Professional Documents
Culture Documents
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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
From 1965
to 1969 Since Introduction
Up
1968 1970
i
b
Estate
c c
1600
PUBLISHED BY
INTEREUROPE
LIMITED
Copyright IC
lb
11
Pnntlld Lan
W ey
England
1Ib1e thRlUllh
SA MexICO City
2nd edition
January
1971
Type Identification
SALOON MODELS E n9108
L13
Model designation
510 U L510 PL510 PL510 T PL510 UT
Type
Gearbox
Three speed remote control
Three
Deluxe
L16
UA
PL510 A
S
PL510 UA
L13 Standard L16
SU
L510
speed
remote
control
PL510 S
PL510 ST
P510 UTK
PL510 TK
SSS
carb
Four
WP510 U
WP510 UT WPL510 WP510
Three Four
speed
remote
control
speed
floor shIft
UA
WPL510
UA
Length
1602
10
4 120mm
mm mm
1 560
Height overall
Saloon Estate Car Wheel base MIO ground clearance Saloon Estate Car Front track Saloon Estate Car Rear track Saloon Estate Car 1 280 1 275 1 280 1 260 24 pSI 28 pSI 24 psi 28 pSI
mm mm In In
1400mm 1 435
mm mm
420 2
190 165
mm mm
In In
mm mm
In In
Tyre
FILLING CAPACITIES
Engine
Max MIn
011 4 0 htres
uiG
US
3 0 htres 0 79 US
gal gal
7 htres 7 39 US qts
SJeerlng
aL 9e
INDEX
lYPE IDENTIFICATION ENGINE LUBRICATION SYSTEM COOLING SYSTEM IGNITION SYSTEM FUEL SYSTEM CLUTCH GEARBOX REAR AXLE REAR SUSPENSION FRONT SUSPENSION STEERING BRAKES ELECTRICAL 4 6 18 20 22 26 36 44 S3 62 68 74 78
EQUIPMENT
TIGHTENING TORQUES
CONVERSION TABLE
Introduction
This Workshop Manual was WrItten wIth the IntentIon of providIng the owner of a Datsun 1300 or 1600 and the non franchised garage with detdlls of dllthe maIntenance and repalf operatIOns that they are hkely Instructions have been to encounter Much InformatIOn from the manufacturer s ongInal selVlce and repalf condensed and Incorporated m the manual In a form which will enable the reader to qUickly become fanfihar with the IdlOsynchrasles and techmcahtles pecuhar to the Datsun range of cars The manual descnbes the 1300 and 1600 c c engmes fitted to the Standard De Luxe and SSS Saloon models and the range of Estate Cars A complete hst of engme tumng data for all models with smgle or tWIn of rear carburettors IS Included m the manual There are also separate secltons covenng the different types Car Models Sdloon and Estate axles and rear suspenSIOns used for the tool In certaIn cases It Will be necessary for the reparrer to make use of speCial tools and the appropnate refered numbers and thelf methods of use are either descnbed In the text or can be taken from Illustraltons
to
m
the chapter
most of the major menlton should be made of the fact that a fault findmg sechon IS annexed to m sechons thus slmphfymg the some tunes difficult task of diagnOSIS The measurement conversIOns gIVen to mches have been converted as closely as pOSSIble from the ongInal mtlhmetre SIZes but It IS preferable and we adhere to the metnc dunenslons whenever pOSSible A conversion table IS mcluded In the manual adVise the reader to crossreference With the table when deahng With cnhcal dlffienslons
SpeCial
Tills We have tned to make thiS manual as bnef as pOSSible tllustratmg rather than detailing the operahons the be able to out the reader whether he Will carry Iffimedlately WIll save valuable tnne and WIll also show car manufacturers work or not Expenence m prodUCIng hundreds of techmcal pubhcatIons for the motor for 15 years has and the expenence gamed by the author who hunself was a skilled motor mechamc for of thiS nature tills IS the best a that pubhcatlOn proven way
Happy motonng
I and the fewer tnnes you have to refer to tills book the better for you
The author would like to thank for the help and 3SSIStance gtven to bun by Mr John Haley 5
inter
llil
p @
Fog A 1
Removal Of the
nslave cluu
cyhllller
Fog
engll
trel Jb
i
n
1t
r
fd
f7
or
0
if1
L161 engIne
flUBd
10
f g A6
FIlI A 5 Removal
of
eket
Engine
INTRODUCTION The 1300 c c and 1600 c c engines are 4 cylinder in line engines with a single overhead camshaft and a five beanng crankshaft The 1300 and 1600 c c engines differ only In size The 1600 c c engine IS available In two versions one of which IS eqUIpped with twin S U carburettors with different cylinder head manifolds pistons and compression ratio whereas the other has
a
Remove the cylinder head assembly Fig A 7 wrench ST49010000 for removing the cylinder
USing
special
llJd bolts h
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
FIg A 9
carburettor
Remove the big end beanng caps pistons and connecting rod assemblies keeping them In sets In the correct assembly order Remove the flywheel and the main beanng caps uSing a special tool ST44630000 for the rear main beanng cap
ENGINE
Removal
Fig
A 11
Drain the coolant engine and gearbox 011 and remove or disconnect the follOWing parts Battery bonnet air cleaner and rocker box breather hose radiator gnll upper and lower radiator hoses radiator torque converter cooling hoses from radiator automatic models only COIling fan and pulley fuel pipe heater hoses If fitted accelerator
Remove the rear 011 seal and 11ft out the crankshaft baffle plate and the cylinder block net F Ig A 11
Remove tne
and the
Remove the piston nngs With a SUitable piston nng expander gudgeon pin With a SUitable mandrel the outer diameter
a
linkage
choke cable
wiring from starter motor alternator Unit and temperature sender Unit Remove the clutch slave Remove or disconnect
COil
of which should not exceed the diameter of the piston pin and handpress There IS also special tool ST4484000D
cylinder Fig
A 1
Remove the valve rocker springs loosen the rocker piVOt lock nuts and remove the rocker anns by presSing down the valve spnngs Remove the camshaft taking care not to score the camshaft bushes Remove the valves With a conventional valve lifter Fig A 12
Speedometer
cable
light
the
SWitch
assembly
propeller
ENGINE
Inspection
and Overhaul
remove
the
rear
mounting
crossmember
Thoroughly
inspection
before
parts of dirt 011 and water scale before attempting to carry out overhaul
operations Blowout all passages With compressed air Remove carbon depOSits from the top of the pistons combustion
chambers
Remove the bolts secunng the front engine mounting brackets the crossmember Fit a lifting hook to the engine hangers and carefully 11ft the engine and gearbox In a tilted poSition e g
to
and valves
uSing
SUitable
crane or hOIst
FIg A 2
as
follows head
Cylinder
ENGINE Remove the
Dismantling
Check
gearbox and the starter motor Mark the clutch and the flywheel SUitably With a centre punch and remove the clutch cover together With the clutch dnven plate
cover
cylinder head for cracks and the mating faces for burrs or uneveness and replace If necessary note that different cylinder heads are used for the Single and twin carburettor verSions of
the 1600
means c c Check the mating surface for flatness by engine of a straight edge placed across the head and checking the clearance With a feeler gauge F g A 13 If the clearance exceeds 1 0 mm 0 0039 In regrind the cylinder head to block face
Remove the
follOWing parts
filter
water
mountings
011
engine 011 pressure SWitch SUitable stand If available Special Tool drain
plug
and
Stand
ST37100000
See
damage
or wear
Remove the d IStnbutor cap together With the spark plug leads unscrew the spark plugs and remove the dlstnbutor Remove the thermostat
hOUSIng
F Ig A 4
If necessary replace valve Inserts To replace the Inserts bore out the old Insert and select the correct Insert Fig A 16 and fit by heating the cylinder head to 150 200oC 300 3900F Valve
guides
the tolerance micrometers Internal and external che between the valve stems and the valve gUides ThiS clearance
USing
cam
sprocket
must
0 073
for Inlet valves and not exceed 0048 mm 00019 In mm 00029 In for exhaust valves An easy way of
the clearance IS to Insert the valve stem Into the gu
checking
inter
E2C0
@F 0
FillA 9
rocket
Removal
S
o
cf
FillA
11 Removal of
FI
12
Inlet
Exhal51
FIllA 13 forfl
rt
carb
With
SIngle
gle
cub
Inl
F
r
OtA J
Almm
Inl
DIA
41016 410
45 016 450
Azmm
57 DIA 0 37 016 37 O 37 016
DIA
Dlmm
37 DIA 6 37 8 41 6 41 8
Exheult
r
II
IlIt
1
I
La
IlIA HU1
D2mm
ExheuU DIA 326 324 326 324
Llmm
t 2mm
1 1
4 1
1 8 20 16
20
FIllA 15 VeIve
to
i nte f
bi G D er
r
8
rrt l
I
r T
1 0 I
051
J r
D
010
17
V rettD
far
L13
and L16
wrth
IingIo
lm I 11
0011
II
11
l
5144
51 031
CII
IM
l11
far
L16
wIth Ill
twIn
A 19 FIlI
squ
CheckIng
the
valve
IIInng
for
cyl
bore
by
Fig 2 A 2 The
bora
nne
by
B ImII
ence
of
the
FtgA Xl
bends or
CheckIng
twIsts
the
10
and
10m
move
It
from left to
10
nght
0 0079
out the old gUide and press the cylinder head has been heated to JOOF 3 Valve gUides are available 10
gUides press
gUide after
300
10m gauge and a spring scale With a feeler gauge of 004 00016 10 1 thickness the pullmg force on the spnng scale 3307 Ibs 1 should be 0 2 15 kg 0441
2000C
00079
the between
10
valve
of 02 10m 1 Fmally ream the valve gUide to the dimenSion of stem observmg the specified running clearance
oversize
If the
cyhnder
bores
are worn
beyond
gUide and
stem
gudgeon
Valves Check the valve face for pitS grooves scores and other damage Check the stem for distortion and wear When mspectmg the valve heads check 10 particular for burrs cracks and corrosion If the valve head edge IS worn down to 0 20 10 0 5 10m replace the valve If necessary gnnd the valve on a valve gnndlng machine taking off only enough matenal to remove pitS and grooves The valve dimenSions
are
Check for wear scratches and seiZing and If necessary replace Check the Side clearance of the piston nngs 10 the grooves of the piston as shown 10 FIg A 25 The correct specificatIOns are given In section TECHNICAL DATA under the same head 109 Place the piston piston nng gap nngs mto the cyhnder bore and measure the Fig A 261 The nng gaps should be as follows nng 0 15 o 0381010 023 00150 00091 In 1 030mm 00059 00118101 030 15
mm
shown
In
Fig
A 17 and A 18
Upper compression
Second compres 011 nng Wear limit
ring
Valve sprmgs Measure the free length of the valve springs and replace If less than speCified Also test the valve sprong pressure Check the valve sprongs for distortion by plaCing a steel square on to a surface plate PosItion the spnng against the square edge and the spring The clearance between the top of the sprmg and the edge should not exceed 1 6 10m 0063 10 Fig A 191 The valve spnng specifications are given In section
0011810 00059 1 0
mm
0 0394
In
slowly
rotate
Measure the gudgeon prn hole and the gudgeon pm diameter and compare the measured results 10 accordance With the dimenSions In section TECHNICAL DATA under the relevant
heading The gudgeon pin should have a finger press fit In the the piston and a tight press fit In the connecting rod at room The fit of the gudgeon pin to temperature erence Interf
connecting
In
0033
10m
00006
00013
bearings
Connecting rods
the connecting rods for bends or twistS uSing a connecting rod aligning tool FI A 27 For each 100 10m 394 I In length a permiSSible bend or twist of 0 03 mm 0 0012 In
IS
Journals cylinder
and If
wear IS
head assembly
Check the camshaft for wear and damage and If these exceed the limits given In sectIOn TECHNICAL DATA replace the camshaft The camshaft
out run on can
allowed
A limit of 005
10m
00020
In
should not be
exceeded Fit the connecting rod to the crankshaft and check the clearance which should be 02 03 mm 00079 00118 In 1 and should not exceed 0 30 10m 0011810 1 Crankshaft Check for the for
wear
be checked
as
shown
In
Fig
A 20 The Indication
10m
005
0002010
Cylmder block Visually check the block for flaws and cracks Check the mating surface the same way as the cylinder head and If the deViation
exceeds 0 1
mm
and
run out In
0 0039
In
0 03
10m
00012
hmlt
IS a
total deViation of
Cylinder
o 05
0 002
In
Check the cylinder bores for excessive wear FlgA 21 1 The measunng pOInts for the shown
10
Check the crankshaft end float at the centre beanng float exceeds 03 10m 00118
In
If the end
replace the
0 15
10
centre
Fig
A 22
If the bores
are
speCified
In
end float
IS
between 005
mm
the carbon depOSit ridge at the top of the cylinder bore USing a SUitable The tool specifications are given 10 section TECHNICAL DATA
Fig
A 28
Journals
and
and
Rebormg cyhnders
When
The
checking
follows
of the
maIO
bl end l
out as
rebonng all bores must be done at the same time As a speclahsed workshop IS dealing With operations of thiS nature It IS necessary to mfonn the workshop of thiS procedure Five
piston sets are available and are hsted 10 section TECHNICAL DATA To obtain the fmlshed bore Size measure the piston across Its skirt as shown 10 FlgA 23 and add the
oversize
Check the conditions of the bearings and clean the bearings Place a piece of Plastlgage on the beanng over Its full Width In
parallel
cap Main lhtemng tl
and Its
cylinder
beanngs
kgm
32 5
39 8 Ib ft
23 9lb ft 1
27 33 kgm
195
been finish
In
shown
Fig
Plastlgage
11
inter
erlLJ @ Pl
FIlIA 32
34
ded Expl
VI8W
of
ooo
pISton
and
FillA 37 InstallatIOn
of
end float
12
mter
i l
jlJ @
E
ih
FogA 40
caps
t
I
l
s
InstallatIOn
of
the bill end beerll18 FillA 41 Checking the side play of the bill end
Fill A 44
1 2
The
tIming chain
earn
3 Cham 4 5
6 Cham guttie
I
FillA 46 AdjUsting the valve clearance
FlgA
13
stnp on the beanng Journal FIQ A 29 If the clearance exceeds the wear limit of 0 10 mm 00039 In for the main beanngs and and for the fit undersize bearings and regrind the crankshaft to SUit the undersize bearings Undersize bearings are available In 1 1000 mm 25 50 75 100 for main bearings and 6 12 25 50 75 and 100 for the big end bearings
big
end
beanngs
rings ensure that the piston ring gaps are opposite each other and neither parallel to or at nght angles to the gudgeon pin Fit the connecting rods With the numbers on the same Side
throughout Fig A 40
and
tighten
to
2 8
3 4
kgm
20 2
24 6 lb ft
the end clearance of the big end bearings which should be 0 20 030 mm 00079 00118 In I Fit the cylinder head spreading JOinting compound either Side of the gasket Tighten the cylinder head borts In the order shown In Fig A 42 to a tightening torque of 5 0 60 kgm 36 2 43 4 Ib ft
In
Check
Crankshaft and camshaft timing gears Check the sprockets and the tlmll19 chain for wear and replace where necessary Check the runout of the camshaft sprocket as shown In Fig A 30 The run out should not exceed the limit of o 1
mm
Note there
came
are
0 043
In
the hole It
out
of
Check
the chain
tenslOner
replace If necessary
Fig
head bolts
Flywheel
Check the clutch contact area of the flywheel for damage and wear and If necessary re alr or replace the flywheel Check the
timing marks
on
and distributor drive and fit the 011 Install the timing chain Fig A 44 With the the crankshaft and camshaft timing sprockets
sprocket
to the right hand Side COinCident With the timing marks chain There must be 42 chain links between the marks chain
on on
the
the
flywheel for
worn or
uSing dial gauge and replace the flywheel If the limit of 0 1 mm 0043 In IS exceeded If the ring gear IS
run out a
the gear ring by heating It to about 150 2000 C 300 3900F and tapping It off Sometimes It might be necessary to split the ring gear With a chisel In thiS case take care not to damage the flywheel Refit the new ring
damaged
remove
Fit the chain gUide to the cylinder block and and Install the chain tensloner FIt a new 011 seal In the front cover ThiS seal should any
always
be
replaced
reason
gear
In reverse
air
temperature
cover In
gasket
removed for and the upper front between cover and cylinder
cover IS cover
ENGINE
Assembly
The gasket should be coated With JOinting compound When fitting the upper cover check that It does not Interfere With the cylinder head gasket Then check the height difference block between the upper faces of the cylinder block and the upper cover The difference should be less than 0 15 mm 0059 In Fit the crankshaft pulley and the water pump Set the engine at T D C position on the No 1 cylinder In Its compressIOn stroke Install the 011 pump and dlstnbutor drive so that the offset slot
IS In
Apply engine 011 to all sliding or rotating parts of the engine I e cylinder walls pistons bearings gears etc and renew all seals gaskets and lock plates
Place the valve spring seat In poSition and fit the valve gUide With the 011 seal Assemble the valves In the follOWing and outer valve springs spring retainer valve cotter halves and valve rocker gUide Compress the valves With a suitable valve compressor Fig A 32 when fitting the cotter halves order Valve
Inner
In
Fig A 45
pump water Inlet elbow thennostat hOUSing thennostat and water outlet elbow Refit the 011 strainer to the bottom of the cylinder block and enclose the engine interior by refIning the 011 sump coating the new gasket Fit the engine
slinger
arms and the valve rocker springs combined With the rocker pivot bushes
The Spring
compound
on
both Sides
pistons gudgeon pinS piston rings and connecting cylinder Fig A 34 and A 35 and place the bearing shells Into the main bearing hOUSings and caps and the connecting rods and caps Lift the crankshaft In the bearings Tighten down the main bearing cap bolts to 4 5 55 kgm 325 39 8 lb ft Arrange the arrow mark on the bearing cap to face the front of the engine The bearing caps shou ld be tightened In gradual steps In three or four stages starting at the centre and working towards the outside Check the crankshaft end playas 015 mm 0002 shown In Fig A 36 which should be 005
Assemble the rods for each 00061n Install the Side 011 seals Into the bearing cap In Fig A 37 Fit the rear 011 seal uSing special tool ST49370000
rear main as
rear engine slinger manifolds and valve tappets Fig A 46 to 020 mm AdjUst 0008 In for the Inlet valve cold and 025 mm 0010 In cold and fit the rocker cover uSing for the exhaust valve
distributor
s
carburettor
JOinting compound
on
the gasket
Fit the clutch and gearbox part of the engine and the
assembly the fuel hose to the front high tenSion lead to the distributor
Remove the engine from the mounting stand and fit the alternator bracket alternator engine mountings Ignition COil 011 filter 011 pressure SWitch 011 level dipstick and the water drain
plug
shown ENGINE The installation Installation in reverse order to the removal be noted
Original crankshaft IS used and the contact face for the 011 shows slgns of wear Install a shim In order to shift the contact face FIt the rear end plate
If the seal Fit the flywheel USing lock washers and tighten the bolts to 95 105 kgm 68 7 75 9Ib ft I Flg A 38 Install the piston and connecting rod assembly into the correct cylinder from the
IS
carned
out
procedure but
Do not
the
tlQhten the nuts and bolts completely until the engine IS resting flnnly on Its mountings Then tlQhten the nuts Fill the
g engine With engine 011 and coolant water o with th recommended lubricant
or
top of the cylinder block as shown In Fig A 39 with the F mark faCing the front of the e gi le Wh en lnsertlng the piston
anti
14
Technical Data
GENERAL SPECIFICATION
Engine model
Number of
L16 4 In line
c cu In
cylinders
Arrangement of cylinders
Cubic capacity Bore
x
1595 c 62 80
mm
c cu In
stroke
59 9
830
73 7
mm
Arrangement
Max B H P
Single
Single
carburettor
TWin carburettors
Flnng
order carburettor
Single
600 rpm
TWin carburettors
Compression
ratio
Single
carburettor
85 38
kglsq Isq
cm In
VALVE GEAR Valve clearance Inlet Exhaust Valve clearance Inlet Exhaust Valve head diameter L 13 and L 16 w SC Inlet Exhaust 38mm 150 33 mm 1 30 42 1 65 33mm 130
mm In In
hot
025 030 cold 020
mm mm mm
400 389 35
mm mm mm
30 7 kg 29 0 kg 12 3
1 57 1 53 1 38
In In In
0010 In
0012
In
L 16
Inner
kg
34 9 24 9
mm
1 37 1 31 0 98
In In In
L 16 L 16
outer
Inner
332mm
mm
025mm 0010
59 0 59 0
mm mm
2 32 2 32
In In
L16wrrC
Inlet Exhaust Valve stem dla Valve length Inlet Exhaust Valve 11ft L13 and L16 L16 wrrc Valve spnng free 1 13 L 16 L16
outer
Inner w In In
Valve gu Ide protrusIOn from head face L13 L16 104 106mm Valve gUide Inlet Exhaust diameter 800 800 8018 8018
mm mm
041
0421n
Inner
Inl
Exh
80mm 031
In
0315
0315
03154 03154
In In
1159mm 1160mm
456In 4571n
11 996 11 996
mm mm
0472 0472
04723 04623
In In
SC
100mm
040
In In
105mm 0413
0045 0070
mm mm
00006 00016
00018 00028
In In
length
4812mm 189In
52 0 44 85
mm mm
2 05 1 77
In In
1 4 1 6
18 mm 0055 2 0
mm
0071 9 079
In In
0 063
15
Valve seat
angle
Inl
Exh
J 4
PISTONS
Valve seat Insert Interference fit Inlet 008 0 11 Exhaust 006 0 10 Valve
mm mm
00031 00024
00043 00039
In In
Matenal
Type
Piston diameters
gUide
Inlet
Standard
1 st O S 2nd O S 3rt
8304
mm mm mm mm mm mm
3267
3 276
In
83 27
8352 83 77 84 02 8452
3 278 In
In In In In
CAMSHAFT AND TIMING GEAR Camshaft end play Camshaft lobe lift L13 L16 w SC L16 TC w o 0838
mm
3286
3 296 3 305 3326
OS
00031 0 0151n
4th O S 5th O S Width of nng grooves Top second 011 control Piston running clearance
665
mm mm
0 261
In In
7 00
0 275
2 0 mm 0 08 40 mm 0 16 o 025 045
mm
In In
Camshaft Journals diameter All 47949 47962 vm 8877 1 8883 Max camshaft
run out
In
0001 0002
In
005
mm
0002
In
beanng
0038 0076
mm
00015
00026
In
20995 72 00
21 000 72 25
mm mm
08266
2 8346
0 8268 2 8445
In In
Camshaft bearing
diameter
Inner
48 SC
48 000
016
mm
1 8898 1 8904
In
Single
carburettor
TC
TWin carburettors
Pin running clearance In piston 0008 Pin Interference fIt In small end bush 0015
0010 0033
mm
00003 00006
00004 00013
In
mm
In
In
8eanng
Side
shell thickness 1 498 ends 1 506 mm 020 030 mm 0059 0008 0593 0012
In In
20
mm 008 40 mm 0 16
In In
Standard
play of big
rod
Top Connecting
clearance
mm
00016
00029
In
L 13
bearing
or
00018 0078mm
0 063
vm
mm
00006
00022
In
Second
011 control
Connecting
twist
0063
mm
mm
00012
In
per 3 937
In
Top
CRANKSHAFT AND MAIN BEARINGS
023
038mm 030
00091 0006
001501n 0012
In
Second
011 control
015 015
mm
030mm 0006
00121n
Crankshaft matenal
Number of
beanngs
54 942 54 955 mm 2 1631 2 1636 003 mm 00012 Max Journal of round out 003 mm 00012 Crankshaft end play o 05015 mm 0 002 0059 Wear limit 03 mm 0012 49 961 Crankpln Journal dla Max crankpln taper Max crankpln of out round Thickness of main beanng 49 975 mm
CYLINDER HEAD Matenal Distortion of sealing face Max distortion Valve seat Insert matenal Inlet Exhaust Fit 003 Aluminium
mm mm
alloy
In In
00012 0004
o 1
Aluminium bronze
In
Special
cast
Hot pressed
shells
Main
1 827 running
1 835
mm
0072
In
beanng
clearance 0 020 Max main bearing running clearance Crankshaft bend limlt
o 062 mm 0 0008
In
CAMSHAFT DRIVE
Dnve From crankshaft Double roller type and 011 pressure control
In In
Chain
Chain tensloner
Spnng
16
Trouble
SYMPTOMS
I
Shooting
ACTIOtJ TO BE TAKEN
PROBABLE CAUSE
Lack of power
Poor compresSion
Incorrect valve clearance Intake valves leaking Sticking valves Valve springs broken Piston rings broken
Adjust valve clearance Lap valve seats Replace valve and gu Ides Replace valve spring Replace piston rings
Overhaul engine
Rings
or
cylinders
worn
Ignition Improperly
set
Re
set re or
Clean Clean
set
or renew
Lack of fuel Clean carburetor Clean fuel pipe Clean fuel tank Check fuel pump Clean or replace element
Clogged
fuel pipe Dirty fuel tank Faulty fuel pump Fuel filter clogged
Overheating
Insufficient coolant Loo e fan belt Fan belt worn or damaged Inoperative thermostat Defective water pump
Top up radiator Adjust fan belt Replace fan belt Replace thermostat Repair or replace
Clean system Re set timing
Adjust clearance
Refill With correct oil grade Clean readlator finS F nd 011 leak and rectify
or
sticking
In
Replace piston rings Replace Piston rll1gs Replace piston or bore cylinder Replace as necessary Change to proper VISCOSity Charge or replace battery Clean and tighten connections Adjust Ignition check plugs Repair Or replace valves
Overhaul enqlne
worn worn
gUide
D fficult starting
cylinders badly
Engine nOIsy
Crankshaft beanngs
or
Journals
worn
worn
Connecting
rod bearings
Replace bearings and grind crankshaft replace crankshaft Replace bearings and gnnd crankshaft or replace crankshaft
or or replace rod Check and replace parts
ConnectIng rod be
l
Stralgten
as
necessary
mterCE
lliJ
Plcel @
FIg B 1 system
General
layout
of
tho
lubricatIOn
rehef valvo
18
Lubrication System
DESCRIPTION The
lubricating system IS a pressurefeed system ronslstlng of a rotor type 011 pump Inoorpotating a regulator valve and driven by the distributor drive shaft and a full flow 011 filter A strainer IS fined to the bonom of the front cover and serves the purpose
to
surfaces for wear Also check the spring for weakness or as necessary The rehef valve F Ig B 4 dImenSIons are as follows
damage Replace
Free length Fitted length
Opening
pressure
38
57 mm 2 24 In 39 mm 1 54 In 42 kg 54 597 Ib
beanng
locations
OIL PUMP
Removal and InstallatIOn the front 011 pump IS held 111 The
Assembly
remove
pump IS a reversal of the dlsmanthng the pump cover gasket IS properly fitted Tighten the 011 pressure rehef valve cap nut to a torque reading of 3 0 3 5 kgm 21 7 25 3 Ib ft
assembly
procedure Make
sure
carned out In reverse order to the removal the 011 pump set the engine so that No 1 cylinder IS at T 0 C position In ItS compression stroke and then fIt the 011 pump and the drive spindle In the front cover With the punched mark on the spindle facing the front of the
IS
procedure
When
replaCing
of the
replaceable cartridge type and can be replaced on the cylinder block by hand
Check the engagement of the drive vIa the distributor fining hole Refit the distributor and fill the engine with the recommended engine 011 Tighten the mounting bolts to 1 5 21kgm 108 1521bft SeealsoFlgA2 I engine
When refitting the filter element do not overtighten and under no circumstances use any tools The filter body With the element should be replaced every 6000 miles 10 000 km The location of the filter
IS
shown
In
Fig
B 5
OIL PUMP
Dismantling
Separate
the body cover from the pump body by unscrewing the Single securrng bolt and take out the pump drrve and driven gears from the pump body Fig B 3
parts In
follOWing
Technical Data
Type Pump type
Drive Pressu re feed system Rotor pump From distributor shaft
Inner
Check the
Worn bearrng faces pump body result In pressure losses If necessary replace the body
0 wear
for
and outer rotors The maximum clearance must not exceed 005 0 12 mm 0002 0005 In If the clearance IS found to be greater a new seat of rotors should be fined
Inner
Clearance between
outer rotor
and 0 05
012mmI0 020005111
0 12mm 0005 In I
Clearance between
3 Check the clearance betWeen the outer rotor and the pump ThiS play must not exceed 0 15 021 mm 10006 If thiS clearance IS excessive a new set of rotors 0008 111
rotor
tipS
Celarance between outer rotor 015 and body 011 pressure rehef valve spring
body
021
mm
0006 0008
In
or a new
pump
body
must be fined
Check the end float of the rotors by placing a straight across the Joint face of the body and measuring clearance between the rotor ends and the
edge
the
75 mm 224 In
Opening
pressure
8 4 2 kg sq 3
cm
54
ii f 3 i m 1 54 60 Ib sq
In In
inserting
In
on
body
can
be
011 pressure at
idhng
1 0 1 2
speed
Oil pressure at
scores
kgsq
cm
14 2
17 1 Ib
sq ln
If
38 42 kg sq
cm
54
60 Ib sq in
Cheek
19
mter
j M
Pl @
Fill C
OY
OperatIon plate
Dust
cover
Drum
SpIder assembly
linnl9
FIlI
C 3
Exploded
of
the fan
h c1u1l
V V
00
o
Fill C 5
parts
V fIW of the radiator and
o
c 4 DlSIllantllng of FIlI
thefan clu1dl
J
component
20
It
Cooling System
DESCRIPTION The cooling system is
radiator
closed pressunsed system It consists of fan clutch thermostat and the water Jackets in cylinder head and block
a
water pump
83 50C 177 182oF The maximum hft of the thermosm valve should be 8 0 mm 0315 In at a temperature
of 80 of
950C 1203oF
WATER PUMP
To remove the system
unsaew
Removal pump drain the cooling belt fan and pulley and
THERMOSTAT
Instellatlon
the water pump from the front cover Fig C 2 It IS recommended that the water pump is not dismantled due to Its design and manufacture If the water pump IS supected of
The installation of the thermostat is carned out In reverse order to the removal procedure Use a SUitable sealing compound to
seal off both Sides of the
gasket
malfunction
an
exchange
RADIATOR
remove
Replace
vanes or
the water pump If It has eXce5Slvely rusted or corroded If there IS excessIVe wear In the beanngs or
IS
squeaking
of
8n NIS
use
the radiator shown In Fig C S drain the cooling and disconnect the top and bottom radiator hoses Remove the radiator after unscrewing the four radiator system bolts Check radiator for water leaks and cracks and repair or replace as necessary The installation of the radiator s earned out In reverse order to the removal procedure
attaching
FAN CLUTCH In the models With air conditIOning a fan clutch IS fitted to the effiCiency of the coohng system and reduce power losses ThiS clutch IS thermostatically controlled by the air
IIlCrease
temperature of the engine compartment If the air temperature In the engine compartment Increases the thermostat beginS to
operate and the fan clutch Will engage
Technical Data
Type
Closed pressunsed system Radiator
FAN CLUTCH
Inspection
Fully warm up the engine Check the operation of the clutch at engine speed of 2500 rpm The clutch should begin to operate at a temperatu re of 61 690C 141 159s o F and shoo Id SWItch automatically off at 50 580C 121 1380F
The temperature should be checked near the clutch and thIS be done several times as there IS a time lag In the operation of the thermostat should To check the operation of the fan clutch thermostat remove the operating plate see Fig C 3 and C 4 and submerge It In hot water 700C for 2 or 3 minutes to check Its operation
13 78 In I 20 24 In Thickness 32 mm 1 26 In 26 IItres 0 7 U S gall 057 Imp gall I Capacity 09 kgsq cm 128 pSI Cap opeOlng pressure
mm mm
Herght
350 514
Width
80 5
1lF 18
at
950C
2 3 0F
THERMOSTAT
R8IllOVlII
Drain the cooling system remove the radiator hose and the water outlet elbow and 11ft out the thermostat To check the thermostat place It in a container filled with water and gradually heat up tha water Immerse a thermometer into the water and observe the Indication Taka C8I 8 that the
thermostllt or the thermometer cannot touch the bottom or the sides of the contalller oth ise false nIlIdinga will be
to
open at
temperature
21
inter e
Ql @
A
I
D2 Fia
Remof
r
FI9 D 1 Explod
YI
the
of
v
FIQ
D 5
The
F
FItI D 4 Removal
4 5 6 1 8
Flyweight rprlnt
RotorpoI
donm
fin
Fig
D 6 Checlull9 1IIe contact FI9 RI IlfP
er
gap
D FIg
wIth
22
Ignition System
DESCRIPTION The 1300
are
Adjultment
and the 1600 c c engines With Single carburettors c c fitted With the Ignition distributor model D41058 whilst the 1600 c c engine With twin carburettors has model D40054 The outside appearance of both distributor models IS alike
in reverse order to the removal the engine until the fibre pad of the contact breaker ann IS at the highest POint of the distributor Slacken the clamping screw at the fixed contact pOint and earn turn the adjuster screw With a screwdriver until a contact gap of fitted
procedure
over
Removal
high tension cables from the spark plugs and the Ignition coli and detach the primary wire from the distributor Remove the vacuum pipe from the distributor connection slacken the distributor clamp bolt and withdraw the distributor
0012 0022 In IS obtained Retighten the and uSing a feeler gauge rlH heck the contact breaker gap to ensure that the fixed contact breaker plate has not moved while the clamping screw was tightened 045 055
mm
clamping
screw
The contact breaker POints can be cleaned by uSing a contact file or an 011 stone The raised areas on the contact should be filed off but do not attempt to remove the crater In the other After cleaning the contacts they should be placed opposite each other meeting over a Wide area If the contacts only meet partially It IS pOSSible that overheating burning and sparking could develop A View of the contact breaker assembly
contact
IS
IGNITION DISTRIBUTOR
Dlsmanthng
Remove the distributor cap and pull off the rotor Loosen the vacuum Unit securing screws and 11ft off the Unit Unscrew the fixed contact POint set screw and 11ft off the pOint Take off
two
shown Fig D8
In
IS
shown
In
the spring clip from the piVOt post of the moveable contact breaker pOint and remove the contact arm From the Side of the distributor body remove the two spring clips and remove the Take care not to loose contact breaker base plate see Fig D 2 the steel balls between the breaker spring and the breaker plate and those between the breaker plates
Adjultment
With
vacuum
underneath and
SUitable punch drive out the drive gear retaining pin uSing Remove the gear and the sI1Ims after marking the Fig D 3 relation of the shaft and the gear and Withdraw the distributor shaft from the other Side Fig D 4 From the InSide of the distributor
cam
USing a stroboscopIC tlml ng light connected In accordance With the instructIOns of the manufacturer check that the timing case pOinter IS In line With the timing mark on the crankshaft which Will be made statIOnary by the effect of the timing IIgt Each of the marks on the crankshaft pulley represents 50 of the
crank angle The tlml ng setting 1300 1600 1600
c c c c c c IS as
remove
the set
engine SC
TC w
1008
TC w
IGNITION DISTRIBUTOR
Assembly wlSC
Single
carburettor
Thoroughly clean all parts and examine the distributor cap for cracks carbon tracking and burnt or corroded terminals Check
defective With
an
the carbon brush for excessive wear and If necessary remove Check the contact breaker gaps for pitting parts replaCing them If badly marked Light damage can be smoothed 011 stone
wear or
CHECKING THE CENTRIFUGAL ADVANCE Disconnect the vaaJum pipe from the distributor hOUSing paint white line on the crankshaft pulley and start the engine Direct the flash of the stroboscopiC timing light on the
and proper fIt In the body Check the open circuits and replace If necessary Unit for operation and the flyweight
and observe the movement of the white line engine speed IS slowly Increased The distance between the IgnitIOn timing pOinter on the timing gear cover and the white line should Increase noticeably Incheatlng a satisfactory operation of the centrifugal advance mechanism If crankshaft whilst
pulley
the
The assembly is a reversal of the removal procedure Refer to Fig D 5 when assembling thJ flyweight mechamsm When the distributor isassembled connect a spring scale on the end of the contact arm and slowly pull the spring scale lIWay from the Read off the indication at the moment fixed contact POint when the arm is lust lifting from the fixed POint See FIg D 61 The correct value IS 0 50 0 65 kg 1 10 1 43 Ib Adjust the con1llct breaker gap as described below
the paint marks appears to move back and forth In an Irregular manner It may be that the flyweights are sticking If necessary lubricate the distributor to free off the weights CHECKING THE VACUUM ADVANCE MECHANISM 1500 rpm until the Increase the engine speed to about 1200 throttle disc valve uncovers the vacuum drllhng With the 8Q8IIIll running dISCOnnect the vacuum pipe from the distributor
housing
and re connect
23
the
connectlOg re
crank
pulley
of the
vacuum
With
each
disconnecting
and
pIpe the line should move back and forth If the line remalOs stationary It IS possible that the pipe IS obstructed or the vacuum unit is damaged
Technical Data
DISTRIBUTOR Contact gap Contact spring pressu re Shaft diameter lower part Shaft diameter upper part 045 055 050
mm
SPARK PLUGS
Removal Inspection
0012
002210
and Installation Remove the spark plug cables from the plug ends and unscrew the spark plugs only uSlOg a spark plug spanner No make sluft tools should be used for thIS purpose Check the plugs for cracks and chips on the IOsulators and check the electrodes for wear If the carbon depOSIt IS excessive thIS IS an Indication of bummg englOe Oil so Install a hotter plug If the plug faces are excesslvle whIte or rapid electrode noted fit a colder plug Clean the plugs With a sand blast cleaner or carefully WIth a Wire brush and adjust the electrode
wear IS
HouslOg
lOner diameter
housmg and
001 0038
mm
00004 0 08
limit
mm
diameter 0 029
mm
In In 10
0 197 00018
00004
10
wlSC
wrrc
1600
c c
SC
3 2
4 1 ohms
wrrc
resistance
Secondary wlSC
SlOgle
carburettor
wrrc
TwlO carburettor
Fully detailed
Data
EnglOe TUOlng
24
II
Trouble
SYMPTOMS
Starter turns but engine will not start Weak battery Excessive mOisture
Shooting
ACTION TO BE TAKEN
PROBABLE CAUSE
Recharge battery
on
spark plugs
or
high
tension or
wires
dry
Cracked
leaky
Replace
cap or rotor
rotor
Broken wire In pnmary CircUit Burned or Improperly adjusted points Defective condenser
Repair or replace wire Adjust or replace points Replace condenser adjUst or replace plugs Replace breaker points Tighten or repair
Clean
Difficult starting
pnmary CircUit
Replace
Clean
cap
or
rotor
Engine misfires
Dirty
or
Loose
or
faulty
adjUst or replace plugs Tighten repair or replace Wires Replace cap AdjUst breaker points AdjUst
contact
points
correctly adjusted
contact
and
Burnt
or
Incorrectly adjusted
loose
breaker gap
or
dirty
or or
COil
Interrupted
and
no
Spark plugs
wet
worn
or
inCOrrect
Clean and
replace plugs
gap Defective condenser Defective broken Ignition cable between COil distributor cap
or
Tracking
and rotor Defective
replace
Ignition COil
replace
COIl
interceM j
@ ce p
J
L
ill
il
T
1
f
A
I a
f 4
Fog
2 E General L 16
r
o
IJ
the
twin
f
c
of
the twm
choke
of
choke
cartJuret1D
englnel
12
1314 IS 16
FJgE 3 V
cars fittedWith
FIg E 4
SectIon L 16
through
the
twin
choke
carburetlllr
englnel
c t 15
2Small
3
IHUnmng Slof
MamllJrble J Jet
bleed
SiChatfpl Mamd zer bleed Econor 16 runmng SIow Jet 17 SJoVN unnmg econonuzs
18 Slowrunning BIf bIet1d 19 AN vent 2Q Fue let1el g JiUgt 21 Mam Jet 22 runnmg SJow flW KJlumtllCl 2 24
SIoMNllnmng
11010 8 Throttle aWe
25
bltJed
FIlI E 5 c a rburetlllr
SectIOll
L13 1
through 1
the
A rWllltptplt
SmsJIWNlbm 5 MatndlS C 6 Mam air bleed a bleed 7 SlorH1lnnmg II bleed IS runnlnfl SIow fIl 19 Vacuum prsfon 20 Power aIw 21 et Ifam
lTbJeed
5 6
7
tunnlllf Slow
runnm6 SIow
f1t
obo
00
FIQ E The dlStll8nt1ed throttle vaJve
22 Maml 23 l ldl 24 8 25
hole W Throttle
26
Fuel System
DESCRIPTION The fuel system consists basically of fuel tank fuel pump fuel strainer air cleaner and carburettor The Datsun 1300 IS fitted with a two barrel carbu rettor whereas the Datsun 1600 has either
a
Check
the
throttle
and
choke
valve
shafts
and
bores
for
eccentriCity Check the slow running Jet needles for burrs and parts as necessary Check
two
barrel
downdraught
carburettor
or
twin
SU type
ndges Replace
carburettors
CARBURETTOR
Single
tWin choke
Removal
choke tube clusters for wear or slackness and If necesssary replace the cluster Check all linkages for excessive wear and the filter screen for blockage and distortion Check the operation of the accelerator pump and the chamber for damage to the diaphragm and air leaks replace any defective components
The single carburettor versions are fitted to the Datsun 1300 Type designation DCK306 and the Datsun 1600 Type
diaphragm
Repair
or
deSignation
carburettor and the
OAF
328
See
Fig
E 2
vacuum
air cleaner pipe from the carburettor end and detach the Remove the throttle linkage and undo the four
E 3
Assembly
reverse
procedure
brittle CARBURETTOR The
or
order to the dismantling taken that no defective Where these are found they be be careful
Dismantling
main Jets slow runnlhg Jets and the needle valves for the pnmary and secondary stage are accessible from the outside of the carburettor body Remove the Jets and needles Fig E 4 E 5
should be replaced When connecting the linkages not to bend or deform any of the components
CARBURETTOR
Adjustments
Float level upper body can be removed by removing the choke connecting rod pp connecting rod return spring stop pin and the four secunng screws Figs E 6 E 7 and E 8 The Mam the gauge line the float IS correctly set If If the fuel level thiS IS not the case hold the float level In ItS chamber and check that the gap between the float seat and the stem of the float
IS
at
needle valve
IS
about 1 0
mm
0039
In
body
mm
059
as
Remove the pnmary and secondary emulSion tubes by removing main air bleeds Fig E 10 Remove the cylinder cover and take out the accelerator pump F Ig E 11 Separate the float the chamber from the throttle butterfly block by removing the rod linking the diaphragm to the secondary throttle valve and the Remove the float chamber four securing screws Fig E 12
cover
seat
Fig E 17
Interlock startJng system With the choke valve fu lIy closed there should be a clearance of 1 3 mm 00512 In between the pnmary throttle valve and the carburettor body In the ase of the OAF 328 carburettor and a
In the case of the DCK 306 clearance of 072 mm 0028 In carburettor Fig E 19 and Fig E 20
Fig
E 13
screws screws
Dismantle the
diaphragm diaphragm
The fuel
diaphragm by removing three chamber and then removing three chamber cover Fig E 14
system
shown
In
holding the
holding
the
secondary
E 15 should not be dismantled If not abolutely necessary When dismantling take care not to damage the bimetal spring
return
Fig
When the pnmary throttle valve IS opened to the speCified degree 590 for OAF 328 or 560 for DCK 306 there should be a clearance of 9 10 mm 03583 In In case of the OAF 328 carburettor and the and A
or
Inner
damper
Fig
on
E 23 the adjustment
between the throttle valve 6 40 mm 0 252 In wall of the throttle chamber See also Figs E 22 To adjUst the clearance bend the pOint marked
throttle vale
linkage
adjustment
screw
CARBURETTOR
Inspection
screw
clean all parts In a su Itable solvent and blowout all Jets and passages With compressed air Check all parts for wear and damage With special attention to the follOWing parts
Thoroughly
Check the float needle and the seat for wear If worn the assembly
replace
the slow runnlng volume control screw and back off three turns Then screw In the throttle stop Unscrew the throttle stop screw screw and start the engine until the engine beginS to rotate unevenly when the englfle Screw
In
by approximately
speed
Will
gradually drop
screw
volume control
until
Now screw In the slow running the engine runs smoothly at the
inter
i D
j1 @
4 4 7 B alh throttle
FIlIE
valves relllDved
caver removed
ll
li
il 4
0
It
u
Fill E 9 The choke
c hamber
F
I
relllDvecI
lOCO ndary
emu
q
o
1 l O Jo
FIg E 13 tor body
The float
ret
28
ImmIIII
1J
F
flp fuoIlpul
4
o 0 o F gE 14 The
return
sys1em
Body PIPe
SImtlttJl
component
parts
of
the
dl8phragm
a
L
i
J
Ll1
1
f i
r L
4
2 4 DAH OCK AnZl Omm
00
1
I
D au
I E 16 FI
Throttle 6 Throm l
ch btK aIw
I E 19 FI
2 rL r
Interloca opemng
Choke vain
5 Choke ItNer 6 Fat dIB connectIng IeYer 1 Throttle chamber 8 Throttle valw
i
r
fr J
L
JhaJi
FIQ
29
adjust Re
screw
to
reduce the
adjusting nut and check again If the second check produces a sharper click than the first repeat the centnng Refit the parts
that have been removed pour thin 011 Into the hollow rod of the piston damper to Within 0 5 In 12 7 mml of the top of the rod
until an engine speed of 550 rpm has been obtained Care should be taken not to screw In the slow running volume control screw to tightly as otherwise the tip of the screw might be damaged
adjustment
CARBURETTOR ThiS Datsum 1600 fitted transmission With the engine at operating temperature check that the throttle lever Will touch the dashpot stem when the 2000 rpm There engine IS running With 1800 should be no load on the engine Fig E 161 If thiS IS not the
IS
adjustment
Adjustments
IS
The proper
adjustment
extremely
With
automatic
synchromzsnon
and
idhng adjustment
slacken the dash pot locknuts and turn the dash pot to the nght or left until the throttle lever touches the dash pot stem at the specified engine speed In thiS condition the clearance
case
cleaner when the engine has reached ItS operating temperature and slacken the throttle adjusting screws The heads of the adjusting screws must not contact the throttle lever
not
between the throttle valve and the throttle chamber wall should be 08 mm 0071 In I corresponding to a throttle valve angle of lO
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
Dismantling
Unscrew the plug and Withdraw the piston damper Take out the two suction chamber secunng screws 11ft off the suction chamber and Withdraw the piston and Jet needle Disconnect the rod from the bottom of the Jet and the nylon feed tube from the base of the float chamber Unscrew the Jet
adjustment descnbed later between the Jet bndge and the needle head should then be approx 1 5 mm 0591 In I
Screw
In the throttle adjustment screws of the front and rear carburettors and start the engine The engine should retain Its operation temperature before carrying out the next step
adjusting
nut
beanng locking
nut
the float
Remove the float chamber cover secunng bolts and Withdraw Screw out the needle valve assembly The dismantling
are
stages
shown
In
Figs
E 24 E 25 and E 26
adjusting
screw
of both carburettors to
CARBURETTOR
InspectIon
reduce the engine speed to approx 600 700 rpm The engine should turn over smoothly and consistent If a flow meter IS available apply the Instrument to the front carburettor flange and turn the adjustment screw on the flow meter so that the upper end of the float In the glass tube IS In line With the scale Llft off the flow meter and re apply It to the rear carburettor Without altering the setting of the flow meter adjusting screw If the pOSItion of the float rear carburettor throttle the mark on the scale
IS
Note the condition of the needle valve and the seating Fit a new needle valve and seating If necessary If the Jet needle IS
or otherwise damaged Withdraw the locking Push the needle piston and fit a new needle shoulder IS flush With the lower face of the piston
bent
screw In In
the
not
In
adjusting
to
align
Clean and
dry
the piston
assembly
WIth thin 011 With the carburettor flow correctly adjusted adjusting nuts of both carburettors by approx CARBURETTOR Reverse the
tighten
1 8 of
the
a
Idling
and
turn
Assembly
and centre the Jet
stop the adjusting of the nuts at a pOint where the engine speed IS fastest and smoothest Without If thiS missing or hunting
be detenmned bnng the nuts back to their positions and unscrewthem from thiS pOSition until the engine runs fastest und smoothest
point
cannot
onglnal
the Jet Screw the Jet adjusting nut up as far as poSSible 11ft the piston With the lifting pin and allow It to drop It should drop freely the bndge With a soft metallic click Repeat wltn adjusting nut screwed fully down If the piston does not freely In either of the tests proceed as follows
onto
the fall
Then slacken the throttle adjusting screws of the front and rear carburettors and adjUst the engine speed to the specified value of 650 rpm for standard engines or 700 rpm for models With 011 cooler Make sure that the air flow of both the carburettors remains unchanged Screw In the throttle adjusting screws until their heads contact the throttle connecting lever Connect up the front and rear throttle shaft Without changing the Idling
Disconnect the rod from the bottom of the Jet and the feed tube from the base of the float chamber Pull out the Jet and the tube Unscrew and remove the Jet adjusting nut and the spnng Refit the
as
speed setting
Move engine
up as far
adjusting pOSSible
Slacken the Jet bearing lock nut until the beanng can be turned With the fingers Remove the piston damper and press the piston down onto the bndge Tighten the lock nut
Idling
interconnecting shaft and accelerate the few times When the engine IS settled once more In Its speed check that the speed IS unchanged Recheck also
a
the throttle
the connection
and nQ 1l
whetlliij
IS
falls
freely
fully 19w ir
the
of the interconnecting shaft Then turn tha Interconnecting shaft adjusting screw to Increase the engine speed to 800 1000 rpm Check y means of the flow meter Jf the Idling air flOW IS the both carburettors If necessary tor same
30
@0 f J
I I
1
I
I
2
I
i I
Ju
Fill E 21
IlltIIrlock
Fill E 23
clearance
between
Throttlfl Throttle
nbtN ch
1I1v6
Adjuster pllltrJ
SUCTION
CHAMBER
SUCTION
PISTON
FUEL PIPE
A
tJ
II
o 0
e
0
SUCTION SPRING
Yo
v
NOZZLE
JET
SLEEVE
SET SCREW
NEEDLE
Fill E
24
of
Rlol on
chamber
Exploded
VIew
of nozzle
assembly
0
0
0 0
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
Removal
mlet and
remove
adJustmg
screws
Stop
air
and
Adjustment
FUEL PUMP
Dismantling
Remove the suction chamber and the suction piston and turn the Idling adJustmg nut Usmg a depth gauge check that the dimension A between the Jet bndge and the top of the needle head
re IS 05 mm 00197 m When this dimension IS obtamed mstall the suction piston and the suction chamber and check the smooth operation of the suction piston The Jet needle IS
Fig E 37 Remove the screws secunng the upper to the lower body and 11ft off the upper bOdy
Remove the
retainer
valve
retamer
secunng
screws
and 11ft
packmg Remove the cover retammg off the cover together With the gasket
valves and
now set
On the lower body half press down the diaphragm and unhook the diaphragm rod from the rocker ann link Lift out the
disconnect the fuel pipe and remove the sleeve nut If a fuel level connect gauge IS avallable the gauge to the fuel pipe connection on the carburettor re connect the fuel pipe and start the engine The fuel level m the glass tube of the level gauge should be b tween 22 and 24
clip
diaphragm
Remove the spnng 011 seal retamer 01 seal packing To remove the rocker ann assembly dnve out the piVOt pm towards the serration and 11ft off the individual parts
FUEL PUMP
Inspection
from the top of the float chamber If level gauge IS available proceed as follows
mm m
0866
0945
no
cover
after
screws
and
11ft
off the
cover
undOing together
cover
wear
for cracks defective threads or wear The and tear and a worn pull rod The sealmg
corrOSion
cover so
faces of the valves and the spnng for weakness and The rocker mechanism for wear
Lift the float lever with the tip of the fmger and then lower It until the float lever seat Just contacts the valve needle stem If the dimenSion H m Fig E 33 IS between 14 to
correct
Assembly
m
15
mm
0551
to
05901
the float
as
the link
the lower
body
and hold
place
while
the pin
the piVOt pin from the Install the rocker arm spnng
fitting
non
serrated Side of
StartIng
To
mterlock opemng
Install the 011 seal and the seal washer and the diaphragm to the lower
body
diaphragm
to
the startmg mterlock opening bend the connectmg rod 4 m Fig E 34 with a suitable pair of pliers The opening IS mcreased by lengthening the connectmg rod and reduced by
adjust
arm link
the upper
the rod The length of the connectmg rod IS correct If the clearance between the throttle valve and the throttle chamber dimenSion 8 m Fig E 34 IS 0 6 08 mm 00234
shortenmg
00315
I with the
starter
lever
pulled
out
completely
packing and the valves correctly mto the upper body half and secure the valves With the valve retamer and the screws POSition the upper body onto the lower body and msert the screws Make sure the screws pass through the diaphragm Without teanng the matenal Tighten the screws evenly and
securely
Hydraulic damper
The 011 should be checked approx every 3000 miles or To check the 011 level remove the 011 cap nut every 3 months as shown m Fig E 35 and check the level markmg on the two grooves on the lower Ime fill
damper
procedure
plunger
rod
dropped
below the
m SAE 20 engme 011 Use an 011 can and fill m the 011 until the level has reached the upper line When msertlng the cap nut take care not to bend or damage the plunger rod Tighten the nut suffiCiently by hand
FUEL PUMP
Testing
Remove the carburettor fuel pipe and connect a pressure gauge to the fuel pump outlet fitting Run the engme and check the fuel pump pressure which should be 0 18 024 kg sq cm
on
FUEL FILTER The fuel filter IS of the throw away cartridge type and should be changed every 40 000 km 24 000 miles To remove the fuel filter disconnect the mlet and outlet PipeS and remove the filter Fig E 36 The mstallatlon of the filter IS a reversal of the removal
256
34 pSI I the
a
If the pressure
readmg
IS
replace
diaphragm sprmg
flow check
a
Conduct
by connectmg the mlet pipe and msertmg SUitable contamer Start the engine and run one mmute The mmlmum quantity of fuel
be 1000
c c
procedure
If not
lines for
blockages
suspected
Compressed
the fuel lines remove the pump and air Repeat the flow test
32
ImmIIII
3B
4
r o
eel
I
19
S 6 7
Valve retainer 8 R8tamer screw 9 D hragm 0 Pullrod Selll washer 13 Seal 14 Lock washer 15 Nut 16 Connection Screw
8 Lock washer 19 ConnectIon 20 Rocker arm sprmg 21 pscer 22 Heat Insulator 23 Fuel pump gask8t 24 25 26 12
DIaPhragm
flng
12
FIg E 41 Exploded
Exploded
VIew of
aIF
cleamr
33
after
re
assembly
POSITIVE CRANKCASE VENTILATION SYSTEM FUE L TANK Removal
cleaner
Fig
ventilation pipe from the rocker box to 43 whilst the l16 engme uses a
Saloon
seat
Remove the
rear
seat
back trim
Open
the
and the seat back and take off the luggage compartment lid and remove Fig E 38 Disconnect the fuel gauge
combmatlon system Fig E 44 which IS Similar to the one used for the l 13 engme but IS fItted addItionally With a tube With a variable Orifice valve fr the crankcase to the mlet vamfold
F g E 39 and the tank filler tube Remove the tank securing bolts and disconnect the fuel outlet pipe and the fuel return Ime lIft out the tank wagon Carry out the same operations as described above With the exception that the fuel tank securmg screws are acceSSible from under the rear floor panel Estate
car
InspectIon Every 12 000 miles 20 000 km remove the hoses and blowout With compressed air If the hose IS blocked or collapsed replace It Check that the crankcase breather valve only allows one way passage of gas mto the mlet manifold Replace the valve If It IS
leakmg
10
statIon
FIg E 40
The mstallatlon of the fuel tank IS removal procedure
10
the opposite dIrection Clean all connections and the which IS sealed and has no connection to the
reversal of the
atmosphere
dIsconnect the To check the operation of the system ventIlation hose from the rocker cover With the engme runmng at Idlmg speed and check that a hlssmg sound can be heard as the aIr passes through the valve A strong vacuum should be felt when
must
a
FUel LINES Examme the fuel hnes for damage and kInks and replace If necessary If dirt IS found 10 the carburettor float chamber or 10 the fuel pump stramer dIsconnect the pipes and blowout WIth com ressed aIr It might be recommendable In thiS connection
remove and clean the fuel tank as depOSits are empty Without doubt 10 the fuel tank whIch would lead to the same fault after a short tIme
fmger
IS
placed
over
the valve
mlet A
damaged
valve
always be replaced
to
AIR CLEANER The air cleaner IS of the VISCOUS paper type and cannot be cleaned but must be replaced every 24 000 mIles 40 000 km ThIS operation IS shown 10 FIg E 41 and IS self explamtory
Technical Data
TWIN CHOKE CARBURETTORS
Engme Model
l16
1600c
l13
1300cc
Primary
Outlet diameter Venturi diameter Main Jet Main air bleed Slow runnmg Jet EconomIzer Jet Economizer bleed Power Jet Float level Fuel pressure 280101 240101 115 240 48 18 1 8
Secondary
32mm 28
x
Primary
26mnt 21 96 80 43
x
Secondary
300101 27x12mm 150 90 180
9 0101
0101
40 23ct 101m 0905 ct 004 024 235 112 109 107 104 101
to
23ct 101m
0905
024
ct
004
to
Weight
Altitude settIng main Jet 100001 3300 ft 2000
01
kg kg
sq em 341 pSI 5 17 Ib
kg 255 kg
94 92
sq cm 341 pSI 5 61 Ib
300001 10 000 ft
400001 5000
01
89
87 85
34
FUEL PUMP
Weight
Needle Float needle valve Jet need Ie Suction spring Float level Fuel pressure 024
kg
6 16 Ib B 0 08 In t M 61 N023
pressure amount
018
024kg
1000
sqcm
c c
256
at
341psl
Diaphragm
Imln
mm
23f 1
mm
kg
sq
cm
341 pSI
Trouble Shooting
SYMPTOMS PROBABLE CAUSE ACTION TO BE TAKEN
CARBURETOR
float
as
necessary
Flooding
ExceSSIve fuel consumption
pressure
Float level too hIgh Loose plug or Jet DefectIve gasket Fuel leaks at pipes or connectIons Choke valves operates Improperly Obstructed air bleed Main Jet obstructed I ncorrect throttle opening Slow running adjustment Incorrect Slow running fuel Jet blocked I ncorrect float level DefectIve accelerator pump Float level too low Incorrect throttle opening Defective accelerator linkage Blocked pump Jet Lean mIxture
TIghten
Replace gaskets
Trace leak and rectIfy Check choke valve Check and clear
Stalling
Clean
main
Jet
Poor acceleratIon
SpItting
Dirty carburetor
fuel pIpes Manifold draws secondary
Clogged
air
TIghten
or
Dismantle and clean carburetor Clean fuel pipe Clean fuel tank Check connections and tighten Repair or replace fuel pump Clean
e or
replace fIlter
Loose fuel pipe connections DefectIve valves Cracked fuel pipes Loose pump mounting Worn or defectIve rocker arm Broken rocker
arm
NOISY pump
spring
35
I nter
O C 1
J
0
o 0
c
r
II
o
starter
lever
tl
adjust
Jht ht1l
Fog E
32
The
tlng shaft
Connecting
Connecting
Connecting
St1Irter
Th
36
Clutch
Chttch dnven
plate
DESCRIPTION
coil spring type clutch st fitted In the case of the diaphragm type clutch the clutch cover and the pressure plate are combined by nine spring setting bolts The diaphragm has nine release fingers which apply pressure to the pressure plate to hold the latter In constant contact With the Either
a
diaphragm type
or
out run between the centres Check the clutch driven plate for of a lathe and replace or straighten the plate If the indicated value exceeds 05 mm 002 In Fig F 8 at a distance of 95
from the centre of the plate If the rivet heads are In below the clutch faCings or there IS abnormal wear or rivets m sslng replace the driven plate or the
mm In
3 74
clutch driven plate and thereby With the flywheel The Call sprlng type clutch consists of the clutch cover and the pressure plate combined by nine pressure springs Three release levers retained by eye bolts and nuts serve to release the clutch mechanism
Check the splines In the clutch driven plate hub for rotational backlash by plaCing the plate on the gearbox clutch shaft and rocking It to and fro If It IS felt that the clearance exceeds 0 4 0016 to replace the complete plate It IS also pOSSible to replace the hub only but thiS IS a Job for the more skilled person and should only be carned out If the necessary
mm
Removal
In
deSCribed
IS
section Insert
GEARBOX
eqUIpment
IS
available
clutch
fitted
speCial
tool
ST49090000 clutch aligning tool or a spare clutch shaft Into the splines of the driven plate In order to support the clutch Remove the
SIX
diagonal
manner
clutch cover bolts by loosening and 11ft off the clutch cover
gradually
If the clutch factogs are SOiled With 011 or grease clean off With SUitable solvent and dress up With a wore brush If pOSSible If the OIling up IS exceSSive the clutch factogs or the complete
a
In a
plate
must be
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
such as dents and Check the pressure plate for damage scratches and lall smooth If necessary Remove the mtolmum of metal necessary to restore the surface UStog a surface plate check that the pressure plate IS not distorted To do th s place the pressure plate on to the surface plate press down the plate and Insert feeler gauges to determine the gallS between the pressure plate and the surface plate If thiS exceeds 0 1 mm 0004 In I repaor or replace pressure plate The pressure plate
can can
CLUTCH
Dismantling
The only dismantling recommended IS the Diaphragm clutch replacement of the clutch cover If the clutch IS damaged to a further extent replace the complete assembly Cod spring clutch A clutch assembly tool Similar as Illustrated In Fig F 3 should be used to dismantle the clutch The parts Illustrated are 1 Base plate 2 Centre SpigOt 3 Distance pieces 4 Height gauge 5 Operating lever 6 Securong bolts The speCial Datsun Tool has the number ST47990000 Included With thiS tool IS a chart giVing the parts to be used for every
maximum In
amount
of metal that
1 0
mm
0004 D
Clutch spring
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
a
In
from
In
the base
to
the plate
Fig
F 10
plate placed on the clutch press down the clutch by 78 mm 0307 to or until the clutch droven
plate hub
Mark clutch cover the pressure plate lugs and the release levers Remove the restraining hooks previously pushed under the ends of the clutch release levers and unscrew the three nuts from the
IS flush With the edge of the clutch cover mounting face when the applied load should be 350 kg 770 Ibs If less replace the diaphragm spring Do not press the clutch spring down by more than 9 mm 035 In as the spring might break
eyebolts Slowly release the pressure on the clutch COil springs by unscrewing the cover bolts gradually In a diagonal pattern
Lift off the clutch the pressure
cover
Clutch spnngs
plate
CLUTCH INSPECTION
If the load on the assembled clutch IS reduced by more then 15 or the free length of the Call springs has altered by more or the deflection between A and B than 1 5 mm 006 In
In In
Fig
It
F 11
IS more
than
mm
becomes necessary to
replace
Clean all parts With the exception of the clutch release bearing k the indiVidual parts as and the clutch driven plate and che follows
Release
beanng
wear IS exceSSive or a
play
or
there
IS
roughness
37
inter eM
f@ CE p
11
Fog F 1
clutch
1
Exploded
v ew
Clutch
driven plBte
cover
BNI7ngslllflW bNrmg
2 Clutrh 4 5
bolt
Spring Wil3htlr
ner
12
13
Return
llWB Wlthdf
nng 11IWIt
pusher
14 Locknut
11
II
Fog F 2
clutch
Exploded
of
the
cod sprong
tlJ l
OIA 257
Eyebolt
6 EYlIlxJ1t pwot pm
Pnmu rlng q 8 Spnng cop lwet 9 R 10 R
18 Boaring re 9 Clutch 1 lwBrlng 2Q Rfltammg rpnng clIp 21 Oust COIffll U Return IPrlng 3 Locknut
F4
Wthdrwwallwer
pulh
mm
DIA 240 mm
1J
IA 216 DIA
J m
nun
235mm
men
diamsJam
for
the
38
clutch cover to inside diameter clearance IS more then 0 5 mm 0 2 In If excessive grease has leaked from the beanng It should be replaced To remove the beanng use a conventional arm two puller as shown In Fig F 12 be pressed on uSing a force of 400 kg 880 When pressing on the bearing for the diaphragm spnng In race as shown type excert the pressure on the outer F 13 In the case of the coil spnng type the pressure must Fig be excerted on the Inner race as In Flg F 14 After assembly The Ibs
to rubber Clean all parts and check for wear With special note bush and lever Replace parts as pedal parts return spring clutch pedal IS a reversal of installation of the The necessary
the removal
procedure
bearing should
CLUTCH PEDAL
Adjustment
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
8 150
In
Press the pin Into the eyebolt and through the pressure plate lug Place three distance pieces on the surface of the base plate and arrange pressure plate pressure spnngs and retainers on the plate Set the retracting springs on to the cover and fit the release levers through the springs Place the clutch cover over the pressure springs
are
assist spnng push rod to 203 mm for for R H D models and 183 mm 7205 In fitted models the rod only L H 0 by rotating push adjuster With COil Spring type clutch
tighten
the
plate and the springs observing that the pressure not dislodged and not hable to distortion Then In a cover bolts gradually diagonal pattern to
Removal
compress the pressure spnngs Place the release levers over the eyebolts and screw on the nuts after nuts Lock the eyebolt adjustment secunng deSCribed below Push retaining hooks under the release levers and remove the clutch assembly from the base plate slackening the bolts In a diagonal pattern to avOid distortion
Remove the push rod cleVIS Pin disconnect the clutch hose and dram the flUid Remove the cyhnder secunng bolts and hft out the
cyhnder
CLUTCH MASTER CYLINDER Dlsmanthng
Fig Empty
cover
F 18
CLUTCH
Adjustment
the flUid from the reservoir pull back the rubber dust and remove the clrchp Withdraw the push rod together With the retaining nng Unscrew the piston stop screw and The piston can be remove the complete piston assembly dismantled by lifting the spnng seat over the piston shoulder Clean all parts In brake flUid Any damaged or abnormally worn clearance parts should be replaced The maximum permissible between piston and cyhnder must not exceed 0 13 mm 0005 m and as a matter of pohcy the piston cup should be replaced every time them If the piston sprmg
or
USing the height gauge on the centre pillar loosen or tighten the eyebolt nuts so that the tops of the release levers are JUst touching the tip of the gauge Fig F 15 When all three levers In the are correctly adjusted remove the centre pillar and screw F Ig F 16 actuating lever Operate the clutch mechanism
the release lever setting as near to the edge as poSSible If the deViation IS more than 04 mm 0016 In re adJust the levers as necessary Finally secure the eyebolt nuts by peening over the matenal several times and
re check
valve spnng
IS
weak
replace
Assembly
Installation
long chamfered end of the clutch dnven plate sphnes gearbox place the clutch on to the flywheel Use a the spare clutch shaft ahgn the clutch dnven plate by Inserting of the and Into the the dnven pilot shaft through beanng plate flywheel crankshaft Turn the clutch cover In order to bnng In facing
the hne the holes for the clutch bolts In the cover With the threaded holes In the flywheel and tighten the bolts In a diagonal manner 174 188 Ib ft 26 kgm to a torque of 24 Remove the dummy shaft Do not forget to remove the clutch spring restnllmng hooks from under the release leversl Fit the release bearing and the bell hOUSing
IS a reversal of the dlsmanthng procedure All moving parts should be lubncated With brake flUid The piston cup should be soaked In brake flUid pnor to assembly
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
gradually
hydraulic system
CLUTCH SLAVE CYLINDER
Removal
Fig
F 19
CLUTCH PEDAL
Disconnect the flUid line from the slave cylinder and the push rod from the clutch withdrawal lever Remove the two cylinder
Remove the cleviS pin from the end of the push rod and disconnect the push rod end Remove the return spnng the push rod and the push rod adjuster If fitted Remove the pedal lever securing bolt loosen the handbrake bracket secUring bolts and 11ft out the pedal
outthe
cyhnder Dismantling
After removal of the rubber dust cover and the clrclip all parts of the slave cyhnder can be eaSily removed Check all parts for
39
mt e refJJ cQ P f
dla
255
mm
3 3
Fill F 5 Y
of the
hragrn clutch
Fill F 6 clutch
1Iel1SlOn O
ng
Fig F 7
W YIf
Fig
dren
plate
to
the diaphragm
tel
bearIng
Fill F 13
1ng bl
FIlI
40
mter
Q1 O
@ ce l
12L
Fill F 15 AdJuSbng the release I heIght
FIg F 16
to
settle
mechanism
i23
ghtemng torque
35
to
4 0
kg
rn
19
13
15 16
14
CiI
11 JI17J
SectIOn
FIg F 18 cyhnder
2
Cylmder body
R turn r cup
AdJust
by adjust
pedal pedal
screw
of
master
cyt
free stroke 2S
9 Sprmg 28t 10 Valin st em fop t 7 Stop pMctt 12 Gasket WIIwr 13 Push rod 14 Pudl rod C 15 Nut 16 Locknut
VIS
Clip
IINVOlr Rft
ClIP
Cap
INJI
Fill F
Fog F 19 cylinder Exploded
of
20
withdrawal
lever
41
wear
especially
replace
If worn or damaged
NOTE
The correct
adjustment
Aaembly 1nI1nsta11atJon
assembly of the slave cylinder IS carned out in reverse order All moving parts should be the dismantling procedure lubricated With brake flu Id and the piston cup soaked In brake
flUid pnor to assembly
inSUffiCient free travel between release bearing and clutch can failure to cause the clutch to slip Excessive free travel can cause the clutch It IS also Important that the clutch dnven disengage plate IS not worn by more than 20 mm 008 In In thickness
from the
new
dimenSion of 7 8
mm
0 307
In
CLUTCH SYSTEM
Bleeding
The installation IS a reversal of the removal procedure Bleed the hydraulic clutch system and adjUst the free play of the clutch withdrawal lever as descnbed below
Remove the rubber dust cap from the bleeder screw on the slalle cylinder and attach a clear plastiC bleeder hose to the screw a Jar partially filled Immersing the free end of the hose Into With clean brake flUid Open the bleeder screw by 3 4 turn Fill the flUid
reservoir
With
Adjustment
the recommended
flUid
and
pump
clutch pedal slowly indicated by a solid flow of has left the system Into the Jar tighten the bleeder screw on a downstroke of the pedal Remove the bleeder hose replace the dust cap and replenish the flUid reservOir When all brake
air
the locknut screw the push rod fully home whilst turning the adjustment nut and then unscrew by 1 3 4 turns to 2 3 mm 0079 009 In on the give an end play of 20 Withdrawal lever giVing a clearance of about 1 3 mm 0 051 In bet
en
flUid
te t
release levers
the release bearing and the diaphragm spnng fingers depending which type of clutch IS fitted
or
Technical Data
Clutch pressu Free length
re
springs 52 3 292 5
mm mm mm
44
per 100
mm
1 15 In 97 Ib 02 In per 3 94 In
kg
mm
0047
0055
In
PermiSSible deterioration of 15
Height diaphragm flywheel Height between release levers and 505t flywheel
Clutch Pedal
between
spnng and 1 44
mm
In
005mm
In
plate
200 mm 7 87 In 13Omm 5 121n 35vm 0 141n 362 sq
em
Outer diameter Inner diameter Thickness of facings Total fnctlon area Thickness of clutch Free
pedal height In
rest
poSition
182
mm
7 17
In
RHO
56 11 sq
In
plate
86 90 765 795
mm mm
pedal
Compressed
03386 03012
03543 03130
In In
Number of torsion springs PermiSSible mln depth from nvet head to facing PermiSSible
out run
6 03
Mastwr
cylinder
1587
mm
Diameter
mm
5 8
In In
0012
In
o 13mm 0005
of clutch 05
on mm
plate
PermiSSible free play
020 In
0016 In
splines
04 mm
1 0 mm
0 394
In
42
Trouble
Troubles Possible InsuffIcient Improper
lever end all
or causes
Shooting
RemedIes free
Shppmg
clutch pedal
of
travel
adjustment play
on
withdrawal
Adjust
end
play
grease
lmmgs
burned sprmg
or
Remove
cause
of lcakage
and
re
ptal c Immg
DISC
if necessary
tmmg
worn or
Clutch
sure 1
dIaphragm plate
springs weak
or
broken
worn
flywheel
Reface
or
replace
dutch pedal
Adjust correctly
release
play
of WIthdrawal lever
Adjust correctly
Replace Pllot bCarlllg
PIlot bushmg stH kmg Splme of clutch diSC hub Clutch dIsc arped
orn
replace
dutch diSC
aSbcmbly
LcakIng
from
master
cylmdel
cup cup
mflLtratIons
Into
the
hydrauhc
Roughncsb
on
Immgs
Rub
hmngs
WIth
metal brush
or re
place them
Low flmd level
In
011
reserVOIr or
Grabbmg
a l
on
facmg
or
burn cd
glazed
diSc
assembly
faCIngs
Loose dISC
lmmgs
due
to poor
rIvet
Rcplat c
defective rIvets
or
replace
tlghteness
Pressure
or
lmmgs
plate
or
flywheel
arped
Replace
them
cracked
Improper lever
adjustment
of
release
Adjust release
er le
mountmgs
of clutch dIbe tor
Tighten Replace
or
replace mountmgs
damage
dISC
assembly
sprmg
NOISY
Worn
release bearmg
assembly assembly
damage
of
sprlng
Replace
diSC
assembly
43
inter
ilj
p @
JG 1 FI
Daconnectll19 the
remote
control
J
I
l
I
Cw
I
I 1
I
c
9
0
fIr
f
gear
JG FI
10
iifih8
F19 G 12
trail
44
Gea rbox
sPEED THREE
GEARBOX Removal Check the gearbox casmg for cracks and indentations Where the surface IS machmed check for burrs and remove where Jack up the vehicle and support on suitable stands Disconnect the handbrake cable at the equahzer bracket loosen two exhaust pipe centre clips and turn the centre section of the Disconnect the exhaust to the left Fig G 1
pOSSible
Clean all bearings and blow dry With compressed air Without 011 spmnmg the bearings Lubricate the bear lOgs With light Check for wear SCOring or plttmg Check the needle roller bearings for wear As wear on needle rollers IS hard to ascertam them after a substantial mileage has been driven Check
assembly
at the rear end by removmg the flange bolts from the rear axle drive flange and wlthdrawmg the shaft to the rear Seal off the gearbox extension housing to prevent loss of 011 Disconnect the speedometer drive cable Fig G 2
propeller shaft
replace
or scores
Dlsconnectthe lower shift rods from the shift levers and remove F Ig G 3 the crossshaft assembly from the gearbox casmg Remove the clutch slave cylinder Fig G 4 Support the engme not under the dram on a Jack placing the Jack under the sump plug With a wooden block between the Jack and the sump and remove the bolts securrng the rear engine mounting to the
all gearwheel teeth and other machined parts of the the gearwheels for scoring scuffing and plttmg Check that on the shaft sphnes With minimum hubs shde synchronizer
out run Check the ma In shaft for usmg V blocks as out run shown 10 Fig G 18 Replace the malnshaft If the exceeds 015 mm 0006 10
clearance
Support the gearbox on a Jack and remove the crossmember Now lower the Jack under the engme to tilt the engine 10 a rearward direction and remove the starter motor and the gearbox to engme mountmg bolts Lower the Jack and
crossmember
remove
the gearbox
10 a
rearward direction
Check the synchronizer rings for wear and replace If necessary Place the synchrOnizer rmg on the cone of the respective gearwheel and push the two parts together Check that the gap The between the gear teeth IS greater than 0 8 mm 00315 10 0063 In See 1 6 mm 0047 correct value IS between 1 2
SPEED GEARBOX
Dlsmanthng
diagram Fig
Place the
G 19 selector rods
on a
011 Remove the dust cover release the sprrng and remove the clutch Withdrawal lever complete Remove the bottom cover With release bear 109 Fig G 5 speedometer driven pmlOn assembly and the rear extension
gearbox
flat
surface
to
check
for
retainer
straightness Check locking pms and mterlocklng balls for damage or wear The standard clearance between the selector
forks and the operatmg sleeve groove 0012 n Check 011 seals for have been checked
wear or IS
0 15
0 30
mm
0 006
hOUSing
Fig
Item
G 6 5
Remove and
remove
the
cross
shaft
retaining rings
the operatmg lever lock pms Usmg a drift knock the pins out of poSition and remove both cross shafts Fig G 8
Fig
G 7
the nuts
holding
removed
Fig
be
front cover and Withdraw the countershaft Lift out the countershaft gear cluster together With the needle roller bearings and spacers Fig G 9 Remove the reverse Idler gear shaft lock bolt and remove the shaft followed Remove
the
Iayshaft
Assembly
bearing
on
to
the
maIO
the Idler gear Fig G 10 Drive out the pms holding the selector forks to the selector rods unscrew the Interlocking plug and remove the spring and the detent ball as shown 10 Fig G 11
by
fit the spacer Select a clrchp so the bearmg and the clrchp There are 7 sizes of clrchps ranging 10 size from 1 52 mm 0 06 10 to 1 89 mm 0 075 In
remove the selector rod for frrst reverse 2nd 3rd speed and hft out the two selector forks
Then
speed
and
Withdraw the maIO shaft assembly from the rear and the drive shaft assembly from the front of the gearbox case Fig G 12 To dismantle the mamshaft remove the clrchp from and G 13 the front of
assembling the synchronizer untl take care that the msert pressure springs are of different size for the 1st reverse and 2nd 3rd speed synchronizers The spring for the reverse l st speed Unit has three Call springs whereas the other uses two
When
synchronizer second speed the speedometer drive wonn and remove the worm gear FIg G 17 Press out the together With the ball and spacer mamshaft bearing under a press Holdmg the shaft With the
ma
mamshaft and remove the fig G 14 Unit for the 2nd and 3rd speed Fig G 15 and the gearwheel Fig G 16 Remove the clrchp securing
the
speed synchronizer Unit msert the clrclips mto the hub as shown 10 Fig G 22 followed by the reflttmg of the shdlng inserts and synchronizer Springs F It the hub complete With Inserts IOta the operatmg sleeve Fig G 23 and G 24 slidmg
msert
mshaft
releaSing gearwheel
reverse gear tap the shaft With a piece of wood so the reverse gear assembly together With the 1 st speed
To assemble the 2nd3rd speed synchronizer fit together With hub and the operating sleeve ensuring that the sleeve shdes
freely
ring THREE SPEED GEARBOX
on
on
the hnes Fit the three Shifting each side of the hub Frg G 25
keys and
frt
SPring
InsplKltlon
as
Thoroughly clean all parts and mspect repairing any defective parts
follows
replacmg
or
To assemble the mamshaft start from the front end of the shaft and slide the 2nd speed gearwheel on to the shaft With the cone facmg forward Fit the correspondmg baulk ring Place the 2nd 3rd speed synchronizer assembly on the front end of the 0 20 haft and IR With a Clrollp giving an end play of 0 6 45
y
i
Removal of the maIn drove shaft FIg G 13 clutch shaft
Fig G 14
speed
1f
r
I II
f
FIg G 16 Removal of the 2nd speed gearw
Ii
VJ
FIg G 19
wear
lV
rIngs for
FRONT COVER
CD
REAR EXTENSION
on
CROSS SHAFT
the geaTbox
F gG 22
e
ns1allatoon of the
In
Fog G
23
ehp
on
to the
46
mm
0002
0009
In
Clrcllps
0071m
are
available
160
180mm
0063
Fit the 1 st speed gear and baulk ring on the rear of the shaft wIth the COnical end facmg the rear F It the first speed
reverse
gear assembly
on
the shaft
Follow the mstructlons for the three speed gearbox except that s a floor mounted gearlever whIch the four speed gearbox should be removed at the control lever bracket FOUR SPEED GEARBOX NOTE There
In
Fit the spacer and press the mamshaft bearing and retamer on the shaft FIt spacer ball and speedometer drive worm uSing a S JItable Clrcllp to secure the drive worm With an end float of 0009 m 005 022 mm 0 002 Clrcllps are avaIlable m 8
sizes
DIsmantling
used
m
gearbox
deSCribed
Borg
from 1 30
1 70
mm
0051
0067
thickness
m
synchromesh
thiS
IS
Check the end float of the whIch should be as follows 1 st speed gearwheel 2nd speed gearwheel Fit the
mam
gearwheels
as
shown
Fig G 26
005 o 1
022 022
mm mm
0002 0004
0009 0009
m m
Dram the gearbox 011 Remove the dust cover the retainer spring Withdrawal lever and clutch release bearing ove the Rem cleVIS pin holdmg the strlkmg rod to the control lever F Ig G 311 speedometer driven p In Ion assembly rear extension housmg dlsengagmg strlkmg rod from the selector rod gates
see
Fig G 32 and
unscrew the
covers
and the mamshaft drive gear clutch shaft assembly mto the gearbox casmg Fit selector rods and selector forks as follows Turn the casmg so that the detent ball hole IS uppermost Fit the spring and the ball m the bottom hole Fig G 27 Hold the ball With a dummy shaft and fit the 1 st reverse selector fork
Unscrew the detent ball plugs and remove the springs and detent balls Drive out the selector fork to rod retalnmg pinS and remove the selector rods and forks Engage the second and fourth gear by pushing the operatmg sleeve of the correspon dmg synchronizer unit to the given gear pOSItions and slacken the main shaft nut Remove the countershaft and the gear cluster together With the needle roller bearings and the spacers Remove the reverse gear clrcllp and remove the reverse Idler gears and the shaft
two
pushmg the dummy shaft out F It the Interlocking plunger 2nd 3rd speed selector fork and rod and Insert the ball and the spring Screw down the mterlockmg plug coatmg the thread With sealing compound Secure the selector forks to the
and the rod rods With the retalnmg pins Fit the
reverse
Fig
secure
G 33
and
Remove the four bolts holding the malnshaft bearing retamer remove the retamer Fig G 341 Withdraw the mamshaft
as
00016 403
assembly
shaft
shown
In
main
drive shaft
clutch
0 151
Washers 0159 In
sizes
from 383
thickness dismantle the malnshaft Fig G 36 release the 3rd 4th synchrOnizer Unit clrcllp and pull off the hub complete With the operating sleeve Remove the third speed gearwheel and the needle roller bearing Remove the mam shaft nut and the locking plate and the speedometer drive worm With the retamlng ball Then WIthdraw the mamshaft reverse gearwheel and the hub and press off the ma Inshaft bearing retainer and the bearing To the thrust washer and the first speed gearwheel With the needle roller bearing taking care not to loose the small thrust washer locating ball Slide off the first speed Next
remove
Fit the cross shafts 11 Fig G 7 thrust washers 2 and operatmg levers 3 Secure cross shafts With retammg rings 5 and lock the operatmg levers to the shafts With the pms 4
extension casmg to the gearbox case and tIghten the 30 kgm 16 22 Ib ft Fit the torque of 22 speedometer driven piniOn set bolt and lockrng plate Check
rear a
Fit the
bolts to
as
shown
rn
Fig
for all gears FIt the front and tighten the bolts to 1 1 1 7 kgm 8 0 12 2 Ib ft the clutch Withdrawal and release bearmg and the bottom
In
0 005
Refit
cover
together
tlghtenmg
123 Ib ft
the bolts to
torque
readmg
of 1 1
1 7
kgm
80
gearwheel bush
Finally
remove
the second
speed gearwheel
together
THREE SPEED GEARBOX Installation reversal of the removal Follow
Inspection
three speed given
The mstallatlon of the gearbox IS procedure Note the follOWing pomts Fill the
for
the
gearbox
m
In
accordance
With
the
speCifications
section
TECHNICAL DATA
gearbox
IS
capacity
With the recommended MP 90 011 The flllmg 1 7 IItres 045 U S gall 0 37 Imp gall AdjUst the
clutch slave
cylinder push
mm
rod to obtain
Assembly
play of
2 2
0087
The assembly IS carried out m Similar manner as deSCribed for the three speed gearbox except for the followmg pomts When
mstalllng
the
mam
drive shaft
clutch shaft
are m
select
SUitable clrcllp to eliminate any end float Clrcllps m 5 Slles from 1 52 1 77 mm 006 007 m
available
thickness
47
inter
M @
1i
FI9
2S Flttlll9 the SPring rongs FI9 G 26 Chedung the end float of the gea eels
FI9 G 28 backla
gear
FI9
G 29
and release
Greasing beanng
POlllts for
withdrawal lever
J f
z
J
I
Fog
G 31
VISW
arm
F G
33 Removal of the
ne
ler geara
Po
pOlello t
I
FigG 38 Exploded
tram
v
FIg
34
Fog
35
a1 of the
r rete
malllshaft
ly
48
ImmIIII
4t1l 3rd Rod
Spring Plug
Plunger
Plunger
FIg n Dlllnm of tile G
Idler FOr
to
show
FIg G 42
bracket
Remoyal
of
the
upper
support
01
49
The Borg Warner type IS dealt with under the three speed gearbox The instructions therefore apply only to the Servo type synchronIzers The assembly procedure
Synchronizer assembly
and take off the upper support bracket by releaSing the locating bolt and the screw The control rod Insert With bush and return spring
IS now
free to
remove
for all synchronizers but the anchor block thrust block and one brake band of the 1st speed synchronizer dIffer from those of the 2nd 3rd and 4th speed
IS same
the
Remove the clrcllp and gear lever piVOt pin and draw out the gear lever By removing the cotter pin the spring and the plain washer disconnect the shift rods from the gear selector levers
Place gears on flat surface fit the synchronizer ring inside the clutch gear and fIt the thrust block Into positIOn anchor block to each gear and fit the brake bands I nsert a clrcllp Into the groove of each gear When
so
Fig G 43 Remove the bolts holding the lower support bracket and the clamp and remove the clamp and the gear change lever retainer 2nd 3rd speed selector lever lower support bracket and 1 st and reverse selector lever from the control rod
Withdraw the control rod by removing the cotter pins DIsconnect the gear change rods remove the cross shaft bracket and Withdraw the cross shaft assembly Fig G 44
assembling the malnshaft observe that the end float of the 3rd speed gearwheel should be 005 0 15 mm 0002 0006 In ClrcllPS for adjusting the end float are available In 5 sizes
from 1 40 1 60
mm rear
0055
0063
In
In
thickness
Tighten
65 GEAR CHANGE CONTROL LINKAGE InstallatIon
11 kgm
reverse Idler gear Fig G 37 place the reverse Idler drive gear 31 14 teeth on the rear end of the Idler shaft 1 with the longest spline and retain with a SUitable Clrcllp 2 Fit the reverse shaft and the gear Into the gearbox casing from the rear with the thrust washer 4 between the gear and the
The installatIOn of the gear change control linkage IS carned out In reverse order to the removal procedure Coat all sliding surfaces With chaSSIS grease prior to assembly
18 teeth 51 and the Idler gear 6 and secure with a SUitable clrcllp 2 The end float of the gear should be 0 1 03 mm 0004 0012 In ThiS can be adjusted by uSing a SUitable clrcllp 2 available In 5 thicknesses between 1 5 mm 0 043 0 06 In 1 1
case
Adjustment
With the linkage assemb led connect change rods With trunnions of the gear change levers Release the adjusting nuts on the shift rods and align the gear change lever With the projection on the head of the lower support bracket F Ig G 45 Check operation of the change levers and lock the adjustment
Adjust
006
In
the countergear end float to 005 015 mm 0002 by uSing thrust washers of SUitable Size which are
In
available
In
5 thicknesses from 2 4
2 6
mm
0 0945
0 102 To
remove
AUTOMATIC TRANSMISSION the gear change control linkage of the automatic follow the removal of the three speed gearbox
as
When
mechanIsm
Fig G 38
fIt the
transmission
selector forks 1st 2nd 1 and 3rd 4th 2 Into the operating sleeves of the synchronizer Units and Insert the selector fork for the 1 st and 2nd speed 3 Fit an interlocking plunger 4 and the 3rd 4th
IS
linkage
as
for
speed
selector
rod
remembering
the
interlocking pin A
mechanism for the
section
through
interlocking
given In Fig G 39 Frt an interlocking plunger 6 and assemble the reverse selector fork 8 and the selector fork
same
By removing cotter Pin plain and spring washer disconnect the upper selector rod from the selector lever Remove the speed range pOSition plate the Clrcllp at the lower control rod end and unscrew and remove the lower support bracket Release the locking
screw
gear
9 10
F g G 46 rods and
and remove the selector lever assembly Withdraw the control rod disconnect the selector the
cross
remove
cross
shaft
assembly
a check ball and a spring In each of the holes and screw down the plug to a torque of 1 7 21 kgm 123 15 21b ft after smearing the threads with sealing compound
The
When
fitting the rear extension hOUSing engage the striker rod with the selector rod gates and tIghten the bolts to 2 2 30 16 22 Ib ft FIt the front and bottom covers and kgm tighten the bolts to 1 1 1 7 kgm 18 0 12 3 Ib ft
AUTOMATIC TRANSMISSION
InstallatIOn of the linkage IS a reversal of the removal Set the converter s de lever and the gear lever to the neutral pOSition Fit the upper selector rod to the selector lever and adjust the gear positron plate so that the selector lever stop
procedure
1 0 mm 002 004 In pin to pOSitIon plate clearance IS 0 5 ThiS can be adjusted by turning the selector rod adjusting nut
nut
on
Although
manual
a as
the
automatic transmiSSion
IS
not
covered
IS
In
thiS
Job
the maintenance
conSidered
Removal
follOWing
cowl
Items
wheel and
steering
column
indicator
Fig light
G 40 swItch
Fig
G 41 d
Remove the
clrcllp
Fig
50
Technical Data
GENERAL SPECIFICATlor S Gearbox model RSW65L Column F4W63L Floor change Warner 33821 F4C63L Floor change Servo 3 382 1 20131 1312 1 10001 33641 22 27 30 36 39
change
Warner 32631
Borg
Borg
on
30 24 15 16 16
31 29 21 15 14 18 5
or
31 29 21 15 14 18 5 16
Speedometer
5 19
17
16
Model Mamshaft end float Max mam shaft end float Cou ntershaft end float Max countershaft end float Reverse Idler gear end float Max Idler gear end float Gearwheel end float 1 st speed gearwheel 2nd speed gearwhee 3rd
R3W6 o 019
mm
mm
0012m
mm In
0005 0002
m
015
mm
0008
mm
040
mm
0008
m
0016
0 008 m 0 30 mm 0 004
m
0012m
0 020
speed gearwheel
0003
m m out n
0002
0 10mm 0002
mm
015
0006
0010
51
inter
r1D
p @
FIg H 3 Removal
member
of
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
DIFFERENTIAL
Dismandlllg
Items
rear end
outer section clamps and turn the to the left saloon pre sl lencer only Remove the adjuster nut from the handbrake cable rear adjuster and dlsoonnect the hand left cable Saloon only D soonnect the rear from
Loosen
a suitable mounting stand Special tool ST 37400510 IS available and check the tooth contact pattern uSing a lead OXide at two or three points
flange
The backlash between the dnve gear and pmion should be 0 10 20 mm 0 004 0 008 In 0 Also check the out run at the rear of the crown wheel If the backlash or the tooth contact pattern IS found to be out of limit IS 008 mm out run adjustment The 0 003 In The turning torque of the drive pin
on
the rear axle flange and draw the shaft from the gearbox ma Inshaft taking care not to damage the propeller shaft by
accidentally dropping
It
should be 3
15
kgem
DIsmantling
al components for assembly 10 correct ma rl position Remove four clrcllps from the Journal assembly and Withdraw the needle beanng cap by tapping the yoke With a wooden mallet Clean all partS and check damage has occured The
as
To dismantle the dlfferent al remove the flange clamp bolt and remove the Side flange as shown In Fig H 4 uSing the special tool ST49250000 and a slide hammer or any home made tool Similar
as
shown
In
remove
the differential
wear or
nght hand Side first as shown In Fig H 5 Mark the beanng camers In order to refit them In their onglnal pOSitIOns The dlfferent al assembly can now be lifted bearing
caps differential from the dIfferentIal
carner
f F Ig H6
spider Journal
In
0006
The standard
spider
seal nngs backlash of the sleeve yoke splu1es to the not exceed 0 5 mm 0002 In
diameter wear should not exceed 0 15 mm size IS 147 mm 0579 In Check the and replace them If necessary The radial
Loosen the dnve pinion nut holding the flange With specIal tool or by other SUItable means and pull off the flange Press the drive pinIOn out of the differential carner together With the front and rear beanng Inner races spacers and shims
ST47340000
Place
With the shaft mounted between centres check the runout of the shaft which should not exceed 06 mm 0023 In The shaft can only be straightened With a hydraulic press however
It
SUitable press plate between drive pinIon head and rear and press out the pinion shaft If the correct tooth pattern has been obtained dunng the d smantllng check and pre crown wheel dnve piniOn carner rear beanng shims etc are
a
bearing
not
recommended that the shaft be replaced Also check that the dynamiC balance does not exceed 15 gnn em 0278 oz 10 at 4000 rpm
IS
remove
Inner races are not to be removed o T of the front and rear pinion bearings special tool ST49290000 or any SUitable
PROPELLER SHAFT
Reverse the removal and
Assembly
and Installation
dismantling
To dismantle the differential cage remove the right hand bearing cone as shown In Fig H 7 uSing a SUitable puller Flatten the lock straps and remove the hYPOJd crown wheel slackening the mounting bolts In a diagonal pattern Remove the left hand beanng cone In the same manner as for the other Side Take care not to mile left hand and right hand pans Punch out the differential shaft secUring pin from the crown wheel SIde USing a SUitable drift Great care should be taken when carrying out thiS operation as the pin is caulked Into the hole In the differential cage Remove the differential gears and thrust washers keeping separated front rear left hand and nght hand parts
procedure
fellowing points
Grease the needle
rollers WIth the into the
noting the
wheel bearing grease before placing bearu19 race Lubncate all splines With gear 011 AdjUst Journal radial end float to less than 0 02 mm 0 0008 in with a suitable circllp which are available In 7 SIZes between 2 00 and 2 12 mm 0 079 and 0 0835 In In thickness Check that the marl on the front sleeve aligns With the marl on the
rear
flange yoke
Replacmg of oil
DIFFERENTIAL Saloon Removal Front 011 seal
Remove the handbrake rear cable propeller and dnve shafts With differential suPPorted on a Jack remove the nuts securing the differential mounting member cross and remove the bolts
holding
the differential to the suspension member Remove the differential and the jack backwards and suppon the SUspension member to avoid straining the parts The removal of the parts to be remoyed Is shown 10 Fig H 2 and H 3
Drain the OIl Jack up and suppan the rear end of the car and remove the propeller shaft from the differential flange and dISCOnnect the hand left rear cable for the handbrake Slacken and remove the dnve pinion nuts holding the dnve flange In suitable manner and remove the flange and the oil seal retainer With a conventional ann two puller as shown In Flg H 8 Remove the 011 seal from the retainer
Replace the
outer diameter or
oil seal into the retainer USing a drift of SUitable special tool ST 49320000 Fill the od seal lips
63
inte r
clJ e
C0LID
6
90H12 F 90H F
I
11
prHoad
Pinion
2 Pmlon dopth
611
lItIJ
ol
Tlf htenlntJ ofpln nut 17 201 11 J 145Ibft 4 fo PtNOtKJ piNon betftntJ without 00 7 IS1 721b ft J 10k 5 Anion bHnng 1IdJU
or
Ii
Amon P8Cf I
lng u IId
90H F
16
Adjsutllll
far
dlff8nntJal
side
cowen
4 Gl
lo
90H F
co
17
The G
maJtuJ18S
of the
dlffwentJal side
FigH 19 ChecIung
wheellDI priOR
the
backof the
54
with grease Fit the oil seal retelllBr end refit the other parts In reverse order to the removel procedure
Also press the outer races of the front and rear pinion into the differential carrier USing a suitable press mandrel cage
beanngs
Acljustment
Fit the
Inner
of drive
pmion
load pre
Inspection
or
follows and
replace
repair
where necessary
Gear teeth for sconng cracklllg and excessIVe wear Note that the dnve pinion and crown wheel should be replaced as a set 2 Gear shaft
excessive
pinion herght adJustlllg washer shlTIS and rear bearrng a dummy shaft as shown In the diagram III Fig H ll Special tool 49300000 If the tooth contact has been satisfactory when It was checked before dismantling use the old washen and shims Then fit the dnve pinion bearing spacer the washer and the special collar ST49310000 and the dnve flange on the dummy shaft and tighten the dnve pinion nut to a torque reading of 17 20 kgm 123 144 5 Ib ft Replace the beanng washer and the spacer with thicker ones If the pinion cannot be turned by hand when the nut IS tightened
rece on
bearrngs
and thrust
washen for
Chipping
or
Measure the drrve pillion bearing preload and select wash en and spacen to give a preload of 7 10 kgcm 972 138 In oz 83 3 In oz for used With new bearrngs or 3 6 kgan 41 7
wear
bearings Flg H 12
between the differential Side 0 008 In IS over 0 2 mm gear and and the
The
preload
should
be
measured
as
shown
In
If the
backlash
differential pinion
AdJustment
of
of mesh
clearance between the differential Side gear and the thrust washer IS over 0 3 mm 0 012 III replace the thrust washer which are available in three thicknesses 4 Measure the out run of the crown wheel at the rear face USing a dial IIIdlcator The permiSSible value IS 008 mm 0 003 In Replace the crown wheel and drive pinion as a set If thiS value IS exceeded Differential distortion 6 In
carner
dummy
Fit the settlllg gauge ST49300000 Into the houslllg With the pinion Installed and measure the clearance between the head of the dummy shaft and the tiP of the setting gauge by means of a feeler gauge as shown In Fig H 13 Flg H 14 shows for the adjustment The dnve pinion adjusting shim S can be found from the follOWing equation S W T H
x
0 01
0 20
and differential
cage
for cracks
or
where W Thickness of Inserted washers and shims Measured thickness Figure engraved In pinion head
general replace
T H S
ReqUired thickness
a
DIFFERENTIAL
ASIlImbly
and
Adjustment
note
As W T H S
to
of the
2 20
024mm 2
thoroughly
sealing lips
order clean all bearings With gear 011 Pack of the 011 seals With grease
In
correct
3AO
0 24
0 01
020
3 46
mm
reqUired
to
the drive
pillion fit
the rear
bearrng
pinion
Fit the differential Side gear and the bevel gear III the cage using the correct thrust washers Insert the differential shaft so that the hole for the secunng pin III the shaft IS In line With the hole in the dlfferentral cage Measure the clearance between the rear face of the side gear and the cage as shown III Flg H l0 and If necessary mange the thrust washer to obtain a 0 2 mm 0 004 Fit the pinion clearance of 0 1 0008 III shaft lock pin and secure It with a punch by caulking the ITllterlBl of the differential cage Lubricate the gear teeth and check the gear for freedom of rotation
beanng bearing
the drrve pillion and press home Fit the drrve Into the differential carner throat together With the spacer and washer front beanng Inner race and front spacer followed
by
the
beanng
flange
mange
the parts With the pimon nut 20 kgm 1122 9 144 6Ib ft
and the washer on to the drive pinion and the nut to 17 lhtening tl
Acljustment
If differential
been shims
carTIer
Fit the crown wheel to the differential cage and tighten the bolts to a torque reading of 7 0 80 kgm 50 6 67 8Ib ft Use lock straps
re
replaced adjust
cage side bearings or bearing covers have the side bearing pre load With adjusting The exact thickness of the shims IS obtained by the
following equations
T1
Might
the width of the differential side bearings by placing e of 2 6 leg 6 5 lb on the bearing The nominal width IS
left
A 8
T2
rrghtl
D F
E H
H
x
x 0 01 0 76 0 01 076
00 mm 20
0787 In
Press the
bearfngs
on
to the differential
56
interl
iill
p m
TOE
TOE
TOE
fr
HEEL DRIVE
SIDE
HEEL SIDE
DRIVE Tooth co
HEEL
DRIVE
SIDE F 22 Tooth H
co
21 FIlI H
TOE
TOE
56
where A C E B D F The
removal
procedure
figure
The figure
Imp pts
08 US qts
08 IItres
1 3
G H Measure
The difference m width of the left hand or nominal width of 20 right hand bearing agamst mm 07874 m gIVen m 11100 mm The figure on the differential bearmg cover
DIFFERENTIAL
Ramoval
Wagon
Fig H 17
The the
to
figure
etched
In
differential
a
mstrument
placmg
brmg
m
bearmg
F
bearing Width with a suitable on top of the load of 2 5 kg 5 5 Ib under load and determme the value En or
shaft pm Ion flange from the propeller refer to section the axle shafts and remove rear yoke flange Unscrew the differential REAR AXLE for thiS procedure carner from the front of the rear axle and 11ft out
DIFFERENTIAL
Dismantling
shown pinIon
FIt the differential cage assembly mto the differential carner Insert shuns and 0 rmgs mto both differential bearing covers and fit the retamers by screwmg the gUide studs ST49330000 or two other sUItable pilot studs mto the differential carner H 18 Measure the tooth backlash as shown m Fig H 19
Clamp the differential carner Into a SUitable support as m Fig H 26 and Inspect the tooth contact and the drive depth before attempting to dismantle the differential
Remove the
Fig
0008 In and adjust It to 0 10 0 20 mm 0004 backlash IS not sufficient move shim from left to excessive from right to left Check
cover
right
If the If
the drive pinIOn turning torque and adjUst the bearing 3 kgcm shims to give an Increased turning torque of 1 compared with the value obtained when thiS was checked before the differential cage was fitted to the carner If any of the shims must be removed
or additional shims must be fitted It becomes necessary to readjust the backlash
Side bearing caps and the differential cage See left and right hand parts separate assembly Bend Fig H 27 Remove the Side bearings With a SUitable puller back the locking straps for the crown wheel mounting bolts and remove the crown wheel bolts Fig H 28 Now measure the backlash between the differential Side gears and pInions Drive
Keep
out
the lock pin for the differential pInion shaft from left to and the right and remove the pinion shaft piniOnS Side gears thrust washers Measure the turning toque of the drive pinion In the differential carner uSing a SUItable pre load gauge and check the drive mesh depth uSing the special tool set ST46200000 Note pinion the values and write down for later reference
Tooth contact
By applYing Prusslan Blue to 4 or 5 teeth and turning gears evenly back and forward by hand check the crown wheel and drive pinIOn tooth contact pattern and adjust as follows Fig H20 Increase the thickness of the drive pinion shim and the washer to brmg the pin Ion closer to the crown wheel
Heel contact Toe contact Fig H 21 Reduce the drive pinion shim and washer thickness to pinion away from crown wheel Flank contact Fig H 22 ThiS pattern should be treated Face contact Fig H 23 ThiS pattern should be treated
Remove the drive pm Ion nut and the flange and tap out the drive pinion shaft to the rear With a plastiC mallet together With the rear bearing Inner race spacer and adjusting washer out Remove the 011 seal and the front bearing Inner race Draw and rear beanng outer races front uSing speCial tools ST47820000 and ST46310000 as shown In Fig H 30 Also remove the drive pinion rear bearing mner race With the speCial If these tools are not tools ST47120000 and ST46320000 available It
move
might by pOSSible
to
use
as
thoroughly
and inSPect
as
follows and
replace
or
necessary
as
for heel contact Cbeck the parts as deSCribed for the Saloon differential With out limit for the crown wheel IS 0 05 the exception that the ru n m the clearance between differential Side gear 0002 and mm and thrust
m
Correct contact Fig H 24 A correct tooth contact IS obtained when the Impression lies within 2 3 to 3 4 of the distance between the tip and the root of the tooth under If shims
or no
available
check the tooth
IS
Thrust
washers
are
washers
changed
crown
wheel backlash
stIli
DIFFERENTIAL
Assembly Fig H 33
of the
and
Adjustment
DIFFERENTIAL
Installation
The 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
Fig
H 25
Fit the
remamlng parts
reverse
order
to
the
Fit the bevel pmlons differential Side gears and thrust washers mto the cage selecting SUitable thrust washers to give a 0 20 mm 0 002 0 008 In between the clearance of 0 05 Side gear and the thrust washer Fit the pinion shaft lock pin
inter
i1 l
PJtE 1D
H 30
I of
tile
pllllOii mv
Ass y
beanng
dlf ereratl al ide
duvt piniOn
31 H F Exploded bly
of d
crown
wheel
for
58
mte
E illj r
P @
dnn pIJUOD
DC
17 k 120
100
to
lb Ct
13
cm q
Gear
ratio
TIhrenma
6
torque
dtff bolt
3SP A
3889
ap 42 to 48 30 to 34 7 ft lb l b
kg m
D
C
4SP 3700 1
FIgH
carr
SectIon
through
the
dofferentl8l
FIg
H 35
CalculetlOn of the
differential side
lbeenng s ums
Fill H 36
IIlIe
entud drtt
s Me ng the
n dlmen
69
from the nght hand Side and peen the secure the prn 10 posItIon
edges
of the hole to
should be 10 and
a
13 kgcm
138 9
180510
oz
for
new
bearings
FIt the crown wheel to the dIfferentIal cage usrng 8 straps and tIghten the bolts to a torque reading of 4 34 7 39 8 Ib ft
10 a
new
lock
less for used bearings Check the plnton value of 20 40 depth and re adJust If necessary Remove the pInion nut and the flange and press the 011 seal well greased IOta the dIfferentIal carner RefIt the flange washer and the pmlOn nut 130 and tIghten the nut to a torque of 14 17 kgm 101 Ib ft If the holes for the spltt pm WIll not altgn WIth the
5 5
kgm
agonal pattern
the special beanng press mandrel ST49260000 or a dnft wIth SlJttable dimenSIons press 10 the SIde beanngs lOner race Fit the crown wheel adjusting shIms behind the bearings to obtain the correct preload After rnsertlng the correct shIms
USing
use a
usrng special the dnve plmon rear bearrng or any mandrel WIth SUItable dImenSIOns Also press the plmon front beanng outer race IOta the pmlon housmg and the rear beanng Inner race on to the dnve plmon press
10
outer
race
replacer ST 47820000
FIt the dIfferentIal cage IOta the housmg tapprng Itdown With plastIC mallet as shown m FIg H 34 and fIt the dIfferentIal bearing caps Tighten the cap bolts to 4 2 48 kgm 30 4 34 7
a
Ib ft
shaft
Adjustment
AdJustmg the dnve pinIOn
of d fferentJal
beanng
10
preload
determme the dnve plmon shIm thIckness fIt the drive lOner race and pm Ion Into the housrng and fit the front beanng the flange TIghten the dnve pmlon nut untIl the dnve plmon 1389 1805 10 oz Now 13 kgcm turnmg torque IS 10 rnstall the dnve prnlon settmg gauge and measure the gap between the pinion head and the gauge as shown 10 FIg H 29 The obtained value IS the pinion depth To To determine the exact thIckness of the shIms
use
AdjUst the dIfferentIal bearing pre load followrng formular see Fig H 35
Left Side Tl A
the
follOWing equatIon
T N H
x
T11T2
A a 0 25 02 C D
Shim thickness
required
on
10
Units
of 1 1000
10
Figure marked
respectIve
differentIal beanng
hOUSing Figure
where T N H The
ElF
required
rear
In
on differentIal cage dIfferentIal beanng differences of thIckness to nommal thIckness of 20 mm 07874 m In Units of 1 100010 under a load of 25 kg 55 Ib
marked
Respective
mllltmetres The gap measured above 10 mllllmetres The figure marked on the dnve prnlon head ThIS eIther
a or a can
FIg
be
H 36
figure
Measure the crown wheel and pinion backlash FIg H 37 and adjUst to 0 15 020 mm 0006 0008 m by movmg the SIde bearing shIms from the left to the right If too small and from
If necessary adjust shIms by removIng the dnve pInion and the and bearing spacer rear bearing outer race FIt the dnve pmlon a torque IOta the pmlon housmg and tIghten the plmon nut to 130 Ib ft Check the pInion pre load by 101 of 14 17
right
to
readmg
ot 4 2
bearing
kgm
attach 109 a preload gauge to he prnlon flange and adjust to the bear 109 correct value by selectrng spacers three sIzes and Inner the front 15 sIzes between beanng adJustmg washers 011 seal race and the spacer The Inlt al turnmg torque WIthout 130 Ib ft 17 kgm 101 and drive prnlon nut tightened to 14
or specIal tool ST46380oo0 measure the dImenSIon between the outSIdes of the bearing caps as shown 10 Fig H 38 If 19855 mm 78110 78169 m which should be 1984 less It should be corrected by msertlng shIms of 0 05 mm 0002
micrometer
out run IS less than I on both Sides Check that the dnve gear 005 mm 0002 In I Finally check the tooth contact pattern as described for the Saloon dIfferentIal In
60
Technical Data
PROPELLER SHAFT
Length
Outer dIameter Inner dIameter
1082 mm 426 In Saloon models 1242 mm 48 9 In I Estate car models 635 mm 25 In Saloon models 750
mm
Thickness of pmlon heIght adJustmg washers ThIckness of pinion heIght shims ThIckness of pmlon Saloon Estate
car
2 0 2 2 24 mm From 1 09 1 27
mm
30
In
Estate
car
models
As Saloon
AXIal play of spIder Journal out run Max of shaft Wear limit of spIder diameter Max unbalance 15 gr
00315ml
m In
06 mm 0024
mm
0006
0 278
In oz
at
4000 rpm
o 10 015
0 20 020
mm mm
0 004 0006
0 008 0008
m m
FINAL GEAR RATIOS Run out of 1 3 Ittres Saloon models 1 6 lItre engine Saloon With 3 speed box Saloon With automatic Saloon With 4 speed box Estate car WIth 3 speed box Estate Estate With automatIc car With 4 speed box
car crown
Saloon Estate
car
Less than 0 05
0003 0 OOl
In In
Estate
car
mm mm
0506 0 723
models
0723 Ib ft I 0940 Ib ft
Clearance between Side gear and washer Saloon 0 10 0 20 Estate car 005 0 20
mm mm
0004
08 00
0008
10 m
0002
centre
models
48 5 610
mm mm
1 909 2402
In m
61
ImDIIIII
I
J
8
tt I
i
c
0 f 1 r
i Y
f 1l
IJ
jjJ
jf
YI
II
AiI
0
r
I
FIg I 2 Parts to be removed
t
or
j
dIsconnected for
unit
Front
O ff
mountmg member
FIg I 3
shock absorber
Fig I 4
Removal
as
of
rear
axle
and
rear
mounting
suspenSion
complete
Unit
I nstallatlon
rear
diagram for
suspension
6@
jj
1
l cod ring
Fig I 6
nuts
FIg I 7
Exploded
vIew
of the
rear
F g 1 11
Removal
of the
rear
wheel
Fig I 10 of
the Or coli sprln9
Removal of the
rear
SIIspel1Slon
ann
bearing
nut
Filii 9
Removal
62
Rea r
DESCRIPTION The Saloon models
semi are
Suspension
COIL SPRINGS Check Installation
rear
fitted WIth
arms
fully Independent
arms
COIl sprrngs traIling suspensIon suspensIOn WIth and telescopIC hydraulic double acting shock absorbers The final drrve Untt IS mounted to the suspension member by four bolts and rubber Insulators The Estate Cars
rear
the sprrng for YIeld deformatIon and cracks Test the and compare the results WIth the information In sprrng TECHNICAL DATA Check the rubber parts for deformatIon
or
If necessary
The installatIon
StatIon
floatlng semt Wagons are fItted With a elltptlc leaf sprrngs and telescopiC hydraulic
procedure
IS carried out In reverse order to the removal ensunng that the flat face of the spring IS at the top
Removal
Remove the boot trrm assembly and the two securrng nuts from Remove the the upper shock absorber mountIng Fig I 8 shock absorber from the lower mountlng bracket and Itft out Test the shock absorber If faCIlitIes the results With the specIfications Check for 011 leaks and
are In
Jack up and support the rear end of the car on Remove the wheels handbrake linkage and return spnngs exhaust tat pipe and Silencer DIsconnect the brake hose from the tube Remove the propeller shaft from the differential The parts to be disconnected from underneath the Refer to
Fig
I 1
SUitable stands
cracks and
straIghtness Check the rubber bushes for deformatIon and replace If necessary
The mstallatlon
IS a
Jack up the suspension arm and shown In Fig I 2 the shock absorber from the lower arm Fig I 3 and retain the rubber bushes Support the dIfferential unit and the suspensIon With a Jack and remove the suspension member
car are remove
REAR SUSPENSION ARMS Jack up the car and place the dlscpnnect the follOWing parts shaft from axle shaft and wheel
rear
Removal
securrng nuts and the nuts secunng the differential mounting Carefully lower the suspensIOn Untt Fig I 4
SUSPENSION
InspectIon
ExamIne all parts for wear and damage WIth special attention to the rubber bushes In the suspensIon arms and bump rubbers sprrng msulators and rubber Insulators In suspensIon Untt and dIfferentIal mountmg member
handbrake cable from equaltzer bracket lever brake hose from brake line by and the lock WithdraWing through connector spring removing wheel bearrng locknut rear axle shaft wheel bearing and 011 seals and the rear brake assembly Jack up the suspensIon arm and remove the shock absorber from the lower mountmg
cyltnder
Replace
where necessary
Lower rubber
remove
the COIl
SUSPENSION ThIS
Installation
Remove the suspension arm securing bolts as shown In FIg I 10 11ft out the arm If necessary remove the rubber bushes from the suspensIon arm by pulltng them out With a SUItable and wlthd rawal tool
IS a reversal of the removal procedure noting the follOWing pOints SuspensIon member and dIfferentIal mounting member must be correctly lined up The Insulators should be correctly altgned as shown In FIg I 5 and fItted from the underside of the members Tighten the suspensIOn member mounting nuts to 10
InstallatIOn
kgm
72 3 Ib ft l the dIfferentIal mounting member to 8 5 kgm 61 6 Ib ft and the lower shock absorber nut to 2 3 kgm 166
Ib ft
the suspensIon arm for dIstortIon or cracks and the rubber bushes for wear damage or separation of the matenals Replace If necessary The installatIon all
IS a
Removal
the suspensIon
arm
on
reversal of the removal procedure TIghten mounting bolts when thevehlclels resting the ground Replace all self locking nuts
of the vehIcle and support on stands Remove ljP Wheels handbrake Itnkage and or disconnect the follOWing return sprrng drrve shaft flange nuts at the wheel end FIg I 6 and the bump rubber securing nut Jack up the suspensIon and Lower the remove the shock absorber from the lower mountIng
OIL SEALS
Dismantling
Jack FIg
bump
rubber
Jack up and support the rear of the vehIcle Remove the wheel and brake drum DIsconnect the drive shaft from the axle shaft Remove the wheel bearing locknut hold Ing the flange WIth a SUItable tool FIg 111 WIthdraw the axle shaft as shown In
Fig
I 12
studs
SUitably flange
fIxed
to
the
flange
63
inter
QJ
@LID
00
0
FIg I 12 Removal of thedrIVe axle
t
j
Bearing hOUSing
mark
beanng
grease
every overhaul
8 6
6
Fog J 16 Exploded
1 2 3 4 5 6 1 8 9 10
of thedrNe
shaft
shaft Or Orwe maftbafl Ballq eer Orwe Ibaft top rmg Rubber gtl ter
GaJrttrcltp
C IdIP SJtJeve SIewe
12 0 119 tIbelllJt1g 13 N 4
Clrcltp
Apply grease
In
thIS area
r
1haft
64
WIth a dnft of suItable SIze dnve out the lOner bearong and the 011 seal Remove the grease catcher and the outer bearmg wIth a conventional beanng puller
The assembly of the drove shaft IS a reversal of the dlsmanthog procedure noting the followmg pOInts Altgn the yokes ensurong balls and spacers are fItted In correct order Select a
to gIve an aXial play of less than 0 02 mm 0 0008 In In Universal JOints Four SIZes avaIlable Apply a SUItable quantIty of multIpurpose grease to the ball groove approx 10 gr 035 oz and addItionally grease the area shown In Fig I 18
clrcltp
the REAR AXLE SHAFTS BEARINGS OIL SEALS
Assembly
Check
and InstallatIon
Replace Replace
the axle shaft for straIghtness cracks damage or wear the 011 seal Check the bearongs for roughness or pIttIng parts
as
necessary
REAR AXLE
Removal
Wagon
The assembly and the follOWing mstallatlon IS a reversal of the dlsmantltng and removal procedures notmg the follOWing pOints Clean parts thoroughly The sealed Sides of the wheel bearongs should face to the wheel and the sealed Side of the Inner bearong the dIfferential The arrangement IS shown In all
Jack up the car and support the rear of the vehIcle on SUItable stands Remove or dIsconnect the follOWing parts Wheels brake drums brake hose at the 3 way connector handbrake
rear cable from the equaltzer lever propeller shaft at the dIfferential flange and the shock absorbers from the lower
Fig I 14
When
to
refItting
pressure should be
applted
When
the
lOner race
replaCing the suspensIon arm check that the dIstance less than the hOUSing dimenSIon pIece IS 0 5 mm 0002 In L See FIg I 15 and has the same code mark as the hOUSing In general It should be remembered that the beanng grease should be replaced every 2 years or 30 000 mIles 50 000 km
Pack the bearongs WIth a good wheel bearing grease shown In Fig I 14 and coat the Itp of the 011 seal wheel bearong nut after It has been used tWice Wheel
In
Jack loosen the U bolts and spnng shackles Withdraw the shackles from the sprong eyes Remove the U bolt nuts completely and lower the jack to WIthdraw the axle as shown In Fig I 19
mountmg Support rear axle remove the nuts from the
on a rear
REAR AXLE
Disconnect the brake pipe from the slave cylinders and remove the brake pipe and the 3 way connector Remove the cross rod clamp equalizer lever and the cross rod ends from the operatmg levers on the brake backplates Drain rear axle 011 Remove the four nuts holding the brake backplate to the axle housmg and draw off the half shaft and the backplate usmg a sliding hammer Press off or cut the bearing retalmng collar Fig I 20 and
su remove
beanngs
AdJustment
With the nut tIghtened to a torque reading of 25 33 kgm 181 239 Ib ft check the axle shaft end float The end float must be less than 015 have
a mm
the
bearing
WIth
beanng puller
or
by other
0006
In
The
rear
turning torque of less than 4 5 kgcm 645 replace the dIstance piece
If not
The backplate IS now free Remove the nuts securing the differential unit to the rear axle and hft out the differential The bearing collars must always be replaced
means
Itable
DIsconnect the end flanges and remove the shaft The drove shafts should be dIsmantled every 30 000 mIles 50 000 km or every 2 years to lubrocate the splines Remove the Universal JOint spIder at the differentIal Side In the same manner as dlsmantltng the propeller shaft see approproate the sleeve yoke plug securmg CorcllpS and take out the plug Compress the drove shaft and remove the corcltp 4 10 FIg I 16 and the stopper Disconnect the boot and spltt the shaft tak Ing care to retam all parts
section
remove
the follOWing Items and replace or repair as Half shafts for wear cracks and straightness The necessary half shafts must not be straIghtened by heatIng Check the 011 seal hps for damage or dIstortion and the beanngs for wear or
roughness
Assembly
the
reverse
of the pOints
and
dIsmantling
noting the
follOWing
clean all parts FIt a new gasket between dIfferentIal Unit and the axle hOUSing TIghten the nuts
Thoroughly dIagonal
the
m a
Inspection Assembly
and Installation
follOWing
shaft
are
the dnve
must
FIt grease torque catcher beanng spacer grease packed beanng sealed Side facmg wheel and new bearing collar A 4 5 tons press fIt IS needed for fitting the collar Coat the 011 seal hps WIth wheel bear 109 pattern
to
the
recommended
complete
replacement parts
Check
not
avaIlable
grease proor to fIttIng Check and adjUst the aXIal play between the wheel bearmg and the axle housmg to 0 3 0 5 mm 0012 002 10 See Fig I 21 Fmally fIll the rear axle WIth the recommended 011 and bleed and adjUst the brake system
0 ring Check the wear Check the steel balls and straIghtness damage the sleeve yoke for damage wear or dIstortIon If any fault IS found 10 the Universal jomts replace It as descnbed In the
plug
shaft for
sectIon
dealtng WIth
sleeve
FIg
I 21
support the
Clean the the shaft lubncate WIth 011 and the drove shaft ball grooves and With the drove shaft compressed check that IS less than 01 mm 000410 Fig I 17
rear
Jack up the centre of the rear axle an of the car on stands Remove the wheel and the
yoke
play
shock absorber from the lower mountmg and undo U bolts bump rubber spring seat location plates and seat pads Remove the sprong front bracket securmg bolts and lower the sprong bracket FIg I 22 Remove the upper and lower
rear
shackle
65
ImDBII
rear
axle
lnlng collar
cold chIsel
rln9 front
hanger
7 8
FillI 23
3
rear
SIIspenSlon and
rear
frtted
to
models
5 Shock obsorlJor 6 RNr spring front henger
7
Ddfenmtt
2 Rear vie 3 4
C8TTI r
hOUSing
HMldbrllktlltnk B ll hO
66
bolts and the front spring eye bolts to separate front spnng The InstallatIon the The the
IS a
hanger and
REAR SHOCK ABSORBER Removal and Instllllatlon
procedure
noting
following bump
pOInts
rubber should be fitted WIth the longated flange to Coat the front hanger mounting bolt bushes and shackle pIn WIth a soap solutIon pnor to assembly The front bolt securtng nut and the shock absorber lower mounting nut WIth the car resting on Its wheels Check should be
rear
Jack up and support the rear axle on stands Remove the lower end of the shock absorber from the spring seat Remove the bolts securing the shock absorber upper bracket Fig I 23 and remove the shock absorber and the bracket The installatIon
IS
tIghtened
procedu
re
Tighten the
car
carrted out In reverse order to the removal lower shock absorber mounting nut WIth
IS
clamped evenly
resting
on
the ground
Technical Data
COIL SPRINGS Model L510S 510 L510 PL510 W
re
dIameter
142
mm
0559
In In
In
142 306
mm
0559 120
In
mm
0559 11 8
In
Same
mm In
mm
In
The value for the 510 P510 models apply for the R H L H sprtng IS the free length which IS 299 mm 11 8 In I
L 510 0984
In In In
25
mm mm mm
0984
In In In
235 578 0 3
9252 22 76
235
9 252 22 76
length
at
m sec
578
DampIng force
ExpanSIon CompressIon
65kg 33 kg
1433Ib 72 8 Ib
50kg 20 kg
1101b 44 Ib
REAR SPRINGS SHOCK ABSORBERS Estate CaB PIston diameter Stroke 25 200 495
at
mm mm
Length
Width 0984 7874 19488
In In In
1200 60 6
mm
47 2 2 362 0 236
In In In
mm mm
Thickness Number of leaves Free camber 24 Laden camber Spring eye bolt diameter Front Rear
mm
mm
0 3 mlsec
at
kg
CompressIon
75kg 23 kg
1653Ib 50 7 Ib
mm mm
In In
67
inter
i ill CQllW
Z I
e
5
tq o
v
O
Frontwheelhub G
I
t 2
FlgJ 1 V
1
enSlon Su
of
umt
the front
Ulator m
spensoon
2
3
Co l Sf rmg
umt 6 embly S crossmem r
SUsptlnSlon 4 SuspensJOlt
Fog J 3 Exploded
J Flg
GreWIth
J FIlI
5 Removal
J7 FIg
l1li8
of the ll1Ibil
bar
For alUlOll1bOnS
an
J 8 Rerniiwal of FIlI
l1li8
text
tIDltl
68
Front
DESCRIPTION
Suspension
REACTION STRUT Removal and Installation
arm
The front suspensIon IS of the spring strut type 10 which shock absorber and wheel sptndle are combtned to form a sIngle Unit Call spnngs are fItted to the upper ends of the suspensIon Untts
Remove the body fltttng nuts 1 10 FIg J 8 and the suspensIon bolts 21 LIft off the reactIon rod
Drum brakes
Removal
Check the rod for distortIon and cracks and rubber parts for damage and fIt by reversIng the remova I tnstructlons
SUSPENSION UNIT Fig J 9 Removal
Jack up the front of the car and support on stands Remove the Remove the hub cap spltt pin wheel and the brake drum beartng nut beartng washer and hub assembly from the spmdle
FIg J 2
beartng
the
bearing cage 011 seals and the Inner sUItable drtft drtve out the outer races of
lOner
Jack up the front of the vehIcle and support on SUItable stands Remove the wheel dIsconnect the brake hose from the connector reaction strut and stablltser bar from the suspensIon
arm Remove the two bolts holdIng the suspension assembly to the SWIvel JOint Fig J 10 Place a Jack under the suspensIon arm and Itft up the suspensIon unIt Remove the mounttng bolts Lower the lack from under the bonnet as shown 10 Fig J 11
clean all parts Replace 011 seals or hub and the grease 10 the bear lOgs
Thoroughly
damaged beartngs
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
SUSPENSION UNIT
Dlsmantltng
and Assembly
Unscrew the nut by 900 and tnsert the split ptn Check that the end float of the hub IS zero and the turntng resIstance when checked With a spnng scale hooked to one of the wheel studs IS 7
re
SUitably clamp the suspension unit Into a vice and take off the dust cover the COil clrcllp UStng sprtng compressor ST49100000 slightly compress the sprtng Then remove the self lock109 nut Fig J 12 and take off the mounting msulator thrust beanng spring seat and bump rubber Slacken the sprtng
compressor and remove the sprtng Push down the shock absorber piston and clean the area around the gland packing USing the specIal tool ST49130000 unscrew the gland packing Remove the 0 nng from the pIston rod gUide piston rod and cyltnder assembly by slowly lifting piston Do not separate pIston and cylinder Dram all flUid from the suspension Untt and shock absorber assembly Wash all parts thoroughly In a SUitable WIth the exceptIon of the rubber parts which should be blown dry With compressed aIr JUst solvent
97 2
WIth
new
beanngs
or
10
case
of
10 oz
Removal
Jack up and support the front of the car remove wheels brake hub cap spltt ptn beartng nut beanng washer pIpe Fig J 5 Remove the bearing collar and 11ft hub and brake dISC FIg J 6
out out the buter races
the outer beartng cage 011 seal lOner beartng cage and drtve Remove the brake dISC from the hub
FRONT WHEEL HUB See descnptlon under drum brake torque setttngs
Installation
Replace the shock absorber flUId gland packtng and 0 nng self lock109 nuts Check the suspension Untt outer casing for deformatIon cracks or damage and the sptndle for cracks at the base or screw portIon Inspect the sprtng rubber parts and
thrust bearing for To assemble
wear
Calliper
bolts
7 3 3 9 27
99 kgm 5 3 37
528 28 2 195
71 6 Ib ft 38 3 Ib ft 268 Ib ft
kgm kgm
fIt the outer casing to the adaptor and tnsert rod and pIston cyltnder Into the castng FIll the outer castng With the correct grade of 011 10 accordance WIth the table below
All ledU models P510 UTK
STABILlSER BAR
Applied
modeIJ
Ex PSIO
UTK
J 1I
model
Remove the securtng bolts on the suspensIon arms 11 In FIg nd the frame bracket bolts 2 and remove the stablltser bar Check for cracks and deformatIon of the bar and
1 0
300 cc
325
cc
290
cc
rubber parts
Reverse the removal procedure 12 3 Ib ft 1 7 kgm 8 7 suspension arm bolts to 1 2 frame bolts to 1 9 25 kgm 137 18 lib ft
quanbty
The 011 quantity IS cntlcal and should be accurately measured as It affects the damptng power of the shock absorber Fit the 0 rtng to the top of the pIston rod and uStng the gland paclcmg WIth specIal tool ST49340000 If It has been removed Before the gland packIng Itft the pIston by 90 mm 3 54 lih 65 kgm 43 4 470 kgm Bleed the and then tighten to 6 shock absorber by pumpIng the pIston assembly up and down
tlghtentng
69
ImDIIEI
1
e 8
5 9
e
FIg J 9 Exploded
1 2 3 4 Nut VIew
Suspension
Unit
5 Dust
Fig
J 12
Removal of
the suspension
unit compressed
spnng
VIew
of S1Jspenslon
unIt
and
Fig J 14 Exploded
voew
70
mmBIIB
Fig
17 The suspension
ann
mounting
nut
arm
bush
JOint on
FIg J 20 The mountmg bolts for the lower ball the RlspenSlon ann
fIiilIII J
I
itJiJ Yf
l
f
Co
p
I
r T
D
fi
L
I
j
F I J 23 the arrowed
Fill J 22 AdjUst
rod
centre
the
In
tube
enng stl
angle bV
means
of
71
IS on
same
the assembly by reversong the dlsmantltng procedure The torque settong of the self Iockong nuts IS 6 0 7 5 kgm 434 54 2 Ib ft
Complet e
Jack up and support the front of the car on stands Remove or disconnect the followong reaction rod and stabl Itser bar from suspension arm suspension Unit from SWIvel Joont arm spltt pon from Joont nut ball JOint from SWivel Joont arm and the lower ball JOInt from the suspensIon arm by removIng the bolts 1 on FIg J 20 lower ball
Fig
J 19
SUSPENSION UNIT
Installation
In
Reverse the removal procedure greasing all parts marked FIg J 15 Tighten to the recommended torque values
Replace
06
the
damaged dust
0001 0014
cover
It must be
mm
follOWing
Upper attachment nuts
3 9 6 0 4 9 1 2 5 2 80
replaced complete
on
As the ball Joont IS a sealed UOIt If the end play IS greater than 0 03 I To grease the ball JOInt remove
SuspensIon
Stablltser
to
Unit to
arm
ReactIon rod to
arm
arm
28 2 37 6 Ib ft 434 57 8 Ib ft 35 4 45 6 Ib ft 87 123 Ib ft
the plug and screw In a grease flttong Flush old grease out of the JOint by pumpong on new grease Refit the plug The Installation all bolts and reversal of the removal procedure Tighten to the torque values Itsted under TIGHTENING TORQUES see Index for page number heading Front Suspension
IS a
nuts
SUSPENSION ARM
Jack up and support the front of the car on stands Disconnect the reaction rod 1 and the stablliser bar 2 from the In suspension arm 3 Fig J 16 Remove the lower ball JOint bolts 4 and the nut 1 In Fig J 17 Lift out the suspension
arm
Adjustments
All checks of the front wheels should be carried out With the tyres at correct pressures Camber and castor angles are pre set and cannot
one
Side
Check the suspension arm for damage cracks or distortion and the rubber parts for abraSion If the dimenSions A on FIg J 18
IS
changing
be adjusted To level the vehIcle In the case that more than the other can be accompltshed by the spnngs
hangs
less than 1
mm
004
In
Toe on
The onstallatlon IS a reversal of the removal procedure the bolts to the follOWing torque values
TIghten
by lengthening
by uSing a gauge shown In FIg J 21 and adJust shortening the track rods The standard length
SuspensIon
member Ball JOint
arm
to
cross
of the track rods between the ball JOints and the centre of the SWivel JOintS IS 3095 mm t1219 In Both Sides should be
12 2 19
13 5 kgm
88 2 137
25kgm
97 6 Ib ft 1811bft
adJusted
In
to
equal length
by turning the
centre
tubes
arrowed
FIg
J 22
Steenng angle
With the
car on a In
turn
bolt arrowed
FIg
angle
uSing the
72
Technical Data
FRONT WHEEL ALIGNMENT All Estate Cars Model All Saloon models except L510 S L51 D S
Castor Camber
King
Toe
pIn
In
Inclination
1040
200
1010
1030
7030
9 12mm 047
In
7050
3 6 n m 024
In
024
035
012
COIL SPRINGS Models L H spring for all models R H sprong for L H 0 models R H spring for all R H D models and and L510 S L H spring for L510 S 12
mm
L Hand R H
air
Except L510 SI
Wire diameter COil diameter Free length F Itled length Fitted load
mm 0472 In 130 mm 5 12 In 3545mm 1394In
12
12
mm
0472
In
130mm 3845
51210
In
736lnl 187mm
243 kg 536 Ibs
mm
795
536Ibs
PL510 TKI
50
50
0
jO
ci
50
50 2 0
2 0
2 0
2 0
2 0
PIston
mm
rod 20 0 787
20 0 787
20 0 787
20 0 787
22 0 866
22 0 866
dIameter
m
hnder
mncr
30 1 181 1
30 181
10 1 181
30 1 181
32 1 260
32 1 260
dIameter
mm
m
Dampmg force
EhpanslOn
at
0 7 22 t 4 8 8 55 147
HO
t 22 7 t4 25 t8 8 1
i t 22 3 147 71 22
kg
Ib
147
t 22 7
251 4 55 t8 8 1
25104
55 t 8 8 1
110
435 17
410
16 1
410
16 1
435
1 17 1
176
25104 40106 t8 8 1 88 2 1 13 2 55
410 16 1
410 16 1
cylinder
mm
tn
length
I
73
interCE QJ
Q @
0 9
I
10
80
Fill
2 3
K 1
Exploded
ng
Smermg gear
lng hou
5 Kbnn
Nfl
9685
In
jffif
FIlI K 6 Measure me n II1OWI1 to dbne determine If the Nfl illtIlIswvlc8lble Fill K 5 Removal of the WIth nng nut
g
column Nfl
74
Steeri ng
DESCRIPTION
The steering Itnkage IS fItted WIth a torsIon rubber Idler arm whIch absorbs the wheel shock The lubricant of the steenng box should be checked every 6 000 miles 10 000 km at Milch tIme It IS also The column grease
beanng
and
has been
changed
Into
It
should be
packed
WIth
then
cemented
steering
IS
of the
reclrcu
adjusting
steering column By bearing shims 4 SIZes 005 0076 mm the InitIal turning torque of the steering
the
kgcm
ThIS
55 5
833 In
oz
WIthout the
Itnkage
STEERING GEAR
Removal
Remove the horn ring by depressIng It and turning It to the left the steering wheel nut and uSing the steering wheel puller ST46430000 or any other puller that WIll fIt WIthdraw the
be carrted out by hookIng a scale to one of the steering wheel spokes whIch for thIS spring purpose should be pushed over the steering column shaft Fig K 7 The end clearance of the sector shaft adjusting screw and should be should be 0 01 003 mm 00004 0 0012 In measured as shown In K 8 There are SIX shIms available In
sector
shaft
being
fitted
can
Fig
thicknesses from 1 45
1 57
mm
0057
0062
In
steering wheel
Remove the steering column cowl dIrection IndIcator and light selector SWItch and dIsconnect the gearchange lever steering column change only from the change control rod Remove the two column attaching bolts arrowed the column bottom flange bolts FIg K 3 and FIg K 2 dIsconnect the gearchange rod and the selector rod from the gearchange lever and the selector lever by removing the cotter
In
WIth the ball nut at the centre of travel and the centre tooth of the sector shaft In line WIth the centre tooth space of the ball nut place a new gasket on the sector shah cover and fit the shaft and the cover ensuring that here IS some backlash between the sector shaft and the ball nut teeth 011 the sector shaft pnor to assembly and tIghten the bolts
sector
pin from the trunnion DIsconnect the steering drop arm and the drag link Remove the steering gear mounting bolts and draw the steering gear and the column assembly forward and remove the gear change control
Lock the adjusting screw locknut and turn the sector shaft several times at the drop arm end FIt the drop arm taking care of the alignment marks on the arm and steermg box AdjUst the backlash at the end of the drop arm as shown In Fig K 9 over a radius of 215
mm
Itnkage
as
deSCribed
In
sectIon
GEARBOX
adjusting
screw
at
0004
In
WIth the
FIg
position screw In the adJusting screw lock In pOSItion With the locknut STEERING GEAR
by
K 10
Dismantling
capacity
Clamp the steering box assembly sUItably Into a Vice and remove the drop arm WIth a SUitable puller or specIal tool ST
011 from the steering box Slacken the and turn the sector shaft adjusting screw several turns antl dockwlse Remove the sector shaft cover and the shaft from the hOUSIng as shown In Fig 4 Remove the steering column tube bolts and WIthdraw the steerrng column as shown 46440000 Drain the
Finally fill the steering box WIth gear 011 90 E P The fllltng IS approx 033 Iltres 0 7 US pts 06 Imp pts
STEERING GEAR In tallatlon
adJustment
nut
procedure
noting
Fig K 5 taking care not to let the ball nut run down to eIther end of the steering worm Pull the steenng column out of the column tube Remove the sector shaft 011 seal Note that the sector shaft needle bearings are a press fIt In the hOUSing USing
In a
the front wheel altgnment and the steenng system for of movement The steenng wheel rrm should have a 30 mm 098 1 18 In measured at the free travel of 20 outSide dlll eter of the rim freedom
tube
rear
outer
Inner
race races
from the column of the front and STEERING LINKAGE Refer to Removal end Dismantling
STEERING GEAR
Check the aXial clearance between the ball nut and the balls If the clearance exceeds 008 mm 0003 In the complete Unit should be replaced Inspect the gear teeth for wear or damage Worn or Imperfect bearings should be replaced Examine the steering column shaft for straIghtness and check that the max
In FIg K 6 IS not deflection at points C exceeding 02 mm 0008 IIr when the shaft IS supported at poInts A and B Check the sector shaft and steermg column shaft serratIons for wear
K 11 With the vehIcle resting In stands remove the the castle nuts holding the track rods to the and split pinS from the levers steering levers Remove the track rod ball JOInts by means of a SUitable puller or by holding a large hammer on
FIg
SIde of the lever boss and tapping the opposIte SIde WIth a hammer In the same manner dIsconnect the steenng connecting rod from the drop arm and the Idler assembly and
one
second
the track rod Inner ball JOint from the connecting rod Unscrew the steering Idler from the chaSSIS Side member To dIsmantle the steering linkage slacken the clamp bolts from the ends of the track rods and unscrew the ball JOints Unscrew the Idler arm bracket nut and dismantle the Idler
Replace parts
as
necessary and
reassemble
the steering
gear as follows
assembly
Grease the 011 seal lips and press the seal Into the hOUSing FIt the steering column assembly Into the column tube and fIt the IMIrm bearing shims and the 0 ring Into the hOUSIng TIghten 25 kgm 130 If the the flange bolts to 18 18 1 Ib ft
STEERING LINKAGE
Assembly
and Installation
Check the rubber parts for damage wear or other form of damage and replace If necessary Check all steering rods for
75
mter
f Qp illJ
the
sector
end shaft
float
between
of
spnng scale
fi jl
I
i
C
l
tJ
y
1
l
q
t
J J
I
4 11
g 8
Ir
J
I i
ri
J
0
7J
0
r r steermg hnkage
seen
WAGON
ann
r
I
I
a
TOLERAHa
1
j
47 to 3 47
ANGlE
AFTER TIGHTENING
TME ARM
Frg K 14 SectIOn thnlugh the ball JOint ltud for the connecting rod
76
damage distortion or cracks The ball JOlOts must play due to weak sprlOgs or damage A workIng clearance
o 5 stud
mm IS
have
no
free
of 0 1
0 004
out
pulled
0 02 In 1 should be felt when the ball JOlOt see of Its socket Fig K 13 and K 141
Idler arm bracket coat the rubber bush press In so that It protrudes equally on both SIdes Fit the Idler arm body IOto the bush With the Idler See also arm centre line parallel to the chaSSIS centre Itne When With
Replace
FIg
The assembly IS a reversal of the dismantling procedure notIng the followlOg pOints TIghten the bolts to the followlOg torque settlOgs Ball stud nut 5 5 7 6 kgm 39 8 55 0 Ib ft 125 140 kgm 90 101 Ib ft 55 7 6 kgm 39 8 550 Ib ft
between the ball stud centres by turnlOg the centre tube 10 the approproate directIon After InstallatIon of the complete steering linkage system check and adJust the wheel 12185
10
Drop
Idler
arm
nut
arm nut
Also as described 10 section Front SuspensIon adjust the toe out 10 turn angle so that the angle of the lOner wheel IS 380 and that of the outer wheel 32 40
alignment
Trouble
SYMPTOMS Hard steenng
Shooting
ACTION TO BE TAKEN Correct pressure Correct alignment Check and replace If neceesary Adjust If necessary
PROBABLE CAUSE
Low tyre pressu re I ncorrect wheel alignment StIff track rod ends
SteerlOg
Tyre
pressure Incorrect
I ncorrect wheel altgnment Wheels and tyres need balanclOg Wheel hub nut loose Wheel beanngs damaged Front suspensIon distorted
necessary
Steermg
Adjust wheel beanngs Replace wheel beanngs Check repaIr or replace Adjust as necessary
to
one
SIde
Uneven tyre pressure Improper wheel alignment Wheel beanngs worn or damaged Brackes Improperly adjusted Sh k absorbers faulty
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
Repair
or
replace
Abnormal tyre
wear
Incorrect tyre pressure I ncorrect wheel alignment ExcessIVe wheel beanng play
Correct Correct
AdJUst
AVOid sharp turnlOg at hIgh speeds rapId startlOg und braklOg etc
Improper dnvlOg
Tyre
nOIses
Improper
Correct Correct
77
inter
MI @
on
the left
12 2
3
11
14
WI
r
P 6
f c
17 Ie
11
fA f
1
16
el
Q
19
I
Reservlor tank disc brake for w
2o
Bleeder CMck
W SiCffJ
Cylll
derbOOY
9 20
ket Ga
ler was
g Vlllvep1u
l Re rvolr
cltp
78
Bra kes
BRAKE PEDAL Removal and Installation Remove the return spring and the push rod cleviS pin and Remove the disconnect the pedal from the master cyltnder See FIg L 2 PIvot pin and 11ft out the pedal Check the
or
and detach the wheel cylinders after disconnecting the bridge pipe between them If the wheel cylinders must be dismantled remove the rubber dust caps and Withdraw the Inner parts Check the brake
mm
pedal
shaft
bushes
or
the
pedal
dIstortIon and replace parts as Install the pedal by necessary reversing the removal procedure Lubncate the shaft bushes and the push rod clevIs pm With brake grease Tighten the PIvot pIn nut to a torque setting of 3 5 40 kgm 25 3 289 Ib ft
damage
excessive
wear
dIameter of 229 6 In Also check the drums for cracks or other damage and replace If necessary If the linings are not seated on In 006 In the shoes properly worn to below 1 5 mm thIckness grease Impregnated Or burnt replace them Check the exceeds 0 05 mm 9040
a maximum
Qut run
run out
adjusting
cams
for freedom
Free
length
Remove or disconnect the follOWing Fig L 3 Push rod cleVIS pin at the brake pedal brake pipe at the master cylmder and master cylinder securing nuts from the bulkhead LIft the master cylinder from ItS mounting parts
reservOir and remove the dust cover and piston stop screw from the bott of the cylinder After removIng the piston retaining ring and the abutment washer shake out the piston assembly the piston return spring valve
215
the brake backplate for distortion Inspect the wheel cylmder bore for scoring and the pIston surface for corroSion or damage The maximum running clearance of the piston In the cylinder bore must not exceed 0 15 mm 0 05 In It
IS
the
recommended to
renew the
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
or
weakness
Inspect dust
cover
and
on stands remove the wheel and disconnect Remove the bolts securing the brake calliper to FIg L 7 JOint flange and remove the calliper
together
With the
brake disc To dismantle the calliper remove the antI rattle clip and remove the brake pads from the callIper Remove the tension spnngs and pull the cylinder out of the callIper Blowout the piston uSing air or hydraulic Itne at the brake hose connection as
In Fig L 8 Remove the rubber seal from the cylinder groove and the retainer and the wiper seal
The assembly of the brake master cylinder IS a reversal of the dismantling procedure noting the follOWing pOints Soak the pIston cup In brake flUid and coat the pIston and the cylinder working surfaces WIth brake flUid prior to assembly After the
complete installatIon adJust the brake pedal height and bleed the hydraultc brake system
shown
BRAKE PIPES plp S or hoses they do not foul any replace the part In question making 1 7 kgm movIng parts Connetors should be tIghtened to 1 5 108 1231bft If any found be due to brake
sure
If for 1
any flUid
wear or
leaks cracks
In
cylinder assembly
It
leakage
IS
to
or defects can be found on the should be replaced Check the brake pads If the pads areworn down to a thIckness of
damage
mm
004
I they
must be
replaced
In
sets
of four
ReplaCing
brake pads causes the brakes to pull to one SIde out run The Check the brake diSC for scoring out of round and run out IS best checked as shown In FIg L 9 w th the hub
only the
worn
mounted to the SWIvel JOint If It IS necessary to re machlne the brake dISC take care that a mln thIckness of 8 4 mm 0331 In IS not exceeded The nominal thIckness of the brake dISC IS 10
mm
Support
the vehIcle
on
004
In
If the dISC be
IS
cracked
must be
or
damaged
In
any other
cap and hub assembly by removing the spilt pIn and the castle DIsconnect the brake hose nut from the SWIvel JOInt spindle from the wheel brake cylinder Unhook the return springs from the brake shoes and 11ft off the brake shoes From the rear of th brake backplate remove the wheel cyltnder securing screws
way
It cannot
salvaged imd
replaced
79
inter E
@ 1J
55 Y
UBE bu
L H I I c
fR
nIL ILl
F 19 L 4
Exploded
view
of
front
brake
bly
by
means
of
lrJ
1
@ @j
Fill L 9 M88I11nIlg the brake daiC for
7
t run
Fog L 6 Exploded
assembly
I Cylmdor 2 PISton I 3W of RetBtner 6 P 6 a 1 Shim
of
10 r
MIOn
rpt lfIg
Spl pin
12 13
14 tIenut c
Suppon btlldr
t
8 9
8 cl
I p IpO
pi
FIg L 10
m 1Mr c
80
rp J
t
Fill L 14 Exploded
YOM
of the rear
brake
jj
I 70
6 M
lM
1I1
Jll
L
1
J
A
I
2
I
J
I
T v
I
lIII lo
I
Fill L 16 posrbon
Tho
In
J Fill L 17
Tho handbnoko cable
the
rear
81
FIg
L 22
mode
r 1
J
J
tc
Ji
T F16
1 f
loo t
if
IJ
r7
I
ifi C J
82
Assembly
and Installation
From
clips
Remove the cable from the handbrake lever underneath the body release the cable from the mounting pull out the lock plates holding the cable retaIner and
cylinder bore thoroughly WIth brake fluid and fIt the piston seal Into the groove as shown In Fig L 10 Fit the wIper seal and Itghtly grease the bore wIth the speclfl grease 91ean the brake dISC and fIt to the hub The hub can now be fitted to
the swIvel JOint fIt the piston Into the cyltnder relteved portIon faCing the PIVOt pin and push In the pIston until It IS almost flush WIth the wiper seal retainer Install the cyltnder Into the calliper plate and secure In posItIon by means of the two torsIon springs FIt the down hold pin spring washer and the nut to the support
Withdraw the cable Pull out the front cable from the car after undotng the outer CllSlng of the cable as shown In F rg L 15 whIch has a pressfIt In the handbrake control bracket
completely
Remove the clevIS pin connecting the lever yoke WIth the lever and the cleVIS ptn connecttng the control Handbreke lever
Carefully
gUIde
shown
assembly
Saloon
bracket and secure the nut With a spltt ptn Assemble the callIper to the mountIng bracket WIth pIVOt pIn WIth spring washer plain washer and castle nut Tighten the nut and secure WIth a Hook the down hold bracket on to the top of the mounting bracket and turn the calltper plate to ensure that It can turn smoothly Then fIt the calltper to the SWivel JOint
dIsconnect the left hand cable from the handbrake adjuster Pull out the lock plates and remove the clevIS pIns securing the See FIg L 17 cables to the rear wheel brake cyltnders Rear handbrake cable the Estate Car
rear
split pin
cable
by removtng
off pull
Remove the cleVIS ptnS Remove the connecttng rods springs and the cleVIS ptns See
flange
FIt
a
Fig
Inner
L 18
shIm to the
Inner
pad Draw
the callIper towards the chaSSIS Then tnsert the lower cuts on the ends of the pads Into the mountIng bracket and push tn the
Installation
pad untIl
the piston Move the calliper away from the chaSSIS and tnsert the upper cuts Centre the tndentatlons of
It contacts
breakage fraytng
lever
or exceSSive
stretchtng
as
springs for weakness and the ratchet for wear The return and the off pull spnngs should be checked for weakness Also check the equalizer lever and the bushes for wear or damage Replace parts as necessary The tnstallatlon of the removed parts IS a reversal of the removal All slidIng parts should be greased pnor to procedure InstallatIon
Examme the
handbrake
Replacement
wear of the diSC brake pads should be checked every 3 000 If the pad thIckness IS less than 1 mm 004 miles 5 000 km In change the pads as a complete set of four
BRAKES Take out the antI rattle clip By movIng the calliper plate away from the chaSSIS push the piston mSlde by 3 4 mm 0 12 0 16 In and remove the outer pad Then draw the calliper plate tnwards and remove the lOner pad Clean the Remove the wheel
Adjustments
Brake pedal See Fig L 19 AdjUst the brake pedal by turntng the master cylinder push rod to obtain the heights shown tn the
dIagram
exposed
IS various
surface of the pIston The InstallatIon of the new pads carned out tn reverse order See FIg L 11 12 and 13 for
pedal stop
Now
WIthout dIsturbIng the brake light SWItch must be free TIghten the locknut the brake
The brake
stages of replacement
screw tn IS
light
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
stands and remove the wheels Release the handbrake and disconnect the connecttng rod from the lever
Support
at
the vehicle
on
pedal
IS
pushed
down
by
1 5
mm
0 06
In
Front brake
the
rear
cylinder
drum Unhook the return spnngs and 11ft off the brake shoes If necessary dIsconnect the brake pipe and remove the brake
Depress the
cams
Jack up the front of the vehicle drum brakesl brake pedal several tImes and then turn the adJuster forward until the wheels are locked From thIS pOSitIon
cyltnder cylinder
I
wheel brake dIsmantled by removtng the corcllp and the rubber dust cover and takIng out the Inner parts Remove the brake adjuster and the brake backplate as descnbed for the removal of the axle dnve shafts
In
dust The
cover
plates
and
then
the
back off the adJuster until the shoes free the brake drum Note that there are two adjusters on each wheel which should be treated NOTE models
completely Independently
The dIsc brakes self adJusttng fItted to the front wheels of some
are
sectIon
assembly
SImilar
as
rear
completely
pedal several tImes to settle the mechantsm Turn the adjuster FIg L 22 and L 23 In a clockWise dorectlon untIl the brake shoes are locked to the depress
drum Then back off the the wheel rotates
the brake
HANDBRAKE
Removal
adjuster by
two or three
notches untIl
freely
holdtng
Release the handbrake remove the clevIS pIn Front cable the cable and unscrew the adJusttng nut at the rear of
83
With the handbrake released and the rear brakes HIlA as described above adjust the front and rear handbrake cable to obtain a lever stroke of 85 95 mm 3 346 3 740 In for the saloon Fig L 24 In the case of the estate car adjust at the front adjuster to give e stroke of 110 120 mm 33 4
adjusted
With the master cylinder reservoir completely fIlled remove the ler dust cap from the bleed plug furthest away from the rub
4 724 in
Fig
L 25
cyhnder and connect a bleed hose lD the bleeder valve ImlTllirse the other end of the hose in a Jar containing a httle brake flu id Depress the brake pedal several tImes to the
master air
keep
expel
valve
the 1 3 to
pedal
at its
2 turn 1
pumping operation until only brake flUid flows into the glass jar Fit the rubber dust cap and topup the reservoir Repeat the bleeder operations for the other bleed plugs finishing with the bleed plug nearest to the master brake cylinder
and open the bleeder and then close the valve Repeat this
eSt 10Vl
position
proceed as follows
Technical Data
BRAKE PEDAL Brake BRAKE DRUM AND BRAKE DISC Drum inner diameter 187
mm mm
pedal height
228 6
mm
900 In
R H D L H D With autom transm Brake pedal height Front diSC brakes R H D L H D With autom transm
187
197 mm
202
length
11 575
C8 c1earal
elSC brakes
Front
39 7
9 0
86 0
mm
Rear Total braking area Front drum brake Front diSC brake
Rear brake
22 22 mm
718
In
50 80 mm 2 0 In 22 22 mm 718 in 20 64 mm 11316 in
0 18 mm 0 709 In
84
Trouble
SYMPTOMS Insufflent performance Leak
Shooting
ACTION TO BE TAKEN
worn
PROBABLE CAUSE
Trace and rectIfy Replace pads or brake shoes Clean or replace linings
worn
Replace
AIr
In reservoir
Bleed system
Pedal
can
Check valve
In
master
cylinder faulty
new
valve
TIghten
In
connections
or
fIt
new
PIpeS
Damaged
brake
or
master
In
questIon
Brakes overheat
CompensatIon port
In
master
cylinder
blocked Return spring weak Rubber parts swollen due to unSUItable brake flUid
use
of
springs flUId remove all rubber parts and flush system Replace all parts In master brake cylinder Drain
new
Brakes pull to
one
SIde
TIghten
Clean
or
AdJust Repair
i nter
10
Mil
0 8 04Ii
OG
0 0
C 81
Vl
f
III
81
e II
e
ClO lle
FlgM
e
M 4 The Fig
COIIl
oo
1l
5 Rotor
II SIIp
IV end
FIg 3 RernlIYaI M
of the drive
pulley nu1
M 6 TIPPing FIII
rotIlr
the dnve
rotIlr
W
Red
or
Black
on bliwot
figures
Fig8 M
M 7 The FIII
Id
of the dIOdes
88
Electrical
ALTERNATOR Precautumay Service NotllS
IS
Equipment
with a hammer The parts separate as shown In Fig M 2 Hold the drIVe end rotor carefully In a VIce and remove the pulley nut the pulley the fan arid tha spacer from the rotor shaft Fig M 3 and M 4 Tap out the rotor from the drive end bracket uSing
a
The following precautions should be taken when serviCing carned outon vehIcles wIth alternator charging systems
1 Reversed
battery
connections
will
damage
the
dIode
IS
hide mallet
IS
battery negatIve
cable
IS
terminal
retainer and
press
removed M6
by
means
of
arm two
puller
deSign
FIg
alternator
when
It
disconnected
regulator
Remove the stator from the dIode 3 negatIVe diodes black fIgures for for pOSitIve dIodes In FIg M6 from care not to overheat the diodes as
end
Earthing
the
main
WIll damage the alternator and even when the IgnitIon SWItch CirCUIt breakers are used 4 Do not
u nit run
cable or the terminal of the alternator or the alternator CIrcUIt IS SWItched off Since no
damage
stator
Then
unscrew
and
as
the cOIl lead WIres but take thIS WIll lead to Irrepalrable remove the brush cover and
In
unsolder the
termlnai
shown
Fig
M8
Lift
ff the
the alternator WIth the battery dIsconnected and the field WindIngs energlsed otherwIse the control WIll be
not
damaged
to
Remove the heat Sink and the brush holder from the rear cover Dismantle the brush holder and unsolder as shown In Fig M 9 black and also the F black whIte and E the lead wires brush holder wires A dIsmantled View can be seen In Fig M l0
Do
attempt
polartse
the
alternator
It
IS
not to
necessary Any attempt to do so may result In the alternator regulator or associated CirCUItS 6 DIsconnect
damage
charger
charger
first control
to to
the battery cables before uSIng a battery prevent damage to the rectIfIer diodes A boost assIst starting the engine cannot be used WIthout
can
replaCIng they should be pressed out of the replaced USing a SUItable press tool Do not drtve out the damaged dIode as the other stIli servIceable dIodes may be damaged through the Impact and shock
If the diodes need heat Sink and ALTERNATOR Rotor check the rotor COIl for open or short USing CirCUItS Connect the Instrument to the shp rings of the rotor and check the indicatIon on the ohmmeter No reading indicates
an
Inspection
dIsconnectIng the
Unit
wire
to
the alternator
an
ohmmeter of the type Incorporating a generator for checking the dIode rectIfIers or
dIsconnected
room
ohms at
to
447
Belt tensIOn
tenSion
aVOid bearing damage when adJustIng belt only on the alternator drtve end leverage apply any other part of the alternator
bracket 9
not on
If arc welding IS carried out on the car disconnect the alternator and control Unit to prevent pOSSIble damage It IS also Important to Inform any welding speclahst of thIS fact as It IS poSSIble that he Will not know that thIS car IS fItted With
an
cbeck the rotor between shp rtng and rotor core If there readIng on the ohmmeter the rotor assembly should be replaced as In thiS case the fIeld COIl or the shp nng must be connected to earth FIg M 11 shows the testIng of the fIeld coil If for conductIVIty top and for earth connectIon bottom
Next
IS
a
there
IS
short
or
open
CirCUIt
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
10
The battery must never be connected dIsconnected while the engine IS running or damage may occur to the devIces conductor seml regulator
0004
In
replace
ALTERNATOR
Removal
Disconnect the battery earth cable and dIsconnect the Wires from the alternator Remove the bolt securtng the fan belt tensIoning strut ana hft away the fan belt Remove the
uSing a CIrcuit tester by the neutral wire of the to connectUlg stator The connections are In order If there IS COndUCtiVity If any of the other leads IS connected to the other Side of the tester If thiS IS not the case replace the stator There should be
yellow
alternator
open CircUit conditIon between the stator M 14 the cOIl leads Fig M 13
an
body
and any of
Diode
Assembly
Dlsmanthng
Fig
M l
Remove the through bolts and remove the diode end hOUSing from the drive end housing by tapping the front bracket hghtly
claSSifIed by the resistance value between the diode holder heat SInk and the diode leads To perform thIS test remove the diode holder from the stator Good
or
defectIVe
diodes
are
f11
inter
cJU
jIJtE @
1
r 1
f
FI9 10 V M 1Ily
M9 FIlI
out run
for Checking the rotor field cod bottOm and earthIng continurty top
M l1 FI9
FI9 13 Chedung M
1he
wlIldmgs for
con1lnurty
rJl
1he
W1ndlriila
for
M 15 DlOlIe FIlI
test
M 16 DIOlIe test g i F
88
unsteady charge
Check drlvlng belt tension Check for high resistance
CirCUit connectIons at
holder and the negatIve lead to the diode pin and check the resIstance A good dIode WIll indIcate no resistance Next turn the polarity of the tester and check agaIn If the the diode IS short needle moves In eIther directIon CirCUIted If any of the dIodes IS defectIve It might be advIsable
tester to
renew In
10
particularly earth
VOLTAGE REGULATOR Disconnect the 6 way connector and secUring the regulator to the bulkhead
Removal
remove
shown
The testing
connections
are
the
screws
2 DIode holder negatIve SIde Check the negative SIde as described above but the CIrCU It tester must be reversed FIg M 16 Broshes Check that the remaining brush length IS 7 5 mm 0 295 In FIg M 17 and check the brush spring pressure by pressmg of the holder The brush down to WIthIn 1 mm 004 10 pressure should be 035 kg mlntmum of 0 2 kg 044 Ib 077 Ib
IS In
Testing
Connect the CirCUIt as shown In FIg M 22 uSIng a fully charged battery and run the alternator at 5000 rpm The voltage read 109 15 0 volts If the voltage IS not correct adjUst should be 140 the regu lator Mechantcal adJustments The gap values of the constant voltage relay and the pIlot lamp relay must be as follows Gl 09 10mm Constant vo Itage relay
permissible
FIg
M 23 G2 G3
0 035 0 8 1 2
0 039
mm
10
Install the bearing Into the drive end bracket and fIt the bearing WIth the three screws Pack the rear bearing With multI purpose grease If no sealed beanng IS used Then press
retamer
on
to
PIlot light
relay
G1 G2 G3
mm
The remammg operatIons are carried out 10 reverse order to the dIsmantling procedure Make sure that the dIodes are connected correctly Fig M 18 and M 19 The mstallatlon of the alternator
IS a
Observe all procedure pomts gIven under the ALTERNATOR PrecautIonary ServIcIng Notes
flOe emery cloth pnor adjustment feeler gauges check the back gap Gl and adjUst If necessary by means of the armature set screw
Usmg
Inspection of output
test
ClrCU It as
Air gap
In
G2
shown
FIg M 20
and dnve by means of a SUItable motor With the alternator at 2 amps rest there Will be a negatIve current to the field cool When the alternator IS turnmg at about 1000 rpm there should be
no
aIr gap between the armature and the top of the COli feeler gauge and If necessary adjust by bending the primary contact support Fig M 25 usmg the adJustmg tool
WIth the
Pomt gap G3 Check the gap WIth feeler gauges and adjust If necessary by bend 109 the secondary contact support With the adJustong tool Yoke gap gl Use feeler gauges and measure the gap between the armature and the yoke and If necessary adJUst be bending the armature
setscrew
slowly reduce the load reSIstance mcreaslng the alternato speed Read off the current value In relation to the alternator speed and check 10 accordance to the speCIfIcatIons If the deVIation IS small the alternator IS 10 good condItion
ALTERNATOR
Flndmg
of faults
Alternator does not charge the battery 1 Check drlvmg belt tensIon 2 3 4 Field cable broken at control Untt NegatIve cable broken at control unIt POSItive and field cables crossed uncontrolled
Air gap g2 Check the gap With feeler gauges and adJUst by loosenIng the contact set screw and raisIng or lowering the contact set WIth a screwdnver
FIg
M 26
Alternator output
1 2 3
y means of a feeler gauge and adjust by the contact po lOt set screw and alsmg or lowerulg the contact set WIth a screwdriver
loosening
POSitive cable broken at control Untt Field and negatIve cables crossed at control unot Field and output connectors touching at alternator
89
IDmZIIIII
1
r
I I I I
jj TBattery
I I I
l
I
I
I
I I I I I I I I I I I I I l I L I J I I I I
F g M 17 The
m nlmum
brush length
Red ftgure
lack flgure
M
POSItIve dIode
NegatIve diode
REGULATOR
for
checkIng
the
performance t
t
Back gap G Air gap G2 08 12 Stopper
PrtmafY
contact
support
Voltage corl
SecomlafY
COntact
support
A V
90
POint gap g3
Sprong
Voltage coIl
See
elr
gap of the
voltage
BendIng dIrection
ghten voltage
I Lower voltage
27 M
g Sllttll
gap of the
pilot
cO
5C h
V
12ij0
i Ct
l
Fog M 29
fnIm The tu onn motor body end drIVe end bracket removlKl
1 0
14
IS 16
17
19
ii
the
if 1
g
M 28 ExplodlKl Fog
lINer 10 O
VlOW
of
motor
lnent t Etrpf 2 a 5
pin
Sulmg
flntI t
12 Slop
C IP
14 Pinion rtap OD
15 Drwe
1er
6 Dud l 7 SoltlnoJd
tbil8 BAnn
tch
16 O 17 Fleldcoll
pimon h nn ngclvtr
IS Sttrter motor body brush 19 brush 20 N 21 Brumllmng 22 Brush dtJr ho 23 BNrtng bush 2tI R co 25 bon lh ThroU
Thnnt
motu end
nt
from
the
dr
end
91
inter
J I1
1 ID
FI M 31 I
I FI
te
on
Round
0 5mm O
8mm
Commutator
Ica
Correct
Incorrect
Fig
34 M
uttlng Unden
gmtlon swItch
Fill M 36
Circuits
Checkmg
the armature
for
short
IT
Battery
Starter motor
l
M38 FI9
II M ng
the starter
motDr
lenood Mrtd1
l panlOl
92
adjustment
voltage
decrease
bend the stopper upwards or bend It the voltage on the voltage relay
test prod to the commutator and the other one to the armature or shaft If the lamp lights the armature coil IS connected to earth and the armature should be replaced The armature can also be tested by using a Circuit tester as shown In Fig M 35 If the Circuit tester needle moves the coil IS earthed
Check the
VOLTAGE REGULATOR lnstallllt101l order to the removal
armature
armature on
The installation
IS
carrted out
10
reverse
procedure
STARTER MOTOR Removal
the growler and hold a hacksaw blade over the armature while rotatmg It If the hacksaw blade vibrates the wmdlngs are shorting and the armature must be replaced Fig M 36
llts by placmg the Check the armature wmdlngs for open crra armature on the growler and connectIng two commutator
Disconnect the battery earth connectIon and the cables from the starter motor termmals Remove the starter motor mountmg bolts and 11ft the motor forward and out of the
car
segments With the test prods Repeat thiS test for all adJacent segments An mconslstent reading mdlcates an open CIrcuIt
Starter motor clutch the running clutch for damage and Inspect the free wheel actIon 10 one direction and the slipping actIon 10 the opposite directIon Replace If faulty Check
over
STARTER MOTOR
Dismantling
DIsconnect the Wire to the M termmal on the starter motor solenoId swItch remove the solenoid swItch securmg screws and 11ft off the solenoid swItch Remove the two through bolts and take off the brush cover Gently tap off the starter motor body WIth
a
Brush holders the brush holders for earth 109 USIng a CIrcuit tester Place one test prod on the rear cover and the other on the pOSItive brush holder If the tester needle moves It becomes Check necessary to replace the Insulator or the brush holder DrIve end Check the clearance between the
at
wooden
hammer
to
as
shown
10
bearing
the dnve
10
end
replace
beanng and the armature shaft If the runnmg clearance exceeds 0 2 mm the beanng Press 10 the new beanng and
size
ream
out to
the correct 0 10
mm
Connect
test
prod
for open CirCUIt us 109 a CirCUIt tester on to the field coli lead and the other If the tester needle does not F Ig M 31
an
pressed 10 so that the end of the WIth the end of the dnve end housmg
should be Solenoid switch
beanng
bush
IS flush
prod
move
to
open CirCUIt
the contacts of the solenOid SWitch weldIng of the contacts has occured Check
no
Check the fIeld COIls for earth Connect one test prod to the field COIl lead and the other prod to the starter motor body If the needle be
moves
ER MOTOR
Assembly
replaced
assembly of the starter motor IS carried out 10 reverse order to the removal procedure Pack the rear cover with grease and lightly 011 the rear beanng and the dnve pmlon
Solenoid SWItch test With the starter motor assembled connect up a test circuit as shown 10 Fig M 37 With the igRltlon SWItched on check that the dimension between the front edge of the drive plnton and 15 nvn 0012 0059 10 Measure the plRlOn stopper IS 0 3 this dimension
as
Check the length of the brushes and replace them If they are Check the contacts and replace them less than 6 mm 024 10 If loose Check that th brush holders Will hold the brushes down to the commutator Check the spnng tensIon With the aid of a spnng balance as shown 10 Fig M 32 The correct tension IS O B 0 7
kg kg
1 76 1 54 lb
Ib
Replace
the
springs
shown in
Fig
M 38 Removal
Armature
Check the armature shaft for distortion as shown In Fig M 33 out run and replace the complete armature if the IS greater then 016 mm 0006 In Check the commutator for roughness burnt or scored surface If necessary skim off the surface 10 a lathe removmg the minimum material necessary to obtam a smooth fiRlsh The round of the commutator should not exceed 0 2 mm of out 0 008 10 Check that the mica inserts areundercut to a depth A mmimum depth of 0 2 mm of 0 5 O B mm 002 0 032 in 0 008 10 must not be exceeded
WINDSCREEN WIPERS
Lift the Wiper arm remove the secunng nut and remove the arm together With the wiper blade Remove the link securing nut Lift the bonnet and remove the screws holding the Wiper
assembly
to
Disconnect the
wiper
motor
Wiring
See Fig M 39
WINDSCREEN WIPER
Remove
ended hook
Dismantling
the
linkage and
bolts
from
growler Connect
one
IlI8gnetized
case
the bracket the nuts of the the motor case and remove the from the gIl8I case Withdraw the annature
91
i nt e fiE
JI DJ OoJ
l P
1 2 3 4 S
Yoke
16 17
B b Rivet
31 32
retainer
Tapping
Worm
Wheel
lCJ ew
Damper
Armature
wheel
ann
stopper
18 19 20 21 2 23 24 2S 26
Spnng
Gear
33
34 3S 36 y 37 38 39 40
Feltwasbe r
Grommet
case screw us
PlaiD washer
Beanng
Hook
Rivet Felt walber Plate sptmg holt
Hexagon
out
6
7 8 9 10 11 12 13 14 t5
Tapping
type nop
nug
Sprmg
BaU
etamer
Beatlng
Auto Lock
stop
cover aA
41 42
Magnet
ball
au
27 y 28 29 30
plate
erew ass
Beanng Hexagon
Tluwt
nut
Armature
43
screw
y 4S
Chp
M FIU
39
Exploded
3
7
28
43
35
nut
sr
Fig
If parlnng
pcIS1tJon
94
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
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 indicator SWitch
Apply
dlsmanthng and removal procedures respectIVely grease to the gear and coat the hOUSing and the cover
JOinting bracket Adjust the the stop cover screw and turn
J AI smear
IS the
surfaces
With JOInting compound compound between hOUSing and end parklng self the cover switch by
as
fitting
correct
relation
the
shown
In
loosentng Fig M 43
stralght ahead
posItion
wheels
Technical Data
ALTERNATOR Armature shaft dla Maker Nominal output Earth connectIon HITACHI 12 volts 30 amps Max permls shaft out run Bush running clearance Clearance Itmlt Commutator outer dla Wear hmlt Brush 11 0
mm
0433
11 5 003
mm
0453
NegatIve
13 500 rpm 1000 rpm 22 amps at 14 volts and 2500 rpm 2251 1 000
Speed
No load
mln
speed
engIne
length
Wear hmlt Brush spring tensIon Drive end bracket bearing bush HITACHI
Inner dIameter Drive end bracket bush bore Inner dIameter
1 76 Ib 0433 0453
In
Type
No load
regulating voltage
mm
In
STARTER MOTOR HITACHI S114 103 12 volts 10kw Less than 480 amps 6 volts 1 1 kgm 8 0 Ib ft Less than 60 amps at 12 volts 7000 rpm Solenoid SWItch 9 120 5 1
LAMPS
Type 1 Type 2
lamp lamp
flywheel ring
gear
Weight
kg
10 4Ib
Engine compartment lamp Interior lamp Rear flasher lamp Tallstop lamp Reversing lamp Number plate lamp IndIcator lamps
25 8 watts 25 watts
8 watts 3 watts
95
Trouble
SYMPTOMS Battery
In
Shooting
ACTION TO BE TAKEN when runntng at about
on
PROBABLE r AUSE
Dynamo
20 mph
not chargIng
30 km WIth swItched
lights
Examine charging and field CIrcuIt TIghten loose connectIons or lead Partlcu larly replace broken wiring
examine
Broken
or
loose
or
connectIon
In
dynamo
CirCUIt
regulator
not
functIonIng correctly
battery
connectIons
dirty
Clean
WIth
soft
rag
mOIstened
In
running
broken
Examine wiring
charging
and
fIeld
CirCUIt
or
dynamo
CirCUIt
TIghten loose
connectlotl
dirty
Clean
WIth
soft
rag
mOistened
In
petrol
Brushes
worn or
not
fitted correctly
Replace
brushes
worn
bed
brushes oronerlv
Regulator
not
functlomng correctly
ExamIne regulator
Battery
overcharged
shown very
by frequent
Regulator
not
functIoning
tly corre
Examine regulator
Starter does not operate or operates and does not turn the engine
Poor contact of starter swItch contact POints Poor brush contact Burnt commutator Shorted field COIl Shorted armature Poor contact of battery leads Weak battery
Replace brushes
Overhau I
or
spnngs
motor
or
starter
clean
commutator
Recharge battery
between starter SWitch Check wlrtng and replace If necessary
Open
CI
rcUlt
Starter does
not
seem
motor to
operates
over
but
turn
engine
qUIckly enough
worn
recondition ring
at
goes
out
only
Charge battery Replace battery Replace bulb Tighten or replace terminals TIghten or replace cables Replace switch Free or replace brushes If necessary replace brush springs Adjust tension or replace belt Replace regulator TIghten connectIon re replace lead Repair generator
Clean commutator
not
when
engine
go out IS rpm
Loose
or
Regular defective
POSitIve lead loose or broken Generator de ECt ve Commutator graphlted Brushes worn Brush spring weak or annealed BInding brush levers
turns WIper motor does not operate II too slowly or comes to a standstl
DIrty
commutator
In
ExcesSive frictIon
wiper linkages
armature
or
complete
motor
WIper
Contacts In hOUSing damaged Contact spring bent Insulating bracket broken Contacts dl rty Wiper motor cannot be SWItched off Bad connection from wIper SWItch to earth
Clean contacts Screw SWitch button back slightly bend contacts Check connectIon replace SWItch
Wiper linkages
POI
n
bushings
running dry
of
armature
spIndle
of
commutator Side against stop brush holder Incorrect pOSItion of motor cover
RepOSItIOn
cover
move
PinIon
or
a rmatu re
shaft
dirty
or
damaged
SolenOId SWItch defective
Remove each sparking plug In turn It on the cylinder head and observe whether a spark occurs at the pOints when the engl ne IS turned Irregular sparking may be due to dirty plugs or defectIve hIgh tenSIon cables If sparking IS regular at all plugs the trouble IS probably due to engine defects
rest
petrol supply
etc
LH
UOHT
R8
J
i R m a
O
0 0
tII
QI 3
nOL
a
O
b
HE
WIRNG
AOIO
DFORIAGRM
DE
o
to
EAfER I
UNIT
r
GW
LUXE
L1GHTlt
eN
eMJI
I
WIPER
Im
0
SW
II
MARK NOTE
SALO N
INCLUDING
T1a 1
l jl
OIL
TS
V 0
IL
up iiill
LIGHT COO
a
TAtf
lHT
QO GAI
AIN
VOL
INITRi NENT u
HT
l3EAM
TAGE
REGULATtIl
AL
CMlNATIO
II 1
REAR
TlIjTAIL STOP Br CJ
UP
LIGHT LeEN
L N
PARTS
Jo4 L
111
I
I
Ill
UP
L
STOP T1JIH
L
nOlLH
T 1I
PARTS
fCNAl Cf
REGULATOft
TAGE
VQ
LIN1lQG
LIGHT IGHT LlCOHT LIGKT LNG I UNG LIGHT PILOT PILOT R WA R ENT INSTR BEAM T10N
hI AIN
GAUGE
DIRECTONAL
Y jr III Plllr li
I
UNIT
NOTE
MARK YO
Il
TS
OIL
fiRB
II SI I
L
11
W
N i
mE
HEAT R
CLOC
fT
el
SALO N
SSS
rm o
A010
rk
l
HEATRU
FOR
LiGHT
DIAGRM
WIRNG
I
fJ
RELAY
BY
idr
l L1CJ
nu
rr m
HEAD
B B
TI
e 8
RW
B1 e R
if
RTcflv OF
RJi
a
l DUGt
Cb
RH
rv
LH
8L
fMK SIGNAL
HE
AOLGHLH I
AU
IS
ENGLISH
Vear Model
1 2 3 CO
CYlinders
1969no
1000 fLC 510
19ssno
l 2 3 3A
1600 510
HCI
Engine type
EEC Number of
3A
4 4 4
4 42 3 1 1595
5 6
7
5 6 7 8 9
63f73 7
95
CompreSSion Compreulon
011 prnsure ROIted output Fuel
V
8 kg
cm2
9 10
11
9
35 57 40 64
116 171 37 60
42 64 00 3 7
kg cm2
2 4
10 11 llA
HPlrpm
Ltr 100 km DINJ
n
6000
96 SAE 5600
consuFnpllonlmpg
nlet utlet
mm
25 0
3 0
0 0101025
12
Valve
n mm
0 12
0012 0 30
12 6
13
14 15 15A 158
Inlet valve
oOTOC oATDe
14 IS lSA 158
19
horsepower
Km h rpm gear
auery B
V lty polal
Ah munn
16 17 18 19
I 12V140An
HITACHI OCK 308 600 23
12
iOAh VI
12 V 50 Ah
16 17 18 19 20 21
Svstem
plus
20 21 22 23
kg cm2
5117
2 HITACHI 0411 5 o 49 91l21 017 55 58 0 4SO 5 HITACHI o 40ll 9021 0017 55 64 05 045
22 23 24 5 26
23 24 25 26
I
mm
Dwellangfe
Stmctlmlng
Degrees oaTDC
timing
27 28
I
oaTDOrpm
type Ohms
o
10 600 CP HITACHI 15
14 650 CP HITACHI
27 28 28A 288 9 0 31 32 3 34
rk locatIOn
2BA
COil make
stance advanCt
288
288 29 30 3 32 33 34
6 1
800 0
129
30 31 32 33 34
Centnf
starts
0800
800 0
dlate Interml
intermediate
rpmE o
o o
ln o ln o
Hg Hg
35 36 37 38
er c Condens ap8C
MId
35 36 37
22 0
NGK
0 24
135
37
6E
BP
BE
OP
BE
n mm
38 3BA
0031 08
HITACHI
0031
8 0
0031
8 0
rter motor
H TACHI
HITACHI
lA
388
ALT
Amps
VolI
ALT I 41K
HITACHI LT 12 30 133
AL T
HITACHI
139 I 11
01
LT 140 4EiK
41
12 30
42 43 44 45 46 47 48 49 50 51
Requlator make
R
42 43
V 44
HITACHI TL1 Z 17
HITACHI TL1 Z 17
HITACHI T1 1 Z 17
ulator type
In
143 145
116
Cut
clO
lnq
voltaQe
V
A
45 46 47 48 49
mln
Open
CirCUit CIrCUit
V
A A V A
Closed
1 148
9 0 1
Current
regulo1tor
egulator
Voltage
NOTES
50 51
52 53
um um
52 53
2 3
TIGHTENING TORQUES
ENGINE
mounting
Drive shaft to differential nuts Drive shaft to 7 0
rear
2 3 8 0 8 0
kgm
SO 6
16 61b ft 57 8 Ib ft
kgm
axle
flange
70 20 8 0
ConnectIng rod nuts Flywheel bolts Main beanng bolts Camshaft sprocket bolt
011 sump 011 pump 011 strainer Crankshaft
27 95 45 50
33 kgm
pulley bolt
nut
Cylinder
head bolts
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
nuts
Bumper
nut
Wheel nuts
kgm kgm
72 3 Ib ft 61 5Ib ft 72 3Ib ft 43 4 Ib ft 61 6 Ib ft
10
kgm
6 0
57 8
kgm
29
40 85 kgm
FRONT SUSPENSION GEARBOX Front hub nut Rear extension to case Gearbox to engine Bottom cover Front cover Drain 30 73 39
arm
3 5 9 9 5 3
plug
Malnshaf
nut
30kgm 160 4 5 5 3 kgm 32 6 1 1 1 7 kgm 8 0 1 7 kgm 80 1 1 3 5 5 0 kgm 25 3 18 21 kgm 130 20 40 kgm 145 07 1 1 kgm 5 1 o 7 1 1 kgm 5 1 90 11 0 kgm 65 1
22
Brake
calltper bolts
Brake diSC bolts Stablltser bolts suspension SIde Stablltser bolts frame SIde ReactIon rod to frame ReactIon rod to suspension
arm
21 7 528 28 2 8 7
253 Ib ft 71 6 Ib ft 38 3 Ib ft 12 3 Ib ft
1 2
1 7
35 4 282 43 4 2
45 6 Ib ft 37 6 Ib ft 578 Ib ft 97 61b ft
SuspensIon
nuts
Untt
upper 3 9
Steering
FINAL DRIVE shaft flange Drive plnton nut 40 170 140 85 kgm 28 9 61 5 Ib ft 1446Ibft 122 91b ft 57 8 Ib ft 39 8 Ib ft
Untt
lever to suspension 60 80
arm to
SuspensIon Propeller
Saloon
Estate Crown wheel bolts Saloon Estate Saloon models only Side cover bolts Dnve member
kgm 88
1229 101 2 SO 6 34 7
Lower ball JOInt Lower ball JOInt nut PIston rod nut Gland packing Wheel nuts
80 kgm 5 5
43 4 434 57 8
47 0 Ib ft 470 Ib ft 65 1 Ib ft
kgm
bo ts
STEERING
1 B 5 5
25 kgm 7 6
130 18 lib ft
Rear cover bolts 1 9 26 Final dnve to final drive mountIng member 60 8 0 Final drive to suspensIon member FInal drive to dnve shafts Final dnve shaft Estate car models only DIfferential carrier to axle Drive 7 0 8 0 8 5
kgm kgm
137 43 4
188 Ib ft 57 8 Ib ft
Drop
Idler
arm arm
nut
nut
screw
AdJustIng
Idler arm
nut
60 kgm 43 4 Ib ft
Steenng gear
kgm 39 8 55 0 Ib ft 125 14 0 kgm 90 01010 Ib ft 55 7 6 kgm 39855 0 Ib ft 18 25kgm 130 181Ibft 100 kgm 72 31b ft 44 1 Ib ft 44 6 1 kgm 31 8
kgm kgm
506 289
57 B Ib ft
flange
to
propeller
40 61 5 Ib ft
BRAKES
Brake pedal PIVOt Brake pipeS 145 13 0 15 91b ft Brake diSC bolts 3 5 15 39 1 7 17 7 3 4 0
11 kgm 108
53 kgm 20 kgm 9 0
kgm
25 3 28 9 Ib ft 12 3 Ib ft 282 38 3lb ft
20 18
22 kgm
Bridge
1591bft
22kgm
123 14 51b ft
cylinder
123 20kgm
kgm 52 8
145Ibft 5 1 Ib ft
REAR
SUSPENSION 25 27 3 33
beanng backplate
nut
ft ft
101
CONVERSION TABLE
mm
lnS
mln
ln
mm
lnS
mm
1m
mm
inS
01 02 03 04 05 06 07 08
09
000394 000787 001181 001575 00 969 002362 002756 003150 003543 003937 004331 004724 005118
0055
020079 020472 020866 021260 021854 022047 022441 022835 023 228 023622 024016 024409 024803 025197 025591 025984 026378 026772 027165 027559 027953 028348 028740 029134 029528 029921 030315 030709 031103 031496 03 890 2 3
4
5 52
53
105 110 15 120 25 130 135 140 145 50 155 60 165 170 175 180 185 190 195 200 210 220 230 240 250 260 270 280 290 300 3
0
4 4 4 4 4
52 53
54
54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69
70
55 56 57 58 59
60
5 6
7
2 204720
2
5 1 81 0 5
5 5 5 3
244090
4950
8 9 10 II 2 13 14 15 16
17
2 283460 2 322830
2
10 1
12 13
393700 433070
472440
362200
61 62 63 64 65 66 67 6B 69 70
71 72 73 74
511810 551180 590550 629920 669290 708660 748030 787400 826770 866140 905510 944880 984250
1
14 15 16 17 18 19 20 21 22
23 24
519680
005906 006299 006693 0070B7 007480 007874 008268 00866l 009005 009149 009841 010236 010630 011024 011417 011811
0 0 2205
2 559050 2 598420
2
086600 283450
637790
18 19 20 21 22 23 24 25 26
27
7 480300 7 677150
7
874000
71 72 73 74 75 76
77
874010 913380
25 26
27
75 76
71
2 952750 2 992120
3
1 1
031490
28 29 30
3
78
79 80
28 29
30
78 79 80 8 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
3 070860
3 3
11 417300 11 811000
81 82
83 84 85
3 32
33
32 33
34
2598
032283 032677 033071 033465 033858 034252 034646 035039 035433 035827 036220 036614 037008 037402 037795 038189 038583 038976 039370
320
330
012992 013386
0
34 35 36 37 38 39 40
41
35 36 37 38 39
40
3780
014173 014567 014961 015354 015748 016142 016535 016929 017323 017717 018110 018504 018898 019291 019685
86
87 88
456689
I 496050
1
484560 503930
89 90 91 92 93
94
535430
I 574800
1 1 I
3 543300 3 582670
3
41
42
500 600
700
42 43
44 45
622040
23 622000 27 559000 31 496000 35 433000 39 370000 78 740000 118 110000 157 380000
43
44 45
3 661410
3 3
700780 740150
95 96 97 98 99 Imm
46
47
46 47 48 49 50
3 779520
3
818890
48 49 50
I 968500
196 850000
I
t
oQUu@ f
1Wrr@LW
71
l oo
if
y I
COV RcS
1300cc and
Estate up to
Saloon and
970
CONTAINS
1
DetaIled
hundreds of illustratIOns
plus
Trouble
Shooting
Tables
l
WIrIng DIagrams
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Parts
Diagrams
dentificatlOn
f
r
Q 1T UJ
5oo U
OO p M 1@ O j@