Datsun 411 Series Service Manual Download Page 137

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Summary of Contents for 411 Series

Page 1: ...SERVICE MANUAL h o t o r co l t d T O K Y O J A P A N P N 9 9 9 9 9 20002 ...

Page 2: ...SERVICE MANUAL expert22 fl ia http rutracker org 1 NISSAN NISSAN HOTOft CO LTD H i W 0 T O K Y O J A P A N P N 99999 20002 ...

Page 3: ... S E R V I C E M A N U A L Hoeoe umx 3ah torrents ru I M S NISSAN NISSAN MOTOR CO LTD O T E M A C H I BLOG OTEMACHI CHIYODA KU T O K Y O J A P A N CABLE ADDRESS N I S M O T O K Y O PHONES 216 2311 expert22 http rutracker org ...

Page 4: ...e and maintenance of the Model P L 411 Each assembly of the major components is described in detail In addition comprehensive instructions are given for complete dismantl ing assembling and inspection of these assemblies It is emphasised that only genuine DATSUN Spare Parts should be used as replacements DATSUN MODEL L 411 U ...

Page 5: ...e 43 C L U T C H 48 T R A N S M I S S I O N 57 Cover of Transmission Case 58 Transmission Case 59 Extension of Transmission Case 65 Disassembly the Transmission Case For 4 Stage Floor Shift 72 CHASSIS ss FRONT AXLE 85 Disassembling the Front Hub 86 Indipendent Front Suspension 88 REAR AXLE 98 STEERING 112 BRAKE 119 Front Brake 120 Rear Brake 123 Hand Brake 126 E L E C T R I C A L S Y S T E M 129 A...

Page 6: ...DISMOUNTING ASSEMBLING ...

Page 7: ...ront Rear 1 198 mm 47 2 in 1 198 mm 47 2 in DIMENSIONS Min Road Clearance 175 mm 6 9 in 175 mm 6 9 in DIMENSIONS Overhang to the Front End without bumper S05 mm 23 8 in 605 mm 23 8 in DIMENSIONS Overhang to the Rear End without bumper 950 mm 37 4 in 947 mm 37 3 in WEIGHT Vehicle Weight 885 kg 1951 lb 960 kg 2116 lb WEIGHT Distribution Front Rear 505 kg 1113 lb 500 kg 1102 lb WEIGHT Distribution Fr...

Page 8: ...ATER FORCED CIRCULATION No of Cylinder Arrang 4 IN LINE Cycle 4 Combustion Chamer BATHTUB TYPE Valve Arrangement OVER HEAD VALVE Bore x Stroke 73 x 77 6 mm 2 874 x 3 055 in Displacement 1299 c c 79 27 cu in w y Compression Ratio 8 2 a o fc w Compression Pressure 11 5 350 kg cm2 r p m a o fc w Max Exploding Pressure 48 3600 kg cm2 r p m Max Mean Effective Press 9 7 28000 kg cm2 r p m Max B H P SAE ...

Page 9: ...ce Exhaust 0 35 mm 0 014 in Starting Method MAGNETIC STARTING SYSTEM K Type N41 14MZ N50 2SMB 1 each w H H Voltage 12V C Q Capacity 40 50 A H Ground Polarity NEGATIVE Type AC300 12WR Make MITSUBISHI K O H Generating Method ALTERNATOR 1 W Voltage 12V W O Capacity 300 W Voltage Regulator RL 2B1 K W H Type S114 92 K W H Make HITACHI H Voltage Power 12 1 4V HP S w H Irt K W Ignition Method BATTERY COI...

Page 10: ...m 0 551 in w Gap 0 7 0 8 mm 0 0275 0 0315 in s h J o Type D2630A 5A C O O Make NIHONKIKAKI w H C O H Throttle Valve Bore P 26 mm S 30 mm M S 3 o Venturi Size 20 mm 27 mm h 1 H h 1 Z Carburetor Main Jet 92 140 Ot Slow Jet 48 48 Pump Jet 45 Power Jet 40 Air Draught DOWN Air Cleaner Type No PAPER TYPE 1 each Air Cleaner Make TSUCHIYA Fuel Pump Type DIAPHRAGM Fuel Pump Make SHOWA KYOSAN Capacity of Fu...

Page 11: ...0 x 130 x 3 5 mm 7 87 x 5 12 x 0 138 in CLUTCH Total Friction Area 181 x 2 cm2 28 06 x 2 sq in CLUTCH In dia of Operating Cylinder 19 05 mm 3 4 in CLUTCH In dia of Master Cylinder 15 87 mm 5 8 in TRANSMISSION Type 3 FORWARD 1 REVERSE ALL SYNCHROMESHED ON FORWARD GEARS 4 FOREARD 1 REVERSE SYNCHROMESHED ON 2ND 3RD 4TH TRANSMISSION Gear Shift Method REMOTE CONTROL FLOOR SHIFT TRANSMISSION Oil Capacit...

Page 12: ...acity 0 33 0 087 U S gal Wheel Arrangement 2 FRONT 2 REAR W o H 1 W Q a Front Axle Type WISHBONE BALL JOINT TYPE W o H 1 W Q a Toe in 3 mm W o H 1 W Q a Camber 1 0 45 h H Caster 0 Inclination Angle of King Pin 6 15 Rear Axle Type SEMI FLOATING TYPE Type FRONT 2 LEADING REAR LEADING AND TRAILING Lining Dimension Width x Thickness x Length r 40 x 4 5 x 215 mm 1 575 x 0 177 x 8 465 in w Lining Dimens...

Page 13: ...dia of Drum 228 6 mm 9 0 in SUSPENSION Front Suspension Type INDEPENDENT SUSPENTION WITH COIL SPRING SUSPENSION Coil Wire dia x Coil dia x Free Length No of Coils R H CAR L H CAR 14 2 x 94 x f f f l f l 8 5 14 2 x 94 x 325 8 5 o 5 L SUSPENSION Rear Suspension Type LONGITUDINAL SEMI ELLIPTENG SPRING SUSPENSION Spring Size Length x Width x Thickness No 6 2 1200 x 60 x c 5 2 1200 x 60 x 6 l 5 Z SUSPE...

Page 14: ...DATSUN 8 ...

Page 15: ...ed ratio 1 000 4th speed ratio Gross vehicle weight 1 160 kg Max grade ability tan 0 0 382 sm0 O 357 Tire effective radius 0 287 m Max torque SAE 10 6m kg 2i00r p m Max BHP SAE 67HP 5200r p m 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 CAR SPEED km h MODEL J ENGINE PERFORMANCE CURVE ENGINE SPEED x 102 r p m ...

Page 16: ... 67HP 5200r p m 45 200 100 5000 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 Car Speed km h f 3000 4000 2 O P D O w pi a 2 3 3 2000 500 i o C U c c Q 300 PS 200 3 B f i 100 Final gear ratio 4 111 1st speed ratio 3 945 2nd speed ratio 2 403 3rd speed ratio 1 490 4th speed ratio 1 000 Gross vehicle weight 1 160 kg Max grade ability tan 0 0 459 sin 0 0 417 T i r e effective radius 0 287 m...

Page 17: ... oil control ring The piston pins are bolted in connecting rods which have steel backed lead and copper alloy changeable big end bearings A counter balanced crankshaft is fitted The end thrust on this component is taken by special washers at the center main bearing The centrifugal water pump and cooling fan are driven by the generator belt GENERAL SPECIFICATIONS Engine type J type No of Cylinder 4...

Page 18: ...DATSUN ENGINE RIGHT SIDE ENGINE LEFT SIDE 2 ...

Page 19: ...rporated in the radiator filler cap controls the pressure at approximately 0 4 kg per sq cm Do not remove the filler cap if the temperature of the coolant is above boiling point or if the engine is running Topping up should only be required occasionally to replace water lost through the overflow pipe Top up when the engine is cold and if possible use clean soft water Fig 1 Radiator Fill to within ...

Page 20: ...chable therefore should be occasion arise it can be removed from its housing and the hose reconnected to avoid laying up the car The thermostat opening is set by the manufacturer and can not be altered During decabonising it is policy to test this opening by immersing the thermostat in water raised to requisite temperature The valve should open under these conditions but if it fails to open a new ...

Page 21: ...cylinder block and the other at the base of the radiator block Both taps must be opened to drain the system and the car must be on level ground while draining The drain taps should be tested at frequent intervals by inserting a piece of wire to ensure that they are clear This should be done immediately the taps are opened so that any obstruction freed by the wire may be flushed out by the water Th...

Page 22: ...e shaft and ball bearings is combined with one unit Put the pulley hub on the bench First press or knock the shaft end with a drift hard bar and draw out the pulley hub on the U type bench Take out the set pin from the slit which locked the shaft assembly to the pump body See Fig 6 Next turn the body upside down and press out the shaft assembly from the vane side on the U type bench The shaft and ...

Page 23: ...le of set ring with a groove of shaft so as to insert and set the said ring correctly Adjusting Clearnace the Van End and Body First press down the shaft fitting with a groove line to insert the set pin Inserting thickness gauge Thickness 0 4 0 5 mm between the vane end on the U block bench Take out the thickness gauge and find out good condition Screw up with the cover and cork washer ...

Page 24: ...element through holes in the cartridge and passes through the element into the annular space round the center oipe This space is sealed top and bottom so that the oil can only escape through a small hole into the hollow center pipe and from this point back into the oil pan Draining the Oil The oil on new and reconditioned engines must be drained and then filled with new oil after first 2000 miles ...

Page 25: ...amshaft journal and chain tensioner and finally returned to the oil pan The oil filter is provided with a relief valve If the temperature of lublicant oil is low at starting oil viscosity is high or if the filtration resistance of the oil filter element is large caused by its choke up the relief valve will be opened with pressure difference to bypass oil Removing the Oil Pan The sump capacity is 3...

Page 26: ... any traces of the paraffin before refitting the oil pan to the engine Pay particular attention to the oil pan and crankcase joint faces and remove any traces of oil jointing material Examine the joint washer and renew it if necessary The oil joint washer can be used again if it is sound but it is advisable to fit a new one Smear the faces of the joint with grease and fit the joint washer Lift the...

Page 27: ... taken not to damage the washer when breaking the joint If damage does occur fit a new washer cleaning of the faces of the joint surfaces beforehand Removing the Timing Gear Fig 2 Fig 3 The timing chain is endless and it is necessary to remove both the crankshaft and camshaft gears together Before doing this notice the timing marks on both gears and their relationship to each other Draw off both t...

Page 28: ...cker shaft fixing nuts also secure the cylinder head If the cylinder head nust are not slackened distonation may result and allow water to find its way from the cooling system into the cylinders and pump Notice that under the right hand rear rocker stud nut is a special locking plate Completely unscrew the rocker shaft blacket nuts and remove the rocker assembly Complete with brackets and rockers ...

Page 29: ... Cylinder Head The vent pipe should be at the front of the engine Secure the cover by means of the two cap nuts ensuring that the rubber bushed and engine lifting plates are in position If the rocker cover gasket or the rubber bushes are found to be faulty they must be renewed other wise oil leaks will result Push Rod Removal If the valve rocker assembly has already been removed all that remains i...

Page 30: ... to note that while the clearance is being set the tappet of the valve being adjusted must be on the back of the cam opposite to its peak Fig 9 Adjusting the Rocker Clearance C Y L I N D E R HEAD Rocker shaft Length 356 4 Outer diameter 15 85 15 88 mm Rocker arm bush Outer diameter before mounting 19 01 19 04 mm i Inner diameter Reamer finished dimension after 15 89 15 90 muijf mounting Clearance ...

Page 31: ...ld now be removed from the piston crowns Rotate the engine until the piston to be worked on is at T D C Protect the other cylinder bore from the entry of carbon particles by pushing a non fluffy rag into them Using a chisel shaped piece of hardwood Carefully remove the carbon from the piston crowns A ring of carbon should be left round the periphery of each piston and the deposit round the top of ...

Page 32: ...e onto its sealing the valve face should be smeared lightly with grinding paste and then lapped in with a suction type grinding tool The valve must be ground to its seat with a semi rotary motiron A light coil spring interposed between the valve head and the port will assist considerably when lifting the valve in order to rotate the face to a different position This should be done frequently to sp...

Page 33: ...p so that it will be placed head in correctly Fig 5 Cylinder Head Distortion Measurement Place the gasket into position and lower the cylinder head into place Fit the cylinder head securing nuts finger tight Insert the push rods replacing them in the positions from which they were taken Screw back all the tappet adjusting screws Replace the rocker assembly and screw down the securing nuts finger t...

Page 34: ...n now be switched on and the engine started When the normal operating temperature has been reached switch off and remove the rocker cover so that the valve clearances may be rechecked Replace the rocker cover and fit the air cleaner when the final check has been made Whilst the engine is running check that the water hose connections and fuel line unions do not leak Tighten them if necessary Removi...

Page 35: ...ifice and locate on the valve head By using the rocker shaft as a fulcrum point the spring can be compressed with two screwdrivers or a fork ended bar Withdraw the valve cotters and renew the valve spring Valve rocker shaft Adjust screw nut Valve rocker Bush Collet Spring retainer _ Rubber ring Outer spring Chain tension I n t a k e v a l v e Exhaust valve Cam shaft gearA Washer Gear bolt Locating...

Page 36: ...off the manifolds Disconnect the high tension leads from the sprking plugs remove the rocker assembly and W i t h d r a w the push rods keeping them in their respective positions so that they will be replaced onto the same tappets Remove the tappet covers and lift out the tappets also keeping them in same locations Fig 13 New tappet should be fitted by selective assembly so that they fall into the...

Page 37: ...ne the bear ing surface for scoring either defect will necessitate the removal of the crankshaft for regrinding CONNECTING ROD Distance between center of 150 0 03 mm large end and small end 150 0 03 mm Large end bearing Type Clevite F500 Overall width 22 0 1 mm Thickness 1 87 2 34 mm Outer diameter 51 35 mm Width of large end 31 mm End play of large end 0 20 0 31 mm Finishing dimension of inner di...

Page 38: ...on and connecting rod assembly into the cylinder from which it was taken it is essential that the split in the skirt of the piston is positioned towards the camshaft Compress the piston rings with inserting piston using tool Fig 18 and gently tap the crown of the piston with the wooden end of a hammer handle until the piston is clear of the piston ring clamp Fig 17 Inserting the Piston Fig 18 Pist...

Page 39: ... or grit Before reassembling always apply a little clean oil to the piston surfaces and into the cylinder bore Never file the connecting rod caps or their mating surfaces as this creates oval in the bearing Removing a Piston Remove the clamping bolt from the small end of the connecting rod and push out the gudgeon pin The gudgeon pin is a push fit in piston at 70 F 21 1 C When reassembling ensure ...

Page 40: ...emoved If this is not done there will be a tendency to noisy operation or a fractured ring caused by the top piston ring striking the lip Piston and rings are available in 0 010 in 0 254 mm 0 020 in 0 508 mm 0 030 in 0 762 mm and 0 040 in 1 016 mm over sizes The piston rings should always befitted from the crown of the piston and never pushed upwards over the skirt Before fitting the rings remove ...

Page 41: ...se or gasket damaged Tighten fuel pump bolts or replace gasket 7 Rear main bearing leaking oil into clutch housing or flywheel housing Adjust or replace main bearing or main bearing oil seal Lack of Engine Power Ignition system improperly adjusted 1 Spark plug faulty Replace or clean adjust and seat spark plugs 2 Distributor points not set correctly Set distributor points and timing engine 3 Ignit...

Page 42: ... 3 Spark plugs improperly gapped Set plug gap correctly 0 7 0 8 mm 0 0275 0 0315 in 24 4 Spark plug codes loose and corroded in distributor cap Clean code and cap terminals 5 Loose connections in primary circuit Tighten all connections in primary circuit 6 Series resistance in condenser circuit Clean all connections in condenser circuit 7 Low capacity condenser Install proper condenser Engine cond...

Page 43: ...motor end Remove the oil gauge and water temper ature gauge leads from their terminals on the engine Fig 1 REFITTING The throttle and choke controls must be disconnected from the carburetor Disconnect the fuel pipe from the fuel pump Next remove the exhaust pipe from the manifold From below the vehicle remove the gear change selector rod from the lever on the transmission casing Disconnect the ear...

Page 44: ... Washer Washer R H Insulator engine mounting Front Bolt Bolt Fig 3 Engine Mounting The following operations are best performed with the engine removed from the car Although it may be found possible to carry out certain attentions with the engine in position it is more convenient to do the work on the bench Fig 4 Removing Crank Gear Cam Gear and Chain Fig 5 Checking Thrust Clearance 26 ...

Page 45: ...drawing the setscrew and lock ing plates The dynamo swinging link must be removed Take out the setscrews securing the cam shaft locating plate when the camshaft can be withdrawn from the cylinder block Camshaft Bearings White metal bearings with steel lining are used for the camshaft They can be taken out renewed whennecessary it being usual to do this when the cylinder block is being reconditione...

Page 46: ... front bearing cap drain Stud to fix tuel pump to crank case Screw set S C R F W i W S H E R l a J fu i B 0 1 a n i M t i i f t g plllf B Illlk W A S H E N l o c k S C R E W R e u s i n g _ Washer lock Plug crank case oil gallery brass Gasket rear plate Plate gear box mounting Fig 7 Cylinder Block A Adapter oil pressure switch A s s y b l o c k c y l i n d e r ith plugs Plug welch J f cylinder f j...

Page 47: ...f of the bearing the other being plain When fitting new bearings no scraping is required as they are machined to give the correct running clearance of 0 0005 0 002 in 0 0 27 0 0508 mm Ensure that the locating tangs are properly engaged in their recesses Handle the new bearings carefully so as not to damage the fine surface finish Remove all traces of dirt and oil from the housings and throughly dr...

Page 48: ...bearing caps tighten the center one first after each cap is tighten rotate the crankshaft to ascertain that it re volves freely If it is tight remove the last cap tightened and examine the bearing and its seating for foreign matter Check the crankshaft end play by means of a dial gauge This should be 0 002 in 0 051 mm If a bearing has run it is essential to clean out all oilways in the crankshaft ...

Page 49: ...wiped clean with a piece of cloth which has been dampened with gasoline If the points are badly burnt they must be replaced Braker points must always be replaced as sets Adjusting the Braker Points To adjust the braker points turn the engine crankshaft with the crank handle until the braker is fully open Then loosen the braker point fixing screw Next by turning the adjusting screw move the plate u...

Page 50: ... of the upHer end of the shaft somewhat to the left as shown in Fig 4 At this time the smaller of the semicircle is placed toward the front Fig 2 Checking the Ignition Timing 3 Next inserting the driving shaft of the distributor at an angle to the engine engage the gear on its lower and with the gear on the camshaft During this assembly place the Fig 3 Setting of Timing Gear Mark 4 Adjusting the d...

Page 51: ...y if the octane number is high the pointer is adjusted to the left A One unit of calibration of the selector corresponds to 2deg of the distributor angle and to 4 deg of the crankshaft angle When a timing lamp is used the standard setting is 15 dge before top dead center with the engine idling 600 620 In any case the optimum adjustment is that in which a slight knocking is heard when with the car ...

Page 52: ... air and supplying the mixture to the engine It is therefore an important part which can influence the performance of the engine The carburetor is a highly efficient one of two barrel two step and down draft type having the following special features Construction and Operation Main air bleed Small venturi assembly Throttle leveF1 assembly Strainer assembly Float valve kit sti Float pin collar Main...

Page 53: ... engine requires dense mixture gas the acceleting pump opens its power valve from where the fuel also flows into the main system The power valve beings to operate when the throttle valve opens 48 from full closed position Slow Speed System Passing through the main jet the fuel passage separate from main line and flows through the slow jet slow air bleed first slow economizer slow air bleed second ...

Page 54: ... valve is also to be in a full open Float Chamber Adjustment of the float level can be done from outside by adding or subtracting the needle valve carrier gasket after removing the float needle valve installed at the inlet connector As ventilation within the float chamber is of a air vent method and pressure within the venturi and the float chamber is always constant no matter how suctional regist...

Page 55: ...it into the carburetor float chamber A large and efficient air cleaner fillers the air supply to the carburetor Draining the Fuel The fuel tank is drained by turning the wrench operated drain cock Fuel Tank Gauge Unit Situated on the top face of the tank is the gauge unit To remove withdraw the set screws which secure the unit to the tank not forgetting to disconnect the electrical lead beforehand...

Page 56: ...the tank and gauge unit must be fuel tight G r o m m e t For SEDAN G r o m m e t T u b e to S c r e w _ s t r a i n e r a c 1 W a s h e r G r o m m e t V e n t i l a t i o n t u b e D C a p a s s y Washer o Joint w a s h e r D r a i n plug F u e l tank f o r w a g o n Band a s s y For WAGON Fig 2 Fuel Tank Mounting 38 ...

Page 57: ...ENGINE 39 ...

Page 58: ...DATSUN 40 ...

Page 59: ...nlet and outlet of the pump chamber gasoline is drawn up from the tank to the carburetor If the float chamber of the carburetor contains enough gasoline and the needle valve is closed gasoline is not allowed into the carburetor Thus gasoline is stored in the pump chamber and due to its pressure the diaphragm is kept down and cannot return Under this condition the rocker arm works in vain as the ro...

Page 60: ... piece of glass plate and grind it lightly with the tip of a finger The standard thickness of the valve is 1 6 mm The hole ofthe joint parts of diaphragm shaft and link may be worn to some extent This is not serious but when serious eccentric wear crack or breakage is found the part must be replaced As a remedial measure such wear can be compensated for at the time of dismantling and reassembling ...

Page 61: ...finger tips Then after operating the rocker arm several times suddenly release the fingers The pump is in good conditions if 3 to 5 seconds thence there can be heard strong inlet and outlet noise respectively The pump is mechanically fit for use when by connecting a hose to the inlet port it is able to draw up gasoline from a height of more than 0 5 m After installing the pump test its functions d...

Page 62: ... 11 Adjustment of slack in fan belt 12 Adjustment of valve tappet clearance 13 Road test While driving in 3rd speed at about 25 km hr suddenly step on the accelerator If only a slight knocking results the ignition timing is correct Slow speed adjustment is made so that the speed is about 15 km hr when driving in 3rd speed Diagnosing of Engine by means of Vacuum Gauge and Combustion Tester In diagn...

Page 63: ... inches at certain time valve are burnt 7 When indicator drops by about 2 in valve leak Faulty seating of valves 2 Normal condition When indicator fluct uates between a range of 0 25 in as engine is raced rings and valves are in good conditions 8 When indicator oscil lates actively between 14 and 18 in valve stem guide is worn out 3 Even if indicator set tles if reading is low rings or oil are in ...

Page 64: ...fold or gasket of carburetor Faulty clamping of gasket 16 When indicator moves slowly between 13 17 in carburetor is poorly adjusted Fig 3 Diagnosing Engine by Means of a Vacuum Gauge r Plug spark Plugs do not spark Sparking at terminals No sparking at terminals No gasoline in carburetor Breaker defective Battery discharged or connections poor Timing poorly adjusted Air being sucked in Plug sparki...

Page 65: ...Cord shorted or connection poor 0 r Wiring shorted or cut Sparking form coil line A Plugs dirty or broken A Trouble Shooting Chart Power weak Engine operation defective during running i Continuous lack of power Intermittent lack of power Engine gives off abnormal noise L Misfiring Sparking irregular Sparking normal Compression weak Valve clearance incorrect Valve spring weak Valve deformed Muffler...

Page 66: ...4 in cylinder Operating liquid Genuine super brake oil Return spring with 1 6 mm drawal wire dia Free length 87 mm Length in used tension 136 mm 5 kg PRESSURE SPRING Free length 49 mm 1 5 Compressed length Less than 25 mm Turn numbers 7 8 Power of comp in full About 300 kg Wire diameter 3 3 mm Length in used and load 29 2 37 5 2 kg RELEASE BEARING Construction Height of release plate Release plate...

Page 67: ...on assembly Interference with this setting unless new parts have to be fitted will throw the pressure plate out causing judder Adjusting nuts are screwed on the bolts of pressure plate Retainers of pressure spring insert to the clutch cover holes and anti rattle springs load release levers Release Bearing The release bearing consists of a carbon bearing shrunk into a bearing cup the cup bearing lo...

Page 68: ...holes in the plate insert the set screws provided and tighten them a little at a time by diagonal selection until the cover is firmly attached to the base plate at all possible points This is most important if the best results are to be achieved Mark the cover pressure plate lugs and release levers with a centre punch so that the parts can be reassembled in their relative position in order to main...

Page 69: ...CLUTCH Fig 7 Disassembling 51 ...

Page 70: ...ease 51 mm Fig 8 Assembling Press the pin into the eye bolt hole through the lug on the pressure plate as shown Place the pressure plate on the base plate with the pressure springs in position on the pressure plate and put the pressure spring retainers on it Cover and set the clutch cover assembly on the base plate Compress the pressure springs by screwing down tihe cover to the base plate by usin...

Page 71: ...Fig 10 53 ...

Page 72: ...not be punched out Rivet one new facing in position then if the correct tool is not available use a bluntended center punch to roll the rivet shanks securely against the plate The second facing should then be riveted on the opposite side of the plate with the clear holes over the heads already formed in fitting the first facing The plate should then be mounted on a mandrel between centers and chec...

Page 73: ...ove the stopper ring with a pair of long nosed pliers The push rod and ring can then be removed and unscrew the release pin When the push rod has been removed the piston with caps attached will be exposed remove the piston assembly complete The assembly can be separated by lifting the spring seat edge over the shouldered end of the piston Depress the piston return spring allowing the valve assembl...

Page 74: ...nder with the bolt and screw in the pipe union Adjust the push rod by the screw driver at top of withdrawal level with the adjustable rod of operating cylinder to give the end play 2 5 3 0 mm Bleading the Clutch System Fig 16 Remove the bleed screw dust cap at the operating cylinder open the bleed screw approximately three quaters of a turn and attach a tube immersing the open end into a clean rec...

Page 75: ...r topend full stroke at the top of end Withdrawal lever excess stroke Clutch pedal fully pushed by foot Pressing strength for pedal in full Brake pedal full stroke Brake pedal stroke at pressing power 60 kg 1 6t each one plate to upper lower side 8 t insert suitably 0 5t 7 1 6t each 3 plates to upper lower side insert suitably 46482 30000 2 places 46460 04100 2 places 46485 32200 T 3 5 v 4 0 mkg 2...

Page 76: ...DATSUN ...

Page 77: ...ge 4 stage for forward synchro for reverse mesh on for speed Remote control Full synchromesh on forward gears Type of gear Synchro meshed helical gear 2nd 3rd 4th gear type Ratio 1 3 197 3 94 Ratio 2 1 725 2 40 Ratio 3 1 000 1 49 Ratio 4 1 00 Reverse 4 125 5 159 57 ...

Page 78: ... position are 14 set nuts all of which must be removed when cover can be taken off Fig 2 Bottom Cover Fig 3 View of Inside of Transmission D I S A S S E B L Y C O U R S E Front Bearing Retainer Release the front bearing retainer situated within the clutch housing by removing the nuts Fig 3 58 ...

Page 79: ...TRANSMISSION TRANSMISSION CASE OIL SEAL CROSS SHAFT Fig 4 Fig 1 Plug Cross Shaft Fig 5 PLUG CROSS SHAFT Fig 2 t f IMMM SPRING CHACK BALL PLUG INTER LOOK HOLE CHACK BALL Fig 6 Fig 3 59 ...

Page 80: ... Press out the pin from fork shaft Disassembly Insert the pin and tap into the shaft and hole fork setting hole Take out the cross shaft from the case Fig 6 Fig 7 Fig 5 Fig 8 Take off the Pin Nut of Cross Shaft 60 ...

Page 81: ...TRANSMISSION Fig 9 Pull out the Cross Shaft Fork Shaft Fig 12 Fig 10 Fig 13 Detach the Fork from the Gear Fig 11 Fig 14 Take out the Fork Shaft 6 1 expert22 Arm http rutracker org ...

Page 82: ...counter shaft forward When the counter gear cluster and two thrust washer will drop in the case Assembling First locate the two washers to the counter gears ensuring that the larger washer is at the front and small one at the rear then place the cluster gears in the case Fig 17 Assembly Course Fig 18 Disassembly Course 62 ...

Page 83: ...TRANSMISSION Main Shaft Pull out the rear bearing and the speed gear sleeve by the bearing puller from the main shaft rear side Fig 24 Take out the Main Drive Gear Fig 22 63 ...

Page 84: ...main drive e a r Bearing main Spacer main drive gea drive gear Ass y pinion Ass y sleeve speedometer s P d o m e t I Pin_ P Piece distance Gear driving speedometer Bearing Main shaft Washer thrust counter front Gear counter Bearing Shaft counter Washer thrust counter rear Shaft reverse idler Bushing reverse gear c r e w s e t k e r s e shaft Fig 26 Components of Transmission Gear 64 ...

Page 85: ... It is almost impossible to take off the seal without damage it consequently a new oil seal should be fitted if the old one has been removed This can removed by using a punch and hammer Main Shaft Counter cluster gear in the case Insert the first gear to the main shaft together with second and third gear assembly from rear hole and fit the first and reverse fork shifter over the first gear Fit the...

Page 86: ... change 2nd 3rd to fix change lever Nut Rod frok 1st Rod fork reverse 2nd 3rd Pin Plunge inter lock I Spring checking 1 ball o mm Lever Pin lock operating operating lever to Washer lock Nut shaft Fig 6 Transmission Fork Rod 66 ...

Page 87: ...TRANSMISSION Fig 7 Components of Transmission Fig 8 Remote Control 67 ...

Page 88: ...DATSUN MAIN SHAFT Fig 9 Assembling order through the Main Shaft 1 Disassembly of Main Shaft Front Side Fig 11 Taking out by the Snap Ring Plier Fig 13 68 ...

Page 89: ...TRANSMISSION Disassembly of Main Shaft Fig 14 Fig 15 Fig 16 Take out the Spacer Fig 17 Press out the Fig 18 Tapping Main Shaft Bearing out Retainer Fig 19 Fig 20 69 ...

Page 90: ...DATSUN Assembling the Baulk Ring Fig 23 Fig 24 70 ...

Page 91: ...TRANSMISSION Fig 25 Fig 26 Fig 27 Fig 29 Fig 30 Fig 31 Fig 28 Fig 32 Oil Seal Front Cover 71 ...

Page 92: ...light downward pressure Removal of Shift Rod Shift Fork Remove the cover from the transmission by detaching six bolts Counter Shaft Gear Using soft metal drift drive out the counter shaft forward and out of case when the counter gear cluster and two thrust washers will drop to the bottom of the case These gears can only be lifted from the casing when the main and drive shafts together with their r...

Page 93: ...rst put the two thrust washers to the counter gears ensuring that the larger washer is at the front and then place the gear cluster in the gear case Check that there is end play for the cluster gears between 0 04 mm and 0 12 mm 0 0015 0 0046 and remedy if necessary by fitting a thicker or thinner rear washer Thickness of front thrust washer P art No Thic knes s 32224 26760 3 91 3 96T Thickness of ...

Page 94: ...hrust washer on to the shaft followed by the baulking ring The phosphor bronze sleeve which carries the second speed is a tight fit on the shaft there it must be first immersed in warm oil and then slid into position on the shaft Fit second speed wheel over the sleeve then the driving washer and the second bronze sleeve which carries the third speed wheel The two sleeves are locked together by the...

Page 95: ...tick oil level dip Ass y plug drain Cover front transmission case Gasket front cover to fix front cover to fix transmission case Stud Washer lock Nut Bolt Bolt Washer lock Nut Ass y pinion speedometer 18T Ass y pinion speedometer 15T Ass y sleeve speedometer pinion Ring 0 speedometer pinion Retainer 0 ring Ring 0 pinion sleeve Plug speedometer pinion Screw set A to fix reverse shaft Washer lock Ga...

Page 96: ...pin reverse fork Rod fork 3rd 4th speed Fork 3rd 4th speed Bracket rod 3rd 4th speed Ball checking Spring poppet pin Screw set Wire lock Ball checking Spring poppet shift rod Pin interlock Ball interlock Plug weld Plug weld PI ate dust Washer lock Bolt Plug Ass y lever control Boot control lever Knob control lever Spring lever control Cap cover transmission case Boot rubber Seat lever spring Screw...

Page 97: ...r 1 74T Ring snap main drive gear 1 77T Shaft main Hub synchroniz er Spring synchronizer hub Ball synchronizer hub Gear main shaft Ring baulk 2nd speed Washer thrust main shaft rear Gear 2nd speed Bushing 2nd speed gear Washer thrust main shaft Bushing 3rd speed gear Gear 3rd speed Washer thrust main shaft front 3 9T Washer thrust main shaft front 4 0T Washer thrust main shaft front 4 IT Peg locki...

Page 98: ...he brake grease Part No 44003 30100 T 240 280 kg cm Dimension A As possible as little end play by the water Part No 32264 26762 32264 6 26761 Adjust and tight here Bearing play 1 5 v 2 0 mm by push rod adjuster before fitting return spring Gear drive speedometer 4T 32701 07200 Dimension C End play 0 0 0 12 mm Adjust by the part No 32264 9 267600 Dimension B Select end play as possible as small by ...

Page 99: ...1 3 657 3 945 2 2 177 2 402 3 1 419 1 490 4 1 000 1 000 Rev 3 638 5 159 1 Transmission case The cover of transmission is attached to the bottom of case Fig 3 2 Rear extension Floor shift rod setting through the rear extension is set in rear extension Fig 4 Fig 2 Fig 5 79 ...

Page 100: ...DATSUN 3 Reverse lamp switch 4 Speedometer pinion sleeve 80 ...

Page 101: ... PLAY OF REVERSE GEAR IDLER SO AS TO FIT 0 05 0 15 mm BY PART No 32285 14600 1 2 3 ADJUST THE END PLAY OF COUNTER GEAR SO AS TO FIT 0 05 0 15 mm BY PART No 32225 14600 1 2 3 4 665 SECTION C C 1 2 1 4 kg m SECTION B B SECTION A A 8 2 expert22 ajia http rutracker org ...

Page 102: ...TRANSMISSION 3RD 1ST 4TH GEAR RATIO 1ST 3 657 2ND 2 l 7 1 41 y 4TH 1 000 REVERE 3 638 SECTION E E 101 ...

Page 103: ...DATSUN ...

Page 104: ...TRANSMISSION 84 ...

Page 105: ...CHASSIS Fig 1 85 ...

Page 106: ...act the split pin from the spindle nut Using a box spanner remove the spindle nut and ease flat washer under the nut clear of the axle thread by carefully using a narrow rod into small holes in turn in each side of the spindle and tapping the race lightly With the hub removed outer bearing can be dismantled and by inserting a drift through the inner bearing and tapping the out bearing clear of the...

Page 107: ...el and nuts are best finally tightened when the car is off the backing blocks but readjust the brake shoes if necessary before the car is lowered to the ground C O L L A R f r o n t s p i n d l e S P A C E R o i l s e a l f r o n t hub A S S Y H U B r o a d w h e e l f o r n t B O L T h u b n I K o a d w h e e l D R U M b B E A R I N C f r o n t w h e e l i n n e r C A P r o a d w h e e l w i t h ...

Page 108: ...he upper spindle bracket is bolted to the front suspension member with caster shims and the lower spindle is connected to the lower bracket of the suspension member Change the number of Shims Camber Caster Adjust for Front side Back side 1 0 01 0 29 Both Camber Caster 1 1 0 16 0 02 0 31 0 31 1 0 04 0 29 1 1 0 15 Camber only 2 1 2 1 0 27 0 15 2 2 0 27 88 Fig 1 T Front suspension 7 Oil pan upper lin...

Page 109: ... of the tyre in a horizontal position If any movement can be detected between the upper and lower swivel joints and the swivel axle assembly the ball joints or the screw bushed are worn and must be stripped for examination Front Coil Spring U P P E R BALL JO I NT U P P E R L I N K S P N D L E LOWER BALL J O I N L O W E R L I N K LOWER L I N K SRINPLE Fig 2 Between the upper and lower links is the ...

Page 110: ...cessive side ways movement in either of these bearings would denote softening of the rubber bushes or screw bushes The screwed bushes or the ball joints may develop excess free play due to wear of either of these parts This assembly can best be checked when the suspension has been dismantled 90 ...

Page 111: ... A 1 Unscrew nut of the shock absorber at the top and take out if from down side after unscrew lower flange of it from lower link Fit the service tool and screw up the spring compressor nut In the absence of the service tool a suitable tool will be required to release the compression from the coil spring Compressing the coil spring unscrew the 3 nuts of lower ball joint which located under the edg...

Page 112: ...Fig 8 Remove Shock Absorber Fig 9 Detachment of Rebound Bumper Fig 10 Releasing the Nuts of Lower Ball Joints 92 ...

Page 113: ... and the bolts of lower side METHOD C Replacing Order of Upper Link 1 Prepare to remove front wheel 2 Jack up and support front suspension lower link 3 Remove wheel 4 Disconnect upper ball joint and rebound bumper from upper link 5 Detach upper link and spindle from suspension member 6 Disassemble upper link spindle from upper link by unscrewing link bushings 7 Reassemble upper link spindle and bu...

Page 114: ...upper link to the suspension member by tightening torque 4 7 5 0 kg m Do not forget to insert the adjusting shims of chamber Front Wheel Alignment Toe in 3 mm l 8 in Caster 1 30 Camber 1 30 King pin inclination angle 6 30 Nuts fixing upper ball joint and rebound bumper to the upper link 2 4 2 6 kgm 17 4 18 8 lb ft Bolt fixing upper link spindle 4 7 5 0 kgm 34 36 2 lb ft Nut fixing lower link spind...

Page 115: ......

Page 116: ...S4 S55 lOeOO RH S4557 WSOOILM v D o a ot C 3 O TO s fl s O s Section A A ...

Page 117: ... 4 o s I C j TO S 00 N O s Tight under condition of T 3 8 JlJ standard loading Center line of lower spindle cs ss x 10 o cn to M to ...

Page 118: ...ar tube 5 Propeller shaft 10 Rear spring shackle pin 15 Rear spring Plug taper 43010 10600 Comp case rear axle 43010 10800 Comp case rear axle Stud gear carrier Ass y plug drain Ass y breather Spacer oil seal rear axle Seal oil rear axle shaft Collar bearing rear axle bearing Bolt road wheel Nut road wheel Drum brake Screw to brake drum 43235 04101 Ass y catcher 43234 04101 Ass y catcher grease L ...

Page 119: ... up the car Lower the axle on to the blocks and remove the wheel using a screw driver unscrew the drum locating screws release the hand brake and tap the drum off with the mallet If the brake linings should hold the drum when the hand brake is release slack off the brake shoe adjuster a few notches Take off the fix bolts of the brake disc and remove the axle shaft as shown Fig Tan with swing hamme...

Page 120: ...ocity The same brand must always be selected The standard capacity of oil is about oil 0 931 The method of feeding oil should be done by taking off the feeler plug at the rear cover of the housing and fill in full up to the feeding hole Dismounting Disassembling of Differential Gear Carrier 1 Take off and drain out the gear oil 2 At the time of dismounting the gear carrier pull out the both left a...

Page 121: ... of companion flange of drive pinion with the drift of soft metal Thus the pinion would be taken out together with the inner lace of rear bear ing and roller distance piece and the adjusting shim and the oil seal outer lace and pinion of front and rear bearing as well as the pinion adjusting shim left in the carrier 11 Pull out the rear bearing inner race of the drive pinion 11 As illustrated in F...

Page 122: ...eplacer Fig 8 Inner Race Replacer Drive pinion nut Tightening torque 14 u 17 kg m 100 120 ft lbs When the drive pin ion nut is tightened with torque 14 17 kg m without the oil seal of hypoid drive gear adjust the fric tion of rotation so as the torque is to be 7 19 kg cm by the adjust washer of drive pinion bearing and pacer 5 4 Tightening torque 4 2 x 4 8 kg m 30 v 35 ft lbs Fig 9 Section of Diff...

Page 123: ...shake with the gauge by houlding the both end The difference over 0 4 mm should be adjusted with 0 8 m m or replaced The clearance between the end of rear axle case and brake disc should be adjusted with the adjusting end shim Part No 43036 04100 3 Every gear should be inspected as to the locking condition defacement or any defects on the surface to see if they can be re used In case of insufficie...

Page 124: ...gear in the differential case Every parts should be cleaned and oiled with new gear oil then the pinion mate side gear and the thrust washer should be assembled by the mentioned inspection and selection before pushing in the pinion mate to shaft Inspection should be made again in the clearance of between the washer or the back lash Adjustment must be made in case any abnormal is found Strike in th...

Page 125: ... mm to decide the thickness of adjusting shim for adjustment of standard position The standard pinion height is 51 0 mm from axle center as shown in Fig 13 17 If the figure is difficult to discriminate due to the corrosion scrape off the oxidize substance on the surface by a some what narrow grind stone with care not to scrape off even the mark Adjust to the direction of on arrow in accordance wit...

Page 126: ... to be the center of carrier as shown Fig 14 then mount it by using adaptor as in a way of mounting the rear outer race 3 Mount the rear bearing inner race and roller to the drive pinion By using the round adapter attached to the drive pinion rear bearing inner race replacer which was employed at disassembling press in the drive pinion Fig 14 This might as well be done in pressing in by the use of...

Page 127: ...pected trouble in future 5 The formal adjustment of the drive pinion bearing and preload After the fixing position of drive pinion is decided as mentioned in the previous paragraph take off the pinion nut companion flange to mount again the drive pinion bearing spacer distance piece and nut Tighten up the nut as Fig 16 by using the torque wrench at the regular torque of 100 120 ft per lbs The prel...

Page 128: ... when the old bearing is to be used again in assembling the adjustment should be made at the lower torque than standard in accordance with the conditions of practical use so as not to give it an over preload 6 When the former adjustment of pre load of the bearing is completed as in the previous paragraph inspect the pinion height again Unless any thing wrong is found loosen the pinion nut take off...

Page 129: ... the following method of computation It may as well be assembled by using the shim of thickness which is in accordance with above method of computation The left and right bearing must be well pressed in otherwise the preload changes Measure the back lash of the drive pinion ring gear as Fig 20 by using the dial indicator to make sure that it is within 0 1 mm 0 2 mm CHASSIS 0 004 0 008 If it is muc...

Page 130: ... thickness of each shim of left right must be reducted for 0 001 0 003 on the basis of 80 or 60 against standard preload in accordance with the practical condition of use becuase over preload is given to the bearing with the shim of thickness calculated from above method of computation Fig 21 Using the Differential Side Bearing Cap Gauge 110 ...

Page 131: ...of precaution measure with michrometer of the large size the L measurement which is within 173 40 173 55 mm as Fig 21 Service No tool DT 4685 If it is insufficient add an additional shim of 0 002 in 0 05 mm left and right In this case the said michrometer Fig 21 or special gauge should be employed for scaling The shake of the back of drive gear which has been fixed with the carrier should be measu...

Page 132: ... numbers 2 96 Distance between sector shaft worm shaft 45 mm Gear oil capacity 0 3 L Steering system consist of the recirculating ball type robust structure and gives light handl ing and stable functioning The worm gear supported with upper and lower angular contact ball bearings to the housing is meshed with the sector arm through the circulating steel ball and ball nut This assembly is enclosed ...

Page 133: ...k bench The gear arm should be with drawn from the shaft concerned using a suitable extractor The gear arm must not be hammered from its shaft Removing the Idler After the side and cross rods disconnected the idler can be detached from the body It is secured by two bolts to the front suspention member Holding the idler body on the bench and take off rubber cover Unscrew the idler shaft out of the ...

Page 134: ...e nut being sure to use a lock washer under the clamp screw then tighten the screw securely Check the assembly by rotating the nut on the worm to see that it moves freely ASSEMBLING 1 Fix the completed gear housing with needle roller beearings and oil on the vice 2 Set the main column unit to the gear housing with b the worm adjust shims and o ring 3 Insert correctly the bearing to the housing 4 T...

Page 135: ...ering sector shaft 1 48103 16500 Arm sector shaft 1 48502 16500 for RH Arm sector shaft 1 48502 17000 for LH b Roller shaft screw 1 48135 32200 cl Roller shaft adjust shim 1 48129 71200 1 575r 1 600 mm 1 c2 Roller shaft adjust shim 48130 71200 1 550 1 575 mm c3 Roller shaft adjust shim 1 48131 71200 1 525 1 550 mm c4 Roller shaft adjust shim 48132 71200 1 500 1 525 mm d Sector shaft gasket 1 48204...

Page 136: ...t meshed point of the clearance O at center of 2 Fix t h e lock nut 3 Make sure smooth rotation of gears 4 The back lash of gear arm should be adjusted by the screw 0 0 1 mm at the neutral position 5 After finishing adjustment rotate the gears repeatedly then lock the nut surely after retightening adjust screw more l 8 l 6up 1 24518 Tightening torque 2 5kg 48204 16500 9 11246 Tightening torque 2 5...

Page 137: ...Secter shaft oil seal Secter shaft adjusting screw Secter shaft cover Secter shaft adjusting shim Secter shaft cover gasket Lock nut Plug Bolt Bolt Lock washer Lock washer Nut Worm bearing shim Washer O ring Steering gear arm Steering column jacket complete Lock washer Steering column bearing assembly Nut Fig 2 Components of Steering Gears 117 ...

Page 138: ...he worm gear through steering column which can be rectified by the removal of shimes located behind the gear housing front cover as already mentioned To check for this end play disconnect ball joint stud at the end of cross rod from gear arm and turn the steering partly to the right or left lock 118 ...

Page 139: ... 2 wheels braked Lining Width x Thickness x Length 40 x 4 5 x 215 mm Same for Front Rear Area of surface cm2 35 Front Rear Brake drum dia Front Rear 228 6 cm2 Same for Front Rear Master cylinder bore Inner dia 22 22 mm Wheel cylinder bore Inner dia Front wheels 25 40 mm Rear wheels 23 81 mm Fig 1 Front Brake Flange Brake Disc 119 ...

Page 140: ...t proportion to the effort supplied at the pedal When the pedal is released the brake shoe spring return the shoe which then return the wheel cylinder pistons and therefore the fluid back into the pipe lines and master cylinder An independent mechanical linkage actuated by a hand brake mounted drivers seat side This is positioned on the right hand side of seat if the car has right hand steering an...

Page 141: ...1 1 h del o n l T O K I C O _COVER du t TOK1KO SPRING pnton b b SPRING P g T l e R E T A I N E R ami rattle N U T WASHER lock B O L T ASS Y CYL1NDER front wheel after L H Fig 3 Front Brake L H Fig 4 Adjusting of Front Brake Adjustment for the front brake shoes is by means of the bolts of adjuster which located at the lower and upper position of the out side of the brake disc Turn adjusting bolt to...

Page 142: ...Rotating direction of drum B Expanding y way of shoe E ESection F o r e c y l ...

Page 143: ... to mis adjusted parking brakes Turn the bolt to screw direction tightly and then turn back screw 2 3 notches until the wheel drum turns just free from the shoe WASHER nylon ASS Y BRAC KET hand brake control SPRING retainer WASHER lock P I N c l e v i SPRING retainer A S S Y L E V E R handbrake control to fix hand brake bracket SPRING nail hand brake control NAIL ratchet hand brake control C O M P...

Page 144: ... This precaution should be taken to eliminate the possibility of brake shoe drag due to mis adjusted parking brakes Turn the bolt to screw direction tightly and then turn back screw 2 3 notches untill the wheel drum turns just f r e e f r o m the shoe 124 ...

Page 145: ...CHASSIS 125 ...

Page 146: ...B C O A S S Y H O U S I N G brake shoe adjuster W A S H E R l o c k NUT T A P P E T a d j u s t e r 1 A P P E T a d j u s t e r L I N I N G b r a k e W E D G E a d j u s t S P R l N G r e t a r n brake shoe A S S Y S H O E j rear brake after adjusting side Fig 9 Rear Brake L H HAND BRAKE The hand brake operates on the rear wheels only and is applied by a pull up type of lever situated along side t...

Page 147: ...ir of long nosed pliers The push rod assembly can then be removed When the push rod has been removed the piston with the secondary cap will be exposed therefore remove the piston assembly complete The aasfmbly can be separated by taking out other small parts Examine all parts especially the rubber primary cap for wear of distortion and replace with new parts where necessary entering the jar is com...

Page 148: ... V ASS Y I C A B L E hand brake a f t e r RETAINER spring TRUNNXON pin NUT adjusting hand brake h a n d b r a k e cable to lever c a b l e SCREW to fix b r a c k e l f V A S H E R _ PIN clevis to fix cable p i n to balance c lever FERRULE BOLT QCross WASHER rubb lain T lock c t f N I P P L E IN T e levis I RING l felt SPRING pull off cross rod lock to fix cross rod to wheel cylinder l e v e r P I ...

Page 149: ... turn signal lamp 3 O S c o Ki Ki Right Fog lamp Left Fog lamp D Left Parking turn signal lamp Left Head lamp Lamp IL Instrument lamp TS Turn signal pilot lamp MB Main beam pilot lamp IG Ignition warning lamp OIL Pressure w a r n i n g lamp m r m o H JO o r 0 H m 3 Inspection lamp ...

Page 150: ...n 14V normal temp Output current 2 500 r p m 14V 24 5A up normal temp 2 500 r p m 14V 21 5A up high temp Pulley ratio 1 1 73 Regulator Mitsubishi Denki Co 23500 12200 Model RL 2B1 Type Tirrill type leaf spring Element Constant voltage relay Pilot lamp relay Constant voltage relay 3 contact point type l Primary side Secondary side Adjust valve Dynamo revolution Load 14 15V 4 000r p m Battery resist...

Page 151: ...10 Ass y cover rear 1 29 23152 12210 Washer spring 1 7 23230 14610 Ass y diode set 1 30 23162 12210 Washer plain 1 8 23133 14610 Ass y holder brush 1 31 23153 35010 Nut 1 9 23135 14610 Ass y brush 2 32 23139 12900 Bolt alternator 1 10 23107 14610 Cover brush 1 33 9 15115 1 Washer lock to bracket 1 11 23352 09160 22156 01302 Screw 4 x 10 2 34 9 11245 1 Nut fix 1 12 23352 09160 22156 01302 Washer sp...

Page 152: ... Ass v 18 Spring washer 5 27 Through bolt 37 Spring washer 10 Diode 19 Stopper nut 28 Pulley Ass y 38 Round head Fig 2 1 1 Sectional View of Dynamo The sealed ball bearing are used to support the rotor Clearance between the brush and brush holder is also made so as to prevent it from dust Thus the AC generator will increase milage without maintenance Each 3 diodes are pressed in the rear cover and...

Page 153: ... magnetism of the field core so that magnetization is necessary until voltage rises to suit charging after the engine has started This is because the diode is used and when the voltage to add to it is so low large proportional resistance shows up and current does not flow through the field coil unless the dynamo makes very high revolution This is because the diode is used and when the voltage to a...

Page 154: ...l off the bearing with such as a hand press Slacken N terminal bolt on the rear cover side and remove the clip terminal then the rear cover and the stator can be separated g Fig 2 2 7 Remove the rear cover and stator Separate the silicon diode 3 ea from the stator coil lead wire 3 ea by melting soldering with an electric iron Slacken N terminal bolt on the rear cover side and remove the clip termi...

Page 155: ...t by using an arbor press as shown the below Press out so as not to injure the mounting bore of the frame or the heat sink Support Tool Installation Support the heat sink or end frame with a suitable tool and then press the diode in the heat sink and end frame by using the tool shaped which fits over the outer diode edge A portion Press down perfectly the diode in the mount ing bore of C portion t...

Page 156: ... the relay A terminal when if the charging current highly increases the relay is in disorder B Short Circuits on Diode Side It can be judged as the pilot lamp does not flare even if the key switch is turned on Actually a trouble such as diode open is very rare and short circuits at the polar line are also rare Ordinarily there are many cases of side short circuits C Inspection of Diode with Tester...

Page 157: ...d Should be non con ductive to Connect to and to Light Good Should be conductive to Connect to and to No Light Defective Should be non con ductive to Connect to and to No Light Defective Should be non con ductive to Connect to A and t o No Light Good Should be con duc tive to Connect 0 to and t o Light Defective Should be non con ductive to Connect to A and t o Light Defective Should be con duc ti...

Page 158: ...eparate Inspection Fig 2 3 8 Fig 2 3 9 Check between the lead wire and the diode set common with the other 2 diodes or the rear cover with the lamp and battery It is all right if one side flares and the other is off If both sides flare there is short circuit and both sides are off there is open E Inspection Field Coil Fig 2 3 10 As shown in Fig 3 10 put the tester be tween the slip ring of rotor a...

Page 159: ...e test stand and make the tester one turn reading the ammeter If there is short circuit on the coil swings of the ammeter abruptly increase and if there is no trouble there will be no change H Inspection of Brush Wipe with clean cloth when oil or dust is on the contact surface of the brush and slip ring Same as in case of DC generator replace the brush when wear of it reached to the wear limit REG...

Page 160: ...P 2 contacts with P the current flows through the circuit of dynamo E terminal field coil F terminal contact points P 2 P j This is repeated according to vibration of the contact point P 2 and the dynamo terminal voltage Fig 3 1 5 When the dynamo revolution gets still higher the movable piece is drawn and the movable contact point P2 sticks to Pg so that current almost does not flow the field and ...

Page 161: ...s all right 2 Check Voltage of Put off Put on Pilot Lamp Relay First put on the lamp with connection as shown in Fig 2 2 and read the voltage between N E by putting off the lamp moving the volt split point of the rubbing resistance This is a put off voltage From this state move the rubbing resistance volt split point and lower the voltage and read the voltage when the lamp flares This is a put on ...

Page 162: ...dynamo must be free from reckless pour of water 13 When the battery is quicklv charged with the quick charger the lead wire or regulator A terminal dynamo A terminal should be disconnected 14 Put the key switch off when the engine in a stop except when particularly needed When the battery poles are connected in reverse large current flows from battery to dynamo resulting in dam ages of diode or le...

Page 163: ...nition switch and relay IG terminal Repair 13 Mal contact or breakage between regulator F terminal and dynamo F terminal Repair 14 Excessive electric load Check power consumed 5 2 Over charge of battery 1 Constant voltage relay adjust voltage is too high Readjust 2 Constant voltage relay coil breakage or rare short Replace 3 Constant voltage relay coil straight resistance breakage Replace 4 Consta...

Page 164: ...rter switch is a key type combined with the ignition switch By turning switch to the right direction the relay on the magnetic switch move to permit current to flow to the starter and cause the armature to start turning suddenly CONTACTOR MAGNETIC SWITCH ARMATURE PLUNGER BRUSH SHIFT LEVER PINION STOPPER Fig 1 Magnetic Shift Type After advancing about 14 mm the pinion completes the meshing into the...

Page 165: ... turning the starter key for over 10 seconds do not continue turning the key time after time but try to save the battery In this case check for the cause of the trouble and correct so that the engine will start Checking While in Operation 1 With a fully charged battery and with the lamps lighted the starter switch is used If the lamps become dim especially when the engine does not start the curren...

Page 166: ...ould be taken when inspecting to also check the flywheel and take remedial measures if the ring gear is found worn or damaged When the pinion is found defective replaced the entire pinion group 2 When inspecting the armature check the armature to core gap shaft to bushing clearance bending in shaft etc in the same manner as that for the generator and are corrected to the specified limits or the ar...

Page 167: ...llowing in Fig 6 L 31 7 32 3 mm This adjustment is carried out at the adjuster and the adjusting nut D I S A S S E M B L I N G A N D A S S E M B L Y O P E R A T I O N 5 1 Disassembling the Armature Gear Case and Pinion Disassembling order is shown by Fig a to Fig c Disassembly is operated by removing magnetic switch fixing bolts through bolts and the armature shaft clip Before disassembling main b...

Page 168: ...sembling Armature S E A R C A S E A R M A T U R E SHIFT LEVER Fig d Disassembling Armature and Gear Case Fig g Removing Pinion Clip S L E E V E PINION S L E E V E SPRING Fig e Removing Pinion Stopper Fig h Disassembling Pinion Subassembly 148 ...

Page 169: ...circuit When the starter switch in pressed and the current falls to pass through the magnetic circuit most of the trouble is due to broken soldered connection between the magnetic coil wire add the magnetic switch terminal and defective ground connection from the coil wire to the magnetic switch body B Defective contact in main circuit S2 When the magnetic circuit is satisfactory and S2 is closing...

Page 170: ...namometer q f r l f U Volt meter 15v L Ammeter 500A Battery 12v Starter motor Construction of Magnetic Switch and Instructions The magnetic switch is an apparatus when the engine is being started by shift lever serves to close the circuit between the battery and the starter motor and permits a large current to flow and actuate the starter motor After starting or when the engine is stopped the swit...

Page 171: ...ing improper meshing the shaft should be cleaned and oiled 2 Starter exceeding noisy when operation The flywheel ring gear is checked and if the teeth are deformed they should be repaired or the gear replaced Rattling noise caused by loose starter mounting bolts are corrected by retightening the bolts Noise caused by brushes improperly contact ing the armature required correcting as this condition...

Page 172: ...net top To remove left or right side way By removing the position of the hood and hood hinge bolts can be adjusted the direction to left or right side Adjusting the Hood Lock Lever In the event of the hook working loose through the lever the hood lock cannot be hold the hood tightly Adjust by removing the position of the hood lock lever as showing the figure Adjust the Position of Hood Lock Lever ...

Page 173: ...g the Position for Upper or Lower Direction Front Fender Detatch the front bumper Jack up the front wheels and take out the tire Disassemble the head lamps and parking lamps from front the body Remove the antena assembly Detatch the fender milar and side emblem Disconnect the bolts and screws as showing the figures 153 ...

Page 174: ...utine for removing a rear door window is adopted as that outlined for a front door window namely removal of trim in this instance front window channel window stop bracket and regulator In addion the window moulds inside and out must be removed also the door glass must be removed from the door upwards through the main aperature Front Door Front door trim panel 1 Take out the door inside handle and ...

Page 175: ... disassembling routine Front Door Glass Take out the panel of front door trim and strip the vinyl cover on the operation hole Loosing the screws remove the door regulator Remove the fixing bolts and screws as show ing figure Remove the Front Door Ventirator Detaching Door Regulator Unscrew the Bolts Screws T3 245 Remove the Ventilator Glass Frame 155 ...

Page 176: ... the weather strip in the bezel and tap with wooden hammer slightly 1 Remove the nut of pivot pin and the spring 2 Detach the rivet and then remove the venti lator window 3 Take off the lock of ventilator 4 Change the glass as same as the method of the front glass replacement Door Lock Mechanism Removing 1 Detach the front door trim panel from the body and strip the vinyl cover of the operation ho...

Page 177: ...emote control as the shown in the figures Front door 1 Removing the pin of the door check linkage detash the check link Unscrew the Front Door Lock 2 Detach the bolts of door hinge at the front pillar take off the door assembly Wind Shield Glass Removing the wind glass 1 Extract the wipper arms 2 Detach the shield molding if used 3 Strip out contact portion between the weather strip and the body w...

Page 178: ...ure Next insert sealing compound between glass and bead on the outside face 4 Offer the window to the aperture frame of the car from the outside and whilst one operator maintains pressure on the glass the operator on the inside of the car should peel out the cord of the inner lip which fits over the ap erture frame The outside operator then arrange the outer edge which will bring the outer rubber ...

Page 179: ......

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Datsun 411 Series, Service Manual

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Summary of Contents for 411 Series

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