Datsun 610 Series 1973 Service Manual Download Page 53

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Summary of Contents for 610 Series 1973

Page 1: ...DATSUN MODEL 610 SERIES CHASSIS AND BODY 1 I NISSANI 1973 l NISSAN MOTOR CO LTD TOKYO I N ...

Page 2: ...Bl B o REAR WINDOW ELECTRIC DEFROSTER OPTIONAL JB o I B itWHllTE B RB GB B GR SIDE MARKER n LAMP m ROOM LAMP fI g NK UNIT RY S B tiJa L iJ P B BW tI RL flL H DOOR SW A C B 0 hR 9A J LW fI B T B Ji TRUNK ROOM sw AGON BR iI LH SEAT SELT SW COLOR CODE B W R Y Black White Red Yellow f lw II II II II t n N OR t 1 HEATER lFU E UNIT 120A B TO AIR CONDITIONG L l t Q KICK DOWN SW LB I LW m u IEY a SEAT 8EL...

Page 3: ... PLUGS DISTRIBUTOR I I I I r I 1 I I I I I I I I i I I i I B B Br i YI B SlOE MARKER LAMP WB R H FRONT COMB LAMP I SA TTER r e I I I m t j o FOSIBLE LINK rn lr 4 B UJ B R C 7Gy BG G8 I r RB r mo W I I RH HEAD LAMP G HO I G FOG LAMP OPTIONAL BLACK RB B R v Ro R GL B GS BL BLACK BBBB B r I I I WHITE r mm I I I i Ii I SEAT BELT 6 STARTER RELAY BW IRBG FOG LAMP OPTIONAL G HORN I RL ttllIICDCDalg CDCDC...

Page 4: ... I I I I I I I t LY FUSE BLOCK I i5G m W 15 g l i REAR WINDOW ELECTRIC DAFROSTER RELAY rd RtBm R tB OF f ON Ll FUSEl5A ml BR tIJ i GB GR Y m GL flJ r B 0 0 rj GW o I I I rt ffih n I RI HEATER I Cw UNIT I lruSE IZOA B TO AIR COl tD1TIONG Il l lBe t I PKICK DOWN SW LB m lEY Ii SEAT BELT H LW WARNING BUZZER B g a STOP LAMP SW YG a i 1l PARKING BRAKE sw t HAZARO FLASHER UNIT t TIS FLASHER UNIT RwLRlFI...

Page 5: ...RL flL 1 DOOR SW C RH SEA BW tI C T 9A MP L H SEAT BELT SW RUNK ROOM SW WAGON GW B 8j RtDIO SPEAKER PTIONAll G f HEATER CONTROL LW GWlO1 ILL LAMP LW B T G w Em c CIG LIGHTER GW I GW W LY REAR WINCO L ELECTRIC W ASH TRA DEFROSTER B ILL Y B PTIONALl SII GW MP REAR WINCO DEFROSTER ELECTRIC OPTIONAL ILOT LAMP r LICENSE lAMP Bi I TACHOM C ETER OPTIONAL i YW I I i i GI GB GL GR HAZAR L D WARNING SW RYI ...

Page 6: ...M qWQ GI J j ojo r ii M E G I NJ r MrogA L lR IN S IA IJAfdON i nkutcH CL C JRAN SMiISSION TM i B R SW Fjr 8tlniflRE E HlfiliAiL1CAiR RI EiRL PD C OM A XUE 7 2 mt FiRnN1Tlm N toIN FA p Y i8 RX R U Ntll O N RA ri fj 4 lJ c r s BR 1 fr r 4 I w 1 iNp l i i WT 1i i i e l r O ijNG ST T Il liN1fr E QP NTROr fUlt FE c j J HA USJ SYSjTlE M iB ODY u BF l u f Bo Y E t RR1C BE r y t 7 f r h SERV ICE E OU J E...

Page 7: ...se this manual describes information concerning the chassis and body only SERVICE MANUAL Model LIB Series Engine SERVICE MANUAL Nissan Automatic Transmission Model3N71B 3 All part names in this manual conform to the PARTS CATALOG Model 610 and only the genuine service parts listed in this PARTS CATALOG must be used for replacements 4 AIl information illustrations and specifications contained in th...

Page 8: ...ERIES CHASSIS BODY I NI AN I NISSAN MOTOR CO LTD TOKYO JAPAN SECTION GI GENERAL INFORMATION MODEl VARIATIONHHHHHHHHHHHHH GI 2 IDENTIFICATION NUMBERS GI 3 APPROXIMATE REFILL CAPAC IlY FINAL TRANSMISSION AND SPEEDOMETER USAGE CHART RECOMMENDED LUBR ICANTS GI 6 JACK UpHH HHHHHHHHHHHHH HH H H GI 8 GI 5 GH ...

Page 9: ...Column PL6IOUWf F4W73 Floor 3 700 WPL6lOUAWf 3N71B Station Wagon WPL6 IOUA Column HI65 3 889 WPL610UWT F4W73 Floor The meaning of prefix and suffix K P L 610 U W A T ROOf shift vehicle Column shift vehicle A Automatic transmission Manual transmission W Reclining separate seat Bench seat L6IOU Destined for U S A and Canada p Equipped wilh Ll8 engine K Hardtop W Station Wagon o Sedan SuffIX PrefIX N...

Page 10: ...ion Caution labels Car serial number JeJ The car serial number is stamped on the left side of the cowl top and broken down as shown in the follow ing figure Fig GI 2 The car number consists of the vehicle model and the seriai number PL61O xxx xxx S0 c I Fig GI 3 Engine serial number location PI O OOOO O SP026 Fig GI 2 Car serial number location Engine serial number The engine serial number is stam...

Page 11: ... L 1 2Mu 3UP L FROKl lH R fRONT tA I I II fU llillPEU 28 PSI 32 24 PSI 28 PSI lOin III m m 28 PSI 32 PSI n 3 2 PSI nil 10 U5SR13 28 PSI 28 PSI 28 PS 28 PSI Gl098 NISSAN MOTOR COMPANY S NEW COOLANT ANTIFREEZE IS INSTALLED IN THIS CAR NISSAN lONG LIFE COOLANT ETHYL ENE GLVeDl BASEl the new combinetion wmmef coolant winter ntifreeze Freeze protectjo 35 ClI Cooling system should be drained every 24 mo...

Page 12: ...i gal 52 Engine cooling system 1 I gal I gal 6 5 Engine crankcase 2 4 Ii qt 3 qt 4 3 Manual transmission 41 pt 3 Ii pt 2 0 Automatic transmission 3 5 i qt 4 i qt 5 5 Differential carrier Sedan 1 pt 1 pt 0 8 Stalion Wagon 2 pi 2 Ipt 1 3 Steering gear box pt Ii pt 0 27 1 Include Ii U S qt Ii Imper qt 0 5 liler for heater 2 Include Ii U S qt Ii Imper qt 0 5 liter for oil filter 3 Include 4 I U S qt 3...

Page 13: ...io 3rd 1 312 1000 1 312 1000 41h 1000 1000 Rev 3 365 2 182 3 365 2 182 Final gear Type RI60 RI60 HI65 HI65 Gear ratio 3 700 3 900 3 889 3 889 Speedometer gear ratio 17 5 20 6 17 5 20 6 MIT Manual Transmission A T Aulomatic Transmission RECOMMENDED LUBRICANTS RECOMMENDED SAE VISCOSITY NUMBER Engine Oil Multi viscosity SW 30 lOW 3O 1OW 40 2OW 40 Single viscosity 10W 20W 20 30 40 30 20 10 0 10 20 30 ...

Page 14: ...EP or GX Spiral 75EP Multipurpose Gear Universal Gear Lub Rigid MIL L 2105 Lub 80 90 140 8Q 90 90 140 80EP 90EP 140EP Lub GL 4 EP OJ 75 80 90 140 80 90 140 80 90 140 l l i5 I R S or APIGLS Universal Gear Lub Gear Oil GX Mobilu oe HD Sflirax HeaVY Duty Multipurpose Gear 34S0 Gear Oil 90 limited MIL L 210SB 75 80 90 140 80 90 140 80 80 90 90 140 80 90 140 Lub GL 5 Multigear Lub EP slip 75 80 90 140 ...

Page 15: ...ge jack under the front suspension member Be sure not 10 lift up the engine oil pan located just behind the suspension member 3 Jack up the vehicle gently jusl high enough to place the safely slands under both the side members Place the stands at the posilion indicaled in Figure GI 8 4 Release the jack slowly Fig GI 8 Front jack up point GI B Fig GI 9 Front supportable points REAR SIDE I When jack...

Page 16: ...6GI07 Fig GI 14 Towing rear Sedan GI075 Fig GI 15 Towing rear Station Wagon Automatic transmission model The car may be towed safely on its rear wheels on the ground wilh Ihe selecl lever in N Neutral posilion of at speeds of less than 30 km h 18 7 MPH However the propeller shaft must be disconnected or the car must be towed on ils front wheels on the ground under Ihe following condi tions I Tow s...

Page 17: ...d irI i6E 0Ro J I I 1M fI lil N oM B41J1 t IaL U J1I c J 1 DATSUN 1800 MODEL 610 SERIES CHASSIS BODY INI NI NISSAN MOTOR CO LTD TOKYO JAPAN SECTION ER ENGINE REMOVAL INSTAllATION ENGINE REMOVAL AND INSTALLATION IR 2 ...

Page 18: ...ocker cover 4 Drain radiator coolant and engine oil 5 Remove radialor grille Note On automatic transmission e quipped vehicles a Remove Wider cover b DiscoDDecl oil cooler hose al oil cooler which is inslalled 10 radialor lower end c Then disconnect vacuum hose lJ 6 Disconnect upper and lower hoses from radiator EA066 Fig ER 1 Disconnecting oil cooler hose 7 Remove four bolts securing radiator and...

Page 19: ...utch operating cylinder 13 Disconnect speedometer cable and reverse lamp wiring I 6 I 11 II Note On automatic transmission equipped vehicles also disconnect wires at a Kickdown swilch b Inhibilor swilch c 14 Disconnect exhaust front tube from exhaust manifold Then loosen connector between center and rear tubes Detach front and center tubes as an assembly 74 Fig ER 9 Disconnecting exhaust front and...

Page 20: ... fIrst secure engine mo uoting rear support 10 body Three insulators are used to mount the engine two at left and right front ends of the cylinder block and one at transmission rear extension housing Front mounting t c W Rear mounting EA078 Fig ER 13 Structural view of engine mounting ER 4 Notes a Replace front or rear insulator assembly when rubber of engine mounting insulator is cracked abnormal...

Page 21: ...insulator to bracket Front mounting insl lator to suspension member kg m ft lb kg m ft Ib 2 5 to 3 5 18 1 to 25 3 2 5 to 3 5 18 1 to 25 3 j kg m ft lb kg m ft lb kg m ft lb kg rn ft lb t 1 C r 0 9 to 1 2 6 5 108 7 0 9 to 1 2 6 5 to 8 7 0 9 to 1 2 6 5 to 8 7 19 to 2 6 13 7 to 18 8 i t f 1 M j it t i v ifi 1 c I i h i i t ER 5 ...

Page 22: ... SERIES CHASSIS BODY I NISSAN I NISSAN MOTOR CO LTD TOKYO JAPAN SECTION CL CLUTCH CLUTCH CL 2 CLUTCH CONTROL CL 6 SERVICE DATA AND CL ll SPECIFICATIONS TROUBLE DIAGNOSES AND CL 12 CORRECTIONS SPECIAL SERVICE TOOLS CL 14 GI ...

Page 23: ...N CL 4 CL 5 CL 5 The clutch is a single dry disc Iype using a diaphragm spring It consists of Ihe clutch disc pressure plate diaphragm spring thrust rings clulch cover and clutch release bearing 31 12201 l 1 ci e 0 is is ci 0 1 oO 00 I 7 8 0 307 1 I I I 52 1 2 047 v 0 7 t o 0 o CL084 Unit mm in Fig CL j Construction ofcutch CL 2 ...

Page 24: ...h cover assembly with plate 3 Bolt 4 Lock washer 5 Outch withdrawal lever 6 Retainer spring 7 Bearing sleeve 8 Outch release bearing 9 Bearing sleeve holder spring 10 Dust cover Fig CL2 Exploded view ofclutch componena Fig CL3 Supporting clutch assembly DISASSEMBLY L Clulch cover assembly cannot be disassembled since diaphragm spring is securely revetted 10 clutch cover and clulch cover assembly i...

Page 25: ...gine rear oil seals and other points for oil leakage 2 The disc should also be replaced when facings are worn locally or worn down less than 0 3 mm 0 0118 in al revets Depth gauge i Above 0 3 mm 0 0118 in CL089 Fig CL 7 Measuring clutch lining 3 Check disc plale for runout whenever the old disc or a new one is installed 4 If runout exceeds 0 5 mm 0 0197 in at the ouler circum ference of facing is ...

Page 26: ... the following points with a Iighl coat of multi purpose grease MIL G2108 or 10924 I Inner groove of release bearing sleeve Pack this recess I CL093 Fig CL 12 Lubricating recess of bearing sleeve 2 Contact surfaces of withdrawal lever lever ball pin and bearing sleeve 3 Contact surfaces of Iransmission front cover CL 5 CL094 Fig CL 13 Lubricating points of withdrawal lever and front cover Nole Ver...

Page 27: ...are used 10 locale c1ulch cover on flywheel properly 4 Remove special 1001 Clulch CLUTCH CONTROL CONTENTS CL 6 CL 7 CL 7 CL 8 CL 8 CL 8 CL 9 CL 9 CL 9 Aligning Bar ST20600000 after tightening bolts to specified torque S Install transmission Nole Make certain Ihal wilhdrawal lever engages ever ball pin 6 Connect push operating cylinder lever rod of clutch to withdrawal Inspection Assembly Installat...

Page 28: ...h disc Fig CL 15 clu fch operciiing sy tem iii clevis pin disco eF t ifus tpd from pedal assembly 2 Unhook return spring Loosen off fulcrum pin and remove pedal assembly CLUTCH PEDAL Removal L pry off cotter pin and take out Stroke 30 mm 11811 in 5 1 Clevis pin 2 Cotter pin 3 Return spring 4 Pedal boss 5 Pedal assembly 6 Bush 7 Sleeve 8 Push rod 9 Fulcrum pin 8 CLOgS CL099 Fig CL 17 Exploded view ...

Page 29: ...the specified torque Turn in or out push rod ad justing screw until a play of I to 5 mm 0 0394 to 0 1969 in at clevis pin is obtained Then tighten lock nut B to the specified torque CL101 Fig CL 19 Bending clevis pin l LJ l CL102 CL B Notes a Exercise care in adjusting the play nol to block the port on masler cylinder A blocked port may result if too small a play at clevis pin exists b Bend clevis...

Page 30: ...iston aS5embly 9ust cover Cylinder J ii I Valve spring 2 Spring seat 3 Valve assembly CL1D5 4 Return spring 5 Piston cup 6 Piston Stopper ring CL104 Fig CL 22 Exploded view of master cylinder Fig CL 23 Piston embly CLog Fig CL 21 Clutch master cylinder Inspection Wash or clean all disassembled parts before inspection Nole To clean or wash all parts of masler cylinder operating cylinder and piping ...

Page 31: ...in the reverse order of disassembly Closely observe the following instructions I Prior to assembly dip piston cup in clean brake fluid In installing cup pay particular attention to its direction 2 Dip cylinder and piston in clean brake fluid before assembly Nole Be sure 10 install pislon as sembly wilh pislon spring in place CLIO Installation Install in the reverse order of removal Closely observe...

Page 32: ...hic s c 1 iflF Clulch pedal Pedal height Play at clevis pin Full stroke Pressing slrength at full stroke Masler cylinder clutch Dia of master cylinder Allowable max clearance between cylinder and piston Clutch operaling cylinder Dia ofoperaling cylinder Tightening torque Clutch mounting bolt less than 0 5 0 0197 395 to 445 5 619 to 6 330 0 1 0 004 10 0 04 335 to 385 4 765 to 5 477 t r l i ti l t 4...

Page 33: ...ifting gears from one posilion into anolher especialIy inlo low gear TO TEST THE CLUTCH FOR DRAGGING OR GRABBING proceed as follows I Slarl up engine Disengage clutch Shift into reverse gear and then inlo Neutral Under this condition gradualIy accelerale engine speed and again shift into reverse gear If clutch is dragging gear grating is heard when shifting gears from Neutral inlo Reverse 2 Stop e...

Page 34: ...ch Is disengaged Damaged release bearing I Replace A noise is heard when clutch is disengaged Insufficient grease on the sliding sur Apply grease face of bearing sleeve Clutch cover and bearing are not Adjust installed correctly A noise is heard when the vehicle is suddenly rolled offwith clutch partially engaged Defective pilot bushing I Replace Rabbit hopping When rabbit hopping of clutch occurs...

Page 35: ...set This clutch assembly tool set is used to adjust height of dia phragm 610 SIO ST20SOOOl0 Base plale Fig CL 9 Page CL4 SE002 Center pole x 3 4 d tf5 0 0295 d Page CL4 ST20S00020 SE119 ST20SOOlOO to Distance piece 7 8 mm Page CL4 SEOQ3 ST20S00210 Height gauge 8 Page CL4 SE120 ST20S00240 Diaphragm spring adjusting wrench Fig CL1O PageCLS SE032 CL 14 ...

Page 36: ...Clutch aligning bar 3 TItis tool is used to conduct disc 610 cenlering by inserting the tool SIO into p ilpl bush in flywheel when A installing c1ulch assembly to fly a cl 1 Fig CL 3 Fig CL 14 Page CL 3 Page CL S Page CL6 r i r L i f t l c Yf 1i ST20400000 Clulch re ise checker t r 610 I i j 1 i r lit o eL1S ...

Page 37: ...t rT SECTION TM TRANSMISSION GI c1i c i i fr i 4 SPEED TRANSMISSION 3 SPEED TRANSMISSION TRANSMISSION GEAR CONTRD L 3 SPEED MANUAL TRANSMISSION AUTOMATIC TRANSMISSION TM 15 SERVICE DATA AND SPECIFICATIONS TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SERVICE TOOL TM 2 TM 9 TM 13 TM ll TM 23 TM 24 ...

Page 38: ... nize the coupling sleeve with the main shaft gear On Servo type this aclion is accomplished by the synchro ring Placing Ihe speed control lever in the reverse position throws the main rID CV I I I Front cover 2 Main drive shaft 3 Baulk ring 4 Coupling sleeve 5 Shifting insert TM 236 6 Synchronizer hub 7 3rd speed gear main shaft 8 2nd 5peed gear main shaft 9 Needle bearing 10 Ist speed gear main ...

Page 39: ... Iransmission can be dismounted from vehicle easily 12 Remove starter motor 13 Remove bolts securing Iransmis sian to engine and move transmission backward and away from the vehicle Nole Take care in dismounling transmission Dot to strike any adjacent parts and drive shaft Disassembly I Thoroughly wipe clean dirt and grease from each component parts of transmission Drain CUt oil in trans mission c...

Page 40: ...shaft from the rear of transmission case Fig TM 12 6 Remove bolts securing main shaft bearing retainer and withdraw main shaft assembly from the rear of transmission case Fig TM 13 7 Take out pilot between main shaft gear 8 Drive out main drive gear as shown using Ihe wooden handle of a hammer C TM249 Fig TM 14 Removing main drive gear assem bly Main shaft assembly I Pry off snap ring on the front...

Page 41: ...8 Driving out main drive shaft bearing iJJ I 9 1st 2nd synchromesh assembly 10 Shifting insert 11 Spread spring 12 Synchronizer hub 13 Coupling sleeve 14 Bush lstgear 15 1st speed gear main shaft 16 Thrust washer main shaft TM254 I Snap ring 2 Spacer 3 Main drive bearing 4 Main drive shaft TM 5 TM252 17 Main shaft bearing 18 Snap ring main shaft bearing 19 Steel ball 20 Reverse gear 21 Reverse hub...

Page 42: ...are excessively worn or damaged 4 Replace rear exlension bushing if worn or cracked Gears and shafts I Check gears for wear crack or damage and if necessary replace 2 Check shafts for wear crack or bending Ifnecessary replace 3 Check gears for end play Standard end play 1st 2nd 3rd and reverse idler gears O OS to O IS mm 0 0020 to 0 ooS9 in Fig TM 22 Mea8Uring gear end play 4 Measure backlash in g...

Page 43: ...4 Install anchor block and brake band in place on gear S Fit cir clip in groove in gear This dr clip is used to secure synchromesh assembly in position CID 1 Thrust block 2 Band brake 3 Synchro ring TM261 4 Anchor block 5 Cir clip 6 Band brake Fig TM 28 Synchromesh assembly 3 InstaII Ihe following parts to main shaft in Ihe order lisled 2nd gear needle roller bearing 2nd gear 2nd gear baulk ring 1...

Page 44: ...mission case Chart Snap ring thickness Spacer TM085 Fig TM 33 Installing snap ring Reverse idler gear assembly 10 Before inslalIing reverne idler shaft in transmission case install spur gear onto shaft G with the larger groove side and fit snap ring into the groove With washer placed in its position inserl reverne idler shaft assembly into transmission case from the rear side Nole Be sure 10 align...

Page 45: ...h the hole of case and drive pin f into its hole on the front side of counlershaft 14 Select and install rear thrust washer CID of the suitable thickness until proper counter gear end play is obtained Standard counter gear end play 0 05 to 0 15 mm 0 0020 to 0 0059 in Rear thrust washer No I 2 3 4 5 Fig TM 37 Bending lock plate 16 Align Ist 2nd shift fork CD and 3rd 4lh shift fork V with the groove...

Page 46: ...insert 6 Synchronizer hub 7 2nd speed gear main shaft 8 Jst speed gear main shaft 9 Synchronizer hub 1 0 Reverse gear 11 Bearing retainer 12 Rear extension housing 13 Transmission case 14 Counter gear a embly 15 Countershaft 16 Reverse idler gear 17 Reverse idler shaft 18 Steel ball 19 Main shaft DISASSEMBLY Cross shaft 1 Drive out retaining pin securing cross shaft to operating lever with Ihe use...

Page 47: ...he end play measured is excessive disassemble and check the parts for condition Replace any pa rt which is worn or defective Standard end play Thickness mm in 1st gear 2nd gear Countergear Reverse idler gear 0 05 to 0 22 0 0217 to 0 0087 0 10 to 0 22 0 0039 to 0 0087 0 04 to 0 12 0 0016 to 0 0047 0 20 to 0 40 0 0079 to 0 0157 TM l1 I y 7 13 Locking peg TM276 14 Main shaft bearing 15 Distance piece...

Page 48: ...0 0512 2 I 45 0 0571 3 1 55 0 0610 4 1 65 0 0650 5 I 40 0 0551 6 1 50 0 0591 7 160 0 0630 8 I 70 0 0669 Hub snap ring Snap ring i TM279 Fig TM 48 Fitting snap ring 6 Install main shaft assembly to transmission case from the rear side 7 Install main drive gear to trans mission case from the front side Reverse idler gear asseJ lhly 8 When inslalling reverse idler gear into transmission case be sure ...

Page 49: ...e parts with retaining rings and lock pin speedometer drive gear into rear extension housing Nole Apply sealanl on each surface of gaskel when installing 18 Move change lever in the directions as shown in Figure TM 53 10 see if gears mesh smoolWy Rev 1 li l T M284 Fig TM 53 Checking chiJflgdever aR iation 6 TRANSMISSION GEAR CONTROL 3 SPEED MANUAL TRANSMISSION Removal Inspection and repair Removal...

Page 50: ... bracket from side member and remove cross shaft assembly TM288 Fig TM 57 Removing cross shaft assembly Inspection and repair Clean parts and check for wear or TM290 Fig TM 59 Adjusting neutral position TM 14 damage If necessary replace Installation and adjustment To inslall reverse the order of removal Adjustment for Neutral Position 1 Install Ist Reverse shift rod and 2nd 3rd shift rod to re spe...

Page 51: ...cting oil cooler tubes 9 Disconnect vacuum tube from vacuum diaphragm and then at connections wiring shift down sole noid T 3 Fig TM 62 Di8connecting vacuum tube wiring to olenoid TM 15 10 Disengage propeller shaft I I Support engine by placing a jack beneath oil pan wilh a wooden block between oil pan and a jack being careful not to aIIow jack striking drain plug 12 Detach converter housing dusl ...

Page 52: ... wilh control rod insert return spring etc Installation and adjustment Floor shift 1 Adjuslmenl of control lever I Prior to installing control knob sel the dimension A to I I to 12 mm 0 433 10 0 472 in 2 After installing control knob make sure that clearances B is 0 1 to 1 1 mm 0 0039 10 0 0433 in and C is 10 mm 0 0394 in respectively 2 Adjustment of control linkage I Set selector lever located on...

Page 53: ...so that the clearance between select lever stopper pin and speed range position plate CID is 0 5 to 1 0 mm 0 0197 to 0 0394 in p R N 1 I c D Ie J f 2 C 30 l V TM296 Fig TM 65 Automatic transmission gear control column shift SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS Type F4W63 F4C63 R3W65 3N71B No of speeds 4forward I reverse 4 forward I reverse 3 forward I reverse 3 forward I reverse ...

Page 54: ...3 10 0 4 8 0 to 13 0 8 to 10 5 8 to 7 2 Front cover securing bolt 1 I to 1 8 5 8 to 7 2 Ll to 17 8 0 to 12 Rear extension inslalIation boll 16 to 2 5 12 to 18 3 3 10 4 4 24 to 32 Bottom cover l l to 18 8 0 to 13 1 I to I 7 8 0 to 12 Reverse idler shaft set screw 0 7 to l l 5 1 to 8 0 Check ball plug 17102 1 1210 15 Main shafl nut 7 0 to 12 0 51 to 87 Main shaft bearing retainer securing bolt 0 8 t...

Page 55: ...r i 2J wer valve body 0 25 to 0 35 19 10 2 5 Govefh y t6 6mdistJjb1itorti 0 t5ii 0 7 3 61h jiiJj i X Oil I WhOOl to oil p mp cover jO Q 6 to 0 8 4 4 to 2 7 u c O S to 0 7 3 6 to n InI1il orlswitsn to transmission case Manualsj lock nul 3 0 to 4 0 22 to 29 Lock nutJ9 oil cooler pipe connector to tran mission case 5 0107 0 30 to 50 Tesl plui Qil pressure inspecti n h le 14102 1 1010 15 Supporl ah tl...

Page 56: ...ion is placed in neulral The outpul shaft is fixed The engine can be started Backward running The transmission is in neutral The engine can be started Up or downshifts aulomatically to and from 1st 2nd and lop Fixed al 2nd Fixed al low or downshifts from 2nd Floor shift and remote control type R Reverse N Neulral D Drive 2 2nd lock I Lock up InlernalIy inlermeshing involute gear pump Automatic tra...

Page 57: ...inglwheel i1 iHQAt S itJ p 0 1 Shift lever positiQn h J i u LI8 i LH 1 io xfi t Column Drive plate iiti l U 0 n O 106 Retaining plate mm in 10 6 OA 17 10 8 OA25 110 OA33 112 0441 114 0 449 116 OA57 Front clutch clearance mm in 1 6 to 18 0 063 to 0 071 numbers 4 Drive plate Ihickness mm in 1 6 0063 u Driven plate numbers 4 TM 21 ...

Page 58: ...0 059 Drive plate numbers 4 thickness mm in 2 0 0 079 Driven plate thickness 4 Fletaining plate mm in 15 8 0 622 16 0 0 630 o l 16 2 0 638 0 J 16 4 0 646 16 6 0 654 16 8 0 661 Clutch clearance mm in 080 to LOS 0 031 to 0 041 Engine idling and stall revolution Engine idling 600 rpm in D range Stall revolution 1 800 to 2 200 rpm TM 22 ...

Page 59: ...akened front and rear engine mounts Transmission is noisy When noise occurs with engine idling and ceases when clulch is disengaged or when noise ocuns while shifting gears the noise is from transmis sion Probable cause Worn gears shaft and or bearing Insufficient operating stroke due to worn or loose sliding part Defective or damaged synchronizer Worn interlock plunger Worn check ball and or weak...

Page 60: ...se ST23110000 2 Counlershaft guide 8011 0911 Same as above R3W65 1d TIM fD G7 ST23540000 3 Fork rod L 501509111 This tool is used to drive out fork F4W63 Fig TM JO pin punch rod pin TIM j I 10 die 0 39 ST235S0000 Cross bar 50 5 911 This 1001 is used to drive oul cross R3W65 4 pin punch bar spring pin 3 speed TIM Fig TM 43 transmission model only 12 die 0 47 ST23620000 5 Inlerlock This 1001 is used...

Page 61: ...MODEL 610 SERIES CHASSIS BODY I NI AN I NI5SAN MOTOR CO LTD TOKYO JAPAN SECTION PD PROPELLER SHAFT DIFFERENTIAL CARRIER PROPELLER SHAFT AND PD 2 CENTER 8JARING DIFFERENTIAL CARRIER PD 6 SPECIAL SERVICE TOOL PO 3D m ...

Page 62: ...ssembly 3 Journal assembly 4 Snap ring 5 Propeller shaft tube assembly 6 Flange yoke Unit mm in Fig PD l Cross sectional view of propeller shaft for 3edan CD cv ID 11 440 17 3 722 28 4 3J 1 378 FRONT REAR PD170 1 Sleeve yoke assembly 2 Ceo ter bearing 3 Center bearing insulator 4 Cushion rubber 5 Companion flange 6 Plain washer 7 Self locking nu t 8 Flange yoke 9 Bearing race assembly 10 Snap ring...

Page 63: ...sassemble 1 Mark relationship across propeller shaft and journal so that the original combination is restored at assembly 2 Remove snap ring with a standard screwdriver 3 Lightly tap base of yoke with a hammer and withdraw bearing race A PD005 Fig PD 4 Removing bearing Note When removing journal from yoke be careful nol 10 damage journal and yoke hole When disassembling and repairing center bearin...

Page 64: ...nd tighten nuts to specified torque Tightening torque 19 to 2 6 kg m 13 7 to 18 8 ft lb INSTALLATION To install reverse the foregoing removal procedure Align propeiler shaft with com panion flange using reference marks prescribed in Removal procedure and assemble with bolts Tightening torque 2 0 to 2 7 kg m 14 5 to 19 5 ft Ib Insert bolts Ihrough the holes of center bearing bracket and torque bolt...

Page 65: ...he shafl causing Clean up shaft unbalance Tire unbalance Balance wheel and tire assembly or replace from known good car Balance weights missing Replace Knocking sound during Worn damaged universal joint Replace starting or noise during Worn sleeve yoke and main shaft spline Replace coasting on propeller shaft Loose propeller shaft installation Retighten Loose joinl installation Adjust snap ring Da...

Page 66: ...USTMENT Precaution in reassembly Assembly of differential gear case Adjustment of pinion height Adjustment of drive pinion preload Adjustment of the side bearing shims INSTALLING GEAR CARRIER ASSEMBlY TROUBLE DIAGNOSES AND COR RECTIONS SERVICE DATA AND SPECIFICATIONS The differentials should be lubri cated with oils meetings requirements of MIL L 21058 or API GL5 Renew the oil for the first 1 000 ...

Page 67: ... mate 15 Thrust washer Adjust the backlash in pinion mate and side gear or the clearance between the differentia case and the rear face of side gear to 0 1 to 0 2 mm 0 0039 to 0 0079 in by 16 Side gear 17 Bolt side flange T 19 to 2 6 kg m 13 7 to 18 8 ft lb 18 Oil seal Supply chassis greue to oil seal lip when assembly 19 Side flange 20 Side retainer 21 Bolt side retainer T 0 9 to 1 2 kg m 6 5 to ...

Page 68: ...ughness which would indicate damaged bearings or chipped gears Check the gear teeth for scoring or signs of abnormal wear Measure preload of drive pinion 4 Sel up a dial indicalor and check the backlash at several poinls around ring gear Backlash should be within 0 1 10 0 2 mm 0 0039 10 0 0079 in 5 Check the gear tooth contact wilh a mixlure powdered red lead and oil apply sparingly to all ring ge...

Page 69: ...n nol 10 confuse Ihe left and righl hand paris 2 Remove ring gear by unfolding lock strap and loosening ring gear bolts Nole Loosen bolts diagonally 3 Punch off pinion mate shaft lock pin from ring gear side using special tool Solid Punch ST23510000 Note Lock pin is caulked al pin hole moulh on differenlial case Do nol punch il off forcibly withoul checking how il is caulked 4 Draw out pinion mate...

Page 70: ...or replacement as a set Iherefore should eilher pari be damaged replace as a sel 2 Check pinion gear shaft and pinion gear for scores and signs of wear replace as required Follow the same procedure for side gear and their seats on dif ferential case 3 Inspect all bearing races and rollers for scoring chipping or evidence of excessive wear They should be in tiptop con dition such as not worn and wi...

Page 71: ...h spacer and washer between front and rear bearing cones regardless of thickness of pinion height adjusting washer This adjustment musl be carried out without oil seal inserted 1 Press fit front and rear bearing Quter races into gear carrier using special tool Drive Pinion Outer Race Drift Set STJ0611000 STJ0612000 and STJ0613000 2 Inserl pinion heighl adjusling washer and rear bearing inner race ...

Page 72: ...uge fST31211000 P018S Fig PD 23 Adjuoting pinion height PD 12 2 Measure the clearance N be tween the tip end of height gauge and the end surface of dummy shaft using a thickness gauge PD091 Fig PD 24 MeCJ3uring the clearance 3 The lhickness of drive pmlOn heighl adjusting washer can be obtained from the following formula T W N H D S x 0 01 0 2 Where T Required thickness of rear bearing adjusting w...

Page 73: ...09 56 in lb Note If drive pinion lock nut is found wilh wear replace it Adjustment of side retainer shims I If the hypoid gear set carrier differential case side bearing or side bearing retainer has been replaced with new parts adjust the side bearing preload with adjusting shim The required Ihicknesses of the left and right retainer shims can be obtained from the following formula Tl A C GI D H x...

Page 74: ...ator and adjust it to 0 10 to PD 14 0 20 mm 0 0039 to 0 0079 in If it is below the specified value move shim from right to left If it is over it move it inversely PD097 Fig PD 33 Mecuuring the back lash ofring gear and pinion 5 Check runout of ring gear side is within 0 05 mm 0 0020 in 6 AI the same time check bearing preload Bearing preload should read 9 to 17 kgm 7 8 to 14 8 in lb of rolaling to...

Page 75: ...3 4 10 57 8 ftlb INSTALLING GEAR CARRIER ASSEMBLY Position gear carrier assembly onto rear suspension member and temporarily tighten it with four bolts together with spacers PD 15 PD198 Fig PD 39 Inserting spacer Thickness mm in 4 5 0 1772 1 0 0 0394 2 Fit differenliaI mounting memo ber of fitting boils by pushing il forwards and lorque nuls 10 7 10 10 kg I l 50 6 10 72 3 ft lb 3 Secure gear carri...

Page 76: ...de gear spline Pinion bearing under preload Loosened drive pinion nut Loosen clamp bolts or nuts holding ring gear side retainers bearing cap etc Shortage of oil or use of unsuitable oil Excessively small backlash Incorrect adjustment of bearings or gears Severe service due to an excessive loading improper use of clutch Loosened bolts and nuts such as ring gear clamp bolts PD 16 Corrective action ...

Page 77: ... oil seal or bruised dented or abnormalIy worn slide face of side flange for sedan Loosened bolts such as side flange side retainer or gear carrier Defective gasket or O ring Loose fJIler or drain plug Clogged or damaged breather Replace the defective oil seal Ammend the affected flange with sand paper or replace if necessary Treat as above Tighlen the bolts to specified torque Replace defective p...

Page 78: ...ring preload and backlash between ring gear and drive pinion by selecting 12 Side bearing 13 Side gear 14 Thrust washer Adjust the backlash in pinion ma te and side gear or the clearance Qj between differential case and the rear face of side gear to 0 1 to 0 2 mm 0 0039 to 0 0079 in by IS Thrust wamer 16 Pinion mate 17 Differential pinion shaft 18 Ring gear Backlash between ring gear and drive pin...

Page 79: ...0 Side bearing 11 Side bearing adjusting shim j Adjust side bearing preload and backlash between ring gear and ii i drive pinion by selecting 12 Side gear 13 Thrust washer Adjust the backlash in pinion mate and side gear or the clearance between differential case and the rear face of side gear to 0 1 to 0 2 mm 0 0039 to 0 0079 in by 14 Thrust washer 15 Pinion mate 16 Differential pinion shaft 17 R...

Page 80: ...e original posilion 2 Remove drive pinion nut using special tool Drive Pinion Flange Wrench ST31530000 and pull off companion flange using a standard puller 5131530000 PD204 Fig PD 45 Removing drive pinion nut 3 Exlract drive pinion assembly to the rearwards by lapping Ihe front end with a soft hammer Drive pinion can be taken out together wilh rear bearing inner race bearing spacer and washer 4 R...

Page 81: ...ing companion flange with special tool Drive Pinion Flange Wrench ST31530000 P0207 Fig PD 50 Removing drive pinion nut 5 Extract companion flange using a standard puller Fig PD 51 Removing companion flange 6 Remove oil seal using speck1 tool Gear Carrier Oil Seal Pull r ST3329000 I l jST33290001 I PD 21 7 Set new oil seal in position Apply grease in between seal lips 8 Fil companion flange and fla...

Page 82: ...g gear on differential case and install bolts and lock washers Torque bolts to specifi cation and bend up lock washers Tightening torque Tightening lorque 7 108 kg m 50 6 to 57 8 ft lb Noles a Only genuine drive gear bolls and new lock washers must be used b Tighlen bolts in diagonal order while lightly lapping around bolt heads wilh a hammer 7 When replacing side bearing measure bearing width usi...

Page 83: ...i 5 Fit determined pinIon height adjusting washer in drive pinion and press fit rear bearing inner race in it using special tool Base ST30032000 Pinion height adjustingiwasher For station vagon Adjustment of drive pinion preload t tt ili w u 2 37 Q B 2 40 0 0945 2 43 0 0957 2 46 d 0969 i 2 49 0 0980 2 52 0 0992 2 55 0 1004 1 2 58 0 1016 2 61 0 1028 2 64 0 1039 2 67 O 105 I i 2 70 O 1063 2 73 0 107...

Page 84: ...on flange with special tool Drive Pinion Flange Wrench ST31530000 and tighten pinion nut As nut is tightened drive pinion is pulled into front bearing cone and into flange As drive pinion is pulled into front bearing cone drive pinion end play is reduced While there is still end play in drive pinion companion flange and cone will be felt to bottom This indicates that bearing cone and com panion fl...

Page 85: ...ness mm in 0 05 0 0020 0 07 0 0028 0 10 0 0039 0 20 0 0079 0 50 0 0197 2 Fit determined side bearing ad justing shim on differential case and press fit left and right side bearing inner races on it using special tool as follows For station wagon Side Bearing Drift ST33210000 and Adaptor ST33052000 For van Side Bearing Drift ST33230000 and Adaptor ST33061000 PD 25 3 Install differential case assemb...

Page 86: ... this specificaVon adjust it with side bearing sl tims 9 Che k and adjust the tooth contact pattern of ring gear and drive pinion This procedure can be ac complished by referring to FOR SEDAN INSTALLING GEAR CARRIER ASSEMBLY Installing can be proceeded in the veverse Qrder of REMOYAL Tightening torque for station wagon and van PD 26 Gear carrier to rear axle case 2 0 to 2 5 kg m 14 5 to 18 1 ft lb...

Page 87: ...0969 2 49 0 0980 2 52 0 0992 2 55 0 1004 2 58 0 1016 2 61 0 1028 2 64 0 1039 2 67 0 105 t 2 70 0 1063 2 73 0 1075 3 76 0 1087 2 79 0 1098 2 82 0 1110 2 85 0 1122 2 88 0 1134 2 91 0 1146 2 94 0 1157 2 97 0 1169 Drive pinion preload djusted by r Drive 0 lfi t r r o t pllll n J 1 lY Preload kg em in lI1 oou i1t Atco t bOlthO 8 w lP f4 h without il1 fi i with oil i1l J c 3 09 0 1217 3 12 0 1228 3 t5 0...

Page 88: ... 0909 Side gear and pinion mate Thickness mm in Thickness mm in Thickness mm in Thickness of side gear thrust washer 0 75 to 0 80 0 0295 to 0 0315 0 785 0 0309 0 75 to 0 80 0 0295100 0315 0 80100 85 0 0315 100 0335 0 835 0 0329 0 80100 85 0 03t5 100 0335 0 885 0 0348 085 to 0 90 0 0335 100 0354 1035 0 0407 0 85 to 0 90 0 0335 to 0 0354 1 185 0 0467 0 90 to 0 95 0 0354 100 0374 Backlash in pinion m...

Page 89: ...fix bolt 1 9 to 2 6 13 7 to 18 8 Rear cover fix bolt 1 9 to 2 6 13 7 to 18 8 Rear cover to mounting 6 to 8 43 4 to 57 8 member lock nut Differential carrier to suspension 5 to 7 36 2 to 50 6 member fix bolt Differential to drive shaft fix bolt 5 to 6 36 2 to 43 4 Differential mounting member 7 to 10 50 6 to 72 3 selflock nut Side bearing cap bolt 5 to 6 36 2 to 46 4 Side bearing cap nut 4 2 to 4 8...

Page 90: ... No J ST06270001 1 hisattachmen t is used with engine Fig PD9 stand ST05OJSOOO Strut and 610 steering gear box mounting holes are 510 Diff provided with engraved identifi S30 attachment RI60 cation marks C30 0 for gear carrier GCIO S for strut G for steering gear box SEQ40 2 ST063 10000 Fig PD 43 This tool is used for attaching gear V610 Diff W510 attachment H190 carrier to ease disassembly or 230...

Page 91: ...ess Before insertion place another drift facing inner race and then press fit These tools are used when assembling drive pinion outer race Use ST306 II000 and ST306112000 for driving in front outer race Use ST306I1000 and ST30613000 for driving in rear outer race For use when pulling out front pilot bearing After drive pinion has been pulled insert this tool from behind the gear carrier case and a...

Page 92: ...Ilis assembly is used to adjust the pinion height V610 521 SE210 12 ST3114S000 Q Page PO22 Drive pinion Fig PO54 setting gauge assembly H165 ST31942000 Dummy shaft W610 Same as above CIO ST31141000 Arrangement gauge SE210 Page PO22 Q Fig PO55 13 ST311OS000 Drive pinion setting gauge assembly H190 ST31942000 Dummy shaft This assembly is used to adjust the V610 ST31101000 pinion height 521 SE210 Arr...

Page 93: ...6 15 ST31190oo0 Page PD11 Fig PD57 Preload This tool is used to measure whether All gauge the specified preload is given to models pinion bearing SE020 16 ST31530000 610 Fig PD5 This tool is used to hold the flange W610 Fig PDI2 V610 Fig POI 5 Drive pinion to ease the operation of tightening 510 Page PO lO flange wrench and drive pinion nut W510 Fig PD 45 S30 Fig PD50 54 230 Page PD21 2 13 pitch d...

Page 94: ...l ST33051oo1 W610 Body This tool is used to pull ou t side CIO bearing BIIO ST33052000 411 Adapter 28 dia l lO SE216 20 ST3306S000 Fig PD14 Diff side i 610 Page PDII bearing V610 Fig PD48 puller W510 Page PD25 S30 ST33051001 a This tool is used to pull out side C30 Body bearing GCIO 38dia 230 ST33061000 1 501 521 Adapter SE049 21 ST332 10000 Page PD25 Diff side Use of this tool makes it possible W...

Page 95: ... drive in bearing witho lt damaging it ii 4 1 li r if I Ii t 1O This tool is used to pull out oil seal from gear carrier This tool also enables to remove side bearing outer race from retainer without damaging This tool is used to hold the puller drive shaft whe lcemoving side retainer by the Ruller PD 35 For use on 610 V610 510 W510 C30 230 521 610 W610 V610 510 W510 S30 C30 GCIO ClO 610 510 S30 C...

Page 96: ...r tool name Unit mm in on figure No 26 ST33720000 Fig PD 31 M8 x 1 2610 051 610 This guide bolt is used when attach 510 Gear carrier side ing retainer to gear carrier Use of S30 retainer guide this tool prevents damaging a ring C30 V 40 1 57 and helps smooth the operation GCIO SE056 PD 36 ...

Page 97: ...IES CHASSIS BODY INI NI NI55AN MOTOR CO LTD TOKYO JAPAN SECTION FA FRONT AXLE FRONT SUSPENSION FRONT AXLE AND FRONT SUSPENSIOM fA 2 ADJUSTMENT fA 14 SERVICE DATA AND SPECIFICATIONS TROUBLE DIAGNOSES AND CORRECTIONS fA ll fA 20 ...

Page 98: ...A 4 FA 4 FA 4 FA 4 FA 5 FA 8 FA 8 SPRING AND STRUT ASSEMBLY Removal Disassembly Inspection Assembly Installation TRANSVERSE LINK AND LOWER BALL JOINT Removal Inspection Installation FA 9 FA 9 FA lO FA l1 FA 11 FA 13 FA 13 FA 13 FA 13 FA 14 FAles 1 Strut mounting insulator 2 Coil 5pring 3 Bound bumper rubber 4 Strut assembly 5 Transverse link 6 Temion rod 7 Stabilizer bar 8 Suspension member Fig FA...

Page 99: ... and those from either side of the vehicle by means of the transverse link I i I I 1 I FA189 Fig FA 2 Sectional view of front axle disc brake FRONT AXLE AND SUSPENSION ASSEMBLY Removal 1 Jack up vehicle and support it with safety stands See relative topic under Section Gl 2 Remove hub nuts take out wheel 3 Remove splash board 4 Remove nut connecting brake tube to vehicle frame take out brake hose ...

Page 100: ...3 ft lb Tension rod bracket bolt 5 1 to 6 9 kg m 37 to 50 ft lb Tensiun rod installation nut 4 5 to 5 5 kg m 33 to 40 ft lb Tension rod to transverse link bolt 4 9 to 6 3 kg m 35 to 46 ft lb FRONT AXLE Removal Jack up vehicle until wheel falls to full down position remove wheel Disconnect brake hose at body side bracket Refer to Removal of Front Axle and Suspension Assembly Remove bolts retaining ...

Page 101: ... finger Also check to be sure that it is free from noise crack pitting or wear At the same time check outer race for condition Removal of outer race from wheel hub is not necessary Shown below is the chart which furnishes the necessary information on Visual Serviceability Standard for Wheel Bearing Visual serviceability standard for wheel bearing FA006 1 Ou ter race 2 Roller 3 Small collar 4 Colla...

Page 102: ...Tapped with a hammer while removing Seizure X X X I In the most cases seizure occurs as result of grown discoloring or flaking Scratch 6 6 6 Shock is given carelessly during installation Bit foreign matter Recess or wear 6 6 6 Careless installation removal or other rough handling scar due made by pressing to striking or striking Recess made by foreign matter Fig e f g Wear 6 6 6 Poor lubricant qua...

Page 103: ...fa pJ1se4 in a higWy moisten d place fo t a 1 long peno iof l1me f l Intrusion jof Th1 i ml t t c or the bearing is todhild tt t J1t t with baref g I uS1p 2 f acfion h s been take IS Slight d i olorUg mall 1001 liRe I idU to grease ln the osh s 4llis occurs yh ipr i J tressure is too hiW d r 1 ti l if i t t l 1 1 1 Fig h a t ill Discoloring o t J t c IA a Inner race flaking b Roller flaking c J j ...

Page 104: ... apply grease to threaded parts of spindle shaft wheel bearing washer and wheel bearing lock nut 2 Tighten spindle nut to 3 0 to 3 5 kg m torque 22 to 25 ft lb using suitable torque wrench F A200 Fig FA 17 Tightening spindle nut 3 Turn wheel hub several times in both directions to seat wheel bearing correctly again tighten spindle nut to the above torque 4 Turn back spindle nut 1 4 turns Install a...

Page 105: ...th individual markings on their wire ends yellow yellow orange and red orange When a spring requires replace ment use the one having the same color identification If this is neglected the vehicle may not settle in a normal level posture Gland packing assembly 2 Oil seal 3 0 ring 4 Piston rod guide assembly 5 Cylinder 6 Rebound stopper 7 Strut outer casing 8 Piston rod 9 Check valve spring retainer...

Page 106: ... turning of strut insulator by hand Remove self locking nut ST3565S00t F A208 Fig FA 27 Installing strut in vise 4 Take out strut insulator strut bearing oil seal upper spring seat and bound bumper rubber in the order listed 5 Remove spring from strut with spring compressor ST3565S001 left on spring 6 Retract piston rod by pushing it down until it bottoms Without disturbing the above setting remov...

Page 107: ...recisely machined to very close tolerances Before assembly clean away all dirt to prevent any possible entry of dirt into strut 1 Set up Steering Gear Housing Attachment ST27700001 in place on bottom of strut and place attach ment in jaws of a suitable vise 2 Install piston rod and cylinder into place in outer casing 3 Pour correct amount of fluid into outer casing F A065 Fig FA 31 Filling outer c...

Page 108: ...n dition retract piston rod all the way in 2 Repeat the above procedure several times so that air will be bled out from strut thoroughly 3 If during the above step an equal pressure is felt through the hand gripping piston rod on both strokes it is an indication that air is expelled from strut thoroughly FA070 FAD71 Fig FA 36 Air bleeding strot FA 12 7 Place special tool Srrut Steering Gear Housin...

Page 109: ...Assembly 2 Loosen bolts holding knuckle arm in place Separate ball joint from strut For details refer to Removal of Front Axle 3 Disconnect tension rod and stabilizer from transverse link For details refer to Removal of Front Axle and Suspension Assembly o FA212 Fig FA 40 Removing nuts 4 Increase space between steering linkage and transverse link to remove transverse link easily loosen off link nu...

Page 110: ...injected slowly and new grease does not come out from the clamp portion Installation Install transverse link and lower ball joint in reverse order of removal In rebushing link use Front Trans verse Link Replace r Se t ST36700000 It is also necessary to install bushings so that they poinl in correct direction as shown Figure FA44 Rebushing should also be in the manner that outer end of bushing is f...

Page 111: ...top I Hard 2 55 to 2025 6025 to 7 55 0 197 to 0 315 0 004 to 0 079 55 to 1025 Suspension 6 t09 o to 3 Standard 1000 to 2030 45 to 2015 6020 to 7050 0 236 to 0 354 0 to 0 1 18 R H drive Suspension 7 to 10 o to 3 Station Wagon Hard 2 1005 to 2035 45 to 2015 6015 to 7 45 0 276 to 0 394 0 to 0 118 Suspension 8 to II I to 4 Standard 1010 to 2040 55 to 2025 6010 to 7040 0 315 to 0 433 0 004 to 0 158 L H...

Page 112: ...row should be adjusted to specifications I I 105 5 mm j 4 15 in 1 6 24 I 9 28 1 6 24 1 9 28 1 6 24 19 28 2 0 28 18 26 2 1 30 1 8 26 2 1 30 2 0 28 2 3 34 3 25 46 Note Primarily both sides side rod ball joint center to center dis tances should be balanced I Front wheel turning angle adjustment I Place front wheels on turn table 2 Turn in or out adjusting bolts as required indicated by arrow until co...

Page 113: ...dtop 1 Hard 2 55 to 2025 6025 to 7055 0 197 to 0 315 0 004 to 0 079 55 to 1025 Suspension 6 to 9 o to 3 Standard 1000 to 2030 45 to 2u15 6020 to 7050 0 236 to 0 354 0 to 0 118 R H drive Suspension 7 to 10 o to 3 Station Wagon Hard 2 1005 to 2035 45 to 20 15 6015 to 7045 0 276 to 0 394 0 to 0 118 Suspension 8 to 11 I to 4 Standard 1 10 to 2040 55 to 2025 6 10 to 7040 0 315 to 0 433 0 004 to 0 158 S...

Page 114: ...5 No of effective coils 6 5 6 5 6 25 Free length mm in 371 14 61 386 15 20 330 12 99 Installed heightlload 185 270 7 28 595 200 270 7 87 595 200 270 7 87 595 mm kg in lb Spring constant 145 81 1 45 81 2 00 112 kglmm lb in Colored mark RedlOrange Yel1ow Orange Yellow Yellow Strut assembly AU models Optional hard suspension Strut outer diameter mm in 50 8 2 000 50 8 2 000 Piston rod diameter mm in 2...

Page 115: ...t kg m ft lb I 4 to 18 10 to 13 Tension rod Tension rod fIXing nut kg m ft lb 4 5 to 5 5 33 to 40 Tension rod to transverse link kg m ft lb 4 9 to 6 3 35 to 46 Tension rod bracket fIxing bolt kg m ft lb 5 1 to 6 9 37 to 50 Transverse link Transverse link to body frame kg m ft lb 9 to 10 65 to 72 Bail joint Ball joint to transverse link kg m ft lb 1 9 to 2 5 14 to 18 Ball joint to knuckle arm kg m ...

Page 116: ...roper adjust ment of the retainer parts Damaged idler arm Worn column bearing weakened column bearing spring or loose clamp Malfunction of shock absorber inside the strut or loose installation bolts Unbalance of vehicle leveL Adjust Correct the un balance or replace Replace or tighten Adjust or tighten Adjust Replace Retighten Replace defective parts Replace Adjust correctly Replace Check and repa...

Page 117: ...eering gear Deformed steering linkage Incorrect wheel alignment Damaged strut upper end bearing Damaged or stiff piston or shock absorber rod in the strut Interference of steering column with turn signal switch Incorrectly adjusted steering gear housing Worn steering linkage Improperly fitted of gear box Incorrectly adjusted wheel bearing Worn transverse link and tension rod fitting bushings Impro...

Page 118: ...eformed knuckle spindle and suspension Replace linkage Jumping of disc wheel Improper air pressure of tire Adjust Unbalanced wheels Adjust Defective shock absorber Replace Defective tire Replace Deformed wheel rim Replace Excessively or partially worn tire Improper air pressure of tire Adjust Incorrect wheel alignment Adjsut Defective wheel bearing Replace Incorrect brake adjustment Adjust Imprope...

Page 119: ...cates hole for steering gear box SE218 2 ST3532S000 This tool is used to remove or 610 Page FA 8 Outer race attach outer race for front wheel 510 drift assembly bearing C30 F ron t wheel CIO bearing ST3532 1000 Removing H ndl adapter Large ST35322000 39 1 5351 49 1 9291 Removing adapter Small ST35323000 f 1417 1811 Installing adapter Large I ST35324000 Installing SE219 adapter Small ST35325000 Bar...

Page 120: ...by covering shock absorber shaft to prevent the marring of oil seal in packing SE093 This tool is used to compress coil spring in disassembling or assembling strut assembly SE221 Bii 70 2 81 This tool is used to replace trans 610 verse link bushing In its application 510 align the tool with the bushing center by using a press SE222 FA 24 For use on 610 510 C30 CI0 GCIO 610 510 530 C30 CIO GCIO Bll...

Page 121: ...610 SERIES CHASSIS BODY I NISSAN I NISSAN MOTOR CO LTD TOKYO JAPAN SECTION RA REAR AXLE REAR SUSPENSION REAR AXLE AND SUSPENSION SEDAN REAR AXLE AND SUSPENSION STATION WAGON AND VAN SPECIAL SERVICE TOOLS RA 2 RA 9 RA 17 ...

Page 122: ...embly Inspection Assembly and installation Wheel bearing adjustment DRIVE SHAFT Removal Disassembly Inspection Assembly SERVICE DATA AND SPECIFICATIONS TROUBLE DIAGNOSES AND CORRECTIONS RA 3 RA 3 RA 4 RA 4 RA 4 RA 4 RA 4 RA 5 RA 5 RA 5 RA 5 RA 5 RA 5 RA 5 RA 5 RA 5 j 1 Suspension member 2 Suspension arm 3 Member mounting insulator 4 Differential mounting insulator 5 Coil spring 6 Bumper rubber 7 S...

Page 123: ...xle and the suspension member assembly may be removed and in stalled using the follo ing procedure I Raise the rear of vehicle high enough to permit working under neath and support it on stands Place stands solidly under body member on both sides RA102 Fig RA 2 Support points 2 Remove rear wheels 3 Disconnect hand brake cables by removing adjusting nut at adjuster CD and return spring 2 4 Remove r...

Page 124: ...correctly lined up e 0 11 0 e 0 0 2 u 0 20mm t 200 mm 0 787 in 47 2 inl Suspension member 410 mm 16 1 in 2 Rubber insulators should be cor rectly lined up as shown in Figure RA 8 and inserted from the underside of member 3 Do not use lesser quality or substitute design parts 4 Tightening torque values must be used as specified during reassembly to assure proper retention of parts IT 110 to 15 0 kg...

Page 125: ... spring is cor rectly in position flat face of spring is top 2 Tightening torque values must be used as follows Shock absorber lower end fixing bolt 6 to 2 2 kg m 12 to 16 ft lb Bound rubber nut 6 to 2 2 kg m 12 to 16 ft lb Drive shaft flange bolt 5 to 6 kg m 36 to 43 ft Ib SHOCK ABSORBER Removal I Open the trunk and remove trunk finisher assembly 2 Remove double nuts which fasten the upper end of...

Page 126: ...38280000 ST38280000 AA037 Fig RA 18 Removing rubber bushing Inspection 1 Examine suspension anns to ensure they are not deformed or cracked 2 Check rubber bushings for wear damage and separation Replace if necessary Installation Install in the reverse order of removal noting the following points I Vehicle weight must be on rear wheels when tightening suspension arm pins in order to clamp rubber bu...

Page 127: ...n the length of housing Example When an axle housing is coded B select 8 coded distance piece Shock absorber lower mounting Bearing housing mark rt Ll AXLE HOUSING DISTANCE PIECE Fig RA 23 Rear axle shaft housing Rear wheel bearing distance piece mm in mm in Mark L t length Mark L2 length A 59 05 to 59 15 A 59 02 to 59 08 2 325 to 2 329 2 324 to 2 320 B 58 59 to 59 05 B 58 92 to 58 98 2 321 to 2 3...

Page 128: ...rive shaft assembly if necessary 3 Check steel balls and sleeve yoke for damage wear and distortion Replace drive shaft assembly if defec tive parts are found 4 If any abnormal condition is found in universal joints replace joint 5 Wash out old grease from sleeve yoke drive shaft ball rolling groove and oil groove 6 Check the play in drive shaft as shown in Figure RA 25 If the play exceeds I mm 0 ...

Page 129: ...N CONTENTS DESCRIPTION REAR AXLE SHAFT AND WHEEL BEARING Removal Inspection Assembly and installation REAR AXLE CASE Removal Inspection Installation SHOCK ABSORBER Removal RA lO Inspection Installation REAR SPRING Removal Inspection and repair Installation SERVICE DATA AND SPECIFICATIONS TROUBLE DIAGNOSES AND CORRECTIONS RA lO RA lO RA lO RA lO RA l1 RA ll RA ll RA ll RA l1 RA l1 RA ll RA ll RA 12...

Page 130: ...pecial tools Rear Axle Stand ST07640oo0 and Sliding Hammer ST36230OO0 ST07640000 RA120 Fig RA 3D Removing rear axle shaft assembly 8 Remove oil seal if necessary and install new one 9 After cut collar with cold chisel remove whee bearing and collar using special tool Rear Axle Shaft Bearing Puller ST37 I20001 Then take out brake disc Fig RA 31 Removing wheel bearing Inspection Inspect the followin...

Page 131: ... and replace if necessary Installation Install the axle case in the reverse order of removal Note Change oil seal and gasket at each overhaul Tightening torque Differential gear carrier fIxing nut 2 0 to 2 5 kg m 14 to 18 ft lb U bolt 6 0 to 6 5 kg m 43 to 47 ft lb Propeller shaft flange bolt 2 0 to 2 7 kg m 14 to 20 ft lb Shock absorber lower end nut 3 5 to 4 5 kg m 25 to 33 ft lb RA ll SHOCK ABS...

Page 132: ...from spring leaves using a wire brush if neces sary Examine spring leaves for frae tures or cracks 2 Check front bracket and pin shackle U bolts and spring seat for wear cracks straightness and RA 12 damaged lhreads If defective parts are found replace with new ones 3 Inspect all rubber parts for wear damage separation and deformation Replace them if necessary Installation Install rear spring in t...

Page 133: ...969 2005 to 35 R H drive Unladen 2 to 12 25 to 1055 c 0 0787 to 0 472 5 to 5 c Laden 2005 to 35 L H drive 0 1969 to 0 1969 55 to 77 33 to SI Co Except U S A 1 to 12 l2t to 170 7410 1l2 E and Canada Unladen 25 to 1055 0 0787 to 0 4 72 r L H drive Laden 6 to 4 2020 to 50 U S A and 0 2362 to 0 1575 Canada Unladen 1 to 11 IS to I 45 0 0394 to 0 43 Rear coil spring Applied Models All models except hard...

Page 134: ... ft lb 1 6 to 2 2 12 to 16 Rear suspension member mountinglock nut kg m ft lb 7 to 10 51 to 72 Differential mounting member lock nut kg m ft Ib 7 to 10 51 to 72 Suspension arm to suspension member fIXing pin kg m ft lb 8 to 10 58 to 72 Differential to differential mounting member nut kg m ft Ib 6 to 8 43 to 58 Propeller shaft flange nut kg m ft lb 2 0 to 2 7 14 to 20 Differential to suspension mem...

Page 135: ...ing torque Shock absorber upper bracket bolt Shock absorber lower end nut Rear spring U bolt clip Spring shackle Spring front pin Spring front bracket fIxing bolt Brake disc back plate fixing nut Station wagon Van kg m ft lb kg m ft lb kg m ft lb kg m ft lb kg m ft Ib kg m ft Ib 0 9 to 1 2 6 5 to 8 7 3 5 to 4 5 25 to 33 6 0 to 6 5 43 to 47 6 0 to 6 5 43 to 47 6 0 to 6 5 43 to 47 6 0 to 6 5 43 to 4...

Page 136: ... universal joints Worn or damaged rear sllspension member mounting insulator Worn or seized sliding portion of drive shaft ball spline Breakage of coil spring Instability in driving Loosening of wheel nuts Damaged rear suspension arm rubber bushes Worn shock absorber Defective wheel alignment I coil spring wear 2 worn out spline portion of drive shaft ball spline Oil leakage Damaged oil seal on re...

Page 137: ...O D 39 mm ST3330001O Diff To take insulator out of place mounting use drift 610 Fig RA 6 insulator 2 Drift O D 52 mm Fig RA 7 drift ST33300020 To push insulator into place use this drift together with a press SE223 3 ST36230000 Sliding This hammer is used together All Fig RA 20 hammer with rear axle stand in driving models Fig RA 30 axle shaft out of place SE059 4 ST37120001 Rear axle shaft bearin...

Page 138: ... This drift is used to set oil seal in 610 its correct position without 510 marring seal C30 This drift is used to install wheel bearing onto rear axle shaft or to install inner bearing in bearing housing or to take out of the housing J This wrench is used to remove bearing lock nut on rear axle shaft This tool is used together with a hydraulic press in driving bearing collar new into place 610 51...

Page 139: ...suspension arm bushing C30 remover GCIO SE067 10 ST38290000 200 10 Rear suspension 0 39 dts 610 This tool is used to install or re member move rear suspension member 510 Fig RA 5 insulator C30 replacer insulator GCIO SE068 II ST38300000 Snap ring pliers o 610 This tool is used to take snap ring 510 out of place after removing rubber S30 boot in disassembling drive shaft C30 GCIO Page RA 8 220 a 1 ...

Page 140: ...IS BODY INI NI NI55AN MOTOR CO LTD TOKYO JAPAN SECTION BR BRAKE BRAKES BR 2 FRONT BRAKE BR Io REAR BRAKE BR 16 MASTER VAC BR l B SERVICE DATA AND SPECIFICATIONS TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SERVICE TOOLS BR 23 BR 25 BR 26 a ...

Page 141: ...ve and brake fluid warning lamp are installed on the vehicle equipped with the disc brakes The brake fluid warning lamps come into two types one is operated on the amount of the brake fluid in the reservoir of the master cylinder and the other on the line pressure of the brake fluid Two types of tandem master cylinder are used on all models one for the disc brake and the other for the drum brake T...

Page 142: ...ame direction as car drives forward BR242 Fig BR 2 Front brake shoe adjust cams 3 Turn a adjusting earn counter clockwise for right wheel clockwise for left wheel until shoes drag against brake drum 4 Turn out the adjusting earn a little at a time until brake drum is free from shoe grab 5 Follow steps 3 and 4 on the remaining cams Rear brake I Make sure that each wheel cyl inder lever of parking b...

Page 143: ...Notes a Carefully monitor brake fluid level at master cylinder during bleeding operation b Do not reuse brake fluid drained during bleeding operation c Bleed air in the following sequence Rear wheel Front wheel d Exercise care not to splash brake fluid on painted portions 5 Close bleeder valve quickly as brake pedal is on down stroke 6 Allow brake pedal to return slowly with bleeder screw closed 7...

Page 144: ...nel comes on to indicate that the brake fluid level in the cylinder is lower than the minimum allowable level Two types of master cylinder are used one for disc brake and the other for drum brake They differ from each other in the reservoir capacity and check valve Drum brake Disc brake Reservoir capacity 45 cc 2 75 cu in 110 cc 6 71 cu in Brake warning light goes on when remaining fluid in 29 cc ...

Page 145: ...y piston assembly 7 Primary piston return spring 8 Secondary piston ao sembly 9 Secondary pi lton return spring 10 Plug 1 t Check valve 12 Reservoir Fig BR 13 Master cylinder BR 6 1 Remove reservoir cap and filter and drain out brake fluid 2 Pry off stopper ring using a screwdriver 3 Remove stopper screw and take out stopper primary piston assembly spring and secondary piston assembly in the order...

Page 146: ...5 1 358 33 1 1 303 4 When master cylinder is disas sembled be sure to discard cups and valves Replace any other parts which show evidence of deformatin wear or otherwise damage 5 Replace damaged oil reservoirs and caps Assembly Assemble master cylinder in the reverse sequence of disassembly paying particular attention to the following notes Notes a Replace gaskets and packings with new ones b Appl...

Page 147: ... that the installed angle of is kept 450 and the arrow marked portion exceeds 25 mm 0 984 in in radius with the car placed on plane ground and posi tioned straight ahead I BR258 Fig BR 17 Front brake hose NP valve The NP valve features a complete separation of rear brake line and front brake line This enables the front brake to function normally even when the rear brake line is affected by trouble...

Page 148: ...nal view of warning light switch HAND BRAKE 1 Control stem 6 Control yoke 2 Control ratchet spring 7 Lever spring 3 Control ratchet 8 Control lever 4 Control guide 9 Front cable 5 Control bracket to Center lever BA261 11 Rear cable adjuster 12 Cable lock plate 13 Return spring 14 Rear cable 15 Oevis Fig BR 20 Hand brake linkage BR 9 Removal Control stern 1 Disconnect terminal from hand brake warni...

Page 149: ...are defective 2 Replace worn or fatigued springs 3 Check wires for evidence of discontinuity or other deterioration Replace ifnecessary 4 Replace defective warning light andlor switch 5 Check parts at each connection and if found deformed or damaged replace Installation Install hand brake assembly in the reverse sequence of removal by closely observing the following instructions 1 When installing ...

Page 150: ... bleeder the bottom cOnIJguration of air bleeder mount ing screw hole lends difference in shape between fore and aft cylinders Care should be taken not to confuse the one with another b Exercise care in disassembling these parts not to damage cylinder piston and piston cup c Apply a coating of brake fluid to piston cup at assembly Inspection Brake drum 1 Replace brake drum whose dia meter is beyon...

Page 151: ...tructions 1 When installing disc to spindle pay due attention not to assemble the disc or the grease catcher upside down 2 After tightening the disc at taching bolts stake the grease catcher flare to secure bolts from turning Tightening torque 2 7 to 3 7 kg m 20 to 28 ft lb 3 Make sure not to confuse fore and aft cylinders Avoid reinstalling the air bleeder only after erroneous installation of bot...

Page 152: ...utomatic adjusting operation Figure BR 32 shows the relation of force s working As brake pedal is depressed hydraulic pressure from the master cylinder forces the piston of wheel cylinder out of the caliper bore and thrusts inner pad forward until it contacts disc and simulta neously pushes outer pad by reaction force F2 These forces cause rotating moment which increases reaction force F2 BR 13 9 ...

Page 153: ... pin and pivot pin and remove nuts BA274 1 Hold down pin 2 Pivot pin Fig BR 35 Removing caliper plate 3 Disengage caliper plate from its mounting bracket Disassembly 1 Remove mud and dust from caliper assembly before disassembly 2 Remove torsion spring and take out cylinder from caliper plate BA275 Fig BR 36 Removing springs BR 14 3 Hold piston with finger feed air at brake line joint and remove p...

Page 154: ...Detach caliper auembly Disassembly Refer to Replacing pad and Replacing piston seal Assembly To assemble reverse the sequence of disassembly Caliper mounting bolts tightening torque 7 3 to 9 9 kg m 53 to 71 ft lb Inspecting rotor Remove caliper assembly Check rotor for evidence of runout or other wise damage and if necessary replace Runout Adjust wheel bearing correctly Using a dial gauge measure ...

Page 155: ...lts 8 mm diameter 1 25 mm pitch to drive it out 2 Turn pin 900 and remove anti rattler spring 3 Remove return springs and brake shoes 4J BR279 8 Return spring cylinder side 9 Bleeder 10 Lock plate A 11 Lock plate B 12 Lock plate C and D 13 Dust cover 14 Brake shoe assembly after Fig BR 42 Rear brake 4 1 Brake shoe adjuster 2 Brake shoe 8S5embly BA280 3 Return spring 4 Anti rattler pin Fig BR 43 Re...

Page 156: ...arks partial or stepped wear on its contact surface Note After brake drum is com pletely re onditioned or replaced check drum and shoes for proper contact pattern Brake assembly 1 Replace linings which are crack ed worn or oil stained 2 Replace linings if their thick nesses are worn down to less than 1 5 mm 0 0591 in 3 Replace shoe return springs which are broken or fatigued 4 Replace fatigued ant...

Page 157: ...eel cyl Made by TOKICO Made by NABca A r Ar B B C J D f c J BA283 Fig BR 46 Lock plate Brake drum 1 To install reverse the sequence of removal Note the following in structions 2 Apply a coating of brake grease to the parts indicated in Figure BR 47 wheel cylinder to disc sliding surfaces cylinder lever pivot adjuster wedge surface and periphery of tappet Note Apply a thin coating of grease to shoe...

Page 158: ... valve 2 Vaeuum gauge Fig BR 50 Air tight test set up 2 Start engine and increase engine speed Stop engine when vacuum gauge indicates 500 mmHg 19 7 inHg Air tight test 1 Fifteen seconds after engine is stopped observe the rate of drop in air pressure registered by vacuum gauge If a pressure drop of 25 mmHg 0 984 inHg is exceeded refer to the following chart to determine the cause of failure Corre...

Page 159: ...sectional view of check value BA289 Operation test 1 Connect an oil pressure gauge in brake line at connection on master cylinder 2 Install a spring scale on brake pedal 3 Start engine and increase engine speed until a vacuum pressure of 500 mmHg 19 7 inHg is registered on vacuum pressure gauge With a vacuum pressure of 500 mmHg 19 7 inHg held measure an oil pressure with respect to each pedal ope...

Page 160: ...n Bolts to be attached on dashboard are not the same in pitch 4 Using special tool Master Vac Wrench ST08080000 remove rear shell seal assembly and disassemble diaphragm plate assembly front shell assembly diaphragm spring and push rod assembly Fig BR 56 Removing rear shell Rear shell seal assembly Pry off retainer with use of a screwdriver as shown and detach bearing and seal Note Do not disassem...

Page 161: ...act portion on the pdphery of plunger assembly iPJ li IL I BR18G Fig BR 66 Requiring grease place BR 22 2 nstall plunger assembly and silencer in diaphragm plate and lightly push plunger stop key in place Note Diaphragm plate is made of bakelite Exercise care in installing plunger assembly not to damage diaphragm plate BA083 Fig BR 67 erling stop key 3 Before installing diaphragm into position app...

Page 162: ...Master Vac is properly installed in car conduct an airtight and operational tests as previously Iescribecl SERVICE DATA AND SPECIFICATIONS Brake type Front Rear Hand brake Brake pedal Free height Full stroke of pedal head Master cylinder Inner diameter Allowable maximum clearance between cylinder and piston Wheel cylinder Inner diameter Front Front Rear disc drum mm in mm in mm in mm in mm in mm i...

Page 163: ...onnector mounting bolt 6 mm 0 2362 in diameter bolt 8 mm 0 3150 in diameter bolt Wheel cylinder mounting boils Caliper fixing bolt Rotor fLxing bolt mm in kg lb nun in mm in mm in mm in mm in mm in mm in mm in mm in kg m ft lb kg m ft lb kg m ft lb kg m fl lb kg m ft Ib kg m ft Ib kg m ft Ib kg m ft lb kg m ft lb kg m ft lb kg m ft lb kg m ft lb BR 24 0 15 0 0059 max to 7 4 4 to 15 4 232 9 228 6 9...

Page 164: ... Insufficient fluid in master cylinder Fill up with specified brake fluid and bleed system Thermal expansion of drums because of Allow drums to cool off excessive overheating Check brake shoe linings and drums Replace damaged parts All brakes drag Insufficient shoe ta drum clearance Adjust clearance Weak shoe return springs Replace Brake shoe return no free travel Adjust pedal height Seized master...

Page 165: ...Tool number tool name Description Unit mm in For use on Reference page or fIgure No GG943 10000 Brake pipe torque wrench This tool is used to tighten and untighten brake tube flared nut A built in torque limiting wrench is provided to assure torque accuracy All models Figure 16 SE227 2 ST08080000 610 W610 V610 Master Vac This tool is used to remove rear 510 shell after aligning rear shell stud 230...

Page 166: ... I A I r l pt L l i f 1 fo t r t if o J 1Ii J rr J i DATSUN 1800 MODEL 610 SERIES CHASSIS BODY I NISSAN I NISSAN MOTOR CO LTD TOKYO JAPAN SECTION WT WHEEL AND TIRE WHEEL AND TIRE TROUBLE DIAGNOSES AND CORRECTIONS WI 2 WI 5 ...

Page 167: ...ed of the 6 45S l3 tire is 175 kmlh 109 MPH and that of 5 60 13 tire is 150 kmlh 94 MPH Furthermore for high speed running the radial tire is newly set up for this model vehicles except for Van As for the detailed combination of tires and vehicle models refer to the Tire and wheel usage chart WHEEL AND TIRE CONTENTS WT 2 WT2 WT2 WT2 WT 2 WT2 WT3 WT3 Tubeless tire repair Wheel repair Wear Radial ti...

Page 168: ... wheel rim and along the tread Exercise care to bead and rim where leakage occurs Wipe out water from area which leaks air bubbles and then mark the place with chalk After removing the materials caused puncture seal the point to avoid dam age to the tire due to entrance of dirt and water When repairing the punc ture use the tire repair kits which are furnished from tire dealers following the instr...

Page 169: ...ting 16 mm i in tread depth When the tires wear and then the marks appear re place them with new ones Tread wear indicator Tire tread z Z WH024 Fig WT 3 Tread wear indicator WT 4 To change tirt with wheel using a jack in the safe manner observe the following procedures l Apply parking brake and block front wheels when rear wheel is being changed 2 Remove wheel cap and loosen wheel nuts 3 Place jac...

Page 170: ...re 2 Ply or tread separation 3 Worn fabric damage on tubeless tire 4 Cracked or damaged side wall etc TROUBLE DIAGNOSES AND CORRECTIONS Condition Wheelwobbles Probable cause Improper tire pressure Damaged tire or distorted wheel rim Unbalanced wheel Loose wheel nuts Worn or damaged wheel bearing or excessive play of wheel bearing Improper front wheel alignment Worn or damaged ball joint Excessive ...

Page 171: ...t and improper speed due to Follow correct and proper driving manner rapid acceleration or improper brake applica tion Tire squeals Improper tire pressure Measure and adjust Improper front wheel alignment Align Distorted knuckle or suspension link Repair or replace WT 6 ...

Page 172: ...EL 610 SERIES CHASSIS BODY I NISSAN I NI55AN MOTOR CO LTD TOKYO JAPAN SECTION ST STEERING STEERING SYSTEM ST 2 SERVICE DATA AND ST 10 SPECIFICATIONS TROUBLE DIAGNOSES AND ST 11 CORRECTIONS SPECIAL SERVICE TOOLS ST ll ...

Page 173: ... The rubber coupling located between the steering column and the steering gear box provides a means of preventing road shocks and linkage vibrations from imparting to the steering wheel during operation On the Hardtop and vehicles destined for U s A and Canada the collapsible steering column is used as a standard equipment On the other s CD ST 2 ST 6 ST 6 ST 6 ST 7 ST 8 ST 8 ST 9 ST 9 models this ...

Page 174: ... gear housing from engine room Fig ST 5 ST168 Withdrawing steering gear housing Disassembly 1 Thoroughly drain steering gear oil by removing filler plug CD Place steering gear in a vise with special tool Steering Gear Attachment ST2770000I in place 2 Loosen lock nut and remove three sector shaft cover attaching bolts ST3 ST165 8 Sector shaft 9 Sector shaft bearing 10 Adjusting screw 11 Lock nut 12...

Page 175: ...bly may be damaged Replace with a new one Note In this inspection be careful not to damage ball guide tube ST037 Fig ST I0 Inspecting wonn shaft and ball nut assembly Bearings Replace worm shaft bearings if pitting wear or any other damage is found on it 2 If sector shaft needle bearings are found to be worn or damaged repiace them as an assembly of gear housing and bearings Oil seals Replace oil ...

Page 176: ...over ftxing bolts to 1 5 to 25 kg m 10 9 to 18 1 ft Ib 10 Push sector shaft against ball nut gear by gradually turning adjust ing screw until sector shaft gear lightly meshes with ball nut gear and temporarily secure adjusting screw with lock nut II Install gear arm to sector shaft and move sector shaft for several times from the side of gear arm and make sure it turns smoothly 12 Adjust the backl...

Page 177: ...lug with a grease nipple and apply recom mended multipurpose grease to ball joint through the grease nipple until grease forced out at grease vent hole 1 Ba11joint 2 Dust cover 3 Ball seat 4 Plug 5 Spring 5eal 0 1 to 0 5 mm 0 0039100 0197 in ST179 Fig ST 17 Sectional view of ball stud side rod Idler arm assembly Check nylon bushing of cross rod joint and rubber bushing of idler arm for breakage we...

Page 178: ...u 1 L 1 ST182 Fig ST 20 Sectional view of collapsible type steering 3 Remove steering wheel nut 4 Using the special tool Steering Wheel Puller ST27180000 thread puller anchor screws into threaded holes provided in steering wheel Turn center bolt of the special tool clockwise to remove steering wheel Note Be sure not to hammer on the steering column shaft Fig ST 22 Removing teering wheel Column sha...

Page 179: ...eel can not be rotated smoothly and steering gear steering linkage and suspension system are normal check the steering system for the following matters and replace effective parts 1 Check column bearings for damage and unsmoothness If so lubricate with recommended multi purpose grease to column bearing or replace with a new one as jacket tube assembly 2 Check jacket tube for de for malion and brea...

Page 180: ...unjn clamp 4 Loosenyv 6ltj and after sliding jackellfiiihe flange to dash Cu out panel nd igJ ttenfour b l s p and r thenbolt c er j fte Ar 1 t f rrra rethat Imtalll1zg c ol 1n cover ste riIlg V he el turils sTI1 c thlX B iiI t 1 T Assembly Assemble steering linkage in the reverse order of disassembly When assembling observe the following notes I Lubricate with recommended multipurpose grease to c...

Page 181: ...o 6 0 55 60 to 83 40 2 0 to 4 0 27 80 to 55 60 mm in 1 5 0 0591 Adjusting shim No Thickness mm in 0 762 0 0300 2 0 254 0 0100 3 0 127 0 0050 4 0 050 0 0020 End play between sector shaft and adjusting screw mm in 0 01 to 0 03 0 0004 to 0 0012 Adjusting shim No Thickness mm in I 1575 0 0618 2 1550 0 0610 3 1 525 0 0598 4 1 500 0 0591 Gear backlash at gear arm top end Tightening torque Steering gear ...

Page 182: ...eering linkage out of adjustment Re adjust and see relative topic under Front Suspension Steering column out of alignment Repair Steering wheel returns but Wheels out of alignment or air pressure Repair or inflate tires to correct air sluggisWy in tires too low pressure Defective steering linkage Replace and see relative topic under Front Suspension Car pulls to one side Wheels out of proper align...

Page 183: ...Steering wheel r steering wheel 230 Fig ST 22 puller Caution Do not hammer on BlIO steering column shaft 780 SEll6 ST27850000 This tool is placed between knuckle ann and steering ball Steering ball L280 11 r4411 13 joint to facilitate the disengage All Page ST 6 3 joint puller ment of ball joint section models Caution Do nofhaminer on bolts SE089 ST12 ...

Page 184: ...DATSUN 1800 MODEL 610 SERIES CHASSIS BODY INI NI NISSAN MOTOR CO LTD TOKYO JAPAN SECTION FE ENGINE CONTROL FUEL EXHAUST SYSTEM ENGINE CONTROL SYSTEM FUEL SYSTEM EXHAUST SYSTEM FE 2 FE 4 FE 1 ...

Page 185: ...m plished through the use of the ball joint at the jointed section On the body side the support of the torsion shaft is the oil wet bearing which is made from polyacetal resin The adoption of this bearing at this portion assures noiseless operation and prevents engine vibrations from imparting to the car body REMOVAL 1 Remove return spring 2 Remove accelerator pedal and pedal arm Note Ball jointed...

Page 186: ...er bolt until it touches pedal arm closely From that position turn stopper bolt one full rotation and tighten with lock nut securely FE052 Fig FE 5 Adjusting stopper bolt 6 On the automatic transmission model it is also necessary to adjust kickdown switch and dash pot as described below I Kickdown switch adjustment The kickdown switch adjustment is correct if kickdown switch is actuated by the sto...

Page 187: ...es The fuel tank unit gauges come into two types two tenninal G E and three terminal S G E The three terminal unit gauge is used on the SSS model On the three terminal unit when the remaining fuel in the tank reaches 8 5 liters 2 4 U S gal 1 ImpeLgal the fuel warning lamp located on the instrument panel goes on a total of four bolts two on the front and one on each side of the tank The capacity of...

Page 188: ...se 3 Filler hose 9 Reservoir tank 4 Filler neck 10 Vapor tube FE056 5 Filler cap 11 Protector 6 Breather tube Fig FE 9 Fuel tank Wagon and Van I Fuel tank 2 Reservoir tank 3 Fuel pipe 4 Vapor pipe 5 Flow guide valve 6 Fuel strainer Sedan and Hardtop 6 Van and Wagon FEOS7 Fig FE lO Fuel piping FE 5 ...

Page 189: ...urning lock plate counter clockwise with a screwdriver 7 Reservoir tank removal 1 Remove trim board from the right side ofrear body 2 Unfasten three clamps and dis connect ventilation hoses 3 Remove grommet from vapor hose and disconnect hose 4 Remove two screws on the top face of reservoir tank 5 Uft up reservoir tank and un fasten latches at lower flange section Slide out reservoir tank Notes a ...

Page 190: ...fold to front tube EXHAUST SYSTEM CONTENTS FE 7 FE 7 INSPECTION INSTAllATION constant of insulator f9T mounting is low in the vertical direction so that exhaust system vibration is not trans mitted to the body l1 Wagon and Van Fig FE 16 Removing front tube FE 7 FE 7 FE 8 On Sedan a protective heat shield is placed over the muffler to prevent trunk room floor from being heated by the muffler FE062 ...

Page 191: ...mm 0 709 in between body or frame and exhaust system component parts b After installation check to be sure that mounting hangers and brackets are placed without an undue stress Failure to follow thiscaution could result in excessive noise or vibration transmitted to car body c Check all tube connections for FE 8 leaks entire system for unusual noise etc with the engine running Tightening torque Ex...

Page 192: ...TIDN SF tf2 Wi Y t ME T i i TDR GRILLE AND FRONT APRON FRONT F RtE S SJl I1 i ENGINE Ho ob AND COWL fI TOP GRiLLE SF 12 TRUNK LID Sedan and Hardtop TAIL GATE Station wagon and Van SF 11 DOOR SEATS WINDSHIELD GLASS Adhesive caulked glass SF 34 INTERIOR TRIMS FLOOR MAT AND CENTER CONSOLE MOULDING SF 14 SF 19 SF 31 SF 31 SF 4D SF 42 ...

Page 193: ...o the lower surface of the floor Also asphalt seats adhere on the upper surface of the floor so that vibration and noise can be reduced in the cabin To wash inside the floor provides th water drain holes The front and rear ends of the body are so constructed as to absorb impact energies during a crash On Hardtop model the front pillar door support roof rail and rear quarter are specially reinforce...

Page 194: ...BODY fl E t 4 t b T rC f j i t c BF406 Fig BF 2 Body construction of the Hardtop BF 3 ...

Page 195: ...BODY ij fl BF407 Fig BF 3 Body construction of the Stahon Wagon and Van BF 4 ...

Page 196: ...ge or locating replacement parts the following underbody dimensions and alignment checking information are presented PRINCIPLES OF TRAMMING Figure BF 4 through BF 6 show reference locations required to deter mine the extent of misalignment present in underbody stracture the reference locations are symmetrical about the center line of the vehicle Tramming underbody correctly calls for two measureme...

Page 197: ...inspection indicates that these locations have been disturbed and are not suitable for mea uring one of the undamaged suspension locations should be used as an initial reference point If a rare situation should exist where all of these locations are not suitable as reference points repair operations should begin with the body floor pan area An other underbody com ponents should be aligned progres ...

Page 198: ...I GtoH 1046 0 41 2 fr t 2 GteE 1137 2 44 8 3 FtcH 1090 5 42 9 E 4 A to D 902 2 35 5 5 DtoH 939 5 37 0 6 H taU 1336 0 52 6 7 B toC 1516 6 59 7 8 EtoE 303 0 51 3 9 CtoG 12815 50 5 10 BtoC 903 2 35 6 11 Ctoe 1116 0 43 9 B 12 D to D 1116 6 44 0 13 AtoD 1516 3 59 7 I 1 400 I 14 EtoF 1033 0 40 7 84 3 3 I S l S 15 FtcH 1374 1 54 1 f l O Tolerance error 2 mm 0 0787 in Point A B Point C C D O Point E E H H...

Page 199: ...E 2 0 r 11 n I III 116136 5 I Ill I I II Il II 11 II J l1 r II C II II I I II I 111 Iltl 1 I I 000 39 4 l J J I c J 11 t 160 9 9 g 6 602 1123 1 o a u c it a l e E S P c c A 0 XI e c S s 2 8 I 0 2 9SS 413S 9 S 693 401 3 160 609 L 5 o e E 2 a n a g 5 l Bf B a ...

Page 200: ... side member and draw front bumper out of body BF413 1 Front bumper stay 2 Front apron Fig BF 9 Removing front bumper tay installation bolts BF BF 9 BF 9 BF 10 Installation Install front bumper in reverse sequence of removal noting the following point Adjust bumper for proper align ment and tighten bolts securing bumper REAR BUMPER Removal 1 Disconnect wire connectors of lamp for license number pl...

Page 201: ...rse sequence of removal RADIATOR GRILLE AND FRONT APRON CONTENTS REMOVAL SF 10 INSTALLATION SF 11 REMOVAL Remove front bumper 2 Remove radiator grille attaching screws and remove radiator grille c o CD f L IW iffirmrf 1 Spring nut 2 Plain washer 3 Spring washer 4 Screw BF416 Fig BE 12 Removing screws attaching radiDtor grille BF417 Fig BF 13 Removing upper attaching screw and spring nut BF l0 ...

Page 202: ... 2 Front fender 3 Baffle filler 4 Fender rubber 5 Front apron 6 Hood lock stay 7 Sealing rubber CD L BF421 i 1 V Fig BF 17 Exploded view offront fenders and apron BF l1 Jml tllilillill1J BF420 1 Front apron 2 Hood lock stay Fig BF 16 Removing screws attaching front apron to h09d lock stay j i fii k rif t i 7 t 4 r l riJ U l 1 c f 4 t t ElF 12 Open engine hood and support it in open position with a...

Page 203: ...protect body with covers to prevent scratch to the paint 2 Mark hood hinge locations on hood for proper reinstallation 3 Support engine hood with hand and remove bolts securing hood hinge to hood taking care not to let the hood slip when the bolts are re moved CONTENTS SF 12 SF 12 SF 12 SF 12 COWL TOP GRILLE AND HOOD HINGE Removal Installation SF 13 SF 13 SF 14 Fig BF 21 Removing bolb attaching ho...

Page 204: ...fenders 6 Tighten hood lock male lock nut after the proper adjustment has been obtained 7 Make sure that female lever locks hood lock male securely when hood is closed and also safety catch retains hood properly when hood lock is released See Figure BF 26 BF429 Stopper Hood lock stay Hood lock female Fig BF 25 Adjusting hood lock female Notes When inspecting the hood lock note the following proced...

Page 205: ...TENTS TRUNK LID Removal and instaHation Adjustment TORSION BAR Removal Installation TRUNK LID HINGE SF 14 SF 14 SF 14 SF 15 SF 15 SF 15 SF 15 Removal and installation TRUNK LID LOCK CYLINDER Removal Installation TRUNK LID WEATHERSTRIP Removal and installation BF 15 BF 16 SF 16 BF 16 BF 16 SF 16 TRUNK LID c II 4 Install trunk lid in reverse sequence of removal Removal and installation 1 Open trunk ...

Page 206: ... bar from torsion bar bracket and hinge 5 Remove right torsion bar in the same manner above 3 BF436 1 Hole for torsion bar end 2 Torsion bar bracket 3 Left torsion bar 4 Left trunk lid hinge Fig BF 32 Installing left torsion bar 2 Position the end of right torsion bar first to right trunk lid hinge SF 15 BF437 Torsion bar 2 Trunk lid hinge Fig BF 33 Positioning the end of right torsion bar to hing...

Page 207: ...moving cylinder attaching screws CD cv p BF443 Lock cylinder 2 Insulator Fig BF 39 Component parts of lock cylinder 3 Clip Installation I Assemble lock cylinder and insert and push it into position until clip secures lock cylinder BF444 Fig BF 40 Pushing lock cylinder into position TRUNK LID WEATHERSTRIP A BF445 1 Trunk lid weatherstrip 2 Adhesive 3 Trunk lid Fig BF41 Sectional view of trunk lid w...

Page 208: ... STRIKER Removal and installation Adjustment TAIL GATE LOCK CYLINDER Removal Installation SF 18 SF 18 8F 18 SF 18 SF 18 eF 18 8F447 Fig BF43 Adjusting tail gate up and down and from side to side BF448 Bolts Fig BF 44 Adjusting tail gate fore and aft TAIL GATE TORSION BAR Removal and installation I Open tail gate and support it in open position 2 Loosen screws attaching tail gate hinge cover and re...

Page 209: ...le 5 Install tail gate lock striker catcher and striker in reverse sequence of removal Adjustment 1 Striker catcher can be adjusted from side to side and striker can be adjusted fore and aft Before adjust ing tail gate lock make sure that tail gate is properly aligned Bolts BF452 Fig BF 48 Adjusting striker catcher from side to side BF IB f 2JiV Fig BF 49 Adju ting striker fore and aft 2 To make g...

Page 210: ...GLASS Hardtop Removal Installation Adjustment SODY SIDE WEATHERSTRIPS Hardtop Removal Installation and adjustment 5 Install front door in reverse sequence of removal Rear door 1 Open front door and keep on the door open 2 Open rear door and place a support under door Use pads be tween door and a support to prevent from damage 3 Loosen bolts attaching rear door hinges to center pillar and remove re...

Page 211: ...moving door finisher 7 Remove watertight seal cover from door panel Installation Install door trim in sequence of removal With door glass up handle should be installed in Figure BF 59 reverse regulator as shown r I L L spring Armrest 2 Cover BF460 Fig BF 56 Remouing bolts attaching ann rest Hardtop BF462 Fig BF 59 Installing regulator handle BF 20 DOOR LOCK AND STRIKER Removal and installation Ope...

Page 212: ...Fig BF 66 Adjusting handle free play Front door o BF470 Outside door handle 2 Adjusting nut 3 Remote control rod Fig BF 67 Adjusting handle free play Rear door 1 1 1 Out ide door handle 2 Adjusting nut BF471 3 Remote control rod Fig BF 68 Adjusting handle free play Rear door BF 21 Inside door handle To adjust inside door handle free play move inside door handle base fore and aft in elongated holes...

Page 213: ...cheon door lock knob door finisher and watertight cover 3 Remove door outside weather strip and door lock knob 4 Remove screws attaching front lower sash and remove front lower sash from door glass It is not necessary to draw front lower sash out of door before removing door glass 5 Support door glass and remove screws retaining guide channel B to glass back plate ll tf 0 rmi W j 2 r J U I I CD Ii...

Page 214: ...s and front lower sash Raise and lower glass to assure a good glass fit 1 11 1 t 111 no BF477 Fig BF 74 Adjusting rear lower sush 3 With glass up adjust glass in parallel with the top rail of door sash by moving guide channel A up and down The sideward free play of glass can be adjusted by moving front lower sash fore and aft CD t I I BF 23 BF478 I Guide channel A 2 Front lower sash Fig BF 75 Adju...

Page 215: ...nside door handle escutch eon door finisher and watertight cover 3 Remove door outside moulding 4 Drive oul inner pin of clip retaining outside finish and then remove retaining clip outside finish and outside weatherstrip from door BF482 I Door ouUide finish 2 Door outside moulding 3 Glass 4 Door finish BF481 5 Raise door glass until glass upper stoppers appear in the upper openings of inside door...

Page 216: ...usting bolts means the center of the elongated holes For lower adjusting bolt tighten it all the way and retum nine turns and secure lock nut at that position BF4B7 I Upper adjusting bolts 2 Spacer 3 Lock nut 4 Guide rail 5 Lower adjusting bolt Fig BF 84 Guide rail adjusting mechanim face becomes 8 5 to 10 5 mm 0 3346 to 04134 in BF 25 8F488 Upper adjusting bolts 2 Scale Fig BF 85 Adjustingguide r...

Page 217: ... of glass and the end of glass guide is 0 to 0 5 mffi 0 to 0 0197 in just before contacting door glass with door side weather strip SF 26 CD cv o to 0 5 mm 0 to 0 0197 in BF497 1 Weatherstrip retainer 2 Glass guide 3 Doorglass Fig BF 94 Proper clearance between glass and glass guide to Raise and lower door glass to be sure the operation of regulator handle is smooth The operating force of regulato...

Page 218: ... mechanism Removal 1 Lower door glass 2 Remove door lock knob and grommet 3 Remove arm rest regulator handle inside handle escutcheon door finish and watertight seal cover from door 4 Remove door outside weather strip and rear sash 5 Remove screws attaching guide channel B to glass back plate and draw door glass out of door N 1 Rear sash 2 Guide channel B Fig BF 97 Removing screws attaching rear Q...

Page 219: ...verse sequence Fig BF 99 Adjusting front lower sash REAR SIDE WINDOW GLASS Hardtop CD 1 J L r d I Z To adjust the sideward free play of door glass move rear sash fore and aft by loosening lower attaching screw Tilt adjustment of glass can be performed by moving guide channel A up and down 8 F 503 1 Rear sash 2 Guide channel A Fig BF 100 Adjusting rear sash and guide channel A BF504 1 Side window g...

Page 220: ...lass with guide panel and remove them toward pas senger room 13 Remove regulator base attach ing screws and draw regulator as sembly out through the lower opening of inside panel BF 29 Installation and adjustment 1 Install window glass and regula tor assembly in reverse sequence of removal 2 With window glass down tem porarily tighten guide plate adjusting bolts in the neutral position The neutral...

Page 221: ...17 Install seat back and cushion BODY SIDE WEATHER STRIP Hardtop Removal 1 Remove rivets retaining body side weatherstrip to front pillar BF512 1 Rivet 2 Weatherstrip Fig BF 109 Removing body side weatherstrip retaining riveta 2 Remove screws installing weath erstrip retainer to roof side rail BF513 Fig BF I10 Removing attaching screws ofweatherstrip retainer 3 Remove front pillar garnish and then...

Page 222: ...erstrip should be install evenly without stretching it out partially 6 Install front pillar garnish and body side welts SEATS CONTENTS BF 32 BF 32 BF 32 BF 32 Removal and installation REAR SEAT Station wagon and Van Removal and installation SEAT BELT ANCHORAGES BF 32 BF 33 BF 33 BF 33 hand brake lever and seat belts at 8 Pre delivery service b Parts replacement J 1 BF517 1 Reclining device assembl...

Page 223: ... V 8F678 Unit mm in FiC BF 118 Weight position for bench seat 2 Using test light check whether light grows when 6 1 kg 13 45 Ib weight is on and light goes out when 10 kg 3 211b is on 3 Seat switch should be installed right position See Figure BF 119 BF 120 and BF 121 8F679 pring Sectional view of X X Inside Outside Fig BF 119 Seat switch location BF 32 BF680 Fig BF 120 Seat switch installation fo...

Page 224: ...r and hinge bracket from body 4 Install rear seat cushion and rear seat back in reverse sequence of removal Fig BF 125 Seat belt anchorages for the Hardtop SEAT BELT ANCHORAGES The weld nuts for seat belt are located at the floor rear quart r panel and roof side rail as shown in Figure BF 124 through Figure BF 126 Seat belts must be used the Nissan Datsun recommended parts and be installed to thes...

Page 225: ...nter pillar and roof D 1 Strap 2 Center pillar 3 Seat belt WINDSHIELD GLASS Adhesive caulked glass CONTENTS SF 34 SF 34 side rail for stowage as shown in Figure BF 128 BFS26 Fig BF 128 Installing shoulder belt straps WATER LEAK CORRECTION SF 37 REMOVAL AND INSTALLATION 1 Protect hood front fenders instrument panel and front seats with covers 2 Remove windshield wipers front pillar garnish instrume...

Page 226: ...ealant 7 Working from inside vehicle push windshield glass out of window opening 8 Using a razor blade or sharp scraper remove caulking material along entire edge of window opening leaving it about 1 to 2 rom 0 0394 to 0 0787 in thick Note Plate surfaces need not be exposed Installation Note Do not allow oil grease and water to get on cleaned sudaces by touching with dirty hand or fouled tool 3 In...

Page 227: ...anner as above coat welded flanges of window opening with primer M a Apply primer M to original caulking material ifleft on flanges b Allow primed surfaces to air dry for at least 10 minutes 10 Insert cartridge in special tool Caulking Hand Gun ST08810000 and place smooth continuous bead on glass 10 mm 0 394 in above glass surfaces SF 36 Masking tape ST08810000 BF333 Fig BF 139 Applyingadhesive ca...

Page 228: ...ing material detennine the extent of leak by pushing on the glass outwards INTERIOR TRIMS FRONT PI LLAR Removal and installation CENTER PI LLAR GARN ISH Removal and installation REAR DOOR GARNISH Removal and installation REAR CORNER GARNISH BF 37 BF 37 BF 38 BF 38 BF 38 BF 3B BF 38 FRONT PILLAR Removal and installation CONTENTS Apply water to leak area while pushlng on the glass Mark the extent of...

Page 229: ...rse sequence of removal REAR DOOR GARNISH Removal and installation 1 Remove screws attaching rear A CD 4 Section A A 1 Remove body side welt which is installed to rear corner flange 2 Remove corner garnish corner garnish clips retaining rear and then remove rear SF 38 A cp 1 Section A A 8F533 Body ide welt 2 Center pillar garnish Fig BF 143 Removing centerpillar garnish door garnish and remove gar...

Page 230: ...nd then draw rear corner garnish forwards Section A A BF536 Fig BF 146 Removing rear corner garnish CID I CID BF 39 3 Install rear corner garnish in reverse sequence of removal REAR PARCEL SHELF Removal and installation 1 Remove rear seat cushion and rear seat back 2 Remove clips retaining rear parcel shelf front end and remove rear parcel shelf forwards o o Fig BF 147 Removing rear parcel shelf 3...

Page 231: ...t and rear listing wires b Wrinkles can prying lining wire be removed by ever along lining 3 Cement the end of head lining to body flange while pulling it down at sides to remove wrinkles 4 Trim the remaining head lining to proper size Note In trimming at front pillars center pillars and rear quarter panels care should be taken to reserve enough end since head lining must be touched at these parts...

Page 232: ... taching screws and then remove front console 4 Install front and rear console in reverse sequence of removal CD v c pJ2 S J I o l i Fig BF 152 Structural view of instrument panel BF 41 Removal and installation Instrument panel assembly I Disconnect battery cable 2 Remove horn bar steering wheel and shell assembly 3 Remove heater control cable clamps from heater assembly BF542 Fig BF 153 Removing ...

Page 233: ...over 2 Remove screws retaining cluster lid A and remove cluster lid A from instrument panel Retaining screw A which secures cluster lid A to instrument panel can be removed from the inside of cluster lid A See Figure BF 157 BF546 Fig BF 157 Removing cluster lid A retaining screws 3 Instan cluster lid A in reverse sequence of removal Cluster lid B I Disconnect battery cable 2 Remove steering column...

Page 234: ...Center pillar cover 8 Door sash cover Fig BF 159 Mouldings of the Sedan BF549 I Center pillar cover 2 Roof drip moulding 3 Sill moulding 4 Body outside moulding 5 Body outside finisher BF550 Front windshield moulding 2 Rear windshield moulding 3 Roof drip moulding 4 Sill moulding 5 Door and rear fender moulding 6 Door and rear fender finisher 7 Rear panel moulding Fig BF 161 Mouldings of the Hardt...

Page 235: ...d mouldings in reverse sequence of removal REAR WINDSHIELD MOULDING CID L Section A A BF553 Windshield glass Lower moulding 3 Fastener for lower moulding Fig BF 164 Sectional view of rear windshield moulding CD 1 J 1 J 1 Fastener 2 Fastener for lower moulding BF554 Fig BF 165 Rear wind8hield moulding fastene1 3 Removal and installation Open trunk lid 2 Drive out inner pin ot lower moulding fastene...

Page 236: ... Finisher 2 Moulding 3 Clip 4 Door glass Fig BF 172 Sectional view of door moulding and finisher Hardtop BF 45 Removal and installation 1 Remove door moulding using a flat headed driver Insert a pad be tween a driver and door panel to protect door paint BF562 Fig BF 73 Removing door moulding 2 Remove door finisher and water tight seal cover and then drive beading clip inner pins out of clip and re...

Page 237: ...r panel 3 Beading dip Fig BF 177 Installing door outside finish and moulding Sedan Station Wagon and Van BF567 1 Outside finish 2 Door panel 3 Beading clip 4 Moulding Fig BF 178 Installing door outside finish and moulding Hardtop 8 8J 3 c Section A A Section B B M t 8F568 I Front pillar 2 Front moulding 3 Center moulding 4 Roof panel 5 Rear moulding SCtt ion C c Fig BF j79 Roofdrip moulding Sedan ...

Page 238: ...Section B B r ID BF57Q A A Section A A 1 Front sash cover 2 Rear sash cover 3 Center pillar cover 4 Adhesive 5 Center pillar FiBF 181 Sectional view of door sash and center pillar cover REAR PANEL AND TRUNK LID MOULDING J CID Section A A A A ID SectIon B B CID 1 Trunk lid panel 2 Trunk lid moulding 3 Beading clip 4 Clip 5 Seal rubber 6 Rear fender 7 Rear fender moulding 8 Rear panel moulding 9 Ret...

Page 239: ...ol number For Reference No Description use page or tool name Unit rom in on figure No ST08800000 Page BF 36 Fig BF 140 This tool is used to secure and set the windshield glass panel on the Sucker spacer This tool also serves for the 610 satisfactory adhesion of glass panel 230 to body under its uniform pressure after setting SE231 2 ST08720000 Page BF 20 Fig BF 55 Door This special wrench is used ...

Page 240: ... t Ir f l f f j f klo rl fJ f iII t I j J f 1 I DATSUN 1800 MODEL 610 SERIES CHASSIS BODY I NISSAN I NI55AN MOTOR CO LTD TOKYO JAPAN SECTION BE BODY ELECTRICAl WIRING BE 2 FUSE AND FUSIBLE LINK BE 3 LIGHTING AND SIGNAl SYSTEM METERS AND GAUGES IGNITION SWnCH AND STEERING LOCK HORN WINDSHIELD WIPER AND WASHER RADIO HEATER BODY ELECTRICAL BE 4 BE 17 BE 25 BE 27 BE 28 BE 33 BE 36 CI ...

Page 241: ... system standard color or supplementaIY color to standard color s generally applied Colors are repre sented respectively by such letters as G Wand Br Applied to minor item of each circuit s terminal is two tone which is composed of standard and supplemental colors Each of such two tone colors is indicated with com bination of two letters like RW or GY and first letter of each combination stands fo...

Page 242: ...ases visual inspection can reveal defective fuse Ifcondition of fuse is questionable conduct conti DUity test with use of circuit tester or test lamp Notes 3 If fuse is blown off be sure to eliminate the cause before installing new fuse in position b Use fuse of specified rating Do not use fuse of more than specified rating BE 3 BE 3 c Check fuse holders for condition If much rust or dirt is found...

Page 243: ...BE 10 BE 10 BE 10 BE 10 BE 11 BE 11 BE 11 BE 11 BE 12 Combination lamp assembly replacement Bulb replacement LICENSE LAMP License lamp assembly replacement Bulb replacement BACK UP LAMP TURN SIGNAL AND LIGHTING SWITCH Removal LIGHTING SWITCH Removal HAZARD WARNING SWITCH Removal BULB SPECIFICATIONS TROUBLE DIAGNOSES AND CORRECTIONS Head lamp system Signal lamp system and left head lamps are indepe...

Page 244: ... switch is not supplied LH D OFF I B with current Keep lever in posi Relay contact trans Either high or low When current is supplied to circuit after tionC fers beam is lit accord lighting switch contact transfers at the iog to relay s same time By operating lever C B 00 C contact B beam repeats flashing and shifting and may serve as passing light Contact point stays Neither high or low Tail lamp ...

Page 245: ... f ON RY I GW 2 GL 3 4 PT TERMINAL FUSE BOX PARKING TAIL ETC LAMPS E R ABC BR 5 RY 6 RY 7 TURN SIGNAL 3 LIGHTING SWITCH C B A Fig BE 4 Circuit diagram for lighting system R H drive vehicle LEVER POSITION BE240 lOA HIGH BEAM PILOT LAMP LIGHTING SWITC H I 2 PT TERMINAL FUSE BOX PARKING TAIL ETC LAMPS LEVER R ABC BR 4 RY 5 6 TURN SIGNAL LIGHTING SWITCH ABC LEVER POSITION BE 6 Fig BE 5 Circuit diagram...

Page 246: ...4 6 LIGHTING 5Wr FOR L H DRIVE VEHICLE W BODY EARTH TAIL LAMP R Hl LICENSE LAMP 8 IL Hl IllUMINATION LAMPS I NSTRUMENT PANEL CONTROL KNO 8 ASH TRY CIGARETTE LIGHTER H EATER CONTROL BE242 Fig BE 6 Circuit diagram for lighting system R H L H drive vehicle BE 7 GW GL O 8 ROOM LAMP REAR ROOM LAMP J t cr Q jj TAIL GATE DOOR SWITCH GW 11 GLOVE BOX LAMP SWITe GW ...

Page 247: ...rille or head lamp fmisher 2 Loosen three head lamp retaining ring screws It may be unnecessary to remove screws Note Do not disturb aiming adjust screws 3 1 Aiming adjusting screw 2 Head lamp retaining ring 3 Head lamp beam 4 Head lamp mounting ring BE244 Fig BE B Head lamp BE 8 3 Remove retaining ring by rotating it clockwise 4 Remove head lamp beam from mounting ring and disconnect wiring conne...

Page 248: ...adiator and engine oil pan filled up to correct levels 2 Without passenger When performing head lamp aiming adjustment use an aiming machine aiming wall screen or headlight tester For operating instructions of any aimee refer to respective operation manuals supplied with the unit I z hi 82 10 m 30 3 ft LZ PASSING BEAM Low Beam BE246 Driving beam High beam Passing beam Low beam d HI WI JI hI L H2 W...

Page 249: ...king pins in base of bulb is in the proper position of socket Press bulb inward rotate it clockwise and lock bulb in socket Lamp assembly replacement 1 Remove two lens retaining screws and detach lens and packing 2 Disconnect lead wires at con nector 3 Remove flange nuts from two mounting studs on back of bumper and dismount lamp assembly 4 Install new assembly in reverse sequence of removal Bulb ...

Page 250: ...II I II 1 11 111 1 11 11 1 T i 1 BE25Q Fig BE 14 Rear room lamp BE 11 two screws from front of lens and disconnecting wires from connector To replace bulb remove lens and change bulb To remove lamp body pull out lamp body from roof and disconnect room lamp wires at connector Room lamp is held by spring pressure against roof To replace bulb remove lens and change bulb To remove lamp body remove two...

Page 251: ...lb into socket mak ing certain that locking pins in base of bulb is in position Press bulb inward rotate it clockwise and lock it in socket 4 Insert socket into lamp housing with locking tab in proper position Rotate socket clockwise to lock it in housing shade 1 Disconnect trunk harness at con nector 2 Remove eight flange nuts on lamp housing shade in trunk 3 Remove lamp housing shade lens and pa...

Page 252: ... Replace bulb with new one 4 Install cover lens and packing in reverse sequence of removal BE253 1 Packing 2 Lens 3 Lens cover Fig BE 17 License lamp Sedan Hardtop License lamp assembly replacement 1 Remove tailgate trim 2 Remove two tailgate handle re taining nuts 3 Disconnect lead wire at con nector 4 Dismount lamp assembly from vehicle CDl9I Bulb replacement 1 Remove two lens retaining screws 2...

Page 253: ...bly LIGHTING SWITCH Removal 1 Remove upper and lower shell covers from steering column by loos ening four screws 2 Loosen two cluster lid cover Ie taining screws and remove cluster lid cover 3 Remove five screws from front of cluster A and remove one screw hold ing cluster A to instrument panel from behind Thus cluster A is detached 4 Remove switch knob by de pressing it and turning it CQunte rdoc...

Page 254: ...p system Condition Probable cause Corrective action Head lamps both of high beam and low beam do not light Neither high beam nOT low beam is lit 1 Even when lighting switch is set to OFF and lighting lever switch is switched to operate passing light it will not do Fusible link blown off When fused detect and eliminate the cause and replace with new one Faulty lighting relay terminal con nectar Che...

Page 255: ... on right side does not light Faulty head lamp terminal coo Check connector for contact and re nector pair as required Head lamps dim Defective head lamp circuit Check head lamp circuit for cable about to break or in faulty contact or check fuse for faulty contact Repair or replace if required 1 Head lamps dim when the engine is Battery partly discharged Measure specific gravity of electrolyte top...

Page 256: ...s operate properly but hazard warning lamps will not operate properly Flashing cycle is too low or high o Defective flasher unit METERS AND GAUGES CONTENTS DESC R I PTI ON CLUSTER LID Removal SPEEDOMETER Removal FUEL METER AND WATER TEMPERATURE METER Replacement Oil PRESSURE WARNING lAMP GENERATOR WARNING lAMP BE 17 BE 19 BE 19 BE 19 BE 19 BE 19 BE 20 BE 20 BE 20 DESCRIPTION Two types of cluster l...

Page 257: ...h 18 Hazard switch 19 Rear window defroster switch 20 CigaI lighter 21 Heater control Urn 1 Fuel meter 2 Oil pressure meter 3 Water temperature meter 4 Clock 5 Speedometer 6 Tachometer 7 Hand brake warning lamp 8 Generator warning lamp 9 Oock control 10 High beam pilot lamp 11 Odometer 12 Trip meter 13 Trip meter fe set control 14 Turn signal pilotlamp 15 Cigar lighter BE lB 16 Radio 17 Heater con...

Page 258: ...owing to the fuel meter The water temperature meter con sists of a meter and thermaltransmitter located in the engine block The ther FUSE BOX IG Gl IGNITION SWITCH FUSIBLE LINK O 3 lHlwN w FROM BATTEin THERMALTRANSMITTER maltransmitter is equipped with a thermistor element which converts cooling water temperature variation to a resistance and thus the thermal transmitter controls current flowing t...

Page 259: ...egulator Fig BE 28 1 When the engine is started and the generator comes into operation the generator output cur rent from N terminal opposes the FUSE BOX 5A G G FROM FUSIBLE LINK BATTER roMETER OLTtlGE REGULATOR 03 BROWN TO SATTER I G TO OTHER WARN I NG lA A GENERA OR oIIItlRNING LAMP C n GENERATOR BE262 Fig BE 26 Removing meter OIL PRESSURE WARNING LAMP The engine lubricating system in corporates...

Page 260: ...s close As the contacts close the lamp glows FUSE BOX 5A 0 3 BROWN IGNITION SWITCH FUSIBLE LINK YG 0 3 BROWN YG FROM BATTERY YG TACHOMETER General areas p U S A Canada 8E266 Fig BE 30 1mtalling tachometer BE 21 YR TO METER VOLTAGE REGULATOR G OTHER WARNING LAMPS HAND BRAKE WARNING LAMP HAND BRAKE SWITCH 0 11 BRAKE LINE SWITCH o jl BE265 Fig BE 29 Circuit diagram for brake warning system Installati...

Page 261: ...ightened speedometer cable Retighten and odometer do not union nut opera e Broken speedometer cable Replace Damaged speedometer drive pinion gear Replace Defective speedometer Replace Speedometer pointer Rapidly bent speedometer cable Correct or replace deflects excessively Damaged speedometer drive pinion gear Replace Defective speedometer Replace Unstable speedometer Improperly tightened speedom...

Page 262: ...is case meter pointer fluctuates slight ly Check cable for improper contact and repair if required Water temperature meter Water temperature Defective thennaltransmitter Replace thermaltransmitter if pointer de meter does not operate flects when thermaltransmitter yellow white cable is grounded Defective water temperature meter Replace meter if pointer does not deflect when thermaltransmitter yell...

Page 263: ... Fuel meter functions Defective tank unit Replace tank unit if pointer indicates a half improperly level when a 32f resistance is applied between tank unit yellow cable and ground Defective fuel meter Replace fuel meter if pointer does not indicate a half level through the above inspection Improper cable contact If fuel meter indicates a level slightly lower than actual level check cable from fuel...

Page 264: ...tive bulb or faulty cable contact Pilot lamp does not light when white red cable in voltage regulator wiring connector is grounded and ignition switch is set to ON Check bulb for burnt out filament and replace if necessary Lamp does not go out Faulty charging system Inspect charging sysytem when engine is started IGNITION SWITCH AND STEERING LOCK CONTENTS IGNITION AND STARTER SWITCH Removal IGNITI...

Page 265: ...equired Break two selfshear type screws with a drill or other proper tool Now remove the steering lock from the steering lock clamp When installing a new steering lock be sure to tighten two new selfshear type screws to shear offtheir heads 1 Steering lock clamp 2 Self shear type screw 3 Ignition switch 4 Steering lock Fig BE 32 Steering lock installation Ignition switch replacement To replace ign...

Page 266: ...enoid is energized the relay contacts close This allows the current to flow to the horn S 1 TO STOP LAMP SWITCH HORN BUTTON Fig BE 34 Circuit diagram for horn system A v Horn Battery I 12V I BE169 Fig BE 35 Circuit for sound adjustment BE 27 2 Set switch to ON and ascertain that voltmeter reading is anywhere between 12 and 12 5 volts 3 Listening horn for sound level volume and tone adjust amperage...

Page 267: ...elay terminal S Replace horn button Reduced volume Improper fuse contact and loose Correct and or tone quality connection Broken cable Repair or replace if required Improper horn button contact Repair WINDSHIELD WIPER AND WASHER CONTENTS DESCRIPTION REMOVAL AND INSTAllATION Wiper motor and wiper linkage BE 28 BE 29 BE 29 Washer nozzle INSPECTION TROUBLE DIAGNOSES AND CORRECTIONS BE 30 BE 31 BE 31 ...

Page 268: ...sly more than 30 seconds or without washer fluid This often causes improper windshield washer operation Normally windshield washer should be operated 10 seconds orJess at one time 4j t fJ i c i f S iiWj0 V jiJli BE212 1 Wiper arm R H 2 Pivot LH 3 Wiper arm LH 4 Pivot R Hl 5 Wiper motor Fig BE 38 Wiper motor and wiper linkage windshield glass and then remove the base of wiper arm from pivot shaft b...

Page 269: ...l Install wiper blade in correct instal lation angle to obtain correct sweeping zones 20 mm 0 787 in BE275 Fig BE 41 Wiper ann imtallation Washer nozzle 1 Remove washer nozzle fIXing screw from cowl top panel 2 Remove wash r nozzle 3 Install washer nozzle in the re verse sequence of removal 4 Adjust nozzle direction so that fluid is sprayed in proper range as shown in Figure BE 43 BE216 1 Washer t...

Page 270: ...e with a suitable tool BE277 Fig BE 43 Nozzle adju5tment INSPECTION I Disconnect wIrIng from wiper motor connector 2 Connect test lead between blue red wire terminal in wiring connector TROUBLE DIAGNOSES AND CORRECTIONS Condition Probable cause Corrective action Windshield wiper Motor No current flows to motor due to does not operate Broken armature Replace motor Worn motor brush Replace motor Mot...

Page 271: ...or in arm operat Lubricate or replace ing cycle due to seized arm shaft Switch Improper switch contact Conduct continuity test and replace if necessary Windshield Windshield wiper blade sticks on wind Raise arm and operate windshield wiper wiper blade shield glass without applying load Clean windshield glass and or replace wiper balde Windshield wiper Motor Motor brush for either low or high speed...

Page 272: ...ment panel 2 Position speaker to instrument panel and install two flange nuts See Figure BE 44 3 Install radio receiver to instru ment panel 4 Connect speaker wires to instru ment harness at connector 5 Connect radio wires to instru ment harness at connector 6 Install antenna Follow procedure given in Radio Antenna in this section 7 Install instrument panel 8 Connect antenna feeder to radio receiv...

Page 273: ...in position and install retaining screw 4 Install antenna rod assembly ADJUSTING ANTENNA TRIMMER BE279 When a new radio receiver antenna or antenna feeder is installed antenna trimmer should be adjusted 1 Extend antenna completely 2 Tune in the weakest station be tween 12 and 16 1 200 to 1 600 KC on dial Noise may be generated but dis regard it 3 Turn antenna trimmer to left and right slowly and s...

Page 274: ... stator Charging system Sound of altemating current pre Alternator Install a 0 51F capacitor to charging termi sents nalA Note Do not use a larger capacitor If capacitor is installed to terminal F alternator coil will be damage When accelerator pedal is depressed Regulator Install a O 5I F capacitor to A terminal of or released noise presents voltage regulator Supplement equipment When engine star...

Page 275: ...ed to the floor area with a small amount going to the defroster nozzle When it is closed all air is discharged from the defroster noz zle The TEMP lever controls the air mix door and mixes heated air with air bypassing the heater core to obtain the desired air temperature In this man ner the temperature of air is effective ly controlled The FAN lever controls switch that is located on the control ...

Page 276: ... N TEMP and FAN levers in any po ition oc I VENT ROOM TEMP I N I AIR lever In any position betweenVENT and ROOM OFF VENT T 1 l j OutSideair ADDU pI TEMP lever in OFF FAN lever in any position To defroster nozzle OFF lENT ROOM I OEF TEMP I N FAN lever in any position err t J I OFF VENT ROOM TEMPi FANI BE 37 BE283 Fig BE 49 Air flow ...

Page 277: ...mps for the air mix door mode door and defroster room door Disconnect cables from door control levers BE286 Fig BE 52 Removing cable retaining clamp 9 Disconnect lead wires at two con nectors 10 Remove three bolts two on each side of heater unit as shown Figure BE 53 and one on the top of this unit as shown Figure BE 54 11 Remove heater unit BE 38 1 Demister nozzle 2 Demister hose 3 Intake box 4 H...

Page 278: ...ever to DEF position o Fit cable to defroster room door lever and fasten with a cable retain ing clamp while pulling outer case with a force of I to 2 kg 2 2 to 4 4 lb o Fit cable to mode door lever and fasten with a cable retaining clamp while pulling outer case with a force of 1 to 2 kg 2 2 to 4 4 lb 3 Move TEMP lever to left stop o Fit cable to air mix door lever and fasten with a cable retaini...

Page 279: ...ance No heated air discharged Cooling water temperature too low Heater core plugged Insufficient cooling water level Water cock out of proper operation Air mix door out of proper operation Insufficient air flow to floor Fan motor speed too low Defroster room door out of proper op eration Check thermostat Replace as necessary Clean Rem Adjust control cable Adjust control cable Check for motor termi...

Page 280: ...ation Adjust control cable Make sure that AIR charged with lever in lever moves smootWy over its entire between VENT and ROOM range Failure of fan to run Fuse melted Replace Motor wire connector disconnected Correct Switch defective Replace Motor defective Check and correct Control lever drags Inner wire rubbing against Quter case end Adjust control cable Control cable bent excessively Correct Doo...

Page 281: ...BODY ELEC1RlCAL J 4 o c 1n o 4 III III lOlll o III oUl UI z X 5 ZO UlZ 610 42 w J 4 o z J UI Z c III III lOlll OUl OZ B B UI z X N zo UlZ o J 4 U1 o BE345 Fig BE 57 Engine compartmenl ...

Page 282: ...ROOM MAIN HARNESS CI ENGINE ROOM HARNESS SUB NO 1 ENGINE ROOM MAIN HARNESS ITO AUTO CHOKE RELAY ENGINE ROOM HARNESS SUB NO 1 ENGINE ROOM MAIN HARNESS ENGINE ROOM MAIN HARNESS TO FUSIBLE LINK ENGINE HARNESS ITO REGULATOR ENGINE ROOM MAIN HARNESS t J ITO HORN RELAY 5 NEUTRAL SWITCH ENGINE ROOM MAIN HARNESS 5 TO RELAY 3 m 1 OC 1 MANUAL TRANSMI SSION COLOR COOE B Black W White R Red Y Yellow G Green l...

Page 283: ...BODY ELEC1RICAL o 0 U1 E E Co 0 J f W U 0 J 0 BE347 Fig BE 59 Instrument 610 44 ...

Page 284: ...H TO AIRCON HARNESS TO THERMO SWITCH TO HEATER UNIT CD TO HEATER MOTOR TO HAZARO FLASHER UNIT TO KICK OOWN SWITCH NO PART NAME TO PARKING BRAKE SWITCH 11 TO BUZZE R 1 TO STOP LAMP SWITCH ITO TIS FLASHER UNIT I TO OEFROSTER SWITCH 1 TO HAZARO FLASHER UNIT 1 TO OEFROSTER PILOT LAMP OPTIONAL TO COMBINATION METER TO WIPER SWITCH TO LIGHT SWITCH ITO RADIO UNIT IOPTIONAL NO PART NAME TO HEATER SWITCH TO...

Page 285: ... to c NO PART NAME TO DASH HARNESS TO ROOM LAMP TO SEAT BELT SWITCH LH TO SEAT BELT SWITCH R H TO SEAT SWITCH NO PART NAME CD TRUNK ROOM HARNESS CV BODY HARNESS CID TO REAR DEFOGGER TO REAR COMBINATION LAMP R H TO LISENSE LAMP TO BODY EARTH NO PART NAME CD TO REAR COMBINATION LAMP LH ID TO TRUNK ROOM LAMP TO TRUNK ROOM LAMP SWITCH l TO FUEL TANK UNIT jJ TO DASH HARNESS m m 1 tQ o c m rm D n r ...

Page 286: ...DATSUN 1800 MODEL 610 SERIES CHASSIS BODY SECTION SE SERVICE EQUIPMENT y l i il P i 1 0 h M 1 7 r 7 J INI NI NISSAN MOTOR CO LTD TOKYO JAPAN SERVICE EQUIPMENT SE 2 ...

Page 287: ...he special tool sets for the 510 models Set D ST09040000 This set is designed for the 610 models shipped to the U S A and Canada It is essentially the same as Set A less four items SERVICE EQUIPMENT CONTENTS SE 2 SE 2 SE 2 SE 2 Set D ST09040000 CLASSIFICATION OF SPECIAL TOOL Tool list GENERAL DESCRIPTION Special tools for R3W65 transmission SE 2 SE 2 SE 3 SE 7 SE 7 CLASSIFICATION OF SPECIAL TOOL C...

Page 288: ... 5 STl3030001 pbton pin press stand X 2 STl5310000 Crankshaft rear oil seal drift X 2 STl65 1 SOOO Crankmaft main bearino can nuDer X X 2 t STl6S11000 Body STl652001 Adaptor STl6610001 Pilot bush puller X X 3 STJi420oo1 Chain stopper X X X 2 STl9200000 Float level gauge X X 2 STl9320000 Oil filtet wrench X X 1 EG16700000 Flow meter X X 1 EM03470oo0 Piston ring comp1 essoI 2 2 Clutch sn050S000 Clut...

Page 289: ...all ST35323000 nsta 1ing adaptor Lar e ST35324000 In taUin i otor small 0rn L ST35325000 liar ST3550000J Grand packing wrench Yo Yo X 2 P ST35530000 Grand packilll guide 20 mOl 0 787 in di j X X Yo 2 ST3565S000 I Coil s ring compressor Yo X Yo 2 t ST35651 001 UodY ST35652001 CbffiP ST36100000 Trans tse link replacer Yo X X X 3 ST01640000 Rear axle stand X X Yo 2 ST36230000 Sliding nammer 5 ST33300...

Page 290: ...al drift fi X X 2 X X X ST3194S000 Drive pinion setting gauge assembly H190 X 2 X ST3114S000 Drive pinion setting gauge assembly HI65 v X X 2 X X ST311 OSOOO Drive pinion setting gauge assembly H 190 X ST31942000 Dummy shaft to 5 ST31141000 Arrangement gauge HI65 a 1ft X ST31101000 Arrangement gauge f ST31941000 Arrangement gauge H190 J if t ST31102000 Spacer it X ST3121S000 Height gauge aSMlmbly ...

Page 291: ... ST33270000 Gear carrier oil seal drift X X X 2 X ST33290001 Gear carrier oil seal puller X X X 2 X X X ST337 10000 Gear carrier side retainer attachment X X X 2 X STJ 3 720000 Gear carrier side retainer guide X X X 5 X 6 Brake GG94310000 Hrake pipe torque wrench 2 ST08060000 Master vac oil seal press fit tool 3 ST08080000 Master vac wrench 3 7 Body ST08800000 Sucker 5 ST08720000 Door adjusting wr...

Page 292: ...s catego ry are thus divided into four types according to the types of the vehicles for which they have to seIVe 1 For the V610 and W510 built after October 1971 ST3I 94S000 tST31942000 Dummy shaft ST31941000 Arrangement gauge 2 For the W610 ST31145000 tST31942000 Dummy shaft ST31141000 Arrangement gauge 3 For the W510 built before Sep tember 1971 ST3II01 000 Arrangement gauge dummy shaft not incl...

Page 293: ...b i p 1ii 2 1 j It ii n J P 1 t t v i t f c 1 1 o i i icJ 2i t ...

Page 294: ...f ...

Page 295: ...I NISSAN I Issue date 30th March 1972 010900 Printed in Japan Publication No SM3E 0610UO ...

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Summary of Contents for 610 Series 1973

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Datsun 610 Series 1973, Service Manual

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Summary of Contents for 610 Series 1973

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