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Datsun 1000, Workshop Manual

The LG 1000 User Manual is available for free download on our website. This comprehensive manual provides step-by-step instructions and helpful tips for properly using and maximizing the features of the LG 1000. Get the most out of your device by accessing the user manual at manualshive.com.

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Page 1: ...SCIENTIFIC PUBLICATIONS WORKSHOP MANUAL SE IES No 87 rl WITH SPECIFICATIONS REPAIR AND MAINTENANCE DATA COVERING AIO AI2 ENGINE STATION WAGON SEDAN PICKUP 1000 Z 1 1 r ProCarManuals com ...

Page 2: ...SCIENTIFIC PU LICATIONS WORKSHOP MANUAL SERIES No 87 DATSITN 14M O 1 00 I ProCarManuals com ...

Page 3: ...ATIONS WORKSHOP MANUAL SERIES No 87 DATSUN 1000 1200 SERIES OIO 0110 SEDAN WAGON PICK UP AUTOMATIC and MANtJAL TRANSMISSIONS With Speelfieations Repair and Maintenanee Data SCIIL C PUBUCADONS S MELBOURNE ProCarManuals com ...

Page 4: ...Scientific Publications Pty Ltd Registered at GPO Sydney for transmission by post as a book First Edition January 1972 National Library of Australia Registry Number SBN 85566 038 4 CK OWLt UC E IE T Scientific Publications wishes to thank Nissan Motor Corp USA and Borg Warner Lid Fairfield for help in aspects of preparing this manual J ProCarManuals com ...

Page 5: ...ISSION REAR AXLE STEERING FRONT SUSPENSION RE R SUSPENSION BRAKES ELECTRIC L SYSTE BODY WHEEL AXD TYRES LUHIUCATION AND MAINTENANCE EMISSIOX CONTROL SYSTI MS IXDEX GLOSSARY OF TERMS ROAD TEST 7 28 14 47 57 73 85 103 I ll 126 131 148 184 195 200 20 1 211 lIlt 217 ProCarManuals com ...

Page 6: ... XW V8 63 238 155 6 25 Standard 8 14 Ford V8 and 1939 46 40 81 51 100 Mercury 1932 48 11 122 132 3 50 Standard 10 1955 58 41 147 134 175 Hillman Hunler Standard Space Arrow HB HC 79 188 121 5 75 master Series 11 42 125 105 3 00 Holden 1948 53 FJ Standard Vanguard III 43 184 149 5 75 FE FC FB EK Toyota Corolla 11 00 73 176 107 5 75 EH EJ HD HR 67 286 128 7 00 Toyota Corolla 1200 93 Holden FE FC FB ...

Page 7: ...33 516 33 50 mm 1 3195 1 3190 in 12 011 12 00 mm 0 4728 0 4724 in Replacement guide 12 211 12 200 mm 0 4807 0 4800 in 450 Valve seat angle Valve seat width Inlet 1 30 mm 0 0512 in 1 80mm 0 p709 in Exhaust Valve seat insert outer diameter standard Inlet 37 080 37 096 mm I 459 1460 iri 33 080 33 096 mm 1 302 1 303 in Exhaust Valve seat insert inner diameter Inlet Exhaust 30 to 1O mm 1181 to 004in 26...

Page 8: ...69 0 6871 in Clearance in piston 0 006 0 008 mm 10 0002 0 0003 in Interference fit in connecting rod 0 017 0 034 mm 0 0007 0 0013 in Length 65 23 6548 mm 2 5681 2 5779 in With pistolJ at a temperature of 200C 680F CRAN SHAFT AND MAIN BEARINGS Crankshaft Main journal diamet r 49 964 49 957 mm I 9671 1 9668 in 0 03 mm 00012 in 0 020 0062 nun 0 0008 0 0024 in 0 5mm 0 0059 in 0 015 0 050 nun 10 0006 0...

Page 9: ...ing plate bolts 0 50 kg m 3 60 ft lb Sump bol ts 0 60 kg in 4 30 ft lb Oil pump attachment bolis 1 50 kg m I0 80 ft lb Oil strainer bolts 1 40 kg in 10 10 ft tb Crankshaft pulley bolt 16kg m 116 ft lb Timing chain tensioner bolts 0 80 klilm 5 80 ft lb Rocker pedestal bolts 2 50 kg m I 8 10 ft lb Mainfolct bolts 1 40kg ni 10 10 ft lb Pump release valve plug 5 00 kg in 36 20 ft lb t I DESRIP i lON T...

Page 10: ...nator leads at the alternator and the starter leads at the starter solenoid 7 Disconnect the oil gauge and temperature gauge wires at the engne 8 Disconnect the choke and throttle con rrollinkage at the carburettor 9 Disconnect the fuel inlet pipe at the fuel pump 10 Remove the flange nuts and disconnect the exhaust outlet pipe at the manifold 11 Raise the car sufficiently take out the split pins ...

Page 11: ... pedestal TO ASSEMBLE AND INSTAL 1 Check each rocker arm and the rocker shaft for wear Check that the oil holes and passages in the rocker arms are clean and free ofany sludge or scale 2 Position the front rocker pedestal on the front end of the shaft and insert the pedestal bol t to hold it in position 3 Instal a spacer washer if fitted followed by the front rocker ann spring rocker ann washer an...

Page 12: ...ocker cover and gasket from the cylinder head 10 Progressively loosen the rocker pedestal securing bolts a few turns at a time until they can be fully unscrewed with the fingers Do not remove the bolts from the pedestals and shaft as they will serve to retain the rocker components on the shaft Remove the rocker and shaft assembly from the cylinder head II Withdraw the push rods keeping them in ord...

Page 13: ...nditioner who has the necessarv specialised equipment to carry out these operations 5 Lap the valves to the valve seats with a lapping compound Apply a smear ofPruss ion blue to the valves after lapping and check the valves on their respective seats to ens ure that a true and concentric seatinghas been gained 6 With a steel straight edge and feeler gauge check the cylinder head face for warping If...

Page 14: ...s removed and that each rod seats correctly in its tappet 7 Position the rocker shaft and tocker ann assembly on the cylinder head and instal the rocker pedestal securing bolts finger tight 8 Tighten the rocker pedestal bolts a few turns at a time evenly and progressively to the specified torque see Specifications 9 Turn the engine crankshaft in the direction of normal totation until each valve ta...

Page 15: ...g with oil TO REMOVE 6 TIMiNG HAIN AND ieUV K 1 vlith the engine rerrloved from the vehicle remove the water pump and fan assembly 2 Take out the retaining bolt and washer and withdraw the crankshaft pulley 3 Remove ihe sump drain plug drain the oil into a suitable container and remove the sump Timing Cover showing Timing Chain Damper Pad 4 Remove the remaining bol ts and washers and withdra the t...

Page 16: ...t so that the second mark circle on the chain link is adjacent to the timing mark dimple on the crankshaft sprocket see illustration 8 Push the camshaft sprocket on to fully engage the locating dowel lnstal the securing bolt and washers and tighten to the specified torque see Specifications 9 Check that both sprocket and chain timing minks register for correct valve timing 10 Instal the chairi ten...

Page 17: ...uel pump from the right hand side of the engine 10 Remove the distributor cap and high tension leads disconnect the vacuum pipe at the vacuum advance unit II Unscrew and remove the iwo bolts from the oistributor retaining plate and withdraw the distributor from the cylinder block 12 Remove the oil pump and tilter as an assembly by unscrewing the three bolts and withdrawing the assembly from the cr...

Page 18: ...ng end of the slipper pad is to the camshaft sprocket 14 Check the side tensioner in the timing cover is serviceable and renew if excessively worn 15 Instal a new oil seal in the timing cover with the lipped face of the seal towards the timing sprocket Instal the oil slinger if fitted with the concave face towards the crankshaft pulley 16 Further installation is a reversal of the removal procedure...

Page 19: ...onnecting rod assembly adequately lubricated with clean engine oil arrange the piston rings so that the top ring gap will be to the side of the piston directly away from the exhaust valve position 2 Fit the second compression ring with the gap at 1800 to the top ring gap 3 Fit the oil ring spacer with the gap to the right side of the engine and the upper and lower oil ring segments with their gaps...

Page 20: ...vailable in three sizes on outer diameter New pistons and rings should still be filted with sleeves NOTE Cl li lder bores that are fit for further service with original pistons but require renOnging should be deglazed with a hone 1 Position plenty of clean rag over the crankshaft and under each cylinder bore to keep abrasive materials from entering the crankcase area 2 De glazing of the cylinder w...

Page 21: ... to the gudgeon pin axis 4 Attach a spring scale to the top end of the feeler strip and withdraw the feeler strip in a plane parallel to the centre line of the cylinder bore noting the reading on the spring scale 5 The correct spring scale reading should be within 0 2 and 15 kg 0 44 and 3 30 Ibs If the reading is not within these specifications then check the original measurements of the piston an...

Page 22: ...ankpin 7 On the AIO engine release the main bearing cap bolts and lift off the three main bearing caps and lower half t F i i tJ Rear Main Bearing Oil Seal with Bearing Cap Removed bearing shells Keep each cap and shell together for reassembly On the A 12 engine release the main bearing cap bolts and remove the five main bearing caps and lower half bearing shells Keep each cap and shell together f...

Page 23: ...Grasp the oil filter body firmly turn it anti clockwise and upscrew it off the oil pump body If the filter is too tight to rotate by hand a special tool is available to fit the lower end of t1ie filter body Take out the three securing screws and withdraw the oil pump from the right hand side of the crankcase Installation is a eversa1 ofthe removal procedure vitti attention to the following points ...

Page 24: ...rance see Specifications 14 f end float of the rotor shaft is excessive remove the drive gear and instal a suitable spacer shim J 5 Instal the drive gear and peen the retaining pin 0p fj L G e Ii I 1 t fJ S r Jr I w Cftlecking Clearance Between Inner and Outer Rotor lobes 16 Apply engine oil to the inner and outer rotor and instal the outer rotor J 7 POsition a new gasket on the cover face of the ...

Page 25: ...tings that are oil soaked should be renewed and the cause of the oil lea rectified to ensure a normq l working flfefor the mounting concerned I J ENGINE FA1JLT DIA NOSIS I Engine wm not start by normal cranking Possible cause a Dirty or corroded distributor points b Carburettor nooding c Moisture on high tension wires and or inside distributor cap d Dirt or water in carburettor and fuel system e I...

Page 26: ...distributor shaft or carn 7 Engine lacks power Possib e cause a Dirty or incorrectly set spark ptugs b Dirt or water in carburettor and fuel system c Incorrect ignition timing d Incorrect carburettor float level e Faulty fuel pump I Incorrect valve clearance g Faulty distributor automatic advance h Restricted muffler or tail pipe J Test and 1 lleW faulty cOlllpollelll Adjust valve clearance Tighte...

Page 27: ...oiling system Engine21 Renew faulty component Renew faulty component Renew faulty components Check and reset as necessary Carry out top overhaul on engine Renew gasket Cnrrv out compression test and rectify Remedy Check and adjust to specifications Check and renew faulty components Renew or reallJ and fit oversize valve Remedy Check oil level in sump condition of oil pump and relief valve Renew oi...

Page 28: ...the cooling system is controlled by a thermostat located in the cylinder head water outlet pipe housing A by pass is incorporated in the system to allow limited circulation of the coolant when the thermostat is closed 2 RADIATOR TO REMOVE I Remove the radiator cap and drain the cooling system via the tap on the lower radiator tank 2 Disconnect and remove the upper and lower radiator hoses 3 On veh...

Page 29: ... at operating temperature check thoroughly for water and or transmission fluid leaks J T ERMOSTAT TO REMOVE AND INSTAL 1 Remove the radiator pressure cap and drain the water from the cooling system via the tap on the lower radiator tank 2 Disconnect and remove the top radiator hose 3 Remove the two bolts securing the water outlet elbow to the front portion of the cylinder head 4 Detach the water o...

Page 30: ...at the system is replenished with clean water TO DISMANTLE I Drain the cooling system and remove the water pump as previously described 2 Using a suitable puller withdraw the pump pulley flange from the fOlWard end of the shaft and bearing assembly 3 Remove the bearing retaining bearing and shaft assembly together impeller out of the pump body 4 Press the impeller off the end of the shaft and bear...

Page 31: ...ents TO RENEW 5 FAN BELT TO ADJUST 1 Loosen the two alternator to mounting bracket bolts 2 Loosen the alternator adjusting bracket bolts 3 Push the alternator as far as possible towards the cylinder block assembly 4 Slip the old belt off the alternator pulley and hen manoeuvre it off the fari and crankshaft pulleys and remove it from the engine 5 Manoeuvre the new belt over the crankshaft and fan ...

Page 32: ...oth heater hoses from within the engine compartmen t and remove the hose clips 4 To gain access to the heater unit remove the parcel tray and the ash tray 5 Disconnect the heater control wires and rod at the heater unit NOTE Before carrying out operation 5 set the upper control lever to the demisting position and the lower lever to the offposition 6 Disconnect the heater fan electrical wires at th...

Page 33: ...ing brakes 5 Coolant circnlation faulty Possible cause a Partial blockage of radiator core tubes b Water sludge deposits in engine water jacket c Fan belt broken or slipping d Faulty water pump or tltermostat e Coll psing lower radiator hose I Insufficient coobnt in systelT Remedy Tighten hose clips or renew faulty components Repair or renew r diator Renew seal assembly Renew water pump bearing an...

Page 34: ...50 80 120 80 210 220 100 60 1000 m 3300 ft 2000 m 6600 ft 3000 m 10000 ft 4000 m 13300 ft 1000 m 3300 ft 2000 m 6600 ft 34 125 Secondary main jet with altitude compensation jetting 1200 135 130 130 125 120 Float level 1000 1200 tFlo t seat clearance 1000 1200 3000 m 10000 ft 4000 m 13300 ft 1000 m 3300 ft 2000 m 6600 ft 3000 m 10000 ft 4oo0m 13300 ft 10 5 mm 0 413 in I2 0mm 0 472 in 1 3 1 7 nun 0 ...

Page 35: ...ROTTLE VALVE T d SPRING lir THROTTLE SCREW E SCREW HIGH SPEED VALVE Carnurettor Flange and Main Body with Main Jets Throttle and Idle Screws Removed Typical of Both Models 7 Remove the four nuts and washer ecuring the carburettor to the inlet manifold and withdraw the carburettor and gasket from the engine Discard the gasket Installation is a reversal of the removal procedure with attention given ...

Page 36: ...move the primary throttle return spring 3 Unscrew the retaining screw and detach the accelerator pump actuating lever from the top cover On 1200 models remove the actuating lever return spring with the lever 4 Take out the five screws and washers and detach screwdrivers and spanners be used when seTvicing the carburettQf TO DISMANTLE FLANGE Right Hand Side View of 1000 Series Carburettor Typical o...

Page 37: ... peening from the ends of the high speed valve retaining screws and mark the valve in relation to the carburettor body to facilitate correct assembly 10 With a suitable screwdriver remove the two high speed valve retaining screws and withdraw the high speed valve 11 Remove the high speed valve shaft from the body NOTE Onlv remove the high speed valve and shaft from the carburettor bodv if it is un...

Page 38: ...raw both throttle valves disconnect the primary to secondary connecting link and then remove both throttle shafts from the flange 6 If necessary unscrew the retaining nut and remove the throttle lever etc from the end of the primary throttle shaft Note how components a re situated before dismantling to ensure correct assembly 7 Inspect the flange for cracks and the gasket surfaces for nicks or bur...

Page 39: ...e on t e actuating lever 5 Attach the primary throttle lever return spring 6 Actuate all throttle and chok linkage by hand to ensure that all mechanism is operating smoothly PLUNGER SPRING TO CHECK AND ADJUST FLOAT LEVEL 1 Remove the air cleaner and carburettor top cover assembly as previously described 2 Invert the carburettor top cover and allow the float seat to rest against the needle valve 3 ...

Page 40: ...le valve opening angle vf 14 degrees from the fully closed position 1 Remove the carburettor from the vehicle as previously described 2 Actuate the choke operating lever by hand until the choice valye is in the fully closed position 3 Using a 1 22 mm 0 048 iiI diameter rod as a gauge check the clearance bet feen the primary throttle valye and the valve bore 4 If the throttle valve clearance is lar...

Page 41: ...ust commences to open In this position the gauge rod should just slide neatly between the primary throttle valve and the primary throttle bore to ADJUST IDLING SPEED AND MiXTURE I Remove the vacuum access plug from the inlet manifold 2 Connect a vacuum gauge with suitable adaptors into the inlet manifold 3 Connect a tachometer to the ignition coil 4 Start anti run the erigine until it reaches rior...

Page 42: ...m and which is retained in the fuel pump lower body by the diaphragm spring prevents engine oil from entering the upper section of the pump lower body The rubber fuel pump diaphragm is held together by two metal discs and is specially treated so that it is not affected by gasoline TO REMOVE AND INSTAL I Raise the engirie bonnet and fit fender covers to both front fenders 2 Disconnect the fuel inle...

Page 43: ...working through the rocker arm aperture in the pump lower body unhook the diaphragm stem from the end of the rocker arm 9 Withdraw the diaphragm and lift off the diaphragm spring take out the seal retainer and withdraw the diaphragm stern oil seal from the pump lower body 10 Relieve the staking on one end of the rocker arm pivot pin and with the pump suitably supported on the pivot pin boss tap in...

Page 44: ...JlG NUT eo LO IfEFlBODY r NOTE Excessivelv high pressure usualv mdicati that an incorrecr diaphragm spring has been Jitted to he pump or hat he diaphragm is pulled lOa right Low pressures could be caused bv worn linkage perforated diaphragm gummed valves or a weak ur broken diaphragm spring FUEL PUMP CAPACITY TEST NOTE This test should be carried out if the pump pressure was checked and found to b...

Page 45: ...r onto the main body and instal and tighten the wing nut 4 Instal the air cleaner assembly to the carburetlor 5 Fit and tighten the two inlet manifold to air cleaner assembly bracket bolts 6 On 1200 models connect the additional bracket which is secured to the inlet manifold to cylinder head retaining stud 7 Reconnect the rocker cover to air cleaner ventilation hose 1 Engine will not start 4 FUEl ...

Page 46: ...f Faulty fuel pump diaphragm g Leaks between fuel pump and fuel tank or fuel pump and carburettor h Powerjet vacuum plunger stuck in release lower position i Faulty power jet j Worn or damaged main or power jets k Excessive use of choke or accelerator pump Remedr Clean and blowout carburettor Renew pump plunger assembly Check and rectify pump linkage Check that pump connecting link is in correct p...

Page 47: ...ic Pedal height Mechanical Hydraulic TORQUE WRENCH SEITINGS Pressure plate to flywheel bolts 2 2 kg m I 5 9 ft lb 1000 SERIES I DES RIPTION The clutch driven plate and pressure plate assembly is of the same design as that fitted to the 1200 Series with the following exceptions The throw out bearing release me chanism differs in that the release fork is mounted on a shaft which extends through the ...

Page 48: ...ngle row ball thrust type mounted on the bearing sleeve which slides on the clutch shaft bearing retainer Where a hydraulically operated clutch release mechanism is fitted the push rod on the slave cylinder is adjusiable to provide clearance between the throw out bearing and diaphragm fingers with the throw out bearing in the released position Where a mechanically operated release mechanism is fit...

Page 49: ...r wear and coring 3 Check the hub of the driven plate for looseness or wear in the hub splines Check effective action of the driven plate hob cushion springs 4 Check that the run out of the flywheel face does not exceed 0 050 nim o ooi in 5 Check that the clutch shaft gearbox input shaft 7 If the driven plate is stilI serviceabie do not allow any cleaning fluid oil or grease to contaminate the pla...

Page 50: ...al un the inlet valve with the lip facing the piston assembly 3 Place the inlet valve spring with the tapered end on the face of the inlet valve flange and press the spring retainer down over the splined end of the piston assembly and secure 4 Place the piston return spring over the spring retainer dip the piston in hydraulic fluid and instal the spring and piston assembly Screw in the inlet valve...

Page 51: ... Ensure that the slave cylinder retaining clip is seated correctly in the groove on the cylinder body and that the rubber boot is correctly fitted over the open end of the cylinder body Bleed the clutch hydraulic system and adjust the withdrawal lever free travel as detailed under the appropriate headings in this section RUBBER COVER to BLEED VA LVE CYLINDER BODY PISTON SEA L I I if tAo Exploded V...

Page 52: ... they are secure 12 Lightly lubricate the input shaft and sleeve with high melting poin t grease 13 Instal the bearing and hub assembly on the input shaft bearing retaining sleeve and position the fork on the bearing hub 14 Instal the bearing return spring on the bearing hub and locate the end of the spring on the fork IS Check the operation of the clutch release mechanism and instal the gearbox a...

Page 53: ...g 5 Using a suitable puller or press remove the throw out bearing from the bearing hub 6 Clean the components excluding the bearing in a suitable solvent and allow to dry 7 Inspect the bearing hub withdrawal lever pivot pin bearing return spring and dust excluder fof wear damage and fatigue Renew worn parts and damaged components where necessary 8 Instal the new throw out bearing on the bearing hu...

Page 54: ...nected to the top of the clutch pedaL I To remove the control cable from the clutch pedal remove the split pin and flat washer withdraw the clevis pin from the clevis thus disconnecting the clutch control cable from the slot at the top of the clutch pedal 2 Withdraw the clevis and the outer cable from the firewall at the upper end 3 Working at the clutch release shaft end disconnect the lower end ...

Page 55: ...ition 3 Check the adjustment by measuring the free travel of the lever from the full off position and the position when the thrust bearing contacts the clutch diaphragm fingers 4 If adjustment is required slacken the lock nut on the slave cylinder push rod and turn the adjustment nut to achieve the specified free travel of the withdrawal lever See Specification section 5 Hold the adjusting nut and...

Page 56: ...acked pressure piate face el Loose or broken engine mountings 4 Throw out bearing noise Possible cause a Dry or seized bearing b Incorrect clutch cable adjustment c Faulty or broken diaphragm spring 5 Insufficient clutch release Possible cause a Excessive free travel of clutch pedal b Excessive play of release lever c Pilot bushing siicking d Clutch disc warped e Leaking master cylinder cup f Leak...

Page 57: ... 014 in 0 1 0 0 25 mm 0 004 0 p1O in 0 05 0 1 mm 6 002 0 006 in 3rd gear 4 speed Reverse ear 3 speed Reverse idler 3 speed Baul ring to gear clearance Standar 105 1 40 mm 0 040 CO 0 055 in PAQT DESCRIffION The three speed gearbox has synchrqme ori all forwar gears The gears are helical cut and run in con taryt mesh with the laygear Revefse gear funs in mesh with a everse i ler gear which i constan...

Page 58: ...on on a jack l 1 13 Remove the bolts attaching the rear gearbox mounting cross member to the chassis and extension housing 14 Unscrew and remove the bolts securing the clutch bell housing to the rear of the engine 15 Carefully draw the gearbox rearward lower it to the floor and remove from beneath the vehicle Installation is a reversal of the removal procedure TO DISMANTLE t I Disconnect the relea...

Page 59: ...lunger located in the carrier plate between the selector rod holes NOTE A n additional detent ball and springare located in a blank ended hole in the carrierplate and should lie removed when practicable 15 Using a soft faced hammer tap the rear end of the mainshaft to dislodge the bearing from the carrier plate It may be also necessary to tap the Jaygear rear bearing to enable the laygear and main...

Page 60: ... CLEAN AND INSPECf I Clean all components in cleaning solvent and blow dry with compressed air 2 Check ball bearings for roughness or excessive side play Do not rotate the bearings at high speed with compressed air particularly when the bearings are dry or damage will result 3 Check needle roller bearings for wear and or pitting 4 Examine the teeth on all gears for wear and or pitting also burring...

Page 61: ...oss Shaft Components 23 Using special tool No ST4367 position the tool across the faces of the pen end of the gear case with the laygear rear bearing located immediately below the cutaway in the tool 24 Insert the thrust washer originally removed on dismantling between the top face of the bearing and the lower edge of the gauge cutaway 25 Using feeler gauges check the remaining gap between the was...

Page 62: ... the interlock plunger 43 Drop the remaining detent ball and spring into the hole on the edge of the carrier plate and screw in the plug until it is flush with the plate edge NOTE The position of the detent plug regulates the amount of tension on the detent ball and spring Normalv it is correct when set as described in operation 43 44 Firmly support the selector rods and forks align the hole in ea...

Page 63: ...ew oil seal with grease anq fit to the front cover 59 Position the front over with gasket ring on the gear case instal nd tighten the ret inlng bo1ts to a torque of 10 I 4 kg m 7 10 ft l 60 Insert the clutch release shaft through the case return spring and release fork 61 Instal the taper pins to secure the shaft and fork Position tne return spring so that one leg engages over the front of the for...

Page 64: ... of the dismantling procedure TQ ADJUST GEAR CHANGE RODS I Ch ck that the tra smission is in neutral 2 l pte that the control rod operating levers are marked with a groove on their top edge and the bearitg boss with a ridge When correctly adjusted in the neutral position all three marks will be aligned 3 If adjustment is required lengthen or shorten the gear ch ge rods as necessary at the adjustih...

Page 65: ...m the clutch withdrawal lever or clutch slave cylinder where fitted from the bell housing 11 Loosen offand remove the starter motqr lST 2ND SELECTOR ROD AND FORK RD TOP SELECTOR ROO AND FORK Gear Case Removed to Show Mainshaft Assembly TO DISMANTLE I Disconnect the release bearing retaining spring from the r lease fork and withdraw tHe eari tg a d sleeve assembly 2 Knock out the taper pins securin...

Page 66: ... its shaft 19 Remove the circlips retaining reverse gear to the mainshaft and reverse idler gear to the layshaft GEAR lEVER BUSH tCllP BOSH SEAl O r SELECTOR LEVER t BOLT CLEVIS PIN 20 Slide both gears from the splines of their respective shafts 21 Using a soft faced hammer tap the rear end of the mainshaft to dislodge the bearing from the carrier plate It may be necessary to tap the laygear shaft...

Page 67: ...ng is necessary remove the circlip and washer and press or draw the bearing from the shaft 29 To remove the gear change control rod assembly from the extension housing remove the wire locking the control rod selector lever retaining bolt and remove the bolt and lever 30 Unscrew the retaining plug and withdraw the double spring and plunger for reverse selector loading 31 Remove the gear lever if no...

Page 68: ...nstal the first gear entering the cone into the baulk ring 8 Instal the thrust washer and press the rear bearing onto the mainshaft 9 For the purpose of checking first gear to thrust washer end float instal the reverse gear and secure with the circlip Check the end float between first gear and thrust w h er also between second gear and the mainshaft flange See specifications for end float Clearanc...

Page 69: ...d secure with the circlip 34 Instal the reverse sliding gear on its shaft 35 Instal the selector forks on the synchro sleeves and the reverse selector fork on the sliding gear 36 Insert the detent spring and ball for the reverse selector rod in the blank ended hole in the carrier plate Using a piece of metal rod depress the ball and spring and hold in this position 37 Insert the reverse selector r...

Page 70: ...e is the thickness of shim required for adjustment 57 Instal the selected shim on the bearing outer race smear a new oil seal with grease and fit to the front cover 58 Position the front cover with gasket ring on the gear case instal and tighten the retaining bolts to a torque of 10 1 4 kg m 7 10 ft lb 59 Insert the clutch release shaft through the case return spring and release fork 60 Instal the...

Page 71: ...arent renew the trunnions and bearings as a kit Never renew individual needle roller bearing assemblies or fit old bearings to a new trunnion Always use new bearing retaining circlips and bearing seal washers Reassembly is a reversal of the dismantling procedure NOTE When dismantling or reassembling do lIor hold the machined section of the front u niversal joint yoke in the unprot cred jaws of a v...

Page 72: ...r shaft out of balance Excessive wear of front joint sleeve in rear exterision bush hearing Rear universal joint to pinion flange bolts loose 2 l xcessive backlash Possible cause a Worn univeroal joint trunnion and bearings b Worn mainshaft and universal joint sleeve splines Check and renew faulty thrust washero Check and renew worn components Check llfld re adjust as necessary Remedy Check and re...

Page 73: ...o low Downshift speeds nil throttle Intermediate to low TORQUE WRENCH SEITINGS Drive plate to crankshaft Drive plate to torque converter Oil pan drain plug Inhibitor switch io transmission case Manual shift lock nut Oil cooling pipe flare nut Oil cooling pipe connecting nut Converter housing to engine I DES iUPTION The automatic transmission combines a fluid coupling or torque converter with a ful...

Page 74: ...onents Lower End of Steering Column 1000 Models An alternative method is to tow the vehicle suspended from the rear The vehicle may be towed for a short distance without disconnecting the propeller shaft provided the towing speed docs not exceed 48 kmh 30 mph and the cause for which the vehicle is being tow J is nut within the trausmissiull ur the rear axle It is not practicable to start the engin...

Page 75: ...sing Select the D or R position and with the transmission fluid under pressure examine the elbow connector oil pressure inspection hole and the gasket between the transmission body and extension housing for leakage 8 Should the vacuum diaphragm be damaged this can be readily detached by checking the emission of smoke at the rear end of the exhaust pipe If white smoke is emitting from the exhaust p...

Page 76: ...t the lever is correctly aligned 4 Check position of the gear indicator when released in relation to the relevant position on the plate 5 Should adjustment be necessary raise the bonnet and working from inside the engine compartment 1000 Models only adjust the linkage Prior to carrying out adjustment select position 0 on the gear indicator mounted on the steering column NOTE all 1200 Models with T...

Page 77: ...the R reverse position is select d 4 If adjustment is necessary unscrew the nut on the gear selector lever and loosen the two bolts securing the switch body then remove the machined screw from the body of the swi tch 5 Move the manual shaft to the N ncutral position noting that the selection of the N neutral position can be determined by a pronounced click 6 Move the switch sufficiently to alig 1 ...

Page 78: ...higher than specified check the following components with suitable electrical test equipment 4 Test the kickdown switch for internal shorting out 5 Test the downshift solenoid for internal shorting out and faulty connections 6 Check the wiring connecting the kickdown switch to the downshift solenoid for continuity 7 Replace defective components where necessary If the solenoid is to be replaced the...

Page 79: ...rator pedal is fully compressed the i I I OISHEO WASHER i BUSH PlN f Oa u l I j Wi ASHE BUSH amll 1 t SPRING BOOT LINK WASHER BlitH I G WASHER I PIN O DISHED WASHER engine speed will become constant and this speed is called the stall point at which the engine speed should be noted The speed should be ihe same in all ranges and shoold be between 1950 and 2000 rpm NOTE Having tested one range and pr...

Page 80: ...e oil pump 7 Select ranges I 2 and D and check the line pressure a t low i le Should the readings in the three respective ranges be below those readings specified and pressure reading in R is within the specified range the cause of the lo pressure reading can be attributed to oil leakage in the governor and rear clutch 8 Select positions R and P and check the line pressure Ifthe pressure reading i...

Page 81: ...ngress of dirt NOTE To preserve the original balance of the propeller shaft mark across the joint and pinion flange to ensure replacement in the original positions II With suitable protection on the Ijack head support under the transmission case and remove the transmission supporting crossmember from the und rbody and from the gearbox 12 Disconnect the wires to the starter safety switch on the sid...

Page 82: ...ULIC FLUID TO CHECK AND TOP UP IEngine will not stariin P or N 9 AUTOMATIC TRANSMISSION FAUI T DIAGNOSIS Possible cause a Incorrect selector linkage adjustment bj Defective inhibitor switch or wiring c Faulty ignition switch or starter motor 2 Engine starts in D or R range Possible couse a Incorrect selector linkage adjustment b Defective inhibitor switch or wiring 3 Harsh engllgement N to D Possi...

Page 83: ...agm or piping c Fault in shift solenoid and kickdown switch wiring d Faulty governor valve servo or control valve e Fluid level low or fluid foaming Automatic Tranllmullion ll Remedy Check and top up fluid level Check and adjust selector linkage Check pressure and regulator valve and plug Free up or renew control valve Remedy Check fluid level and top up Check and adjust linkage Check pressure reg...

Page 84: ... 15 mm 0 004 0 006 in 0 08 mm 0 003 in 17 5mm 0 69 in 0 05 0 50 mm increments 0 002 0 020 in incremen 1s Side gears Thickness range of thrust washers Gear to thrust washer clearance 0 76 0 91 mm increments of 0 05 mm 0 030 0 036 in increments of 0 002 in 0 1 0 2 mm 0 004 0 008 in TORQUE WRENCH SETTINGS Maximum Settings Differential carrier to axle housing Propeller shaft flange nuts Pinion nut Cro...

Page 85: ...the four securing bolts and nuts to release the propeller shaft if The rear axle is a semi floating type with hypoid final drive gears mounted in a detachable carrier The crownwheel and differential case assembly is supported in the carrier by two tapered roller bearings the bearing preload and crownwheel backlash is adjusted by means of shims The drive pinion is supported in the carrier by two ta...

Page 86: ...6 in NOTE Having completed the foregoing checks dismantle the assemblv as follows 1 Remove the carrier bearing cap nuts and detach the caps Check that the caps are marked in relation to he carrier to ensure installation in their original positions Rear A xle 3 FLANGE WASHER BEAI NG fIt1 o I Wij 91 t OUTER CONE Oil SEAL NUT Exploded View of Differential Final Drive Componen 2 Lift out the different...

Page 87: ...oi wear pitting or damage Check that the thrust washers are in a serviceable condition 6 Check the differential shaft for wear pitting or damage Replace parts listed in 5 and 6 if not in serTiceable condition 7 Examine the differential case for damage and or distortion and renew if necessary Check also the pinion and side gear thrust faces in the case for wear and or pitting 8 Ensure that all shim...

Page 88: ...of the arbor and gauge kit not being avai1 ble it will be necessary tQ use the shims removed f om behind the re r bearing o ter cone plus or minus as the case may be the figure etched on the new pinion as a starting point foi pinion position adjustment This method ofadjus ment entails asseini ling the pinion and adjusting pillion bearing pre load fitting crownwheel and differential a sembly and ad...

Page 89: ...Reset BacHash All models V I J TOE OF TOOT EEl HIGH TOE HIGH High Profile Marlcing on Both Sides of Crownwheel Tooth Rectify by Increasing of Pinion Positioning Shims and Reset Backlash IA 1 models TOE OF TOOT i TOE CENTRE TOE SLIGHTLY LOW Toe Marlcing on Drive Side and low Profile Marlcing on Overdrive Side of Crownwheel Tooth To Rectify Increase Backlash It may be Necessary to Increase Thickness...

Page 90: ... from the available sizes NOTE Reducing the overall length of the spacer and washer will increase the tuming torque Increasing the overal length will reduce rhe turning torque When used bearings are taken back into service the preload should be adjusted to the lower limit h t 6 Recheck the pinion position to ensure that there has been no alteration in height 7 On final assembly instal a new oil se...

Page 91: ...J 0 07 mm 0 001 0 003 in J 1 Instal the selected shims nn their respective ends of the differential case and fit the carrier bearing inner cone assemblies 12 With the carrier bearing outer cones mated with the correct inner cone assemply instal the differential in the carrier osing a soft faced hammer to tap the assembly in to the bearing seats 13 Instal the carrier bearing caps and nuts according...

Page 92: ...haft 4 Detach the bearing spacer brake backing plate and grease trap 5 Clean all parts and check the condition of the axle shaft for wear damage or distortion 6 If necessary remove the old oil seal from the axle casing grease the seal lips of the new seal and instal into the casing 7 Position the grease trap brake backing plate bearing spacer and bearing on the axle shaft 8 Press a new bearing ret...

Page 93: ...the shafts by means of collars End float in the axle shaft assembly is adjusted by shims located at the brake backing plate With the removal of the axle shafts the differential carrier assembly can be detached from the axle without removing the axle casing from the vehicle It is important to note that adjustment figures stamped on the final drive components are in units of 0 01 mm which must be ta...

Page 94: ... CASE AND BEARINGS CROWNWHEEL OOTER CONE O Exploded View of Differential Final Drive Components R ar Ax e ll 4 Using a suitable puller withdraw the pinion flange from the end of ihe pinion shaft 5 Using a soft metal drift tap the pinion shaft with rear bearing inner cone anq rollers and bearing spacer out of the differential carrier housing 6 Working through tpr rear bearing outer cup drift out th...

Page 95: ...mage Replace parts listed in 5 and 6 if not in serviceable condition CARRIER l i DIFFERENTIAL LOCK PIN CARRIER BEARING 7 Examine the differential case for damage and or distortion and renew if necessary Check alsn the pinion and side gear thrust faces in the case for wear and or pitting 8 Ensure that all shims and spacers are free of dam ge TO ASSEMBLE AND ADJUST DRIVE PINION Where the old pinion ...

Page 96: ... tip of the gauge rod and note the measurement 7 Calculate the thickness of washer required to obtain correct pinion position from the following equation W N H xO OI 0 2 T in mm Definition W thickness of adjusting washer fitted N clearance figure obtained in 6 with feeler gauges H pinion head variation figure on the pinion head T thickness of washer reR uired to correctly position pinion Example W...

Page 97: ...usting washer is awards the pinion head 2 Instal a new oil seal in the carrier and insert the pinion assembly into the carrier and through the front taper bearing and oil seal NOTE Lubricate the oil seal lips and bearings bur ensure that the pinion thread nut and washer are free of oil or grease 3 Fit the plOlOn flange washer and retaining nut during the tightening of the retaining nut rotate the ...

Page 98: ... 07 mm 0 001 0 003 in II Instal the selected shims on their respective ends of the differential case and fit the carrier bearing inner cone assemblies 12 With the carrier bearing outer cones mated with the correct inner cone assembly instal the differential in the carrier using a soft faced hammer to tap the assembly in to he bearing seats 13 Instal the carrier bearing caps and bolts according to ...

Page 99: ... grovl ed ur rough A new jlange should be a reasonably right fit on the shaft splines 11 Hold the tlange against rotation and carefully tighten the pinion retaining nut until there is just a slight end float in the pinion shaft and bearings 14 Using a pre load measuring gauge measure the torque required at the flange end to rotate the pinion with negative pinion bearing pre load but with the origi...

Page 100: ...ase 2 Position the shims originally removed on the brake backing plate 3 Insert the axle shaft assembly into the rear axle casing engaging the splines of the shaft and differential side gear NOTE Ensure that the oiLseal lip is not damaged as the shaft is passed through it 4 Instal and tighten the retaining nuts to secure the assembly to the axle casing flange 5 Mount a dial gauge to the brake back...

Page 101: ...y components dl Incorrectly adjusted crownwheel and pininn e Incorrectly adjusted bearing pre load pinion or carrier bearings f Excessive noise or grind under load g Excessive noise or grind on overdrive h Excessive noise on coast i Bent axle housing 3 Excessive backlash in differential Possible cause Remedy a b c d e Looseness between axle shaft and differential side gear splines Worn dtfferentia...

Page 102: ...eqing worm shaft bearing adjustment is controlled by shims between the steering box and the s eering column flange Sector shaft end thrust is controlled by an adjusting screw and lock nut in the top cover d attached to a recessed slot in the upper end of the sector shaft The steering gear li kage omprises a steeriI1g connecting rod connected by a ball join at oe end to the steering gear pitman arm...

Page 103: ...ut to rotate on the worm as damage will be incurred to the ball guides NOTE The cover plate shim are situated with a gasket o the cover plate Ensure tho the shims are not dahlaged during dismantling procedure Store shims and gasket in a safe place for reassembly 6 Remove the worm shaft frum the column tubt o 7 Remove the upper bearing outer cup from the olumn tube tlange with a suitable puller 8 R...

Page 104: ...removed Instal the foor bolts and adjust the worm shaft bearing pre load by adding or removing shims See Specifications 9 To determine the correct end clearance and lash adjustment on the sector shaft fit the lash adjuster bolt to the slot and check the clearance with a feeler gauge Clearance should be 0 01 0 03 mm 0 0004 0 0012 in Shim sizes are available in different thicknesses see Specificatio...

Page 105: ...force applied to the steering wheel forces the upper shaft down shearing the nylon pinS connecting the upper and lower shaft allowing the upper shaft to move down over the lower shaft The jacket is constructed of a fibre glass material and is of the convoluted design This design allows the jacket to absorb initial shock then collapse when the upper shaft is forced down over the lower shaft PLASTIC...

Page 106: ...ing 5 TO ASSEMBLE AND INSTAL TO INSPECT AND INSTAL a 4 OLUMl LAMP I Inspect the two aluminium spacer blocks for damage with particular attention to the nylon pins 2 Check the colomn clamp for damage and cracking 3 Check that the bolts connecting the clamp to the jacket lock collar are of the correct length Fit the clamp to the jack lock collar ensuring that the bolts do not contact the steering sh...

Page 107: ...ing the idler arm to the connecting rod and detach the connecting rod 2 Remove the two nuts and bolts securing the idler bracket assembly to the body side member and remove the assembly from the vehicle 3 Remove the split pin and castellated nut and press the idler arm pivot bolt out of the bracket body TO ASSEMBLE AND INSTAL I With the idler assembly removed check the bushes for wear and fatigue ...

Page 108: ...escopic gauge measure the distance between the two marks on the tyre een tees and record the measurements 6 Maintain the wheels in the straight ahead position roll the vehicle lurwanJ until the marks are the same distance above the floor at the rear of the front suspension 7 Again use the telescopic gauge to measure and record the distance between the maries on the tyres The distance measured at t...

Page 109: ...ont lyres c Excessive play in steering gear and or linkage d Excessively high or low tyre pressures e Loose or incorrectly adjusted front wheel bearings Remedv Overhaul steering gear renew faulty components and adjust Tighten or renew faulty components Tighten pitman ann retainingnut Renew and adjust idler lever bush and bolt Tighten mounting bolts and check alignment of steering gear mounting Rem...

Page 110: ...shock absorber to the radius rod and lower control ann 4 Remove the bolts attaching the radius rod to the lower control arm 5 Sopport the lower control arm with a floor jack and remove the split pin and castellated nut and lowering the floor jack to withdraw the lower ball joint from the stub axle swivel 6 Working at the opposite end of the control arm unscrew the nut remove the washers and withdr...

Page 111: ...fur wear 13 Check the lower ball join t for wear 14 Disconnect the shock absorber from its upper mounting and remove it from the vehicle Check for oil leaks damage and recoil action TO INSTAL Installation procedure is the reversal to that of removal with attention to the following points I With the two swivel insulator rubbers fitted to the crossmember offer the spring to the crossmember and suppo...

Page 112: ...nd lift off the control arm assembly noting the position and number of shims between the pivot shaft and the body frame 5 Clean the arm assembly and inspect for fatigue or distortion 6 Inspect the bushes for wear If replacement is necessary press t e bushes out from the opposite ends and remove the pivot shaft To fit new bushes place the pivot shaft in the upper control arm and press the bushes ho...

Page 113: ...swivel from the upper and lower control arms and withdraw the assembly from the vehicle 6 Check the swivel and stub axle for distortion 7 Remove and inspect the wheel bearings cups and seals and assembly as described in the 1200 Series TO INSTAL Installation is the reversal of the removal procedure with attentionto the following points I Bleed the hydraulic system and top op the master cylinder 2 ...

Page 114: ...L JOINTS I Raise the front of the vehicle support on stands and remove the road wheel NOTE It will also be necessarv to support the lower control arm on a jack to relieve the springpressure on the upper rebound rubber 2 To remove the upper and lower bali joints separately remove the split pin and nut from the upper ball joint and using a suitable spreader press the ball joint tapered spindle oot o...

Page 115: ...end alignment side to side c High road camber d Weak or broken rear spring e Front brake dragging f Steering gear off centre Remedy Inflate tyres to recommended pressures Check and renew faulty onit Check and adjust alignment as necessary Check and tighten or renew member Check and renew spring Check and renew leaf or complete rear spring Adjust or renewhub bearings Adjust or renew faulty componen...

Page 116: ...Ibfft 360 t O Backing plate installation bolts 3 7 kgfm 261b ft 5 lmm Lower ball joint to 2 t 04 in control arm 3 0 kg m 6tlmm 21Ib ft 24 t 04 in Back off to nearest castellation I DES RIPTION Each McPherson strut type front suspension unit comprises a vertical tubular shOCk absorber surrounded at the upper end by a coil on top of which is the upper spring mounting attached to the underside of the...

Page 117: ...LE AND INSTAL I Drift the two hub bearing cups into position in the hub ensuring that their tapers are opposed to each other 2 Pack the space in the hub between the cups with BEARING SEAL B A NG CUP 1 I 0 o t BACKING PLATE AND BRAKE ASSY wheel bearing grease apply grease to the rollers of the inner cone and place it in position in the hub 3 Place a new grease retaining seal on the inner end of the...

Page 118: ...uts rubber bUshes and washers attaching the stabiliser bar link to the lower suspension arms 4 Take out the retaining bolts attaching ihe stabiliser supporting brackets to the chassis and withdraw the stabiliser bar from the vehicle 5 Inspect the bar for distortion and fatigue Renew all rubber bushes if necessary TO INSTAL NOTE Instal the stabiliser bar with the painted iden tification mark to rhe...

Page 119: ...uring the tie rod end ball bolt to the steering arm Remove the ball bolt from the steering aim 9 Disconnect the radius rod and stabiliser bar from the lower suspension control arm 10 Place a jack under the lower suspension control ann I I Remove the two bolts securing the suspension control arm to the suspension unit and ball joint 12 Raise the bonnet and working from the engine compartment remove...

Page 120: ...nt Suspension II NUT 1 WASHER ISTON ROD t 8EARING r STU r STRUT ASSEMBLY BUMP U88ER e Strut and Coil Spring Co ponimts 1200 Model could lodge in the cylinder and result in faulty operation 2 To reassemble fit the outer casing to the t i suspension unit bo y 3 Place the piston rod and cylinder assembly in the outer casing and fill the casjng with the specified quantity and type of oil The operating...

Page 121: ...ecting the control arm to the body member and withdraw the control arm from the member TO INSPECT 1 Clean the conirol arm and inspect the metalic section for distortion and fatigue Replace if damaged 7 LOWER BALI JOINT TO REMOVE I Block the rear wheels raise the vehicle and support on jack stands Remove the road wheel 2 Remove the bolts and nuts attaching the stabiIiser bar and radius rod to the l...

Page 122: ...bly from the vehicle TO CLEAN AND INSPECT I Inspect all insulator rubbers and rubber bushes for fatigue and wear 2 Check the stabiliser bar and radius rod for distortion and thread damage 3 Check the suspension crossmember for cracking with particular attention to the mounting bolt holes 4 Inspect the lower control arm for distortion or d ge 5 Remove the brake drum and hub assembly and inspect the...

Page 123: ...inclination according to the instructions set down for alignmen t equipment being used and compare with the manufacturers specifications 5 If the caster angle is incorrect check the radius rod brackets and rubber bushes Also check the suspension control arm rubber pivot bushes for wear 6 If the camber and swivel inclination angles are both incorrect check the suspension unit upper mounting and low...

Page 124: ...g gear and or linkage d Excessively high or low lyre pressures e Loose or incorrectly adjusted front wheel bearings Front Suapenaion 15 Remedy Check tyres and inflate to recommended pressures Check and readjust steering gear Ascertain cause of loss of lubricant and lubricate steering linkage where applicable Check front end for wear renew worn components and re align front end Check and align stee...

Page 125: ... just to the rear of the axle housing and connect to the spring mounting plate at the lower end and to the body at the upper end Shock absorber mountings are in the form of rubber bushes The bump rubbers on the 1200 Series differ to the conventional type in that they are mounted on the shock absorber spindle The front end of the spring on 1200 Series is connect to the vehicle by two plates three s...

Page 126: ...nuts washers and rubber bushes Renew the rubber bushes as required LOCKNUT N JT WA HER 8 TOt SHOCK ABSORBER RU BER SHOCK ABsoRBER Shock Absorber Assembly with Bump Rubber Component 1200 Models LOWER MOUNTING TO REMOVE AND OISMANTLE I SPRlNf S I Jack up the vehicle and support on stands placed just forward of the rear spring front hanger 2 With a jack under the centre of the fear axle case raise th...

Page 127: ... wheels This will prevent the rubber bushes from being overstressed when in the normal working position 3 Rear SU31Xm3ion SHACKLE PLATE AND PINS T L SUMP RUBBER A SY I n SPRING EYE UBOLTS PLATE PAO I J CENTRE BOLT 7 SPRING BUSHES PLATE WASHERSYV NUTS 1 d WASHER NUT OJ 1 Ope SHOCK ABOSRBER BUSHES SPRING ASSV I Exploded View of Rear Spring Components 1000 Models AACKlE PINS AND PLATE ASY f CLAMP I I...

Page 128: ...casing Check and renew inserts Check and adjust Tighten or renew faulty clamps 2 Rear wheels not in alignment with front wheels Possible I ause Remedv a Broken main leaf of spring forward of spring seat b Broken main leaf of spring at rear of spring seat c Broken spring mounting bolts or rear shackle d Spring badly sagging on one side el Sprong or bent axle casing Renew main leaf or complete sprin...

Page 129: ...n out limit 0 03 mm 0 687 in 0 0012 in Piston clearance limit 0 13mm Front pads 1200 0005 in Width 42 5 mm Brake pedal height 1 673 in 1000 144 5 mm Thickness 10 3 mm 5 688 in 0 406 in 1200 1415mm Length 53 1 mm 5 570 in 2 091 in Available brake pedal height Front and rear linings adjusting shim thickness Width 35 0 mm First size 0 50 mm 1 378 in 0 0197 in Thickness 4 8mm Second size 0 80 mm 0 189...

Page 130: ...alve at each of the wheel cylinder assemblies DISC BRAKES As a safety item for high speed driving later model J 200 vehicles are available with front wheel disc type brakes The caliper assemblies are of the floating type and are allowed to float in a lateral direction As found with most disc type brakes the assemblies are self adjusting and require no adjustment in service As pad wear takes place ...

Page 131: ...leading lip of the cup is facing to the front of the piston 3 Instal the check valve seat check valve spring primary cup and piston in that order into the rear end of the cylinder Ensure that the leading lip of the primary cup is facing towards the front of the cylinder 4 Fit the push rod assembly to the rear of thc cylinder and instal the snap ring 5 Instal the dust boot to the rear of the cylind...

Page 132: ...der and detach the push rod assembly 5 Tap the open end of the cylinder on a block of wood and allow the primary piston assembly to become dislodged from the cylinder bore 6 Using the same procedure remove the secondary piston assembly from the cylinder bore 7 Using the correct fitting ring spanner and with the master cylinder body assembly securely clamped in a vice remove the two cap bolts and w...

Page 133: ...linder if the clearance is in excess of that specified see SPECIFICATION section for piston clearance limit 5 Check the lips on all cups for wear and the check valve rubbers for swelling or distortion 6 Check the piston compression springs and the check valve springs for weakness or rusting 7 Renew all components of the cylinder assembly that upon inspection proves to be unserviceable NOTE Once a ...

Page 134: ... the reservoirs to the cylinder if they were removed and securely tighten the two retaining clips 8 Instal a check valve spring seat and valve into each cap bolt aperture in the cylinder body 9 Secure the master cylinder in a vice and fit and tighten both cap bolts and washers 10 Screw the bleeder valve s into position in the cylinder body 11 Position the reservoir filters into the reservoir chamb...

Page 135: ...ear Renew the linings if thickness is found t be less than 1 5 mm 0 059 in BRAKE BACKING PLATE 2 If the linings are still serviceable check for oil saturation and gumminess and renew 3S required 3 Check the brake drum for cracks ovality or scoring and renew or machine as found necessary See SPEClFICAnON section for drum ovality and machining limits 4 Wash the wheel cylinder components in methylate...

Page 136: ...wjth the two ret jining nuls and lockwashers Position an elastic band around the assembly to prevent the tappets from becoming dislodged 3 Lubrieate the wheel cvlinder bore with clean brake fluid also dip the piston and seal in the fluid and instal the seal on the piston so that the lip of the seal will be facing towards the spigot end of the piston NOTE Ensure thut the seal is seatiilg correct v ...

Page 137: ...TAINING WASHER RETURN SPRING RETAINING N I u If e SPRING 1BlEEO VE I BfllDGE PIPE NT CYLlNOER BOO SPRING WASHER SlRIN D I cup RING SEAT l6 PISTON cuP ft sPRING SEAT 1 SPRING CY BODY Y 7m iT IJ PISTON SPRING WASHER SPRING r RETAINING WASHER R E11r 1M NG filM liiiit BOOT Exploded View of Right Hand Front Brake Shoe Components 6 Remove the bolts and nuts securing one wheel cylinder to the backing pla...

Page 138: ...e in the brake backing plate and instal and tighten the retaining bolls and stud nuts 5 Fit the cylinder bleeder valve where necessary 6 Repeat operation I and 5 inclusive to assemble and instal the other wheel cylinder 7 Instal the short connecting pipe between the two cylinders and tighten the unions 8 Place a smear of high melling point grease on each of the brake shoe support pads on the brake...

Page 139: ...ON section for correct torque setting Instal the brake pads and anti squeal shims according to the marks made when dismantling If new shims are being tiUed then instal with shim arrows facing towards wheet rotation Renew the brake pads if lining thickness is worn down to less than 16 mm 0 063 in NOTE Brake pads should Dilly be renewed in sets offour It will be necessafl to bleed the hl drau ic Sl ...

Page 140: ...e hub bearings as described in the FRONT SUSPENSION section of this manual 14 Mount a dial gauge to the brake disc as pr viously described and again check the disc run out 15 If the run out is in excess of the limit specified recheck the hub flange and disc mating surfaces for dirt or burrs and the hub bearings for correct adjustment NOTE Ifa flew brake disc wasJUtedand excessive ron out is still ...

Page 141: ... PIATt TO REMOVE AND INSTAL DRUM BRAKES I Raise the front of the vehicle and support on chassis stands 2 Remove the road wheel with the brake drum and hub as previously described NOTE It mav be necessarv Co back ojf the brake shoe adjusting cams in order to withdraw the brake dmm from the shnes 3 Disconnect the steel hydraulic brake pipe which runs from the whee cylinder to the flexible hose at th...

Page 142: ...lso the handbrake pull set spring to ensure correct assembly 11 Check the handbrake poll lever components and the front cable for serviceability and make replacements as found necessary NOTE Renew cables that are excessively stretched or that have chaffed or broken braid Installation is a reversal of the removal procedure with attention to the following Lubricate all working points of the handbrak...

Page 143: ...now be removed from the vehicle 5 If found necessary disengage the return springs and remove the cross rods which run from the balance lever assembly on the differential housing across 0 both rear wheel cylinder assemblies TO REMOVE 1200 II Raise the vehicle to a suitable working height and support on chassis staf ds 1 Working from underneath the vehicle back off the turn buckle adjusting nut and ...

Page 144: ... is obtained on the handbrake pull lever stem within the vehicle This wiJ be accornpJjshed easJer with two operators one underneath the vehicle arid the other sitting in the driving position assessing the pull lever stroke 3 Lower the vehicle to the ground ahd check the handbrake operation on an incline Check that no brake binding is evident when the handbrake is in the fully released position TO ...

Page 145: ...isc brakes one on each rear wheel cylinder and one on the master cylinder assembly 1 Fillthe fluid reservoir on the master cylinder with clean hydraulic brake fluid and maintain it at least half full throughout the entire bleeding operation 2 Remove the dust cover from the bleeder valve on the master cylinder attach a rubber bleeder tube to the valve and allow the other end of the tube to be immer...

Page 146: ... adjustment d Frozen wheel cylinder pistons e Obstructed or damaged hydraulic hose or line f Obstructed master cylinder compensating port g Blocked vent inmaster cylinder reservoir cap Ii Broken rear spring main leaf or centre bolt Remedy Check and replace linings with recommended type Rectify or renew pivot pin and bush if fitted Check brake line u Id remove restriction or renew line Check free u...

Page 147: ...rush spring tensiun LT 125 02 LT125 06 LTl33 05 AS202SA 1 Drive belt detlection Rotor shaft run out aU units 300 380g II 13 oz 250 350 g 9 120z 250 350 g 9 120z 300 400 g I1 140z 13mm 0 5 in 0 10 mm 0 004 in ALTERNATOR REGULATOR Application and model LT12S 02 alternator L T12S 06 alternator AS2025A 1 alternator LTl33 05 alternator Type Mechanical Settings TLlZIOA Voltage regulator Armature to fram...

Page 148: ...volts 60 amps maximum 7000 rpm minimum II volts Electrical System 2 60 amps maximum 4800 rpm minimum Amperage draw Revolutions Lock test Hitachi Volts Amperage draw Torque minimum Mitsubishi Volts Amperage draw Torque minimum Brush length new Hitachi Mitsubishi Brush length worn Hitachi Mitsubishi Brush spring tension all Armature shaft maximwn bend all Commutator out of round maximum all Undercut...

Page 149: ...7 9 5 deg at 1000 rpm 110 13 0 deg at 1440 rpm 547 rpm 11 5 deg at 2400rpm 550 rpm 12 5 deg at 2100 rpm I SO mm hg 5 905 in hg 9 5 deg at 305 mm hg 9 5 deg at 12 in hg TVA 4 F1 L 0411 61 commences Maximum 0412 63 commences Maximum Contact point gap all Contact spring tension all Shaft to housing clearance Maximum Shaft to earn clearance Maximum I 7 deg at 160 mm hg 1 7 deg at 6 299 in hg 5 5 8 7 d...

Page 150: ...be sought If overcharging is suspected check the regulator setting If one cell in particular is at fault check the case for cracks Never transfer electrolite from one cell to another 6 Keep the positive and negative terminals clean and apply a small amount of petroleum jelly to the terminals to prevent corrosion TO REMOVE AND INSTAL I Release the terminal screws and carefully remove the cables fro...

Page 151: ...arth the alternator frame to the negative battery terminal 7 Connect a variable load resistance of 3S amps IS ohms with a switch in series across the battery 8 Open circuit the variable resistapce with the switch 9 When testing Hitachi LT12S 02 and Mitsubishi AS202SA 1 alternators close the On Off switch at the positive battery terminals leaving the variable resistance switch open slowly increase ...

Page 152: ...ipate some of the heat and so protect the diode from being damaged All wiringcorulections should be marked and tagged before rem oval to avoid wrong connections during reassembling L i Mark the assembled position of both end brackets and the stator winding lamination 2 Remove the brush cover screws and brush cover On models LTl25 06 and LTl33 05 remove the brush holder mounting screws and remove t...

Page 153: ...bridging wires from the diodes in preparation for testing Models L Tl25 06 alld f TU3 05 Unsolder the stator leads from the rectitler diode pack using a hot soldering iron while holding the diode leads with a pair of pointed pliers Remove the A terminal nut and the rectifier diode pack retainirlg nut and remove the rectifier diode pack assembly from the end bracket Separate the stator windings fro...

Page 154: ...UP FELT SEAL I I o 0 RETAINER C BRUS END BRACKET NAL NUTS WASHERS AND INSULATORS I lit 0 o Q 00 C C o C t I 04 SCREWS 0 BRUSH COVER I COVER SCREWS o the test leads one to each field wire and note the ammeter reading a high reading over 3 5 amps indicates a bridged circuit within the coil No reading on the armf1eter indicates an open circuit exists in the field coiL In both the above cases a new ro...

Page 155: ... Fit new bearings when in doubt of the serviceability of the old bearings TO ASSEMBLE The assembly procedure is the reverse of the dismantling operations with attention to the following poin ts I Carry out the cleaning operations and the testing and checking of component parts as laid down in the appropriate sections 2 Replace all worn damaged shorted or open circuited components 3 Take care not t...

Page 156: ... of the rotor to supply a starting current for the alternator to commence charging This is necessary as the residual magnetism retained by the alternator is insufficient to start a voltage build up within the alternator The voltage regulator controls the alternator output according to the voltage of the battery and pm of the engine REGULATOR ADJUSTMENTS When testing or adjusting the alternator reg...

Page 157: ...tery negative terminal 2 Remove the regulator mounting screws 3 Disconnect the wiring terminal block and remove the unit from the vehicle Installation is the reverse to the removal procedure MECHANICAL ADJUSTMENTS The mechanical adjustmellls should be carried out in the following order starting with the vultage regulatur unit Voltage Regulator TLlZ IOA and RL2220BS I Remove the regulator from the ...

Page 158: ...ed Showing Regulator Adjusting Screws 4 Check the air gap between the bobbin core and armature blade using a feeler gauge of the correct dimension adjust by bending the primary contact support bracket 5 Check the point gap with the armature at rest using a feeler gauge of the correct dimension adjust the point gap by bending the secondary contact support bracket Pilot Lamp Relay TLIZIOA 2 f r f 1 ...

Page 159: ...he thermometer can be held in place with a lump of putty or similar substancec 10 wJien the engine reaches operating temperature and the ambient temperature reaches its maximum allow the e gine to idle then slowly increase the rp and rote the voltmeter reading which will rise with he engine speed until the regulator voltage is reached when the voltmeter needle will give a sligl t kickback refer Sp...

Page 160: ...disconnect the test instruments and reconnect the alternator A terminal and wiring 19 Reconnect the negative battery terminal DESCRIPTION 4 STARTER MOTOR The starter motor is a 12 volt series wound four pole four brush or two brush unit The starter motor is equipped wi a solenoid actuated pre engaging starter drive and over running clutch assembly The solenoid is attached to the start r frame the ...

Page 161: ...antled check the brush holder insulation using a 11 0 volt test prod equipment with a globe in series with one lead Connect one test prod lead on the brush holder positive side and the other lead on the negative side If ihere is ally indication of leakage the globe will light or an arcing will occur at the point of short ng ei1 l1er r pair or replace the brush holder ifa short circuit is evident 2...

Page 162: ...es and solenoid switch moving stud with a light coating ofmulti purpose grease 2 Instal the centre bracket to the armature shaft 3 Assemble the clutch and pinion to the shaft fit the collar with the cup away from the pinion fit the circlip and stake in position and fit the collar over the circlip 4 Check the protruding length of the plunger adjusting nut by pressing the solenoid plunger against a ...

Page 163: ...eries coil test then remove the M terminal connection The solenoid plunger should remain held in the solenoid if the hold in winding is serviceable 5 To check the pinion to pinion stop clearance energise the solenoid as above to move the pinion into its mesh position 6 Measure the clearance between the pinion and the pinion stop Refer Specifications for the correct clearance NOTE Only hold the sol...

Page 164: ...ntrol springs The vacuum advance consists of a diapragrn unit mounted externally onto the distributor body with linkage to the breaker plate from the diaphragm advance is controlled by engine loadings TO CLEAN AND ADJUST BREAKER POINTS At intervals of 4000 km 3000 miles the contact breaker points should be checked for excessive burning and MOVING POINT CONTACT POIN FIXED POIN ADJUSTING SCRE I pitt...

Page 165: ...lace a smear of high melting point grease on the lobes of the earn assembly and instal the rotor arm and the distribotor cap 10 Connect the dwell meter and check the contact dwell adjust if necessary to specifications II Connect the timing light and check the ignition timing TO REMOVE I With the distributor cap removed turn the engine until the ignition timing mark indicates number one cylinder is...

Page 166: ...never use emery cloth or sandpap r El ctrical Syatem 20 CIRCLIP M Check the low tension and earth yires for possible fractures S Check the distributor shaft and body for wear and renew as necessary Maximum clearance betweel1 s4aft and body should not exceed 0 08 mm 0 p03 in if the clearance is in excess of this figure it will necessitate the renevial of the shaft and body 6 Check the cams for wear...

Page 167: ...acitor terminal connections earth pigtail wire and cap retaining clips 13 Lightly lubricate the pivot post of the contact breaker set and assemble ie breaker points 14 Instal the breaker points onto the breaker plate lightly lubricate the carns and apply a small dab of high melting point grease to the rubbing block of the moving point J 5 Adjust the contact breaker gap as described in the section ...

Page 168: ...g light each division on the crankshaft pulley equals 5 degrees refer specifications for the correct setting 5 Adjust the timing position by loosening the mounting plate retaining bolt and rotate the distributor body in the slot if the adjustment is not possible at this point it will be necessary to loosen the screw holding the mounting plate to the distributor body both these screw holes are elon...

Page 169: ...firing Check the cables for perishing or cracking and renew as required Never attempt to repair defective cables The cables may be carefully cleaned using a cloth moistened with kerosene then wiping completely dry Also check the distributor cap for cracks or tracking between the high tension tenninals on both the inside and outside of the cap Renew the cap if cracks or tracking is evident Check th...

Page 170: ...orn button remove the three screws and the non conductive retaining blocks from the horn button 6 Remove the contact plate and sponge rubber ring from the horn ring 7 The assembling and installation procedure is the reverse to removal and dismantling operations To Remove af d Instal 1200 I Disconnect the battery negative terminal 2 Remove the two screws holding the horn button and medallion assemb...

Page 171: ...the quadrant light wires and remove the quadrant assembly 7 Disconnect the turn signal wiring at the terminal connecting block a t the dash panel 8 On 1000 models loosen the mounting screw in the top of the switch and tap downwards to release the locating wedge remove the switch from the steering jacket 9 On 1200 models remove the switch retaining screws from the clamp loosen the switch from the s...

Page 172: ...isconnect the wire terminals Remove the cover and remove the two mounting screws Installation is the reversal of the removal procedure Refer to the AUTOMATIC TRANSMISSION section for adjustment and service procedure STOP LIGHT SWITCH The 1000 model vehicles use a hydraulically operated switch which is mounted on the four way connection attached to the engine firewall The 1200 model vehicles use a ...

Page 173: ... cable according to instruction in the FUEL SYSTEMsectiull HEATER CONTROLS 1000 The hearer controls on the 1000 model vehicles are attached to the heater unit with the booster fan control switch mounted in the dash panel 1 To remove the booster fan control switch press in on the knob and turn anti c1ockwise to release the knob from the switch stem 2 Remove the escutcheon nut using a special tool 3...

Page 174: ...of the removal procedure TO REMOVE AND INSTAL 12 WINDSCREll WIPER I Disconnect the ne ative battery terminal 2 FroI1 under the dash panel on the left side remove the wiper spindle to linkage retairiing nut and disconnect the linkage 3 Disconnect the wiring terminal connector at the wipe r motot 4 Remove the wiper motor retainirig bolts 5 Remove th e wiper m tor from the vehicle Installation is a r...

Page 175: ...or and remove the lamp unit lnstaHation is a reversal of the removal procedure REAR COMBINATION LAM On sedan model vehicles it is not necessary to remove the lens or lamp unit to replace a faulty bulb as access to the bulb holder is from inside the luggage compartment turn he bulb holder and remove the holder and bulb from the lamp body On cotipe models remove the cover retaining screws and remove...

Page 176: ...ERSE LAMP LENS it REVERSE LAMP BULB 1 1 r p STOPTAIL BULB fI J i4 0 G 4 7 j tV S BODY TURN SIGNAL BULB 1 MOUNTING NUTS AND WASHERS BEZElL I SEAL Exploded View of Rea Combination lamp 1000 Models BULB SOCKETS BOOY TURN SIGNAL BULB TURN SIGNAL LENS f I sJTAIlBULB 1 L SEALS D REVERSE LAMP BULB L MOUNTING NUTS AND WASHERS BEZEll REVERSE LAMP LENS Exploded View of Rear Combination lamp 1200 Models 177 ...

Page 177: ...s Renew or repair Overhaul or renew unit Check and repair or renew defective coniponents 3 Indicator light remains on Possible caUse Remedy a Loose or broken drive belt b Incorrectly adjusted regulator unit c Faulty alternator regulator d Low regulator voltage seding A ljl1s1 or renew drive belt Check and adjust regulator lInit Check and overhaul faulty unit Check and adjust voltage setting t regu...

Page 178: ...c Fault in coil primary winding d Burnt or dirty contact breaker points e Faulty capacitor or capacitor lead f Fused or broken wire between breaker arm and low tension terminal g Fault in coil high tension circuit h Cracks in distributor cap i Crack in distributor rotor OJ Faulty high tension leads k Faulty or incorrectly adjusted spark plugs Check circuit and repair as necessary Renew ignition sw...

Page 179: ...r Remedy Check and readjust ignition timing and or contact points Overhaul distributor Check for faulty vacuum pipe or faulty advance unit Advance unit link disconnected or requires adjustment DATSUN 1000 MANUAL TRANSMISSION COLOR CODE V B G W R BL WR WB RB BW VB GV BG GB GR VW RW GW BR BY WBL GBL BBL BLR BLW BWtw BIG 180 Yellow Black Green White Red Blue White red tracer Whiteblack tracer Red bla...

Page 180: ... Starter motor and solenoid 25 R H fog lamp 26 R H front side turn signal lamp 27 R H turn signal and parking lamp 28 Fog lamp switch 29 R H headlamp 30 LH headlamp 31 LH turn signal and parking lamp 32 LH front side turn signal lamp 33 L H fog lamp 34 Turn signal and combination switch 35 T signal relay unit 181 Electrical System 34 fi W w I g CD 1 p T wt fjj w 36 Engine temperature sender unit 3...

Page 181: ...regauge 37 Ignition warning lamp 38 Oil pressure warning lamp 39 High beam indicator lamp 40 Ignition switch 41 Revening lamp switch 42 licence plate lamp 43 L H tail and stop lamps 44 L H turn signal lamp 45 L H reversing lamp 46 Fuel gauge sender it 47 Cigar lighter 48 Radio 49 Fuse 50 R H turn signal indicator lamp 51 L H turn signal indicator lamp 52 Turn signal relay 53 Turn signal and combin...

Page 182: ... 40 Igine temPerature gauge 41 Ignition warning lamPs 42 Oil pr8ssur warning lImp 43 H i9h beam indicitor lamp 44 Tachometer 45 Ignition switch 46 Handbrake warning lamp sWitCh 47 Dual brake warning lamp sWitch 48 licenee pl lte lamp 49 LH tail and stop lamps O LH tUrl signal lamp 51 H r 8 iersing lamp 52 Fuel Puge sender unit Si Cigar lighter 54 Radio 55 Fus 56 Lighting switch 57 R H tur signal i...

Page 183: ...mpound apply the compound to the rubber to glass groove 8 Replace the finish strip in its groove in the weatherstrip with the use of the lipping tool Replace the joint cover clip 9 Clean off any excess sealing compound with a cloth soaked in petrol and wipe the assembly clean 10 Replace the windscreen wiper arms and blades REAR WINDOW GLASS To Remove and Instal The procedures for removing the rear...

Page 184: ... handles and door trim panel 2 RemQve the dust and splash shields from the door inner apertures 3 Raise the window to the closed position and hold in this position with rubber wedges 4 Remove the screws holding the regulator to the door panel and lowbr the regulator down inside the door Bod 2 DIVISIO AR TRIM RETAINER INSERTS TRIM RETA N R INSERTS Front Qoor with Trim Pane and SplashShiel s Removed...

Page 185: ...ve the dust and splash shields from the door inner pertu es 3 Remove the window regulator RellJqve the window stop and lower the glass to the bbttdm ofthe door 5 Remove the quarter window ptounting screws and the lower division bar wounting scr w 6 lemove the quarter window assembly from the door 7 Rptate the door glass so that the glass lift channel is tQ Vards the front of the vehicle and remove...

Page 186: ... of the removal procedure with attention to the following adjustment points I With the door lock installed adjust the position of the remote control so that the remote control lever of the lock is just touching the lock body when the inside handle is at rest then tighten the remote control mounting screws and check the lock operation t Cy8ARAEl LOCKING LEVER L L REMOTE CONTROL ROD LOCKING ADD 1 NI...

Page 187: ...t the three set bolts but only tighten them sufficiently to hold the striker plate in position 5 Close the door and push it firmly shut 6 Press the outside release button and carefully open the door without moving the striker plate 7 Tighten the three mounting set bolts and again close the door checking the operation of the door lock and striker plate If further adjustment is necessary open the do...

Page 188: ...e trim panel WINDOW GLASS To Remove and Instal 1 Remove the interior handles and door trirn panel 2 Remove the dust and splash shields from the door inner apertures 3 Remove the window regulator and let the glass rest in the bottom of the door it will be necessary to remove the window stop on 1200 models 4 Remove the screws at the top of the division bar and the screws holding the bottom of the di...

Page 189: ...R ARM C THRUST WASHER c I HANDLE y It RETAINING SCREW Showing Method of Removing Rear DoOr Window Glass Rear Door with Trim Panel and Splash Shield Removed M f Ie r z j G i j 1 c THRUST WASHER OLLER ARM RETAINING SCREW Rear Door Window Regulator Assembly 1200 Model 190 ProCarManuals com ...

Page 190: ...ing he division bar PLATE 1 REMOTE CONTROL REMOTE CONTROL lI K rsJ t RETAI I G SCREW THRUST WASHER HANDLE DOOR WCK AND REMOTE CONTROL 0 Rear Door Lock A sembly Removed with loor Lock Reversed to ShOw Detail Lock Barre and Lever Shown in In et 1000 rodel To Remove and Instal 1000 I Remove the interior handles and door trim panels 2 RelIlove the dust ine splash shields from the door inner apef ures ...

Page 191: ...rew washer and nylon bush 8 Remove the snipper rod from the door panel and the rod retaining tapes 9 Remove the door lock retaining screws and remove the door lock through the aperture Installation is a reversal of the removal procedure OUTSIDE HANDLE To Remove and Instal I Remove the interior handles and door trim 2 Remove the dust jDd splash shields from the top rear door panel aperture 3 Remove...

Page 192: ...e bolt in or out using a screw driyer Bodyl0 MALE SECTION OF C TCHFI MOUNTING BO t LOCK NurJ SAfPY CATCH L r l li 1 W f 1 j f f I b I OVE A 9lT 0 To Remove 5 LUGGAGIl COMPARTMENT 1 10 Engine Bonnet Lock Components I Open the lid with a pencil mark the edges of the mounting plate to lid position on both sides 2 Support the lid and remove the torsion bars 3 While supporting the lid remove the two bo...

Page 193: ...C wSlots 1000 Model LOCKING BARREL To Remove and Instal I Open the lid and lever the retaining clip from the Jock and remove me locking baIfel In tallat on is a reversal of the removal procedure A r I riD View of luggage Compartment lid ock and Striker 1200 MOdels 194 ProCarManuals com ...

Page 194: ...nd the leakage rectified NOTE Never adjust tyre pressures when the tyres are wann otherwise pressures will be incorrect when the lyres cool down 2 Inspect tyres regularly for damage and abnormal wear Any abnormal wear may be due to one or more of the faults shown in the illustrations or listed in the Fault Diagnosis section Attention should e give l to penetrations or cuts in the tyre which will a...

Page 195: ...and allow the assembly to float ensuring the channel between the rim flange and the tyre is filled with water carefully check for air bubbles emitting from this area 4 Turn the wheel assembly over and submerge the wheel rivets if not already submerged and check for leaks 5 Submerge the assembly and fill the channel between the flange and the tyre allow to float and check for leaks If leaking wipe ...

Page 196: ...e until the beads have sealed correctly It may be necessary to bounce the tyre while inflating 3 Remove the air hose fit the valve core and infiate the tyre to 2 81 kg cm2 40 psi Test the tyre for leaks and deflate to the normal pressure TO INFLATE USING A TOURNIQUET l Inflate the tyre with the assistance of a tourniquet use Dunlop tool No TT l or its equivalent follow the fitting instructions inc...

Page 197: ... s S Spotty or irregular wear Possible cause Remedy a Static or dynamic unbalance of wheel and tyre assembly b Lateral run out of wheel c Excessive play in wheel hub bearing d Excessive play in steering knuckle ball joints Check and balance wheel and tyre assembly Check and true up or renew wheel Check and adjust or renew hub bearing Check and renew ball joints 6 Lightly worn spots at centre of tr...

Page 198: ...thered edge on one side of tread pattern Revise max um loading Avoid as far as possible Revise driving h bits Possible cause Remedy a Sharp inside edge excessive toe in b One tyre sharp inside edge other tyre sharp outside edge Check and adjust wheel alignment Check for bent steering arm and renew 199 ProCarManuals com ...

Page 199: ...S pt 2 50 US pt SAE 90 HD Lubricant grade SAE 90 HD AUTOMATIC TRANSMISSION 5 250 litre Capacity 5 5 litre 9 125 Imp pt 9750 Imp pt 11 1 US pt II 750 US pt 3N71 A Type F Lubricant grade 3N71A Type F or equivalent or equivalent REAR AXLE 0 710 litre Capacity 0 75 litre 1 250 Imp pt 1 375 Imp pt 1 5 US pt 1 625 US pt SAE 90 HD Lubricant grade SAE 90 HD STEERING BOX 0 240 litre Capacity 0 23 litre 0 5...

Page 200: ... points with a few drops of engine oil every 10 000 km 6000 miles 4 Lubricate the carburettor linkage every 10 000 km 6000 miles with a few drops of engine oil GEARBOX 2 TRANSMISSION I Check the oil level and top up as necessary every 5 000 km 3 000 miles with correct grade of lubricant 2 Drain and refill the gearbox when the vehicle has completed 1000 km 600 miles and subsequently every 40 000 km...

Page 201: ...he distributor earn lobes with a high melting point grease when the contact points have been removed for cleaning or renewal Check and top lip electrolite with distilled water as required or at least fortnightly TYRES I Test and inflate when cold to recommended pressures as required or at least fortnightly 2 Rotate tyres every 10 000 km 6000 miles BODY I Check and lubricate the following component...

Page 202: ... are sealed from the atmosphere This system is most effective at part throttle operation where a pa ticularly high vacuum is present in the inlet manifold to allow the regulating valve to open and for all crankcase vapours to be scavenged from the crankcase At full throttle operation the manifold vacuum is insufficient to draw all crankcase vapours through the regulating valve and into the inlet m...

Page 203: ...s on the engine oil filler cap and the Q O RING dipstiCk Renew the seals if they are damaged or if their sealing qualities are suspect 3 Check the operation of the ventilation regulating valve as follows With the engine running at a steady idle speed disconnect the hose from the regulating valve A sharp hissing noise will be heard at the valve when the hose is disconnected Now place a finger over ...

Page 204: ...g then renew the valve as an aHem bly To Instal I Position the control valve back in the engine compartment on the inlet manifold 2 Instal and tighten the control valve assembly attaching screws Emission Control B 3 Connect the inlet manifold to control valve vacuum tube 4 Connect the control valve to servo diaphragm vacuum tube 5 Check the operation of the valve and adjust if necessary as describ...

Page 205: ...ed decrease time IS When satisfied the adjustment is correct tighten the control valve lock screw and recheck the engine speed adjustment to ensure that the vacuum adjusting screw has not altered position CARBURETfOR To obtain effective exhaust emission control it is important that the carburettor idle speed and mixture setting are periodically checked and accurately adjusted The choke setting sho...

Page 206: ...to the engine 3 J Wipe the crankshaft pulley s o that the iimihg marks are clearly visible 4 Warm up the engine and set the idling speed to 100 rpm 5 Loosen the distributor reiaining screw far enough to allow ihe distributor to be moved by hand 6 With ihe aid of the ii ing light adjust the ignition iiniing to 5 deg btdc NOTE The 5 deg mark on the crank shaft pulley is the first graduation on the r...

Page 207: ...apertures are clearly engraved with A F and C denoting Air Cleaner Fuel Tank Crankcase FROM AIR CLEANER J FROM VALVE COVER AIR CLEANER I FLOW GUIDE VALVE i T TO INLET MANIFOLD OR CRANKCASE TO TEST I Raise the engine bonnet 2 Disconnect all hoses and then remove the now wide valve from the vehicle 3 Apply a low pressure of air to the fuel tank F side aperture of the valve The air shuuld flow throug...

Page 208: ...or Remedy Adjust throttle opener Check throttie cable or linkage and rectify Renew control valve Remedy Adjust carburettor Reset ignition timing RIlCO MIlNDIlD I INTF NANCt To ensure efficient operation of the emission control system it is important that the following service procedure be carried out on the items mentioned at the recommcndeu mileage intervals ENGINE I Carry out the following servi...

Page 209: ... 000 km 12 000 miles Check and adjust control valve and servo diaphragm EVAPORATIVE CONTROL SYSTEM I Carry out the following service procedure every 20 000 km 12 000 miles Check hoses pipes and connections for leakage Remove and test flow guide valve for correct operation 210 ProCarManuals com ...

Page 210: ... Clean and Inspect SO To Check Cylinder Bores 20 To Assemble SO Deglazing Cylinder Bores 20 Slave Cylinder 50 Checking Piston Skirt Clearance 21 To Remove and Dismantle SO Crankshaft and Main Bearings 21 To Clean and Inspect 51 To Remove and Instal 21 To Assemble and Instal 51 Oil Pump and Filter 23 Hydraulic System 51 To Remove and Instal 23 To Bleed 51 To Dismantle and Assemble 23 Outch Throw ou...

Page 211: ...102 AUTOMATIC TRANSMISSIONS Specifications 73 STEERING Description 73 Specifications 103 Engine Tuning 74 Description 103 Towing 74 Steering Gear Assembly 103 Hydraulic Fluid 74 To Dismantle 104 To Check and Top Up 74 To Clean and Inspect 104 To Drain and Fill 76 To Assemble 104 Transmission Selector Linkage 76 Collapsible Steering 106 To Adjust 76 Description 106 Neutral Safety Switch 76 Jacket T...

Page 212: ...l To Dismantle Nabco To Dismantle Tokico To Clean and Inspect Nabco and Tokico To Assemble Nab co To Assemble Tokico Rear Brake Assembly To Remove and Dismantle To Clean and Inspect To Assemble and Instal Front Wheel Drum Brakes To Remove and Dismantle To Clean and Inspect To Assemble and Instal Front Wheel Disc Brakes To Remove and Instal Brake Caliper To Dismantle and Assemble To Remove and Inst...

Page 213: ...just Ignition Timing and Dwell Angle 169 Wheel and Tyre Assembly 195 Sparking Plugs 170 To Remove 195 To Service 170 To Instal 195 High Tensiun Leads 170 To Maintain 195 Ignition Coil 170 Tubed Tyres 195 Turn Signal Switch Headlight Dipper To Remove 195 and Horn Button 170 To Instal 196 Description 170 Tubeless Tyres 196 Horn Button 170 To Test for Leaks 196 Turn Signal Switch 172 To Repair Leaks ...

Page 214: ...rative Control System De cription Flow Guide Valve 203 203 204 204 205 205 205 206 206 206 206 206 207 207 207 208 To Test Fuel Tank Vapour Liquid Separator and Vapour Vent Line Exhaust Control System Fault Diagnosis Recommended Maintenance Engine Crankcase Ventilation System Exhaust Control System Evaporative Control System Index S 208 208 209 209 209 209 210 210 GLOSSARY OF TERMS ROAD TESTS Da t...

Page 215: ...h vlind r operating cylinder actuating vlinder WITHDRAWAL LEVER Throw oUl lever clutch fork release fork TRANSMISSION CIRCLlP Snap ring spring clip GEAR SHIFT LEVER Change speed lever gear selector lever gear change lever INPUT SHAFT Clutch shaft first motion shaft main drive shaft primary shJfl main drive gear spigot shaft LAYGEAR Cluster gear second motion gear intermediate gear LAYSHAFT Cluster...

Page 216: ... Dimmer switch FUEL GAUGE Petrol gauge GENERATOR Dynamo GENERATOR REGULATOR Voltage regulator control box GLOBE Bulb lamp TURN SIGNAL LIGHT Direction indicator light llasher light trafficator light TURN SIGNAL SWITCH Direction indicator switch flasher switch trafficator switch HEADLAMP Head light main light HIGH TENSION LEADS Plug wires HORN PUSH Horn switch horn button INSTRUMENT LIGHT Panel ligh...

Page 217: ...PEED 82 KP H x 1ST 2 PH ACCDERATION THROUGH GEARS WITH CHANGE POtNTS 0 1 6 1 1 L I4 4 10 1520 n 10 1S 40 MPH eLAPSED TIME IN SECONDS Road test figures courtesy Wheels Magazine from its October 68 Sydney report SPECIFIC TIONS ENGINE Cylinders Bore and stroke Cubic capacity Compression ratio Valves Carburettor Fuel pump Oil filter Power at rpm Torque at rpm TRANSMISSION Type Clutch Gear lever locati...

Page 218: ...NTS t 1J 5 C 15 H ELAPSED TIME IN SECONDS 20 Road test figures courtesy Wheels Magazine from its August 1969 Sydney report 20 40 mph 30 50 mph 40 60 mph 50 70 mph STANDING QUARTER Fastest run Average of all rWlS 3rd gear 6 4 sees 6 7 sees 7 6 sees 10 0 sees MILE 4thgear 9 9 sees 10 1 sees 11 2 sees 13 7 sees Drive 5 5sees 7 0 sees 10 7 sees 218 sees SPECIFI ATIONS 20 3 sees 23 5 sees 20 4 sees 24 ...

Page 219: ... PH MPH Road test figures courtesy Wheels Magazine from its September 1970 Sydney report 20 40 mph 30 50mph 40 60 mph 50 70 mph STANDING QUARTER MILE Fastest run Average all runs BRAKING From 30 mph to 0 From 60 mph to 0 SPE IFlf TIO S ENGINE Cylinders Bore and stroke CUbic capacity Compression ratio Valves Carburettors Power at rpm Torque at rpm TRANSMISSION Type 4 speed all syncro Borg Warner Ty...

Page 220: ...NDING OUARTER MtLE Fastest run Average all runs BRAKING From 30 mph to 0 From 60 mph to 0 2nd gear 4 0 see 4 2 see 5 4 see 77 see 10 9 see 15 5 see 22 1 see 32 see 4th gear 11 6 see 9 6 see 10 5 see 12 4 see 3rd gear 8 0 see 7 0 see 8 2 see 83 see 19 1 see 19 3 see 1 7 see 3 6 sec SPECI FICATIONS ENGINE Cylinders Bore and Stroke Cubic Capacity Compression Ratio Varves Carburettors Fuel Pump Oil Fi...

Page 221: ...DATE REMARKS 222 ProCarManuals com ...

Page 222: ...QATE 1 REMARKS J 223 ProCarManuals com ...

Page 223: ...DATE REMARKS J Printed by Kenmure Press Pty Ltd 50 Derby Street North Lidcombe New South Wales 2141 r ProCarManuals com ...

Page 224: ...D i T at t t t l J ic 1 b iid 5d b j r iT 1Z iizk jj 0 tiJt ProCarManuals com ...

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