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Man
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INTER EUROPE WORKSHOP MANUALS

Titles available NOW

f
1

121
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d
r
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f7

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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

1969
1968
1968
1969
1968

From 1965
to 1969
Since Introduction

Up

1968 1970

i
b

WORKSHOP MANUAL
for
DATSUN Saloon
1300

1600

c c

Estate
c c

COMPILED AND WRITIEN

BY
PETER R

D RUSSEK

PUBLISHED BY

INTEREUROPE

LIMITED

AUTODATA DIVISION
2
4 QUEENS DRIVE
LONDON W 3
ENGLAND

lb

Pnntlld

IntIInlUrope LIlDtIld AulJllt 1970

Copyright IC
11

110 IYIIIIbIe in Spanish

av

1Ib1e thRlUllh

Lan

W
ey

SA MexICO City

2nd edition

January

England

1971

Type Identification
SALOON MODELS

Model designation
510

Type

L510

P510 U

L13

P510 UT

PL510 T

PL510

P510

PL510 A

PL510 UA

510

SU

L510

P510 SU

speed remote control

speed floor shIft
AutomatIc three speed
Four

Three

L13

PL510 S

P510 SUT

Three
L16

UT

Standard

SSS

PL510 TK

speed

remote

control

Three
Four

speed remote control

speed floor shIft

Four

speed floor sluft

L16

PL510 ST

P510 UTK

Gearbox
Three speed remote control

Deluxe

PL510

UA

E n9108

L16 WIth SU
tWIn

carb

ESTATE CAR MODELS

I

WP510 U

WPL510

WP510 UT

WPL510

Three
Deluxe

WPL510
WP510

UT

UA

WPL510

remote

speed

control

T
Four

L16

floor shIft

speed

WPL510 A
AutomatIc three spl ed

UA

DIMENSIONS AND TYRf PRESSURES

Length

overall

Standard Saloon
De Luxe
SSS Saloon

4 070

4 120mm

162210

Estate Car

4 145

163210

Width overall

1602

mm

mm

1 560

mm

10

61 410

Height overall
Saloon
Estate Car

1400mm

551

In

1 435

mm

56 5

In

mm

953

In

Wheel base

420
2

MIO ground clearance

Saloon
Estate Car

190

mm

74

In

165

mm

64

In

504
50 2

In

Front track
Saloon

1 280
1 275

mm

Saloon

1 280

mm

50 4

In

Estate Car

1 260

mm

496

In

Estate Car
Rear track

mm

In

Tyre

pressures
Front
Rear

24 pSI
28 pSI
24 psi

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

28 pSI

20 kg sq

em

High speed driVing

FILLING CAPACITIES

Engine

011
4 0 htres

MIn

3 0 htres 0 79 US

Gearbox 011
Autom transmission
Differential 011
Saloon
Estate Car

SJeerlng

uiG

Max

9eaL

US

gal
gal

0 88 Imp gal
0 66 Imp gal

1 7 htres l 79 US qts 3 Imp pts

123 Imp pts

7 htres 7 39 US qts

08 htres 084 US qts

1 4

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

Imp pts
Imp pts
Imp Pts

INDEX
4

lYPE IDENTIFICATION

ENGINE
LUBRICATION SYSTEM

18

COOLING SYSTEM

20

IGNITION SYSTEM

22

FUEL SYSTEM

26

CLUTCH

36

GEARBOX

44

REAR AXLE

S3

REAR SUSPENSION

62

FRONT SUSPENSION

68

STEERING

74

BRAKES

78

ELECTRICAL

86

EQUIPMENT

98

WIRING DIAGRAMS
ENGINE 1 JNING DATA

100

TIGHTENING TORQUES

101

CONVERSION TABLE

102

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

the chapter

most of the major

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

SpeCial

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

Happy motonng

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

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

inter

llil

p
@

Fog A 1

Removal Of the

nslave
cluu

trel
Jb
i

cyhllller

Fog

2 The removal of the

A

engll

1t

fd

f7

if1
or

L161

engIne

flUBd

10

f g A6

FIlI A 5 Removal

of

the manifold assembly

FIIA7 Removal of the cyhnder h8I

eket

g 8 Removal of the oil straaner

A

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

INTRODUCTION
The

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

single twin choke

Turn the engine

over and remove the sump and the Internal 011

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

and the chain dnve sprocket

FIg A 9

tool ST44630000 for the rear main beanng cap

Removal

Fig

Drain the coolant engine and gearbox 011 and remove or

disconnect the follOWing parts Battery bonnet air cleaner and

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

rocker box breather hose

radiator gnll upper and lower
radiator hoses radiator torque converter cooling hoses from
radiator automatic models only
COIling fan and pulley fuel

and the

pipe

heater

hoses If fitted

accelerator

wiring from starter motor alternator

Unit and temperature sender Unit
Remove the clutch slave
Remove or disconnect

Speedometer

cable

cylinder Fig

special

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

carburettor

ENGINE

USing

llJd bolts
h

linkage

COil

A 1

choke cable

011 pressure sender

and ItS return spnng

flat connector from reversing

light

SWitch

A 11

Remove tne

Remove the piston nngs With a SUitable piston nng expander

gudgeon pin With a SUitable mandrel the outer diameter

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

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

gearchange linkage front exhaust pipe from manifold then the

front pipe first Silencer and centre pipe
shaft at the front
Jack

up the gearbox slightly and

bracket
the
mounting
handbrake cable clamps

mounting

assembly

the

propeller
ENGINE

remove

the

rear

crossmember

engine
and
the

Thoroughly
inspection

clean all
and

Inspection

parts of dirt 011 and water scale before

attempting to carry out overhaul

before

operations Blowout all passages With compressed air Remove

carbon depOSits from the top of the pistons
combustion

Remove the bolts secunng the front engine mounting brackets

the crossmember Fit a lifting hook to the engine hangers and
carefully 11ft the engine and gearbox In a tilted poSition e g

chambers

forwards and upwards

I nspect and overhaul the parts

to

uSing

SUitable

crane or hOIst

FIg A 2

cylinder head
from any of the parts

and valves

as

Cylinder
ENGINE

Dismantling

Remove the

gearbox and the starter motor Mark the clutch

and the flywheel SUitably With a centre punch and
remove the clutch cover together With the clutch dnven plate

mountings

Alternator and bracket

follOWing parts

011

filter

engine
011 pressure SWitch
SUitable stand If available Special Tool

water

Mount the engine In a

ST37200510
attachment
Flg A3

drain

and

plug

Stand

ST37100000

See

hOUSIng

F Ig A 4

Remove the fuel pump drive

FlgA 6

cam

head

the 1600

c c
Check the mating surface for flatness by
engine
of a straight edge placed across the head and checking
the clearance With a feeler gauge
F g A 13
If the clearance
exceeds 1 0 mm 0 0039 In regrind the cylinder head to block
face
means

Check the valve seats for

sprocket

or wear

and If necessary reface

In Fig A 14 and A 15

If necessary replace valve Inserts To replace the Inserts bore

out the old Insert and select the correct Insert Fig A 16 and fit
by heating the cylinder head to 150 200oC 300 3900F
Valve

fuel pump and

and the crankshaft

damage

accordance With the dimenSions given

Remove the inlet and exhaust manifolds Flg A 5

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

follows

cylinder head for cracks and the mating faces for burrs or
uneveness and replace If necessary
note that different cylinder
heads are used for the Single and twin carburettor verSions of

In

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

but do not remove metal

Check

cover

Remove the

and Overhaul

guides

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

USing

must

0 073

for Inlet valves and

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

checking

the clearance IS to Insert the valve stem Into the gu

inter

E2C0

@F
0

FillA 9

Removal

of the crankshaft challl

rocket

S
o

cf
FillA

11

Removal

of

the baffle plata and

FI

12

cyhrder block net

Exhal51

Inlet

Standard valve
gUIde hole
diameter

FIllA 13
forfl

rt

Checlul19 the cyhnder heud

Ll3 and Ll6

L16 WIth

twin

carb

With

SIngle

cub
U3 and L16
S

Inl

F
t

Ll6

cub

gle

TWlD cub

Almm

OtA
J

Inl

41016
410

DIA

45 016
450

Azmm
57

37 016

37

37

37 8

41 6

DIA

r
II

1
I
La

IlIt

IlIA

41 8

D2mm
ExheuU

326
324

DIA

Llmm

t 2mm

4 1

326
324

1 8

HU1

FIlIA 14 St8nd8nI valve Il

8inwt

37 016

Dlmm

DIA

DIA

Exheult

20

20
16

FIllA 15 VeIve

to

i nte f

bi G D
er

r
8

rrt
l

1
0
051

J
r

D
r
T
010

FI9A 16 Ch c1ung the camshaft beanng

Inner

17

IingIo

far

L13

and L16

wrth

rettD

lm
I

II

5144

51
031

Fig A 18 Valves
C81bunmon

0011

0
11

11

far

L16

CII

IM

l11

wIth
Ill

A 19
FIlI

twIn

CheckIng

the

Fig
2
A
2 The

nne

JIlIIII18 of the cyllncllr

IIInng

bore

by

The
nng of the pilllln
of 8 mlcrom8lar

F A 21 MlI8SUnng the
of 8 doallllU98

bora

valve

for

squ

by

cyl

B
ImII

Fog A26 CheckIng the ade cl

pISton Flngs

ence

of

the

FIg A 24 CheckIng the pIston runnIng clearan

ce In the
bore
cyhnd

FtgA Xl
bends or

CheckIng

the

connectIng rod for

twIsts

Fill A 28 CheckIng the crankshaft end float

FI9A 29 CheckIng the running clearance for

the maIn beaFlngs

for
FogA 30 Checlllllg the crenkshaft sprocklJt
FUIHlllt

10

A31 The camshaft drIVe mechanam

Fog

and

from left to

It

move

0 0079

10m

10

If thiS movement exceeds 0 2

nght

1 the guide needs replacmg When replacmg valve

out the old gUide and press

the cylinder head has been heated to
JOOF
3
Valve gUides are available 10

gUides press

00079
the

10

valve

between

the
150

10

new

gUide after

2000C

300

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

gUide and

oversize

If the valve head edge IS worn down to 0 20 10

0 5 10m
replace the valve If necessary gnnd the valve on a valve gnndlng
machine taking off only enough matenal to remove pitS and
The valve dimenSions

are

shown

In

Fig

A 17 and A 18

Valve sprmgs
Measure the free length of the valve springs and replace If less
than speCified Also test the valve sprong pressure Check the
valve sprongs for distortion by plaCing a steel square on to a
surface plate

PosItion the spnng against the square edge and

the spring The clearance between the top of the
sprmg and the edge should not exceed 1 6 10m 0063 10
Fig A 191 The valve spnng specifications are given In section
rotate

TECHNICAL DATA

re

inSide the blackets replace the

limit IS C 1 10m 00039 In 1

Journals
cylinder

bearings

and If

Place the piston

piston nng gap

The camshaft

out
run

A 20 The Indication

005

10m

on

nngs mto the cyhnder bore and measure the

Fig A 261 The nng gaps should be as follows

Upper compression
Second compres
011 nng
Wear limit

head assembly

The

be checked

can

as

shown

0 15
o

0 0039

Cylinder

10

Fig

A 22

If the bores

In

Measure the gudgeon prn hole and the gudgeon pm diameter

and compare the measured results 10 accordance With the
dimenSions In section TECHNICAL DATA under the relevant

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

0033

00013

00006

10m

Connecting rods
Check

the connecting rods for bends or twistS uSing a

connecting rod aligning tool
FI A 27 For each 100 10m 394
I
In
length a permiSSible bend or twist of 0 03 mm 0 0012 In
IS

allowed

A limit of 005

are

00020

10m

should not be

In

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

Check for
the
for

ovallty and taper

cylinder bores are

Within the limits

remove

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

10m

0 002

scores cracks

The limitS

are

hmlt

out
run

0 03

IS a

and

10m

speCified
In

end float

IS

00118

In

Crankshaft
of the

replace the

between 005

1 Check the end float as shown

checking

run out

00012

In

total deViation of

In

float exceeds 03 10m

out as

rebonng all bores must be done at the same time As a

speclahsed workshop IS dealing With operations of thiS nature It
IS necessary to mfonn the
workshop of thiS procedure Five

ovahty and general

Check the crankshaft end float at the centre beanng

The

Rebormg cyhnders

wear

Journals and crankplns

ovallty and taper The

o 05

bore

Check the cylinder bores for excessive wear

FlgA 21 1 The measunng pOInts for the
shown

0 0394

mm

Crankshaft

regnnd the block

In

0011810
00059

mm

1 0

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

030
15

In

the dial gauge should not exceed

0002010

exceeds 0 1

0381010
023
00150
00091
In 1
030mm 00059 00118101

nng

ring

found

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

Fig

pins and piston rmgs

gudgeon

and the

wear IS

wear

camshaft

the maximum oversize

beyond

In

the InSide diameter of the camshaft

outside diameter of the camshaft

are worn

Check for wear scratches and seiZing and If necessary replace

Check the Side clearance of the piston nngs 10 the grooves of
the piston as shown 10 FIg A 25 The correct specificatIOns are
given In section TECHNICAL DATA under the same head 109

connecting
Camshaft
Measu

bores

cyhnder

Pistons

Check the valve face for pitS grooves scores and other damage
Check the stem for distortion and wear When mspectmg the
valve heads check 10 particular for burrs cracks and corrosion

slowly

If the

there are cyhnder hners available

stem

Valves

grooves

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

Journals

maIO

and

and

10

0 15

Fig

If the end

shims The
0002
00059

centre

mm

A 28

big end bearings

bl end
l

beanngs should be

carned

follows

When

Check the conditions of the bearings and clean the bearings

Place a piece of Plastlgage on the beanng over Its full Width In

piston sets are available and are hsted 10 section

TECHNICAL DATA To obtain the fmlshed bore Size measure
the piston across Its skirt as shown 10 FlgA 23 and add the

parallel

average value of the piston to

Main

oversize

cylinder

clearance

81g
When the

cyhnder bores
piston cyhnder clearance

have
as

With the crankshaft and fit

lhtemng
tl

cap

the bolts to the

beanngs

end bean ngs

together the bearing

follOWing torques
4 5

5 5

and Its

kgm

32 5

39 8 Ib ft

27 33 kgm

195

23 9lb ft 1

been finish

shown

In

Fig

honed check the

A 24 usmg a feeler

Then remove the cap and check the Width of the

Plastlgage

11

inter

erlLJ @
Pl

FIlIA
32

34

FI9A
connectIng rod

InstallatIon of the vaJves

ded
Expl

VI8W

ooo

of

pISton

and

FillA 37 InstallatIOn

the crankshaft
A36 Chedung
19

the sKle oil seal

end float

the flywheel
A38 InstallatIOn of
FIlI

12

of

FillA 39 InstallatIOn of pISton end conllllCtmg

rodaay

mter

E
ih

i
l

jlJ
@

t
I

l
s

FogA 40

InstallatIOn

of

the bill end beerll18

caps

FillA 41 Checking the side play of the bill end

Fill A 42 InstallatIOn of the cylinder head

FogA 43 V 1fW of the crankshaft sprocket end

Fill A 44
1
2

dIStributor drive geer

tIming chain

Fuelpump dflve
Cham guide

3 Cham
4
5

The

earn

nSlone

Cntnkshm sprocket
Camshaft IProcbt

6 Cham guttie

45 FIttIng
drIVing slIaft

FlgA

pOSItIon of the dIStrIbutor

FillA 46 AdjUsting the valve clearance

13

stnp on the beanng Journal FIQ A 29 If the clearance exceeds

the wear limit of 0 10 mm 00039 In
for the main beanngs
and and for the

fit undersize bearings and

regrind the crankshaft to SUit the undersize bearings Undersize
bearings are available In 1 1000 mm 25 50 75 100 for main
bearings and 6 12 25 50 75 and 100 for the big end bearings

big

end

beanngs

Crankshaft and camshaft timing gears

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

0 043

mm

Check

In

the chain

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

throughout
Fig A 40

and the chain gu Ide for wear and

A 31

replace If necessary

Fig

Flywheel

tighten

2 8

to

3 4

20 2

kgm

24 6 lb ft

the end clearance of the big end bearings

which should be 0 20 030 mm 00079 00118 In I

Check

Fit the cylinder head spreading JOinting compound either Side

of the gasket Tighten the cylinder head borts In the order
shown In Fig A 42 to a tightening torque of 5 0 60 kgm 36 2
43 4 Ib ft
In

tenslOner

and

Note there

the hole It

came

tlQhten the cylinder

Fit the crankshaft
thrower Fig A 43

timing marks

on

are

out

of

3 types of bolts and each should go

Use special tool ST49010000 to

head bolts

and distributor drive and fit the 011

Install the timing chain Fig A 44 With the
the crankshaft and camshaft timing sprockets

sprocket

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

to the right hand Side COinCident With the timing marks

chain There must be 42 chain links between the marks

flywheel for

chain

uSing dial gauge and replace the flywheel

If the limit of 0 1 mm 0043 In
IS exceeded
If the ring gear IS
run out

the gear ring by heating It to about

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

gear

damaged

In reverse

remove

order and cool at normal

air

the

on

the

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

always

be

when the front

replaced

I nstall the lower front

reason

cover In

temperature

on

that order With

gasket

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

cover

The gasket should be coated With JOinting compound

When fitting the upper cover check that It does not Interfere
With the cylinder head gasket Then check the height difference
block

ENGINE

Assembly

Apply engine 011 to all sliding or rotating parts of the engine I e

cylinder walls pistons bearings gears etc and renew all seals
gaskets and lock plates
Place the valve spring seat In poSition and fit the valve gUide
With
the 011 seal
Assemble the valves In the follOWing
and outer valve springs spring retainer
valve cotter halves and valve rocker gUide Compress the valves
With a suitable valve compressor Fig A 32 when fitting the
cotter halves
order

Valve

are

arms and the valve

rocker springs
combined With the rocker pivot bushes

The Spring

IS In

the position shown

In

Fig A 45

pump water Inlet elbow thennostat hOUSing

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

engine

pistons gudgeon pinS piston rings and connecting

cylinder Fig A 34 and A 35 and place the
bearing shells Into the main bearing hOUSings and caps and the
connecting rods and caps Lift the crankshaft In the bearings
Tighten down the main bearing cap bolts to 4 5 55 kgm 325
39 8 lb ft
Arrange the arrow mark on the bearing cap to face
the front of the engine The bearing caps shou ld be tightened In
gradual steps In three or four stages starting at the centre and
working towards the outside Check the crankshaft end playas
015 mm 0002
shown In Fig A 36 which should be 005
each

00061n

fuel

slinger

With JOinting

compound

the

JOinting compound

on

the gasket

Fit the clutch and gearbox

part of the engine and the

assembly the fuel hose to the front

high tenSion lead to the distributor

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

plug

shown

Install the Side 011 seals Into the

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

both Sides

distributor

carburettor

drain
rear main

on

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

Fit

Assemble the
rods for

Fit the crankshaft pulley and the water pump Set the engine at
T D C position on the No 1 cylinder In Its compressIOn stroke
Install the 011 pump and dlstnbutor drive so that the offset slot

Inner

Fit the rocker

holders

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

Original crankshaft IS used and the contact face for the 011
shows slgns of wear Install a shim In order to shift the
contact face FIt the rear end plate

ENGINE

If the

Installation

seal

Fit the flywheel USing lock washers and tighten the bolts to
95
105 kgm 68 7 75 9Ib ft I Flg A 38 Install the piston
and connecting rod assembly into the correct cylinder from the

top of the cylinder block as shown In Fig A 39 with the F

mark faCing the front of the e
gi le Wh en lnsertlng the piston

14

The installation

procedure but

IS

the

carned

out

in reverse order to the removal

be noted

follOWing points should

tlQhten the nuts and bolts completely until the engine IS

resting flnnly on Its mountings Then tlQhten the nuts Fill the
Do not

engine With engine 011 and coolant water

o with th recommended lubricant

or

anti

freeze and the

Technical Data
GENERAL SPECIFICATION

Engine model

L13

L16

Number of

4
In line

cylinders

Arrangement of cylinders

In line
1296 c

Cubic capacity

51 02
Bore

stroke

830
of valves

Arrangement

1595 c
62 80

cu In

830

73 7

c
cu In

59 9

mm

mm

3 2677 x 2 3583 In
Overhead camshaft

32677 x 2 9016 In
Overhead camshaft

77 at 6000 rpm

96 at 5600 rpm
109 at 6000 rpm

11 1 kgm at 3600 rpm

80 3 Ib ft

13 8

Max B H P

Single

carburettor
TWin carbu rettors
Max torque

Single

carburettor

kgm at 3600 rpm

110 0 Ib ft
143 kgm at 4000 rpm
1030Ibft

TWin carburettors

Flnng

order

Engine Idling speed

Single

carburettor

600 rpm

600 rpm
650 rpm

85

85

TWin carburettors

Compression

Single

ratio

carburettor

TWin carburettors
011 pressure

38

4 2 kg sq
54 60 Ib Isq

cm

54

In

1
1
4 2

kglsq
Isq

60 Ib

cm
In

Valve spnng fitted length

L13
L 16 outer

VALVE GEAR

hot

Valve clearance

95
38

Inlet

025

mm

Exhaust

030

mm

0010 In
0012

L 16

400

mm

389

mm

35

Inner

30 7 kg
29 0 kg
12 3

mm

kg

1 57

In

1 53
1 38

In
In

167 7 Ib
163 9 Ib
271 Ib

In

Valve spnng COIl diameter

L13

1 37

In

Inlet

020

0008

In

L 16

outer

332mm

1 31

In

Exhaust

025mm 0010

In

L 16

Inner

24 9

mm

0 98

In

59 0

mm

2 32

In

59 0

mm

2 32

In

Valve clearance

cold
mm

Valve gu Ide length

Inlet

Valve head diameter

L 13 and L 16 w SC
Inlet
Exhaust

38mm 150
33 mm 1 30

In

Inlet

42

In

1 65
33mm 130

Exhaust
Inl

Exh

mm

80mm 031

Exhaust

mm

In

L16wrrC

Valve stem dla

34 9

Valve gu Ide protrusIOn from head face

L13
L16
104 106mm

041

0421n

In

In

Valve gUide
Inlet

Inner

Exhaust
Valve length
Inlet

1159mm

456In

Exhaust

1160mm

4571n

diameter
800

8018

mm

0315

03154

In

800

8018

mm

0315

03154

In

11 996

mm
mm

0472
0472

04723
04623

In

11 996

Valve gUide outer diameter

Inlet
11 985
Exhaust

11 985

In

Valve 11ft
L13 and L16

SC

L16 wrrc

040

In

105mm 0413

100mm

In

Valve guide to stem clearance

Inlet
0015
Exhaust

Valve spnng free

1 13
L 16
L16

0040

0045

mm

00006

00018

In

0070

mm

00016

00028

In

length
4812mm 189In

outer

52 0

mm

2 05

In

Inner

44 85

mm

1 77

In

Valve seat Width

Inlet
Exhaust

1 4

18 mm 0055

0071

In

1 6

2 0

9 079

In

mm

0 063

15

Valve seat

Inl

angle

J
4

Exh

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

mm

00031

00043

In

Matenal

mm

00024

00039

In

Type

Interference fit

gUide

Inlet

type

Slipper
sklrt

Piston diameters

0027

0049 mm 00011

00019

mm

CAMSHAFT AND TIMING GEAR

Camshaft end play

0838

00031 0 0151n

mm

Camshaft lobe lift

L13
L16 w SC
L16
TC
w

665

7 00

mm

0 261

In

mm

0 275

In

Camshaft Journals diameter

All
47949 47962 vm 8877 1 8883
Max camshaft

Cast aluminium

run out

005

mm

8299

8304

mm

3267

3 269

1 st O S
2nd O S

83 22
8347

83 27

mm

3 276

3 278 In

3286

3 288

In

mm

3 296

3 298

In

4th O S

83 72
83 97

8352
83 77

mm

3rt

mm

8447

3 308
3328

In

5th O S

3 305
3326

2 0 mm 0 08
40 mm 0 16

In

OS

84 02
8452

mm

Width of nng grooves

Top second
011 control
Piston running clearance

In

0002

Standard

025
045

mm

In

In

In

0001 0002

In

In

In

PISTON PIN
Camshaft Journal to
clearance

beanng
0038

0076

00015

mm

00026

In

Pin diameter

20995

Pin length

Camshaft bearing

72 00

21 000
72 25

mm

08266

mm

2 8346

0 8268
2 8445

0010

mm

00003

00004

In

0033

mm

00006

00013

In

mm 008
40 mm 0 16

In

In

Inner

diameter

48
SC

Single

48
000

016

carburettor

mm

1 8898 1 8904

TC

TWin carburettors

In

Pin running clearance In

piston
0008
Pin Interference fIt In small
end bush
0015

CONNECTING RODS
PISTON RINGS
Distance from centre to

13297133 03 mm 5235 5237

centre

8eanng

shell thickness
1 498

Standard
Side

Piston nng heIght

Top second
011 control

In

play of big

1 506 mm
020 030 mm

ends

0059

0593

In

0008

0012

In

Side clearance

In

Top
Connecting

rod

bearing

clearance

Connecting

rod bend
003

twist

running
0014 0056

grooves
0040 0073

00006

mm

00022

Second

In

mm

00012

In

per 3 937

0030
0025

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

beanng

1 827

clearance
0 020
Max main bearing running
clearance

16

023

038mm

00091

Second

015

030

011 control

015

030mm 0006

In

mm

001501n

0006

0012

In

00121n

In
In
In
In

49 975 mm

1 967 1 9675 In
003mm 00121n
o 03

1 835

mm

0 012

In

0072

00722

In

o 062 mm 0 0008

0 0024

In

mm

CYLINDER HEAD

In

Matenal

o 12mm 00047
005 mm 0002

Aluminium

Distortion of sealing face

Max distortion

003

mm

o 1

Valve seat Insert matenal

Inlet

mm

alloy

00012

In

0004

In

Aluminium bronze

Exhaust

Special

Fit

Hot pressed

running

Crankshaft bend limlt

00025

54 942 54 955 mm 2 1631 2 1636

003 mm 00012
Max Journal
of round
out
003 mm 00012
Crankshaft end play
o
05015 mm 0
002
0059
Wear limit
03 mm 0012

shells

0001

mm

Special forged steel

beanngs

Main Journal dla

Max Journal taper

Main

vm

0063

L 13

In

000311n
L16
00012 0 0025 In

Piston ring gaps

Top

Number of

0 063

00029

In

In

CRANKSHAFT AND MAIN BEARINGS

Crankshaft matenal

00016

00018
0078mm

011 control
per 100

mm

0045

or
mm

20

cast

CAMSHAFT DRIVE
Dnve

From crankshaft

In

Chain

Double roller type

In

Chain tensloner

Spnng

and 011 pressure control

Trouble

Shooting

PROBABLE CAUSE

SYMPTOMS

ACTIOtJ TO BE TAKEN

Lack of power

Poor compresSion

Valve springs broken

Piston rings broken

Adjust valve clearance

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

Rings

Overhaul engine

Incorrect valve clearance

Intake valves leaking
Sticking valves

or

cylinders

worn

Ignition Improperly

set

Incorrect Ignition limIng

DefectIve spark plugs
Contact breakers defective

Re

or renew

Check fuel pump

Clean or replace element

Fuel filter clogged

Insufficient coolant

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

Loo e fan belt

Fan belt worn or damaged
Inoperative thermostat
Defective water pump

Clean system
Re set timing

Clogged cooling system

Incorrect Ignition liming
Incorrect valve clearance

Adjust clearance

Incorrect 011 used

Radiator finS clogged

Refill With correct oil grade

Clean readlator finS

Oil leaks
DefectIve piston rings
worn
Piston
rings

F nd 011 leak and rectify

grooves
Piston or cylinder
Valve stem

D fficult starting

set

replace adjust gap

Clean carburetor
Clean fuel pipe
Clean fuel tank

fuel pipe
Dirty fuel tank
Faulty fuel pump

Clogged

ExceSSive oil consumptIon

re
or

Lack of fuel

Clogged carburetor Jet

Overheating

set

Clean
Clean

or

or

sticking

Replace piston rings

Replace Piston rll1gs

In

Replace piston or bore cylinder

Replace as necessary

worn

gUide

worn

Improper 0 1
Discharged or defective battery

Change to proper VISCOSity

Charge or replace battery
Clean and tighten connections
Adjust Ignition check plugs
Repair Or replace valves

Loose connections
Defective Ignition system
Burnt valves
PIstons piston nngs

or

Overhaul enqlne

cylinders badly

worn

Engine nOIsy

Crankshaft beanngs

or

Journals

worn

Replace bearings and grind crankshaft

replace crankshaft
Replace bearings and gnnd crankshaft
or replace crankshaft
or

Connecting

rod bearings

ConnectIng rod be

worn

Piston piston nngs and pinS damaged

or replace rod
Check and replace parts

Stralgten

as

necessary

mterCE

lliJ

Plcel
@

FIg B 1
system

General

layout

of

tho

lubricatIOn

Fig B 4 SectIOn through the

Frg B 3 Tho oil pump components

18

rehef valvo

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

DESCRIPTION

damage Replace
The

lubricating system IS a pressurefeed system ronslstlng of a

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

filter the 011 before It can reach the

OIL PUMP

beanng

38

pressure

OIL PUMP

remove

the front

The

guard and remove the

spindle The 011 pump

011 pump
IS held 111

procedure Make

Remove the distributor drain the engll1e Oil

poSition by four bolts

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

pump IS a reversal of the dlsmanthng

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

assembly

of the

Assembly

sure

IS

When

procedure

Opening

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

locations

Removal and InstallatIOn

engine bearer and the splash

body together With the dnve

The II1stallatlon

Free length
Fitted length

OIL FILTER

replaCing

Check the engagement of the drive vIa the distributor

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

OIL PUMP

The 011 filter

IS

of the

removed from and

replaceable cartridge type and can be

replaced on the cylinder block by hand

When refitting the filter element do not overtighten and under

no circumstances use any
tools The filter body With the
element should be replaced every 6000 miles 10 000 km The
location of the filter

IS

shown

In

Fig

B 5

Dismantling

Separate

the body cover from the pump body by unscrewing

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

OIL PUMP
Clean all

parts In

InspectIOn and Overhaul

SUitable solvent and check the

follOWing

Items

Check the

Technical Data

Worn bearrng faces

pump body
result In pressure losses If necessary replace the body
2

for

wear

Check the clearance between the lobes of the

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

Pressu re feed system

Rotor pump

Type
Pump type

From distributor shaft

Drive

Clearance between

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

body

or a new

pump

body

and
0 05

outer rotor

Clearance between
3

Inner

012mmI0
020005111

rotor

0 12mm 0005 In I

tipS
Celarance between outer rotor
015
and body

021

mm

0006 0008

In

must be fined
011 pressure rehef valve spring

Check the end float of the rotors by placing a straight

across the Joint face of the body and measuring
clearance between the rotor ends and the

inserting
In

on

edge
the

straight edge by

75 mm 224 In

Free length
Fitted length

Opening

8 4 2 kg sq
3

pressure

cm

ii
f
3
i
m 1 54
60 Ib sq

54

In
In

feeler gauge IMust not exceed 0 13 mm 0005

If necessary the pump

flat surface

body

can

be

carefully lapped

011 pressure at

idhng

speed

1 0

1 2

kgsq

cm

14 2

17 1 Ib

sq ln

Oil pressure at
5

Check the rotor drive shaft for excessive wear or

scores

If

2000 rpm lhot

38 42 kg sq

cm

54

60 Ib sq in

the rotor set

necessary

renew

Cheek

fllJief IiIWe
the

1I aACI tile IidIng

for proper f
t
sprlll

19

mter

j
M

Pl
@

Fill C

General arrangement of the cooling

OY

OperatIon plate

Dust

SpIder assembly

FIlI

V V

o
thefan clu1dl

Fill C 5
parts

20
It

Exploded

Drum

linnl9

of

the fan

h
c1u1l

00

c 4 DlSIllantllng of
FIlI

C 3

cover

V fIW of the radiator and

component

Cooling System
DESCRIPTION
The cooling system is

closed pressunsed system It consists of

fan clutch thermostat and the water
Jackets in cylinder head and block
radiator

water pump

WATER PUMP

centrifugal type water

completely and remow the fan

pump drain the cooling

belt fan and pulley and

the water pump from the front cover

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

Replace
vanes or

an

exchange

To prevent squeak the

recommended

use

of

8n
NIS

IS

The pump should be cleaned WIth Nlssan COOling system cleaner

before It

IS

seal off both Sides of the

RADIATOR

squeaking

refitted to the front cover

Instellatlon

The installation of the thermostat is carned out In reverse order

to the removal
procedure Use a SUitable sealing compound to

water pump should be fitted

the water pump If It has eXce5Slvely rusted or corroded

If there IS excessIVe wear In the beanngs or

With the engine running

cooling system protector

950C 1203oF

THERMOSTAT

unsaew

malfunction

of

Removal

To remove the
system

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

To

gasket

Removal and Installation

the radiator shown In Fig C S drain the cooling

and disconnect the top and bottom radiator hoses
Remove the radiator after unscrewing the four radiator
remove

system

bolts Check radiator for water leaks and cracks and

repair or replace as necessary The installation of the radiator s
earned out In reverse order to the removal procedure

attaching

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

temperature of the engine compartment If the air temperature

In the engine compartment Increases the thermostat beginS to
operate and the fan clutch Will engage

FAN CLUTCH

Technical Data

Inspection
Type

Fully warm up the engine Check the operation of the clutch at

engine speed of 2500 rpm The clutch should begin to operate
at a temperatu re of 61
690C 141
159s o F and shoo Id
SWItch automatically off at 50 580C 121
1380F
The temperature should be checked near the clutch and thIS
be done several times as there IS a time lag In the
operation of the thermostat
should

To check the operation of the fan clutch thermostat remove

the operating plate see Fig C 3 and C 4 and submerge It In hot
water 700C for 2 or 3 minutes to check Its operation

THERMOSTAT

Closed pressunsed system

Radiator

Herght

350

mm

Width

514

mm

13 78 In I
20 24 In
Thickness
32 mm 1 26 In
26 IItres 0 7 U S gall 057 Imp gall I
Capacity
09 kgsq cm 128 pSI
Cap opeOlng pressure
Thermostat
Valve opening
Max valve 11ft

83 SOC 11 7
Morethen 8 mm

1lF
18

80 5

0 315 In at

at

950C

2
3
0F

R8IllOVlII

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

obtained The thermostat should start

to

open at

temperature
21

inter e

Ql
@

r
FI9 D 1 Explod

YI

of

Remof

D2
Fia

contact beI8 plaia

the

1118 ognrtlOn dlltnbutor

v
FIQ

D 5

bly of 1118 flyweight mecherlillll

The
F

FI9 D 3 Removal of 1IIe dIstrIbutor drMlllllllr

FItI D 4 Removal

1111I1Inln9 pin

of 1IIe dlllnbutar drive Iheft

nd ond
Oftronco for
at IfInltlOll lranctl MI
IIe

Hook

4
5
6
1

22

RI
IlfP

D
FIg

View of 1118 distrillutar

wIth

ght rprll1l
Flywo
Dtltrrburor cam pkrte
ywetg ltpm
F
H

Flyweight rprlnt

RotorpoI

Fig
D 6 Checlull9 1IIe contact
FI9

It
tg

donm

fin

8 AdJUlling 1118 cantBCt

D

er

gap

Ignition System
CONTACT BREAKER GAP

DESCRIPTION

in reverse order to the removal

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

The 1300

With

are

procedure

and the 1600 c c engines With Single carburettors

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

the distributor

Removal

high tension cables from the spark plugs and the

Ignition coli and detach the primary wire from the distributor
Remove the vacuum pipe from the distributor connection
slacken the distributor clamp bolt and withdraw the distributor
Disconnect the

turn

fitted

over

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

IGNITION DISTRIBUTOR

Adjultment

055

clamping

mm

screw

The contact breaker POints can be cleaned by uSing a contact

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

IGNITION DISTRIBUTOR

Dlsmanthng

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

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

SUitably support the distributor shaft from

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

distributor

cam

remove

the set

Carefully unhook the flyweight

deforming them

and pull off the cam

springs Without stretching or
screw

IGNITION DISTRIBUTOR

shown
Fig D8

IS

Remove the distributor

the carbon brush for excessive wear and If necessary remove

Check the contact breaker gaps for pitting
parts
replaCing them If badly marked Light damage can be smoothed

Check

In

Adjultment

line and start the engine

as follows

With

USing a stroboscopIC tlml ng light connected In accordance With

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

1600

1600

IS as

engine
SC

follows

1008

T DC 1600 rpm

100 8 T D C 1600 rpm

1408TDC 650rpm

TC
w

Single

carburettor

TC
w

TWin carburettor

CHECKING THE CENTRIFUGAL ADVANCE

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

011 stone

condensor for short

shown

Assembly

defective

Check the shaft for

vacuum

IS

the engine running at Idle speed proceed

wlSC

an

Fig D 7 The adjustment of the pOints

IGNITION TIMING

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

With

In

and proper fIt In the body Check the

open circuits and replace If necessary
Unit for operation
and the flyweight

wear
or

the vacuum
mechamsm for freedom of movement

and observe the movement of the white line

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

pulley

the

The assembly is a reversal of the removal procedure Refer to

Fig D 5 when assembling thJ flyweight mechamsm When the
distributor isassembled connect a spring scale on the end of the
contact arm and slowly pull the spring scale lIWay from the

the paint marks appears to move back and forth In an Irregular

manner It may be that the flyweights are sticking If necessary
lubricate the distributor to free off the weights

Read off the indication at the moment

fixed contact POint
when the arm is lust lifting from the fixed POint See FIg D 61
The correct value IS 0 50 0 65 kg 1 10 1 43 Ib
Adjust the
con1llct breaker gap as described below

CHECKING THE VACUUM ADVANCE MECHANISM

1500 rpm until the
Increase the engine speed to about 1200
throttle disc valve uncovers the vacuum drllhng With the 8Q8IIIll
running dISCOnnect the vacuum pipe from the distributor

housing

and re
connect

in turn Observe the white paint hne on

23

the

crank

pulley
of the

With

each

disconnecting

and

pIpe the line should move back

and forth If the line remalOs stationary It IS possible that the
pipe IS obstructed or the vacuum unit is damaged
connectlOg
re

vacuum

Technical Data
DISTRIBUTOR

SPARK PLUGS

Removal Inspection

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

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

055
050

Clearance between
shaft
Clearance

wear

lOner

In

0490210

housmg and
001

0038

mm

limit

00004
0 08

diameter

Clearance between shaft and

cam
0 005

0 029

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

Clearance between pIVOt and piVOt

hole
001
046

flttmg the plugs

002210

80mm 03151O

PIVot hole dla

to
gapS

0012

065 kg 1 1
1 43 Ib
1245 mm 0490210
1245

noted fit a colder plug Clean the plugs With a sand blast
cleaner or carefully WIth a Wire brush and adjust the electrode
wear IS

mm

upper part

lOner diameter

HouslOg

Cam

045

mm

Flyweight piVOt dla

0 003

10

80 mm 0315

10

00002 00011
50 mm 0197

In

50
mm

0001510

mm

00004

In

0 197

10

00018

10

mm

IGNITION COIL
Model
1300
1600

1600

c c

wlSC

C14 51
C6R 50

wrrc

c c

Primary voltage
Primary resistance
1300
1600

1600
c

Secondary
wlSC

c c

12 volts
w

SC

3 2

wrrc
resistance

SlOgle

carburettor

4 1 ohms

2 1 2 7 ohms
11 2 168 ohms

wrrc

TwlO carburettor

IGNITION TIMING AND IGNITION ADVANCE

Fully detailed
Data

24

II

IOformatlon are gIven under

See Index for page number

EnglOe TUOlng

Trouble

Shooting
ACTION TO BE TAKEN

PROBABLE CAUSE

SYMPTOMS

Starter turns but engine will not start

Weak battery
Excessive mOisture

high

tension

Cracked

or

Recharge battery
spark plugs

or

dlStnbutor cap

or

on

wires

leaky

Remove moisture and

Replace

dry

cap or rotor

rotor

Difficult starting

Broken wire In pnmary CircUit

Burned or Improperly adjusted points
Defective condenser

Repair or replace wire

Adjust or replace points
Replace condenser

Defective spark plugs

Defective breaker points

Clean

Loose connection

In

pnmary CircUit

Replace condenser
Replace Ignition coil

Defective condenser
Defective Ignition COil
Defective rotor or dlstnbutor cap

Engine misfires

Dirty

or

Replace

faulty spark plugs

Loose

wire

Ignition

adjUst or replace plugs

Replace breaker points
Tighten or repair

cap

or

rotor

adjUst or replace plugs

Tighten repair or replace Wires
Clean

faulty

or

Insulation
Cracked dlstnbutor cap
Breaker

Ignition CirCUit Interrupted

voltage drop In pnmary CircUit

and

Burnt

points

or

not

correctly adjusted

Incorrectly adjusted

breaker gap
Defective
leads

loose

contact

or

dirty

Replace cap
AdjUst breaker points
AdjUst

contact

breaker gap

Check leads clean connections

connections

Ignition SWitch defective

Ignition COil defective
Secondary
current

circuit

Interrupted

and

no

Spark plugs

wet

worn

or

inCOrrect

gap
Defective condenser
Defective

Tracking

broken Ignition cable

between COil distributor cap
or

Check

or

Check

or

replace SWItch
replace IgnitIOn

Clean and

adjust

or

replace plugs

Replace condenser
Replace ignition cable
Clean and check parts or

and rotor
Defective

Ignition COil

COil

Check

or

replace

COIl

replace

interceM
j

@ ce
p

J
L

ill

il

I
a

IJ

r
o

of

the

Fog
Fill E 1 General
Cllburettor

t
1

twin

choke

2
E

General

cartJuret1D

L 16

of

the twm

choke

englnel

12

1314 IS 16

of the tWin choke cartJurettor for

FJgE 3 V

cars fittedWith

ilJtomatlC transnllSSlOft

FIg E 4

SectIon
L16

carburetlllr

through

IHUnmng
Slof

9 M lnJflf
10 s
110
77 Throttle aIwl
12
13

FIlI E 5
ac
rburetlllr

SectIOll

through
1

A rWllltptplt

w
a

MII

18 Slowrunning BIf bIet1d

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

SIoMNllnmng

24

11010
8
Throttle aWe

25

bltJed

the

SmsJIWNlbm
5
MatndlS
C
6 Mam air bleed

lTbJeed

tunnlllf
Slow
runnm6
SIow

f1t

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

bleed

7 SlorH1lnnmg II bleed
IS
runnlnfl
SIow
fIl
19 Vacuum prsfon

obo

20 Power aIw
21
et
Ifam

22 Maml
23
l
ldl
24 8
25

00
hole
W
Throttle

FIQ E

26

bleed

L13 1

2 Small venturI
1MlJmd
5
6

rok
C

choke

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

MamllJrble
J
Jet

5 SlowrunnmglII
G N
tI aM
7 FI
8 Emublon tubtJ

twin

c
t
15

MIl
dach
venturi

2Small
3

the

englnel

The dlStll8nt1ed throttle vaJve

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

Check

either

Check the slow running Jet needles for burrs and

parts as necessary

two

barrel

downdraught

carburettor

or

twin

SU type

carburettors

throttle

the

and

choke

valve

shafts

and

bores

for

eccentriCity

ndges Replace

choke
tube clusters for wear or slackness and If
necesssary replace the cluster Check all linkages for excessive
wear and the filter screen for blockage and distortion
Check

CARBURETTOR

tWin choke

Single

Removal

The single carburettor versions are fitted to the Datsun 1300

Type designation DCK306 and the Datsun 1600 Type

deSignation

OAF

carburettor

take off the

and the

328

See

Fig

E 2

E 3

To remove the
disconnect the fuel pipe

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

Check the operation of the accelerator pump and the

chamber for damage to the diaphragm and air leaks
replace any defective components

diaphragm
Repair

or

vacuum

choke cable
nuts and washers

CARBURETTOR

Assembly

securing the carburettor to the manifold Lift

off the carburettor

The assembly
brittle

CARBURETTOR

Dismantling

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

The

IS

carned out

In

order to the dismantling

taken that no defective
Where these are found they

reverse

Special care should

hard gaskets are used

procedure
or

be

should be replaced When connecting the linkages

not to bend or deform any of the components

CARBURETTOR

be careful

Adjustments

Float level
upper body can be removed by removing the choke
connecting rod pp connecting rod return spring stop pin and
the four secunng screws
Figs E 6 E 7 and E 8
The

the gauge line the float IS correctly set If

If the fuel level
thiS IS not the case hold the float level In ItS chamber and check
that the gap between the float seat and the stem of the float
IS

needle valve
Mam

body

059

mm

IS

at

about 1 0

mm

0039

for the L 16 engine

shown In Fig E 18
In

In

for the L 13 and 1 5

Bend the float

Fig E 17

Remove the pnmary and secondary emulSion tubes by removing

main air bleeds
Fig E 10 Remove the cylinder cover and
take out the accelerator pump
F Ig E 11
Separate the float

seat

chamber from the throttle butterfly block by removing the rod

linking the diaphragm to the secondary throttle valve and the
Remove the float chamber
four securing screws
Fig E 12

With the choke valve fu lIy closed there should be a clearance of

1 3 mm 00512 In between the pnmary throttle valve and the
carburettor body In the ase of the OAF 328 carburettor and a

as

the

cover

and the float

Fig

E 13

Dismantle the

screws

holding the

diaphragm
diaphragm

screws

holding

The

fuel

diaphragm by removing three

chamber and then removing three
chamber cover
Fig E 14
system

shown

Dash pot
This mechanISm
With

automatic

throttle vale

In

In the case of the DCK 306

clearance of 072 mm 0028 In
carburettor
Fig E 19 and Fig E 20

the

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

Interlock startJng system

Fig

Interlock opemng of prunary and

throttle valves

When the pnmary throttle valve IS opened to the speCified

degree 590 for OAF 328 or 560 for DCK 306 there should be
a clearance of 9 10 mm
03583 In In case of the OAF 328
carburettor
and the

damper

fltteto thecarburettor Fig E 16 on vehicles

transmission and IS linked to the pnmary

IS

and
A

Fig
on

or

Inner

between the throttle valve

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

E 23
the adjustment

The

slow running
throttle valve stop

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

adjustment
screw

screw

Inspection

clean all parts In a su Itable solvent and blowout all

Jets and passages With compressed air Check all parts for wear
and damage With special attention to the follOWing parts

Thoroughly

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

plate

Slow

linkage

CARBURETTOR

secondary

replace

the slow runnlng volume control screw and back off

three turns Then screw In the throttle stop
Unscrew the throttle stop screw
screw and start the engine
until the engine beginS to rotate unevenly when the englfle
Screw

In

by approximately

speed

Will

gradually drop

volume control

screw

until

Now screw In the slow running

the engine runs smoothly at the

inter

i
D

j1
@

4
4

FIlIE

7 B alh throttle

valves relllDved

FIlI E B The carburettor top

caver removed

ll
li

4il
I

It

u
Fill E 9 The choke

c hamber

FIlI E 10 The pnmary end

tubes removell

relllDvecI

lOCO ndary

emu

q
o

1
l
O
Jo

FIlI E 12 The lower and upper carburetlDr

bodsepara18d

FIg E 13
tor body

28

The float

reIIICJII8II from the

ret

ImmIIII

1J
F

flp
fuoIlpul

FIQ E 15 The fuel

return

sys1em

Valve
2
3
if

o
0

Body
PIPe
SImtlttJl

F gE 14

The

parts

component

of

the

dl8phragm

Ll1

f
i

r
L
4
2
4
DAH

00

AnZl

OCK

Omm

D au

I
I

Fill E 17 The flollllevel adJullment

5

I E 16
FI

FIQ E 18 Adlusanent of the float 18111

Float SlHt
2 FIo t
3 FINt ltop

The dashpot mechBlllsm

JIII
Ne

van

7
2

Locknut
Jblearm
Chok cl
3 OGhpot
ThlO 0
5

ch btK
aIw

Throttle
6 Throm l

I E 19
FI
2

tlng
AdJuotment of slllI

Interloca opemng

Choke bell rod

2 Choke connctlllfl rod
3 S11Irtlng
Ie

rL

Choke vain

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

Throttle valw

i
r

JhaJi

fr J
L

FIQ

20 MeaRltlng the clearance of the start

E

ng Interlock valve Opel1l11l1

29

highest speed
engine speed
Repeat

thiS

adjust
Re

the throttle stop

screw

to

reduce the

adjustment

until an engine speed of 550 rpm has

been obtained
Care should be taken not to screw In the
slow running volume control screw to
tightly as otherwise the
tip of the screw might be damaged

adjusting nut and check again If the second check produces a

sharper click than the first repeat the centnng Refit the parts
that have been removed pour thin 011 Into the hollow rod of
the piston damper to Within 0 5 In
12 7 mml of the top of the
rod

CARBURETTOR
ThiS

adjustment

With

automatic

Dashpot adjustment
only necessary on the

Datsum 1600 fitted

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

The proper

Remove

IS

Adjustments

of the two carburettors

adjustment

IS

extremely

Important In obtaining peak vehicle performance and redUCing

fuel consumption
Carburettor

synchromzsnon

and

idhng adjustment

case

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

cleaner when the engine has reached ItS

operating temperature and slacken the throttle adjusting screws
The heads of the adjusting screws must not contact the throttle

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

lever

SU TYPE TWIN CARBURETTORS

Dismantling

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

adjusting

nut

and the spnng Unscrew the Jet

beanng locking

nut

Remove the float chamber cover secunng bolts and Withdraw

Screw out the needle valve assembly The dismantling

the float

stages

are

shown

In

Figs

E 24 E 25 and E 26

CARBURETTOR

Clean and

dry

the piston

assembly

rear

throttle shafts

are

connected Tighten the Idling adjusting nuts of the front

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

adjustment descnbed later between the Jet bndge and the

needle head should then be approx 1 5 mm 0591 In I
Screw

In the throttle adjustment screws of the front and rear

carburettors and start the engine The engine should retain Its
operation temperature before carrying out the next step

adjusting

screw

of both carburettors to

reduce the engine speed to approx 600

700 rpm The engine
should turn over smoothly and consistent If a flow meter IS
available apply the Instrument to the front carburettor flange

InspectIon

or otherwise damaged Withdraw the

locking
Push the needle
piston and fit a new needle
shoulder IS flush With the lower face of the piston

Also make sure that the front and

not

Now turn the throttle

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

the

air

screw In
In

the

until the
Fig A 271

Lubncate the piston

rod

and turn the adjustment screw on the flow meter so that the
upper end of the float In the glass tube IS In line With the scale
Llft off the flow meter and re apply It to the rear carburettor
Without altering the setting of the flow meter adjusting screw If
the pOSItion of the float
rear carburettor throttle
the mark on the scale

IS

not

In

adjusting

line With the scale

screw

to

align

adjUst the
the float With

WIth thin 011

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

dlamantllng procedure

tighten
1 8 of

the
a

Idling

turn

and

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

Assembly
and centre the Jet

be detenmned bnng the nuts back to their

positions and unscrewthem from thiS pOSition until the
engine runs fastest und smoothest

point

cannot

onglnal
Centnng

the Jet

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

the
fall

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

Refit the

up as far

as

adjusting
pOSSible

nut Without the spnng and screw It

30

and nQ 1l

whetlliij

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

speed setting
Move
engine

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

tift lhe pjS on

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

IS

falls

freely

fully
19w
ir

the

Idling

the throttle

interconnecting shaft and accelerate the

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

the connection

of the interconnecting shaft Then turn tha

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

mterc rlOU @@ce

c

@0
f
J
1

I
I

I
u

I
2

@
i

Fill E 21

opelung of pnmary
ary throttle valves L16 eng ne

4
5

Throttlfl
Throttle

Ju

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

IlltIIrlock

1 ConntJCttn9 mvu
2 RftUm plate

Fill E 23

Checlung the
body

clearance

between

throttle valve

nbtN
ch

1I1v6

ConnectIng IrHr
Return plate

Throttle chlmbtK

Throttle v Jve

Adjuster pllltrJ

OIL CAP NUT

SUCTION

CHAMBER
PISTON

SUCTION

FUEL PIPE

A
tJ

II
o

e
0

Yo

NOZZLE
JET

SUCTION SPRING

Fill E

24

Exploded
BOO suction piston

of

Rlol on

SLEEVE

SET SCREW

IDLE ADJUST SPRING

NEEDLE

chamber

IDLE ADJUST NUT

NOZZLE
Fill E 25

Exploded

VIew

of nozzle

assembly

0
0

0
Fill E Xl Installation of the lat needle

O
Fill E 28 Exploded

of the float cIIMIber

31

the length of the throttle connectmg rod Fmally back

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

adjust

the throttle
cleaner

adJustmg

screws

Stop

Adjustment

the engme and refit the

air

FUEL PUMP
Disconnect the
and

connection

Fig E 37 Remove the screws secunng the upper to the

lower body and 11ft off the upper bOdy
Remove the

re

retainer

IS 05 mm
00197 m
When this dimension IS obtamed
mstall the suction piston and the suction chamber and check
the smooth operation of the suction piston The Jet needle IS

basic position

disconnect the fuel pipe and

remove the sleeve nut If a fuel level
connect
gauge IS
avallable
the gauge to the fuel pipe connection on the carburettor
re connect the fuel pipe and start the engine
The fuel level m
the glass tube of the level gauge should be b tween 22 and 24
0866

0945

clip

from the top of the float chamber If

level gauge IS available proceed as follows
mm

Remove the float chamber

cover

screws

and

11ft

cover

off the

attached float lever Hold the

Side IS faCing upwards
2

15

mm

0551

to

after

cover

05901

the four
with the

the float

I f necessary bend the float lever

Illustration

To

as

level IS
shown m the

the rod The length of the connectmg rod IS correct

If the clearance between the throttle valve and the throttle
chamber dimenSion 8
m
Fig E 34 IS 0 6 08 mm 00234

shortenmg

I with the

starter

lever

and 11ft out the

screws

pulled

out

Remove the spnng 011 seal retamer 01 seal packing

To remove the rocker ann assembly dnve out the piVOt pm
towards the serration and 11ft off the individual parts

FUEL PUMP

Inspection

Thorouqhly clean all parts and check as follows

body and
diaphragm for

cover

wear

for cracks defective threads or wear The

and tear and a worn pull rod The sealmg

faces of the valves and the spnng for weakness and

The rocker mechanism for wear

FUEL PUMP
Insert the rocker

place

while

arm and

corrOSion

Assembly

the link

the lower

the piVOt pin from the

Install the rocker arm spnng

the pin

lower

the startmg mterlock opening bend the connectmg

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

screws

fitting

body

non

and hold

serrated Side of

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

mterlock opemng

adjust

00315

secunng

diaphragm

The

undOing
together

that the float lever

cover so

correct

StartIng

retamer

packmg Remove the cover retammg

off the cover together With the gasket

no

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

and 11ft

valve

valves and

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

Float level
Remove the float chamber

Dismantling

Refer to

head

outlet hoses from the fuel pump

the two mounting nuts

FUEL PUMP

of Jet needle

Remove the suction chamber and the suction piston and turn
the Idling adJustmg nut Usmg a depth gauge check that the
dimension A between the Jet bndge and the top of the needle

now set

mlet and
remove

Removal

completely

body

the rocker

half Press down the

arm link

Fit the

diaphragm

cover

and engage It With

body half

the upper

to

Install the

packing and the valves correctly mto the upper body

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

Hydraulic damper
The

damper

011 should be checked approx every 3000 miles or

To check the 011 level remove the 011 cap nut
every 3 months
as shown m Fig E 35 and check the level
markmg on the two
grooves on the
lower Ime fill

plunger

rod

If the level has

dropped

below the

m SAE 20 engme 011

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

FUEL PUMP
Reverse the removal

procedure

Installation
Start up the engine and check

for fuel leaks

FUEL PUMP

Testing

Remove the carburettor fuel pipe and connect a pressure gauge

to the fuel pump outlet fitting Run the engme and check
the fuel pump pressure which should be 0 18
024 kg sq cm
on

FUEL FILTER
The fuel filter IS of the throw away cartridge type and should be
changed every 40 000 km 24 000 miles To remove the fuel

256

replace

34 pSI I
the

If the pressure

readmg

IS

below the settmg

diaphragm sprmg

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

the outlet pipe m

at 1000 rpm for

by connectmg the mlet pipe and msertmg

SUitable contamer Start the engine and run
one mmute
The mmlmum quantity of fuel

removal

delivered

be 1000

procedure

Conduct

flow check

should

malfunction and the fuel

restnctlons are

suspected

blowout the lines With

32

c c

If not

lines for

check the pump for

If blocking or

blockages

the fuel lines remove the pump and

air
Repeat the flow test

Compressed

ImmIIII

3B
4

16
17
Screw

eel

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

Valve retainer
8 R8tamer screw
9
D hragm
0 Pullrod

19

FIg E 36 Removal of the fuel folter

DIaPhragm

12

he fuel tank of Saloon Cars

flng

Selll washer
13 Seal
14 Lock washer
15 Nut
16 Connection

6
7

Screw

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

24
25
26

Rocker arm
Rockerarm pivot pm
Spacer
20

24

12

FIg E 41 Exploded

of the aIF cleaner

13

FIg E 39 The fuel tank f ller tube

22

Exploded

Fog E 42 Removal of the

with SIngle carbunrtlDrl

aIF

VIew of

23

the fuel pump

cleamr

33

after

assembly

re

POSITIVE CRANKCASE VENTILATION SYSTEM

FUE L TANK

The l 13 engme has

Removal

the
Saloon
seat

Remove the

back trim

the

the board flmsher board

and the seat back and take off the

luggage compartment lid and remove
Fig E 38 Disconnect the fuel gauge

cleaner

ventilation pipe from the rocker box to

43 whilst the l16 engme uses a

Fig

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

seat

rear

Open

aIr

F g E 39
and the tank filler tube
Remove the tank
securing bolts and disconnect the fuel outlet pipe and the fuel
return Ime lIft out the tank
wire

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

wagon
Carry out the same operations as
described above With the exception that the fuel tank securmg
screws
are
acceSSible
from
under the rear floor panel
Estate

car

statIon

leakmg

FIg E 40

10

the opposite dIrection Clean all connections and the

which IS sealed and has no connection to the

011 filler cap

The mstallatlon of the fuel tank IS
removal procedure

10

both

cases a

reversal of the

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

FUel LINES
Examme the fuel hnes for damage and kInks and replace If
necessary If dirt IS found 10 the carburettor float chamber or 10
the fuel pump stramer dIsconnect the pipes and blowout WIth
com ressed aIr It might be recommendable In thiS connection

when
must

fmger

IS

placed

over

the valve

always be replaced

remove and
clean the fuel tank as depOSits are
empty
Without doubt 10 the fuel tank whIch would lead to the same
fault after a short tIme

to

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

Technical Data
TWIN CHOKE CARBURETTORS

Engme Model

l16

1600c

1300cc

Primary

Secondary

Primary

Secondary

Outlet diameter
Venturi diameter

280101

32mm

26mnt

300101

240101

28

21

27x12mm

Main Jet
Main air bleed

115

155

96

150

240

120
180

80
43

90
180

Slow runnmg Jet

EconomIzer Jet
Economizer bleed
Power Jet

48

Float level

23ct 101m

Fuel pressure

Weight
Altitude settIng main Jet
100001 3300 ft

9 0101

024
235

kg
kg

23ct 101m
to

sq em 341 pSI
5 17 Ib

0905
024

92

300001 10 000 ft

107

89

400001

104

87

101

85

5000

01

13 300 ft I
16 600 ft

ct

kg
255 kg
94

6600 ft

0101

40

109

01

1 8

112

2000

18

0905 ct 004

34

l13

004

to

sq cm 341 pSI
5 61 Ib

mlet A

damaged

valve

SU TYPE TWIN CARBURETTORS

FUEL PUMP
38mm

Bore diameter
28

Weight

kg

Delivery
Delivery
Type

6 16 Ib
B

Needle
Float needle valve

2 0

mm

Jet need Ie

0 08 In t
M 61

018

pressure

024kg
1000

amount

Diaphragm

sqcm

256

Imln

341psl

1000 rpm
pump driven from camshaft
c

at

N023

Suction spring
Float level

23f 1
024

Fuel pressure

kg

sq

cm

mm

341 pSI

Trouble Shooting
CARBURETOR

Improper seating or damaged

needle valve or seat
Incorrect float level

Flooding

Fuel pump has

ExceSSIve fuel consumption

Stalling

Poor acceleratIon

excessive

Fuel leaks at pipes or connectIons

Choke valves operates Improperly
Obstructed air bleed

Trace leak and rectIfy

Check choke valve

Main Jet obstructed

I ncorrect throttle opening
Slow running adjustment Incorrect

Clean

Slow running fuel Jet blocked

I ncorrect float level

Clean Jet
Adjust float level

TIghten
Replace gaskets

DefectIve accelerator pump

Float level too low
Incorrect throttle opening

Lean mIxture

Check and clear

main

Jet

Adjust throttle
Adjust slow running

Overhaul pump
Adjust float level

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

air

or

TIghten

replace pIpes
replace gasket

or

Dismantle and clean carburetor

Clogged carburetor
Clogged fuel pIpe

Clean fuel pipe

Clean fuel tank

Dirty fuel

Check connections and tighten

Repair or replace fuel pump

Air

In fuel system
DefectIve fuel pump
Clogged fuel filter

NOISY pump

necessary

Check fuel pump

Adjust float level

fuel pIpes
Manifold draws secondary

Loss of fuel delivery

as

Adjust float level

Float level too hIgh

Loose plug or Jet
DefectIve gasket

Clogged

FUEL PUMP

Check and replace parts

Dirty carburetor

InsuffiCient fuel supply

float

pressure

Defective accelerator linkage

Blocked pump Jet

SpItting

ACTION TO BE TAKEN

PROBABLE CAUSE

SYMPTOMS

Slotted body screws loo

DIaphragm cracked

Clean

or

replace fIlter

Loose fuel pipe connections

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

arm

spring

Tighten mounting bolts

Replace rocker arm
Replace spring

35

I nter

O
C
1

0
c

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

starter

lever

tl

Fog E 33 Adjustment of thefloat level

7
2

Floatlever
Bend hrre

to

adjust

Jht
ht1l

FI90E 30 The throttle valve IKlJUltlng screw

Fig E 34 Adjustment of the startIng

Interlock opening

Fog E

32

tlng shaft

The

IKIJustment of the In1erconnec

FanIdle
2

Connecting
Connecting

4
5

36

lever

Connecting
St1Irter
Th

pl
m
Imk
rod

lever
Jve
ttler

Fig E 35 Checkong the hydraulIC damper 001

Clutch
Chttch dnven

plate

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

diaphragm type

or

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

3 74

from the centre of the plate If the rivet heads are

In
below the clutch faCings or there IS
abnormal wear or rivets m sslng replace the driven plate or the
mm

In

less then 03 mm 0012

clutch driven plate and thereby With the flywheel

clutch factogs

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

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

CLUTCH
Remove the gearbox
When a
diaphragm

as

Removal

deSCribed

clutch

IS

In

section

fitted

Insert

GEARBOX

speCial

tool

ST49090000 clutch aligning tool or a spare clutch shaft Into

the splines of the driven plate In order to support the clutch
Remove the

diagonal

SIX

manner

clutch cover bolts by loosening

and 11ft off the clutch cover

gradually

In a

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

diaphragm type clutch

CLUTCH

Dismantling

The only dismantling recommended IS the

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

particular type of clutch

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

cover

holes COinCide With the threaded holes

plate Bolt down the

cover

to

In

the base

the plate

eqUIpment

IS

available

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

must be

plate

renewed
Pressure plate

such as dents and

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

be skimmed off but the

can

be removed

IS

1 0

mm

maximum

0004

Clutch spring

amount

of metal that

In

aphragm

clutch

With the diaphragm sprong assembled to the pressure plate

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

fingers should be between 43 45 mm 1 693 1 772

the base plate If thiS IS not the case replace the sprong
With

Fig

In

from

plate placed on the clutch press down the clutch

by 78 mm 0307 to or until the clutch droven

F 10

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

IS flush With the

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

eyebolts Slowly release the pressure on the clutch COil springs

by unscrewing the cover bolts gradually In a diagonal pattern
Lift off the clutch
the pressure

cover

spring caps springs spring seats and

plate
CLUTCH INSPECTION

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

Clutch spnngs

Cot spong clutch

If the load on the assembled clutch IS reduced by more then

15
or the free length of the Call springs has altered by more
or the deflection between
A and B
than 1 5 mm 006 In
In

Fig

In

It

F 11

IS more

than

becomes necessary to

mm

per 100 mm 02 In per 394

the clutch springs as a set

replace

Release

beanng

Replace the release bearing If the

much

play

or

there

IS

roughness

causing too
step formed or If the

wear IS exceSSive
or a

37

f@ CE
p

inter
eM

11

Fog F 1

Exploded

v ew

of the doaphragm sprong

clutch
1

Clutch

2 Clutrh
4
5

driven plBte
cover

Pressure pla
Clutch ICunng

bolt

Spring Wil3htlr

BNI7ngslllflW

se
Ies
9 Clutch
10 Rtlf8tnmg dip
11 Dust cover

12

Return

6 Clutch WlthdrawW lever

13

7 R

14 Locknut

ner

spnng

llWB
Wlthdf

bNrmg

nng
11IWIt

pusher

11

Fog F 2

II

of

Exploded

the

cod sprong

clutch

ltlJ

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

Eyebolt

IT

6 EYlIlxJ1t pwot pm
7

Pnmu
rlng
q
8 Spnng cop
lwet
9 R
10 R

Locknut
12 Release IftltJT wpport

OIA 257

mm

DIA 240 mm

1J

FIg F 3 Specull toolset for dutch overhaul

J
m

IA 216
DIA

D
Fig F 4
dmphragm clutch

38

nun

235mm

men

diamsJam

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

for

the

mmr
R

spring

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

F4

Wthdrwwallwer

pulh

clutch cover to inside diameter clearance IS more then 0 5 mm

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

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

the removal

procedure

bearing should

Ibs

check the bearing for smooth rotation

CLUTCH PEDAL

Adjustment

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

height

CLUTCH

Assembly
Call spring type

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

tighten

are

the

plate and the springs observing that the pressure

not dislodged and not hable to distortion Then
In
a
cover bolts gradually
diagonal pattern to

compress the pressure spnngs

8 150

assist spnng push rod to 203 mm

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

AdjUst the length of the

7992

In

CLUTCH MASTER CYLINDER

Removal

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

cyhnder

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

for L H 0 models and lock the stop bracket

In

CLUTCH MASTER CYLINDER

Fig

Dlsmanthng

F 18

the flUid from the reservoir pull back the rubber dust
and remove the clrchp Withdraw the push rod together
With the retaining nng Unscrew the piston stop screw and
The piston can be
remove the complete piston assembly
dismantled by lifting the spnng seat over the piston shoulder

Empty
cover

CLUTCH

Adjustment

Call spring type

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

recheck

Clean all parts In brake flUid Any damaged or abnormally worn

clearance
parts should be replaced The maximum permissible
between piston and cyhnder must not exceed 0 13 mm 0005
m
and as a matter of pohcy the piston cup should be replaced
every time
them

If the piston sprmg

or

valve spnng

CLUTCH MASTER CYLINDER

IS

weak

replace

Assembly

IS a reversal of the dlsmanthng procedure All moving parts

should be lubncated With brake flUid The piston cup should be
soaked In brake flUid pnor to assembly

ThiS
CLUTCH

Installation

long chamfered end of the clutch dnven plate sphnes

gearbox place the clutch on to the flywheel Use a
the
spare clutch shaft ahgn the clutch dnven plate by Inserting
of
the
and
Into
the
the
dnven
pilot
shaft through
beanng
plate
flywheel crankshaft Turn the clutch cover In order to bnng In
With the

facing

the

hne the holes for the clutch bolts In the cover With the threaded
holes In the flywheel and tighten the bolts In a diagonal manner
174
188 Ib ft
26 kgm
to a torque of 24

gradually

Remove the dummy shaft Do not forget to remove the clutch

spring restnllmng hooks from under the release leversl Fit the
release bearing and the bell hOUSing

CLUTCH PEDAL

Removal 8IId Installation

CLUTCH MASTER CYLINDER

Installation

The installation of the master cyhnder IS a reversal of the

removal procedure Take care that the threads of the clutch
hose are not damaged Check the pedal height and adjUst If
necessary

as

descnbed

earher

on

Finally

bleed the clutch

hydraulic system
CLUTCH SLAVE CYLINDER

Fig

Removal

F 19

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

cyhnder

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

mounting bolts and hft

and 11ft out the pedal

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

CLUTCH SLAVE CYLINDER

Dismantling

39

mt e refJJ cQ P f

dla

255

mm

3
3

Fill F 5 Y

Fig F 7

W
YIf

of the

Fill F 6
clutch

hragrn clutch

1Iel1SlOn
O

dlllgralll for the coil

ng

of the cod spring clutch

Fig

F 8

Checking the clutch

dren

plate

to

Fig F 9 Checking the release finger height of

dutch

the diaphragm

out
run

Checking the load of the diaphragm

Fill F 13
1ng
bl

40

Inspecting the
Fill F 11
distOrtIOn

InstallatIOn of the dutch

diaphragm dutch

dutch spnngs for

F U F 12 Removal of the clutch

F 14 InstaJlatlOn of the dutch

bearing coillPrlng dutch

FIlI

tel

bearIng

mter

FIg F 16

12L
Fill F 15 AdJuSbng the release I

ghtemng torque

35

heIght

to

4 0

ActuatIng the clutch

to

settle

Q1 O

@ ce
l

mechanism

i23

kg

rn

19

13

15
16

14

CiI

11JI17J

FIg F 18
cyhnder

SectIOn

through the clutch master

Cylmder body
2

AdJust

by adjust

screw

of

master

cyt

LubricatIon
Clutch
Clutch

pedal

full

pedal

free stroke 2S

troke 140

turn
r

1 Piston
4 5
ondaTy
5 PISton
1
8

mm

cup

cup
t
Valve
Va stem
Valve
mng
q

9 Sprmg 28t
10 Valin st
em fop

1m

t 7 Stop pMctt
12 Gasket WIIwr

Fill F 17 The clutch pedal adjustment

13 Push rod
14 Pudl rod C

VIS

15 Nut
16 Locknut
17 P stOn fop
18 Abutment wahar

19 Rubber boot
20 Flutd rtnelVOlf
21
22
23

Clip
IINVOlr
Rft

Cap

ClIP

INJI

Fill F
Fog F 19
cylinder

Exploded

of

the clutch slave

20

withdrawal

lever

41

wear

especially

the piston cup and

replace

If worn or damaged

Aaembly 1nI1nsta11atJon

CLUTCH SLAVE CYLINDER

assembly of the slave cylinder IS carned out in reverse order

All moving parts should be
the dismantling procedure
lubricated With brake flu Id and the piston cup soaked In brake

The

NOTE

The correct

adjustment

of the clearance is essential as

inSUffiCient free travel between release bearing and clutch can

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

new

dimenSion of 7 8

0 307

mm

In

to

CLUTCH SYSTEM

flUid pnor to assembly

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

Adjustment

the locknut screw the push rod fully home whilst

turning the adjustment nut and then unscrew by 1 3 4 turns to
2 3 mm 0079
009 In
on the
give an end play of 20
Withdrawal lever giVing a clearance of about 1 3 mm 0 051 In

te
t

en

reservoir

With

the recommended

flUid

and

pump

clutch pedal slowly

Loosen

bet

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

CLUTCH WITHDRAWAL LEVER

Fig F 20

Bleeding

the release bearing and the diaphragm spnng fingers

depending which type of clutch IS fitted

indicated by a solid flow of

has left the system
Into the Jar
tighten the bleeder screw on a
downstroke of the pedal Remove the bleeder hose replace the
dust cap and replenish the flUid reservOir
When all
brake

air

flUid

or

release levers

Technical Data
Clutch pressu
Free length

re

Clutch release levers

springs
52 3

Fitted length load

Side distortion

292
5

mm

mm

per 100

44

mm

mm

2 059

Clearance between release bearing and

1 2
1 4
release levers

In

1 15 In 97 Ib
02 In per 3 94 In

kg

Height
diaphragm
flywheel
Height between release levers and
505t
flywheel

PermiSSible deterioration of
15

spring force
Clutch driven

200 mm 7 87 In
13Omm 5 121n

Inner diameter
Thickness of facings
Total fnctlon area
Thickness of clutch

Pedal

362 sq

em

56 11 sq

In

pedal
height In

03543
03130

In

Free stroke of
Pedal effort

plate
86 90

Free

765

795

Number of torsion springs

PermiSSible mln depth from nvet
head to facing
out
run

Clutch

rest

poSition

35vm 0 141n

Compressed

In

mm

1 732 to 039

In

002
1988

In

005mm

mm
mm

03386
03012

pedal

Mastwr

0012

7 17

In

RHO

cylinder

Diameter
mm

mm

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

In

6
03

182

In

Max piston clearance

5 8

In

o 13mm 0005

1587

In

mm

of clutch
05

plate
PermiSSible free play

42

0055

0047

mm

plate

Outer diameter

PermiSSible

spnng and
441

between

on

splines

mm

04 mm

020 In
0016 In

Pressure plate
Perm ISSlble refaclng

1 0 mm

0 394

In

Trouble
Troubles

Shppmg

Possible
InsuffIcient
Improper

all

or

RemedIes

causes

free

clutch pedal
of

adjustment
play

lever end

on

grease

Shooting
travel

withdrawal

Adjust pedal free travel

Adjust

end

Remove

lmmgs

play

tmmg

DISC

Clutch

dIaphragm
plate

Pressure
InsuffICIent
clutch

release

or

Excessive free travel of

Exce

play

lve

Replace sprmgs

Reface

worn

dutch pedal

of WIthdrawal lever

PIlot bushmg stH kmg

replace

or

Adjust correctly

Adjust correctly
Replace Pllot bCarlllg

Splme of clutch diSC hub

Clutch dIsc

Replacl dutch diSC assembly

orn

Sct

arped

Ie vcl

of

dutch diSC

LcakIng

from

cylmdel

master

cup

Leakmg from operatmg cylmder

mflLtratIons

Air

re

broken

flywheel

or

and

if necessary

RepLace Imlngs
and pres

sprmg

springs weak

sure
1

burned

worn or

of lcakage

cause

ptal c Immg

Into

the

cup

hydrauhc

clutch

dISc

or

replace

aSbcmbly

Replace cyLinder cup

Replace cup
Bleed out completely

lme

Roughncsb

Rub

Immgs

on

hmngs

WIth

metal brush

or re

place them
Low flmd level

Grabbmg

a l

on

facmg

011

In

or

Top up With brake flUid

reserVOIr

burn cd

or

glazed

Install

new

diSc

assembly

faCIngs
Loose dISC

lmmgs

due

to poor

rIvet

tlghteness
Pressure
or

Rcplat c

defective rIvets

or

replace

lmmgs
plate

or

flywheel

arped

Replace

them

cracked

Improper

adjustment

of

release

Adjust release

er
le

lever
Loose engme
Wear
sian

NOISY

or

mountmgs

damage

of clutch

dIbe tor

or

Replace

dISC

replace mountmgs

assembly

sprmg

Worn

release bearmg

Cracked clutch dlSC plate

Wear
sian

Tighten

or

damage

of

clutch diSC tor

Replace bearmg
Replace

dISC

assembly

Replace

diSC

assembly

Replace

diSC

assembly

sprlng

Loose clutch diSC hub

43

inter

ilj

JG 1
FI

p
@

Removar of the propeller shaft

Daconnectll19 the

remote

control

Fig G 6 RelMVill of the extensIOn housmg

J
I

I 1
I

Cw

fIr

gear

FI9 G 7 Removal of the crosHhafts For

anno1atlons see text

JG
FI

10

iifih8

iine idler gear

F19 G 12
trail

44

Withdrawal of the mall1Shaft gear

Gea rbox
sPEED
THREE

Check the gearbox casmg for cracks and indentations Where

the surface IS machmed check for burrs and remove where

Removal

GEARBOX

Jack up the vehicle and support on suitable stands Disconnect

the handbrake cable at the equahzer bracket loosen two
exhaust pipe centre clips and turn the centre section of the
Disconnect the
exhaust
to
the left
Fig G 1

assembly

at the rear end by removmg the flange bolts

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

propeller shaft

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

Support the gearbox on a Jack and remove the

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

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

replace

shafts for burrs

or scores

all gearwheel teeth and other machined parts of the

the
gearwheels for scoring scuffing and plttmg Check that
on the shaft sphnes With
minimum
hubs
shde
synchronizer
Check

out
run
Check the ma In shaft for
usmg V blocks as
out
run
shown 10 Fig G 18
Replace the malnshaft If the
exceeds 015 mm 0006 10

clearance

crossmember

remove

the gearbox

THREE

10 a

rearward direction

diagram Fig

Dlsmanthng

SPEED GEARBOX

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

the

gearbox

retainer

Fig

hOUSing
G 7

G 6

Item

Remove
and

the

shaft

cross

remove

the nuts

retaining rings

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

Fig

Check the synchronizer rings for wear and replace If necessary

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

Place

the

G 19
selector

rods

on

flat

surface

to

check

for

straightness Check locking pms and mterlocklng balls for

damage or wear The standard clearance between the selector
forks and the operatmg sleeve groove
0012 n

holding

Check 011 seals for

have

been

wear or

Fig

removed

IS

0 15

0 30

mm

0 006

damage Replace any 0 rmgs that

G 20 shows

the

011

seals

to

be

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

Press the

the Idler gear

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

fit the spacer Select a clrchp so

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

Remove

the

Iayshaft

by

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

speed

Then

front

of

mshaft

releaSing
gearwheel

the

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

reverse gear tap the shaft With a piece of wood so

the reverse gear assembly together With the 1 st speed

InsplKltlon
as

follows

the

expand 109 type springs

To assemble the reverse 1st

speed synchronizer Unit msert the

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

replacmg

or

msert

To assemble the 2nd3rd speed synchronizer fit together With

hub and the operating sleeve ensuring that the sleeve shdes
ring

Thoroughly clean all parts and mspect

repairing any defective parts

to

assembling the synchronizer untl take care that the msert

pressure springs are of different size for the 1st reverse and
2nd 3rd speed synchronizers The spring for the reverse l st
speed Unit has three Call springs whereas the other uses two

freely
THREE SPEED GEARBOX

on

Assembly

drive shaft clutch shaft and

that there IS no play between

When

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

bearing

maIO

and

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

THREE SPEED GEARBOX

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

on

on

keys and

frt

SPring

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

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

Fig G 14

Removal of the securIng

e
the2nd and
3 speed synchronoser hub

1f

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

speed

I
II

f
Ii
r

FIg G 16 Removal of the 2nd speed gearw

VJ
FIg G 19

CD

lV

CheckIng the synchron

rIngs for

wear

FRONT COVER

REAR EXTENSION

Fog G 20 The oil seals ulOd

on

CROSS SHAFT

the geaTbox

F gG 22

ehp

46

ns1allatoon of the

In

Fog G

23

Insortlng the shtftll1ll keys

Fog G 24 FittIng the synchronaer hub

operating sleeve

on

to the

mm

160

0002

0009

180mm

Clrcllps

In

0063

are

available

5 Slles from
FOUR SPEED GEARBOX

0071m

Removal and Installation

I

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

synchronlser and the

gear assembly

reverse

on

the shaft

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

from 1 30

1 70

0051

mm

0067

thickness

Check the end float of the

whIch should be as follows

gearwheels

as

shown

Fig G 26

1 st speed gearwheel
2nd speed gearwheel

005

022

mm

0002

0009

o 1

022

mm

0004

0009

Follow the mstructlons for the three speed gearbox except that
s
a floor mounted gearlever whIch
the four speed gearbox
should be removed at the control lever bracket

NOTE

two types of
Warner and Servo
Three speed gearbox

There

gearbox

Borg

deSCribed

In

are

synchromesh

used

thiS

The Borg Warner type

IS

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

and the mamshaft

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

DIsmantling

FOUR SPEED GEARBOX

Fig G 32 and

unscrew the

top and bottom

covers

mam

Turn the casmg so that the detent ball hole IS uppermost Fit
the spring and the ball m the bottom hole Fig G 27 Hold the
ball With a dummy shaft and fit the 1 st reverse selector fork

pushmg the dummy shaft out F It the Interlocking

plunger 2nd 3rd speed selector fork and rod and Insert the ball
and the spring Screw down the mterlockmg plug coatmg the
thread With sealing compound Secure the selector forks to the

Unscrew the detent ball plugs and remove the springs and
detent balls Drive out the selector fork to rod retalnmg pinS
and remove the selector rods and forks Engage the second and
fourth gear by pushing the operatmg sleeve of the correspon
dmg synchronizer unit to the given gear pOSItions and slacken
the main shaft nut

and the rod

rods With the retalnmg pins

Fit the

reverse

Fig

Idler gear and shaft and

secure

With lock bolt and

a SUitable

plate F It the countergear cluster and the shaft usmg

thrust washer to obtarn
00047
mm

In

0 151

Washers
0159 In

Remove the countershaft and the gear cluster together With the
needle roller bearings and the spacers Remove the reverse
gear clrcllp and remove the reverse Idler gears and the shaft
two

end float of 0 04

an

available

are

rn

sizes

0 12

mm

00016

from 383

403

G 33

Remove the four bolts holding the malnshaft bearing retamer

remove the retamer
Fig G 341 Withdraw the mamshaft

and

assembly

shown

as

In

Fig G 35 and the

main

drive shaft

clutch

shaft

thickness

dismantle the malnshaft

Fig G 36 release the 3rd 4th
synchrOnizer Unit clrcllp and pull off the hub complete With the
operating sleeve Remove the third speed gearwheel and the
needle roller bearing
Remove the mam shaft nut and the
locking plate and the speedometer drive worm With the
retamlng ball Then WIthdraw the mamshaft reverse gearwheel
and the hub and press off the ma Inshaft bearing retainer and
the bearing
To

Fit the cross shafts 11 Fig G 7 thrust washers 2 and operatmg

levers 3
Secure cross shafts With retammg rings 5 and lock
the operatmg levers to the shafts With the pms 4
Fit the

extension casmg to the gearbox case and tIghten the

30 kgm 16
22 Ib ft
Fit the
torque of 22
speedometer driven piniOn set bolt and lockrng plate Check
rear

bolts to

the gear backlash

o 13 mm 0 003

as

shown

0 005

rn

Fig

G 28 which should be 008

for all gears FIt the front

and tighten the bolts to 1 1
1 7 kgm 8 0
12 2 Ib ft
the clutch Withdrawal and release bearmg and the bottom
the bolts to

tlghtenmg

In

torque

readmg

of 1 1

1 7

kgm

cover

Refit
cover

80

123 Ib ft

the thrust washer and the first speed gearwheel

With the needle roller bearing taking care not to loose
the small thrust washer locating ball Slide off the first speed
Next

remove

together

gearwheel bush

together
THREE SPEED GEARBOX

The mstallatlon of the gearbox IS

procedure Note the follOWing pomts

Installation
reversal of

the removal

Finally

remove

the second

FOUR SPEED GEARBOX

Follow

speed gearwheel

With the needle roller bearing

the

mstructlons

accordance

With

the

for

the

Inspection
three speed

speCifications

given

gearbox
m

In

section

TECHNICAL DATA
Fill the

capacity

IS

clutch slave

play of

With the recommended MP 90 011 The flllmg

1 7 IItres 045 U S gall 0 37 Imp gall
AdjUst the

gearbox

2 2

cylinder push
mm

0087

rod to obtain

withdrawal lever free

FOUR SPEED GEARBOX

Assembly

The assembly IS carried out m Similar manner as deSCribed for

the three speed gearbox except for the followmg pomts
When

mstalllng

the

mam

drive shaft

clutch shaft

SUitable clrcllp to eliminate any end float Clrcllps

m 5 Slles from 1 52
1 77 mm 006
007 m

select

are
m

available

thickness

47

inter

M@

FI9

1i

2S Flttlll9 the SPring rongs

FI9 G 26 Chedung the end float of the
gea eels

FI9 G 28
backla

gear

FI9

G 29

Greasing
beanng

POlllts for

withdrawal lever

and release

J
f
J

Fog

G 31

VISW

of the gearchange contrOl

arm

F G

33 Removal of the

ne

ler geara

Po

pOlello t

I
FigG 38 Exploded
tram

FIg

34

r
rete

48

Fog

35

a1 of the

malllshaft

ly

of the mamshaft goer

ImmIIII
4t1l
3rd

Rod

Spring
Plug
Plunger

Plunger
FIg

n Dlllnm of tile
G

Idler FOr

FIg G 39 SectIOn through tile gearbox

FI9 G 38 Assembly of tile selector fol1 s

to

show

the Interlodung system

FIg G 42

ll G 40 Removal of the steenng wheel

F

Remoyal

of

the

upper

support

bracket

Gnxw
naltnd wttmg

01

G 45 Adjustment for neutral setting

FIQ
FIQ G 46 View of the selectar

49

The Borg Warner type IS dealt with

under the three speed gearbox The instructions therefore apply
only to the Servo type synchronIzers The assembly procedure

Synchronizer assembly

for all synchronizers but the anchor block thrust

block and one brake band of the 1st speed synchronizer dIffer
from those of the 2nd 3rd and 4th speed
IS

the

spring

IS now

free to

remove

same

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

so

securing the synchronIzer assembly

When

assembling the malnshaft observe that the end float of the

3rd speed gearwheel should be 005 0 15 mm 0002
0006
In
ClrcllPS for adjusting the end float are available In 5 sizes
from

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

1 40

1 60

0055

mm

the locknut at the

79 5 Ib ft

0063

In

In

thickness

end of the malnshaft to 9

rear

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

Fig G 43 Remove the bolts holding the lower support bracket

and the clamp and remove the clamp and the gear change lever
retainer 2nd
3rd speed selector lever lower support bracket
and 1 st and reverse selector lever from the control rod
Withdraw

the control rod by removing the cotter pins

DIsconnect the gear change rods remove the cross shaft bracket
and Withdraw the cross shaft assembly
Fig G 44

Tighten

11 kgm

65
GEAR CHANGE CONTROL LINKAGE

To assemble the

reverse Idler gear

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

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

The installatIOn of the gear change control linkage IS carned out

In
reverse
order to the removal procedure Coat all sliding
surfaces With chaSSIS grease prior to assembly

GEAR CHANGE CONTROL LINKAGE

FII the thrust washer

case

Adjust
006

In

InstallatIon

Adjustment

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

the countergear end float to 005

015 mm 0002
by uSing thrust washers of SUitable Size which are

available

In

5 thicknesses from 2 4

2 6

mm

0 0945

AUTOMATIC TRANSMISSION

0 102

In

To
When

assembling the selector

mechanIsm

Fig G 38

fIt the

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

3rd 4th

interlocking pin A
mechanism

selector

speed

section

rod

through

remembering

the selector and

the

interlocking

given In Fig G 39 Frt an interlocking plunger 6

and assemble the reverse selector fork 8 and the selector fork
for the

IS

same

gear

the retaining pinS

Secure the selector forks to the rods with

10

remove

transmission

linkage

the gear change control linkage of the automatic

follow the removal of the three speed gearbox

for

as

as

and including the gear lever

By removing cotter Pin plain and spring washer disconnect the

upper selector rod from the selector lever Remove the speed
range pOSition plate the Clrcllp at the lower control rod end and
unscrew and
remove the lower support bracket
Release the
locking

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

screw

F g G 46
rods and

remove

the

cross

shaft bracket and the

cross

shaft

assembly
Place

a check ball and a spring In each of the holes and screw

down the plug to a torque of 1 7
21 kgm 123
15 21b ft
after smearing the threads with sealing compound

When

fitting the rear extension hOUSing engage the striker rod

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

Although
manual
a

Job

automatic transmiSSion

IS

not

covered

inspection and repair

far experts the control linkage IS discussed
as

the maintenance

GEAR CHANGE CONTROL LINKAGES

Three
Remove

the

Fig

G 41
d

50

follOWing

column

steering

cowl

Remove the

IS

In

thiS

conSidered

Removal

speed gearbox

indicator

clrcllp

wheel

Steering

Items

switch
In

Fig

and

Fig
light

G 40
swItch

G 42 and the washer

The

InstallatIOn of the linkage IS a reversal of the removal

Set the converter s de lever and the gear lever to the
neutral pOSition Fit the upper selector rod to the selector lever
and adjust the gear positron plate so that the selector lever stop

procedure

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

Finally tighten the

nut

on

each Side of the trunnion

Technical Data
GENERAL SPECIFICATlor S

Gearbox model

RSW65L

Gearchange type
Synchromesh type

Column

Gear ratios

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

Number of teeth

F4C63L

Floor change

Floor change
Servo

Borg

Warner
32631

Borg

Warner
33821

16451

20131

1000 1

1 312 1

20131
1312 1

33551

10001
33641

33641

3 382 1

10001

on

mamshaft

Number of teeth

change

F4W63L

Drive gear
3rd speed

19

22
27

22

2nd speed
1 st speed
Reverse speed

25
31

30

30
36

34

36
39

Driven gear
3rd speed

30

31

31

29

29

2nd speed
1 st speed

24

21

15

15

21
15

Reverse speed

16

14

14

16

18

18

5
16

27

39

on

countershaft

Reverse dler gear

Speedometer

Drive gear

5
19

Driven gear

or

17

16

CLEARANCES AND PLAYS

I

Model

R3W6

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

F4W63L and F4C63L

019

mm

0008

020mm 0008
004 0 12 mm

020

020
o 50

mm

0008

040
mm

mm

0 020

0005
0002
0008

0016

008029

mm

030mm

0012m

005
o 20
o 10

015

0006
0002

mm

0 008 m
0 30 mm 0 004

In

mm

o 50 mm 0 020

0 011
0003

0012m

Gearwheel end float

1 st speed gearwheel
2nd speed gearwhee
3rd

o 05
010

0 22 mm 0 002
022 mm 0004

0009m
0009m

speed gearwheel

Gear backlash
Max shaft ru

008
out
n

015

013
mm

mm

0006

0003
m

0005

005
005

o 15 mm 0 002
o 15mm 0002

0006m

005

015

0002

0006m

005

0 10mm 0002

0004m

025

mm

mm

0010

0006m

51

inter

FIg H 3 Removal

r1D

p
@

of

FIg H 4 Removal of the SIde drIVe flange

member

FIg H 5 Removal of dlfferentlallKle cover

t
FIg H 6 Removal of drffarentl8l Clllle

Fill H 7 Removal of dlfferentlalllde bearing

FIQG 10 Measunng the clearance between the

dJfferentl8l SIde gear and the thnllt washer tapl
eel n1rHlut
end checkIng the crown
ttomL

52

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

rear

Removal

rear end

DIFFERENTIAL
While

of the car and place

of the vehicle on suitable stands

Loosen

the

dismantling check the follOWing

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

flange

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

a suitable mounting stand Special tool

ST 37400510 IS available and check the tooth contact
pattern
uSing a lead OXide at two or three points

The backlash between the dnve gear and

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

PROPELLER SHAFT

DIsmantling

Clean and

al components for assembly 10 correct

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

as

follows replacing them If

wear or

In

diameter wear should not exceed 0 15 mm

size IS 147 mm 0579 In
Check the
and replace them If necessary The radial

The standard

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

spider

gearbox splines should

With the shaft mounted between centres check the runout of

the shaft which should not exceed 06 mm 0023 In
The
shaft can only be straightened With a hydraulic press however
It

recommended that the shaft be replaced Also check that

the dynamiC balance does not exceed 15 gnn em 0278 oz 10
at 4000 rpm
IS

PROPELLER SHAFT
Reverse the

removal and

Assembly

dismantling

and Installation

procedure

fellowing points
Grease the needle

noting the

rollers WIth

wheel bearing grease before

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

rear

flange yoke

Similar

Removal

Remove the handbrake rear cable propeller and dnve shafts

With differential suPPorted on a Jack remove the nuts securing
the differential mounting
member
cross
and remove the bolts

holding

the differential to the suspension member Remove the

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

should be 3

15

kgem

as

shown

In

the Illustration Next

remove

the differential

nght hand Side first as shown In Fig H 5 Mark the

beanng camers In order to refit them In their
onglnal pOSitIOns The dlfferent al assembly can now be lifted
bearing

caps
differential

carner

f F Ig H6

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

ST47340000

Place

SUitable press plate between drive pinIon head and rear

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

bearing

not

betng replaced the

remove

the outer

Inner races are not to be removed

o
T
of the front and rear pinion bearings
special tool ST49290000 or any SUitable

races

drive them out With

drift

To dismantle the differential cage remove the right hand bearing

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

Replacmg of oil
DIFFERENTIAL
Saloon

on

To dismantle the dlfferent al remove the

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

from the dIfferentIal

spider Journal

0006

Items

Clamp the differentIal In

exhaust

accidentally dropping

Dismandlllg

seals wilh dIfferential titted

Front 011 seal

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

Replace the

oil seal into the retainer USing a drift of SUitable

special tool ST 49320000 Fill the od seal lips

outer diameter or

63

inte r

clJ
e

C0LID

6
90H12
F
90H
F
I

11

Pinion

Secbon through the drive pinion

prHoad

bHn1Id
UltJ f

2 Pmlon dopth

lItIJ

611

ol

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

Ii

Amon

lng
u
IId

P8Cf
I

90H
F

side

Adjsutllll

far

dlff8nntJal

16

cowen

4 Gl

90H
F
co

17

The
G

maJtuJ18S

lo

of the

dlffwentJal side

FigH 19 ChecIung
wheellDI priOR

54

the

backof the

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

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

beanngs

Side 011 seel

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

DIFFERENTIAL
Clean all parts

as

follows and

Inspection

replace

or

repair

where necessary

Gear teeth for sconng cracklllg and excessIVe wear Note

that the dnve pinion and crown wheel should be replaced
as a set
2

Gear shaft
excessive

If the

bearrngs

and thrust

washen for

Chipping

or

backlash

between the differential Side

0 008 In
IS over 0 2 mm

Measure the
out
run
of the crown wheel at the rear face
USing a dial IIIdlcator The permiSSible value IS 008 mm
0 003 In
Replace the crown wheel and drive pinion as a
set If thiS value IS exceeded
Differential

and differential

carner

cage

for cracks

Measure the drrve pillion bearing preload and select wash en

and spacen to give a preload of 7 10 kgcm 972 138 In oz
83 3 In oz
for used
With new bearrngs or 3
6 kgan 41 7
The

preload

In

all 011 seals

DIFFERENTIAL

Assembly is the reversal

the follOWing pOlllts

ASIlImbly

of the

and

Adjustment

dismantling procedure With

the shlTIS

surfaces

thoroughly

order clean all

bearings With gear 011 Pack
of the 011 seals With grease

washen etc
and lubrrcate

the space between the

sealing lips

In

correct

in the dlfferentral cage Measure the clearance between the rear

face of the side gear and the cage as shown III Flg H l0 and
If necessary mange the thrust washer to obtain a
0 2 mm 0 004
Fit the pinion
clearance of 0 1
0008 III
shaft lock pin and secure It with a punch by caulking the
ITllterlBl of the differential cage Lubricate the gear teeth and
check the gear for freedom of rotation

mange

the
tJp
set
shlckness

In

of mesh

for the adjustment The dnve pinion adjusting shim

S can be found from the follOWing equation
W

0 01

0 20

where

T
H

Thickness of Inserted washers and shims

Measured thickness
Figure engraved In pinion head

ReqUired thickness

of washers and shims

lxample the follOWing might apply

As

W
T

2 20

3 40

1 20

H
S

mm

024mm
2

3AO

0 24

Fit the shims

beanng
bearing

0 01

reqUired

to

020

the drive

3 46

pillion fit

the rear

mm

bearrng

the drrve pillion and press home Fit the drrve

Into the differential carner throat together With the
spacer and washer front beanng Inner race and front

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

Fit the dnve

Press the

bearfngs

on

flange

by

the

beanng

retalller and the 011 seal

and the washer on to the drive pinion and

the nut to 17
lhtening
tl

the parts With the pimon nut

20 kgm 1122 9 144 6Ib ft

Acljustment

shims

of differential bearing covers

cage side bearings or bearing covers have

the side bearing pre load With adjusting
The exact thickness of the shims IS obtained by the

If differential

carTIer

replaced adjust

following equations
T1

the width of the differential side bearings by placing e

of 2 6 leg 6 5 lb on the bearing The nominal width IS

re

followed

spacer

secure

been

0787 In

shown

Fit the settlllg gauge ST49300000 Into the houslllg With the
pinion Installed and measure the clearance between the
head of the dummy shaft and the tiP of the setting gauge by
means of a feeler gauge as shown In Fig H 13 Flg H 14 shows

pinion

Fit the differential Side gear and the bevel gear III the cage using
the correct thrust washers Insert the differential shaft so that
the hole for the secunng pin III the shaft IS In line With the hole

00 mm
20

pinton height depth

as

Inner race on

Differential cage

Might

measured

note

to

Arrange

be

dummy

general replace

of

AdJustment

should

or

distortion

load
pre

rece on

S
5

pmion

pinion herght adJustlllg washer shlTIS and rear bearrng

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

gear and
and the

clearance between the differential Side gear and the thrust

washer IS over 0 3 mm 0 012 III
replace the thrust
washer which are available in three thicknesses

of drive

Fit the

bearings
Flg H 12

wear

differential pinion

Acljustment

T2

left

rrghtl

A
8

D
F

E
H

H
x

x 0 01
0 76
0 01 076

to the differential

56

interl

iill

p
m

TOE

TOE

TOE

fr
HEEL DRIVE

HEEL COAST
SIDE
FillH2O Tooth contact on heel

HEEL
SIDE

SIDE

DRIVE

21
FIlI H

Tooth co

56

DRIVE

SIDE

on toe

TOE

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

HEEL

HEEL COAST
SIDE

22 Tooth
H

TOE

HEEL DRIVE
SIDE
24
H
C
F

HEEL COAST
SIDE
tooth contact

co

HEEL COAST
SIDE
on fImc

removal

where
A
C
E

The

D
F

The figure

figure

the differential carner

on the differential cage

The difference m width of the left hand or

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

Fig H 17
The

H
Measure

the
to

etched

In

the crown wheel Side

bearing Width with a suitable

on top of the
load of 2 5 kg 5 5 Ib
under load and determme the value En or

differential

placmg

mstrument

bearmg

figure

brmg

and fill the fmal drive With

of the recommended 011

procedure

Imp pts

on

08 IItres

1 3

08 US qts

DIFFERENTIAL

Ramoval

Estate Car Stetlon

Wagon

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

the drive

DIFFERENTIAL

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

Dismantling

Clamp the differential carner Into a SUitable support as

m Fig H 26 and Inspect the tooth contact and the drive
depth before attempting to dismantle the differential

shown
pinIon

Check

Side bearing caps and the differential cage

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

cover

out

Fig

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

If the
If

right

the drive pinIOn turning torque and adjUst the bearing

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

Remove

the

Keep

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

the shims must be removed

Tooth contact

Measure the turning toque of the drive pinion In the differential

carner
uSing a SUItable pre load gauge and check the drive
mesh
depth uSing the special tool set ST46200000 Note
pinion
the values and write down for later reference

By applYing Prusslan Blue to 4 or 5 teeth and turning gears

evenly back and forward by hand check the crown wheel and
drive pinIOn tooth contact pattern and adjust as follows
Fig H20
Increase the thickness of the drive pinion shim and the washer
to brmg the pin Ion closer to the crown wheel
Heel contact

Toe contact Fig H 21

Reduce the drive pinion shim and washer thickness to
pinion away from crown wheel
Flank contact Fig H 22
ThiS pattern should be treated

as

move

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

might by pOSSible

for toe contact

repair
as

If

shims

or

no

washers

load condition
have

been

Also check that the

wlthm 008 mm 0003 m
backlash

changed

check

IS

and inSPect

as

follows and

replace

or

necessary

and

thrust

reverse

washer 0 2 mm 0 008
7 different thicknesses

DIFFERENTIAL

The

Installation

remamlng parts

Cbeck the parts as deSCribed for the Saloon differential With

out
limit for the crown wheel IS 0 05
the exception that the ru n
m
the
clearance
between differential Side gear
0002
and
mm

stIli

the

caITIer mto the rear suspension member

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

Fit the

thoroughly

Thrust

washers

are

the tooth

wheel backlash

Secure the differential

H 25

as

available

crown

DIFFERENTIAL

Fig

other SUitable equipment

for heel contact

Correct contact Fig H 24

A correct tooth contact IS obtained when the Impression lies
within 2 3 to 3 4 of the distance between the tip and the root
of the tooth under

use

DIFFERENTIAL
Inspection
Fig H 31l
Clean all parts

Face contact Fig H 23

ThiS pattern should be treated

to

order

to

the

assembly IS a reversal
followmg pomts

Assembly
Fig H 33
of the

and

Adjustment

dismantling procedure notmg

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

inter

i1 l

PJtE
1D

Ass y

H 30

beanng
dlf ereratl
al

ide

duvt piniOn

31
H
F
Exploded
bly

of d

FigH 32 MeIIsllnng 1he

NIHIUt

58

crown

wheel

for

I of

tile

pllllOii mv

mte

E illj
r

P
@

DC

J1ahtenJnc torque
lrmo p
nu
nlDn
14

to

100

17 k

to

Gear

odj
Adj drlnu
bearina wttbout

dnn pIJUOD

oD
drift hypoid Ie w
pat
Preload or pinion beannc

120

lb
Ct

10

ratio

3SP
A

TIM

to

13

TIhrenma
6

3889

TIM

cm
q

torque

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

dtff
bolt

kg m
D

C
4SP

TIM

FIgH

3700

SectIon

through

carr

Fill H 36
IIlIe

Me mng the
bearing thockness

entud
drtt

the

dofferentl8l

FIg

H 35

CalculetlOn of the

differential side

lbeenng s ums

Fill H 37 Measunng the crown wheel back

s
Me
ng the

n
dlmen

69

from the nght hand Side and peen the

secure the prn 10 posItIon

edges

of the hole to

39 8 Ib ft

10 a

new

5 5

lock

kgm

agonal pattern

13 kgcm

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

press

10

race

replacer ST 47820000

new

bearings

use a

washer of dIfferent thIckness Do

Ib ft

Adjustment

determme the dnve plmon shIm thIckness fIt the drive

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

for

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

shaft

AdJustmg the dnve pinIOn

oz

dIfferentIal carner RefIt the flange washer and the pmlOn nut
130
and tIghten the nut to a torque of 14
17 kgm 101
Ib ft
If the holes for the spltt pm WIll not altgn WIth the

specIfIed torque readmg

not overtighten the nut

outer

180510

the special beanng press mandrel ST49260000 or a dnft

wIth SlJttable dimenSIons press 10 the SIde beanngs lOner race
Fit the crown wheel adjusting shIms behind the bearings to
obtain the correct preload After rnsertlng the correct shIms

USing

138 9

less for used bearings Check the plnton

value of 20 40
depth and re adJust If necessary Remove the pInion nut and
the flange and press the 011 seal
well greased IOta the
and

FIt the crown wheel to the dIfferentIal cage usrng

8
straps and tIghten the bolts to a torque reading of 4
34 7

should be 10

of d fferentJal

preload

beanng

AdjUst the dIfferentIal bearing pre load

followrng formular see Fig H 35

10

accordance WIth the

To

Left Side
Tl

Crown wheel SIde

C
D
E
7

RIght SIde DIfferential assembly SIde

T2

where
To

determine

the

exact

thIckness

of

the

shIms

use

the

T11T2

follOWing equatIon

Shim thickness

A a
T

0 25

02

hOUSing
Figure

ElF
The

required

rear

bearing adJustmg shIm thickness

In

FIg

The gap measured above 10 mllllmetres

The figure marked on the dnve prnlon head ThIS
eIther

or a

can

be

figure

If necessary adjust shIms by removIng the dnve pInion and the

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

kgm

attach 109 a preload gauge to he prnlon flange and adjust to the

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

60

10

Units

respectIve

of 1 1000

10

differentIal beanng

marked

Respective

mllltmetres
N

on

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

C D
where

required

Figure marked

H 36

Measure the crown wheel and pinion backlash FIg H 37 and

adjUst to 0 15 020 mm 0006 0008 m by movmg the SIde
bearing shIms from the left to the right If too small and from

right

to

readmg

left If too great TIghten

48 kgm 304

ot 4 2

cap bolts to a torque

347 Ib ft
Usmg a large

bearing

or specIal tool ST46380oo0 measure the dImenSIon

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

micrometer

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

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

Length
Outer dIameter

750
Inner dIameter

mm

30

In

Estate

car

models

603 mm 24m Saloon models

71 8 mm 28 In
Estate car models

AXIal play of spIder Journal

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

008mm

cm

0 278

mm

In oz

2 0 2 2 24 mm

shims

From 1 09

ThIckness of pmlon
Saloon
Estate

1 27

mm

beanng adJustmg washers

From 2 31

car

257

mm

As Saloon

00315ml

06 mm 0024
015

Thickness of pmlon heIght adJustmg

washers
ThIckness of pinion heIght

at

0006

CROWN WHEEL

m
In

4000 rpm

Backlash between gears

Saloon
Estate

car

o 10

0 20

mm

015

020

mm

0 004
0006

0 008
0008

0003
0 OOl

In

FINAL GEAR RATIOS

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

43751

Estate

car

wheel
Less than 0 08

mm

Less than 0 05

mm

37001
38891
38891

With automatIc
car With 4 speed box
car

DIFFERENTIAL GEARS

37001
Thickness of Side gear thrust washers
Saloon

DRIVE PINION
InitIal turnmg torque
Saloon models
Estate

car

Depth from axle

car

10

13 kgcm

Estate

0506
0 723

0723 Ib ft I
0940 Ib ft

car

o 775 0 825 0 875

178 083 088 1 03 1 23

Clearance between Side gear and washer

Saloon
0 10 0 20
Estate car
005 0 20

mm

0004

mm

0002

08
00
0008

mm
mm

10
m

centre

Saloon modesl
Estate

without 011 seal

7
10 kgcm

models

In

3900 1
39001

Saloon With automatic

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

crown

Saloon

models

48 5
610

mm
mm

1 909
2402

In
m

61

ImDIIIII
I

0
f
1
r

ttI

i
Y

f 1l

jjJ

jf

YI

IJ

AiI
II

I
FIg I 2 Parts to be removed

or

the removal of the fmal drive

dIsconnected for

unit

Brake Ime connector

2 Handbr b cable adjuster
3 Rerum spong
4

Propeller thaft flange

Front

O ff

mountmg
member

FIg I 3

Removal of the lower

shock absorber

Fig I 4

Removal

suspenSion

mounting

as

of

complete

rear

axle

and

rear

I nstallatlon

Unit

rear

diagram for

suspension

6@

jj

1
l

Fig I 6

Removal of the drIVe shaft securing

FIg I 7

Exploded

vIew

of the

rear

cod

ring

nuts

F g 1 11

Filii 9

62

Removal

FIg I 8 The upper shock absorber mounting

Fig I 10
of

the Or coli sprln9

Removal of the

rear

SIIspel1Slon

ann

nut

Removal

of the

rear

wheel

bearing

Rea r

Suspension
COIL SPRINGS

DESCRIPTION

The Saloon models

are

fitted WIth

fully Independent

rear

COIl sprrngs
traIling
suspensIon
suspensIOn WIth
and telescopIC hydraulic double acting shock absorbers The
final drrve Untt IS mounted to the suspension member by four
semi

arms

arms

bolts and rubber Insulators

The Estate Cars

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

Jack up and support the rear end of the car on

Remove the wheels handbrake linkage and
return spnngs
exhaust tat pipe and Silencer DIsconnect the
brake hose from the tube Remove the propeller shaft from the
differential The parts to be disconnected from underneath the
I 1

SUitable stands

Jack up the suspension arm and

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

or

damage and replace

If necessary

procedure

IS carried out In reverse order to the removal

ensunng that the flat face of the spring IS at the top

Removal and Installation

Remove the boot trrm assembly and the two securrng nuts from
Remove the
the upper shock absorber mountIng
Fig I 8
shock absorber from the lower mountlng bracket and Itft out

Removal

Saloon models

Fig

the sprrng for YIeld deformatIon and cracks Test the

and compare the results WIth the information In
sprrng
TECHNICAL DATA Check the rubber parts for deformatIon

REAR SHOCK ABSORBERS

REAR AXLE AND SUSPENSION

Refer to

Check

The installatIon

StatIon

axle WIth seml

shock absorbers
rear

Installation

are

Test the shock absorber If faCIlitIes

the results With the specIfications
Check

for

011

leaks

and

are
In

cracks and

available and compare

TECHNICAL DATA
check

the

shaft

straIghtness Check the rubber bushes for deformatIon

and replace If necessary
The mstallatlon

for

or wear

reversal of the removal procedure

IS a

remove

securrng nuts and the nuts secunng the differential mounting

Carefully lower the suspensIOn Untt Fig I 4

REAR SUSPENSION ARMS

Jack up the car and place the
dlscpnnect the follOWing parts
and

InspectIon

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

Replace

where necessary

from axle shaft

wheel

Lower

cyltnder

the Jack and

Fig 19

rubber

SUSPENSION

IS a reversal of the removal procedure noting the follOWing

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

72 3 Ib ft l the dIfferentIal mounting member to 8 5 kgm

61 6 Ib ft and the lower shock absorber nut to 2 3 kgm 166

kgm

Ib ft

REAR SUSPENSION ARM

Removal

the suspensIon arm for dIstortIon or cracks and the

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

IS a

the suspensIon

WIth the wheels

of the vehIcle and support on stands Remove

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

InstallatIOn

Check

The installatIon

Jack
FIg

spnng and the bump

wlthd rawal tool

all

the

the COIl

and

ThIS

Jack

remove

Remove the suspension arm securing bolts as shown In FIg I 10

11ft out the arm If necessary remove the rubber bushes
from the suspensIon arm by pulltng them out With a SUItable

Installation

COIL SPRINGS

end on stands Remove or

Wheels brake drum drive

rear

handbrake cable from equaltzer bracket

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

SUSPENSION

Removal

arm

on

rear

and remove the COIl spring

I 7

the seat and the

bump

rubber

OIL SEALS

REAR AXLE SHAFTS BEARINGS

Removal and

Dismantling

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

Fig

USIng a slide hammer

Remove the rear axle dnve

I 12

studs

SUitably
flange

fIxed

to

the

flange

63

inter

QJ

@LID

00
0
FIg I 12 Removal of thedrIVe axle

Shock absorber lower mountIng

Bearing hOUSing
mark

Pack With wheel

MP2

or MP3

beanng

grease

every overhaul

AXLE HOUSING

DISTANCE PIECE

Fog 115

The critIcal dane

ons
mstallatlOn of the RlsponSlOn ann

8
6
6

Fog J 16 Exploded
1
2
3
4
5

of thedrNe

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

6
1

GaJrttrcltp

8
9

SJtJeve
SIewe

10

shaft

C IdIP

yoke
yoktl plUf
Spider Joomal
F
yoke

12 0 119
tIbelllJt1g
13 N
4

Clrcltp

Apply grease

In

Fig18 Sec1IOn through the

64

thIS area

1haft

for

the

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

The assembly of the drove shaft IS a reversal of the dlsmanthog

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

clrcltp
the
REAR AXLE SHAFTS BEARINGS

Check

OIL SEALS

and InstallatIon

Assembly

the axle shaft for straIghtness cracks damage or wear

the 011 seal Check the bearongs for roughness or pIttIng

Replace
Replace

parts

as

pOints
all

parts thoroughly The sealed Sides of the wheel

bearongs should face to the wheel and the sealed Side of the
Inner
bearong the dIfferential The arrangement IS shown In

Fig I 14

applted

When
to

the

the bearings the

refItting

pressure should be

lOner race

When

replaCing the suspensIon arm check that the dIstance

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

the spaces
Replace the

In

wheel bearong nut after It has been used tWice

Wheel

beanngs

have

mm

0006

In

The

rear

Wagon

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

Jack loosen the U bolts and

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

REAR AXLE

on a

rear

Dlsmantltng and Inspection

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

AdJustment

With the nut tIghtened to a torque reading of 25 33 kgm 181

239 Ib ft
check the axle shaft end float The end float must
be less than 015

Removal

Estate Car Station

The assembly and the follOWing mstallatlon IS a reversal of the

dlsmantltng and removal procedures notmg the follOWing

Clean

REAR AXLE

necessary

axle shaft should

turning torque of less than 4 5 kgcm 645

replace the dIstance piece
a

In oz

If not

and

the

remove

Itable

bearing

WIth

beanng puller

or

by other

The backplate IS now free Remove the nuts

securing the differential unit to the rear axle and hft out the
differential The bearing collars must always be replaced
su

means

Check
DRIVE SHAFTS

Removal and D smantltng

DIsconnect the end flanges and remove the shaft

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

roughness
The

drove shafts should be dIsmantled every 30 000 mIles

50 000 km or every 2 years to lubrocate the splines Remove
the Universal JOint spIder at the differentIal Side In the same
manner as
dlsmantltng the propeller shaft see approproate
and

the sleeve yoke plug securmg CorcllpS and

take out the plug Compress the drove shaft and remove the
corcltp 4 10 FIg I 16 and the stopper Disconnect the boot and
spltt the shaft tak Ing care to retam all parts
section

remove

REAR AXLE
ThiS

IS

the

noting the

Check

the

the dnve

follOWing
shaft

are

and Installation

parts and replace If necessary Note that

be replaced as a
assembly as

must

replacement parts
Check

Inspection Assembly

not

complete

avaIlable

the boots and the sleeve yoke

0 ring Check the

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

sectIon

plug

dIsmantling

and removal procedure

pOints

clean all parts

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

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

to

the

the
m

recommended

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

or

dealtng WIth

the propeller shaft

REAR SPRINGS
Refer to

FIg

support the
Clean the

sleeve

and the drove shaft ball grooves and

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

lubncate WIth 011

the shaft

and InstallatIon

Thoroughly
dIagonal

DRIVE SHAFT

of the

reverse

follOWing

Assembly

play

yoke

Removal and Installation

I 21

rear

Jack up the centre of the rear axle an

of the car on stands Remove the wheel and the

shock absorber from the lower mountmg and undo U

bolts
bump rubber spring seat location plates and seat pads Remove
the sprong front bracket securmg bolts and lower the sprong
bracket

FIg I 22

Remove the upper and lower

rear

shackle

65

ImDBII

Fig I 19 Removal of the

rear

axle

together WIth

the rear springs

Fog I 20
WIth

CuttIng the bearing

lnlng collar

cold chIsel

Filii 21 Meosunng the axle shaft end float

FI91 22 The

rear

rln9 front

hanger

7
8

FillI 23
3

Voew of the
axle

as

frtted

Ddfenmtt
2 Rear vie
3
4

66

to

C8TTI r

hOUSing

LBet sp mi
Bump rubber

rear

SIIspenSlon and

rear

models
5 Shock obsorlJor
6 RNr spring front henger
7

HMldbrllktlltnk
B
ll
hO

The upper shock absorber mounting

bolts and the front spring eye bolts to separate front

hanger and

spnng

REAR SHOCK ABSORBER

The InstallatIon
the

following

IS a

reversal of the removal

procedure

noting

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

pOInts

rubber should be fitted WIth the longated flange to

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

Removal and Instllllatlon

bump

rear

The installatIon

procedu

tIghtened

that the shackle bush flange

IS

re

the wheels of the

clamped evenly

IS

carrted out In reverse order to the removal

lower shock absorber mounting nut WIth

Tighten the
car

resting

on

the ground

Technical Data
COIL SPRINGS
Model

L510S

L510

510

PL510
W

re

dIameter

COil dIameter
Free length

142

mm

0559

90 mm 3 543
311 mm 122

142

In

0559

mm

In

Same

In

306

142

In

mm

0559

In

Same
120

mm

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

299

In

mm

11 8

In

sprtng The only dIfference for the

HOCIC ABSORBERS
L 510

Model

P L 510

PIston diameter
Stroke

25

235

mm

9252

In

Max

578

mm

22 76

In

length

DampIng force

at

0 3

0984

mm

25

In

0984

mm

In

235

mm

9 252

In

578

mm

22 76

In

m sec

ExpanSIon
CompressIon

65kg
33 kg

1433Ib
72 8 Ib

50kg
20 kg

1101b
44 Ib

REAR SPRINGS
SHOCK ABSORBERS
1200

Length

Estate CaB

Width
PIston diameter
Stroke

length
Damping force
ExpanSion

mm

0984

In

Thickness

200

mm

7874
19488

In

Number of leaves

In

Free camber

495

Max

CompressIon

25

at

mm

0 3 mlsec

75kg
23 kg

1653Ib
50 7 Ib

24
Laden camber
Spring eye bolt diameter

60
6

47 2

In

mm

2 362

In

mm

0 236

In

mm

mm

at

246

kg

153 mm 6023 In
0938 In at 542 Ib

Front

45

mm

1 772

In

Rear

30

mm

1 181

In

67

inter

iCQllW
ill

J 2 Removal of the wheel hub

FIlI

Z
I

FlgJ 1 V
1

of

enSlon
Su

SUsptlnSlon
4 SuspensJOlt

GreWIth

J7
FIg
l1li8

68

text

Ulator
m

umt 6
embly
S
crossmem

StabllMr bar
6 Reaction strut
7 SrnpenSlon ann
8 Steenng lever

ated poInts
Indoc

of the ll1Ibil

t
2

spensoon

J
FIlI

bar

Fog J 3 Exploded

5 Removal

Frontwheelhub
G

Inner WMeI bearing

4 Outer wheel beanng
5 Spmdltl nut

Co l Sfrmg

J
Flg

umt

the front

tq
o

of front wheel hub

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

the cnon Ilrut

J 8 Rerniiwal of
FIlI

For alUlOll1bOnS
an

l1li8

tIDltl

Front

Suspension

The front suspensIon IS of the spring strut type 10 which shock

absorber and wheel sptndle are combtned to form a sIngle Unit
Call spnngs are fItted to the upper ends of the suspensIon Untts

FRONT WHEEL HUBS

Drum brakes

Removal

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

FIg J 2

beartng
the

Remove the outer

bearing cage 011 seals and the Inner

sUItable drtft drtve out the outer races of

cage UStng
and outer beartngs
a

lOner

clean all parts Replace 011 seals

or hub and the grease 10 the bear lOgs

Thoroughly

damaged beartngs

Remove the body fltttng nuts 1 10 FIg J 8 and the suspensIon

bolts 21 LIft off the reactIon rod

arm

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

arm Remove the two bolts holdIng the suspension assembly to

the SWIvel JOint
Fig J 10 Place a Jack under the suspensIon
arm and Itft up the suspensIon unIt Remove the mounttng bolts
Lower the lack
from under the bonnet as shown 10 Fig J 11
remove

IS a reversal of the removal

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

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

97 2

WIth

kgcm
adJustment 4 kgcm 555
10 OZ

new

beanngs

or

10

case

of

10 oz

FRONT WHEEL HUB DISC brakes

Removal

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

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

out the buter races

FRONT WHEEL HUB

See descnptlon under drum brake

Installation

type nottng the followtng

torque setttngs

Calliper

bolts

Brake dISC bolts

Baclc plate bolts

the suspension untt

Installation

The installatIon

Removal

Jack up the front of the vehIcle and support on SUItable stands

Remove the wheel
dIsconnect the brake hose from the
connector reaction strut and stablltser bar from the suspensIon

and
FRONT WHEEL HUBS

Removal and Installation

REACTION STRUT

DESCRIPTION

Dlsmantltng

SUSPENSION UNIT

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

Replace the shock absorber flUId gland packtng and 0 nng

self lock109 nuts Check the suspension Untt outer casing for
deformatIon cracks or damage and the sptndle for cracks at the
base or screw portIon Inspect the sprtng rubber parts and
thrust bearing for

wear

deformatIon and cracks

7 3
3 9

99 kgm

528

71 6 Ib ft

5 3

28 2

38 3 Ib ft

fIt the outer casing to the adaptor and tnsert

rod
and
pIston
cyltnder Into the castng FIll the outer castng
With the correct grade of 011 10 accordance WIth the table

27

37

195

268 Ib ft

below

To

kgm
kgm

assemble

P510 UTK

All ledU models

STABILlSER BAR

Removal and Installation

Remove the securtng bolts on the suspensIon arms 11 In FIg

nd the frame bracket bolts 2 and remove the stablltser bar
Check

for cracks and deformatIon

rubber parts

and Assembly

Ex PSIO

modeIJ

PLSI0 TI aud

damaged
tlghtentng the
and the

UTK

J 1I

wagon PLSIO TI

model

and LS 105

LSIO S

J 7
1
0

300 cc

325

cc

290

cc

quanbty

of the bar and

Reverse the removal procedure

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

Applied

The 011 quantity IS cntlcal and should be accurately measured as

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

tlghtentng

69

ImDIIEI
1

8
e

Fill J 10 Removal of the SWIvel JOint essembly

e
FIg J 9 Exploded
1
2
3
4

J 12

of the front RlspenSlon umt

6

Upper mount
Gland packmg
Upper sprmg eat

7 Coli Pring
8 BumlHf rubber

5 Dust

Fig

VIew

Nut

Clip

Suspension

The upper mounting of the Rlspenslon

Unit

cover

Removal of

the suspension

the self locklng nut With

unit compressed

Fog J 13 Exploded
mbly

VIew

of S1Jspenslon

unIt

spnng

Fig J 14 Exploded

70

voew

of the shock absorber

Fill J 15 Grease the pOints marked With

and

mmBIIB

Fig

17 The suspension

ann

mounting

nut

FIg J 18 The suspenSIon

arm

bush

FIg J 20 The mountmg bolts for the lower ball

the RlspenSlon ann

JOint on

fIiilIII
J

itJiJ
Yf
l

Co

p
I

fi

r T
D

L
I

Fill J 22 AdjUst
rod

centre

tube

the

In

by turnIng the track

F I J 23

AdjUst the
bolt

enng
stl

angle bV

means

of

the arrowed

71

untIl the pressure

IS on

both dIrections the

LOWER BALL JOINT

same

Complet
e

the assembly by reversong the dlsmantltng procedure

The torque settong of the self Iockong nuts IS 6 0 7 5
kgm 434
54 2 Ib ft

Jack up and support the front of the car on stands Remove or

disconnect the followong
reaction rod and stabl Itser bar from
suspension arm suspension Unit from SWIvel Joont arm spltt pon
from

Joont nut ball JOint from SWivel Joont arm

and the lower ball JOInt from the suspensIon arm by
removIng the bolts 1 on FIg J 20

Fig

SUSPENSION UNIT

Installation

Reverse the removal procedure greasing all parts marked

FIg J 15 Tighten to the recommended torque values

In

the

follOWing
Upper attachment nuts

3 9
6 0

Unit to

ReactIon rod to

Stablltser

to

arm

4 9
1 2

arm

arm

SUSPENSION ARM

5 2
80

kgm
kgm
63 kgm
1 7 kgm

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

123 Ib ft

Removal and InstallatIOn

lower ball

J 19

Replace

It must be

06

SuspensIon

Removal and Installation

damaged dust
0001

mm

As the ball Joont IS a sealed UOIt

If the end play IS greater than 0 03
I To grease the ball JOInt remove

cover

replaced complete
0014

on

the plug and screw In a grease flttong Flush old grease out of
the JOint by pumpong on new grease Refit the plug
The Installation

reversal of the removal procedure Tighten

to
the torque values
Itsted
under
TIGHTENING TORQUES see Index for page
number
heading
Front Suspension
all

bolts

IS a

and

nuts

Jack up and support the front of the car on stands Disconnect

the reaction rod
1
and the stablliser bar 2
from the
In
suspension arm 3
Fig J 16 Remove the lower ball JOint
bolts 4 and the nut 1 In Fig J 17 Lift out the suspension

FRONT WHEEL ALIGNMENT

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

arm

and cannot
one

Check the suspension arm for damage cracks or distortion and

the rubber parts for abraSion If the dimenSions A on FIg J 18
IS

less than 1

mm

004

In

SuspensIon
member
Ball JOint

to

changing

be adjusted To level the vehIcle In the case that

more than the other can be accompltshed by
the spnngs

hangs

Toe on

replace the rubber parts

The onstallatlon IS a reversal of the removal procedure

the bolts to the follOWing torque values
arm

Side

TIghten

cross

12 2
19

13 5 kgm

88 2

25kgm

137

97 6 Ib ft
1811bft

Adjustments

Check the toe

In

by lengthening

or

by uSing a gauge shown In FIg J 21 and adJust

shortening the track rods The standard length

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

adJusted
In

FIg

to

equal length

by turning the

centre

tubes

arrowed

angle

uSing the

J 22

Steenng angle
With the

car on a

bolt arrowed

72

In

turn

FIg

table adJUst the steerrng

J 23 on both SIdes

Technical Data
FRONT WHEEL ALIGNMENT

Model

All Saloon models

except L510 S

L51 D S

All Estate Cars

Castor
Camber

1040
1000
8000

1040

200

King
Toe

pIn

Inclination

In

1010

7030

7050

9mm

024

1030

035

12mm

035

In

047

n
m

012

In

024

In

COIL SPRINGS
Models

L H spring for all

models R H sprong
for L H 0 models

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

spring
for all models WIth
air

cond Itloner

12

mm

spring for L510 S

12

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

12

536 Ibs

0472111 I

mm

130mm
3695
202

736lnl
187mm
243 kg

L Hand R H

R H spring for all

R H D models and
and L510 S L H

mm

795

mm

243

In

51210

3845

mm
1514
217mm 8541O
243 kg 536 Ib

III

0472

130mm

512
1455 III

536Ibs

In

FROIH SUSPENSION UNITS

Models

All Saloons

Saloons With

All Estates

Estate

With drum

disc brakes

With drum

With disc

brakes

Exc SSS

brakes

brakes

Exc

50
mm

PL510 TKI

50

rod

50
2 0

2 0

20

20

20

20

0 787

0 787

22

0 787

22
0 866

0 866

hnder

mncr

30

10

30
1

1 181

32

30
1 181

1 181

181

32
1 260

1 260

Dampmg force

at

pIshon speed 0 3 mls 1 08 ft

t 10
67

EhpanslOn

kg

50

ci

2 0

0 787

dIameter
mm

jO

50

2 0

2 0

dIameter

and

PIston
mm

P510 UTK

S
L51G

Strut outer
diameter

L510S

SSS

Ib

147

CompressIOn
kg Ib
Shock absorber
inner

cylinder

length

tn

mm

t 22
7

251 4
55

t8 8
1

410
16

b7 1 10
t 22
7

147

25104
55

t 8 8
1

410
1

16

7 22
t

147
25
55

110

8 8

17

t 22
7
t4
25

55

t8 8
1

435

435
1

HO
147

17

176

i
147 71 22

t 22
3

25104
40106
t8 8
1
88 2 1 13 2 55

410
16

410
16

I
73

interCE QJ

Q
@

0
9

I
10

80

Fill

K 1

Exploded

Smermg gear
2
3

lng
hou

mg eCtoTdudt
Sector sh h ccwer
Adu ttng IC
W

5 Kbnn

beanng um
0 nng
6 HouSIng
cOW

of the steering I8IIr

tIng bolts of the

FIlI K 2 The
column

ng

StltJrm8 column tube

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

rlll K 4 Removal of the

Nfl

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

74

column Nfl

9685

In

Steeri ng
column

DESCRIPTION

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

steering

IS

of the

reclrcu

latlng ball type

necessary to grease all grease flttmgs of the steering

Itnkage

Removal

STEERING GEAR

Remove the horn ring by depressIng It and turning It to the left

the steering wheel nut and uSing the steering wheel puller
ST46430000 or any other puller that WIll fIt WIthdraw the

steering wheel

Remove the steering column cowl dIrection

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

pin from the trunnion

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

Itnkage

as

deSCribed

In

sectIon

GEARBOX

011 from the steering box Slacken the

and turn the sector shaft adjusting screw several
turns antl dockwlse Remove the sector shaft cover and the
shaft from the hOUSIng as shown In Fig 4 Remove the steering
column tube bolts and WIthdraw the steerrng column as shown
46440000

Drain the

adJustment

nut

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

puller remove the rear beanng

Finally remove the bearing

tube

steenng

worm

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

Into

outer

race

from the column

Inner

races

of the front and

Inspection and Assembly

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

packed

WIth

the

55 5

kgcm

833 In

WIthout the

oz

be carrted out by hookIng a

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

sector

being

fitted

ThIS

can

Fig

thicknesses from 1 45

1 57

mm

0057

0062

In

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

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

adjusting

mm

screw

at

to less than 01 mm
the end of the cover

by

0004

In

WIth the

From thiS
1 8 to 1 6 turn and

FIg

K 10

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

capacity

STEERING GEAR

necessary and

reassemble

the steering

gear as follows

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

In tallatlon

The installation IS a reversal of the removal

the followmg pOints

procedure

noting

the front wheel altgnment and the steenng system for

of movement The steenng wheel rrm should have a
30 mm 098
1 18 In
measured at the
free travel of 20
outSide dlll eter of the rim
Check

freedom

STEERING LINKAGE

Removal end Dismantling

K 11 With the vehIcle resting In stands remove the

the castle nuts holding the track rods to the
and
split pinS
from the levers
steering levers Remove the track rod ball JOInts
by means of a SUitable puller or by holding a large hammer on
Refer to

Replace parts

should be

It

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

adjusting

bearmgs and the steering column bearing

STEERING GEAR

wear

changed

cemented

Dismantling

Clamp the steering box assembly sUItably Into a Vice and

remove the drop arm WIth a SUitable puller or specIal tool ST

rear

has been

then

position screw In the adJusting screw

lock In pOSItion With the locknut
STEERING GEAR

beanng
and

FIg

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

second

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

STEERING LINKAGE

Assembly

assembly

and Installation

Check the rubber parts for damage wear or other form of

damage and replace If necessary Check all steering rods for

75

mter

f Qp
illJ

Fill K 8 Checking
adjusting ICrewand

Fill K 1 Measunng the initial turning torque by

mean

jlfi
F

of

i
0

C
I

y
1

between

float

shaft

7J

q
t

4 11

Ir
J

ri

I
i

g
8

end

spnng scale

tJ

the
sector

TIGHTENING TORQUE
55to76kgm
RAD 140rrm SEDAN

145mm

WAGON

r
steermg

hnkage

FIg K 12 Section through the Klier

seen

ann

1 Nylon bush
2 Dust co
r
3
e arm
ld

I
I

ANGlE

TOLERAHa

47

to 3 47

AFTER TIGHTENING
TME ARM

Fig K 15 Adjustment of Idler bracket and Klier

arm

Clearance
01to05mm
Frg K 13

Section

forthe track rod

76

thnlugh the ball JOint IItud

Frg K 14 SectIOn thnlugh the ball JOint ltud

for the connecting rod

have

damage distortion or cracks The ball JOlOts must

play due to weak sprlOgs or damage A workIng clearance
o 5

mm

stud

IS

Replace

0 004

pulled

out

no

free

Idler arm bracket coat the rubber bush

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

of 0 1

With

0 02 In 1 should be felt when the ball JOlOt

see
of Its socket
Fig K 13 and K 141

FIg

ball JOInts If necessary

Drop

arm

Idler

arm nut

12185

alignment

Shooting

Low tyre pressu re

I ncorrect wheel alignment
StIff track rod ends

SteerlOg

Tyre

Steenng wheel shimmy

box needs adJustment

pressure Incorrect

I ncorrect wheel altgnment

Wheels and tyres need balanclOg
Wheel hub nut loose
Wheel beanngs damaged
Front suspensIon distorted

Steermg

Steenng wheel pulls

to

one

SIde

box needs adJustment

Uneven tyre pressure

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

SuspensIon dIstorted
Steenng box worn
Wheel tramp

Abnormal tyre

Tyre

nOIses

wear

ACTION TO BE TAKEN

PROBABLE CAUSE

SYMPTOMS

Hard steenng

their baSIC length adjustment of 309 5

10

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

7 6 kgm 39 8 55 0 Ib ft
125 140 kgm 90 101 Ib ft
55 7 6 kgm 39 8 550 Ib ft

Trouble

to

between the ball stud centres by turnlOg the

centre tube 10 the approproate directIon After InstallatIon of
the complete steering linkage system check and adJust the wheel
mm

5 5

nut

K 15 for the dImenSion to be obtained

Bring the track rods

The assembly IS a reversal of the dismantling procedure notIng

the followlOg pOints TIghten the bolts to the followlOg torque
settlOgs
Ball stud nut

assembltng the
liqUid soap and

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

Correct
Correct alignment
Balance

as

necessary

Adjust wheel beanngs

Replace wheel beanngs
Check repaIr or replace
Adjust as necessary

Correct
Correct

Replace and adjust

Adjust brakes
Check and rectIfy
Check and rectIfy
Adjust or replace

Over Inflated tyres

Unbalanced tyre and wheel
Defective shock absorber
DefectIve tyre

Correct pressure
Check and balance If necessary
Check and rectIfy

Incorrect tyre pressure

I ncorrect wheel alignment

Correct

ExcessIVe wheel beanng play

AdJUst

Improper dnvlOg

AVOid sharp turnlOg at hIgh speeds

rapId startlOg und braklOg etc

tyre IOflatlon
I ncorrect wheel altgnment

Improper

Repair

or

replace

Correct

Correct
Correct

77

inter

MI
@

brake system
FIg L 1 Layout of thebrake systems wIth thedIsc

on

the left

12
2
3
4

11

11

WI

14

P
6
f
c

fA
f

17

Ie

1
16

el
Q

19

Reservlor tank
disc brake

2o

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

Retalnmg ring
Secondary piston cup

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

Cylll

derbOOY

cltp

l
Re
rvolr

Fig L 2 Exploded
mbly
for

of tho master brake

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

Bleeder
CMck

W
SiCffJ

a
spnng
Chk vaM
tl Gasket ring
18 Paton stop bolt

16

9
20

ket
Ga

ler
was
g
Vlllvep1u

fitted to the car

Fill L 5 The front drum brake

78

Bra kes
BRAKE PEDAL

Removal and Installation

Remove the return spring and the push rod cleviS pin and
Remove the
disconnect the pedal from the master cyltnder
See FIg L 2
PIvot pin and 11ft out the pedal
Check

the

pedal

shaft

bushes

the

pedal

and other parts for

dIstortIon and replace parts as

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

damage

or

excessive

wear

or

and detach the wheel cylinders after disconnecting the bridge

pipe between them If the wheel cylinders must be dismantled
remove the rubber dust caps and Withdraw the Inner parts
Check

the brake

drums for
0002 In
to

Qut
run

and skim If the

adjusting

mm

cams

for freedom

a maximum

of rotation and the springs for

are as follows

weakness The standard dimenSions

35mm

Wire dIameter
BRAKE MASTER CYLINDER

Removal and DIsmantling

Remove
or
disconnect the follOWing
Fig L 3
Push rod cleVIS pin at the brake pedal brake pipe at the
master cylmder and master cylinder securing nuts from the
bulkhead LIft the master cylinder from ItS mounting
Refer

run out

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

Free

77 5

length

mm

215

Number of turns

to

parts

reservOir and remove the dust cover and

piston stop screw from the bott of the cylinder After
removIng the piston retaining ring and the abutment washer
shake out the piston assembly the piston return spring valve

Drain all flUid from the

the

cap and check valve

BRAKE MASTER CYLINDER

Assembly and InstallatIon

the brake backplate for distortion Inspect the wheel

cylmder bore for scoring and the pIston surface for
corroSion or damage
The maximum running clearance of the
piston In the cylinder bore must not exceed 0 15 mm 0 05 In
Check
brake

It

IS

recommended to

renew the

FRONT DRUIV BRAKE

piston cups every time

Assembly and InstallatIOn

Reverse the dIsmantling and removal procedures

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

Thoroughly clean all parts and check as follows replacmg any

defectIve parts Cups and valves shou Id be renewed as a matter
of

course

FRONT DISC BRAKE

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

for

damage
reservoIr for damage

or

weakness

Inspect dust

cover

and

Support the vehicle

on stands remove the wheel and disconnect

Remove the bolts securing the brake calliper to
FIg L 7
JOint flange and remove the calliper

the brake hose

the

SWivel
Remove the hub nut and Withdraw the hub

complete installatIon adJust the brake pedal height and bleed

the hydraultc brake system

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

found

to

be due to brake
sure

FRONT DRUM BRAKE

Support

the vehIcle

on

With the

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

shown

If

any flUid

leaks

Removal and InspectIon

stands and remove the brake drum hub

cap and hub assembly by removing the spilt pIn and the castle
DIsconnect the brake hose
nut from the SWIvel JOInt spindle
from the wheel brake cylinder Unhook the return springs from

for
1

wear or

mm

004

cracks
In

or defects can be found

on the
should be replaced Check the brake pads
If the pads areworn down to a thIckness of

damage

It

cylinder assembly

leakage

together

brake disc

The assembly of the brake master cylinder IS a reversal of the

dismantling procedure noting the follOWing pOints Soak the
pIston cup In brake flUid and coat the pIston and the cylinder
working surfaces WIth brake flUid prior to assembly After the

If any

Removal and DIsmantling

I they

must be

replaced

In

sets

of four

ReplaCing

brake pads causes the brakes to pull to one SIde

out
run
The
Check the brake diSC for scoring out of round and
run out IS best
checked as shown In FIg L 9 w th the hub

only the

worn

mounted to the SWIvel JOint If It IS necessary to re machlne the

brake dISC take care that a mln thIckness of 8 4 mm 0331 In
IS not exceeded
The nominal thIckness of the brake dISC IS 10
mm

004

way

It cannot

In

If the dISC
be

IS

salvaged imd

cracked
must be

or

damaged

In

any other

replaced

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

79

inter
E

1J@

55 Y

UBE
bu

L H I
I
c

Fog L 7 Removal of the brake calliper

fR

F 19 L 4

Exploded

view

of

front

nIL ILl

brake

bly

Fill L 8
SSlld
comptl

the plSlDn
EJectJ

by

means

of

aD

lrJ
1
@

@j
Fill L 9 M88I11nIlg the brake daiC for

runt

Fog L 6 Exploded

of

the front dE brake

assembly
I Cylmdor
2 PISton
I

10 r

3W

12
13

tIenut
c

14

Suppon btlldr

of RetBtner
6 P
6
a
1 Shim

8
9

80

8
cl

I
p
IpO

pi

MIOn

rptlfIg

Spl pin
t

15 Hold down pin

16 Pwotpin
Ut
17 Mounting brIIc
18 Spnrv

FIg L 10
m 1Mr
c

rp
J

Fig L 13 Removal of thobrake pads

t
Fill L 14 Exploded

of the rear

YOM

brake

jj
I
70

6
M

lM

1I1

Jll

T v

Tho

In

lIII
lo

I
Fill L 16
posrbon

J
Fill L 17

Tho

handbnoko cable

foung pOints of
Saloon models

the

rear

81

FIg l19 The brake pedal adJustment

FIg L 20 Adjusting the brake hght swItch

FIg

L 22

mode

Ji

T F16

tc

if

82

IJ

r7

loo t

ifi C
J

Remove the cable from the handbrake lever

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

the front cable

FRONT DISC BRAKE

Assembly

From

and Installation

clips

Withdraw the cable Pull out the front cable from

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

Rinse the

cylinder bore thoroughly WIth brake fluid and fIt the

piston seal Into the groove as shown In Fig L 10 Fit the wIper
seal and Itghtly grease the bore wIth the speclfl
grease 91ean
the brake dISC and fIt to the hub The hub can now be fitted to

completely

the swIvel JOint

Handbreke lever

fIt the piston Into the cyltnder relteved portIon faCing

the PIVOt pin and push In the pIston until It IS almost flush WIth
the wiper seal retainer Install the cyltnder Into the calliper plate
and secure In posItIon by means of the two torsIon springs FIt
the
down
hold
pin spring washer and the nut to the support

gUIde

Remove the clevIS pin connecting the lever

yoke WIth the lever and the cleVIS ptn connecttng the control

Carefully

bracket and secure the nut With a spltt ptn Assemble the callIper
to the mountIng bracket WIth pIVOt pIn WIth spring washer
plain washer and castle nut Tighten the nut and secure WIth a

flange

Fig

shIm to the

Inner

brake pad and msert the

Inner

pad untIl

the piston Move the calliper away from

the chaSSIS and tnsert the upper cuts Centre the tndentatlons of
It contacts

the outer pad to the callIper plate

shown tn FIg L 11

BRAKE PADS

Fit the anti rattle cltp

as

Replacement

The

wear of the diSC brake pads should be checked every 3 000

If the pad thIckness IS less than 1 mm 004
miles 5 000 km
In
change the pads as a complete set of four

Saloon

handbrake cable

from both ends of the

the

by removtng

Remove the adJusttng nut and

Estate Car
rear

Remove the cleVIS ptnS

Remove the connecttng rods
springs and the cleVIS ptns See

cable

off
pull

HANDBRAKE MECHANISM
Check

the cables for

Examme the

breakage fraytng

handbrake

Installation

or exceSSive

stretchtng

lever

springs for weakness and the

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

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

assembly

L 18

pad Draw

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

LIft out the handbrake lever

In FIg L 16

shown

Rear handbrake cable

Rear

FIt

IS

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

Hook the
down
hold
bracket on to the top of the
mounting bracket and turn the calltper plate to ensure that It
can turn smoothly
Then fIt the calltper to the SWivel JOint

split pin

and the bracket

The tnstalled lever

Adjustments

Remove the wheel

surface of the pIston The InstallatIon of the new pads

carned out tn reverse order
See FIg L 11 12 and 13 for

exposed
IS

various

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

dIagram

Now

stages of replacement

WIthout dIsturbIng the brake light SWItch

must be free TIghten the locknut

The brake

pedal stop

screw tn

the SWItch

IS

the brake

light

SWItch untIl the threaded part of

touching the front of the stop bracket FIg L 20

Lock the SWItch

REAR BRAKES

the vehicle

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

Removal and Instal ation

Fig L 14

stands and remove the wheels Release

the handbrake and disconnect the connecttng rod from the lever

Support
at

the

rear

on

of the wheel brake

cylinder

Remove the brake

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

cyltnder
cylinder

dust
The

cover

plates

adJusttng shIms
cylinder can be

and

then

the

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

sectIon

Rear Axle

IS

pedal

pushed

assembly

and installation

IS

SImilar

as

deSCribed for the

front drum brakes

HANDBRAKE

Removal

by

1 5

mm

0 06

In

Front brake

Jack up the front of the vehicle

drum brakesl
brake pedal several tImes and then turn the adJuster
forward until the wheels are locked From thIS pOSitIon

Depress the
cams

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

completely Independently
The dIsc brakes
self adJusttng

fItted to the front wheels of some

are

Rear brakes
The

down

completely

Jack up the
released

rear

wheel and WIth the handbrake

pedal several tImes to

settle the mechantsm Turn the adjuster FIg L 22 and L 23 In
a clockWise dorectlon untIl the brake shoes are locked to the
depress

drum Then back off the

the wheel rotates

the brake

adjuster by

two or three

notches untIl

freely

Release the handbrake remove the clevIS pIn

Front cable
the cable and unscrew the adJusttng nut at the rear of

holdtng

83

HIlAWith the handbrake released and the rear brakes

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

adjusted

4 724 in

Fig

L 25

With the master cylinder reservoir completely fIlled remove the

ler dust cap from the bleed plug furthest away from the
rub

cyhnder and connect a bleed hose lD the bleeder valve

ImlTllirse the other end of the hose in a Jar
containing a httle
brake flu id Depress the brake pedal several tImes to
the
master

air

keep

valve

BLEEDING THE BRAKE SYSTEM

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

the
1 3 to

expel

pedal

at its

2 turn
1

eSt
10Vl

position

and open the bleeder

and then close the valve
Repeat this

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

proceed as follows

Technical Data
BRAKE PEDAL
Brake

pedal height

BRAKE DRUM AND BRAKE DISC

Front drum brakes

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

Drum inner diameter

187

mm

187

mm

197 mm

7 362 In
7 362 In
7 756 in

228 6

DISC outer dIameter

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

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

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

BRAKE LININGS
Drum brakes
Width x thick

length
11 575

C8
c1earal

19 05 mm 34
0 13 mm 0 005

In

WHEEL BRAKE CYLINDERS

elSC brakes

Rear

With front drum

Rear with front disc

Piston running clearance

84

Rear

22 22 mm

718

In

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

4Ox4 5x219mm
0 In x 8 642 in

In

Front

Inner diameter
Front drum
Front diSC

900 In

202

MASTER BRAKE CYLINDER

Inner diameter
Piston running

mm

232 mm 9130 In
0 05 mm 0 002 in max

0 709 In

Total braking area

Front drum brake
Front diSC brake
Rear brake

39 7

9 0

86 0

mm

1 563 x 0 354 x 3386 In

As for drum brake models

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

Trouble

PROBABLE CAUSE

SYMPTOMS
Insufflent performance

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

Pads or linIngs
No brake flUid

Pedal feels spongy

AIr

can

Check valve

worn

In

as necessary
Refill and bleed system

Bleed system

In reservoir

Top up flUId system

cylinder faulty

master

Valve seat dIrty

Brake effort decreases and pedal goes

slowly to floor

Brake pipes or hoses leaking

Damaged
brake

Brakes overheat

or

or defectIve cups
wheel cylinders

CompensatIon port

In

In

master

master

cylinder

of

SIde

new

connections

and hoses
Overhaul cylinder

In

or

fIt

new

PIpeS

questIon

new

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

Loose back plate mounting bolts

Oil on Itnlngs or pads

TIghten

Loose

damaged wheel beanngs

Improper operation of wheel cylinder

AdJust
Repair

Improper tyre inflation

Correct tyre pressure

or

valve

Clean master brake cylinder

Fit

use

unSUItable brake flUid

one

Check and repaIr

Clean valve seat fIt

TIghten

blocked
Return spring weak
Rubber parts swollen due to

Brakes pull to

Trace and rectIfy

Replace pads or brake shoes
Clean or replace linings

Replace

worn

n system
InsuffICIent flUId

be depressed WIthout actIon

ACTION TO BE TAKEN

Leak

Pedal contacts floor

Pedal

Shooting

Clean

replace
replace
or replace

or

or

i nter

10

Mil

OG

08
04Ii

Vl

C 81

III

0
0

e
ClO

81

lle
e

FlgM

t
r
Exploded vlBW of the h

I O
pul
2 ThfOugh bolt
30
end brodrn

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

5 Rotor

II SIIp

IVend

II

e
M 4 The
Fig

COIIl

1l

oo

of the drmt pulley

FIg 3 RernlIYaI
M

of the drive

pulley nu1

M 6 TIPPing
FIII

the dnve

end bndtet off the

rotIlr

M6 Remon of the
FII
bearing

W
Red

M 7 The
FIII

88

or

Id

rotIlr

Black
on
bliwot

slip ring end

figures

of the dIOdes

Fig8
M

ctenng the temlmal UN

Electrical
Precautumay Service NotllS

ALTERNATOR

The following precautions should be taken when serviCing

carned outon vehIcles wIth alternator charging systems
1

battery

Reversed

Ensure that the

rectifIers
connected to earth
2

Never

the

earth

disconnected

at

will

connections

Earthing

the

cable

the alternator If thiS cable

main

dIode
IS

IS

when

It

IS

earthed With

regulator

and the

cable or the terminal of the alternator

or the alternator CIrcUIt
IS SWItched off Since no

the alternator WIth the battery dIsconnected

and the field WindIngs energlsed otherwIse the control
Do not

run

u nit

WIll be

Do

not

damaged

attempt

to

polartse

the

alternator

necessary Any attempt to do so may result In

the alternator regulator or associated CirCUItS
6

charger
first

IS

not
to

the battery cables before uSIng a battery

prevent damage to the rectIfIer diodes A boost
assIst starting the engine cannot be used WIthout

to

can

Unit

connecting
Never

wire

to

control unit
be Isolated

voltage regulator
by disconnecting

Then

damage

unsolder the

removed

by

unscrew

of

arm
two

puller

end

hOUSing by unsoldering
negative diodes red fIgures

the cOIl lead WIres but take

thIS WIll lead to Irrepalrable
remove the brush cover and

and

termlnai

means

M6

FIg

as

shown

In

Fig

M8

Lift

ff the

stator

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

replaCIng they should be pressed out of the

replaced USing a SUItable press tool Do not drtve
out the damaged dIode as the other stIli servIceable dIodes may
be damaged through the Impact and shock
If the diodes need

heat Sink and

ALTERNATOR

to

not on

any other part of the alternator

If arc welding IS carried out on the car disconnect the

alternator and control Unit to prevent pOSSIble damage It
IS also
Important to Inform any welding speclahst of thIS
fact as It IS poSSIble that he Will not know that thIS car IS
an

Inspection

Rotor
check the rotor COIl for open or short
USing
CirCUItS Connect the Instrument to the shp rings of the rotor
and check the indicatIon on the ohmmeter No reading indicates
a

alternator chargrng system

The battery must never be connected

dIsconnected
while the engine IS running or damage may occur to the
devIces
conductor
seml
regulator
or

ohmmeter

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

dIsconnected

ohms at

aVOid bearing damage when adJustIng belt

only on the alternator drtve end
leverage
apply

fItted With
10

IS

Remove the stator from the dIode

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

an

an

Belt tensIOn
bracket

rotor

deSign

the

the alternator

transIstor

tenSion

press

out the beartng

The

ohmmeter of the type Incorporating a

generator for checking the dIode rectIfIers or

use

lrtven
hand

FIg M 5
Remove the beartng
from the beartng hOUSing The

hide mallet

uSing

retainer and

to

dIsconnectIng the

control

It

damage

DIsconnect

charger

bracket

bearing from the

WIll damage the alternator and

even when the IgnitIon SWItch
CirCUIt breakers are used
4

with a hammer The parts separate as shown In Fig M 2 Hold

the drIVe end rotor carefully In a VIce and remove the pulley
nut the pulley the fan arid tha spacer from the rotor shaft
Fig M 3 and M 4
Tap out the rotor from the drive end

of conventlonal

the IgnitIon SWItched on the voltage

assocIated wlrtng may be damaged
3

the

terminal

battery negatIve

alternator

main

damage

IS

Equipment

room

447

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

there

IS

short

or

open

CirCUIt

then the rotor should be

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

0004

In

replace

the rotor
Stator

Disconnect the battery earth cable and dIsconnect the Wires

from the alternator Remove the bolt securtng the fan belt
tensIoning strut ana hft away the fan belt Remove the

uSing a CIrcuit tester by

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

alternator

an

ALTERNATOR

Removal

Check the stator for conductIVity

the lead

retaIning bolts and lift the alternator from the

mounting bracket

yellow

open CircUit conditIon between the stator

M 14
the cOIl leads Fig M 13
Diode

ALTERNATOR

Fig

Dlsmanthng

M l

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

diodes

body

and any of

Assembly

claSSifIed by the resistance value

between the diode holder heat SInk and the diode leads To
perform thIS test remove the diode holder from the stator
Good

or

defectIVe

are

f11

inter

cJU

jIJtE
@

1
r
1
f

FI9 10 V
M
1Ily

of the removed dIode holder

M9
FIlI

al of 1he heat smIl 811d brush

Remo
the cover

holder assembly from

for
Fig M 12 Checking the rotor

out
run

for
Checking the rotor field cod
bottOm
and
earthIng
continurty top

M l1
FI9

FI9 13 Chedung
M

1he

wlIldmgs for

con1lnurty

rJl
1he

88

W1ndlriila

for

M 15 DlOlIe
FIlI

test

M 16 DIOlIe test
g
i F

Low

DIode holder posItIve sIde

Connect the posItIve lead of the CirCUIt

the diode

tester to

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

unsteady charge
Check drlvlng belt tension
Check for high resistance

1
2

CirCUit connectIons

the whole assembly

FIg M 15

The testing

renew

shown

In

connections

are

Check that the remaining brush length IS 7 5 mm 0 295 In

FIg M 17 and check the brush spring pressure by pressmg
of the holder The
brush down to WIthIn 1 mm 004 10
pressure should be 035 kg
mlntmum of 0 2 kg 044 Ib

ALTERNATOR
Install the stator COIl

077 Ib
IS

In

thIS condition but

Removal

VOLTAGE REGULATOR

remove

the

screws

Testing

ElectrIcal test
Connect the CirCUIt as shown In FIg M 22 uSIng a fully charged
battery and run the alternator at 5000 rpm The voltage read 109
15 0 volts If the voltage IS not correct adjUst
should be 140
the regu lator

permissible

10

connectIons

Disconnect the 6 way connector and

secUring the regulator to the bulkhead

2 DIode holder negatIve SIde

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

battery termInals and

VOLTAGE REGULATOR

tester

to

at

particularly earth

Mechantcal adJustments
The gap values of the constant voltage relay and the pIlot lamp
relay must be as follows
Gl
09 10mm
Constant vo Itage relay

Assembly and Installation

termmal to the brush holder and fit

FIg

0 035

M 23

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

10

0 8

G3

0032 004710
0 4 0 5 mm
0016 0020 In

the term mal msulator

1 2

0 039

G2

mm

retamer

the drive end bracket

on

to

the rotor shaft dnve end bearing

PIlot light

relay

The remammg operatIons are carried out 10 reverse order to the

dIsmantling procedure Make sure that the dIodes are connected
correctly Fig M 18 and M 19
The mstallatlon of the alternator

IS a

reversal of the removal

Observe all
procedure
pomts gIven under the
ALTERNATOR
PrecautIonary ServIcIng Notes

ALTERNATOR

head 109

0 008

G1
G2

0 2

G3

0 4 0 5 mm
0016 02010

mm

10

08 1 2 mm
0 2 0 024 In

Back gap G 1
Clean all contacts With

flOe emery cloth pnor adjustment

feeler gauges check the back gap Gl and adjUst If
necessary by means of the armature set screw

Usmg

Air gap

Inspection of output

G2

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

Check the
Connect the alternator

10

test

ClrCU It as

shown

In

FIg M 20

and dnve by means of a SUItable motor With the alternator at

2 amps
rest there Will be a negatIve current to the field cool
When the alternator IS turnmg at about 1000 rpm there should
be

no

negative current

WIth the

SWItch closed and the load resIstance at

maxImum

slowly reduce the load reSIstance mcreaslng the alternato

speed Read off the current value In relation to the alternator
speed and check 10 accordance to the speCIfIcatIons If the
deVIation IS small the alternator IS 10 good condItion
ALTERNATOR

Flndmg

of faults

Alternator does not charge the battery

1
Check drlvmg belt tensIon
2
3
4

Field cable broken at control Untt

NegatIve cable broken at control unIt
POSItive and field cables crossed

Alternator output
1
2
3

uncontrolled

WIth

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

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

FIg

M 26

Pomt gap g3
h
he gap

y means of a feeler gauge and adjust by

the contact po lOt set screw and alsmg or lowerulg the
contact set WIth a screwdriver

loosening

POSitive cable broken at control Untt

Field and negatIve cables crossed at control unot
Field and output connectors touching at alternator

89

IDmZIIIII
1
r
I
I
I
I

jj
TBattery
I

l
I
I

I
I

I
I
I
I
I
I
I
I
I

F g M 17 The

m nlmum

I
I

brush length

I
I
I
I
I
I

I
J
I

L
l

Alternator
Current flow

Current flow

Red ftgure

lack flgure
M

POSItIve dIode

F g M 18

Voltage regulator
nng pressure
Checking the brush

Diode
terminal
PILOT LAMP
RELAY

NegatIve diode

Fill M 21 V
prlot lamp relay
Test

ahemator

rcult

for

checkIng

REGULATOR

dIodes
FIg M t9 The current flow In the

FI9 M 20

VOLTAGE

of the voltage regulatof and

the

performance
t

t
Back gap

Air gap G2
08
12
Stopper

PrtmafY
contact

support

Voltage corl

SecomlafY
COntact

support
A
V

Ammeler
V ollago meter
FIlIM 23 The voltage reagulator

Woro harneSS
foo the voltage regulatOO
M22 Test Cllcurt
g
F

90

See text

mter E itl i j2J

CQJ E

Air gap 112

POint gap g3

Sprong

Voltage coIl

Fog M 25 Adjusting the

regulotor G2 In text

See

M 24 The pilot lamp relay

g

elr

BendIng dIrection

gap of the

voltage

ghten voltage

I Lower voltage

Fog
Fog M 26 Adjusting the
lemp relay g2 In text

cO

air

gap of the

27
M

Adjusting the voltage

g
Sllttll

pilot

3
9

5C h
I

12ij0
i
Ct

1
0

IS 16

14

Fog M 29
fnIm

The
tu
onn

motor body
end drIVe end bracket

removlKl

if 1

17

M 28 ExplodlKl
Fog

lnent
t
Etrpf
2

Sulmg

lINer

Thnnt

12 Slop

the

C IP

14 Pinion rtap OD

efMntltwer
lI
Etrf

tbil8
BAnn

of

Thrun

Dr rod brsck
4 Dun protectIOn

6 Dud
l
7 SoltlnoJd

VlOW

rod brocktlt bush

10 O

flntI

a
5

pin

ii

19

15 Drwe

tch

1er

pimon
nn ngclvtrh

16 O
17 Fleldcoll

g
motor

IS Sttrter motor body

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

Fog M 30 The
moclIanllll1 removed
br8ckoL

nt

motu
end

from

the

dr

end

91

inter

J
I1

1
ID

FI M 31
I

Testmg the f 1d COIl for continuity

32 CheckIng the brush spring

M

I
FI

Round

0 5mm O

8mm

te

on

Commutator
Ica

Correct

Fig

34
M

Incorrect

uttlng
Unden

the mICa Insulators

35 Testing the Innature

I M
FI
Wlndmgs for
earth connectIOn

gmtlon swItch

Fill M 36

Checkmg

the armature

for

short

Circuits

IT

Battery

FI9 37 TesI circuit for

M

92

Starter motor

lenood Mrtd1

M38
FI9
II

ng

the starter

motDr

l
panlOl

V ol1age
To increase the

voltage

downwards
Fig M 27

decrease

to

adjustment

bend the stopper upwards or bend It

the voltage on the voltage relay

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

Check the
VOLTAGE REGULATOR

The installation

IS

carrted out

10

lnstallllt101l

reverse

order to the removal

procedure
STARTER MOTOR

armature
on

Check the armature wmdlngs for open crrallts by placmg the

armature on the growler and connectIng two commutator

Removal

Disconnect the battery earth connectIon and the cables from

the starter
motor
termmals
Remove the starter
motor
mountmg bolts and 11ft the motor forward and out of the

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

car

Starter motor clutch

the
running clutch for damage and Inspect the
free wheel actIon 10 one direction and the slipping actIon 10 the
opposite directIon Replace If faulty
Check

STARTER MOTOR

Dismantling

DIsconnect the Wire to the M termmal on the starter motor

solenoId swItch remove the solenoid swItch securmg screws and
11ft off the solenoid swItch Remove the two through bolts and
take off the brush cover Gently tap off the starter motor body
WIth

wooden

hammer

to

separate the parts

as

shown

10

FIg M 29 Remove the armature assembly and the engagement

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

over

Brush holders
the brush holders for earth 109 USIng a CIrcuit tester
Place one test prod on the rear cover and the other on the
pOSItive brush holder If the tester needle moves It becomes
Check

necessary to replace the Insulator or the brush holder

DrIve end

Inspection and Overhaul

at

the dnve

end

replace

10

clearance of 003

Check

the fIeld COIls

Connect

prod

to

move

one

test

prod

the fIeld Call has

an

If the tester needle does not

open CirCUIt

be

moves

F Ig M 31

down to the commutator Check the spnng tensIon With the aid
of a spnng balance as shown 10 Fig M 32 The correct tension IS
0 7

1 54 lb

bush

IS flush

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

ER MOTOR

and see that

no

Assembly

assembly of the starter motor IS carried out 10 reverse order

to the removal procedure Pack the rear cover with grease and
lightly 011 the rear beanng and the dnve pmlon

Brushes

1 76

beanng

The

Check the length of the brushes and replace them If they are
Check the contacts and replace them
less than 6 mm 024 10
If loose Check that th brush holders Will hold the brushes

kg
kg

of the armature to give a runRlng

0004 10
The beanng
0001

mm

Check

the fIeld COlliS connected to earth and should

replaced

O B

size

pressed 10 so that the end of the

WIth the end of the dnve end housmg

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

0 10

should be

for open CirCUIt us 109 a CirCUIt tester

on to the field coli lead and the other

the other fIeld COIl lead

beanng and the armature shaft

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

the correct

out to

ream

FIeld coIls

bearing

Check the clearance between the

OOOB

STARTER MOTOR

wmdlngs for mternal shorts by placing the

the growler and hold a hacksaw blade over the

armature while rotatmg It If the hacksaw blade vibrates the
wmdlngs are shorting and the armature must be replaced
Fig M 36
armature

Ib

Ifthe tension IS less than

to lift the spnng of the brush

Replace

the

springs

Solenoid SWItch test

With the starter motor assembled connect up a test circuit as
shown 10 Fig M 37 With the igRltlon SWItched on check that
the dimension between the front edge of the drive plnton and
15 nvn 0012 0059 10
Measure
the plRlOn stopper IS 0
3
this dimension

Armature

shown in

Fig

M 38

WINDSCREEN WIPERS

Check the armature shaft for distortion as shown In Fig M 33

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

Check the armature cod for earth usmg

as

growler Connect

one

Removal

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

assembly

to

the bulk head

and remove the

Disconnect the

wiper motor and the 1Inkagi

WINDSCREEN WIPER
Remove

the

ended
hook

IlI8gnetized

wiper

motor

Wiring

See Fig M 39

Dismantling

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

linkage and
bolts

case

from

91

i nt e fiE

JI DJ
OoJ

l
P

Yoke

16

B b

31

Tapping

Damper

17

Rivet

32

Worm

Armature

18

Spnng

33

Wheel

19

Grommet

34

PlaiD washer

20

Gear

3S

Hexagon

21

Tapping

36

Lock washer

stopper

Feltwasbe
r

retainer

lCJew

wheel
ann

Beanng

Hook

Rivet

Brush holder

37

PlatD wamer

Felt walber

23

Plate spnng

38

Plate sptmg

24

Felt

39

Thtust washer

10

Sprmg

2S

Beatlng

40

Wave washer

11

BaU

26

Auto

stop

41

12

Magnet

27

Lock

plate

Beanng
Hexagon

13

Armature

28

PIa m Imall

14

Commutator

29

Gear COVei

t5

Brush spnng

30

Chp

holt

etamer

ball

M
FIU

au

39

Exploded

case
screw
us

wa her

cover aA

42
43

erew
ass

out

type nop

Tluwt

nug

nut

screw

Thrust washer

y
4S

Gear shatt

aD

of the windlcnen wiper motor

3
7

28

35

43

M 40 Removal of the wiper drIVln9 IIl1ndle

g

nut

M 43
Justment for the
of the W1P8r blades

Fig
M 42 Removal of the brush h
FIg

94

sr

If parlnng

pcIS1tJon

Pull the carbon brush

from Its holder and remove the brush

Unsolder the brush and

remove It From the gearbox

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

spring

COYer unscrew

DIRECTION INDICATOR SWITCH

Removal and

Installation

Disconnect the wiring from the connector at the dashboard

remove the horn ring and remove the steering wheel
Remove the steering column COYer and take off the dIrection

panel
WINDSCREEN WIPER MOTOR

Assembly and InstlIlllItJOn

indicator SWitch

Reverse the

Apply

dlsmanthng and removal procedures respectIVely

grease to the gear and coat the hOUSing and the cover

surfaces

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

switch by
as

shown

In

loosentng
Fig M 43

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

smear

The InstallatIon
When

fitting

correct

IS the

reversal of the removal procedure

the steering wheel make

relation

to

the

sure

that the spokes are In

of the front

posItion

stralght
ahead

wheels

Technical Data
ALTERNATOR
Armature shaft dla

12 volts 30 amps

Nominal output
Earth connectIon

NegatIve
1 000

Speed
No load

mln

speed

Output current
Pulley ratIo to

engIne

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

HITACHI

regulating voltage

Max permls shaft

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

Constant voltage relay

14 15 volts5000 rpm

HITACHI S114 103

Lock torque
No load current

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

Weight

12 volts
10kw
Less than 480 amps
6 volts

flywheel ring

pinIon SIde
rear end
008 mm 004 In
In

0453

In

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

Inner dIameter
Drive end bracket bush bore
Inner dIameter

o B kg

1 76 Ib

11 0

mm

0433

In

11 5

mm

0453

In

LAMPS

Type
Voltage
Output
Starting current
Starting voltage

Number of teeth on pinIon

Number of teetn on engine

0433

mm

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

length

STARTER MOTOR

Free running speed

OperatIon medIum

003

Brush spring tensIon

Drive end bracket bearing bush

Maker

Type

mm

11 5

Wear hmlt

VOLTAGE REGULATOR

No load

11 0

HITACHI

Maker

120

gear
5 1

kg

10 4Ib

Type 1
Type 2

sealed beam
sealed beam

Park 109 lamp

Front flasher
SIde flasher

lamp
lamp

Engine compartment lamp

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

37 5 watts
37 5 50 watts
B watts
I

25 watts
6 watts
8 watts
10 watts
25 watts

25 8 watts
25 watts
8 watts
3 watts

95

Trouble
SYMPTOMS

Battery

In

Shooting
ACTION TO BE TAKEN

PROBABLE rAUSE

low state of charge shown by

lack of power when starting

when runntng at about

Dynamo

not chargIng

20 mph

30 km WIth swItched

Broken

or

dynamo

CirCUIt

loose

on

lights

connectIon

regulator

or

In

not

functIonIng correctly

Examine charging and field CIrcuIt

TIghten loose connectIons or
lead
Partlcu larly
replace broken
wiring

battery

examine

connectIons

Examine regulator
Commutator greasy

or

Clean

dirty

WIth

soft

mOIstened

rag

In

petrol
GIVing low
when

car IS

or

Intennittent output
In top gear

running

Dynamo belt sli pplng

Loose

or

dynamo

CirCUIt

broken

Adjust belt tensIon

connectIons

In

Examine

and

charging

TIghten loose

wiring

fIeld

CirCUIt

connectlotl

or

lead
replace broken
PartIcularly
Inspect battery connections
Brushes greasy

or

Clean

dirty

WIth

soft

rag

mOistened

In

petrol
Brushes

worn or

Regulator

not

not

fitted correctly

Replace

worn

brushes

bed

brushes
oronerlv

See that the

functlomng correctly
ExamIne regulator

Battery

shown

overcharged

burnt out bulbs and

need for tOpping up

very

by
frequent

Starter does not operate or operates

and does not turn the engine

Regulator

not

functIoning

tly
corre

Poor contact of starter swItch contact

Examine regulator

Check sWItch and replace If necessary

POints
Poor brush contact

Replace brushes

Burnt commutator

Overhau I

or

spnngs

starter

motor

or

clean

commutator

Shorted field COIl

Replace COIl

Shorted armature

Replace

Poor contact of battery leads

Clean and tIghten leads

Weak battery

Recharge battery

Open

CI

rcUlt

between starter SWitch

armature

Check wlrtng and replace If necessary

and solenOId

Starter
does

not

seem

motor
to

operates

turn

over

but

Poor earth connectIon

Check and rectI fy

Drive plnton defectIve

Replace drove pinIon

engine

qUIckly enough

Flywheel ring gear

worn

Replace flywheel
gear teeth

IgnItIon wamlng lamp

high rpm

at

goes

out

only

Generator faulty
Regulator fau Ity

Repair generator
Replace regulator

or

recondition ring

IgnItIon warning lamp does not light

With Ignition SWItched on

Ignttlon warntng lamp does

fli ckers
Increased
or

when

engine

go out
IS
rpm

not

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

Loose

or

broken fan belt

Adjust tension or replace belt

Replace regulator
TIghten connectIon re replace lead
Repair generator

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

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

Clean commutator

Brushes worn
Brush spring weak or annealed
BInding brush levers

DIrty

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

commutator

ExcesSive frictIon

In

Charge battery
Replace battery
Replace bulb
Tighten or replace terminals
TIghten or replace cables
Replace switch
Free or replace brushes If necessary
replace brush springs

wiper linkages

Low operating voltage

connections

motor continues to run after

SWItch IS turned off or does not return
blades to parking pOSItion

WIper

Burnt out armature

Replace

Contacts In hOUSing damaged

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

Replace
Replace
Replace

Bad connection from wIper SWItch to

earth
Motor squeaks sometimes combined
WIth slow operatIon

Wiper linkages
POI

of

running dry

bushings

armature

move

PinIon

or

a rmatu re

shaft

dirty

of

complete

motor

contacts
contacts
contacts

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

Grease all moving parts of linkage

Bend stop to clear

RepOSItIOn

or

cover

Overhau I starter motor

damaged
SolenOId SWItch defective

Engine mlsfl res

or

spIndle

commutator
Side
against stop
brush holder
Incorrect pOSItion of motor cover

Starter motor pinIon does not

out of mesh

armature

Remove each sparking plug In turn

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

Replace solenOId SWItch

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

petrol supply

etc

LH

UOHT

R8

J
i

m
a
0
0

tII

QI
3

nOL
a

HE

DFORIAGRM

AOIO

DE

to

LUXE

EAfER
I

eN

L1GHTlt

eMJI
l
jl

Im

up
iiill
a

CMlNATIO

LIGHT LeEN

TlIjTAIL STOP BrCJ

TS

PADSlRE OIRECT NAl

flirtNG

lHT

VlMNG

QO
GAI

LIGHT

TAtf

GW

REAR

OIL

OIL
E
A
I
R
H
TERMHIol IGNTO

LIGHT COO

SALO N

WIPER

HT
U

SW

UNIT

WIRNG

IL

VOL

AIN

l3EAM

NENTINITRi

PILOT PILOT
LIGHT UGHT

u
HT

TAGE

REGULATtIl

II
MARK

NOTE

INCLUDING
T1a
1

AL

PARTS

UP
N

Jo4
L

111

I
I

II
1

Ill

UP

STOP T1JIH
L

nOlLH

1IT

CffCNAl

REGULATOft

LIN1lQG

TAGE

hI AIN

VQ

NOTE

MARK YO

GAUGE

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

DIRECTONAL

Yli
jr III Plllr
I

OIL

1
611

Il

UNIT

PRESU EOIm TERMNAL

PARTS

OIL

TS

fiRB

11

II SI I

mE
HEAT R

W
N

fT

CLOC

el

SALO N

rk

HEATRU
l

rm o

SSS

LiGHT

A010

FOR

DIAGRM

fJ

RELAY

WIRNG

BY

idr

nu

L1CJl

HEAD

rr

B
B

I
m

TI

e
8

RTcflv OF
RJi

RW
i

B1
e

rv

Cb

l
DUGt

LH

8L

fMK SIGNAL

if

HE

RH

IAOLGHLH

AU

IS

ENGLISH

Vear

1969no

1969no

Model

1300

1000 fLC

Engine type

510

510

3A

EEC

Number of

Flnng order

Capacity

Bore Stroke

mm

CompreSSion

ratIO

Compreulon

preswre

CO

pSI

kg

cm2

kg cm2

10

10

011 prnsure

11

ROIted output

HPlrpm

I1A

Fuel

12

342
1

4
42
3
1

1595

1595

83159 9

83n3 7

63f73 7

85

85

95

50

35
57

n SAE

8
9

116
171
40

37
60

64

6000

42

64

00 3 7

109 SAE 6000

12

0010

25
0

0 0101025

n mm

13

12

0012

3
0

0012 0
30

13

12

12

14

15

Valve

14

Inlet valve

IS

Outlet valve closes

lSA

Rood

158

Km h rpm gear

16

auery
B

17

Svstem

16

CarburettQt make

18

HITACHI

HITACHI

HITACHI

19

Carburettor

19

OCK 308

OAF 328

AJL3fffl

20

Idllna sperd

20

600

600

600

HITACHI

HITACHI

0411

o 40ll

utlet

opens

oOTOC

14

oATDe

IS

3
01110

12

19

lSA

horsepower

15A

158
V

plus

lty
polal

16

Ah
munn

type
om

kg cm2

158

I 12V140An

Fuel

21

23

Dlstnbutor make

22

HITACHI

23

Distributor type

23

0411

24

Contact breaker gap

25

Dwellangfe

26

psl

25

Stmctlmlng

Degrees
oaTDC

27

StroboscopIC

oaTDOrpm

27

28

Timing

2BA

Ignition

288

1ry
Pnm

timing

Centnf

advanCt

30

32

34

35

Sparking plug

make

37

Sparlung plug

type

38

Sparking
St

rter motor

make

26

28

HITACHI

HITACHI

28A

Ohms

288

32

15

6
1

288

29

0800

rpmE

41

800
0

ln
o

mm

ln
o

nwn

31

32

32

Hg

33

Hg

34

34

35

022 024

36

NGK

38
3BA

tYpe

Amps

VolI

8P

6E

0031

HITACHI

H TACHI

HITACHI

ALT I

HITACHI

40

LT 130

41K

LT

42

Requlator make

42

HITACHI

43

43

TL1

44

Cut

45

voltaQe

c ff voltage
Drop

46

Reverse current

47

Open

48

Closed

CirCUit
CIrCUit

49

Current

regulo1tor

50

Voltage

egulator

51

NOTES

52

tromchassls

53

from

BE

0031

37

8
0

lA

HITACHI

388

39

Generator output

lnq

OP

8
0

388

Generator type

ulator type

BE

BP

135

022 024
NGK

003108

41

AN IrpmG

0 24

22
0
NGK

40

clO

0800

30

Generator make

In

24
5

55

HITACHI

n mm

Lockdraw

55

28A

37

plug gap

23
05
045

9021
0017

27

MId

lty

er c
Condens
ap8C

36

49

0 4SO 5

CP

rpmE

end

91l21
017

14 650

no

22

64

10 600

rpmE

ends

55

58

CP

rpmE
o

Vacuum advance

57 K

CP

intermediate

21

10 650

dlate
Interml

31

33

starts

19
20

104
49

18

28

type

stance

16

12 V 50 Ah

25

rk locatIOn

COil make

5117

24

mm

iOAh
VI

17

22

pump pressure

12

17

21

129

11
llA

0010

13

C1earanee

10

2
4

96 SAE 5600

llA

mm

510

1296

11
170

11

Ltr 100 km DINJ

nlet

42
3
1

cucm

w clearance

3A

consuFnpllonlmpg

HCI

1600

3A

CYlinders

19ssno

41

12
30

133

ALT

01

HITACHI
17

TL1

ALT

LT 140 4EiK

12
30

12
30

HITACHI

139
I
11

HITACHI
17

T1 1

17

143

44

45

145

46

116

47

48

1
148

49

50

51

52

53

V A

mln

nglOe

um
um

I
Lower shock absorber

nuts
Drive shaft to

ConnectIng rod nuts

Flywheel bolts
Main beanng bolts
Camshaft sprocket bolt

27
45
50

pulley bolt

head bolts

011 relief valve

19 5 23 9Ib ft
687 75 9Ibft

105kgm
5 5 kgm 32 5 398 Ib ft
60 kgm 36 2 434 Ib ft
o 4 0 7 kgm 2 9 5 1 Ib ft
1 5 21 kgm 108 15 21b ft
o 8 1 2 kgm 5 8 8 7 Ib ft
160 180kgm 11571300Ibft
5 5 kgm 39 8 Ib ft
3 0 35 kgm 21 7 25 3 Ib ft
24 26kgm 174 18 8Ibft
95

011 sump
011 pump
011 strainer
Crankshaft

33 kgm

nut

Clutch bolts

kgm

16 61b ft

SO 6

57 8 Ib ft

Drive shaft to differential

ENGINE

Cylinder

2 3

mounting

TIGHTENING TORQUES

rear

axle

nuts

Bumper

7 0

8 0

70

8 0

kgm

flange
20

nut

Wheel nuts

8 0

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

Rear suspension member mounting

10

nuts

kgm

72 3 Ib ft

kgm

61 5Ib ft
72 3Ib ft

Differential member mounting

85

nuts

Suspension arm nuts

DifferentIal to dIfferential
member
Propeller shaft flange

10

kgm

57 8

6 0

kgm

43 4 Ib ft

40 85 kgm

29

61 6 Ib ft

21 7
528

253 Ib ft
71 6 Ib ft

28 2

38 3 Ib ft

8 7

12 3 Ib ft

FRONT SUSPENSION
GEARBOX
22

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

Rear extension to case

Gearbox to engine
Bottom cover
Front cover
Drain

plug

Selector lever bolt

Reverse lamp SWitch
Idler shaft screw

Cross shaft lock pIn

Malnshaf

nut

2171bft

Front hub nut

30

3 5

Brake

73
39

9 9
5 3

calltper bolts

38 3 Ib ft

Brake diSC bolts

12 3 Ib ft
123 Ib ft

Stablltser bolts suspension

SIde

36 2 Ib ft

Stablltser bolts frame

1521bft
28 91b ft
8 0 Ib ft

SIde
ReactIon rod to frame
ReactIon rod to suspension

8 0 Ib ft
79 5 Ib ft

SuspensIon

arm

arm

Untt

FINAL DRIVE

Untt

40

shaft flange
Drive plnton nut

Saloon

170

Estate

140

Crown wheel bolts

Saloon
Estate
Saloon models only
Side cover bolts
Dnve

85 kgm

200kgm
170 kgm

28 9

1229
101 2

61 5 Ib ft
1446Ibft
122 91b ft

7 0

80 kgm

SO 6

57 8 Ib ft

4 8

5 5

34 7

39 8 Ib ft

kgm

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

bo ts

flange
Beanng retainer bolts

Rear cover bolts

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

kgm

137

188 Ib ft

kgm

43 4

57 8 Ib ft

60 kgm 43 4 Ib ft

arm to

flange

to

7 0

8 0

kgm

506

57 B Ib ft

40

8 5

kgm

289

61 5 Ib ft

member

hOUSing
flange to propeller

20

22 kgm

145

15 91b ft

shaft

18

22kgm

13 0

1591bft

Drive

Rear wheel
Brake

beanng
backplate

REAR

nut

6 3

kgm

35 4

45 6 Ib ft

3 9

5 2

kgm

282

37 6 Ib ft

60 80

kgm

43 4

578 Ib ft

97 61b ft

kgm 88

1 9 25 kgm 137 18 lib ft

5576 kgm 398 550 Ib ft

PIston rod nut

6 0

Gland packing
Wheel nuts

60 65
8 0

7 5
9 0

kgm
kgm
kgm

43 4

47 0 Ib ft

434

470 Ib ft

57 8

65 1 Ib ft

STEERING

Flange mounting bolts

1 B

25 kgm

Ball stud nut

5 5

7 6

Drop

arm
arm

AdJustIng

nut

nut
screw

nut

mounttng bolts
bolts

Steenng gear
Idler arm

Brake pedal PIVOt

Brake pipeS

Estate car models only

DIfferential carrier to axle

REAR AXLE AND

4 9

130 18 lib ft

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

BRAKES

propeller

shaft

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

suspensIon cross
122 135

FInal drive to dnve

shafts
Final dnve

kgm

Lower ball JOInt

Lower ball JOInt nut

Idler

Final drive to suspensIon

member

1 7

lever to suspension

SuspensIon
Propeller

1 2

upper

nuts

Steering

kgm
kgm
kgm

3 5
15

4 0

kgm

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

11 kgm 108

Brake diSC bolts

39

53 kgm

Bridge

1 7

20 kgm

pipe
Brake hose to
Calliper bolts

cylinder

17
7 3

123 14 51b ft

123
20kgm
9 0

kgm 52 8

145Ibft
5 1 Ib ft

SUSPENSION
25
27

33

kgm 181 239 Ib

7kgm 195 268 Ib

ft
ft

Upper shock absorber

mounting

23 kgm

16 61b ft

101

CONVERSION TABLE

mm

lnS

mln

ln

mm

lnS

1m

mm

mm

inS

01

000394

020079

030370

2 007870

105

133848

02

000787

52

020472

078740

52

2 047240

110

330700

03

001181

53

020866

118110

53

2 0866 0

15

527550

04

001575

54

021260

157480

54

2 125980

120

724400

05

00 969

55

021854

196850

55

65350

25

921250

06

002362

56

022047

236220

56

2 204720

130

5 181 0

07

002756

57

022441

275590

57

135

08

003150

58

022835

314960

58

2 283460

140

51800

09

003543

59

023 228

354330

59

2 322830

145

708650

10

003937

60

023622

10

393700

60

362200

50

905500

004331

61

024016

II

433070

61

2 401570

155

6 102350

12

004724

62

024409

472440

62

2 440940

60

6 299200

13

005118

63

024803

13

511810

63

2 480310

165

6 496050

14

0055

64

025197

14

551180

64

170

6 692900

15

005906

65

025591

15

590550

65

2 559050

175

6 889750

16

006299

66

025984

16

629920

66

2 598420

180

086600

17

006693

67

026378

17

669290

67

637790

185

283450

18

0070B7

6B

026772

18

708660

68

2 677160

190

7 480300

19

007480

69

027165

19

748030

69

2 716530

195

7 677150

20

007874

70

027559

20

787400

70

2 755900

200

21

008268

71

027953

21

826770

71

2 795270

210

8 267700

22

00866l

72

028348

22

866140

72

2 834640

220

8 661400

23

009005

73

028740

23

905510

73

874010

230

9 055100

24

009149

74

029134

24

944880

74

913380

240

9 448800

25

009841

75

029528

25

984250

75

2 952750

250

26

010236

76

029921

26

023620

76

2 992120

260

10 236200

27

010630

71

030315

27

062990

77

031490

270

10 629900

28

011024

78

030709

28

102360

78

3 070860

280

11

29

011417

79

031103

29

141730

79

110230

290

11 417300

30

011811

80

031496

30

181100

80

149600

300

11

2205

81

03

220470

188970

32

2598

82

032283

32

259840

82

3 228340

320

2 598400

33

012992

83

032677

33

2992

83

3 267710

330

12 992100

34

013386

84

033071

34

I 338580

84

3 307080

340

13 385800

35

3780

85

033465

35

I 377949

85

3 346450

350

13

36

014173

86

033858

36

I 417319

86

3 385820

360

14 173200

37

014567

87

034252

37

456689

87

3 425190

370

14 566900

38

014961

88

034646

38

I 496050

88

484560

380

14 960600

39

015354

89

035039

39

535430

89

503930

390

15 354300

40

015748

90

035433

40

I 574800

90

3 543300

400

15 748000

3 582670

500

19

890

244090

519680

4950

874000

9 842600

032600

811000

12 204700

779500

41

016142

91

035827

41

614170

91

42

016535

92

036220

42

653540

92

622040

600

23 622000

43

016929

93

036614

43

692910

93

3 661410

700

27 559000

44

017323

94

037008

44

I 732280

94

700780

800

31 496000

45

017717

95

037402

45

I 771650

95

740150

900

35 433000

46

018110

96

037795

46

1 811020

96

3 779520

1000

39 370000

47

018504

97

038189

47

1 850390

97

818890

2000

78 740000

48

018898

98

038583

48

I 889760

98

3 858260

3000

118 110000

49

019291

99

038976

49

929130

99

3 897630

4000

157

50

019685

039370

50

I 968500

100

3 937000

5000

196 850000

Imm

685000

380000

oQUu@
f

1Wrr@LW

71

if
l
oo

y
I

COV RcS
600cc Standard De Luxe SSS

1300cc and

Saloon and

970

Estate up to

CONTAINS
1

DetaIled

descriptIon of ServIce RepaIr and Overhaul OperatIons

dearly explamed and

shown

hundreds of illustratIOns

plus
Trouble

Shooting

Tables
l

Tune up Data Tables

WIrIng DIagrams

Exploded

Parts

Diagrams

wIth DetaIled Parts

dentificatlOn

f
r

Q 1T UJ

5oo
U

OO p
M 1@ O j@