Datsun 1300 Workshop Manual Download Page 44

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Summary of Contents for 1300

Page 1: ......

Page 2: ...UN 130014001600 610 series I l A 160B 180B COMPILED AND WRlTTEN av C R Newton SBN 901610 13 5 PUBUSHED BY OOEREUROPE AUTODAT A DIVISION NICHOLSON HOUSE MAIDENHEAD BERKSHIRE ENGLAND C Copyrirt lnt eurupe Cktoblr 1972 WSM 137 Printed Engl w ...

Page 3: ...al backers forming the syllable DAT To avoid confusion with a similar Japanese word the name was eventually changed to DATSUN The various models covered in this Manual together with alternative namt s used for the world markets are listed below MODELS COVERED MODEL ALTERNATIVE IDENT 510 SERIES Datsun 1300 510 SERIES Datsun 1400 510 SERIES Datsun 1600 610 SERIES Bluebird 160 B 610 SERIES Bluebird 1...

Page 4: ...ossession of the genuine spare parts which may be needed for replacement The information in the Manual has been checked against that provided by the vehicle manufacturer and any peculiarities have been mentioned if they depart rom usual work shop practice A fault finding and trouble shooting chart has been inserted at the end of the Manual to enable the reader to pin point faults and so save time ...

Page 5: ...echnical Data BLUEBIRD 400 1600 1600 U4 U6 0 4 120 162 20 1 560 6142 410 55 51 420 55 91 10 2 33 5 270 50 0 2 420 95 281 215 8 5 885 1 950 210 8 27 930 2 050 10 1 12 33 2 27 7 50 931 28 2123 5 60 99 L 16 4 215 165 941 1 600 62 99 405 55 3 Ii 0 6 34 8 290 50 79 1 300 51 18 2 500 98 43 185 7 281 955 2 1061 12 14 5 28 2 23 5 60 991 BLUEBIRD1800 L 18 3 0 5 57 320 5 971 000 2 2051 165 103 BLUEBIRD 1800...

Page 6: ...disconnect the fuel pipe from the fuel pump and the heater hoses from the engine attachments 6 Disconnect the accelerator control linkage and the choke CRANKSHAFT AND MAIN BEARINGS CAMSHAFT AND SPROCKET FLYWHEEL ENGINE Assembling VALVE CLEARANCES Adjusting ENGINE LUBRICATION SYSTEM OIL PUMP OIL FILTER CHANGING THE ENGINE OIL cable from the carburettor 7 Disconnect the wirings from the starter alte...

Page 7: ...engine 600 tb tllroogh Section S O sef1es ofenll A o ne l Right S 0 61 ttor bure n car l tWI thS hi4 t V ne ofengJ vie lJlt side Gene ol Engine FIS to ...

Page 8: ...I 0 120000 CI j 91 7 m I3L I T IC t J i1 C J 6 i 11 j 1j 4 I UO J I Ll LJJ 1r9i V 1 EM092 Fig AA Removing the camshaft sprocket Fig A 5 Cylinder head bolt removal sequence t J1 I J 1 1 i I G qt 7 r J O I IS Fig A 6 Removing the chain tensioner and timing chain Fig A 7 Removing the drive sprocket 7 ...

Page 9: ...ng the pistons and connecting rods Fig A II Removing the baffle plate and net c 1 1i t1 I c2 r Id f tij Fig A IO Removing the Tear main bearing cap Fig A 12 Removing the piston pin Fig A 13 Removing the valves Fig A l4 OIecking the cylinder head joinlface Fig A I 5 Reaming the valve guide 8 ...

Page 10: ... the diameter of the stem with a micro meter The diameter of the inlet valves should be 7 965 7 980 mm 0 3136 0 3142 in and the diameter of the exhaust valves 7 945 7 960 mm 0 3128 0 3134 in If the seating face of the valve is excessively burned damaged or distorted it must be discarded A badly pitted seating face should be refaced on a valve grinding machine removing only the minimum amount of me...

Page 11: ...6 12835 dia 37 1 4561 dia Unll In Llb thtwin 1 13 Ut WiTh Ie ro rLl Incak h C 1 q J j Exhaust Fig A I Standard valve seat dimensions U l and liS 11tJ 1l ioo l j 1 4 u 055i1 r m JA9bIJUI4 l 9 611 559lldia 4L80 6457 dlll 45 J 1717 liS 311 fJ 90o LJ 1 3 0 0512 r 1 II I i 30 n Il i1 I tlla 32 60 2835 di L 34 6 1 3622 dla 37 1 4561lia Fig A IS Valve at grinding dimensions 10 ...

Page 12: ...ld be noted that the actual runout will be half the the value indicated on the dial gauge When the camshaft is turned one full revolution with the dial gauge positioned against the second and third journals CYLINDER BLOCK Inspection and Overhaul Ensure that the cylinder block is thoroughly clean and check it for cracks and flaws Check the joint face of the block for distortion using a straight edg...

Page 13: ...s Fig A 2 Measuring lbe cy n 1 I 1l or r i r m O 1874 r I abllUI O I I Q k t diameters h pistons tr F A 23 Measunng t e g the piston ring side fi A 25 Measurmg g clearance 12 k oint face I der bloc J ki gthecym A20Chec n FIg 1 7 rb I tinder ositions for the cy A 22 Measunng p F g bores the piston ring gap A 26 Measunng F g ...

Page 14: ...rankshaft to the required undersize See Technical I INNER DIAMETER 82 45 82 60mm 3 24613 2520 in 82 4S 82 60mm 3 24613 2520 in 82 4S 82 60mm 3 24613 2520 in Data Place the crankshaft in V blocks as shown in Fig A 28 and check with the aid of a dial gauge that the shaft bending limit of 0 05 mm 0 002 in is not exceeded With the dial gauge positioned against the centre journal the crankshaft should ...

Page 15: ...king the big end play Fig A 28 Checking the crankshaft for run out Weight Fig A 29 Checking the bearing crush Fig A 30 Checking the camshaft sprocket for run out Fig A 31 OIecking the camshaft end float Fig A 32 Installing he valves 14 ...

Page 16: ...nd oil seals throughout All sliding parts such as bearing shells must be smeared with engine oil before installing B Ensure that the specified tightening torque readings are strictly followed A mbling the cylinder Head To install the valves and valve springs place the valve spring seatsinto position and fit the valve guides and oil lip seals Assemble in the following order valve springs spring ret...

Page 17: ...nce Fig A 36 Installing the piston and connecting rod assembly J 0 k2 CD 1 1 r 1 P l b S LM J Jr T9T J I J C I 3 TimJn mark Lt j Location hole Oblonl groon I I Afteradju5tment 1 i Before adjustment AtT D C or No I piston Fig A 37 Cylinder head bolts tightening sequence Fig A 38 Adjusting the camshaft sprocket Fig A 39 Fitting the chain tensioner Fig A 40 Valve clearance adjusting 16 ...

Page 18: ...sioner must be fitted if the spindle protrudes Press a new oil seal into the timing cover and fit the cover into position using a new gasket Apply sealing compound to the front of the cylinder block and to the gasket and to the top of the timing cover Ensure that the difference in height between the top of the timing cover and the upper face of the cylinder block does not exceed 0 15 mm 0 006 in T...

Page 19: ...18 II l o CD I Fig A 42 Component parts of the oil pump L Pump body 2 Inner rotor and wft 3 OutOrotor 4 Pump coper 5 Reliefvalve 6 Relief valve Jpring 7 Washer 8 S alp 9 ConT 613ut I Sideclruance 2 TIp clearance 3 Guier 10 00 body clearance t 4 Rotor to bottom cover cleatance Fig A 43 Checking the rotor clearance ...

Page 20: ...the heading CHANGING THE ENGINE OIL 2 Remove the front stabiliser and the splash shield board 3 Withdraw the securing bolts and detach the oil pump body together with the drive gear spindle Take out the bolts securing the pump cover to the pump body and withdraw the rotors and drive shaft See Fig A 42 The pin securing the driven shaft and inner rotor mustnot 00 taken out as the shaft is press fitt...

Page 21: ...2 0 4723 in 11985 11996 mm 0 4172 0 4723 in 0 015 0 045 mm 0 00060 0018 in 0 040 0 070 mm 0 00160 0028 in Valve seat width Inlet Exhaust V lve seat angle Valve seat insert interference fit Inlet Exhaust Valve guide interference fit Inlet 1 4 18 mm 0 055 0 071 in 1 6 2 0 mm 0 063 0 079 in 450 0 080 11 mm 0 0031 0 0043 in 0 06 0 10 mm 0 00240 0039 in 0 027 0 049 mm 0 0011 0 0019 in CAMSHAFT AND TIMI...

Page 22: ...0 mm 0 00030 0004 in Pin interference fit in small end bush 0 015 0 033 mm 0 00060 0013 in Piston ring height Top and second Oil control Side clearance in grooves Top PISTON RINGS 2 0 mm 0 08 in 4 0 mm 0 16 in 0 040 0 073 mm 0 00160 0029 in Second Oil control Piston ring gaps Top Second Oil control Material Distortion of sealing face Max distortion Valve seat insert material Inlet Exhaust Fit Driv...

Page 23: ... line 1428 cc 87 1 cu in 1595 cc 97 3 cu in 1770 cc 108 0 cu in 83 x 66 mm 3 27 x 2 60 in 83 x 73 7 mm 3 27 x 2 90 in 85 x 7B mm 3 35 x 3 07 in 9 0 8 5 9 5 8 5 9 5 Overhead valve I 3 4 600 r p m single carburettor 650 r p m twin carburettor 650 r p m single carburettor 700 r p m twin carburettor 3 5 4 0 kg sq cm 5057Ib sq in VALVES Valve lift Single carburettor Valve lift Twin carburettor 10 0 mm ...

Page 24: ...0 0588 0 0593 in 0 20 0 30 mm 0 0079 0 0118 in 0 025 0 055 mm 0 0010 0 0022 in less than 0 025 mm 0 001 in per 100 mm 2 937 in Bearing thickness Big end play Connecting rod bearing clearance Connecting rod bend or twist CRANKSHAFI AND MAIN BEARINGS Journal diameter Journal taper and out of round Crankshaft free end play Wear limit Crank pin diameter Crankpin taperand out of round Thickness of main...

Page 25: ...mm 13 3844 33864 in 0 mm CO 0787 in 0 mm 0 0787 in 4 0 mm 0 1 q c in 0 025 0 045 mm 0 0010 0 0018 in PISTON PIN 20 995 1000 mm 0 8266 0 8168 in 7200 72 25 0 001 0 Dl5 72 25 mm 2 8346 2 8445 in 73 00 mm 2 8445 2 8740 in 0 013 mm 0 00004 0 00051 in 0 033 mm 0 0006 0 0013 in PISTON RING 1977 mm 0 0778 in 1977 mm 0 0778 in 0 040 0 080 mm 0 0016 0 0031 in 0 045 0 080 mm 0 0018 0 0031 in 0 030 0 070 mm ...

Page 26: ...R2 If adjustment is neces ary slacken the alternator mounting and adjustment bolts and pivot the alternator away from the engine to tighten the belt to towards the engine if the belt is to be slackened NOTE Always apply leverage to the drive end housing when pivoting the alternator and never to the diode end housing or the alternator will be damaged Retighten the alternator bolts and make SUfe tha...

Page 27: ...Pl i i n i II L Vi It q n lli J j tr rl t lli 3 t11 1 i l Wt r till I cj L f0 co 7 Fig B l The cooling system Fig 8 2 Olecking the fan belt tension Fig B 3 Removing the water pump Fig B 4 Removing the thermostat 26 ...

Page 28: ...vehicles fitted with an air conditioner The fluid coupling Limits the maximum fan speed to approximately 3000 rp ro and eliminates noise and loss of power at high engine speeds A fault in the coupling may be caused by the entry of foreign matter If a fault developes the oupling must be removed and dismantled and the interior cleaned by washing in solvent The condition of the seal and bearing must ...

Page 29: ... HEAD r SPARK PLUG Fig C t Ignition sys em circuit diagram i II 1 1 J i 9 28 l I i 1 I I G N 7 Fig C 2lgnition distributor 1 Shaft assembly 2 Collar assembly 3 Cam assembly 4 Governor weights 5 Governor spring 6 Rowr head 7 Breaker plate 8 Contact set 9 Tennirtal assembly 10 Vacuum control J1 Condenser 12 Distributor cap 13 Carbon point 14 Plate 15 CIilmp ...

Page 30: ...ents a 50 division of the crank angle Disconnect the distributor vacuum line start the engine and allow it to run at normal idling speed or slightly below Point the timing light at the timing pointer on the front cover Fig C 3 The crankshaft pulley groove should appear to be stationery and aligned with the pointer on the front cover The top dead centre mark is located at the extreme right as shown...

Page 31: ...p Fig C 7 Removing the retaining pin 30 J Fig C 4 Adjusting the contact points gap L Fig C 6 Removing the earn 2 1 1 I 7 V J J 1 Governor weight 2 Oearance for startand nd ofadvanc angle 1 Hook 4 GOllernor spring B 5 Com plate 6 F7YWtight pin 7 Hook 8 Goverrwrspring A 9 Rotor positioning tip Fig C 8 Centrifugaladvance mechanism ...

Page 32: ...aining pin with a drift and hammer Fig e and remove the pinion and washer Take care not to stretch or deform the governor springs when detaching them from the weights IGNITION DISTRIBUTOR Assembling and Installing Assembly is a reversal of the dismantling procedure Lubricate the moving contact pivot and smear the lobes of the cam with multi purpose grease If the centrifugal advance mechanism has b...

Page 33: ...ckwise 100 at 600 r p m 140 at 650 c p m 80 at 600 r p m 49 550 Contact point gap setting Contact spring tension 0 45 0 55 mm O OI77 0 0217 in 0 50 0 65 kg l l0 I 43 lb Condenser capacity 0 22 0 44 F IGNITION COil Type Spark plugs With single carb With twin carb Plug gap Tightening torque Hitachi 6 R 200 NGK BP 5ES NGK BP 6ES 0 8 0 9 mm 0 031 0 035 in 1 5 2 5 kgm II 15Ib ft 1300cc engine IGNITION ...

Page 34: ... is opened causes the suction piston to rise or fall under the intluence of the engine suction The pozzle opening therefore changes and provides an optimum air fuel mixture at all engine speeds The cartridge type fuel strainer utilizes a fibre strainer element which should be replaced every 20 000 km 12 000 miles Removal of the fuel strainer is a simple operation but as it cannot be drained the st...

Page 35: ... 1ni1 n air bleed 19 Slowrunning jet 20 Slow running air bhYd 34 1 G o 1 u 40 j t 1 fE SV 11 t 9 Fig D l The fuel pump I Cop 2 Gasket 3 Packing 4 Valveouembly 5 YaM tain 6 Diaphragm assembly 7 DiaphTagm spring 8 Prdlrod 9 Seal washer 10 Seal 11 nletconnector 12 Outln connector JJ Rocker arm sprint J 4 Rocker ann 15 Rocker ann pin J 6 Packing 7 Spacer If C1l T l I I 51 lID ID I 9J lJi 22 ill 21 23 ...

Page 36: ... worn and should be renewed Assembly is a reversal of the dismantling procedure noting the following points Fit new gaskets and lubricate the rocker arm link and the rocker arm pin before installing The pump can be tested by holding it approximately I metre 3 feet above the level of fuel and with a pipe connected between the pump and fuel strainer Operate the rocker ann by hand the pump is operati...

Page 37: ...p injuror 2 Weight 2 Outklvolve 4 Piston 5 Damper spring 6 Piston return spring 7 Clip 8 Strainu 9 Inlet lmlJe I Fig D 6 Idling compensator 1 lit 21 Fig D 5 Section through the SU twin carbureUor J Suction chamber Suctiull spring 3 Hoat chamber corer 4 Guide 5 Nipple 6 Throttle chamber 7 Piston rod 8 Needle valve 9 T7trollle l ob e J O Float chtzmber J 1 Float Iel cr J 2 Float 13 Sleel e 4 aip 5 F...

Page 38: ...e carburettor Remove the choke connecting rod pump lever return spring and set screws and take offthe choke chamber The primary and secondary emulsion tubes can be with drawn after removing the main air bleed screws If the accelerator pump is to be checked take offthe pump cover but take care not to lose the return spring and inlet valve ball situated at the lower part of the piston Separate the t...

Page 39: ...ew t c l 1 cl rfC L t 0 i I SID jID L v i s A Fig 0 9 Fast idle opening adjustment I Choke lever Crank rod 1 a ok arm 4 Chob valve 5 Starring lever 6 Throttle ann 7 Throttle lYl J1e Fig 0 10 Adjusting the interlock throttle valve opening J Throttle valve 2 Connecling kv r 3 Throttle ann 4 Rocking ann 5 Secondary throttle ann 6 Return pring 38 ...

Page 40: ...ngine a few times then check that the idling speed is unchanged Turn the fast idle setting screw to increase the engine speed to approximately 1500 r p m and recheck with the flow meter that the air flow for both carburettors is correctly matched If the air flow is uneven it will be necessary to readjust the balance screw Finally back off the fast idle setting screw Fig D 16 and decrease the engin...

Page 41: ...7rrottle roM FIB D II Adjusting the dash pot clearance Fig D 13 Adjusting the float seal Frg D 15 Id1ing adjustment SU twin cuburettors 40 i g ID l i f J Ir c 11 J It Frg D 12 Adjusting the float level Fig D 14 Adjusting the float stopper Fig D 16 Adjusting the fast idle setting SU twin carburettors ...

Page 42: ...d lever 7 Throttle adjusting p1at 8 Throttle valv 9 Throttlevalv cletlran B Fig D 22 Adjusting the starting interlock opening inteN lliiD U I i n 1 Jet n edle 2 Set screw Fig D 18 Installing the jet needle 1 Nozzle sleeve 2 Wa sher 3 Nozz det V d C1e W 4 Ad u ting him 5 dlingadjustment spring 6 Idling adjustment nut Z Nozz c J Fig D l9 Dismantling the nozzle assembly 3 I Float lever 2 Bend here lo...

Page 43: ... point indicated SU TWIN CARBURETTOR Starting interlock valve opening adjustment To adjust the starting interlock opening the connecting rod 4 in Fig D 22 1 must be bent using a suitable pair of pliers The throttle opening can be increased by lengthening the connecting rod or reduced by shortening the rod The throttle opening is correctly adjusted when the clearance 8 between the throttle valve an...

Page 44: ...rred Make sure that the friction face of the pressure plate CLUTCH PEDAL Adjusting CLUTCH MASTER CYLINDER CLUTCH SLAVE CYLINDER CLUTCH WITHDRAWAL LEVER Adjusting CLUTCH SYSTEM Bleeding is perfectly flat and smooth Coil spring clutch A special tool No ST200S0000 is available to ensure that the clutch can be dismantled and accurately reassembled The tool shown in Fig E 3 consists of a Base plate I C...

Page 45: ...hdrawal lacr 6 Retainerspring 7 BeaMI u ve 8 Relmsf bearing 9 Beving s vc holder spring 10 Dust co r 11 Fig E 2 The coil spring clutch 7 Inssure spring 8 Spring tainer 9 Release InO 10 Retf t1sc InleT seat 11 Locknut 12 Releme leversupport 19 R hmr beDrin8 20 Retaining clip 21 DllJt xw0 22 Return sprint 23 Locknut 24 Wil u lnrrJ raJ Innpusher 44 13 Retaining SProw 14 8011 15 LockwruheT 16 CTutch w...

Page 46: ...be applied at the inner race as shown in Fig E IO It should be possible to turn the bearing freely and smoothly when it is pressed into place CLUTCH Assembly Coil spring type Press the pin into the eyebolt and through the lug on the pressure plate Place the three distance pieces on the surface of the base plate of the special tool ST20050000 and position the pressure plate pressure springs and ret...

Page 47: ...81 I 1 1111 11 I rA I 1 1111111111 if jI 4 J J J FiB E 5 Checking the height of the diaphragm spring Fig E 6 Olecking the load of the dt b spring I I I A j I 1 1 I l i y 8 Fig E 7 Inspecting the clutch spnngs for distortion Fig E 8 Removing the releaSe bearing p l 0 I 0 W Illmi i hm 17 9 FiB E 9 Installing the leabearing diaphragm spring FiB E I 0 Installing the lease bearing coil spring 46 ...

Page 48: ...awal lever 4 Take out the mounting bolts and withdraw the slave cylinder from the clutch housing To dismantle the slave cylinder remove the dust cover and snap ring and withdraw the remaining parts from the cylinder Oean all components carefully and check them for signs of damage or wear renew any part found to be defective and fit a new piston seal CLUTCH SLAVE CYLINDER Assembly and Installation ...

Page 49: ...ning torque 3 5 to 4 0 kltm 125 to 29 h lb Rs A l I l 1 3 fP I 01 I 8J I Jt I Lock A 2 Lock ul Bn Adjwt by adjust of master cyl Lubricatic l Clutch dal full trek 140 4 mm 5 51 0 16 Clutch pedal free stroke 25 mm 0 98 Pedal height 175 mm 6 89 nl Pcdalfullstrokc b 135mm 5 JI n Multipurpo greasc 510 series 610 series Fig E l3 Adjusting the clutch pedal I 48 ...

Page 50: ...r gasket 12 Gasket ring 13 Push rod 14 Push rod ht lld 15 Wdd nut 16 Lock nut 17 Piston stopper 18 Stopper ring 19 Boots 20 Oil reservoir 21 Rese1l Oir band 22 Reservoir cop 23 Cap 24 Pipe seat J J 5 9 a ID 1 Cylinder 2 Return spring C1 3 Piston 4 Spring seat 5 Push rod 6 Nut 7 Stopper ring 8 Stopper 9 Dust cover 10 on reservoir 1J Reservoir balld 12 Reservoir cap Fig E 14 Section through the clut...

Page 51: ...and diaphragm spring release levers Height between diaphragm spring and flywheel Height between release levers and flywheel Outch driven plate Outer diameter Inner diameter Thickness of facingS Total friction area TIrickness of clutch plate Free Compressed No of torsion springs Permissible minimum depth of rivet heads from facing surface Permissible run out of clutch facing P rmissible free play o...

Page 52: ...lutch housing to the engine Lower the jack slowly and withdraw the gearbox towards the rear of the vehicle THREE SPEED GEARBOX Dismantling Drain the gearbox oil Remove the dust cover release the retainer spring and remove the withdrawal lever complete with release bearing from the clutch housing See section CLUTCH Remove the gearbox bottom cover the speedometer drive pinion assembly and the rear e...

Page 53: ...g F 1 View through the four speed gearbox It j j 4 C J f e V tJ J I P Fig F 2 The propeUer shaft Fig F 3 Disconnecting the speedometer cable Fig F 4 Disconnecting the remote control linkage Fig F 5 Removing the clutch slave cylinder 52 ...

Page 54: ...moving the reverse idler gear JO Fig F 9 Removing the interlock plug F 8 F I0 Withdrawing the mainshaft gear assembly Fig F lI Removing the main drive shaft Fig F 12 Removing the 2nd and 3rd speed syndlroniur hub circlup f Ii ii jjf vr O Fig F 13 Removins the 2nd and 3rd speed hub and 2nd speed gearwheel S3 ...

Page 55: ...nd spacer Fill F 15 Checking the IIlJIDlShofllor ron ol Fig F I7 Installing the insert snap ring Fill F 16 Checking the clearance between baulk ring and gear Fig F 18 InsWlins the shifting inserlll 54 Fig F 19 Fitting the synchronizer hub to the coupling sleeve ...

Page 56: ...1 in Fit the first speed gear and baulk ring on the rear of the shaft so that the tapered cone faces to the rear Assemble the first speed synchronizer and reverse gear on the shaft Fit the spacer and press the mainshaft bearing complete with retainer onto the shaft Install the spacer ball and speedometer drive pinion Select a snap ring which will give an end float of 0 05 0 22mm 0 002 0 009 in on ...

Page 57: ...lock mechanism c Fig F 23 Installing the cross shaft 1 crossshil t 2 l hnut washers 3 OperatirJ8levm 4 Lock pim 5 Retaining rings Fig F 24 Ole king the gear backlash hk rmJ t 0 o y 9 Ll 7 1l i A I f 0 Fig F 25 Withdrawal lever and reIe e bearing Fig F 26 View of the four speed gearbox with bottom cover removed II 56 ...

Page 58: ...select a new snap ring to eliminate all end float between bearing and snap ring Snap rings are available in five thicknesses from 1 52 1 77mm 0 06 0 07 in The assembly procedures for the Warner type synchronizers are similar to the instructions previously described for the three speed gearbox Refer to THREE SPEED GEARBOX Assembly for further details To assemble the Servo F4C63 type synchronizers p...

Page 59: ...4th selector fork 6 Inter ock phmgtr 3 Fork rod 7 Intulock pin 4 Interlock plunger 8 Revene selLetor fork 9 Fori rod 10 Retaining pin Fig F 33 Assembly of the selector forks 1 17uu t block 2 md bruke 3Synchro rint 4 Anchorblock 5 Circlip 6 Band b ke r 1 R nt shaft SntJpring 3 R idler driving geor UT 4 Thrust washer 5 1 hnat washer 6 Idlergeor 18T Fig F 32 Reverse idler gear F 8 F 31 Syncbromesh as...

Page 60: ... removed if slackness is detected Coat the sliding surfaces with grease before assembling them Acijusting Set the gear lever to the neutral position and temporarily connect the trunnion on the lower support bracket to each rod Fig F41 Set the rod on the lever so that the neutral adjustment grooves on the uppersurface of the lower support bracket are aligned with the grooves on each lever When the ...

Page 61: ...moving the indicator and lighting switch 60 k Upper bracket id m mb r Control rod eros shalt er i 2nd Steerin Reve e lu Reverle Neutral od 3 Neutral H C dl n 3 Note Fig F 38 Removing the upper support bracket lO br Gr fOf trllllett il ll 1 Ch lwer i Fig F 41 Neutral setting adjustment T 0 350 5 kg m 2 S 3 6 ft lb 1 2 T Tightening torque Chauis grease Apply grease to the points shown by when recnse...

Page 62: ...m 0 008 0 016 in 0 10 0 30 mm 0 004 0 012 In Max idler gear end float 0 50mm 0 020 in 0 50mm 0 020 in Gearwheel end float Ist speed gearwheel 0 20 0 30mm 0 008 0 012 in 0 05 0 15mm 0 002 0 006 in 2nd speed gearwheel 0 20 0 30mm 0 008 0 012 in 0 05 0 15mm 0 002 0 006 in 3rd speed gearwheel 0 05 0 15mm 0 002 0 006 in Gear backlash all gears 0 05 0 20mm 0 002 0 008 in 0 05 0 20mm 0 002 0 008 in Oeara...

Page 63: ... bolt head with Jj41b3 hamTMr 7 Lock pin 8 Rearcover 9 Ring gmr 10 Diff mounting member 1 J Bolt diff to diff mounting member T 6 0 to 80kKm 43 4 0 7 8 b ft 12 ShIlf pinion m1te 13 Thnl lWlJIJer 14 Pinion mate 15 17vust washer Adjust the backla h in pinion mate and ide gear or the clearance betwun thedifferential ctlSIand the rear fact ofridt gror to 0 1 to 0 2 mm 00039 0 0 0079 bv 16 16 Side ar 1...

Page 64: ...579 in Check the spider seal rings and replace them if necessary The radial backlash of the sleeve yoke splines to gearbox splines should not exceed 0 5mm 0002 in Renew the sleeve yoke if the figures are in excess of the specified value E Mount the shaft between the centres of a suitable fixture and use a dial gauge to check that the run out of the shaft does not exceed 0 6mm 0 024 in at the centr...

Page 65: ... Removing the side flange Fig G S Removing the side retainer Fig G 6 Removing the differential cage snl530000 r f Fig G 7 Removing the driye pinion nut Fig G B Removing the differential side bearing Fig G 9 Removing the drive flange FIg G IO Removing the gear canier side flange 64 ...

Page 66: ...the vehicle Front oil seal Drain the oil from the differential unit and jack up the vehicle at the rear Remove the propeller shaft from the differential flange Disconnect the handbrake left hand rear cable Slacken and remove the drive pinion nuts whilst holding the drive flange with a suitable wrench or special tool ST 31530000 Withdraw the drive flange with a conventional two l arm puller as show...

Page 67: ... J 6 Pillion bt flrillgadjusti lg s Jtu er fl i Ji l I I J lJ i V r IHei t giluge I lST31210c 0 l B I 0QJ DUrnmYPinlOn Drive pinion collar lST3121QOCX f 1 L r IST315000001 Dummvspacer ST318500001 I Fig G ll Measuring the clearance between the differential side gear and thrust washer Fig G t3 Drive pinion markings Fig G 14 Adjusting the pinion height 1 Fig G t5 Adjustment diagram for the dif feren ...

Page 68: ... and shims between the rear bearing cone and the drive pinion Install the setting gauge 5T 31210000 on the carrier with the dummy pinion installed Sce Fig G 14 Measure the clearance between the head of the dummy shaft and the tip of the setting g wge using a feeler gauge as shown in Fig G 15 The clearance is also shown at the point T in Fig G 14 The required thickness of the adj lsting washer can ...

Page 69: ...s V 1 tj l fl4j P ff P tffST23510000 f S I l 1 rig G 22 Punching out the pinion shaft lock pin j Fig C 21 Removing the crownwheel bolts Fig C 23 Removing the drive pinion nut t 1 Fig G 24 Removing the pinion rear bearing inner race rig G 25 Checking the crownwheel for run out I u l o F Ice idth Ol 1 lction Ibvr ti 3 3S6 L i 1 Fig G 26 Drive pinion markings Estate cars Fig G 27 Standard pinion heig...

Page 70: ... contact pattern Check the backlash between the teeth of the crownwheel and pinion with a dial gauge Hold the drive pinion with one hand and move the crownwheel backwards and forwards to check that the backlash is Io ithin thL speL ified limits Shims and adjusting washers must bL altered if the tooth con tact pattern and backlash is incorre L the neL cssary details for these operations can be foun...

Page 71: ...ed by the figure on the pinion and the minus sign that it must b decreased To determine the thickness of the drive pinion shim press the front and rear bearing outer races into the carrier fit the 70 rear be ring and dummy shafr and place the Ippropriatt ettil1g gauge on the carrier See Fig C 2S l The fOllowing setting gaUges and dUlllmy shaft houlJ bt llsed for th various modds I OO and 1600 Esta...

Page 72: ... equals the figure marked on the left side bearing housing B equals the figure marked on the right side bearing housing C and 0 equals the figure marked on the differential case and E and F is the difference bctween the width of the side bearings and the standard bearing width H the figure marked on the crownwhcel Fig G 31 The following formulae can now be used to deter mine the required shim thic...

Page 73: ...uge Fig G JO Measuring the width of the side bearing under load j Fig G 32 Measuring the dimension between left and right hand bearing caps see text Fig G 3 Calculating the differential side bearing shims Af A A HEEL DRIVE HEEL COAST HEEL DRIVE HEEL COAST HEEL DRIVE HEEL COAST SIDE SIDE SlOE SIDE SIDE SIDE Fig G 33 Heel contact Fig G 34 Toe contact Fig G 35 Flank contact TOE TOE A A HEEL DRIVE HEE...

Page 74: ...Axial play of spider journal 0800 Axial play of spider journal 1400 and 1600 cc 0 Q2 mm 0 0008 in 0 08 mm 0 003 in Max run out of shaft Wear limit of spider diameter 0 6 mm 0 024 in 0 15 mm 0 006 in Permissible dynamic unbalance Two joint shaft Three joint sh lft 15 gr em 0 208 in oz at 4000 rpm 35 gr cm 0 5 in oz at 5800 rpm FINAL GEAR RATIOS 1800cc Saloon 6101 ISOOcc Estate Car 610 1800cc Van 61...

Page 75: ...ashers Saloon Estate Qearance between side gear and washer Saloon aearance between side gear and washer Estate 74 L09 1 27 mm 0 0429 0 0500 in in increments of 0 02 mm 0 0008 in 0 75 0 50 0 25 0 125 mm 0 0295 0 0197 0 0098 0 0049 in 2 31 2 59mm 0 0909 0 1020 in in increments of 0 02 mm 0 0008 in 56 20 57 20 mm 2 213 2 252 in in increments of 0 02 mm 0 0008 in 59 25 59 50 597Omm 2 338 2 343 2 358 i...

Page 76: ... replaced if the dimension A in FigH 4 is less than 5mm 0 2 in REAR AXLE SHAFTS BEARINGS AND SEALS Saloons DRNE SHAFTS REAR AXLE Removal Estate cars and Vans REAR SPRING Estate cars and Vans REAR SHOCK ABSORBERS Estate cars and Vans REAR SUSPENSION Installation Saloons Installation is a reversal of the removal procedures noting the following points Ensure that the suspension member and differentia...

Page 77: ...Iii I 1 V 1 A 3 1DiffomtiDJ CtUTio 2 R I1 u eazu I 1 3 L ll Sf11inI 4 Shock abJOriJer FJ8 H 2 Rear r utate cars and Vans FJ8 H 4 OIecking the mounting insulators wn 0 6 t iO T t 1Vt1 1 j J3 J 111 1 Q i n f I 1 I J 0 J I I I 0 l 5 i 1 a c u T 11 0 to lS Oq m 80 to 108 ft lb J iI Front 20mm 1 200 mm O 787 n 041 2 in1 410mm 16 1 n Di member CD T 7 0 to 10 0 q m 51 to 72 ft lb T 20 0 to 30 0 kg m 145 ...

Page 78: ...r mounting sn 060001 FIg H 9 Removing the rear wheel bearing nut 0 Fig H t0 Removing the sU ipension ann I 4 J l To Fig H l1 Removing the suspension arm bush Fig H 12 Removing the wheel bearing nut f jY FI l H 13 Removing the rear axle shaft Fig H 14 Removing the oil seaJ and inner bearing 77 ...

Page 79: ...jounvzl 11 F1mrge yoke 12 0U 1 1J N dk bctrri1w 4 Smp ring fig H 17 Exploded view of the drive shaft I r mrG 1JJNf Apply grease in thi Fig RI9 Section through the drive shaft Fig B 21 Removing the locknuts and U Bolts 78 Shock absorber lower mounting Bearing housing u mark Dinancc piece mart j L2 AXLE HOUSING DISTANCE PIECE fig H l6 Installing the suspension ann lee text fig H l8 Measuring the dri...

Page 80: ...tainer and withdraw the outer bearing with a conventional puller DO NOT reuse this outer bearing REAR AXLE SHAFTS BEARINGS AND SEALS Saloon Assembly and Installation Oleck the axle shaft for straightness make sure that it is not cracked or damaged in any way 00 NOT heat the shaft if attempting to re straighten Make sure that the lip of the oil seal is not damaged or distorted Check the bearing for...

Page 81: ... H 23 Removing the 10 shock absorb attaclunent F H 22 Measuring the axl o shaft end float R 0 tJ j 8 1J o fT jJ J F H 24 Removing the shock absor upper attachment Fig H 25 Disconnectins the shock absor and rear spring U bolts fI fJ o SO Fia H 26 Rear spring shackle 80 ...

Page 82: ...Remove the brake backplate and withdraw the gear carrier from the axle case Check the axle shafts for straightness wear and cracks 00 NOT attempt to straighten a bent shaft by heating Check the oil seal lips for signs of damage or distortion Make sure that the bearing is not worn or damaged REAR AXLE Assembly and Installation Assembly is a reversal of the removal procedure noting the following poi...

Page 83: ...b 21 39 kg 46 86 lb SHOCK ABSORBERS Estate cars and Vans 1400 and 1600cc estate cars and rigid axle sedan Piston diameter 2S mm 0 984 in Stroke 205 mm 8 071 in Max length 518 mm 20 39 in Damping force at 0 3 in see Estate cars Expansion Compression Damping force at 0 3m jsec Sedan Expansion Compression 1400 and 1600 cc Piston diameter Piston diameter Hard suspension Stroke Max length Damping force...

Page 84: ...he lip of the grease seal with the same type of grease Lightly smear the spindle shaft and threads the bearing washer and bearing lock SPRING AND STRUT ASSEMBLY TRANSVERSE LINK AND LOWER BALL JOINT FRONT WHEEL ALIGNMENT ADJUSTING THE STEERING ANGLE nut with grease and assemble the parts onto the wheel spindle Make sure that dirt and foreign matter does not adhere to the greased surfaces Adjust the...

Page 85: ... Inner race surfaa 7 Outer race fitted surfacr A W 8 Outer race ruTfa Q l 9 Ro JerrolJing surface w 1a Inner race IJ wrgecolltu j 12 Supporter 1 8 J 4 Checking the wheel bearing assemblies 84 Frg J l Front axle and suspension assembly h P J 9 1 Fig J 3 Removing the wheel bearing outer race Fig J 5 Front wheel hub greasing points ...

Page 86: ...he strut nter i Fig J 7 Removing the tension rod Fig J 9 Removing the strut to knucke arm bolts Fig J 11 Suspension unit upper mountings 3 a t 1 8 7 Fig J 12 View of the front suspension unit 1 Selflocking nut 6 Oip 2 Suspension mounting insukltion 7 bit spring 3 Thrust bauing 8 Bumper TUb r 4 Upper s 7ing setJt 9 Strut assembly J Dust cover 85 ...

Page 87: ...points 0 if Fig J 17 Removing the link bush FiB J 16 Removing the transverse link 0 1 mm O039 n AI FiB J 19 Section through the lower ball joint FiB J 18 Section through the transverse link bush 1 r1 J I r 11 e 0 f F 8 J 20 Adjusting the toe in setting FiB J 21 Adjusting the steering angle 86 ...

Page 88: ...UT ASSEMBLY Dismantling and Assembly Care must be taken when dismantling the assembly to ensure that aU parts are maintained in a clean condition Clamp the suspension strut assembly in a vice and fit the special attachment ST 2770000 I to the lower end of the strut Prise offthe dust cover snap ring Use the coil spring compressor ST 35650001 to slightly compress the spring Remove the self locking n...

Page 89: ...that the distances from the transverse link collar ends are equal at both sides 88 Install the lower ball joint on the transverse link and tighten the installation bolt to a torque reading of 1 9 5kgm 14 18Ib ft Oean the knuckle arm and the ball joint stud install the knuckle arm on the ball joint and tighten the castle nut to a torque reading of 5 5 74 kgm 4o53Ib ft fit the cotterpin and bend it ...

Page 90: ... to 0 394 0 to 0 118 Sedan Hardtop Hard 2 1000 to 2030 45 to 2015 6020 to 7050 6 to 9 o to 3 Suspension 0 236 to 0 354 0 to 0 118 Standard 1000 to 2030 40 to 2010 6020 to 7050 6 to 9 o to 3 Suspension 0 236 to 0 354 0 to 0 118 LH Drive Sedan Hardtop Hard 2 55 to 1025 45 to 2015 6025 to 7055 5 to 8 I to 2 Suspension 0 197 to 0 315 0 004 to 0 079 Standard 1000 to 2030 45 to 2015 6020 to 7050 6 to 9 ...

Page 91: ... Piston rod dia mm in Cylinder inner dia mm in Damping force at piston 0 3 m s 108 ft s Expansion kg Ib Compression kg Ob Stroke mm in 90 54302 UO 100 50 8 2 0 20 0 787 30 I 181 40 88 2 25 55 1 178 7 01 COIL SPRINGS 12 mill 0 4 in 130 mm 5 I in 8 371 mm 04 61 in 386 mm 15 20 in 386 mm 15 20 in 354 mm 13 94 369 mm 14 52 in 185 mm 270 kg 729 in 560 lb 200 mm 270 kg 7 87 in 560 lb FRONT SUSPENSION UN...

Page 92: ...emove the cotterpin from the trunnion and detach the gearchange rod and selector rod from the change lever and selector lever STEERING GEAR Assembly and Adjustment COLLAPSIBLE STEERING COLLAPSIBLE STEERING Removal and Inspection COLLAPSIBLE STEERING Installation STEERING LINKAGE 6 Remove the bolts securing the steering gear housing to the car body Fig K 6 and pull the steering gear towards the eng...

Page 93: ...ler ann fit Fig K l The steering system components Fig K 3 Removing the steering wheel nut FIg K S Steering column cover plate 92 y AA 11 N E l I J Drop Urn 2 Centre tie rod J Outer tierod 4 Tie rod outer ocket 5 Ti rod inner rocket 6 ldkr arm auembly Fig K 2 The steering linkage component Fig KA Steering column upper attachment bolts Fig K 6 Removing the steering gear mounting bolts ...

Page 94: ... and B Check the sector shaft and steering column shaft serrations for wear Renew the parts as necessary STEERING GEAR Assembly and Adjustment Grease the lip of the oil seal and press it into the housing Insert the column assembly into the column jacket and fit the worm bearing shims to the gear housing Install the flange securing bolts and tighten them to a torque reading of 1 8 2 5 kgm 13 18lb f...

Page 95: ...aft F 8 K 13 The coUapsible steering assembly 1 Upper bmrins 7 Lower jacket tube 2 UPIX jacket shaft 8 Lower jacket tu flange 3 Steering post clamp 9 Lower aring 4 Upper jacket tube J 0 Rubber coupling 5 Sled ball II blumn dU31 cover 6 LoWf 1 jacket shaft ig K ll Checking the steering gear bacldah Fig K 12 Adjusting the steering gear baclda h l7 h 2 6 5 I J r j 1 L1lI11 T1 e tQj L J II tL L I D 11...

Page 96: ... as it collapses COLLAPSffiLE STEERING Removal and Inspection Steering Wheel I Disconnect the battery earth cable 2 Disconnect the horn wiring and remove the horn pad 3 Remove the steering wheel nut using the special puller ST 27180000 Eig K 15 Remove the column shell covers Fig K 16 and the turn signal switch assembly Column shaft 4 Remove the cotter pin and detach the shift rod Automatic Transmi...

Page 97: ... ube 2 Column clamp Fig K 19 Steering lock installation Fig K 18 The standard dimension between coluDDl clamp and lower jacket J A 6 c V 1 Rubbt r coupling 2 Steen column 3 Worm 1 4 Dash ptmd 5 ColUmrl 3hDf 6 Colli clamp 7 Lowtr jacket flangt FIg K 20 Installing tbe steering column assembly 96 f ftb Fig K 21 The outer tie rod ball joint I I t I Fig K 22 The centre tie rod ball joint ...

Page 98: ...the bushing protrudes equally at both sides Fit the idler arm body in the rubber bushing Ensure that the centre line of the idler arm is parallel with the centre line of the chassis Installation is a reversal of the removal procedure The outer tie rods must be set so that the lengths between the ball stud centres are 309 5 mm 12 18 in for the 1400 and 1600cc models and 313 2 mm 12 33 in for the 18...

Page 99: ... Primary piston 7 uvd gau Fl L I Tandem master cylinder level gauge on SSS models only Fig L2 Section through the single master cylinder I Independent axle Rigid axle Fig L 3 Layout of brake lines with tandem master cylinder A Ji I I f tf A1 r Fig L 4 Section through the brake warning light switch Fl L 5 View of the front drum brake 98 ...

Page 100: ...0 006 in REAR DRUM BRAKE Adjusting FRONT DISC BRAKE Friction pads FRONT DISC BRAKE Removal and Dismantling FRONT DISC BRAKE Assembly and Installation HANDBRAKE Removal and Installation BLEEDING THE HYDRAULIC SYSTEM BRAKE PEDAL ADJUSTMENT Check the return springs for damage or lossof tension Replace any part which is in an unsatisfactory condition MASfER CYLINDER Assembly and Installation Assembly ...

Page 101: ...Broke rim Return Print J rhoe cmembly 4 Front wM 1 cylinder 5 RearwMtl cylindu 6 A iT bleed W o 1 Fig L I0 Rear drum brake components 1 BllIke ckp tzrc 2 RthUn spring 3 Brate ad JlSkr 4 Front brake h 5 Anti rottk pin 6 Lever 7 Wheel cylinder 8 Return sprins 9 Air bleed JCrew 10 Lockp orc 11 Lockp tzrc 12 Lockplizte 13 Dust cover 14 Rt t1T brake droe Fig L II View of the rear drum brake I Broke 3Iw...

Page 102: ...s of the cylinder should be dipped in brake fluid and assembled whilst still wet Install the wheel cylinders on the brake backplate and smear the cylinder backplate and cylinder lever fulcrum with grease Fig L8 Tighten the backplate mounting bolts to a torque reading of 2 7 3 7 kgm 19 5 26 71b ft Adjust the brake shoes and bleed the hydraulic system as described under the appropriate headings REAR...

Page 103: ...LI7 Removing the brake pad 102 Al g b5m tts t td Fig L 14 Front disc brake components 1 Retainer 2 Wiper It tZI J Paton seal 4 PiJton 5 Hold downpin 6 S 7 Support bracket 8 Ollliper plate 9 Clip 10 Bleed sarw 11 Cylinder 12 Tension spring 13 Brake pad 14 MountinK bmcket 1 5 Pi lOtpin Fig L t 6 Moving the piston Fig L IS Removing the brake calliper ...

Page 104: ...g the brake calliper to the knuckle flange and remove the calliper assembly Fig L IS 4 Remove the hub nut and withdraw the hub and disc To dismantle the calliper remove the anti rattle clip and withdraw the brake pads Remove the tension springs and pull the cylinder out of the calliper Blow out the piston with com pressed air applied at the brake hose connection Oean the components in brake fluid ...

Page 105: ... J I Aj Fran able Rear cable L I r f 7 n t i Adjust position A Fig L 22 Handbrake linkage 1400 and 1600 c c Estate cars 1 Control sUm 2 Control ratchet Xing 3 O mtrol ratchet 4 O mtro guide 5 Control bracket 6 OJntrol yoke 7 wer spring 8 Control lever Fig L23 Handbrake linkage 1800 c c models 104 able s Fig L 19 Checking the brake disc for run out 1 j v fti r v r Fig L20 As embling the piston seal...

Page 106: ...lation Check the cables for signs of deterioration fraying etc Examine the handbrake lever and ratchet for wear and renew as necessry Check the springs for evidence of weakness and make sure that the balance lever and bushes are satisfactory Installation is a reversal of the removal procedure Make sure that all sliding parts are greased Adjust the hand brake in the following manner Release the han...

Page 107: ... 7 I i 1 i 1 0 1 e V O V I r r if1 1i cl t JiY a t 3 F ll L 28 Rear cable layout 1800 C c SatOOWl ok pedat height H 87 mm 7 362 in 202 mm 7 953 ill Jltznual transmission AutomItic transmission y Brake pedal fullstroke L 141 0149 mm 5 55 to 5 86 in Brake pedal p tJv P 5 to 15 mm 0 2 to 0 6 ilL Fig L 31 Brake pedal adjWltment 1400 and 1600 c c models l car Ll 1 f 1 J 111 I l j u n l 71 t i1 Unit mfl...

Page 108: ... a pedal free play of I 5mm 0 04 D 2in is obtained then retighten the locknut Depress the brake pedal several times to make sure that a full travel of 145mm 5 7 in is available and that the pedal moves freely and without noise Technical Data BRAKE PEDAL Pedal height 1400 and 1600cc models I 87mm 7362in manual gearbox 202mm 7 953in auto matic 185mm 7 28in 145mm 5 71 in 1800cc models Full stroke MAS...

Page 109: ...rive mil Nackt 3 DultCOPD 4 E mmtle r 5 Aut mzl 6 Solmoid mlch 7 Arm zturr 8 Thnut 9 IJriv mil blllckt bush 10 17uust WdSMr 11 Stop washer 12 CiTc ip 13 PirUon srap collar 14 Pinion IS IWfni1l6 clutch 16 Field coil 17 Yok 18 Politive brwh 19 N J1iP bnuh 20 Bnuh rprinK 21 Brullr holder 22 Bearing bwh 23 Rmr COJIU 24 Through botrr FIg M 5 Yoke assembly removed Fill M 4 Solenoid switch 1 108 Fig M 6 ...

Page 110: ... 200C Conversely 0 0035 must be deducted for every SOC below 200C Test each cell separately and draw the liquid into the hydrometer several times if a built in thermometer type is used The correct specific gravity readings should be as follows ALTERNATOR Assembly and Installation HEADLAMPS Replacing HORN INSTRUMENT PANEL Removal WINDSCREEN WIPERS WINDSCREEN WASHERS IGNITION SWITCH AND STEERING LOC...

Page 111: ...g the field coils for continuity 5 y SERIES COIL 5 r SHUNT COIL Fig M 13 Testing the solenoid witch 10 J Fig M 8 Checking the brush pring tension Fig M lO Checking the armature shaft for run out J I I J I L j J j Fig M 12 Testing the field coils for earthing 1 rl wr vE L DIMENSION 131 7 to 32 3mm 1 248 to 1 272 in I Adjus llUt 2 PluJlKeradjuster F 8 M 14 Measuring the gap between pinion and pinion...

Page 112: ...that they are flush with the end of the case and reamed ou t to give a clearance of 0 03 0 10 mm 0 0012 0 0039 in H Solenoid assembly Inspect the solenoid contact surface and replaceif showing signs of wear or roughness Replace the pinion sleeve spring if weakened Check the series coil by connecting an 8 12 volt supply between the Sand M terminals as shown in Fig M 13 The series coil is normal if ...

Page 113: ...ng the front and rear covers t 112 FJ8 M 17 Removing the brush bolder 1 PuOey assembly 2 Front CCJVU 3 Front bearing 4 Rotor 5 Rear betrrint 6 Stator 7 RetlTcoPO 8 8 h assembly 9 Diode ph 10 Diode COPO 1lI81 11 Throughbolt i Fig M l6Tbe altematorc Is it4 1ttDr lOa Fig M 19 Removing the rotor from me front cover ...

Page 114: ...tor for conduction Fig M 25 Inspecting the positive diodes inteN Il1JIi OJaIlir J Fig M lI Testing the rotor coils for conduction Fig M ll Testing the rotor coils for earthing Fig M 24 Testing the stator for earthing TERMINAL OPLATE Fig M 26 Inspecting the negative diodes 113 ...

Page 115: ...o SA HO N SWITCH 1 VOLTMETER 115 to 2OV I I Fig M 31 Testing and adjusting the horn 114 J GJ Fig M 28 Tightening the puUey nut HORN RELAY L IBGIGY tt t e q HO N r FUSIBLE LINK IO e5 REO FUS E BOX 20A El Sl I 10 STOP LAMP SWITCH HORN eu TTON eATT RY Fig M JO Circuitdiagram for the horn system Fig M 32 Adjusting the horn volume and tone ...

Page 116: ...ld be 255 345 grammes 9 0 12 2 oz the pressure will however decrease by approxi mately 20 grammes per I amm 0 039 in of wear ALTERNATOR Assembly and Installation Asssembly is a reversal of the dismantling prQcedure noting the following points The stator coil lead wires must be resoldered to the diode assembly terminal as quickly as possible or the diodes may be damaged When installing the diode A ...

Page 117: ...WITCH FUSE BOX IDA 0 W ACC r WIPER SWITCH P I 2 W I X 9 LWI t j LR Fig M 36 Circuit diagram for the windshield wipers and washer Fig M 35 Removing the wiper arm 116 Fig M 34 Wiper motor and linkage 1 Wiper arm 2 Pivot 3 Wiper ann 4 Pirot 5 WiTNr motor f Fig M 37 Steering lock installation 1 Steering lode cwmp 2 Self hear ty screw 3 Ignition switch 4 SUmng lock ...

Page 118: ...g M 36 the washers can be operated by turning the switch in the appropriate direction It should be pointed out that it is inadvisable to operate the washers for more than 30 seconds at a time If the washers are operated in short spells of approximately 10 seconds duration their working efficiency will remain unimpaired for a considerable length of time IGNITION SWITCH AND STEERING LOCK The steerin...

Page 119: ... I U iT J I I i i I m I 1111 I III i ll i l I r I lllr g I Q J lJ I l rp I 1J 19 11 6 I I 1 I i li I I R 111 ml f I II lI 11 W n Jj lilll I1IJllir im J1il j cfl I rL J I J tljt jjl t ilW I c i l J I Q 1 Q llLl I 1 1 f1r j I i IIlri 1 q Ju I t liOO I L f 11 rCD I I i I 1 ql i Wi c IF i I j Jk t r 2 s i l z ...

Page 120: ... jm cm H If r im r J i 1Hffi I IIII g ii r j e I 1 11 II IIJ I lJ r I J 1 loo l Iii 1IIIIr t Ia cm 1IIIlliilliW lj i J 4 I l o o a i ll I f r 1 i c5 IQrr if g fbr Ii I I 1T i l g o c I 0 dl ri1 I rrrc L I II i r L l v r1 I I III Vii 1J r M n II inter lliJ iYQ j2 I 0 E c 0 C 0 c j a E E 9 tl 2 l E t a iill 19 ...

Page 121: ...iiI 1 i rr i Wf I IWI I O tw 11 e d lTITllfI 0 J C IIII o i 1 ij jj i lL il tlriF i l OJ r AAfttt V o ii l W I I i P i f Lib fi p t p l lJll1 fTl II r JL 0 ol JJ1 it bBl1l1 C r It i 1r II rw o t r 1 U ii 0 It 3 1F 11 B u i t D t i I r E i iHi I 120 0 E 1 S 2 E E 0 ll c 0 2 2 1 ...

Page 122: ... llitJ ll 9 111 it b OJ l I 1ftJj ll I J I 1 III II I 1 10 I l i liJ i illw o g 1 OJ i 11J I j lli rm H t I i iJ H rc III jII fl ij J L ii I 11 I rr J I iEI l r r1 I 1 tt l w t Gl T1 b 1 fT l ILrEl 1 l i 1 I J 1111 1 11 l Il r r f ill IIIII1I I Lilli I JI r t l I J t1 l I IIIIIIII jl jd ll lil 11 H 1Iiii LJ LLbl L lQ JJ c j I I 1 W JrSi I l JI J 1 J I Q lJ j J II I iT i I j 0 1 il ll 1 to rr j h i...

Page 123: ...II I 0 L t I rf 1 I I I ill rtnJ I i l ll i Lo l tIli1Illll t r Ll li m nnmmiIIlIlHlIH II 8 I F Jfrr illillb t L i Uifflt1ir L Ifi 1 J X Irrt I Ul IS 1 f iEm 1 tlr I fi 1 l ffil11 h I I I W A j l I I y f 3Jkl r D l i ii Ci tl j i 1 0 1 II J g 81 gh i J i 122 c E ii ...

Page 124: ...interl DB j illfjl c 0 E 0 S 3 A 0 a J 5 11 l E e 1 1 t c g illJI l fl g i i c o ia i I 8 iiia 5ji 9 18 a 12 ...

Page 125: ...1 3 III 1i ITIII II F ill II L I I i J Ll I l 5 II iiirt Ii I Iiij I I L 1I11II I h I im I 1 I I 1111 1 1 1l1 I I L lr IIi B llli mg e m li Hij tiiQlJr 0 11111 IIIJ Hillll 11 llli t rQhoei 1 0 11 i e lIi II e 0 i Jig i I Ii i g I lFCJ E I I J b II I 1 1 III II 0 D ii ii r i li 11 1 mf ji ill ili 7 e LJJ I III r 10 t I S l I I I i I III l i j 8 1 i if i 124 ...

Page 126: ...ow yaJYe dcffe WO n oil pump J Dlmllfd om maUl Ind or bl nd b lnnll l lncorreCllndeofentpneoill Oil level 10 m Oillevel tnnhllh Oillelk the preuunled Ilde of the lubn IYSfem p Tldc Rel1 f1nd yllOde1 ne OVCntZl nd nnJ b Rcpltte v lve and Iltd c Repl cc 5c l d Sullu rt pl cp aI kCl e Trice Ind rtClify f heel lod replace if nccess T RemoYcblQChJCh Chcck Ind repllcclfncct i ry i Repll e rump J Renew n...

Page 127: ...fne rl EllImlne and Oillpllln ly p Cheek Ind rectlly q aepllccddectkol plnl r Chlnp comct Il adl of fuel Fuel System ENGINE CRANKS 8lTf DOES NOT START ENGINE STARTS BUT RUNS FOR SHORT PERIODS ONLY ENGINE MISARES AT LOW SPEED ENGINE MISflRE5 AT HIGH SPEED ENGINE MISFIRES AT ALL SPEEDS ENGINE MISAKES ON ACCELERA110N AND FAILS TO REV ROUGH IDLE ENGINE RUNS ROUGH AT HIGH SPEED LACK OF POWER POOR ACCEL...

Page 128: ...USE I Adj t IinbF tI Replace elutchdlK c CIUlllnd l eIlIedy CIII d ae prln lInSl llem f AdJ t tnweL Niju st gII It Irom put lLaealipllReIl CIU gfbUadiJll j aepllC t1utdl dK 11 Pit ne puta 1 lI epla c m TIk lIp pia ae dK aepl cellub p Reiin b 4 Strlilhtenorf To I p hy4rw1k ftuid Tyre pnlUUI1IIlncoo ct or un no b Lec1l oIJ l brk l ltlnltlt r Co uck oflubric t1on t t lU IliDt p ball Joillta 4 Inc t M...

Page 129: ... J 5 i l 7 O 10 l H g a c G c t 01 JIll z I Oz V z J i lJ 0 z z iS i l ttr u So lZ aII I v i n iH 1i 1 i t lto l s u Ot 58 T sfl t i t i ii i t i O li J i i e P 3 o 1 P E a Ii i Q i g t Q 11 a 5 oc D j ll g g l S B oS 0 1 p oj Of i i fi e o d8 e 1 po t t g t 0 Q Q u aliD 3 c ci E g t if l OfJ e v i ll 9 M1Ol l t l lt i l c o G lo I 6 g lo I Gl z l ca VI 1 t i5 l ia a a i i i il i t 1 c t 0 5 H 1 H...

Page 130: ... Ll6 Ll8 2 4 2 6kgm 174 18 8 Ib ft 16 2 2 kgm 12 16Ib fl PROPELLER SHAFf AND DIFFERENTIAL GEARBOX 17 20kgm l22 145IbJI 14 17 kgm 101 123Ib ft 13 20 kgm 94 145Ib fI Drive pinion nuts Saloon Drive pinion nuts Estate car Drive pinion nuts Van Ll4 and L16 engines Three speed Gearbox Rear extension to case bolts 2 8 4 4 kgm 20 32lb ft Gearbox 10 engine 2 5 4 0 kgm 18 29Ib fI Bnttom cover L1 17 kgm 8 0 ...

Page 131: ...e ca1liper bolts 7 3 9 9 kgm 52 8 71 6 Ib ft Brake disc bolts 3 9 5 3 kgm 28 381b ft Stabilizer bolts suspension armside 1 2 I 7kgm 8 7 12 3 Ib ft 130 Tension rod to frame Tension rod to transverse link Strut assembly upper nuts Steering lever to strut Ball joint to transverse link Ball joint to knuckle ann Piston rod nut Gland packing 1400 and 1600 CC models Flange mounting bolts Bali stud nut Ge...

Page 132: ... FUEL SYSTEM FRONT SUSPENSION STEERING BRAKING SYSTEM TIGhlGJ u GTORQUES SI S2 SI7 S22 S30 S36 IntroductIon This supplement has been added to include Series C 30 model with the G 18 engine Main changes only are detailed in the following pages and for aU other information please CI to the Manual s parent sections SI ...

Page 133: ...e nstatlstion 8 15 mm 0 3150 0 5906 1 i 1 1 1 Fig A 3 Remo Ying the canuohaft sprocket Fig A 1 Front mounting insulator f A J A 0 0 L I o i r 1 m if 0 1 l r t I IJ t o ll gf Ii o unted Vi 6 mm10 2362 1 t more than 6 mrn 0 2362 in Fig A 2 Rear mounting insulator Fig A 4 Removing the cylinder head 52 ...

Page 134: ... alternator thennal EngIne OIL PUMP OIL PRESSURE RELIEF VALVE OIL FILTER EMISSION CONTROL SYSTEM IGNITION TIMING AND IDLING SPEED Emission control system EMISSION CONTROL SYSTEM Maintenance IGNITION SYSTEM IGNITION TIMING IGNITION DISTRIBUTOR Maintenance SPARKING PLUGS transmitter the primary side of the distributor oil pressure switch starter motor and reverse light switch 7 Remove the clutch sla...

Page 135: ...t l Fig A7 Measuring the ctankshaft journals and crankpins FigA g Removing the main drive shaft pilot hearing 16mm 0236 in PILOT BEARING Apply grease FigA 9 Fitting the main drive shaftpilot hearing Fig A 11 Camshaft and camshaft bracket alignment marl s i IRScIItIon Olrllole ton front r or tM rocbr ft IIWI e No a I j OIM kImIII roa lIfIaft oiIl 1or nshclwn in tM fil In Fig A lO the rocker shaft a...

Page 136: ...e cam bracket will fall from the rocker ann shaft when it is removed Remove the valve cotters using the special tool ST47450000 and dismantle the valve assemblies Keep the parts together so they can be installed in their original order ENGINE Inspection and Overhaul Cylinder head and valves Inspection and overhaul procedures can be carried out by following the instructions previously given for the...

Page 137: ...linder block oil se l Apply liquid packing he e Fig A IS Rear be ring cap 9 3 6 8 r r Q iigJtJl f it I 1 f l O 2 1 lJ O j 0 i4i Front o 7 5 2 4 10 FigA 16 Connecting rod caps and lock wIshers Fig A 18 Cylinder head boils lightening sequence Fig A 19 Imta1ling the ignition distn1 utOT note the position of rotOf 56 Fig A 20 Tensioning the oil pump drive dlain ...

Page 138: ...the side clearance of the rings in the ring grooves and check the piston ring gaps as previously described for the L14 Ll6 and Ll8 engines Compare the figures obtained with those given in the tables opposite Side clearance in grooves Top ring Second ring Oil ring Standard 0 040 08 mm 0 0016 0031 in 0 02 0 06 mm 0 0008 0 0024 in 0 02 0 06 mm 0 0008 0 0024 in Limit LO mm 0 0039 in LO mm 0 0039 in LO...

Page 139: ...T TIMING MARK AOJUSTING SCREW OIL JET CHA N GU DE CRANK SPROCKET Fi3 A17 TiminS Jsm Ai m I Jjr c rtIuNtor t 1 I I II I Y uum ing Ii Antlb cktire ChedC s p cialellibnt8d AI llJ ion nOzzle Fig A 23 Details of the exhaust emission control system 58 ...

Page 140: ...ance with the cylinder numbers Heat the piston to a temperature of 500 to 600 1220 to 1400F and press the gudgeon pin in by hand The pistons and connecting rods must be assembled as shown in Fig A 12 with the arrow mark on the head of the piston pointing to the front of the engine Fit new clips to both ends of the gudgeon pins as indicated in Fig A 13 Fit the piston rings with the marks facing upw...

Page 141: ...retor ir cleaner I 7 Control aln Ialiable orifice alve Fig A 21 Section through the pressure relief valve DiIIchqe w Fig A 22 Details of the positive crankcase ventilation system I Bal Ifttrk ion orif c Fig A 2S Sectional view of antibackCue valve Fig A 26 Adjusting the ignition timing and idling speed mixture emission control system 510 ...

Page 142: ...te sections VALVE CLEARANCES Adjusting The valves clearances can be adjusted in a similar manner to the instructions given for the L14 LI6 L18 engines Initially adjust the clearances with the engine switched offand cold to 0 2 mm 0 0079 in for both intake and exhaust valves Set the final clearances to 0 28 mm 0 011 in for both intake and exhaust valves with the engine warmed up to its normal opera...

Page 143: ...in the intake manifold is too rich to bum and ignites as it combines with air injected by the pump The valve shuts off the air delivered SI2 to the exhaust system during the flrstpredetennined period of dCl cleration and prevents back firing from occuring To check valve is located between the air pump and air injection nozzle and is fitted to prevent a backflow of exhaust gases from entering the s...

Page 144: ...ontact breaker points Check the ignition timing and adjust if necessary The distributor dwell angle should be adjusted to 49 55 degrees and the points gap to 0 45 0 55 mm 0 0177 0 0217 in 3 Remove and clean the sparking plugs Renew any plug with badly worn electrodes Set the plug gaps to 0 80 0 90 mm 0 0315 0 0355 in by adjusting the earth electrode IGNITION SYSTEM The maintenance and servicing pr...

Page 145: ... 457 in Inner 34 0 mm 1 339 in Valve spring effective wind number Outer 4 5mm 0 1772 in Inner 6 25 mm 0 2461 in Valve spring wire diameter Outer 4 2mm 0 1654 in Inner 29mm 0 1142 in Valve spring coil diameter Outer 27 5 mm 1 083 in Inner 19 9mm 0 733 in Valve guide length In 48mm 1 890 in Ex 60mm 2 362 in Valve guide height from cylinder head In Ex 16 7mm 0 657 in Valve guide inner diameter In Ex ...

Page 146: ... 997 mm 48 975 48 991 mm 0 081 0 0786 in I 928 1929 in Bearing size S T D 25 U S 50 U S 75 U S d Crankshaft and main bearing Wear limit of ditto clearance Crank pin taper and out of round Main bearing clearance Less than 0 01 mm 0 060 0 192 mm 0 0024 0 0008 in 0 3mm Less than 0 01 mm 0 03 0 06 mm 0 0012 0 0024 in 10mm 0 0004 in Journal taper and out of round Crankshaft free end play 0 0118 in 0 00...

Page 147: ...cond 0 01 0 0004 2 0 03 mm 0 0787 0 0012 in Oil 0 Q1 0 0004 4 0 03mm 0 I575 0 0012in Ring height Piston pin interferenl c fit of piston pin to piston o 0 09 mm 0 0 0035 in 0 003 0 013 mm 0 0001 0 0005 in Clearance between piston pin a connecting rod bushing Piston pin outer diameter 21 991 22 0 mm 0 8658 0 8661 in Connecting rod bushing inner diameter 21995 22 008 mm 0 8659 0 8664 in EMISSION CONT...

Page 148: ... Spark gap Primary resistance Secondary resistance SPARKING PLUGS Type Gap Fuel Systenl DESCRIPTION FUEL PUMP Testing FUEL PUMP Removing and Dismantling CARBURETTOR Idling adjustment FUEL LEVEL Adjusting STARTING INTERLOCK VALVE OPENING THROTTLE VALVE INTERLOCK OPENING CARBURETIOR Removing and Dismantling DESCRIPTION A dual barrel down draught type carburettor is fitted to vehicles with the G 18 e...

Page 149: ...pump SI8 A It I IL o l Cfd rj 1 l o j 11 111 r J l l b I 1 1 F700t vahle 2 Vacuum piJton 3 P Slow air bleed 4 Slowjtt 5 Slow onomUt T 6 P Slowair bleM 7 Air Fent 8 PMainair bl d 9 P MiJin nozzle 10 P SmaU venturi 1 J Ozokt valPe 12 Pumpnozzk 13 Pump wd6h1 14 Discharft check valve 15 S SnwU venturi 17 S Mainair bleed 18 Stepair bleed 19 Pumparm Fig B 2 Sectional view of the D3034C carburet tor fitt...

Page 150: ...e the bolts attaching the fuel pump cover to the floor panel see Fig B S Remove the bolts attaching the pump to the cover 2 Disconnect the cable and fuel hoses Withdraw the pump Dismantle as follows Slacken the locking band screws and remove the strainer strainer spring filter strainer seal and locking band Remove the snap ring Withdraw the four screws from the yoke and remove the electromagnetic ...

Page 151: ...I J Th 1 Chokemr r 2 Otoke m LuL 3 Conn ting rod 4 Connectinllao 5 TIuottle lever Fig B S Adjusting the starting interlock opening 6 O 1 Co1UJeCdrlK lev 2 Rerum plate 3 Adiust pWe 4 17rrottle clrzmber 5 Throttle valve 1 S Throttle arm 2 S Throttle ntum lever 3 Link 4 P1lIrortle tml 5 P 1lIro lle valve l I 4 J L 5 iF l 1 L Fig B 9 Adjusting the throttle valve interlock opening OAK340 carburettor Fi...

Page 152: ... and withdraw the piston piston return spring and inlet valve Remove the primary main air bleed the secondary main air bleed and emulsion tube Take off the small venturi and remove the primary and secondary slow jets and slow air bleeds Remove the drain plugs and take out the primary and secondary main jets To dismantle the throttle chamber remove the throttle adjusting screw and spring and the id...

Page 153: ...i L St Ting wheel 2 Steering column maft J Rubb rCOfl linK 4 Sturing lowerjoint 5 Strinuotlr IwusUr8 6 Sid rod XlI Fig C 1 Front suspension assembly FigC2 The steering gear iQ r y y v I Ii 1 1 Fig C3 Collapsible steering Fig C 4 Disconnecting the brake hose I f41 I I th I t t Il t k I Fig C 5 Removing the front hub and brake disc Fig C 6 Detaching the brake disc 522 ...

Page 154: ...nt of the suspension is controlled by the strut assembly Forward and rearward movement is absorbed by compression rods 6 and side movement controlled by the transverse links Front suspension servicing procedures are similar to those given for vehicle fitted with L14 Ll6 and LIB engines and can be carried out by reference to the instructions given in the appropriate section Camber and castor angles...

Page 155: ...emofing the stabilizer Fig C t0 View of the front sospension Fig C 13 Adjusting the toe in 524 FRONT l I I I REAR Fig C 9 Section through the transverse link bush r I r Fig C t 1 Supporting the engine fig el2 Removing the suspension member Fig C 14 Removing the rubber coupling bolts R H D ...

Page 156: ... less than 1 0 mm 0 039 in Replace the bushes if necessary The lower ball joint should be replaced if the axial play of the joint exceeds 0 03 to 0 6 mm 0 0012 to 0 0136 in A grease nipple must be installed in place of the ball joint plug so that the joint can be lubricated with multi purpose grease as previously described SUSPENSION MEMBER Removing and Installing Jack up the vehicle and support i...

Page 157: ...FiJILr p1u 1a Steering gear boot 11 Locknut 12 Sid rodinmr f1fUtl 13 Side rod 5 Jring seat 4 Inner socket 15 Sid rod baD stud 16 DustceJVqclomp 1 Z Side rod assembly 7 5 2 Fig Cl6 9 The rack and pinion with tierod I 1 il1 W y o Ol l r I J I t4 I J Z i I i r t I 1 Ball studmil 2 Knuckkamr 3 DultCOver 4 lll tud 5 Sid rod Fig C IS Tie rod ban stud 526 J 1 26 3 Windiameler 26mm al02in FfflI ngth J6 3 ...

Page 158: ... 0197 in for the outer joints Use a spring balance to check the force required to swing the ball joints this should be between 0 8 to LS kgm 5 8 to 10 8Ib ft Renew the oil seal Examine the retainer and tierod springs and compare them with the values given in Figs C20 and c n RACK AND PINION AND TIE ROD Assembling and Adjusting Press the bearing on to the pinion gear and fi t the tightest snap ring...

Page 159: ...nner socket stop nut S rod I p ing Boot Spring I Boot cl np Side rod 1 t I I Lock n rt 38 5n m 1 5115in Staaj xial p1 Y o l5errm 0 02 5in Fig C26 Measuring the torque required to swing the tierod Fig C 2 Section through the tierod ball joint Slila niversatjoint Punch mariflocated on upper nd of upper steering shaft Fig C28 Aligning the universal joint with upper steering shaft 528 ...

Page 160: ...arate the upper and lower tubes Assembly is a reversal of the dismantling procedure Note that the slot in the universal joint must be aligned with the punch mark at the top of the upper steering shaft as shown in Fig C 28 When installing the column make sure that the bellows do not become bent of twisted as the clamp and bottom plate bolts are tightened TechnICal Data TYP Gear I1ltio Rack and pini...

Page 161: ...8 Gtuket 9 b ynzJpa 10 Vah etpriIog 11 Valve Uflt 12 Stopper 1CTe W Components of the tandem master cylinder 13 Itukin8 U b y pbto A 15 PUlon cup 16 Cylbukr 17 Au y puto B 18 A yvoba tpriIog 19 1nktvahatprilog 20 PUlan cup 21 40 ypw rrod 22 Stopper rinr 23 Dwt coper Fig D Fig D 2 4 1 A Sy catft7a 2 Equalizu hmuJ broke J RB Tt lJ1 cab 4 AdiU3tt T cailk rmr 5 S 1TiIw retum 6 LH ntu Ofbk 7 Pirfulcrum...

Page 162: ...ion Refer to the section BRAKING SYSTEM for the Ll4 L16 and LIB engines for full details of the removal and installation procedures Check the thickness of the friction pads as previously described and replace them if necessary Check the brake disc for scoring and out of round The standard diSc thickness is 10 0 mm 0 394 in and must not be reground below 8 40 mm 0 331 in The run out of the disc sho...

Page 163: ...r 12 V4lveopt l t1tintrod 13 Vobe rdunuJNin8 14 lbppetmum Pri If 15 AiTvah e 16 RDut 17 Valve plunger 18 Reaction dUe 19 lJttp rrqmmum Pri If 20 Front s relJ IS Fig D Section through the MasterVac unit J Bralee rube A 2 Front COfIMctor 3 Bralee tube B 4 PreS lJ hOefront RH 5 Brake tube C 6 tubeD 7 Pressure hose front LH 8 2 wayconnector 9 Brake tube E 10 Rearconnector 11 Pressure hose rear R 12 Br...

Page 164: ...andbrake front cable Fig D 13 Removing the rear cable Jt A G L J CD I I I I I I I I I I 1 l I lSOt4 831 B Fig D S Adjusting the brnke pedal J Fig D 14 Adjusting the handbrake cable Fig D 16 Setting the brake light switch Fig D I7 Adjusting the rear brakes S33 ...

Page 165: ...val of the control stem is a straight forward opera tion Refer to FigD 12 and take out the clevis pin I connect ing the yoke 2 to the lever 3 Remove the clevis pin 4 secur ing the guide 5 to the bracket 6 then withdraw the control stem S34 Re lf rnble Remove the nut from the adjuster and disconnect the left hand rear cable Disconnect the rear cables from the wheel cylinders Refer to FigD 13 pull o...

Page 166: ...ng drum in dia Run out of the rotor Limit of reconditioning rotor in thickness 183 mm 7 2 in 150 4 mm 5 9 0 158 in 22 22 mm 7 8 in 19 05 mm 3 4 in Lining dimension Front width x thickness x length 0 13 mm 0 0051 in Rear width x thickness x length 50 8 mm 2 in 20 64 mm 13 16 in Material Pad width x thickness x length 0 18 mm 0 0709 in Pad material 228 6 mm 9 in 232 mm 9 130 in Total braking area Fr...

Page 167: ...g knuckle arm to strut assembly 6 0 8 0 kg m 43 4 57 8Ib ft Transverse link to suspension cross member fixing nut 12 2 13 5 kg m 88 2 87 6Ib ft S36 Lower ball joint to transverse link fixing nut Lower b JH joint stud nut Suspension aoss member mounting boils Engine mounting bracket bolts Piston rod self locking nut Gland packing Wheel nuts BRAKING SYSTEM Fulcrum pin of brake pedal Connection of br...

Page 168: ...eck Adjust CAR UP I l lletksumpbulttortM 1 Clled rque i6 ServiceJndclean J1 Adjult brake bandl tB RtnMsumpgal tt fiS Check llJmpbnlttort PROP lOAIVE SHAFT S Check lor wear JJ Tiglltenbolu Jl Check tor wear n Tiglltenboltl Clllckbootgeiltrl Clleckoperltion Ch CQmpon l welr Tighten bolts Clleclbootgaiterl Checktorqu Gheck edjult Clllck ljust CIIRCk adjult Clleck tighltnbolts W M KSI1 t heCklMliiili ...

Page 169: ...llcold c OUTlET m mm incbll mmJinc r dIgreer BIDC dIar BTDC n m RMer to Technical Data lYRES I STANDARD SIZE IFRDNT PRESSUREI REAR PflESSUm I OPTIONAl51ZE I FRONT PRESSURE I REAlI l lIESSUIE I BRAKES PrwaulWkWem2 p si Ilarmlll full narltlll full normalJfull nonnlllfull W1NIIIUIII TlUCKNEA SHOE mm in PAD Ref to Technical Data TEST lOAD I TOI IN iIlDUTlo l kO lbl front mmin CAIllBER delftlllmin CAST...

Page 170: ...link Side tube Steering connecting rod CLUTCH Steering column Steering gear shaft Clutch release bearing Throwout bearing Thrust bearing Steering column bearing Mast jacket bearing Clutch lining Disc facing Friction ring Steering arm Steering knuckle ann Spigot bearing Clutch pilot bearing Stator tube Control tube Clutch housing Bell housing Steering joints Steering knuckles GEARBOX BRAKES Gearbox...

Page 171: ... 3 0 I I M6m f1 o I 21 32 1 115 0 I GIIM nl llll 111 11 C lI1U 1 111 lUB7 5 11 4Gp1 o I o Xl313IJ 1 I 0 I 13132 011 15 1 R ln a I 7 Q J3ol38il BJll2o a 1 lI4 Q 75 1 0li0 o I 4 Q 78I5Ut ln I 25132 D 1I12S1UC31E I III D 7SIIlI lll MOll 0 II t CUlI 25 I 1 13 2 1 tOMbo o 1 D IM375 2U313 n 0 I 5III lo Q1I6D 1 13113 0 I ICUl15 122 225 Im a I 51 E21 bo O 1 IQ 1IIQ6Z n alM I o I 5IIe4 G nIMD 4I lSb2 D 115...

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Datsun 1300, Workshop Manual

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