

Three

L13

PL510 S

P510 SUT

Three L16

UT

Standard

SSS

PL510 TK

speed

remote

control

Three Four

speed remote control speed floor shIft

Four

speed floor sluft

L16

PL510 ST

P510 UTK

Gearbox Three speed remote control

Deluxe

PL510

UA

E n9108

L16 WIth SU tWIn

carb

ESTATE CAR MODELS I

WP510 U

WPL510

WP510 UT

WPL510

Three Deluxe

WPL510 WP510

UT

UA

WPL510

remote

speed

control

T Four

L16

floor shIft

speed

WPL510 A AutomatIc three spl ed

UA

DIMENSIONS AND TYRf PRESSURES

Length

overall

Standard Saloon De Luxe SSS Saloon

4 070

4 120mm

162210

Estate Car

4 145

163210

Width overall

1602

mm

mm

1 560

mm

10

I

61 410

Height overall Saloon Estate Car

1400mm

551

In

1 435

mm

56 5

In

mm

953

In

Wheel base

420 2

MIO ground clearance Saloon Estate Car

190

mm

74

In

165

mm

64

In

504 50 2

In

Front track Saloon

1 280 1 275

mm

Saloon

1 280

mm

50 4

In

Estate Car

1 260

mm

496

In

Estate Car Rear track

mm

In

I

Tyre

pressures Front Rear

24 pSI 28 pSI 24 psi

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

28 pSI

20 kg sq

em

High speed driVing

FILLING CAPACITIES

Engine

011 4 0 htres

MIn

3 0 htres 0 79 US

Gearbox 011 Autom transmission Differential 011 Saloon Estate Car

SJeerlng

4

uiG

Max

9eaL

US

gal gal

0 88 Imp gal 0 66 Imp gal

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

7 htres 7 39 US qts

08 htres 084 US qts

1 4

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

Imp pts Imp pts Imp Pts

l

INDEX 4

lYPE IDENTIFICATION

6

ENGINE LUBRICATION SYSTEM

18

COOLING SYSTEM

20

IGNITION SYSTEM

22

FUEL SYSTEM

26

CLUTCH

36

GEARBOX

44

REAR AXLE

S3

REAR SUSPENSION

62

FRONT SUSPENSION

68

STEERING

74

BRAKES

78

ELECTRICAL

86

EQUIPMENT

98

WIRING DIAGRAMS ENGINE 1 JNING DATA

100

TIGHTENING TORQUES

101

CONVERSION TABLE

102

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

trel Jb i

cyhllller

Fog

2 The removal of the A

engll

1t

n

fd

r

f7

r

if1 or

L161

engIne

flUBd

10

0

f g A6

FIlI A 5 Removal

of

the manifold assembly

FIIA7 Removal of the cyhnder h8I

6

eket

F

g 8 Removal of the oil straaner A

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

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

single twin choke

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

tool ST44630000 for the rear main beanng cap

Removal

Fig

Drain the coolant engine and gearbox 011 and remove or disconnect the follOWing parts Battery bonnet air cleaner and

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

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

and the

pipe

heater

hoses If fitted

accelerator

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

Speedometer

cable

cylinder Fig

special

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

carburettor

ENGINE

USing

llJd bolts h

linkage

COil

A 1

choke cable

011 pressure sender

and ItS return spnng

flat connector from reversing

light

SWitch

A 11

Remove tne

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

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

a

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

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

mounting

assembly

the

propeller ENGINE

remove

the

rear

crossmember

engine and the

Thoroughly inspection

clean all and

Inspection

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

before

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

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

chambers

forwards and upwards

I nspect and overhaul the parts

to

uSing

a

SUitable

crane or hOIst

FIg A 2

cylinder head from any of the parts

and valves

as

Cylinder ENGINE

Dismantling

Remove the

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

mountings

Alternator and bracket

follOWing parts

011

filter

engine 011 pressure SWitch SUitable stand If available Special Tool

water

Mount the engine In a ST37200510 attachment Flg A3

drain

and

plug

Stand

ST37100000

See

hOUSIng

F Ig A 4

Remove the fuel pump drive FlgA 6

cam

head

the 1600

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 means

Check the valve seats for

sprocket

or wear

and If necessary reface In Fig A 14 and A 15

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

fuel pump and

and the crankshaft

damage

accordance With the dimenSions given

Remove the inlet and exhaust manifolds Flg A 5 Remove the crankshaft pulley Remove the fan pulley and the water pump rocker cover

follows

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

In

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

but do not remove metal

Check

cover

Remove the

and Overhaul

guides

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

USing

must

0 073

for Inlet valves and not exceed 0048 mm 00019 In mm 00029 In for exhaust valves An easy way of

checking

the clearance IS to Insert the valve stem Into the gu

d

7

r

inter

E2C0

@F 0

1

1

FillA 9

Removal

of the crankshaft challl

rocket

S o

0

cf FillA

11

Removal

of

the baffle plata and

FI

A

12

cyhrder block net

Exhal51

Inlet

Standard valve gUIde hole diameter

FIllA 13 forfl

rt

Checlul19 the cyhnder heud

Ll3 and Ll6 L16 WIth

twin

carb

With

SIngle

cub U3 and L16 S

Inl

F t

Q

Ll6

cub

gle

TWlD cub

Almm

OtA J

I

Inl

r

41016 410

DIA

45 016 450

Azmm 57

0

37 016

37

37

6

37 8

41 6

DIA

i

r

1

r

r II

1 I La

IlIt

1

IlIA

41 8

D2mm ExheuU

326 324

DIA

Llmm

1

t 2mm

1

4 1

8

326 324

1

1 8

HU1

FIlIA 14 St8nd8nI valve Il 8inwt

8

37 016

Dlmm

DIA

DIA

Exheult

O

6

20

20 16

FIllA 15 VeIve

to

i nte f

bi G D er

W

J

I

r 8

r

rrt l

I

1 0 051

I

J r

I

D r T 010

r

FI9A 16 Ch c1ung the camshaft beanng Inner

F

d

17

IingIo

V

far

L13

and L16

wrth

rettD

lm I

II

5144

j

51 031

Fig A 18 Valves C81bunmon

0011

l

0 11

11

far

L16

CII

IM

l11

wIth Ill

J

A 19 FIlI

twIn

CheckIng

the

Fig 2 A 2 The

nne

JIlIIII18 of the cyllncllr

IIInng

bore

by

The nng of the pilllln of 8 mlcrom8lar

d

F A 21 MlI8SUnng the of 8 doallllU98

bora

valve

for

squ

F

by

cyl

9

B ImII

Fog A26 CheckIng the ade cl pISton Flngs

ence

of

the

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

FtgA Xl bends or

CheckIng

the

connectIng rod for

twIsts

Fill A 28 CheckIng the crankshaft end float

FI9A 29 CheckIng the running clearance for the maIn beaFlngs

0

o

for FogA 30 Checlllllg the crenkshaft sprocklJt FUIHlllt

10

A31 The camshaft drIVe mechanam Fog

I

and

from left to

It

move

0 0079

10m

10

If thiS movement exceeds 0 2

nght

1 the guide needs replacmg When replacmg valve

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

gUides press

00079 the

10

valve

between

the 150

10

new

gUide after

2000C

300

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

gUide and

oversize

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 The valve dimenSions

are

shown

In

Fig

A 17 and A 18

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 rotate

TECHNICAL DATA

re

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

Journals cylinder

bearings

and If

Place the piston piston nng gap

The camshaft

out run

A 20 The Indication

005

10m

on

nngs mto the cyhnder bore and measure the Fig A 261 The nng gaps should be as follows

Upper compression Second compres 011 nng Wear limit

head assembly

The

be checked

can

as

shown

0 15 o

0 0039

Cylinder

10

Fig

A 22

If the bores

In

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

heading The gudgeon pin should have a finger press fit In the the piston and a tight press fit In the connecting rod at room The fit of the gudgeon pin to temperature erence Interf rod should be 0015

0033

00013

00006

10m

Connecting rods Check

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

allowed

A limit of 005

are

00020

10m

should not be

In

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

Check for the for

ovallty and taper cylinder bores are

Within the limits

remove

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

10m

0 002

scores cracks

The limitS

are

hmlt

out run

0 03

IS a

and

10m

speCified In

end float

IS

00118

In

Crankshaft of the

replace the

between 005

1 Check the end float as shown

checking

run out

00012

In

total deViation of

In

float exceeds 03 10m

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

ovahty and general

Check the crankshaft end float at the centre beanng

The

Rebormg cyhnders

wear

Journals and crankplns ovallty and taper The

o 05

bore

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

0 0394

mm

Crankshaft

regnnd the block

In

0011810 00059

mm

1 0

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 mm

030 15

In

the dial gauge should not exceed

0002010

exceeds 0 1

0381010 023 00150 00091 In 1 030mm 00059 00118101

nng

ring

found

Check the camshaft for wear and damage and If these exceed the limits given In sectIOn TECHNICAL DATA replace the

Fig

pins and piston rmgs

gudgeon

and the

wear IS

wear

camshaft

the maximum oversize

beyond

In

the InSide diameter of the camshaft

outside diameter of the camshaft

are worn

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

connecting Camshaft Measu

bores

cyhnder

Pistons

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

slowly

If the

there are cyhnder hners available

stem

Valves

grooves

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

Journals

maIO

and

and

10

0 15

Fig

If the end

shims The 0002 00059

centre

mm

A 28

big end bearings

bl end l

beanngs should be

carned

follows

When

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

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

parallel

average value of the piston to

Main

oversize

cylinder

clearance

81g When the

cyhnder bores piston cyhnder clearance

have as

With the crankshaft and fit

lhtemng tl

cap

the bolts to the

beanngs

end bean ngs

together the bearing follOWing torques 4 5

5 5

and Its

kgm

32 5

39 8 Ib ft

27 33 kgm

195

23 9lb ft 1

been finish

shown

In

Fig

honed check the A 24 usmg a feeler

Then remove the cap and check the Width of the

Plastlgage

11

inter

erlLJ @ Pl

FIlIA 32

34

FI9A connectIng rod

InstallatIon of the vaJves

ded Expl

VI8W

ooo

of

pISton

and

FillA 37 InstallatIOn

F

the crankshaft A36 Chedung 19

the sKle oil seal

end float

the flywheel A38 InstallatIOn of FIlI

12

of

FillA 39 InstallatIOn of pISton end conllllCtmg rodaay

mter

E ih

i l

jlJ @

t I

l s

c

FogA 40

InstallatIOn

of

the bill end beerll18

caps

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

dIStributor drive geer

tIming chain

Fuelpump dflve Cham guide

3 Cham 4 5

The

earn

nSlone

Cntnkshm sprocket Camshaft IProcbt

6 Cham guttie

I

45 FIttIng drIVing slIaft

FlgA

pOSItIon of the dIStrIbutor

FillA 46 AdjUsting the valve clearance

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

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

0 043

mm

Check

In

the chain

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 the chain gu Ide for wear and A 31

replace If necessary

Fig

Flywheel

tighten

2 8

to

3 4

20 2

kgm

24 6 lb ft

the end clearance of the big end bearings which should be 0 20 030 mm 00079 00118 In I

Check

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

tenslOner

and

Note there

the hole It

came

tlQhten the cylinder Fit the crankshaft thrower Fig A 43

timing marks

on

are

out

of

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

head bolts

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

sprocket

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

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

flywheel for

chain

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 worn or

gear

damaged

In reverse

remove

order and cool at normal

air

the

on

the

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

when the front

replaced

I nstall the lower front

reason

cover In

temperature

on

that order With

a

gasket

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

cover

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

ENGINE

Assembly

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

are

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

The Spring

IS In

the position shown

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

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 each

00061n

fuel

slinger

With JOinting

compound

the

s

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

plug

shown

Install the Side 011 seals Into the bearing cap In Fig A 37 Fit the rear 011 seal uSing special tool ST49370000 as

both Sides

distributor

carburettor

drain rear main

on

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

Fit

Assemble the rods for

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

Inner

Fit the rocker holders

between the upper faces of the cylinder block and the upper cover The difference should be less than 0 15 mm 0059 In

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

ENGINE

If the

Installation

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

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

14

The installation

procedure but

IS

the

carned

out

in reverse order to the removal be noted

follOWing points should

tlQhten the nuts and bolts completely until the engine IS resting flnnly on Its mountings Then tlQhten the nuts Fill the Do not

engine With engine 011 and coolant water o with th recommended lubricant

g

or

anti

freeze and the

Technical Data GENERAL SPECIFICATION

Engine model

L13

L16

Number of

4

4 In line

cylinders

Arrangement of cylinders

In line 1296 c

Cubic capacity

51 02 Bore

stroke

x

830 of valves

Arrangement

x

1595 c 62 80

cu In

830

73 7

c cu In

59 9

mm

x

c

mm

3 2677 x 2 3583 In Overhead camshaft

32677 x 2 9016 In Overhead camshaft

77 at 6000 rpm

96 at 5600 rpm 109 at 6000 rpm

11 1 kgm at 3600 rpm 80 3 Ib ft

13 8

Max B H P

Single

carburettor TWin carbu rettors Max torque

Single

carburettor

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

TWin carburettors

Flnng

order

1

3

4

2

1

3

4

2

Engine Idling speed

Single

carburettor

600 rpm

600 rpm 650 rpm

85

85

TWin carburettors

Compression

Single

ratio

carburettor

1

TWin carburettors 011 pressure

38

4 2 kg sq 54 60 Ib Isq

cm

54

In

1 1 4 2

kglsq Isq

60 Ib

cm In

Valve spnng fitted length L13 L 16 outer

VALVE GEAR

hot

Valve clearance

95 38

Inlet

025

mm

Exhaust

030

mm

0010 In 0012

L 16

400

mm

389

mm

35

Inner

30 7 kg 29 0 kg 12 3

mm

kg

1 57

In

1 53 1 38

In In

167 7 Ib 163 9 Ib 271 Ib

In

Valve spnng COIl diameter L13

1 37

In

Inlet

020

0008

In

L 16

outer

332mm

1 31

In

Exhaust

025mm 0010

In

L 16

Inner

24 9

mm

0 98

In

59 0

mm

2 32

In

59 0

mm

2 32

In

Valve clearance

cold mm

Valve gu Ide length Inlet

Valve head diameter L 13 and L 16 w SC Inlet Exhaust

38mm 150 33 mm 1 30

In

Inlet

42

In

1 65 33mm 130

Exhaust Inl

Exh

mm

80mm 031

Exhaust

mm

In

L16wrrC

Valve stem dla

34 9

Valve gu Ide protrusIOn from head face L13 L16 104 106mm

041

0421n

In

In

Valve gUide Inlet

Inner

Exhaust Valve length Inlet

1159mm

456In

Exhaust

1160mm

4571n

diameter 800

8018

mm

0315

03154

In

800

8018

mm

0315

03154

In

11 996

mm mm

0472 0472

04723 04623

In

11 996

Valve gUide outer diameter Inlet 11 985 Exhaust

11 985

In

Valve 11ft L13 and L16

w

SC

L16 wrrc

040

In

105mm 0413

100mm

In

Valve guide to stem clearance Inlet 0015 Exhaust

Valve spnng free 1 13 L 16 L16

0040

0045

mm

00006

00018

In

0070

mm

00016

00028

In

length 4812mm 189In

outer

52 0

mm

2 05

In

Inner

44 85

mm

1 77

In

Valve seat Width Inlet Exhaust

1 4

18 mm 0055

0071

In

1 6

2 0

9 079

In

mm

0 063

15

r

Valve seat

Inl

angle

J 4

Exh

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

mm

00031

00043

In

Matenal

mm

00024

00039

In

Type

Interference fit

gUide

Inlet

type

Slipper sklrt

Piston diameters

0027

0049 mm 00011

00019

mm

CAMSHAFT AND TIMING GEAR Camshaft end play

o

0838

00031 0 0151n

mm

Camshaft lobe lift L13 L16 w SC L16 TC w

665

7 00

mm

0 261

In

mm

0 275

In

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

Cast aluminium

run out

005

mm

8299

8304

mm

3267

3 269

1 st O S 2nd O S

83 22 8347

83 27

mm

3 276

3 278 In

3286

3 288

In

mm

3 296

3 298

In

4th O S

83 72 83 97

8352 83 77

mm

3rt

mm

8447

3 308 3328

In

5th O S

3 305 3326

2 0 mm 0 08 40 mm 0 16

In

OS

84 02 8452

mm

Width of nng grooves Top second 011 control Piston running clearance

In

0002

Standard

o

025 045

mm

In

In

In

0001 0002

In

In

In

PISTON PIN Camshaft Journal to clearance

beanng 0038

0076

00015

mm

00026

In

Pin diameter

20995

Pin length

Camshaft bearing

72 00

21 000 72 25

mm

08266

mm

2 8346

0 8268 2 8445

0010

mm

00003

00004

In

0033

mm

00006

00013

In

mm 008 40 mm 0 16

In

In

Inner

diameter

48 SC

Single

48 000

016

carburettor

mm

1 8898 1 8904

TC

TWin carburettors

In

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

CONNECTING RODS PISTON RINGS Distance from centre to

13297133 03 mm 5235 5237

centre

8eanng

shell thickness 1 498

Standard Side

Piston nng heIght Top second 011 control

In

play of big

1 506 mm 020 030 mm

ends

0059

0593

In

0008

0012

In

Side clearance

In

Top Connecting

rod

bearing

clearance

Connecting

rod bend 003

twist

running 0014 0056

grooves 0040 0073

00006

mm

00022

Second

In

mm

00012

In

per 3 937

0030 0025

49 961 Crankpln Journal dla Max crankpln taper Max crankpln of out round Thickness of main beanng

beanng

1 827

clearance 0 020 Max main bearing running clearance

16

023

038mm

00091

Second

015

030

011 control

015

030mm 0006

In

mm

001501n

0006

0012

In

00121n

In In In In

49 975 mm

1 967 1 9675 In 003mm 00121n o 03

1 835

mm

0 012

In

0072

00722

In

o 062 mm 0 0008

0 0024

In

mm

CYLINDER HEAD

In

Matenal

o 12mm 00047 005 mm 0002

Aluminium

Distortion of sealing face Max distortion

003

mm

o 1

Valve seat Insert matenal Inlet

mm

alloy

00012

In

0004

In

Aluminium bronze

Exhaust

Special

Fit

Hot pressed

running

Crankshaft bend limlt

00025

5

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

shells

0001

mm

Special forged steel

beanngs

Main Journal dla Max Journal taper

Main

vm

0063

L 13

In

000311n L16 00012 0 0025 In

Piston ring gaps

Top

Number of

0 063

00029

In

In

CRANKSHAFT AND MAIN BEARINGS

Crankshaft matenal

00016

00018 0078mm

011 control per 100

mm

0045

or mm

20

cast

CAMSHAFT DRIVE Dnve

From crankshaft

In

Chain

Double roller type

In

Chain tensloner

Spnng

and 011 pressure control

Trouble

Shooting

PROBABLE CAUSE

SYMPTOMS

ACTIOtJ TO BE TAKEN

I

Lack of power

1

Poor compresSion

Valve springs broken Piston rings broken

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

Rings

Overhaul engine

Incorrect valve clearance Intake valves leaking Sticking valves

2

or

cylinders

worn

Ignition Improperly

set

Incorrect Ignition limIng DefectIve spark plugs Contact breakers defective

3

Re

or renew

Check fuel pump Clean or replace element

Fuel filter clogged Insufficient coolant

Top up radiator Adjust fan belt Replace fan belt Replace thermostat Repair or replace

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

Clean system Re set timing

Clogged cooling system Incorrect Ignition liming Incorrect valve clearance

Adjust clearance

Incorrect 011 used Radiator finS clogged

Refill With correct oil grade Clean readlator finS

Oil leaks DefectIve piston rings worn Piston rings

F nd 011 leak and rectify

grooves Piston or cylinder Valve stem

D fficult starting

set

replace adjust gap

Clean carburetor Clean fuel pipe Clean fuel tank

fuel pipe Dirty fuel tank Faulty fuel pump

Clogged

ExceSSive oil consumptIon

re or

Lack of fuel

Clogged carburetor Jet

Overheating

set

Clean Clean

or

or

sticking

Replace piston rings Replace Piston rll1gs

In

Replace piston or bore cylinder Replace as necessary

worn

gUide

worn

Improper 0 1 Discharged or defective battery

Change to proper VISCOSity Charge or replace battery Clean and tighten connections Adjust Ignition check plugs Repair Or replace valves

Loose connections Defective Ignition system Burnt valves PIstons piston nngs

or

Overhaul enqlne

cylinders badly

worn

Engine nOIsy

Crankshaft beanngs

or

Journals

worn

Replace bearings and grind crankshaft replace crankshaft Replace bearings and gnnd crankshaft or replace crankshaft or

Connecting

rod bearings

ConnectIng rod be

worn

l

Piston piston nngs and pinS damaged

I

or replace rod Check and replace parts

Stralgten

as

necessary

mterCE

lliJ

Plcel @

FIg B 1 system

General

layout

of

tho

lubricatIOn

Fig B 4 SectIOn through the

o

Frg B 3 Tho oil pump components

18

0

rehef valvo

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

DESCRIPTION

damage Replace 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

filter the 011 before It can reach the

OIL PUMP

beanng

38

pressure

OIL PUMP

remove

the front

The

guard and remove the spindle The 011 pump

011 pump IS held 111

procedure Make

Remove the distributor drain the engll1e Oil

poSition by four bolts 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

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

of the

Assembly

0

sure

IS

When

procedure

Opening

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

locations

Removal and InstallatIOn

engine bearer and the splash body together With the dnve

The II1stallatlon

Free length Fitted length

OIL FILTER

replaCing

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

OIL PUMP

The 011 filter

IS

of the

removed from and

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

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

IS

shown

In

Fig

B 5

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

parts In

a

InspectIOn and Overhaul

SUitable solvent and check the

follOWing

Items

Check the

Technical Data

Worn bearrng faces pump body result In pressure losses If necessary replace the body 2

for

0

wear

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

Pressu re feed system Rotor pump

Type Pump type

From distributor shaft

Drive

Clearance between

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

body

or a new

pump

body

and 0 05

outer rotor

Clearance between 3

Inner

012mmI0 020005111

rotor

0 12mm 0005 In I

tipS Celarance between outer rotor 015 and body

021

mm

0006 0008

In

I

must be fined 011 pressure rehef valve spring

4

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

inserting In

on

a

a

edge the

straight edge by

75 mm 224 In

Free length Fitted length

Opening

8 4 2 kg sq 3

pressure

cm

ii f 3 i m 1 54 60 Ib sq

54

In In

feeler gauge IMust not exceed 0 13 mm 0005

If necessary the pump flat surface

body

can

be

carefully lapped

011 pressure at

idhng

speed

1 0

1 2

kgsq

cm

14 2

17 1 Ib

sq ln

Oil pressure at 5

6

Check the rotor drive shaft for excessive wear or

scores

If

2000 rpm lhot

38 42 kg sq

cm

54

60 Ib sq in

the rotor set

necessary

renew

Cheek

fllJief IiIWe the

1I aACI tile IidIng for proper f t sprlll

19

mter

j M

Pl @

Fill C

1

General arrangement of the cooling

OY

OperatIon plate

Dust

SpIder assembly

FIlI

V V

o thefan clu1dl

Fill C 5 parts

20 It

Exploded

Drum

linnl9

v

of

the fan

h c1u1l

o

00

c 4 DlSIllantllng of FIlI

C 3

cover

J

V fIW of the radiator and

component

Cooling System DESCRIPTION The cooling system is

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

a

water pump

WATER PUMP

centrifugal type water completely and remow the fan

pump drain the cooling belt fan and pulley and

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

Replace vanes or

an

exchange

To prevent squeak the recommended

use

of

8n NIS

IS

The pump should be cleaned WIth Nlssan COOling system cleaner before It

IS

seal off both Sides of the

RADIATOR

squeaking

refitted to the front cover

Instellatlon

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

water pump should be fitted

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

With the engine running cooling system protector

950C 1203oF

THERMOSTAT

unsaew

malfunction

of

Removal

To remove the system

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

To

gasket

Removal and Installation

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 remove

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

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

FAN CLUTCH

Technical Data

Inspection Type

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

THERMOSTAT

Closed pressunsed system

Radiator

Herght

350

mm

Width

514

mm

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 Thermostat Valve opening Max valve 11ft

83 SOC 11 7 Morethen 8 mm

1lF 18

80 5

0 315 In at

at

950C

2 3 0F

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 8that the thermostllt or the thermometer cannot touch the bottom or the sides of the contalller oth ise false nIlIdinga will be

obtained The thermostat should start

to

open at

a

temperature 21

inter e

l

Ql @

0

A

0

r FI9 D 1 Explod

YI

I

of

Remof

D2 Fia

contact beI8 plaia

the

1118 ognrtlOn dlltnbutor

7

v FIQ

D 5

bly of 1118 flyweight mecherlillll

The F

FI9 D 3 Removal of 1IIe dIstrIbutor drMlllllllr

FItI D 4 Removal

1111I1Inln9 pin

of 1IIe dlllnbutar drive Iheft

nd ond Oftronco for at IfInltlOll lranctl MI IIe

3

Hook

4 5 6 1

22

RI IlfP

D FIg

7

View of 1118 distrillutar

wIth

ght rprll1l Flywo Dtltrrburor cam pkrte ywetg ltpm F H

8

Flyweight rprlnt

9

RotorpoI

Fig D 6 Checlull9 1IIe contact FI9

It tg

2

donm

fin

8 AdJUlling 1118 cantBCt D

b

er

gap

Ignition System CONTACT BREAKER GAP

DESCRIPTION

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

The 1300

With

are

procedure

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

the distributor

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 Disconnect the

turn

fitted

over

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

IGNITION DISTRIBUTOR

Adjultment

055

clamping

mm

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

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

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 underneath and

SUitably support the distributor shaft from

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 a

distributor

cam

remove

the set

Carefully unhook the flyweight deforming them

and pull off the cam springs Without stretching or screw

IGNITION DISTRIBUTOR

shown Fig D8

IS

Remove the distributor

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

Check

In

Adjultment

line and start the engine as follows

With

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

c

c

1600

c

c

1600

c

c

IS as

engine SC

follows

1008

T DC 1600 rpm

100 8 T D C 1600 rpm 1408TDC 650rpm

w

TC w

Single

carburettor

TC w

TWin carburettor

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

a

011 stone

condensor for short

shown

Assembly

defective

Check the shaft for

vacuum

IS

the engine running at Idle speed proceed

wlSC

an

Fig D 7 The adjustment of the pOints

IGNITION TIMING

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

With

In

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

wear or

the vacuum mechamsm for freedom of movement

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

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

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

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

crank

pulley of the

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 connectlOg re

vacuum

Technical Data DISTRIBUTOR

SPARK PLUGS

Removal Inspection

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

Contact gap Contact spring pressu re Shaft diameter lower part Shaft diameter

055 050

Clearance between shaft Clearance

wear

lOner

In

0490210

housmg and 001

0038

mm

limit

00004 0 08

diameter

Clearance between shaft and cam 0 005

0 029

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

Clearance between pIVOt and piVOt hole 001 046

flttmg the plugs

002210

80mm 03151O

PIVot hole dla

to gapS

0012

065 kg 1 1 1 43 Ib 1245 mm 0490210 1245

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

mm

upper part

lOner diameter

HouslOg

Cam

045

mm

Flyweight piVOt dla

0 003

10

80 mm 0315

10

00002 00011 50 mm 0197

In

50 mm

0001510

mm

00004

In

0 197

10

00018

10

mm

IGNITION COIL Model 1300 1600

1600

c c

wlSC

C14 51 C6R 50

wrrc

c c

Primary voltage Primary resistance 1300 1600

1600 c

c

Secondary wlSC

c c

12 volts w

SC

3 2

wrrc resistance

SlOgle

carburettor

4 1 ohms

2 1 2 7 ohms 11 2 168 ohms

wrrc

TwlO carburettor

IGNITION TIMING AND IGNITION ADVANCE

Fully detailed Data

24

II

IOformatlon are gIven under See Index for page number

EnglOe TUOlng

Trouble

Shooting ACTION TO BE TAKEN

PROBABLE CAUSE

SYMPTOMS

Starter turns but engine will not start

Weak battery Excessive mOisture

high

tension

Cracked

or

Recharge battery spark plugs

or

dlStnbutor cap

or

on

wires

leaky

Remove moisture and

Replace

dry

cap or rotor

rotor

Difficult starting

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

Repair or replace wire Adjust or replace points Replace condenser

Defective spark plugs Defective breaker points

Clean

Loose connection

In

pnmary CircUit

Replace condenser Replace Ignition coil

Defective condenser Defective Ignition COil Defective rotor or dlstnbutor cap

Engine misfires

Dirty

or

Replace

faulty spark plugs

Loose

wire

Ignition

adjUst or replace plugs Replace breaker points Tighten or repair

cap

or

rotor

adjUst or replace plugs Tighten repair or replace Wires Clean

faulty

or

Insulation Cracked dlstnbutor cap Breaker

Ignition CirCUit Interrupted voltage drop In pnmary CircUit

and

Burnt

points

or

not

correctly adjusted

Incorrectly adjusted

breaker gap Defective leads

loose

contact

or

dirty

Replace cap AdjUst breaker points AdjUst

contact

breaker gap

Check leads clean connections

connections

Ignition SWitch defective Ignition COil defective Secondary current

circuit

Interrupted

and

no

Spark plugs

wet

worn

or

inCOrrect

gap Defective condenser Defective

Tracking

broken Ignition cable between COil distributor cap or

Check

or

Check

or

replace SWItch replace IgnitIOn

Clean and

adjust

or

replace plugs

Replace condenser Replace ignition cable Clean and check parts or

and rotor Defective

Ignition COil

COil

Check

or

replace

COIl

replace

interceM j

@ ce p

J L

ill

T

0

il

l

i

7

f

f

I a

IJ

A

r o

of

the

f

4

c

Fog Fill E 1 General Cllburettor

t 1

twin

choke

2 E

General

cartJuret1D

L 16

of

the twm

choke

englnel

12

1314 IS 16

6

7

of the tWin choke cartJurettor for

FJgE 3 V

cars fittedWith

ilJtomatlC transnllSSlOft

FIg E 4

SectIon L16

carburetlllr

through

4

IHUnmng Slof

9 M lnJflf 10 s 110 77 Throttle aIwl 12 13

FIlI E 5 ac rburetlllr

SectIOll

through 1

A rWllltptplt

M

m

w a

MII

18 Slowrunning BIf bIet1d 19 AN vent 2Q Fue let1el g JiUgt 21 Mam Jet 22 runnmg SJow flW KJlumtllCl 2

SIoMNllnmng

24

11010 8 Throttle aWe

25

bltJed

the

SmsJIWNlbm 5 MatndlS C 6 Mam air bleed

lTbJeed

tunnlllf Slow runnm6 SIow

a

f1t

7

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

bleed

7 SlorH1lnnmg II bleed IS runnlnfl SIow fIl 19 Vacuum prsfon

obo

20 Power aIw 21 et Ifam

22 Maml 23 l ldl 24 8 25

00 hole W Throttle

FIQ E

26

bleed

L13 1

2 Small venturI 1MlJmd 5 6

rok C

choke

SiChatfpl Mamd zer bleed Econor 16 runmng SIow Jet 17 SJoVN unnmg econonuzs

MamllJrble J Jet

5 SlowrunnmglII G N tI aM 7 FI 8 Emublon tubtJ

twin

c t 15

MIl dach venturi

2Small 3

the

englnel

The dlStll8nt1ed throttle vaJve

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

Check

either

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

two

a

barrel

downdraught

carburettor

or

twin

SU type

carburettors

throttle

the

and

choke

valve

shafts

and

bores

for

eccentriCity

ndges Replace

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

CARBURETTOR

tWin choke

Single

Removal

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

deSignation

OAF

carburettor

take off the

and the

328

See

Fig

E 2

E 3

To remove the disconnect the fuel pipe

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

Check the operation of the accelerator pump and the chamber for damage to the diaphragm and air leaks replace any defective components

diaphragm Repair

or

vacuum

choke cable nuts and washers

CARBURETTOR

Assembly

securing the carburettor to the manifold Lift

off the carburettor

The assembly brittle

CARBURETTOR

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

The

IS

carned out

In

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

reverse

Special care should hard gaskets are used

procedure or

be

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

CARBURETTOR

be careful

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

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

needle valve Mam

body

059

mm

IS

at

about 1 0

mm

0039

for the L 16 engine shown In Fig E 18 In

In

for the L 13 and 1 5 Bend the float

Fig E 17

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

seat

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

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

as

the

cover

and the float

Fig

E 13

Dismantle the

screws

holding the

diaphragm diaphragm

screws

holding

The

fuel

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

shown

Dash pot This mechanISm With

automatic

throttle vale

In

In the case of the DCK 306 clearance of 072 mm 0028 In carburettor Fig E 19 and Fig E 20

the

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

Interlock startJng system

Fig

Interlock opemng of prunary and throttle valves

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

damper

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

IS

and A

Fig on

or

Inner

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

E 23 the adjustment

The

slow running throttle valve stop

roORing adjustment IS obtained by adjusting the and the slow running volume control

adjustment screw

screw

Inspection

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

plate

Slow

linkage

CARBURETTOR

secondary

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

volume control

screw

until

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

D

inter

i D

j1 @

4 4

FIlIE

7 B alh throttle

valves relllDved

FIlI E B The carburettor top

caver removed

ll li

4il I

0

It

f

0

u Fill E 9 The choke

D

c hamber

F

j

I

FIlI E 10 The pnmary end tubes removell

relllDvecI

lOCO ndary

emu

q o

i

0

0

1 l O Jo

0

FIlI E 12 The lower and upper carburetlDr bodsepara18d

FIg E 13 tor body

28

The float

reIIICJII8II from the

ret

ImmIIII

3

1J F

4

flp fuoIlpul

FIQ E 15 The fuel

return

sys1em

Valve 2 3 if

o 0

Body PIPe SImtlttJl

o

F gE 14

The

parts

component

of

the

dl8phragm

r

r

I

Ll1

i

a

1

f i

L

J

r L 4 2 4 DAH

00

AnZl

OCK

Omm

1

D au

I I

Fill E 17 The flollllevel adJullment 5

I E 16 FI

FIQ E 18 Adlusanent of the float 18111

Float SlHt 2 FIo t 3 FINt ltop

6

The dashpot mechBlllsm

4

JIII Ne

van

7 2

Locknut Jblearm Chok cl 3 OGhpot ThlO 0 5

ch btK aIw

Throttle 6 Throm l

I E 19 FI 2

r

tlng AdJuotment of slllI

Interloca opemng

Choke bell rod 2 Choke connctlllfl rod 3 S11Irtlng Ie

rL

4

Choke vain

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

Throttle valw

L

i r

JhaJi

fr J L

J

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

adjustment

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

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

CARBURETTOR ThiS

adjustment

With

automatic

Dashpot adjustment only necessary on the

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

The proper

Remove

IS

Adjustments

of the two carburettors

adjustment

IS

extremely

Important In obtaining peak vehicle performance and redUCing fuel consumption Carburettor

synchromzsnon

and

idhng adjustment

case

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

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

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

lever

SU TYPE TWIN CARBURETTORS

Dismantling

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

adjusting

nut

and the spnng Unscrew the Jet

beanng locking

nut

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

the float

stages

are

shown

In

Figs

E 24 E 25 and E 26

CARBURETTOR

Clean and

dry

the piston

assembly

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

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

screw

of both carburettors to

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

InspectIon

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

Also make sure that the front and

not

Now turn the throttle

Note the condition of the needle valve and the seating Fit a new needle valve and seating If necessary If the Jet needle IS bent

the

air

screw In In

the

until the Fig A 271

Lubncate the piston

rod

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

not

In

adjusting

line With the scale screw

to

align

adjUst the the float With

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

dlamantllng procedure

tighten 1 8 of

the a

Idling

turn

and

stop the adjusting of the nuts at a pOint where the engine speed IS fastest and smoothest Without If thiS missing or hunting

Assembly and centre the Jet

be detenmned bnng the nuts back to their positions and unscrewthem from thiS pOSition until the engine runs fastest und smoothest

point

cannot

onglnal Centnng

the Jet

Screw the Jet adjusting nut up as far as poSSible 11ft the piston With the lifting pin and allow It to drop It should drop freely 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

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

up as far

as

adjusting pOSSible

nut Without the spnng and screw It

30

and nQ 1l

whetlliij

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

speed setting Move engine

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

tift lhe pjS on

Then slacken the throttle adjusting screws of the front and rear carburettors and adjUst the engine speed to the specified value

IS

falls

freely

fully 19w ir

the

Idling

the throttle

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 connection

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

mterc rlOU @@ce c

@0 f J 1

I

I I

I u

I 2

I

@ i

3

Fill E 21

opelung of pnmary ary throttle valves L16 eng ne

3

4 5

Throttlfl Throttle

Ju

4

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

IlltIIrlock

1 ConntJCttn9 mvu 2 RftUm plate

I

Fill E 23

Checlung the body

clearance

between

throttle valve

nbtN ch

1

1I1v6

2

ConnectIng IrHr Return plate

3

Throttle chlmbtK

4

Throttle v Jve

Adjuster pllltrJ

OIL CAP NUT

SUCTION

CHAMBER PISTON

SUCTION

FUEL PIPE

A tJ

II o

0

e 0

Yo

NOZZLE JET

SUCTION SPRING

Fill E

24

Exploded BOO suction piston

v

of

Rlol on

SLEEVE

SET SCREW

IDLE ADJUST SPRING

NEEDLE

chamber

IDLE ADJUST NUT NOZZLE Fill E 25

Exploded

VIew

of nozzle

assembly

e

0

0 0

0 Fill E Xl Installation of the lat needle

O Fill E 28 Exploded

of the float cIIMIber

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

the throttle cleaner

adJustmg

screws

Stop

Adjustment

the engme and refit the

air

FUEL PUMP Disconnect the and

connection

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

re

retainer

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

basic position

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 0866

0945

clip

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

m

Remove the float chamber cover

screws

and

11ft

cover

off the

attached float lever Hold the Side IS faCing upwards 2

15

mm

0551

to

after

cover

05901

m

the four with the

the float

I

I f necessary bend the float lever Illustration

To

as

level IS shown m the

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

I with the

starter

lever

and 11ft out the screws

pulled

out

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

Thorouqhly clean all parts and check as follows

body and diaphragm for

cover

wear

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

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

FUEL PUMP Insert the rocker

place

while

arm and

corrOSion

Assembly

the link

m

the lower

the piVOt pin from the Install the rocker arm spnng

the pin

lower

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

m

screws

fitting

body

non

and hold

m

serrated Side of

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

mterlock opemng

adjust

00315

secunng

diaphragm

The

undOing together

that the float lever

cover so

correct

StartIng

retamer

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

no

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

and 11ft

valve

valves and

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

Float level Remove the float chamber

Dismantling

Refer to

head

m

outlet hoses from the fuel pump

the two mounting nuts

FUEL PUMP

of Jet needle

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

now set

mlet and remove

Removal

completely

body

the rocker

half Press down the

arm link

Fit the

diaphragm

cover

and engage It With body half

the upper

to

Install the

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

damper

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

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 Reverse the removal

procedure

Installation Start up the engine and check

for fuel leaks

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

256

replace

34 pSI I the

If the pressure

readmg

IS

below the settmg

diaphragm sprmg

filter disconnect the mlet and outlet PipeS and remove the filter Fig E 36 The mstallatlon of the filter IS a reversal of the

the outlet pipe m at 1000 rpm for

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

removal

delivered

be 1000

procedure

Conduct

a

flow check

should

a

malfunction and the fuel restnctlons are

suspected

blowout the lines With

32

m

c c

If not

lines for

check the pump for If blocking or

blockages

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

Compressed

ImmIIII

3B 4

r

o

J

16 17 Screw

eel

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

Valve retainer 8 R8tamer screw 9 D hragm 0 Pullrod

19

t

@

S

1

FIg E 36 Removal of the fuel folter

@

DIaPhragm

12

he fuel tank of Saloon Cars

flng

Selll washer 13 Seal 14 Lock washer 15 Nut 16 Connection

6 7

Screw

o

8 Lock washer 19 ConnectIon 20 Rocker arm sprmg 21 pscer 22 Heat Insulator 23 Fuel pump gask8t

0

24 25 26

Rocker arm Rockerarm pivot pm Spacer 20

24

12

FIg E 41 Exploded

v

of the aIF cleaner 13

FIg E 39 The fuel tank f ller tube 22

Exploded

Fog E 42 Removal of the with SIngle carbunrtlDrl

aIF

VIew of

23

the fuel pump

cleamr

33

after

assembly

re

POSITIVE CRANKCASE VENTILATION SYSTEM FUE L TANK

The l 13 engme has

Removal

the Saloon seat

Remove the

back trim

the

the board flmsher board

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

cleaner

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

a

Fig

E

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

seat

rear

Open

aIr

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 wire

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

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

statIon

leakmg

FIg E 40

10

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

011 filler cap The mstallatlon of the fuel tank IS removal procedure

10

both

cases a

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

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

when must

a

fmger

IS

placed

over

the valve

always be replaced

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

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

1300cc

Primary

Secondary

Primary

Secondary

Outlet diameter Venturi diameter

280101

32mm

26mnt

300101

240101

28

21

27x12mm

Main Jet Main air bleed

115

155

96

150

240

120 180

80 43

90 180

Slow runnmg Jet EconomIzer Jet Economizer bleed Power Jet

48

Float level

23ct 101m

Fuel pressure

Weight Altitude settIng main Jet 100001 3300 ft

9 0101

x

024 235

kg kg

23ct 101m to

I

sq em 341 pSI 5 17 Ib

0905 024

92

300001 10 000 ft

107

89

400001

104

87

101

85

5000

01

13 300 ft I 16 600 ft

ct

kg 255 kg 94

6600 ft

0101

40

109

01

8

1 8

112

2000

x

18

0905 ct 004

34

l13

c

004

to

I

sq cm 341 pSI 5 61 Ib

mlet A

damaged

valve

SU TYPE TWIN CARBURETTORS

FUEL PUMP 38mm

Bore diameter 28

Weight

kg

Delivery Delivery Type

6 16 Ib B

Needle Float needle valve

2 0

mm

Jet need Ie

0 08 In t M 61

018

pressure

024kg 1000

amount

Diaphragm

sqcm

256

Imln

341psl

1000 rpm pump driven from camshaft c

c

at

N023

Suction spring Float level

23f 1 024

Fuel pressure

kg

sq

cm

mm

341 pSI

Trouble Shooting CARBURETOR

Improper seating or damaged needle valve or seat Incorrect float level

Flooding

Fuel pump has

ExceSSIve fuel consumption

Stalling

Poor acceleratIon

excessive

Fuel leaks at pipes or connectIons Choke valves operates Improperly Obstructed air bleed

Trace leak and rectIfy Check choke valve

Main Jet obstructed I ncorrect throttle opening Slow running adjustment Incorrect

Clean

Slow running fuel Jet blocked I ncorrect float level

Clean Jet Adjust float level

TIghten Replace gaskets

DefectIve accelerator pump Float level too low Incorrect throttle opening

Lean mIxture

Check and clear

main

Jet

Adjust throttle Adjust slow running

Overhaul pump Adjust float level

Adjust throttle Adjust accelerator linkage Clean pump Jet Clean and adjust carburetor Clean carburetor Clean

air

or

TIghten

replace pIpes replace gasket

or

Dismantle and clean carburetor

Clogged carburetor Clogged fuel pIpe

Clean fuel pipe Clean fuel tank

Dirty fuel

Check connections and tighten Repair or replace fuel pump

Air

In fuel system DefectIve fuel pump Clogged fuel filter

NOISY pump

necessary

Check fuel pump

Adjust float level

fuel pIpes Manifold draws secondary

Loss of fuel delivery

as

Adjust float level

Float level too hIgh Loose plug or Jet DefectIve gasket

Clogged

FUEL PUMP

Check and replace parts

I

Dirty carburetor

InsuffiCient fuel supply

float

pressure

Defective accelerator linkage Blocked pump Jet

SpItting

ACTION TO BE TAKEN

PROBABLE CAUSE

SYMPTOMS

Slotted body screws loo DIaphragm cracked

Clean

or

replace fIlter

e

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

arm

spring

Tighten mounting bolts Replace rocker arm Replace spring

35

I nter

O C 1

J

J

I

o

0

o

o

r

0 c

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

starter

o

lever

tl

Fog E 33 Adjustment of thefloat level 7 2

Floatlever Bend hrre

to

adjust

Jht ht1l

H

FI90E 30 The throttle valve IKlJUltlng screw

4

5

2

Fig E 34 Adjustment of the startIng Interlock opening

Fog E

32

tlng shaft

The

IKIJustment of the In1erconnec

FanIdle 2

Connecting Connecting

4 5

6

36

lever

Connecting St1Irter Th

pl m Imk rod

lever Jve ttler

Fig E 35 Checkong the hydraulIC damper 001

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

3 74

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

less then 03 mm 0012

clutch driven plate and thereby With the flywheel

clutch factogs

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

deSCribed

clutch

IS

In

section

fitted

Insert

GEARBOX

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

diagonal

SIX

manner

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

gradually

In a

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

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

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

holes COinCide With the threaded holes

plate Bolt down the

cover

to

In

the base

the plate

eqUIpment

IS

available

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

must be

plate

renewed Pressure plate

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

be skimmed off but the

can

be removed

IS

1 0

mm

maximum

0004

Clutch spring

D

amount

of metal that

In

aphragm

clutch

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

Fig

a

In

from

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

F 10

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

spring caps springs spring seats and

plate CLUTCH INSPECTION

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

Clutch spnngs

Cot spong clutch

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

Fig

In

It

F 11

IS more

than

5

becomes necessary to

mm

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

replace

Release

beanng

Replace the release bearing If the much

play

or

there

IS

roughness

causing too step formed or If the

wear IS exceSSive or a

37

f@ CE p

inter eM

a

11

Fog F 1

Exploded

v ew

of the doaphragm sprong

clutch 1

Clutch

2 Clutrh 4 5

driven plBte cover

Pressure pla Clutch ICunng

bolt

Spring Wil3htlr

8

BNI7ngslllflW

se Ies 9 Clutch 10 Rtlf8tnmg dip 11 Dust cover

12

Return

6 Clutch WlthdrawW lever

13

7 R

14 Locknut

ner

spnng

llWB Wlthdf

bNrmg

nng 11IWIt

pusher

11

Fog F 2

I

II

of

Exploded

2

the

cod sprong

clutch

ltlJ

CIlrtch drltIon 2 Outrh y b 3 Clutch CD c Clutch PlWSUfe pine 5

Eyebolt

IT

6 EYlIlxJ1t pwot pm 7

Pnmu rlng q 8 Spnng cop lwet 9 R 10 R

Locknut 12 Release IftltJT wpport

OIA 257

mm

DIA 240 mm

1J

FIg F 3 Specull toolset for dutch overhaul

J m

IA 216 DIA

D Fig F 4 dmphragm clutch

38

nun

235mm

men

diamsJam

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

for

the

mmr R

spring

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

F4

Wthdrwwallwer

pulh

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

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

Ibs

check the bearing for smooth rotation

CLUTCH PEDAL

Adjustment

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

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

tighten

are

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

compress the pressure spnngs

8 150

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

CLUTCH MASTER CYLINDER

Removal

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

cyhnder

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

for L H 0 models and lock the stop bracket

In

CLUTCH MASTER CYLINDER

Fig

Dlsmanthng

F 18

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

Empty cover

CLUTCH

Adjustment

Call spring type

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 readJust the levers as necessary Finally secure the eyebolt nuts by peening over the matenal several times and

recheck

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

valve spnng

CLUTCH MASTER CYLINDER

IS

weak

replace

Assembly

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

ThiS CLUTCH

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 With the

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

gradually

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

CLUTCH PEDAL

Removal 8IId Installation

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

hydraulic system CLUTCH SLAVE CYLINDER

Fig

Removal

F 19

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

cyhnder

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

mounting bolts and hft

and 11ft out the pedal

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

CLUTCH SLAVE CYLINDER

Dismantling

39

mt e refJJ cQ P f

dla

255

mm

3 3

Fill F 5 Y

Fig F 7

W YIf

of the

d

Fill F 6 clutch

hragrn clutch

1Iel1SlOn O

dlllgralll for the coil

ng

of the cod spring clutch

Fig

F 8

Checking the clutch

dren

plate

to

Fig F 9 Checking the release finger height of dutch

the diaphragm

out run

Checking the load of the diaphragm

Fill F 13 1ng bl

40

Inspecting the Fill F 11 distOrtIOn

InstallatIOn of the dutch diaphragm dutch

dutch spnngs for

F U F 12 Removal of the clutch

F 14 InstaJlatlOn of the dutch bearing coillPrlng dutch

FIlI

tel

bearIng

mter

FIg F 16

12L Fill F 15 AdJuSbng the release I

T

ghtemng torque

35

heIght

to

4 0

ActuatIng the clutch

to

settle

Q1 O

@ ce l

t

mechanism

i23

kg

rn

19

13

15 16

14

D

2

CiI

11JI17J

8

FIg F 18 cyhnder

SectIOn

through the clutch master

Cylmder body 2

AdJust

by adjust

screw

of

master

cyt

6

LubricatIon Clutch Clutch

pedal

full

pedal

free stroke 2S

troke 140

4

R

turn r

1 Piston 4 5 ondaTy 5 PISton 1 8

mm

cup

cup t Valve Va stem Valve mng q

9 Sprmg 28t 10 Valin st em fop

1m

t 7 Stop pMctt 12 Gasket WIIwr

Fill F 17 The clutch pedal adjustment

13 Push rod 14 Pudl rod C

VIS

15 Nut 16 Locknut 17 P stOn fop 18 Abutment wahar

f

19 Rubber boot 20 Flutd rtnelVOlf 21 22 23

Clip IINVOlr Rft

Cap

ClIP

INJI

O

Fill F Fog F 19 cylinder

Exploded

of

the clutch slave

20

withdrawal

lever

41

wear

especially

the piston cup and

replace

If worn or damaged

Aaembly 1nI1nsta11atJon

CLUTCH SLAVE CYLINDER

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

The

NOTE

The correct

adjustment

of the clearance is essential as

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

0 307

mm

In

to

CLUTCH SYSTEM

flUid pnor to assembly 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

Adjustment

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

te t

en

reservoir

With

the recommended

flUid

and

pump

clutch pedal slowly

Loosen

bet

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

CLUTCH WITHDRAWAL LEVER Fig F 20

Bleeding

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

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

flUid

or

release levers

Technical Data Clutch pressu Free length

re

Clutch release levers

springs 52 3

Fitted length load Side distortion

292 5

mm

mm

per 100

44

mm

mm

2 059

Clearance between release bearing and 1 2 1 4 release levers

In

1 15 In 97 Ib 02 In per 3 94 In

kg

Height diaphragm flywheel Height between release levers and 505t flywheel

PermiSSible deterioration of 15

spring force Clutch driven

200 mm 7 87 In 13Omm 5 121n

Inner diameter Thickness of facings Total fnctlon area Thickness of clutch

Pedal

362 sq

em

56 11 sq

In

pedal height In

03543 03130

In

Free stroke of Pedal effort

plate 86 90

Free

765

795

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

Clutch

rest

poSition

35vm 0 141n

Compressed

In

mm

1 732 to 039

In

002 1988

In

005mm

mm mm

03386 03012

pedal

Mastwr

0012

7 17

In

RHO

cylinder

Diameter mm

mm

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

In

6 03

182

In

Max piston clearance

5 8

In

o 13mm 0005

1587

In

mm

of clutch 05

plate PermiSSible free play

42

0055

0047

mm

plate

Outer diameter

PermiSSible

spnng and 441

between

on

splines

mm

04 mm

020 In 0016 In

Pressure plate Perm ISSlble refaclng

1 0 mm

0 394

In

Trouble Troubles

Shppmg

Possible InsuffIcient Improper

all

or

RemedIes

causes

free

clutch pedal of

adjustment play

lever end

on

grease

Shooting travel

withdrawal

Adjust pedal free travel

Adjust

end

Remove

lmmgs

play

tmmg

DISC

Clutch

dIaphragm plate

Pressure InsuffICIent clutch

release

or

Excessive free travel of Exce

play

lve

Replace sprmgs

Reface

worn

dutch pedal

of WIthdrawal lever

PIlot bushmg stH kmg

replace

or

Adjust correctly

Adjust correctly Replace Pllot bCarlllg

Splme of clutch diSC hub Clutch dIsc

Replacl dutch diSC assembly

orn

Sct

arped

Ie vcl

of

dutch diSC

LcakIng

from

cylmdel

master

cup

Leakmg from operatmg cylmder mflLtratIons

Air

re

broken

flywheel

or

and

if necessary

RepLace Imlngs and pres

sprmg

springs weak

sure 1

burned

worn or

of lcakage

cause

ptal c Immg

Into

the

cup

hydrauhc

clutch

dISc

or

replace

aSbcmbly

Replace cyLinder cup Replace cup Bleed out completely

lme

Roughncsb

Rub

Immgs

on

hmngs

WIth

a

metal brush

or re

place them Low flmd level

Grabbmg

a l

on

facmg

011

In

or

Top up With brake flUid

reserVOIr

burn cd

or

glazed

Install

new

diSc

assembly

faCIngs Loose dISC

lmmgs

due

to poor

rIvet

tlghteness Pressure or

Rcplat c

defective rIvets

or

replace

lmmgs plate

or

flywheel

arped

v

Replace

them

cracked

Improper

adjustment

of

release

Adjust release

er le

lever Loose engme Wear sian

NOISY

or

mountmgs

damage

of clutch

dIbe tor

or

Replace

dISC

replace mountmgs

assembly

sprmg

Worn

release bearmg

Cracked clutch dlSC plate Wear sian

Tighten

or

damage

of

clutch diSC tor

Replace bearmg Replace

dISC

assembly

Replace

diSC

assembly

Replace

diSC

assembly

sprlng

Loose clutch diSC hub

43

inter

ilj

JG 1 FI

p @

Removar of the propeller shaft

Daconnectll19 the

remote

control

Fig G 6 RelMVill of the extensIOn housmg

2

J I

l

I 1 I

I

Cw

f

c

0

r

fIr

I

9

f

t

i

gear

FI9 G 7 Removal of the crosHhafts For anno1atlons see text

JG FI

10

R

iifih8

iine idler gear

F19 G 12 trail

44

Withdrawal of the mall1Shaft gear

Gea rbox sPEED THREE

Check the gearbox casmg for cracks and indentations Where the surface IS machmed check for burrs and remove where

Removal

GEARBOX

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

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

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

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

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

replace

shafts for burrs

or scores

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 Check

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

crossmember

remove

the gearbox

THREE

10 a

rearward direction

diagram Fig

Dlsmanthng

SPEED GEARBOX

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 Dram

the

gearbox

retainer

Fig

hOUSing G 7

G 6

Item

5

Remove and

the

shaft

cross

remove

the nuts

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

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

Place

the

G 19 selector

rods

on

a

flat

surface

to

check

for

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

holding

Check 011 seals for have

been

wear or

Fig

removed

IS

0 15

0 30

mm

0 006

damage Replace any 0 rmgs that G 20 shows

the

011

seals

to

be

checked 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

Press the

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

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

Remove

the

Iayshaft

by

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

speed

Then

front

of

mshaft

releaSing gearwheel

the

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

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

InsplKltlon as

follows

the

expand 109 type springs To assemble the reverse 1st

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

replacmg

or

msert

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

Thoroughly clean all parts and mspect repairing any defective parts

to

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

freely THREE SPEED GEARBOX

on

Assembly

drive shaft clutch shaft and that there IS no play between

When

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

bearing

maIO

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

THREE SPEED GEARBOX

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

on

on

keys and

frt

a

SPring

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

i

I

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

1f

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

3

speed

I II

f Ii r

FIg G 16 Removal of the 2nd speed gearw

k

VJ FIg G 19

CD

lV

CheckIng the synchron

rIngs for

wear

FRONT COVER

REAR EXTENSION

Fog G 20 The oil seals ulOd

on

CROSS SHAFT

the geaTbox

v

F gG 22

ehp

e

46

I

ns1allatoon of the

In

Fog G

23

Insortlng the shtftll1ll keys

Fog G 24 FittIng the synchronaer hub operating sleeve

on

to the

mm

160

0002

0009

180mm

Clrcllps

In

0063

are

available

m

5 Slles from FOUR SPEED GEARBOX

0071m

Removal and Installation I

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

gear assembly

reverse

on

the shaft

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

from 1 30

1 70

0051

mm

0067

m

m

thickness

Check the end float of the whIch should be as follows

gearwheels

as

shown

Fig G 26

1 st speed gearwheel 2nd speed gearwheel

005

022

mm

0002

0009

m

o 1

022

mm

0004

0009

m

m

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

NOTE

two types of Warner and Servo Three speed gearbox

There

gearbox

Borg

deSCribed

In

are

synchromesh

used

m

thiS

The Borg Warner type

IS

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

and the mamshaft drive gear clutch shaft assembly mto the gearbox casmg Fit selector rods and selector forks as follows Fit the

DIsmantling

FOUR SPEED GEARBOX

Fig G 32 and

unscrew the

top and bottom

covers

mam

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

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

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

and the rod

rods With the retalnmg pins Fit the

reverse

Fig

Idler gear and shaft and

secure

With lock bolt and a SUitable

plate F It the countergear cluster and the shaft usmg thrust washer to obtarn 00047 mm

In

0 151

Washers 0159 In

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

end float of 0 04

an

available

are

rn

5

sizes

0 12

mm

00016

from 383

403

G 33

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

and

assembly

shown

as

In

Fig G 35 and the

main

drive shaft

clutch

shaft

thickness

m

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

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 Fit the

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

bolts to

a

the gear backlash o 13 mm 0 003

as

shown

0 005

rn

Fig

G 28 which should be 008

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 the bolts to

tlghtenmg

a

In

torque

readmg

of 1 1

1 7

kgm

cover

Refit cover

80

123 Ib ft

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

together

gearwheel bush

together THREE SPEED GEARBOX

The mstallatlon of the gearbox IS procedure Note the follOWing pomts

a

Installation reversal of

the removal

Finally

remove

the second

FOUR SPEED GEARBOX Follow

speed gearwheel

With the needle roller bearing

the

mstructlons

accordance

With

the

for

the

Inspection three speed

speCifications

given

gearbox m

In

section

TECHNICAL DATA Fill the

capacity

IS

clutch slave

play of

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

gearbox

2 2

cylinder push mm

0087

rod to obtain

a

withdrawal lever free

FOUR SPEED GEARBOX

Assembly

m

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

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

select

are m

a

available

thickness

47

inter

M@

f

FI9

G

A

1i

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

FI9 G 28 backla

gear

FI9

G 29

Greasing beanng

POlllts for

withdrawal lever

and release

J f J

z

Fog

G 31

I

VISW

of the gearchange contrOl

arm

F G

33 Removal of the

ne

ler geara

Po

pOlello t

a

I FigG 38 Exploded tram

FIg

G

34

r rete

48

Fog

G

35

R

a1 of the

malllshaft

ly

v

of the mamshaft goer

ImmIIII 4t1l 3rd

Rod

Spring Plug Plunger

Plunger FIg

n Dlllnm of tile G

Idler FOr

FIg G 39 SectIOn through tile gearbox

FI9 G 38 Assembly of tile selector fol1 s

to

show

the Interlodung system

FIg G 42

ll G 40 Removal of the steenng wheel F

Remoyal

of

the

upper

support

bracket

Gnxw naltnd wttmg

01

1

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

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

the

spring

IS now

free to

remove

same

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

so

securing the synchronIzer assembly

When

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

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

1 40

1 60

0055

mm

the locknut at the 79 5 Ib ft

0063

In

In

thickness

end of the malnshaft to 9

rear

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

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

Tighten

11 kgm

65 GEAR CHANGE CONTROL LINKAGE

To assemble the

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

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

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

FII the thrust washer

case

Adjust 006

In

InstallatIon

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

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

available

In

5 thicknesses from 2 4

2 6

mm

0 0945

AUTOMATIC TRANSMISSION

0 102

In

To When

assembling the selector

mechanIsm

Fig G 38

fIt the

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

interlocking pin A mechanism

selector

speed

section

rod

through

5

remembering

the selector and

the

interlocking

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

IS

same

gear

the retaining pinS

9

Secure the selector forks to the rods with

10

remove

transmission

linkage

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

for

as

as

and including the gear lever

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

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

screw

F g G 46 rods and

remove

the

cross

shaft bracket and the

cross

shaft

assembly Place

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

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 the

Although manual a

Job

automatic transmiSSion

IS

not

covered

inspection and repair far experts the control linkage IS discussed as

the maintenance

GEAR CHANGE CONTROL LINKAGES Three Remove

the

Fig

G 41 d

50

follOWing

column

steering

cowl

Remove the

IS

In

thiS

conSidered

Removal

speed gearbox

indicator

clrcllp

wheel

Steering

Items

1

switch In

Fig

and

Fig light

G 40 swItch

G 42 and the washer

The

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

Technical Data GENERAL SPECIFICATlor S

Gearbox model

RSW65L

Gearchange type Synchromesh type

Column

Gear ratios

1 st gear 2nd gear 3rd gear 4th gear Reverse gear

Number of teeth

F4C63L

Floor change

Floor change Servo

Borg

Warner 32631

Borg

Warner 33821

16451

20131

1000 1

1 312 1

20131 1312 1

33551

10001 33641

33641

3 382 1

10001

on

mamshaft

Number of teeth

change

F4W63L

Drive gear 3rd speed

19

22 27

22

2nd speed 1 st speed Reverse speed

25 31

30

30 36

34

36 39

Driven gear 3rd speed

30

31

31

29

29

2nd speed 1 st speed

24

21

15

15

21 15

Reverse speed

16

14

14

16

18

18

5

5 16

27

39

on

countershaft

Reverse dler gear

Speedometer

Drive gear

5 19

Driven gear

or

17

16

I

CLEARANCES AND PLAYS I

Model

R3W6

Mamshaft end float Max mam shaft end float

o

Cou ntershaft end float Max countershaft end float Reverse Idler gear end float Max Idler gear end float

F4W63L and F4C63L

019

mm

0

0008

020mm 0008 004 0 12 mm

m

020

m

020 o 50

mm

0008

040 mm

mm

0 020

m

0005 0002 0008

m

0016

m

008029

mm

030mm

0012m

005 o 20 o 10

015

0006 0002

mm

0 008 m 0 30 mm 0 004

m

In

mm

o 50 mm 0 020

m

0 011 0003

0012m

m

Gearwheel end float 1 st speed gearwheel 2nd speed gearwhee 3rd

o 05 010

0 22 mm 0 002 022 mm 0004

0009m 0009m

speed gearwheel

Gear backlash Max shaft ru

008 out n

015

013 mm

mm

0006

0003 m

0005

m

005 005

o 15 mm 0 002 o 15mm 0002

0006m

005

015

0002

0006m

005

0 10mm 0002

0004m

025

mm

mm

0010

0006m

m

51

inter

FIg H 3 Removal

r1D

p @

of

FIg H 4 Removal of the SIde drIVe flange

member

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

rear end

DIFFERENTIAL While

of the car and place

of the vehicle on suitable stands

Loosen

the

dismantling check the follOWing

outer section clamps and turn the to the left saloon slpre 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

flange

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

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

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

PROPELLER SHAFT

DIsmantling

Clean and

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

follows replacing them If

wear or

In

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

The standard

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

spider

gearbox splines should

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

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

PROPELLER SHAFT Reverse the

removal and

Assembly

dismantling

and Installation

procedure

fellowing points Grease the needle

noting the

rollers WIth

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 the into the

rear

flange yoke

Similar

Removal

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

should be 3

15

kgem

as

shown

In

the Illustration Next

remove

the differential

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

carner

f F Ig H6

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

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

remove

the outer

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

races

drive them out With drift

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

Replacmg of oil DIFFERENTIAL Saloon

on

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

from the dIfferentIal

spider Journal

0006

Items

Clamp the differentIal In

exhaust

accidentally dropping

Dismandlllg

seals wilh dIfferential titted

Front 011 seal 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

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

outer diameter or

63

inte r

clJ e

C0LID

6 90H12 F 90H F I

11

Pinion

Secbon through the drive pinion

prHoad

bHn1Id UltJ f

2 Pmlon dopth

lItIJ

611

ol

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

Ii

Amon

lng u IId

P8Cf I

90H F

side

Adjsutllll

d

far

dlff8nntJal

u

2

16

cowen

i

4 Gl

90H F co

17

I

The G

maJtuJ18S

lo

of the

dlffwentJal side

FigH 19 ChecIung wheellDI priOR

54

the

backof the

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

DIFFERENTIAL Clean all parts

as

follows and

Inspection

replace

or

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

3

If the

bearrngs

and thrust

washen for

Chipping

or

backlash

between the differential Side 0 008 In IS over 0 2 mm

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

and differential

carner

cage

for cracks

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 The

preload

6

In

all 011 seals

DIFFERENTIAL

Assembly is the reversal the follOWing pOlllts

ASIlImbly

of the

and

Adjustment

dismantling procedure With

the shlTIS

surfaces

thoroughly

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

washen etc and lubrrcate

the space between the

sealing lips

In

correct

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

mange

the tJp set shlckness

In

of mesh

for the adjustment The dnve pinion adjusting shim S can be found from the follOWing equation W

T

H

x

0 01

0 20

where

T H

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

S

ReqUired thickness

of washers and shims

lxample the follOWing might apply

As

a

W T

2 20

3 40

1 20

H S

mm

024mm 2

3AO

0 24

Fit the shims

beanng bearing

2

0 01

x

reqUired

to

020

the drive

3 46

pillion fit

the rear

mm

bearrng

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

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

Fit the dnve

Press the

bearfngs

on

flange

by

the

beanng

retalller and the 011 seal

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

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

Acljustment

shims

of differential bearing covers

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

If differential

carTIer

replaced adjust

following equations T1

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

re

followed

spacer

secure

been

0787 In

shown

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

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

00 mm 20

pinton height depth

as

Inner race on

Differential cage

Might

measured

note

to

Arrange

be

dummy

W

general replace

of

AdJustment

should

or

distortion

load pre

rece on

S 5

pmion

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 Inner

gear and and the

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

of drive

Fit the

bearings Flg H 12

wear

differential pinion

4

Acljustment

T2

left

rrghtl

A 8

C

0

G

G

D F

E H

H x

x 0 01 0 76 0 01 076

to the differential

56

interl

iill

p m

TOE

TOE

TOE

fr HEEL DRIVE

HEEL COAST SIDE FillH2O Tooth contact on heel

HEEL SIDE

SIDE

DRIVE

21 FIlI H

Tooth co

56

DRIVE

SIDE

on toe

TOE

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

HEEL

HEEL COAST SIDE

F

22 Tooth H

TOE

HEEL DRIVE SIDE 24 H C F

HEEL COAST SIDE tooth contact

co

HEEL COAST SIDE on fImc

removal

where A C E

B

The

D F

The figure

figure

the differential carner on the differential cage

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

G

Fig H 17 The

H Measure

the to

etched

In

the crown wheel Side

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

differential

placmg

mstrument

bearmg

figure

brmg

m

and fill the fmal drive With of the recommended 011

procedure

Imp pts

on

08 IItres

1 3

08 US qts

DIFFERENTIAL

Ramoval

Estate Car Stetlon

Wagon

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 Disconnect

the drive

a

DIFFERENTIAL

F 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

Dismantling

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

shown pinIon

Check

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

cover

out

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

If the If

right

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 or additional shims must be fitted It becomes necessary to readjust the backlash

Remove

the

Keep

the lock pin for the differential pInion shaft from left to and the right and remove the pinion shaft piniOnS Side gears thrust washers

the shims must be removed

Tooth contact

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

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

as

move

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

might by pOSSible

for toe contact

repair as

If

shims

or

no

washers

load condition have

been

Also check that the wlthm 008 mm 0003 m backlash

changed

check

IS

and inSPect

as

follows and

replace

or

necessary

and

thrust

m

reverse

m

washer 0 2 mm 0 008 7 different thicknesses

DIFFERENTIAL

The

Installation

remamlng parts

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

stIli

the

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

Fit the

thoroughly

m

Thrust

washers

are

the tooth

wheel backlash

Secure the differential

H 25

as

available

crown

DIFFERENTIAL

Fig

other SUitable equipment

for heel contact

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

use

DIFFERENTIAL Inspection Fig H 31l Clean all parts

Face contact Fig H 23 ThiS pattern should be treated

to

order

to

the

assembly IS a reversal followmg pomts

Assembly Fig H 33 of the

and

Adjustment

dismantling procedure notmg

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

F

Ass y

H 30

R

beanng dlf ereratl al

ide

duvt piniOn

31 H F Exploded bly

of d

FigH 32 MeIIsllnng 1he NIHIUt

58

crown

wheel

for

I of

tile

pllllOii mv

mte

E illj r

P @

DC

J1ahtenJnc torque lrmo p nu nlDn 14

to

100

17 k

to

Gear

odj Adj drlnu bearina wttbout

o

dnn pIJUOD

oD drift hypoid Ie w pat Preload or pinion beannc

m

120

lb Ct

10

ratio

3SP A

TIM

to

13

TIhrenma 6

3889

1

TIM

cm q

torque

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

dtff bolt

kg m D

C 4SP

I

TIM

FIgH

3700

SectIon

1

L

through

carr

Fill H 36 IIlIe

Me mng the bearing thockness

entud drtt

the

dofferentl8l

FIg

H 35

CalculetlOn of the

differential side

lbeenng s ums

Fill H 37 Measunng the crown wheel back

s Me ng the

n dlmen

L

69

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

edges

of the hole to

39 8 Ib ft

10 a

d

new

5 5

lock

kgm

agonal pattern

13 kgcm

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

a

press

10

race

replacer ST 47820000

new

bearings

use a

washer of dIfferent thIckness Do

Ib ft

Adjustment

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

for

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

shaft

AdJustmg the dnve pinIOn

oz

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

specIfIed torque readmg not overtighten the nut

outer

180510

a

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

138 9

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 and

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

should be 10

of d fferentJal

preload

beanng

AdjUst the dIfferentIal bearing pre load followrng formular see Fig H 35

10

accordance WIth the

To

Left Side Tl

A

Crown wheel SIde C D E 7

RIght SIde DIfferential assembly SIde T2

a

0

0

F

6

where To

determine

the

exact

thIckness

of

the

shIms

use

the

T11T2

follOWing equatIon

Shim thickness

A a T

N

H

x

0 25

02

hOUSing Figure

T

ElF The

required

rear

bearing adJustmg shIm thickness

In

H

FIg

The gap measured above 10 mllllmetres The figure marked on the dnve prnlon head ThIS eIther

a

or a

can

be

figure

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

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

60

10

Units

respectIve

of 1 1000

10

differentIal beanng

marked

Respective

mllltmetres N

on

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

C D where

required

Figure marked

H 36

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

right

to

readmg

left If too great TIghten 48 kgm 304

ot 4 2

cap bolts to a torque 347 Ib ft Usmg a large

bearing

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

Technical Data PROPELLER SHAFT 1082 mm 426 In Saloon models 1242 mm 48 9 In I Estate car models 635 mm 25 In Saloon models

Length Outer dIameter

750 Inner dIameter

mm

30

In

Estate

car

models

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

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

008mm

cm

0 278

mm

In oz

2 0 2 2 24 mm

shims

From 1 09

ThIckness of pmlon Saloon Estate

1 27

mm

beanng adJustmg washers From 2 31

car

257

mm

As Saloon

00315ml

06 mm 0024 015

Thickness of pmlon heIght adJustmg washers ThIckness of pinion heIght

at

0006

CROWN WHEEL

m In

4000 rpm

Backlash between gears Saloon Estate

car

o 10

0 20

mm

015

020

mm

0 004 0006

0 008 0008

m

0003 0 OOl

In

m

I

FINAL GEAR RATIOS Run out of 1 3 Ittres Saloon models 1 6 lItre engine Saloon With 3 speed box

43751

Estate

car

wheel Less than 0 08

mm

Less than 0 05

mm

37001 38891 38891

With automatIc car With 4 speed box car

DIFFERENTIAL GEARS

37001 Thickness of Side gear thrust washers Saloon

DRIVE PINION InitIal turnmg torque Saloon models Estate

car

Depth from axle car

10

13 kgcm

Estate

0506 0 723

0723 Ib ft I 0940 Ib ft

car

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

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

mm

0004

mm

0002

08 00 0008

mm mm

10 m

centre

Saloon modesl Estate

without 011 seal 7 10 kgcm

models

In

3900 1 39001

Saloon With automatic Saloon With 4 speed box Estate car WIth 3 speed box Estate Estate

crown

Saloon

models

48 5 610

mm mm

1 909 2402

In m

61

ImDIIIII I

J

0 f 1 r

i

1

ttI

i

i Y

c

1

j

8

f 1l

7

jjJ

jf

0

YI

IJ

1

7

AiI II

r

j

I FIg I 2 Parts to be removed

or

the removal of the fmal drive

dIsconnected for

unit

t

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

Propeller thaft flange

Front

I

O ff

mountmg member

I

L

FIg I 3

Removal of the lower

shock absorber

Fig I 4

Removal

suspenSion

mounting

as

a

of

complete

rear

axle

and

rear

I nstallatlon

Unit

rear

diagram for

suspension

o

6@

I

I

jj

I

1 l

Fig I 6

Removal of the drIVe shaft securing

FIg I 7

Exploded

vIew

of the

rear

cod

ring

nuts

F g 1 11

1

Filii 9

62

Removal

FIg I 8 The upper shock absorber mounting

Fig I 10 of

the Or coli sprln9

Removal of the

rear

SIIspel1Slon

ann

nut

Removal

of the

rear

wheel

bearing

Rea r

Suspension COIL SPRINGS

DESCRIPTION

The Saloon models

are

fitted WIth

a

fully Independent

rear

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 semi

arms

arms

bolts and rubber Insulators The Estate Cars

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

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 I 1

SUitable stands

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

or

damage and replace

If necessary

procedure

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

Removal and Installation

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

Removal

Saloon models

Fig

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

REAR SHOCK ABSORBERS

REAR AXLE AND SUSPENSION

Refer to

Check

The installatIon

StatIon

axle WIth seml shock absorbers rear

Installation

are

Test the shock absorber If faCIlitIes the results With the specIfications Check

for

011

leaks

and

are In

cracks and

available and compare TECHNICAL DATA check

the

shaft

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

for

or wear

reversal of the removal procedure

IS a

remove

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

REAR SUSPENSION ARMS Jack up the car and place the dlscpnnect the follOWing parts and

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

Replace

where necessary

from axle shaft

wheel

Lower

cyltnder

the Jack and Fig 19

rubber

SUSPENSION

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

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

kgm

Ib ft

REAR SUSPENSION ARM

Removal

the suspensIon arm for dIstortIon or cracks and the rubber bushes for wear damage or separation of the matenals Replace If necessary reversal of the removal procedure TIghten mounting bolts when thevehlclels resting the ground Replace all self locking nuts

IS a

the suspensIon

WIth the wheels

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

InstallatIOn

Check

The installatIon

Jack FIg

spnng and the bump

wlthd rawal tool

all

the

the COIl

and

ThIS

Jack

remove

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

Installation

COIL SPRINGS

end on stands Remove or Wheels brake drum drive

rear

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 shaft

SUSPENSION

Removal

arm

on

rear

and remove the COIl spring I 7

the seat and the

bump

rubber

OIL SEALS

REAR AXLE SHAFTS BEARINGS Removal and

Dismantling

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

USIng a slide hammer Remove the rear axle dnve

I 12

studs

SUitably flange

fIxed

to

the

flange

63

inter

QJ

@LID

I

00 0 FIg I 12 Removal of thedrIVe axle

t

Shock absorber lower mountIng

Bearing hOUSing mark

j

D

Pack With wheel MP2

or MP3

beanng

grease

every overhaul

AXLE HOUSING

DISTANCE PIECE

Fog 115

The critIcal dane ons mstallatlOn of the RlsponSlOn ann

8 6 6

7

Fog J 16 Exploded 1 2 3 4 5

of thedrNe

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

6 1

GaJrttrcltp

8 9

SJtJeve SIewe

10

shaft

C IdIP

yoke yoktl plUf Spider Joomal F yoke

12 0 119 tIbelllJt1g 13 N 4

Clrcltp

Apply grease

In

Fig18 Sec1IOn through the

64

r

thIS area

d

1haft

for

the

O

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

Check

OIL SEALS

and InstallatIon

Assembly

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

Replace Replace

parts

as

pOints all

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

Fig I 14

applted

When to

the

the bearings the

refItting

pressure should be

lOner race

When

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

the spaces Replace the

In

wheel bearong nut after It has been used tWice Wheel

beanngs

have

mm

0006

In

The

rear

Wagon

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

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

REAR AXLE

on a

rear

Dlsmantltng and Inspection

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

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

Removal

Estate Car Station

The assembly and the follOWing mstallatlon IS a reversal of the dlsmantltng and removal procedures notmg the follOWing

Clean

REAR AXLE

necessary

axle shaft should

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

In oz

If not

and

the

remove

Itable

bearing

WIth

a

beanng puller

or

by other

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 su

means

Check DRIVE SHAFTS

Removal and D smantltng

DIsconnect the end flanges and remove the shaft

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 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 and

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

REAR AXLE ThiS

IS

the

noting the

Check

the

the dnve

follOWing shaft

are

and Installation

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

must

replacement parts Check

Inspection Assembly

not

complete

avaIlable

the boots and the sleeve yoke

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 shaft for

sectIon

plug

dIsmantling

and removal procedure

pOints

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

a

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

the m

recommended

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

or

dealtng WIth

the propeller shaft

REAR SPRINGS Refer to

FIg

support the Clean the

sleeve

and the drove shaft ball grooves and With the drove shaft compressed check that IS less than 01 mm 000410 Fig I 17

lubncate WIth 011 the shaft

and InstallatIon

Thoroughly dIagonal

DRIVE SHAFT

of the

reverse

follOWing

Assembly

play

yoke

Removal and Installation

I 21

rear

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

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

rear

axle

together WIth

the rear springs

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

s

7 8

FillI 23 3

Voew of the axle

as

frtted

Ddfenmtt 2 Rear vie 3 4

66

to

C8TTI r

hOUSing

LBet sp mi Bump rubber

rear

SIIspenSlon and

rear

models 5 Shock obsorlJor 6 RNr spring front henger 7

8

HMldbrllktlltnk B ll hO

The upper shock absorber mounting

bolts and the front spring eye bolts to separate front

hanger and

spnng

REAR SHOCK ABSORBER

The InstallatIon the

following

IS a

reversal of the removal

procedure

noting

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

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 The the

Removal and Instllllatlon

bump

rear

The installatIon

procedu

tIghtened

that the shackle bush flange

IS

re

the wheels of the

clamped evenly

IS

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

Tighten the car

resting

on

the ground

Technical Data COIL SPRINGS Model

L510S

L510

510

PL510 W

re

dIameter

COil dIameter Free length

142

mm

0559

90 mm 3 543 311 mm 122

142

In

0559

mm

In

Same

In

306

142

In

mm

0559

In

Same 120

mm

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

299

In

mm

11 8

In

sprtng The only dIfference for the

HOCIC ABSORBERS L 510

Model

P L 510

PIston diameter Stroke

25

235

mm

9252

In

Max

578

mm

22 76

In

length

DampIng force

at

0 3

0984

mm

25

In

I

0984

mm

In

235

mm

9 252

In

578

mm

22 76

In

m sec

ExpanSIon CompressIon

65kg 33 kg

1433Ib 72 8 Ib

50kg 20 kg

1101b 44 Ib

REAR SPRINGS SHOCK ABSORBERS 1200

Length

Estate CaB

Width PIston diameter Stroke

length Damping force ExpanSion

mm

0984

In

Thickness

200

mm

7874 19488

In

Number of leaves

In

Free camber

495

Max

CompressIon

25

at

mm

0 3 mlsec

75kg 23 kg

1653Ib 50 7 Ib

24 Laden camber Spring eye bolt diameter

60 6

47 2

In

mm

2 362

In

mm

0 236

In

mm

4

mm

at

246

kg

153 mm 6023 In 0938 In at 542 Ib

Front

45

mm

1 772

In

Rear

30

mm

1 181

In

67

inter

iCQllW ill

J 2 Removal of the wheel hub FIlI

Z I

6

5

FlgJ 1 V 1

2

of

enSlon Su

SUsptlnSlon 4 SuspensJOlt

4

GreWIth

J7 FIg l1li8

68

text

Ulator m

R

umt 6 embly S crossmem

StabllMr bar 6 Reaction strut 7 SrnpenSlon ann 8 Steenng lever

r

ated poInts Indoc

of the ll1Ibil

t 2

spensoon

J FIlI

bar

5

Fog J 3 Exploded

5 Removal

Frontwheelhub G

I

Inner WMeI bearing 4 Outer wheel beanng 5 Spmdltl nut

5

Co l Sfrmg

3

J Flg

umt

the front

tq o

e

7

O

v

of front wheel hub

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

the cnon Ilrut

J 8 Rerniiwal of FIlI

For alUlOll1bOnS an

l1li8

tIDltl

Front

Suspension

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

FRONT WHEEL HUBS

Drum brakes

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

beartng the

Remove the outer

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

cage UStng and outer beartngs a

lOner

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

Thoroughly

damaged beartngs

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

arm

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

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 remove

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

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 re

97 2

WIth

kgcm adJustment 4 kgcm 555 10 OZ

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

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

out the buter races

FRONT WHEEL HUB See descnptlon under drum brake

Installation

type nottng the followtng

torque setttngs

Calliper

bolts

Brake dISC bolts Baclc plate bolts

the suspension untt

Installation

The installatIon

7

Removal

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

and FRONT WHEEL HUBS

Removal and Installation

REACTION STRUT

DESCRIPTION

Dlsmantltng

SUSPENSION UNIT

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

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

wear

deformatIon and cracks

7 3 3 9

99 kgm

528

71 6 Ib ft

5 3

28 2

38 3 Ib ft

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

27

37

195

268 Ib ft

below

To

kgm kgm

assemble

P510 UTK

All ledU models

STABILlSER BAR

Removal and Installation

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

rubber parts

and Assembly

Ex PSIO

modeIJ

PLSI0 TI aud

damaged tlghtentng the and the

UTK

J 1I

wagon PLSIO TI

model

and LS 105

LSIO S

J 7 1 0

300 cc

325

cc

290

cc

quanbty

of the bar and

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

Applied

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

8 e

2

3

4

5

y

9

Fill J 10 Removal of the SWIvel JOint essembly

6

7

P

e FIg J 9 Exploded 1 2 3 4

J 12

of the front RlspenSlon umt 6

Upper mount Gland packmg Upper sprmg eat

7 Coli Pring 8 BumlHf rubber

5 Dust

Fig

VIew

Nut

9

Clip

Suspension

The upper mounting of the Rlspenslon

Unit

cover

Removal of

the suspension

the self locklng nut With

unit compressed

Fog J 13 Exploded mbly

VIew

of S1Jspenslon

unIt

spnng

o

Fig J 14 Exploded

70

voew

of the shock absorber

Fill J 15 Grease the pOints marked With

and

mmBIIB

Fig

J

17 The suspension

ann

mounting

nut

A

FIg J 18 The suspenSIon

arm

bush

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

JOint on

fIiilIII J

itJiJ Yf l

I

t

j

f

h

Co

p I

fi

r T D

L I

Fill J 22 AdjUst rod

centre

tube

the

In

j

by turnIng the track

F I J 23

AdjUst the bolt

enng stl

angle bV

means

of

the arrowed

71

untIl the pressure

IS on

both dIrections the

LOWER BALL JOINT

same

Complet e

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

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

Fig

SUSPENSION UNIT

Installation

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

In

the

follOWing Upper attachment nuts

3 9 6 0

Unit to

ReactIon rod to

Stablltser

to

arm

4 9 1 2

arm

arm

SUSPENSION ARM

5 2 80

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

Removal and InstallatIOn

lower ball

J 19

Replace

a

It must be

06

SuspensIon

Removal and Installation

damaged dust 0001

mm

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

cover

replaced complete 0014

on

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

reversal of the removal procedure Tighten to the torque values Itsted under TIGHTENING TORQUES see Index for page number heading Front Suspension all

bolts

IS a

and

nuts

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

FRONT WHEEL ALIGNMENT

All checks of the front wheels should be carried out With the tyres at correct pressures Camber and castor angles are pre set

arm

and cannot one

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

less than 1

mm

004

In

SuspensIon member Ball JOint

to

changing

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

hangs

Toe on

replace the rubber parts

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

Side

TIghten

cross

12 2 19

13 5 kgm

88 2

25kgm

137

97 6 Ib ft 1811bft

Adjustments

Check the toe

In

by lengthening

or

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

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

adJusted In

FIg

to

equal length

by turning the

centre

tubes

arrowed

angle

uSing the

J 22

Steenng angle With the

car on a

bolt arrowed

72

In

turn

FIg

table adJUst the steerrng J 23 on both SIdes

Technical Data FRONT WHEEL ALIGNMENT

Model

All Saloon models except L510 S

L51 D S

All Estate Cars

Castor Camber

1040 1000 8000

1040

200

King Toe

pIn

Inclination

6

In

1010

7030

7050

9

9mm

024

1030

035

3

12mm

035

In

047

6

n m

012

In

024

In

COIL SPRINGS Models

L H spring for all models R H sprong for L H 0 models

Except L510 SI Wire diameter COil diameter Free length F Itled length Fitted load

spring for all models WIth air

cond Itloner

12

mm

spring for L510 S

12

mm 0472 In 130 mm 5 12 In 3545mm 1394In

12

536 Ibs

0472111 I

mm

130mm 3695 202

736lnl 187mm 243 kg

L Hand R H

R H spring for all R H D models and and L510 S L H

mm

795

mm

243

In

51210

3845

mm 1514 217mm 8541O 243 kg 536 Ib

I

III

0472

130mm

512 1455 III

536Ibs

In

FROIH SUSPENSION UNITS

Models

All Saloons

Saloons With

All Estates

Estate

With drum

disc brakes

With drum

With disc

brakes

Exc SSS

brakes

brakes

Exc

50 mm

PL510 TKI

50

8

0

rod

8

50 2 0

2 0

20

20

20

20

0 787

0 787

22

0 787

22 0 866

0 866

m

hnder

mncr

30

10

30 1

1 181

32

30 1 181

1 181

181

32 1 260

1 260

m

Dampmg force

at

pIshon speed 0 3 mls 1 08 ft t 10 67

EhpanslOn

kg

50

ci

2 0

0 787

dIameter mm

jO

50

8

2 0

2 0

dIameter

C

and

m

PIston mm

P510 UTK

S L51G

Strut outer diameter

I

L510S

SSS

Ib

147

CompressIOn kg Ib Shock absorber inner

cylinder

length

tn

mm

t 22 7

251 4 55

t8 8 1

410 16

0

b7 1 10 t 22 7

147

25104 55

t 8 8 1

410 1

s

16

7 22 t

147 25 55

4

110

8 8

17

t 22 7 t4 25

55

t8 8 1

435

435 1

1

H

HO 147

17

1

l

176

i 147 71 22

t 22 3

25104 40106 t8 8 1 88 2 1 13 2 55

I

410 16

1

410 16

1

I 73

interCE QJ

Q @

6

0 9

2

I 10

80

Fill

K 1

Exploded

Smermg gear 2 3

v

lng hou

mg eCtoTdudt Sector sh h ccwer Adu ttng IC W

5 Kbnn

beanng um 0 nng 6 HouSIng cOW

of the steering I8IIr

tIng bolts of the

FIlI K 2 The column

ng

1

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

rlll K 4 Removal of the

Nfl

g

I

c

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

74

g

column Nfl

1

9685

In

Steeri ng column

DESCRIPTION

grease 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

steering

IS

of the

reclrcu

latlng ball type

necessary to grease all grease flttmgs of the steering

Itnkage

Removal

STEERING GEAR

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

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

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

Itnkage

as

deSCribed

In

sectIon

GEARBOX

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

adJustment

nut

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

puller remove the rear beanng Finally remove the bearing

tube

steenng

worm

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

Into

outer

race

from the column

Inner

races

of the front and

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 as

packed

WIth

the

55 5

kgcm

833 In

WIthout the

oz

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 shaft

sector

being

fitted

ThIS

can

Fig

thicknesses from 1 45

1 57

mm

0057

0062

In

I

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

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

adjusting

mm

screw

at

to less than 01 mm the end of the cover

by

0004

In

WIth the

From thiS 1 8 to 1 6 turn and

FIg

K 10

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

capacity

STEERING GEAR

necessary and

reassemble

the steering

gear as follows

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

In tallatlon

The installation IS a reversal of the removal the followmg pOints

procedure

noting

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 Check

freedom

STEERING LINKAGE

Removal end Dismantling

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 Refer to

Replace parts

should be

It

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

adjusting

bearmgs and the steering column bearing

STEERING GEAR

wear

changed

cemented

Dismantling

Clamp the steering box assembly sUItably Into a Vice and remove the drop arm WIth a SUitable puller or specIal tool ST

rear

has been

then

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

a

beanng and

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

STEERING LINKAGE

Assembly

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 8 Checking adjusting ICrewand

Fill K 1 Measunng the initial turning torque by mean

jlfi F

of

a

i 0

C I

G

y 1

between

float

shaft

7J

2

r

I

0

l

J

I

q t

I

l

J

4 11

Ir J

f

f

ri

I i

J

g 8

J

Q

end

spnng scale

t

tJ

the sector

TIGHTENING TORQUE 55to76kgm RAD 140rrm SEDAN

0

r

0

145mm

WAGON

r steermg

hnkage

FIg K 12 Section through the Klier

seen

ann

1 Nylon bush 2 Dust co r 3 e arm ld

a

r

2

j

I I

ANGlE

TOLERAHa

1

47

to 3 47

AFTER TIGHTENING TME ARM

Fig K 15 Adjustment of Idler bracket and Klier arm

Clearance 01to05mm Frg K 13

Section

forthe track rod

76

thnlugh the ball JOint IItud

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

have

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

mm

stud

IS

Replace

0 004

pulled

out

no

free

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

of 0 1

With

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

FIg

ball JOInts If necessary

Drop

arm

Idler

arm nut

12185

alignment

Shooting

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

SteerlOg

Tyre

Steenng wheel shimmy

box needs adJustment

pressure Incorrect

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

Steermg

Steenng wheel pulls

to

one

SIde

box needs adJustment

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

SuspensIon dIstorted Steenng box worn Wheel tramp

Abnormal tyre

Tyre

nOIses

wear

ACTION TO BE TAKEN

PROBABLE CAUSE

SYMPTOMS

Hard steenng

their baSIC length adjustment of 309 5

10

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

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

Trouble

to

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 mm

5 5

nut

K 15 for the dImenSion to be obtained

Bring the track rods

The assembly IS a reversal of the dismantling procedure notIng the followlOg pOints TIghten the bolts to the followlOg torque settlOgs Ball stud nut

assembltng the liqUid soap and

Correct pressure Correct alignment Check and replace If neceesary Adjust If necessary

Correct Correct alignment Balance

as

necessary

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

Correct Correct

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

Incorrect tyre pressure I ncorrect wheel alignment

Correct

ExcessIVe wheel beanng play

AdJUst

Improper dnvlOg

AVOid sharp turnlOg at hIgh speeds rapId startlOg und braklOg etc

tyre IOflatlon I ncorrect wheel altgnment

Improper

Repair

or

replace

Correct

Correct Correct

77

inter

MI @

brake system FIg L 1 Layout of thebrake systems wIth thedIsc

on

the left

1

12 2 3 4

11

@

11

WI

14

V

I

P 6 f c

fA f

r

17

Ie

I

1 16

el Q

19

Reservlor tank disc brake

2o

FIg L 3 Exploded cyl ncler t Push rod 2 Dust cover 3 4

Retalnmg ring Secondary piston cup

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

Cylll

derbOOY

cltp

l Re rvolr

w

Fig L 2 Exploded mbly for

of tho master brake

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

Bleeder CMck

W SiCffJ

a spnng Chk vaM tl Gasket ring 18 Paton stop bolt

16

9 20

ket Ga

ler was g Vlllvep1u

fitted to the car Fill L 5 The front drum brake

2

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

pedal

shaft

bushes

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

or

excessive

wear

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

drums for 0002 In to

Qut run

and skim If the

adjusting

mm

cams

for freedom

a maximum

of rotation and the springs for are as follows

weakness The standard dimenSions

35mm

Wire dIameter BRAKE MASTER CYLINDER

Removal and DIsmantling

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 Refer

run out

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

Free

77 5

length

mm

215

Number of turns

to

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

Drain all flUid from the

the

cap and check valve

BRAKE MASTER CYLINDER

Assembly and InstallatIon

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 Check brake

It

IS

recommended to

renew the

FRONT DRUIV BRAKE

piston cups every time

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

for

damage reservoIr for damage

or

weakness

Inspect dust

cover

and

Support the vehicle

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

the brake hose the

SWivel Remove the hub nut and Withdraw the hub

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

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 IS

found

to

be due to brake sure

FRONT DRUM BRAKE

Support

the vehIcle

on

With the

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

shown

If

any flUid

leaks

Removal and InspectIon

stands and remove the brake drum hub

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

for 1

wear or

mm

004

cracks In

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

damage

It

cylinder assembly

leakage

together

brake disc

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

If any

Removal and DIsmantling

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

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

004

way

It cannot

In

If the dISC be

IS

salvaged imd

cracked must be

or

damaged

In

any other

replaced

the brake shoes and 11ft off the brake shoes From the rear of th brake backplate remove the wheel cyltnder securing screws

79

inter E

1J@

55 Y

UBE bu

L H I I c

Fog L 7 Removal of the brake calliper

fR

F 19 L 4

Exploded

view

of

front

I

nIL ILl

brake

bly

Fill L 8 SSlld comptl

the plSlDn EJectJ

by

means

of

aD

lrJ 1 @

@j Fill L 9 M88I11nIlg the brake daiC for

runt

7

7

Fog L 6 Exploded

v

of

the front dE brake

assembly I Cylmdor 2 PISton I

10 r

3W

12 13

tIenut c

14

Suppon btlldr

of RetBtner 6 P 6 a 1 Shim

8 9

80

8 cl

I p IpO

pi

MIOn

rptlfIg

Spl pin t

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

FIg L 10 m 1Mr c

rp J

Fig L 13 Removal of thobrake pads

t Fill L 14 Exploded

of the rear

YOM

brake

jj I 70

6 M

lM

1I1

Jll

t

A

J

I

1

L

2

J

T v

I

I

I

Tho

In

f

lIII lo

1

I Fill L 16 posrbon

J

J Fill L 17

Tho

handbnoko cable

foung pOints of Saloon models

the

rear

I

81

FIg l19 The brake pedal adJustment

FIg L 20 Adjusting the brake hght swItch

FIg

L 22

mode

r

I

Ji

J

J

1

T F16

r

1

tc

I

if

82

f

l

1

f

IJ

r7

f

K

q

i

loo t

I

ifi C J

I

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

the front cable FRONT DISC BRAKE

Assembly

From

and Installation

clips

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

Rinse the

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

completely

the swIvel JOint

Handbreke lever

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

gUIde

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

Carefully

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

flange

Fig

a

shIm to the

Inner

brake pad and msert the

Inner

pad untIl

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

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

BRAKE PADS

Fit the anti rattle cltp

as

Replacement

The

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

Saloon

handbrake cable

from both ends of the the

by removtng

Remove the adJusttng nut and

Estate Car rear

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

cable

off pull

HANDBRAKE MECHANISM Check

the cables for

Examme the

breakage fraytng

handbrake

Installation

or exceSSive

stretchtng

lever

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

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

assembly

L 18

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

LIft out the handbrake lever In FIg L 16

shown

Rear handbrake cable

Rear

FIt

IS

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

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

split pin

and the bracket

The tnstalled lever

Adjustments

Remove the wheel

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

exposed IS

various

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

Now

stages of replacement

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

The brake

pedal stop

screw tn

the SWItch

IS

the brake

light

SWItch untIl the threaded part of

touching the front of the stop bracket FIg L 20

Lock the SWItch

REAR BRAKES

the vehicle

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

Removal and Instal ation Fig L 14

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

Support at

the

rear

on

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

I

cyltnder cylinder

dust The

cover

plates

adJusttng shIms cylinder can be

and

then

the

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

sectIon

Rear Axle

IS

pedal

pushed

assembly

and installation

IS

SImilar

as

deSCribed for the

front drum brakes

HANDBRAKE

Removal

by

1 5

mm

0 06

In

Front brake

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

Depress the cams

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

Rear brakes The

down

completely

Jack up the released

rear

wheel and WIth the handbrake

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

adjuster by

two or three

notches untIl

freely

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

holdtng

83

HIlAWith the handbrake released and the rear brakes 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

4 724 in

Fig

L 25

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

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

valve

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

the 1 3 to

expel

pedal

at its

2 turn 1

eSt 10Vl

position

and open the bleeder and then close the valve Repeat 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

proceed as follows

Technical Data BRAKE PEDAL Brake

pedal height

BRAKE DRUM AND BRAKE DISC

Front drum brakes

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

Drum inner diameter 187

mm

187

mm

197 mm

7 362 In 7 362 In 7 756 in

228 6

DISC outer dIameter of Out round of drum Max permissible drum dla Max permissible disc Ut H rul

229 6 mm 9 039 In 0 06 mm 0 0024 in

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

BRAKE LININGS Drum brakes Width x thick

x

length 11 575

C8 c1earal

19 05 mm 34 0 13 mm 0 005

In

WHEEL BRAKE CYLINDERS

elSC brakes

Rear

With front drum

Rear with front disc Piston running clearance

84

Rear

22 22 mm

718

In

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

4Ox4 5x219mm 0 In x 8 642 in

x

In

Front

Inner diameter Front drum Front diSC

900 In

202

MASTER BRAKE CYLINDER Inner diameter Piston running

mm

232 mm 9130 In 0 05 mm 0 002 in max

0 709 In

Total braking area Front drum brake Front diSC brake Rear brake

39 7

x

9 0

x

86 0

mm

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

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

Trouble

PROBABLE CAUSE

SYMPTOMS Insufflent performance

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

Pads or linIngs No brake flUid

Pedal feels spongy

AIr

can

Check valve

worn

In

as necessary Refill and bleed system

Bleed system

In reservoir

Top up flUId system

cylinder faulty

master

Valve seat dIrty

Brake effort decreases and pedal goes slowly to floor

Brake pipes or hoses leaking

Damaged brake

Brakes overheat

or

or defectIve cups wheel cylinders

CompensatIon port

In

In

master

master

cylinder

of

SIde

new

connections

and hoses Overhaul cylinder

In

or

fIt

new

PIpeS

questIon

new

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

Loose back plate mounting bolts Oil on Itnlngs or pads

TIghten

Loose

damaged wheel beanngs Improper operation of wheel cylinder

AdJust Repair

Improper tyre inflation

Correct tyre pressure

or

valve

Clean master brake cylinder Fit

use

unSUItable brake flUid

one

Check and repaIr Clean valve seat fIt

TIghten

blocked Return spring weak Rubber parts swollen due to

Brakes pull to

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

Replace

worn

n system InsuffICIent flUId

be depressed WIthout actIon

ACTION TO BE TAKEN

Leak

Pedal contacts floor

Pedal

Shooting

Clean

replace replace or replace

or

or

i nter

C

S

10

Mil

OG

08 04Ii

Vl

C 81

III

0 0

e ClO

f

81

lle e

FlgM

t r Exploded vlBW of the h

1

I O pul 2 ThfOugh bolt 30 end brodrn

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

0

5 Rotor

II SIIp

IVend

II

e M 4 The Fig

COIIl

1l

oo

of the drmt pulley

6

FIg 3 RernlIYaI M

of the drive

t

pulley nu1

M 6 TIPPing FIII

the dnve

end bndtet off the

rotIlr

M6 Remon of the FII bearing

W Red

M 7 The FIII

88

or

Id

rotIlr

D

Black on bliwot

slip ring end

figures

of the dIOdes

Fig8 M

U

ctenng the temlmal UN

Electrical Precautumay Service NotllS

ALTERNATOR

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

battery

Reversed

Ensure that the rectifIers connected to earth 2

Never

the

earth

disconnected

at

will

connections

Earthing

the

cable

the alternator If thiS cable

main

dIode IS

IS

when

It

IS

earthed With

regulator

and the

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

5

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

run

u nit

WIll be

Do

not

damaged

attempt

to

polartse

the

alternator

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

charger first

IS

not to

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

to

can

Unit

connecting Never

wire

to

control unit be Isolated

voltage regulator by disconnecting

9

Then

damage

unsolder the

removed

by

unscrew

of

a

arm two

puller

end

hOUSing by unsoldering negative diodes red fIgures

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

and

termlnai

N

means

M6

FIg

as

shown

In

Fig

M8

Lift

ff the

stator

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

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

to

not on

any other part of the alternator

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 an

Inspection

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 a

alternator chargrng system

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

ohmmeter

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

dIsconnected

ohms at

aVOid bearing damage when adJustIng belt only on the alternator drtve end leverage apply

fItted With 10

IS

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

an

an

Belt tensIOn bracket

rotor

deSign

the

the alternator

transIstor

tenSion

press

out the beartng

The

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

use

lrtven hand

8

FIg M 5 Remove the beartng from the beartng hOUSing The

hide mallet

a

uSing

retainer and

to

dIsconnectIng the

control

7

It

damage

DIsconnect

charger

bracket

bearing from the

WIll damage the alternator and even when the IgnitIon SWItch CirCUIt breakers are used 4

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

of conventlonal

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

the

terminal

battery negatIve

alternator

main

damage

IS

Equipment

room

447

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

a

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

0004

In

replace

the rotor Stator

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

alternator

an

ALTERNATOR

Removal

Check the stator for conductIVity the lead

retaIning bolts and lift the alternator from the

mounting bracket

N

yellow

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

ALTERNATOR

Fig

Dlsmanthng

M l

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

diodes

body

and any of

Assembly

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

are

f11

inter

cJU

jIJtE @

1 r 1 f

FI9 10 V M 1Ily

1

1

of the removed dIode holder

J

M9 FIlI

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

holder assembly from

for Fig M 12 Checking the rotor

out run

for Checking the rotor field cod bottOm and earthIng continurty top

M l1 FI9

t

FI9 13 Chedung M

1he

wlIldmgs for

con1lnurty

I

rJl 1he

88

W1ndlriila

for

M 15 DlOlIe FIlI

test

M 16 DIOlIe test g i F

1

Low

DIode holder posItIve sIde

Connect the posItIve lead of the CirCUIt

the diode

tester to

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

unsteady charge Check drlvlng belt tension Check for high resistance

1 2

CirCUit connectIons

the whole assembly FIg M 15

The testing

renew

shown

In

connections

are

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

ALTERNATOR Install the stator COIl

N

077 Ib IS

In

thIS condition but

Removal

VOLTAGE REGULATOR

remove

the

screws

Testing

ElectrIcal test 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

a

permissible

10

connectIons

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

2 DIode holder negatIve SIde Check the negative SIde as described above but the CIrCU It tester must be reversed FIg M 16 Broshes

battery termInals and

VOLTAGE REGULATOR

tester

to

at

particularly earth

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

Assembly and Installation termmal to the brush holder and fit

FIg

0 035

M 23

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

10

0 8

G3

0032 004710 0 4 0 5 mm 0016 0020 In

the term mal msulator

1 2

0 039

G2

mm

retamer

the drive end bracket

on

to

the rotor shaft dnve end bearing

PIlot light

relay

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

reversal of the removal

Observe all procedure pomts gIven under the ALTERNATOR PrecautIonary ServIcIng Notes

ALTERNATOR

head 109

0 008

G1 G2

0 2

G3

0 4 0 5 mm 0016 02010

mm

10

08 1 2 mm 0 2 0 024 In

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

Air gap

Inspection of output

G2

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 Connect the alternator

10

a

test

ClrCU It as

shown

In

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

negative current

WIth the

SWItch closed and the load resIstance at

maxImum

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

Alternator output 1 2 3

uncontrolled

WIth

a

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

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

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

l I I

I I

r

I I I I I I I I I

F g M 17 The

m nlmum

I I

brush length

I I I I I I

I J I

I

L l

Alternator Current flow

Current flow

Red ftgure

lack flgure M

POSItIve dIode

F g M 18

Voltage regulator nng pressure Checking the brush

Diode terminal PILOT LAMP RELAY

NegatIve diode

Fill M 21 V prlot lamp relay Test

ahemator

rcult

for

checkIng

REGULATOR

I

dIodes FIg M t9 The current flow In the

FI9 M 20

VOLTAGE

of the voltage regulatof and

the

performance t

t Back gap

G

Air gap G2 08 12 Stopper

T

PrtmafY contact

support

Voltage corl

SecomlafY COntact

support A V

Ammeler V ollago meter FIlIM 23 The voltage reagulator

Woro harneSS foo the voltage regulatOO M22 Test Cllcurt g F

90

See text

mter E itl i j2J CQJ E

Air gap 112

POint gap g3

Sprong

Voltage coIl

F

Fog M 25 Adjusting the regulotor G2 In text

See

M 24 The pilot lamp relay g

elr

BendIng dIrection

gap of the

H

voltage

ghten voltage

I Lower voltage

Fog Fog M 26 Adjusting the lemp relay g2 In text

1

cO

2

j

air

gap of the

27 M

Adjusting the voltage

g Sllttll

pilot

3 9

5C h I

l

V

12ij0 i Ct

1 0

IS 16

14

Fog M 29 fnIm

The tu onn

motor body end drIVe end bracket

removlKl

if 1

17

M 28 ExplodlKl Fog

lnent t Etrpf 2

Sulmg

lINer

Thnnt

t

12 Slop

the

w

r

C IP

14 Pinion rtap OD

efMntltwer lI Etrf

tbil8 BAnn

9

of

Thrun

Dr rod brsck 4 Dun protectIOn

6 Dud l 7 SoltlnoJd

VlOW

rod brocktlt bush

10 O

flntI

a 5

pin

ii

19

15 Drwe

tch

1er

pimon nn ngclvtrh

16 O 17 Fleldcoll

0

g motor

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

Fog M 30 The moclIanllll1 removed br8ckoL

nt

motu end

from

the

dr

end

91

inter

J I1

1 ID

FI M 31 I

Testmg the f 1d COIl for continuity

32 CheckIng the brush spring M

I FI

Round

0 5mm O

8mm

te

on

Commutator Ica

Correct

Fig

34 M

Incorrect

uttlng Unden

the mICa Insulators

35 Testing the Innature I M FI Wlndmgs for earth connectIOn

I

gmtlon swItch

Fill M 36

Checkmg

the armature

for

short

Circuits

I

IT

Battery

FI9 37 TesI circuit for M

92

l

Starter motor

lenood Mrtd1

M38 FI9 II

M

ng

the starter

motDr

l panlOl

V ol1age To increase the

voltage

downwards Fig M 27

decrease

to

adjustment

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

The installation

IS

carrted out

10

lnstallllt101l

reverse

order to the removal

procedure STARTER MOTOR

armature on

Check the armature wmdlngs for open crrallts by placmg the armature on the growler and connectIng two commutator

Removal

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

segments With the test prods Repeat thiS test for all adJacent segments An mconslstent reading mdlcates an open CIrcuIt

car

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

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

wooden

a

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

over

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

Inspection and Overhaul

at

the dnve

end

replace

10

clearance of 003

Check

the fIeld COIls

Connect

prod

to

move

one

test

prod

the fIeld Call has

an

If the tester needle does not

open CirCUIt

be

moves

F Ig M 31

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 0 7

1 54 lb

bush

IS flush

Solenoid switch the contacts of the solenOid SWitch weldIng of the contacts has occured

ER MOTOR

and see that

no

Assembly

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

Brushes

1 76

beanng

The

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

kg kg

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

mm

Check

the fIeld COlliS connected to earth and should

replaced

O B

size

pressed 10 so that the end of the WIth the end of the dnve end housmg

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

0 10

should be

for open CirCUIt us 109 a CirCUIt tester on to the field coli lead and the other

the other fIeld COIl lead

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

the correct

out to

ream

FIeld coIls

bearing

Check the clearance between the OOOB

STARTER MOTOR

wmdlngs for mternal shorts by placing the

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 armature

Ib

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

Replace

the

springs

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

Armature

shown in

Fig

M 38

WINDSCREEN WIPERS

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

Check the armature cod for earth usmg

as

a

growler Connect

one

Removal

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

and remove the

Disconnect the

wiper motor and the 1Inkagi

WINDSCREEN WIPER Remove

the

ended hook

IlI8gnetized

wiper

motor

Wiring

See Fig M 39

Dismantling

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

linkage and bolts

case

from

91

i nt e fiE

JI DJ OoJ

l P

1

Yoke

16

B b

31

Tapping

2

Damper

17

Rivet

32

Worm

3

Armature

18

Spnng

33

Wheel

19

Grommet

34

PlaiD washer

20

Gear

3S

Hexagon

21

Tapping

36

Lock washer

4

stopper

Feltwasbe r

retainer

lCJew

wheel ann

S

Beanng

6

Hook

7

Rivet

2

Brush holder

37

PlatD wamer

8

Felt walber

23

Plate spnng

38

C

9

Plate sptmg

24

Felt

39

Thtust washer

10

Sprmg

2S

Beatlng

40

Wave washer

11

BaU

26

Auto

stop

41

12

Magnet

27

Lock

plate

Beanng Hexagon

13

Armature

28

PIa m Imall

14

Commutator

29

Gear COVei

t5

Brush spnng

30

Chp

holt

etamer

ball

M FIU

au

39

y

Exploded

v

case screw us

y

wa her

cover aA

y

42 43

erew ass

out

type nop

Tluwt

nug

nut

screw

Thrust washer

y 4S

Gear shatt

aD

y

of the windlcnen wiper motor

3 7

28

35

43

F

M 40 Removal of the wiper drIVln9 IIl1ndle g

nut

M 43 Justment for the of the W1P8r blades

Fig M 42 Removal of the brush h FIg

94

sr

If parlnng

pcIS1tJon

Pull the carbon brush

from Its holder and remove the brush

Unsolder the brush and

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

COYer unscrew

DIRECTION INDICATOR SWITCH

Removal and

Installation

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

panel WINDSCREEN WIPER MOTOR

Assembly and InstlIlllItJOn

indicator SWitch

Reverse the

Apply

dlsmanthng and removal procedures respectIVely grease to the gear and coat the hOUSing and the cover

surfaces

With JOInting compound compound between hOUSing and end parklng self the cover

switch by as

shown

In

loosentng Fig M 43

JOinting bracket Adjust the the stop cover screw and turn J AI

smear

The InstallatIon When

fitting

correct

IS the

reversal of the removal procedure

the steering wheel make

relation

to

the

sure

that the spokes are In of the front

posItion

stralght ahead

wheels

Technical Data ALTERNATOR Armature shaft dla

12 volts 30 amps

Nominal output Earth connectIon

NegatIve 1 000

Speed No load

mln

speed

Output current Pulley ratIo to

engIne

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

HITACHI

regulating voltage

Max permls shaft out run Bush running clearance Clearance Itmlt Commutator outer dla Wear hmlt Brush

Constant voltage relay 14 15 volts5000 rpm

HITACHI S114 103

Lock torque No load current

1 1 kgm 8 0 Ib ft Less than 60 amps at 12 volts 7000 rpm Solenoid SWItch

Weight

12 volts 10kw Less than 480 amps 6 volts

9

flywheel ring

pinIon SIde rear end 008 mm 004 In In

0453

In

001 mm OOOl 0004 In 02 mm 0008 In 35 0 mm 1 38 In

Inner dIameter Drive end bracket bush bore Inner dIameter

o B kg

1 76 Ib

11 0

mm

0433

In

11 5

mm

0453

In

LAMPS

Type Voltage Output Starting current Starting voltage

Number of teeth on pinIon Number of teetn on engine

0433

mm

less 2 0 mm 0 079 In lB5 mm 0728 10 6 0 mm 0236 In

length

STARTER MOTOR

Free running speed OperatIon medIum

003

Brush spring tensIon Drive end bracket bearing bush

Maker

Type

mm

11 5

Wear hmlt

VOLTAGE REGULATOR

No load

11 0

HITACHI

Maker

120

gear 5 1

kg

10 4Ib

Type 1 Type 2

sealed beam sealed beam

Park 109 lamp Front flasher SIde flasher

lamp lamp

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

37 5 watts 37 5 50 watts B watts I

25 watts 6 watts 8 watts 10 watts 25 watts

25 8 watts 25 watts 8 watts 3 watts

95

Trouble SYMPTOMS

Battery

In

Shooting ACTION TO BE TAKEN

PROBABLE rAUSE

low state of charge shown by

lack of power when starting

when runntng at about

Dynamo

not chargIng

20 mph

30 km WIth swItched

Broken

or

dynamo

CirCUIt

loose

on

lights

connectIon

regulator

or

In

not

functIonIng correctly

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

battery

examine

connectIons

Examine regulator Commutator greasy

or

Clean

dirty

WIth

soft

mOIstened

rag

In

petrol GIVing low when

car IS

or

Intennittent output In top gear

running

Dynamo belt sli pplng Loose

or

dynamo

CirCUIt

broken

Adjust belt tensIon connectIons

In

Examine

and

charging

TIghten loose

wiring

fIeld

CirCUIt

connectlotl

or

lead replace broken PartIcularly Inspect battery connections Brushes greasy

or

Clean

dirty

WIth

soft

rag

mOistened

In

petrol Brushes

worn or

Regulator

not

not

fitted correctly

Replace

worn

brushes

bed

brushes oronerlv

See that the

functlomng correctly ExamIne regulator

Battery

shown

overcharged

burnt out bulbs and need for tOpping up

very

by frequent

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

Regulator

not

functIoning

tly corre

Poor contact of starter swItch contact

Examine regulator

Check sWItch and replace If necessary

POints Poor brush contact

Replace brushes

Burnt commutator

Overhau I

or

spnngs

starter

motor

or

clean

commutator

Shorted field COIl

Replace COIl

Shorted armature

Replace

Poor contact of battery leads

Clean and tIghten leads

Weak battery

Recharge battery

Open

CI

rcUlt

between starter SWitch

armature

Check wlrtng and replace If necessary

and solenOId

Starter does

not

seem

motor to

operates

turn

over

but

Poor earth connectIon

Check and rectI fy

Drive plnton defectIve

Replace drove pinIon

engine

qUIckly enough

Flywheel ring gear

worn

Replace flywheel gear teeth

IgnItIon wamlng lamp high rpm

at

goes

out

only

Generator faulty Regulator fau Ity

Repair generator Replace regulator

or

recondition ring

IgnItIon warning lamp does not light With Ignition SWItched on

Ignttlon warntng lamp does fli ckers Increased or

when

engine

go out IS rpm

not

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

Loose

or

broken fan belt

Adjust tension or replace belt Replace regulator TIghten connectIon re replace lead Repair generator

Regular defective POSitIve lead loose or broken Generator de ECt ve Commutator graphlted

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

Clean commutator

Brushes worn Brush spring weak or annealed BInding brush levers

DIrty

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

commutator

ExcesSive frictIon

In

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

wiper linkages

Low operating voltage

connections

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

WIper

Burnt out armature

Replace

Contacts In hOUSing damaged Contact spring bent Insulating bracket broken Contacts dl rty Wiper motor cannot be SWItched off

Replace Replace Replace

Bad connection from wIper SWItch to earth Motor squeaks sometimes combined WIth slow operatIon

Wiper linkages POI

n

of

t

running dry

bushings

armature

move

PinIon

or

a rmatu re

shaft

dirty

of

complete

motor

contacts contacts contacts

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

Grease all moving parts of linkage Bend stop to clear

RepOSItIOn

or

cover

Overhau I starter motor

damaged SolenOId SWItch defective

Engine mlsfl res

or

spIndle

commutator Side against stop brush holder Incorrect pOSItion of motor cover

Starter motor pinIon does not out of mesh

armature

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

o

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

petrol supply

etc

LH

UOHT

R8

O

J i

R

m a 0 0

tII

o

QI 3

nOL a

r

O

0

HE

b

DFORIAGRM

AOIO

DE

to

LUXE

EAfER I

r

o

eN

L1GHTlt

eMJI l jl

Im

up iiill a

CMlNATIO

L

LIGHT LeEN

TlIjTAIL STOP BrCJ

TS

0

PADSlRE OIRECT NAl flirtNG

lHT

VlMNG

QO GAI

LIGHT

TAtf

GW

REAR

OIL

OIL E A I R H TERMHIol IGNTO

LIGHT COO

SALO N

WIPER

HT U

SW

V

I

UNIT

WIRNG

0

IL

VOL

AIN

l3EAM

NENTINITRi

PILOT PILOT LIGHT UGHT

u HT

TAGE

REGULATtIl

II MARK

NOTE

INCLUDING T1a 1

AL

PARTS

L

UP N

I

Jo4 L

I

I

111

I I

II 1

I

Ill

UP

L

STOP T1JIH L

L

nOlLH

1IT

CffCNAl

REGULATOft

LIN1lQG

TAGE

hI AIN

VQ

NOTE

MARK YO

GAUGE

LIGHT LlCOHT LIGKT LNGIGHT LIGHT PILOT PILOT RIUNG WAR ENT INSTR BEAM T10N

DIRECTONAL

Yli jr III Plllr I

OIL

1 611

B

Il

UNIT

PRESU EOIm TERMNAL

1

PARTS

OIL

TS

fiRB

11

II SI I

mE HEAT R

L

W N

J

i

fT

CLOC

el

SALO N

rk

HEATRU l

rm o

SSS

LiGHT

A010

FOR

DIAGRM

fJ

RELAY

WIRNG

BY

idr

nu

L1CJl

HEAD

I

rr

m

B B

I m

TI

m

e 8

RTcflv OF RJi

RW i

B1 e

rv

Cb

l DUGt

LH

8L

a

fMK SIGNAL

if

R

HE

RH

IAOLGHLH

AU

IS

ENGLISH

1

Vear

1

1969no

1969no

2

Model

2

1300

1000 fLC

3

Engine type

3

510

510

3A

EEC

4

Number of

4

4

5

Flnng order

6

Capacity

7

Bore Stroke

mm

6

CompreSSion

ratIO

1

9

Compreulon

preswre

I

I

I

I

I

CO

5

7

8

pSI

kg

cm2

9

kg cm2

10

10

011 prnsure

P

11

ROIted output

HPlrpm

I1A

Fuel

12

V

3

4

342 1

4 42 3 1

5

1595

1595

6

83159 9

83n3 7

63f73 7

7

85

85

95

9

50

35 57

n SAE

8 9

116 171 40

37 60

64

6000

42

64

00 3 7

109 SAE 6000

12

0010

25 0

0 0101025

n mm

13

12

0012

3 0

0012 0 30

13

12

12

14

8

6

15

Valve

14

Inlet valve

IS

Outlet valve closes

lSA

Rood

158

Km h rpm gear

16

auery B

17

Svstem

16

CarburettQt make

18

HITACHI

HITACHI

HITACHI

19

Carburettor

19

OCK 308

OAF 328

AJL3fffl

20

Idllna sperd

20

600

600

600

HITACHI

HITACHI

0411

o 40ll

utlet

opens

oOTOC

14

oATDe

IS

I

0

3 01110

12

19

lSA

horsepower

15A

158 V

plus

lty polal

16

Ah munn

type om

kg cm2

158

I 12V140An

Fuel

21

23

Dlstnbutor make

22

HITACHI

23

Distributor type

23

0411

24

Contact breaker gap

25

Dwellangfe

26

psl

n

25

Stmctlmlng

Degrees oaTDC

27

StroboscopIC

oaTDOrpm

27

28

Timing

2BA

Ignition

288

1ry Pnm

timing

Centnf

advanCt

30

32

34

35

Sparking plug

make

37

Sparlung plug

type

38

Sparking St

rter motor

make

26

28

HITACHI

HITACHI

28A

Ohms

288

32

15

6 1

288

o

29

0800

rpmE

41

800 0

ln o

mm

ln o

nwn

31

32

32

Hg

33

3

Hg

34

34

35

022 024

36

NGK

38 3BA

tYpe

Amps

0

3

VolI

8P

6E

0031

HITACHI

H TACHI

HITACHI

ALT I

HITACHI

40

LT 130

41K

LT

42

Requlator make

42

HITACHI

43

R

43

TL1

44

Cut

45

voltaQe

c ff voltage Drop

46

Reverse current

47

Open

48

Closed

CirCUit CIrCUit

49

Current

regulo1tor

50

Voltage

egulator

51

NOTES

52

tromchassls

53

from

BE

0031

37

8 0

lA

HITACHI

388

39

Generator output

lnq

OP

8 0

388

Generator type

ulator type

BE

BP

135

022 024 NGK

003108

41

AN IrpmG

0 24

22 0 NGK

40

clO

9

0800

30

Generator make

In

24 5

55

HITACHI

n mm

Lockdraw

55

28A

37

plug gap

23 05 045

9021 0017

27

MId

lty

er c Condens ap8C

36

49

0 4SO 5

CP

rpmE

end

91l21 017

14 650

o

no

o

22

64

10 600

rpmE

ends

55

5

58

CP

rpmE o

Vacuum advance

57 K

CP

o

intermediate

21

10 650

dlate Interml

31

33

starts

19 20

2

104 49

18

28

type

stance

16

12 V 50 Ah

25

rk locatIOn

COil make

5117

24

mm

iOAh VI

17

22

pump pressure

12

17

21

129

11 llA

0010

13

C1earanee

10

2 4

96 SAE 5600

llA

mm

n

510

1296

11 170

11

Ltr 100 km DINJ

nlet

42 3 1

6

cucm

w clearance

2

3A

4

consuFnpllonlmpg

l

HCI

1600

3A

CYlinders

I

19ssno

I

41

12 30

133

ALT

01

HITACHI 17

TL1

ALT

LT 140 4EiK

12 30

12 30

Z

K

HITACHI

Z

139 I 11

HITACHI 17

T1 1

Z

17

143

V

44

V

45

145

A

46

116

V

47

A

48

1 148

A

49

9

50

0

51

1

52

2

53

3

V A

mln

I

nglOe

um um

I

I Lower shock absorber

nuts Drive shaft to

ConnectIng rod nuts Flywheel bolts Main beanng bolts Camshaft sprocket bolt

27 45 50

pulley bolt

head bolts

011 relief valve

19 5 23 9Ib ft 687 75 9Ibft

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 95

011 sump 011 pump 011 strainer Crankshaft

33 kgm

nut

Clutch bolts

kgm

16 61b ft

SO 6

57 8 Ib ft

Drive shaft to differential

ENGINE

Cylinder

2 3

mounting

TIGHTENING TORQUES

rear

axle

nuts

Bumper

7 0

8 0

70

8 0

kgm

flange 20

nut

Wheel nuts

8 0

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

Rear suspension member mounting 10

nuts

kgm

72 3 Ib ft

kgm

61 5Ib ft 72 3Ib ft

Differential member mounting 85

nuts

8

Suspension arm nuts DifferentIal to dIfferential member Propeller shaft flange

10

kgm

57 8

6 0

kgm

43 4 Ib ft

40 85 kgm

29

61 6 Ib ft

21 7 528

253 Ib ft 71 6 Ib ft

28 2

38 3 Ib ft

8 7

12 3 Ib ft

FRONT SUSPENSION GEARBOX 22

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

Rear extension to case Gearbox to engine Bottom cover Front cover Drain

plug

Selector lever bolt Reverse lamp SWitch Idler shaft screw

Cross shaft lock pIn

Malnshaf

nut

2171bft

Front hub nut

30

3 5

Brake

73 39

9 9 5 3

calltper bolts

38 3 Ib ft

Brake diSC bolts

12 3 Ib ft 123 Ib ft

Stablltser bolts suspension SIde

36 2 Ib ft

Stablltser bolts frame

1521bft 28 91b ft 8 0 Ib ft

SIde ReactIon rod to frame ReactIon rod to suspension

8 0 Ib ft 79 5 Ib ft

SuspensIon

arm

arm

Untt

FINAL DRIVE

Untt

40

shaft flange Drive plnton nut

Saloon

170

Estate

140

Crown wheel bolts Saloon Estate Saloon models only Side cover bolts Dnve

85 kgm

200kgm 170 kgm

28 9

1229 101 2

61 5 Ib ft 1446Ibft 122 91b ft

7 0

80 kgm

SO 6

57 8 Ib ft

4 8

5 5

34 7

39 8 Ib ft

kgm

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

bo ts

flange Beanng retainer bolts

Rear cover bolts 1 9 26 Final dnve to final drive mountIng member 60 8 0

kgm

137

188 Ib ft

kgm

43 4

57 8 Ib ft

60 kgm 43 4 Ib ft

arm to

flange

to

7 0

8 0

kgm

506

57 B Ib ft

40

8 5

kgm

289

61 5 Ib ft

member

hOUSing flange to propeller

20

22 kgm

145

15 91b ft

shaft

18

22kgm

13 0

1591bft

Drive

Rear wheel Brake

beanng backplate

REAR

nut

6 3

kgm

35 4

45 6 Ib ft

3 9

5 2

kgm

282

37 6 Ib ft

60 80

kgm

43 4

578 Ib ft

2

97 61b ft

kgm 88

1 9 25 kgm 137 18 lib ft 5576 kgm 398 550 Ib ft

PIston rod nut

6 0

Gland packing Wheel nuts

60 65 8 0

7 5 9 0

kgm kgm kgm

43 4

47 0 Ib ft

434

470 Ib ft

57 8

65 1 Ib ft

STEERING

Flange mounting bolts

1 B

25 kgm

Ball stud nut

5 5

7 6

Drop

arm arm

AdJustIng

nut

nut screw

nut

mounttng bolts bolts

Steenng gear Idler arm

Brake pedal PIVOt Brake pipeS

Estate car models only DIfferential carrier to axle

REAR AXLE AND

4 9

130 18 lib ft

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

BRAKES

propeller

shaft

1 9 25 kgm 137 18 1 Ib ft 7 2 96 kgm 52 1 9 2 Ib ft

suspensIon cross 122 135

FInal drive to dnve shafts Final dnve

kgm

Lower ball JOInt Lower ball JOInt nut

Idler

Final drive to suspensIon member

1 7

lever to suspension

SuspensIon Propeller

1 2

upper

nuts

Steering

kgm kgm kgm

3 5 15

4 0

kgm

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

11 kgm 108

Brake diSC bolts

39

53 kgm

Bridge

1 7

20 kgm

pipe Brake hose to Calliper bolts

cylinder

17 7 3

123 14 51b ft

123 20kgm 9 0

kgm 52 8

145Ibft 5 1 Ib ft

SUSPENSION 25 27

3

33

kgm 181 239 Ib 7kgm 195 268 Ib

ft ft

Upper shock absorber mounting

23 kgm

16 61b ft

101

F

CONVERSION TABLE

I

mm

lnS

mln

ln

mm

lnS

1m

mm

mm

inS

01

000394

5

020079

030370

5

2 007870

105

4

133848

02

000787

52

020472

2

078740

52

2 047240

110

4

330700

03

001181

53

020866

3

118110

53

2 0866 0

15

4

527550

04

001575

54

021260

4

157480

54

2 125980

120

4

724400

05

00 969

55

021854

5

196850

55

2

65350

25

4

921250

06

002362

56

022047

6

236220

56

2 204720

130

5 181 0

07

002756

57

022441

7

275590

57

2

135

5

3

08

003150

58

022835

8

314960

58

2 283460

140

5

51800

09

003543

59

023 228

9

354330

59

2 322830

145

5

708650

10

003937

60

023622

10

393700

60

2

362200

50

5

905500

1

004331

61

024016

II

433070

61

2 401570

155

6 102350

12

004724

62

024409

2

472440

62

2 440940

60

6 299200

13

005118

63

024803

13

511810

63

2 480310

165

6 496050

14

0055

2

64

025197

14

551180

64

2

170

6 692900

15

005906

65

025591

15

590550

65

2 559050

175

6 889750

16

006299

66

025984

16

629920

66

2 598420

180

7

086600

17

006693

67

026378

17

669290

67

2

637790

185

7

283450

18

0070B7

6B

026772

18

708660

68

2 677160

190

7 480300

19

007480

69

027165

19

748030

69

2 716530

195

7 677150

20

007874

70

027559

20

787400

70

2 755900

200

7

21

008268

71

027953

21

826770

71

2 795270

210

8 267700

22

00866l

72

028348

22

866140

72

2 834640

220

8 661400

23

009005

73

028740

23

905510

73

2

874010

230

9 055100

24

009149

74

029134

24

944880

74

2

913380

240

9 448800

25

009841

75

029528

25

984250

75

2 952750

250

26

010236

76

029921

26

1

023620

76

2 992120

260

10 236200

27

010630

71

030315

27

1

062990

77

3

031490

270

10 629900

28

011024

78

030709

28

1

102360

78

3 070860

280

11

29

011417

79

031103

29

141730

79

3

110230

290

11 417300

30

011811

80

031496

30

181100

80

3

149600

300

11

3

0

2205

81

03

3

220470

8

3

188970

3

32

0

2598

82

032283

32

259840

82

3 228340

320

2 598400

33

012992

83

032677

33

2992

0

83

3 267710

330

12 992100

34

013386

84

033071

34

I 338580

84

3 307080

340

13 385800

35

0

3780

85

033465

35

I 377949

85

3 346450

350

13

36

014173

86

033858

36

I 417319

86

3 385820

360

14 173200

37

014567

87

034252

37

1

456689

87

3 425190

370

14 566900

38

014961

88

034646

38

I 496050

88

3

484560

380

14 960600

39

015354

89

035039

39

1

535430

89

3

503930

390

15 354300

40

015748

90

035433

40

I 574800

90

3 543300

400

15 748000

1

3 582670

500

19

890

244090

519680

0

4950

874000

9 842600

032600

811000

12 204700

779500

41

016142

91

035827

41

614170

91

42

016535

92

036220

42

1

653540

92

3

622040

600

23 622000

43

016929

93

036614

43

I

692910

93

3 661410

700

27 559000

44

017323

94

037008

44

I 732280

94

3

700780

800

31 496000

45

017717

95

037402

45

I 771650

95

3

740150

900

35 433000

46

018110

96

037795

46

1 811020

96

3 779520

1000

39 370000

47

018504

97

038189

47

1 850390

97

3

818890

2000

78 740000

48

018898

98

038583

48

I 889760

98

3 858260

3000

118 110000

49

019291

99

038976

49

1

929130

99

3 897630

4000

157

50

019685

039370

50

I 968500

100

3 937000

5000

196 850000

Imm

685000

380000

1

t

I

oQUu@ f

I

1Wrr@LW

71

t

if l oo

r

r

y I

c

4

J

COV RcS 600cc Standard De Luxe SSS

1300cc and

Saloon and

I

970

Estate up to

CONTAINS 1

DetaIled

descriptIon of ServIce RepaIr and Overhaul OperatIons

dearly explamed and

shown

m

hundreds of illustratIOns

plus Trouble

Shooting

Tables l

Tune up Data Tables

WIrIng DIagrams

Exploded

Parts

Diagrams

wIth DetaIled Parts

dentificatlOn

I

f r

Q 1T UJ

5oo U

OO p M 1@ O j@