Datsun Estate I300 Workshop Manual Download

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Summary of Contents for Estate I300

Page 1: ...0f 1D CQ u ill t if 1cr l 1 9 f Jor lOP Man la 1 t h O j ...

Page 2: ...MK II 1300 1500 ENGINES VOLVO 140 SERIES FORD CORTINA 1300 GT 1600 1600E ENGINES VAUXHALL VIVA HB HOLDEN HB TORANA OPEL KADETT RALL YE KADETT ALFA ROMEO RANGE ROOTES IMP RANGE MERCEDES BENZ 230 250 MODELS FORD CAPRI 1300 1600 etc RENAULT R16 16TS 16TA FORD 17 20M TOYOTA COROLLA 1100 1200 PEUGEOT 403 404 SAAB 99 I 1964 1964 1967 to 1967 to 1967 to 1968 1963 1968 1968 1969 1967 to 1969 1968 1967 196...

Page 3: ...D WRITIEN BY PETER R D RUSSEK PUBLISHED BY INTEREUROPE LIMITED AUTODATA DIVISION 2 4 QUEENS DRIVE LONDON W 3 ENGLAND Copyright IC IntIInlUrope LIlDtIld AulJllt 1970 lb 11 110 IYIIIIbIe inSpanish av 1Ib1e thRlUllh Lan W ey SA MexICO City Pnntlld n England 2nd edition January 1971 A ...

Page 4: ...SSS Saloon Estate Car Width overall Height overall Saloon Estate Car Wheel base MIO ground clearance Saloon Estate Car Front track Saloon Estate Car Rear track Saloon Estate Car Tyre pressures Front 4 070 mm 1602 10 I 4 120mm 162210 4 145 mm 163210 1 560 mm 61 410 1400mm 551 In 1 435 mm 56 5 In 2 420 mm 953 In 190 mm 74 In 165 mm 64 In 1 280 mm 504 In 1 275 mm 50 2 In 1 280 mm 50 4 In I 1 260 mm 4...

Page 5: ...Car Models In certaIn cases It Will be necessary for the reparrer to make use of speCial tools and the appropnate tool numbers and thelf methods of use are either descnbed In the text or can be taken from Illustraltons refered to m the chapter SpeCial menlton should be made of the fact that a fault findmg sechon IS annexed to most of the major sechons thus slmphfymg the sometunes difficult task of...

Page 6: ... the engll Fog A 1 Removal Of the cluu nslave cyhllller or L161 engIne flUBd 10 1 Jb trel t i n fd r f7 r if1 0 FIlI A 5 Removal of the manifold assembly f g A6 eket FIIA7 Removal of the cyhnder h8I F g A 8 Removal of the oil straaner 6 ...

Page 7: ...A 7 USing special wrench ST49010000 for removing the cylinder h llJd bolts Turn the engine over and remove the sump and the Internal 011 strainer Fig A 8 timing chain cover chain tensloner and timing chain Remove the 011 thrower the crankshaft wonn gear and the chain dnve sprocket FIg A 9 Remove the big end beanng caps pistons and connecting rod assemblies keeping them In sets In the correct assem...

Page 8: ... Standard valve gUIde hole diameter L16 WIth twin carb Ll3 and Ll6 With SIngle cub U3 and L16 Ll6 S gle cub TWlD cub Almm 410 41016 450 45 016 DIA Azmm 57 0 37 016 37 O 37 016 DIA Dlmm 37 6 37 8 41 6 41 8 DIA D2mm 324 326 DIA 324 326 Llmm 1 4 1 8 1 1 8 t 2mm 1 6 20 16 20 FIllA 15 VeIve to Inl t F Q OtA J I Inl r i 1 DIA r Exheult r r 1 II IlIt 1 I ExheuU La IlIA HU1 FIlIA 14 St8nd8nI valve Il 8 in...

Page 9: ...r L13 and L16 wrth IingIo rettD lm I 11 0011 II 0 11 5144 031 51 j l CII IM l11 J Fig A 18 Valves far L16 Ill wIth twIn C81bunmon FIlI A 19 CheckIng the valve IIInng for squ F A 21 MlI8SUnng the cyl bore by of 8 doallllU98 Fig A 22 The nne JIlIIII18 of the cyllncllr bora F The nng of the pilllln d by of 8 mlcrom8lar 9 ...

Page 10: ...e running clearance for the maIn beaFlngs FogA 30 Checlllllg the crenkshaft sprocklJt for FUIHlllt 10 Fog A 26 CheckIng the ade cl ence of the pISton Flngs FtgA Xl CheckIng the connectIng rod for bends or twIsts Fill A 28 CheckIng thecrankshaft end float 0 o Fog A31 The camshaft drIVe mechanam ...

Page 11: ...lshed bore Size measure the piston across Its skirt as shown 10 FlgA 23 and add the average value of the piston to cylinder clearance When the cyhnder bores have been finish honed check the piston cyhnder clearance as shown In Fig A 24 usmg a feeler gauge and a spring scale With a feeler gauge of 004 10m 00016 10 1 thickness the pullmg force on the spnng scale should be 0 2 15 kg 0441 3307 Ibs 1 I...

Page 12: ... vaJves ooo FI9A 34 Expl ded VI8W of pISton and connectIng rod FillA 37 InstallatIOn of the sKle oil seal F 19 A36 Chedung the crankshaft end float FIlI A 38 InstallatIOn of the flywheel FillA 39 InstallatIOn of pISton end conllllCtmg rodaay 12 ...

Page 13: ...he tIming chain 1 Fuelpump dflve earn 2 Cham guide 3 Cham nSlone 4 Cntnkshm sprocket 5 Camshaft IProcbt 6 Cham guttie FillA 41 Checking the side play of the bill end FogA 43 V 1fW of the crankshaft sprocket end dIStributor drivegeer FillA 46 AdjUsting the valve clearance I FlgA 45 FIttIng pOSItIon of the dIStrIbutor drIVing slIaft 13 ...

Page 14: ...er block as shown In Fig A 39 with the F mark faCing the front of the e gi le When lnsertlng the piston 14 rings ensure that the piston ring gaps are opposite each other and neither parallel to or at nght angles to the gudgeon pin Fit the connecting rods With the numbers on the same Side throughout and tighten to 2 8 3 4 kgm 20 2 24 6 lb ft Fig A 40 Check the end clearance of the big end bearings ...

Page 15: ... rpm Compression ratio Single carburettor 85 1 85 1 TWin carburettors 95 1 011 pressure 38 4 2 kg sq cm 38 4 2 kglsq cm 54 60 Ib Isq In 54 60 Ib Isq In VALVE GEAR Valve spnng fitted length L13 L 16 outer L 16 Inner 400 mm 30 7 kg 1 57 In 167 7 Ib 389 mm 29 0 kg 1 53 In 163 9 Ib 35 mm 12 3 kg 1 38 In 271 Ib 025 mm 0010 In 030 mm 0012 In 020 mm 0008 In 025mm 0010 In Valve spnng COIl diameter L13 L 1...

Page 16: ... 1636 In 003 mm 00012 In 003 mm 00012 In o 05015 mm 0 002 0059 In 03 mm 0012 In 49 961 49 975 mm 1 967 1 9675 In 003mm 00121n o 03 mm 0 012 In 1 835 mm 0072 00722 In o 062 mm 0 0008 0 0024 In o 12mm 00047 In 005 mm 0002 In 16 Matenal Type Piston diameters Standard 1 st O S 2nd O S 3rt OS 4th O S 5th O S Width of nng grooves Top second 011 control Piston running clearance Pin diameter Pin length PI...

Page 17: ...gged cooling system Clean system Incorrect Ignition liming Re set timing Incorrect valve clearance Adjust clearance Incorrect 011 used Refill With correct oil grade Radiator finS clogged Clean readlator finS ExceSSive oil consumptIon Oil leaks F nd 011 leak and rectify DefectIve piston rings Replace piston rings Piston rings worn or sticking In Replace Piston rll1gs grooves Piston or cylinder worn...

Page 18: ...mterCE lliJ Plcel FIg B 1 General layout of tho lubricatIOn system o Fig B 4 SectIOn through the 0 rehef valvo Frg B 3 Tho oil pump components 18 ...

Page 19: ...or and the pump body ThiS play must not exceed 0 15 021 mm 10006 0008 111 If thiS clearance IS excessive a new set of rotors or a new pump body must be fined 4 Check the end float of the rotors by placing a straight edge across the Joint face of the body and measuring the clearance between the rotor ends and the straight edge by inserting a feeler gauge IMust not exceed 0 13 mm 0005 In If necessar...

Page 20: ...arrangement of the cooling OY OperatIon plate Dust cover Drum SpIder assembly linnl9 FIlI C 3 Exploded v of the fan c1u1l h o V V 00 o J FIlI c4DlSIllantllng of thefan clu1dl FillC 5 V fIW of the radiator and component parts 20 It ...

Page 21: ...be done several times as there IS a time lag In the operation of the thermostat To check the operation of the fan clutch thermostat remove the operating plate see Fig C 3 and C 4 and submerge It In hot water 700C for 2 or 3 minutes to check Its operation THERMOSTAT R8IllOVlII Drain the cooling system remove the radiator hose and the water outlet elbow and 11ft out the thermostat To check the therm...

Page 22: ...eft FI9 D 6 Checlull9 1IIe contact IlfP RI FIg D 7 View of 1118 distrillutar wIth 22 I Fia D2 Remof the contact beI8 plaia 7 FIQ D 5 The bly of 1118 flyweight mecherlillll F tg It 2 Oftronco for nd ond at IfInltlOll lranctl MI IIe 3 Hook 4 Flywo ght rprll1l 5 Dtltrrburorcam pkrte 6 F ywetg ltpm 1 H 8 Flyweight rprlnt 9 RotorpoI donm fin Fig D 8 AdJUlling 1118 cantBCt b er gap ...

Page 23: ...st the con1llct breaker gap as described below CONTACT BREAKER GAP Adjultment With the distributor fitted in reverse order to the removal procedure turn over the engine until the fibre pad of the contact breaker ann IS at the highest POint of the distributor earn Slacken the clamping screw at the fixed contact pOint and turn the adjuster screw With a screwdriver until a contact gap of 045 055 mm 0...

Page 24: ... 0 9 mm 0 03 0 035 ln When flttmg the plugs tighten them to 1 5 2 0 kgm 11 15 Ib ft 24 II Technical Data DISTRIBUTOR 045 055 mm 0012 002210 050 065 kg 1 1 1 43 Ib 1245 mm 0490210 80mm 03151O 1245 In 0490210 Contact gap Contact spring pressu re Shaft diameter lower part Shaft diameter upper part HouslOg lOnerdiameter Clearance between housmg and shaft 001 0038 mm 00004 0001510 Clearance wear limit ...

Page 25: ...place cap or rotor Engine misfires Dirty or faulty spark plugs Clean adjUst or replace plugs Loose Ignition wire or faulty Tighten repair or replace Wires Insulation Cracked dlstnbutor cap Replace cap Breaker points not correctly adjusted AdjUst breaker points Ignition CirCUit Interrupted and Burnt or Incorrectly adjusted contact AdjUst contact breaker gap voltagedrop In pnmary CircUit breaker gap...

Page 26: ...acuum prsfon 20 Power aIw 21 Ifam et 22 Maml 23 ldl l 24 8 hole 25 Throttle W 26 J T t 1 4 f c Fog E 2 General of the twm choke cartJuret1D L 16 englnel 12 1314 IS 16 FIg E 4 SectIon through the twin choke carburetlllr L 16 englnel MIl dach 2Small venturi 3 MamllJrble J 4 Slof IHUnmng Jet 5 SlowrunnmglII bleed G N tI aM 7 FI 8 Emublon tubtJ 9 M lnJflf 10 s 110 77 Throttle aIwl 12 C rok a w 13 MII ...

Page 27: ...If worn replace the assembly Check the throttle and choke valve shafts and bores for eccentriCity Check the slow running Jet needles for burrs and ndges Replace parts as necessary Check choke tube clusters for wear or slackness and If necesssary replace the cluster Check all linkages for excessive wearand the filter screen for blockage and distortion Check the operation of the accelerator pump and...

Page 28: ...op caver FIlIE B The O l 1 Jo u 0 ll li il 4 I f It F I 0 D j hamber relllDvecI 9 The choke c Fill E ndary emu end lOCO 10 The pnmary FIlI E ell tubes remov q o i 0 0 0 carburetlDr The lower and upper FIlI E 12 bod separa18d ret from the reIIICJII8II FIg E 13 The float torbody 28 ...

Page 29: ...tK 6 Throm l aIw 2 r rL i r L fr J L J JhaJi DAH 4 2 AnZl OCK 00 1 I Omm D au I Fill E 17 The flolllleveladJullment FloatSlHt 2 FIo t 3 FINt ltop 4 Ne JIII van FIQ E 18 Adlusanent of the float 18111 FI I E 19 AdJuotment of slllI tlng Interloca opemng Choke bell rod 2 Choke connctlllfl rod 3 S11Irtlng Ie 4 Choke vain 5 Choke ItNer 6 Fat dIB connectIng IeYer 1 Throttle chamber 8 Throttle valw FIQ E ...

Page 30: ...damper to Within 0 5 In 12 7 mml of the top of the rod CARBURETTOR Adjustments The proper adjustment of the two carburettors IS extremely Important In obtaining peak vehicle performance and redUCing fuel consumption Carburettor synchromzsnon and idhng adjustment Remove the air cleaner when the engine has reached ItS operating temperature and slacken the throttle adjusting screws The heads of the a...

Page 31: ...2 Return plate 3 Throttle chlmbtK 4 Throttle v Jve OIL CAP NUT SUCTION CHAMBER SUCTION PISTON o 0 0 Yo SUCTION SPRING JET NEEDLE Fill E 24 Exploded v of Rlol on chamber BOO suction piston tJ II mterc rlOU ce c Fill E 23 Checlung the clearance between throttle valve body FUEL PIPE A e NOZZLE SLEEVE SET SCREW IDLE ADJUST SPRING IDLE ADJUST NUT NOZZLE Fill E 25 Exploded VIew of nozzle assembly e 0 0 ...

Page 32: ...hand FUEL FILTER The fuel filter IS of the throw away cartridge type and should be changed every 40 000 km 24 000 miles To remove the fuel filter disconnect the mlet and outlet PipeS and remove the filter Fig E 36 The mstallatlon of the filter IS a reversal of the removal procedure 32 FUEL PUMP Removal Disconnect the mlet and outlet hoses from the fuel pump connection and remove the two mounting n...

Page 33: ...Jw Valve retainer 8 R8tamer screw 9 D hragm 0 Pullrod DIaPhragm flng 12 Selll washer 13 Seal 14 Lock washer 15 Nut 16 Connection Screw 8 Lock washer 19 ConnectIon 20 Rocker arm sprmg 21 pscer 22 Heat Insulator 23 Fuel pump gask8t 24 Rocker arm 25 Rockerarm pivot pm 26 Spacer 20 24 FIg E 41 Exploded v of the aIF cleaner 13 Fog E 42 Removal of the aIF cleamr withSIngle carbunrtlDrl 22 23 Exploded VI...

Page 34: ... the l16 engme uses a combmatlon system Fig E 44 which IS Similar to the one used for the l 13 engme but IS fItted addItionally With a tube With a variable Orifice valve frthe crankcase to the mlet vamfold InspectIon Every 12 000 miles 20 000 km remove the hoses and blowout With compressed air If the hose IS blocked or collapsed replace It Check that the crankcase breather valve only allows one wa...

Page 35: ...ttle opening Adjust throttle Slow running adjustment Incorrect Adjust slow running Slow running fuel Jet blocked Clean Jet I ncorrect float level Adjust float level Poor acceleratIon DefectIve accelerator pump Overhaul pump Float level too low Adjust float level Incorrect throttle opening Adjust throttle Defective accelerator linkage Adjust accelerator linkage Blocked pump Jet Clean pump Jet SpItt...

Page 36: ...screw Fog E 32 The IKIJustment of the In1erconnec tlng shaft 36 4 5 2 Fig E 34 Adjustment of the startIng Interlock opening FanIdle lever 2 Connecting pl m Connecting Imk 4 Connecting rod 5 St1Irter lever 6 Th ttler Jve o tl Fog E 33 Adjustment of thefloat level 7 Floatlever 2 Bendhrre to adjust ht1l Jht H Fig E 35 Checkong the hydraulIC damper 001 ...

Page 37: ...centres of a lathe and replace or straighten the plate If the indicated value exceeds 05 mm 002 In Fig F 8 at a distance of 95 mm 3 74 In from the centreof the plate If the rivet heads are less then 03 mm 0012 In below the clutch faCings or there IS abnormal wear or rivets m sslng replace the driven plate or the clutch factogs Check the splines In the clutch driven plate hub for rotational backlas...

Page 38: ...II 2 Fog F 2 Exploded of the cod sprong clutch CIlrtch drltIon 2 Outrh b y 3 Clutch CD c Clutch PlWSUfe pine 5 Eyebolt 6 EYlIlxJ1tpwot pm 7 Pnmu q rlng 8 Spnng cop 9 R lwet 10 R Locknut 12 Release IftltJT wpport 13 Roroln ng rpnng 14 Bolt 15 Spring If 16 m I IT R mmr spring 18 Boaring 1 9 Clutch re lwBrlng 2Q Rfltammg rpnng clIp 21 Oust COIffll UReturn IPrlng 3 Locknut F4 Wthdrwwallwer pulh OIA 25...

Page 39: ...leversl Fit the release bearing and the bell hOUSing CLUTCH PEDAL Removal 8IId Installation Remove the cleviS pin from the end of the push rod and disconnect the push rod end Remove the return spnng the push rod and the push rod adjuster If fitted Remove the pedal lever securing bolt loosen the handbrake bracket secUring bolts and 11ft out the pedal Clean all parts and check for wear With special ...

Page 40: ... d hragrn clutch Fig F 7 YIf W of the cod spring clutch dla 255 mm 3 3 Fill F 6 O 1Iel1SlOn dlllgralll for the coil ng clutch Fig F 9 Checking the release finger height of Fig F 8 Checking the clutch dren plate to the diaphragm dutch run out Fill F 13 InstallatIOn of the dutch bl 1ng diaphragm dutch FIlI F 14 InstaJlatlOn of the dutch bearing coillPrlng dutch 40 ...

Page 41: ...28t 10 Valinst em fop t 7 Stop pMctt 12 Gasket WIIwr 13 Push rod 14 Pudl rodC VIS 15 Nut 16 Locknut 17 P stOn fop 18 Abutment wahar 19 Rubber boot 20 FlutdrtnelVOlf 21 Clip 22 Rft IINVOlr ClIP 23 Cap INJI T ghtemng torque 3 5 to 4 0 kg rn AdJust by adjust screw of master cyt LubricatIon Clutch pedal full troke 140 4 mm Clutch pedal free stroke 2S 1m Fill F 17 The clutch pedal adjustment f O Fog F ...

Page 42: ...e screw Immersing the free end of the hose Into a Jar partially filled With clean brake flUid Open the bleeder screw by 3 4 turn Fill the flUid reservoir With the recommended flUid and pump clutch pedal slowly When all air has left the system indicated by a solid flow of brake flUid Into the Jar tighten the bleeder screw on a downstroke of the pedal Remove the bleeder hose replace the dust cap and...

Page 43: ...or replace dutch diSC aSbcmbly LcakIng from master cylmdel cup Replace cyLinder cup Leakmg from operatmg cylmder cup Replace cup Air mflLtratIons Into the hydrauhc Bleed out completely lme Roughncsb on Immgs Rub hmngs WIth a metal brush or re place them Low flmd level In 011 reserVOIr Top up With brake flUid Grabbmg a l on facmg or burn cd or glazed Install new diSc assembly faCIngs Loose dISC lmm...

Page 44: ...w J l I I 1 I c f 9 fIr 0 r f I t i FI9 G 7 Removal of the crosHhafts For anno1atlons see text FI JG 10 R iifih8 iine idler gear 44 Daconnectll19 the remote control Fig G 6 RelMVillof the extensIOn housmg gear F19 G 12 Withdrawal of the mall1Shaft gear trail ...

Page 45: ... gear assembly together With the 1 st speed gearwheel THREE SPEED GEARBOX InsplKltlon Thoroughly clean all parts and mspect as follows replacmg or repairing any defective parts Check the gearbox casmg for cracks and indentations Where the surface IS machmed check for burrs and remove where pOSSible Clean all bearings and blow dry With compressed air Without spmnmg the bearings Lubricate the bear l...

Page 46: ...e2nd and 3 speed synchronoser hub Fig G 15 Removal of the 2nd and 3 speed sychronlser VJ lV CD FIg G 19 CheckIng the synchron rIngs for FRONT COVER REAR EXTENSION CROSS SHAFT wear FogG 20 The oil seals ulOd on thegeaTbox F gG 22 I ns1allatoon of the e ehp In 46 v FogG 23 Insortlng theshtftll1ll keys Fog G 24 FittIng the synchronaer hub on to the operating sleeve ...

Page 47: ...cylinder push rod to obtain a withdrawal lever free play of 2 2 mm 0087 m FOUR SPEED GEARBOX Removal and Installation I Follow the mstructlons for the three speed gearbox except that the four speed gearbox s a floor mounted gearlever whIch should be removed at the control lever bracket FOUR SPEED GEARBOX DIsmantling NOTE There are two types of synchromesh used m thiS gearbox Borg Warner and Servo ...

Page 48: ...at of the gea eels gear FI9 G 29 Greasing POlllts for withdrawal lever and release beanng f J z J I Fog G 31 VISW of the gearchange contrOl arm FIg G 34 rete r 48 Fog G 35 R a1 of the malllshaft ly F G 33 Removal of the ne ler geara Po pOlello t a I FigG 38 Exploded v of the mamshaft goer tram ...

Page 49: ...mbly of tile selector fol1 s ImmIIII 3rd 4t1l Rod Spring Plug Plunger Plunger FIg G 39 SectIOn through tile gearbox to show the Interlodung system FIg G 42 Remoyal of the upper support bracket FIQ G 46 Viewof the selectar Gnxw naltnd wttmg 01 1 FIQ G45 Adjustment for neutral setting 49 ...

Page 50: ...kgm 18 0 12 3 Ib ft AUTOMATIC TRANSMISSION Although the automatic transmiSSion IS not covered In thiS manual as the maintenance inspection and repair IS conSidered a Job far experts the control linkage IS discussed GEAR CHANGE CONTROL LINKAGES Removal Three speed gearbox Remove the follOWing Items Steering wheel Fig G 40 steering column cowl indicator switch and light swItch Fig G 41 Remove the cl...

Page 51: ... gear 16 18 18 Speedometer Drive gear 5 5 5 Driven gear 19 or 17 16 16 CLEARANCES AND PLAYS I Model I R3W6 F4W63L and F4C63L Mamshaft end float o 019 mm 0 0008 m 008029 mm 0003 0 011 m Max mam shaft end float 020mm 0008 m 030mm 0012m Cou ntershaft end float 004 0 12 mm 0002 0005 m 005 015 mm 0002 0006 In Max countershaft end float 020 mm 0008 m o 20 mm 0 008 m Reverse Idler gear end float 020 040 ...

Page 52: ...Clllle 52 FIg H 4 Removal of the SIde drIVe flange t Fill H 7 Removal of dlfferentlalllde bearing FIg H 5 Removal of dlfferentlallKle cover FIQG 10 Measunng the clearance between the dJfferentl8l SIde gear and the thnllt washer tapl end checkIng thecrown eel n1rHlut ttomL ...

Page 53: ... or three points The backlash between the dnve gear and pmion should be 0 10 0 20 mm 0 004 0 008 In Also check the run out at the rear of the crown wheel If the backlash or the tooth contact pattern IS found to be out of adjustment The run out limit IS 008 mm 0 003 In The turning torque of the drive pin on should be 3 15 kgem To dismantle the dlfferent al remove the flange clamp bolt and remove th...

Page 54: ...ntJ ofpln nut 17 201 11 145Ibft J 4 PtNOtKJfo piNon betftntJ without 00 7 10k IS1 721b ft J 5 Anion bHnng 1IdJU or Ii Amon IId u lng I P8Cf I F 90H12 prHoad 54 F 90H 16 Adjsutllll d far dlff8nntJal side cowen 2 u i 4 Gl lo F 90H 17 The maJtuJ18S of the dlffwentJal side co I G FigH 19 ChecIung the backof the wheellDI priOR ...

Page 55: ...g e Might of 2 6 leg 6 5 lb on the bearing The nominal width IS 20 00 mm 0787 In Press the bearfngs on to the differential cage Also press the outer races of the front and rear pinion beanngs into the differential carrier USing a suitable press mandrel Acljustment of drive pmion pre load Fit the pinion herght adJustlllg washer shlTIS and rear bearrng Inner rece on a dummy shaft as shown In the dia...

Page 56: ...th contact on heel TOE TOE HEEL DRIVE HEEL COAST SIDE SIDE FIlI H 21 Tooth co on toe HEEL DRIVE HEEL COAST SIDE SIDE F H 22 Tooth co on fImc TOE HEEL DRIVE HEEL COAST SIDE SIDE F H 23 Tooth contact on face 56 TOE HEEL DRIVE HEEL COAST SIDE SIDE F H 24 C tooth contact ...

Page 57: ...it the remamlng parts m reverse order to the removal procedure and fill the fmal drive With 08 IItres 1 3 Imp pts 08 US qts of the recommended 011 DIFFERENTIAL Ramoval Estate Car Stetlon Wagon Disconnect the drive pmIon flange from the propeller shaft yoke flange and remove the rear axle shafts refer to section REAR AXLE for thiS procedure Unscrew the differential carner from the front of the rear...

Page 58: ...inter i1 l 1D PJtE F H 30 R I of tile pllllOii mv Ass y beanng dlffereratl al ide duvt piniOn F H 31 Exploded of d bly FigH 32 MeIIsllnng 1he crown wheel for NIHIUt 58 ...

Page 59: ...n beannc 10 to 13 q cm Gear ratio 3SP TIM 6 A TIM 3889 1 4SP TIM 3700 1 SectIon through the dofferentl8l I FIgH carr Fill H 36 Me mng the drtt entud IIlIe bearing thockness TIhrenma torque bolt dtff b l ap 42 to 48 kgm 30 to 34 7 ftlb D C L FIg H 35 CalculetlOn of the differential lbeenng s ums Fill H 37 Measunng the crown wheel back side Me s ng the dlmen n L 69 ...

Page 60: ...nng Inner race and the spacer The Inlt al turnmg torque WIthout 011 seal and drive prnlon nut tightened to 14 17 kgm 101 130 Ib ft 60 should be 10 13 kgcm 138 9 180510 oz for new bearings and a value of 20 40 less for used bearings Check the plnton depth and re adJust If necessary Remove the pInion nut and the flange and press the 011 seal well greased IOta the dIfferentIal carner RefIt the flange...

Page 61: ... 38891 38891 37001 InitIal turnmg torque without 011 seal Saloon models 7 10 kgcm 0506 0723 Ib ft I Estate car models 10 13 kgcm 0 723 0940 Ib ft Depth from axle centre Saloon modesl Estate car models 48 5 mm 1 909 In 610 mm 2402 m Data Thickness of pmlon heIght adJustmg washers ThIckness of pinion heIght shims 2 0 2 2 24 mm From 1 09 1 27 mm ThIckness of pmlon beanng adJustmg washers Saloon From ...

Page 62: ...suspenSion as a complete Unit 6 o I I jj I 1 l FIg I 7 Exploded vIew of the rear cod ring Fig I 10 Removal of the rear SIIspel1Slon ann FIg I 2 Parts to be removed or dIsconnected for the removal of the fmal drive unit t Brake Ime connector 2 Handbr b cable adjuster 3 Rerum spong 4 Propeller thaft flange Front I O ff mountmg I member L I nstallatlon diagram for rear suspension FIg I 8 The upper sh...

Page 63: ...rubber FIg I 7 COIL SPRINGS Installation Check the sprrng for YIeld deformatIon and cracks Test the sprrng and compare the results WIth the information In TECHNICAL DATA Check the rubber parts for deformatIon or damage and replace If necessary The installatIon IS carried out In reverse order to the removal procedure ensunng that the flat face of the spring IS at the top REAR SHOCK ABSORBERS Remova...

Page 64: ... 4 Orwe Ibaft top rmg 5 Rubber gtl ter 6 GaJrttrcltp 1 CIdIP 8 SJtJeve yoke 9 SIewe yoktl plUf 10 SpiderJoomal F yoke 12 0 119 13 N tIbelllJt1g 4 Clrcltp 64 I 00 0 tO Shock absorber lower mountIng Bearing hOUSing mark D j AXLE HOUSING DISTANCE PIECE Fog 115 The critIcal dane ons for the mstallatlOn of the RlsponSlOn ann r Apply grease In thIS area Fig 18 Sec1IOn through the d 1haft ...

Page 65: ...rocedure noting the followmg pOInts Altgn the yokes ensurong balls and spacers are fItted In correct order Select a clrcltp to gIve an aXial play of less than 0 02 mm 0 0008 In In the Universal JOints Four SIZes avaIlable Apply a SUItable quantIty of multIpurpose grease to the ball groove approx 10 gr 035 oz and addItionally grease the area shown In Fig I 18 REAR AXLE Removal Estate Car Station Wa...

Page 66: ... the rear SIIspenSlon and rear axle as frtted to models Ddfenmtt C8TTI r 2 Rear vie hOUSing 3 LBetsp mi 4 Bump rubber 5 Shock obsorlJor 6 RNr springfront henger 7 HMldbrllktlltnk 8 B hO ll 66 Fog I 20 CuttIng the bearing lnlng collar WIth a cold chIsel FI91 22 The rear rln9 front hanger FillI 23 The upper shock absorber mounting ...

Page 67: ... mounting nut WIth the wheels of the car resting on the ground Data COIL SPRINGS Model L510S 510 L510 PL510 W re dIameter 142 mm 0559 In 142 mm 0559 In 142 mm 0559 In COil dIameter 90 mm 3 543 In Same Same Free length 311 mm 122 In 306 mm 120 In 299 mm 11 8 In The value for the 510 P510 models apply for the R H sprtng The only dIfference for the L H sprtng IS the free length which IS 299 mm 11 8 I...

Page 68: ...Steenng lever Flg J 4 GreWIth Indoc ated poInts FIlI J 5 Removal of thebrake Pipe FIg J 7 R of the ll1Ibil bar For alUlOll1bOnS l1li8 text 68 FIlI J 2 Removal of thewheel hub Z I o tq O e t Frontwheelhub 2 G I Inner WMeI bearing 4 Outer wheel beanng 5 5 Spmdltl nut Fog J 3 Exploded v of front wheel hub FIg J 6 Removal of wheel hub and brake dISC FIlI J 8 Rerniiwal of the cnon Ilrut an l1li8 tIDltl...

Page 69: ...bolts 21 LIft off the reactIon rod Check the rod for distortIon and cracks and rubber parts for damage and fIt by reversIng the removaI tnstructlons SUSPENSION UNIT Removal Fig J 9 Jack up the front of the vehIcle and support on SUItable stands Remove the wheel dIsconnect the brake hose from the connector reaction strut and stablltser bar from the suspensIon arm Remove the two bolts holdIng the su...

Page 70: ...iPring 8 BumlHf rubber 9 Suspension Unit Fig J 12 Removal of the self locklng nut With thesuspension unit compressed o Fig J 14 Exploded voew of the shock absorber 70 8 9 y P Fill J 10 Removal of the SWIvel JOint essembly The upper mounting of theRlspenslon Fog J 13 Exploded VIew of S1Jspenslon unIt and spnng mbly Fill J 15 Grease thepOints marked With ...

Page 71: ...lower ball JOint on the RlspenSlon ann fIiilIII itJiJ J Y f l I j t h f Co j p I f i r T L D I Fill J 22 AdjUst the In by turnIng the track rod centre tube mmBIIB Fig J 17 The suspension ann mounting nut F I I J 23 AdjUst the stl enng angle bV means of thearrowed bolt 71 ...

Page 72: ...he followong reaction rod and stabl Itser bar from suspension arm suspension Unit from SWIvel Joont arm spltt pon from lower ball Joont nut ball JOint from SWivel Joont arm Fig J 19 and the lower ball JOInt from the suspensIon arm by removIng the bolts 1 on FIg J 20 Replace a damaged dust cover As the ball Joont IS a sealed UOIt It must be replaced complete If the end play IS greater than 0 03 06 ...

Page 73: ...217mm 8541O Fitted load 243 kg 536 Ibs 243 536Ibs 243 kg 536 Ib FROIH SUSPENSION UNITS All Saloons Saloons With All Estates Estate I SSS L510S With drum disc brakes With drum With disc P510 UTK Models brakes Exc SSS brakes brakes and Exc L51G S PL510 TKI Strut outer 50 8 50 8 50 jO ci 50 8 50 diameter 2 0 2 0 0 2 0 2 0 2 0 mm m PIston rod 20 20 20 20 22 22 dIameter 0 787 0 787 0 787 0 787 0 866 0 ...

Page 74: ...3 Sector sh h ccwer 9 SttJefmg worm best lng Adu ttng IC W 70 StHnng nut 5 Kbnn beanng um SttteTmg column Ih6ft 6 HouSIng cOW 0 nng FIlI K 2 The tIng bolts of the ng column rlll K 4 Removal of the g Nfl I jffif Fill K 5 Removal of the g column Nfl WIth nng nut 74 c 1 9685 In FIlIK 6 Measure me dbne n II1OWI1 to determine If the Nfl illtIlIswvlc8lble ...

Page 75: ...nd fIt the IMIrm bearing shims and the 0 ring Into the hOUSIng TIghten the flange bolts to 18 25 kgm 130 18 1 Ib ft If the column beanng has been changed It should be packed WIth grease and then cemented Into the steering column By adjusting the worm bearing shims 4 SIZes 005 0076 mm 0002 003 m adJUst the InitIal turning torque of the steering column shaft to 40 6 0 kgcm 55 5 833 In oz WIthout the...

Page 76: ...0 Q J 0 r r Clearance 01to05mm Frg K 13 Section thnlugh the ball JOint IItud forthe track rod 76 steermg hnkage seen Frg K 14 SectIOn thnlugh the ball JOint ltud for theconnecting rod 7J 2 TIGHTENING TORQUE 55to76kgm RAD 140rrm SEDAN 145mm WAGON FIg K 12 Section through the Klier ann 1 Nylon bush 2 Dust co r 3 ld e arm 2 ra j II ANGlE TOLERAHa 1 47 to 3 47 AFTER TIGHTENING TME ARM Fig K 15 Adjustm...

Page 77: ...0 and that of the outer wheel 32 40 Trouble Shooting SYMPTOMS PROBABLE CAUSE ACTION TO BE TAKEN Hard steenng Low tyre pressu re Correct pressure I ncorrect wheel alignment Correct alignment StIff track rod ends Check and replace If neceesary SteerlOg box needs adJustment Adjust If necessary Steenng wheel shimmy Tyre pressure Incorrect Correct Incorrect wheel altgnment Correct alignment Wheels and ...

Page 78: ...ke cyl ncler t Push rod 2 Dust cover 3 Retalnmg ring 4 Secondary piston cup 5 PISton 6 PrImarypiston CliP 7 Inlet aWe 8 p ton return spring 9 Cylll derbOOY 10 Re l rvolrcltp t 1 ReseflfOlr 12 ResIHVOlr ClIP 13 Bleeder ICrtlW ClIP 14 Bleeder SiCffJ W 15 CMck a spnng 16 Ch k vaM tl Gasket ring 18 Paton stop bolt 9 Ga ket was ler 20 Vlllvep1u g 78 Fig L 2 Exploded mbly Fill L 5 The front drum brake f...

Page 79: ...ch the wheel cylinders after disconnecting the bridge pipe between them If the wheel cylinders must be dismantled remove the rubber dust caps and Withdraw the Inner parts Check the brake drums for run Qut and skim If the run out exceeds 0 05 mm 0002 In to a maximum dIameter of 229 6 mm 9040 In Also check the drums for cracks or other damage and replace If necessary If the linings are not seated on...

Page 80: ...ly I Cylmdor 2 PISton I 3W of RetBtner 6 P 6 a 1 Shim 8 8 p I 9 c l IpO pi 10 r MIOn rpt lfIg Spl pin 12 c tIenut 13 14 Suppon btlldr t 15 Holddownpin 16 Pwotpin 17 Mounting brIIc Ut 18 Spnrv 80 Fog L 7 Removal of the brake calliper Fill L 8 EJectJ the plSlDn by means of comptl SSlld aD Fill L 9 M88I11nIlg the brake daiC for run t FIg L 10 m1Mr c ...

Page 81: ...brake pads I 70 t 2 J I I Fill L 16 Tho posrbon In I r p J t Fill L 14 Exploded YOM of the rear brake jj 6 lM 1I1 M Jll A 1 J I L J T v I f lo lIII I 1 J Fill L 17 Tho foung pOints of the rear handbnoko cable Saloon models 81 ...

Page 82: ...FIg L 20 Adjusting the brake hght swItch FIg L 22 mode r I 1 l f Ji J J 1 r 1 tc TF16 I f loo t J I r7 if f q I K i ifi C J 82 FIg l19 The brake pedal adJustment ...

Page 83: ...moval Front cable Release the handbrake remove the clevIS pIn holdtng the cable and unscrew the adJusttng nut at the rear of I the front cable Remove the cable from the handbrake lever From underneath the body release the cable from the mounting clips pull out the lock plates holding the cable retaIner and completely Withdraw the cable Pull out the front cable from the car after undotng the outer ...

Page 84: ...the reservoir Repeat the bleeder operations for the other bleed plugs finishing with the bleed plug nearest to the master brake cylinder Technical Data BRAKE PEDAL Brake pedal height Front drum brakes R H D L H D With autom transm Brake pedal height Front diSC brakes R H D L H D With autom transm 187 mm 7 362 In 187 mm 7 362 In 197 mm 7 756 in 202 mm 7 953 In 207 mm 8 150 In 197 mm 7 756 In MASTER...

Page 85: ... fIt new valve Brake effort decreases and pedal goes Brake pipes or hoses leaking TIghten connections or fIt new PIpeS slowly to floor and hoses Damaged or defectIve cups In master Overhaul cylinder In questIon brake or wheel cylinders Brakes overheat CompensatIon port In master cylinder Clean master brake cylinder blocked Return spring weak Fit new springs Rubber parts swollen due to use of Drain...

Page 86: ...I SIIp IV end 6 StoIor 8 Olodo 9 L Ia Brush b y I I Slip r IV nd FIg M3 RernlIYaI of thedrive pulley nu1 FII M 6 Remon of the rotIlr slip ring end bearing WD Red or Black figures FIII M7 The Id bliwot on of the dIOdes 88 e oo Fig M 4 The COIIl 1l of the drmt pulley t FIII M6 TIPPing the dnve end bndtet off the rotIlr Fig M8 U ctenng the temlmal UN ...

Page 87: ... carefully In a VIce and remove the pulley nut the pulley the fan arid tha spacer from the rotor shaft Fig M 3 and M 4 Tap out the rotor from the drive end bracket uSing a hide mallet FIg M 5 Remove the beartng retainer and press out the beartng from the beartng hOUSing The bearing from the rotor IS removed by means of a two arm puller of conventlonal deSign FIg M 6 Remove the stator from the dIod...

Page 88: ...the cover FI9 M l1 Checking the rotor field cod for continurty top and earthIng bottOm 1 1 FI9 M 10 V of the removed dIode holder 1Ily Fig M 12 Checking the rotor for run out t FI9 M13 Chedung 1he wlIldmgs for con1lnurty 1he W1ndlriila for 88 FIlI M 15 DlOlIe test I rJl i F g M16 DIOlIe test ...

Page 89: ...e speCIfIcatIons If the deVIation IS small the alternator IS 10 good condItion ALTERNATOR Flndmg of faults Alternator does not charge the battery 1 Check drlvmg belt tensIon 2 Field cable broken at control Untt 3 NegatIve cable broken at control unIt 4 POSItive and field cables crossed Alternator output uncontrolled 1 POSitive cable broken at control Untt 2 Field and negatIve cables crossed at con...

Page 90: ...nal POSItIve dIode NegatIve diode PILOT LAMP RELAY VOLTAGE I REGULATOR FIg M t9 The current flow In the dIodes FI9 M 20 Test rcult for checkIng the ahemator performance Fill M 21 V of the voltage regulatof and prlot lamp relay t t SecomlafY COntact support Air gap G2 08 12 Stopper Back gap G T PrtmafY contact support Voltage corl A Ammeler V Vollago meter FIlIM 23 The voltage reagulator See text W...

Page 91: ...Thnnt 10 O rod brocktltbush Thrun 12 Slop w r C IP 14 Pinion rtap OD 1er 15 Drwe pimon 16 O nn ngclvtrh 17 Fleldcoll IS Sttrter motorbody 19 brush 20 N brush 21 Brumllmng 22 Brush ho dtJr 23 BNrtng bush 2tI R co 25 ThroU lh bon mter Eitl i CQJ j2J E Fog M 25 Adjusting the elr gap of the voltage regulotor G2 In text 9 l BendIng dIrection H ghten voltage I Lower voltage Fog M 27 Adjusting the voltag...

Page 92: ... 8mm Commutator Ica Correct Incorrect Fig M 34 Unden uttlng themICa Insulators I gmtlon swItch Fill M 36 Checkmg the armature for short Circuits FI I M 35 Testing the Innature Wlndmgs for earth connectIOn Battery Starter motor I IT l FI9 M38 M ng the starter motDr panlOl l II FI9 M37 TesI circuit for lenood Mrtd1 92 ...

Page 93: ...ler Connect one test prod to the commutator and the other one to the armature or shaft If the lamp lights the armature coil IS connected to earth and the armature should be replaced The armature can also be tested by using a Circuit tester as shown In Fig M 35 If the Circuit tester needle moves the coil IS earthed Check the armature wmdlngs for mternal shorts by placing the armature on the growler...

Page 94: ...ype nop nug 9 Plate sptmg 24 Felt wa her 39 Thtust washer 10 Sprmg etamer 2S Beatlng 40 Wave washer 11 BaU 26 Auto stop cover aA y 41 Beanng 12 Magnet ball 27 Lock plate 42 Hexagon nut 13 Armature au y 28 PIa m Imall erew 43 Tluwt screw 14 Commutator 29 GearCOVei ass y Thrust washer t5 Brush spnng 30 Chp 4S Gearshatt aD y FIU M 39 Exploded v of the windlcnen wiper motor 3 7 28 43 35 F g M 40 Remov...

Page 95: ...nt Pulley ratIo to engIne HITACHI 12 volts 30 amps NegatIve 1 000 13 500 rpm 1000 rpm 22 amps at 14 volts and 2500 rpm 2251 VOLTAGE REGULATOR Maker Type No load regulating voltage HITACHI Constant voltage relay 14 15 volts5000 rpm STARTER MOTOR Type Voltage Output Starting current Starting voltage Lock torque No load current Free running speed OperatIon medIum Number of teeth on pinIon Number ofte...

Page 96: ...ctly Replace worn brushes See that the brushes bed oronerlv Regulator not functlomng correctly ExamIne regulator Battery overcharged shown by burnt out bulbs and very frequent Regulator not functIoning corre tly Examine regulator need for tOpping up Starter does not operate or operates Poor contact of starter swItch contact Check sWItch and replace If necessary and does not turn the engine POints ...

Page 97: ...otor WIper motor continues to run after Contacts In hOUSing damaged Replace contacts SWItch IS turned off or does not return Contact spring bent Replace contacts blades to parking pOSItion Insulating bracket broken Replace contacts Contacts dl rty Clean contacts Wiper motor cannot be SWItched off Screw SWitch button back slightly bend contacts Bad connection from wIper SWItch to Check connectIon r...

Page 98: ...I 0 OIL jl l VOL TAGE REGULATtIl INITRi NENT u HT AIN l3EAM PILOT UGHT OIRECTIONAlPILOT LIGHT IGNITION flirtiNG U HT OIL PADSlRE VlMNNG LIGHT EAIRH TERMHIol eMJI TAtf lHT GAI QO L N L1GHTlt up COO LIGHT a o eN iiill GW LeENeE LIGHT o I II Q t 3 AOIO to r I EAfER UNIT Br CJ UP STOP jTAIL TlI REAR CCMlNATIONL L Jo4 Ill I I I 111 I I I 1 II ...

Page 99: ...RK fJ NOTE INQ L1lNG Cf fCNAl PARTS fMK a TlRfc e SIGNAL RJi v 8 idr nu BY YO Il B TS OIL 611 1 VQ TAGE REGULATOft INSTR ENT LIGHT hIIAIN BEAM PILOT LlCOHT DIRECTIONAL PILOT LIGKT 1 T10N WAR NG LIGHT OIL PRESSURE IU R IIING LIGHT E OIm TERMNAL B B m m Cb R I AOLGH B LH 1 A010 rm CLOC o rk LiGHT mE HEATER UP STOP L T1JIH nOlllLLH AU 8 rL LH v if HEATERUl IS ...

Page 100: ... 58 o 40ll 64 23 24 Contact breaker gap n mm 24 104 5 o 017 91l21 0 4SO 5 0017 9021 045 05 24 25 Dwellangfe Degrees 25 49 55 49 55 55 5 26 Stmctlmlng oaTDC 25 26 I 27 StroboscopIC timing oaTDOrpm 27 10 650 10 600 14 650 27 28 Timing rk locatIOn 28 CP CP CP 28 I 2BA Ignition COil make type 28A HITACHI HITACHI HITACHI 28A I 288 Pnm 1ry stance Ohms 288 32 41 15 1 6 288 129 Centnf advanCt starts o rpm...

Page 101: ... wheel beanng nut Brake backplate Upper shock absorber mounting 25 33 kgm 181 239 Ib ft 27 3 7kgm 195 268 Ib ft 23 kgm 16 61b ft Lower shock absorber mounting Drive shaft to differential nuts Drive shaft to rear axle flange nuts 70 8 0 kgm 506 57 8 Ib ft Bumper nut 20 25kgm 145 188Ibft Wheel nuts 8 0 9 0 kgm 57 8 65 1 Ib ft Rear suspension member mounting nuts Differential member mounting nuts Sus...

Page 102: ...0 74 2 913380 240 9 448800 25 009841 75 029528 25 984250 75 2 952750 250 9 842600 26 010236 76 029921 26 1 023620 76 2 992120 260 10 236200 27 010630 71 030315 27 1 062990 77 3 031490 270 10 629900 28 011024 78 030709 28 1 102360 78 3 070860 280 11 032600 29 011417 79 031103 29 141730 79 3 110230 290 11 417300 30 011811 80 031496 30 181100 80 3 149600 300 11 811000 3 0 2205 81 03 890 3 220470 8 3 ...

Page 103: ......

Page 104: ...d I Estate up to 970 1 CONTAINS DetaIled descriptIon of ServIce RepaIr and Overhaul OperatIons dearly explamed and shown m hundreds of illustratIOns plus Trouble Shooting Tables Tune up Data Tables WIrIng DIagrams Exploded Parts Diagrams wIth DetaIled Parts dentificatlOn l I f r Q 1T UJ U 5oo OO M p 1 O j ...

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Summary of Contents for Estate I300

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Datsun Estate I300, Workshop Manual

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Summary of Contents for Estate I300

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