Workshop Manual Datsun 510, 1300-1600, L13 ... - Datsun510.com
Workshop Manual Datsun 510, 1300-1600, L13 ... - Datsun510.com
Workshop Manual Datsun 510, 1300-1600, L13 ... - Datsun510.com
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S IENTI IC I UBLI ATIONS<br />
VORKSIIOI IUANIJAL SERIES No 88<br />
DATStIN <strong>1600</strong> <strong>1300</strong><br />
SIfRIES <strong>510</strong><br />
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SED oN VA ON <strong>1600</strong> sss PICKln<br />
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AIJTOMATI<br />
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and MANIJAL TRANSMISSIONS<br />
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1 13 L16 LI4 Specifications<br />
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With Specifications<br />
Repair and Maintenance Data<br />
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SCIENTIFIC PUBLICAnONS<br />
SYDNEY DURHAM<br />
BRISBANE LONDON<br />
1<br />
MELBOURNE<br />
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PUBLISHED BY SCIENTIFIC PUBLICATIONS PTY LTO<br />
J j<br />
AustrahaJ<br />
89 97 Jones Stre t<br />
ULTIMO N S W 2007<br />
PhO<br />
J<br />
21T6I1<br />
j<br />
J<br />
England<br />
Umt4<br />
Hetton Lyons Industnal Estate<br />
HETION LE HOLE<br />
TYNE AND WEAR DHS ORH<br />
Phone Hetton Ie Hole 2443<br />
Pnnted by Tjmes Pnnters Sdn Bhd<br />
Smgapore<br />
@ Copynght by SCIentIfIc PubhcatIons Pty Ltd<br />
RegIstered at GPO Sydney for transnussJOn by post as a book<br />
FlfSt EdItIon December 1971<br />
Reprmted May 1972<br />
Repnnted December 1973<br />
Repnnted November 1975<br />
Repnnted June 1977<br />
ISBN 85566 039 2<br />
The informatIOn In thiS manual IS deTlved from the latest models<br />
available for our workshop research and from other available<br />
sources at the tlme of wTltmg Any subsequent modificatIOns will<br />
need to be taken mto consideratIOn by the operator<br />
While every precaution IS taken to ensure the accuracy of the<br />
contests onus can not be acceptedfor any miSinterpretatIOn of the<br />
descTlbed repalT operations or for any errors<br />
vertently made<br />
Il<br />
or omiSSIOns inad<br />
n Nowum F NT<br />
Sclentlfic PubhcatlOns WIshes to thank NlSSan Motor<br />
Corp USA and Borg Warner Ltd FaIrfield for help ill<br />
aspects of preparIng thIS manual<br />
l<br />
o<br />
v OVERSE S REPRESENTATIVES<br />
Canada Repco Auto Parts Canada Ltd 325 West 6th Avenue Vancouver IOBC<br />
New Zealand ME P Bookshop 82 TaranakI St WellIngton<br />
Pubhshers ServIces 13 Eden St Newmarket Auckland<br />
E Slme anll Co 82 Tory St<br />
J<br />
Welhngton and 140 Target Rd Glenfield Auckland<br />
SouthAfrica Austrahan Industnes Export Pty Ltd PO Box 2016 Johannesburg<br />
United Kingdom AIItech Distnbutors 15 HIgh St Hampton MIddlesex<br />
Fredenck MuIler Ltd Vlctona Works Edgware Road London<br />
SCjentIfic PublIcations Urnt 4 Hetton Lyons Industnal Estate<br />
HETION LE HOLE TYNE and WEAR DH5 ORH<br />
IJ<br />
fJ
d<br />
ENGINE<br />
COOLING SYSTEM<br />
FUEL SYSTEM<br />
CLUTCH<br />
MANUAL TRANSIUISSION<br />
AUTOMATIC TRANSMISSION<br />
REAR AXLE<br />
FRONT SUSPENSION<br />
RRotR SUSPENSION<br />
STEERING<br />
BRAKES<br />
ELECTRICAL SYSTEM<br />
ROAD TEST<br />
BODY<br />
WHEELS AND TYRES<br />
LUBRICATION AND MAINTENANCE<br />
EMISSION CONTROL SYSTEMS<br />
INDEX<br />
GLOSSARY OF TERMS<br />
J<br />
v<br />
4<br />
I<br />
b<br />
7<br />
40<br />
46<br />
35<br />
143<br />
150<br />
167<br />
216<br />
217<br />
226<br />
231<br />
233<br />
252<br />
255<br />
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1 1<br />
MOTOR VEIDCLFS<br />
Austin<br />
AustIn lillO <strong>1300</strong><br />
AustIn Met 1<br />
Allegro OHV<br />
lillO <strong>1300</strong> 1973 76<br />
Allegro OHC<br />
1500 1750 1973 76<br />
ChrysIer MrtsuInslu<br />
Galant GA GB Colt<br />
<strong>1300</strong> <strong>1600</strong> 1971 74<br />
Galant GC GD Colt<br />
600 177477<br />
Dalslm<br />
1000 1200<br />
<strong>510</strong> <strong>1300</strong> 1400 <strong>1600</strong><br />
1968 72<br />
180B 16OB<br />
Sunny 120Y<br />
Ford<br />
Capn Mk I<br />
Consul Zephyr Mk II<br />
1956 62<br />
CortlDa 1200 1500<br />
<strong>1600</strong> Mk I II<br />
196471<br />
Cortma Mk III <strong>1600</strong><br />
2000 1971 74<br />
Cortma Mk III 6 cyl<br />
1972 74<br />
Excort Mk I<br />
Escort Mk II<br />
Falcon XK to XW<br />
6<br />
l<br />
cyl 196070<br />
tb t Rican XY to XB<br />
I<br />
J 1 6 yl 1970 76<br />
Falcon XR to XY<br />
t V8 1966 71<br />
Falcon XA and XB<br />
V8 1971 76<br />
c<br />
Ii<br />
1<br />
j1t<br />
If<br />
HlnuUl<br />
Avenger<br />
Hunter<br />
New Hunter<br />
Holden<br />
GerolDl<br />
FX FJ FE FC FB<br />
EK EJ EH HD<br />
HR 1948 i8<br />
HK HT HG V8<br />
1968 71<br />
HK HT HG 6 cyl<br />
1968 71<br />
HQ HI 6 eyl<br />
HQ HJ V8<br />
Torana LC U 6 cyl<br />
1969 74<br />
Torana LH LX 6 cyl<br />
197476<br />
T orana HB<br />
Torana LC LJ TA<br />
4 cyl 1969 75 ohv<br />
Torana LC U TA<br />
4 cyl 1969 75 ohc<br />
Torana LH LX 4 cyl<br />
197476<br />
Honda<br />
ElVIe HondamatIc<br />
CIVIC <strong>Manual</strong><br />
f<br />
I 1 1 11<br />
SCIENTD1C PUBLICATIONS MANUAL SERIES<br />
Bool Pagea m Bool PaIfSIh<br />
No<br />
tre1 No tretioDS<br />
148<br />
149 192 298<br />
25<br />
51<br />
192 37<br />
r<br />
I<br />
200 129<br />
05 192 202<br />
17<br />
87<br />
88<br />
110<br />
III<br />
82<br />
08<br />
68<br />
60<br />
59<br />
81<br />
20<br />
62<br />
155<br />
154<br />
156<br />
80<br />
79<br />
37<br />
224 208<br />
256 241<br />
224 208<br />
224 278<br />
173 108<br />
184<br />
124<br />
288 192<br />
240 239<br />
176 135<br />
192 172<br />
192 240<br />
290 188<br />
272 226<br />
272 190<br />
240<br />
327<br />
176 267<br />
188 121<br />
113 160 215<br />
67<br />
85<br />
86<br />
146<br />
147<br />
84<br />
58<br />
72<br />
56<br />
145<br />
16<br />
139<br />
140<br />
286<br />
272<br />
128<br />
215<br />
224 188<br />
208 194<br />
256 240<br />
192 172<br />
192 200<br />
192 120<br />
196 287<br />
196 295<br />
180<br />
197<br />
176 350<br />
176 339<br />
Leyland<br />
Allegro OHV<br />
lillO <strong>1300</strong> 1973 76 25<br />
Allegro OHC<br />
1500 1750 1973 76 51<br />
Manna I 3 I 8<br />
1971 75 142<br />
Manna 1500 1750 03<br />
P76 V8 04<br />
P76 6 cyl 141<br />
BL 1100 <strong>1300</strong> 148<br />
Mazda<br />
Capella 616 <strong>1600</strong><br />
1970 73 89<br />
1500 1800 90<br />
RX2 R I 00 Rotanes 91<br />
1000 <strong>1300</strong> 92<br />
MG<br />
TC to MGB Mk I 70<br />
Moms<br />
MlDor 1000 24<br />
Manna see Leyland<br />
MIDI 1961 72 64<br />
MmJ 1971 76 02<br />
1100 65<br />
1800 Mk I Mk II 66a<br />
Peugeot<br />
403 404 31<br />
Renaalt<br />
12 32<br />
DauphIne<br />
34<br />
R8 and RIO 74<br />
Toyota<br />
Corolla 1100 73<br />
Corolla 1200<br />
122<br />
Corona 2R 83<br />
Corona 2000 16R 18R 120<br />
Corona 12R RT80 81 123<br />
Vabant<br />
AP6 VC VE VF<br />
V8 1965 70 69<br />
R S AP5 AP6 VC<br />
VE VF 6 cyl<br />
1962 70 78<br />
Heml VG VH<br />
6 eyl 1970 74 52<br />
Galant see under Chrysler<br />
Veuxhall<br />
VIva HA HB 90 76<br />
Viva HC OHV<br />
57<br />
Chevette 1256 ce 114<br />
Volkswagen<br />
Super bug 1302S <strong>1600</strong><br />
1971 73 45<br />
Beetle 1100 1200<br />
1200A <strong>1300</strong> 1500<br />
1954 71<br />
46<br />
Fastback Type 3 <strong>1600</strong> 47<br />
Transporter 1954 72 48<br />
Type 2 1700<br />
1800 2000 151<br />
Passat <strong>1300</strong><br />
1500 <strong>1600</strong> 152<br />
Golf 1500 <strong>1600</strong> 153<br />
192 277<br />
160 291<br />
180 274<br />
180 324<br />
160 134<br />
212 196<br />
200 199<br />
160 305<br />
320 204<br />
96<br />
96<br />
236 187<br />
224 276<br />
146 106<br />
224 174<br />
122 171<br />
160 317 J<br />
134 158<br />
164 97<br />
176 107<br />
240 217<br />
224 186<br />
176 256<br />
160 220<br />
174 95<br />
280<br />
145<br />
224 183<br />
200 140<br />
160 239<br />
224<br />
1 88<br />
260 240<br />
232 167<br />
272 205<br />
168<br />
240<br />
168 235<br />
Volvo Senes 140<br />
WIth Carb es<br />
With Fuel Inject<br />
HARD TO GET AND<br />
VINTAGE MANUALS<br />
Austm<br />
A40 Devon Dorset<br />
A40 Somerset<br />
Jagoar<br />
Mks VII VIII IX<br />
XK 120 140 150<br />
Mk I II 2 4 3 4 3 8<br />
E Type 3 8 4 2<br />
1962 69<br />
Staodanl<br />
8 14 1939 46<br />
Ten 1955 58<br />
Spa aster II<br />
TR2 TR3 TR4<br />
MOWERS AND<br />
SMALL ENGINFS<br />
Rover Senes to 1977<br />
Small EngInes<br />
Vlcta Series to 1977<br />
Scott Bonnar 1976 77<br />
MOTOR CYCLFS<br />
Bool Pagea m<br />
No treb<br />
53 212<br />
54 196<br />
00 106<br />
01 100<br />
21 274<br />
22 274<br />
77 202<br />
40 82<br />
41 148<br />
42 126<br />
44 168<br />
99<br />
112 160<br />
103 128<br />
97<br />
Honda<br />
QA50 MmJblke 129 64<br />
SL70 Cf90 130 128<br />
CIS 50 65 70 131 96<br />
StreetTfrad 175 132 112<br />
125 Vert eal TWIn 133 112<br />
250 350 134 128<br />
100 125 VertIcal SmgIe 135 112<br />
OUTBOARDS<br />
Ennrude JoImson<br />
34 hp 196472 105 64<br />
5 6 hp 1965 74 106 96<br />
9 hp 196473 107 80<br />
18 20 25 hp 1960 73 108 112<br />
18 20 25 hp 196073 108 112<br />
33 40 hp 1965 74 109 128<br />
40 hp Lark 1965 74 104 112<br />
MANUALS IN PRODUCfION<br />
Austm 1100 <strong>1300</strong> 148<br />
HillmanNew Hunter 37<br />
Vahant VJ VK 157<br />
Golf 1500 <strong>1600</strong> 153<br />
Rovers Mowers 99<br />
Scott Bonnar Mowers 97<br />
l<br />
172<br />
147<br />
89<br />
84<br />
237<br />
281<br />
124<br />
51<br />
134<br />
105<br />
130<br />
231<br />
138<br />
95<br />
224<br />
182<br />
341<br />
346<br />
376<br />
374<br />
92<br />
177<br />
198<br />
260<br />
260<br />
300<br />
250<br />
f
Engllle type<br />
Engllle models<br />
Fmng order<br />
CompressIOn ratio<br />
<strong>L13</strong> 16 slllgle carb<br />
L14<br />
L16 tWill carb<br />
Bore<br />
Stroke<br />
<strong>L13</strong><br />
L14<br />
L16<br />
CapacIties<br />
<strong>L13</strong><br />
L14<br />
L16<br />
Brake horsepower<br />
<strong>L13</strong><br />
L14<br />
L16 slllgle carb<br />
L16 twill carb<br />
Maximum torque<br />
<strong>L13</strong><br />
L14<br />
L16 single carb<br />
L16 tWin carb<br />
Standard compressIOn pressure<br />
@ 350 rpm<br />
<strong>L13</strong> L14 L16 single carb<br />
L16 tWin carb<br />
Minimum compressIOn pressure<br />
@ 350 rpm<br />
4 cyl OHC<br />
ENGINE l<br />
SPECIFICATIO S<br />
<strong>L13</strong> L14 L16<br />
1 3 4 2<br />
85<br />
90<br />
95 J<br />
83mm<br />
3 2677 Ill<br />
59 9 mm<br />
2358 Ill<br />
660mm<br />
2598 In<br />
73 7 mm<br />
2901 In<br />
1296 cc<br />
79 086 cu In<br />
1428 cc<br />
87 141 cu In<br />
1595 cc<br />
97331<br />
cu In<br />
77 @ 6000 rpm<br />
85 @ 6000 rpm<br />
96 @ 5600 rpm<br />
109 @6000 rpm<br />
III kg m<br />
@ 3600 rpm<br />
803 ft lb<br />
@ 3600 rpm<br />
119 kg m<br />
@ 3600 rpm<br />
86 0 ft lb<br />
@ 3600 rpm<br />
13 8 kg m<br />
@ 3600 rpm<br />
99 8ft lb<br />
@ 3600 rpm<br />
143 kg m<br />
@ 4000 rpm<br />
ft lb<br />
1034<br />
@ 4000 rpm<br />
120 kg cm2<br />
171 pSI<br />
125 kg cm2<br />
178 pSI<br />
II 5 kg cm2<br />
159 pSI<br />
7<br />
EngIne IdlIng speed I<br />
<strong>L13</strong> L14 L16 single carb<br />
L16 tWIn carb<br />
Igmtlon tIming<br />
InItIal settIng at IdlIng speed<br />
LJ3 LJ4 LJ6 single carb<br />
LJ6 tWin carb<br />
Type<br />
Bore dIameter standard<br />
Bore wear lImit<br />
Bore measunng pOInts<br />
from block face<br />
depth<br />
J<br />
Fust<br />
Second<br />
Thud<br />
I<br />
CYLINDER BLOCK<br />
CylInder block face warp IInut<br />
O S pistons avaIlable<br />
FIrSt O S<br />
Second O S<br />
l<br />
ThIrd O S<br />
r<br />
FourtJi O S<br />
t<br />
FIfth O S<br />
Type<br />
Matenal<br />
Valve Eeat Width In<br />
tc<br />
cylInder head<br />
Inlet<br />
Exhaust<br />
t i<br />
J C<br />
i<br />
4<br />
K<br />
t<br />
J<br />
CYtINDER HEAD<br />
l<br />
1J<br />
600 rpm<br />
650 rpm<br />
10deg btd<br />
14 deg btdc<br />
4 cyl In lIne<br />
Integral WIth<br />
crankcase<br />
83000<br />
83 050 mm<br />
3 2677<br />
3 2697 In<br />
o 20 mm<br />
0008 on<br />
20mm<br />
0787 In<br />
60mm<br />
2 362 In<br />
7<br />
100mm<br />
39371<br />
910mm<br />
0004 In<br />
o 250 mm<br />
0010 on approx<br />
o 500 mm<br />
0 020 In approx<br />
0750 mm<br />
0030 on approx<br />
I 000 mm<br />
0040 In approx<br />
I 500 mm<br />
0060 In approx iL<br />
Wt<br />
One piece<br />
AlumInIUm Alloy<br />
I 40 I 80 mm<br />
0055<br />
0071 In<br />
160 200mm<br />
0063<br />
o 079 In<br />
t<br />
I<br />
w<br />
tFr<br />
f<br />
1<br />
r<br />
J<br />
i<br />
fe<br />
to<br />
Y
2 Engine<br />
Valye seat angle<br />
Inlet and exhaust<br />
Valve seat msert mterference<br />
fit m cyhnder head<br />
Inlet<br />
Exhaust<br />
Cyhnder head tempera ture<br />
for fittmg valve seat mserts<br />
Valve gUide mterference<br />
fit m cylmder head<br />
Inlet and exhaust<br />
1<br />
Cylulder iiead face warp hmlt<br />
J<br />
j45 deg<br />
008 0 II mm<br />
00031<br />
00043 m<br />
006 01Omm<br />
00024<br />
00039 m<br />
150<br />
200 deg C<br />
302<br />
392 deg F<br />
o 027<br />
o 049 mm<br />
00011<br />
00019 m<br />
o 10mm<br />
0 004 m<br />
CRANKSHAFT AND MAIN BEARINGS<br />
Type<br />
rJiMatenal<br />
jIl Number of mam Journals<br />
End thrust taken at<br />
y<br />
Thrust clearance<br />
Thrust clearance IUTIlt<br />
Mam beanngJournal<br />
diameter standard<br />
Mam beanng Journal<br />
taper and ovahty hmlt<br />
VIS beanng avaIlable for<br />
VIS Journals<br />
Fust VIS<br />
Second VIS<br />
Third VIS<br />
yli ffi<br />
Fourth VIS<br />
c<br />
1<br />
Counter balanced<br />
Forged steel<br />
5<br />
No 3 mam beanng<br />
o 05 0 15 mm<br />
0002<br />
0006 m<br />
03mm<br />
0012 m<br />
54 942<br />
54955 mm<br />
21631<br />
2 1636 on<br />
003 mm<br />
00012m<br />
o 250 mm<br />
OOIOm<br />
approx<br />
o 500 mm<br />
0020 m<br />
approx<br />
0750 mm<br />
0 OJO m<br />
approx I<br />
I 00 mm I<br />
0040 u<br />
T<br />
r<br />
approx<br />
Ot<br />
r tt<br />
A<br />
Ii I tr t<br />
l<br />
J1tJ<br />
d<br />
8<br />
J<br />
Maon beanng oIl clearance<br />
<strong>L13</strong> L14 o 020<br />
L16<br />
Mam beanng oIl clearance hmlt<br />
0062 mm<br />
00008<br />
o 0024 m<br />
o 020<br />
0072 mm<br />
00008<br />
o 0028 m<br />
<strong>L13</strong> LI4 L16 o IOmm<br />
Crankpon diameter standard<br />
Crankpon taper and ovahty hmlt<br />
00039 m<br />
49961<br />
49 975 mm<br />
I 9670<br />
I 9675 m<br />
003 mm<br />
00012 on<br />
CONNECTING RODS AND BEARINGS<br />
Connectmg rod type<br />
Matenal<br />
Length<br />
<strong>L13</strong><br />
L14<br />
L16<br />
centre to centre<br />
Connectmg rod bend or tWIst<br />
H sectIOn<br />
Forged steel<br />
139 87<br />
139 93 mm<br />
5507<br />
5 509 m<br />
1366 mm<br />
5371 m<br />
13297<br />
133 03 mm<br />
5235<br />
5 237 m<br />
maxnnum lumt per 100 mm 394 m 005 mm<br />
00020 m<br />
Big Replaceable<br />
end beanng type<br />
BIg end beanng 011 clearance<br />
<strong>L13</strong> L14 0014<br />
L16<br />
Big end bearmg oIl clearance hmlt<br />
<strong>L13</strong> L14 L16<br />
VIS beanngs avaIlable<br />
for VIS crankpms<br />
FITSt VIS<br />
Second VIS<br />
0056mm<br />
00006<br />
00022 m<br />
0014<br />
o 066 mm<br />
00006<br />
00026 m<br />
o IOmm<br />
00039 m<br />
o 060 mm<br />
0 002 m<br />
approx<br />
o 120 mm<br />
0004 on<br />
approx
Thud U S o 250 mm<br />
Fourth UIS<br />
0010 In<br />
approx<br />
o 500 mm<br />
0 020 In<br />
approx<br />
FIfth U S 0750 mm<br />
0030 In<br />
approx<br />
SIxth U S 100mm<br />
Type<br />
DIameter<br />
Length<br />
Clearance In pIston<br />
Interference fit In rod<br />
GUDGEON PINS<br />
PISTONS<br />
0040 In<br />
approx<br />
Interference fit<br />
In rod<br />
20995<br />
21 000 mm<br />
0 8266<br />
08268 In<br />
72 00<br />
72 25 mOl<br />
2 8346<br />
28445 In<br />
o 008<br />
0010 mm<br />
00003<br />
00004 In<br />
0015<br />
0033 mm<br />
00006<br />
00013 In<br />
Type<br />
<strong>L13</strong> L14 Flat top<br />
L16<br />
Matenal<br />
Removal<br />
DIameter standard<br />
DIameters O S<br />
FIrSt O S<br />
Second O S<br />
Invar strut<br />
slipper skut<br />
Concave top<br />
Invar strut<br />
slipper skIrt<br />
Cast alumInIUm<br />
Top of cylinder<br />
82 99<br />
83 04 mm<br />
3 267<br />
3 269 In<br />
83 22<br />
83 27 mm<br />
3 276<br />
3 278 In<br />
8347<br />
83 52 mm<br />
3 286<br />
3288 In<br />
9<br />
Thud O S<br />
Fourth O S<br />
FIfth O S<br />
PIston measunng pOInt<br />
Skut clearance In bore<br />
Gudgeon pIn bore offset<br />
DIstance below centre lIne of gudgeon pm<br />
LocatIOn<br />
Number<br />
Width<br />
Upper compressIOn<br />
Lower compressIOn<br />
011 control<br />
Clearance 10 grooves<br />
Upper compressIOn<br />
<strong>L13</strong> L14<br />
L16<br />
Lower compressIOn<br />
<strong>L13</strong> L14 L16<br />
011 control<br />
<strong>L13</strong> L14 L16<br />
i<br />
i<br />
PISTON RINGS<br />
r<br />
Ji<br />
83 72<br />
83 77 mm<br />
3 296<br />
3 298 m<br />
83 97<br />
84 02 mm<br />
3 305<br />
3 308 In<br />
8447<br />
84 52 mm<br />
3 326<br />
3 328m<br />
18 6 mm<br />
9<br />
732 In<br />
o 025<br />
o 045 mm<br />
0001<br />
00018 In<br />
o 950<br />
1 050 mm tli<br />
003740 J<br />
004134 In<br />
4<br />
f k1 I<br />
t V gudgeon<br />
pin<br />
3<br />
20mm<br />
0078 In<br />
20mm<br />
007810<br />
40mm<br />
015610<br />
0040<br />
0073 mm<br />
00016<br />
00029 10<br />
o 045<br />
0078 mm<br />
00018<br />
00031 10<br />
0030<br />
o 063 mm<br />
00012<br />
o 0025 10<br />
o 025<br />
0 063 mm<br />
0001<br />
00025m<br />
3<br />
Engine<br />
0 4<br />
j<br />
e<br />
r<br />
It l<br />
11<br />
r<br />
f
k<br />
t iff<br />
Engine<br />
Rmg gap<br />
Upper compressIOn<br />
Lower compressIOn<br />
011 control<br />
VALVES<br />
II it Ji<br />
if Head dIameter mlet<br />
i1 tC l 13 LI4 LI6 sIngle carb<br />
J J t<br />
i lt6 tWIn carb<br />
fl<br />
oIf<br />
y<br />
Head dIameter exhaust<br />
t<br />
d<br />
itr<br />
J<br />
Stem dIameter<br />
Inlet and exhaust<br />
Clearance In gUide bore<br />
Inlet<br />
Exhaust<br />
Valve length<br />
Inlet<br />
Exhaust<br />
l VaJve hft<br />
r<br />
I<br />
Inlet andexhaust<br />
LI3 LI4 LI6 smgle carb<br />
Ll6 twm carb<br />
Valve face angle<br />
Inlet and exhaust<br />
Valve clearance<br />
Hot<br />
Inlet<br />
5Jt i<br />
liflj Exhaust<br />
oj<br />
Cold<br />
Inlet<br />
Exhaust<br />
o 023<br />
o 38 mm<br />
00091<br />
0015 m<br />
015 030mm<br />
00059<br />
00118 In<br />
o 15 0 30 mm<br />
0 0059<br />
00118 m<br />
38 00 mm<br />
1<br />
50 In<br />
42 0 mm<br />
I 65 m<br />
33mm<br />
1<br />
30 In<br />
8mm<br />
0 31 m<br />
0015<br />
0045 mm<br />
00006<br />
00018 In<br />
0040<br />
o 070 mm<br />
00016<br />
00028 m<br />
1159mm<br />
456 m<br />
1160mm<br />
457 In<br />
100mrl<br />
03937 m<br />
10 5 mm<br />
04l24m<br />
45 deg 30 mm<br />
o 25 mm<br />
0010 In<br />
o 30 mm<br />
0012 m<br />
o 20 mm<br />
0008 m<br />
o 25 mm<br />
OOIOm<br />
10<br />
Type<br />
Free length<br />
Outer<br />
LI3 Ll4<br />
Ll6<br />
Inner<br />
LI6<br />
Length at load valve closed<br />
Outer<br />
LI3 Ll4<br />
Ll6<br />
Inner<br />
Ll6<br />
Length at load valve open<br />
OUJer<br />
Ll3 Ll4<br />
LI6<br />
Inner<br />
LI6<br />
Valve spnng squar eness hmlt<br />
1r t<br />
3<br />
VALVE SPRINGS<br />
r<br />
t<br />
Hehcal<br />
48 12 mm<br />
I 89 m<br />
52 00 mm<br />
20472 m<br />
44 85 mm<br />
1 7657 m<br />
400mm<br />
@ 29 2<br />
322 k g<br />
1 57 m<br />
@ 64 39<br />
71011b<br />
38 9 mm<br />
@ 27 5<br />
30 5 k g<br />
1 53 In<br />
@ 60 62<br />
67241b<br />
35mm<br />
@116<br />
13 0 k g<br />
1<br />
38 m<br />
@ 25 58<br />
28661b<br />
30 0 mm<br />
@ 67 7<br />
74 7 k g<br />
118m<br />
@ 149 19<br />
164611b<br />
30 7 mm<br />
@ 45 4<br />
50 2 k g<br />
307m<br />
@10009<br />
11667Ib<br />
245 mm<br />
6 @ 24 2<br />
j 26 8 ktl<br />
eb 96 Ini<br />
y 5i31f<br />
59 Olflb<br />
1 J<br />
I 6Inm<br />
0063 m<br />
J<br />
t 4 1f<br />
t<br />
J 4<br />
i j<br />
A l<br />
rt<br />
r<br />
I<br />
Ii<br />
l<br />
1<br />
ft<br />
l<br />
w<br />
fJ<br />
r<br />
r<br />
t f<br />
i<br />
J<br />
f<br />
1<br />
j<br />
t
4<br />
dJ<br />
C<br />
t<br />
Type<br />
Length<br />
Inner diameter<br />
Outer diameter<br />
Fitted height above<br />
cyhnder head<br />
VALVE GUIDES<br />
q<br />
GUide to yalve stem clearance<br />
Inlet<br />
Exhaust j1ft<br />
ll<br />
Type<br />
Number of beanngs<br />
Camshaft Journal diameter<br />
aj<br />
wear CamshaWJournal hmlt<br />
Camshaftbearmg diameter<br />
Camshaft lobe hft<br />
<strong>L13</strong> Ll4 Ll9 smgle carb<br />
L16 twm carb<br />
CamshaftJournal to<br />
beanng clearance<br />
Beanng clearance hmlt<br />
M CfiTshaft nd float<br />
f<br />
1<br />
1<br />
bend I1I1 t l<br />
Plmshaft<br />
r<br />
J qr<br />
0 Cf<br />
r tL<br />
J<br />
Jt<br />
tyr r<br />
I<br />
u<br />
t<br />
J t i h<br />
CAMSHAFT<br />
It<br />
f<br />
Renewable<br />
59 0 mm<br />
232111<br />
8000<br />
8 018 mm<br />
03150<br />
03154 m<br />
11 985<br />
11 996 mrn<br />
04718<br />
04723111<br />
104 106mm<br />
0 409<br />
0417111<br />
p<br />
0015<br />
o 045 mm<br />
00006<br />
00018 m<br />
0040<br />
0070 mm<br />
00016<br />
00028 m<br />
Overhead<br />
4<br />
47949<br />
47962 mrn<br />
1 8877<br />
1 8883 m<br />
o 10 mm<br />
00039 m<br />
48 000<br />
48016 mrn<br />
1 8898<br />
1 8904 m<br />
6 65 mm<br />
0261 m<br />
7 00 mm<br />
0275 m<br />
o 038<br />
0076 mm<br />
00015<br />
00026 m<br />
o 10mm<br />
0 0039 m<br />
008 0 38 mrn<br />
00031<br />
00150m<br />
005 mm<br />
0 002 m<br />
11<br />
Type<br />
i<br />
Camshaft sprocket<br />
Fit on camshaft<br />
Method of secunng<br />
ctankshaft sprocket<br />
Fit on crankshaft<br />
Method of secunng<br />
Pump type<br />
Outer rotor to pump<br />
body<br />
clearance max<br />
Inner rotor tIp<br />
clearance<br />
CAMSHAFf DRIVE<br />
LUBRICAnON<br />
Sprocket and<br />
cham<br />
Light fit<br />
One bolt and<br />
peg<br />
Light fit<br />
Key<br />
Engine 5<br />
Eccentnc rotor<br />
021<br />
mm<br />
0 009 lOW<br />
max o 12mm<br />
Inner and outer rotor end<br />
clearance JTlax<br />
Ou pressure at Idle<br />
Rehef valve spnng<br />
Free length<br />
Length at load<br />
Rehef valve opemng pressure<br />
Ou capacity<br />
Sump Without filter<br />
Sump mcludmg filter<br />
Cylmder head bolts<br />
Mam beanng cap bolts<br />
Big end beanng nuts<br />
Camshaft sprocket bolt<br />
0005 11 J<br />
012mm<br />
0005 m<br />
I 0 I 2 kg cm2<br />
142 171 pSI<br />
57mm<br />
2 24 m<br />
39mm<br />
I<br />
38<br />
TORQUE WRENCH SETTINGS<br />
540 m<br />
42 kg cm2<br />
l54 00<br />
59 7 pSI<br />
I f Yl<br />
k<br />
J1 1h<br />
w<br />
o 4<br />
0<br />
il<br />
flf tral<br />
1i<br />
J<br />
111<br />
t
Jf<br />
Itt t<br />
t<br />
J<br />
J<br />
1 Yi t<br />
t<br />
i<br />
1<br />
6Engine<br />
Sump bolts o 7 kg m Rear crossmember to body bolts 5 2 kg m<br />
50 ft lb 38 0 ft lb<br />
011 pump bolts 2 1 kg m Front engme mountmg<br />
IS 0 ft lb bracket to engme bolts 3 0 m kg<br />
Flywheel bolts 105 kg m 220 ft lb<br />
76 0 ftlb Front engme mountmg<br />
Rear engme mountmg to bracket bolts 3 2 kg m<br />
to transmISSIOn bolts 3 2 kg m 23 0 ft lb<br />
23 0 ft lb Front engme mountmg<br />
Rear engme mountmg to crossmember 1 7 kg m<br />
to crossmember bolts 1 6 kg m<br />
120ft lb<br />
The <strong>L13</strong> and L16 overhead camshaft engmes are almost<br />
IdentIcal m deSIgn The L16 engrne wIth ItS longer stroke<br />
and thus mcreased capacIty develops more horsepower<br />
DImenSIOns of some components m the L16 engme haye<br />
b n mcreased to take the load of the hIgher output The<br />
L16 engme IS also avaIlable m a sports type versIOn and<br />
utlhzes twm carburettors and hIgher compressIOn ratIo to<br />
mcrease power by 13 bhp over that of the L16 standard<br />
versIon of the engme<br />
The engInes have a cast Iron deep slmt deSIgn cyhnder<br />
block The five mam bearIngs whIch are used to support the<br />
crankshaft aH of the precIsIon msert replaceable type The<br />
mam bearIn m al1 engInes must l ot be adjusted by filmg<br />
or by scrapmg<br />
The cran 1t end float IS control1ed by thrust faces<br />
which are mtegraJ With the centre mam bearIng halfshel1s<br />
y<br />
il<br />
r<br />
l l<br />
l<br />
l 10<br />
tJ<br />
li<br />
f<br />
t I t<br />
011 leaks from the front and rear of the crankshaft are<br />
ff<br />
4<br />
I DESCRIPTION<br />
120 ft lb<br />
prevented by seals whIch are mstal1ed m the tlmmg coyer<br />
and rear mam beanng The front seal runs on the crankshaft<br />
pul1ey hub and the rear seal runs on the crankshaft flange<br />
The cyLmder head IS constructed of alummlUm al10y<br />
SpecIal alurmrnum bronze valve seats are used for the mlet<br />
valves and specIal cast seats are mstalled for the exhaust<br />
valves<br />
Both mlet and exhaust valve seats are a hot press fit<br />
mto the cyhnder head The camshaft IS supported over the<br />
top of the cyhnder head by four alummlUm alloy brackets<br />
A long double row roller cham drIves the camshaft from the<br />
crankshaft sprocket Cham tensIon IS controlled by a<br />
tenslOner whIch IS operated by a sprmg and OIL pressure A<br />
shoe type Neoprene pad whIch IS bolted on the face of the<br />
crankcase keeps cham VIbration down to a mmlmum<br />
Left Hand Side View of <strong>1600</strong> Engone and Transmission Assembly<br />
12<br />
Connectmg rods are H section forgmgs fitted WIth<br />
replaceable bIg end preCISIon msert bearIngs The gudgeon<br />
pms are a hollow type bemg fully floatmg m the pIston and<br />
a press fit m the connectmg rod<br />
The hght weIght shpper skIrt type pIstons have a flat<br />
top m the <strong>L13</strong> engIne and a concave top m the L16 engIne<br />
The 011 pump IS a bl rotor type and IS drIven by the<br />
dIstrIbutor dnve shaft assembly whIch m turn IS drIven by<br />
a gear whIch IS keyed to the front of the crankshaft
RIght Hand SIde V ew of <strong>1600</strong> Engone and TransmiSSion Assembly<br />
TO REMOVE AND INSTAL<br />
I Raise the engine bonnet and fit fender covers to<br />
both front fenders<br />
2 Mark around the bonnet hinge plates on the<br />
bonnet wIth a soft lead pencil to facilitate correct<br />
replacement and remove the bonnet<br />
3 Remove the radiator cap and drain the coohng<br />
system vra the drain tap on the lower radiator tank<br />
4 Remove the sump and transmission drain plugs and<br />
drain the lubricant from both assemblies<br />
5 Disconnect the leads at the battery terminals and<br />
remove the battery from the engine compartment<br />
6 Disconnect the ventilatIOn hose from the I<br />
rocker<br />
cover and remove the air cleaner assembly<br />
7 Disconnect and remoye the upper and lower<br />
radiator hoses and the heater hoses where apphcable<br />
8 Unscrew the fixing bolts and detach the radiator<br />
grille<br />
9 On vehicles fitted wIth automatic transmiSSIOn<br />
disconnect the torque converter cooling pipes<br />
at the lower<br />
radiator tank plug the pipes and umons to prevent entry of<br />
dirt<br />
10 Remove the radiator retaining bolts and hft out<br />
the radiator<br />
II Slacken the alternator mountlllg boIts and remove<br />
the fan belt Remove the four boIts fan and pulley from<br />
the water pump<br />
12 Disconnect the wlfes at the 011 pressure switch<br />
temperature sender umt coil and alternator<br />
r<br />
2 ENGINE ASSE BLY<br />
0<br />
5 I<br />
t<br />
r tv<br />
i t I<br />
13 Disconnect the throttle control linkage and the<br />
choke control wIre at the carburettor I<br />
14 Disconnect the fuel pipe from the mlet S e of the<br />
tiue1 pump<br />
v<br />
l l I<br />
IS Remove the nuts and detach the exhaust PIP<br />
from the exhaust mamfold TIe the exhaust plpe away frifp<br />
the engine assembly<br />
Jl1<br />
I<br />
j<br />
16 Raise the front and rear of the vehicle and<br />
support safely onJour sUitable chaSSIS stands fj<br />
17 Remove the clutch actuating cyhnder and ret n<br />
spring Tie the cylinder to a<br />
cO lYement<br />
out of the way<br />
posItion on the underbody<br />
18 Disconnect the reversing hght sWltctplug 9 h<br />
inhibitor and reverSing hght sWitch i plug J wlucheveiI isi t<br />
l<br />
apphcable for either manual or automatic transmlsslqi1n<br />
19 Disconnect the speedometer ca le<br />
20 On manual floor shift transmISsion from inSide<br />
the vehicle remove the gaiter from the gear shIft lever undo<br />
the self locking nut from the lower end of the lever and<br />
remove the lever<br />
On manual column<br />
Shdlft<br />
transmISsIOn disconnect<br />
select and shift rods un 0 the cross shaft bracket to Sl e<br />
member retaining bolts and remove the cross shaft bracket<br />
assembly<br />
On automatic transmiSSIOn<br />
thde<br />
disconnect the selector<br />
hnkage at the cross shaft bracket undo the cross shaff<br />
bracket to SIde member retaining bolts and remove the<br />
cross shaft bracket assembly<br />
21 Remove the four bolts and nuts from the<br />
I<br />
y jt<br />
2<br />
r<br />
d
J<br />
R<br />
propeller shaft rear flange and WIthdraw the shaft from the<br />
transmISSion<br />
NOTE To remove the propeller shaft It may be necessary<br />
to disconnect the rear handbrake cable where It runs under<br />
the rear seetlOn of the propeller shaft<br />
22 Detach the handbrake cable from ItS retammg clIp<br />
at the transmission rear crossmember<br />
23 Remove the two transmISSIOn rear crossmember<br />
to mountmg secunng bolts<br />
24 Interpose a wooden block between the<br />
transmiSSIOn and a Jack and take the weight of the rear<br />
engme and transmISSIOn assembly<br />
25 Remove the four bolts which attach the rear<br />
transmISSIOn crossmember to the underbody and remove<br />
the crossmember<br />
26 Instal a sUitable IIftmg cable or cham to the IIftmg<br />
hooks which are posItIoned at the front and the rear of the<br />
engme cylmder head and With sUitable IIftmg tackle take<br />
the weight of the engme assembly<br />
I ROCKER AR f ND IIVOTS<br />
relevant arm before attemptmg to co rf kss the valve sprmg<br />
and removmg the arm<br />
8 Place the rocker arms m a rack or lay them out m<br />
TO REMOVE<br />
I Detach the rocker cover to atr cleaner ventIlatIOn<br />
hose and the thermostatIc au bleed hose where fitted<br />
2 Loosen the au cleaner assembly thumb screw<br />
remove the two bolts whIch secure the atr cleaner assembly<br />
0 bracket to the mlet manIfold and remove the au cleaner<br />
assembly<br />
t e NOTE On engines fitted With twm SU carburettors ItWill<br />
not be necessafY to remove the arr cleaner ssembly<br />
3 Detach the hIgh tensIOn leads at the spark plugs<br />
and carefully tIe the hIgh tensIOn leads at a convement<br />
pomt away from the rocker cover<br />
NOTE Carbon filled high tensIOn leads should be handled<br />
carefully at all times Mlshandlmg of leads Will cause a<br />
breakdown m lead wntmUlty<br />
4 Remove the rocker cover secunng bolts and detach<br />
the rocker cover and rocker cover gasket<br />
5 UnclIp and remove the small steady spnng from<br />
each rocker arm<br />
6 Back off the rocker pivOt locknuts and screw the<br />
PIvOtS down as far as possible mto the cylInder head<br />
7 With a screwdnver push down on each valve spnng<br />
l<br />
see IllustratIon and manoeuvre out each rocker arm<br />
Dunng this operatIon take care that the valve rocker gUides<br />
which are located on the end of the valve stems are not<br />
dIslodged and lost<br />
NOTE When removlIIg rocker arms ensure that the cam<br />
el for the rocker arm bel1lg removed IS adjacent<br />
t t<br />
1t<br />
to Its<br />
14<br />
1<br />
order to ensure that they wIll be mstalled m theu ongmal<br />
pOSItIons m the cylInder head<br />
9 Unscrew the rocker arm PIvOtS from the cylInder<br />
head and remove the rocker guides from the yalve stem<br />
ends<br />
27 Remove the front engme mountmg to front<br />
crossmember secunng bolts<br />
28 Check around the engme and transmISSIOn<br />
assembly to ensure that notlung will foul on the assembly<br />
and also that all relevant Items have been disconnected<br />
29 Gradually taIse the engme WIth the front tuted<br />
upwards to clear the body and at the same tune lowenng<br />
the transmiSSIOn on the jack untu the engme assembly can<br />
be lIfted clear of the vehicle<br />
InstallatIon IS a reversal of the removal procedure With<br />
attentIon to the followmg pomts<br />
Ensure that the engme assembly IS mstalled and bolted<br />
securely to all mountmgs and that the full engme assembly<br />
weIght IS taken by the mountmgs before connectmg up the<br />
vanous components to the engine and transmission<br />
FIll the radiator With water and add condItIoner and or<br />
antI freeze If necessary<br />
FIll the crankcase With the correct amount of the<br />
recommended grade of M S engine ou<br />
Start and run the engme untu It reaches normal<br />
operatmg temperature and check for ou and water leaks<br />
Lay these Items also out m order to ensure correct<br />
replacement to cylmder head<br />
Method of RemOVing Valve Rocker Arms<br />
J
TO CHECK<br />
Engine Rocker Cover Removed Showing Val e Rocker Arm and P vOt Layout<br />
1 Wash all components In cleanmg solvent and blow<br />
dry wIth compressed an<br />
2 Check the rocker arm Pivot head surface for wear<br />
or damage<br />
3 Check the rocker arm to cam and the rocker arm<br />
to p vot contact surfaces for wear or damage<br />
4 Wear or damage to one of the above mentIOned<br />
components will necessitate the renewal of the<br />
correspondmg Pivot or rocker arm as the case may be<br />
TO REMOVE AND INSTAL<br />
J Disconnect the rocker cover to an cleaner<br />
ventIlatIOn hose and where fitted the mlet mamfold to air<br />
cleaner thermostatic au bleed hose<br />
2 Remove the air cleaner assembly<br />
3 Remove the carburettor s as follows<br />
Smgle applicatIon dISconnect the fuel mlet pipe and fuel<br />
by pass hose where fitted<br />
Disconnect the dlStnbutor vacuum feed pipe<br />
Disconnect the choke control cable<br />
Disconnect the throttle hnkage at the carburettor throttle<br />
lever<br />
Remove the carburettor to marufold retammg nuts and lift<br />
offthe carburettor<br />
Twm apphcatlOn<br />
carburettor<br />
remove the mlet elbows fJ 2m<br />
TO INSTAL<br />
J<br />
f<br />
If l<br />
InstallatIon IS a reversal of the removal procedure With<br />
attentIon to the followmg<br />
Assemble the rocker arm components With engme ou<br />
to ensure lubncatlOn for InitIal start up<br />
Adjust the valve clearance See TO ADJUST VALVE<br />
LASHsection<br />
Clean the gasket surfaces on the cyhnder head and<br />
rocker cover Use a new gasket when mstalhngilhe rocker<br />
cover<br />
4 CYLINDER HEAD<br />
the<br />
15<br />
Disconnect thS fuel mlet pipes<br />
Disconnect the choke control cables<br />
Remove the fuel overflow pipes from the float chambers<br />
Disconnect the throttle hnkage<br />
Detach the dlstnbutor vacuum feed pipe<br />
Unbolt and remove each carburettor from the mlet<br />
mamfold<br />
4 Dram the coohng system Via the tap on the<br />
radiator bottom tank and the plug m the cyhnder block<br />
5 DIsconnect and remove the top radiator hose<br />
6 Disconnect the heater hose at the rear of the<br />
cyhnder head<br />
7 Detach the high tensIOn leads at the spark plug<br />
and IgmtlOn cou tower unchp the dlstnbutor cap and<br />
remove the cap With leads<br />
8 Disconnect and remove the crankcase to Inlet<br />
mamfold vent lahon hose<br />
t<br />
1iiI<br />
7<br />
w<br />
I<br />
C<br />
1
Engine<br />
p 9 Remove the retammg clip and then disconnect and<br />
r remove the mlet mamfold water pIpe<br />
10 Detach the wire from the temperature sender<br />
I<br />
umt<br />
11 Disconnect the fuel mlet and outlet pIpes from<br />
the fuel pump<br />
II2 Remove the two nuts secunng the fuel pump to<br />
tlie cylmder head and Withdraw the fuel pump gasket and<br />
msulator block<br />
13 Remove the exhaust mamfold to exhaust pipe<br />
flange nuts and detach the exhaust pipe from the mamfold<br />
14 Progressively slacken and remove the mlet<br />
J manifold to cylinder head attachmg nuts and 11ft away the<br />
mlet mamfold<br />
15 Progressively slacken and remove the exhaust<br />
mamfold to cylinder head attachmg nuts and lift away the<br />
exha st malufold DIscard the Inlet and exhaust mamfold<br />
1<br />
f<br />
I I<br />
gaskefA<br />
16 Remove the rocker cover securIng boIts and<br />
getach the rocker cover Discard the rocker covergasket<br />
Correct PosItIon of Support Tool to WIthdraw Camshaft<br />
Sprocket<br />
t<br />
iIJ<br />
1<br />
III<br />
16<br />
14<br />
6<br />
DImenSIons of Wooden Wedge for Holding TIming Chain<br />
when Camshaft and Cylinder Head are Removed<br />
NOTE Adhered rocker wvers can be dislodged from the<br />
cylmder head by bumping fmnly with the palm of the<br />
hand Under 10 circumstances use screwdrivers or Similar<br />
tools to pme between the alumlllumcover and head<br />
17 Remove the two external bolts which secure the<br />
protruded front porhon of the cylinder head to the hmIng<br />
coyer<br />
18 Rotate the crankshaft unlil the 0 tunIng lark<br />
on the cham IS alIgned and clearly VISible With the hmmg<br />
mark dimple on the camshaft sprocket penphery<br />
mark number which IS<br />
19 The sprocket hmmg<br />
stamped adjacent to the mark dimple wIll be found to be<br />
elther a I 2 or 3 dependIng whether the tlmmg cham has<br />
N<br />
been prevIOusly readjusted due to stretchmg<br />
These numbers are also staIJiped on the sprocket boss<br />
I<br />
adjacent to the camshaft dowellqcatmg holes<br />
For example If a 2 number on the sprocket penphery<br />
IS found to be aligned With the limmg cham 0 mark then<br />
the 2 number on the sprocket boss wIll be adjacent to the<br />
camshaft sprocket dowel locatmg hole and also the<br />
camshaft dowel<br />
20 Usmg a correct fittmg metnc socket spanner and<br />
SUItable bar unscrew the camshaft sprocket retalmng bolt<br />
Remove the bolt and the uel<br />
pump actuatmg cam<br />
21 Instal the special limmg cham support tool down<br />
between the tracks of the hmIng cham to retam the cham<br />
on the crankshaft sprocket and also to prevent the hmmg<br />
cham tenslOner plunger from becommg dislodged from the<br />
hmmg cham tenslOner bore<br />
The support tool can be readily fabncated from a<br />
sUitable piece of wood to the dimenSIOns shOWn IIT the<br />
I1lustratlon<br />
NOTE If through unforeseen cmumstances the t1mmg<br />
cham IS dropped off the crankshaft sproLket and correct<br />
valve t111l1ng IS lost It Will be necessary to remove the sump<br />
and t1mmg wver to readjust the valve t1mmg<br />
22 With the tumng cham firmly wedged by the<br />
support tool Withdraw the camshaft sprocket from the<br />
camshaft disconnect the tumng cham from the sprocket<br />
and remoYe the sprocket<br />
23 In the reverse order of the tlghtemng sequence<br />
progresslyely loosen and remove the cylinder head secunng<br />
bolts<br />
Lift the cylinder head upwards from thecylinder block<br />
far enough to clear the tlmmg cham and support tool<br />
I<br />
I<br />
1<br />
Ii<br />
I
Section of Cylinder Head Showing Exhaust and Inlet Valve<br />
and Rocker PivOt and Seat Assembly Removed<br />
before movmg It forward and out of the engme<br />
compartment<br />
NOTE For both Li3 and Li6 engl les<br />
It wLll be necessary<br />
to use Tool No ST490i 0000 to remove the special headed<br />
c vlmder head sewrmg bolts<br />
24 Remove and discard the cylmder hedd gasket<br />
NOTE Do notrotate the crankshaft while the timing cham<br />
IS wedged by the support tool<br />
InstallatIOn IS a reversal of the removal procedure with<br />
particular attention to the folloWIng pOInts<br />
Use new gaskets throughout<br />
Smear both sides of the cylinder head gasket With an<br />
approved grade of JomtIng compound before mstaltIng the<br />
oylmd h d<br />
1<br />
7<br />
17<br />
EJ<br />
IMPORTANT it IS essentzal when installing the c<br />
head to make sure that the valves are clear of the p<br />
crowns<br />
If the cylznder head IS mstalled with the camshaft<br />
In Its<br />
ongmal positIOn I e when the cham was sprocket removed<br />
pnor to head removal then the posslbllzty of the val<br />
contactmg thepistons willbe ellmmated<br />
Do not rotate the camshaft untzl the tzmmg cham and<br />
sprocket have been Installed on the camshaft and the cham<br />
tool removed<br />
support<br />
Use gUIde studs screwed mto dIagonal holes at opposite<br />
ends of the block face to pOSll1on both the cylinder head<br />
and gasket<br />
Instal and tighten the cylInder head bolts evenly and<br />
progressIVely In the order as shown In the IllustratIOn to<br />
the specified torque see Speclfical1ons<br />
Check and adjust the rocker arm to valve stem<br />
slearance as outlined m TO ADJUST VALVE<br />
CLEARANCE sectIOn<br />
Check and adjust the cl1rburettor Idling mixture and<br />
engme Idling speed as necessary<br />
Check for engIne 011 or water leaks<br />
TO DISMANTLE<br />
I Remove the cylinder head assembly from the<br />
engine as descnbed earlier and pJ ace on a SUitable bench<br />
2 Unclip and remove the small steady spnng from<br />
each rocker arm<br />
3 Back off the rocker piVOt locknuts and screw the<br />
piVOtS down as far as pOSSible mto the cylinder head<br />
4 With a screwdnver push down on each valv sru1g<br />
and manoeuvre each rocker arm from the cylmder heiid<br />
Dunng thiS operation take care that the valve16gke<br />
If<br />
guides which are located on the end of the valve s e s<br />
not dislodged and lost<br />
91<br />
fl<br />
NOTE When removmg the rocker arms ensure that the<br />
cam heel fof1he rocker arm bemg removed IS adJ e to ItS<br />
o<br />
o<br />
10<br />
U<br />
ar8 1<br />
i<br />
J<br />
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I j<br />
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4Y 1 r<br />
L jf 11<br />
t<br />
1 1 I7<br />
t J i<br />
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7t
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to l<br />
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1<br />
12 Engine<br />
I<br />
A<br />
ro m<br />
SPRING RETAINERS<br />
OIL SEALS<br />
A<br />
I<br />
J OUTER SPR NG 9<br />
0<br />
INNER SPRING SEATS<br />
l<br />
J OIhiRlsPRING SEATS<br />
It<br />
INLET VALVE<br />
EXHAUST VALVE<br />
Q<br />
Exploded View of Valve and Spring Components<br />
relevant arm before attemptmg to compress the valve and<br />
remove the iirm<br />
f place the rocker arms In a rack or lay them out In<br />
order to ensure that they will be Installed back In theu<br />
iigmal posIlons<br />
4 6 Unsc wthe rocker arm pivots from the cyhnder<br />
head and<br />
remove<br />
the rocker gUIdes from the valve stem<br />
ends<br />
f<br />
Lay tliese components also out In order to ensure<br />
r cofrec eplacement<br />
7 Re ove the two camshaft thrust plates to<br />
caii1s i 1fro<br />
nkbeanng secunng bolts and detach the thrust<br />
plate f<br />
8 Carefully withdraw the camshaft from the cyhnder<br />
head ensurIng that the camshaft Journals or lobes do not<br />
dama e the camshaft bearings<br />
IMPORTANT Do not remove tHe j<br />
camshaft bearmg bracket<br />
i l s or brackets from the cylmder head assembly If<br />
i bracket bolts or f<br />
brackets are removed<br />
1 beanng misalignment<br />
Idl J<br />
result<br />
J<br />
which will neceSSItate the renewal of the<br />
gylmder head assembly<br />
v<br />
9 USIng a sUItable valve spnng compressor compress t<br />
each valve In<br />
spnng turn and remove the valve retaInIng<br />
coHets<br />
IO Remove the compressor and hft off the spnng<br />
retaIner valve spnng s valve stem 011 seal and spnng<br />
seat s DIscard the 011 seals<br />
18<br />
I<br />
I I Remove any burrs from the valve stem ends with<br />
a wardIng file to ensure that the valve gUIdes are no<br />
damaged when the valves are withdrawn<br />
12 WIthdraw the valves from the cyhnder head and<br />
place them In a rack so they can be Installed In theu<br />
ongInal pOSitIOns when reassembhng the cyhnder head<br />
TO CHECK AND INSPECT<br />
I Clean the Valves thoroughly of carbon depOSIt and<br />
discard any valve that IS cracked or burnt<br />
2 Reface each valve face to the recommended angle<br />
as shown In the specIficatIons and each valve stem flat and<br />
true on a sUitable valve refacIng machIne Discard any valve<br />
that proves to be excessIvely bent tr J<br />
If a valve head has een reduced to 0 50 mm 0 020 In<br />
or less after the grindIng operatIon then the valve<br />
concerned should be renewed<br />
Valve stem ends may only be reduced up to 050 mm<br />
3 Measure the valve stem outer d13meter and the t<br />
valve gUide Inner dIameter to calcull te the actual valvy stem f<br />
to gUIde clearance If clearance IS In excess of the hrillt of<br />
o I mm 0004 In then he valve guides and or valves<br />
should be renewed<br />
4 Remove the<br />
carbo l from the<br />
Cdep oslts<br />
cyhnder<br />
head face and the valve throats andcheck the condltIons of<br />
the valve seats<br />
If necessary recut the seats wItlf a valve seat cutter to<br />
the recommended a gre and wIdth<br />
NOTE If the seats m the head are worn or recesseq<br />
excessively then new mserts will have to be mstalled It IS<br />
recommended that the mstallatlOn of new valve mserts<br />
and or valve guides If necessary be entrusted to an<br />
automotive engmetrecondlllOner who has the necessary<br />
spepallsed equIPfrfe W carry out these operdllons<br />
5 Lap the valves to the valve seats with a lappIng<br />
c01J1p mnd Apply a smear of prusslon blue to the valves<br />
Jafter<br />
IappIng and check the valves on theu respectIve seats<br />
to ensure that a true and concentnc seatmg has been<br />
gaIned 6 With a steel straight edge and feeler gauge check<br />
the cyhnder head face for warpmg If the cyhnder<br />
I<br />
head IS<br />
found to be warped In excess of the hmlt speCified see<br />
SpecificatIons then It Will be necessary to have the head<br />
surface ground to bnng the head back to a serYlceable<br />
condItIOn<br />
7 With a valve spnng tester check the valve spnng<br />
tensIOns and lengths see SpeCificatIons If a yalve<br />
spnng<br />
tester IS unavatlable then the test can be made by<br />
companng the used<br />
spnngs with a new spnng<br />
Also check the valve spnngs for<br />
squareness See<br />
SpeCificatIons for squareness hmIt Renew spnngs that<br />
upon testIng prove to be unserYlceable<br />
i<br />
J<br />
I<br />
1<br />
f<br />
I<br />
j<br />
10<br />
1<br />
4 l<br />
Il A<br />
1<br />
L<br />
I<br />
F<br />
1
1i<br />
t<br />
TO ASSEMBLE<br />
Assembly IS a reversal of the d smanthng procedure<br />
with<br />
atte ntlOn to the following<br />
Lubncate all component wear surfaces with engine orl<br />
before<br />
starting<br />
asserrtbly to ensure adequate lubncalion when<br />
The special flared type valve stem seals should be<br />
Installed below the spnng retamers with the flared end<br />
posllioned over the ends of the valve gUides<br />
Use care when compressing the yalve spnngs to avoid<br />
damage to the seals<br />
Ensure that the valve retamlng collets are fully seatmg<br />
In the valve stem grooves before releasmg the spnng<br />
compressor<br />
TO ADJUST VALVE CLEARANCE<br />
Valve clearance may be adjusted either hot or cold If<br />
the cylinder head has been removed from the vehicle then It<br />
wrll be found more convement to adjust the valve clearance<br />
With the cylinder head sitting on the work bench<br />
If the valve clearance IS adjusted cold It IS sttll adVIsable<br />
to recheck the clearance when the engme S hot and make<br />
any necessary<br />
See<br />
readjustments SpecificatIOns for valve<br />
clearances for hot or cold whichever IS apphcable<br />
NOTE It IS not praGtlcable to adJust the valve clearance<br />
with the engme runnmg<br />
I Rotate the camshaft unlil the heel of the No I<br />
Ji<br />
I<br />
f<br />
TO REMpVE AND INSTAL<br />
I Raise the engine bonnet and fit fender covers to<br />
both front fenders<br />
tank<br />
2 Dram the coohng system at the radiator bottom<br />
3 Disconnect the upper and lower radiator hoses and<br />
the heater hoses where apphcable<br />
A<br />
Engine 13<br />
carn on the camshaft IS adjacent to the valve rocker arm for<br />
No I exhaust valve<br />
NOTE In this pOSitIOn the lobe of the abovementIOned<br />
cam Will be pomtmg vertical from the cylmder head<br />
assembly<br />
Q Back off the rocker arm piVOt lock nut and with<br />
the correct thickness feeler gauge positIOned<br />
between the<br />
heel of the cam and the rocker arm adjust the piVOt untrl<br />
the feeler gauge IS a light sliding fit between the cam heel<br />
and the rocker arm<br />
3 When the deSlfed IS adjustment obtamed lighten<br />
the rocker piVOt locknut and recheck the adjustment<br />
4 Adjust the clearance on the remalnmg seven valves<br />
m turn ensunng that each valye that IS being adjusted has<br />
INLET<br />
ItS carn m the heel posllion as prevIOusly explamed<br />
Valve localion commencing from the front of the<br />
cyhnder head IS as follows<br />
Exhaust nle nlel exhaust exhaust mlet mlet exhaust<br />
NOTE It IS Important that valve clearana IS measured<br />
between the camshaft and rocker arm and NOT between<br />
the rocker armand valve stems<br />
k<br />
5 If the valve clearance S to be<br />
dJ s ed With the<br />
engme hot ensure that the engme ls mHactl at norrnal<br />
operatmg temperature If necessary ru<br />
t2 V<br />
1 fast<br />
Idle to obtain the correct tclnperature1<br />
Carry out the m e adjustment proced ordei<br />
already outlined usmg the appropn i sJttngs f r the hot<br />
1 1 1<br />
ll<br />
e ne b t<br />
Cylinder Head Face Showong Valve Arra gement and Water Corcula lon Holes<br />
5 ENGINE SUMP<br />
19<br />
I<br />
tJt<br />
r<br />
il<br />
4 Disconnect the fuel pipe from the Inlet Side of the<br />
fuel pump and detach the throttle hnkage<br />
carburettor<br />
5 On vehicles fitted with automatrc transnf<br />
dISconnect the torque converter coohng pipes<br />
at t<br />
radiator tank plug the pipes an umons to prevent e<br />
dut<br />
from the<br />
1<br />
t1 b t<br />
1<br />
y<br />
l<br />
II<br />
1
Y1<br />
l4 Engine<br />
6 Remove the nuts and detach the exhaust pIpe from<br />
the exhaust mamfold<br />
7 RaIse the front and rear ofthe velucle and support<br />
safely on four sUItable ChasSIS stands<br />
8 Unscrew the sump plug and draIn the englj e 011<br />
9 Remove the cover plate from the front of the<br />
clutch housmg or torque converter hOUSIng where<br />
automatIc transmISSIOn IS fitted<br />
10 Djsconnect the steenng connectIng rod at the<br />
Idler arm and steenng box and lower the lInkage away from<br />
the sump<br />
II Remove the engine front splash tray<br />
12 Interpose a wooden block between the sump and<br />
a Jack and take the weIght of the engine assembly<br />
13 Remove the front engIne mountmg<br />
to front<br />
crossmember secunng bolts<br />
14 RaIse the front of the engme assembly and Insert<br />
two blocks of wood of SUItable dunensIOns between the<br />
1<br />
TO REMOVE<br />
I RaIse the engine bonnet and fit fender covers to<br />
both front fenders<br />
2 Rotate the crankshaft untIl the tdc mark on the<br />
crankshaft pulley IS alIgned with the pomter on the engine<br />
tunIng cover With No I piston on the top of ItS<br />
compreSSIOn stroke<br />
t<br />
NOTE The tdc mark on the crankshaft pulley IS the mark<br />
on the extreme left ofthepulley looking Infrom thefront<br />
of the engine compartment The graduated marks on the<br />
nght hand Side of the tdc mark are In 5 deg Incrementsand<br />
are used for IgmtlOn timing purposes only<br />
3 Disconnect the hIgh tensIOn leads at the spark<br />
plugs and cod and remove the dlstnbutor cap and leads<br />
4 DIsconnect the dlstnbutor low tensIOn lead and the<br />
rllstnbutor vacuum advance hose<br />
t Scnbe a mark o the dlstnbutor mountmg bracket<br />
and filrimg cover to faclljtate correct replacement<br />
6 Remove the two bolts secunng the dlstnbutor and<br />
mountmg racJset assembly to the tunmg over and<br />
WIthdraw the aSsembly from the tImIng cover<br />
7 To facIlItate correct replacement of the OIl pump<br />
dnve gear spIndle scnbe a pencll or crayon mark across the<br />
tunIng cover to dlstnbiitor assembly mountIng flange m lIne<br />
WIth the offset dnvmg dog on<br />
the dnve gear spmdle Note<br />
t the dnvmg dog IS offset towards the front of the<br />
e<br />
18 Ralse the front of the velucle and support on<br />
SlS stands<br />
t<br />
9 DraIn the engine 011<br />
10 DIsconnect and remo ve the front stabllIser bar<br />
II Remove the engine fron t splash tray<br />
6 OIL PITMP<br />
20<br />
engine mountmgs and the front crossmember Lower the<br />
Jack and allow the blocks of wood to take the weight ofthe<br />
engine assembly<br />
15 Remove the screws secunng the sump to the<br />
engine crankcase and tunmg cover and manoeuvre the sump<br />
clear of the engIne<br />
InstallatIon IS a reversal of the removal procedure WIth<br />
attentIon to the follOWIng pOInts<br />
Scrape the sump and cylInder block faces free of the<br />
old gasket<br />
With cleamng solvent wash the mSlde of the sump free<br />
of carbon or sludge depOSits<br />
Apply JOIntmg compound to both SIdes of the new<br />
sump gasket and attach the gasket In pOSItIon on the<br />
crankcase<br />
Instal the sump and tIghten the secunng screws<br />
progressIVely andevenly<br />
12 Remove the 011 pump secunng bolts and<br />
WIthdraw the OIl pump together WIth the dnve gear spIndle<br />
TO INSTAL<br />
I Check to ensure that the tdc marks are st1l1 alIgned<br />
at the crankshaft 4<br />
pulley<br />
If the engme has been rotated smce the 011 pump has<br />
been removed then realIgn the tdc marks as descnbed m the<br />
removal operatIOn<br />
2 Instal the oil<br />
pump and dnve gear spIndle to the<br />
tImmg cover With a new gasket so that when mstalled the<br />
offset dog on the gear spIndle IS aligned WIth the pencil or<br />
crayon mark before removal<br />
Ensure that the offset dog IS facmg towards the front<br />
of the engme Instal and securely tIghten the pump<br />
mountmg bolts<br />
NOTE To mlnlmlse the chance of Oil leakage<br />
coat both<br />
Sides of the new Oil pump mounting gasket with an<br />
approved Jomtmg compound<br />
3 With a new gasket Instal and secure the dlStnbutor<br />
r<br />
and mountmg bracket assembly allgnmg the marks on the<br />
tunIng cover and mountIng bracket wluch were made<br />
before removal<br />
The dlStnbutor offset dnve tongue Will only engage<br />
WIth the oll pump dnve gear spmdle dog m one posItIon but<br />
Itmay be necessary to rotate the dlStnbutor shaft by th I<br />
2for untI engagement of these component takes place I<br />
1LFurther nstallatIOn Is a reversal of t removal<br />
procedure<br />
Ensure that the sump IS replemshed With the correct<br />
amount and grde of engme oll<br />
Check for oll leaks WIth the engine runnmg at operatmg<br />
temperature<br />
i<br />
7
Q<br />
TO DISMANTLE<br />
I Withdraw the dnve gear spmdle from the 011 pump<br />
2 Remove the small bolt from the pump end cover<br />
and detach the cover and gasket from the pump body<br />
3 Clean the face of the outer rotor and mark It so<br />
that It can be mstalled correctly on assembly<br />
4 Withdraw the mner rotor with drive shaft and<br />
outerrotor from the pump body<br />
5 Unscrew the relief valve cap bolt from the pump<br />
end cover and Withdraw the spnng and valve<br />
TO CHECK AND INSPECT<br />
I Wash all pump components thoroughly m cleanmg<br />
solvent and blow dry With compressed au<br />
2 Temporanly assemble the mner and outer rotors to<br />
the pump body and With a feeler gauge check the clearance<br />
between the outer rotor and the pump body Clearance<br />
should not exceed 0 21 mm 0 009 m<br />
3 Check the clearance between the tips of the mner<br />
rotor and the shoulders of the outer rotor Clearance at<br />
these pomts should not exceed 0 12 mm 0 005 m<br />
4 Lay a straight edge across the end face of the pump<br />
and check the end clearance of the mner and outer rotor<br />
Clearance should not exceed 0 12 mm 0 005 m<br />
5 Check the pump end cover for wear or<br />
sconng<br />
6 Check the mner rotor dnve shaft for wear m the<br />
pump housmg<br />
7 Check the pressure rehefvalve for free fittmg m Its<br />
PUMP BODY<br />
OIL STRAINER<br />
Exploded VIew of 011 Pump Assembly<br />
1 Dram the engme ad and coolIng system and<br />
remove the cyhnder headand sump as prevIOusly descnbed<br />
2 Remove the tllmpg cover and tlmmg ch un See<br />
TIMlNG CHA1N TENSIONER AND SPROCKETS section<br />
3 Remove the two bolts which sec re the 011 pick up<br />
r<br />
bore and the rehef valve<br />
c01ls<br />
Enginel<br />
spnng for weakness or broKen<br />
8 Renew all components of the 011 pump assembly<br />
that prove to be unsemceable Both rotors of the Oil pump<br />
should be renewed If one IS found unserviceable<br />
TO ASSEMBLE<br />
1 HaVIng cleaned all components and effected<br />
replacements as necessary llght1y ml the components With<br />
engme 011 and msert the mner rotor and shaft mto the<br />
pump housmg<br />
2 PositIOn the outer rotor to mesh With the mner<br />
rotor and mstal It mto the pump body With the mark made<br />
on dlsmanthng facmg uppermost<br />
3 Instal the pump end cover With a new gasket<br />
hghtly smeared With omtlng compound and mstal and<br />
ugh ten the cover retammg bolts<br />
4 Lubncate the rellef valve bore With engme 011 and<br />
fit the valve<br />
spnng copper waslier and cap bolt m that<br />
order IOta the pump end cover<br />
5 Instal the dnve gear spmdle to the pump rotatmg<br />
the spmdle gently Ult1l the spmdle dnve tongue IS engaged<br />
wlthm the 011 pump<br />
INNER ROTOR<br />
b<br />
J<br />
1<br />
J<br />
1<br />
iitiSW<br />
V<br />
t<br />
fP
f<br />
J<br />
I<br />
I f<br />
f<br />
i<br />
1<br />
J<br />
6 1<br />
f J<br />
W<br />
16Engine<br />
NOTE If there IS an exceSSiVe ndge at the top of the<br />
cylinder bore or If new nngs are to be Installed then<br />
remove the rzdge with a suitable rzdge removing tool before<br />
the piston assemblzes are wIthdrawn from the cylinder<br />
block<br />
7 Replace the big end beanng cap<br />
shell and nuts on<br />
each respectiVe assembly as It IS removed from the engine<br />
8 If the piston nngs are to be removed remove the<br />
nngs over the top of the piston and discard<br />
J<br />
t<br />
9 With a broken piece of piston nng remove all<br />
t<br />
j<br />
l<br />
UPPER COMPRESSION RING<br />
a<br />
11<br />
PISTON<br />
CAP RETAINING BOLTS<br />
cAP ReTAINING NUTS<br />
1<br />
911<br />
Piston and Connectmg Rod Components<br />
22<br />
carbon depOSit from the bottom of the nng grooves Care<br />
must be exercised when scraping to ensure that the bottom<br />
and sides of the nng grooves are not scored<br />
10 If wear is apparent at the gudgeon pm assembly<br />
the piston and connectmg rod w1l1 have to be supported m<br />
a press With the special pressmg tools and the gudgeon pm<br />
pressed from the piston and connectmg rod<br />
NOTE Pressing force needed to remove the gudgeon pin<br />
will be In the VICinIty of from one to three tons It IS<br />
therefore recommended that the piston and connecting rod<br />
assemblIes only bedIsmantled when It IS necessary to renew<br />
thepiston and gudgeon pin assemblzes<br />
Gudgeon pms are a selectivefit In the piston bosses and<br />
are available only as assemblzes wIth their mated p stons<br />
The new gudgeon pinS should be a hand push fit mto the<br />
new pIston at room temperature and a tight press fit Into<br />
the connecting rod small end<br />
TO ASSEMBLE AND lNSTAL<br />
I Assemble the piston to the connectmg rod so that<br />
when mstalled to the engine the letter F on the piston<br />
denotmg front w1l1 be facmg towards the radiator and the<br />
011 SqUllt hole m the connectmg rod side W1l1 be facmg<br />
toward the nght hand side of the cyhnder block lookmg<br />
from the dnving posil1on<br />
NOTE As the gudgeon pm hole In the IS It IS<br />
pIston offset<br />
Important that the piston and connectingrod beassembled<br />
and then Installed to the engme correctly<br />
2 Lightly lubncate the gudgeon pm and With the aid<br />
of a press and the special pressmg eqUipment press the<br />
gudgeon pm mto the connectmg rod Only press the pm far<br />
enough mto the assembly untllit becomes centrahsed in the<br />
connec mg rod<br />
3 If new piston nngs are bemg mstalled check the<br />
clearance of each nng m itS groove and usmg a nng<br />
expandmg tool Instal the nngs on the piston<br />
NOTE Ensure that the nngs bemg Installed on each piston<br />
have beefitted In the cylmder for that particular piston<br />
and the rmg gap correctly adlusted Iffound necessary<br />
Both compressIOn rings are marked on correct fittings<br />
tlell top for<br />
The Oil control ring can be liist ned either<br />
way up on thepiston<br />
4 Posil1on the nng gaps 180 degrees apart With the<br />
gap m the top compresslOn nng away from the exhaust<br />
valve AVOld fittmg the nng gaps duectly at the piston<br />
thrust and gudgeon pm axial pomts<br />
5 Liberally coat the piston assembly With engine 011<br />
and msert it mto itS correct cyhnder bore allowmg the 011<br />
control nng to contact the top of the cyhnder block<br />
If
Ensure that the F front marking on the pIston IS<br />
facing to the front of the engine<br />
6 a USing rIng compressor to compress the rmgs<br />
press the piston assembly down Into the cyhnder bore<br />
7 Apply 001 to the crankpln and beanng upper shell<br />
In the connectmg rod and Wlth a plece of wood or hammer<br />
handle tap the pIston down the cylmder bore untol the<br />
connectmg rod and upper beanng shell seat correctly on the<br />
crankpm<br />
8 Instal the bIg end beanng cap and lower half<br />
beanng wIth the numbers on both connectmg rod and<br />
lower cap correspondmg<br />
9 Instal the bIg end beanng cap retammg nuts and<br />
tighten the nuts to the speclfied torque see SpecIficatIOns<br />
J 0 Rotate the crankshaft after each pIston and<br />
connecting rod assembly has been Installed to check for<br />
freeness<br />
NOTE When fitteng new big end beareng shells ensure that<br />
the small tang on each beareng fits ento the mathilled<br />
groove en the connecteng rod or cap<br />
Beanngs must not be adjusted by filIng or scrapmg<br />
See SpeCIficatIOns for undefSlze beanngs avaIlable for<br />
reground crankshafts<br />
II Instal the cyhnder head<br />
sump timing cham and<br />
timing cover as descnbed In the relevant sectIOns of thIS<br />
manual<br />
TO CHECK CYLINDER BORES<br />
NOTE To accurately check cylmder bore condllIon and<br />
wear II IS essentlal that all pistons and connectmg rod<br />
assemblzes be removed from the cylender block also that<br />
accurate measurmg eqUIpment be available to determene the<br />
actual cylmder bore overall wear mcludmg taper and<br />
ovallly The cylmder bores should be wiped thoroughly<br />
clean with a clean rag before checkmg<br />
1 VIsually check the bores for cracks flaws scuffing<br />
or sconng<br />
2<br />
E J<br />
12 FIll the coohng system with water and the sump<br />
with the specIfied grade and quantIty of engme OIl<br />
water leak<br />
u U lnm IIOH S A n O S<br />
3<br />
13 Run the engine and check for engme<br />
GRADING MARKING<br />
FRONT MARKING<br />
on and If<br />
If<br />
lJ<br />
1 J<br />
Markmgs on PIston Crown and Gudgeon Pm Boss to<br />
IndIcate P ston Gradmg and Front t<br />
2 Check each cyhnder bore for wear mcludmg taper<br />
and ovalJty See SpecIficatIOns for cylmder bore wear limIt<br />
3 Cyhnder bores that upon checking prove be 1<br />
t IR<br />
unseIVIceable shoul d be rebored and honed to the if<br />
mallest j<br />
llTImed13te oversIze and new oversIze plstons ang nngs t2f iJ<br />
fitted<br />
NOTE If illSfound that the tylmders neea boring select<br />
r<br />
the tvlmder wllh the most wear to determIne whatoverstze<br />
jr1<br />
pistons are to be used Bore all cylmdersTio that oversize<br />
See SpecificatIOns for available ove rslze<br />
pistons and rmgs<br />
Engines that have been bored to fhelr extreme limit can<br />
3<br />
PIstons Installed to Cylinder Biock showmg P ston Gradmg<br />
Marks on PIston Crowns and CY Ifder Block Face<br />
23<br />
l<br />
1
t<br />
if<br />
3Engine<br />
be fitted with cylmder sleeves which are available m three<br />
sizes on outer diameters New pistons and nngs should still<br />
befitted with sleeves<br />
DEGLAZING CYLINDER BORES<br />
NOTE Cylmder bores that are fit for further service with<br />
ongmal pistons but reqUire re rmgmg should be deglazed<br />
with a hone<br />
1 PosItion plenty of clean rag<br />
over the crankshaft<br />
and under each cyhnder bore to keep abraSive matenals<br />
from entenng the crankcase area<br />
2 Deglazmg of the cyhnder walls may be done by<br />
usmg a cyhnder surfacmg hone eqUIpped wIth 280 gnt<br />
stones<br />
to<br />
3 HOnIng should be carned out by mOVIng the hone<br />
up and down the cyhnder walls fast enough<br />
to achIeve a<br />
cross hatcll p ttern fien h ne marks Intersect at 60 deg<br />
the cross hatch angle IS most satIsfactory for the correct<br />
seatmg of piston nngs<br />
NOTE When degl zmg It IS lmportan t that only enough<br />
strokes of the hone are made to gilmmate the glazmg<br />
conditIOn of the cylmder ExceSSIve honmg Will mcrease<br />
bore size and thus Increase piston skirt clearance<br />
4 Use hOnIng 01 whIch IS avaolable from all major<br />
dlstnbutors Do not use engine or transmiSSIOn 011 mu eral<br />
splflts<br />
or kerosme<br />
5 After hOnIng It IS necessary Jhattthe cylInder block<br />
be thoroughly cleaned to remove all traces of abraSive<br />
1<br />
CA UTJON Be sure thqt all abraSives are remov d from the<br />
engLnlf after Ironmg It IS recommended that a solutlq n of<br />
soap and water be used with a brush and the affectea<br />
components thoroughly dned<br />
i<br />
The cylmder bores an be consldered cle 1n when they<br />
can beWiped clean With a white cloth and the cloth remams y<br />
clean Smear th oores with engm II after cleqnmg to<br />
prevenfrUstmg<br />
4V<br />
CHECKING PISTON SKIRT CLEARANCE<br />
l l<br />
NOTE Cylmders that have been rebdred andhoned to tak<br />
the appropnate overSIZe pistons should have each piston<br />
measured for and<br />
the tned m ItS respectlve bore with a<br />
feeler Strlp and spnng scale to ensure that correct skirt<br />
t<br />
clearance IS obtamed I<br />
t40<br />
I Measure he oitslde dIameter ofthe piston skut at<br />
nght angles to the gudgeon pm s and 18 6 mm 0 732 m<br />
down from the gudgeon pm centre<br />
The piston temperature when measunng should be<br />
approximately<br />
200e 680F<br />
2 Select a feeler strIp 004 mm 00016<br />
In In<br />
thIckness and approximately 12 mm 0 50 In In Width The<br />
stnp should be long rpough to extend the full length of the<br />
pIston<br />
24<br />
3 Insert the feeler stnp Into the cyhnder bore Invert<br />
the pIston and pOSitIOn It Into the cyhnder bore so that the<br />
feeler stnp IS located lengthWise between the cyhnder wall<br />
and the full length of the piston at 90 degrees<br />
to the<br />
gudgeon pIn axiS<br />
4 Attach a spnng scale to the top end of the feeler<br />
stnp and Withdraw the feeler stnp In a plane parallel to the<br />
centre lIne of the cyhnder bore notmg the readIng on the<br />
spnng scale<br />
5 The correct spnng scale readIng should be Within<br />
02 and I 5 k g 044 and 3 30 lbs If the readIng<br />
IS not<br />
WIthIn these speCifications then check the ongInal<br />
measurements of the pIston and bore also check the p ston<br />
skIrt for hIgh spots If necessary select measure and check<br />
another piston to obtain the reqUIred fit<br />
6 Follow the same procedure to fit the remaInIng<br />
pIstons as required<br />
TO FIT NEW PISTON RINGS<br />
i With the cylinder bore measured select a set of<br />
piston nngs standard or ovefSlze wluchever may be<br />
apphcable<br />
2 PosItion each pIston nng In the relatIVely unworn<br />
portIOn of the cyhnder bore to which It IS to be fi tted and<br />
wall ThiS can be<br />
align It squarely With the cyhnder<br />
accomphshed by Insertmg an mverted pIston from above<br />
and pushmg the<br />
nng down the bore to a lower posItion of<br />
the bore where the wear IS at a mmnnum<br />
3 Withdraw the pIston and measure the gap m the<br />
nng WIth feeler gauges If found necessary adjust the end<br />
gap by fihng to the dimenSions as gIVen m the<br />
SpeCIficatIons<br />
Treat each nng and cyhnder bore lndlvldually and<br />
ensure that nngs are assembled to the respectIve pIston for<br />
the cyhnder bore m whIch they were fItted for end gap<br />
check<br />
4 Each of the compressIOn nngs are proVIded With a<br />
mark to denote top These m rks should be facmg upwards<br />
upon mstallatlOn The oJ control eIther way up<br />
nng can be Installed<br />
5 PosItIon the<br />
nng gaps 180 degrees apart WIth the<br />
gap In the top compressIOn nng away from the exhaust<br />
valve m the cyhnder head AVOId fittIng the rmg gaps<br />
dIrectly at the piston thrust and gudgeon pm axml pomts<br />
6 L ubncate tl e pIston asse bly and cyhnder wall<br />
WithlengJiie 011<br />
7 Insert the plstQn concerned Into ItS correct<br />
cyhnder bore a1lowmg the 011 control nng to contact the<br />
top race of the cyhnder block<br />
NOTE Enrur that theF front markmg on thepiston pm<br />
boss IS facmg towards thefront of the engine<br />
8 Use a SUItable nng compressor to compress the<br />
I nngs and Instal the piston mto Its respectIve cyhnder bore<br />
NOTE Conne tmg rod and piston assemblies must be<br />
replaced m the qlmders from vhlch they were removed on<br />
dlsman mg<br />
r
TO REMOVE<br />
9 CRANKSHAFT AND MAl BEARINf S<br />
1 Remove the engme and transmiSSion assembly<br />
from the vehicle<br />
2 Remove the transmiSSion from the engme<br />
3 Remove the sump and the engme OIl pick up pipe<br />
and screen assembly<br />
4 Remove the tmung cover<br />
5 Remove the tUllIng sprockets and tmung cham<br />
See appropnate sectJons for all of the above operattons<br />
6 Remove the spark plugs<br />
7 Remove the starter motor<br />
8 Remove the big end beanng nuts and take off the<br />
beanng caps Carefully push each connectmg rod and piston<br />
assembly up the bores as far as pOSSible without exceedmg<br />
the upper hmlts of the piston stroke<br />
NOTE Ensure that the big end bearmg caps and connectmg<br />
rods are numbered m relatIOn to eath other to fac lztate<br />
correct assembly<br />
9 Check the crankshaft end float either With a feeler<br />
gauge at the centre mam beanng or by attaclung a dIal<br />
mdlcator gauge to the front face of the cyhnder block so<br />
that ItS plunger bears on the front end of the crankshaft<br />
10 Pnse the crankshaft rearwards and zero the gauge<br />
11 Next pnse the crankshaft forward as far as It wIll<br />
go and check the readmg on the dial gauge Ifthe centre<br />
mam beanng thrust surfaces are serviceable then the gauge<br />
readmg Will be wlthm the hmlts speCified See<br />
SpeCificatIOns sectIon for end float hmlt<br />
Method of Checkmg Crankshaft End Float<br />
WIth Feeler Gauge at Centre Maon Bea lng<br />
25<br />
j<br />
Engin<br />
I2 Remove the clutch pressure plate assembly and<br />
the clutch dnven plate<br />
13 Unscrew the flywheel retammg bolts and<br />
WIthdraw the flywheel from the rear of the crankshaft On<br />
automattc transmIsSIOn remove the torque converter dnve<br />
plate With remforcmg plate<br />
14 Check that the mam beanng caps are marked m<br />
relatIOn to their locatton m the engme Note that the caps<br />
are marked With an arrow which must pomt to the front of<br />
the engme when correctly mstalled<br />
15 Unscrew eaih mam beanng cap bolt and<br />
WIthdraw each<br />
cap and beanng half shell<br />
NOTE The speCial remover tool No ST446jOOOD may be<br />
needed to w thdraw the rfjar mam bearz g cap from the<br />
crankcase<br />
16 Withdraw the oIl seal froJ ihe cr nkshaft rear<br />
flange and the two Side seals from the rear mam beanng<br />
cap<br />
i<br />
NOTE Before remo1mg the crankshilft bearmg clearance<br />
may be determmed by usmg the Plastzgage method as<br />
follows<br />
a Remove one beanng cap aQd With a piece of rag<br />
wipe the Journal and beapn g clean<br />
b POSitIOn a pIece of Plashgage the approximate<br />
length o t e beanng Width and shghtly off centre on to<br />
the beanng s1rface of the crankshaft Journal<br />
e Instal the beanng cap and ttghten the cap bolts to<br />
h fi d<br />
t e Sp CI Ie torque<br />
IMPORTANT Do not rotate the crankshaft while the<br />
plast gage IS lPOSttIOn I<br />
I<br />
1<br />
J<br />
d R move the e p bolts and caref lly M CJt the cap<br />
and low er half beat 1ng<br />
e W th the PI stJg ge sca e JJleasure the compressed<br />
P1isttgage stnp to determ ne the o clear nce<br />
0 The Widest ponlt or the stnp will mdlcate the<br />
t<br />
t<br />
1<br />
minimum clearance and tlie narrowest pomt the maxunum<br />
f 1<br />
clearance<br />
g Therremammg anngs bt san be checked m turn uS j<br />
mg<br />
the same procedure<br />
17 Carefully ft tl1e cranKShaft from the crankcase<br />
usmg care not to dlslodge or damage the upper<br />
mam beanng iliell fthey<br />
hal Ves of the<br />
are to be d eq atl1n I i<br />
I t 18 Ifnew bear ng shells are to lie mstalled remove<br />
the upper halves pf th beahngs from th crankcase<br />
l<br />
fTO CHECK ANDINSPECT<br />
1 Check and meaSure the am beanng Jounials and<br />
erankpms for wear taper and sconng Ifwear Is excesslve<br />
the Journals and or crankpms snoulg be r<br />
1<br />
reground to<br />
11t 2<br />
I<br />
I<br />
l<br />
r<br />
1<br />
i<br />
L<br />
l<br />
to f<br />
W<br />
4<br />
l
201<br />
I<br />
I i<br />
1 1<br />
J<br />
1<br />
j<br />
q<br />
accornmoda te the nearest undersIze beanng shells<br />
One worn or d3maged journalr or cr mkpm will<br />
necessttate tl e gnndmg of alLjOlrlals o ralkpw nithe<br />
fittmg ofnew undenhze ISeaung shells<br />
If wear fJf d age slJ chlt af the jo J1als p crinlpms<br />
the avaJiable<br />
cannot be reground to taJe any one rangeJof<br />
t<br />
1<br />
J<br />
1<br />
feed holes m the beanng and beanng housmg should<br />
comClde<br />
Ensure that the crankshaft mam beanng journals<br />
undersize beanngs thefl the cr nksnaf wit ha e t<br />
1 lIf cle<br />
l<br />
renewed<br />
m Lubncate the<br />
upper half beanngs m the crankcase<br />
2 t the n shaft t<br />
Supp eaf eI d rn blocks and with clean hght engme Oil<br />
wIth a dJaJ a g che tte craRk shaft fq oend r<br />
at 1h<br />
Cl ref lIy lower the crankshaft mto pOSItion m the<br />
centre mam ourmil Renewthe crankshaft IftheAbend ISill r crankqse Ensure that the upper half beanngs are not<br />
exces M iie 5ifow ble hmlt See Speclficafi 1s t so ged dunng the operatIon<br />
ti3 Chec l i<br />
thecentr mam beanng th1V tl fiUs l<br />
fOri<br />
Place the lower half of each beanng m Its<br />
Jlflng or wear 1f p itmg or we J IS ev ienr enew me I appropmite beanng cap so that the locatmg tang on the<br />
rn rel mUp bean g s el s h Cl s be<br />
olid b in cfaP hJ1ft<br />
n<br />
gtJgage s correctly WIth the groove m the beanng<br />
Y cap<br />
end float back te SpecificatIOns<br />
4U lwaY 1J1Sta1 f ne tar c nkshaf<br />
5 Lu<br />
oil e and<br />
rlcate the beanng cap and shell assembly WIth<br />
n Its<br />
1sld s als ifrthe cr anksiiaft has beeh ie1noved i 1eaengme lIL and posItion each cap assembly<br />
1<br />
I<br />
orrect locat IO d t0 the numbers noted or made<br />
5 Ch iili<br />
1 e<br />
s aI and r w<br />
tIlTIWp cove l necessary aC90r lg<br />
lf i<br />
l d r<br />
f1ng movalanft lth the arrows 01 the caps pomling to<br />
i 1<br />
R n w<br />
IIjmg c e gas et 1<br />
J<br />
pE u e 1hat tJ1e o x dqItI gs m e cran<br />
tf<br />
tflrtt<br />
tIi ont o th engl le<br />
n<br />
cl al<br />
shaft<br />
C r<br />
lt fr e i H bstIUC 6ns t ensule adequa e 5 Inst l tle beanng retammg b lts and tlgh en<br />
OIl suppl 9te b af n 1 1 t progrt vely from I<br />
t<br />
1<br />
t<br />
c ntre mam outwards to the<br />
Jh<br />
d<br />
speq1fil tor 1le See peclficatlons Rotate the<br />
ci ks aftto<br />
TOINSTAL<br />
if<br />
n urethllt bmdmglseV1dent Agamcheck<br />
the cr nkshaft end float as detailed earher<br />
f<br />
b<br />
IT<br />
r<br />
t<br />
J<br />
i 71 Lubncate and mstal the rear oil seal over the<br />
ll ks 1aft reaf flange nd mto the rear mam beanng cap<br />
q PI lch th I pe f of ea h JUam beanng m ci<br />
P sltl n n tlie an case so thaU e locatmg1a g on th and cl1nk JserSpec aI tool No SH9370000 should be<br />
be<br />
nngl gagest h rpove m the b anng housmg The OIl usefl to nistal the seal<br />
r<br />
1<br />
e<br />
t f i<br />
j r<br />
26<br />
f<br />
41<br />
j f<br />
r<br />
to<br />
h<br />
t t<br />
oJfj<br />
r<br />
0 t<br />
lt<br />
VIew of<br />
Location<br />
It<br />
Engine With Sump Removed ShOWing Correct<br />
of Main Bearong Caps Note Arrows IndIcating<br />
I<br />
J<br />
Front Side of Caps<br />
J<br />
r
I<br />
I I<br />
NOTE If the crankshaft rear flange shows eVidence of<br />
groovzng where the seal has been prevIOusly ronning It may<br />
be necessary to Instal a shun between the seal and the<br />
crankcase This Will allow the seal to ronon an unworn<br />
lip<br />
portIOn of the crankshaft flange<br />
8 Tap the new Side seals down between the rear mam<br />
beanng cap and crankcase<br />
9 Instal the flywheel to the rear of the crankshaft<br />
makmg sure that It IS seatmg squarely on the crankshaft<br />
flange<br />
10 FIt and tighten the flywheel secunng bolts wIth<br />
new lock washers to the speCIfied torque<br />
On automatic transnusslOn fit the torque converter<br />
nve plate with remforcmg plate and fit and tighten the<br />
retammg bolts to the speCIfied torque<br />
See SpeCIfications for torque setting<br />
11 Draw each connectmg rod down mto posItion on<br />
the crankpm Instal the bIg end bearmg caps With clean<br />
engtne oil Ensure that the cap numbers are alIgned With the<br />
correspondmg numbers on the connectmg rods Tighten<br />
bIg end beanng cap retammg nuts to the speCified torque<br />
ther<br />
E 21<br />
I2 Further InstallatIOn IS a 0<br />
reversal of the removal<br />
b<br />
Re<br />
procedure See TIMING CHAIN TENSIONER AND Centre Main Bearnfg Cap oved ShowIn9 Flimged TYPe<br />
SPROCKETS sectIOn for valve I tlmmg procedure BeanrigTo Take Crankshaft End ThrustT tl<br />
f<br />
I 1<br />
IO TIMING CHAIN TENSICtNER ANn SPROCKETS<br />
J<br />
J<br />
r<br />
1 Raise the engme bonnet and fit felfder covers TO REMOVE<br />
to<br />
both front fenders<br />
I<br />
I<br />
i<br />
6<br />
II Remove the rocker cqver secunng bolts and<br />
detach the rocker covet and rocker cover g asket<br />
u le and upport on<br />
t<br />
2 Dram the coohng syytem<br />
f t<br />
VIa the tap on th P RaJse the chas S sta lds<br />
fro t tJ1 veJ<br />
r r<br />
3 Dlsconne ttfelupper and lower radiator hoses 13<br />
radIator bottom tank andtle plug m the cyhnder block<br />
4 On vehlloles fitted WIth automatic tri lssIOn engme I1<br />
f<br />
Uls rewo engt1 e y p m plug and dram the<br />
f<br />
disconnect the torque converter coohng plp S at the lmyer 14 emqye tlie elgt e slIllP See ENGINE SyMP<br />
radiator tank lug the pipes and umons to prevent entry of TO REMOYB A INSTA<br />
dIrt r r l5tREmlOve tJit otl pUmp and dtstfloutor Seep<br />
oJ<br />
oj If p<br />
if<br />
j<br />
w<br />
5 Remove the radIator retauung bolts and hft out the releva1Jt eftlOns<br />
J ftf f th<br />
16 R h f<br />
f1<br />
d<br />
J<br />
ra lator el1 ve t e fu purnp Ol e cyhnCl rhea r v<br />
t<br />
6 JSlacken the alternator mountmg bolts and 17<br />
remove<br />
Rotate the crahkshaft unttl the 1dc marklon the<br />
ksli f n<br />
the alternator adJustmg bracket cran t<br />
and fan belt<br />
pu ey IS rgned Ith ftle pOtp e pn fhe engtn<br />
I<br />
fj<br />
t 1 f t oJ<br />
7 Remove the four retaml g bolts and de ch pe fan ng covet WIth r o r p ton o he t ipV f It J<br />
1 and fan pulley from the water pump<br />
o pIeSS1 nstroke 8 Detach the rocker cover to<br />
r<br />
t<br />
j<br />
j<br />
014<br />
at v ntIlatlon<br />
cleaner J I tRe TIs Ye tfie tat shaft Hose and the thermostatic<br />
ulley blh and w tl<br />
au bleed hose where fitted anCl wIth a sUltable pulIw Withdraw the t<br />
r<br />
1<br />
lulley from the<br />
9 Loqsen the alf clea ass mbly ih umb screw cran s a L 1r l I<br />
remove the two bolts which secure e<br />
at clel er 1ts e j 19 r w<br />
mby<br />
UJl s 2e ter pum to JlnuJl cove bJlts<br />
an<br />
bracket to the mlet mamfold remove the atr cleall li and the frawar w ter pqn tp an4 qsket Qlsfard the<br />
f<br />
J<br />
r assembly<br />
gasket l<br />
I 20 ReIJ1ov e the two 5olts wlu h secure the protruded<br />
NOTE On engines fitted with tWin Sf type ci1rburdttorsh fr Ont pqitl npfthe yIInder F o thi mg c el<br />
Will notbe necessary t6 remove illrc er<br />
ean assembly of2 t Remoy th r JI1 nmg 6l arlaChtl tllnlpg I<br />
thl<br />
0<br />
cover to the engtne assembl<br />
7<br />
AU I<br />
t t I<br />
10 Remove the dlstnbutor cap<br />
wlth h1gh tension f 22 Carefu r ep arate<br />
t<br />
leads<br />
from thelocatll g dowels q the<br />
yh1 blQc J<br />
J d<br />
If<br />
v<br />
J<br />
k hlf<br />
a1d 1 hdraw e t I COVer<br />
oft i J 1<br />
J 1 1<br />
27<br />
l<br />
t<br />
1<br />
t<br />
I<br />
s<br />
4 If f tI<br />
p<br />
t4<br />
j<br />
J<br />
h<br />
t<br />
r<br />
I<br />
r<br />
l<br />
i<br />
a Pt<br />
1<br />
i<br />
r<br />
Ii<br />
f<br />
to
c<br />
p<br />
r I<br />
22 Engine<br />
NOTE Care must be tiiken to ensure tfiat the cylmder head<br />
to tlmmg cover gasket which IS ji portlOn of the cylmder<br />
head gasket Is not broken when removmg thecover<br />
If necessary run a fine feeler Strip between the gasket<br />
and the t1mmg cover to prevent the gasket from adhenng<br />
and brepkmg<br />
23 Wlthd aw the 011 shng Jand<br />
from the front of the crankshaft<br />
J<br />
J<br />
the worm drIve gear<br />
24 Check the tmung cham and sprockets for<br />
I<br />
TIM NG MARKS ON<br />
CAMSHAFT SPROCKET<br />
BOSS<br />
l<br />
t<br />
d<br />
or<br />
r<br />
t ri 1<br />
t lf<br />
y t<br />
it<br />
i<br />
t<br />
t<br />
r<br />
1<br />
N e<br />
r<br />
h<br />
s<br />
j<br />
J<br />
l<br />
1<br />
r<br />
l<br />
4<br />
c r a<br />
f<br />
TIMING MARKS ON CRANKSHAFl<br />
SPROCKET PERIPHERY<br />
l 111 r<br />
Timm9 Marks Ah9nel on It<br />
I<br />
T ll1 Im9<br />
Cham and Sprockets for<br />
t<br />
f Correct Va ve I<br />
Tlmlng t<br />
J<br />
1<br />
to<br />
l<br />
1<br />
6<br />
TENSIONER BODY SPRING<br />
f<br />
d J1 f<br />
ri<br />
t J<br />
1<br />
j<br />
o<br />
I<br />
t<br />
GASKET<br />
1<br />
j<br />
DlSlnantled View of Tlmm9 Chaml rensloner and Sprocket<br />
t<br />
1<br />
T<br />
J Comil9neiits j<br />
I<br />
t<br />
V 4<br />
1<br />
41 f<br />
I 1 i<br />
1<br />
4<br />
4<br />
I h<br />
I<br />
J t<br />
l<br />
J I<br />
3<br />
1<br />
r<br />
tr<br />
i l<br />
r<br />
markmgs Both sproCkets<br />
should be marked and the marks<br />
should beYahgned wIth the 0 marks on the tlmmg cham<br />
hnks<br />
The 0 marks on the tumng cham are 42 Imks apart<br />
See 1IIustratlOn for tlmmg mark locatoon<br />
25 Usmg a correct fittmg metnc socket spanner and<br />
sl ltable bar unscrew the camshaft sprocket retammg bolt<br />
Remove the bolt aha the fuel pump actuatmg cam<br />
26 It WIll be notoced that three trmmg marks are<br />
VISIble on the camshaft sprocket outer penphery The<br />
marks are numbered numencally I 2 and 3 Correspondmg<br />
numbers are also stamped on the sprocket boss adjacent to<br />
the three camshaft dowellocatmg holes<br />
The extra dowellocatmg holes and tunmg marks on the<br />
sprocket are ava1lable to readjust the tlmmg cham If<br />
stretchmg of the cham occurs<br />
27 As a check for tlmmg cham stretch the camshaft<br />
thrust plate wtuch IS located ommedJately behmd the<br />
camshaft sprocket IS marked wIth an elongated mdent see<br />
Illustratoon The rear boss of the camshaft sprocket IS also<br />
marked wIth three notches One of the notches will be<br />
adjacent to the elongated mdent dependmg on what tommg<br />
markI 2 or 3 on the sprocket outer penphery IS alIgned<br />
wIth the 0 mark on the tunmg cham<br />
28 o Consldenng that the No I tunmg mark on tpelf5<br />
TIMING CHAIN t<br />
I It<br />
I<br />
f<br />
TENSIONER PLUNGER<br />
fj<br />
WASHER<br />
tjt<br />
If<br />
i8 t t<br />
If It i r<br />
i<br />
t tr<br />
V<br />
r<br />
r<br />
f<br />
i<br />
t<br />
i<br />
r<br />
l<br />
f V 11<br />
CRANKSHAFT sPROCKETl ettt J<br />
t<br />
I<br />
r<br />
4<br />
it I<br />
la<br />
GUIDE<br />
I l
r<br />
h<br />
Qj<br />
t<br />
NOTCHES<br />
9<br />
i<br />
I<br />
1<br />
I<br />
t<br />
V<br />
3<br />
j<br />
v<br />
Engine23<br />
t<br />
r r<br />
A<br />
f<br />
J<br />
lnp J<br />
i<br />
h i<br />
t<br />
I<br />
1 J<br />
a<br />
1 I<br />
1 1<br />
1 q<br />
f 1<br />
j
i<br />
i 1<br />
tE<br />
24 Engine<br />
TO INSTAL<br />
OIL FEEO HOLE<br />
ft<br />
TENSIONER eODY<br />
TENSIONER<br />
Co<br />
PLUNGER<br />
l tl<br />
ExplOdeil VIew of Tlmmg Cham Tensloner Assembly<br />
I<br />
L Nr 1 0<br />
1 1<br />
10 PasltlOn a new tunmg caver gasket aver the<br />
1<br />
4 dawels an the crankcase frant face LIberally caat bath<br />
I Usmg a sUItable tubular dnftkdpve the crankshaft sIdes of the gasket wIth sealIng campaund before mstalling<br />
sprock t an to the crank haft untll the sprocket abuts the Alsa apply sealIng campaund ta the front partIan of the<br />
shaulder pf the frant mam beanng JaurnaI Ensure that the head gasket I<br />
tlIrung mark on the spracket IS facmg outwards 11 Instal the tImmg cover and tIghten all fixmg baits<br />
2 Engage tpe turung cham an the crankshaftspracket securely<br />
sb that the lawer 0 tunmg mark an the cham<br />
WIth the mark an the crankshaft sprocket<br />
Is<br />
alIgned<br />
3 Naw engage the portIan<br />
camshaft sprocket onto the upper<br />
cof the cham and alIgn the 0 tunmg mark an the<br />
cham wIth the 1lumbered tmung mark an the penphery of<br />
the sprocket<br />
If a new tII1 lmg clmm IS bemg stalled then alIgn the<br />
Jo Na I tImmg mirk all fue spracket WIth the I 0 mark an<br />
the cham v f<br />
Ifa used tunmg cham IS bemg remstalled then alIgn the<br />
mark I 2 or 3 vluch was faund mast sUItable for the<br />
stretched candltIan of the cham as checked aut prevIOusly<br />
m tlie dlsmantlmg operatIOn<br />
t<br />
t 4 FIt the camshaft spracket ant the front of the<br />
camshaft engagmg lh camsJtaft dawel Ith the<br />
appropnate numbered hokm the camshaft bass<br />
Far example If the number I tlmmg mark an the<br />
sprocket penpllery was alIgned wIth the 0 mark an the<br />
tunmg chaIIb then the Na I lacatIan hale m the sprockei<br />
bas nust be ngaged ylth he canisl tdawel<br />
r<br />
S Instal the camshaft sprockef retammg bOlt lld the<br />
el fuel pump actuatmg carn<br />
ft<br />
1<br />
Jrtorqu<br />
TI h Yten<br />
the bait ta the specified<br />
r<br />
l<br />
6 FIt the tnrung cham guIdes ta bath SIdes af thel<br />
t rrung chaI Adjust 1 fChand chaIn guIde agamst e<br />
1 cham befare tIghtenml the secl nng baits<br />
1 t<br />
f<br />
r<br />
I r<br />
j t J<br />
NOTE The mountmg holes of the left hand c1fu l guzde are<br />
R elopgptetj to enable t e guide tr be adJ stedfjL J drs ed<br />
f<br />
tenslOn agaznst the ham<br />
t I lti 11<br />
l<br />
l<br />
7 i<br />
f I J<br />
r<br />
It<br />
j<br />
7 FIt the tenslOner assembly ta the czli<br />
t facet r J<br />
t<br />
wIth a new gasket t<br />
8 Instal tlie Warm dnve gear andJhelhhc I I sTInger<br />
t<br />
ta the front ofthe crankShaft Make sure that the all slInger<br />
I<br />
IS mst ed the carrect ay around<br />
y Ii JIf 9 ilbncat the tunlI g cham ant sprockets W1<br />
c1eaii engme all to ensure l<br />
f<br />
t<br />
O<br />
adequate<br />
s rtbp<br />
r<br />
sJ<br />
z<br />
f<br />
s<br />
fi<br />
J L<br />
1 fIr I<br />
t<br />
j<br />
1<br />
1<br />
1<br />
c<br />
t<br />
f<br />
J tV4<br />
v<br />
I<br />
i<br />
l t<br />
o<br />
l<br />
r r l<br />
rl<br />
I<br />
f<br />
I<br />
r<br />
t<br />
I<br />
JP<br />
o<br />
A<br />
p<br />
lt<br />
t<br />
L<br />
lubncatlOn for lrutJal<br />
l<br />
I<br />
s<br />
l<br />
t<br />
I<br />
1<br />
kf<br />
ii t<br />
lJ Of<br />
Camshaft Sprocket Removed Showmg Tlmmg Cham Held<br />
By Support TgoL<br />
l<br />
s t<br />
il<br />
YJr<br />
t30<br />
r<br />
Y<br />
y J<br />
I<br />
0<br />
t<br />
rl<br />
l<br />
j
J<br />
tI E<br />
L<br />
Ij<br />
v<br />
BOLTS<br />
NOTE When installing the timing cover tighten the bolts<br />
which secure the extended portIOn of the cylinder head to<br />
the cover before tlghtemng the remawlng bolts<br />
t l<br />
12 Lubncate the boss of the crankshaft pulley wIth<br />
engme OIL IOstal the pulley on the crankshaft and secure<br />
TO REMOVE<br />
1 RaIse the engme hood and fi t fender coyers to both<br />
front fenders<br />
2 Dram the coolIng system vIa the tap on the<br />
radIator bottom tank<br />
3 Remove the necessary bolts and remove the gnlle<br />
4 Disconnect the upper and lower radIator hoses<br />
5 On vehIcles fitted WIth automatIC transmIssIOn<br />
dIsconnect the torque converter coolIng pIpes at the lower<br />
radIator tank plug the pipes and UnIons to prevent the<br />
entry of dut<br />
6 Remove the radIator secunng bolts and 11ft out the<br />
radIator<br />
7 DIsconnect the heater hoses where applIcable<br />
p<br />
J<br />
1<br />
c<br />
Engine25<br />
Engone TlIl10ng Cover and l<br />
l<br />
Assocljlted Components JU t<br />
I<br />
f t tr Jq<br />
r i<br />
Kt<br />
WIth the bolt and<br />
retammg washer 7<br />
13 Further mstallatljn IS a reversal of e r oval<br />
procedure<br />
Ensure that the swnp IS replenIshed tl WIthlit correct<br />
grade and amount of MS engme 011 and thatt tlfe coolmg<br />
system IS refilled t t<br />
i<br />
3<br />
CAM HAFT<br />
8 DIsconnect the fuel pIpe from tlig rlde jth<br />
fuel pump<br />
9 Remove the nuts and det ch th ejlvaust pIpe from<br />
the exhaust marufold<br />
10 DIsconnect the throttle lInkage from the<br />
carburettor throttle lever<br />
II Detach the rocRercover to au cleaner ventilation<br />
hose and the thermostatIc au bleed hose I<br />
Wlthdrawong the Camshaft From the Cylinder Head Assembly<br />
i it<br />
12 Remove the au cleaner assembly suigle il<br />
carburettor applI atlOri only 1 t J<br />
13 Detach the hJgh tensIOn leads at the spark plugs u<br />
and carefully tItthe ugh tensIOn leads at a convenIent I<br />
M<br />
I<br />
If<br />
p01 t away from the rocker cover<br />
14 Remove th rocKer cov r secunng bolts and gl 0 v 4<br />
detach tne rocKer cover ana rocker cover gasket<br />
1 4<br />
4 c I J<br />
1<br />
V 1 rj<br />
31 r<br />
7t<br />
j<br />
to<br />
J<br />
s<br />
i<br />
r S<br />
1<br />
l<br />
t t<br />
J<br />
ii<br />
f<br />
tn<br />
I<br />
riF<br />
J<br />
J<br />
t<br />
t<br />
J<br />
2<br />
L i<br />
E r<br />
t<br />
Il<br />
J<br />
C<br />
i f i<br />
1 l<br />
f<br />
4<br />
tl<br />
Yf<br />
r<br />
l<br />
I<br />
I<br />
J<br />
1 J<br />
j
F<br />
I<br />
it<br />
j<br />
26Erigine<br />
IS Unchp and remove the small steady spnng from<br />
each rocker arm<br />
16 Back off the rocker PIvot locknuts and screw the<br />
PIvots down as far as possIble mto the cyImder head<br />
17 WIth a screwdnver push down on each valve<br />
spnlg and manoeuvre out ea ch rocker arm Dunng thIS<br />
operatIon take care that the valve rocker gUides which are<br />
located on the end of the valye stems are not dIslodged and<br />
lost<br />
NOTE When removmg the rocker arms ensure that the<br />
cani heel for the rockerarm bemg removed IS adjacent to ItS<br />
relevant arm before attemptmg to compress the valve spnng<br />
and removIng the arm<br />
18 Place the rocker arms In a rack or lay them out In<br />
order to ensure that they will be Installed back m theIr<br />
ongInal pOSItIOns In the engIne<br />
19 Rotate the crankshaft untIl the 0 tImIng mark<br />
on the tunIng chaIn IS VISIble and ahgned WIth the tImIng<br />
mark on the carnshaft sprocket penphery Note whICh<br />
number IS adjacent to the tunIng mark<br />
20 USIng a correct fittIng metnc socket spanner and<br />
SUItable bar unscrew the camshaft sprocket retamIng bolt<br />
Remove the bolt and the fuel pump actuatmg cam<br />
2I Instal the speCial tunIng chaIn support tool down<br />
between the tracks of the tnlling chaIn to retaIn the chaIn<br />
on the crankshaft sprocket and also to prevent the hmIng<br />
chaIn plunger from becommg dIslodged<br />
22 WIth the tunIng chaIn firmly wedged by the<br />
support tool WIthdraw the camshaft sprocket from the<br />
camshaft dIsengage the tlllling chaIn from the sprocket and<br />
remove the sprocket<br />
23 Unscrew the two camshaft thrust plate retaInIng<br />
screws and WIthdraw the thrust plate<br />
24 Interpose a wooden block between the sump and<br />
a jack and take the weIght of the enbne assembly<br />
25 Remove the front engine mountIng<br />
crossmember secunng bolts<br />
to front<br />
26 RaIse the engIne on the jack untlllt IS apparent<br />
that the camshaft IS capable of beIng WIthdrawn from the<br />
cyhnder head assembly wlth ut fouhng on the radIator<br />
upper support panel<br />
27 Carefully WIthdraw the camshaft from the<br />
cyhnder he d ensunng that the camshaft journal s or lobes<br />
do not damage tlie camshaft beanngs<br />
I<br />
r<br />
iMPURTANi Do not remove the camshaft beaTing bracket<br />
bOlts or brackets from the cylmder head assembly if<br />
bracketbolts or brackets are removed bearmg mlsaltgnment<br />
WIll result which WIll nixesSltate the renewal a the cylmder<br />
heaa assembly<br />
rorn K<br />
I Check the1calnshaft lobes for pIttIng or wear<br />
f<br />
2 Support the camshaft at each end on V blocks and<br />
USIng a dial gauge With ItS plunger beanng on the centre<br />
t<br />
journals rotate the cams aft and check for bend See<br />
32<br />
STEADY<br />
G<br />
e<br />
PIVOT<br />
to LOCK NUT<br />
V CLIP<br />
SEAT<br />
ROCKER ARM<br />
OROCKER<br />
t<br />
CAMSHAFT<br />
GUIDE<br />
Dismantled VIew of Camshaft and Rocker<br />
Components<br />
fLPJ<br />
f<br />
t<br />
SpeCIficatIons for camshaft bend hmlt 3Jf 3 Usmg accurate measunng eqUipment measure thi<br />
mSlde dIameter of each camshaft beanng and the outSide<br />
dIameter of each camshaft journal<br />
WorkIng from the measurements In<br />
gIven the<br />
SpeCIficatIons and the measurements just taken calculate<br />
the actual beanng clearance on each journal If the beanng<br />
clearance IS beyond the tolerance a check can be made to<br />
ascertaIn whIch components are worn beyond hmlts I e<br />
beanngs or the camshaft journals<br />
4 If the camshaft beanngs are worn then the<br />
complete cyhnder head assembly Will have to be renewed<br />
5 LIght scratchIng on the camshaft beanngs may be<br />
removed by carefully homng With very fine carborundum<br />
paper<br />
6 See CYLINDER HEAD SECTION to REMOVE<br />
AND INSTAL If It IS found that the camshaft beanngs are<br />
unservIceable<br />
7 Check the camshafrthlust plate for wear or sconng<br />
and renew the plate as reqUIred f<br />
TO INSTAL<br />
installatIon IS a reversal of the removal procedure WIth<br />
attentIon to the follOWIng pOInts<br />
Lubncate the camshaft and camshaft beanngs WIth<br />
clean engine Oll before assembhng<br />
Instal the camshaft sprocket and chaIn and WIthdraw<br />
the chaIn support tool before rotatIng the engine and fittIng<br />
the rocker arms<br />
NOTE it IS most Important that the engme IS not rotated<br />
with Its pistons and valves out oftlmmg Failure to observe<br />
thiS Will result m pistons and valves contactmg each other<br />
WIth a dIal gauge mounted on the front end of the<br />
cyhnder head assembly check the end float of the camshaft<br />
Renew the camshaft thrust plate If the end float IS not<br />
wlthIn th specjfied hnut See SpecIficatIOns for end float<br />
hnut<br />
Renew all gaskets which were dIsturbed durIng the<br />
dlSmanthng procedure<br />
Adjust the valve clearance as outlmed In the<br />
CYLINDER HEAD sectIon of thiS manual<br />
1<br />
J
INLET MANIFOLD Smgle Apphcatlon<br />
I Disconnect the rocker cover to au cleaner<br />
ventilation hose and the mlet mamfold to au cleaner<br />
thermostatic au bleed hose where fitted<br />
2 Remove the au cleaner assembly<br />
3 DIsconnect the fuel mlet pIpe and the fuel by pass<br />
hose where fitted<br />
4 DIsconnect the dlstnbutor vacuum feed pIpe<br />
5 DIsconnect the choke control cable<br />
6 DIsconnect the throttle lmkage<br />
throttle lever<br />
12 INI ET ANn EXHAUST IAI 1FOI DS<br />
at the carburettor<br />
7 Remove the carburettor to mamfold retammg nuts<br />
and hft off the carburettor<br />
8 Remove the radIator cap and dram the coohng<br />
system Yla the tap on the lower radIator tank sufficIently to<br />
lower the water level below the mlet mamfold<br />
9 DIsconnect and remove the mlet manIfold to<br />
crankcase ventIlation hose<br />
IO DIsconnect the mlet mamfold water hose<br />
II ProgressIVely slacken and remove the mlet<br />
mamfold to cyhnder head attachmg nuts and 11ft away the<br />
mlet mamfold<br />
Installation IS a reversal of the removal procedure WIth<br />
attention gIven to the followmg<br />
Always mstal a new marufold and carburettor gasket<br />
when assemblIng the mamfold and carburettor to the<br />
engme<br />
NOTE As the mlet and exhaust mamfold gasket Is one<br />
piece It Will be necessary to remove the exhaust mamfold<br />
to renewthe gasket<br />
Check the mamfold mountmg face wIth a steel straIght<br />
edge for warpage If warpage IS excessIve rectIfy by surface<br />
gnndmg<br />
Ensure that the mountmg faces of the cylInder head<br />
and marufold are clean of old gaskets and free of burrs<br />
INLET MANIFOLD Twm ApplIcatIOn<br />
I Disconnect the rocker cover to aIr cleaner<br />
ventilatIOn hose<br />
pipe<br />
chambers<br />
manifold<br />
2 Remove the aIr cleaner assembly<br />
3 Remove the mlet elbow from each carburettor<br />
4 DIsconnect the fuel mlet pIpes and the fuel return<br />
where fitted<br />
5 DIsconnect the choke control cables<br />
6 Remove the fuel overflow pIpes from the float<br />
7 DIsconnect the throttle lInkage<br />
8 Detach the dlstnbutor vacuum feed pIpe<br />
9 Unbolt and remove each carburettor from the mlet<br />
10 DIsconnect and remove the crankcase to mlet<br />
mamfold ventilation hose<br />
11 DraIn the coolmg system and dIsconnect the mlet<br />
mamfold water hose<br />
33<br />
r<br />
Engine27<br />
12 Progressively slacken and remove the mlet<br />
mamfold to cylmder head attachmg nuts and 11ft away the<br />
mlet mamfold<br />
InstallatIOn IS a reversal of the removal procedure WIth<br />
attentIon to the followmg pomts<br />
Instal new mlet mamfold and carburettor gaskets when<br />
assembhng<br />
Check the mamfold mountmg face WIth a steel straight<br />
edge for warpage If warpage IS excessIve rectIfy by surface<br />
gnndmg<br />
Ensur that the mountmg faces of the cylInder head<br />
and mamfold are clean of old gasket and free ofburrs<br />
EXHAUST MANIFOLD All Models t<br />
1 Remove the mlet mamfold as preVIOusly descnbed<br />
2 Remove the exhaust manIfold to exhaust pIpe<br />
flange nuts and detach the pIpe from the mamfold DIscard<br />
the flange gasket<br />
3 Unscrew the exhaust mamfold to cylInder head<br />
retammg nuts and WIthdraw the mamfold and ga ket from<br />
the studs<br />
InstallatI nIs<br />
a reversal Of fhe removal procedure WIth<br />
attentIOn given to th followmg pomts<br />
1<br />
Check the exhaust manIfold for excessive warpage and<br />
Iffound necessary rectIfy by surface ghndmg<br />
Ensure that the mountmg faces of he cylInder head<br />
and mamfold are fre of old gasket 9r burrs<br />
Instal a new manIfold to syhnder head gasket and new<br />
mamfold exhaust flange gaskets<br />
L 16 Engone Inlet and Exhaust<br />
Mamfold and Gasket<br />
1t R<br />
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28Enlline<br />
Timing Cover Removed ShoWln9<br />
LocatIon of Worm Drove Gear<br />
Sr<br />
t<br />
and 001 Slinger<br />
o<br />
Engine at tdc POinter on TIming Cover to be aligned WIth<br />
Left Hand Mark on Pulley as Shown All other marks are In<br />
41<br />
5 degree Increments BTDC<br />
JPy<br />
34<br />
TO REMOVE<br />
1 1<br />
DISTRIRUTUR<br />
I Disconnect the high tensIOn leads at the spark<br />
plugs and coil and remove the dlstnbutor cap<br />
and leads<br />
from the<br />
engme<br />
2 Disconnect the prunary<br />
lead wire and the<br />
dJstnbutor vacuum advance<br />
pipe<br />
at the dlstnbutor<br />
3 Scnbe a mark on the dlstnbutor mountmg bracket<br />
and tunmg cover to facilitate correct replacement<br />
4 Remove the two bolts secunng the dlstnbutor and<br />
mountIng bracket assembly to the limIng<br />
Withdraw the assembly from the tunIng cover<br />
cover and<br />
NOTE Do not disturb the graduated plate at the<br />
dlStnbutor body stem or the IgnitIOn tlmmg Will be lost<br />
See OIL PUMP seclion If the dlstnbutor and 011 pump<br />
dnve spIndle needs replacement<br />
c<br />
1 l<br />
f tOl 11<br />
f<br />
r<br />
j v<br />
l3j<br />
r
TO INSTAL<br />
I With a new gasket mstal and secure the dlstnbutor<br />
and mountmg bracket assembly allgmng the marks on the<br />
tumng cover and mountmg bracket which were made<br />
before removal Ensure that the retammg bolts are<br />
tightened securely<br />
NOTE The dIStributor offset drive tongue will only engage<br />
with the Oil pump drive gear spmdle dog In one poslflon<br />
but It may be necessary to rotate the dlstnbutor shaft via<br />
the rotor untll engagement of these components takes<br />
place<br />
DESCRIPTION<br />
Two types of crankcase ventt atlOn systems are used as<br />
standard eqUipment<br />
The sealed IS type system used on sports cars and the<br />
closed type system used on sedans statIOn wagons and<br />
utilities<br />
The Sealed Type System consISts of a hose connectmg<br />
the rocker cover to the aIr cleaner assembly Pressure drop<br />
created In the alf cleaner by aIr flow allows crankcase<br />
vapours to flow from the crankcase vIa the rocker cover<br />
Into the au cleaner where they are drawn mto the mlet<br />
mamfold and consumed m the cylinders<br />
The engme ot dIpstick and filler cap are sealed to<br />
prevent crankcase fumes from escapIng Into the<br />
atmosphere<br />
The Closed Type System draws aIr from the aIr cleaner<br />
through a meshed flame trap and a hose Into the rocker<br />
cover<br />
The alf IS then passed through the engIne and Into the<br />
mlet mamfold vIa a hose and regulatIng valve Crankcase<br />
vapours are thereby fed back mto the cylmders and<br />
consumed<br />
As WIth the sealed type system the ot lipstick and<br />
filler cap are sealed from the atmosphere<br />
At full throttle dnvIng the manifold vacuum IS<br />
Insufficlent to draw all crankcase blow by through the<br />
regulatmg valve and Into the mlet mamfold Under these<br />
condItions the crankcase venttatlon flow I reversed wIth<br />
the fumes draWIng Into the aIr cleaner mstead of the mlet<br />
manIfold<br />
A baffle plate and a meshed ftlter which IS located<br />
W1thm the crankcase prevents engme ot bemg dr 11wn<br />
the mlet mamfold<br />
TO CHECK AND TEST OPERATION<br />
Sealed System<br />
As thIS system IS relatively sunple<br />
mcorporate a regulatmg valve It IS only<br />
penodlcally checkmg the followmg<br />
Engine29<br />
2 Connect up the dlstnbutor pnmary lead wlfe and<br />
the dlStnbutor vacuum advance pIpe<br />
3 Instal the cbstnbutor cap and fit the ugh tensIOn<br />
leads to the spark plugs and IgmtlOn cot tower<br />
NOTE If the graduated plate at the dIStributor body has<br />
been disturbed and co ect Ignition tlmmg has been lost If<br />
wiI be necessary to readjust the Ignltlon tlmmg with a<br />
stroboscope IgmtlOn tlmmg light<br />
See Dlstnbutor In ELECTRICAL SECTION for<br />
IgmtlOn tmung adjustment procedure<br />
14 CRNKCASE VENTII ATION<br />
mto<br />
and does not<br />
a matter of<br />
35<br />
I Check the rocker<br />
c ver t aIr cleaner assembly<br />
hose for collapsmg blockmg or detenoratJon Renew the<br />
hose as tound<br />
necessary<br />
1<br />
j 1<br />
2 Check the seals on the engIne ot filler<br />
cap<br />
and the<br />
dipstick Renew the seals If they are damaged or If theu<br />
sealmg quahtles are suspect<br />
Closed System<br />
1 Check the condition of the rocker cover to au<br />
cleaner assembly hose and the crankcase to Inlet mamfold<br />
hose Check for blockmg collapsmg Pf detenoration<br />
Renew the hoses as found necessary<br />
II<br />
Removong Crankcase VentilatIon Baffle Plate and 011<br />
Separator<br />
s<br />
r<br />
t<br />
j<br />
J<br />
f<br />
Y ic<br />
tlK<br />
t<br />
I<br />
s
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7<br />
l I<br />
l<br />
If<br />
I<br />
30 Engine<br />
2 Check the seals on the engme 011 filler cap and the<br />
dipstIck Renew the seals If they are damaged or If their<br />
sealmg quailtIes are suspect<br />
3 Check the operatIon of the ventIlatIon regulatmg<br />
valve as follows<br />
With the engme runmng at a steady Idle speed<br />
disconnect the hose from the regulatmg valve<br />
A sharp Iussmg nOise woll be heard at the valve when<br />
the hose IS disconnected<br />
Place a finger over the valve mlet A strong vacuum<br />
should be Immediately felt as the finger IS placed<br />
valve<br />
TO REMOVE AND INSTAL FRONT<br />
over the<br />
I Raise the front of the vehicle and support on<br />
chaSSIS stands<br />
2 Remove the bolts fixmg the engme mountmgs to<br />
the front crossmember<br />
3 Interpose a wooden block between the engme<br />
sump and a jack and Jack up the front of the engme<br />
assembly<br />
4 Remove the nuts secunng each engIne mountmg to<br />
the engme mountmg brackets<br />
5 Remove both front mountmgs from the brackets<br />
InstallatIOn IS a reversal of the removal procedure<br />
Allow the full weight of the engme assembly to bear on<br />
the mountmgs before tIghtemng the secunng bolts and<br />
nuts<br />
TO REMOVE AN INSTAL REAR<br />
1 Rillse the front of the vehicle and support on<br />
chaSSIS stands<br />
1<br />
If the valve IS found to be partIally or fully moperatIve<br />
then renew the valve<br />
It IS not practicable to dismantle and clean the valve<br />
4 A faulty ventolatIon regulatmg valve may give nse<br />
to anyone or more of the followmg conditIons<br />
a Black smoke emergmg from the exhaust<br />
b Engme huntmg<br />
Iii ENGINE M01TNTINGS<br />
1<br />
36<br />
at Idle<br />
c EngIne Idle fluctuates but engIne does not stall<br />
d Loss of power and surgIng at speeds above Idle<br />
e Engme stalls after stops and runs roughly after<br />
bemg restarted WIth mdlcatIons of a lean mIXture<br />
2 Place a Jack under the transmission to take the<br />
weight of the engIne and transmiSSion assembly<br />
3 Remove the two transmiSSion rear crossmember to<br />
mountmg secunng bolts<br />
4 Remove the four bolts which attach the rear<br />
transmissIOn crossmember to the underbody and remove<br />
the crossmember<br />
5 Undo the bolts connectmg the rear engme<br />
mountmg to the transmISsIOn extensIOn housmg and<br />
remove the mountmg<br />
Installation IS a reyersal of the removal procedure<br />
Ensure that the mountmg IS centralized and that engIne<br />
and transmISsIOn weight IS taken on the mountmg before<br />
finally tIghtemng the mountmg secunng bolts<br />
See SpecificatIon sectIOn for torque settmgs for front<br />
and rear mountmg bolts and nuts<br />
NOTE Engme mountzngs that are 011 soaked should be<br />
renewed and the cause of the 011 leak rectified<br />
normal worklllg lzfe for the mountmg concerned<br />
to ensure a<br />
J
Engme wdl not start by normal crankmg<br />
Possible cause<br />
a Dlfty or corroded dIstrIbutor pomts<br />
b Carburettor floodml<br />
c MOIsture on ugh tensIOn wlfes and or mSlde<br />
distrIbutor cap<br />
d Out or water m carburettor and fuel system<br />
e Incorrectly set spark plug gaps<br />
f Faulty cod or capacitor<br />
g Faulty low or high tension wlfes<br />
11 Fuel vapor lock<br />
I Faulty fuel pump<br />
j Incorrectly set Igmtlon tImmg<br />
k Broken or short cIrcuited low tensIOn lead to<br />
distributor pomts<br />
2 Engme wdl not start weak or erratic crankmg<br />
Possible cause<br />
a Weak or faulty battery<br />
b Fault m starter lead or solenoid<br />
c Faulty starter<br />
3 Engme stalls<br />
d Idhng speed<br />
Possible cause<br />
set too slow<br />
b Idhng mixture too lean or rIch<br />
c Carburettor floodmg or float level mcorrectly set<br />
d Fault m cod or capacl tor<br />
e Valve clearance out of adjustment<br />
f AIr leak at mlet manIfold or carburettor flange<br />
g Carbon trackmg or cracked distributor cap<br />
h Weak or faulty battery and or corroded termmals<br />
I Carburettor floodmg or mcorrect float level<br />
settmg<br />
j Faulty cod or capacItor<br />
k ExcessIve wear m dIstributor shaft and bushes or<br />
contact breaker cam<br />
I Burned warped or pitted valves<br />
J6 ENINE FAULT DIAGNOSIS<br />
Engine31<br />
Remedy<br />
Clean or renew and adjust pomts<br />
Check needle valve and float clean out fuel system<br />
Dry out ugh tensIOn WIres and cap<br />
Clean out carburettor and fuel system<br />
Reset spark plug gaps to specIficatIon<br />
Test and renew faulty components<br />
Test and renew faulty wIres<br />
Check source of vapor lock and msulate agamst heat<br />
Test and overhaul fuel pump<br />
Check and retIme IgIutIon<br />
Test and renew lead<br />
Remedv<br />
Recharge or renew battery<br />
Test and renew faulty components<br />
Test and overhaul starter<br />
Remedy<br />
Readjust Idlmg speed stop screw<br />
Readjust Hlhng mixture screw wd I dhng speed screw<br />
Check needle valve or reset float level<br />
Test and renew faulty component<br />
Adjust valve clearance<br />
TIghten securIng bolts or renew gaskets<br />
Clean or renew cap<br />
Recharge or renew battery and or clean or termmals<br />
renew<br />
Check needle valve or reset float lev l<br />
Test and renewfaulty component<br />
Renew worn components<br />
Carry out top overhaul on engIne<br />
4 Engme nussmg at Idling speed<br />
Possible cause Remedy<br />
a Duty defectIve or mcorrectly set spark plugs Clean or renew and set spark plugs<br />
b Burned or pItted dlStnbutor contact pomts Clean or renew and adJust contacts<br />
c Loose or broken low or hIgh tension wIres m TIghten or renew defectIve comp nents<br />
d<br />
IgnItIon system<br />
Carburettor IClhng mixture out of adjustment Adjust Idhng mIXture Screw<br />
e Burned or cracked dlstrIbutor rotor Renew faulty component<br />
f MOIsture on gh tensIOn WIres spark plug Ol Dry out ugh tensIOn system and cap<br />
dIStrIbutor cap<br />
37<br />
t<br />
l
t t<br />
1<br />
32 Engine<br />
5 Engme misses on acceleration<br />
Possible cause<br />
a Dlstnbutor pOints duty or Incorrectly adjusted<br />
b Spark plug s dirty faulty or gap set too wide<br />
c Dut or water In carburettor<br />
d Carburettor accelerator pump discharge Jet<br />
blocked or pump defective<br />
e CoIl or capacitor faul ty<br />
I Incorrect Igmtlon hmmg<br />
g Burned warped or pitted valves<br />
6 Engme misses at high speed<br />
POSSible cause<br />
a Dlstnbutor pOints duty or Incorrectly adjusted<br />
b Spark plug s dirty faulty or gap<br />
c Dirt or water In carburettor<br />
d Burned or cracked dlstnbutor rotor<br />
set too Wide<br />
e Faulty coIl orcapacitor I Dut In carburettor power Jet<br />
g Incorrect Ignition timing<br />
h ExceSSIVe wear In dlstnbutor shaft or carn<br />
7 Engine lacks power<br />
POSSible cause<br />
a Duty or Incorrectly set spark plugs<br />
b Dut or wat r In carburettor and fuel system<br />
c Incorrect Ignition tuning<br />
d Incorrect carburettor float level<br />
e Faulty fuel pump<br />
I Incorrect valve clearance<br />
g Faulty dlstnbutor automatic advance<br />
h Restncted muffler or tall pipe<br />
I Faulty cool or capacltor<br />
J Burned or cracked dlstnbutor rotor<br />
k ExceSSive wear In dlstnbutor shaft or carn<br />
I Inc<br />
valve timing<br />
rrect<br />
m Burned warped or pitted valves<br />
n Blown cyhnder head gasket<br />
0 Loss of compressIOn<br />
8 NOISY valve operation<br />
POSSible cause<br />
a Incorrectly adjusted clearance<br />
b W ak or bwken valve spnngs<br />
c Worn valve gUides<br />
9 Big end beanng nOIse<br />
POSSIble cause<br />
a Lack of adequate 011 supply<br />
I b ExceSSive beanng clearance<br />
Y SJItc r 1n ool or crankcase dIlution<br />
d Low 001 pressure<br />
e Misaligned big end bearings<br />
38<br />
Clean and readjust pOints<br />
Remedy<br />
Clean or renewand reset faulty plug s<br />
Clean and blowout carburettor and fuel pump filter<br />
Clean out carburettor<br />
Renew defective component<br />
Check and reset IgnltJon timing<br />
Carry out top over Jaul<br />
on engme<br />
Remedy<br />
Clean and readjust pOints<br />
Clean or renewand reset faulty plugs<br />
Clean out carburettor and fuel pump filter<br />
Renew faulty component<br />
Renew faulty component<br />
Clean and blowout carburettor<br />
Check and reset IgnltJon tuning<br />
Renew faulty components<br />
Remedy<br />
Clean and reset<br />
gap<br />
to speclficatJons<br />
Dram and clean out fuel system and carburettor<br />
Check and reset Ignition tuning<br />
Check and reset float level<br />
Check and overhaul fuel pump<br />
Check and readjust valve clearance<br />
Check and rectJfy or renew<br />
Check and clean as necessary<br />
Renew faulty component<br />
Renew faulty component<br />
Renew faulty components<br />
Check and reset as necessary<br />
Carry out top overhaul on engine<br />
Renew gasket<br />
Carry out compression test and rectJfy<br />
Remedy<br />
Check and adjust to speCifications<br />
Check and renew faulty components<br />
Renew or rearn and fit oversize valve<br />
Remedy<br />
Check 011 level In sump condition of 011 pump and<br />
rehefvalve Renew 011 filter element<br />
Renew beanng shells check and regrmd Journals If<br />
oval<br />
Change to correct 011 grade Check operating<br />
conditions and cooling system thennostat<br />
Check pressure rehef valve an spnng 011 fIlter by pass<br />
valve I<br />
Ahgn connecting rods and renew beanngs If necessary
10 Apparent maIO beanng noise<br />
PossIble cause<br />
a Loose flywheel<br />
b Loose crankshaft pulley<br />
c Low oil pressure<br />
d ExcessIve crankshaft end play<br />
e Crankshaft Journals out of round and excessIVe<br />
beallng to Journal clearance<br />
I InsufficIent oil supply<br />
11 Excessive oil consumptIon<br />
PossIble cause<br />
a 011 leaks<br />
b Damaged or worn valve stem oil seals<br />
c ExcessIve clearance valve stem to valve guide<br />
d Worn or broken lings<br />
e Rmgs too tight or stuck 10 groves<br />
I ExceSSive wear 10 cylInders pIstons and nngs<br />
g CompressIOn nngs mcorrectly mstalled oil nngs<br />
clogged or broken<br />
12 Drop 10 oil pressure<br />
a<br />
PossIble cause<br />
011 level low 10 sump<br />
b Thm or diluted oil<br />
c ChI pump rellef valve stuck or spnng broken<br />
d ExceSSIve beanng clearance<br />
e ExceSSIve wear of oil pump components<br />
I Au leak 10 oilmg system<br />
39<br />
Engine 3 J<br />
Remedy<br />
TIghten secunng bolts to specIfied torque<br />
Renew or tighten pulley<br />
Check beanng to Journal clearance check condItIon of<br />
oil pump and pressure relIef valve RecondItIOn as<br />
necessary<br />
Renew centre maIO beanng thrust washers<br />
Regrmd Journals and fit undemze beanngs<br />
Replemsh oil 10 sump to correct level<br />
Remedy<br />
Check and renew gaskets as necessary<br />
Renew damaged or worn components<br />
Renew valve guIdes bushes and valves o rlJ1 and fit<br />
ove rSlZe valves fi<br />
Renew nngs<br />
Renew nngs and clean out nng grooves<br />
ReconditIon cylInders and renew pIstons an<br />
Renew nngs<br />
Remedy<br />
Check and replemsh to full mark<br />
Change to correct oil grade and<br />
dilutIon<br />
Free valve or renewbroken spnng<br />
Renew beanng shells or recondItIon<br />
necessary<br />
Renew or recondItion oil Hump<br />
RectIfy as necessary<br />
i<br />
J<br />
t<br />
r<br />
1<br />
t<br />
c<br />
t<br />
4 1<br />
rectIfy source of<br />
k<br />
r t tI<br />
IJ<br />
l<br />
Journals as<br />
v<br />
r
Water pump<br />
Type<br />
Beanng type<br />
Thermostat<br />
Type<br />
Openmg temperature<br />
MaxmlUm valve lift<br />
COOLING SYSTEM<br />
Centnfugal<br />
unpelIer<br />
Double row<br />
ball beanng<br />
and shaft<br />
assembly<br />
Wax pellet<br />
82 deg C<br />
80 deg F<br />
8mm@<br />
95 deg C<br />
0315m@<br />
203 deg F<br />
The cooling system IS of the thermo syphon type With<br />
fan and water pump assistance Two drammg pomts are<br />
mcorporated m the system one at the lower radiator tank<br />
and the other at the starter motor side of the engme<br />
assembly<br />
The system IS also pressunsed m order to ratse the<br />
bolling pomt of the coolant within the system<br />
mcrease the effiCiency of the engine<br />
PEcnleATIONS<br />
RadIator cap<br />
Type<br />
Workmg pressure<br />
RadIator type<br />
Cooling system<br />
CapacJty<br />
1 DESCRIPTION<br />
and so<br />
NOTE To avoId acculental scalding use cautIOn when<br />
releasing the radzator cap of an engine that IS at normal<br />
operating temperature<br />
TO REMOVE<br />
I Remove the radiator cap and dratn the cooling<br />
system via the tap on the lower radiator tank and the plug<br />
on the starter motor SIde of the cylInder block<br />
2 DIsconnect and remove the upper and lower<br />
radIator hoses<br />
3 On vehicles fitted WIth automatic transmISSIOn<br />
disconnect the torque converter cooling pipes at the lower<br />
radIator tank plug the pipes and UnIons to prevent entry of<br />
dut<br />
4 Unscrew the fiXIng bolts and remove the radIator<br />
grille 5 Remove the four radiator retinnIng bolts and lift<br />
out the radIator<br />
NOTE When a radIator that has been In use for some time<br />
IS removed from the vehIcle to enable repairs to be camed<br />
out to the engine It should not be aIowed to stand empty<br />
for any length of time The radIator should be Immersed In<br />
2 RADIATOR<br />
40<br />
Pressure<br />
09 kg cm2<br />
28 pSI<br />
Corrugated fin<br />
6 4 litre<br />
1 41 unp gal<br />
70 US gal<br />
Fan belt deflectIOn 1O 15mm<br />
0 394<br />
o 590 m<br />
The fan and water pump are dnven by a V belt from the<br />
crankshaft pulley TIns belt also drIves the alternator<br />
The water IS<br />
pump fitted With a shaft and baIl beanng<br />
assembly whIch IS pre lubrIcated and reqUires no further<br />
lubncatlOn In serYlce<br />
The water pump seal IS a sprIng loaded carbon thrust<br />
washer and rubber bellows assembly<br />
Temperature wIthm the cooling system IS controlled by<br />
a thermostat located m the cylinder head water outlet pIpe<br />
housmg<br />
A by pass IS Incorporated m the system to allow lunlted<br />
clfculatlOn of the coolant when the thermostat<br />
IS closed<br />
a tank of water or otherwIse kept full Failure to observe<br />
thiS precautIOn may result In overheating when the engme IS<br />
put back Into servIce<br />
This IS caused by mternal deposits m the radzator<br />
drymg andflakIng and so obstructmg theCIrculatIOn of the<br />
coolant m the system<br />
6 Securely plug the water outlets m the upper and<br />
lower radIator tanks and fill the radIator assembly With<br />
clean water<br />
TO CHECK<br />
1<br />
WIth the radIator removed from the veJucle turn It<br />
upSIde down and apply a hose to the lower tank outlet and<br />
revelSe flush the UnIt<br />
2 Stand the radiator upnght and usmg a Jet ofwater<br />
or air pressure at the rear Side of the core remove any dlft
or foreign matter that may have accumulated on the front<br />
sIde of the core<br />
3 With the aid of a hght make a ViSUal check down<br />
through the radiator filler neck onto the radiator tubes IfIt<br />
IS apparent that the tubes are severely unpregnated With<br />
flakes of rust It will be necessary to have the upper and<br />
lower radiator tanks un sweated from the radIator core and<br />
the tubes thoroughly cleaned It IS recommended that this<br />
operahon be carned out by a radiator speclahst who has the<br />
necessary speclallsed equipment to carry out tlus type of<br />
work<br />
TO INSTAL<br />
1 PositIOn the radiator assembly m the front panel<br />
opemng and mstal and l1ghten the four secunng boits<br />
2 Connect the upper dIld lower radIator hoses<br />
between the radiator and the engme Use a hght smear of<br />
grease between the hoses and pIpes<br />
TO REMOVE AND INSTAL<br />
1 Remove the radiator or pressure cap and dram the<br />
water from the coolmg system Via the tap on the lower<br />
radiator tank<br />
2 Disconnect and remove the top radiator hose<br />
3 Remove the two bolts secunng the water outlet<br />
elbow to the thermostat housmg<br />
4 Detach the water outlet elbow and gasket and<br />
Withdraw the thermostat assembly from the recess m the<br />
thermostat housmg<br />
5 If the thermostat housmg or gasket reqUIre<br />
removal disconnect the wife from the heat sender umt and<br />
remove the thermostat housmg to cyhnder head securmg<br />
bolts Withdraw the housmg and gasket from the cylinder<br />
head<br />
NOTE A visual exammaflon of the thermostat Will often<br />
determme Its servzceablltty and obViate the necessity for<br />
further testIng For mstance a thermostat with ItS valve<br />
open when removed from a cold engme IS obvIOUSly faulty<br />
and shouldbe discarded and a new umtfitted<br />
InstallatIOn IS a reversal of the remoyal procedure<br />
Ensure that new gaskets are fitted when assemblmg<br />
F1l1 the coolmg system With clean water to<br />
approxunately 127 mm 050 m below the radiator ruler<br />
neck and check for water leaks<br />
1 TH K nSTAT<br />
41<br />
Cooling System 2<br />
NOTE Inspect all hoses before mstallmg for crackmg or<br />
penshmg and renew any hose that upon mspectlOn proves<br />
to beunservIceable<br />
3 On vehicles fitted With automatIc transrmsslOn<br />
connect up the torque converter cooling pipes at the lower<br />
radiator tank<br />
4 Close the radiator dram tap and mstal the dram<br />
plug at the cylinder block Fill the system with clean water<br />
and mstal the pressure cap<br />
5 Start the engme and check that the water level m<br />
the radiator IS wlthm approximately 12 7 mm 050 m of<br />
the bottom ofthe filler neck<br />
NOTE Use care to aVOid the rISk ofscaldmg If the engme<br />
IS at operatmg temperature remove the radiator cap slowly<br />
to allow pressure to escape before removmg the cap<br />
6 With the engme<br />
temperature thoroughly<br />
transmiSSiOn flUId leaks<br />
CLIP t<br />
e<br />
lfj<br />
THERMOSTAT HOlJSING<br />
t<br />
runmng and at operatmg<br />
check for water and or<br />
HEAT SENDER UNIT<br />
SLEEVE<br />
Exploded VIew of Thermostat Housmg Assembly
JCooling System<br />
TO CHECK<br />
I Check that the thermostat IS closed when It IS cold<br />
2 Suspend and Ilnmerse the thermostat together wIth<br />
a reloable thermometer m a vessel of cold water ensunng<br />
tliat neither the thermostat or thermometer IS touchmg the<br />
SIdes or bottom of the vessel<br />
3 Progre slvelv heat the water notmg the<br />
TO REMOVE AND INSTAL<br />
I Remove the radiator cap and dram the coohng<br />
system VIa the tap on the lower radiator tank and the plug<br />
on the starter motor Side of the cyhnder block<br />
2 Disconnect and remoye the upper and lower<br />
radIator hoses<br />
3 On vehicles fitted with automatic transmiSSIon<br />
dIsconnect the torque converter coolmg pipes at the lower<br />
radiator tank plug the pIpes and umons to preyent entry of<br />
dllt<br />
4 Unscrew the fixmK bolts and remove the radIator<br />
gnlle 5 Remove the four radiator retammg bolts and loft<br />
out the radIator<br />
6 Slacken the fan belt adjustmg bracket bolt and the<br />
two bolts attachmg the lternator to the mounting bracket<br />
on the cyhnder block<br />
7 Push the alternator towards the cylonder block and<br />
remove the fan belt<br />
8 Bend back the lock tabs where applocable and<br />
remove the four bolts secunng the fan and fan pulley to the<br />
water<br />
pUIlJP<br />
and withdraw the fan and pulley<br />
9 Unscrew the water pump to tlmmg case secunng<br />
bolts and detach the water pump and gasket Discard the<br />
gasket<br />
Installahon IS a reversal of the removal procedure with<br />
attentoon given to the followmg<br />
Use a new gasket between the water pump and tlmmg<br />
cover when Installong the pump Apply a smear of jomtmg<br />
compound to both SIdes of the new gasket<br />
Adjust the fan belt as descnbed under FAN BELT<br />
TO ADJUST<br />
Ensure that the coohng system dram pomts are closed<br />
and that the system IS replemshed With clean water<br />
Vehicles fitted with automatIc transmission ensure<br />
that the torque converter coohng pipes are connected at the<br />
radIator bottom tank<br />
Check the water and transmISSion flUId leakage with<br />
the engme running at operatmg temperature<br />
TO DISMANTLE<br />
I Dram the coohng system and remove the water<br />
pump as prevIOusly descnbed<br />
2 USing a sUItable puller Withdraw the pump pulley<br />
tfk<br />
p<br />
ifr<br />
lA11<br />
temperature readmg on the thermometer as the thermostat<br />
valye commences to open<br />
4 Contmue heatmg untol the valve IS completely open<br />
and then measure the maxunum loft of the thermostat<br />
valve<br />
t WATEll PUlUa<br />
42<br />
See SpecIficatIOn sectIOn for maxImum valve loft and<br />
valve opemng temperature<br />
A thermostat with openmg temperature and maxImum<br />
valve hft not wlthm specIfications should be renewed<br />
flange from the forward end of the shaft and beanng<br />
assembly<br />
3 Remove the beanng retammg clop and press the<br />
beanng and shaft assembly together With the seal and<br />
unpeller out of the pump body<br />
4 Press the Impeller off the end of the shaft and<br />
beanng assembly and Withdraw the seal assembly<br />
5 Remove the seal rubbmg block and shaft seal from<br />
the recess m the unpeller<br />
TO CHECK<br />
NOTE It IS generally unnecessary to dismantle the water<br />
pump assembly unless It IS lealang waterpast the seal or If<br />
the ball beaTIng has become nOIsy OnGe dIsmantled It IS a<br />
good polICY to Instal a complete water pump kit whIch<br />
COnsistS of seal assembly bearing and shaft assembly and<br />
Impeller<br />
When the pump IS removed from the vehicle make a<br />
Visual inspectIOn of the pump body If It IS apparent that<br />
the pump body IS corroded or Gracked thell It can be<br />
assumed that the pump body IS unserViceable In which case<br />
the complete water pump assembly should bediscarded and<br />
a new umt fitted<br />
I Check the pump body for corrOSion cracks or<br />
damage<br />
PULLEY FLANGE<br />
CLIP<br />
BEAR NG<br />
RUeBING elOCK<br />
I @ q<br />
SEAL v SHAFT SEAL<br />
V ew of Assembled and D smantled Water Pump Components
2 Check the beanng for looseness m the pwnp body<br />
bore and for roughness when rotated<br />
3 Check that the water by pass hole m the pwnp<br />
body and tlmmg cover are free of obstruction<br />
NOTE When cleanmg the pump components do not<br />
Immerse the shaft and beaTIng assembly In cleamng solvent<br />
If the assembly IS to beused again<br />
TO ASSEMBLE<br />
I With a small amount of waterproof seahng<br />
compound apphed to the large end of the new seal<br />
assembly press the new seal assembly Into posJtlon In the<br />
pwnp body so that the carbon face of the seal will be facIng<br />
towards the pwnp unpeller<br />
2 ApplYIng pressure to the outer portIOn of the<br />
beanng press the beanng and shaft assembly mto the pwnp<br />
body from the front side of the pump<br />
NOTE Only press the beaTIng far enough Into the pump<br />
body to align the bearing retalmng clIp grooves<br />
TO RENEW<br />
I Loosen the two alternator to mountIng bracket<br />
bolts<br />
2 Loosen the alternator adjustIng bracket bolts<br />
3 Push the alternator as far as possIble towards the<br />
cyhnder block assembly<br />
4 Shp the old belt off the alternator pulley and then<br />
manoeuvre It offthe fan and crankshaft pulleys and remove<br />
It from the engIne<br />
5 Manoeuvre the new belt over the crankshaft and<br />
fan pulleys and posItion It on the alternator<br />
6 Adjust the tensIOn on the fan belt and tIghten the<br />
adJustmg bracket bolts<br />
7 Securely tighten the two alternator to engme<br />
mountmg bracket secunng bolts<br />
TO REMOVE AND INSTAL<br />
1 RaISe the engine bonnet<br />
2 Remove the radIator cap and dram the coohng<br />
system at the lower radllltor tank and at the plug wluch IS<br />
sItuated on the starter motor SIde of the engine assembly<br />
3 DIsconnect both heater water hoses from WithIn<br />
the<br />
engme compartment<br />
NOTE The mlet hose can be dIsconnected at the engzne<br />
bulkhead and the outlet hose at the front of the engzne<br />
assembly A retaIning clip whIch secures the outlet hose to<br />
6<br />
Cooling Sy<br />
tem4<br />
3 Instal the beanng retamIng chp<br />
4 PosItion the shaft seal and rubbIng block mto the<br />
recessm the unpeller<br />
5 Support the<br />
pump on the front end of the shaft<br />
assembly and press the unpeller onto the shaft untIl a<br />
clearance of approximately 0 76 nun 030 m IS obtaIned<br />
between the unpeller and pwnp body<br />
6 Invert the pwnp and support It on the unpeller end<br />
of the shaft<br />
7 WIth the bossed SIde of the pulley flange faCIng<br />
towards the pump press the flange onto the front end of<br />
the pump beanng shaft untIl the ends of the shaft and<br />
flange<br />
are flush<br />
NOTE When pressIng the pulley flange onto the shaft as<br />
detaIled In operatIOn<br />
7 ensure that the assembly IS<br />
supported dIrectly on the end of the shaft and not on the<br />
Impeller otherwIse the clearance between the Impeller and<br />
the rear face of the pump as gzven In operation 5 may be<br />
decreased with possIble damage to the Impeller and seal<br />
assembly<br />
a FAN BELT<br />
TO ADJUST<br />
1 Loosen the two alternator mountmg bracket bolts<br />
2 Loosen the alternator adJustmg bracket bolts and<br />
pull the alternator away from the cylInder block<br />
suffiCIently to give the belt enough tensIon to prevent It<br />
shppmg on the pulleys<br />
3 Hold the alternator m thiS posItion and securely<br />
tighten the adJustmg bracket and mountmg rack t bolts<br />
NOTE Do not over tzghten the fan belt An over tensIOned<br />
fan belt WIll cause rapId wear In the water pump and<br />
alternator beaTIngs<br />
The belt WIll be deemed to have suffiCIent tensIOn<br />
when It can be flexed between 10 and 15 mm 0394 and<br />
0590 In with finger and thumb between the alternator and<br />
water pump pulleys<br />
HE TER UNIT<br />
43<br />
the engzne OIl dIpstIck tube WIll also have to be<br />
dIsconnected<br />
4 Remove the retammg screws and detach the<br />
denustmg ducts from each Side of the heater assembly<br />
5 DIsconnect the heater fan electncal WIres at the<br />
bayonet type connector whIch IS located near the heater<br />
urut<br />
6 Disconnect the three heater control WIres at the<br />
heater umt<br />
7 Unscrew the two secunng bolts and remove the<br />
heater ventIlator<br />
j
5Cooling System<br />
Heater VentIlator Unit Removed from VehIcle<br />
8 Remove the four heater assembly mounting bolts<br />
and remoye the heater assembly from the vehicle<br />
NOTE The heater umt IS mounted to the vehicle by two<br />
bolts at the engme bulkhead and by two bolts at the dash<br />
panel tays<br />
r<br />
VENTILATOR MOUNTING POINTS<br />
VENTilATOR SEAL<br />
Rear Vlr<br />
IN of Heater Assemblv<br />
44<br />
Installation IS a reversal of the removal procedure<br />
Ensure that the cooling system IS refilled after heater<br />
umt installatIOn<br />
Start and run the engine until It reaches normal<br />
operating temperature and check that the heater IS<br />
operating correctly Allow the engine to cool off and check<br />
the coolant leyel<br />
I<br />
HEATER MOUNTING<br />
POINTS
Coolant leakage external<br />
Possible cause<br />
a Loose hose chps or faulty hoses<br />
b Lealang radJator core or tanks<br />
c<br />
7 COfn INf S ST M FAUI T BIAf NOSIS<br />
Worn or damaged water pump seal assembly<br />
d Worn or damaged water pump beanng assembly<br />
e Loose or rusted expansIOn plugs<br />
I External crack m cyhnder block or head<br />
g<br />
Faulty cyhnder head gasket or loose holdmg down<br />
bolts<br />
h Leaks at thermostat cover and or water pump<br />
lOIn t gaskets<br />
2 Coolant leakage mternal<br />
Possible cause<br />
a Crack m cyhnder bore wall<br />
b Crack m cyhnder head combustion chambers or<br />
valve ports<br />
c Cyhnder head cracked and lealang<br />
mto valve<br />
rocker compartment<br />
d Cracked cyhnder block water pcket leakmg mto<br />
engme tappet compartment<br />
e Cyhnder head gasket leak due to warped head<br />
3 Coolant loss by overflow<br />
a<br />
Over full system<br />
Possible wuse<br />
b Faulty pressunsed radiator cap<br />
c Blo ked radiator core tubes<br />
d Coolant foannng due to poor quahty<br />
corrosIOn InhIbItor<br />
4 EngIne overheatmg<br />
Possible cause<br />
a Obstructed alT passage through<br />
front to rear<br />
b Incorrect IgmtIon tmllng<br />
c<br />
Incorrect valve tmung<br />
d Low engIne all level<br />
e EngIne tIght<br />
after overhaul<br />
I Poor clTculatJOn<br />
g<br />
Loss ofcoolant due to overflow<br />
h Faulty thermostat<br />
antI freeze or<br />
radIator core from<br />
I Restncted muffler or tall pIpe accomparned by<br />
lossof power<br />
1 Inwrrectly adjusted or draggmg brakes<br />
5 Coolant clfculatlOn faulty<br />
PosSible cause<br />
a PartJaI blockage of radIator core tubes<br />
b Water sludge depOSits In engme water Jacket<br />
c Fan belt broken or shppmg<br />
d Faulty water pump or thermostat<br />
e Collapsmg lower radIator hose<br />
I InsufficIent coolant m system<br />
I<br />
45<br />
Cooling System 6<br />
Remedy<br />
TIghten hose chps or renew faulty components<br />
RepalT or renew radiator<br />
Renew seal assembly<br />
Renew water pump beanng and shaft Jssembly<br />
Renew faulty components<br />
Renew faulty components<br />
Renew gasket and correctly tIghten yhnder head<br />
bolts<br />
RectIfy leaks<br />
Remedy<br />
Renew cylmder block<br />
Renew cyhnder head<br />
Renew cyhnder head lt l<br />
l<br />
Renew cyhnder blo k to<br />
Reface cylmder head and renew gasket<br />
Remedy<br />
Dram and refill to W below fillerneck<br />
Renew faulty cap<br />
Clean or renew radIator core<br />
Dram system and renew coolant and additive<br />
Remedy<br />
Blowout obstructIOn from rear to front of radla tor<br />
core WIth compressed alT or water pressure<br />
Check and reset Igmtlon tInnng<br />
Check and reset yalve tJnnng<br />
Stop engIne ImmedJately and replemsh Oil m sump<br />
Check and IfsatIsfactory stop engme<br />
and allow to cool<br />
out<br />
Check and re tIfy as under Item 5<br />
Check and rectIfy as under Item 3<br />
Renew thermostat<br />
Remove restnctJOns or renew component s<br />
Check and rectIfy by adjustment or renewal of<br />
components<br />
Remedy<br />
Clean out or renew radJJtor core<br />
Clean and flush engme water Jacket and add rust<br />
mJubltor to coolant<br />
Renew or adjust fan belt<br />
Overhaul or renew water pump<br />
Check and renew lower radJator<br />
radIator core tubes<br />
Replemsh coolant<br />
2<br />
renew thermostat<br />
hose and check<br />
1
CARBURETIOR<br />
FUEL SYSTEM<br />
SPECIFICATIONS<br />
Pnmary slow air bleed<br />
Lt3 220<br />
Make Lt6 180<br />
Ll3 Hltaclu Secondary slow air bleed<br />
Ll4 Ntklo Lt3 L16 100<br />
Lt6 sIngle carb llltaclu PumpJet<br />
Lt6 tWIn carb SU type Lt4 50<br />
Carburettor number Economy bleed<br />
Lt3 DCK306 Ll4 160<br />
Ll4 213282 22 Lt6 180<br />
I LI6 smgle carb DAF328 Power Jet<br />
DAF328 IE <strong>L13</strong> 40<br />
t<br />
I<br />
DAF328 3D Slow economy<br />
DAF328 6A LI6 180<br />
DAF328 8A Pnmary mam Jet altItude<br />
DAF328 3E compensatIon Jettmg<br />
LI6 twm carb lUL38W <strong>L13</strong><br />
HJL38W 4 94@ looOm<br />
HITACHI NIKKI 3300 ft<br />
Pnmary throttle barreldIameter 92@ 2000 m<br />
<strong>L13</strong> 26mm 6600 ft<br />
tJ LI4 LI6 28mm 89@ 3000 m<br />
Secondary throttle barrel dIameter<br />
10<br />
000 ft<br />
ILI3 30mm ILI 4 LI 6 32mm<br />
87@ 4000 m<br />
13 300 ft<br />
Prunary ventUrI dIameter 85@ 5oo0m<br />
LI3 L14 21 mm 16 600 ft<br />
Ll6 early 24mm Ll6<br />
Ll6 reVIsed 23mm 112@ 1000 m<br />
Secondary ventun dIameter<br />
3300 ft<br />
Ll3 27mm 109@ 2000 m<br />
L14 L16 28mm 6600 ft<br />
Prunary mam Jet 107@ 3000 m<br />
LI3 L14 96 10 000 ft<br />
L16 1I 5 117 104@ 4000 m<br />
Secondary maIn Jet<br />
13 300 ft<br />
LI3 150 101 @ 5000 m<br />
L14 165 16 600 ft<br />
Lt6 155 165 Float level<br />
Prunary slow runmng Jet <strong>L13</strong> L16 23mm<br />
LI3 43 0 905 m<br />
Ll4 52 Float seat and needle valve travel<br />
L16 48 <strong>L13</strong> 10mm<br />
0039 m<br />
Secondary slow mnrung Jet<br />
Ll3 180 L16 I 5 mm<br />
L14 L16 180 0058 In<br />
Prunary mam air bleed SUTYPE ft<br />
Ll3 80 Bore dIameter 38mm<br />
Ll6 240 Nozzle sIze B<br />
Secondary mam air bleed Jet needle M61<br />
<strong>L13</strong> 90 Needle valve 20mm<br />
Lt6 120 SuctIon spnng<br />
46<br />
23
Float level using gauge<br />
Float lever height from cover<br />
Type<br />
Dehvery pressure<br />
DESCRIPTION<br />
FUEL PUMP<br />
23mm<br />
0905 In<br />
14 I5mm<br />
0551<br />
o 590 In<br />
Mechamcal<br />
diaphragm<br />
018<br />
024 kgjcm2<br />
2 56<br />
341 pSI<br />
I t UIHUIIETTUR HITA III BAF 128<br />
The Hitachi DAF328 carburettor as fitted to the L16<br />
engine IS a tWin barrel down draught type incorporating<br />
pnmary and secondary systems<br />
The pnmary system IS of the Solex type with the<br />
secondary system being ofthe Zemth Stromberg type<br />
Each system shares a common top cover assembly and<br />
a separate main nozzle and throttle valve<br />
The pnmary system provides sUitable mIXtures for low<br />
speed moderate speed and acceleratIOn It also provides<br />
Earher Type DAF328 Carburettor FItted WIth Fuel Return<br />
System<br />
47<br />
Fuel System 2<br />
Dehvery rate 1000 cc<br />
Fuel tank capacity<br />
AIR CLEANER<br />
per mln<br />
I 4 unp pt<br />
per mln<br />
I 6 US pt<br />
per mln<br />
10 Imp gal<br />
455 htre<br />
I2 US gal<br />
Type Paper element<br />
adequate mixtures for starting when the choke plate IS<br />
closed<br />
The secondary bore which consists of a mull1ple<br />
ventun provides mixtures for high speed and also for full<br />
throttle openings at low speed<br />
The secondary sw tch over mechamsm which controls<br />
the secondary throttle valve for full throttle opemngs at<br />
high and low speeds IS actuated by a vacuum diaphragm<br />
assembly One Side of the diaphragm IS open to the<br />
atmosphere whereas the other Side IS connected through a<br />
passage to au Jets In both the prunary and secondary<br />
systems When vacuum IS Increased at the ventuns the<br />
diaphragm IS pulled against ItS spnng hnkages runmng from<br />
the diaphragm then allows the secondary throttle valve to<br />
open<br />
TO REMOVE AND INSTAL<br />
I Raise the engine bonnet and fit fender covers to<br />
both front fenders<br />
2 Remove the au cleaner assembly<br />
3 Disconnect the fuel feed pipe and where fitted the<br />
fuel return pipe<br />
4 Disconnect the dlstnbutor vacuum advance pipe<br />
5 Disconnect the choke control cable<br />
6 Detach the throttle rod from the carburettor<br />
throttle lever<br />
7 Remove the four nuts and washers secunng the<br />
carburettor to the Inlet mamfold and Withdraw the<br />
carburettor and gasket from the engine Discard the gasket<br />
InstallatIOn IS a reversal of the removal procedure With<br />
attentIOn given to the follOWing<br />
Use a new gasket between the carburettor and the Inlet<br />
manifold If necessary scrape the gasket surfaces clean<br />
making sure that no foreign matter IS dropped Into the Inlet<br />
mamfold<br />
NOTE It IS good practzce to LOverthe mlet manifold with<br />
cloth when the carburettor IS removed for overhaul<br />
ExtenSIve engme damage may be sustamed If objects are<br />
aCCidentally dropped mto the mductlon offlce<br />
1
r<br />
J Fuel System<br />
later Type DAF328 Carburettor Installed to VehIcle Note<br />
absence of Fuel Return System<br />
Ensure that the choke valve IS fully open when the<br />
choke control knob IS In the full off posItIOn at the dash<br />
panel Check the carburettor for fuel and vacuum leaks and<br />
adjust the IdlIng speed to the specIfied rpm after warm up<br />
TO SERV CE<br />
When overhaulIng the carburettor several Items of<br />
Importance should be observed to ensure a thorough Job<br />
I All components should be carefully<br />
s1ltable<br />
cleaned In a<br />
solvent and then Inspected for or wear<br />
damage<br />
2 Use au<br />
pressure only to clear the Yanous onfices<br />
and channels<br />
3 Replace faulty components wIth new ones When<br />
checkIng components removed from the carburettor It IS at<br />
tImes yery dIfficult to be sure whether they are satIsfactory<br />
for further semce<br />
It IS therefore recommended that In such cases new<br />
components be Installed<br />
GASKET<br />
I<br />
4 Always use a new gasket kIt when overhaulIng the<br />
carburettor<br />
5 It IS most unportant that the correct fittIng<br />
screwdnvers and spanners be used when semcIng the<br />
carburettor<br />
TO DISMANTLE<br />
1 Remove the carburettor from the engIne as<br />
preVIously descnbed<br />
2 Remoye the small E clIp and detach the accelerator<br />
pump actuatIng lever from the top cover assembly<br />
3 Detach the throttle lever return spnng and also the<br />
return spnng for the pnmary to secondary mterlock<br />
mecharusm<br />
4 Take out the four screws and washers and detach<br />
the carburettor top cover assembly DIsconnect the choke<br />
Imk dunng thIs operatIOn<br />
5 DIsconnect the throttle vacuum chamber<br />
d13phragm rod from the secondary throttle lever<br />
6 Remove the four retammg screws and separate the<br />
carburettor flange from the mam body<br />
7 The carburettor has now been dIsmantled mto ItS<br />
three major components bemg mam body flange or<br />
throttle body and top cover<br />
TO CLEAN PARTS<br />
J Clean all carburettor components m clean petrol or<br />
c1eamng solvent and place ill a sUItable clean contaIner<br />
2 If compressed au IS available blow each component<br />
clean when assemblIng<br />
NOTE Do not clean Jets With Wire drills or by any other<br />
mechanical means as orifices may become enlarged causing<br />
too rich a mIXture for proper performance<br />
3 Clean away any carbon depOSIts that may have<br />
accumulated around the throttle valves<br />
4 DIscard all used gaskets and packmgs<br />
5 Before assemblIng check all fuel<br />
bloWIng through WIth compressed au<br />
GLASS<br />
t<br />
SPACER<br />
Needle Valve and Float Removed from Main Body of late Type DAF328 Carburettor<br />
48<br />
passages by
CHOKE LINK<br />
THROTTLE LEVER<br />
TO SERVICE MAIN BODY<br />
PUMP ACTUATING LEVER<br />
ADJUSTING PLATE<br />
I Remoye the pnmary and secondary mam au bleeds<br />
and emulSIOn tubes<br />
2 Unscrew the two plugs to gam access to the mam<br />
Jets and then remove both mam Jets<br />
3 Remove the pnmary and secondary slow au bleeds<br />
and the pnmary and secondary slow Jets<br />
4 Remove the two screws from the accelerator pump<br />
bore cover and WIthdraw the accelerator pump plunger<br />
853<br />
and ball valve<br />
J<br />
to I<br />
Y ho<br />
lr uPL nnn 1<br />
5 Withdraw the small pm from the pump plunger<br />
assembly and dIsmantle the assocIated components Note<br />
how components are sItuated before dlsmanthng to<br />
faCIlItate correct assembly<br />
BALL<br />
I<br />
o<br />
SPR NG<br />
Ii CLIP PUMP PLUNGER<br />
Fuel System 4<br />
RIght Hand SIde View of DAF328 HitachI Carburettor<br />
6 Unscrew the pump mJector secunng<br />
bolt and hft<br />
away the mJector and seahng washers Invert the<br />
carburettor and remove the small spnng and ball from the<br />
mJector bore<br />
7 Remove the three screws and WIthdraw the ventun<br />
from the secondary bore Discard the gasket 4<br />
8 Remove the fuel return assembly where fitted to<br />
gam access to the needle valve and seat and then WIth a<br />
correct fittmg nng spanner unscrew and remove the nee dleW<br />
valve and seat assembly I<br />
C 1oove the float chamber unng screws<br />
and detach the chamber cover glass and gasket and then<br />
WIthdraw thespacer and float from the chamber<br />
10 Unscrew the three screws which secure the<br />
secondary throttle yacuum chamber assembly to the<br />
I<br />
carburettor mam body and detach the assembly and gasKet<br />
II If necessary dIsmantle the vacuum chamber<br />
assembly by removmg the three screws at the outi sover<br />
separatmg the two portIOns ofthe assembly and then takmg<br />
out the dIaphragm spnng and also the small clleck ball and<br />
spnng<br />
SPRING SEAT<br />
PIN<br />
GAlKET CrVER<br />
BOOT<br />
SPRING<br />
PLUNGER<br />
PISTpN l Ai L<br />
wf wma y<br />
SCREWS<br />
Accelerator Pump Plunger Components Dismantled from DAF328 Carb ttor Body<br />
Br<br />
49 ffJ<br />
b<br />
Xr<br />
i<br />
I<br />
i
l<br />
5 Fuel System<br />
CHAMBER COVER<br />
COVER SCREWS<br />
wASHER<br />
MAIN o<br />
V PLUG<br />
SPRING<br />
hJ<br />
r I<br />
CHAMBER BODY<br />
MOUNTING SCREWS<br />
NOTE Only dismantle vacuum chamber assembly If IfIS<br />
thoughtthat the dwphragm or IS<br />
sprmg<br />
unserviceable<br />
12 Where fitted remove the dash pot assembly and<br />
assocIated mechamsm automatic tranSIlllSSlOn only<br />
13 If the fuel return system was operatmg correctly<br />
before dlsmanthng the carburettor then do not dIsmantle<br />
the assembly If on the other hand<br />
j J<br />
Dismantled View of Secondary Throttle Vacuum Chamber Assembly<br />
JET<br />
a malfunctIOn was<br />
eVIdent m the assembly then dIsmantle the assembly but<br />
leave the bunetal portion mtact<br />
14 Now that the mam body IS dIsmantled check all<br />
components for servlceablhty and make replacements as<br />
found necessary<br />
15 Reassembly IS a reversal of the dlSmantlmg<br />
procedure<br />
See relevant followmg sectIOns for float level and other<br />
necessary adjustments<br />
TO SERVICE TOP COVER<br />
The carburettor top cover whIch houses the choke<br />
valve and shaft assembly normally requlfes very httle<br />
serVIce Do notremove the choke yalve and shaft unless It IS<br />
absolutely necessary<br />
I Mark the choke valve m relation to the cover to<br />
faCIlitate correct assembly<br />
SLOW AIR eLEED<br />
I<br />
GjKET<br />
DAF328 Carburettor<br />
2 WIth a small me remove the peenmg from the ends<br />
of the choke yalve retammg screws<br />
shaft<br />
3 DIsconnect the lInkage from the end of the choke<br />
4 With a SUItable screwdnver remove the two choke<br />
valve retammg screws and WIthdraw the choke valve<br />
5 Remove the choke valve shaft from the cover<br />
6 Lay a str31ght edge across the gasket face of the<br />
cover to check for warpage<br />
File the cover gasket face back<br />
to a true condItion IfexcessIve warpage IS eVident<br />
7 Reassemble by carrymg out the dlsmantlmg<br />
procedure m reverse WIth attention gIven to the followmg<br />
pomts<br />
Check the choke valve for proper operation<br />
Instal two new choke valve retammg screws and peen<br />
the ends of the screws to ensure that they WIll not work<br />
loose and fall mto the mductlOn mamfold<br />
TO SERVICE FLANGE<br />
I Screw out and remove the Idle mIXture adJustmg<br />
screw and spnng<br />
2 Remove the throttle adJustmg screw and spnng<br />
3 Check the pnmary and secondary throttle valve<br />
shafts for wear m the flange body<br />
NOTE If wear IS not eVident then do not dismantle the<br />
shaft assemblies<br />
4 Mark the pnmarv and secondary throttle valves m<br />
MAIN AIR BLEED<br />
t 1<br />
EMULSION T<br />
B<br />
ENTURI SECURING SCREWS<br />
Components DIsmantled from Secondary Throttle SIde of DAF328 Carburettor Mam Body<br />
50
ET<br />
SCREWS<br />
GASKET<br />
e<br />
SCREW<br />
METAL<br />
l a<br />
tst<br />
VALVE<br />
0<br />
SPRING WASHER<br />
Exploded Vi of Fuel Retum DniCII Early 1800 Modell<br />
SECONDARY MAIN AIR BLEED<br />
SECONDARY SLOW JET<br />
SECONDARY SLOW AIR BLEED<br />
DAF328 Carburettor Top Cover Assembly<br />
51<br />
Fuel System 6<br />
Internal View of DAF328 Carburettor Main Body<br />
J<br />
l1<br />
tJ
1<br />
t 7 Fuel System<br />
SLOW JET PLU<br />
PUMP INJECTOR<br />
MAIN AIR BLEED<br />
AND EMULSION TUBE<br />
LT<br />
illll<br />
SLOW AIR eLEEO<br />
SLOW JET<br />
I<br />
WASHER<br />
SPRING<br />
conjunction With thelT respecllve bores File the peerung<br />
away from the ends of the throttle plate retammg screws<br />
and remove the screws<br />
5 Withdraw both throttle valves and then remove<br />
both throttle shafts from the flange<br />
6 If necessary unscrew the retammg nut and remove<br />
the throttle lever etc from the end ofthe pnmary throttle<br />
shaft<br />
Note how components are situated before dlsmantlmg<br />
to ensure correct assembly<br />
7 Inspect the flange for cracks and the gasket<br />
surfaces for nicks or burrs<br />
8 Lay a straight edge across the gasket surfaces and<br />
check for warp<br />
9 Check the seatmg surface and the thread of the Idle<br />
adJustmg screw for damage<br />
i 0 Place both pnmary and secondary throttle shafts<br />
mto thelT respective bores m the flange and check for<br />
exceSSIve clearance Renew the shafts or flange<br />
as found<br />
necessary<br />
i I Assemble the flange m the reverse order of<br />
removal wIth attenlion gIVen to the followmg<br />
Adjust the pnmary and secondary throttle valves to<br />
close fully<br />
Check both pnmary and secondary throttle valves and<br />
shafts for smooth operalion and peen over the ends ofthe<br />
valve retammg screws<br />
Turn the Idle adJustmg screw and spnng m gently with<br />
52<br />
WASHER<br />
I<br />
o<br />
PLUG<br />
GO<br />
Components DIsmantled from Primary Throttle S de<br />
of DAF328 Carburettor Mam Body<br />
the fingers until It Just seats and then back It off<br />
approxImately<br />
turn<br />
3 turns<br />
Screw the throttle adJustmg screw III two or three<br />
NOTE The abovementloned adJustments on the throttle<br />
and uile screw are only preliminary adlustments Engine<br />
uile mIXture and speed must be adJusted correctly with the<br />
engine at operating temperature tSee ADJUSTMENTS<br />
sectIOn for procedure<br />
Float Chamber Glass Removed Showmg Float<br />
AdJusting POints HItachI DAF328 Carburettor
l<br />
TO ASSEMBLE<br />
1 Assemble the flange with a new gasket onto the<br />
carburettor mam body and mstal and tighten the four<br />
retammg screws<br />
2 Assemble the top cover to the mam body With a<br />
new gasket and mstal and tighten the four retammg screws<br />
3 Connect<br />
up the choke hnk dunng the above<br />
operatIOn<br />
4 Attach the throttle lever return spnng and also the<br />
return spnng for the pnmary to secondary mterlock<br />
mechamsm<br />
5 Fit the accelerator pump actuatmg lever to the top<br />
cover and mstal the small Echp to retam the lever<br />
6 Connect up the throttle vacuum chamber<br />
diaphragm rod to the secondary throttle lever<br />
7 Actuate all throttle and choke hnkage by hand to<br />
ensure that all mechamsm isoperatmg smoothly<br />
ADJUSTMENTS<br />
Fuel Level Check<br />
NOTE A hOrlzontallme marked on the float chamber glass<br />
mdlcates the co ect fuel level If the fuel level was co ect<br />
before the carburettor was removed anddismantled and no<br />
new float or needle valve components were fitted dunng<br />
overhaul then zt should not be necessary to re adJust the<br />
fuel level<br />
If the float or needle valve and seat assembly was<br />
renewed then It may be necessary to adjust the float to<br />
obtam the co ectfuel level<br />
I As a startmg pomt and with the float chamber<br />
cover glass removed rover the carburettor and allow the<br />
float seat to rest agamst the needle yalve<br />
NOTE If the carburettor IS m poslflOn on the vehicle then<br />
11ft thefloat with the fingers until the needle valve IS closed<br />
q Bend the float seat tab gently With a pan of long<br />
nosed phers untIl the upper face of the float IS m a<br />
honz ntal pOSitIOn<br />
3 Turn the carburettor nght way up or If the<br />
carburettor IS In posItIon on the vehicle allow the float to<br />
settle mto Its lowered posItion<br />
4 Now check the effectIve stroke of the float I e the<br />
dIStance the float seat ttavels from the float lowered<br />
pOSItion to the float raised posItIon Travel should be 1 5<br />
rum 0 059 In<br />
5 Iffound necessary bend the float stopper tab With<br />
a paIr of long nosed phers untIl the correct travel IS<br />
obtamed<br />
6 Instal the float chamber gaSket glass and cover and<br />
fit and tighten the three secunng scr ws<br />
7 Instal the carburettor run the engine and check<br />
the fuel level agaInst the honzontal hneYon the glass Ifthe<br />
fuel level IS too high or too low then the cover and glass wIll<br />
53<br />
Fuel System 8<br />
13 MM 0051 IN I DIA ROD PRIMARy THROTTLE VALVE<br />
Method of Checkmg Choke Interlock Fast Idle<br />
Adjustment DAF328 Carburettor 1<br />
have to be removed and the float seat tab bent agam to<br />
obtaIn the correct level<br />
NOTE Whenel er the float seat tab IS adjusted then the<br />
float stopper must be adjusted to obtam the co ect<br />
effectIve stroke ofthe float<br />
Choke Interlock Adjustment<br />
NOTE When the choke valve zs In the fully closed positIOn<br />
the pnmary throttle valve should be opened 13 mm 0 051<br />
m which Will consfltute a throttle valve openmg angle of<br />
16 degfrom thefully closed poslflOn<br />
J Remove the carburettor from the vehicle as<br />
prevIOusly descnbed<br />
2 Actuate the choke operatmg lever by hand until<br />
the choke val ve S m the fully closed posItIon<br />
3 a 1 3 mm 0 051 m diameter rod as USl1g a gauge<br />
check the clearance between the prunary throttle valve and<br />
the valve bore<br />
4 If the throttle valve clearance IS larger or smaller<br />
than the gauge rod then carefully bend the choke<br />
connectmg rod with a pair of phers until the gauge WIll Just<br />
shde neatly between the choke valve and the bore<br />
Pnmary and Secondary Throttle<br />
Interlock Opemng Adjustment<br />
The secondary throttle valve should commence to open<br />
when the pnmary throttle valve IS opened 59 deg from the<br />
fully closed posItion<br />
This angle can be assessed by pOSltlomng a 9 0 mm<br />
J<br />
i
t<br />
I<br />
9Fuel System<br />
0 358 m diameter rod between the pnmary throttle valve<br />
and the valve bore<br />
1 Remove the carburettor from the velucle as<br />
prevIOusly descnbed<br />
2 POSItIon a 910 mm 0358 m dIameter rod as<br />
shown m the illustratIOn between the pnmary throttle<br />
valve and the throttle bore<br />
closed<br />
3 Ensure that the secondary throttle valve IS fully<br />
4 Bend the adjustIng plate m the dIrectIon requIred<br />
With a paIr of plIers until It Just comes mto contact WIth the<br />
actuatmg lever lug on the pnmary throttle shaft See<br />
illustratIOn<br />
5 Check the adjustment by wIthdrawmg the gauge<br />
rod closmg both throttle valves and then gradually open<br />
the pnmary throttle valve VIa the throttle lever until the<br />
secondary throttle valve IS Just permitted to open In tlus<br />
pOSItIon the gauge rod should Just shde between the<br />
pnmary throttle valve and the pnmary throttle bore<br />
Dash Pot Adjustment<br />
AutomatIc TransmISSIon<br />
r<br />
NOTE The dash pot IS a device fitted to the carburettor<br />
only when aUtomatic type transmiSSIOn IS fitted to the<br />
i SECONDARY THROTTLE<br />
t<br />
r<br />
VALVE FULLY CLOsEDI 910 MM 10 358 IN I DIA ROD<br />
Method of Checkong Primary and Secondary Throttle<br />
PIC No 51<br />
Interlock Openongs DAF328 Carburettor<br />
DAF328 Carburettor Flange With Idle Mixture Screw and<br />
3<br />
A J<br />
C I<br />
Spring Removed<br />
l<br />
It<br />
II<br />
l<br />
54<br />
vehicle Its pnmary purpose IS to prevent the enlJlne from<br />
stalling when the throttle IS suddenly closed The throttle<br />
lever stnkes the dash potstem at approximately 1900 rpm<br />
This creates a dampenmg effect on the pnmary throttle<br />
valve mcludlng a slight mcrease m throttle valve opemng<br />
which prevents the enlJlne rom stallmg<br />
I Connect a tachometer to the engme<br />
2 Start and run the engme until It reaches normal<br />
operatmg temperature<br />
3 RaIse the engme speed unttl a readmg Qf between<br />
1800 and 2000 rpm IS obtamed on the tachometer<br />
4 At the abovementIoned engme speed the dash pot<br />
stem should be m contact WIth the pnmary throttle lever<br />
5 If the dash pot stem IS not m contact With the<br />
throttle lever then back off the dash pot lock nuts and<br />
adjust the dash pot unttl the dash pot stem abuts the<br />
throttle lever<br />
6 TIghten the dash pot lock nuts<br />
7 WIth the engme stIll runnmg at between 1800 and<br />
2000 rpm release the throttle and observe the tachometer<br />
dIal If the dash pot IS adjusted correctly a shght<br />
mcrease m<br />
engme rpm will be noted before returrung to normal engme<br />
Idle speed<br />
8 If an mcrease m engme rpm IS not observed then<br />
back off the dash pot lock nuts and readjust the dash pot<br />
until correct operatIon IS obtamed<br />
NOTE Pnmary throttle valve openmg<br />
should be<br />
approximately 08 mm 0070 m at the abovementIOned<br />
checking enlJlne speed or alternatlvely 100 m valve openmg<br />
angle<br />
SPRINGI<br />
DLE MIXTURE SCREW<br />
CHOKE CONNECTING ROD<br />
SECONDARY THROTTLE LEVE<br />
PUMP CONNECTING ROD
l<br />
To Adjust Idling Speed and MIXture<br />
1 Remove the vacuum access plug<br />
mamfold<br />
from the mlet<br />
2 Connect a va uum gauge wIth unable adapLOI<br />
mto the mlet manifold<br />
3 Connect a tachometer to the IgnitIOn coIl<br />
4 Start and run the engme until It reaches normal<br />
operatmg temperature<br />
5 Adjust the throttle Idling screw untIl an engme Idle<br />
speed of 600 rpm IS obtamed on the tachometer<br />
6 Adjust the Idling mIXture screw until the highest<br />
DESCRIPTION<br />
The liItachl DCK306 carburettor as fitted to the Ll3<br />
engIne IS a twm barrel down draught type mcorporating<br />
pnmary and secondary systems<br />
Both the pnmary and secondary systems of thiS<br />
carburettor are of the Zemth Stromberg type<br />
Each system shares a common top cover assembly and<br />
a separate mamnozzle and throttle valve<br />
The pnmary system proVIdes sUltable mIxtures for low<br />
speed moderate speed and acceleratIOn It also proVIdes<br />
adequate mIxtures for startmg when the choke plate IS<br />
closed<br />
CHOKE LINK<br />
llIROTTLE LEVER<br />
Fuel System l0<br />
vacuum readmg on the vacuum gauge IS obtamed It may be<br />
necessary to readjust the Idle speed dunng thiS operatIOn<br />
7 Stop the engme and disconnect the vacuum gauge<br />
and tachometer<br />
NOTE An exhaust gas analyser If available Lan be used to<br />
adjust the mixture or to check as a comparison wllh the<br />
vacuum gauge readings An opt mum mixture strength<br />
reading IS desired on the gasanalyser at engine Idle Turning<br />
the Idling mIXture screw In a clockwise directIOn gives a<br />
leaner mixture and antl cloclnwse a rlcher mixture<br />
2 AllInJR TTOIl HIT HI un 1045<br />
PUMP ACTUATING LEVER<br />
E CLIP<br />
A power valve mechamsm dIscharges fuel mto the<br />
pnmary system at full load and at acceleratIOn<br />
The secondary bore whIch IS SimIlar In construction to<br />
the pnmary SIde proVIdes mIxtures for hIgh speed and also<br />
for full throttle openmgs at low speed<br />
If the pnmary and secondary emulSIOn tubes and<br />
ventun are dIsmantled they should be carefully marked to<br />
ensure that they WIll be respective systems<br />
reassembled back mtoAthew<br />
rj IoL J<br />
The secondary SWitch over mechamsm whIch controls Y<br />
the secondary throttle valve for Jull throttle openmgs at<br />
high and low speeds IS actua by a vacuum diaphragm<br />
assembly<br />
Right Hand Side View of HItachi Carburettor TYPIcal of DCK306 Carburettor<br />
55<br />
1<br />
Olo<br />
f<br />
l<br />
t<br />
n<br />
J<br />
i
L l<br />
II Fuel System<br />
One side of the dJaphragm IS open to the atmosphere<br />
whereas the other side IS connected through a passage<br />
to au<br />
Jets m both the pnmary and secondary systems When<br />
vacuum IS mcreased at the ventuns the diaphragm IS pulled<br />
agamst lts spnng hnkages runrung from the diaphragm then<br />
allow the secondary throttle valve to open<br />
TO REMOVE AND INSTAL<br />
1 Raise the engme bonnet and fit fender covers to<br />
both front fenders<br />
2 Remove the au cleaner assembly<br />
3 Disconnect the fuel feed pipe and where fitted the<br />
fuel return pipe<br />
4 Disconnect the dlStnbutor vacuum advance pipe<br />
5 Disconnect the choke control cable<br />
6 Detach the throttle rod from the carburettor<br />
throttle lever<br />
7 Remove the four nuts and washers whIch secure<br />
the carburettor to the mlet mamfold and wIthdraw the<br />
carburettor and gasket from the engme DIscard the gasket<br />
InstallatIOn IS a reversal of the removal procedure With<br />
attentIon given to the followmg<br />
Use a new gasket between the carburettor and the mIet<br />
mamfold If necessary scrape<br />
the gasket surfaces clean<br />
makmg sure that no foreign matter IS dropped mto the mlet<br />
marufold<br />
NOTE It IS a good practice to 1over the mlet manifold<br />
With cloth when the carburettor IS removed for overhaul<br />
ExtenSive engme damage may be sustamed If obJects are<br />
accidentally dropped mto the mductlon onflce<br />
Ensure that the choke valve IS fully open<br />
when the<br />
choke control knob IS m the full off posItIon at the dash<br />
panel Check the carburettor for fuel and vacuum leaks and<br />
adjust the Hlhng speed to the speCIfied rpm after warm up<br />
TO SERVICE<br />
When overhauhng the carburettor several Items of<br />
nnportance should be observed to ensure a thorough Job<br />
1 All components should be carefully cleaned m a<br />
SUItable solvent and then mspected for damage or wear<br />
2 Use au pressure only to clear the varIOus onfices<br />
and channels<br />
3 Replace faulty components WIth new ones When<br />
checkmg components removed from the carburettor It IS at<br />
tnnes very difficult to be sure whether they are satISfactory<br />
for further service<br />
It IS therefore recommended that m such cases new<br />
components be mstalled<br />
4 Always use a new gasket lut when overhauhng the<br />
carburettor<br />
5 It IS most nnportant that the correct fittmg<br />
screwdnvers and spanners be used when servlcmg the<br />
carburettor<br />
1<br />
56<br />
TO DISMANTLE<br />
1 Remove the carburettor from the engme as<br />
preVIOusly descnbed<br />
2 Remove the small E chp and detach the accelerator<br />
pump actuatmg lever from the top cover assembly<br />
3 Detach the throttle lever return spnng and also the<br />
return spnng for the pnmary to secondary mterlock<br />
mechamsm<br />
4 Take out the four screws and washers and detach<br />
the carburettor top cover assembly DIsconnect the choke<br />
hnk dunng tlus operatIon<br />
5 Disconnect the throttle vacuum chamber<br />
diaphragm rod from the secondary throttle lever<br />
6 Remove the four retammg screws and separate the<br />
carburettor flange from the mam body<br />
7 The carburettor has now been dIsmantled mto ItS<br />
three major components bemg mam body flange and top<br />
cover<br />
TO CLEAN PARTS<br />
1 Clean all carburettor components m clean petrol or<br />
cleamng solvent and place m a SUItable clean contamer<br />
2 If compressed au IS avaIlable blow each<br />
component clean when assembhng<br />
NOTE Do notclean lets with Wire dnlls or by any other<br />
mechanical means as onflces may become enlarged causmg<br />
too nch a mIXturefor proper performance<br />
3 Clean away any carbon depOSIts that may have<br />
acc mulated around the throttle valves<br />
4 Discard all used gasket and packmgs<br />
5 Before assembhng check all fuel passages by<br />
blowmg through With compressed aIr<br />
TO SERVICE MAIN BODY<br />
1 Remove the pnmary and secondary mam au bleeds<br />
and emulSIOn tubes<br />
2 Unscrew the two plugs to gam access to the mam<br />
Jets and then remove both mam Jets<br />
3 Remove the prnnary and secondary slow aIr bleeds<br />
and the prnnary and secondary slow Jets<br />
4 Remove the power valve and the vacuum pIston<br />
5 Remove the two screws from the accelerator pump<br />
bore cover and WIthdraw the accelerator pump plunger<br />
assembly Invert the carburettor to remove the bottom<br />
spnng and ball<br />
6 Withdraw the small pm from the pump plunger and<br />
carefully dismantle the pump plunger assembly Note how<br />
components are sItuated before dIsmantling<br />
to facIlitate<br />
correct assembly<br />
7 Unscrew the pump mJector secunng bolt and hft<br />
away the mJector and sealmg washers Invert the<br />
carburettor to remove the weIght and check ball from the<br />
mJector bore
f<br />
COVE<br />
REWS<br />
t<br />
SPRING<br />
DIAPHRAGM<br />
CHAMBER COVER Fuel Systern 12<br />
3S<br />
5F<br />
BALL<br />
i<br />
MOUNTING SCREWS<br />
SPRING<br />
GASKET<br />
Dismantled View of Secondary Throttle Vacuum Chamber Assembly DCK306 Carburettor<br />
8 Remove the fuel return assembly where fitted to<br />
gam access to the needle valve and seat and then With a<br />
correct fittmg nng spanner unscrew and remoYe the needle<br />
valve and seat assembly<br />
9 Remove the float chamber cover secunng screws<br />
and detach the chamber cover glass and gasket Withdraw<br />
the spacer and then the float from the float chamber<br />
10 Unscrew the three screws which secure the<br />
secondary throttle vacuum chamber assembly to the<br />
carburettor malO body and detach the assembly and gasket<br />
1 1 If necessary dIsmantle the vacuum chamber<br />
the three screws at the outer cover<br />
assembly by remoVIng<br />
separatmg the two portIOns of theassembly and then takmg<br />
out the diaphragm spong andcheck ball and spong<br />
NOTE Only dISmantle the vacuum chamber assembly Iflt<br />
IS thought that the diaphragm or spnng IS unserviceable<br />
12 If the fuel return system was operating correctly<br />
before dismantlIng the carburettor then do not dismantle<br />
the assembly If on the other hand a malfunction was<br />
eVident m the assembly then dtsmantle the assembly but<br />
leave the bl metal portIon mtact<br />
13 Now that the malO body IS dismantled check all<br />
components for serviceabilIty and make replacements as<br />
found necessary<br />
14 Reassembly IS a revenal of the removal<br />
procedure<br />
See relevant followmg sections for float level and other<br />
necessary adjustments<br />
TO SERVICE TOP COVER<br />
The carburettor top cover which houses the choke<br />
valve and shaft assembly nonnally reqwres very httle<br />
semce Do not remove the choke valve and shaft unless It IS<br />
absolutely necessary<br />
l Mark the choke valve m relation to the cover to<br />
facilitate correct assembly<br />
2 WIth a small file remove the peemng from the ends<br />
ofthe choke valve ret31mng screws<br />
shaft<br />
3 DIsconnect the linkage from the end of the choke<br />
4 With a sUitable screwdnver remove the two choke<br />
57<br />
valve retammg screws and WIthdraw the choke valve<br />
5 Remove the choke valve shaft from the cover<br />
6 Lay a straight edge across the gasket face of the<br />
cover to check for warpage File thecover gasket face back<br />
to a true condItIOn IfexceSSIve<br />
warpage IS eVIdent<br />
7 Reassemble by carrymg out the dIsmantlmg<br />
procedure m reven e WIth attentIon gIven to the followmg<br />
pomts<br />
Check the choke valve for proper operatIon<br />
Instal two new choke valve retammg screws and peen<br />
the ends of the screws to ensure that they wIll not work<br />
loose and fall mto the mductlOn mamfold<br />
TO SERVICE FLANGE<br />
1 Screw out and remove the Idle nuxture adjusting<br />
screw andspnng 2 Remove the throttle adjusting screw and spnng<br />
3 Check the<br />
pnmary<br />
and secondary throttle valve<br />
shafts for wear m the flange body<br />
NOTE If wear IS not evuJent then do notdISmantle the<br />
shaft<br />
assemb zes<br />
4 Mark the pnmary and secondary throttle valve m<br />
conjunction WIth theu respective bores File the peemng<br />
away from the ends of the throttle plate retammg screws<br />
and remove the screws<br />
5 Withdraw both throttle valves and en remove<br />
both throttle shafts from the flange<br />
6 If necessary unscrew the ret31mng nut and remove<br />
the throttle lever etc from the end of the pnmary throttle<br />
shaft Note how components are situated before<br />
dlSmantlmg to ensure correct assembly<br />
7 Inspect the flange for cracks and the gasket<br />
surfaces for mcks or burrs<br />
8 Lay a straight edge across the gasket surfaces ang<br />
check for warp<br />
9 Check the seatmg surface and the thread of the Idle<br />
adJustmg screw for damage<br />
10 Place both prunary and secondary throttle shafts l<br />
and check for<br />
mto thelT respective bores m the flange<br />
excessive clearance Renew the shafts or flange as found<br />
necessary<br />
V l<br />
i<br />
J I<br />
Ifi<br />
i<br />
A
t<br />
1<br />
13 Fuel System<br />
11 Assemble the flange In the reverse order of<br />
removal with attentIon gIven to the following<br />
Adjust the pnmary and secondary valves to close fully<br />
Check both pnmary and secondary throttle valve and<br />
over the ends of the<br />
shafts f6r smooth operatIOn and peen<br />
valve retamlng screws<br />
Turn the Idle adjusting screw and spnng III gently wIth<br />
the fingers untrl It Just seats and then back It off<br />
approxImately 3 turns<br />
Screw the throttle adJustmg screw In two<br />
turns<br />
or three<br />
NOTE The abovementIOned adlustments on the throttle<br />
and Idle screw are only prellmmary adjustments Engrne<br />
Idle mIxture and speed must beadlusted co ectly with the<br />
engrne at operatmg temperature See adjustment sectIOn for<br />
procedure<br />
TO ASSEMBLE<br />
I Assemble the flange wIth a new gasket<br />
onto the<br />
carburettor main body and mstal and tIghten the four<br />
91 ret mlng screws<br />
2 Assemble the top cover to the main body WIth a<br />
nefgaske and mstal and tighten the four retalmng screws<br />
3 onnect up the choke link dunng the above<br />
operatIon<br />
4 Attach the throttle lever return spnng and alsothe<br />
return sprmg for the pnmary to secondary mterlock<br />
mechanISm<br />
5 FIt the accelerator pump actuatmg leyer to the top<br />
cover and mstal the small E cllp to retain the lever<br />
6 Connect up the throttle vacuum chamber<br />
diaphragm rod to the secondary throttle lever<br />
7 Actuate all throttle and choke linkage by hand to<br />
ensure that all mechamsm IS operatmg smoothly<br />
ADJUSTMENTS<br />
Fuel Level Check<br />
NOTE A horrzontallme marked on thefloat chamber glass<br />
indIcates the correct fuel level If the fuel level was co ect<br />
before the carburettorwas removed and dIsmantled and no<br />
new float or needle valve components were fitted dunng<br />
overhaul then It should not be necessary to readlust the<br />
fucl cl<br />
If the float or needle valve and seat assembly was<br />
renewed then It may be necessary to adjust the float to<br />
obtain the correct fuel level<br />
and WIth the float chamber<br />
I As a starting pomt<br />
over glass r moved myert the carburettor and allow the<br />
float seat to rest agamst the needle valve<br />
NOTE If the carburettor IS In posrtJon on the vehIcle then<br />
11ft thefloat wIth the fingers until the needle valve IS closed<br />
to<br />
58<br />
2 Bend the float seat tab gently wIth a paH of<br />
long nosed pliers untIl the upper face of the float IS ill a<br />
honzontal pOSItion<br />
3 Turn the carburettor nght way up or If the<br />
carburettor IS m posItion on the vehIcle allow the float to<br />
settle mto ItS lowered pOSItIOn<br />
4 Now check the effective stroke of the float I e the<br />
dIstance the float seat travels from the float lowered<br />
pOSItIOn to the float raIsed posItIon Travel should be I 0<br />
mm 0 039 m<br />
5 If found necessary bend the float stopper tab WIth<br />
a parr of long nosed pliers untrl the correct travel IS<br />
obtamed<br />
6 Instal the float chamber gasket glass and cover and<br />
fit and tighten the three secunng screws<br />
7 Instal the carburettor run the engme and ch k<br />
the fuel level against the honzontallme on the glass Ifthe<br />
fuel level IS too high or too low then the cover and glass wll<br />
have to be removed and the float seat tab bent agam to<br />
obtam the correct level<br />
NOTE Whenever the float seat tab IS adjUsted then the<br />
float stopper must be adjusted to obtain the co ect<br />
effeLtlve stroke of thefloat<br />
Choke Interlock Adjustment<br />
NOTE When the choke valve IS In thefully closed positIOn<br />
the pnmary throttle valve should be opened 0 72 mm<br />
0283 In whIch WIll constItute a throttle valve opemng of<br />
15 degreesfrom the fully closed pOSitIOn<br />
I Remove the carburettor from the vehlcle as<br />
preVIOusly descnbed<br />
2 Actuate the choke operatmg lever by hand untIl<br />
the choke valve IS m the fully closed J<br />
pOSItIOnif<br />
l<br />
3 a Usmg 072 mm 0283 m diameter rod as a<br />
gauge check the clearance between the phmary throttle<br />
valve and the valve bore<br />
4 If the throttle valve clearance IS larger or smaller<br />
than the gauge rod then carefully bend the choke<br />
connectmg rod wIth a pau of pliers untIl the gauge rod wJI<br />
Just slide neatly between the bore and yalve<br />
Pnmary iid Secondary Throttle<br />
Interlock Opening Adjustment<br />
The secondary throttle valve should commence to open<br />
when the pnmary throttle valve IS opened 56 deg from the<br />
fully closed posItion<br />
This angle can be assessed by posltlonmg a 640 mm<br />
0252 In drameter rod between the pnmary throttle valve<br />
and the valve bore<br />
1 Remove the carburettor from the velucle as<br />
preVIOusly descnbed<br />
2 PosItion a 640 mm 0252 m dIameter rod as<br />
shown m the Illustration between the pnmary throttle<br />
valve and the throttle bore<br />
It<br />
r<br />
kl
CHOKE CONNECTING ROD<br />
072MM 0 Il2B IN 01A ROO<br />
Method of Checking Choke Interlock Adjustment for<br />
DCK306 Carburettor<br />
Me1hod of CheckIng Promary and Secondary Throttle<br />
Interlock Openrng for DCK306 Carburettor<br />
Carburettor Flange wIth Idle MIxture Screw and<br />
Removed Typical of DCK306 Carburettor<br />
59<br />
Fuel Syatem 14<br />
FUEL lEVEL LINE FLOAT SEAT TAB FLOAT STOPPER TAB<br />
V ew of Float Chamber ShOWIng Fuel level line and Float t<br />
j<br />
Adjusting POints DCK306 Carburettor<br />
7t jj<br />
2 in<br />
l<br />
t P<br />
i<br />
IDLE MIXTURE<br />
SCREW<br />
LROTTLE ADJUSTING<br />
SCREW<br />
l<br />
CHOKE CONNECTING<br />
ROD<br />
I<br />
1<br />
I<br />
ft<br />
l<br />
IlW J<br />
A<br />
tt L J1<br />
t<br />
I
t<br />
I5 Fuel SYlltem<br />
closed<br />
3 Ensure that the secondary throttle valve IS fully<br />
4 Bend the adjusting plate m the duectlon requlfed<br />
with a pau of phers untult Just comes mto contact wIth the<br />
actuatmg lever on the pnmary throttle shaft<br />
5 Check the adjustment by Wlthdrawmg the gauge<br />
rod clOSIng both throttle valves and then gradually open<br />
the pnmary throttle valve Via the throttle lever untu the<br />
secondary throttle valve IS Just perrmtted to open In thiS<br />
posItion the gauge rod should Just shde between the<br />
pnmary throttle valve and the pnmary throttle bore<br />
To Adjust IdlIng Speed and Mixture<br />
1 Remove the vacuum access plug from the mlet<br />
mamfold<br />
2 Connect a vacuum gauge With sUItable adaptors<br />
mto the mlet mamfold<br />
DESCRIPTION<br />
The tWIn SU type HJL38W carburettors as fitted to the<br />
sports vemon of the Ll6 engine are of the smgle<br />
Side draught type<br />
A smgle nozzle m each carburettor supphes adequate<br />
nuxtures for all throttle opemngs<br />
The sIZe of the mam au passage over the Jet and<br />
effective area of the Jet IS automatIcally vanable accordmg<br />
to the throttle opemng requued<br />
Fuel from the carburettor bowl IS fed to the Jet and<br />
tube assembly a tapered metenng<br />
3 Connect a tachometer to the Igmtlon con<br />
4 Start and run the engme untu It reaches normal<br />
operatmg temperature<br />
5 Adjust the throttle ullIng screw untn an engine Idle<br />
speed of 600 rpm IS obtaIned on the tachometer<br />
6 Adjust the Ilmg ffiJxture screw untIl the highest<br />
vacuum readmg on the vacuum gauge IS obtamed It may be<br />
necessary to readjust the Idle speed dunng thIS operation<br />
7 Stop the engine and disconnect the vacuum gauge<br />
and tachometer<br />
NOTE An exhaust gas analyser If available can be used to<br />
adjust the mIXture or to check as a comparzson with the<br />
vacuum gauge readmgs<br />
An Optimum mIXture strength readmg IS desued on the<br />
gas analyser at engme Idle Turmng the Idlmg mIXture screw<br />
m a clockwise direction gives a leaner mIXture and<br />
anti clockwise a ncher mIXture<br />
J CAHHlJRETTOR SlJ TPE lI n 18W<br />
needle attached to the<br />
piston works wlthm the upper part of the Jet and governs<br />
the amountof fuel fed to the engme<br />
The piston wluch slIdes wlthm the carburettor top<br />
suction chamber IS cushIOned byra damper The damper<br />
must be checked penodlcally and replemshed WIth hght<br />
engme ou to the level mdlcator hne on the plunger<br />
The spnng loaded needle valve and seat assembly m the<br />
float chamber IS operated by a float and lever wluch<br />
controls the level of the fuel m the float chamber<br />
Although the operation of the SU type<br />
CAP<br />
WASHER<br />
I<br />
Qr<br />
SUCTION CHAMBER<br />
DAMPER PISTON E CLIP<br />
SCREWS JIb l ASHERS<br />
carburettor IS<br />
SCREWS e<br />
0<br />
r<br />
Y WASHERS<br />
SPRING<br />
60<br />
relatively SImple It IS always adVisable to overhaul and<br />
adjust both carburettors together even when only one<br />
carburettor IS found to be unsemceable<br />
TO REMOVE AND INSTAL<br />
I DIsconnect<br />
ventnatlOnhose<br />
the rocker cover to air cleaner<br />
pipe<br />
chambers<br />
2 Remove the au cleaner assembly<br />
3 Remove tIle mlet elbow from each carburettor<br />
4 DISconnect the fuel Inlet pipes and the fuel return<br />
where fitted<br />
5 DIsconnect the choke control cables<br />
6 Remove the fuel overflow pipes from the float<br />
7 Disconnect the throttle hnkage<br />
8 Detach the dlstnbutor vacuum advance pIpe<br />
9 Unbolt and remove each carburettor from the mlet<br />
manIfold DIscard the I<br />
gaskets<br />
InstallatIOn IS a reversal of the removal procedure WIth<br />
attentIon gIVen to the followmg<br />
Use new gasket between the carburettors and Inlet<br />
JET NEEDLE<br />
Exploded VieW of P ston and SuctIon Chamber Aay
mamfolds If necessary scrape the gasket<br />
surfaces clean<br />
makmg sure that no foreign matter IS dropped mto the mlet<br />
mamfold<br />
NOTE It IS good practlce to cover the Inlet mamfold with<br />
rag when the carburettors are removed for overhaul<br />
Check the carburettors for fuel orvacuum leaks<br />
Make the necessary adjustments when the carburettors<br />
are Installed See ADJUSTMENT section for relevant<br />
carburettor adjusting procedure<br />
TO SERVICE<br />
WASHER<br />
MAIN BODY<br />
ET SLEEVE<br />
When overhauling the carburettors several Items of<br />
unportance should be observed to ensure a thorough Job<br />
i All components should be carefully cleaned<br />
swtable solvent and then mspected for damage or wear<br />
2 Use air pressure only to clear the onfices<br />
SET SCREW<br />
In a<br />
3 Replace faulty components with new ones When<br />
checlong components removed from the carburettor It IS at<br />
times very difficult to be sure whether they are satisfactory<br />
for further semce<br />
It IS therefore recommended that In such cases new<br />
components be Installed<br />
4 Always use new gasket lots when overhauling the<br />
carburettors<br />
5 It IS most unportant that the correct fittmg<br />
screwdnvers and spanners be used when servicing the<br />
carburettor<br />
TO DISMANTLE<br />
I Remove the carburettor as prevIOusly descnbed<br />
2 Unscrew the four retaInmg screws and 11ft away the<br />
suction chamber assembly<br />
3 Take out the piSton damper by unscrewmg the cap<br />
located at the top ofthe suctIon chamber<br />
packmg<br />
4 Carefully withdraw the piston spnng<br />
and nylon<br />
washer from the suctIOn chamber<br />
61<br />
i<br />
D<br />
I<br />
JET ADJUSTING NUT<br />
Fuel Sy tem l<br />
NOTE Extreme care should be exercised when<br />
withdrawing the piston to enSUre that the Jet needle IS not<br />
bumped and thus bent It IS therefore recommended that<br />
the SUchon chamber assembly IS laid In a honzontal<br />
posltlon on the work bench to withdraw thepistOn<br />
5 Usmg a SUitable screwdnver loosen thJet needle<br />
lockmg screw a few turns<br />
6 Carefully grasp the Jet needle with a pal of pl1ers<br />
approxunately 2 mm 007 m from ItS shoulder and by<br />
gently pulling and turmng the needle at the same tune<br />
remove the needle from the piston<br />
NOTE Only remove the needle from the piston If It IS<br />
absolutely necessary<br />
7 Disconnect the linkage from the Jet tube and the<br />
fuellme from the float chamber Withdraw the fuel I1ne and<br />
the Jet tube as an assembly<br />
8 Unscrew the Jet adJustmg nut and remove the lock<br />
spnng<br />
9 With a correct fittIng nng spanner remove the Jet<br />
sleeve set screw lj<br />
IO Withdraw the washer and Jet sleeve<br />
J<br />
SCREW<br />
SPACER<br />
WASHER<br />
FLOAT CHAMBER<br />
Float Chamber and Jet Assembly DIsmantled<br />
from Carburettor Mam Body<br />
NOTE As with the Jet needle only remove theJet sleeve If<br />
It IS absolutely necessary<br />
II Remove the four retammg SCrews from the float<br />
chamber cover<br />
12 Lift off the float chamber cover and float lever<br />
together DiScard the cover gasket<br />
13 Invert the carburettor and remove the float<br />
14 Withdraw the hInge pm from the float lever and<br />
remove the float lever<br />
IS Ifthe needle valve and seat assembly was suspect<br />
pnor to overhaul then unscrew theassembly from the float<br />
chamber cover
f<br />
i<br />
I t I<br />
r t<br />
i 7 Frul Sy em<br />
TO ASSEMBLE<br />
CHAMeER COVER<br />
HINGE PIN<br />
Reassembly of the carburettor IS a reversal of the above<br />
procedure but must be used 10 conjunctIon With the<br />
followmg mformatlOn regardmg adjustments<br />
I l To Instal Jet Needle<br />
t<br />
1<br />
I Ensure that the Jet needle locking screw IS<br />
unscrewed enough to allow the Jet needle to be Illstalled<br />
mto the piston<br />
2 Carefully msert the shoulder portIOn of the Jet<br />
needle mto the piston onfice<br />
Method of Installing Jet Needle Accurately to SuctIon<br />
ChamberPiston<br />
FLOAT LEVER<br />
jcet fLOAT<br />
GASkET<br />
Exploded Vum of Carburettor Float Chamber Components<br />
3 PosItIon a steel rule or any other type of SUitable<br />
straight edge across the Jet needle end of the piston as<br />
shown m the illustratIOn<br />
4 RaISe or lower the jet needle untIl the shoulder of<br />
the needle IS abuttmg the straight edge<br />
5 When satIsfied that the needle shoulder IS correctly<br />
posltlOned III relatIOn to the stri1ght edge securely tIghten<br />
the jet needle locking screw<br />
Ensure that a screwdnver Wlth a correct fittmg blade IS<br />
used on I<br />
the screw<br />
NOTE It IS Important that the let needle mstallatlOn IS<br />
carned out accurately on both carburettors otherwIse<br />
Idlmg and other Important carburettor performance<br />
charactenstlcs WIll be adversely effected<br />
To Centre the Jet<br />
I Disconnect the Jet lever rod at the Jet head<br />
2 Disconnect the petrol feed tube at the float<br />
chamber anll wlthdraw the Jet and f ed tube<br />
fro11<br />
the sleeve<br />
Jet<br />
PosItIon of Carburettor Jet Sleeve when Correctly Centred<br />
6L
3 Remove the Jet adJustmg nut and spnng replace<br />
the nut mmus the spnng replace the Jet and petrol feed<br />
tube<br />
4 Screw the adJustmg nut up to Its full extent and<br />
push the Jet head up agamst the adJustmg nut<br />
5 Release the Jet locknut to a pomt where It IS Just<br />
possible to move the Jet sleeve under hght pressure<br />
6 Remove the piston damper and carefully press the<br />
suchon piston and needle down mto the Jet tube One or<br />
two light taps on the carburettor body with the handle of a<br />
screwdnver will help to centre the Jet Tighten the Jet sleeve<br />
locknut<br />
7 Raise the suchon piston Via the hftmg pm and<br />
allow It to fall under ItS own weight If the Jet IS correctly<br />
centred a soft metallic click should be heard as the piston<br />
stop stnkes on the ventun<br />
8 Repeat the test with the m Jet the fully lowered<br />
poslhon If there IS any audible difference m the tone or<br />
mtenslty of the chck m the two positIOns of the Jet It Will<br />
be necessary to repeat the centnng operatIOns until a<br />
sahsfactory positIOn IS obtamed<br />
9 Remove the Jet tube and fuel supply tube assembly<br />
and also the adJustmg nut<br />
IO Replace the spnng and adjusting<br />
the Jet tube assembly Connect the fuel feed tube to the<br />
bottom of the float chamber<br />
To Adjust Float Level<br />
cover<br />
nut and mstal<br />
I Disconnect the fuel pipe at the float chamber<br />
2 Remove the four retammg screws and hft off the<br />
float chamber cover assembly<br />
3 Invert the cover and raise the lever with the fingers<br />
until the lever seat IS Just clear of the needle yalve stem<br />
4 Now carefully lower the lever until the lever seat IS<br />
lust beanng on the needle valve stem<br />
5 In thiS poslhon measure the distance from the<br />
gasket surface of the cover to the lughest pomt ofthe float<br />
lever ThIS wmenslOn should be between 14 and 15 mm<br />
0551 and 0590 m<br />
6 If necessary bend the float lever at the pomt shown<br />
m the illustratIon until the above mentIOned d1ll1enSlOn IS<br />
obtamed<br />
7 Instal the top cover assembly<br />
float chamber<br />
To Adjust Choke Interlock<br />
to the carburettor<br />
NOTE When the choke operatzng lever IS pulled to thefull<br />
out positon the throttle valve should be opened between<br />
06 and 08 mm 0023 and 0 031 zn whIch WIll constitute<br />
a throttle valve opemng angle ot approximately 6 deg from<br />
thefully closed posit on<br />
I Remove the carburettor from the vehicle as<br />
preViously descnbed<br />
r<br />
ojl 1<br />
Ifj<br />
63<br />
Fuel System 18<br />
LEVER BENDING POINT<br />
Carburettor Top Cover Assy ShOWing Float lever to Gasket<br />
Surface DImensIon and lever BendIng POint to Obtain<br />
Correct Float level<br />
2 Actuate the choke operating lever by hand to Its<br />
extreme pullout lumt<br />
3 Usmg a 06 mm 0 023 m wameter gauge check 1<br />
the clearance between the throttle valve and the throttle<br />
bore<br />
4 If the throttle valve clearance IS Iarger or smaller<br />
than the<br />
gauge rod then carefully bend the choke<br />
connecting rod With a pan of swtable pliers until the gauge I<br />
Will Just shde neatly between the throttle valve a<br />
bJ Y ft<br />
u 1<br />
To Adjust Slow Runmng and<br />
Synchromze Carburettors<br />
1 Remove the air cleaner assembly<br />
2 Slacken the throttle shaft mterconnechon and<br />
close each throttle valve by unscrewmg the Idling speed<br />
adJustmg<br />
3 Open each throttle valve by turmng the Idlil1g<br />
screws r<br />
speed adjusting screws m approxunately two complete Vi<br />
turns Tighten the throttle shaft mterconnechon<br />
4 Unscrew the four retalmng screws and hIt away the<br />
suchon chamber and piston assembly of each carburettor<br />
f<br />
NOTE Extreme care should be exerCised when rttlirgaway tt<br />
the assemblIes to ensure that the Jet needles are not<br />
bumped<br />
Lay the suction chamber and pIston assemblIes<br />
honzontally on a work bench until the necessary<br />
adjustments have been made<br />
5 DIsconnect the choke control cables at each<br />
carburettor and screw the Jet adJustmg nuts up or down as<br />
necessary untIl a measurement of 2 5 mm 0098 m IS<br />
obtained between the top of each Jet and the carburettor<br />
bodge<br />
The measurement can be assessed by usmg the depth<br />
end of a pair of Vernier callipers<br />
6 Fit each piston and suchon chamber assembly to<br />
ItS respectiVe carburettor body and Instal and evenly hghten<br />
the attachlOg screws<br />
t<br />
V<br />
l<br />
C
I<br />
0<br />
t<br />
19 Fuel System<br />
7 Check that each piston falls freely on to the<br />
carburettor bndge piece with a distinct metallic chnk when<br />
raISed with the piston hftlng pin situated In the base of the<br />
carburettor<br />
If the above condition does not preva1l the Jet IS off<br />
centre and It will be necessary to centre the Jet as detailed<br />
earher<br />
8 Start the engme and adjust to a SUitable Idhng<br />
speed at operating temperature by turrung each Idlmg speed<br />
screw by an equal amount<br />
9 Synchromze the throttle settIngs by equalIzing the<br />
intensity of the au Intake and a1tenng the Idhng speed<br />
adjusting screws accordingly TJus can be aclueved by<br />
hstenlng at each au Intake In turn uSIng a piece of rubber<br />
tube or a stethescope<br />
10 Adjust the mIXture by turmng the Jet adjusting<br />
nuts by equal amounts either up or down untJI the engme<br />
f J 1S ldhng at a fauly fast even speed WithOUt a1tenng the<br />
t<br />
I<br />
Hlh lg speed adjusting screws<br />
It IS unportant that dunng tIus adjusting operation the<br />
Jet heads are kept In contact With the adjusting nuts<br />
NOTE The uile adJUstmg nuts should not need to be<br />
screwed more than one halfof a turn either way dunng the<br />
adJUSting operatIOn<br />
II If necessary reduce the HlIlng speed by<br />
unscreWing the Idhng speed adjusting screws by equal<br />
amounts<br />
12 Check the mIXture adjustment of each<br />
carburettor In turn starting With the left hand carburettor<br />
by hftlng the piston approxunately 08 mm 0030 In and<br />
holding It In iJus position<br />
I p fl If the speed of the engIne Increases the mIXture of the<br />
n<br />
b ettor IS too nch and It should be re adJusted by<br />
i J<br />
ii<br />
iI l<br />
if<br />
of<br />
F<br />
tuiIjmg the Jet adjusting nut In a clockWIse duection to<br />
obtain a fast even Idle<br />
If the speed of the engine Immediately decreases then<br />
the mIXture IS too weak and the nchness of the mIXture<br />
should be 11lcreased shghtly by turrung the Jet adjusting nut<br />
m an anti clockWise duectIon<br />
The mIXture adjustment of the carburettor bemg<br />
adJust p correct If the engIne speed mcreases shghtly<br />
when the piston IS raised to the above mentIoned checkmg<br />
height 13 Repeat these operations on the nght hand<br />
carburettor and adjust as necessary then follow by<br />
checking the adjustment again on the left hand carburettor<br />
TO RECTIFY PISTON STICKING<br />
Piston sticking IS generally caused by an accumulatIOn<br />
of wrt or gumrmness mfue suction chamber and piston<br />
assembly necessltatmg the removal and cleamng of tIus<br />
assembly<br />
It may be necessary to make a shght re adJustment to<br />
the Idhng speed<br />
The mIXture IS correct when the beat of the exhaust IS<br />
even and regulated A lea cil st 1re will cause megular<br />
mlsfinng of the engIne while a nch mIXture Will cause the<br />
engine to hunt With the probablhty of black exhaust<br />
fumes<br />
14 When satisfied that the carburettors are adjusted<br />
correctly screw In the auxiliary shaft throttle adjusting<br />
screw until the screw end Just contacts the throttle<br />
connecting lever<br />
ClIOKE<br />
O1 ERATING LEVE<br />
JET ADJUSTING NUT<br />
4 CARBURETTOR SERVICE FAUITS<br />
SUT PE ARBURETTOIl<br />
64<br />
y<br />
r<br />
u<br />
1 I<br />
Side VUNV ofrCarburettor Showmg Throttle Choke and Jet<br />
Lmkage<br />
I Remove<br />
chamber<br />
the piston damper from the suctIon<br />
2 Mark the suctIon chami ier and carburettor body<br />
remove the suction chamber attaclung screws and 11ft off<br />
I<br />
the suctIon chamber and piston assembly from the<br />
carburettor body<br />
l 4 t
3 Remove the piston and needle assembly from the<br />
suction chamber bore and take off the damper spnng and<br />
washer Handle the piston assembly carefully to avoid<br />
bendmg the needle Do not stretch or alter the tensIOn of<br />
the damper spnng m any way<br />
4 Clean all parts thoroughly m petrol or solvent and<br />
blow dry With compressed au Do not use emery cloth or<br />
any sundar abraSive on the suctIOn chamber bore or the<br />
piston 5 POSitIOn the damper sprmg and washer on the<br />
piston rod lubncate the piston rod spanngly with one or<br />
two drops of hght engme oil and msert the piston assembly<br />
mto the suction chamber bore<br />
6 Fit the suctIOn chamber and piston assembly to the<br />
carburettor entenng the needle m the Jet align the marks<br />
made on dlsmantlmg and fit the retammg screws Raise the<br />
piston and needle and tighten the screws Check that the Jet<br />
IS centred and that the suction chamber SitS squarely on the<br />
carburettor body<br />
7 Pour the recommended amount of hght engIne 011<br />
mto the top of the piston rod and replace the piston<br />
damper tlghtemng the nut firmly<br />
TO RECTIFY FLOAT NEEDLE STICKING<br />
A sticking float needle IS generally indicated by a lack<br />
of fuel m the float chamber proVided<br />
of course the fuel<br />
pump IS dehvenng an adequate supply of petrol when the<br />
dehvery pipe IS disconnected at the carburettor<br />
Float needle IS stIcking usually caused by a gnt or<br />
foreign matter In the needle and seat assembly<br />
DESCRIPTION<br />
or b a<br />
The fuel pump IS a mechanically operated diaphragm<br />
type actuated by a rocker rIl lIsembly which m turn IS<br />
operated by an eccentnc on the front of the engIne<br />
camshaft<br />
When the carburettor float chamber IS full and the<br />
carburettor needle valve IS closed pressure m the pump<br />
outlet pipe will hold the pump diaphragm downwards<br />
agamst the pressure of the waphragm spnng<br />
At thiS time the rocker arm assembly will run freely on<br />
the diaphragm shaft until the pressure m the outlet pipe IS<br />
reheved<br />
When the outlet pipe pressure IS reheved the pump<br />
diaphragm agam nses under pressure from the diaphragm<br />
spnng and mto operation by the rocker armassembly<br />
A<br />
spnng<br />
holds the rocker armm constant contact With<br />
the eccentnc on the camshaft to mmlmlSe operatmg nOISe<br />
A seal wluch runs on the diaphragm shaft and wluch IS<br />
retamed m the fuel pump lower body by the diaphragm<br />
spnng prevents engine oil from entenng the upper sectIOn<br />
of the pump lowerbody<br />
Fuel System 20<br />
defectIve needle valve and seat assembly To rectify proceed<br />
as follows<br />
5 FUtl P J IP<br />
6S<br />
Disconnect the fuel dehvery pipe and remove the float<br />
chamber cover Remove the needle and seat assembly from<br />
the cover Usmg compressed a r blow through the needle<br />
valve and seat assembly and the passage m the cover<br />
Remove the float and blowout the float chamber<br />
To aVOid a recurrence 01 the trouble It IS usually<br />
necessary to dram and flush the fuel tank clear the fuel<br />
filter and blowout the fuel hnes<br />
If necessary renew the needle valve and seat assembly<br />
and check the float level<br />
TO RECT FY FLOAT CHAMBER FLOODING<br />
Float chamber floodmg IS mdlcated by fuel leakage<br />
from the dram hole m the float chamber cover and IS<br />
usually caused by gnt or foreign matter between the float<br />
needle and ItS gUide<br />
To rectify proceed as for aIn TO RECTIFY FLOAT<br />
NEEDLE STICKING<br />
TO RECTIFY JET BLOCKAGE<br />
w<br />
Ii lt<br />
To check for raise Jet blockage the suctIOn plSt l<br />
flood the carburettor and watch the Jet Absence of a f e<br />
l lt<br />
flow of petrol will mdlcate a blockage proVided the fU<br />
t<br />
pump IS dehvenng fuel to the float chamber<br />
To clean the blockage start the engIne open the<br />
throttle and block off the carburettor au Intake<br />
momentanly With the hand until the engIne starts to race<br />
If thiS fails to clear the blockage then the Jet will have<br />
to be removed for clearung<br />
The rubbensed fuel pump diaphragm IS supported by<br />
two metal diSCS and IS speCially treated so that It IS not<br />
effected by gasohne<br />
UPPER BODY TOP COVER INLET CONNECTION<br />
r<br />
ld<br />
tf<br />
t<br />
J<br />
11<br />
1I<br />
I<br />
2
21 Fllel System VALVE<br />
TOP COVER<br />
i I flit<br />
SCREWS<br />
GASKET<br />
TO REMOVE AND INSTAL<br />
I RaISe the engIne bonnet and fit fender covers to<br />
both front fenders<br />
2 Disconnect the fuel Inlet and outlet pipes at the<br />
fuel pump connectIOns<br />
3 Remove the two nuts and spnng washers wluch<br />
secure the fuel pump to the cyhnder head and withdraw the<br />
fuel pump With spacer and gaskets<br />
NOTE Dunng operatIOn 3 loosen the nuts progressrvely<br />
until pressure of the dliIphragm and rocker ann Spring IS<br />
relleved<br />
InstallatIOn IS a reversal of the removal procedure with<br />
attentIOn to the follOWing<br />
Instal new gaskets to both Sides of the fuel pump<br />
spacer<br />
Ensure that all traces of old gasket are removed before<br />
the new gaskets are fitted and the pump Installed<br />
A smear of JOlntmg compound apphed to both Sides of<br />
the gaskets Will help sealing<br />
TO DISMANTLE<br />
1 Remove the fuel pump from the engine as<br />
prevIOusly descnbed<br />
2 Actuate the rocker arm by hand and expel all fuel<br />
out ofthe pump Into a SUitable contamer<br />
3 Remove the pump top cover retalnmg screws and<br />
detach the top cover and gasket<br />
NOTE Five screws secure the top cover to thepump upper<br />
body four around the periphery and one In the centre<br />
4 With the comer of a file mark the assembled<br />
pOSItion of the upper and lower body sectIon of the pump<br />
to facilitate correct assembly<br />
5 Remove the nng of screws from the pump upper<br />
body and separate the two pump body sectIOns<br />
6 Mark or note the posItion of the uilet and outlet<br />
valves In relatIOn to the pump upper body sectIOn<br />
7 Remove the two screws from the valve retainer and<br />
take out the retamer valves and gaskets Discard the<br />
gaskets 8 Press down on the diaphragm and by using a probe<br />
and working through the rocker arm aperture In the pump<br />
66<br />
BALLS<br />
Exploded View of Fuel Pump Components<br />
ROCKER ARM<br />
lower body unhook the diaphragm stem from the end of<br />
the rocker arm<br />
9 Withdraw the waphragm and hft off the diaphragm<br />
spnng<br />
take out the seal retamer and Withdraw the<br />
diaphragm stem oil seal from the pump lower body<br />
I0 Reheve the staking on the rocker arm piVOt pin<br />
balls and With the pump SUitably supported on the piVOt<br />
pm boss m tap one end of the piVOt pin With a pm punch<br />
and remove the ball from the opposite end<br />
Now tap the piVOt pin the other way to remove the<br />
remammg ball and piVOt pm<br />
11 Withdraw the pin punch and hft out the rocker<br />
armand the rocker arm spnng<br />
OUTLET CONNECTION<br />
Fuel Pump Valves Installed to Upper Body<br />
RETAINER SECURING SCREWS
TO CLEAN AND CHECK<br />
1 Wash all component parts thoroughly m cIeamng<br />
solvent<br />
2 Check the<br />
pump dmphragIfl and stem 011 seal for<br />
perforatIon and or detenoratlon<br />
3 Check the valve assembhes and mechanical hnkage<br />
for undue wear<br />
4 USing a SUitable flat surface or surface plate check<br />
the gasket and dmphragIfl surfaces of the three sections of<br />
the pump for distortIOn Rectify by fihng If necessary<br />
5 Renew faulty components as found necessary<br />
NOTE Ifa fuel pump has seen consuierable servIce and IS<br />
dIsmantled for repair or inspectIOn It IS adVIsable to fit a<br />
repaIr kit whIch Includes diaphragm seal valves and gasket<br />
ThIS WIll ensure a thorough lob and further trouble free<br />
servIce for the unit<br />
TO ASSEMBLE<br />
Assembly IS a reversal of the dlsmanthng procedure<br />
With attention to the follOWing<br />
Ensure that the valve assembhes are Installed correctly<br />
In then respective seats and that each valve IS fitted With a<br />
new gasket<br />
Lubncate the mechamcal hnkage and the diaphragm<br />
stem With engIne 011 when assembhng<br />
FUEL PUMP PRESSURE TEST<br />
NOTE The fuelpump can be checked for delivery pressure<br />
In the followlnlf manner<br />
1 Disconnect the fuel feed pipe at the carburettor<br />
2 Fit a T fitting to the fuel feed pipe and from one<br />
Junction connect a pipe back to the carburettor<br />
Fuel System 22<br />
3 Connect a SUitable pressure gauge to the remaining<br />
JunctIon ofthe T piece<br />
4 Start and run the engIne at varying speeds<br />
obserVIng the pressure reawngs on the pressure gauge<br />
Check the speCifications In the front of the sectIOn to<br />
compare recommended pressures With pressure readings<br />
A fuel pump that has a dehvery pressure above or<br />
below that recommended IS unserVIceable and should be<br />
removed and dismantled for inspectIOn<br />
NOTE ExcessIvely hIgh pressures usually indIcate that an<br />
Incorrect dlllphragm spnng has been fitted to the pump or<br />
that thediaphragm IS pulled too tIght<br />
Low pressures could be caused by worn linkage<br />
perforated dIaphragm gummed valves or<br />
dIaphragm spnng<br />
FUEL PUMP CAPACITY TEST<br />
a weak or broken<br />
NOTE ThIs test should only be camed out If the pump<br />
pressure was checked and found to be within speCIficatIOns<br />
1 Run the engine for a few mmutes to ensure that<br />
the carburettor float chamber IS full offuel<br />
2 Stop the engIne and disconnect the fuel pump<br />
dehvery pipe at the carburettor<br />
3 Position a measunng beaker under the<br />
pipe and<br />
start and run the engIne at 1000 rpm for one rmnute<br />
4 Stop the engIne and check the amount of fuel In<br />
the beaker<br />
5 If the capacity of fuel dehvered In the beaker IS<br />
below that speCified see SPECIFICATIONS then either a<br />
partial blockage In the system may be eVident or the pump<br />
IS unsemceable Check the conditIOn of the fuel filter and<br />
blowout the fuel hnes before remoVing the pump for<br />
inspectIOn<br />
Timing Cover Removed ShOWing Fuel Pump Oriye Arrangement<br />
67<br />
FUEL PUMP ACTUATING CAM<br />
SPROCKET RETAINING BOLT
23 Fuel System<br />
DESCRIPTION<br />
The au cleaner assembhes on all models covered In thiS<br />
manual are fitted With VISCOUS paper type elements<br />
The elements should not be cleaned In semce but<br />
should be renewed at the recommended mIleage of40 000<br />
kilometres 24 000miles<br />
ThIS mIleage IS only a gUide for normal operatIng<br />
conditions and should be reduced accordingly If the vehicle<br />
IS operating under extremely dusty conditIOns<br />
On later type L14 and L16 engInes a thermostatic au<br />
bleed deVice IS Installed to the au cleaner assembly and<br />
replaces the fuel return system<br />
earher models<br />
wuch was fitted to some<br />
A by metal valve situated In the au cleaner assembly<br />
opens when the engIne temperature nses above 52 deg C<br />
126 deg F and allows fresh auto flow from Within the au<br />
cleaner body Via a connecting tube Into the Inlet mamfold<br />
The umt IS factory set and should not be dISmantled In<br />
semce If a malfunctIOn occurs then renew the umt<br />
l<br />
WING NUT<br />
WASHER<br />
PAPER ELEMENT<br />
THERMOSTATIC AIR BLEED VALVE<br />
8 Am CLEtNER<br />
CLEANER MAIN BODY<br />
ASSY BRACKET<br />
Exploded View of <strong>1600</strong> Engine Later Type Air Cleaner<br />
Assembly Single Application<br />
68<br />
TO REMOVE Smgle ApplIcation<br />
I Detach the rocker cover to au cleaner ventJIatlon<br />
hose and the thermostatIc au bleed hose where fitted<br />
2 Loosen the au cleaner assembly thumb screw<br />
remove the two bolts wluch secure the au cleaner assembly<br />
bracket to the mlet manifold and remove the au cleaner<br />
assembly<br />
3 Unscrew the wing nut and remove the top cover<br />
from the au cleaner main body and Withdraw the paper<br />
element<br />
TO REMOVE TWIn ApplIcation<br />
I Remove the two thumb screws from the au cleaner<br />
cover and hft off the cover<br />
2 Withdraw the paper element from the maIn body<br />
of the au cleaner<br />
3 Disconnect the rocker cover to au cleaner<br />
ventilation hose<br />
4 Remove the four bolts wluch secure the mam body<br />
of the au cleaner to the carburettor flanges<br />
5 Detach the au cleaner main body With gaskets<br />
from the carburettor flanges<br />
TO INSTAL Smgle ApphcatIon<br />
I With a piece of clean cloth thoroughly wipe<br />
accumulated dust away from the inSide of both portions of<br />
the aJr cleaner assembly<br />
2 Place the paper element Into the au cleaner body<br />
and centre It on ItS seat<br />
3 PosItion the au cleaner top cover on to the mam<br />
body and mstal and tIghten the wing nut<br />
4 Instal the au cleaner assembly to the carburettor<br />
5 Fit and tIghten the two au cleaner to mlet<br />
mamfold bracket bolts<br />
6 Securely tighten the thumb screw by hand only<br />
wuch IS situated at the base of the au cleaner assembly<br />
7 Connect the rocker cover to au cleaner ventilatIOn<br />
hose and<br />
Where fitted the thermostatic au bleed hose<br />
TO INSTAL Twin ApplIcatIon<br />
I With a piece of clean cloth thoroughly wipe<br />
accumulated dust away from the inSide ofboth portIOns of<br />
the au cleaner assembly<br />
2 Instal the au cleaner mam body With gaskets to<br />
the carburettor flange and fit and tighten the four secunng<br />
bolts<br />
hose<br />
3 Connect the rocker cover to crankcase ventilatIOn<br />
4 Place the paper element Into the au cleaner body<br />
and centre It on ItS seat<br />
5 PosItion the au cleaner top cover on to the mam<br />
body and Instal and tIghten the two thumb screws
TO REMOVE AND INSTAL<br />
container<br />
1 Drain the contents of the tank Into a sUitable<br />
2 Remove the rear seat and squab<br />
3 Remove the tnm board<br />
4 Raise the luggage compartment hd and remove the<br />
luggage compartment finisher board<br />
5 Disconnect the fuel gauge sender umt Wlfes<br />
6 Loosen the chp and disconnect the fuel fill hose<br />
7 Disconnect the fuel feed pipe and where fitted the<br />
fuel return pipe<br />
8 Remove the fuel tank retaining bolts and Withdraw<br />
the tank<br />
NOTE On statIOn wagons the fuel tank can be readily<br />
removed from underneath the vehicle by dlsconnectmg the<br />
I Engme W1l1 not start<br />
a<br />
POSSible cause<br />
Lack of fuel In float bowl<br />
b Engine flooded With fuel when cold by<br />
of choke or accelerator<br />
c EngIne flooded when hot as In b above<br />
2 EngIne stalls at idling speed<br />
POSSible cause<br />
a Incorrect adJustment of Idhng speed<br />
b Carburettor float bowl flooding<br />
c Carburettor stamng for fuel<br />
d Blocked Jet SU type carb<br />
e Blocked Idhng tube jet on Idle air bleed<br />
7 FUEl TANK<br />
FILel System 24<br />
necessary pipes and sender umt Wires removing the four<br />
secunng bolts and lowenng the tank to the floor<br />
9 If necessary remove the fuel gauge sender umt and<br />
discard the gasket<br />
NOTE It IS extremely Important that the fuel tank be<br />
steamed cleaned or otherwise rendered gasfree IfrepaIrS are<br />
to be earned out on the tank<br />
Installation IS a reversal of the removal procedure With<br />
attention to the followmg<br />
If the gauge sender umt was removed then Instal a new<br />
gasket when refitting the umt<br />
Check the pipe<br />
connections for leaks after the tank has<br />
been refilled With fuel<br />
8 FUEL SYST IFAUI T DIAGNOSIS<br />
excessive use<br />
and or mixture<br />
conventIOnal type carb<br />
f Leaking at carburettor or flange Intake mamfold<br />
gasket<br />
g Carburettor to mamfold attachment boltsloose<br />
h Faulty gasket or loose attachment screws<br />
carburettor main body to top cover assembly<br />
conventIonal type carb<br />
3 Flat spot on acceleratIon<br />
POSSible cause<br />
a Metenng needle blnd1ng SU type carb<br />
b StIcking piston SU type carb<br />
Remedy<br />
Check fuel delivery stIcking or clogged needle<br />
valve<br />
Contmued next page<br />
69<br />
Hold accelerator flat until engine starts and<br />
revise starting procedure<br />
Hold accelerator pedal flat untIl engine starts<br />
Remedy<br />
AdJust Idle speed and check mixture<br />
Check float level and for stIcking needle valve or<br />
punctured float Clean and blowout carburettor<br />
Check fuel dehvery at needle valve Clean and blow<br />
out carburettor Check fuel pump<br />
See carburettor semce fault sectIOn<br />
Clean and blowout carburettor<br />
Check and renew faulty gaskets<br />
Check and tIghten bolts<br />
Renew faulty gaskets and tighten secunng screws<br />
Remedy<br />
Centre Jet<br />
See Carburettor service fault sectIOn
25 Fllel System<br />
c<br />
Bent worn and or damaged metenng needle or Jet<br />
SU type carb<br />
d Blocked accelerator pump dIScharge Jet or stl klng<br />
check valve conventIOnal type carburettor<br />
e Faulty accelerator pump hnkage conventIonal type<br />
carburettor<br />
4 Engine misfues or cuts out at high speed<br />
a<br />
Possible cause<br />
Low fuel level In float chamber or starving for<br />
fuel<br />
b Fa1Iure of fuel pump to dehver sufficient fuel<br />
c Blockage In fuel filter<br />
d Au leakbetween fuel pump and tank<br />
e Water In carburettor<br />
f ObstructIon In malO or power Jet ConventIOnal<br />
g<br />
type carburettor<br />
Obstruction In Jet SU type carb<br />
5 ExcessIve fuel consumptIon<br />
Possible cause<br />
a Float level too high<br />
b Air cleanerelement requues renewal<br />
c Fuel pump dehvery pressure too high<br />
d Faulty fuel pump diaphragm<br />
Fuel leak In fuel supply line or damaged tank<br />
e<br />
f Choke valve partially closed ConventIOnal type<br />
carb<br />
g<br />
Worn or damaged Jet s<br />
h ExceSSIVe use of choke or accelerator pump<br />
70<br />
Renew faulty components<br />
Clean and blowout carburettor<br />
Check and rectIfy hnkage<br />
Remedy<br />
Check float level setting check fuel pump and supply<br />
hnes<br />
Overhaul fuel pump<br />
Renew filter<br />
Rectify<br />
au leak<br />
DraIn and clean carburettor and fuel system<br />
Dismantle and blowout carburettor<br />
See carburettor semce faults<br />
Remedy<br />
Check and readJust float level<br />
Renew element<br />
Overhaul fuel pump<br />
Overhaul fuel pump<br />
Check for leaks and rectIfy<br />
Check and adJust<br />
Check and renew faulty components<br />
ReVise dnvlng habits
Type<br />
OperatIOn<br />
Type of dnven plate hub<br />
Dnven plate<br />
Outside diameter<br />
FaCing thickness<br />
Inside diameter<br />
CLUTCH<br />
SPECIFICATIOXS<br />
Single dry plate Total fnctIon area 362 cm2<br />
Hydraulic<br />
Spnng cusluon<br />
The single dry plate clutch compnses a pressure plate<br />
and cover assembly and a dnven plate assembly<br />
There are two different types of<br />
pressure plate<br />
assemblies fitted Diaphragm and coil spnng types<br />
The coil spnng type pressure plate assembly IS<br />
compnsed of a pressure plate nine coil spnngs With spnng<br />
containers and three release fingers<br />
The three release levers are retained by adJustable<br />
eye bolts and fulcrum pinS and are attached to the pressure<br />
plate and cover<br />
The diaphragm type pressure plate assembly has<br />
eighteen tapered fingers which are Integral With the<br />
diaphragm spnng and mamtaln constant pressure on ItS<br />
pressure plate thus holding the dnven plate to the<br />
flywheel The pressure plate diaphragm and pressure plate<br />
cover are coupled together by nine sprmg setting nvets<br />
The release levers m the pressure plate assembly coil<br />
spnng type are adJustable but they should not reqUire<br />
In serVIce adJustment Release lever adJustment<br />
IS carned<br />
HUB SPLINES<br />
56 II 1n2<br />
Master cylinder diameter 1587 mm<br />
0 625 In<br />
Clutch throw out beanng free travel 23mm<br />
00906 In<br />
200 mm Pressure plate to flywheel bolt torque 2 6 kg m<br />
7874 In 188 ftlb<br />
35mm Pedal pivot bolt torque 4 0 kg m<br />
0137 In 29 0 ft Ib<br />
130mm Clutch pedal free travel 25mm<br />
5lI81n 0 984 m<br />
I DESCRIPTIO1<br />
out dunng mltlal assembly of the<br />
pressure plate<br />
and IS only necessary when the<br />
assembly IS dISmantled for<br />
and cover<br />
reconwtlOnlng The dnven plate has a spnng cushioned<br />
hub spllned to shde on the clutch shaft gear box mput<br />
shaft<br />
The spigot bearing for the clutch shaft gearbox Input<br />
shaft located In the end of the engIne crankshaft IS a<br />
porous bronze bush<br />
The clutch throw out beanng IS a sealed single<br />
thrust type mounted on the beanng sleeve<br />
row ball<br />
The slave cyhnder push rod IS adJustable to proVide<br />
clearance between the throw out beanng and the release<br />
levers also diaphragm fingers With the throw out bearing<br />
In the released pOSItIon<br />
RELEASE FINGER ADJUSTERS<br />
View of Coli Spring Type Pressure Plate Assembly and Pressure Plate Side View of Clutch Plate<br />
71
2<br />
lutch<br />
TO REMOVE AND INSTAL<br />
I Raise the vehicle and remove the propeller shaft<br />
and gearbox as descnbed In the MANUAL TRANS<br />
MISSION sectIOn<br />
2 Mark the pressure plate cover ill relatIOn to the<br />
flywheel so that they may be assembled In then onglnal<br />
posItIons<br />
3 Take out the SIX bolts and spnng washers secunng<br />
the pressure plate assembly to the flywheel releaSing them<br />
evenly and progresSIvely and remove the clutch pressure<br />
plate and cover assembly andclutch dnven plate<br />
Installation IS a reversal of the removal procedure With<br />
partIcular attentIon to the follOWing pOints<br />
Use a speCial ahgnlng tool or used gearbox mput shaft<br />
to align the centre of the dnven plate hub With the spigot<br />
beanng In the rear end of the crankshaft<br />
NOTE The raised Ide of the dnven plate hub must face<br />
the pressure plate<br />
Ahgn the marks on the pressure plate cover and<br />
flywheel made on dismantling<br />
Tighten the SIX secunng bolts evenly and progressIVely<br />
to the speCified torque<br />
If the flexible hydraulic pipe has been disconnected It<br />
Will be necessary to bleed the hydrauhc system<br />
Fill the gearbox With the recommended grade and<br />
quantIty of 011 and ensure that the propeller<br />
2 CLUTCH IJNIT<br />
shaft rear<br />
umversal JOint flange and pinIOn flange are connected to the<br />
marks made on dlsmanthng In order to maintain the<br />
ongInal balance of the shaft<br />
TO CHECK AND INSPECT<br />
I Check that the dnven plate facmgs are not highly<br />
glazed or gummed With burned 011<br />
2 If the dnven plate faCings are worn down to the<br />
nvets tcheck the flywheel and pressure plate faces for wear<br />
and sconng<br />
3 Check the hub of the dnven plate for looseness or<br />
wear In the hub splines Check effectIve actIon of the dnven<br />
plate hub cusluon spnngs<br />
4 Check that the runout of the flywheel face does<br />
not exceed 002 In<br />
5 Check that the mam dnve gearbox Input shaft<br />
spigot beartrJg In the flywheel flange<br />
IS In semceable<br />
conditIon ThiS beanng IS a slntered bronze bush and<br />
reqUires no lubncatlOn In semce<br />
1<br />
6 Check<br />
roughhess<br />
the throw out beanng for nOise or<br />
NOTE When cleamng the clutch parts do notImmerse the<br />
throw out bearmg m cleanmg flUid ThiS bearmg IS<br />
lubncated wh n assembled and reqUires no further<br />
lubncatlon m serVice<br />
7 If the dnven plate IS stili semceable do not allow<br />
any cleaning flUid oil or grease to contaminate the plate<br />
faCings<br />
8 Do not ream the Input shaft spigot bush Apply<br />
hght coating of ugh melting pOint grease to the bore of the<br />
bush before assemb ng the clutch<br />
9 Check the pressure plate and flywheel for ugh<br />
spots glaZing and cracking<br />
If g1azmg and high spots are In eVidence remove the<br />
flywheel from the crankshaft and illsmantIe pressure plate<br />
Machine both surfaces removing equal amount of matenal<br />
View of Cod Spring Type Pressure Plate Assembly and Flywheel Side View of Clutch Plate<br />
72<br />
c<br />
J
from flywheel and pressure plate MaxunWTI amount 1 0<br />
mm 0 039 In<br />
coils<br />
10 Check COIl spnngs for correct tensIOn or broken<br />
HU SPLINES<br />
Clutch 3<br />
I1 01 the diaphragm type pressure plate check<br />
diaphragm spnng for bendmg cracks or fatigued fingers If<br />
any faults are In eVidence the diaphragm spnng should be<br />
replaced<br />
View of Diaphragm Spring Type Pressure Plate Assembly and Flywheel Side V ew of Clutch Plate<br />
TO REMOVE AND INSTAL <strong>1600</strong> Senes<br />
1 Remove the spht pm and cleVIS pin secunng the<br />
master cyhnder push rod to the clutch pedal Remove the<br />
clutch pedal return spnig<br />
2 Disconnect the ftexlble hydrauhc pipe at the umon<br />
on the master cylinder and plug the pIpe to prevent dirt<br />
entenng the hydrauhc system<br />
3 Undo the two bolts and remove the master<br />
cyhnder from the velucle<br />
InstallatIOn IS a reversal of the removal procedure It<br />
will be necessary to bleed the clutch hydraulic system<br />
Ensure that the hydrauhc flUid IS not Spilt on any<br />
lacquered surface<br />
TO DISMANTLE<br />
1 Take off the filler cap and empty flUid from the<br />
master cylinder<br />
2 Pull the rubber boot off the open end of the<br />
cyhnder remove the retaining Clrchp and Withdraw the<br />
push rod and retaining washer<br />
3 Withdraw the piston valve and spnng as an<br />
assembly from the cylinder bore<br />
4 Remove the spnng spnng retaIner valve stem<br />
Inlet valve spnng and valve seal from the end of the piston<br />
r<br />
I IASTEH VLINDER<br />
73<br />
stem<br />
5<br />
6<br />
piston<br />
Remove the valve seal from the spigot on the valve<br />
Remove the piston seal over the spigot end of the<br />
TO CLEAN AND INSPECT<br />
I Thorougl1ly clean the master cyhnder components<br />
and the inSIde of the master cylinder bore With methylated<br />
spmts Do not use petrol or other ITIlneral spmts<br />
2 Check the inSide of the bore for wear and or<br />
plttmg Ifnecessary hone the cyhnder bore<br />
3 Check the piston for wear and renew the piston<br />
seal and valve seal Check the valve spnng tensIOn<br />
4 Renew the rubber boot If It shows SignS of<br />
deteno atlon<br />
of dut<br />
5 Check that the breather hole In the reservolf IS free<br />
6 Remove any sewment that may have accumulated<br />
In the bottom of the reservolf<br />
TO ASSEMBLE<br />
i<br />
I Dip the master cylInder components In a container<br />
of clean hydrauhc flUid and Instal the new seal on the<br />
4 1<br />
o<br />
I
N<br />
I<br />
0<br />
4Clutch<br />
pIston With the hp of the seal faCing the spIgot end of the<br />
piston<br />
2 Ensure that the seal IS seating correctly<br />
SNAP RING SECONOARY CUP<br />
PUSH ROD ASSY<br />
I<br />
In the<br />
groove on the piston<br />
3 Place the valve spnng on the valve stern so that the<br />
tapered end IS fitting against the shoulder of the valve stem<br />
flange 4 Instal the valve seal on the valve stem so that the<br />
hp faces the bhnd end of the cyhnder<br />
5 Shde the valve spnng retainer over the valve stem<br />
6 Fit the return spnng to both retamers compress<br />
the spnng and valve assembly and couple the valve stem to<br />
the piston<br />
7 Dip the piston and valve assembly m clean<br />
hydrauhc brake flwd msert the assembly In the bore ofthe<br />
master cyhnder valve end first taking care that the hp of<br />
the piston seal IS not turned back or damaged and push the<br />
assembly In until the end of the plston is<br />
below the end of<br />
the cyhnder bore Hold In thiS position<br />
8 Insert the ball end of the push rod to hold the<br />
piston assembly against the pressure of the return spnng<br />
position the retaining washer and Instal the cuchp to the<br />
groove In the end of the cylinder to secure the assembly<br />
Ensure that the clrclIp IS correctly seated In the groove<br />
9 Draw the rubber boot over the push rod and<br />
pOSItIOn the large end of the boot over the master cyhnder<br />
Ensure that It IS seating correctly<br />
IO Pour a small quantity ofclean hydraulic flUid Into<br />
the master cyhnder reservOIr Instal the reservolf cap and<br />
pump the master cyhnder push rod until the flUid begIns to<br />
emerge from the cyhnder outlet ThIS should reqUire<br />
approxunately five or SIX strokes ofthe piston<br />
TO REMOVE AND INSTAL <strong>1300</strong> Sene<br />
1 Removal and Installation procedure IS the same as<br />
for the <strong>1600</strong> senes except that<br />
spacer<br />
shuns are mounted<br />
between the cyhnder flange and the fire walls<br />
TO DISMANTLE<br />
I Take off the filler cap and empty flwd from the<br />
master cyhnder<br />
2 Pull the rubber boot off the open end of the<br />
cyhnder remove the retalnmg cuchp and Withdraw the<br />
push rod and retaining washer<br />
PR7ARY<br />
CUP<br />
lJ e<br />
CAP<br />
RESERVOIR<br />
0<br />
CLIP<br />
INLET VALVE ERBOOY<br />
PIlTON R TAINER I INLET VALVE SPRING<br />
SPtNG<br />
3 Remove the piston stop screw from the body of<br />
the master cyhnder and Withdraw the piston assembly<br />
pnmary cup and return sprmg assembly<br />
4 Remove the return spnng from the spnng retainer<br />
hft the spnng retainer from the sphned spigot on the end of<br />
the piston and take out the spnng and the wet valve Take<br />
care not to lose the Inlet valve spnng<br />
5 Remove the seal from the Irllet valve and remove<br />
the piston seals from the piston assembly<br />
TO CLEAN AND INSPECT<br />
I Thoroughly clean the master cyhnder components<br />
and the Inside of the master cyhnder With methylated<br />
spmts<br />
2 Check the inSide of the bore for wear and or<br />
pitting If necessary hone the bore<br />
3 Check the piston groove and piston body for wear<br />
and renew the piston seals Check the valve spnng ten lOn<br />
4 Check the tensIOn ofthe piston return spnng<br />
5 Renew the rubber boot If It shows signs of<br />
detenoratlon<br />
6 Check the breather hole In the reservou to ensure<br />
that It IS clear<br />
7 Remove any sedunent that may have accumulated<br />
m the bottom of the reservoir<br />
TO REASSEMBLE<br />
I Dip the master cyhnder components<br />
In a contamer<br />
of clean hydrauhc flUid and Instal the new seals on the<br />
piston ensunng that the seals are seated correctly<br />
and the<br />
hp IS faCing the spigot end of the piston<br />
2 Place the Irllet valve seal on the Irllet valve With the<br />
hp faCing the piston assembly<br />
3 Place the Irllet valve sprmg With the tapered end on<br />
the face of the Inlet valve flange and press the spnng<br />
retamer down over the sphned end of the piston assembly<br />
and secure<br />
Exploded View of Early Type Clutch Master Cyhnder<br />
r<br />
74<br />
0 WASHER<br />
SEALING RING 0<br />
b<br />
SToP SCREW
4 Place the pIston return spnng over the spnng<br />
retainer dip the cyhnder In hydrauhc flUid and Instal the<br />
spnng and piston assembly Screw In ttIe uIlet valve release<br />
pin<br />
CYLINDER BODY<br />
C CAP<br />
SEAL<br />
C FLOAT<br />
tRESERVOIR<br />
CLIP<br />
TO REMOVE AND INSTAL<br />
SPRING<br />
STEM AND SEAL<br />
SPRING<br />
mOOO 090QfO rJfJ<br />
SPRING RETAINER<br />
1 Unhook and remove the clutch throW Qut lever<br />
return spnng between the throw out lever and the lug on<br />
the slave cyhnder<br />
2 Disconnect the fleXible hydraulic pipe at the slave<br />
cyhnder and plug the pipe to prevent loss of flUid and entry<br />
of dut<br />
3 Remove the two bolts attaching the slave cyhnder<br />
to the clutch hOUSing and remove the slave cyhnder from<br />
the vehicle<br />
4 Draw back the slave cyhnder rubber boot remove<br />
the retaining chp and Withdraw the piston from the slave<br />
cylinder<br />
InstallatIon IS a reversal of the removal procedure With<br />
particular attentIOn to the following pOints<br />
Ensure that the slave cylinder assembly IS correctly<br />
PISTON AND SEAL<br />
Clutch5<br />
5 Insert the push rod push In and Instal the retaining<br />
washer cuchp and rubber boot<br />
6 Partially fill the reservoir With clean hydrauhc flUid<br />
and pump the push rod until flUid emits from the cylinder<br />
outlet<br />
7 Fit the master cyhnder to the velucle and ensure<br />
that the correct number of spacer shims arefitted between<br />
the master cyhnder retaining flange and the fire wall to<br />
aclueve correct pedal clearance<br />
8 Bleed the master cylinder<br />
for the <strong>1600</strong> senes<br />
PUSH ROO<br />
0<br />
WASHER<br />
Exploded View of Late Type Clutch Master Cyhnder<br />
n<br />
ftf DUSTCOVER<br />
4 SLAVE VLINDER<br />
J i<br />
PISTOt SEAL<br />
Exploded View of Clutch Slave Cyhnder Components<br />
75<br />
In the same manner as<br />
CIRCLlP CLEVIS<br />
NUT<br />
OC<br />
TO CLEAN AND INSPECT<br />
I<br />
Ct o<br />
BOOT<br />
j<br />
CIJ<br />
located on the nght Side of the clutch hOUSing and that the<br />
rubber boot IS correctly fitted over the open<br />
cylinder body<br />
end of the<br />
It Will be necessary to bleed the clutch hydraulic<br />
system and adJust the clutch throw out lever free travel as<br />
detailed In the speCificatIOn sectIOn<br />
TO DISMANTLE<br />
1 With the slave cyhnder removed from the vehIcle<br />
apply a low air pressure to the hydrauhc pipe hole In the<br />
bhnd end of the cyhnder to remove the pIston and seal<br />
from the cyhnder bore<br />
2 If the piston seal IS to be removed ease the seal out<br />
of the groove and off the small end of the pISton<br />
3 If necessary unscrew and remove the bleeder valve<br />
and dust cover<br />
I Clean and wash all parts m methylated spmtlf Do<br />
not use petrol or mineral solvents for thiS purpose<br />
2 Check the bore of the cyhnder for wear or pitting<br />
Hone If necessary and fit ovefSlze seal on reassembly<br />
3 Check the pISton for wear scores and pitting and<br />
renew as necessary<br />
4 C heck the piston seal and rubber boot for wear and<br />
detenoratlon and renew as necessary<br />
5 Check the cyhnder retalnmg chp and renew Ifweak<br />
or worn m the cyhnder groove<br />
ii
I<br />
6Clutch<br />
TO REASSEMBLE<br />
1 Dip the piston and piston seal In clean hydrauhc<br />
flUid and Instal the seal on the piston easmg It Into the<br />
groove so that the hp of the seal faces the spigot end of the<br />
piston Ensure that the seal IS correctly seated m the<br />
groove<br />
2 Screw In the bleeder valve but do not tighten past<br />
finger tight<br />
TO BLEED<br />
I Remove the cap and fill the flUid reservou With<br />
clean hydrauhc flUid to Within approxunately half an Inch<br />
ofthe reservolf top<br />
2 Attach a bleeder tube to the bleeder valve on the<br />
slave cylinder and Immerse the other end of the tube m a<br />
glass container partially filled With hydrauhc flUid<br />
3 Open the bleeder valve approxunately one turn<br />
plJmp the clutch pedal slowly until all au IS expelled from<br />
TO RENEW<br />
1 Remove the gearbox and clutch bell hOUSing<br />
assembly as preViously descnbed<br />
2 Remove the rubber dust excluder from the end of<br />
the throw out lever andthe aperture In the bell hOUSing<br />
3 Remove the retaining spring from the throw out<br />
lever piVOt pm and lever Withdraw the throw out bearing<br />
and lever assembly off the front end of the Input shaft<br />
beanng retainer and remove from the bell hOUSing<br />
4 Remove the hnk from between the throw out<br />
beanng and the beanng lever by slidmg out the beanng<br />
from between the two components<br />
5 Remove the retammg spnng attaclung the<br />
hub<br />
throw out beanng to the lever<br />
6 Remove the throw out beanng from the bearing<br />
7 Clean all components In a SUitable cleanmg solvent<br />
and allow to dry Do not unmerse the throw out beanng In<br />
the solvent If It IS to be used again<br />
8 Instal the throw out bearing on the bearing hub so<br />
that the thrust face of the beanng IS faCing away from the<br />
lever end ofthe hub<br />
NOTE There are two types of throwout beanngs utllzsed<br />
for clutch release operatIOn and extreme cautIOn mu t be<br />
exercised when fitting the throw out beaTIng to the bearing<br />
hub<br />
When fitting the bearing for the COil spnng type<br />
pressure plate the pressure must be applied to the surface<br />
of the Inner race<br />
3 Insert the piston and seal assembly spigot end of<br />
the piston first In the bore of the cyhnder taking care not<br />
to bend back or damage the hp of the seal<br />
4 If the slave cyhnder IS not to be fitted to the<br />
vehicle munewately fit the rubber boot to the open end of<br />
the cyhnder as a guard against the pISton falling out of<br />
pOSitIon or entry of wrt<br />
5 HYDRAUUC SYSTEM<br />
the system I e until orily flUid free of au bubbles emerges<br />
from the free end of the bleeder tube<br />
NOTE Dunng the above operatIOn It IS Important to allow<br />
the pedal to return slowly to aVOId draWing air Into the<br />
system and to maintain the fluui level to at leasthalfway In<br />
theflUid reservOIr<br />
4 Close the bleeder valve remove the bleeder tube<br />
and top up the master cylinder reservolf to Within<br />
approximately half an Inch ofthe fillerneck<br />
6 CLUTfH THROW OUT BEAIUNt<br />
7 6<br />
Clutch Release Components Installed to Transmission Bell<br />
HOUSing
When fitting the bearing to the beaTIng hub for the<br />
dlllphragm type pressure plate the pressure must be applied<br />
to the outer raceofthe throw out beanng<br />
Unless thIS procedure IS adhered to the bearing WIll be<br />
damaged and WIll have to be replaced<br />
9 Hold the throw out lever In a Vice and fit the<br />
throw out beanng and retaining spnng<br />
TO REMOVE INSTAL AND ADJUST<br />
DUST EXCLUDER<br />
I Disconnect and remove the clutch pedal return<br />
spnng For coil type pressure plate loosen offrod adJuster<br />
pnor to removal of return spnng<br />
2 Remove the spht pin and cleVIS pin secunng the<br />
clutch master cylinder push rod to the clutch pedal<br />
3 Remove the pedal lever retalnmg bolt loosen the<br />
handbrake retamlng bolts and withdraw the clutch pedal<br />
4 Check the pedal bush and piVOt pm for wear and<br />
the tensIOn ofthe return spnng<br />
5 If necessary remove the old bush and uSing a<br />
shouldered type dnft of the correct Size Instal a new bush<br />
Ream the new bush to the correct sIZe to receive the pin<br />
6 Lightly apply high melting pOint grease to the<br />
pedal bush and piVOt pin and Instal the pedal on the piVOt<br />
pin Secure the piVOt pin<br />
7 Replace the cleVIS pin In the hole of the push rod<br />
and clutch pedal and secure With a spht pin<br />
10 Fit the lever to the pivot pin<br />
Clutch 7<br />
and secure With the<br />
retalnmg spnng<br />
II Instal the rubber dust excluder ensunng that It IS<br />
correctly located In the bell housmg<br />
I2 Instal the gearbox and bell hOUSing assembly to<br />
the vehicle<br />
13 AdJust the clutch throw out lever free travel to<br />
the clearance gIven In the speCification section<br />
RELEASE BEARING<br />
Exploded V ew of Clutch Release Components<br />
7 CLlJTCH PEDAl<br />
77<br />
8 Instal the clutch pedal return spnng With the<br />
longer plain end hooked to the pedal Check the operatIOn<br />
of the pedal<br />
NOTE Adjustment procedure IS as follows<br />
a AdJust the pedal height to 183 mm 7 205 In for<br />
nght hand dnve velucles and 208 mm 8 189 In for left<br />
hand dnve veluc1es by adJusting the master cylinder push<br />
rod length<br />
b AdJust<br />
the pedal height to 182 mm 7 165 In for<br />
nght hand dnve vehicles and 207 mm 8 150 m for left<br />
and lock<br />
hand dnve velucles by screwing the pedal stopper<br />
up the lock nut<br />
c AdJust the length of the aSSIst spnng push rod to<br />
203 mm 7992 In for nght hand dnve vehicles and 183<br />
mm 7 205 In for left hand dnve vehicles by turnIng the<br />
rod adJuster coil spring type pressure plate orily
8Clutch<br />
Clutch Slave Cyhnder Installed to Vehicle<br />
8 AD JUST IENTS<br />
TO ADJUST THROW OUT LEVER FREE TRAVEL the lever from the full off positIOn and the posItion when<br />
I RaIse the front of the vehicle and support on<br />
stands or support the complete vehIcle on a hOISt<br />
2 Apply the clutch pedal and allow It to return to<br />
the off posItion<br />
3 Check the adJustment by feehng the free travel of<br />
78<br />
the thrust bearing contacts the clutch release levers or<br />
waphragIn fingers<br />
4 If adJustment IS reqUired slacken the lock nut on<br />
the slave cyhnder push rod and turn the adJustIng nut to<br />
achieve thespeCified free travel ofthe throw out lever<br />
5 Hold the adJusting nut and push rod and lock the<br />
lock nut Recheck the free travel
I Qutch shppmg<br />
a Insufficient pedal<br />
9IUTC FtUI T DIAf XOSIS<br />
Possible cause Remedy<br />
free travel<br />
b Weak or broken pressure plate dJaphragIfl spnng<br />
c Worn dnven plate facings<br />
d Worn or scored or<br />
pressure plate flywheel face<br />
e Insufficient throw out lever free travel<br />
2 Qutch shudder<br />
a Oil on gummy dnven plate faCings<br />
b Scored pressure plate or flywheel face<br />
c Loose or damaged engIne mountings<br />
d Loose or damaged dnven plate hub<br />
e Loose or damaged dnven plate faCings<br />
f Cracked pressure plate face<br />
g<br />
Check free travel and adJust<br />
Clutch 9<br />
release cable<br />
Renew pressure plate and cover assembly<br />
Renew dnven plate assembly<br />
Check and renew pressure plate assembly and or flywheel<br />
Check free travel and adJust slave cylinder rod<br />
Possible cause Remedy<br />
Release mechanISm not operating freely<br />
3 Qutch grab<br />
POSSIble cause<br />
a Gummy dnven plate faCings<br />
b Cracked pressure plate face<br />
c Loose or broken engine mountings<br />
d Sticking release mechanism<br />
e Sluggish or detenorated slave cyhnder rubber<br />
4 InsuffiCient clutch release<br />
POSSible cause<br />
a ExceSSive free travel of clutch pedal<br />
ExceSSIve play ofrelease lever<br />
b<br />
c Pilot bushing sticking<br />
d Clutch dnven plate warped<br />
e leaking master cyhnder cup<br />
f leaking slave cyhnder cup<br />
g<br />
h<br />
Au m hydrauhc system<br />
Low flUId level In reservou<br />
5 Release beanng nOise<br />
a Dry or worn bearmg<br />
b InsuffiCient pedal free travel<br />
c Damaged pressure dmphragIfl spnng<br />
Check and renewdnven plate<br />
Renew pressure plate and cover assembly or flywheel<br />
and nng gear<br />
Check and renewmountings as reqUIred<br />
Renew dnven plate<br />
Renew dnven plate<br />
Renew pressure plate andcover assembly<br />
Check and free up or renew as necessary<br />
Remedy<br />
Renew dnven plate<br />
Renew pressure plate and cover assembly<br />
Check and renew engIne mountings<br />
Check and free up or renew as necessary<br />
Check and renewslave cyhnder components Bleed<br />
hydrauhc system<br />
Remedy<br />
AdJust correctly<br />
AdJust correctly<br />
Replace pilot beanng<br />
Replace clutch dnven plate<br />
Replace cup<br />
Replace cup<br />
Bleed system<br />
WIth brake flUId<br />
Top up<br />
POSSible cause Remedy<br />
79<br />
Check and renew bearing<br />
Check and adJust pedal free travel<br />
Check and renew pressure plate and dlaphragIfl<br />
spnng assembly
GEARBOX<br />
Type<br />
LI3 models 3 speed<br />
column change<br />
LI4 LI6 models<br />
4 speed<br />
floor change<br />
or 3 speed<br />
column change<br />
Synchromesh<br />
On all forward<br />
Synchromesh type<br />
All except SSS model<br />
SSS model<br />
RatIOS 3 speed gearbox<br />
Top<br />
Second<br />
FlfSt<br />
Reverse<br />
RatIOS 4 speed gearbox<br />
Top<br />
Thud<br />
Second<br />
Fust<br />
Reverse<br />
MANUAL TRANSMISSION<br />
gears<br />
Borg Warner<br />
Servo<br />
1000<br />
1645<br />
3263<br />
3355<br />
1 000 I sedan<br />
1<br />
000 I<br />
stn sedan<br />
1312 1 sedan<br />
1419 1<br />
stn sedan<br />
2013 I sedan<br />
2177 I<br />
stn sedan<br />
3 382 I sedan<br />
3 657 I<br />
stn sedan<br />
3364 1<br />
3 638 I<br />
stn sedan<br />
Malnshaft end float<br />
r<br />
3 speed 0 019mm<br />
4 speed<br />
Laygear end float<br />
0 00075 In<br />
SPECIFICATIONS<br />
008 0 29 mm<br />
00031<br />
00114 In<br />
3 speed 004 012mm<br />
4 speed<br />
Reverse Idler gear end float<br />
00016<br />
00047 In<br />
005 0 15mm<br />
00020<br />
00060 In<br />
3 speed 020 0 40 mm<br />
4 speed<br />
0 008<br />
00157 In<br />
o 10 0 30 mm<br />
0004<br />
001181n<br />
80<br />
Malnshaft run out<br />
3 speed<br />
4 speed<br />
Gear end float 3 speed<br />
Ist gear<br />
2nd gear<br />
Gear end float 4 speed<br />
1st 2nd and 3rd gears<br />
Gear backlash<br />
3 speed<br />
4 speed<br />
Shift fork to synchro sleeve<br />
clearance all<br />
Baulk ring face to gear<br />
synchro teeth clearance<br />
Selective fit cuchps aVllllable<br />
3 speed gearbox<br />
7 sizes for Input shaft<br />
5 sIZes for 2nd gear<br />
8 sizes for Ist gear<br />
Selective fit clfchps available<br />
4 speed gearbox<br />
5 sizes for Input shaft<br />
5 sizes for 3rd gear<br />
I<br />
I<br />
I<br />
015 mm<br />
0006 In<br />
025 mm<br />
0010 In<br />
005 0 22 mm<br />
0002<br />
00087 In<br />
010 022mm<br />
0004<br />
00087 In<br />
005 0 15 mm<br />
0002<br />
0006 In<br />
008 013mm<br />
o 003<br />
o 005 In<br />
o 05 0 10 mm<br />
0002<br />
0004 In<br />
o 15 0 30 mm<br />
0006<br />
0012 In<br />
12 16mm<br />
00472<br />
o 0630 In<br />
Prom 1 52 mm<br />
to I 89 mm<br />
Prom 0 0598<br />
to 0 0747 In<br />
From I 60<br />
to I 80 mm<br />
Prom 0 063<br />
to0071 In<br />
Prom 1 30<br />
to I 70 mm<br />
From 0 0512<br />
to 0 067 In<br />
Prom I 52<br />
to I 77 mm<br />
Prom 00598<br />
to 0 0697 In<br />
From I 40<br />
to 160mm<br />
Prom 0 0551<br />
to 0 063 In
5 sizes for Idler gear From 1 I<br />
to I 5 mm<br />
From 00433 SelectIVe fitclrchps<br />
ava1lable<br />
to 0 0591 m<br />
Thrust washers for laygear 7 sizes<br />
3 speed<br />
4 speed<br />
From 3 83<br />
to 4 03 mm<br />
Prom 0151<br />
to 0 159 In<br />
From 2 40<br />
<strong>Manual</strong> Transmission 2<br />
Shaft run out l1illlt 06mm<br />
0024 In<br />
From 2 0<br />
t0212mm<br />
Prom 0 0787<br />
to 0 0835 In<br />
to 2 60 mm<br />
Prom 0 0945<br />
TORQUE WRENCH SElTINGS<br />
to 01024 m Maxunum settmgs<br />
PROPELLER SHAFT<br />
Dram plug<br />
5 0 m kg<br />
36 ftflb<br />
Cover screws I 7 kgfm<br />
Type Open tubular<br />
12 ft Number of umversal JOints<br />
Type<br />
2 Rear extensIOn bolts<br />
lb<br />
30kgfm<br />
of universal<br />
JOint Needle roller 22ft Ib<br />
beanng and Input shaft front cover 17kgfm<br />
trunnion 12 ftflb<br />
Spline backlash wear hmlt 05mm Gearbox to engIne bolts 5 3 m kg<br />
0 02 In<br />
38 ftflb<br />
Trunnion diameter wear hrnlt o 15mm Reverse lamp sWitch 4 kgfm<br />
0006 m 29 ft lb<br />
P4IIT I flIIIEE S EED TII NS nSSIO<br />
The three speed gearbox has synchromesh on all<br />
forward gears The gears are hehcal cut and run In constant<br />
mesh With the laygear The reverse shdlng gear engages a<br />
reverse Idler gear running m mesh With the layshaft<br />
Needle roller beanngs are used to mount the laygear to<br />
the layshaft which IS supported at both ends by the gearbox<br />
casmg Laygear end float IS adJusted by thrust washers<br />
wluch can be obtamed In wfferent thicknesses for thIS<br />
purpose<br />
The mamshaft assembly IS supported In ball beanngs<br />
located at each end of the gearcase Selective fit Clfchps are<br />
TO REMOVE AND INSTAL<br />
I Jack up the vehicle and support on stands<br />
2 Disconnect the battery leads and the lead at the<br />
starter motor<br />
gearbox<br />
3 Remove the draIn plug and drain the oil from the<br />
4 Disconnect the speedometer cable at the gearbox<br />
extensIOn hOUSing<br />
5 Disconnect thehandbrake cable at the equahser<br />
6 Mark a line across the umversal JOint and pinIOn<br />
flanges to ensure reassembly In theu ongInal pOSItions<br />
I DESCRIPTIO<br />
2 GEARBOX<br />
81<br />
aVaIlable In wfferent thicknesses for adJustment of beanng<br />
and gear end float<br />
A needle roller bearing located In the end of the Input<br />
shaft supports the spigot end of the mamshaft<br />
The gearchange IS the remote control type mounted on<br />
the steenng column Rods transfer the gear change lever<br />
movement to operating levers located In the gearbox case<br />
and through shIft forks to the synchromser sleeves Rod<br />
adJustment IS carned out at the steenng box end of the<br />
rods<br />
Take out the four retaining bolts and Withdraw the<br />
propeller shaft from the rear of the gearbox<br />
NOTE It may be necessary to release the exhaust pIpe<br />
clamps and turn the muffler to obtain clearance for<br />
propeller shaft removal<br />
7 Disconnect the clutch slave cyhnder return spnng<br />
remove the retaining screws and detach the cyhnder and<br />
push rod from the gearbox<br />
8 Disconnect the gear change rods from the<br />
operating levers and relay shaft
o<br />
3 <strong>Manual</strong> Transmission<br />
IDLER SHAFT<br />
jr<br />
Reverse Idler Gear Components<br />
View of Gearbox with Cover Plate Removed<br />
9 Detach the relay shaft from between the gearbox<br />
@<br />
and side plate<br />
10 Loosen off and remove the starter motor<br />
11 Support the gearbox assembly with a Jack<br />
posltlOrnng a wood block between the Jack head and the<br />
gearbox cover plate<br />
LOCKPLATE NOTE Do not take the weight oj the assembly on the<br />
82<br />
gearbox drain plug<br />
12 Remove the screws attaclung the gearbox rear<br />
mounting crossmember to the underbody and extensIOn<br />
hOUSing Detach the crossmember<br />
I3 Unscrew and remove the bolts secunng the clutch<br />
bell hOUSing to the rear of the engine<br />
14 Lower the Jack and draw the assembly rearwards<br />
to remove from the velucle<br />
Installation IS a reversal ofthe removal procedure<br />
Ensure that the gearbox IS filled With the correct<br />
quantIty and grade ofoil<br />
TO DISMANTLE<br />
I Remove the clutch release lever rubber dust cover<br />
from the aperture In the gearbox release the retainer spnng<br />
and detach the lever and release beanng<br />
o
<strong>Manual</strong> Transmission 4<br />
J<br />
SPRING<br />
Gearbox WIth Laygear and Cross Shafts Removed to Show ShIft Fork Arrangement<br />
2 Invert the assembly and remove the cover plate<br />
screws and cover plate<br />
3 Remove the<br />
retaining screw and lockplate and<br />
Withdraw the speedometer pinIOn assembly from the<br />
extensIOn housmg<br />
4 Take out the extensIOn hOUSing retammg screws<br />
and Withdraw the hOUSing from the gear case and mam<br />
shaft<br />
shafts<br />
5 Remove the cuchps from the gear sluft cross<br />
6 Remove the nuts and knock out the cotter pms<br />
retamlng the shift levers to the cross shafts<br />
7 Pull the cross shafts out of the gear case and<br />
remove the thrust washers and s1uft levers wluch will now<br />
be released<br />
8 Take out the bolts retammg the mamshaft front<br />
beanng cover and Withdraw the cover and oil seal<br />
9 Tap out the layshaft and ltft the laygear and thrust<br />
washers out ofthe gear case<br />
10 Remove the reverse Idler shaft retalnmg screw<br />
tap out the shaft and remove the Idler gear<br />
II Unscrew the plug from the mterlock hole and<br />
remove the spring and detent ball If fitted remove the<br />
reverse lamp sWitch<br />
12 Knock out the spnng pinS retaining the shift forks<br />
to the sluft rods<br />
13 Tap the sluft rods one at a time from the gear<br />
case and remove the s1uft forks<br />
NOTE Recover the Interlock plunger fitted In the case<br />
83<br />
between the shift rods and the detent ball and spnng from<br />
the blanked hole abovefirst reverse shift rod t<br />
14 Pull out the mam shaft assembly from the rear of<br />
the gear case<br />
15 Remove the Input shaft and beanng assembly<br />
from the front of the gear case<br />
16 Remove the cuchp at the front of the mamshaft<br />
and detach top gear bauIk nng and synchroIDser assembly<br />
followed by a second baulk nng and mtermedlate gear<br />
17 Remove the cuchp at the rear of the mamshaft<br />
and detach the speedometer dnve gear and ball beanng and<br />
spacer<br />
18 Fmrily support the rear malnshaft beanng and<br />
retainer assembly and press out the malnshaft<br />
19 Detach the first reverse synchromser assembly<br />
together With first gear baulk nng and first gear I<br />
20 If necessary dismantle each of the two<br />
synchromser assembhes<br />
NOTE On the 1st reverse assembly the shift plates are<br />
tensioned by Call spnngs fitted Into the hubdirectly below<br />
the plates On the 2nd top assembly a spnng ring located at<br />
each end of the hub serves to tensIOn the shift plates<br />
Components are not Interchangeable between the v<br />
assemblies<br />
21 If necessary remove the Clfchp and washer and<br />
press the beanng from the Input shaft
5 <strong>Manual</strong> Transmission<br />
REVERSE GEAR AND<br />
1ST GEAR SVNCHRO ASSV<br />
2NDITOP GEAR<br />
SVNCHRD ASSV<br />
TO CLEAN AND INSPECT<br />
Malnshaft Assembly<br />
I Clean all components In cleamng solvent and blow<br />
dry with compressed au<br />
2 Check ball beanngs for roughness or excessive Side<br />
play Do not rotate the bearmgs at Iugh speed with<br />
compressed au particularly when the beanngs are dry or<br />
damage will result<br />
3 Check the needle roller bearings for wear and or<br />
pitting 4 Examine the teeth on all gears for wear and or<br />
pitting also bUffing on the teeth ends<br />
5 Check the gear teeth for wear burrmg and damage<br />
6 Check the baulk nngs on theu correspondmg gear<br />
cones for wear See SpeCifications for wear hnuts<br />
7 Check the sluft forks for wear the detent balls for<br />
wear and the detent<br />
springs for breakage or loss oftensIOn<br />
8 Examine the shift rods and mamshaft for damage<br />
and warp<br />
9 Check the synchronlSer components for wear and<br />
damage also the fit ofthe hubs to the mamshaft splInes<br />
10 Renew all worn or damaged components as<br />
necessary<br />
00<br />
CIRCLlP<br />
i<br />
BEARING<br />
REVERSE GEAR AND<br />
1ST GEAR<br />
MAINSHAFT<br />
SrNCHRO<br />
ASSV<br />
8L<br />
12 1Smm<br />
10047 0063<br />
Check Baulk Ring for Wear Renew If dimenSion less than<br />
TO ASSEMBLE<br />
08 mm 0030 In<br />
1 If removed press the bearmg onto the Input shaft<br />
and fit the washer Select a cuchp ofappropnate thickness<br />
to give nil end float to the beanng<br />
2 Instal the snap nng Into the groove of the<br />
1st reverse synchro hub Insert the shift plate spnngs and<br />
pOSItion the sluft plates over the spnngs Compress the Slllft<br />
BAULK RING<br />
KEY<br />
1ST GEAR<br />
il<br />
BAULK RING CIRCLlP<br />
0<br />
Exploded View of Malnshaft Components<br />
I
HUB<br />
SHIFT PLATE SP NGS<br />
tfi<br />
It<br />
SH I FT PLATES<br />
Exploded View of First Gear Synchronlser Components<br />
plates and slide the sleeve reverse gear correct way round<br />
over the hub assembly<br />
3 Check that 2nd top synchro sleeve moves freely on<br />
the synchro hub sphnes posItion the shift plates In the hub<br />
and shde the sleeve over the hub assembly Instal a spnng<br />
nng at each end of the hub so that It locates under the<br />
bottom edge of each of the shift plates<br />
4 Instal 1 st gear on the rear of the malnshaft with<br />
the cone towards the rear end of the shaft posItion a baulk<br />
nng over the gear cone<br />
Exploded View of<br />
SHIFT PLATES<br />
t<br />
I<br />
Second Top Gear Synchronlser Components<br />
85<br />
<strong>Manual</strong> Transmusion 6<br />
5 Instal the 1st reverse synchronlSer assembly with<br />
the plam end of the sleeve towards the rear end of the<br />
malnshaft<br />
6 Fit the spacer washer and press onto the malnshaft<br />
the mamshaft bearing and retamer assembly<br />
7 Instal the distance piece ball bearing and<br />
speedometer dnve gear and secure by fitting a clfchp<br />
mamshaft<br />
to the<br />
Select a cuchp of appropnate thickness to gIve 1st gear<br />
end float of 005 to 022 mm 0002 to 00087 In check<br />
by feeler gauge between the face of 1st gear and the<br />
malnshaft flange<br />
8 Instal 2nd gear on the front of the malnshaft With<br />
the cone towards the front end of the shaft pOSitIOn a<br />
baulk nng over the gear cone<br />
9 Instal the 2nd top synchromser assembly onto the<br />
mainshaft and secure With a clfclIp<br />
Select a clfchp of appropnate thickness to gIve 2nd<br />
gear end float of 0 10 022 mm 0004 to 00087 In<br />
check by feeler gauge between the face of 2nd gear and the<br />
malnshaft flange<br />
Second and Top Gear Synchronlser Assembly
7 <strong>Manual</strong> Transmission<br />
8AULK RING<br />
a<br />
IO Smear the needle beanng With oil and Instal mto<br />
the end of the Input shaft Insert the shaft assembly mto<br />
posItion from the front of the case and fit a baulk nng over<br />
the gear cone<br />
II Insert the mamshaft assembly Into the case and<br />
engage the spigot end of the malnshaft In the Input shaft<br />
needle roller bearing Locate the beanng retamer m the case<br />
aperture<br />
I2 PosItIon the gear case so that the Interlock hole m<br />
the case faces upward<br />
I3 Instal a detent spnng and ball Into the blank<br />
ended hole Hold m agamst the spnng pressure so that a<br />
dummy shaft of the same diameter as the s1uft rod can be<br />
Inserted In the 1st reverse shift rodhole<br />
I4 PosItion the sluft forks on the synchromser<br />
sleeves<br />
IS Insert the I st reverse shift rod through the case<br />
and sluft fork to dislodge the dummy shaft and allow the<br />
detent ball to engage on the centre detent of the s1uft rod<br />
16 Instal the Interlock plunger Into the case to abut<br />
the 1st reverse s1uft rod<br />
I7 Insert the 2nd top sluft rod through the case and<br />
shift fork until the centre detent on the rod IS aligned With<br />
the Interlock hole In the case<br />
I8 Instal the remamlng detent ball and spnng and<br />
secure With the plug Smear the plug threads before fitting<br />
With a lIttle sealing compound<br />
ShIft Rod Detent and Interlock Components<br />
BEARING<br />
CIRCLIP<br />
INPUT SHAFT WASHER<br />
t<br />
I<br />
CIRCLlP<br />
Exploded VIew of Input Shaft Components<br />
SELECTIVE FIT<br />
I9 Align the spnng pm holes m the sluft forks and<br />
rods and tap m the spnng pinS<br />
20 Hold the reverse Idler gear In pOSItion m the case<br />
and Insert the Idler shaft through the gear and case Align<br />
the holes In the shaft and case and screw In the retalnmg<br />
screw secure the screw With the lock plate Check the<br />
end float on specifications<br />
the Idler gear wluch should be wltlun<br />
21 Instal the needle roller bearings In each end of the<br />
laygear pOSItIon the laygear In the case With the thrust<br />
washers pOSItioned at each end Insert the layshaft through<br />
the case thrust washer and laygear<br />
22 Check the laygear end float which must be Within<br />
the speCified hmlts see SpecificatIOns If necessary<br />
replace the thrust washers from the wfferent tlucknesses<br />
ava1lable to correct the end float<br />
23 PosItIon the shiftlevers In the case to engage With<br />
the sluft forks<br />
24 Fit new oil seals to the cross shafts and Insert the<br />
shafts through the case thrust washers and s1uft levers<br />
25 Hold the thrust washers against the Side of the<br />
case and fit the ClfCl1pS to the grooves In the cross shafts<br />
26 Align the notches In the cross shafts With the<br />
cotter pin holes In the shift levers Instal the cotter pinS and<br />
secure With the washers and nuts<br />
27 Fit a new 011 seal to the mput shaft beanng cover<br />
and mstal the cover With a new gasket Tighten the<br />
retaining screws to the speCified torque<br />
28 Instal the extensIOn hOUSing With a new gasket<br />
and tighten the retaining screws to the speCified torque<br />
29 Insert the speedometer pinIOn assembly Into the<br />
extensIOn hOUSing and secure With the screw and lock plate<br />
30 Instal the reversing lamp SWitch<br />
31 Mount a dial gauge onto the case so that the<br />
plunger bears on a gear tooth Check the gear backlash and<br />
check the remaining gears In the same manner See<br />
SpeCificatIons for backlash hrllits<br />
32 Instal the cover plate With a new gasket and<br />
tighten the retaining screws to the speCified torque<br />
33 Instal the clutch release lever beanng retainer<br />
spnng and rubber dust cover<br />
34 Instal the assembly In the vehicle as descnbed In<br />
TO REMOVE AND INSTAL Fill the gearbox With the<br />
correct grade and quantity of oil and carry out any<br />
adJustments to the clutch push rod and gearchange rods as<br />
descnbed In the appropnate sectIons<br />
86 o
THRUST<br />
WASHER<br />
BU E<br />
I<br />
Y<br />
NG PIN<br />
t<br />
t<br />
BEARING<br />
@ II fi<br />
t<br />
Exploded View of Laygear Components<br />
1ST REVERSE GEAR SHIFT ROO<br />
l<br />
2NDITOP tAR SHIFT ROD<br />
Gear ShIft Rods and Forks<br />
COTTER PIN SHIFT<br />
tRK LEVER<br />
4<br />
00<br />
<strong>Manual</strong> 7 ranllmillllion 8<br />
SPRING<br />
NUT COTTER PIN SHIFT FORK LEVER<br />
r<br />
ru<br />
CIRCLlPS<br />
tlt<br />
LA AFT<br />
87<br />
J tit<br />
Gearshift Cross Shaft Components<br />
THRUST<br />
BEARING WASHER<br />
a I
9 <strong>Manual</strong> Transmission<br />
TO REMOVE AND INSTAL<br />
1 Remove the horn nng steenng wheel column shell<br />
and sWitch assembly as described In the ELECTRICAL<br />
section<br />
bracket<br />
2 Remove the clfchp at the control rod top support<br />
3 Release the support bracket clamp screw and<br />
remove the bracket<br />
4 Detach the control rod Insert bush and spnng<br />
5 Remove the Clfchp and cleVIS pin retaining the<br />
column gear change lever to the control rod and detach the<br />
lever<br />
6 Working at the steenng box end of the Imkage<br />
disconnect the gear change rods from the control rod levers<br />
by remOVing the spht pin and flat and spnng washers on<br />
each rod trunnIon<br />
7 Take out the lower support bracket retaining<br />
screws and detach the clamp and control rod levers retainer<br />
8 Detach the 2nd top gear change lever followed by<br />
the lower support bracket and 1st reverse lever from the<br />
end of the control rod<br />
9 Pull out the control rod<br />
PLUG<br />
WASHER<br />
WASHERS 0 LEVER<br />
a<br />
PIN<br />
1<br />
SUPPORT<br />
i<br />
Q<br />
BRACKET<br />
aUSH<br />
SCRE<br />
f<br />
aUSH<br />
SCREW<br />
LEVER<br />
3 GEAR CIIANGE ASSEIUBI<br />
AT<br />
WASHERS S ING<br />
WASHER<br />
Exploded View of Column Type Gear Shift Components<br />
88<br />
10 If necessary disconnect the gear change rods<br />
from the operating levers and relay shaft loosen off and<br />
remove the relay shaft from between the gearbox and Side<br />
plate Installation IS a reversal of the removal procedure but<br />
lubncate all moving parts With multl purpose grease<br />
View of Steering Column ShOWing<br />
Gear Shift Arrangement<br />
ING<br />
USH<br />
A<br />
f<br />
f<br />
SCREW<br />
SUPPORT<br />
c<br />
ciip
TO ADJUST<br />
I Check that the tranSmISSIOn IS In neutral<br />
2 Note that the control rod levers are marked with a<br />
groove on theu top edge and the control rod lower support<br />
<strong>Manual</strong> TransmissiQn IO<br />
bracket wIth a ridge When correctly adJusted In the neutral<br />
poSI tlon all three marks will be aligned<br />
3 If adJustment IS reqUired lengthen or shorten the<br />
gear change rods as necessary at the adJustmg nuts located<br />
above and below the trunmons<br />
PART 2 OUR SPEED TJlANSMISSJON<br />
The four speed gearbox has synchromesh on all<br />
forward gears The gears are hehcal cut and run In constant<br />
mesh With the laygear<br />
The reverse Idler shaft IS fi tted WIth an Idler gear In<br />
constant mesh With and drIVIng off the laygear An<br />
additIonal Idler gear sphned to the opposite end of the Idler<br />
shaft IS engaged by the reverse shdmg gear for reverse<br />
operatIOn<br />
Needle roller beanngs are used to mount the laygear to<br />
the layshaft wluch IS supported at both ends by the gearbox<br />
casing Laygear end float IS adJusted by thrust washers<br />
wIDch can be obtained 10 different thicknesses for tlus<br />
purpose<br />
The mamshaft assembly IS supported In ball beanngs<br />
located at each end of the gearcase Selecl1ve fit clfchps are<br />
aVailable In different thicknesses for adJustment of<br />
malnshaft and gear end float<br />
Needle roller beanngs are Interposed between the<br />
p<br />
I DESCRIPTU X<br />
1ST 2ND SHIFT<br />
ADO AND FORK<br />
maInshaft and first second and third gears A needle roller<br />
bearing located In the end of the Input shaft supports the<br />
spigot end of the mainshaft<br />
Two types of synchromser are used dependmg upon<br />
the model On all except the sports sedan the Borg Warner<br />
type baulk nng and cone are standard eqUipment On the<br />
sports sedan a Servo type synchromser IS employed the<br />
components of wIDch are mounted duectly on the clutch<br />
gear wIDch IS pressed onto the malnshaft gear When<br />
dismantlIng Servo type synchromsers It should be<br />
particularly noted that the thrust and anchor blocks for 1st<br />
gear synchronlSlng differ from that of the other three gears<br />
and therefore must not be Interchanged<br />
The gear change IS the floor shift type mounted<br />
wrectly on the extensIOn hOUSing Gear shift movement IS<br />
transferred through a stnkmg rod to gates located on the<br />
sluft rods wluch In turn pass the movement to shift forks<br />
for gear selectIOn<br />
View of Gearbox With Cover Plate Removed<br />
89<br />
3RD 4TM SHIFT<br />
ROD AND FORK<br />
lAYGEAR
II <strong>Manual</strong> Transmission<br />
TO REMOVE AND INSTAL<br />
Removal and installatIOn of the gearbox assembly IS<br />
smular to that descnbed for the three speed gearbox With<br />
the exceptIOn of the gearchange mechanISm carry out the<br />
procedure descnbed and also release the floor shift type<br />
gear lever from the control lever bracket<br />
TO DISMANTLE<br />
I Remove the clutch release lever rubber dust cover<br />
from the aperture In the gearbox release the retamer sprmg<br />
and detach the lever and release beanng<br />
2 Remove the retaining screw and lock plate and<br />
withdraw the speedometer pinIOn assembly from the<br />
extensIOn hOUSing<br />
3 Remove the cuchp and cleVIS pin retaining the<br />
stnkmg rod to the gear change lever mountmg bracket<br />
ExtensIon HOUSing Removed to Show Reverse Gear<br />
Arrangement<br />
SVNCHROIt<br />
2 GEARBOX<br />
4 Take out the extensIOn hOUSing retaining bolts and<br />
withdraw the hOUSing to permit the wsengaglng of the<br />
stnklng rod lever from the sluft rod gates Remove the<br />
hOUSing and stnklng rod together<br />
5 Take out the three plugs and remove the three<br />
detent spnngs andballs from the Side of the gearcase<br />
6 Remove the retaining screws and detach the<br />
gearbox cover plate and gasket<br />
7 Remove the retaining screws and detach the Input<br />
shaft bearing cover and gasket<br />
8 Knock out the spnng pinS retaining the s1uft forks<br />
to the sluft rods<br />
9 Slide both synchromser sleeves Into gear to lock<br />
the mamshaft and unscrew the nut on the malnshaft<br />
Neutrahse both synchromsers<br />
IO Take out the layshaft and remove the laygear and<br />
thrust washers<br />
II Remove the cuchp at the front end ofthe reverse<br />
Idler shaft and detach the gear Withdraw the shaft together<br />
With the remamlng gear from the rear of the gearcase<br />
Recover the thrust washers<br />
I2 Pull out the sluft rods and remove the sluft forks<br />
from the case<br />
NOTE Mark the upper leg of each shift fork to ensure<br />
replacement In their orzgznal posltlons Recover the<br />
Interlock plungers which are located In the case between<br />
the shift rod holes<br />
screws<br />
BEARING AND RETAINER<br />
90<br />
13 Take out the four malnshaft rear bearing retainer<br />
14 Withdraw the malnshaft assembly from the rear<br />
of the gearcase and the Input shaft assembly from the front<br />
ofthe gearcase<br />
IS Remove the cuchp at the front of the mamshaft<br />
and detach 3rdjtop gear synchromser and 3rd gear<br />
complete With needle roller bearing<br />
NOTE On baulk nng type synchronzsers a baulk nng IS<br />
located at each end of the synchromser On Servo type the<br />
nchronlSer components With the exceptIOn of the sleeve<br />
and hub assembly are attached to the gear cones<br />
Malnshaft Assembly
16 Remove the nut and lock plate from the rear of<br />
the malnshaft Withdraw the speedo drIVIng gear<br />
ball<br />
17 Withdraw reverse gear and the sphned<br />
the malnshaft<br />
and dnve<br />
hub from<br />
18 Firmly support the rear malnshaft beanng and<br />
retainer assembly and press out the mamshaft<br />
19 Detach the thrust washers and 1st gear together<br />
with the needle roller beanng and sleeve Recover the thrust<br />
washer ball located In the malnshaft<br />
20 Remove 1st 2nd gear synchromser assembly and<br />
2nd gear complete with needle roller beanng<br />
NOTE On baulk nng type synchromsers a baulk nng IS<br />
located at each end of the syncromser On Servo type the<br />
synchromser components with the exceptIOn of the sleeve<br />
and hub assembly are attached to thegear cones<br />
21 If necessary remove the cuchp and press out the<br />
rear malnshaft bearing from the retainer<br />
22 If necessary remove the cuchp and press the<br />
Input shaft beanng from the shaft and out of the sleeve<br />
To DISmantle Synchrofl1Ser Assembhes<br />
Borg Warner Type<br />
NOTE Mark the front face of the hub and sleeve on each<br />
synchromser to ensure correct assembly<br />
SLEEVE<br />
Exploded View of Input Shaft Components<br />
Exploded View of Synchromser Components Borg Warner Type<br />
91<br />
<strong>Manual</strong> Transmission 12<br />
I Remove the spnng nng from each end of the<br />
assembly to release the sluft plate tensIOn<br />
2 Shde the sleeve off the hub and remove the three<br />
sluft plates<br />
Servo Type<br />
NOTE Mark or note the posltlons of the synchromser<br />
components when dismantling and ensure that the<br />
components of each synchromser are kept separate as they<br />
arenot Interchangeable<br />
I Remove the cuchp retaImng the components to<br />
the clutch gear<br />
2 Detach the synchromser nng thrust block both<br />
brake bands and the anchor block from the clutch gear<br />
3 Slide the sleeve offthe synchronlSer hub<br />
TO CLEAN AND INSPECT<br />
I Clean all components In cleaning solvent andblow<br />
dry With compressed aIr<br />
2 Check ball beanngs for roughness or excessive Side<br />
a D<br />
SHIFT PLATES<br />
U
13 Manllal Transmission<br />
CLUTCH GEAR<br />
play Do not rotate the bearings at Iugh speed With<br />
compressed au partIcularly when the beanngs are dry or<br />
damage will result<br />
3 Check the needle roller beanngs for wear and or<br />
pitting 4 Exarmne the teeth on all gears for wear and or<br />
plttmg also burnng on the teeth ends<br />
5 On Borg Warner type synchromsers check the<br />
baulk nngs on theu correspondrng gear cones for wear See<br />
SpecificatIOns for wear hmlts<br />
6 On Servo type synchronlSers check the<br />
components for wear and damage<br />
7<br />
or<br />
warp<br />
Examine the sluft rods and mamshaft for damage<br />
8 Check the sluft forks for wear the detent balls for<br />
wear and the detent<br />
spnngs for breakage or loss oftensIOn<br />
9 Renew all worn or damaged components as<br />
necessary<br />
TO ASSEMBLE<br />
1 If removed press the beanng onto the mput shaft<br />
and fit the washer Select a cuchp of appropnate thickness<br />
to giVe nil end float to the beanng Press the assembly Into<br />
the sleeve<br />
2 If removed press the mamshaft rear beanng mto<br />
the retamer and secure With the cuchp<br />
3 Assemble the synchromser assembhes<br />
a On Borg Warner type mstal the sluft plates Into the<br />
notches m the hubs and shde the sleeve onto the hub<br />
according to the marks made on dlsmantlmg Instal a spnng<br />
nng at each end of the hub so that It locates under the<br />
bottom edge ofeach ofthe sluft plates<br />
HUB<br />
92<br />
SYNCHRO RING<br />
I<br />
ANCHOR BLOCK<br />
END VIEW OF SYNCHRO<br />
COMPONENTS ASSEMBLED<br />
TO CLUTCH GEAR<br />
Exploded View of Servo Type Synchromser Components<br />
Note that gears are helical cut and notspur type as shown<br />
b On Servo type Instal the synchronlSer nng to the<br />
clutch gear Fit the anchor and thrust blocks together With<br />
the brake bands accorwng to the marks made on<br />
wsmantlmg and secure the assembly With the cuchp<br />
4 Instal 2nd gear together With the needle roller<br />
beanng onto the mamshaft on baulk nng type locate a<br />
baulk nng over the gear cone<br />
5 Instal the 1st 2nd synchronlSer sleeve and hub<br />
assembly and on baulk nng type ensure that the<br />
synchromser s1uft plate ends engage In the 2nd gear baulk<br />
nng notches<br />
6 PosItion 1st gear baulk nng mto the opposite end<br />
of the synchronlSer and Instal 1st gear together With needle<br />
roller beanng and sleeve<br />
7 Locate the ball In th e mamshaft and posItIon the<br />
thrust washer over the ball and maInshaft<br />
8 Press the maInshaft rear bearing and retainer<br />
assembly onto the malnshaft<br />
9 Instal the sphned hub together With the reverse<br />
gear so that the large boss on the gear IS towards the rear of<br />
the malnshaft<br />
10 Locate the dnve ball ill the mamshaft and shde<br />
Into posItIon the speedometer dnvillg gear<br />
11 Instal the retalfung nut lock plate and screw on<br />
the nut finger tight<br />
12 Instal 3rd gear together With the needle roller
REVERSE GEAR<br />
I<br />
Nl 0 0<br />
LOCK P E<br />
I<br />
RETAINER<br />
I<br />
BEARING<br />
SPEEOO DRIVE GEAR<br />
C RCLlP<br />
SLEEV e<br />
1ST GEAR<br />
WASHER BAULK RING<br />
I<br />
bearing on the front of the malnshaft on baulk nng type<br />
locate the nng over the gear cone<br />
13 Instal the 3rd top gear synchrofllser sleeve and<br />
hub assembly and on baulk nng type ensure that<br />
synchrofllser shift plate ends engage In the 3rd gear baulk<br />
nng notches<br />
14 Secure the assembly with a cHchp selected from<br />
the range of thicknesses to gIve the appropnate end float to<br />
3rd gear See Specifications<br />
15 Instal the malnshaft assembly Into the gear case<br />
and fit and tighten the beanng retamer bolts<br />
16 Ensure that the needle roller beanng IS located In<br />
the end of the Input shaft and pOSitIOn top gear baulk nng<br />
over the gear cone<br />
17 Insert the Input shaft through the fron t of the<br />
gear case to engage the needle roller beanng on the<br />
mamshaft spigot Where fitted ensure that the notches In<br />
the baulk nng locate over the synchrofllser shift plate ends<br />
18 Shde both synchromser sleeves mto gear to lock<br />
the malnshaft and tighten the retaining nut to a torque of<br />
II m kg 80 ft lb Secure the nut by bending over the lock<br />
plate tab and move the synchrofllser sleeves to the neutral<br />
posItIon<br />
19 Attach the reverse Idler gear With straight teeth<br />
to the end of the Idler shaft With the longest spline and<br />
secure With a cHchp<br />
3RD 4TH GEAR<br />
SYNCHRO ASSY<br />
o<br />
BALLS v<br />
93<br />
SYNCHRO<br />
f<br />
oS<br />
i<br />
f<br />
2ND GEAR<br />
<strong>Manual</strong> Transmission 14<br />
II BAULK<br />
RING<br />
Exploded View of Mainshah Components<br />
SYNCHRO ASSY<br />
fI 01<br />
CIRCLlP<br />
Assembled Synchronlser ShOWing Spring Ring Location<br />
MAINSHAFT SPIGOT<br />
Borg Warner type<br />
Third Gear End Float by Instalhng Clrchp of<br />
Appropriate Thickness<br />
it
15 <strong>Manual</strong> Transmission<br />
o<br />
a<br />
l<br />
Exploded View of Laygear Components<br />
20 PositIOn a thrust washer on the shaft to abut the<br />
gear and Insert the shaft tluough the gear<br />
rear<br />
SPACERS<br />
0 0<br />
NEEDLEROLLER aEARING<br />
case from the<br />
21 PosItion a thrust washer on the front of the shaft<br />
followed by the reverse Idler dnven gear hehcal teeth<br />
Secure With a cuchp of the appropnate tIuckness to obtain<br />
the correct end float See SpeCificatIOns<br />
22 With the needle roller beanngs and spacers<br />
correctly located m the laygear Instal the In<br />
laygear the<br />
gearcase With a thrust washer at each end and Insert the<br />
layshaft through the gear case thrust washers and laygear<br />
23 Check the end float on the laygear and 1f<br />
necessary adJust to specifications by Jnstalllng thrust<br />
washers of the appropnate tIuckness<br />
Reverse Idler Gear Components Note that driVing<br />
gear IS fitted to longest spline end of shaft<br />
t<br />
LAYSHAFT<br />
94<br />
THRUST WASHER<br />
d<br />
a<br />
24 PosItion the sluft forks on the synchromser<br />
sleeves according to the marks made on wsmanthng<br />
25 Insert the 1st 2nd gear sluft rod through the case<br />
and shift fork until the centre detent on the rod I aligned<br />
With the detent ball hole<br />
26 Instal an Interlock plunger<br />
1st 2nd s1uft rod<br />
Into the case to abut<br />
27 Insert the 3rd top sluft rod through the case and<br />
DRIVEN GEAR<br />
s1uft fork ensure that the Interlock pin IS In posItIon In the<br />
sluft rod and push the rod through until the centre detent IS<br />
aligned With the detent ball hole<br />
28 Instal the second ofthe Interlock plungers to abut<br />
the sluft rod detent<br />
29 Hold the reverse gear shift fork In pos tlon on<br />
reverse gear and Instal the s1uft rod through the fork and<br />
case<br />
30 Align the spnng pin holes In the shift forks and<br />
rods and tap m the spnng pinS<br />
31 Instal the three detent balls and spnngs and<br />
secure With the plugs Smear the plug threads before fittmg<br />
With a sealing compound
SPRING<br />
PLU<br />
DETENT BALL<br />
INTERLOCK<br />
PLUNGER<br />
W ETENT BALL<br />
I<br />
SPRINGQ<br />
T PLUG<br />
INTERLOCK<br />
PLUNGER<br />
w<br />
Shift Rod Interlock and Detent Components<br />
32 Fit a new 011 seal to the front malnshaft bearmg<br />
cover and Instal the cover with a new gasket Tighten the<br />
retaining screws to the speCified torque<br />
33 Instal the extensIOn hOUSing With a new gasket<br />
engagIng the stnking rod lever In the sluft rod gates<br />
Tighten the retamlng screws to the speCified torque<br />
34 Instal the cover plate With a new gasket and<br />
tighten the retamlng screws to the speCified torque<br />
35 Insert the speedometer dnve pmlOn assembly mto<br />
the extensIOn hOUSing and secure With the lockplate and<br />
screw<br />
36 Connect the gearchange lever mountIng bracket<br />
to the stnklng rod and Instal the cleViS pin and cuchp<br />
37 Instal the clutch release lever beanng retainer<br />
spnng and rubber dust cover<br />
38 Instal the assembly to the vehicle as descnbed In<br />
TO REMOVE AND INSTAL Fill the gearbox With the<br />
correct grade and quantIty ofoil<br />
Gear Change Lever Attachment to Strlkmg Rod<br />
95<br />
<strong>Manual</strong> Transmission16<br />
Ahgn the Holes In the Shift Rods and Forks and Knock m<br />
the Spnng Pins
17 <strong>Manual</strong> Transmission<br />
DESCRIPTION<br />
PAIIT 3 I IIOI I II SUA<br />
The one piece tubular propeller shaft IS fitted With two<br />
needle roller and trunmon type umversal JOints<br />
The rear yoke of the rear umversal JOint IS flanged and<br />
bolted to the rear axle pinIOn shaft flange<br />
The sleeve on the front yoke of the front umversal<br />
JOint has Internal sphnes wluch shde on mating splmes on<br />
the rear end of the mamshaft The sleeve IS supported on ItS<br />
outer cIrcumference by a bush With an oil seal III the<br />
gearbox rear extensIOn<br />
Oversize cuchps are ava1lable to compensate for any<br />
end float In the beanng cups<br />
Note that propeller shafts for sedan and station sedan<br />
have wfferent dunenslOns<br />
TO REMOVE AND INSTAL<br />
stands<br />
I Jack up the rear of the vehicle and support on<br />
2 On sedan models only disconnect the handbrake<br />
cable at the adJuster to separate left and nght hand cables<br />
3 Also on sedan models release the exhaust pipe<br />
clamps and turn the muffler to obtain clearance for the<br />
shaft removal<br />
4 Mark a line across the umversal JOint and<br />
pinIOn<br />
flanges to ensure reassembly In theIr ongInal pOSItIons<br />
Take out the four retalnmg bolts and Withdraw the<br />
propeller shaft from the rear of the gearbox<br />
5 Plug the rear of the gearbox to prevent loss of011<br />
Installation IS a reversal of the removal procedure<br />
NEEDLE BEARING CUPS<br />
CIRCLlPS<br />
Exploded View of Rear Umversal JOint Components<br />
TO DISMANTLE AND REASSEMBLE<br />
I Remove the two secunng cuchps on opposed<br />
needle roller bearings ofthe front umversal JOint<br />
2 USing a soft metal dnft tap on the end of one of<br />
the beanng cups to drive the other bearillg out of the yoke<br />
Lift the beanng out With the fingers to aVOid dISlodging the<br />
needle rollers<br />
3 Agalll usmg a soft drift tap on the end of the<br />
trunnIon of the bearing Just removed to dnft the other<br />
bearing out of the yoke and agam carefully remove to aVOid<br />
dislodgIng the needle rollers<br />
4 Manoeuvre the yoke over the ends of the trunmon<br />
and Withdraw from the shaft assembly<br />
5 Treat the other two bearings of the front umversal<br />
JOint and the bearings of the rear universal JOint In a Similar<br />
mannerto completely dismantle the propeller shaft<br />
6 Check the needle roller bearings and trunmons for<br />
wear If wear IS apparent renew the trunruons and beanngs<br />
as a kit Never renew mdlVldual needle roller bearing<br />
assembhes or fit old bearings to a new trunmon Always use<br />
new beanng retamlng cuchps and beanng seal washers<br />
Reassembly IS a reversal of the dismantling procedure<br />
NOTE When dlsmanrllng or reassembling do nothold the<br />
machined sectIOn of the front universal JOint yoke In the<br />
unprotected Jaws of a vice or the seal surface of the yoke<br />
Will be damaged Where necessary reduce any beaTIng cup<br />
end float by installing oversize clrcllps<br />
fit<br />
r U CIRCLlPS<br />
96<br />
SELECTIVE FITl<br />
NEEDLE BEARING CUPS
GEARBOX<br />
PART 4<br />
1 DIffIcult gear change<br />
Possible cause<br />
a Worn selector mechamsm<br />
b Faulty gear synchromser mechanIsm<br />
c Faulty clutch or clutch release mechanIsm<br />
d Distorted transmission shaft sphnes<br />
2 Gear clash on changmg down<br />
Manltal Transmission I8<br />
TR Ns nSSI N AIJLT DIAf NOSIS<br />
MANUAl<br />
Remedy<br />
Check and renew faulty components<br />
Overhaul gearbox<br />
Check and overhaul clutch and or adJust release<br />
mechamsm<br />
Renew damaged components<br />
Possible cause Remedy<br />
a Faulty clutch or clutch release mechanIsm<br />
b Faulty synchro nngs and cones or Servo synchro<br />
components<br />
c Broken or Incorrect posltlomng of synchro shift<br />
plate retaining spnngs<br />
d Lubncatlng 011 too heavy<br />
3 SlIpping out of gear<br />
1st and 2nd<br />
Overhaul clutch and or adJust release mechamsm<br />
Check and overhaul gearbox renew components<br />
as reqUired<br />
Check and overhaul gearbox renew components as<br />
requued<br />
Drain gear case and refill With correct quantity and<br />
grade<br />
of oil<br />
POSSible Gause Remedy<br />
a Weak or broken selector plunger spnng<br />
b Worn or chipped synchro teeth on 1st and or<br />
2nd speed<br />
c ExceSSIve end float oflaygear<br />
d Worn gearbox front or rear beanngs<br />
e Worn shIft or selector mechanIsm<br />
4 SlIppIng out of gear 3rd and top<br />
a<br />
Renew plunger spnng<br />
Check and overhaul gearbox renew components as<br />
reqUired<br />
Check and renew faulty thrust washers<br />
Check and renew worn beanngs<br />
Check and renewfaulty components<br />
POSSible cause Remedy<br />
Weak or broken selector plunger spnng<br />
b Worn synchro teeth on thud and or top speeds<br />
c<br />
ExceSSIVe end float of laygear<br />
d Worn gearbox front or rear ball beanngs<br />
or selector mechanIsm<br />
e Worn sluft<br />
5 Gearbox noise in neutral<br />
Renew plunger spnng<br />
Check and overhaul gearbox renew components as<br />
requued<br />
Check and renew worn thrust washers<br />
Check and renew worn beanngs<br />
Check and renew faulty components<br />
POSSible cause Remedy<br />
a Worn front gearbox beanng<br />
b Chipped or pitted constant mesh gears Iaygear<br />
front dnve gear or 1st 2nd or 3rd malnshaft<br />
gears<br />
c ExceSSive laygear<br />
end float<br />
d Lack ofsuffiCient lubncant<br />
97<br />
Overhaul and renew beanng<br />
Overhaul and renewcomponents as necessary<br />
thrust washers<br />
Fill gear case With the correct quantIty and grade<br />
ofgear oil<br />
Check and renew laygear
19 <strong>Manual</strong> Transmission<br />
6 Gearbox nOISe forward gearli engaged<br />
POSSIble cause<br />
a Worn front and or rear gearbox ball beanngs<br />
b Chipped or pitted constant mesh gears Iaygear<br />
front dnve gear on 1st 2nd or 3rd speed malnshaft<br />
c<br />
gears<br />
ExceSSIVe laygear end float<br />
d Chipped reverse Idler<br />
gear<br />
e Lack ofsufficIent Iubncant<br />
PROPELLER SHAFT<br />
a<br />
Shaft VIbration<br />
Bent propeller shaft s<br />
Possible cause<br />
b ExceSSive wear In umversal JOint trunmon and<br />
beanngs<br />
c Propeller shaft s out of balance<br />
d ExceSSIVe wearof front JOint sleeve In rear<br />
e<br />
extensIOn hOUSing<br />
Rear umversal JOint to pinIOn flange bolts loose<br />
I Worn centre support beanng<br />
2 ExcessIve backlash<br />
Possible cause<br />
a Worn umversal JOint trunnIon and beanngs<br />
b Worn malnshaft and umversal JOint sleeve<br />
98<br />
Remedy<br />
Overhaul and renew beanngs<br />
Overhaul and renew components as necessary<br />
Check and renew laygear thrust washers<br />
Check and renew as components necessary<br />
Fill gear case With correct quantity and grade of<br />
lubncant<br />
Renew shaft s<br />
Remedy<br />
Renew complete umversal JOint trunmon and<br />
beanngs<br />
Renew complete propeller shaft s<br />
Renew extensIOn hOUSing bush assembly<br />
Renew and tighten loose bolts<br />
Renew centre beanng<br />
Remedy<br />
Renew JOint trunmon and bearings as an assembly<br />
Renew worn components
Type<br />
Rfl If<br />
OperatIOn<br />
RatIOS<br />
Low<br />
i<br />
Intermewate<br />
High<br />
Reverse<br />
Converter range<br />
Lubncant<br />
Type<br />
Total cdpaclty With<br />
converter<br />
rc<br />
L<br />
to<br />
l<br />
i 1<br />
f<br />
ji<br />
r J<br />
Upshift speeds hglit throttle<br />
Low to intermediate<br />
Intermewate to hl<br />
Upshift speeds tri throttle<br />
Low to Interrnewate<br />
Intermewate to high<br />
Upsluft speeds onkick down<br />
Low to Interrnewate<br />
Intermediate to high<br />
of<br />
b<br />
It<br />
240 I<br />
1 450 1<br />
1000 1<br />
2100 I<br />
2 I 1<br />
to 100 1<br />
Dexron Auto<br />
if<br />
h t<br />
matlc TranSffi1sslOn<br />
Fluid for<br />
Austrahan<br />
manufactured<br />
transnusslOn 4t<br />
I<br />
Specified Auto<br />
matic Transml slOnt<br />
FlUid for<br />
English manu<br />
factured transmiSSIOn<br />
II 25 Imp pt<br />
638 htre<br />
135 US pt<br />
11 16 kph<br />
7 10mph<br />
19 25 kph<br />
12 16 mph<br />
37 43 kph<br />
23 27 mph<br />
50 72 kph<br />
35 45 mph<br />
53 64<br />
33 40<br />
91 99<br />
57 62<br />
The automatic tian nusslOn combines a flUid couphng<br />
99<br />
011 pan drain plug<br />
011 pan screws<br />
It<br />
l<br />
on klcdown<br />
late<br />
TORQUE WRENCH SETTINGS<br />
Torque converter to flywheel bolts<br />
Starter safety SWitch locknut<br />
ExtenSIOn housillg to transmiSSIOn<br />
case<br />
Transmission case to converter<br />
hOUSing<br />
TransnusslOn mountl1g centre<br />
bolt<br />
I DESCIlII TIO<br />
Filler tube sleeve nut<br />
j<br />
1<br />
Filler tube adaptor<br />
f<br />
FlUid level ill the transmISSIOn IS checked by a dlPJitlck<br />
or torque converter With a fully automatic three speed type indicator I ted In the oIl filler tube<br />
1ft I Wi<br />
04<br />
eplcychc gear system 1orque converter hoUSing andjthe The spee Jor quadrant attached to the steenng<br />
transmiSSIOn case are separate column IS marke L low D<br />
casings<br />
dnve or direct N neutnilif<br />
The transinlsslOn1 p11iVldes three forward ratlos and one R reverse an uMk The selector lever ri ttSt b d<br />
reverse J to clear a gate P1 the steenng column<br />
The hydrauhc system consISts of a single front pUmp<br />
J 1 0 3<br />
either reverse or park pOSltlons<br />
I 93 kg m<br />
14 ft lb<br />
1 38 kg m<br />
In order t ect<br />
and valve arrangement ThIs IS a af ty lm asure to prevent thel 4 Xe nlfiom<br />
I<br />
10<br />
ft lb<br />
414 kg m<br />
30 ft lb<br />
o 829 kg m<br />
6 ftlb<br />
I 38 kg m<br />
10 ft lb<br />
1 38 kg m<br />
10 ft lb<br />
I 65 kg m<br />
12 ft lb<br />
2 48 kg m<br />
18 ft lb<br />
331 kg m<br />
24 ft lb
2 Automatic Transmission<br />
selecting either of these pOSItions wlule the vehicle IS<br />
travelling forward<br />
It IS necessary for the selector lever to be on the N or P<br />
posItIon before the engme can be started<br />
ENGINE TUNING<br />
When tuning or testing the engIne the handbrake must<br />
be firmly apphed and the selector lever must be In the P<br />
park or N neutral pOSItIon otherwise the vehicle will<br />
move forward or backward as the engine speed IS Increased<br />
When adJusting the Idling speed move the selector lever<br />
to the D pOSitIOn In order that the correct Idhng speed<br />
adJustment may be obtained<br />
Only a recommended grade of AutomatIc TranSmIssion<br />
FlUId should be used In the transmiSSion when topping up<br />
or changing flUId In the system<br />
The flUid level In the tranSmISSion case should be<br />
checked at regular Intervals of not greater than 6 000<br />
kilometres 4 000 rrules and It IS good pohcy to check the<br />
flUId level at each lubncatIon semce<br />
Every 50 000 kilometres 30 000miles the flUid In the<br />
tranSIlliSSlon should be draIned off while the tranSmISSion<br />
assembly IS at operating temperature<br />
As It IS necessary to remove the oil pan In order to<br />
adJust the forward speed band the band checking and<br />
adJustIng procedure should be carned out at the same time<br />
that the hydrauhc flUid IS being drained and renewed<br />
TO CHECK AND TOP UP<br />
1 Place the vehIcle on a level floor and open the<br />
engIne bonnet<br />
2 Carefully clean around the top of the tranSmISSion<br />
case filler tube and dipstick to ensure that no wrt or<br />
foreign matter can enter the filler tube as the dipstIck IS<br />
Withdrawn<br />
3 Place the selector lever In the P park posItion on<br />
the selector quadrant and firmly apply the handbrake<br />
4 Start the engIne and run at a fast Idle to bnng the<br />
engIne and transllliSslOn assembly to normal operating<br />
temperature<br />
NOTE As an alternative to operatIOn 4 run the vehicle<br />
on the road for approximately 5 miles<br />
TOWING<br />
F or long wstance tOWing the propeller shaft should be<br />
wsconnected at the rear umversal flange and removed from<br />
the vehicle and a SUitable plug apphed to the rear of the<br />
transmiSSIOn case to prevent loss offlUId or entry ofdut<br />
An alternative method IS to tow the vehicle suspended<br />
from the rear<br />
The vehicle may be towed for short distances Without<br />
dISconnecting the propeller shaft proVided the towing speed<br />
does not exceed 30 mph and the cause for which the<br />
vehicle IS being towed IS not Within the transmission or the<br />
r<br />
rear axle<br />
It IS not practIcable to start the engIne by either tOWing<br />
or pushing<br />
2 HYDIlAUI IC LUIU<br />
100<br />
the velucle<br />
5 Return the engine to the correct Idhng speed<br />
Withdraw the dipstick and check the level of the hydrauliC<br />
flUid If necessary add suffiCient flUId to the tranSmISSion<br />
case Via the filler tube to bnng<br />
on the dipstick<br />
the level to the FULL mark<br />
NOTE Use only a recommendedAutomatic TransmiSSIOn<br />
FlUId for Englzsh manufactured Borg Warner 35 Type<br />
transmlsszon For Australzan manufactured Borg Warner 35<br />
type transmiSSIOn use Dexron flUId only Do not overfill or<br />
foamzng and unsatisfactory operatIOn of the assembly Will<br />
result<br />
TO DRAIN AND REFILL<br />
1 Bnng the transmISsIOn to the normal operating<br />
temperature and raise the vehicle on a hOiSt or place It over<br />
a pit so that the transmiSSIOn case IS reasonably level<br />
2 Unscrew and remove the transllliSslOn case oil pan<br />
dram plug and dram the hydrauhc flUid Into a SUItable<br />
container<br />
NOTE Use care to avOid scaldzng If the flUId IS very hot<br />
after a long run<br />
3 Replace and tIghten the 011 pan drain plug to a<br />
torque ofI 93 kgm 14 ft lb<br />
4 Refill the tranSmISSion case With the correct grade<br />
and quantIty of flUid as recommended start the engIne<br />
and<br />
bnng It to the normal operating temperature<br />
5 Check the flUId level on the dipstick and top up If<br />
necessary as detailed In TO CHECK AND TOP UP
If<br />
TO ADJUST<br />
This IS not a normal service operatIOn but adJustment<br />
will be indicated by a harsh sluft pattern or a loose<br />
adJusting<br />
screw lock nut<br />
It IS necessary to drain the hydrauhc flUid and remove<br />
the oil pan In order to adJust the forward band and Ifthe<br />
hydrauhc flUid has seen considerable sefVlce the<br />
transrmsslOn should be refilled With new flUid of the correct<br />
grade after the adJustment procedure has been completed<br />
1 Carry out operatIOns 1 and 2 In TO DRAIN<br />
AND REFILL<br />
2 Clean around the transmISSion case oil pan and<br />
remove the pan and gasket Discard the gasket<br />
3 Release the forward speed band adJustIng screw<br />
several turns<br />
4 Hold the servo lever out at the top and place a<br />
The reverse speed band adJustment IS not a penodlcal<br />
service operatIOn and may only become necessary as<br />
indicated by a harsh shift pattern a loose adJusting screw<br />
locknut or no dnve In the reverse posItion<br />
I WIth the engine stopped raise the vehicle on a<br />
hOist or place It over a pIt<br />
2 Clean around the band adJusting screw and locknut<br />
Gear Selector Arrangement at Lower End of Steering<br />
Column<br />
5<br />
3 FORWAIU SPEED BAXD<br />
4 IlEVEHSE BAND<br />
Automafic<br />
6350 mm 0250 In thick gauge block between the servo<br />
piston pin and the adJusting screw<br />
5 USing a SUitable tensIOn wrench tIghten the<br />
adJusting screw to a torque of 0 11 kg m 10 mlb and<br />
secure the screw by tIghtemng the locknut Remove the<br />
gauge block from between the servo piston pm and the<br />
adJusting screw<br />
6 Clean the mating surfaces of the transmiSSIOn case<br />
and the oil pan Instal the pan using a new gasket and<br />
tIghten the secunng screws to a torque of I 38 kg<br />
ft lb<br />
Transmission<br />
m 10<br />
7 Refill the transmission case With hydraulic flUid as<br />
descnbed In TO DRAIN AND REFILL<br />
NOTE Carry out mltlal adJustment at 1500 kllometres<br />
1000 miles and followmg adJustments at 25000<br />
kllometres 15 000 miles<br />
on the nght hand Side of the transmISSion case<br />
3 Slacken the adJusting screw locknut several turns<br />
4 Tighten the band adJusting screw to a torque of<br />
1 38 kg m 10 ftflb and back offthe screw of a turn<br />
Hold the screw In thiS posItIon and tIghten the locknut<br />
to a torque of approximately 4 14 kgfm 30 ftflb<br />
TR1 XS ISSION SHIFT LIl K t<br />
101<br />
TO ADJUST<br />
I USing a spanner of the correct Size loosen the<br />
locknut on the trunmon at the upper end of the speed<br />
selector rod so that the rod can shde smoothly In the<br />
trunmon<br />
2 Set the equahser and the selector lever on the<br />
transrmsslOn case In the dnve posItIon by puslung down on<br />
the selector rod to the lowest pOSItion and then raise the<br />
lever to the dnve posItion by pulhng up on the selector rod<br />
to the first detent posItIon<br />
3 Move the selector lever on the steenng column so<br />
that the indicator IS on the D dnve posItIon on the<br />
selector quadrant and tIghten the locknuts agamst the flat<br />
SIdes of the selector rod trunmon<br />
Ensure that the equahser and the selector lever on the<br />
transrmSSlOn case have not been moved dunng thIS<br />
operatIOn<br />
4 Move the speed selector through the speed detent<br />
posItions to ensure that the quadrant indicator pOints<br />
centrally to the appropnate speed letter on the quadrant<br />
5 Select the P park pOSitIOn and check the parking<br />
pawl engagement by trYing to move the velucle<br />
6 Check and If necessary adJust the starter neutral<br />
safety SWitch
4Automatic Transmissiun<br />
ft NEUTIlIU SAFET<br />
The neutral safety sWitch incorporating the reverse<br />
light sWitch IS attached to the left hand Side of the<br />
transmiSSIOn case SWitch terminals I and 3 are connected<br />
m senes With the starter solenoid sWitch to ensure that the<br />
engIne can be started only With the transmiSSion In either<br />
the N neutral or P park posItion<br />
SWitch terminals 2 and 4 are connected In senes With<br />
the reverse light wluch should operate only when the R<br />
reverse posItion IS selected on the selector quadrant<br />
Any adJustment to the tranSmISSion hnkage should be<br />
followed by the neutral safety SWitch adJustment<br />
TO ADJUST<br />
I With the engIne stopped select D orL pOSItion on<br />
the selector quadrant With the selector lever and apply the<br />
handbrake<br />
2 Slacken the locknut on the stem of the neutral<br />
safety SWitch suffiCiently<br />
out In relation to the tranSmISSion case<br />
for the SWitch to be screwed In or<br />
3 Disconnect the wues to the neutral safety SWitch<br />
terminals I and 3 and connect a 12 volt test lamp In senes<br />
With these tenmnals and the battery and earth SImIlarly<br />
connect a second test lamp cross the reverse hght termmals<br />
2 and 4 on the SWitch<br />
4 Screw the safety SWitch In slowly<br />
hght test lamp goes out and note thiS posItion<br />
until the reverse<br />
SWIT<br />
H<br />
5 Continue to screw the SWitch In until the starter<br />
test lamp lights and again note the position of the SWitch<br />
Screw the SWitch out to a pomt mIdway between the two<br />
pOSItions and tighten<br />
test lamp IS out<br />
the locknut Check that the starter<br />
6 Move the selector lever to the P park pOSItion<br />
The lamp should be as extinguished the Inwcator moves to<br />
the R reverse pOSItion on the quadrant and then hght<br />
again as the Inwcator regIsters With the P park pOSitIOn on<br />
the quadrant The reverse hght test lamp must hght only<br />
when the R reverse pOSItIon IS selected<br />
7 If necessary move the safety SWitch shghtly<br />
In or<br />
out untJI the conwtlOns descnbed m operatIOns 4 5 and<br />
6 preVail and tighten the locknut on the SWitch mountIng<br />
stem<br />
8 Move the speed selector lever to the D dnve and<br />
L low posItIons In turn Both test lamps should be<br />
extingUished In these positions If the SWitch IS serVIceable<br />
and correctly adJusted<br />
If It IS unposslble to adJust the SWitch as descnbed a<br />
new neutral safety SWitch must be Installed<br />
9 Remove the test lamps and restore the onglnal<br />
connectIOns<br />
NOTE Late senes vehIcles are fitted WIth a non adJustable<br />
neutral safety SWItch Ifdefective It must be replaced<br />
7 ARBURETTOn ND DOWNSHIFT VAI E CARI E<br />
Accelerator Linkage and Downshift Klckdownl Valve<br />
Cable Adjustment<br />
102<br />
TO ADJUST<br />
I Carry out the Idhng speed and mIXture adJustments<br />
as descnbed In the FUEL sectIOn ofthiS manual<br />
2 Disconnect the control cable at the carburettor<br />
throttle lever allow the accelerator to return to the off<br />
pOSItion<br />
3 Ensure that the engIne and transmiSSIOn are at<br />
normal operating temperature and check the flUid level In<br />
the transmiSSIOn<br />
4 With the engine stopped connect an electncal<br />
tachometer In parallel With the Ignition pnmary CUCUlt<br />
accorwng to the manufacturers instructions and connect a<br />
pressure test gauge calibrated to 21 kgjcm2 300 pSI to<br />
the take off pOint on the rear transnusslOn case<br />
5 Check the choke valve IS fully open and that there<br />
IS no free play In the accelerator linkage<br />
6 Release the ferrule on the mner cable by squeezmg<br />
the Sides opposite to the cnmps With a palf of phers<br />
7 Start the engIne and check that the Idle speed IS to<br />
speCificatIons<br />
8 Note and record the pressure reading on the gauge<br />
9 Reconnect the Inner cable to the throttle hnkage<br />
10 AdJust the outer cable to gIve a reading of 0 07<br />
kgcm2 I pSI above the pressure noted and recorded In<br />
OperatIon 8 and tighten the locknut
11 Increase the engIne speed by 500 rpm and check<br />
that a nse In pressure indicated on the line pressure IS a<br />
mmunum of 0 70 kg cm2 10 pSI To Increase the pressure<br />
lengthen the outer cable To decrease pressure shorten the<br />
outer cable<br />
12 POSitIOn the ferrule on the Inner cable against the<br />
end of the outer cable and cnmp It firmly to the Inner<br />
cable<br />
13 Stop the engIne and remove the tachometer and<br />
the hne pressure gauge and refit the plug to the pressure<br />
gauge connectIOn In the transmISSion case Tighten to<br />
speCifications<br />
NOTE It IS adVisable to carry out thiS pressure test and<br />
check after mstallmg and manual adjustment of a new<br />
cable<br />
TO RENEW CABLE AND ADJUST<br />
1 Carry out the throttle hnkage check and Idling<br />
speed adJustment as descnbed In the FUEL sectIOn of thiS<br />
manual<br />
2 Remove the transmiSSIOn drain plug and drain off<br />
the hydraulic flUid<br />
3 Take out the secunng screws and remove the<br />
transmission 011 pan and gasket Discard the gasket<br />
4 Detach the Inner cable from the throttle hnkage<br />
5 Remove the outer cable adJusting locknut and<br />
remove the Inner and outer cables from the mounting<br />
bracket<br />
6 Rotate the cam on the valve body to enable the<br />
hole In the<br />
cable end to be removed from the mounting<br />
cam assembly<br />
7 Remove the outer cable by unscreWing It from the<br />
tranSffi1SSlOn case<br />
8 Instal the new outer cable Into the transmiSSIOn<br />
case uSing a new sealing washer between the adaptor and<br />
the case Tighten the adaptor to speCifications<br />
9 Instal the Inner cable to the cam assembly In the<br />
reverse to the removal method<br />
10 Instal the cables Into the mounting bracket and<br />
TO REMOVE<br />
I Disconnect the earth lead at the battery terminal<br />
and the posItive lead at the terffi1nal on the starter solenOid<br />
SWitch<br />
2 Take out the secunng screws and remove the<br />
starter from the engIne<br />
3 Raise the vehicle support It on stands remove the<br />
drain plug and drain off the transmission flUid Instal the<br />
drain plug<br />
4 Disconnect the transmISSion filler tube and dipstick<br />
and remove from the tranSffi1SSlOn case Disconnect the<br />
transmiSSIOn cooler pipes Iffitted<br />
Automatic Tralll mission<br />
I<br />
Cam Position at Idling Speed for Correct Cable Adjustment<br />
fit the locknut to the outer cable but do not tighten at thIS<br />
stage and do not cnmp the ferrule<br />
II Make sure the carburettor hot Idle settmg has not<br />
been altered during the cable removal and Installation<br />
operation<br />
12 Flex the Inner cable to remove any Ianks and<br />
connect the cable to the throttle hnkage<br />
13 Insert the 0 13 mm 0005 In feeler gauge or<br />
stnp between the throttle valve and the flat on the cam<br />
face<br />
14 Tighten the adJusting nut on the outer cable untIl<br />
a very light drag IS felt on the feeler gauge or stnp<br />
15 Tighten the locknut and recheck the gap Leave<br />
the feeler gauge or stnp In pOSitIOn<br />
16 Position the ferrule on the Inner cable to JIlSt<br />
contact the end of the outer cable and crunp It firmly to<br />
the Inner cable at thiS posItion<br />
17 Remove the feeler gauge or stnp<br />
18 Instal the 011 pan With a new gasket and tighten<br />
the retaining bolts to speCifications<br />
19 Instal the drain plug and tighten to speCificatIOns<br />
20 Refill the transmiSSIOn With Dexron transffi1SSlOn<br />
flUid<br />
21<br />
pattern<br />
Road test the vehicle and check the change<br />
22 Recheck the flUid level Refer to section TO<br />
CHECK AND TOP UP<br />
II TRANSMISSION l SSEMBLV<br />
103<br />
5 Disconnect the transmiSSion kIckdown control<br />
cable at the throttle hnkage<br />
6 Disconnect the speed selector equaliser and lever<br />
assembly at the Side of the transmiSSIOn<br />
7 Disconnect the propeller shaft at the rear umversal<br />
JOint flange Withdraw the propeller shaft from the rear of<br />
the transmiSSion and remove the shaft assembly from the<br />
vehicle Plug the rear of the transmission case to prevent<br />
entry ofdut or loss offlUid from the rear extensIOn<br />
NOTE To preserve the ongmal balance of the propeller<br />
shaft mark across Jomt and pinIOn flanges to ensure<br />
replacement In the onglnal positions
6Automatic Tran mission<br />
8 Remove the speedometer cable and dnven gear<br />
from the transmiSSIon case and plug the hole to prevent<br />
entry of dut Disconnect the hand brake secondary cable<br />
from the lower end of the relay lever<br />
9 Disconnect the exhaust outlet pipe at the mamfold<br />
flange 10 Disconnect the WIres at the starter safety sWitch<br />
on the side of the transmission case noting the correct<br />
posItions of the wues for reassembly<br />
I I With sUitable protectIOn on the Jack head<br />
support the rear of the engine and transmiSSion under the<br />
rear of the engme sump<br />
12 Remove the attachment bolts secunng the<br />
mounting support to the underbody Remove the bolts<br />
secunng the mounting to the rear extensIOn hOUSing and<br />
Withdraw the mounting assembly<br />
I3 Remove the bolts secunng the torque converter<br />
to the flywheel<br />
14 Remove the top transmiSSIOn to engine securing<br />
bolts and SUitably support the transmiSSIOn assembly<br />
NOTE Ensure that the transmISSIOn IS supported on and<br />
secured to a SUitable Jack so that It cannot become<br />
dislodged as It IS withdrawn from the vehIcle Ensure that<br />
the Jack cannot damage the 011 pan<br />
IS Remove the remaining bolts secunng the<br />
transmISSIOn to the engine and carefully Withdraw the<br />
assembly rearwards to clear the converter from the<br />
flywheel<br />
NOTE Use care to ensure that the torque converter does<br />
not become dislodged from the front of the transmiSSIOn<br />
I6 Attach a SUitable to retaining strap the converter<br />
cover holes so that It<br />
housmg bolting It to the hOUSing<br />
1O<br />
retains the converter In posItion when the transmiSSIOn IS<br />
Withdrawn from the rear of the engine<br />
17 Lower the Jack supporting<br />
the transmiSSion<br />
assembly and Withdraw It from beneath the vehicle<br />
TO INSTAL<br />
Installation IS a reversal of the removal procedure With<br />
particular attention to the follOWing pOints<br />
I Ensure that the converter IS fully engaged In the<br />
front of the transmiSSIOn and m the spigot In the rearof the<br />
crankshaft<br />
2 Ensure that the attachment faces of the torque<br />
converter hOUSing and the rear of the engIne crankcase are<br />
both perfectly clean and free of any burrs<br />
3 Ensure that the rear engine plate IS correctly<br />
pOSItioned<br />
4 Instal the bolts secunng the converter to the<br />
flywheel and tighten evenly to the speCified torque<br />
NOTE The head of these bolts must be on the engme SIde<br />
of theflywheel<br />
5 Tighten the bolts secunng the converter hOUSing to<br />
the rear of the engine to the speCified torque<br />
6 Fill the transrrnsslOn With the speCified grade and<br />
quantity of the recommended hydrauhc flUid<br />
7 Check and If necessary adJust the selector rod<br />
throttle klckdown cable and neutral safety SWitch as<br />
preVIOusly descnbed<br />
8 Road test the vehicle and recheck the hydrauhc<br />
flUid level as descnbed In HYDRAULIC FLUID TO<br />
CHECK AND TOP UP
No dnve In D range<br />
a Low flUid level In transmiSSIOn<br />
b Incorrectly adJusted<br />
ft AUTO I TIC TIlANSMISSION FAUI T DIAf NOSIS<br />
The following transmiSSIOn operating faults<br />
Automatic Transmission 7<br />
can be<br />
caused by conwtIons that may be rectIfied within the scope<br />
ofthe informatIOn gIven In this section<br />
POSSible cause Remedy<br />
selector rod<br />
c Incorrect transmiSSion flUid In umt<br />
d Incorrectly adJusted downshift valve control<br />
cable<br />
2 No reverse drive In R on quadrant<br />
a<br />
Low flUid level In transmiSSIOn<br />
b Incorrectly adJusted selector rod<br />
c Reverse band Incorrectly adJusted<br />
3 Shpplng or rough In up shift<br />
Check flUid level and top up<br />
Check and readJust rod as detailed<br />
Drain and refill With recommended grade of flUid<br />
see SpeCifications<br />
Check and adJust cable as detailed<br />
POSSible cause Remedy<br />
Check flUid level and top up<br />
Check and adJust selector rod as detailed<br />
AdJust<br />
reverse band as detailed<br />
POSSible cause Remedv<br />
a Incorrectly adJusted throttle hnkage<br />
b Incorrectly adJusted downshift valve control<br />
cable<br />
4 ShppIng In all speeds<br />
a Low flUid level<br />
POSSible<br />
m transmiSSIOn<br />
b Incorrect grade of flUid In umt<br />
c Incorrectly adJusted selector rod<br />
5 No transmiSSion kIckdown<br />
POSSible cause<br />
a Incorrectly adjusted carburettor and<br />
accelerator hnkage<br />
b Incorrectly adJusted downshIft valve control<br />
cable<br />
6 EngIne Will not start In P or N POSItions<br />
or will start In any range<br />
Check and adJust hnkage as detailed<br />
Check and adJust cable as detailed<br />
cause Remedy<br />
Check flUid level and top up<br />
Drain and refill With recommended grade of flUid<br />
See SpeCIfIcations<br />
Check and adJust selector rod as detailed<br />
Check and adJust hnkage<br />
Remedy<br />
as detailed<br />
Check and adJust cable as detailed<br />
POSSible cause Remedy<br />
a Neutral safety SWitch Incorrectly adJusted<br />
b Neutral safety SWitch faulty<br />
c Incorrectly adJusted selector rod<br />
105<br />
Check and adJust SWitch as detailed<br />
Check and renew SWitch<br />
Check and adJust selector rod as detailed
SEDAN<br />
Type<br />
Ratio<br />
Fitted with 3 speed transmiSSion<br />
<strong>L13</strong> LI4<br />
L16<br />
Fitted with 4 speed transmiSSion<br />
L14<br />
L16<br />
Fitted with auto tranSffi1SSlOn<br />
LI6<br />
Number of crownwheel and<br />
pinIOn teeth<br />
4111 Iratlo<br />
4375 I ratio<br />
3 700 I ratio<br />
3 900 I ratIO<br />
Bearmg type<br />
Dnve pinIOn<br />
Dnve pmlon pilot<br />
Crownwheel carner<br />
Dnve pinIOn<br />
DimenSIOn pinIOn head to<br />
carner centre approx<br />
Turning torque Without<br />
011 seal inItial<br />
Thickness range of selective fit<br />
washers pinIOn height adJustment<br />
Thickness range of selective fit<br />
shims pinion height adJustment<br />
Length range of selective fit spacers<br />
pinIOn beanng adJustment<br />
HypOld<br />
4375<br />
3900<br />
4111<br />
3700<br />
3900<br />
37 9<br />
35 8<br />
37 10<br />
39 10<br />
Tapered roller<br />
Ball<br />
Tapered roller<br />
485mm<br />
I 909 In<br />
7 10 kg cm<br />
6 861n lb<br />
20 2 4 mm<br />
Increments<br />
of 0 2 mm<br />
0078<br />
o 094 1n<br />
Increments<br />
of 0008 In app<br />
I 09 I 27 mm<br />
mcrements<br />
of002mm<br />
00429<br />
00500 In<br />
mcrements<br />
of 0 0008 In<br />
56 2 57 2 mm<br />
Incremen18<br />
of 0 2 mm<br />
2 213<br />
2 252 In<br />
mcreinents<br />
of 0008 In app<br />
REAR AXLE<br />
SPEC ICA TIOl S<br />
106<br />
Thickness range ofselectIve fit<br />
washers pinIOn beanng<br />
adJustment<br />
Crownwheel<br />
Backlash between crownwheel and<br />
pinIOn teeth<br />
Maximumrunout at crownwheel<br />
face<br />
Carner beanng retainers<br />
Thickness range of adJusting<br />
shims<br />
Side gears<br />
Thickness range of thrust washers<br />
Gear to thrust washer clearance<br />
23l 257mm<br />
Increments<br />
of 0 02 mm<br />
0091<br />
o 101m<br />
Increments<br />
of 0 0008 In<br />
01 02mm<br />
0 004<br />
o 008 In<br />
008 mm<br />
0003 In<br />
o 05 0 50 mm<br />
Increments<br />
0 002<br />
o 020 In<br />
Increments<br />
0775<br />
TORQUE WRENCH SETTINGS<br />
MaxImum Settings<br />
Final dnve assembly to suspensIOn<br />
member bolts<br />
Rear mounting leaf nuts<br />
Mounting leaf to casing nuts<br />
Propeller shaft flange nuts<br />
Dnve shaft to dIfferential nuts<br />
PinIOn nut<br />
Crownwheel bolts<br />
o 875 mm<br />
Increments<br />
of 0 05 mm<br />
0 0305<br />
o 0344 In<br />
mcrements<br />
of0002 In<br />
o 1 02mm<br />
0 004<br />
0008 In<br />
6 kg m<br />
43 ft lb<br />
8 5 kg m<br />
61 5 ft lb<br />
8 kg m<br />
58 ft lb<br />
8 5 kg m<br />
61 5 ft lb<br />
8 kg m<br />
58 ft lb<br />
20 kg m<br />
145 ft lb<br />
8 kg m<br />
58 ft lb
Carner bearing retainer bolts<br />
Pilot beanng retainer bolts<br />
Rear cover bolts<br />
STATION SEDAN AND PICKUP<br />
Type<br />
RatIo<br />
Fitted With 3 speed transmISSion<br />
L16<br />
Fitted With 4 speed transmiSSIOn<br />
L16<br />
Fitted With auto transmiSSIOn<br />
L16<br />
Number of crownwheel and<br />
plmon teeth<br />
3 889 I ratIo<br />
3 700 I ratIo<br />
Beanng type<br />
Dnve pinion<br />
Crownwheel carner<br />
Dnve pinIOn<br />
Dlmen on pmlon head to carner<br />
centre appro<br />
Turning torque Without 011 seal<br />
inItial<br />
Thickness range ofselective<br />
fit shims pinIOn height<br />
adjustment<br />
Length range of selectIve fit<br />
spacers pinion beanng<br />
adJustment<br />
I 2 kg m<br />
8 7 ft lb<br />
I 2 kg m<br />
8 7 ft lb<br />
2 6 kg m<br />
19ft lb<br />
HypOld<br />
3889<br />
59 25<br />
59 70 mm<br />
Increments<br />
of0 25 mm<br />
2 332<br />
2 350 In<br />
Increments<br />
ofOOIOIn<br />
107<br />
Thickness range of selectIve fit<br />
washers pinIOn beanng adJustment<br />
Crownwheel<br />
PinIOn nut<br />
Crownwheel bolts<br />
Carner beanng cap bolts<br />
AUT I IU AII XI S ItA<br />
1 Dt nlll TIUN<br />
Rear Axle 2<br />
231<br />
2 57 mm<br />
Increments<br />
of 0 02 mm<br />
0091<br />
0101 In<br />
Increments<br />
of 0 0008 In<br />
015 02mm<br />
0006<br />
o 008 In<br />
005 mm<br />
0002 In<br />
005 0 75 mm<br />
5 Increments<br />
0002<br />
o 0295 In<br />
5 Increments<br />
078 I 23 mm<br />
5 Increments<br />
0 031<br />
o 0484 In<br />
5 Increments<br />
005 0 20 mm<br />
0 002<br />
TORQUE WRENCH SETTINGS<br />
0008 In<br />
2 2 kg m<br />
J 6 ft lb<br />
2 2 kg m<br />
16 ft lb<br />
17 kg m<br />
J23 ft lb<br />
5 5 kg m<br />
40 ft lb<br />
4 8 kg m<br />
35 ft lb<br />
The differential final dnve assembly IS mounted at the mounted It becomes an additional support for the rear<br />
forward end to the rear suspensIOn crossmember and at the<br />
suspensIOn crossmember<br />
rear end to the body a by leaf spnng Both the Dnve from the IS assembly taken to the wheel hubs<br />
crossmember and leaf spnng are Insulated from the body by through short dnve shafts fitted With a umversal JOint at<br />
rubber Insulators to prevent Vibration each end<br />
Backlash between crownwheel and<br />
pinIOn teeth<br />
3700 Maxunum run out at crownwheel face<br />
3889 Thickness range of carner beanng<br />
35 9<br />
37 10<br />
Tapered roller<br />
Tapered roller<br />
6l0mm<br />
2402 In<br />
10 13 kg cm<br />
86 11 In lb<br />
0075<br />
075 mm<br />
5 Increments<br />
0003<br />
0030 In<br />
5 Increments<br />
adJusting shims<br />
SIde gears<br />
Thickness range of thrust washers<br />
Gear to thrust washer clearance<br />
MaXimum settings<br />
Differential carner to axle nuts<br />
Propeller shaft flange nuts<br />
Because of the manner In which the assembly IS The crownwheel and wfferentlal case assembly IS
f<br />
l<br />
l Rear Axle<br />
supported In the carner by two tapered beanngs the<br />
beanng preload and crownwheel backlash IS adJusted by<br />
means ofslums<br />
The dnve pinIOn IS supported In the carner by two<br />
tapered beanngs and one ball beanng the beanng preload IS<br />
adJusted by means of spacers and washers<br />
PinIOn height In relation to the crownwheel IS<br />
controlled by the thickness of washer and slum located<br />
between the pinIOn head and rear tapered beanng The<br />
dnve pinion oil seal may be renewed If necessary without<br />
TO REMOVE AND INSTAL<br />
I Jack up the vehicle and support on axle stands<br />
2 Release the hand brake and disconnect the rear<br />
hand brake cable at the equahser<br />
3 Mark a hne across the propeller shaft umversal<br />
JOint flange and the pinIOn flange remove the four retaining<br />
nuts and bolts<br />
4 Separate the two flanges and eIther fasten the shaft<br />
out of the<br />
way or Withdraw the shaft from the rear of the<br />
gearbox<br />
5 Disconnect the dnve shafts at each Side of the<br />
differential assembly by removing the four nuts and bolts<br />
DRAIN PLUG FITTED<br />
WITH MAGNET<br />
InSide Face of End Cover<br />
2 FINAL DRIVE ASSE IBIY<br />
to r<br />
remoVIng the final dnve assembly from the vehicle<br />
The output shafts at each Side of the assembly to<br />
wluch the dnve shafts are attached are retained In the<br />
differential by bolts Output shaft 011 seals can also be<br />
renewed Without removing the final dnve assembly from<br />
the vehicle<br />
It IS unportant to note that adJustment figures stamped<br />
on the final dnve components are metnc which must be<br />
taken Into consideratIOn when calculating the vanous<br />
differential and pinIOn adJustments<br />
retaining each shaft to the flanges adJacent to the<br />
differential<br />
6 Remove the four bolts and nuts attaching the front<br />
end of the final dnve assembly to the rear suspensIOn<br />
crossmember and detach the shuns<br />
7 Support the final dnve assembly on a Jack<br />
8 Remove the nut at each end of the assembly rear<br />
mounting leaf<br />
9 Withdraw the assembly from the rear suspensIOn<br />
crossmember together with the Jack<br />
NOTE To aVOId stress on the crossmember msulators<br />
whIlst the assembly IS removed pOsition a Jack or stand<br />
under the centre of the crossmember<br />
InstallatIOn IS a reversal of the removal procedure<br />
TO DISMANTLE<br />
I With the final dnve assembly removed from the<br />
vehicle as preVIOusly descnbed remove the plug and drain<br />
offthe 011<br />
2 wose n 6W and femovetjT fear mounting leaf<br />
from the differential rear cover<br />
3 Take out the rear cover retaining bolts and detach<br />
the cover and gasket<br />
NOTE Before dlsmantlmg the assembly further carry out<br />
the followmg checks The mformatlOn gamed from the<br />
checks WIll prove helpful when assemblmg the umt<br />
a Check the tooth contact of the crownwheel and<br />
pinIOn by applYing a thin coating of red lead and engIne oil<br />
to both Sides of about SIX or eight of the crownwheel teeth<br />
b Rotate the pinIOn both ways plaCing a bar between<br />
the differential case and the carner to apply a load to the<br />
gear teeth to obtain a good markmg If the pinion height<br />
beanng pre load and backlash are correct the area of<br />
contact should be as shown In the teeth marking<br />
illustratIOn<br />
c The margIns above and below the area of contact<br />
should be the same and the contact margin should run<br />
approximately three quarters of the length of the tooth<br />
Check the patterns on both Sides ofthe tooth
d Mount a dial mwcator gauge on the dIfferential<br />
carner housmg so that the plunger IS In contact with and at<br />
nght angles to the heel of a crownwheel tooth then zero<br />
the dial ga uge<br />
e Hold the<br />
pmlOn firmly and rock the crownwheel<br />
back and forth to check the backlash reading on the dial<br />
gauge Check the backlash at approximately three pOSItIons<br />
around the crownwheel Backlash IS correct when within<br />
the hmlts of0 1 0 2 mm 0 004 0 008 In<br />
f If the backlash or tooth contact pattern IS Incorrect<br />
check the crownwheel run out by positIOnIng the dial<br />
indIcator plunger on the rear face of the crownwheel<br />
g Zero the gauge rotate the crownwheel and check<br />
for any vanatlon In gauge reading Maximum run out IS<br />
008 mm 0 003 m<br />
h USing a preload measunng gauge or spnng scale and<br />
cord check the torque required to rotate the pinIOn at the<br />
flange end Torque reqUired should be Within the hmlts of 3<br />
15 kg cm 2 5 13 In I b<br />
NOTE HaVing completed the foregOing checks and noted<br />
the relevant readings continue to dismantle the assembly as<br />
follows<br />
4 Remove the retamlng bolts from the output shafts<br />
at each Side of the assembly<br />
5 USing a sbde hammer Withdraw each output shaft<br />
from the dIfferentIal assembly<br />
Measurtng Crownwheel to Pinion Backlash See<br />
SpeCifications<br />
109<br />
Rear<br />
4xle<br />
4<br />
Turn the Differential Assembly at an Angle With the<br />
Crownwheel Uppermost to Remove or Instal<br />
NOTE To faCIlitate assembly It IS Important that each<br />
component as It IS removed IS marked In relatIOn to the<br />
dlfferentlal camer hOUSing to ensure replacement of shims<br />
and components In their oTlglnal positions<br />
6 Take out the differentIal carner beanng retainer<br />
bolts at each SIde of the assembly USing a SUitable puller<br />
Withdraw each retainer from the hOUSing<br />
7 Turn the dlfferenttal assembly at an angle With the<br />
crownwheel uppermost and Withdraw the assembly from<br />
the hOUSing<br />
8 With the<br />
pmlOn flange held to prevent It from<br />
turnmg remove the flange retamlng nut and washer<br />
9 USIng a SUitable puller Withdraw the pinIOn flange<br />
together WIth the 011 seal and dust cover<br />
10 Press out the pinIOn shaft With a hydrauhc press<br />
NOTE The rear beanng Inner cone and the spacer and<br />
adJUStIng washer for the taper bearings Will be removed<br />
with thepinIOn shaft<br />
II Take out the front beanng retainer screws and<br />
remove the retamer and pIlot bearIng
5 Rear Axle<br />
NOTE On later models the pilot bearmg and oil seal are<br />
pressed directly mto the hOUSing as the retainer has been<br />
dispensed with<br />
12 Remove the fron t spacer and the front taper<br />
beanng cone from the hOUSing<br />
NOTE Unless replacement of the pinIOn taper bearings IS<br />
Intended do not remove the taper bearmg outer cones from<br />
the housmg<br />
PrOVided replacement of the pmlOn IS not reqlllred and<br />
the checks camed out earller m dismantling proved<br />
to be<br />
satISfactory then do not remove the rear bearing mner cone<br />
from the pmlon<br />
Ifhowever replacement ofone or both of the above IS<br />
necessary wntmue dismantling as follows<br />
I3 Knock or press the taper beanng<br />
of the houSing<br />
I4 USing a SUitable puller or press<br />
outer cones out<br />
remove the rear<br />
taper beanng Inner cone from the pinIOn note the pinion<br />
height adJusting washer and slum between the beanng and<br />
pinIOn head<br />
If the old pinIOn IS to be used on assembly and the<br />
dlsmanthng checks were satisfactory mark the shun and<br />
washer to ensure correct fitment In onglnal pOSItion<br />
NOTE Before dismantling the dlfferentwl check the camer<br />
bearings on each Side of the differential case and the outer<br />
wnes In the beanng retamers PrOVided the bearings arefit<br />
for fUrther servIce do not remove them from posltlon<br />
Where the old pinIOn and beanngs are serYlceable and<br />
the tooth contact turning torque run out and backlash<br />
checks made on dlsmanthng are satisfactory then assembly<br />
15 Mark the posItion of the crownwheel In relatIOn IS a reversal of the dismantling procedure<br />
to the differential case If any of the above factors proved Incorrect on the<br />
16 Release the locks from the crownwheel retaining check It Will be necessary to carry out the appropnate<br />
bolts and remove the bolts and<br />
crownwheel adjustment as descnbed in thlS sectlon<br />
I7 Knock out the differential shaft lock pm<br />
from the ThIS IS not the case however when a new pinIOn and<br />
crownwheel Side of the differential case<br />
crownwheel IS to be Installed and or the beanngs renewed<br />
I8 Knock out the differential shaft and remove the Adjustment of the pinion posItion and beanng preload then<br />
pinIOns and Side gears together With the thrust washers becomes essential<br />
NOTE It IS Important that each pmlOn and Side gear<br />
together with ItS thmst washer IS marked m relatIOn to the<br />
dlfferentlal case to ensure ongmal mstallatlOn on assembly<br />
I9 If necessary for bearmg replacement<br />
puller and draw the carner beanngs from each Side of the<br />
dIfferential case<br />
use a SUitable<br />
20 Remove the 011 seals and carner beanng outer<br />
cones from the carner beanng retainers<br />
TO CLEAN AND INSPECT<br />
1 Wash all components In a cleaning<br />
blow dry With compressed au<br />
solvent and<br />
2 Check the crownwheel and pinIOn teeth for wear<br />
plttmg or damage<br />
140<br />
NOTE Crownwheel and pmlOn are supplled<br />
There are two methods of obtalnmg the correct pinIOn<br />
pOSItion which IS controlled by the washer and shim fitted<br />
between the pinIOn head and rear beanng cone One<br />
method reqUires the use of a dummy pinIOn and arbor kIt<br />
to calculate the thickness ofwasher and shim reqUired The<br />
second method entaIls the alteratIOn of the eXisting washer<br />
and shim thickness to compensate for the new pmlOn head<br />
vanatlOn uSing the old pinIOn head vanatlon as a gUide<br />
There are also two methods of obtaining the correct<br />
plmon taper beanng pre load which IS adjusted by a spacer<br />
and washer Inserted between the taper beanng Inner cones<br />
The first method agam reqUires the use of the dummy<br />
pinIOn kit and the second method employs the pmlOn and<br />
related components<br />
As the pinIOn head vanatlOn from standard IS given In<br />
umts of 001 mm metnc dimenSIOns are used for the<br />
purpose of calculatIOn<br />
as matched<br />
sets only therefore damage to one Item requires<br />
replacement ofboth<br />
3 Check the differential carner beanngs<br />
the<br />
for wear<br />
pitting or damage If a beanng IS faulty renew the complete<br />
beanng compnslng Inner cone rollers and outer cup<br />
4 Check the pinIOn taper beanngs and renew as<br />
descnbed In 3<br />
5 Check the pmlOn pilot beanng for roughness and<br />
Side play and renew If necessary<br />
6 ExamIne the dIfferential pinIOn and Side gear teeth<br />
and thrust faces for wear pitting or damage Check that the<br />
thrust washers are In serviceable condition<br />
7 Check the differential shaft for wear pittIng or<br />
damage Replace parts hsted In 6 and 7 If not In<br />
serviceable conditIOn<br />
8 ExamIne the differential case for damage<br />
and or<br />
distortIOn and renew If necessary Check also the plmon<br />
and Side gear thrust faces In the case for wear and or<br />
pitting<br />
9 Ensure that all slums and spacers are free of<br />
damage<br />
IO Instal new seals and O nngs dunng the assembly<br />
procedure<br />
TO ASSEMBLE AND ADJUST DRIVE PINION
Exploded View of Drive Pinion Components<br />
Spacers washers and shIms are selective fit<br />
Pimon Bearing Pre Load<br />
Method 1<br />
WIth specIal tools<br />
Vpr WASHER<br />
SPAC R<br />
J<br />
BEARING<br />
i Instal the taper beanng outer cones to the hOUSing<br />
and ensure that they are correctly seated<br />
2 Instal the onglnal piniOn posItioning washer and<br />
shim behind the head of the dummy pinIOn and press onto<br />
the shaft the rear beanng Inner cone assembly<br />
3 Shde onto the dummy pmlOn the onglnal taper<br />
beanng spacer and washer and Insert the dummy pinIOn<br />
mto pOSitIOn In the hOUSing<br />
4 Instal the front taper beanng followed by the<br />
pinIOn beanng collar from the special tool kit<br />
5 FIt the pinIOn flange and retalnmg nut and tighten<br />
the nut to a maxunum torque of 20 kg m l45 ft lb<br />
NOTE Durmg the tlghtemng of the retammg nutrotate the<br />
dummy pmlOn by the flange If the pre load on the taper<br />
bearmgs becomes excessive before the torque figure IS<br />
reached substltute the spacer and washer With thlLker ones<br />
to relieve the loadmg<br />
6 With the retaining nut tightened to the correct<br />
torque check the to torque reqUired rotate the pinIOn<br />
assembly either With a pre load gauge or spnng balance and<br />
cord<br />
NOTE Turnmg torque should be wlthm the followmg<br />
limits<br />
a old bearmgs 3 6 kg cm 2 6 52 m lb<br />
b new beanngs 7 10 kg cm 6i Il 3<br />
m lb<br />
7 If necessary adJust the beanng pre load to<br />
i<br />
sHIM<br />
O CONE<br />
I<br />
PILOT BEAR<br />
Pillion Beanng Pre Load<br />
INn<br />
J<br />
Ft AND DUST COVER<br />
ANGtlE<br />
NUl<br />
I<br />
0<br />
WASHER<br />
OIL SEAL<br />
DUTE CONE Method 2 WIthout special tools<br />
obtain a<br />
torque Within the above hmlts by replaCing the pre load<br />
washer and or spacer<br />
NOTE Reduung the overall length of the spaLer and<br />
washer Will mcrease the turnmg torque increasmg the<br />
overall length of the spacer and washer Will reduce the<br />
turning torque<br />
III<br />
I Instal the taper beanng outer cones to the hOUSing<br />
and ensure that they are correctly seated<br />
washer and<br />
2 Instal the onglnal pinIOn posltIomng<br />
shun behind the<br />
pinIOn head and press onto the shaft the<br />
rear beanng Inner cone assembly<br />
3 Fit the onglnal taper beanng spacer and washer to<br />
the pinIOn shaft and Insert the shaft Into posItion In the<br />
hOUSing<br />
4 Instal the front taper beanng followed by the front<br />
beanng spacer pilot beanng and retainer and retalnmg<br />
screws<br />
Rear Axle 6<br />
NOTE Do not mstal the all seal for thiS operatIOn<br />
Later<br />
models do not have the pilot bearmg retamer llstead the<br />
beanng IS pressed dlrealy mto the housmg<br />
5 Fit the pinIOn flange and retaining nut and tighten<br />
the nut to a maximum torque of 20 m kg 145 ft lb<br />
NOTE Dunng the tlghtenmg of the retammg nutrotate the<br />
pmlOn assembly if the pre load on the taper bearmgs<br />
becomes excessive before the torque figure IS reaLhed<br />
substltute the taper beanng spaar and washer with thicker<br />
ones to relzeve the loadmg<br />
6 With the retaining nut tightened<br />
to the correct<br />
torque check the torque reqUired to rotate the pinIOn<br />
assembly either With a pre load gauge or spnng balance and<br />
cord<br />
NOTE Turmng torque should be within the follOWing<br />
lmllts<br />
a old bearings 3 6 kg cm 26 52 In lb<br />
b new bearings 7 iO kg cm 6 i 11 3 In lb<br />
7 If necessary adJust the beanng pre load to obtain a<br />
torque figure Within the above hmlts by replaCing the<br />
pre load washer and or spacer<br />
NOTE Reduung the overall length of the paLer and<br />
washer Will Increase the turning torque IncreaSing the<br />
overall length of the spacer and washer will reduce the<br />
turning torque<br />
14
7 Rear Axle<br />
To AdJust Piruon Position<br />
Method 1 WIth specIal tools<br />
1 Instal the dummy plmon assembly In the hOUSing<br />
as descnbed In Plmon Beanng Pre load Method I<br />
2 Insert the arbor Into the hOUSing so that the radIUs<br />
at each end IS seated In the aperture for the carner beanng<br />
retainer and the gauge block IS faCing the head of the<br />
dummy pmlOn<br />
3 USing metnc feeler gauges check the clearance<br />
between the face of the gauge block and the face of the<br />
dummy pinIOn<br />
4 Calculate the thickness of shuns requued<br />
correct pinIOn pOSItion from the follOWing equatIOn<br />
WT H x 0 01 0 20 S<br />
DefimtlOn<br />
to obtain<br />
W total thickness of washer and shims located<br />
beneath dummy pinIOn head<br />
T clearance figure obtained With feeler gauge<br />
H pmlOn head vanatlon figure<br />
S thickness of washer and shims requued to correctly<br />
pOSItion pinIOn the old pinIOn beanngs It IS a relatively sunple<br />
matter to<br />
Example calculate the thickness of the pinIOn posItioning shims If<br />
W 2 0 I 20 3 20<br />
the shims from the old pImon are kept Intact and used<br />
T 0 26 mm<br />
again taIang mto conSideration the markings on the old<br />
H 2<br />
and new pinIOn<br />
Therefore 3 20 026 2 x 0 01 0 20<br />
Example 1 If both pinIOn markings are 0 or zero the<br />
346 mm thickness ofwasher and slums requued ongInal shim pack will be correct<br />
5 Remove the dununy p1llion assembly from the<br />
hOUSing and dismantle<br />
If the old plnlon marklng Is O or zero and th e new<br />
pinIOn marking IS 2 then 002 mm thickness of shims<br />
6 Instal the washer and shun as calculated In 4 must be SUBTRACTED from the onglnal shim pack<br />
behind the pinIOn head and press the rear taper beanng Again If the new pinIOn mark IS 2 then 002 mm<br />
onto the shaft<br />
7 Instal the taper beanng pre load spacer and washer correct pinIOn posItion<br />
as determmed m PImon Bearing Pre load sectIOn<br />
must be ADDED to the onglnal shim tluckness to give the<br />
Example 2 Where the old pinIOn marking IS 2 and<br />
8 Insert the assemblY lnto the hOUSing and InstaI the the new plmonrrlarklliglS 2 1IiepciSitlon IS slightly more<br />
front taper beanng If removed followed by the front<br />
comphcated<br />
space and pilot beanng As 002 mm was added to the shim tluckness for a zero<br />
9 Fit a new 011 seal and the retainer where fitted marked pinIOn to compensate for the 2 mark on the old<br />
and secure<br />
10 Instal the pinIOn flange<br />
and secure With the<br />
pinIOn head 002 mm must now be subtracted from the<br />
present shim thickness and a further 002 mm subtracted<br />
washer and locknut Tighten the nut to a maxunum torque for the 2 marking on the new pinIOn head Thus 0 04 mm<br />
of 20 kg m 145 ft lb<br />
To AdJust Plruon PosItIOn<br />
Method 2 WIthout SpecIal tools<br />
In the event of the arbor and dummy pinIOn not being<br />
aVailable It will be necessary to use the shims removed<br />
from the old pinIOn plus or minUS as the case may be the<br />
figure etched on the new pinIOn as a starting pOint for<br />
pinIOn pOSitIOn adJustment This method of adJustment<br />
entails assembhng the pinIOn and adJusting pinIOn beanng<br />
pre load fitting crownwheel and differential assembly and<br />
adJusting the backlash and taking teeth markings With red<br />
lead or engIneers blue ThiS IS a tnal and error method until<br />
a satisfactory tooth marking IS obtained<br />
If a new crownwheel and pinIOn are to be fitted WIth<br />
112<br />
Crownwheel and PinIon VarIation from Standard Figures<br />
Umts of 0 01 mml<br />
should be subtracted from the shim thickness when<br />
replaCing an old pinIOn marked 2 With a new pinIOn<br />
marked 2<br />
The pinIOn head tluckness as calculated In the prevIOus<br />
paragraph IS an accurate starting pOint for pinIOn pOSItion<br />
adJustment but final assessment will be Influenced by the<br />
crownwheel tooth contact markings taken after the<br />
crownwheel to pinIOn backlash adJustment has been made<br />
TO ASSEMBLE AND ADJUST DIFFERENTIAL<br />
ASSEMBLY<br />
I Instal the Side gears and pinIOns together With<br />
mating thrust washers Into theu former pOSItions m the<br />
dlfferentml case
jNGWASH<br />
C I<br />
FLAT WASHER<br />
t<br />
SEAL<br />
0<br />
THRUST WASHER<br />
SIDE GEA<br />
THRUST<br />
PINION<br />
WASHER lJ CK<br />
A<br />
SHAFT 4 TH ST WASHER<br />
PIN<br />
lil<br />
PINION<br />
2 Instal the differential shaft aligning the hole In the<br />
shaft with the hole In the case for the lock pin<br />
3 Check the clearance by feeler gauge between the<br />
side gear and differential case Clearance should be within<br />
the hmlts of 0 I 0 2 mm 0 004 0008 In If necessary<br />
replace the thrust washers to obtain the correct clearance<br />
4 Instal the differential shaft lock pm and secure In<br />
posItion by peening the hole<br />
5 PosItion the crownwheel<br />
according to the marks made on dismantling<br />
on the differentIal case<br />
6 Instdl the crownwheel retamlng bolts With new<br />
lock plates Tighten the bolts progressively a httle at a time<br />
m a diagonal pattern to a torque of 70 80 m kg 51<br />
58 ft lb Secure the bolts by turning the lock plate tabs<br />
against the bolt heads<br />
NOTE Durmg the tlghtenmg procedure ltghtly tap each<br />
bolt head to assist seatmgof the aownwheel on the case<br />
7 PrOVided the ongInal dIfferential case retainer<br />
carner beanngs and cups are to be used mount the<br />
differential case assembly Into the carner<br />
fN<br />
I<br />
SIDE GEAR<br />
CASE AND BEARINGS<br />
j<br />
f<br />
FLAT WASHER<br />
SEAL<br />
SPRING WASHER<br />
BbLT<br />
Exploded View of Differential Case Components<br />
Rear Axle8<br />
8 Instal the Side retamers With the onglnal shims and<br />
secure WIth the retamlng bolts<br />
9 Check the torque reqUIred to rotate the differential<br />
case assembly eIther With a pre load gauge or spnng balance<br />
and cord Without the pinIOn Installed thiS should be I 0<br />
30 kg cmI 26 In lb<br />
NOTE Any variatIOn reqUired In the carner beanng<br />
pre load can be obtamed by addmg to or subtractmg from<br />
the thickness of the eXlstmg shims m the Side retamers<br />
10 Check the backlash and crownwheel run out as<br />
descnbed preViously m TO DISMANTLE<br />
Backlash IS adJusted by transfernng the appropnate<br />
thickness of fitted Side retainer shims from one Side to the<br />
other according to the reqUirement<br />
Vanatlon from Standard Figures on Differential Carner Units of 0 01 mml<br />
113
9Rear Axle<br />
If crownwheel run out exceeds specIficatIOns remove<br />
the differentIal assembly detach the crownwheel from the<br />
case and check the contact faces of the case and<br />
crownwheel for dut or burrs Dunng assembly ensure that<br />
the crownwheel IS pulled down squarely to the case<br />
NOTE However If the dIfferential case orcarner bearings<br />
or retainers have been replaced It WIll be necessary to<br />
calculate the shImming reqUIred to obtain the co ect<br />
carner bearingpre load<br />
11 USing a surface plate and dial indicator measure<br />
the vanatIon from standard Width standard Width 20mm<br />
of each carner beanng when subJect to a 2 5 kg 5 5 Ib<br />
load VanatIon should be m umts of001 mm<br />
12 Calculate the tluckness ofslums requued for each<br />
beanng retainer by the followmg equation<br />
Left hand retainer II<br />
A C G D E H x 0 01 0 76<br />
Right hand retainer T2<br />
B DG F H x 0 01 076<br />
DefimtlOn<br />
figures<br />
locatIOn of letters and vanatlOn from standard<br />
A and B Differential carner<br />
C and D Differential case<br />
E and F Bearing Width vanatlon from standard In<br />
umtsofOOI mm<br />
G Camer bearing retainers<br />
H Elgure marked on crownwheel<br />
Vanatlon from Standard Figures on Differential Case Units<br />
of 0 01 mm<br />
15 Instal a new plmon 011 seal and smear grease on<br />
the seal hps Fit the flange and retaining nut and tIghten the<br />
nut to the speCified torque<br />
16 Instal new O nngs and 011 seals to the carner<br />
beanng Side retainers<br />
17 Instal the differentIal assembly mto the carner fit<br />
the Side retainers With the selected shims tIghten the<br />
retameLScrews toJh peclfied torque<br />
18 Check the overall turmng torque of the<br />
NOTE If the old carner bearings are to be taken back Into completed assembly by pre load gauge or spnng balance<br />
servIce the preload reqUIred WIll be slightly less than that and cord PrOVided adJustments are correct thiS will be 4 9<br />
ne essary on bearings To compensate for the old kg cm 35 78 In lb where the old beanngs have been<br />
bearings reduceUhe shIm thIckness already calculated by taken back mto sernce and 8 13 kg cm 6 9 11 3 In lb<br />
003 to 007 mm 0 001 to 0 003 In when new beanngs have been mstalled<br />
19 Check the tooth contact of tlfe crownwlieel and<br />
13 Check the crownwheel backlash and run out as plmon by applymg a thin coatmg of red lead and engme 011<br />
already descnbed effectmg any adJustment necessary but<br />
to both Sides of about SIX or eight of the crownwheel teeth<br />
mamtalnlng the overall thickness of the slums Intact 20 Rotate the pinIOn both ways plaCing<br />
14 Instal the pinIOn assembly With selected slums between the differentIal case and the carner to apply a load<br />
and<br />
spacers fit a new O nng to the front beanng retainer to the gear teeth to obtain a good markmg<br />
early models orily<br />
If the pmlOn height beanng pre load and backlash have<br />
Variation from Standard Figures on Side Bearing Retainers Units of 0 01 mm<br />
114<br />
a bar
een adJusted correctly the area of contact should be as<br />
shown In the teeth marking illustratIOn<br />
The margins above and below the area of contact<br />
should be the same and the contact margIn should run<br />
approximately three quarters of the length of the tooth<br />
Check the patterns on both Sides of the tooth<br />
21 Instal the output shafts and retaining bolts<br />
tighten the bolts to the speCified torque<br />
I<br />
RETAINER<br />
SHIMS<br />
TO RENEW Assembly fitted to vehIcle<br />
Dnve PmlOn Oil Seal<br />
Rear 4 1e10<br />
22 Instal the rear cover With a new gasket tighten<br />
the retaining bolts to the speCified torque<br />
23 Instal the assembly In the vehicle In the reverse<br />
order of removal fill With the correct quantity and grade of<br />
oil<br />
o<br />
SEAL<br />
06<br />
Ensure that the Retainers and Shims are Fitted to the<br />
Side of the HOUSing From Which They Were Removed<br />
1 DRIVE PI ION AND SIIIU YI n 011 S AI S<br />
1 Raise the rear of the vehicle and support on axle<br />
stands or raise the vehicle on a hOist<br />
2 Mark across the flanges of the pinIOn and rear<br />
universal JOint take out the four secunng bolts and nuts<br />
and tie the rear of the propeller shaft out of the way<br />
NOTE If necessary disconnect the left hand brake cable<br />
and loosen off and turn the front muffler to allow the<br />
propeller shaft to drop giVinggreater workmg clearance<br />
3 Hofdlng the pmlOn flange against rotation unscrew<br />
and remove the nut and washer secunng<br />
the flange to the<br />
pinIOn shaft<br />
4 If necessary use a SUitable puller and Withdraw the<br />
flange from the sphnes on the pinIOn shaft<br />
5 On models fitted With front bearing retainer<br />
remove the retainer and extract the 011 seal On later models<br />
WIthout retainer extract the 011 seal from the housmg<br />
6 Clean the bore of the hOUSing or retainer of any<br />
burrs or old sealing compound<br />
7 Apply a coating of SUitable sealmg compound to<br />
the outer cucumference of the new seal and lubncate the<br />
seal hps With grease<br />
8 Carefully dnft the seal Into pOSitIOn In the hOUSing<br />
or retainer<br />
115<br />
9 Instal the front beanng retainer If fitted and<br />
tighten the screws to the speCified torque<br />
10 The remainder of the operatIOn IS a reversal of the<br />
dISmantling procedure Tighten the pinIOn flange nut to the<br />
speCified torque and ensure that the oil level In the umt IS<br />
correct<br />
SIde Retamer Oil Seals Apphcable to both SIdes<br />
I Carry out operatIOns I and 2 as descnbed In the<br />
prevIOus sectIOn read dnve shaft for propeller shaft<br />
2 Remove the output shaft retamlng bolt and uSing a<br />
shde hammer or SUitable puller Withdraw the shaft from the<br />
assembly<br />
3 Extract the old seal from the Side retainer<br />
4 Clean the bore of the retainer of any burrs<br />
or old<br />
sealing compound<br />
5 Apply a coating of SUitable sealing compound to<br />
the outer cucumference of the new seal<br />
retainer<br />
6 Carefully dnft the seal squarely Into posItion<br />
In the<br />
7 Lubncate the oil seal hps With grease<br />
8 The remamder of the operation IS a reversal ofthe<br />
dlsmanthng procedure Tighten the output shaft retamlng<br />
bolt to the speCified torque and ensure that the 011 level In<br />
the Unit IS correct
ll Rear Ade<br />
TO REMOVE AND INSTAL<br />
1 Raise the rear of the vehicle and support on stands<br />
or raISe the vehIcle on a hOISt<br />
2 Mark across the dnve shaft and output shaft<br />
flanges and the dnve shaft and stub axle flanges to ensure<br />
replacement In onglnal posItions<br />
3 Take out the four nuts and bolts at the flange at<br />
each end of the dnve shaft and detach the shaft<br />
InstallatIOn IS a reversal of the removal procedure<br />
TO DISMANTLE<br />
NOTE Normally the dIsmantling of the drive shaft WIll<br />
only be reqUired for lubncatlOn purposes at Intervals of<br />
50000 km 30 000 miles<br />
I Remove the Clfchp at each of the needle beanng<br />
cups at the differential sleeve end of the shaft<br />
NOTE PrOVIded the drive shaft IS being dIsmantled for<br />
lubncatlOn only It Will be necessary to disconnect the<br />
trnnmon and cups from the sleeve yoke only<br />
2 a USing soft dnft tap one of the beanng cups In to<br />
push the other beanng through the yoke Lift the beanng<br />
out With the fingers to aVOid dislodging the needle rollers<br />
3 Agam uSlngtlfe soft drlft tap tlie endoftne<br />
trunmon of the beanng Just removed to push<br />
CjQ JliILI<br />
0<br />
bliJ<br />
8<br />
9<br />
4 DRIVE SHtFTS<br />
o6 0<br />
9<br />
8<br />
1<br />
c<br />
o<br />
O C 0 J<br />
GJO o<br />
OOO lc<br />
1<br />
the other<br />
beanng through the yoke and again carefully<br />
the fingers to aVOid dislodgIng the needle rollers<br />
o<br />
it 1<br />
remove With<br />
4 Manoeuvre the yoke over the ends ofthe trunmon<br />
to remove the flange and trunmon from the sleeve yokes<br />
NOTE If replacement of the needle bearing and trunmon<br />
assembly IS necessary follow the procedure already<br />
descnbed to remove the needle bearing and trnnmon from<br />
the flange yoke If necessary treat the drIVe shaft assembly<br />
In the same way<br />
5 Remove the Clfchp plug and O ring from the yoke<br />
end of the sleeve<br />
6 Push the sleeve down the shaft to faclhtate removal<br />
of the Clfchp and stop plate located on the end of the shaft<br />
7 Release the chp retaining the rubber dust boot to<br />
the sleeve and ease the boot off the sleeve<br />
sleeve<br />
8 Remove the cuchp and nng from the end of the<br />
VOTE Mark the sleeve and shaft to ensure replacement In<br />
the anginal position<br />
9 Pull the shaft out of the sleeve taking care not to<br />
lose any of the balls and<br />
spacers<br />
10 Release the<br />
remaining chp retalnmg the rubber<br />
dust boot to the shaft and ease the boot off the shaft<br />
TO CLEAN AND INSPECT<br />
1 Thoroughly clean all components except the<br />
trunmon beanngs In a cleaning solvent and blow dry With<br />
compressed au<br />
Exploded View of Drive Shaft Components<br />
116<br />
G<br />
1<br />
2<br />
3<br />
4<br />
5<br />
6<br />
7<br />
8<br />
9<br />
10<br />
11<br />
12<br />
13<br />
14<br />
15<br />
Sleeve<br />
Ring<br />
Clrchp<br />
o lng fo 51<br />
Sleeve plug<br />
Flange and trunmon<br />
Needlebearing cups<br />
C rclops fo 7<br />
Seals fo 10<br />
Trunmon<br />
Shaft and dusl boot<br />
Stop plate<br />
Clrchp<br />
Ball bearings and spacers<br />
Flange<br />
15
2 Check the dnve shaft for wear or damage and<br />
ensure that It IS straight and free from distortion<br />
3 Check the sleeve as for the dnve shaft<br />
4 Examine the steel balls and spacers for wear and<br />
damage<br />
5 Check the yoke plug O nng and the rubber boot for<br />
damage and replace If necessary<br />
6 Check the yoke eyes In the sleeve shaft and flanges<br />
for wear and check for wear between the needle roller<br />
Instal new needle roller<br />
beanngs and trunnIon If necessary<br />
beanngs and trunnIon assembhes<br />
7 Instal the dnve shaft to the sleeve and push to the<br />
fully retracted posItion USing a dial gauge check the<br />
amount of play between the shaft and sleeve thiS should<br />
not exceed 0 I mm 0 004 In<br />
8 Check for radial play between the shaft and sleeve<br />
NOTE If the check shows any part of the assembly to be<br />
worn or damaged or the wear lzmlts are exceeded the drive<br />
shaft assembly Will reqUire replaCing<br />
TO ASSEMBLE<br />
I Instal a new rubber dust boot and chp<br />
dnve shaft<br />
onto the<br />
2 Liberally coat the shaft sphnes With multi purpose<br />
grease posItion the steel balls and spacers In the correct<br />
Rear AxleZ2<br />
sequence In theu grooves and pack grease between them<br />
3 Insert the dnve shaft In the sleeve alignIng the<br />
marks made on wsmantllng and WithOut dislodging any of<br />
the balls or spacers<br />
4 Instal the ring and clrchp In the end of the sleeve<br />
5 Push the shaft up the sleeve and fit the stop plate<br />
and cuchp to the end of the shaft Pull the shaft out to the<br />
extended posItion<br />
6 Instal 35 g I 25 oz of multi purpose grease Into<br />
the sleeve from the yoke end<br />
7 With a new O nng Installed on the yoke plug fit the<br />
plug and Clfchp<br />
8 PosItion the rubber dust boot over the sleeve and<br />
secure both ends of the boot With the chps<br />
9 Manoeuvre the trunnIon Into pOSItion In the yoke<br />
lubncate the needle roller beanngs With multi purpose<br />
grease<br />
10 Instal the needle beanng cups and seals Into<br />
pOSItIOn In the yoke<br />
I I Instal a cuchp to each of the needle bearing cups<br />
NOTE Four thicknesses of clrcllp are available for<br />
adjustment of axial play In the JOint Play should not<br />
exceed 0 02 mm 0 0008 In<br />
I2 Instal the dnve shaft assembly to the velucle In<br />
the reverse order ofremoval<br />
PART 2 RIAII AXL S JATIO SIDA<br />
The rear axle IS a semi floating type With hYPold final<br />
dnve gears mounted In a detachable carner<br />
The crownwheel and differential case assembly IS<br />
supported ill the carner by two tapered roller beanngs the<br />
beanng pre load and crownwheel backlash IS adJusted by<br />
means ofshims<br />
The dnve pinIOn IS supported In the carner by two<br />
tapered roller beanngs which are adJusted for pre load by<br />
shuns and a spacer Installed between the front and rear<br />
beanng<br />
Inner cone assembhes<br />
PinIOn height In relatIon to the crownwheel IS<br />
controlled by shuns located between the rear beanng outer<br />
cone and the carner<br />
TO REMOVE AND INSTAL<br />
I Raise the rear of the vehicle and support on axle<br />
stands<br />
2 Loosen off and remove the rear wheels and brake<br />
drums<br />
3 Dlsconned the handbrake cables and hydrauhc<br />
brake pipes at the rearof the brake backing plates Plug the<br />
pipes to prevent loss of flUid and entry of dut<br />
1 DESf RIPTION<br />
Axle shaft beanngs are the pre lubncated ball type<br />
which reqUIre no lubncatlOn In service and are retained to<br />
the shafts by means of collars End float In the axle shaft<br />
assembly IS adJusted by shims located at the brake backmg<br />
plate<br />
With the removal of the axle shafts the differential<br />
carner assembly can be detached from the axle Without<br />
removing the axle casing from the vehicle<br />
2 DIFFER NTIAI C UlIlIER ASE lIn Y<br />
117<br />
It IS Important to note that adJustment figures stamped<br />
on the final dnve components are In UnIts of 0 001 In and<br />
not metnc whteftoTnust be taken Into consideratIOn when<br />
calculating the vanous differential and pinIOn adJustments<br />
4 Remove the nuts retaining the brake backmg plates<br />
to the axle casing through the holes proVided In the axle<br />
shaft flange<br />
5 Withdraw each axle shaft assembly from the axle<br />
casing uSing a shde hammer and adaptor If necessary<br />
6 Take out the 011 drain plug and dram the<br />
differential 011 Into a clean SUItable container PrOVided the<br />
oil IS In good condition It may be re used<br />
7 Mark across the flanges of the pinIon and rear
13 Rear Axle<br />
OUTER CONE<br />
Q SEARING<br />
SHIMS<br />
Oa<br />
LOCK PLATE<br />
0<br />
ft<br />
C E<br />
jW<br />
tl J<br />
Or<br />
n<br />
VOQ<br />
OUTER CONE<br />
Exploded View of Final Drive Components<br />
UnIversal Jomt take out the four secunng bolts and nuts to<br />
release the propeller shaft<br />
8 Remove the nuts retaining the differential camer<br />
assembly to the axle casing and withdraw the assembly<br />
InstallatIon IS a reversal of the removal procedure but It<br />
will be necessary to bleed the brake hydrauhc system<br />
TO DISMANTLE<br />
NOTE Before dlsmantlmg the assembly carry out the<br />
followmg checks The mformatlon gamed from the checks<br />
Will prove helpful when assemblmg the unit<br />
a Check the tooth contact of the crownwheel and<br />
pInIOn by applYing a thin coatIng of red lead and engme oil<br />
J<br />
to both SIdes of SIX or eight of the crownwheel teeth<br />
b Rotate the plnlon bothways plaCing a bar betweeii<br />
the differential case and the carner to apply a load to the<br />
gear teeth and so obtain a good marking<br />
If the pmlOn height beanng pre load and backlash are<br />
correct the area ofcontact should be as shown In the teeth<br />
marking IllustratIOn<br />
c The margIn above and below the area of contact<br />
should be the same and the contact margIn should run<br />
approximately three quarters of the tooth length Check<br />
the patterns on both Sides ofthe tooth<br />
SEARING<br />
d Mount a dial indicator on<br />
gauge<br />
to the differential<br />
carner housmg so that the plunger IS 10 contact With and at<br />
DRIVE PINION<br />
nght angles to the heel of a crownwheel tooth then zero<br />
the dIal gauge<br />
e Hold the pinIOn firrr1ly and rock the crownwheel<br />
back and forth to check the backlash reading on the dial<br />
gauge Check the backlash at approx1ffiately three pOSItIons<br />
around the crownwheel Backlash IS correct when Within<br />
the hnuts of0 15 0 2 mm 0 006 0 008 In<br />
NOTE Havmg completed the foregOing checks dismantle<br />
the assembly as follows<br />
us<br />
CAP 8OLTS<br />
CAP<br />
0<br />
eo Ie<br />
if J<br />
SH1MS<br />
C<br />
OO t<br />
SHIM<br />
SPA ER<br />
O<br />
CAP<br />
OUTER CONE 1 W ER<br />
CAPSOLTS<br />
J<br />
V FLANGE<br />
SEARING OUTER CONE<br />
OIL SEAL<br />
AND<br />
DUST COVER<br />
NUT<br />
I Take out the camer beanng cap<br />
bolts and detach<br />
the caps Check that the caps are marked In relatIOn to the<br />
carner to ensure installatIOn In their ongmal pOSItIons<br />
2 LIft out the differentIal assembly from the carner<br />
but ensure that the beanng outer cones are kept<br />
respectlVe bearings<br />
NOTE<br />
check<br />
With theu<br />
To faCilitate assembly carry out the followmg<br />
a USing a pre load measunng gauge or spnng<br />
scale and<br />
cord check the torque requlred to rotate the plnlon at the<br />
flange end Torque reqUired should be wlthm the limits of<br />
10 13kgfcm 86 1I 3lnflb Note the readmg<br />
3 With the pmlOn flange held to prevent It from<br />
turmng remove the flange retammg nut and washer<br />
4 USing a SUitable puller Withdraw the pinIOn flange<br />
from the end of the<br />
pinIOn<br />
shaft<br />
5 Usuig a sofCmetal dnft tap the pinIOn shaff wlth<br />
rear beanng Inner cone and rollers and beanng spacer and<br />
washers out ofthe differential carner hoUSing<br />
6 Working through the rear beanng outer cup dnft<br />
out the front bearing Inner cone and rollers and the pinIOn<br />
flange 011 seal<br />
NOTE Unless replacement of the pmlOn taper bearmgs IS<br />
Intended do not remove the taper beanng aliter wpsJrum<br />
the carner<br />
PrOVided replacement of the pm On IS not reqUIred do<br />
not remove the rear bearmg mner cone assembly from the<br />
pm IOn<br />
If however replacement of one or both oftheabove IS<br />
reqUIred contmue dlsmantlmg as follows<br />
7 USing a SUitable puller or press<br />
remove the rear<br />
taper beanng Inner cone assembly from the pinIOn<br />
8 Knock or press the taper beanng outer cups from<br />
the carner taking partIcular note of the pinIOn height<br />
adJusting slum located between the rear outer cup and<br />
carner<br />
7
NOTE Before dIsmantling the dIfferentIal check the camer<br />
bearings at each end of the dIfferentIal case ProvIded the<br />
bearings are fit for further servIce do not remove them<br />
from position<br />
9 Mark the pOSItion of the crownwheel In relation to<br />
the differential case<br />
10 Release the locks from the crownwheel retaining<br />
bolts and remove the bolts and crownwheel<br />
I I Knock out the differential shaft lock pin from the<br />
crownwheel Side of the differentIal case<br />
12 Knock out the differential shaft and remove the<br />
pinIOns and SIde gears together wIth the thrust washers<br />
NOTE It IS Important that each pinIOn and SIde gear<br />
together wIth Its thrust washer IS marked In relatIOn to the<br />
dIfferential case to ensure onglnal installatIOn on assembly<br />
I3 If necessary for beanng replacement or beanng<br />
pre load or backlash setting use a SUItable puller and draw<br />
the carner beanngs from each SIde of the differential case<br />
Note the adJusting shims between the beanngs<br />
TO CLEAN AND INSPECT<br />
I Wash all components In a deamng<br />
blow dry wIth compressed au<br />
or damage<br />
OIL SEAL<br />
WASHER BEARING<br />
0 FLANGE<br />
NUT O<br />
AND<br />
DUSTCOVER<br />
and case<br />
solvent and<br />
2 Check the crownwheel and p1fllon for wear plttmg<br />
NOTE Crownwheel and pinIOn are supplted as matched<br />
sets only therefore damage to one Item requIres the<br />
replacement of both<br />
3 Check the dIfferential carner beanngs<br />
for wear<br />
pitting or damage If a bearing IS faulty renew the complete<br />
beanng compnsmg lOner cone rollers and outer cup<br />
4 Check the pinIOn taper beanngs and renew as<br />
descnbed 10 3<br />
5 Examine the differential pinIOn and SIde gear teeth<br />
and thrust faces for wear pitting or damage Check that the<br />
thrust washers are<br />
10 a serviceable condltlon<br />
6 Check the differentIal shaft for wear pitting or<br />
case for damage and or<br />
f AA<br />
J 0<br />
OUTER CONE damage Replace parts<br />
OUTER CONE<br />
A JSHIMS<br />
IPINION HEIGHT AOJUSTMENT<br />
hsted In 5 and 6 If not In<br />
serviceable condition<br />
7 Examine the differential<br />
N<br />
SPACER<br />
WASHER BEARING PRELOAD ADJUSTMENn<br />
119<br />
Rear 4xle14<br />
dIStortIOn and renew If necessary Check also the pillion<br />
and Side gear thrust faces III the case for wear and or<br />
pittlng<br />
8 Ensure that all shims and spacers are free of<br />
damage<br />
TO ASSEMBLE AND ADJUST DRIVE PINION<br />
Where the old pInIOn and beanngs are serViceable and<br />
the tooth contact turnmg torque and backlash checks<br />
made on dlsmanthng are satisfactory then assembly IS a<br />
reversal ofthe dismantling procedure<br />
If any of the above factors proved Incorrect on the<br />
check It Will be necessary to carry out the appropnate<br />
adJustmen t as descnbed m thiS sectIOn<br />
This IS not the case however when a new plmon and<br />
crownwheel IS to be Installed and or the beanngs renewed<br />
AdJustment of the pinIOn posltlOn and beanng pre load<br />
then becomes essential<br />
There are two methods of obtaining the correct pinIOn<br />
pOSItIOn which IS regulated by the shims located between<br />
the rear beanng outer cup and carner One method reqUires<br />
the use of an arbor and gauge kit to calculate the thIckness<br />
of shim reqUired The second method entails the alteration<br />
of the eXisting shim thickness to compensate for the new<br />
pillIOn head vanatJon uSing the old plnlOn head vanatlOn as<br />
a gUide<br />
Note that the pinion head vanahon from standard<br />
figure IS given m umts of 0 001 m<br />
To Adjust PImon POSItIon<br />
Method I With special tools<br />
I<br />
carner<br />
2<br />
pinIOn<br />
Instal the front and rear beanng outer cups to the<br />
Instal the rear beanng Inner cone assembly to the<br />
Exploded View of Drive PInion Components
15 Rear Axle<br />
3 Fit the pinIOn to the carner and Instal the front<br />
taper beanng and the pinIOn flange<br />
NOTE Do not Instal the beaTIng preload spacer and<br />
washers at thiS pOint<br />
4 Instal and tighten the flange retamlng<br />
nut until the<br />
initIal turnmg torque of the pinIOn IS 10 13 kg cm 8 6<br />
11 3 In lb This should be checked With<br />
pre load<br />
measuring<br />
scale and cord<br />
gauge or spnng<br />
5 Mount the arbor Into the differential case carner<br />
beanng bores so that the gauge rod IS duectly<br />
pinIOn head<br />
over the<br />
6 USing feeler gauges check the clearance between<br />
the pinIOn head and the tip of the gauge rod and note the<br />
measurement<br />
7 Calculate the tIuckness of shun reqUired to obtain<br />
correct pinIOn pOSItion from the follOWing equation<br />
N H x 0 25 0 2 T In mm<br />
or N H 000787 T In Inches<br />
DefimtlOn<br />
N clearance figure obtamed In 6 With feeler gauges<br />
H pillIOn head vanatIon figure on the pinIOn head<br />
T thickness of sh1n1S reqUired to correctly pOSitIOn<br />
pinIOn<br />
Example<br />
N 0 4 mm or 0 0158 Inch<br />
H 005 mm or 0002 Inch figure on pinIOn head<br />
2<br />
Therefore<br />
04 2 x 0 025 0 2 025 mmor<br />
00158 0 002 0 0079 0 0099 Inch<br />
Thickness of shim requued to correctly pOSItion pinIOn<br />
IS 0 25 mm 0 010 Ill<br />
8 Remove the pinIOn assembly from the carner and<br />
take ounhe rear beanng outeccup<br />
9 Instal the slum as calculated to the carner and refit<br />
the rear bearing outer cup<br />
To Adjust PIllion PositIon<br />
Method 2 WIthout special tools<br />
In the event of the arbor and gauge kit not being<br />
ava1lable It will be necessary to use the SlunlS removed from<br />
belund the rear bearing outer cup plus or nunus as the case<br />
may be the figure etched on the new pinIOn as a startlllg<br />
pOint for pmlOn posItion adJustment<br />
ThIS method of adJustment entails assembhng the<br />
pinIOn and adJustIng pinIOn beanng pre load fitting<br />
crownwheel and wfferentlal assembly and adJusting the<br />
backlash and<br />
taking teeth markings With red lead or<br />
engllleers blue ThIS IS a tnal and error method until a<br />
satisfactory tooth marking IS obtamed<br />
If a new crownwheel and pinIOn are to be fitted With<br />
the old pinIOn beanngs It IS a relatively Simple matter to<br />
calculate the thickness of the pinIOn pOSItioning sh1n1S If<br />
the slums from the old pinion are kept Intact and used<br />
f<br />
120<br />
again takmg Into conSideration the markings on the old<br />
and new pillIOns<br />
Example I If both pinIOn markmgs are 0 or zero the<br />
onglnal slum pack will be correct<br />
If the old pinIOn marking IS 0 or zero and the new<br />
pillIOn marking IS 2 then 0 002 In tluckness ofsh1n1S must<br />
be SUBTRACTED from the ongInal slumpack<br />
Agam If the new pillion mark IS 2 then 0002 In<br />
must be ADDED to the ongInal shun thickness to gIve the<br />
correct pinIOn pOSItion<br />
Example 2 Where the old pmlOn marking IS 2 and<br />
the new pinIOn marking IS 2 the posItion IS shghtly more<br />
comphcated<br />
As 0 002 In was added to the slum thickness for a zero<br />
marked pillIOn to compensate for the 2 mark on the old<br />
pinIOn head 0 002 In must now be subtracted from the<br />
present slum tluckness and a further 0 002 In subtracted for<br />
the 2 marking on the new pinIOn head Thus 0004 ill<br />
should be subtracted from the shim thickness when<br />
replaCing an old pinIOn marked 2 With a new pillIOn<br />
marked 2<br />
The pinIOn head thickness as calculated In the prevIous<br />
paragraph IS an accurate starting pOint for pinIOn posItion<br />
adJustment but final assessment will be Influenced by the<br />
crownwheel tooth contact markings taken after the<br />
crownwheel to pinion backlash adJustment has been made<br />
TO ADJUST PINION BEARING PRE LOAD<br />
1 With the selected pinIOn pOSltlomng slum fitted<br />
between the rear bearmg outer cone and carner Instal the<br />
beanng spacer and OflgInal adJustlllg washers to the pinIOn<br />
2 Insert the pinIOn assembly Into the carner and<br />
through the front taper beanng<br />
NOTE Do not Instahhe 011 seal at thiS pomt<br />
Crownwheel and Pinion Variation from Standard Figures<br />
Umts of 0 001 In
Q<br />
TliRUST WASHER<br />
VI PINION<br />
LOCK PIN<br />
THRUST WASHER<br />
THRUST WASHER<br />
VARIATION FROM<br />
STANDARD FIGURES<br />
CASE<br />
MS<br />
01<br />
0<br />
Rear Axl 16<br />
1<br />
TAPER BEARING<br />
Exploded View of Differential Case Components Note that varoatlon from standard figures are In Units of 0 001 In<br />
3 FIt the pInIOn flange and retammg nut dunng the<br />
tIghtemng of the retauung nut rotate the pinIOn to seat the<br />
beanngs<br />
NOTE If the pre load on the taper bearmgs becomes<br />
excessIve before the maxImum tlghtenmg torque of I7<br />
kg m 130 ft lb IS reached substltute the washer and or<br />
spacer for thicker ones to relzeve the loadmg<br />
4 With the retaining nut tightened to the correct<br />
torque check the torque requued to rotate the pinion<br />
assembly either with a pre load gauge or spnng balance and<br />
cord<br />
NOTE Turnmg torque should be wlthm the followmg<br />
llmlts 10 13 kg cm 86 11 3 m lb for new bearrngs<br />
but thiS figure should be reduced by approximately 30per<br />
cent If the old camer beaTIngs are to be taken back mto<br />
servIce<br />
5 If<br />
necessary adJust the bearing pre load to obtain a<br />
turnIng torque figure wltIun the above hmlts by replacmg<br />
the washer and or spacer from the aVailable sizes<br />
NOTE Reducmg the overall length of the spacer and<br />
washer Will mcrease the turnmg torque Increasmg the<br />
overall length Will reduce the turnIng torque<br />
6 Recheck the pinIOn posItion to ensure that there<br />
has been no alteratIOn In height<br />
121<br />
7 On final assembly mstal a new oil seal tighten the<br />
retaining nut to the specified torque and secure With a new<br />
spht pin<br />
TO ASSEMBLE AND ADJUST DIFFERENTIAL<br />
I Instal the Side gears and pinIOns together With<br />
mating thrust washers Into their former posItIons In the<br />
dIfferential case<br />
2 Instal the differential shaft allgmng the hole In the<br />
shaft With the hole In the case for the lock pm<br />
3 Check the clearance by feeler gauge between the<br />
Side gears and thrust washers Clearance should be Within<br />
the hrnltS of 005 0 20 mm 0002 0008 In If<br />
necessary replace the thrust washers to obtain the correct<br />
clearance<br />
4 Instal the differentIal shaft lock pin from the nght<br />
Side of the case and secure In posItIon by peemng the hole<br />
5 PosItion the crownwheel on the differentIal case<br />
according to the marks made on dlsmanthng<br />
6 Instal the crownwheel retaining bolts With new<br />
lock plates Tighten the bolts progreSSIVely a httle at a time<br />
m a diagonal pattern to a torque of 4 8 5 5 kgfm 35<br />
40 ft lb<br />
Secure the bolts by turning up thelock plate tabs<br />
against the bolt heads<br />
NOTE Dunng the tlghtenmg procedure lightly tap each<br />
bolt head to assIStseatmg of the crownwheel on the case
17 Rear Axle<br />
7 ProVided the ongInal wfferentlal case and carner<br />
beanng assembhes are to be used mount the differentIal<br />
case assembly With the onglnal pre load shmlS between the<br />
carner beanng Inner cones and case Into the carner<br />
8 Instal the carner beanng caps and bolts according<br />
to the mating marks on the cap and hOUSing Tighten the<br />
retamlng bolts to a torque of42 48 kgfm 30 35<br />
ftflb<br />
NOTE OperatIOns 7 and 8 are only practlcal when Jhe<br />
dlSmantlmg check on tooth contact pattern backlash and<br />
preload proved satISfactory<br />
Howl Ver If the differential case or carner bearmgs<br />
have been replaced or the differential checks proved<br />
unsatisfactory It Will be necessary to adJust the dlfferent lll<br />
as follows<br />
9 a USing surface plate and dial Inwcator measure the<br />
vanatlOn from standard Width standard Width 200 rom<br />
07874 In of each carner beanng when subJect to a 2 5 kg<br />
5 SIb load VanatlOns should be m umts of 0001 Inch<br />
10 Calculate the tluckness ofshims requlfed for each<br />
carner beanng by the follOWing equation<br />
Left Side n A C D E 7<br />
Right Side T2 B DtF6<br />
Defimtlon locatIon of letters and vanatlOn from<br />
standard figures In uruts of0001 Inch<br />
A left Side carner beanng hOUSing<br />
B nght slde carner beanng houslng<br />
C D Differential case<br />
E F Beanng Width vanatlOn from standard for each<br />
carner bearmg m umts of0001 Inch<br />
Thickness of shImS reqUired for each carner bearmg<br />
calculated by the equation will be m thousandths ofan Inch<br />
0001 Inch to obtain the metnc eqUivalent multiply<br />
answer by 0 025 mm<br />
NOTE Ifthe old camer beanngs are to be taken back mto<br />
service the preload reqUired Will be slzghtly less than that<br />
necessary for new bearmgs To compensate for the old<br />
TO RENEW Assembly fitted to vehicle<br />
I Raise the rear of the velucle and support on axle<br />
stands or raISe the vehicle on a hOist<br />
2 Mark across the flanges of the pinIOn and rear<br />
umversal JOint take out the four securing bolts and nuts<br />
and tIe the rear of the propeller shaft out of the way or<br />
detach the shaft from the transmiSSion<br />
3 Remove the split pin from the plruon flange nut<br />
4 Holdmg the pinIOn flange against rotation unscrew<br />
and remove the nut and washer secunng the flange to the<br />
plmon shaft<br />
5 Ifnecessary use a SUItablepuller and Withdraw the<br />
flange from the sphnes on the pinIOn haft<br />
bearmgs reduce the shim thickness already calculated by<br />
003 007mm 0001 0003m<br />
I I Instal the selected ShillS on thelf respective ends<br />
of the differential case and fit the carner beanng mner cone<br />
assembhes<br />
12 With the carner beanng outer cups mated With<br />
the correct Inner cone assembly Instal the differential In<br />
the carner uSing a soft faced hammer to tap the assembly<br />
Into the beanng seats<br />
I3 Instal the carner bearing caps and bolts according<br />
to the mating marks on the cap and hOUSing Tighten the<br />
retaining bolts to a torque of 4 2 4 8 kgfm 30 35<br />
ftflb 14 Check the crownwheel backlash as preViously<br />
descnbed In TO DISMANTLE If necessary adJust the<br />
backlash by transfernng the appropnate thickness ofcarner<br />
beanng shims from one Side to the other according to the<br />
requlfement<br />
IS Check the crownwheel run out If the run out<br />
exceeds speCifications remove the differential assembly<br />
detach the crownwheel from the case and check the contact<br />
faces of the case and crownwheel for dlft or burrs Dunng<br />
assembly ensure that the crownwheel IS pulJed down<br />
squarely to the case If the run out<br />
still exceeds<br />
speCificatIOn a new crownwheel and pinIOn set will have to<br />
be Installed<br />
16 USing a large mIcrometer check the overall<br />
wmenslOn between the outer lugs on the carner beanng<br />
caps ProVlded the15eanng pre Ioao hasoeen aOJuste<br />
correctly the wmenslOn should be Within the hmIts of<br />
1984 19855 mm 7 811 7817 In<br />
I7 Carry out the tooth contact pattern check as<br />
descnbed preViOUsly In TO DISMANTLE ProVided pinIOn<br />
height backlash and pre loads are correct the desued tooth<br />
pattern will be obtained<br />
I8 With the beanng cap retaining bolts tightened to<br />
the correct torque lock each pau of bolts With locking<br />
wire<br />
J DRIVE PINION 011 SEAl<br />
122<br />
I9 Instal the assembly In the vehicle In the reverse<br />
order of removal fill With correct quantity and grade of011<br />
6 Ifavailable use an extractor to Withdraw the old 011<br />
seal or alternatively pnse the seal out of the end of the<br />
hOUSing With a SUitable lever<br />
7 Clean the bore of the hOUSing of any burrs or old<br />
sealing compound<br />
8 Apply a coating of SUitable sealing cOmpound to<br />
the outer clfcumference of the new seal and lubncate the<br />
seal hps With grease<br />
9 Carefully dnft the seal Into posItion In the hOUSing<br />
10 The remamder of the operation IS a reversal of the<br />
dlSmanthng procedure Tighten the pinIOn flange nut to the<br />
speCified torque and ensure that the oil level m the rear axle<br />
IS correct
Y<br />
TO REMOVE<br />
drum<br />
1 RaISe the rearof the vehicle and support on stands<br />
2 Loosen off and remove the rear wheel and brake<br />
NOTE It may be necessary to release the brake adJuster<br />
several notches If the brake drnm proves difficult to<br />
remove<br />
3 Disconnect the hand brake cable and hydrauhc<br />
brake pipe<br />
at the rear of the brake backmg plate Plug the<br />
pipe to prevent loss of flUid or entry of dlft<br />
4 Remove the nuts retaining the brake backIng plate<br />
to the axle casing through the holes provided In the axle<br />
shaft flange<br />
5 Withdraw the axle shaft from the axle casing uSing<br />
a shde hanuner and adaptor If necessary<br />
NOTE Keep mtact the end float adJustment shims fitted<br />
between the backmg plate and casmg<br />
TO RENEW AXLE SHAFT BEARING<br />
1 Remove the axle shaft as descnbed above<br />
2 Place the axle shaft so that the beanng retainIng<br />
collar IS resting on an anVil and USIng a hammer and cold<br />
chisel make a cut In the top ofthe retaining collar<br />
NOTE Use care not to damage the axle shaft with the<br />
chisel If It IS necessary to cut completely through the collar<br />
Usually If will be necessary to make shallow cuts only m<br />
order to expand the collar suffiCiently for<br />
4 AXI E SHAFT AND BEARING<br />
If to beremoved<br />
3 USing a press and press plates support the bearing<br />
COLLAR<br />
Axle Shaft Assembly With Shims for End Float Adjustment<br />
123<br />
Rear AxlelR<br />
on the Inner race and press the axle shaft out of the<br />
beanng or use special tool No ST46940000 to pull the<br />
beanng from the shaft<br />
4 Detach the bearmg spacer brake backing plate and<br />
grease trap<br />
5 Clean all parts and check the condition ofthe axle<br />
shaft for wear or damage wstortIon<br />
6 If necessary remove the old oil seal from the axle<br />
casing grease the seal hps of the new seal and Instal Into the<br />
axle casing<br />
7 PosItion the grease trap brake backmg plate<br />
bearing spacer and beanng on the axle shaft<br />
8 Press a new bearing retamlng collar onto the shaft<br />
to secure the beanng a load of 4 5 tons will be necessary<br />
for collar installatIon<br />
TO INSTAL<br />
1 Pack the axle shaft beanng With SUitable grease and<br />
smear the outer face of the retainIng collar With grease<br />
2 PosItIon the shims ongInally removed on the brake<br />
backmg plate<br />
3 Insert the axle shaft assembly<br />
mto the rear axle<br />
casing engaging the sphnes of the shaft and differentIal Side<br />
gear<br />
NOTE Ensure that the OIl seal IIp IS not damaged as the<br />
shaft IS passed through It<br />
4 Instal and tighten the retainIng nuts to secure the<br />
assembly to the axle casing flange<br />
5 Mount a dial gauge to the brake backIng plate With<br />
the on<br />
gauge plunger beanng the axle shaft flange and zero<br />
the gauge Check the end float on the axle shaft which<br />
should be wltIun the lumts of03 0 5 mm 0 012 002<br />
In<br />
6 If adJustment to the shaft end float IS necessary<br />
add to or subtract from the shims located between the<br />
brake backing plate and axle casing untJI the correct<br />
end float IS obtained<br />
7 Connect the brake cable and hydrauhc brake pipe<br />
and refit the brake drum<br />
8 AdJust and bleed the brakIng system as descnbed<br />
In the BRAKES sectIon<br />
9 Ensure that the rear axle oil level IS correct refit<br />
the road wheel and lower the velucle to the ground<br />
AXLE SHAFT<br />
I
1i<br />
19 Rear Axle<br />
TO REMOVE AND INSTAL<br />
5 REAR<br />
i XIE<br />
1 Jack up the rear of the vehIcle and support It on<br />
stands placed under theJackmg pomts<br />
2 RaISe the axle hOUSing and remove the road wheels<br />
lever<br />
3 Disconnect the handbrake cable at the equallser<br />
4 Mark across the pinIOn and umversal Jomt flanges<br />
to ensure assembly In the onglnal posItion<br />
5 Remove the four nuts and bolts connectmg the<br />
umversal JOint flange to the pinIOn flange tIe the shaft to<br />
the underbody out of the way<br />
6 Disconnect the hydrauhc brake hose from the<br />
I Rear wheel nOISe<br />
a<br />
b<br />
c<br />
d<br />
e<br />
f<br />
g<br />
h<br />
I<br />
POSSible cause<br />
Wheel loose on axle flange<br />
Defective brake components shoes or wheel<br />
cylmder<br />
Worn or defectIve axle shaft beanng lack of<br />
IubncatlOnL wagon<br />
Bent axle tube or shaft wagon<br />
Wheel out of balance or bent<br />
Broken COli or leaf spnng<br />
Faulty umversal JOints In dnve shafts sedan<br />
Worn or damaged dnve shaft shdlngJolnt<br />
sedan<br />
Axle shaft end float Incorrectly adJusted<br />
wagon<br />
2 F1l1al drIve gear nOIse<br />
POSSible cause<br />
a Faulty pinIOn beanngs<br />
b Faulty differentIal carner bearings<br />
c Lack oflubricatIon<br />
d Incorrectly adJusted crownwheel and pinIOn<br />
e Incorrectly adJusted bearing pre load pinIOn or<br />
carner beanngs<br />
f ExceSSive nOISe or gnnd under load<br />
g ExceSSive nOISe or grind on overdrive<br />
h ExceSSive nOise on coast<br />
I Bent axle hOUSing<br />
V<br />
ttSSEMBI<br />
three way connector on the axle casing and plug the<br />
fleXible hose to prevent loss of flUid and entry of dut<br />
7 Remove the shock absorber lower mounting<br />
retaining nut on each rear shock absorber and detach them<br />
from the spnng seats<br />
8 Unscrew and remove the secunng nuts from each<br />
of the spnng U bolts and detach the spnng<br />
seats and pads<br />
9 Lift the axle assembly and Withdraw It from one<br />
Side clear of the vehicle or alternatively disconnect the rear<br />
spnng shackles and lower the assembly to the ground<br />
InstallatIOn IS a reversal of the removal procedure but It<br />
Will be necessary to bleed the hydrauliC brake system and<br />
check the handbrake adJustment<br />
ft n AIl AXI E Fl UI T DIAf NOSIS<br />
124<br />
Remedy<br />
Check condition of axle and tighten or renew<br />
components<br />
Renew faulty components<br />
Renew faulty components lubncate With<br />
recommended oil<br />
Renew axle houSing and or shaft<br />
Check and rectify wheel balance or renew or<br />
true up<br />
Replace broken spnng<br />
Check and renew faulty JOlnt s<br />
Remove dnve shaft and overhaul assembly<br />
Check end float With dial indicator and adJust<br />
as necessary<br />
Remedy<br />
Renew pmlOn beanngs and readJust gears<br />
Renew carner bearmgs and readJust gears<br />
Check condition ofassembly flush and renew<br />
lubncant<br />
Check conwtlOn ofgears and readJust or renew<br />
as mated pau<br />
Check conditIon of assembly adJust beanng pre<br />
load or renew faulty components<br />
Overhaul assembly and renew faulty components<br />
Overhaul assembly and renew faulty components<br />
Faulty final dnve gears andadJustment Renew and<br />
readJust<br />
Renew hOUSing and faulty components
a<br />
b<br />
c<br />
d<br />
e<br />
Q 1<br />
c<br />
POSSIble cause f<br />
Looseness between axle sfiaft anQ differentIal Side<br />
gear spbnes<br />
Worn differentIal Side g ar thrust washers<br />
Worn differentIal plOlon thrust washers<br />
ExceSSIVe backlash between differentIal SIde gears<br />
and pillIOns<br />
ExceSSive wear betw en differentIal shaft and<br />
pillIOns and or shaft bore In case<br />
4 PInIOn shaft rotates but WIll not drIve vehIcle no nOISe<br />
I<br />
a Broken axle shaft<br />
POSSible cause<br />
S Repeated axle shaft breakage<br />
POSSIble cause<br />
a Bent axle hOUSing<br />
b Repeated over loadmg<br />
c Abnormal clutch operation<br />
6 Loss of rear axle lubncant<br />
a<br />
b<br />
c<br />
d<br />
POSSIble cause<br />
Faulty final dnve plmon or axle shaft 011 seals<br />
Clogged axle hou mg breather<br />
Le kmg gasket between cover and axle hOUSing<br />
Incorrect type of Iubncant causing excessive<br />
foaming<br />
f<br />
i<br />
r<br />
1<br />
1Iti<br />
4<br />
j<br />
4<br />
J<br />
j R ar AXl 2<br />
J I<br />
Check and renew iiXI anl or sll le gears f<br />
M<br />
Check and renew differentIal side gear thrust washers<br />
Check and renew differentIal pinIOn thrust washers<br />
Check condition of gear and pinIOn teeth and renew<br />
or renew gear and or pmlOn thrust washers<br />
Check and renew faulty components<br />
Remedy<br />
Check and renew axle shaft<br />
Check and renew housmg<br />
ReVise load capacity<br />
Remedy<br />
7 Rc vlse dnvlng hablts or check conditIon of clutch<br />
t d<br />
f J<br />
Remedy<br />
Check and renew oil seal s<br />
Remove and wash out breather In cleaning flW<br />
Renew faulty gasket<br />
f<br />
Drain flush and refill axle hOUSIng to correct<br />
With recommended lubncant<br />
tll it<br />
iJi2s<br />
j<br />
4<br />
t 1 i<br />
jt<br />
J<br />
r<br />
i<br />
IWe1 r<br />
y I<br />
I<br />
1<br />
i<br />
t4<br />
1
I<br />
G<br />
s<br />
Type<br />
Coil spnng diameter<br />
Number of spnng coils<br />
Spnng wue diameter<br />
Spnng free length<br />
LH on all models and<br />
RH on LHD models<br />
RH on RHD models and<br />
LH on L51OS models<br />
On all models with au condltlomng<br />
Loaded length<br />
LH on all models and<br />
RH on LHD models<br />
RH on RHO models and<br />
LH for L<strong>510</strong>S models<br />
All models with au conditioning<br />
Load at loaded length<br />
Caster angle<br />
Sedan models<br />
L<strong>510</strong>Smodel<br />
Station wagon<br />
Camber angle<br />
Sedan models<br />
L<strong>510</strong>S model<br />
StatIon wagon<br />
SWivel InchnatlOn<br />
Sedan models<br />
L<strong>510</strong>Smodel<br />
StatIOn wagon<br />
Toe out on turns<br />
Inner wheel<br />
Outer wheel<br />
Toe m wheel alignment<br />
Sedan models<br />
FRONT SUSPENSION<br />
SPECIFICA<br />
Independent<br />
McPherson strut<br />
type With coil<br />
spnng and<br />
lower control<br />
arm<br />
130mm<br />
8<br />
5 12 m<br />
12mm<br />
0472 In<br />
3545 mm<br />
13956 m<br />
369 5 mm<br />
1455 In<br />
384 5 mm<br />
15 14 m<br />
187 mm 1<br />
7 36 In<br />
202 mm<br />
t7 95 In<br />
217 mm<br />
854 In<br />
243 kg<br />
536Ib<br />
1040<br />
1040<br />
2000<br />
1000<br />
1030<br />
1010<br />
8000<br />
7030<br />
7050<br />
380 390<br />
22030 330<br />
6 9mm<br />
0 236<br />
0354 In<br />
126<br />
TIOl S<br />
L<strong>510</strong>Smodels 9 12mm<br />
Station wagon<br />
0354<br />
0472 In<br />
3 6 mm<br />
0118<br />
0236 In<br />
<strong>L13</strong> With 3 speed remote control transmission<br />
I<br />
TORQUE WRENCH SETIINGS q<br />
Upper mounting beanng nut<br />
Piston rod seal nut<br />
Upper mounting bolts<br />
Stabillser bar retalmng nuts<br />
StabIllser bar bracket bolt<br />
Stub axle nut<br />
Radlus rod to frame<br />
RadIUS rodto control arm<br />
7 5 kg m<br />
54 ft lb<br />
6 5 kg m<br />
47 ft lb<br />
5 2 kg m<br />
37 ft lb<br />
I 7 kg m<br />
12ft 1b<br />
2 5 kg m<br />
18 ft lb<br />
3 5 kg m<br />
US ft lb<br />
9 6 kg m<br />
69 ft lb<br />
6 3 kg m<br />
45 ft lb<br />
Stub axle to suspensIOn umt 8 kg m<br />
Low balllolll t Jrol arm<br />
m<br />
57 ftlb<br />
2 5 kg m<br />
18ft lbY<br />
Lower ball JOint retaining nut 7 6 kg m<br />
Crossmember mountmg bolts<br />
EngIne mounting bracket bolts I<br />
Wheel nuts<br />
SuspensIOn umt to diSC brake<br />
backing plate<br />
DISC brake cahper retaining bolts<br />
DISC to hub assembly<br />
Back off y turn<br />
55 ft lb<br />
2 5 kg m<br />
I8 ft lb<br />
7 kg m<br />
12ft Ib<br />
9 kg m<br />
65 ft lb<br />
3 7 kg m<br />
26 ft lb<br />
9 9 kg m<br />
71 ft lb<br />
5 3 kg m<br />
38 ft lb<br />
T<br />
v
Each front suspensIOn<br />
umt compnses a vertical tubular<br />
strut and shock absorber UnIt surrounded at the upper end<br />
by a coil spnng on the top of which IS the upper mountmg<br />
attached to the underSide of the front wheel housing<br />
The piston rod of the shock absorber IS In turn<br />
attached to the upper centre of the spnng upper mounting<br />
by a rubber mounted thrust beanng assembly<br />
The suspensIOn UnIt foot mtegral With the wheel stub<br />
axle IS attached to the lower end of the strut and shock<br />
absorber tube<br />
A ball JOint incorporating the steenng<br />
to the suspensIOn UnIt foot by two bolts and spnng<br />
washers<br />
I DESCRIPTION<br />
arm IS attached<br />
The ball bolt of the ball JOint attaches the suspensIOn<br />
TO REMOVE AND DISMANTLE Drum Type Brakes<br />
I Place blocks at rear and front of rear wheels<br />
2 Raise front of vehicle and support With jack stands<br />
3<br />
Remove wheel nuts then take offwheel and drum<br />
4 Remove the dust cover Withdraw the spht pin and<br />
remove hub retainingnut and washer<br />
assembly<br />
5 Remove the outer beanng cone and Withdraw hub<br />
from the stub aXle<br />
6 Place the assembly In a Vice and uSing a dnft or<br />
SUitable hand tool tap out the grease seals<br />
7 Lift out the mner beanng cone re mount the hub<br />
assembly In a vice and uSing a SUitable dnft tap out both<br />
Inner and outer beanng cups from the hub assembly<br />
TO CLEAN AND INSPECT<br />
I Wash beanngs cups and hub assembly In a SUitable<br />
cleamng agent y1d carry out a thorough inspectIOn of<br />
component parts<br />
2 Inspect beanng cups and cones for sconng and<br />
TO REMOVE DISC Type Brakes<br />
I<br />
wheel<br />
Place blocksat front and rear of rear wheels<br />
2 Raise front ofvehicle and support With Jack stands<br />
3 Screw off wheel retaining<br />
Front Suspension 2<br />
umt to the suspensIOn control arm wluch PivotS at ItS Inner<br />
end on a bolt and rubber bush attaclung It to the<br />
suspensIOn crossmember A stablhser bar attached to body<br />
sub frame forward of the suspensIOn and connected<br />
between the outer end of each suspensIOn UnIt control arm<br />
by a rubber bush<br />
Caster camber and SWivel InchnatlOn are set m<br />
productIOn and carmot be adJusted Any vanatlons In these<br />
angles will be caused by wornor damaged components<br />
Ifthe cot spnng IS to be removed from the umt special<br />
clIps must be used to hold the spnng m a compressed<br />
condition to assist In the removal and installation of the<br />
umt<br />
2 WHEEL HUB AND BEARIN<br />
chipping Replace where necessary<br />
3 Once haVing removed the grease seals they should<br />
be renewed<br />
TO INSTAL<br />
InstallatIOn IS a reversal of the removal procedure With<br />
attention to the follOWing pOints<br />
I Repack the hub assembly and wheel bearings With<br />
a swtable grease or to maker s speCifications<br />
Vehicles fitted With wsc brakes should use a heaVier<br />
base grease<br />
2 Tighten the stub axle nut to a torque of 3 0 3 5<br />
kg<br />
m 21 7 25 3 ft lb<br />
3 Turn the hub assembly several tunes to seat the<br />
beanng Recheck the jitub axle nut torque to read a<br />
maXimum of 35 kg m 253 ft lb<br />
4 Back off the stub axle nut a quarter turn or until<br />
there IS no end play between nut and beanngs Line up the<br />
hole In the stub axle and slot In castellated nut and fit new<br />
spht pin<br />
1 WHEEL HUB AND WHEEL BEARINf<br />
nuts and hft off road<br />
4 Disconnect the hydraulIc brake hose adJacent to<br />
the chaSSIS from the brake tube and plug the tube to<br />
aVOid leakage ofhydrauhc flUid<br />
5 Remove the retaining bolts secunng the calliper to<br />
the stub axle flange and Withdraw the calhper assembly<br />
127<br />
stub axle<br />
axle<br />
6 Remove dust cover spht pin and unscrewnut from<br />
7 Withdraw the hub and dISC assembly from the stub<br />
8 Remove washer and outer beanng cone<br />
9 Place assembly In the Vice and uSing a dnft or<br />
SUitable hand tool tap out the<br />
grease seal<br />
10 Lift out the Inner bearing cone re mount the<br />
assembly m the Vice and uSing a SUitable dnft tap out both<br />
Inner and outer bearing cups from the hub assembly<br />
11 Remove the bolts connecting the dISC to the hub<br />
assembly and separate diSC from assembly
3 Front Suspension<br />
Dismantled View of Front Hub Components<br />
oI r<br />
CASTELLATED NUT OUTER BEARING<br />
TO CLEAN AND INSPECT<br />
HUB LOCK WASHER<br />
BOLT<br />
1 Wash beanngs cups hub assembly and wsc<br />
Inspect beanngs and cups for sconng chips and pitting If<br />
damaged replace as complete assembly<br />
Inspect the diSC for distortion or chipping cracking<br />
TO REMOVE<br />
I Block the rear wheels and jack up the front of<br />
vehicle<br />
2 Remove the engine dust cover<br />
3 Remove the retalnlng nuts rubber busJles ana<br />
washers attaclung the stablllser bar to the lower suspensIOn<br />
arm<br />
4 Take out the retaining bolts attaching the stabdlser<br />
supporting brackets to the chaSSIS and Withdraw the<br />
stabillser bar from the velucle<br />
5 Inspect the stablllser bar for distortIOn and fatIgue<br />
Renew all rubber bushes<br />
TO REMOVE<br />
arm<br />
I Remove the retaining bolts from the lower support<br />
2 Remove the retaining nut washer and rubber bush<br />
from chasSIS and Withdraw the rod<br />
Check the radIUS rod for distortIOn and fatigue Renew<br />
all rubber bushes and washers Replace the radIUS rod where<br />
necessary<br />
BRAKE DISC OUTER CUP SEAL<br />
Replace when necessary<br />
bolts<br />
When replaCing the diSC renew<br />
2 Renew the grease seals<br />
TO INSTAL<br />
4 SI BlIoISER DAIl<br />
I InstallatIOn procedure IS the reversal to that of<br />
removal<br />
2 When reassembhng the beanngs to the hub pack<br />
the beanngs and hub With heavy duty grease to<br />
manufacturer s speCificatIOns<br />
TO INSTAL<br />
d RADIUS ROD<br />
128<br />
Installation IS the reversal of the removal procedure<br />
With the exceptIOn of the follOWing pOints<br />
Maxunum tightening torgue lur ng as eTIbly S onaws<br />
l1<br />
Stabillser Imk retaining nuts I 7 m or kg 12 ft lb<br />
Stablllser bracket bolts<br />
2 5 kg m or 18 ft lb<br />
Velucle IS to be In the lowered pOSItion when the final<br />
tightening procedure IS carned out<br />
TO INSTAL<br />
Installation procedure IS the reversal of removal<br />
procedure With the exception ofthe follOWing pOints<br />
Maxunum tlghtemng torque dunng assembly IS as<br />
follows<br />
Rod retaining nut to chasSIS 9 6 kg m or 69 ft lb<br />
Rod retaining nut to suspensIOn arm 6 3 kg m or 45 ft lb
TO REMOVE<br />
i9i<br />
SPACER WASHER<br />
6 SUSI El SIOl UNIT<br />
I Place blocks at the front and rear of the rear<br />
wheels Raise the vehIcle with a Jack under the suspensIOn<br />
control arm on the side to be removed and remove the road<br />
wheel<br />
2 With the full weight of the vehicle stIll on the coil<br />
spnng fit the special spnng chps to maintain the coil sprillg<br />
ill the compressed poslhon<br />
3 RaIse the front of the vehicle and support With<br />
Jack stands<br />
4 Remove the hub grease retaining cap Withdraw the<br />
spht pm and remove the stub axle and washer<br />
5 Withdraw the brake drum and hub assembly from<br />
the stub axJe Remove the outer wheel beanng<br />
NOTE Where dzsc brakes are fitted remove the hub dl C<br />
and calzper DzsconneU the brake hose and plug the<br />
hydraulzc lme<br />
6 Unscrew the four retaining nuts and Withdraw the<br />
four bolts secunng the bdckmg plate to the stub axle flange<br />
7 Remove the hydrauhc brake line retaining chps<br />
from the suspensIOn Unit Withdraw the backing plate<br />
assembly from the stub axle and support the backing pldte<br />
to aVOid ddmage to hydrauhc line and hose<br />
8 Withdraw the spht pin and unscrew the castellated<br />
nut secunng the he rod end ball bolt to the steellllg Jrm<br />
Remove the tie rod end ball bolt from the steenng arm<br />
t<br />
RADIUS ROD<br />
WASHER<br />
c<br />
Frollt SIIspension 1<br />
CONTROL ARM<br />
Dismantled VIew of RadIUS Rod and Control Arm<br />
9 Disconnect the radIUS rod and stablhser drm from<br />
the lower suspensIOn control arm<br />
arm<br />
IO Place a Jack under the lower suspensIOn control<br />
I I Remove the two bolts secunng the suspensIOn<br />
control arm to the suspensIOn umt and ball JOint<br />
I2 RaIse the bonnet and working from the engine<br />
compartment remove the retamlng nuts secunng the<br />
suspensIOn Unit to the upper support member<br />
13 Lower the Jack and remove the suspensIOn umt<br />
from the vehicle<br />
TO DISMANTlE<br />
I Pnor to dlsmanthng of the suspensIOn Unit clean<br />
thoroughly and ensure that a clean workmg<br />
area IS available<br />
pnor to dlsmanthng<br />
2 Fit a coil spnng compressor to the suspensIOn umt<br />
Compress the spnng and remove the self locking nut and<br />
washer<br />
3 Remove the suspensIOn mountmg Insulator thrust<br />
Layout of RIght Hand Side SuspensIon as Viewed from Front of Underbody<br />
129<br />
e
lJ<br />
7F<br />
5 Front SUSIJension<br />
bearing spnng seat bumper rubber and dust cover<br />
4 Back offthe<br />
spring compressor and remove the coil<br />
spnng<br />
5 USing gland packing<br />
the gland packing<br />
5 USing tool No ST49<strong>1300</strong>00 tighten the gland<br />
packing to a torque of 6 5 kg m or 47 ft lb<br />
6 To bleed the air from the hydrauhc system pump<br />
the piston up and 1<br />
down until all au IS expelled<br />
Dram oil from the<br />
casing and cyhnder wash ThiS IS carned out In the followmg manner Have the<br />
components and dry off With au compressed Non metalhc stub axle In the down pOSItion when the piston IS drawn<br />
parts should be cleaned by au only upwards and In the upper posItion when the IS piston<br />
2 New gland packing 0 nng and hydrauhc flwd are pushed down the cylmder bore<br />
TO CLEAN AND INSPECT<br />
to be used every time the assembly IS dismantled ExpulSIOn of all au from the system can be determined<br />
3 Check the strut outer casing for distortion and by equal pressure In either duectlon of the piston With no<br />
cracks I<br />
flat spots<br />
4 Inspect the spindle for distortIon Check the base 7 Fully extend the piston rod and fit the coil spnng<br />
and threaded sectlon for fahgue Replace where necessary bump rubber sprlng seat and dust cover<br />
5 Test the coil<br />
spnng for sag and fatIgue and check Compress the spring With tool ST49100000 and fit the<br />
the rubber components Replace where necessary mounting Insulator and beanng assembly<br />
6 Check the thrust beanng for pitting sconng and<br />
general wear Replace where necessary<br />
wrench ST49<strong>1300</strong>00 remove<br />
NOTE PrIOr to removal push the piston rod down to the<br />
lowest pOint clean the gland nut and surrounding area If<br />
the gland nut has been caulked break the seal and remove<br />
the gland nut<br />
6 Pull the piston rod slowly upwards remove the 0<br />
and Withdraw the<br />
nng from the top of the piston gUide<br />
piston rod and cyhnder assembly<br />
NOTE Do not remove the piston rod and guide from the<br />
cylinder as they are serviced as an assembly<br />
TO ASSEMBLE<br />
1 Pnor to assembly ensure that all parts are cI an<br />
Do not use cotton waste for Wiping down Particles<br />
could lodge In the cyhnder and result In faulty operatIOn<br />
2 To reassemble fit the outer casing to the<br />
suspensIOn umt body<br />
3 Place the piston rod and cyhnder assembly In the<br />
TO REMOVE<br />
1 Block the velucle rear wheels front and rear Raise<br />
the velucle and support With Jack stands<br />
2 Remove the retaining bolts and nuts connecting<br />
the rawus rod andstablhser bar to the control arm<br />
outer casing and fill the casing With the speCified quantity<br />
and type ofoil<br />
NOTE The operating effiCiency of the suspensIOn<br />
umt IS<br />
greatly Influenced by the speCified quantity and quality of<br />
hydraulic flUid<br />
4 Fit the 0 nng to the top of the piston rod guide<br />
and assemble the gland packing Take care not to damage<br />
the oil seal dunng assembly<br />
Use speCial tool ST49340000 gland packing guide to<br />
Instal gland packing<br />
NOTE PrIOr to tlghtemng the gland packing withdraw the<br />
piston rod approximately 90 mm or 354 In to faCilitate<br />
bleeding of thehydraulic system<br />
NOTE Ensure that the thrust bearing gland packing and<br />
011 seal are lubncated prror to assembly<br />
8 Fit a new washer and self lockmg nut and tighten<br />
to a maxunum torque of 7 5 kg m or 54 ft lb<br />
TO INSTAL<br />
7 SUSPEl SION CONTIl4t1 1101<br />
1 USing the reverse procedure to that of removal<br />
observing torque settings set out In SpeCifications sectIOn<br />
fit the suspensIon umt to the vehicle<br />
130<br />
3 Remove the lower ball JOint retaining bolts<br />
4 Unscrew the retaImng nut connecting the control<br />
arm to the body member and Withdraw the control arm<br />
from the velucle<br />
5 Clean the control arm and Inspect the metalhc
DIsmantled VIew of Lower SuspensIon Unit<br />
SPLIT PIN<br />
BAll BOLT NUT<br />
sectIon for distortIOn and fatIgue Replace where<br />
necessary<br />
6 Check the rubber bushillgs for damage and or<br />
fatigue<br />
7 Measure the distance between the Inner and outer<br />
penphery at the tapered sectIon of bush and Jf the reading<br />
IS less than 1 mmor 0 039 In renew the bushes<br />
TO REMOVE<br />
1 Block the vehicle rear wheel front and rear Jack<br />
up the vehicle support With Jack stands and remove the<br />
road wheels<br />
2 Remove the stablliser armand radIUS rod from the<br />
control arm Disconnect the tIe rod ball JOint from the<br />
steenng arm<br />
3 Take out the retaining bolts attaclung the stub axle<br />
and suspensIOn strut assembly to the steenng arm and ball<br />
JOint assembly<br />
4 Withdraw the split pm remove the lower ball JOint<br />
retazmng nut and dISconnect the ball JOlnt from the steering<br />
arm<br />
5 Take out the retamillg bolt connecting the ball<br />
JOint to the control arm and remove the ball Jomt<br />
BO<br />
STEERING ARM<br />
BAll BOLT<br />
I<br />
fi<br />
BALL JOINT<br />
Front Suspension 6<br />
Underbody View of R ght Hand SIde Front SuspensIon<br />
Assembly<br />
TO INSTAL<br />
8 LOWtill IIA L JOINT<br />
131<br />
Installation procedure IS the reverse to thatof removal<br />
NOTE Tlghtenmg torque for respectIve nuts and bolts IS<br />
wnJamed m torque Speufu atwn SeLflon<br />
TO CLEAN AND INSPECT<br />
1 Clean the ball JOint In SUitable c1eamng flUid and<br />
carry out inspection<br />
2 Inspect the ball JOint for excessIVe end play and<br />
metal fatIgue<br />
When the end play between the upper spnng seat and<br />
top of spnng exceeds 06 mm or 0013 In the ball JOint<br />
showd be replaced<br />
Check spnng tensIOn by mounting the ball JOint In a<br />
spnng compressIOn gauge and allowmg for the<br />
pre detenruned clearance<br />
compress the spnng Requued<br />
IS 120 110 kg or 265t<br />
readmg With the spnng compressed<br />
22 Ib If spnng compressIOn IS not wltlun thiS tolerance<br />
renew the ball JOillt Renew the dust cover at all times<br />
3 The ball JOint assembly IS not repazrable and must<br />
be renewed when found defective
7 Front Sus Jension<br />
NOTE To lubricate the ball Jomt remove the plug at the<br />
base of the ball Jomt fit a grease mpple and fill with new<br />
grease until the old grease IS expelled<br />
When lubricating With a high pressure gun ensure that<br />
the dust cover IS not damaged<br />
TO REMOVE<br />
I Block the rear wheels front and rear Raise the<br />
front of the vehIcle and support on Jack stands<br />
2 Remove the stabJllser rod and radIUS rod from the<br />
lower control arms<br />
3 Remove the lower control arms from the<br />
suspension crossmember<br />
4 USing a SUitable engine hftlng deVice support the<br />
engine and remove the engine mounting<br />
crossmember<br />
ADJUSTMENT<br />
I Pnor to carrYing out a wheel alignment<br />
TO INSTAL<br />
9 SUS ENSION U OSSME II R<br />
bolts from the<br />
Installation IS the reverse procedure<br />
to that of<br />
dismantling<br />
Tlghtemng torque IS set out In torque SpeCification<br />
SectIOn<br />
Raise the engine shghtly to allow working clearance<br />
Take out the crossmember to body retaining bolts and<br />
remove the crossmember<br />
Clean the crossmember In SUitable solutIOn and Inspect<br />
for cracks distortIOn or general damage<br />
Pay particular attention to each end of crossmember<br />
for cracking and fatigue<br />
TO INSTAL<br />
10 SUSPENSION AND STEI IlING i NGI ES<br />
select a<br />
clean and level area on which to carry out the necessary<br />
adJustments<br />
2 Carry out a thorough inspectIOn of the steenng<br />
hnkages front wheel beanng adJustment suspensIOn JOints<br />
and rods spnngs and suspenSIOn umt recoil action Replace<br />
or repau where necessary<br />
3 Inspect the tyres for even tread Iffound defective<br />
replace With serviceable tyres<br />
4 Inflate tyres to correct pressure<br />
TO CHECK AND ADJUST TOE IN<br />
1 With the velucle on a level floor Jack up the front<br />
ofthe vehicle<br />
2 Spin each front wheel In turn and uSing a piece of<br />
chalk mark a lme around the penphery of each tyre as near<br />
to the centre as pOSSible<br />
3 Lower the front of the vehicle to the floor and<br />
bounce the velucle up and down several tunes and let It find<br />
ItS own level Set the front wheels In the straight ahead<br />
posItion<br />
4 Mark the centre chalk line on both tyres at<br />
approXimately 8 In to 10 In above the floor and In front of<br />
the front<br />
suspensIOn<br />
5 USing a SUitable telescopic gauge place It between<br />
the two front tyres on the chalk marks and record the<br />
distance between the centres of the tyres<br />
6 Mamtalnlng the wheels ill a straight ahead pOSItion<br />
roll the vehicle forward until the marks are the same<br />
distance above the floor but to the rear of the suspensIOn<br />
132<br />
Installation procedure IS the reverse to that of removal<br />
7 Agam use the telescopic gauge to measure and<br />
record the distance between the marks on the tyres The<br />
distance measured at the front of the tyres should be less<br />
than the measurement at the rear of the tyres<br />
@ If adJustment of the toe m IS necessarYJ loosen the<br />
clamp bolts on each end of the adJustable sleeves on each<br />
he rod and turn each sleeve by equal amounts unhI the<br />
toe In IS correct Tighten the lour adJustable sleeve clamp<br />
bolts<br />
NOTE It IS Important to make equal adJustments on each<br />
tierod to mamtam the central pOSltlon of the steenng gear<br />
If an optical or other type of toem gauge IS used<br />
follow the manufacturer s mstrnctlOns<br />
TO CHECK CAMBER AND CASTER<br />
Before any attempt IS made to check the camber or<br />
caster angles or to check and adJust<br />
front wheel toe In the<br />
suspensIOn umt should be thoroughly checked to ascertam<br />
that It IS In a serViceable condition<br />
The tread of the front tyres should be examined for<br />
excessive or uneven wear as certam conwtlOns of tyre wear<br />
are indicative of damaged or worn components In the<br />
suspenSIOn steenng hnkage and or wheels and bearings<br />
The velucle should be unladen except for the normal<br />
amount of petrol oil and water With the tyres Inflated to<br />
the normal pressure<br />
I Check and adJust the tyre pressures and set the<br />
velucle up With the alignment eqUipment being used<br />
according to the manufacturer s instructions<br />
Bounce the velucle up and down several times andlet It<br />
find ItS own level
1f<br />
2 Check the front wheel ahgnment toe m and If<br />
necessary adJust as preViously descnbed<br />
3 Check the caster camber and SWivel Inchnatlon<br />
according to the instructions set down for ahgnment<br />
equipment bemg used and compare With the manufacturer s<br />
speCifications<br />
4 If the caster angle IS Incorrect check the stabillser<br />
bar brackets and rubber bushes Also check the suspensIOn<br />
control armrubber pivot bushes for wear<br />
5 Ifthe camber and SWivel Inchnation angles are both<br />
Incorrect check the suspensIOn umt upper mounting and<br />
lower ball JOint for wear or looseness Check the suspensIOn<br />
control arm for distortIOn and ItS rubber piVOt bushes for<br />
wear<br />
6 If the SWivel inclination angle IS correct and the<br />
camber angle IS Incorrect the stub axle IS bent A new<br />
suspensIOn<br />
Unit should be Installed<br />
I Front end nOise<br />
NOTE A speCIal gauge<br />
dIStortIOn<br />
Front Suspension 8<br />
View of Right Hand Side Steering<br />
Linkage Mounted to Vehicle<br />
IS avaIlable to check stub axle<br />
7 Measure the toe out on turns of the front wheels<br />
uSing the eqUipment according to instructIOns<br />
If the toe m IS correctly adJusted and the toe out on<br />
either or both left or nght hand turn IS Incorrect then the<br />
tie rods are of unequal length or one or both steenng arms<br />
may be bent In the latter case the steenng armis must be<br />
renewed and the steerIng hnkage readJusted<br />
NOTE The maximum minimum steering angle toe In<br />
toeout on turns IS also determmed by the distance<br />
between the face of the adJustable stop fitted to the<br />
steering arm and the stop on the lower sectIOn of thestrut<br />
when the wheels are turned from lock to lock<br />
11 FRONT SUS1 NSION FI11 T BIAt NOSIS<br />
POSSIble cause<br />
a Loose uppersuspensIOn mountmg or piston rod<br />
bearing<br />
b Loose or worn suspension umt lower ball JOint<br />
c NOise In shock absorber umt<br />
d Worn steenng lmkage or Idler arm components<br />
e Mal adJusted front hub bearings<br />
133<br />
Remedy<br />
Tighten mounting and or adJust piston rod bearmg<br />
AdJust tIghten or renew lower ball JOint<br />
Renew shock absorber umt<br />
Renew defective components<br />
ReadJust or renewhub bearings
9 Front SusI ension<br />
2 Poor or erratIc road holwng abIlIty<br />
Possible cause<br />
a Low or uneven tyre pressure<br />
b Defective shock absorber operation<br />
c Incorrect front end alIgnment<br />
d Loose or defective front crossmember<br />
e Weak or uneven front coil spnngs<br />
0 Broken leaf In or weak rear spnng<br />
g Loose or defective front hub bearings<br />
h Mal adJusted or defective steenng gear or Idler<br />
I Defective tyres or front wheel balance<br />
3 Heavy steenng<br />
Possible cause<br />
a Low or uneven tyre pressure<br />
b Incorrect front end alignment<br />
c Lack of lubncant III steenng gear and<br />
components<br />
d Worn or damaged front suspensIOn components<br />
e Sagging or broken coil spnng s<br />
0 Incorrect adJustment of steenng gear<br />
4 Front wheel wobble or shImmy<br />
Possible cause<br />
a Tyre and or wheel unbalance<br />
b Rapid and uneven tyre wear<br />
c Worn or loose hub beanngs<br />
d Worn or damaged steering hnkage<br />
e Incorrect front end alignment<br />
0 Mal adJusted or worn steenng gear<br />
g Steenng gear loose on frame mounting oroff<br />
centre<br />
5 VehIcle pulls to one SIde<br />
POSSible cause<br />
a Low or uneven tyre pressure<br />
b Incorrect or unequal front end ahgnment Side<br />
to Side<br />
c High road camber<br />
d Unequal coil spnng length<br />
e Weak or broken rear spnng<br />
0 Front brake draggIng<br />
g Steenng gear<br />
off centre<br />
134<br />
Remedy<br />
Inflate tyres to recommended pressures<br />
Check and renew faulty umt<br />
Check and readJust alignment as necessary<br />
Check and tighten or renew member<br />
Check and renew spnngs<br />
Check and renew leaf or complete rear spnng<br />
AdJust or renewhub beanngs<br />
AdJust or renew faulty components<br />
Renew defectIve tyres and balance front wheels<br />
Remedy<br />
Check and Inflate tyres to recommended pressures<br />
Check and adJust alignment<br />
Check oil level In steenng gear and apply grease gun<br />
to all grease mpples<br />
Check and renew worn or damaged components and<br />
adJust<br />
front end alignment<br />
Renew coil spnng s<br />
Check and adJust steenng gear<br />
Remedy<br />
Check and balance tyre and wheel as a umt<br />
Check fronCehd1tlignmimf see WIieels ancfryres<br />
Check and renew or adJust hub beanngs<br />
Check renew faulty components and adJust<br />
AdJust and or renew suspensIOn components to<br />
restore ahgnment<br />
Renew and or adJust steenng gear components<br />
Check and tIghten mounting and or centre steenng<br />
gear<br />
Remedy<br />
Check and mflate tyres to recommended pressures<br />
Check and adJust to restore correct alignment<br />
AVOId as far as pOSSible<br />
Check and renew sagging spnng<br />
Renew faulty spnng<br />
AdJust or rectIfy cause<br />
Check and re centre steenng<br />
u
REAR SUSPENSION<br />
PART I SED N SI ECI JATIONS<br />
Type Independent semi<br />
Coil spnng length<br />
L5IOS LH and RH dnve model<br />
P51O RH dnve model<br />
P<strong>510</strong> LH dnve model<br />
L<strong>510</strong> and PL<strong>510</strong> LH and<br />
tralhng<br />
coil<br />
spnng With<br />
arm and<br />
double actIng<br />
shock absorber<br />
311 mm<br />
12244 In<br />
306 mm<br />
120 In<br />
299 mm<br />
II 8 In<br />
RH dnve models 299 mm<br />
Wue wameter<br />
Cod diameter<br />
Wheel alignment<br />
vehicle laden<br />
11<br />
8 m<br />
142mm<br />
0 56 In<br />
90 mm<br />
3 543 In<br />
Toe In angle 10 30<br />
Camber angle 00 30<br />
L<strong>510</strong> <strong>1300</strong> Senes P<strong>510</strong> <strong>1600</strong> Senes<br />
Axle hOUSing length<br />
Code A<br />
Code B<br />
Code c<br />
59 05<br />
5915 rom<br />
2325<br />
2329 In<br />
58 95<br />
59 05 mm<br />
2321<br />
2 325 In<br />
58 85<br />
58 95 mm<br />
2 317<br />
2321 In<br />
Bearmg spacer length<br />
Code A 59 02<br />
59 08 mm<br />
2 320<br />
2 324 In<br />
The rear suspensIOn assembly IS fully Independent<br />
bemg the tralhng arm deSign incorporating a suspensIOn<br />
member suspensIOn arms telescopic double acting type<br />
shock absorbers and cod spnngs<br />
The differential assembly IS connected to the<br />
suspensIOn member by four bolts and to the body member<br />
through two rubber Insulators<br />
Both traIlmg arms pivOt on the two mountings<br />
attached to the<br />
suspensIOn member through the rubber<br />
Insulators<br />
Code B 58 72<br />
58 98 mm<br />
2311<br />
2 322 m<br />
Code c 58 82<br />
58 88 mm<br />
2316<br />
2318 In<br />
TORQUE WRENCH SETIINGS<br />
Rear wheel bearing lock nut 33 kg m<br />
Backing plate bolts<br />
Shock absorber lock nuts<br />
Bumper<br />
I DESCRIPTION<br />
135<br />
rubber nut<br />
2<br />
239 ft lb<br />
4 0 kg m<br />
27 ft lb<br />
2 3 kg m<br />
17 ft lb<br />
5 kg m<br />
18 ft lb<br />
Wheel nuts 9 kg m<br />
SuspensIOn member mountmg nuts<br />
65 ft lb<br />
10 kg m<br />
72ft Ib<br />
Dnve shaft axle compamon flange nuts 8 kg m<br />
Dnve shaft to differential mountIng<br />
58 ft lb<br />
nuts 8kg m<br />
Differential mounting member<br />
58 ft lb<br />
locknuts 8 5 kg m<br />
62 ft lb<br />
SuspensIOn arm to suspension<br />
member<br />
nuts 10 m kg<br />
Differential to differentIal mounting<br />
72 ft lb<br />
member nuts 6 kg m<br />
Propeller shaft flange nuts<br />
Differential suspensIOn member nut<br />
43 ftlb<br />
8 5 kg m<br />
61 ft lb<br />
6 kg m<br />
43 ft lb<br />
Each shock absorber lower bracket and wheel beanng<br />
hOUSing IS welded to the trading end of the suspensIOn arm<br />
The cod spnngs are mounted between the suspenSIOn arms<br />
and the vehicle body With the bound rubber situated on the<br />
suspensIOn member In the centre of the COIl spnng<br />
SuspensIOn of the axle shaft IS by two ball beanngs<br />
which normally only reqUire semclng and lubncatlng when<br />
replacement<br />
non adJustable type<br />
IS being carned out They are the
J<br />
2 Re r SIlSpt SiOIl<br />
TO REMOVE<br />
I Jack up the rear of the vehicle and support on<br />
stands under the frame<br />
2 Release the handbrake and disconnect the rear<br />
cable at the equahser<br />
3 Mark the propeller shaft rear universal JOint and<br />
dnve pinIOn flanges and remove the four retaining nuts and<br />
bolts<br />
4 Separate the two flanges and either fasten the shaft<br />
out of the way or WIthdraw the shaft from the rear ofthe<br />
gearbox<br />
5 Disconnect the exhaust pipe at the JOint adJacent<br />
to the dnve pinIOn flange and at the rear muffler and<br />
Withdraw the muffler and pIpe<br />
6 Disconnect both rear brake fleXible pipes at the<br />
umon on the suspensIOn arms Plug the pipes to prevent<br />
entry of dIrt<br />
7 Remove both rear road wheels<br />
8 Place a Jack under one Side suspensIOn arm and<br />
raise the arm suffiCiently to take the weight of the coil<br />
spnng off the shock absorbers<br />
9 Remove the nut and washer and disconnect the<br />
shock absorber at the lower mounting Do not lose the<br />
rubber bushes<br />
IO Lower the suspensIOn<br />
2 lj P SKlIlU<br />
arm to release the COIl<br />
spnng and repeat operations 8 and 9 on the other Side<br />
suspensIOn unit<br />
I I Support the suspensIOn and final dnve assembly<br />
on a SUitable trolley Jack remove the four selflocking nuts<br />
and washers one at each suspenSiOn member mounting and<br />
I<br />
I<br />
DRIVE SHAFT<br />
SUSPENSION ARM<br />
one at each final dnve hOUSing member mounting attaching<br />
the complete assembly to the body<br />
12 Lower the Jack so that the fleXible mounting wIll<br />
clear the mounting bolts and Withdraw It from beneath the<br />
vehicle Use care to prevent damage by dislodging the<br />
assembly from the Jack<br />
I3 If necessary remove the spnng seats from the<br />
upper end of the spnngs and hft each spnng from ItS lower<br />
seat In the suspensIOn arm<br />
TO INSTAL<br />
I InstallatIOn IS the reversal to that of the removal<br />
procedure paYing attentIOn to the followtng pOints<br />
2 If the clearance between the outer hp of the rubber<br />
msulator and the face of the washer exceeded 5 mm 0 197<br />
Underbody View of Right Hand Rear SuspensIon Layout Sedan<br />
136<br />
RemOVing COIl Spring from<br />
Rear Suspension Arm Sedan<br />
BRAKE BACKING<br />
PLATE ASSV
Right Hand Rear Suspension Arm and Associated Components Sedan<br />
Re r SlIspells on J<br />
In use special tool No ST49l70000 and Insert new 5 Check retamlng bolts for wear dnd ddmage<br />
Insulator rubbers from the lower side of the suspensIOn<br />
6 Replace worn or damaged components where<br />
member and the differential support<br />
ne essary<br />
3 ExamIne suspension member for cracks and 7 Fit the suspensIOn member to the vehicle and<br />
distortIOn tighten the suspensIOn member differential mounting and<br />
ahgnment<br />
4 Check the msulator rubbers for correct fit and shock absorber retalnmg bolts to the speCifIed torque as set<br />
TO REMOVE AND INSTAL<br />
I Raise the rear of the vehicle block the front<br />
wheels support the vehicle on Jack stands and remove the<br />
rear road wheels<br />
I nUl M III<br />
2 Remove the dnve shaft flange nuts adJacent to the<br />
backing plate<br />
3 Remove the spht pin take out the cleVIS pin and<br />
release the hand brake cable<br />
4 Remove the re bound rubber retamlng nuts<br />
5 Raise the suspensIOn arm With the Jack take off<br />
the shock absorber retalnmg nut and WIthdraw the shock<br />
r<br />
J t lc<br />
i<br />
1 1 II t t<br />
I i I I I I I 1<br />
J I<br />
137<br />
out m the SpeCIfications section<br />
absorber from ItS lower support mounting<br />
6 Lower the Jack and Withdraw the COlI spllng<br />
re bound rubber and spnng seat<br />
7 Installation IS the reversal to that of the removal<br />
procedure With attention to the follOWing pOints<br />
8 Examme spnng pOSItion for correct seating<br />
ensunng that the flat face on the spnng IS In the uppermost<br />
posItion<br />
9 Tighten the dnve flange nuts and shock absorber<br />
nut to the speCified tightening torque as detailed<br />
SpeCification section<br />
itPLATE<br />
OJ T<br />
08<br />
In the<br />
Spring and Rebound Rubber Removed from Rear<br />
Suspension Arm Sedan
4Rear Suspension<br />
TO CLEAN AND INSPECT<br />
1 Clean the spnng In a sUItable solvent and examine<br />
for cracks and distortIOn<br />
2 Measure the free length of the spnng to determine<br />
If the spnng length IS within the speCified measurement as<br />
TO REMOVE AND INSTAL<br />
1 Open the boot and remove the two nuts from the<br />
end of the shock absorber<br />
upper<br />
2 Unscrew the retaining nut from the lower support<br />
mounting and Withdraw<br />
vehicle<br />
the shock absorber from the<br />
3 Installation IS the reversal to that of the removal<br />
procedure paYing attentIOn to the following<br />
4 Tighten the retalmng nuts to the speCified torque<br />
as stated In SpeCification section<br />
TO REMOVE AND INSTAL<br />
1 Raise the rear of the vehicle support on Jack<br />
stands chock the front wheels and remove the rear road<br />
wheel and brake drum<br />
2 Remove the four bolts and dlsconnect the dnve<br />
shaft from the axle flange<br />
3 Remove the hand brake cable from the wheel<br />
cylmder lever and the equallser lever<br />
4 Withdraw the hydrauliC brake hose pipe spnng<br />
lock and disconnect the fleXible hose from the pipe Plug<br />
NUT<br />
r2<br />
@<br />
WASHER<br />
i d<br />
TBOLT<br />
SUSPENSION ARM<br />
FLANGE<br />
NER BEARIJO<br />
set out In the SpeCificatIOn section<br />
If the spnng length IS not In accordance with the<br />
speCificatIOn It should be replaced<br />
3 Check the spnng seat and re bound rubber for<br />
fatigue and damage<br />
4 SHO K AII iORU 1l<br />
TO CLEAN AND INSPECT<br />
1<br />
Clean the shock absorber In a SUItable solvent and<br />
eXamIne the shaft for distortIOn and the body for damage<br />
and oil leaks<br />
2 Check the damping expansIOn and compresslon<br />
action of the shock absorber If the damper actIOn IS<br />
ineffective the shock absorber should be replaced<br />
3 Check the rubber bushes and washers for damage<br />
and replace If necessary<br />
a SlJSP XSIOX AIUI<br />
Pil @ NUT<br />
the fleXible hose With a SUItable plug to dVOld spillage of<br />
hydrauhc brake flUId<br />
lock nuts andWithdraw<br />
5 Remove the wheel beanng<br />
the axle shaft wheel beanngs and 011 seals as descnbed In<br />
REAR AXLE SHAFT AND BEARING section<br />
6 Unscrew the four backmg plate retamlng bolts and<br />
remove the backing plate and brake assembly<br />
7 Place the Jack under the suspensIOn arms and raISe<br />
the arm to take the weight<br />
off the shock absorber Remove<br />
the shock absorber retaining nut from the lower support<br />
mounting and Withdraw the shock absorber<br />
8 Gradually lower the Jack and remove the coil<br />
spnng spnng seat and re bound rubber<br />
9 Remove the self lockmg nuts from the two bolts<br />
connecting the suspensIOn arm to the suspensIOn member<br />
and Withdraw the suspensIOn arm<br />
10 USing the suspensIOn arm bush remover tool<br />
ST49<strong>1600</strong>00 remove the bushes from the suspensIOn arm<br />
11 Installation procedure IS the reversal to that of<br />
removal With special attentIon to the follOWing pOints<br />
12 With the vehicle fully laden re check the tensIOn<br />
of the bolts connecting the suspensIOn arm to the<br />
suspensIOn umt<br />
13 New self locking nuts must be fitted each time<br />
the suspensIOn arm IS removed<br />
14 Bleed the hydrauhc braking system<br />
Exploded VIew of L 16 sedan Rear Suspension Arm Components<br />
138
TO REMOVE<br />
6 IU 8 AX SIIAFT WK I HK ln 4S<br />
I Jack up the rear of the vehicle chock the front<br />
wheels remove the rear road wheel andbrake drum<br />
2 Remove the four secunng bolts and disconnect the<br />
dnve shaft from the axle shaft comparuon flange<br />
3 Secure the companion flange With special tool<br />
ST49190000 and remove the axle shaft and wheel beanng<br />
lock nut<br />
4 Remove the axle shaft With special tool<br />
ST46780000 and hft out the compamon flange<br />
5 Take out the four screws and remove the grease<br />
catcher from the axle flange<br />
6 USing a sUitable dnft remove the mner bearing and<br />
011 seal<br />
7 Select a sUitable beanng puller and Withdraw the<br />
outer beanng<br />
NOTE The outer beanng Will be damaged durmg removal<br />
and must berenewed pnor to assembly<br />
TO CLEAN AND INSPECT<br />
I Clean all components parts In a sUitable cleaning<br />
solvent<br />
2 Check the Inner beanng for wear and chipping<br />
3 Check the compamon flange machined surface for<br />
damage<br />
4 Check the axle shaft for cracking<br />
wear and<br />
alignment<br />
5 Check the beanng spacer for wear or distortIon<br />
TO ASSEMBLE AND INSTAL<br />
I Pack the beanngs With a lubncant speCified by the<br />
manufacturer and lubncate inSide the beanng hub<br />
2 Dnft the mner beanng Into the hOUSing ensunng<br />
that the dnft face IS In contact With the centre race oruy<br />
The bearing IS of the semi sealed type and the sealed<br />
face must be toward the differential<br />
Type<br />
Spnngs<br />
Number of leaves<br />
Width of leaf<br />
EnSure that the beanng IS correctly<br />
Rear Sus lens on 5<br />
seated In the<br />
hOUSing<br />
3 Insert the beanng spacer In the hOUSing firstly<br />
ensunng that the coding on the<br />
spacer corresponds With the<br />
coding on the arm<br />
suspensIOn<br />
hub<br />
4 Dnft the new outer beanng Into the hOUSing<br />
ensunng that the dnft face IS In contact With the centre<br />
race only<br />
5 The beanng IS of a semi sealed type and the sealed<br />
face must be faCing outwards<br />
Ensure that the beanng IS correctly seated In relation to<br />
the beanng spacer<br />
6 Lightly Iubncate the Inner penphery of the Oil<br />
seals and fit the Inner and outer 011 seals In the hOUSing<br />
7 Screw the<br />
grease<br />
catcher to the axle flange<br />
8 Fit the axle In the hOUSing place the compamon<br />
flange over the end of the axle fit the washer and the new<br />
castellated nut Tighten the beanng retalmng nut to the<br />
speCified torque as deta1led In the SpecificatIOns and check<br />
the axle end play wluch should be 0 0 15 mm 0<br />
0006 In<br />
NOTE When It IS necessary to fit a new suspensIOn arm<br />
ensure that a co espondmg coded bearing spacer IS fitted<br />
e g should the suspenSIOn armhub be marked S then the<br />
bearing spacer must also be marked S<br />
In 110 circumstances should a diSSimilar spacer and<br />
suspension arm befitted as a crltlcal clearance of0 05 mm<br />
0002 In eXists between the bearmg spacer and the<br />
beaTIng<br />
I ART 2 STA TION lV AON<br />
Seml elhptlc<br />
leaf spnng<br />
With double<br />
acting shock<br />
absorbers<br />
Four<br />
60 mm<br />
2362 In<br />
Hub length and beanng spacer length IS detailed<br />
In the<br />
SpeCificatIons<br />
8 Couple the dnve shaft to the companion flange and<br />
tIghten the four retaining bolts<br />
9 Replace the brake drum and the road wheel then<br />
tighten the wheel nuts<br />
IO Remove the vehicle from the jack stands and road<br />
test the vehicle<br />
SP CIFI A TIO S<br />
139<br />
Leaf thickness<br />
Free camber<br />
Front pin diameter<br />
Rear pin diameter<br />
6mm<br />
0236 In<br />
153 mm<br />
6023 In<br />
45mm<br />
1 772 In<br />
30mm<br />
I<br />
181 In
6Rear Suspension<br />
TORQUE WRENCH SETTINGS<br />
Shock absorber upper bracket to body 2 5 kg m<br />
Shock absorber to upper bracket<br />
Shock absorber to u bolt plate<br />
I8 ft lb<br />
2 2 kg m<br />
I6 ft lb<br />
4 5 kg m<br />
32 ft lb<br />
The rear suspensIOn compnses seml elhptlc leaf spnngs<br />
WIth double acting tubular shock absorbers mounted Just<br />
forward of the rear axle hOUSing and connected to the<br />
spnng mounting plate at the lower end and the vehicle<br />
underbody at the upper end<br />
Shock absorber mountings are In the form of rubber<br />
bushes<br />
The IS<br />
spnng mounted at the forward end an by anchor<br />
bolt and nut and rubber bush and rubber bushes With plates<br />
TO REMOVE AND INSTAL<br />
u bolt nuts<br />
Shackle nuts<br />
DESCllIPTION<br />
Front shackle pin nuts<br />
Front bracket retaining bolts<br />
and bolts at the rear shackle<br />
6 5 kg m<br />
47 ft lb<br />
5 0 kg m<br />
36 ftlb<br />
5 0 kg m<br />
36 ftlb<br />
2 3 kg m<br />
I6 ft lb<br />
A bump rubber IS mounted on t e underb dy duectly<br />
above the cen tre of the axle casing on which bUlr ynpltct<br />
IS taken<br />
2 1I0CK 110118 1<br />
The spnng centre bolt IS located In a hole In the axle<br />
hOUSing bracket and the spnng IS attached to the assembly<br />
by two U bolts With selfIockmg nuts and mounting plate<br />
Plastic Inserts are fitted to the ends of the lower spnng<br />
leaves to reduce metal fnctlOn<br />
I Mount the shock absorber upnght In the vice by<br />
the lower mounting eye or stem<br />
I Raise the rear of the vehicle and support on stands 2 Grasp the upper half of the shock absorber pull up<br />
placed under the rear axle to the fully extended posItion and then slowly push down<br />
2 Dlsconnect the shock absorber at the body untIl the shock absorber Is fully compressed<br />
attachment at Its upper end 3 Repeat operatIon 2 SIX or eight tImes to remove<br />
3 Disconnect the shock absorber at the spnng plate any slack spots caused by au In the system If slack spots<br />
attachment at ItS lower end and remove the shock absorber eXist and cannot be removed by thiS method the shock<br />
from the vehicle absorber IS eVidently defective and should be renewed<br />
InstallatIOn IS a reversal of the removal procedure<br />
Check test and bleed the shock absorber as descnbed<br />
under TO TEST AND BLEED<br />
TO TEST AND BLEED<br />
The extent to which a shock absorber can be tested<br />
Without special testIng equipment IS limited to the<br />
follOWing<br />
TO REMOVE AND DISMANTLE<br />
I Jack up the rear of the vehicle and support on<br />
stands placed Just orward of the rear spnng front anchor<br />
2 WIth a Jack under the centre of the rear axle case<br />
raise the axle assembly suffiCiently to take the strain offthe<br />
shock absorbers<br />
3 Disconnect the shock absorber lower mounting at<br />
the spnng mounting plate and push the shock absorber up<br />
clear of the axle hOUSing<br />
4 Lower the axle hOUSing to take the weight off the<br />
I SPKIN tS<br />
l O<br />
NOTE The resistance Will be gretJter on the upward stroke<br />
of the shock absorber than on the downward stroke<br />
4 Check the body of the shock absorber for denb or<br />
damage and for flUid leakage The shock absorbers cannot<br />
be repaued In sernce and should be renewed If defective<br />
spnngs remove the nuts from the U bolts and take off the<br />
mounting plate<br />
5 Remove the rear shackle nuts and washers<br />
6 Remove the shackle plates noting the posItion of<br />
the shackle pinS bottom retaining nut IS Installed towards<br />
thecentre of the vehicle<br />
7 Support the axle hOUSing on stands and lower the<br />
rear of the spnng to the floor remove the two rubber<br />
bushes from the body spnng shackle hanger<br />
8 Remove the nut from the front hanger bolt and<br />
remove the bolt remove the spnng from the vehicle<br />
9 Remove the bushes from the front spnng eye
TO ASSEMBLE AND INSTAl<br />
I Instal the front spnng eye bush with the special<br />
tools used for removing the old bush ensure that the new<br />
bush IS fitted squarely In the spnng eye<br />
2 Instal the rear spnng eye tnangular shaped bush<br />
With one pOint of the tnangle pOinting downwards the<br />
special tool used for removing the old bush IS used to Instal<br />
the new bush<br />
TRAILING ARM SEDAN<br />
I<br />
NOISe In suspensIOn<br />
POSSIble cause<br />
a Worn wheel beanngs<br />
b Worn suspensIOn rubbers differential assembly<br />
c Incorrect wheel balance<br />
d Incorrect axle shaft end play<br />
e Unserviceable suspensIOn mounting rubbers<br />
f Damaged differentIal mounting member<br />
g Broken coiled spnng<br />
h Defective shock absorber and or mounting<br />
I Loose or worn mounting bolts<br />
2 Directional Instability<br />
a Loose wheel nuts<br />
POSSIble cause<br />
b Worn suspensIOn arm bushes<br />
c DefectIve shock absorbers and or mountings<br />
d FatIgued or damaged coil spnngs<br />
SEMI ELUPTIC TYPE WAGON PICKUP<br />
NOISe m suspension<br />
POSSible cause<br />
a DefectIve shock absorber and or mounting<br />
b Loose or worn rear shackle bolts and bushes<br />
c Loose or worn spnng anchor bolt and or bushes<br />
d Broken rear spnng leaf or leaves<br />
e Sprung or bent axle tube<br />
f Worn or detenorated spnng leaf Inserts<br />
g Faulty or overtIght spring seat<br />
h Loose or broken spnng leaf clamps<br />
Rear Suspension 7<br />
3 Refit the spnng to the vehicle uSing the reverse<br />
procedure to removal with attentIOn to the follOWing<br />
pOints a Do not tighten the U bolt nuts In excess of the<br />
speCified torque or the spnng and the rear axle casing may<br />
be affected<br />
b Do not fully tighten the shackle bolt or front<br />
anchor bolt nuts until the full weight of the vehicle IS on<br />
the rear wheels ThiS Will prevent the rubber bushes from<br />
being over stressed when In the normal working pOSItion<br />
4 IU AIl SUSI MO AUI T InA O IS<br />
141<br />
Remedy<br />
Renew beanngs<br />
Renew faulty components<br />
Balance wheels<br />
Check adJustment<br />
Renew faulty components<br />
Renew the member<br />
Renew cod spnng<br />
Renew faulty components<br />
Check and tighten or replace components<br />
Check and tIghten nuts<br />
Renew components<br />
Renew faulty components<br />
Renew coil spnngs<br />
Remedy<br />
Remedy<br />
Renew faulty components<br />
Tighten or renewloose or worn components<br />
Tighten or renewloose or worn components<br />
Renew broken leaves or complete spnng<br />
Renew axle casing<br />
Check and renew Inserts<br />
Check and adJust<br />
Tighten or renew faulty clamps
8 Rear Suspension<br />
2 Rear wheels not in alIgnment wIth front wheels<br />
a<br />
Possible cause<br />
Broken mam leaf of spnng forward of spnng seat<br />
b Broken main leaf of spnng at rear of spnng seat<br />
c Broken spnng mountIng bolts or rearshackle<br />
d Spnng badly saggIng on one Side<br />
e Sprung or bent axle casing<br />
3 Rear brake locked on one SIde<br />
Possible cause<br />
a Broken spnng main leaf forward of spnng seat<br />
b Broken spnng mounting bolts<br />
c Broken spnng anchor bolt<br />
142<br />
Remedy<br />
Renew mam leaf or complete spnng<br />
Renew main leaf or complete spnng<br />
Renew faulty components<br />
Renew defective spnng<br />
Renewaxle casing<br />
Remedy<br />
Renew main leaf or complete spnng<br />
Renew spnng centre bolt<br />
Renew anchor bolt
Type<br />
Ratio<br />
Pre load adJustment<br />
Worm shaft beanngs<br />
Sector shaft end thrust<br />
Shun thickness<br />
Four sizes for worm shaft<br />
SIX sizes for sector shaft<br />
Steerillg worm shalt beanng preload<br />
Sector shaft end clearance<br />
Ball nut balls<br />
Number<br />
SIze new<br />
GUide tubes<br />
Number<br />
SIze new<br />
Recuculatlng<br />
ball nut and<br />
worm<br />
150 I<br />
Steel shims<br />
Steel shims<br />
005 0 762 mm<br />
0002<br />
0030 In<br />
I 45 I 57 mm<br />
0057<br />
00618 In<br />
6 kgfcm<br />
83 Infoz<br />
o 03 mm<br />
00012 In<br />
36<br />
6 35 mm<br />
0 250 In<br />
22<br />
635 mm<br />
0250 In<br />
The steenng gear IS the wormand reclfculatlng ball nut<br />
type<br />
The steeling shaft at the worm end operates ill two ball<br />
thrust beanngs and at the steenng wheel end In a nylon<br />
bush<br />
The sector shaft operates In bronze bushes and has an<br />
oil seal at ItS lower end<br />
The upper end of the sector shaft engages a rack wluch<br />
IS Integral With the ball nut<br />
There are 36 steel balls 635 rom 0250 ill In<br />
diameter In the ball nut and 22 steel balls 6 35 mm 0 250<br />
In In diameter In each of the two steenng shaft beanngs<br />
The steenng shaft beanng adJustment IS controlled by<br />
shuns between the steering box and the steering column<br />
flange<br />
TO REMOVE<br />
1 Disconnect the lead at the pOSItive terminal of the<br />
battery<br />
2 Press down on the horn nng and turn<br />
antI clockWISe to remove from the steenng wheel<br />
3 Loosen off and remove the steenng wheel retaining<br />
2<br />
STEERING<br />
SPCIFICATIONS<br />
Oil capacity<br />
Oil grade<br />
o 33 htre<br />
TORQUE WRENCH SETTINGS<br />
0697 US pts<br />
0581 Imp pts<br />
SAE 90 EP<br />
Column flange fiXing bolts 2 5 kgfm<br />
18 ft Ib<br />
Ball JOint nut<br />
8 kgfm<br />
55 ft lb<br />
Pitman arm nut<br />
14 kgfm<br />
101 ft lb<br />
Idler arm nut<br />
8 kgfm<br />
55 ftflb<br />
Sector shaft 2 5<br />
adJusting kgfm<br />
18 ftflb<br />
10 kgfm<br />
72 ftflb<br />
6 kgfm<br />
44 ftflb<br />
screw nut<br />
Steenng box secullng bolts<br />
Idler arm seculIng bolts<br />
I DSt KnoTtO<br />
Sector shaft end thrust IS controlled by an adJusting<br />
screw and lock nut on the steeling box top cover<br />
The a<br />
steenng gear hnkage compnses steenng<br />
connecting rod connected by a ball JOint at one end to the<br />
steenng gear pitman arm and at the other end to the Idler<br />
arm which In turn pivotS on a bracket to the underbody<br />
frame<br />
An adJustable tie rod on either Side of the steenng<br />
hnkage IS attached by ball JOints to the steenng arms on the<br />
suspensIOn Units These tie rods<br />
ale means r setting the<br />
alignment of the t t t<br />
front wheels toe In and inust both be<br />
the same length to maintain the steenng box on centre<br />
when the front wheels are In a straight ahead pqsltlOn<br />
STEElll1 G f EAR 1 S I<br />
143<br />
nut USing a SUitable puller draw the wheel from the end of<br />
the shaft<br />
4 Take out the retaining screws and detach the<br />
column shell from the steenng column<br />
5 Remove the screws attachillg the combined SWitch<br />
Unit to the column and detach the SWitch assembly<br />
6 Release the shIft control rod upper support bracket
2 Steerillg<br />
COVER<br />
f1 f<br />
BOLT<br />
l n<br />
SPRING WASHER<br />
fi<br />
BEARI NGS<br />
WORM<br />
SHIM h<br />
V<br />
Exploded View of Steer1Dg Box Components<br />
BAL N<br />
clamp bolt remove the locating screw and take off the<br />
clrchp at the top of the control rod Withdraw the bracket<br />
from the column<br />
7 Take out the two retaining bolts attaching the<br />
steenng column to the faCia panel<br />
8 Take out the four bolts secunng the steenng<br />
col umndust cover to the floor<br />
9 Detach the shift control rod bush and spnng<br />
l0 Remove the clrchp and pin retaining the column<br />
gear change lever to the on rol rod and detach the lever<br />
II Working at the steenng box end of the hnkage<br />
disconnect the gear change rods from the control levers by<br />
removing the spht pin and washers on each end of the rod<br />
trunnIon<br />
l2 Take out the lower support bracket retaining<br />
screws and detach the clamp and control rod lever retainer<br />
13 Place all hnkages to one Side and secure<br />
14 Withdraw the shift control rod from the vehIcle<br />
15 Disconnect the steenng hnkage connecting rod at<br />
the steenng gear pitman arm ball Jomt<br />
16 Remove the three retaining bolts secunng the<br />
steenng box to the body<br />
17 Withdraw the steenng box from the engme<br />
compartment<br />
TO DISMANTLE<br />
I WIth the steenng box removed from the vehicle as<br />
alreddy descnbed remove the filler plug turn the steenng<br />
box upSIde down and drain off the 011<br />
2 Remove the pItman arm retaining nut and spnng<br />
washer USing a SUitable puller remove the pitman arm<br />
CO<br />
144<br />
SECTOR SHAFT AOJUSTING SCREW<br />
L<br />
J<br />
tJ CLNN<br />
SPACER<br />
COVER<br />
I<br />
I<br />
I<br />
fv<br />
t Q<br />
J w<br />
NOTE PrIOr to removal ensure that the pitman arm IS<br />
marked In relatIOn to the sector shaft ThiS Will facilitate<br />
assembly<br />
3 Loosen the sector shaft adJusting bolt nut and back<br />
offadJusting nut<br />
4 To remove the sector shaft from the hOUSing<br />
remove the three retaining bolts attaching the cover to the<br />
hous1Dg and remove the cover and sector shaft<br />
5 Take out the retaining bolts secunng the steenng<br />
column cover to the hOUSing Withdraw the column<br />
assembly Do not allow the ball nut to rotate on worm as<br />
damage will be Incurred to the ball gUides<br />
NOTE The LOver plate shims aresituated between the two<br />
gaskets on the LOver plate Ensure that the shims are not<br />
damaged during dlsmantlmg procedure Store shims and<br />
gaskets 111 a safe place for assembly<br />
6 Remove the wormshaft from the column tube<br />
7 Remove the upper beanng outer cup from the<br />
column tube With a SUitable puller<br />
8 Remove the lower beanng outer cup from the<br />
steenng box With a SUitable puller<br />
9 Remove the sector shaft 011 seal from the steenng<br />
box<br />
10 Before dlsmanthng the ball nut and worm shaft<br />
check for correct ahgnmen t and excesSive wear<br />
11 Remove the clamp fitted to the ball gUide tube<br />
and Withdraw the ball gUide tube from the ball nut<br />
12 Invert the nut and rotate the worm shaft left to<br />
nght until all 36 balls have been removed from the nut<br />
HaVing removed the balls the nut can be Withdrawn from<br />
the column<br />
TO CLEAN AND INSPECT<br />
I Wash all components In clean solvent and dry off<br />
2 Check the steenng shaft worm beanng Inner cones<br />
for wear or pittIng<br />
3 Check the outer cups and balls of the steenng<br />
wormshaft bearings for wear and pitting<br />
4 Check the ball nut and track gUide and balls for<br />
wear or pItting<br />
5 Check the ball tracks on the steenng worm for<br />
wear and pitting<br />
6 Check the sector shaft and bush for<br />
ahgnment<br />
wear and
TO ASSEMBLE<br />
1 Fit the ball nut to the worm With the ball gUide<br />
holes uppermost<br />
2 Place 18 balls In each of the two holes on the same<br />
side as the nut As the balls are being<br />
fitted turn the worm<br />
gradually away from the holes until the 36 balls are<br />
Installed<br />
NOTE If the balls are stopped bv the end of the column<br />
use a dean punch orrod to hold down the balls prevlOus v<br />
fitted and turn the column In the opposite directIOn untIl<br />
the passage IS dear<br />
Add remainder of balls filhng the ClfCUlt fully<br />
3 Instal the remaining 22 balls In the gUide tubes 11<br />
balls to edch tube Hold the gUide tubes together and plug<br />
with vasehne ready for installatIOn<br />
nut<br />
4 Fit the gUide tubes to the gUide holes of the ball<br />
5 Fit the ball gUide retaining clamp to the ball nut<br />
6 When replacing the sector shaft bushes In the<br />
steenng box press the new bushes Into pOSitIOn so that the<br />
plain end of the lower bush IS flush With the 011 seal<br />
shoulder m the bore hOUSing<br />
NOTE Ensure that the open<br />
end of the all groove In the<br />
bush IS faCing the ball nut and not the pitman arm Failure<br />
to do thiS Will result In a leaking 011 seal<br />
Apply SUitable grease to outer penphery<br />
of 011 seal<br />
press the seal Into hOUSing<br />
7 Fit beanng cups and cones to column hOUSing and<br />
steenng box Fit the worm shaft Into the column hOUSing<br />
Fit slums and 0 nng to gear hOUSing and attach secunng<br />
With the three flange bolts<br />
shaft<br />
8 LubrIcate upper and lower bearIngs<br />
on the worm<br />
9 Pnor to Instalhng the sector shaft adJust the worm<br />
beanng preload by adding to or subtracting from the<br />
eXIsting shim pack Shims are available<br />
TO REMOVE<br />
In different<br />
1 Jack up the front of the vehicle block the rear<br />
wheels and support the vehicle on Jack stands<br />
2 Take out the cotter pinS and remove castellated<br />
nuts<br />
3 To remove the ball bolts from steenng arms place a<br />
SUitable dolly or hammer agamst one Side of the arm eye<br />
and stnke the opposite Side With a hammer<br />
4 Removal of the ball Jomts from the pitman and<br />
Idler arms IS In the same manner Now remove steenng<br />
Steering 3<br />
thicknesses see Specifications for the purpose of obtamlng<br />
the correct pre load<br />
The ll11t1al torque reading on the column should be 4<br />
of the<br />
6 cm kg 55 5 83 3 In oz pnor to the fitting<br />
cctor shaft See speCIfications<br />
10 To determme the correct end clearance and lash<br />
adJustment on the sector shaft fit lash adJuster bolt to the<br />
slot In the sector shaft and check clearance With a feeler<br />
gauge Clearance should be 01 03 mm 0 0004 0 0012<br />
In Shim sizes are available In different thicknesses see<br />
SpecificatIOns for the purpose of obtaining the correct<br />
clearance between the head of the bolt and the slot In the<br />
end of the sector shaft<br />
11 Rotate the worm shaft by hand until the ball nut<br />
IS located In the centre posItion to allow the centre tooth of<br />
the sector shaft to engage<br />
the centre tooth of the ball nut<br />
Insert the sector shaft and cover Into place and check<br />
for correct backlash between ball nut and sector shaft<br />
teeth then tighten Side cover bolts<br />
011<br />
Pnor to Instalhng the sector shaft smear the shaft With<br />
12 Temporanl y secure the adJustmg screw With the<br />
lock nut<br />
13 Rotate the sector shaft several times ensunng It<br />
turns smoothly<br />
14 Fit the pitman arm to the sector shaft and ensure<br />
that marking on pitman arm IS In line With the marking on<br />
the sector shaft<br />
15 Select the central pOint ill the steenng box<br />
release the adiustlng screw lock nut and adjust screw until<br />
the backlash movement of the pItman arm does not exceed<br />
01 mm 004 In<br />
16 Turn the adJusting screw In 1 8th to 1 16th of a<br />
turn and lock up With lock nut<br />
17 Refill the steenng box With SAE90EP oil and<br />
Instal the pi ug<br />
18 Instal the steenng box assembly to the vehicle<br />
InstallatIOn IS a reversal of the removal procedure<br />
19 Determine free movement and travel of the<br />
steenng wheel Free travel should be 25 30 mm 0 9843<br />
I 1811<br />
In at the wheel nm<br />
20 Finally check the steenng wheel alignment and<br />
lubnc tte all applicable pomts<br />
s STtlml 4 U KA t<br />
145<br />
connecting rod and tie rods as an assembly<br />
5 Take out retaining bolts from body member and<br />
remove Idler assembly<br />
INSPECTION AND REPAIR<br />
I Examine rubber bushing fitted to Idler arm for<br />
fatigue and wear Ifdefective replace<br />
2 Inspect tie rods and connectmg rod for any bends<br />
or fatigue If defective replace<br />
3 Inspect ball JOints for exceSSIve play and wear If
4Sieering<br />
BALL JOINT<br />
found defectIve replace as complete umt Not serVIced as a<br />
separate umt<br />
Now fit Idler arm body In the rubber buslung<br />
When Idler arm IS mounted on the chaSSIS the centre<br />
hne of the Idler arm should be parallel to the chaSSIS<br />
Angle tolerance allowable IS 1047 to 3047<br />
TO ASSEMBLE<br />
I Procedure for assembly IS the reversal of the<br />
dismantling procedure With attentIOn to the follOWing<br />
pOints<br />
2 To assemble Idler arm apply soap and water to<br />
outer penphery of bushing and carefully press Into Idler<br />
armuntil bushing protrudes equally at eIther end<br />
The wetting procedure IS unnecessary where nylon<br />
bushes are fitted When fitted the centre of the Idler arm<br />
should be parallel to the centre hne of the vehicle<br />
0<br />
DESCRIPTION<br />
CROSS ROO<br />
t<br />
Steering Linkage Removed From Vehicle Underbody<br />
TO INSTAL<br />
1 InstallatIOn IS a reversal of the removal procedure<br />
With attention to the follOWing pOints<br />
2 Measure length of tie rods between ball stud<br />
centres Distance between centres should be 309 5 mm or<br />
12 185 In<br />
3 Inspect wheel alignment and adJust If necessary<br />
TO ADJUST WHEEL ALIGNMENT<br />
1 AdJustment procedure<br />
to obtain correct toe In<br />
adJustment IS situated In FRONT AXLE AND<br />
SUSPENSION section<br />
2 To aclueve correct steenng angle carry out<br />
adJustment With four passenger load to the stopper<br />
bolt of the knuckle arm<br />
Steering Idler Arm Assembly Removed From VehIcle ShOWing Correct Armto Bracket Setting Angle<br />
The pnnclple of the collapsible steenng column IS to<br />
compress on unpact at a predetermined force<br />
The operatIOn of the collapsible type steenng column<br />
assembly IS the same as that of the conventIOnal type The<br />
only vanance IS that caution must be exercised when<br />
working on the column when In Situ Severe bumpmg or<br />
downward pressure of the steenng wheel could result In the<br />
column assembly collapSing<br />
The column assembly compnses an upper<br />
and lower<br />
steenng shaft upper and lower column Jacket column<br />
support bracket nylon spacer two rubber coated nylon<br />
bearings three screws two flat washers two collets and a<br />
cuchp<br />
4 COUi PSIBLE STEEIIIN4<br />
I46<br />
The column assembly IS so deSigned that on unpact the<br />
pressure apphed to the steerillg wheel forces the upper shaft<br />
down over the lower shaft at the same tune collapses the<br />
convoluted lowerJacket<br />
TO REMOVE AND INSPECT<br />
I Remove the steenng gear assembly In the same<br />
manner as the conventIonal assembly Or alternatively<br />
wsconnect the column shaft at the umversal JOint leaVing<br />
the steenng box In pOSItIon<br />
2 Remove the horn nog unscrew the steenng wheel<br />
retaining nut hft off the washer and uSing a SUitable puller<br />
remove the steenng wheel
LOWER JACKET<br />
3<br />
assembly<br />
Remove the column shell cover and SWitch<br />
4 When fitted With automahc transmlSslOn remove<br />
the Pivot pin and 11ft out the shift lever<br />
5 Remove the bolt connecting the umversal JOInt to<br />
the worm shaft<br />
6 Secure the lower steenng shaft With wife or<br />
sUitable matenal to prevent the shaft from mOVing<br />
7 Remove the four bolts connecting the Jacket seal<br />
flange to the fire wall<br />
8 Remove the bolts connecting the column assembly<br />
to the Instrument panel<br />
9 Withdraw the column assembly complete with<br />
steenng shaft toward the front seat<br />
10 With the assembly removed from the vehIcle<br />
Withdraw the shaft from the column tube<br />
II When the vehIcle IS fi tted With an automatic<br />
transmission remove the control hnkage<br />
12 Slide the column assembly bracket off the upper<br />
Jacket<br />
13 Take out the screws connecting the upper and<br />
lowerJackets and separate the Jackets<br />
14 Inspect the convoluted Jacket for fatigue<br />
IS Inspect the sphnes and UnIversal Jomt on the<br />
lower shaft Check shaft for alignment<br />
16 Inspect the beanng surface and sphnes on the<br />
upper shaft Check shaft for correct alIgnment<br />
17 Inspect the spacer bushes coil spnng collets<br />
washers and clrchp for fatigue or wear<br />
18 Check<br />
and fatigue<br />
br cket for cracklOg and the bush for wear<br />
STEERING JACKET<br />
Assembled View of Collapsible Type Steering Column Assembly<br />
Steering S<br />
I9 When an automatic transmiSSion IS fitted check<br />
the change rod for alignment and the convoluted section<br />
for fatigue and damage Check the clamps attaching the<br />
change rod to the column assembly for contact and wear<br />
Check the shafts for alignment<br />
20 Replace all unserVIceable parts where necessary<br />
TO ASSEMBLE AND INSTAL<br />
1 Place the lower shaft In the lower Jacket and fit the<br />
upper shaft on the lower shaft<br />
2 Place the COIl tensIOn<br />
spnng spacer washer and<br />
beanng on the upper shaft<br />
3 Connect the<br />
upper Jacket to the lower Jacket lIne<br />
up the screw holes and fit the three retaining screws<br />
4 Place the nylon spacer bearmg and spacer washer<br />
on the upper steenng shaft and fit the cuclIp Ensure that<br />
the clrchp IS seated correctly In the groove<br />
5 Connect the automatic transmlSSlOn change rod to<br />
the column assembly If preViously fitted<br />
1iilIIIIIIIiI l l<br />
rop SUPPORT BRACKET TUR<br />
TURN SIGNAL SWITCH<br />
LAMP SCREWS<br />
SIGNAL SWITCH CLAMP<br />
6 Lubncate components where necessary<br />
STEERING SHAF<br />
STEERING WHEEL CENTERING COLLETS<br />
Exploded View of the Top of CollapSible Steenng Column<br />
147<br />
jj<br />
HORN CONTACT RUBBING PLATE<br />
ORN RING RETAINER<br />
RETA1NYR SCREWS<br />
q Y 0 e NUT<br />
CIRCLlP I PLUN1lER<br />
LOCK WASHER<br />
CONTACT SPRING<br />
TACT RING SCREWS<br />
i
6Steering<br />
t<br />
LOWER SHAFT<br />
SPROIIIG<br />
Exploded View of CollapSIble Type Steering Column Assembly<br />
ExceSSIVe play or looseness m steenng gear<br />
NOTE When connecting the upper and lower steenng<br />
shafts ensure that the punch mark on the upper shaft IS m<br />
lme with the split m the universal Jomt<br />
7 Instal the column assembly on the vehicle<br />
InstallatIOn procedure IS the reversal to that of the<br />
removal operatIons<br />
SPACER WASHER<br />
NYLOIII SPACER j<br />
0A SPACER WASHER rL<br />
a STEEIUNf FAUIT DIA6NOSIS<br />
I<br />
80<br />
SUPPORT BRACKET<br />
COLLUS<br />
LOCK WASHER<br />
BEARING 0j<br />
SIIIAP ROlli 0r tg NUT<br />
Possible cause Remedy<br />
SIIIAP ROIIIG<br />
a Steenng gear worn or out of adjustment Overhaul steenng gear renew faulty components and<br />
b Steenng hnkage ballJOints worn or loose<br />
c Pitman arm loose on sector shaft<br />
d Idler lever bush andbolt worn<br />
e Steenng gear loose on sub frame mounting bolts<br />
2 Heavy steenng<br />
adJust<br />
Tighten or renew faulty components<br />
Tighten pitman arm retaining nut<br />
Renew and adJust Idler lever bush and bolt<br />
I<br />
Tighten mounting bolts and cliecK alignmerit of<br />
steenng gear moun tlng<br />
POSSible cause Remedy<br />
a Low or uneven tyre pressure<br />
b Steenng gear mcorrectly adJusted<br />
c Lack oflubncant In steenng hnkage JOints<br />
d Front suspension worn or out of ahgnment<br />
e Mls ahgnment between steenng gear and column<br />
mountings<br />
f Soft or sagging front spnngs<br />
3 Steenng pulls to one Side<br />
POSSible cause<br />
a Uneven tyre wear or pressure<br />
b<br />
Incorrect front end adJustment<br />
148<br />
Check tyres and Inflate to recommended pressures<br />
Check and readJust steenng gear<br />
Ascertam cause of loss of lubncant and lubncate<br />
steenng hnkage where apphcable<br />
Check front end for wear renew worn components<br />
and re ahgn front end<br />
Check and align steenng gear and column mountings<br />
Renew spnngs and check front end alignment<br />
Remedv<br />
Check conditIon of tyres and Inflate to<br />
recommended pressures<br />
C eck front end ahgnment<br />
n<br />
l<br />
t c
g<br />
jI<br />
4 Front wheel wobble or shImmy<br />
T<br />
a Looseness In steenng gear<br />
J<br />
iIiif<br />
If<br />
hit J<br />
u t briflie shoestIi simngs WI<br />
t<br />
L flew W ty<br />
compon ents 1<br />
Clieck anQrenew damaged component<br />
Check and renew front crossmefuber<br />
Possible cause Remedy<br />
b Uneven tyre wear or Incorrect tyre pressures<br />
c Tyre and or wheel unbalance<br />
d Front end damaged or out of ahgnment<br />
e Worn or badly adJusted front wheel beanng<br />
I Front wheel alignment Incorrectly adJusted<br />
g<br />
Loose or worn tie rod ends<br />
h Faulty shock absorbers<br />
5 Steenng erratIc or wandenng<br />
a<br />
b<br />
c<br />
d<br />
e<br />
Ii<br />
tC<br />
POSSible cause Remedy<br />
Incorrect or uneven camber and or castor set lng<br />
Smooth front tyres<br />
ExceSSive play In steenng gear and or llnkag Jt Jt<br />
Excessively high or low tyre pressures<br />
Loose or Incorrectly adJust efJron w eel<br />
bearings<br />
OZ<br />
h<br />
t<br />
r<br />
f J<br />
1<br />
i J<br />
f i i<br />
d Ji it<br />
1<br />
c<br />
7<br />
T<br />
l<br />
Check and renew components to rectify<br />
t<br />
Check and renew as tyres nms sary<br />
Check and renew faulty components readJust<br />
Check and Inflate to recommended pressures<br />
Gfieck and adJust front wheel beanngs<br />
i Ii<br />
1i<br />
I I<br />
1<br />
W<br />
1 ih<br />
X<br />
f<br />
E<br />
tJj<br />
f<br />
r<br />
f1<br />
c<br />
t<br />
ft<br />
r<br />
j<br />
Olo<br />
4<br />
1 Steering 7<br />
l<br />
It<br />
l<br />
i<br />
1 1<br />
j<br />
1<br />
i<br />
1<br />
j 1<br />
fA i<br />
l
Type<br />
Front<br />
Rear<br />
Opera tlon<br />
Footbrake<br />
Handbrake<br />
Front and rear drums<br />
Diameter<br />
Out of round lunlt In dIameter<br />
Maclumng hmIt m diameter<br />
Front WSC<br />
Diameter<br />
Thickness<br />
Run out hmlt<br />
Maclunmg bout In tIuckness<br />
Front and rear Immgs<br />
Width<br />
Thickness<br />
Length<br />
Front pads<br />
Width<br />
Thickness<br />
Length<br />
BraIang area<br />
Front drums<br />
Rear drums<br />
Front diSCS<br />
Wheel cyhnder diameter<br />
Front and rear<br />
Rear with diSC only<br />
BRAKES<br />
SPECIFICATIONS<br />
DISC or drum<br />
Drum<br />
Hydrauhc<br />
Cable rear<br />
wheels only<br />
228 6 mm<br />
9 0 In<br />
o 05 mm<br />
0002 In<br />
229 6 mm<br />
9039 In<br />
232 0 mm<br />
9 130 In<br />
100mm<br />
0 393 In<br />
006mm<br />
00024 In<br />
84mm<br />
0331 In<br />
40 0 mm<br />
I 575 m<br />
45mm<br />
0 177 In<br />
2195 mm<br />
8 642 In<br />
39 7 mm<br />
1<br />
90mm<br />
563 In<br />
0354 In<br />
860mm<br />
3 386 In<br />
351 cm2<br />
54 1n2<br />
351 cm2<br />
544 1n2<br />
1142 cm2<br />
177 1n2<br />
22 22 mm<br />
0 875 m<br />
20 64 mm<br />
0 812 In<br />
150<br />
Wheel cyhnder piston clearance hmlt o 18mm<br />
Calliper bore diameter<br />
Calhper piston clearance hmIt<br />
0007 In<br />
50 80 mm<br />
2000 In<br />
o 18mm<br />
0007 In<br />
Master cyhnder<br />
Bore wameter 1905 mm<br />
Piston clearance hmlt<br />
Brake pedal height<br />
drum brakes<br />
0750 In<br />
013mm<br />
0005 In<br />
RH and LH 187 mm<br />
LH auto trans<br />
Brake pedal height diSC brakes<br />
RHD<br />
LHD<br />
LHD auto trans<br />
TORQUE WRENCH SETTINGS<br />
7 362 In<br />
197mm<br />
7756 m<br />
202 mm<br />
7953 In<br />
207 mm<br />
8150 In<br />
197 mm<br />
7757 In<br />
Brake pipe connection 1 7 kg m<br />
Brake hose to wheel cyhnder<br />
Brake wsc retaining bolts<br />
123 ft lb<br />
2 0 kg m<br />
144 ft lb<br />
5 3 kg m<br />
38 3 ft lb<br />
Brake backmg plate retaining<br />
bolts 3 7 kg m<br />
Stub axle nut<br />
CaJhper secunng bolts<br />
Brake pedal fulcrum pin<br />
Wheel cyhnder secunng nuts<br />
Wheel cyhnder secunng bolts<br />
Wheel cylmder bndge tube<br />
27 0 ft lb<br />
see text<br />
100 kg m<br />
72 ft lb<br />
40 kg m<br />
29 ft lb<br />
o 7 kg m<br />
5 ft lb<br />
2 1 kg m<br />
152 ft lb<br />
2 0 kgm<br />
145 ft lb<br />
See relevant text In FRONT SUSPENSION section for<br />
adJusting procedure and torque setting
DRUM BRAKES<br />
The four wheel hydrauhcally operated drum brakes are<br />
fitted as standard equipment to all models except the <strong>1600</strong><br />
SSS model<br />
Two leadmg shoe type brakes are fitted on each of the<br />
front brake assembhes and trailing shoe type on each rear<br />
assembly<br />
The front brakes use a separate wheel cylinder to<br />
operate each shoe whereas the rear wheel shoes are<br />
operated by a single ended type wheel cyhnder only<br />
The rear wheel cyhnders also Incorporate the hand<br />
brake operatmg levers wmch protrude from the rear<br />
backing plates Hand brake cable pull apphed at the outer<br />
ends of the levers allows the Inner ends of the levers to<br />
operate dIrectly on the rear wheel cyhnder pistons<br />
The rear wheel cyhnders are not ngldly attached to<br />
theu respective backing plates and are capable of shdlng on<br />
the plates Within hmlts to proVide a self centenng actIOn<br />
for the rear brake shoes<br />
Each front brake shoe IS adJusted by a hexagonal<br />
headed cam wmch IS located on the outer sectIon of the<br />
brake backing plate<br />
Rear wheel shoe IS adJustment by a Single tapered<br />
adJuster umt bolted ngIdly on the brake backing plate<br />
positIOned dmmetncally opposite the wheel cyhnder The<br />
adJuster operates on both shoes at the same tIme and also<br />
acts as a shoe anchor when the brakes are apphed A square<br />
end on the outer portIOn of the adJuster and which<br />
protrudes through the brake backmg plate enables rear<br />
brake shoe adJustment to be carned out<br />
The hydrauhc system Incorporates<br />
TO REMOVE AND INSTAL<br />
1 DESCRIPTION<br />
a bleeder valve at<br />
I Raise the engIne bonnet and fit fender covers to<br />
both front fenders<br />
2 Disconnect the brake flUid pipe at the front end of<br />
the master cyhnder and plug the pipe to prevent entry of<br />
dirt<br />
3 Remove the spht pin and Withdraw the cleVIS pin<br />
from the master cyhnder push rod cleViS and pedal<br />
4 Unscrew the two nuts secunng the brake master<br />
cylinder to the engine bulkhead and remove the cyhnder<br />
NOTE Care should be exerCised when removmg or<br />
mstallmg the master cylmder assembly to ensure that brake<br />
flUid IS not permitted to drop<br />
Brakes 2<br />
the master cyhnder and a bleeder valve at each of the wheel<br />
cyhnder assembhes<br />
The smgle type master cyhnder which IS eqUipped With<br />
ItS Own reservOir IS operated duectly by the pendent brake<br />
pedal<br />
DISC BRAKES<br />
DISC brakes are fitted as standard equipment to th<br />
front wheels of the <strong>1600</strong> SSS models and later <strong>1600</strong> senes<br />
vehicles<br />
Except for the front calhper and diSC assembhes and a<br />
decrease In dimenSIOns of some components the remainder<br />
of the brake system IS the same as for drum type brakes<br />
type<br />
The calhper and pad assembly IS of the self energlZlng<br />
As found With most diSC type brakes the assemblies are<br />
self adJusting and need no In serVIce As<br />
adJustment pad<br />
wear takes place the calliper piston IS allowed to shde<br />
outwards through ItS seal to take a new In<br />
up posItion the<br />
calliper bore When the brakes are In the off posItIon a<br />
constant clearance IS maintained between the pads and wsc<br />
Elastic deformatIOn of the piston seal on the pistons<br />
takes place when the brakes are apphed and returns the<br />
piston to ItS normal off posItIon when the brakes are<br />
released<br />
As only one piston IS used In each calliper assembly In<br />
conJunction With the two brake pads the calhper assembly<br />
IS fully floating and IS allowed to float In a lateral directIon<br />
thiS enables the pad on the opposite Side of the piston to<br />
come Into contact With the diSC when the brakes are<br />
apphed<br />
2 SINt I E CnlCIJIT lUi SIEIl t UND 1l<br />
onto the surroundmg<br />
pamtwork of the vehicle Brake flUid If accuientally spilt<br />
should be Immediately IWshed away with water and then<br />
allowed to dry naturally and not Wiped<br />
with cloth<br />
Installation IS a reversal of the removal procedure With<br />
attentIOn given to the follOWing<br />
151<br />
Fill the master cyhnder reservOir With clean brake flUId<br />
Bleed all all from the system as descnbed In the<br />
HYDRAULIC SYSTEM sectIon<br />
AdJust the brake pedal height If found necessary With<br />
the stop hght SWitch to obtain the speCIfied height see<br />
SPECIFICATIONS sectIOn for pedal heights and<br />
ELECTRICAL sectIon for SWitch adJustIng procedure<br />
Check the master cyhnder for flUId leaks<br />
TO DISMANTLE<br />
1 Remove the reservou cap and seal and drain the<br />
flUId from the cylinder reservou Where fitted remove the<br />
float from the reservou chamber when draining<br />
2 Remove the piston stop screw and sealing nng<br />
from the cyhnder body<br />
3 Pull back the dust boot from the rear end of the<br />
cyhnder and With a SUItable pau of snap nng phers remove<br />
the snap nng<br />
4 Withdraw the push rod assembly With dust boot
J<br />
Brakes<br />
piston and then compressIOn spnng In that order from the<br />
rearof the cylinder<br />
5 Remove the pnmary and secondary cups from the<br />
pIston being careful not to score the piston<br />
6 Remove the cyhnder bleeder valve<br />
7 Loosen the reservoir to master cylinder body<br />
retalnmg clip and detach the reservou<br />
8 With the correct fitting nng spanner and With the<br />
master cyhnder securely clamped In a Vice remove the valve<br />
cap and washer from the front lower end of the cylinder<br />
9 Lift out the check valve and spnng assembly from<br />
the cap aperture<br />
TO CLEAN AND INSPECT<br />
1 Wash all<br />
component parts thoroughly<br />
brake flUid or alcohol<br />
BLEEDER vALve At<br />
CAP<br />
SEAL<br />
FLOAT<br />
DUST CAP ORESERVOIR<br />
CLIP<br />
jIlij il<br />
CYLINDER I nnOOnll<br />
BODY QQWWllJ W<br />
SPRING<br />
SEAT<br />
y<br />
ECK VALVE<br />
C WASHER<br />
CU BOLT<br />
oSEALlNG RING<br />
WASHEfr O<br />
STOP SCREW I<br />
In clean<br />
2 Check the master cyhnder bore for excessIVe wear<br />
sconng or pitting<br />
3 Inspect the piston for pittIng excessive wear or<br />
sconng<br />
4 Check the piston to cyhnder clearance and renew<br />
the piston and or cylinder If the clearance IS In excess of<br />
that specified See SPECIFICATION sectIOn for pISton<br />
clearance hmlt<br />
5 Check the hps on the pnmary and secondary cups<br />
for wear and the check valve rubber for swelhng or<br />
distortIon<br />
CLEVIS<br />
INLET VALVE<br />
PISTON<br />
I<br />
PUSH ROD<br />
6 Check the piston compressIOn spnng and the check<br />
valve spnng for weakness or rusting<br />
7 Renew all parts of the master cyhnder assembly<br />
that upon checking are found to be defectIve<br />
NOTE It IS always adVisable to Instal new cups check valve<br />
and dust boot to a master cylinder that has been<br />
dismantled ThiS Will ensure a thorough overhaul and long<br />
servicefrom the umt<br />
TO ASSEMBLE<br />
1 Soak all Internal components of the cylinder In<br />
clean brake flUid before assembhng<br />
2 Instal the pnmary and secondary cups on to the<br />
piston Ensure that the leading hps of both cups are faCing<br />
to the front ofthe piston<br />
NOTE The Inlet valve end IV the front end of the piston<br />
W<br />
WASHER<br />
6<br />
V j I<br />
SNAP RING<br />
I<br />
DUST BOOT<br />
CAP<br />
BLEEDER VALVE<br />
Assembled View of Smgle CircUit Type Master Cylinder<br />
Exploded View of Smgle CirCUit Type Master Cylinder<br />
152<br />
LOCk NUT<br />
CLEVIS
3 Slide the compressIOn spnng followed by the<br />
piston Into the open end of the cylinder being careful not<br />
to damage the pnmary and secondary cup hps<br />
4 Fit the push rod assembly In the cyhnder and Instal<br />
the snap nng<br />
5 Instal the dust boot over the end of the cyhnder<br />
makmg sure that It IS pOSItioned correctly over ItS retaining<br />
hp on the cylinder body<br />
6 Attach the reservoH to the cyhnder and fit and<br />
securely tighten the retaining chp<br />
7 Instal the check valve spnng seat and valve In that<br />
order Into the cap aperture In the cyhnder<br />
The dual CUCUlt type master cyhnder assembly has<br />
been Introduced as a safety factor on later type vehicles<br />
The front and rear brakes are apphed by Independent<br />
CHCUltS If a malfunction occurs In one CHCUlt the<br />
remamlng CHCUlt IS capable of stopping the vehicle safely<br />
A brake line pressure differential warnIng hght SWitch<br />
Incorporated Within the system allows a bulb to glow on<br />
the dash panel when a malfunction occurs Within the<br />
system<br />
Ihe wltch IS actudted by a shuttle valve when d<br />
pressure difference of between 13 and 17 kg cm2 185 and<br />
242 pSI IS encountered between the two hydraulic ClfCUlts<br />
NOTE The complete swztch assembly should be renewed If<br />
zt IS found to be unserviceable In no circumstances should<br />
anv attempt be made to repair the switch<br />
TO REMOVE AND INSTAL<br />
Brakes 4<br />
8 Secure the master cyhnder In a vice and fit and<br />
tighten the cap and washer<br />
9 PosItion the reservOir float Into the reservou and<br />
fill the reservOirWith clean brake flUid<br />
10 Screw the bleeder valve Into the master cyhnder<br />
body<br />
nng<br />
I DUAl IKUIT IASTEIl Ul I m<br />
11 Instal the piston stop screw With a new sealing<br />
I2 Fit the reservOir cap and seal and bleed the<br />
cylinder by slowly pumping the piston Via the push rod<br />
assembly until all aH IS expelled from the cylinder<br />
8<br />
fjI RESERVOIRS<br />
SPRINGS v<br />
LVE ASSY<br />
BLEEDER VALVE<br />
CLIPS Y<br />
SEATS I<br />
RETAINER I<br />
o<br />
WASHERS<br />
U i<br />
ALlNG VrJ V l<br />
RING o<br />
l CUP<br />
OJ<br />
CYLINDER BODY<br />
0<br />
sp c 1 4iin<br />
1 P VALVES BLEEDER VALVE<br />
RETAINER l<br />
CAP BOLTS<br />
ST01 SCREW<br />
I<br />
SECONDARY PISTON<br />
fJ<br />
VALVE SPRING<br />
SPRING<br />
I Ij VALVE<br />
RETAINER<br />
c fI<br />
I fender covers to<br />
Raise the engIne bonnet and fit<br />
both front fenders<br />
2 Disconnect the two brake flUid pipes<br />
from the<br />
outlets on the cyhnder plug the pipes to prevent entry of<br />
dIrt<br />
3 Remove the spht pin and Withdraw the cleVIS pm<br />
from the master cyhnder push rod cleVIS and brake pedal<br />
4 Unscrew the two nuts secuflng the brake master<br />
cylinder to the engine bulkhead and remove the cylinder<br />
NOTE Care should be exeTClsed when removmg or<br />
I11stallmg the master cyllllder assembly to ensure that brake<br />
153<br />
juui IS not permztted to drop onto the surroundlllg<br />
pamtwork of the vehicle Brake jUld If aCCidentally spilt<br />
should be unmedlately washed away wzth water and then<br />
allowed to dry naturally and not Wiped With cloth<br />
Installation IS a reversal of the removal procedure With<br />
attentIOn given to the follOWing<br />
Fill the master cyhnder reserVOHS With clean brake<br />
flUid<br />
Bleed all air from the system<br />
HYDRAULIC SYSTEM section<br />
PRIMARY PISTON<br />
CUP<br />
Ii USH ROD<br />
I I<br />
WASHER<br />
A<br />
SNAP RING<br />
J DUST BOOT<br />
as descnbed In the<br />
AdJust the brake pedal height Iffound necessary With<br />
c1<br />
Exploded View of Dual CirCUIt Type<br />
Master Cylinder Assy<br />
Qi<br />
LOCK NUT<br />
CLEVIS<br />
f<br />
10<br />
I<br />
ij
i Brakes<br />
the stop hght sWitch to obtain the specified height see<br />
SPECIFICATIONS section for pedal height and<br />
ELECTRICAL sectIon for sWitch adJusting procedure<br />
TO DISMANTLE<br />
I Remove the reservou caps and seals and drain the<br />
flUid from the cyhnder reservolfS Where fitted remove the<br />
floats from the reservOir chambers when draining<br />
2 Remove the piston stop screw and sealing nng<br />
from the cyhnder body<br />
3 Pull back the dust boot from the rear end of the<br />
cyhnder<br />
4 With a SUitable pau of snap nng phers remove the<br />
snap nng from the groove at the rear of the cyhnder and<br />
detach the push rod assembly<br />
5 Tap the cyhnder gently on a block of wood and<br />
allow the pnrnary and secondary piston and valve<br />
assembhes to be dislodged from the cylinder bore<br />
6 With the correct fitting nng spanner and With the<br />
master cyhnder securely clamped In a Vice remove the two<br />
valve caps and washers from below the cyhnder body<br />
7 Lift out the front and rear check valve and spnng<br />
assemblies from the cap apertures<br />
8 Remove the cups from the piston assembhes being<br />
careful not to score the pistons<br />
9 Unscrew both bleeder valves from the cylinder<br />
body 10 If found necessary loosen the reservou retamlng<br />
chps and detach the reservous<br />
TO CLEAN AND INSPECT<br />
I Wash all components thoroughly In clean brake<br />
flUid or alcohol<br />
2 Check the master cyhnder bore for excessive wear<br />
sconng or pitting<br />
3 Check both pistons for pitting exceSSIve wear or<br />
sconng<br />
4 Check the piston to cylinder clearance and renew<br />
the pistons and or cyhnder<br />
that specIfied see SPECIFICATION section for piston<br />
clearance hmlt<br />
TO REMOVE AND DISMANTLE<br />
stands<br />
Ifthe clearance IS In excess of<br />
I Raise the rear ofthe vehicle and support on chassIS<br />
2 Remove the road wheel release the hand brake and<br />
Withdraw the brake drum<br />
NOTE It may be necessary to back off the brake shoe<br />
adJuster m order to remove the brake drnm<br />
F<br />
5 Check the hps on all cups for wear and the check<br />
valve rubbers for swelling or distortIOn<br />
6 Check the piston compressIOn spnngs the check<br />
valve spnngs and the uilet valve spnng for weakness or<br />
rusting 7 Renew all components of the cylinder assembly<br />
that upon inspectIon prove<br />
to be defective<br />
NOTE Once a cylmder IS dismantled It IS always adVisable<br />
to Instal all new rnbber components ThiS Will ensure a<br />
thorough overhaul and long service from the umt<br />
TO ASSEMBLE<br />
I Soak all Internal components of the cyhnder In<br />
clean brake flUid before assembhng<br />
2 Carefully Instal the new cups to the pnmary and<br />
secondary piston assembhes Ensure that all piston cups<br />
except the rear cup on the secondary piston have their<br />
leawng hps faCing towards the front ofthe pistons<br />
3 Instal the vanous components Into the cyhnder<br />
bore In the follOWing order secondary valve assembly<br />
retainer spnng spnng retamer secondary piston spnng<br />
spnng retamer pnmary valve assembly and pnmary piston<br />
4 Fit the push rod assembly to the rear of the<br />
cyhnder and Instal the snap nng<br />
5 Instal the dust boot to the rear of the cyhnder<br />
making sure that the dust boot IS pOSItioned correctly over<br />
Its on retaining hp the cyhnder body<br />
6 Attach the reservOirs to the cyhnders Ifthey were<br />
removed and securely tighten the retaining chps<br />
7 Instal a check valve spnng seat and valve mto each<br />
ofthe valve In<br />
cap apertures the cylinder body<br />
8 Secure the master cyhnder In a vice and fit and<br />
tIghten both caps and washers<br />
9 Instal the piston stop screw With a new sealmg nng<br />
10 Screw the two bleeder valves Into posItion In the<br />
cylinder body<br />
11 Where fitted pOSItIon the reservOir floats Into the<br />
reservOirs and fill both reservous With clean hydrauhc brake<br />
flUid<br />
4 REAR BRAKE<br />
154<br />
12 Fit the reservou caps and seals and bleed the<br />
cyhnder by hand by slowly pumping the piStOns Via the<br />
push rod assembly until all au IS expelled from the cyhnder<br />
3 Remove the cleVIS pin and wsconnect the<br />
handbrake cable or rod whichever IS apphcable from the<br />
hand brake operating lever protrud1ng from the rear wheel<br />
cylinder<br />
4 Mark each brake shoe for correct assembly<br />
compress the shoe retaining spnng on one shoe turn the<br />
top washer through 90 deg and remove the<br />
spnng washer<br />
and retainer pin Use the same procedure to remove the<br />
retamer spnng washers and<br />
pin<br />
from the<br />
remamlng<br />
shoe
Left Hand Rear Brake Shoe Assembly HANOBRAKE LEVER<br />
5 Back off the brake shoe adJuster<br />
In an<br />
anti clockwise wrectlon until It IS In the full offpOSItIon 6 Ease the ends of the brake shoes from the adJuster<br />
tappets andwheel cyhnders and detach the brake shoes<br />
7 POSitIOn a rubber band lengthWise around the<br />
wheel cyhnder to prevent the piston and cup from<br />
becommg dislodged<br />
8 Disconnect the brake shoe return spnngs from the<br />
brake shoes<br />
9 Disconnect the brake fl Uld pipe from the wheel<br />
cyhnder at the rear of the baclang plate and plug the pipe<br />
to prevent entry of wrt<br />
10 Remove the rubber dusCcover from belund the<br />
brake backing plate and unscrew the bleeder valve from the<br />
back of the wheel cyhnder assembly<br />
II Withdraw the retainer plates and adJustIng slums<br />
and reinove the Yheel cyhnder assembly from the brake<br />
baclang plate<br />
12 Detach the retaining chp and rubber boot from<br />
the open endof the wheel cyhnder and Withdraw the piston<br />
155<br />
WHEEL CYLINDER<br />
1<br />
Brakes 6<br />
and seal Detach the seal from the spigot end ofthe piston<br />
13 If It IS necessary to remove and dismantle the<br />
brake shoe adJuster unscrew and remove the two nuts and<br />
lock washers and Withdraw the assembly from the brake<br />
backing plate<br />
14 Mark the adJuster tappets and Withdraw them<br />
from the adJuster hOUSing Unscrew the adjuster wedge bolt<br />
from the hOUSing<br />
TO CLEAN AND INSPECT<br />
I Check the shoe hnlngs for wear Renew the hmngs<br />
Iftluckness IS found to be less than I 5 mm 0 059 In<br />
2 If the hnlngs are still serYlceable check for oil<br />
saturatIOn and gumrmness and renew as requued<br />
3 Check the brake drum for cracks ovallty or sco 1ng<br />
and renew or maclune as found necessary See<br />
SPECIFICATION section for drum ovahty and maclumng<br />
hnuts<br />
4 Wash the wheel cyhnder components In
1<br />
7 Brakes NUTS<br />
BRAKE SHOE<br />
AETA1NING<br />
WASHERS<br />
IID<br />
@<br />
HANDBRAKE OPERATtNG LEVER<br />
DUST BOOT<br />
ir<br />
methylat d spmts and blow dry with compressed au<br />
5 Check the rubber boot and piston seal for<br />
detenoratlOn or damage and renew as necessary<br />
6 Check the wheel c llnder piston and cylinder bore<br />
for wear and or pitting and renew the assembly If<br />
necessary<br />
7 Clean the adJuster components In solvent and<br />
check for wear or damage and renew If reqUired<br />
8 Check the tensIOn of the brake shoe return spnngs<br />
by companson With new springs<br />
TO ASSEMBLE AND INSTAL<br />
RETAINING PIN<br />
I<br />
I<br />
I G<br />
I Lubncate the components ofthe adJuster assembly<br />
With zmc OXide grease screw the wedge bolt Into the<br />
adJuster hOUSing andInstal the adJuster tappets accorwng to<br />
the marks made on dismantling<br />
2 PosItion the adJuster assembly on the brake<br />
backing plate and secure With the two retaining nuts and<br />
lockwashers PosItion an elastic band around the assembly<br />
to prevent the tappets from becomillg dislodged<br />
gJ<br />
RETURN SPRING<br />
@ SPRING WASHERS<br />
HOE ADJUSTER<br />
TAPPETS E<br />
S<br />
RETAINING PIN<br />
1<br />
RETAINING PLATE<br />
P<br />
SPA<br />
DUST COVER<br />
DUST BOOT<br />
Icr<br />
BLEEDER VALVE<br />
BRAKE SHOE<br />
ETAINING<br />
WASHERS<br />
WHEEL CYLINDER<br />
0<br />
CLlr Exploded View of Rear Brake Components<br />
PISTON AND SEAL<br />
3 Lubncate the wheel cylinder bore With clean brake<br />
flUid also dip the piston and seal In the flUid and Instal the<br />
seal on the piston so that the hp of the seal Will be faCing<br />
towards the spigot end of the piston<br />
NOTE Ensure that the seal IS seating correctly<br />
groove In the piston<br />
In the<br />
4 Dip the piston and seal assembly Into clean<br />
hydrauhc brake flUId and Insert It Into the cylinder bore<br />
Take care not to turn back the hp of the seal on entry<br />
NOTE The seallzp must face the blind end of thecylinder<br />
bore<br />
5 PosItion the rubber boot on the open end of the<br />
wheel cylmder and secure It With the boot retaining chp<br />
6 PosItion the hand brake operatillg lever In the slot<br />
end of the wheel cyhnder body locating the lever piVOt In<br />
the recess In the wheel cylinder body<br />
7 Insert the hand brake operating lever m the<br />
1 6 r<br />
I<br />
11<br />
Jf<br />
u
acking plate and posItion the wheel cyhnder on the plate<br />
from Inside<br />
8 Instal the adJusting plates and spnng<br />
retainers on<br />
to the wheel cyhnder from the rear of the brake backmg<br />
plate 9 Instal the rubber dust boot over the wheel cyhnder<br />
and hand brake operating hnk at the rear of the backing<br />
plate Check that the wheel cyhnder assembly IS free to<br />
move on the backing plate face<br />
10 Place a smear of ZinC oXide grease on each brake<br />
shoe support pad on the brake backing plate Inner face<br />
II Connect the brake shoes together with the brake<br />
shoe return spnngs<br />
NOTE The return sprmg with the double row of COlis must<br />
be mstalled adjacent to the wheel cylmder assembly<br />
12 PositIOn the brake shoes on the backing plate<br />
according to the marks made on dlsmanthng locating the<br />
rear shoe on the adJuster tappet and with the hand brake<br />
operatlng lever entered In the brake shoe<br />
aperture proVided In the<br />
TO REMOVE AND DISMANTLE<br />
I Raise the front of the vehicle and support on<br />
chaSSIS stands<br />
2 Remove the hub and grease retalnmg caps<br />
Withdraw the spht pin undo the stub axle nut and remove<br />
the road wheel and brake drum<br />
NOTE It may be necessary to baLk off each shoe adJustmg<br />
carn m order to remove the wheel and drum assembly<br />
3 Mark each brake shoe for correct assembly<br />
compress the shoe retaining spnng on one shoe turn the<br />
top washer through 90 deg and remove the spnng washers<br />
and retainer pin Use the same procedure to remove the<br />
retamer spnng washers and pin from the remaining shoe<br />
4 PuIl the shoe away from the wheel cyhnder piston<br />
and wsengage the other end of the shoe from the bhnd end<br />
of the other wheel cyhnder Unhook the return spnng at<br />
the shoe web and at the brake backing plate and remove the<br />
shoe and spnng Remove the other shoe In the same<br />
manner<br />
5 Disconnect and remove the short hydrauhc<br />
at the<br />
bndgIng pipe wluch connects the two wheel cyhnders<br />
rear of the backing plate Disconnect the fleXible pipe at<br />
the umon on the steel pipe and unscrew the fleXible pipe<br />
from the wheel cyhnder<br />
6 Remove the bolts and nuts secunng one wheel<br />
cylinder to the backing plate and Withdraw the cyhnder<br />
7 Remove the rubber boot and withdraw the piston<br />
cup spnng seat and spnng In that order from the open end<br />
of the wheel cyhnder<br />
1<br />
Bral es<br />
iI1<br />
13 Pull the other shoe Into posltlOh on the adJuster<br />
tappet and wheel cylinder<br />
14 Insert the shoe retaining pin through the hole In<br />
the backing plate and shoe from belund and Instal the<br />
retaining washers and spnng turn th<br />
op washer through<br />
90 deg to lock Into pOSition Instal th ther shoe retaining<br />
pin washers andspnng In a sunllar manner<br />
IS Fit the brake flwd pipe and the bieeder valve to<br />
the wheel cylinder<br />
16 Instal the brake drum to tile axle flange and fit<br />
and tIghten the road wheel<br />
NOTE It Will be necessary to fully tighten the road wheel<br />
when the vehicle IS lowered to the ground<br />
FIlONT WHEEl nnu 1 Blll KES<br />
157<br />
17 AdJust the brake shoes and bleed the hydraulic<br />
system as descnbed In the appropnate sections<br />
18 Reconnect the hand brake cable to the hand<br />
brake operating lever It may be necessary to back off the<br />
hand brake cable adJuster to connect the cable<br />
o<br />
19 Lower the vehicle to the ground fully tighten the<br />
road wheel retaining nuts and road test the vehicle<br />
cylinder<br />
8 If necessary unscrew and remove the wheel<br />
bleeder valve<br />
9 Repeat operatIOns 6 7 and 8 to remove and<br />
dISmantle the other wheel cylinder Any further<br />
msmantllng will be unnecessary<br />
TO CLEAN AND INSPECT<br />
I Check the shoe hmngs for wear Renew1the hnmgs<br />
If tluckness IS found to be less than 1 5 mm 0 059 In<br />
2 If the hrungs are stIIl serVIceable chec for oil<br />
saturatIon and gumminess and renew as reqUired<br />
NOTE Lmmgs must be renewed as sets only With the<br />
correspondmg lmmgs on the other front wheel<br />
3 Check the brake drum for cracks ovallty or sconng<br />
and renew or maclune as found necessary See<br />
SPECIFICATION sectIOn for drum ovahty and machining<br />
hrruts<br />
4 Wash the wheel cyhnder components In<br />
methylated spmts and blow dry With compressed au<br />
5 Check the rubber boot and cyhnder cup for<br />
detenoratlOn or damage and renew as necessary<br />
6 Check the wheel cyhnder piston and cyhnder bore<br />
for wear and or pitting and renew the assembly as<br />
necessary<br />
7 Check the adJusters on the backmg plate for wear<br />
or looseness and renew as requued<br />
8 Check the tensIOn of the brake shoe return spnngs<br />
by companson With new spnngs and renew as found<br />
necessary<br />
i<br />
it i<br />
1<br />
l<br />
0<br />
1<br />
oe
9 Brakes<br />
BOLT<br />
DUST BOOT<br />
PISTON<br />
CUP<br />
@ SEAT<br />
RING<br />
WHEEL CYLINDER<br />
0<br />
1@P<br />
WASHER<br />
TO ASSEMBLE AND INSTAI<br />
NUT<br />
RETAINING PIN SPRING<br />
f<br />
SHOE RETURN SPRING @ rMl<br />
RETAINING WASHERS<br />
DUST<br />
SPRING WASHERS<br />
SPRrNG<br />
CUP<br />
PISTON<br />
SEAT<br />
Booi<br />
Exploded View of Right Hand Front Brake Components Typical<br />
I Lubncate the Internal components and the wheel<br />
cyhnder bore with clean hydraulIc brake flUid<br />
2 Instal the spnng spnng seat cup and piston to the<br />
open end of the cylinder Ensure that the cup IS Installed<br />
With ItS hp faCing towards the bhnd end of the cyhnder<br />
3 PosItion the rubber dust boot over the spigot<br />
portIOn of the piston and over the open end of the cyhnder<br />
Fit a rubber band lengthwise around the assembly to<br />
prevent the piston and cup from becoming dislodged from<br />
the cyhnder bore<br />
4 PosItion the wheel cyhnder assembly In the<br />
locating hole In the brake backing plate and Instal and<br />
tighten the retammg bolts and nuts<br />
5 Fit the cylInder bleeder valve where necessary<br />
6 Repeat operations 1 to 5 inclUSIVe to assemble<br />
andInstal the other wheel cylmder<br />
7 Instal the short connecting pipe<br />
between the two<br />
cyhnders and tIghten the umons<br />
8 Place a smear of ugh melting pOint grease on each<br />
of the brake shoe support pads on the brake backing plate<br />
58<br />
and Instal each brake shoe and return spnng according to<br />
the marks made on dismantling<br />
9 Insert the shoe retamIng pin through the hole m<br />
the brake backing plate and shoe from belund and mstal<br />
the retaining washer and spnng turn the top washer<br />
through 90 deg to lock Into posItIon<br />
Instal the other shoe<br />
retaining pin washers and spnng In a Similar manner<br />
NOTE Ensure that the brake shoe ends are properly<br />
located on the wheel cylinder pistons and also on the blind<br />
end of the cylmder Ensure that the brake shoe adJustlng<br />
cams areIn thefull offposition<br />
10 Screw the end of the fleXible hydrauliC pipe mto<br />
the top wheel cyhnder and connect the remamlng end of<br />
the fleXible pipe to the umon of the steel hydrauhc brake<br />
line<br />
II Instal the brake drum and road wheel assembly<br />
onto the stub axle and adJust thehub beanngs as detailed In<br />
the FRONT SUSPENSION sectIon Refit the grease and<br />
hub caps<br />
12 Bleed the hydrauhc system and adJust the brake<br />
shoes lower the front ofthe vehicle and road test
TO REMOVE AND INSTAL BRAKE CALIPER<br />
1 RaIse the front of the velucle and support on<br />
chaSSIS stands<br />
2 Remove thehub cap and road wheel<br />
SHOE RETAINER<br />
Right Hand Front Brake Assembly Typical<br />
3 Remove the as caliper pads follows<br />
Disengage the anti rattle chp from the caliper plate<br />
Loosen the caliper bleeder valve<br />
Mark the pads with chalk or crayon to facilitate correct<br />
assembly<br />
Ease the caliper plate outwards away from the chaSSIS<br />
to allow the piston to retract mto ItS bore by<br />
approxunately 4 mm 0 157 In<br />
Withdraw the outer pad with a pm of long nosed<br />
phers Ease the caliper plate Inwards towards the chasSIS and<br />
agam uSing the long nosed plIers withdraw the mner pad<br />
and anti squeal slum where fitted<br />
4 Disconnect the caliper fleXible hydrauhc hose at<br />
the brake tube and bracket situated on the body Side<br />
frame<br />
6 FRONT VHEELDISC BRAKES<br />
159<br />
Brakes l0<br />
5 Plug the brake tube to prevent entry of drrt<br />
6 Remove the caliper assembly to stub axle flange<br />
retalnmg bolts and withdraw the caliper assembly<br />
InstallatIOn IS a reversal of the removal procedure with<br />
attentIon to the follOWing pOints<br />
Tighten the caliper assembly to stub axle flange<br />
retaining bolts to the correct speCified torque See<br />
SPECIFICAnON sectIOn for correct torque settmg<br />
Instal the brake pads and slumwhere fitted according<br />
to the marks made when dlsmanthng<br />
Renew the brake pads Iflining tluckness IS worn down<br />
to less than 1 mm 0 040 m<br />
NOTE Brake pads should only be renewed In sets offour<br />
Ensure that the anti rattle IS chp In a seMceable<br />
conditIon and that It IS Installed as per<br />
diSC rotatIOn as<br />
mwcated by the sticker on the outer face ofthe chp<br />
It will be necessary to bleed the hydrauhc system when<br />
mstallatlOn IS completed
ll Brakes<br />
View of Right Hand DIsc Brake Calliper Mounted to<br />
ANTI RATTLE CLIP<br />
Vehicle<br />
TO DISMANTLE AND ASSEMBLE<br />
1 Disengage the tensIOn spnngs and detach the<br />
cyhnder from the caliper plate<br />
2 Unscrew the fleXible brake hose from the cyhnder<br />
3 Tighten the bleeder valve and apply a low pressure<br />
of au to the fleXible hydrauhc pipe onfice In the cyhnder<br />
to gently expel the pIston from the cyhnder bore<br />
4 Usmg a thin blunt probe hft and remove the piston<br />
seal from ItS groove In the cyhnder bore<br />
5 Carefully pry the wiper seal retainer from the<br />
recess on the open end of the cyhnder and hft out the<br />
wIper seal<br />
6 Remove the cyhnder bleeder valve<br />
7 Further dlsmanthng of the assembly will be<br />
unnecessary unless It IS obvIOUS that components are worn<br />
or damaged and In wluch case the complete caliper<br />
assembly should be renewed<br />
8 Clean all caliper cyhnder components except diSC<br />
pads In methylated spmts and exanune for wear<br />
Discard the piston seal and wIper seal<br />
9 Lubncate the caliper cyhnder bore and piston seal<br />
with clean hydrauhc brake flUId and posItion the new seal<br />
In ItS groove In the cyhnder bore<br />
NOTE Where available smear a small amount of speual<br />
caliper grease m the cylmder bore<br />
10 Carefully seat the wiper seal Into ItS recess In the<br />
cyhnder and then fit the retainer<br />
11 Insert the piston mto the cyhnder bore until the<br />
pIston nm IS almost flush With the wiper seal retamer<br />
NOTE The piston must be entered squarely m the cylmder<br />
bore If the piston IS tiltedand Jammed m the cylmder bore<br />
damage to the piston or seals couldresult<br />
12 Attach the cyhnder to the caliper plate and secure<br />
WIth the two tensIOn spnngs<br />
13 Fit the fleXible hydrauhc brake hose and bleeder<br />
valve to the cyhnder body<br />
BRACKET SPRING<br />
NUTb<br />
SPLIT<br />
tJt 0 PIN1<br />
RETnP IN<br />
AD PISTON<br />
PI<br />
I SPRING<br />
SPLIT PIN<br />
WIPER SE<br />
1<br />
Yy g 0GliiiiiiI<br />
NUT<br />
l J t<br />
WASHERS PIVOT PIN<br />
69<br />
WAstER<br />
V I<br />
TENSION SPRINGS<br />
00<br />
PISTON SEAL<br />
CYLINDER<br />
BLEEDER VALVE t<br />
FlEXIBLE<br />
HOSE<br />
J<br />
WASHER<br />
Exploded View of Brake Caliper Components
TO REMOVE AND INSTAL BRAKE DISCS<br />
PIVOT PIN AND NUT<br />
1 Raise the front of the vehicle and support on<br />
chaSSIS stands<br />
2 Remove the hub cap and road wheel<br />
3 Remove the anti rattle chp and brake pads as<br />
prevIOusly descnbed<br />
4 Unscrew the caliper assembly to stub axle flange<br />
retaining bolts and remove the caliper assembly away from<br />
the brake diSC<br />
5 Tie the cahper assembly to a convement pOint<br />
awa y from the brake diSC It will not be necessary to<br />
disconnect the fleXible hydrauhc hose from the caliper<br />
assembly<br />
6 Detach the grease cup from the diSC hub<br />
7 Withdraw the spht pin from the castellated nut on<br />
the stub axle and tighten the nut shghtly to ehmlnate any<br />
end float that may be on present the hub and beanng<br />
assembly<br />
8 Mount a d131 mdlcator gauge on the suspensIOn<br />
umt so that the dial plunger IS beanng on the outer<br />
penphery ofthe diSC<br />
161<br />
Brakes 12<br />
Brake Caliper Assembly with Anti Rattle Clip Removed<br />
9 Zero the dial gJuge and rotate the diSC to assess the<br />
maximum run out of the brake diSC<br />
10 If the diSC run out IS In excess of the hmlts<br />
speCified and or If the diSC IS scored then machmlng of the<br />
diSC will be necessary<br />
See SPECIFICAnON sectIOn for brake diSC run out<br />
hmlt and recondltlomng hmlt<br />
11 Remove the stub axle nut thrust washer and<br />
outer hub beanng and withdraw the hub and diSC assembly<br />
from the stub axle<br />
12 Mark the hub In relation to the diSC and remove<br />
the four secunng bolts Separate the hub and brake diSC<br />
13 If necessary remove the hub beanngs and seal as<br />
descnbed In the FRONT SUSPENSION section of thiS<br />
manual<br />
14 Clean the mating faces of the brake diSC and the<br />
hub flange and Instal and correctly torque the four secunng<br />
bolts See SPECIFICATIONS for torque setting<br />
15 If the hub bearings and seal have been removed<br />
assemble Instal and adJust the hub beanngs as descnbed In<br />
the FRONT SUSPENSION section of thiS manual<br />
16 Mount a dial indicator gauge to the brake diSC as
13 Brakes<br />
preViously descnbed and again check the disc run out<br />
17 If the run out IS In excess of the hffi1t specified<br />
recheck the hub flange and diSC mating surfaces for dut or<br />
burrs and the hub beanngs for correct adJustment<br />
NOTE If a new brake diSC wasfitted and excessive ron out<br />
IS still evident even though the abovementioned checks have<br />
been made and proved to be not the cause then check the<br />
ronout on the hub flange and brake diSC separately Ifthe<br />
fault IS In the hubflange then renew the hubassembly<br />
If the hub flange IS true and the fault IS In the diSC then<br />
fit a new diSC and again<br />
check the run out<br />
procedure<br />
7 IUAIlIIIlAKE Bl CKI l AT<br />
18 Further installation IS a reversal of the removal<br />
TO REMOVE AND INSTAL Sedan several notches If the brake drom proves difficult to<br />
I Raise the rear of the vehicle and support on chassIS<br />
stands<br />
2 Take off the hub cap remove the road wheel and<br />
detach the brake drum<br />
NOTE It may be necessary to back off the rear brake shoes<br />
with the adjuster to allow the brake drum to be removed<br />
3 Disconnect the hand brake cable and hydrauhc<br />
brake pipe at the rear of the brake backing plate Plug the<br />
pipe to prevent loss of flUId and entry of dirt<br />
4 Remove the four bolts and nuts and detach the<br />
dnve shaft flange from the companIOn flange<br />
on the axle<br />
shaft Tie the dnve shaft to a SUItable pomt on the<br />
underbody away from the axle shaft<br />
5 USing the special axle shaft compamon flange<br />
holwng tool In conJunction With a SUItable socket andbar<br />
remove the large nut on the Inner end ofthe axle shaft<br />
6 With a shde hammer or a SUItable puller remove the<br />
compamon flange from the Inner end of the axle shaft<br />
7 Attach a SUitable shde hammer to the outer flange<br />
ohhe axle shaft and Withdraw the axle shaft from the rear<br />
beanng asselilbly<br />
8 Unscrew the four bolts and remove the brake<br />
backing plate assembly from the flange<br />
on the rear<br />
suspensIOn arm<br />
InstallatIon IS a reversal of the removal procedure With<br />
attentIOn to the follOWing pOints<br />
Tighten the large rear axle shaft Inner flange nut to 33<br />
kgfm 239 ft lb and check the axle shaft end float as<br />
descnbed m the REAR SUSPENSION section<br />
AdJust the brake shoes and bleed the hydrauhc system<br />
after installatIOn See relevant sectIOns<br />
TO REMOVE AND INSTAL StatIon Sedan<br />
I RaIse the rear of the velucle and support on chasSIS<br />
stands<br />
drum<br />
2 Remove the wheel hub cap<br />
3 Loosen off and remove the rear wheel and brake<br />
NOTE It may be necessary to release the brake adjuster<br />
remove<br />
4 Disconnect the hand brake cable and hydrauhc<br />
brake pipe at the rear of the brake backmg plate Plug the<br />
pipe to prevent loss offlUId and entry of wrt<br />
5 Remove the nuts retaining the brake backmg plate<br />
to the axle casing through the holes proVided In the axle<br />
shaft flange<br />
6 Withdraw the axle shaft from the axle casIng Use a<br />
slide hammer and adaptor Iffound necessary<br />
NOTE Keep intact the end float adjustment shuns which<br />
are fitted between the backing plate and casmg<br />
7 Place the axle shaft assembly<br />
on an anvil so that<br />
the beanng retaining collar IS supported by the anvil USing<br />
a hammer and cold chISel make a cut In the top of the<br />
retamlng collar<br />
NOTE Use care not to damage the axle shaft with the<br />
chisel If It IS found necessary to cut completely through the<br />
collar<br />
Usually It will be necessary to lifakeshallow cuts only<br />
In order to expand the collar suffiCIently for It to be<br />
removed<br />
8 USing a press and press plates support the beanng<br />
on the Inner race and press the axle shaft out of the<br />
beanng or use speCial tool No ST46940000 to puIJ the<br />
beanng from the shaft<br />
9 Detach the brake backmg plate With the bearing<br />
and grease trap<br />
installatIOn IS a reversal of the removal procedure With<br />
attention to the follOWing pOints<br />
Use a new bearing retaining collar when reassembling<br />
the axle shaft assembly<br />
Check the axle shaft end float as descnbed In AXLE<br />
SHAFT AND BEARING of the REAR AXLE section<br />
AdJust end float If necessary by subtractIon or addition of<br />
shims to the shun pack between the brake backing plate<br />
and axle casing<br />
AdJust and bleed the braking system<br />
sectIOns<br />
162<br />
See relevant
TO REMOVE AND lNSTAL Drum Brakes<br />
I Raise the front of the vehicle and support on<br />
chasSIS stands<br />
2 Remove the road wheel with the brake drum and<br />
hub as previously descnbed<br />
NOTE It may be necessary to back off the brake shoe<br />
adJustmg cams m order to withdraw the brake drum from<br />
the shoes<br />
3 Disconnect the flexible hydraulic pipe from the<br />
steel brake pipe at the bracket end and unscrew the flexible<br />
pipe out of the top wheel cyhnder<br />
4 Unscrew and remove the four bol ts secunng the<br />
HAND BRAKE PULL LEVER AND FRONT CABLE<br />
To Remove and Instal<br />
I Chock the two rear road wheels and release the<br />
hand brake to the full offpOSItIon<br />
2 Withdraw the spnng retamer and cleVIS pm and<br />
disconnect the front cable from the hand brake lever<br />
3 Remove the spnng retamer and cleVIS pm and<br />
disconnect the hand brake pull lever yoke from the lower<br />
end ofthe hand brake lever<br />
4 On the upper end of the pull lever and at the pull<br />
u IlUNT HII KE HAK t AT<br />
Brakes 14<br />
brake backmg plate and grease shield to the stub axle flange<br />
and withdraw the backmg plate and grease shield off the<br />
stub axle Separate the backmg plate and grease shield<br />
InstallatIon IS a reversal of the removal procedure with<br />
attentIon to the followmg<br />
TIghten the brake backmg plate secunng bolts to the<br />
correct specified torque See SPECIFICAnON sectIon for<br />
torque settmg<br />
Ensure that the hub beanngs are adequately lubncated<br />
with wheel beanng grease and mstal and adjust the hub<br />
beanngs as detaIled m the FRONT SUSPENSION sectIon of<br />
tlus manual<br />
On completIon of mstallatIon bleed the hydrauhc<br />
on both front wheels<br />
system and adjust the brake shoes<br />
before road testmg<br />
9 HA D HIlAKE ASSE BLY<br />
gUide wIthdraw the spnng retamer and cleVIS pm and<br />
dIsconnect the pull gUide from the assembly bracket<br />
5 The hand brake pull lever assembly can now be<br />
removed from the vehicle<br />
6 With the vehicle raIsed to a sUitable workmg height<br />
and supported on stands disconnect the clamp wluch<br />
secures the hand brake cable to the underbody<br />
7 From underneath the vehicle unscrew the cable<br />
adJustmg nut and detach the cable from the bottom lever<br />
8 StIll workmg from under the vehicle WIthdraw the<br />
lock plate at the lower cable fixmg pomt and pull<br />
clear of the underbody<br />
Underbody View of Hand brake Cable Arrangement Sedan<br />
163<br />
the cable
IS Brakes<br />
9 Pull the cable through the top assembly bracket<br />
and remove the cable from the vehicle<br />
10 If found necessary drIve out the hand brake pull<br />
lever sprIng pm and dismantle the pull lever assembly<br />
Observe the pOSItIon of the pawl and sprIng and also the<br />
hand brake pull set sprIng to ensure correct assembly<br />
II Check the hand brake pull lever components and<br />
the front cable for serYIceabillty and make replacements as<br />
found necessary<br />
NOTE Renew cables that are excessIVely stretched or that<br />
have chaffed or broken brmd or wires<br />
InstallatIOn IS a reversal of the removal procedure With<br />
attentIOn to the followmg<br />
LubrIcate all workmg pomts of the hand brake<br />
mechamsm when assembling<br />
AdJust the hand brake as<br />
ADJUSTMENT sectIon<br />
descrIbed m the BRAKE<br />
REAR HAND BRAKE CABLES<br />
To Remove Sedan<br />
1 Jrt t5 IUS the vehicle to a SUitable workmg height and<br />
support on ssls<br />
ch<br />
stands<br />
2 WorkIng from underneath the vehicle back offthe<br />
front cable adJustmg nut several turns<br />
3 Withdraw the cleViS pm and disconnect the left<br />
hand rear brake cable frorn the front cable adJustmg lever<br />
4 Disconnect the left hand and rIght hand rear cables<br />
at the hand brake operatmg levers at the rear wheel cyhnder<br />
assembhes<br />
5 Separate the two cables at the combmed adJustmg<br />
and Jommg hnk which IS situated at the rear rIght hand Side<br />
of the underbody<br />
6 Withdraw the lock plates which secure the rear<br />
cables to the suspensIOn arms and crossmember and remove<br />
the cables from the vehicle<br />
7 If necessary back off the lock nut and unscrew the<br />
combmed adJuster and Jommg link from the rIght hand<br />
cable<br />
TO ADJUST FRONT BRAKE SHOES Drum Type<br />
I Raise the front ofthe vehicle so that the wheels are<br />
clear ofthe floor and support on chasSIS stands<br />
2 Check that the wheels rotate freely and that there<br />
IS no end float m the hub bearmgs<br />
3 Workmg from under the vehicle and at the back of<br />
the brake backmg plate rotate oneof the adJustIng cams m<br />
a forward duectIon untIl the brake shoe locks the brake<br />
drum<br />
4 Slowly back off the adJuster untIl the wheel Will<br />
To Remove StatIOn Sedan<br />
lI f<br />
I Raise the vehicle to a SUItable workmg height and<br />
support on chasSIS stands<br />
2 Workmg from underneath the velucle Withdraw the<br />
split pm and cleViS pm and detach the rear cable from the<br />
balance lever which IS located on the dlfferenual housmg<br />
NOTE It may be necessary to back offthe adJustmg nut at<br />
the rear of the front cable to allow the cleVIS pm to be<br />
withdrawn<br />
3 Remove the spht pm and cleViS pm and disconnect<br />
the front porhon of the rear cable at the lever protrudmg<br />
down from the centre ofthe underbody<br />
vehicle<br />
4 The rear cable can<br />
now be removed from the<br />
5 If found necessary detach the return sprIngs and<br />
remove the cross rods which run from the balance lever<br />
assembly on the differentIal housmg across to both wheel<br />
cylmder assemblies<br />
To Inspect Both Models<br />
Check the cables for excessive stretchmg chaffing or<br />
broken braId<br />
Check all cleVIS pms and cleViS eyes for wear<br />
Check the equallser and balance lever eyes for<br />
elongatIOn<br />
Renew all components that upon mspectIon prove to<br />
be unserviceable<br />
To Instal Both Models<br />
O BUAK AD JST ENTS<br />
164<br />
InstallatIOn IS a reversal of the removal procedure for<br />
the model applIcable<br />
Apply lubrIcant to all workmg pomts when mstalhng<br />
AdJust the rear brake shoes and then the hand brake as<br />
descnbed m the followmg BRAKE ADJUSTMENT sechon<br />
Just rotate freely Without any Sign of brake drag<br />
5 Carry out operatIons 3 and 4 on the other shoe<br />
adJuster for the same wheel and agam check that the wheel<br />
wIll rotate freely<br />
6 Usmg the same procedure adJust the shoes on the<br />
other front wheel and lower the front of the vehicle to the<br />
ground<br />
NOTE DISC brakes where fitted to the front wheels are<br />
selfadJustmg and no manual adJustment IS provIded or<br />
reqUIred
TO ADJUST REAR BRAKE SHOES All Models<br />
1 Raise the rear of the vehicle and support on stands<br />
placed under the axJe hOUSIng or suspensIOn arms so that<br />
the wheels are clear of the ground<br />
2 Release the hand brake pull lever to the full off<br />
position<br />
3 Back the front hand brake cable adJustIng nut off<br />
several turns at the adJustmg pOInt under the vehicle<br />
4 Check that both rear wheels are capable of bemg<br />
rotated without any sign of brake drag<br />
5 Workmg from beneath the vehicle and at the rear<br />
of the backIng plate turn the square on the adJuster<br />
In a<br />
clockwise duectIon untIl the brake drum IS locked by the<br />
rear shoes<br />
6 Back off the adJuster a httle at a tune untIl the<br />
wheeliS Just free to rotate without draggIng<br />
7 USIng the same procedure adJust the shoes on the<br />
other rear wheel<br />
8 AdJust the hand brake cable as descrIbed In the<br />
followmg sectIon lower the velucle to the floor and road<br />
test<br />
TO ADJUST HAND BRAKE CABLE Sedan<br />
1 Raise the rear of the vehicle support on chasSIS<br />
stands and adJust the rear brake shoes as preViously<br />
descrIbed<br />
2 WorkIng from beneath the vehicle actuate the front<br />
hand brake cable adJustIng lever by hand to assess If<br />
excessive stretchIng has occurred at the rear cables AdJust<br />
TO BLEED<br />
BleedIng the hydraulic system IS not a routIne<br />
mamtenance operatIOn and should only be necessary when<br />
some portIOn of the hydraulic equipment has been<br />
disconnected or flUId draIned off thereby allOWIng au to<br />
enter the system<br />
There are five pOInts In the system where bleeder valves<br />
are fitted I e one on each front wheel cylInder or caliper<br />
where fitted With diSC brakes one on each rear wheel<br />
cylInder and one on the master cyhnder assembly<br />
NOTE On the dual CIrCUIt brakmg system two bleeder<br />
valves are fitted to the master cylmder<br />
I FIll the flUid reservou on the master cylinder With<br />
clean hydraulic brake flUid and maIntaIn It at least half full<br />
throughout the enure bleedmg operatIon<br />
2 Remove the dust cover from the bleeder valve on<br />
the master cyhnder attach a rubber bleeder tube to the<br />
valve and allow the other end ofthe tube to be unmersed m<br />
a small amount of flUid contaIned m a clean glass Jar<br />
3 Unscrew the bleeder valve one complete turn<br />
i<br />
Brakes<br />
i<br />
or<br />
the rear cables Ifnecessary via the rIght hand cable adJuster<br />
to allow the front cable lever to return to the off centre<br />
positIOn<br />
3 AdJust the front cable adJustIng nut a little at a<br />
time untIl an applicatIOn stroke of between 85 and 95 mm<br />
3 346 and 3 740 In IS obtaIned on the hand brake pull<br />
lever stem wllhIn the vehicle Tills Will be accomphshed<br />
easier With two operators one underneath the vehicle<br />
adJustIng and the other sittIng In the drIVIng posItIon<br />
asseSSIng the pull 1ever stroke<br />
4 Lower ilie vehicle to the ground and check the<br />
hand brake operatIon on an mchne Check that no brake<br />
bmdIng IS present when the hand brake IS In the ll<br />
l<br />
full<br />
released plsltIon<br />
I<br />
1sf<br />
TO ADJUST HAND BRAKE CABLE Stahon Sedan<br />
I Raise the rear of the vehicle support on chaSSIS<br />
stands and adJust the rear brake shoes as preViously<br />
descrIbed<br />
II DHAUI I S STEM<br />
165<br />
2 From underneath the vehicle adJust the front cable<br />
adJustIng nut untIl an apphcahon stroke of between 11 0<br />
and 120 mm 4 330 and 4 724 In IS obtaIned on the hand<br />
brake pull lever stem WithIn the vehicle This wIll be<br />
accomplished easier With two operators one underneath<br />
the vehicle and the other In slttmg the drIVIng pOSItIon<br />
assessIng the pull lever stroke<br />
3 Lower the vehicle to the ground and check the<br />
hand brake operatIon on an InclIne Check that no brake<br />
bmdIng IS eVident when the hand brake IS In the fully<br />
released pOSItIon<br />
4 Depress the brake peddl slowly to the full extent of<br />
ItS travel and lock up the bleeder valve Allow the pedal to<br />
return Without assistance<br />
5 Repeat operatIOn 4 unl1l a constant stream of<br />
clean flUid Without air bubbles IS bemg discharged Into the<br />
glass Jar<br />
6 Carry out the bleedmg operatIons In the same<br />
manner on the remaInIng bleeder valves In the system<br />
Always work from the longest Ime In the system down to<br />
the shortest<br />
NOTE Do not allow theflUId m the reservOIr to fall below<br />
the halffUll level at any time dunng the bleedmg operatIOn<br />
or aIr may enter thesystem and a fresh start WIll have to be<br />
made<br />
Always use new flUIdfor tOppIng up the reservoir<br />
7 Fmally remove the bleeder tube refit the dust<br />
covers to the bleeder valves and top up<br />
reservoir<br />
It<br />
the flUId m the<br />
NOTE It IS obVIOUS that two operators Will be needed to<br />
bleed the brakes when usmg theabovementIOned system<br />
rl
I<br />
jil<br />
v<br />
I7 Brakes<br />
Brake pedal hard<br />
a<br />
b<br />
c<br />
d<br />
e<br />
PossIblecause<br />
Incorrect shoe hnmgs fitted<br />
Frozen pedal pivot i<br />
Restncted brake lIne from master cylinder<br />
Frozen wheel cyhnder orcalliper Plston s<br />
Vacuum servo system InoperatIve<br />
2 Brake drag due to pressure budd up<br />
POSSIble cause<br />
a Clogged master cylinder ports<br />
b Frozen wheel cylinder or calliper plSton s<br />
c Frozen handbrake lInkage<br />
d Broken orstretchedbrake shoe return sprIngs<br />
e Frozen handbrake cables<br />
I Blocked vent m flUid reservou cap<br />
3 Lower spongy brake pedal<br />
POSSIble cause<br />
brake shoes<br />
a Incorrectly adjusted<br />
b Lack of sufficient flUid In system<br />
c Air In brake hxdrauhc system<br />
f<br />
4 Brakel cks on appli ton<br />
POSSIble cause<br />
li<br />
J<br />
1<br />
a Gummy hnIngs or diSC pads due to OIl or flUid<br />
contallUnatJon<br />
b Bent or eccentrICbrake drum s<br />
c Incorrectl1nIngs fitted<br />
d Broken orstretched brake shoe returnsprmg s<br />
5 Brake pedal pulo ates<br />
POSSible cause<br />
a Bent or eccentrIC brake drumor diSC<br />
b Loose or worn front hub beanngs<br />
c Bent rearaxle shaft<br />
6 Brake fade at ugh speed<br />
POSSIble cause<br />
a Incorrect shoe adjustment<br />
b EccentrIC orbent brake drum<br />
c LInmgs saturated With hydraulic flUid<br />
d Incorrect hRIngs fitted<br />
7 Brakes overheat<br />
Pvsslble calise<br />
a Incorrect shoe adjustment<br />
b Broken shoe return spnng s<br />
c Faulty handbrake cables and oradJustment<br />
d Frozen wheel cylInder pistons<br />
e Obstructed or damaged hydrauhc hose or lme<br />
I Obstructed master cyhnder compensatmg port<br />
g Blocked vent m master cylmder reserVOir cap<br />
h Broken rear spnng mam leaf orcentre bolt<br />
12 111l KI tUJI T In t USIS<br />
166<br />
Remedy<br />
Check and replace IImngs With recommended type<br />
RectIfy orrenew piVOt pm and bushIffitted<br />
Check brake lIne and removerestnctIon or renewlIne<br />
Check free up or renew pistons<br />
Check servo system and rectIfy<br />
Remedy<br />
Check and clean master cylmder and flwd reservou<br />
Check free up or renew piStOns<br />
Free up or renew lInkage<br />
Renewdefective spnngs<br />
Free up or renewcables<br />
Check vent and remove obstructIOn<br />
Remedy<br />
Checkand adJust brake shoes<br />
Check for leaks replemsh flwd to speCified level and<br />
bleed brake system<br />
Bleed hydraulic system<br />
Remedy<br />
Clean and renew hmngs or diSC pads<br />
Checkand renew faulty drum s<br />
Check and renew IIrungs m paIrS With recommended<br />
type<br />
Check and renew faulty sprmg s<br />
1<br />
Remedy<br />
Check and renewdrums ordiSC as requued<br />
AdJust or renewfront hub beanngs<br />
Checkand renewfaulty compone nts<br />
Remedy<br />
Checkand adJust shoe to drum clearance<br />
Checkand renew faulty component<br />
Renew contallUnatedlirung s<br />
Check and U1Stal recommended IIrungs m sets<br />
Remedy<br />
Checkand adJust shoe to drum clearance<br />
Renew faulty sPrIng s<br />
Check cables renew or adJust<br />
Free up or renewfaulty components<br />
Remove obstructIOn orrenewhydraulic hose or lIne<br />
Clear compensatIng port<br />
Checkand removeobstructIon m vent<br />
Check and renew faulty components
Type<br />
Capacity<br />
USA<br />
Canada<br />
PolarIty<br />
JAPANESE PRODUCTION<br />
Make<br />
Model<br />
PolarIty<br />
Stator wIndmgs<br />
Diode IdentIficatIon<br />
PosItIve<br />
NegatIve<br />
Output current<br />
Field resistance<br />
Pulley ratIo<br />
Brush length<br />
New<br />
Worn rrurumum length<br />
Brush sprIng tensIOn<br />
Rotor and shaft maxunum<br />
eccentrIcity<br />
Fan belt deflectIon<br />
DrIve pulley nut torque<br />
BATTERY<br />
ALTERNATOR<br />
AUSTRALIAN PRODUCTION<br />
Make<br />
Model<br />
PolarIty<br />
Output<br />
Voltage<br />
Amperage<br />
ELECTRICAL SYSTEM<br />
12 volt<br />
7 pia te<br />
40 amp hrs<br />
optIOnal 50<br />
amp hrs<br />
50 amp hrs<br />
60<br />
amp<br />
hrs<br />
NegatIve<br />
earth<br />
HItaclu<br />
LTl30 41<br />
NegatIve<br />
earth<br />
Star wound<br />
Red letters<br />
on base<br />
Black letters<br />
on base<br />
22 amps at<br />
14 volts and<br />
2 500 rpm<br />
447 ohms<br />
225 I<br />
1400 mm<br />
0551 In<br />
7 50 mm<br />
0295 m<br />
020 035 kg<br />
7 12 ozs<br />
OIOmm<br />
0004 In<br />
13mm<br />
0500 m<br />
3 8 kg m<br />
27 ft lb<br />
Lucas<br />
15AC<br />
NegatIVe<br />
earth<br />
143<br />
147 volts<br />
28 amps<br />
SPECIFICATIONS<br />
1<br />
167<br />
Brush length mInimum protrudIng<br />
from holder<br />
Brush sprIng tensIOn<br />
Fan belt deflechon<br />
DrIve pulley nut tensIOn<br />
JAPANESE PRODUCTION<br />
Make<br />
Model<br />
Type<br />
Voltage relay type<br />
Mechalllcal settIngs<br />
5mm<br />
0200 In<br />
200 280 grms<br />
7 10 ozs<br />
13mm<br />
ALTERNATOR REGULATOR<br />
0 500 In<br />
3 80 kg m<br />
27 ft lb<br />
Hitachi<br />
TLlZ 17<br />
Tlml<br />
constant<br />
voltage relay<br />
3 contact<br />
pomts<br />
Voltage relay<br />
Armature to core air gap o 80 1 20 mm<br />
0031<br />
0047 In<br />
Armature to frame au gap o 90 I 00 mm<br />
0 035<br />
o 039 m<br />
Armature blade pOInt to secondary<br />
v<br />
contact pomt 040 0 50 mm f<br />
0015<br />
o 020 In<br />
PIlot lamp relay<br />
Armature to core air gap o 50 0 60 mm<br />
Armature to frame yoke au gap<br />
POInt gap<br />
Electrical settmgs<br />
0020<br />
o 024 In<br />
020mm<br />
0 008 In<br />
040 0 50 mm<br />
0015<br />
o 020 In<br />
AdJust engIne speed to 2200 rpm<br />
Or alternator speed to 5000 rpm<br />
Set voltage to 142 volts at<br />
ambient temperature of 20 deg C<br />
Reduce voltage settmg by 0 I volts for<br />
every ambient temperature rIse of<br />
Increase voltage settmg by 0 I volts<br />
60 deg F<br />
10 deg C<br />
20 deg F<br />
for every ambient temperature drop of 10 deg C<br />
20 deg F<br />
r<br />
11J<br />
J<br />
t
2 Electrical System<br />
AUSTRALIAN PRODUCTION<br />
Make<br />
Model<br />
This regulator IS not adJustable<br />
JAPANESE PRODUCTION<br />
Make<br />
Model<br />
Type<br />
Dnve<br />
Number of poles<br />
Number ofbrushes<br />
Number of pmlOn teeth<br />
Number of rIng gear teeth<br />
No load current draw<br />
No load rpm<br />
Lock torque ffilmmum<br />
Brush length mlmmum<br />
Brush sprIng tensIOn<br />
STARTER MOTOR<br />
Armature shaft maxunum bend<br />
Commutator out of round maximum<br />
Undercut of commutator egments<br />
DrIve end bush maxunum wear<br />
PImon clearance pmlOn to stop<br />
With solenOId energized<br />
AUSTRALIAN PRODUCTION<br />
Make<br />
Model<br />
DrIve<br />
Number of poles<br />
Number of brushes<br />
Number of pmlOn teeth<br />
Number of rIng gear teeth<br />
Lucas<br />
8TR<br />
fhtachl<br />
S1I4 103<br />
Compound wound<br />
Over runmng<br />
clutch solenOId<br />
operated<br />
4<br />
4<br />
9<br />
120<br />
60 amps at<br />
12 volts<br />
7000 mmunum<br />
rpm<br />
II kg m<br />
8 ft lb<br />
6 00 mm<br />
0236 Ill<br />
o 70 0 80 kg<br />
24 28 ozs<br />
008 mm<br />
0003 m<br />
020 mm<br />
0008 m<br />
o 5 O 8 mm<br />
0 020<br />
0031 m<br />
020mm<br />
0008 m<br />
o 30 I 50 mm<br />
0010<br />
0060 m<br />
Lucas<br />
M40<br />
Over runlllng<br />
clutch solenOId<br />
operated<br />
4<br />
4<br />
9<br />
120<br />
168<br />
Commutator<br />
Brush length<br />
New<br />
Worn mllllmum length<br />
Brush sprIng tensIOn<br />
PmlOn clearance pm IOn to stop<br />
with solenOId energized<br />
Make<br />
Model<br />
DISTRIBUTOR<br />
<strong>1600</strong> <strong>1300</strong> with smgle carburettors<br />
<strong>1600</strong> with twm carburettors<br />
RotatIOn<br />
Fmng order<br />
Control<br />
IgmtIon tImmg<br />
<strong>1300</strong> <strong>1600</strong><br />
<strong>1600</strong> twm carburettors<br />
1400<br />
Dwell angle all dlstnbutors<br />
Capacitor capacIty<br />
Contact pomt gap<br />
Contact sprIng tensIOn<br />
Make<br />
Type<br />
Fmng order<br />
High tensIOn leads<br />
Plug gap<br />
Plug<br />
Reach<br />
thread size<br />
SPARK PLUGS AND LEADS<br />
Tlghtemng torque maxunum<br />
F ace type<br />
1500 mm<br />
0600 m<br />
1000 mm<br />
0400 Ill<br />
o 79 0 99 kg<br />
28 35 oz<br />
030 I 50 mm<br />
0010<br />
0060 m<br />
fhtachl<br />
0410 58<br />
D411 58<br />
D409 54<br />
AntI clockWise<br />
at rotor button<br />
1 3 4 2<br />
Vacuum advance<br />
and centrIfugal<br />
advance<br />
10 deg at<br />
600 rpm<br />
14 deg at<br />
650 rpm<br />
8 deg at<br />
600 rpm<br />
49 55 deg<br />
022 0 24 mfd<br />
045 0 55 mm<br />
0 OI 8<br />
0022 Ill<br />
500 650 grrn<br />
18 230z<br />
NGK<br />
BP 5E S<br />
1 3 4 2<br />
RadIO suppressed<br />
o 80 0 90 mm<br />
0031<br />
0035 m<br />
14mm<br />
19mm<br />
0750 m<br />
200 kg m<br />
15 ft lb
JAPANESE PRODUCTION<br />
Early models<br />
Make<br />
PrImary voltage<br />
PrImary resistance<br />
Secondary resistance<br />
Spark length mllllmum<br />
MAINTENANCE<br />
servIcIng<br />
IGNITION COIL<br />
Hitachi<br />
I 2 volts<br />
320<br />
4 10 ohms at<br />
20 deg C<br />
3 20<br />
410 ohms at<br />
68 deg F<br />
1 200<br />
16800 ohms at<br />
20 deg C<br />
11 200<br />
16800 ohms at<br />
68 deg F<br />
6mm<br />
0236 111<br />
Mamtenance consists malllly of regular mspectlOn dnd<br />
1 Keep the bat ery and ItS surroundIngs clean and<br />
dry Give the top of the battery partIcular attentIOn to<br />
prevent electrIcal leakage between the cell termlllals<br />
2 Remove the vent plugs and see that the vent holes<br />
are clear<br />
3 Check the e ectrohte level and top up as necessary<br />
The correct level IS Just over the top of the separators Do<br />
not overfill or aCid will escape through the vent holes With<br />
detrImental effect to the connectIons and adJacent parts of<br />
the car<br />
4 Use only distilled water for tOppIng up<br />
NOTE Never use a naked light when examllllng the<br />
battery as the gases gIven off by the battery<br />
dangerously explOSive<br />
DESCRIPTION<br />
The alternator chargmg umt uses a rotatmg<br />
can be<br />
Later models and SSS<br />
Make<br />
Pnmary resistance<br />
Secondary resistance<br />
PrImary voltage<br />
Spark length mlmmum<br />
SerIes reslstdnce<br />
AUSTRALIAN PRODUCTION<br />
Make<br />
IUTTtln<br />
PrImary voltage<br />
SerIes resistance<br />
2 1 TtHNi TOIl<br />
field and<br />
pole shoe assembly and together form a rotor umt Low<br />
amperage current IS fed through the slip rIngs and brushes<br />
to the field WIndIngs so wear on brushes and shp rIngs IS<br />
very slight and mamtenance IS reduced to a mmlmum<br />
The output current IS m generated the fixed stator<br />
wmdIngs and IS three phase alternatIng current AC<br />
169<br />
Electrical System 3<br />
HItachi or<br />
Hanshlll<br />
210<br />
2 70 ohms<br />
11200<br />
16800 ohms at<br />
20 deg C<br />
11200<br />
16800 ohms at<br />
68 deg F<br />
12 volts<br />
6mm<br />
0236 In<br />
I 60 ohms<br />
Lucas<br />
2 volts<br />
I 60 ohms<br />
5 If the battery required an excessive amount of<br />
tOppIng up the Cduse should be sought If overchdrglllg IS<br />
suspected check the reguldtor settmg f one cell 111<br />
pdrtIcular IS at fault check the case for cracks Never<br />
trdnsfer electrohte from one cell to another<br />
6 Keep the pOSItIve and negative termmals clean and<br />
apply a small amount of petroleum Jelly to the termInals to<br />
prevent corrosIOn<br />
TO REMOVE AND INSTAL<br />
1 Release the termInal screws and carefully remove<br />
the cables from the termmal posts<br />
2 Release the battery holdIng clamp and hft the<br />
bdttery from the car<br />
Reverse the above operatIOn to Instal the battery and<br />
smear petroleum Jelly on the termmals to prevent<br />
corrosIOn Do not over tIghten the termInal screws dnd<br />
make sure of the correct earth polarIty<br />
The stator wmdIngs are wound on a lallUndted soft Iron<br />
former and are star connected<br />
As It IS not pOSSible to recharge a storage battery With<br />
alternatIng current It IS necessary to rectIfy the output of<br />
the stator wmdmgs to direct current DC ThiS IS done by<br />
the bank of dIOdes mounted WithIn the alternator end<br />
bracket<br />
I<br />
The output of the alternator IS governed by the c<br />
5Itr l 1<br />
umt and buIlt m characterIstIcs of the alternator<br />
frlj<br />
f<br />
i<br />
01
t r<br />
4Electrical System<br />
An electrIcal cut out Ulllt IS not necessary with the<br />
alternator chargIng system as the dIOdes stop a reverse<br />
current flow through the alternator<br />
SERVICE PRECAUTIONS<br />
I Make sure the battery IS connected the correct<br />
way Refer to SpeCificatIons<br />
2 Do not short out or ground any terrlllnals common<br />
to the chargmg CIrCUIt<br />
3 Always disconnect the battery before connectIng a<br />
battery charger<br />
4 If a booster battery IS used always connect It In a<br />
parallel CIrCUIt I e pOSItIve to posItIve to and negatIve<br />
to negatIve to to maIntaIn a 12volt supply pressure<br />
5 Never disconnect the battery or termmals In the<br />
chargmg CirCUit whIle the engme IS runnmg<br />
6 Regularly check fan belt tensIOn deflectIon should<br />
be 13 mm O 5 In<br />
7 Keep battery termInals clean and all electrIcal<br />
connectIons tIght<br />
8 Disconnect the battery and alternator when arc<br />
weldIng on the vehicle<br />
9 Never connect a condenser to the field F<br />
termInal<br />
TO REMOVE AND INSTAL THE ALTERNATOR<br />
1 Fit covers to both fenders and disconnect the<br />
battery termInal<br />
2 Disconnect the termInal block at the alternator If<br />
used by pullmg on the terrlllnal block not the wues or<br />
remove the terrlllnal nuts and lock washers to remove the<br />
wIrIng from the termInals<br />
3 Loosen both mountIng bolt nuts<br />
4 Remove the fan belt from the pulley<br />
5 Remove both mountIng bolts while supportIng the<br />
alternator With the hand do not drop or bump the<br />
alternator<br />
InstallatIOn IS the reverse of removal With partIcular<br />
attentIon to the followmg<br />
I Do not over tighten the mountIng bolts as broken<br />
mountIng lugs could result<br />
2 Do not over tensIOn the fan belt<br />
3 Apply pressure to the<br />
mountmg end bracket only<br />
when adJustmg the fan belt<br />
4 Check the<br />
wUlng where soldered to the shde on<br />
terrlllnals In the termInal block or where soldered to the eye<br />
tennInals<br />
J TO CLEAN PARTS<br />
I Do not unmerse UllltS of the alternator m clealllng<br />
solvents as damage to the WIndIngs wIll result<br />
2 The end brackets and bearIngs may be washed In<br />
Kerosene or sunllar cleanmg flUid after they<br />
90mpletely dismantled from the Ulllt They<br />
thoroughly drIed after cleanmg<br />
JJT<br />
i v<br />
have been<br />
should be<br />
170<br />
3 Compressed au can be used to carefully blowout<br />
the dust from the stator wIndmg and the field WIndIng on<br />
the rotor<br />
4 Usmg a petrol damp rag carefully clean the slip rIng<br />
assembly and check for any damage or wear Never maclune<br />
the slip nngs Any burrs or burn marks can be polished out<br />
With very fine sand paper not emery paper<br />
5 Clean the brushes and brush holders USIng a damp<br />
petrol rag and check and remove any burrs from the<br />
holders<br />
TO CHECK AND TEST COMPONENT PARTS<br />
All parts beIng electrIcally tested should be restmg on a<br />
non conductIve pad<br />
Shp Rmgs<br />
I Visually check the slip nng assembly for damage<br />
2 Remove all burrs and burn marks With fine sand<br />
paper not emery paper<br />
3 With a 110 volt AC test lamp and prods test the<br />
slIp nng Ulllt for an electrIcal brIdge between the slIp rIngs<br />
The test lamp should not lIght<br />
NOTE The above test IS carned out WIth the field leads<br />
dIsconnected<br />
4 If the test lamp hghts up or burns dimly IndicatIng<br />
an electrIcal bndge a new slip nng assembly wIll have to be<br />
fitted<br />
5 USIng the 110 volt AC test lamp and prods check<br />
the shp rIng to earth msulatIon by holdmg one prod<br />
on the<br />
rotor shaft and touchmg the otheriprod to each shp rIng In<br />
turn<br />
6 If the test lamp hghts up or burns dimly IndicatIng<br />
an electrIcal short a new shp rIng assembly Will have to be<br />
fitted<br />
Field Wmdings and Rotor Assembly<br />
1 The msulatIon to earth test IS done With the 11 0<br />
volt test eqUIpment connect one of the test prods to oneof<br />
the field wires and the other test prod to one pole piece of<br />
the rotor<br />
2 If the test lamp hghts or burns dimly and no ViSUal<br />
earthIng can be seen and rectIfied a new rotor assembly<br />
wIll have to be fitted<br />
3 To check for brIdged or mternal shortIng of the<br />
field COli connect a pau of test leads to a 12 volt battery<br />
With an ammeter connected m serIes With one lead connect<br />
the test leads one to each field WIre and note the ammeter<br />
readIng a high readmg over 3 5 amps mdlcates a brIdged<br />
CIrCUit wlthm the coIl No readIng on the ammeter Indicates<br />
an open CUCUlt eXists m the field COIl In both the above<br />
cases a new rotor assembly Will have to be fitted
PULLEY<br />
BEARliG<br />
DIODE HEAT SINK TERMINAL BOLT WASHERS<br />
CI t Q<br />
U SCREW l<br />
Op<br />
N T<br />
lOCK WASHER<br />
Exploded View of Hitachi Alternator Notelabels<br />
on stator wires to facilitate reassembly I<br />
Stator Wmdmgs<br />
Electrical System S<br />
Jl<br />
THROUGH BOLTS<br />
i<br />
BEARING RETAINER J 1 II NUT<br />
PACER<br />
r<br />
T<br />
SLEEVE<br />
S O<br />
I<br />
BRUSH SCRE<br />
l1F lt0<br />
Soe<br />
Ot<br />
COVER<br />
Or COVER SCREWS<br />
J<br />
BEARING RETAINER SCREWS<br />
INSULATORS<br />
SCREW<br />
1 The InsulatIOn to earth test IS done With the liD<br />
volt test equipment connect one test prod to one stator<br />
WIre and the other test prod to the lamlllated stator<br />
wlIldmg frame<br />
2 If the lamp lIghts or burns dimly lIldlcatIng a short<br />
CircUit a new stator wlIldlllg assembly must be fitted<br />
3 To test the contlllulty of the stdtor WIndIng<br />
connect a paIr of test leads to a 12 volt battery connect m<br />
serIes With one of the ledds a 36 watt globe<br />
4 Connect the test leads across any two leads of the<br />
statol lrIg the lamp should hght Repeat the operation<br />
to the remiiInIng leads alternately<br />
5 If the hght fails to light on anyone of the tests<br />
then the stator wlIldmg assembly wIll have to be renewed<br />
Diodes<br />
Before the diodes can be tested the wmng has to be<br />
unsoldered from the dIOde leads USIng a very hot solderIng<br />
Iron and holdIng the dIOde lead With a paIr of pomted phers<br />
to diSSipate the heat and protect the dIOde unsolder each<br />
WIre 1Il turn after markIng and notmg theIr connected<br />
posItions<br />
I Connect a paIr of test leads to a 12 volt battery<br />
With a I 5 watt globe In serIes With one lead touch the<br />
diode wire With one lead and he heat smk of that diode<br />
With the other lead then reverse the leads<br />
2 Repeat the tests to all diodes 1Il turn The globe<br />
should hght when the leads are connected 1Il one way onlY<br />
3 If anyone or more of the diodes prove fdulty d<br />
new rectIfier dIOde pack mllst be fitted on Lucas models or<br />
a new heat SInk or dIOde fit on Hltachl models<br />
t t<br />
NOTE Never use a hand dflv n generator type<br />
test dIOdes<br />
DIODE HEAT SINK<br />
tester to<br />
171<br />
BRUSH ASSY<br />
B hSpnngsandB hes<br />
I Brush sprIng tension IS tested With a push type<br />
sprIng tensIOn gauge push the sprIng and brush lIlto the<br />
brush holder With the gauge untIl the face of the brushes<br />
and holder are flush A serYIceable sprIng should give a<br />
readlllg wlthlll speCificatIon lunlts Replace unserviceable<br />
sprIngs<br />
2 The brushes should protrude from their holders<br />
Without tenSIOn on theIr sprIngs when checklllg brush<br />
length Fit new brushes when the measurement IS less than<br />
speCified<br />
BearIngs<br />
After cleanlllg and drymg the both bearIngs check both<br />
tracks and balls or rollers for chips and roughness Fit new<br />
bearIngs when 1Il doubt of bearIngs<br />
the serYIceabIllty of the old<br />
TO TEST THE ALTERNATOR HITACHI<br />
I Remove the alternator from the vehicle as<br />
deSCrIbed under the headIng TO REMOVE AND INSTAL<br />
THE ALTERNATOR<br />
2 Mount the alternator on an electncal test bench<br />
eqUIpped for testIng chargIng CIrCUItS<br />
3 USIng a fully charged battery connect a 0 50 amp t<br />
test ammeter In serIes between the posItive<br />
battery<br />
terrlllnal and the alternator A termInal j<br />
4 BrIdge the F termInal and A termInal at the I<br />
alternator f I<br />
5 Connect a test voltmeter 0 20 volts between the<br />
termInal of the alternator and the nega tlVe<br />
termInal of<br />
theba ttery<br />
6 Earth the alternator frame to the negatIve<br />
battery termInal<br />
A<br />
if<br />
f<br />
J
J<br />
fl<br />
6Electrical System<br />
7 Connect a varIable load resIStance of 35 amps 15<br />
ohms with a sWitch In serIes across the battery<br />
8 Open CircUIt the varIable resistance With the<br />
SWItch<br />
9 Slowly mcrease the speed of the alternator untIl<br />
the reverse current flow IS elunInated and a 2 amp charge IS<br />
Indicated on the ammeter The speed of the alternator<br />
should be approxunately 1000 rpm at this pOInt<br />
J0 Close the SWitch of the varIable resistance and<br />
slowly Increase the alternator speed to approxunately 2000<br />
the varIable resIStance untIl the voltmeter reads<br />
rpm adJust<br />
14 volts The alternator output should be at maxunum<br />
readlllg refer SpecificatIOn<br />
NOTE Do not leave the variable resistance m circuit longer<br />
than IS necessary to do the test<br />
II Should the alternator not meet the above tests It<br />
will have to be dismantled and all components tested<br />
J 2 Ifthe alternator test proves that the alternator IS<br />
serviceable but the battery IS not receIVIng an electrIcal<br />
charge carry out the regulator Ulllt test procedure<br />
NOTE The alternator may be tested on the vehIcle usmg<br />
the above test CIrCUIt with the additIOn of an engme<br />
tachometer The engme may beused as the drlvmg medIum<br />
for the alternator bearmg m mmd the dnve ratIO between<br />
the engme and the alternator requmng the engme Idle speed<br />
to be reduced to a mInimum<br />
The regulator Unit mustnotbe m CIrCUIt when carrymg<br />
out thIs test dIsconnect the battery before connectmg any<br />
of the test eqUIpment<br />
TO DISMANTLE HITACHI<br />
1 Mark the assembled pOSition of both end brackets<br />
and the stator WIndIng lamInatIon<br />
2 Remove the brush cover screws and brush cover<br />
3 Remove the through bolts and separate the dnve<br />
end bracket and rotor from the stator Wlndlllgs and brush<br />
end bracket<br />
NOTE It may be necessary to gently tap the drive end<br />
bracket with a soft faced hammer to separate Itfrom the<br />
stator lammatlOns andbrush end bracket<br />
l 4 Carefully support the rotor In a Vice fitted With<br />
I soft Jaws and remove the pulley nut pulley fan woodruff<br />
I key and spacer<br />
i<br />
5 Remove the bearIng plate retaInIng screws from the<br />
drIve end bracket<br />
6 Support the dnve end bracket on the bed ofa<br />
press<br />
ard carefully press the rotor and drIve end bearIng from the<br />
liracket<br />
w<br />
7 USlllg a beamlgi ull re TIove the bearIng from the<br />
rotor shaft rem6ve the bearIng retaIner plate from the shaft<br />
and the bearIng dust sealfQm the end bracket<br />
172<br />
8 Remove the shp rIng end bearIng USIng the bearIng<br />
puller 9 Remove the heat SInk retalllIng<br />
washers from the endbracket<br />
bolts nuts and<br />
J 0 On UllltS fitted With one heat SInk With the<br />
dIOdes fitted duectly mto the end bracket<br />
negatIve<br />
unsolder the stator leads uSlllg a very hot soldenng uon<br />
whIle holdlllg the dIOde WIre With a pau ofpOlllted plIers<br />
remove the brush holder retalllIng screws<br />
I I Remove the end bracket from the stator WIndIng<br />
and heat slllks at the same tIme easmg the WirIng tenrunal<br />
connector through the end bracket cover plate hole note<br />
the posItIon of all<br />
reassembly<br />
msulator washers and spacers for<br />
J2 Remove the brush holder screws from the two<br />
heat slllk type UllltS and remove the brush terrlllnal screws<br />
and wmng remove the brush holder<br />
13 Unsolder the stator leads from the dIOdes USIng a<br />
very hot solderIng Iron whIle holdIng the dIode wue With a<br />
pau of pOInted phers<br />
14 Unsolder the brIdglllg wires from the dIOdes In<br />
preparatIOn for testlllg<br />
NOTE It IS Important that the dIOde wIre be held with a<br />
paIr of pomted pliers when soldenng and unsoldermg the<br />
leads the plIers diSSIpate some of the heat and so protect<br />
the dIOdefrom bemg damaged<br />
All wmng connectIOns should be marked and tagged<br />
before removal to aOId wrQng connectIOns dunng<br />
reassemblmg<br />
TO ASSEMBLE HITACID<br />
The assembly procedure IS the reverse of the<br />
dismantling operatIOns With attentIOn to the follOWIng<br />
pOInts I Carry out the cleall1ng operatIOns and the testIng<br />
and checkmg of component parts as laId down In the<br />
SERVICING THE ALTERNATOR sectIOn<br />
2 Replace all worn damaged and short or open<br />
circUited components<br />
3 Take care not to damage the shp nng assembly<br />
when refittmg<br />
4 Resolder the field leads to the slip rIngs USIng a<br />
very hot soldenng uon<br />
5 LubrIcate both ball races With a SUitable grease<br />
Shell Alvall1a RA or eqUivalent<br />
6 Press the slip rIng end bearIng onto the rotor shaft<br />
7 Instal the bearIng dust seal Into the drIve end<br />
bracket With the bearIng bearlllg retaIner and retaIner<br />
screws<br />
8 Press the bearIng and drIve end bracket onto the<br />
rotor shaft USIng a hollow arbor that wIll fit over the rotor<br />
shaft and contact the bearIng centre<br />
NOTE When fittmg bearmgs always apply the fittmg<br />
pressure on the sectIOn of the bearmg bemg fitted Do not<br />
apply the pressure through the balls or rollers<br />
l
Nd WASHER<br />
PULLEY<br />
SoI<br />
FAN<br />
DRIVE END BRACKET<br />
Exploded VlflW of Lucas Alternator<br />
BRUSH END BRACkET<br />
THROUGH BOLTS<br />
9 Instal the fan spacer and fit the woodruff key Into<br />
Its keyway<br />
10 Fit the fan with the blades towards the alternator<br />
11 Instal the pulley lock washer and nut tIghten the<br />
nut to 3 8 kg m 27 ft lb<br />
12 Resolder the stator leads to the dIOdes accordlllg<br />
to the tags and marks made before unsolderIng the leads<br />
take the necessary precautIOns to protect the dIodes from<br />
belllg damaged by<br />
excessive heat<br />
13 Resolder the termInal wIrIng back onto theIr<br />
OrIglllal pOSItIons<br />
14 Align the mark made on the brush end bracket<br />
and stator IanunatlOns before dismantling and assemble the<br />
two components while feedIng the termInal wHlng through<br />
t end brac et cover plate hole<br />
15 Instal the heat SInk assembling bolts and<br />
InsulatIon washers as noted when dismantling and tighten<br />
the retallllllg nuts evenly I<br />
16 Instal the brush holder to the end bracket and or<br />
heat smks<br />
17 Instal the rotor assembly alignmg the marks made<br />
before dismantling<br />
18 Instal the through bolts and tIghten them evenly<br />
19 Instal the brushes and termInal screws<br />
20 Refit the end bracket cover plate<br />
TO CHECK AND TEST ALTERNATOR<br />
ON VEHICLE LUCAS<br />
If the Igmtlon warnIng hght stays on after the engllle<br />
has been started and run at approXimately 1000 rpm carry<br />
out the followlIlg tests and precauhons<br />
I Do not open CIrCUIt any parts of the charglllg<br />
gIne ls runnIng<br />
Circuit while the en<br />
2 Do not sho fput or brIdge any wIrIng or termInals<br />
at any tIme<br />
3 Clean battery terImnals tighten<br />
RECTIFIER PACK NUT AND WASHERS<br />
tftie PIG TAIL t<br />
SEAjo I<br />
CUP WAiHER l WASHER<br />
V<br />
CIRCUP<br />
I COLLAR<br />
all electrIcal<br />
connechons check wIrIng for shorts to earth and or<br />
At<br />
4<br />
a<br />
RECTIFIER DIODE PACK<br />
173<br />
BEARING<br />
BRUSH HOLDER SCREWS<br />
l t tES<br />
SP t ll<br />
BRUSH HOLDER<br />
PIG TAIL SCREW<br />
Electrical System 7<br />
brIdged CUCUltS make sure the battery IS fully charged If<br />
the battery I low either charge It or It replace With one<br />
fully charged<br />
4 Start the engllle and allow It to run untIl normal<br />
operatlllg temperature IS reached<br />
5 Stop the<br />
engine when It reaches operatIng<br />
tempera ture and disconnect the negative battery termInal<br />
6 Remove the wIrIng connector from the alternator<br />
by holdIng the plastic cover and pulhng It straight out<br />
7 Reconnect the field termlllallead<br />
8 Earth the negative alternator termInal With a<br />
Jumper lead<br />
9 Connect a 0 50 amp ammeter to the alternator<br />
output termlllal and the posItIve battery termlllal<br />
10 Connect a 0 20 volt voltmeter between the<br />
pOSItIve battery termlllal and a good earth<br />
11 Connect a 12 volt 22 watt globe<br />
between the<br />
pOSItIve battery termInal and the IND Indicator light<br />
termlllal of the alternator With SUitable wIrIng and make<br />
sure the globe cannot earth out<br />
12 Connect a 35 amp 0 15 ohm varIable reSIStance<br />
between the posItive battery termlllal and a good earth<br />
IMPORTANT Only leave thiS umt connected long enough<br />
to complete the test<br />
13 Connect a tachometer to the engIne<br />
14 Reconnect the negative battery termlllal<br />
15 Restart the engIne and brIng the engIne speed up<br />
to 750 rpm and the 2 2 watt globe should go out<br />
16 Increase the engIne speed to 3000 rpm AdJust<br />
the varIable resistance until the voltmeter reads 140 volts<br />
the ammeter should now read approxunately 28 amps<br />
i 7 If the 22 watt globe stays on from a dull glow to<br />
brIght or fluctuates and the ammeter readlllg varik greatly<br />
lolli<br />
TO<br />
the alternator Will have to be removed for repaIri see<br />
REMOVE AND INSTAL THE ALTERNATOR sectH n<br />
18 After the test IS completed stop the engIne and<br />
remove the negative battery termlllal and the test<br />
eqUipment<br />
19 If the test proves the alternator to be serviceable<br />
check the external control umt<br />
t<br />
i<br />
y
8 Electrical System<br />
TO DISMANTLE LUCAS<br />
Mter the Ulllt IS removed from the velucle proceed to<br />
rusmantle m the followmg steps<br />
I Remove the plastJc cover by first remoVing the two<br />
mountIng screws<br />
2 SUitably tag the three stator WIres so that they can<br />
be soldered back m theu correct posItion<br />
3 With a hot soldenng Iron and holdIng the dIOde<br />
WIre link With a pair oflong nosed pliers unsolder the three<br />
stator WIres<br />
NOTE If a very hot soldermg Iron IS used the solder melts<br />
ImmedIately and the transfer of heat IS reduced to a<br />
mmlmum and so there IS less likelihood of damage to the<br />
dIOdes also by holdmg the wlrmg with a paIr ofpliers the<br />
pliers absorb some of the heat agam protectmg the dIOdes<br />
4 Loosen the nuts holdIng the rectJfier umt<br />
The reassemblIng of the alternator IS the reverse to<br />
5 Remove the screws holdmg the brush holder dismantling with particular attentIOn to the followmg<br />
assembly<br />
pOInts<br />
6 Remove the brush holder and rechfier urut I LubrIcate both ball races with a sUItable grease<br />
7 Remove the three assembly screws after markmg<br />
the posltJon of each end bracket and the stator wmdIng<br />
Shell A1vallla RA or eqUIvalent<br />
2 The ball race on the slip rIng end of the shaft IS<br />
relative to each other<br />
fitted with one shielded side next to the shp rIng assembly<br />
8 Usmg the special tool tap out the bearIng In the<br />
shp rIng<br />
3 When fittmg bearIngs always apply the fittmg<br />
end bracket pressure on the sectJon of the bearIng bemg fitted Do not<br />
9 Remove the bearIng slip rIng assembly and rotor as apply the pressure through the balls or rollers<br />
4 Take care not to damage the slip rIng assembly<br />
a umt<br />
10 Remove the nut washer pulley fan woodruff<br />
when refitting<br />
key and 5<br />
spacer from the shaft at the drIve end bracket<br />
Resolder the field leads<br />
J9 shp nngs with a hot<br />
II Press the rotor and shaft from the drIve end solderIng uon<br />
bracket and bearIng 6 When fittmg the bearIng a d the drIve end bracket<br />
12 Remove the bearIng retamer chp and remove the assembly to the shaft centre of the suppod 1he<br />
beanng<br />
bearIng and shields from the end bracket refer operatIOn 3<br />
I3 With a hot soldenng Iron unsolder the two field 7 Make sure the brushes are slttmg In theIr holders<br />
WIres from the shp rIng assembly 8 Fit the fan With blades towards the alternator<br />
li Carefully remove the shp nng assembly from the 9 Fit the woodruffkey Into ItS keyway<br />
l l ghaff<br />
IO Tighten the I<br />
pulley nut to 3 8 kg m 27 ft lb<br />
r ilTEIl ATOK Htt ITI ATUIl<br />
DESCRIPTION HITACHI regulator controls the to alternator output accordmg the<br />
voltage of the battery and rpm of the engme<br />
The alternator regulator IS a two Ulllt a<br />
type comprIsmg<br />
pilot lamp relay and a voltage regulator<br />
A cut out relay IS not reqUIred as a REGULATOR ADJUSTMENTS HITACHI<br />
reverse current<br />
cannot flow from the battery to the alternator at any time When testIng or adJustIng the alternator regulator on<br />
4<br />
i t<br />
c<br />
t<br />
even With the engine stopped due to the effect of the dIOde<br />
rectIfiers<br />
The voltage relay duects the charging system voltage to<br />
the field CIrCUit when the engIne IS runlllng<br />
Wh n the Ignition IS sWitched on current from the<br />
battery flows through the charge Indicator hght a parallel<br />
resistance and the voltage regulator contacts to the field<br />
coil of thel rotor to supply a startIng current for the<br />
alternator to commence chargIng ThiS IS necessary as the<br />
J resldu 1 magnetIsm retamed br the lternator IS Insufficient<br />
o start a voltage bUild up wlthIn tlfe alternator The voltage<br />
ft y e<br />
4<br />
I<br />
C<br />
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r<br />
4<br />
J<br />
174<br />
15 Remove the bearmg from the slip rIng end ofthe<br />
shaft USIng a beanng removmg tool or by supportmg the<br />
centre of the bearIng m a SUitable Jig and pressIt off USIng a<br />
press SpecificatIOns for makIng the special tool referred to<br />
m operatIon 8<br />
Select a piece of steel tubIng to the follOWIng<br />
dimensIOns<br />
Length<br />
InSide diameter<br />
Outside diameter<br />
Cap and plug one end leaVIng<br />
a recess ofat least<br />
TO REASSEMBLE LUCAS<br />
76 mm 3 m<br />
31 5 mmI 24m<br />
33 5 mmI 32 In<br />
38<br />
mmI 5 In<br />
the vehicle disconnect the earth lead at the battery<br />
negatIve termmal before attemptIng to connect the test<br />
Instruments removmg or replacmg the regulator cover or<br />
makIng any adJustments ThiS IS to obvl3te the pOSSibility<br />
of short CIrculhng any of the regulator termInals or wires to<br />
earth which would result m serIOUS damage to the<br />
alternator or regulator<br />
Voltage relay and voltage regulator gap adJustment<br />
should be made With the regulator Ulllt removed from the<br />
vehicle<br />
ElectrIcal tests and adjustments should be made With
FRAME<br />
PILOT LAMP RELAY<br />
the regulator umt on the vehicle uSlllg rehabIe test<br />
eqUIpment<br />
Apart from the normal testIng and adJustlllg no<br />
attempt should be made to repaIr the alternator regulator<br />
DIrty contact pOInts should be dressed With fine emery<br />
cloth or carborundum stone and washed thoroughly after m<br />
a clealllng solvent Burned or pitted pOInts wIll necessitate<br />
the Ulllt bemg replaced<br />
Regulator with Cover Removed Showing Components<br />
175<br />
ARMATURE<br />
BLADE<br />
Electrical System 9<br />
FRAME<br />
NOTE Do not Immerse the regulator UllIt m dealllng<br />
solvent as damage to the COIL wmdmgs wuld result<br />
TO TEST THE REGULATOR ON THE<br />
VEHICLE HITACHI<br />
I Disconnect the negatIve battery terrnlllal<br />
2 Instal a 0 50 amp test ammeter between the A<br />
PRIMARY CONTACT SUPPORT<br />
f<br />
f<br />
End View of Regulator Showing Voltage Control Un<br />
f<br />
r l<br />
I<br />
I<br />
I<br />
I
10 Electrical System SECONDARY CONTACT SUPPOR TS<br />
Regulator Showing Contact POlnU and Armature Blade to Frame Air Gap AdJusting Screws<br />
termmal of the regulator and the pOSItIve<br />
the battery<br />
termmal of<br />
3 Disconnect the F lead from the regulator and<br />
brIdge It to the A termInal<br />
4 Reconnect the battery negatIve<br />
lead and start<br />
the engme<br />
IIlcrease the engme speed to approxunately<br />
2000 rpm the ammeter readIng should be close to the<br />
maxunum output of the alternator allow the engllle to Idle<br />
and reconnect the F lead to the F termlllal of the regulator<br />
and remove the bridge wue If used Increase the engme<br />
speed agalll and note the ammeter readIng A very low<br />
readmg Indicates a fault In the regulator UllIt which will<br />
have to be removed for repaIrS or replacement<br />
TO REMOVE AND INSTAL HITACHI<br />
I Disconnect the battery negative termlllal<br />
2 Remove the regulator mountlllg screws<br />
3 Disconnect the wIrIng terIrunal block and remove<br />
the umt from the vehIcle<br />
41111 YOKECP NTGAP<br />
0<br />
4<br />
L<br />
Pilot Lamp Relay TLlZ17 Regulator<br />
lA<br />
L<br />
A1RGAP<br />
17<br />
SPRING BLADE<br />
Installation IS the reverse to the removal procedure<br />
MECHANICAL ADJUSTMENTS HITACHI<br />
The mechalllcal adjustments should be carn d Ollt In<br />
the followlllg order startIng WIth the voltage regulator umt<br />
Voltage Regulator<br />
1 Remove the<br />
regl at 1 fr om the vehicle With ItS<br />
harness and connector<br />
2 Check the air gap<br />
between the armature blade and<br />
frame usmg a feeler gauge of the correct dimenSIOn adjust<br />
the au gap by loosenlllg the armature blade screw and<br />
mOVing the blade against the feeler gauge and retIghten the<br />
armature blade screw<br />
3 Check the air gap between the bobbIn core and<br />
armature blade USIng a feeler gauge of the correct<br />
dimenSIOn adjust by bendmg the prImary contact support<br />
bracket<br />
4 Check the pomt gap With the armature at rest<br />
uSlllg a feeler gauge of the correct dimenSIOn adJust the<br />
pOlllt gap by bendIng the secondary contact support<br />
bracket<br />
Pilot Lamp Relay<br />
I Check the yoke air gap between the armature blade<br />
yoke frame usmg a feeler gauge<br />
of the correct dimenSIOn<br />
adJust the gap<br />
at the armature set screw<br />
2 Check the au gap between the bobbIn core and<br />
armature blade USIng a feeler gauge of the correct<br />
dimenSIOn adJust<br />
the air gap by loosemng the retalllIng
screw of the upper contdct pomt blade and movIng the<br />
blade m the dIrectIOn requIred usmg a screwdnver<br />
posItioned m the adJustmg slot<br />
3 Check the pOInt gap between the armature blade<br />
pomt and the lower fixed pOInt with the armature blade at<br />
rest agamst the top pOInt use a feeler gauge of the correct<br />
dimensIOn to check the gap adJust the gap by loosenIng the<br />
pomt support screw and mOVing the pomt support up or<br />
down to obtam the correct gap<br />
ELECTRICAL ADJUSTMENTS HITACHI<br />
I Check the state of charge of the vehicle battery<br />
should It be under three quarters charged recharge or<br />
replace It with a fully charged one before the electrIcal tests<br />
and adJustments are attempted<br />
2 Disconnect the negatIve battery termmal<br />
3 Disconnect the wire from the battery termmal on<br />
the alternator<br />
4 Connect a 0 50 amp test ammeter In serIes<br />
between the disconnected wlre and the alternator battery<br />
termmal<br />
5 Connect a 0 20 volt test voltmeter m parallel<br />
between the al ternator battery termInal and a good earth<br />
such as th ne tIVe battery lead<br />
6 Make sure the regulator umt IS firnIly mounted to<br />
the vehicle and that the wIrIng termInal connectIon IS<br />
firmly JOIned<br />
7 Connect a tachometer to the engIne accordIng to<br />
the manufacturer s Instructions<br />
8 Reconnect the negative battery terIrunal and<br />
start the engme and brIng to operatIng temperature<br />
9 Mount a thermometer on the cover of the regulator<br />
to register the ambient temperature the thermometer can<br />
be held In place With a lump of putty or smular substance<br />
177<br />
Electriclll System II<br />
Bobbin Side of Regulator<br />
10 When the engllle reaches operatIng temperature<br />
and the ambient temperature reaches ItS maXimum allow<br />
the engine to Idle then slowly mcrease the rpm and note the<br />
voltmeter readlllg which Will rIse With the engIne speed<br />
untIl the regulated voltage IS reached when the voltmeter<br />
needle will give a shght k1ckback refer SpeCificatIons for<br />
correct settmg<br />
J I Increase the engine speed to approximately 2200<br />
rpm and check that the voltage readIng remaInS wlthm<br />
specificatIOns<br />
12 Should the voltage settmg of the regulator not<br />
meet With speCificatIons stop the engme<br />
and remove the<br />
negatIve battery termlllal remove the regulator cover<br />
and bend the voltage regulator armature sprIng blade stop<br />
up to mcrease the voltage settIng and down to decrease the<br />
voltage settmg<br />
NOTE It IS only necessary to bend the stop a mmute<br />
amount to alter the voltage settmg<br />
13 After makmg the adjustment replace the cover of<br />
the regulator reconnect the negatIve battery termmal<br />
and restart the engine<br />
14 Repeat operatIons<br />
voltage settIng IS obtaIned<br />
9 to 13 untIl the correc<br />
NOTE If the voltage bUIld up of the alternator cannot b<br />
controlled by the regulator It mdlcates that the regulatp r<br />
umt IS at fault and should be replaced with a servIceable<br />
unit<br />
t<br />
15 After the voltage regulator adjustment has tbeen<br />
corrected stop the engme and dls onnect the neg a ve<br />
tJ 1<br />
1<br />
f<br />
I<br />
I<br />
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I<br />
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7<br />
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I J<br />
I2 Electrical System<br />
I<br />
I<br />
I<br />
L<br />
Lucas 8TR Alternator Regulator<br />
battery termInal remove the test In truments and<br />
reconnect all wIrIng to the correct termInals reconnect the<br />
negatIve battery terrlllnal<br />
TO TEST THE REGULATOR CONTROL<br />
UNIT LUCAS<br />
I To test the control umt connect a 0 50 amp<br />
ammeter m serIes with the mam alternator lead<br />
f I<br />
2 Connect a 0 20 volt voltmeter from the posItIve<br />
terrmnal to<br />
batter<br />
a good earth<br />
0<br />
1<br />
DESCRIPTION<br />
The lhtaclu sjarter motor IS a 12 volt serIes wound<br />
I four pole four I<br />
brush mt<br />
i The Lucas starter motor used on Australian<br />
I<br />
produced<br />
four brush umt With a face<br />
rehlcles IS a I f volt four pole<br />
a<br />
L J<br />
T y I<br />
lI<br />
I<br />
It<br />
L<br />
t<br />
o<br />
Lucas 4TR Alternator Regulator<br />
3 R econnect the negatIve terrmnal of the battery<br />
4 Start the engme and Increase speed untIl a readmg<br />
of not more than 5 amps IS obtamed It may be necessary<br />
to put the on parkmg lights to give an external hght load to<br />
the CUCUlt<br />
volts<br />
5 The voltmeter readIng should now be 14 3 to 14 7<br />
6 If the readIng IS not WithIn these limits the control<br />
urut bemg non adJustable wIll have to be replaced<br />
7 Stop the engIne d1sconnect the negatIve battery<br />
termInal remove all test eqUipment and reconnect the<br />
wIrIng to the correct termInals<br />
STAIlT U IOTOR<br />
type commutator Should the starter faIl to operate when the sWitch IS<br />
Both starter motors are equipped With solenoid moved to thestart pOSItIon check the followmg pomts<br />
actuatlpre engagm tstarter drIve and over runmng clutch J Check the battery<br />
condltIon and state of<br />
assemb The solenol YIs attached to the starter frame the refer to BATTERY sectIon of thiS manual<br />
solenOId plunger IS c Qected to the over runnIng clutch 2 Clean the battery terrmnals takmg parucular care<br />
and drIve pmlOn assem1Jly tnrough a lInk lever and pivot to remove the scale from the pOSItIve terrmnal post and<br />
pIn arrangement<br />
termInal<br />
When the solenoICI wlfidmgs are energll<br />
the ptunger<br />
3 Check the earth connectIOns for tIghtness and<br />
cleanhness do not over lIghten the termmals<br />
actIng on the lever and piVOt elgages the strIve pmlOn With<br />
the flywheel rIng gear and at the same tIm e closes the 4 SWItch on the headlamps and operate the starter<br />
sWitch supplymg power from the posItIve lead jof the control sWitch If the hghts go dim but the starter IS not<br />
battery to Jhe starter motor field colis to operate the heard to operate It could Ind1cate that a short CIrCUIt or<br />
r<br />
motor I<br />
high resistance has developed In the startIng system which<br />
As the ngine fires the over rUijnIng clutch ofthe drI e could be either external or IIlternal<br />
pillIOn assembly preyents high speed r9tatlOn of and 5 Check all the external wIrIng to make sure the fault<br />
posslble 4 mage to tlt starte<br />
1 arI 1atur If the solenOId IS not externaJ If the external CIrCUit proves satIsfactory<br />
wIndmgs are not Immed1ately de ene rgised by releaSIng the mdlcatIng that the problem IS m the starter assembly the<br />
t l<br />
sWitch key<br />
t<br />
ltr<br />
01<br />
umt Will haye to be removed and bench checked<br />
f<br />
I<br />
I<br />
The starter solenOId sWitch wInd1ngs are energlsed by<br />
the key operated combInatIOn Igmllon and starter sWitch<br />
TO TEST ON THE VEIDCLE<br />
I<br />
r<br />
charge
SOLENOID<br />
BRUSH PLATE BRACKET SHIM SPRING<br />
q<br />
I<br />
SRUSH ES<br />
8RUSH PLATE SCREWS<br />
YOKE<br />
HRU<br />
Exploded View of HItachI Starter Motor<br />
TO REMOVE AND INSTAL<br />
solenOId<br />
washers<br />
DUST PLUG<br />
tI<br />
ARMATURE<br />
t<br />
J<br />
WD BRACKET<br />
I<br />
PIVOT<br />
SOLENOID SCREWS<br />
PINION LEVER<br />
BOLT<br />
fNUTS AND WASHERS<br />
COLLAR<br />
TH<br />
ST bSHER<br />
Q I STOP WASHER<br />
THRUST PLATES r CLUTCH ASSY CIRCLlP<br />
ORS o I 10<br />
BRUSH PLATE<br />
t<br />
fF<br />
IN<br />
THROUGH BOLTS<br />
1 Disconnect the battery termInal negatIve lead<br />
2 Disconnect the battery lead from the starter<br />
3 Disconnect the sWitch wue from the solenoid<br />
4 Remove the two starter mountmg nuts and lock<br />
5 Remove the starter motor from the engIne<br />
6 The InstallatIOn procedure IS the reverse to the<br />
removal operations<br />
TO DISMANTLE HITACHI<br />
termInal<br />
I Disconnect the field lead from the solenOId<br />
2 Remove the three solenOId mountmg screws and<br />
unhook le solenOId plunger from the pInIOn lever and<br />
remove the solenOId and plunger assembly With the<br />
adJustIng shim and dust seal<br />
3 Remove the two screws that hold the brush plate<br />
to the commutator end bracket<br />
4 Remove the two assembly through bolts and<br />
remove the commutator end bracket<br />
5 Remove the t o pOSItive brushes from their brush<br />
holders and remove the brush plate remove the brakIng<br />
diSC Iffitted<br />
6 Remove the piVOt bolt from the pmlOn lever<br />
7 Separate the drIve end bracket and armature from<br />
the yoke<br />
8 Remove the armature pmlOn and clutch assembly<br />
With the pInion lever from the drIve end bracket<br />
9 Remove the cuchp and collar from the armature<br />
shaft tap the collar towards the pmlon to gam access to the<br />
clrch p<br />
I<br />
l<br />
179<br />
Electrical System 13<br />
10 Remove the clutch and pInIOn assembly from the<br />
armature shaft<br />
1 I If the field coIls are to be removed mark the<br />
locatIOn I of each mdlVldual pole shoe before remOVIng the<br />
mounung screws The pole shoes must be replaced m the<br />
same posltJon from which they were removed<br />
i<br />
TO CHECK AND INSPECT HITACHI<br />
1 With the starter motor dismantled check the brush<br />
holder InsulatIon USIng a 110 volt test prod eqUIpment<br />
With a globe m serIes With one lead<br />
Connect one test prod lead on the brush holder pOSItIve<br />
side and the other lead on the negatJve side If there IS any<br />
IndlcatJon of leakage the globe Will hght or an arcmg will<br />
occur at the pomt of shortIng either repaIr or replace the<br />
brush holder If a short CirCUit<br />
IS eVident<br />
2 Check the brushes for adequate length Brushes<br />
should be renewed when theIr length IS below<br />
specificatIons They should be a free slIdmg<br />
gUides<br />
3 Check the brush sprIng tensIOn With a pull scale<br />
fit In the brush<br />
Compare With speclficatJons<br />
4 Check that the commutator IS free from plttmg<br />
and burnmg clean With a petrol mOIstened cloth and<br />
pohsh With a strIp of fine glass paper<br />
A badly worn commutator may be cleaned up by<br />
mountIng In a lathe spmnIng at ugh speed and a light cut<br />
taken wIth a very sharp tool After turlling recut the<br />
msulatlOn between segments to speclficatJons<br />
5 Check the armature for short cucwt usmg a<br />
growler or by USIng the 110 test volt prods and globe<br />
6 Place one of the test prods on the armature core or<br />
shaft and move the other prod around the circumference of<br />
the commutator If the test lamp hghts at any pOInt the<br />
armature IS faulty and should be replaced<br />
7 Test the field coIls for contInUIty by connectIng<br />
the test prods m serIes With the field wmdmgs<br />
Fallure of the lamp to lIght Indicates an open CIrCUIt In<br />
the wUlng of the field coils<br />
I
1<br />
I4 Electrical System<br />
8 Check the field coIl for ground by plaCIng one<br />
prod on the field coIl lead and the other lead on the starter<br />
yoke If the globe lIghts or an arcmg occurs between the<br />
field coIls and earth remove the field coIls and repau or<br />
renew<br />
v<br />
9 Check the drIve assembly clutch pInIOn teeth for<br />
wear scorIng or cluppIng A clutch In good conditIOn<br />
should take up the drIve m one duectlOn ortiy It should<br />
rotate easIly and smoothly m the non drIve directIOn and<br />
the assembly should move smoothly along<br />
helical splmes<br />
the armature<br />
NOTE Do not wash the drive assembly or clutch In solvent<br />
as thIS wIll destroy the cJutch lubncant and cause early<br />
failure of the umt<br />
10 To replace the thrust plate and sprIng remove the<br />
clrclip from the sleeve whtle compressmg the sprIng WIth<br />
the thrust plate<br />
11 Check the armature shaft bushes for wear Check<br />
With speCificatIons and replace as necessary The old bushes<br />
must be removed and the new ones pressed mto the end<br />
brackets USIng a pohshed<br />
the armature shaft<br />
NOTE Make sure the thrnst washer assembly and the lever<br />
are co ectly meshed<br />
mandrel of the exact diameter of<br />
NOTE The new bushes must not be reamed to SIze as<br />
10 reammg wIlllmpazr the poroSIty of the bushes and cause<br />
early failure New bushes should be allowed to stand<br />
Immersed m clean light engzne 011 for 24 hours before<br />
fittmg ThIS tIme penod may be shortened to two hours m<br />
case ofurgency Ifthe OllIS heated to 1000C 2120F<br />
12 Check the armature shaft for bend between<br />
centres USIng a dial gauge Refer SpeCificatIons for<br />
tolerances Replace the armature If It IS not WItlun the<br />
specificatIOns<br />
TO ASSEMBLE HITACHI<br />
I Lubncate the drIve assembly on the armature shaft<br />
sphnes armature shaft bushIngs and solenOId sWItch movmg<br />
stud WIth a hght coatmg ofmulu purpose grease<br />
2 Assemble the clutch and pmlOn umt to the shaft<br />
fit the collar With the cup away from the pmlOn fit the<br />
cHclIp and stake In pOSitIOn and fit the collar over the<br />
cuchp 3 Assemble the armature st r clutch and pInIOn<br />
lever to the drIve end bracket and mstal the lever pivot bolt<br />
and tIghten<br />
4 Instal the armature and dnve end bracket assembly<br />
to the yoke<br />
5 Align the brush plate With the through bolts and<br />
Instal It onto the armature shaft<br />
G<br />
180<br />
r<br />
Measuring Armature Shaft End Float on HitachI Starter<br />
6 Fit the brushes Into their correct holders<br />
7 Refit the commutator end thrust washers and<br />
bracket mstal the through bolts and tIghten<br />
8 Check the armature end float refer to<br />
speclflcanons for correct settIng AdJust the end float by<br />
the tIllckness of the thrust washer<br />
f JtC rHook the olenOld stud to the lever and Instal the<br />
solenoid umt fit the mountIng screws and tIghten<br />
f<br />
I<br />
STARTER SOLENOID TO TEST AND<br />
ADJUSt HITACHr<br />
j<br />
fTh solenOld umt should be tested With the umt<br />
mounf d on Jthe starter motor and connected In Its<br />
operatlllg oslhon but With the starter field lead<br />
disconnected<br />
I MoOnt the starter motor securely In a Vice connect<br />
thenegatlvlnernuffalof a fiillfCliarged I2volrbattery to<br />
the M termmal of the solenOId usmg a sUitable Jumper lead<br />
2 onnect the pOSItIve ternunal ofthe battery to the<br />
S terrnmal of the solenOId usmg a sUitable Jumper lead With<br />
a SWitch In serIes<br />
3 90se the SWitch the solenOId should be actIvated<br />
and the plunger pulled smartly Into the solenoid mOVing the<br />
pInIOn assembly forward on the shaft<br />
5 If the pInlOn o pmlOn stop clearance IS not wltlun<br />
C<br />
y<br />
4 Measure the clearance between the pInIOn and the<br />
pmlOn stop Refer SpeCificatIons for the correct clearance<br />
NOTE Only hold the solenoId eneTglsed long enough to<br />
make the measurement as damage to the solenoid could<br />
occur from overheating<br />
A
speclficatJons<br />
Cso<br />
add or subtract to the solenOId to hOUSIng TO DISMANTLE LUCAS<br />
shim thickness illfferent tluckness shims are av31lable<br />
6 After changIng the solenOId to housll1 g slum<br />
thickness recheck the pInIOn to pmlOn stop clearance<br />
7 When the pInIOn to pInIOn stop clearance IS<br />
correctly adjusted remove the Jumper leads and connect the<br />
field wife to the terrlllnal of the solenoId<br />
STARTER MOTOR TO TEST HITACHI<br />
I Proceed with the no load test after checkIng and<br />
adJustlllg the solenOId and pillIOn clearance<br />
2 Connect an ammeter capable of readIng 0 500<br />
amps III senes with the pOSltJve battery terrlllnal and the<br />
solenOId B ternunal USIng heavy core cable<br />
3 Earth the negatJve battery termmal to the starter<br />
body USIng heavy core cable<br />
4 Bndge the B termlllal and the S termInal of the<br />
solenOId usmg a Jumper lead with a SWitch connected In<br />
serIes<br />
shaft<br />
5 Connect a revolutIon counter to the armature<br />
6 Close the SWitch In the Jumper lead between the B<br />
and S termInals and note the rpm and current draw of the<br />
starter motor compare the readIngs with specificatIOns<br />
7 After completIng the starter no load test remove<br />
the test Instruments and leads<br />
NOTE HIgh amperage readmg with low revolutIOns check<br />
for shorted armature shorted fields worn bushes bent<br />
armature shaft or poling armature hIgh amperage draw<br />
with no revolutions check for shorted field coils shorted<br />
armature or shorted brnshes<br />
BRUSH PLATE BRACKET<br />
SOLENOID<br />
181<br />
tr<br />
Mount the starter motor m a vice<br />
System I<br />
2 Loosen the lock nut of the pmlOn lever piVOt bolt<br />
and remove the eccentrIC pivot bolt<br />
3 Remove the field termlllal from the solenoid<br />
4 Remove the two solenOId retaInmg nuts and<br />
washers from the drIve end bracket and remove the<br />
solenoid<br />
sprIng<br />
care takIng not to lose or damage the plunger<br />
5 Remove the plunger sprIng and plunger<br />
6 Remove the two Inner screws from the<br />
commutator end bracket these screws hold the bakelite<br />
brush holder Into the end bracket and act as the earthmg<br />
medIUm for the earth brushes<br />
7 Remove the through bolts wluch are the two outer<br />
bolts which have screwdrIver slotted heads<br />
8 Remove the commutator end bracket takIng care<br />
not to lose or damage the brush sprIngs or InsulatJon plate<br />
9 Remove the posltJve brushes from the brush holder<br />
and remove the brush holder WIth the earth brushes<br />
attached<br />
0 Shde the earth brush termlllals off the brush<br />
holder and remove the earth brushes<br />
II<br />
shaft<br />
Remove the thrust washer from the armature<br />
12 Remove the pillIOn lever and drIve end bracket<br />
13 Remove the armature from the yoke<br />
4 Support the armature In a vertJcal pOSitIOn With<br />
the pillIOn and clutch assembly to the top<br />
15 Remove the drIve end thrust washer<br />
16 USIng a SUitable hollow drIft tap the clrchp<br />
retamer towards the pInIOn and remove the clrclip and<br />
retamer<br />
PIVOT BOtT<br />
DRIVE END BRACKET<br />
ARIllATURE END FLOAT MEASURE HERE<br />
Assembled VIfIW of Lucas Starter Motor
4<br />
s<br />
17 I<br />
16Electrical System<br />
17 Remove the clutch and pmlOn assembl from t 5 Check the armature for short CUCUlt usmg a<br />
armature<br />
shaft Y growler or by USIng the I 10volt test prods and globe<br />
18 lf the field coIls are to be removed mark the 6 Place one ofthe test prods on the armature core or<br />
10c Of each mdlVldual pole shoe before removIng the shaft and movethe other prod around the circumference of<br />
mountlng screws USIng a wheel operated screwdrIver the commutator If the test lamp lights at any pomt the<br />
armature IS faulty and should be replaced<br />
NiJpfE Do not remove thefield coils unless they areproved unse if able when tested The pole shoes must be replaced<br />
r III the same poslflon from whIch they were removed to<br />
6<br />
r<br />
1<br />
avOId the pOSSIbIlity of the armature poling<br />
starter motor IS reassembled<br />
TO CHECK AND INSPECT LUCAS<br />
when the<br />
Mter dIsmantling the starter motor check and test the<br />
component parts as follows<br />
1 Check the bakehte brush holder for Sracks and<br />
burn marks check the brush sprIng InsulatIOn plate for<br />
cracks and burns replace as necessary<br />
2 Check the brushes for adequate length Brushes<br />
should be renewed when their length IS below<br />
speclficahons They should be a free slidmg fit m the brush<br />
guIdes<br />
NOTE To renew the field coil brushes cut the old brush<br />
leads about 4 mm 0187 m from the press welded JOint on<br />
thefield COIL post thIS WIll give a good base onto whIch the<br />
new brush leads can be softsoldered<br />
3 Check the brush<br />
spnng tensIOn With a push scale<br />
Compare With specificatIOns<br />
4 Check that the commutator IS free from plttmg<br />
nd burrung clean With a petrol mOIStened cloth and<br />
po Jsh With a strIp offine glass paper<br />
A tJadly worn commutator may be cleaned up by<br />
mountlpg m a lathe spInmng at lugh speed and a hght cut<br />
taK n Ith a very sharp tool after turrung polIsh With fine<br />
g1ass paper Do not undercut the segments<br />
1<br />
LOCK NUT<br />
i PIVOT BOLT<br />
DRIVE END BRACKET<br />
THRUST WASHER<br />
J crCLlP<br />
ovp<br />
COLLAf<br />
PINION LEVER<br />
PLU<br />
T<br />
CLUTCH SSY<br />
PLUNGER SPRING<br />
SOLENOIO NUTS AND WASHERS<br />
C<br />
THROUGH BOLTS<br />
182<br />
J<br />
7 Test the field coIls for contmUlty by connectmg<br />
the test prods m serIes With the field wmdmgs<br />
FaIlure of the lamp to hght mdlcates an open<br />
the wmng ofthe field coIls<br />
CirCUit In<br />
8 Check the field coIl for ground by plaCIng one test<br />
prod on the field coIl lead and the otherlead on the starter<br />
yoke If the globe lIghts or an<br />
arcIng occurs between the<br />
field coIls and earth remove the field cOIls and repair or<br />
renew<br />
9 Check the drIve assembly clutch pInIOn teeth for<br />
wear sconng or cluppmg A clutch In good condition<br />
should take up the drIve m one directIOn only It should<br />
rotate easily and smoothly III the non drIve directIOn and<br />
the assembly should move smoothJy along the armature<br />
hehcal splines<br />
NOTE Do not wash the dnve assembly clutch m solvent as<br />
thIS WIll destroy the clutch lubncant and cause early faIlure<br />
ofthe umt<br />
10 Check the armature shaft bushes for wear Check<br />
With specifications and replace as necessary The drIve end<br />
bracket bush must be removed and the new one pressed<br />
mto the end bracket USIng a polIshed mandrel ofthe exact<br />
dIameter of the armature shaft The commutator end<br />
YOKE<br />
SOLENOID<br />
t 2<br />
il il<br />
BRUSHES END BRACKET<br />
EARTH BRUSHES<br />
BRUSH HOLDER<br />
SCREWS<br />
Q<br />
Exploded VIew of Lucas Starter Motor
v<br />
lr<br />
bracket bush can be removed by uSlllg a tap screwed Into<br />
the bush then grIp the end of the tap In a Vice tap the<br />
bracket from the bush USIng a soft faced hammer Instal the<br />
new bush usmg the same method as for the drIve end<br />
bracket bush<br />
NOTE The new bushes must not be reamed to SIZe as<br />
reammg will ImpaIr the porOsity of the bushes and cause<br />
early failure New bushes should be allowed to stand<br />
Immersed m clean lIght engzne 011 for 24 hours before<br />
fittmg ThIS time penod may be reduced to two hours m<br />
case ofemergency If the ollIS heated to lOOOC 2120F<br />
TO ASSEMBLE LUCAS<br />
The assembling of the starter motor IS the reverse to<br />
the dlsmanthng procedure with attentIOn to the followmg<br />
pomts<br />
I LubrIcate the drIve assembly on the armature shaft<br />
sphnes armature shaft bushIngs and solenoid SWitch movmg<br />
stud with a hght coatmg of multi purpose grease<br />
2 Assemble the clutch and pillion Ulllt to the shaft<br />
fit the collar with the cup away from the pmlOn fit the<br />
cuchp and stake m posItIon fit the collar over the CIrclIp<br />
and fit the thrust washer to the shaft<br />
3 Assemble the armature starter clutch and pmlon<br />
lever to the dnve end bracket and IIlstal the lever piVOt bolt<br />
andtighten<br />
NOTE Make sure the pmlOn<br />
are correctly meshed<br />
thrust washer and the lever<br />
4 Instal the solenOId plunger to the pillion lever and<br />
Instal the plunger spnng and solenOId fit and tIghten the<br />
mountIng nuts and washers<br />
5 Fit the brushes Into the correct pOSItIons In the<br />
brush holder mstal the brush sprIngs and InsulatIOn plate<br />
6 Fit the brush holder assembly mto the commutator<br />
end bracket and fit the retaInIng screws<br />
7 POSitIOn the commutator end bracket<br />
near ItS<br />
mounted posItIon and Instal the armature and drIve end<br />
bracket assembly Into the yoke checkIng the pOSltIOlllng of<br />
the brushes as the Ulllts are assembled<br />
8 Instal the through bolts and tIghten<br />
9 Check the armature end float refer to<br />
SpeCificatIons for correct settIng AdJust the end float by<br />
the thickness of the thrust washer fitted to the<br />
commutator end of the armature shaft<br />
STARTER SOLENOID TO TEST AND<br />
ADJUST LUCAS<br />
The solenOId Ulllt should be tested With the Ulllt<br />
mounted on the starter motor and connected In ItS<br />
operatIng posItIon but With starter field coIl disconnected<br />
I Mount the starter motor securely In a Vice connect<br />
the negatIve termlllal of a fully charged 12 volt battery to<br />
field lead termInal of the solenOId usmg a SUItable Jumper<br />
lead<br />
183<br />
J<br />
J<br />
oi<br />
Electrical System 17<br />
ShOWing Pinion to Pinion Stop Clearance<br />
Oe<br />
A<br />
r<br />
1<br />
tV J<br />
lead from an 8 volt<br />
2 Connect a swtable Jumper<br />
tappIng on the battery to the battery termInal of the<br />
solenOId<br />
3 Connect a<br />
Jumper<br />
lead With a SWitch In senes<br />
between the solenOId battery termInal and the solenOId<br />
SWI tch termmal<br />
4 Close the SWitch the solenOId should be activated<br />
and the plunger pulled smartly mto the solenOId mOVing<br />
the pillion assembly forward on the shaft<br />
5 With the solenOId energJsed measure the pInIOn to<br />
pInIOn stop clearance Refer to SpeCificatIons for the<br />
correct settIng<br />
6 AdJust the pillion to pInIOn stop clearance by<br />
loosenIng the pInion lever pivot bolt lock nut and turlllng<br />
the cam pivot bolt untIl the desued clearance IS obtallled<br />
NOTE Only hold the solenoid energzsed long enough to<br />
take the measurement as damage<br />
occur from overheatmg<br />
to the solenOId could<br />
7 When the pInIOn to pInIOn stop clearance IS<br />
correctly adJusted remove the Jumper leads and connect the<br />
field lead to the termlllal of the solenOId<br />
STARTER MOTOR TO TEST LUCAS<br />
Check the operatIon of the starter motor In the<br />
follOWIng manner<br />
I Connect the negatIve battery termInal to the<br />
starter body USIng heavy core cable<br />
2 Connect an ammeter capable of readlllg 0 500<br />
amps In senes With the pOSItIve battery termInal and the<br />
solenOId battery terrlllnal USIng heavy core cable<br />
3 Bndge the battery termInal to the SWitch termInal<br />
I<br />
r<br />
p<br />
4<br />
1<br />
s
R t<br />
N<br />
r<br />
18 Electrical System fV<br />
of the solenOId usmg a Jumper lead With a sWitch conne<br />
t<br />
owJ<br />
cted 6 After completmg the starter no load test remove<br />
In serIes the test mstruments and leads<br />
4 Connect a revoluhon counter to the armature<br />
shaft PI J<br />
5 Close the sWitch m the Jumper lead between the<br />
battery and sWitch tenrunals and note the rpm and current<br />
draw of the starter motor the current draw should be<br />
approxunately 60 amps With the revolutions greater than<br />
7000 rpm<br />
t<br />
Itf DESCRIPTION<br />
l<br />
J<br />
c P t 4f1 t<br />
7w<br />
r<br />
r<br />
The distrIbutor IS drIven from an extensIOn of the oIl<br />
pump dnve shaft which IS drIven by geanng from the front<br />
end ofthe crankshaft<br />
Mechalllcal advance and vacuum advance systems are<br />
mcorporated In tlie distrIbutor Mechalllcal advance IS by<br />
centrIfugal weights mounted to the shaft and governed by<br />
one advance sprIng The vacuum advance consists of a<br />
diaphragm Ulllt mounted externally on the distrIbutor<br />
body With hnkage to the breaker plate from the diaphragm<br />
advance IS controlled by engIne loadmgs<br />
r<br />
TO CLEAN AND ADJUST BREAKER POINTS<br />
At mtervals of 4000 Ian 3000 ffilles the contact<br />
breaker pOlllts should be checked for excessive burnmg and<br />
pittIng and the dYell angle should be checked and adJusted<br />
Ifnecessary<br />
V Pomts that are badly pitted and burned should be<br />
replaced POllltS that are stIli serVIceable should be cleaned<br />
or o<br />
VACUUM ADVANCE UNIT<br />
SCALE<br />
f<br />
5 DISTRIUUT4Itll<br />
ANCHOR PLATE<br />
POINTS<br />
1J1 Wit 10Y rrVrl lons check<br />
NOTE High amperage readmg<br />
for shorted armature shorted fields wn bushes bent<br />
armature shaft or polmg armature lflgh amperage draw<br />
WIth no revolutIons check for shorted field COIls shorted<br />
armature or shorted brnshes<br />
to a smooth square surface on a fine oIl stone Remove all<br />
traces of oil from the pomts by washIng them In petrol as<br />
oIl or grease on the pOInts wIll cause pittIng and burnIng<br />
I To remove the breaker pOInts firstly remove the<br />
distrIbutor cap and rotor button then loosen the low<br />
tensIOn lead screw on the fixed pOInt and slide the wue<br />
terffilnaI from behInd the screw<br />
2 Loosen the fIxed plate retamlllg<br />
remove the screws<br />
screws do not<br />
3 SlIde the breaker pOInt assembly away from the<br />
retalllIng screws and adJustlllg screw at the same ume 11ft<br />
the breaker pomt clear of the dIStrIbutor<br />
4 To mstal the breaker pOInts reverse the removal<br />
procedure<br />
5 Turn the engllle untIl the rubblllg block of the<br />
mOVing contact IS on the highest pOInt ofa cam lobe<br />
6 Shghtly loosen the fIxed contact plate lock screws<br />
and USIng a SUitable screwdrIver move the contact plate In<br />
the necessary dIrectIon until a clean feeler gauge blade of<br />
the specified thickness IS a neat slIdIng fit m the pOInt gap<br />
then retIghten the contact plate lock screws AgaIn check<br />
the fit ofthe feeler gauge blade between the contact pomts<br />
MOVING CONTACT<br />
CAM ASSY<br />
Ii<br />
Ill<br />
CAPACITOR<br />
CAP CLIP<br />
i<br />
Dlstrlbutor wlth Cap and Rotor Button Removed<br />
184 r<br />
l<br />
k c
NOTE If new pomts are bemg fitted set the gap at the<br />
upper limit f the specIficatIOn as the initial wearofa new<br />
breaker arm rubbmg block wIll be rapid Ifthe pomts have<br />
been m use for some time but are still servIceable set the<br />
gap at approxImately mIdway between the upper and lower<br />
limIts ofthe speCIficatIOns<br />
7 Turn the engllle and measure the contact pOInt gap<br />
at each cam lobe belllg lfpre that the heel of the breaker<br />
arm rubbIng block IS m the pOSItion of maxunum lift on<br />
each cam<br />
8 Measure the breaker arm preSSure with a<br />
sprIng<br />
tensIOn tester by pulhng at rIght angles to the breaker<br />
pomts See SpecIficatIOns<br />
9 Place a smear of high meltlllg pOlllt grease on the<br />
lobes of the cam assembly and IIlstal the rotor arm and the<br />
distrIbutor cap<br />
10 Connect the dwell meter and check the contact<br />
dwell adJust If necessary to specificatIOns<br />
timIng<br />
11 Connect the tlmmg light and check the IgmtlOn<br />
TO REMOVE<br />
I With the dlstnbutor cap removed turn the engllle<br />
unW the IgnitIon tlmmg mark Indicates number one<br />
cylInder IS on tdc that IS with the pomter In lIne with the<br />
extreme left hand mark on the pulley when lookmg at the<br />
engme from the front of the velucle and the rotor button m<br />
lIne With number one high tensIOn lead termmal pOSItIon<br />
2 Remove the vacuum advance Ime from the vacuum<br />
advance control urut<br />
3 Remove the prImary Ignition lead from the<br />
termmarblock<br />
4 Remove the two set bolts from the mountmg<br />
bracket and remove the distrIbutor from the engIne<br />
TO DISMANTLE<br />
I Remove the rotor button<br />
2 Remove the vacuum advance control umt<br />
mountmg screws disconnect the linkage from the<br />
diaphragm to breaker plate and remove the advance umt<br />
3 Loosen the cpntact breaker pomt retammg screws<br />
and terpunal screw shde out the wue termmal and remove<br />
the contact breaker pOInts<br />
4 Remove the E clip from the movmg pOInt piVOt<br />
post and separate the breaker pOInts<br />
5 Remove the low tensIOn termInal block and<br />
capacitor from the distrIbutor body<br />
6 Remove the two screws holdlllg the fixed breaker<br />
plate to the dIStrIbutor body and remove the breaker plate<br />
assembly<br />
7 To dISmantle the breaker plates compress the<br />
spnng to gam access to the clrchp and remove the cuclip<br />
and sprIng takmg care not to lose the balls between the<br />
sprIng and plate and the two breaker plates<br />
185<br />
FIXED CONTA<br />
CONTROL SPRING<br />
EARTH PIG TAil<br />
BREAKER PLATE SCR W<br />
VACUUM ADVANCE<br />
UNIT<br />
AiIIIr<br />
SCREW<br />
SPRING CLI v<br />
T Ir<br />
Electrical System 19<br />
1<br />
ROTOtl BUTTON<br />
CLlP<br />
0<br />
ETAINING SCREWS<br />
MOVING CONTACT<br />
6B<br />
SHIM<br />
EAKER PLATES<br />
AM ASSY<br />
ADVANCE PLATE<br />
SHAFT<br />
ASySY A<br />
ENTRIFUGAL WEIGHTS<br />
pIG TAil WIRE<br />
fjWASHERS mI It<br />
i<br />
TERMINAL SCREW<br />
B<br />
I<br />
r<br />
i Iv<br />
RETAINING W BREAKER PLATE SCREW<br />
rf If<br />
ANCHORPlAT<br />
o RING SEAL 0<br />
o ACER<br />
DRIVE A SSY<br />
CAPIaACITOR<br />
sPRING CLIP<br />
V<br />
CAPACITOR RETAINING SCREW<br />
MOUNTI T<br />
DRIVE PIN<br />
Exploded View of the Distributor<br />
ANCHOR PLATE SCREW<br />
8 Remove the screw holdIng the distrIbutor body<br />
anchor plate to the mounting bracket<br />
9 Invert the dlstnbutor body and remove the screw t<br />
holdIng the anchor plate to the distrIbutor body<br />
IO Support the distrIbutor shaft near the dnve end<br />
and uslllg a harruner and sUitable dnft tap the drIve pIn<br />
from the shaft and dnve assembly<br />
NOTE Mark the pOSItion of the dnve m assembly relatIOn<br />
to the shaft for correct assembly<br />
I<br />
c<br />
r<br />
J<br />
f<br />
f 1<br />
Iiftt tk<br />
J<br />
it<br />
oj
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if<br />
v<br />
I<br />
41 t<br />
1<br />
20 Electrical System<br />
1<br />
I<br />
CENTRIFUGAL WEIGHTS<br />
Showing Centnfugal Advance Mechanism and Position of Long Slot III Cam Assembly Advance Plate III Relation to Control<br />
Ii Remove the drIve assembly spacer washer<br />
mounl1ng bracket 0 nng oIl seal and anchor plate from<br />
the dIStrIbutor body I<br />
12 Remove the shaft assembly spacer washers and<br />
shims from the dIstrIbutor body<br />
13 Mark the pOSItIon of tl rotor drIve key<br />
of the<br />
cam assembly In relatIon to theshaft With a daub of qUick<br />
drymg paint on the centnfugal weight carner of the shaft<br />
and an aml ofthe advance plate of the cam assembly<br />
14 Remove the cam assembly retammg screw and the<br />
cam assembly<br />
15 Mark the pOSItIon of the centrIfugal weight and<br />
the control<br />
spnng usmg qUick dryIng p31llt<br />
16 Remove both centnfugal weights the advance<br />
control sprIng<br />
and cam assembly thrust washer from the<br />
shaft<br />
TO CLEAN AND INSPECT<br />
1 ThorouglIl clean all parts WIth clearung solvent<br />
taIang care not to unmerse the capacitor or vacuum<br />
advance umt m solvent<br />
2 Check and test the capacitor USIng a capacitor<br />
tester<br />
3 Check the contacts for pittIng and burnIng and If<br />
necessary renew as a set ortiy<br />
NOTE Pomts should be cleaned WIth a contact file or oil<br />
stone never use emery cloth or sand paper<br />
j<br />
O G SLOT<br />
Spring<br />
J<br />
1<br />
CAMASSY RETAINING SCREW<br />
SCALE<br />
186<br />
4 Check the low tensIOn and earth wues for possible<br />
fractures<br />
5 Check the dlstnbutor shaft and body for wear and<br />
renew as necessary<br />
Maxunum clearance between shaft and<br />
body should not exceed 008 mm 0003 Ill If the<br />
clearance IS m excess of thiS figure It wIll necessItate the<br />
renewal ofthe shaft and body<br />
6 Check the cams for wear or roughness VarIatIons<br />
m lift between any two cams In excess of 0 05 mm 0002<br />
m wtll necessitate renewIng the cam assembly<br />
7 Check the clearance between the shaft and cam<br />
assembly maxunum clearance IS 0029 mm 00015 m<br />
Clearance In excess of thIS figure will necesSitate the<br />
renewal ofthe shaft and cam assembly<br />
8 Inspect the governor weights for bmdmg With the<br />
piVOt pm<br />
9 Check the distrIbutor cap for cracks carbon tracks<br />
burned or corroded termmals<br />
10 Check centre carbon for wear and protrusIOn<br />
II Inspect rotor for damage or deterIoratIOn<br />
12 Check the vacuum advance urut for leakIng<br />
diaphragm To do Ius push III on the diaphragm<br />
connectIng lInk place a finger over the suctJon pipe and<br />
release the connectmg link The vacuum on the finger<br />
shouldhold for at least 30 seconds<br />
necessary<br />
13 Check the rubber 0 nng seal and renew as
TO ASSEMBLE<br />
Showing Distributor Drive Positioned Ready to Instal the Distributor<br />
Assembly IS a reversal of the dISmantlIng procedure<br />
With attenuon to the followlIlg pOInts<br />
I Apply a small amount ofhigh meltlllg pOInt grease<br />
to the centrIfugal weight piVOt posts and rubblllg pOInts of<br />
the weights before assembling<br />
2 Instal the control spnng as marked or noted on<br />
dismantling<br />
3 Instal the cam assembly thrust washer and cam<br />
assembly as marked on dismantlIng and check that the long<br />
slot m the cam assembly advance plate IS fitted to the<br />
weight With the control sprIng attached and the short slot IS<br />
fitted to the weight Without the control sprIng<br />
4 Instal the cam assembly retalllIng screw and<br />
tIghten<br />
5 Place the washers on the distrIbutor shaft and<br />
mstal the shaft Into the hOUSIng<br />
NOTE Starting from the top the washers<br />
are m the<br />
followmg order washer bakelue washer and adJusting<br />
washer Lubncate the shaft WIth engine 011 before mstallmg<br />
6 Instal the anchor plate and mountlllg bracket With<br />
the 0<br />
rIng<br />
011 seal to the dtstnbutor body and IIlstal the<br />
retamlllg screws and tIghten the anchor plate to dIStrIbutor<br />
body screw With the scale at the centre posItIon<br />
7 Instal the drIve assembly and thrust washer on the<br />
shaft and align the marks made on dismantling<br />
Instal the<br />
drIve pIn<br />
8 Measure the end thfllSt of the shaft With a feeler<br />
gauge or dial ga lge the end float should not exceed 040<br />
mm 0015 In If the end float exceeds the maxunum<br />
l<br />
t r v<br />
1<br />
t<br />
1<br />
i<br />
187<br />
Electrical System 214<br />
restore to the correct clearance by Installing a sUItable<br />
adJustlllg washer<br />
9 Assemble the breaker plates and lubncate the balls<br />
between the plates and between the<br />
sprmg<br />
and lower plate<br />
with lugh meltmg pOlllt grease<br />
10 Instal the breaker plates and fit the e IIlIng<br />
screws f<br />
11 Instal the vacuum advance unIt and connect the<br />
lInk to the pIn on the movable plate and lightlrribrIcate<br />
with ugh meltlllg pOInt grease<br />
Underside of Fixed Breaker Plate ShOWing TenSIOn Spring<br />
for Moveable Plate<br />
4<br />
i<br />
j<br />
l<br />
di<br />
I r<br />
J<br />
I<br />
J
1ft<br />
1H<br />
1<br />
tift<br />
I Jt<br />
1<br />
f<br />
22 Electrical System<br />
12 Instal the capacitor termmal connectIons earth<br />
pigtaIl WIre and cap retammg clips<br />
13 Lightly lubrIcate the pivot post of the contact<br />
breaker set and assemble the breaker pomts<br />
14 Instal the breaker pomts onto the breaker plate<br />
hghtly lubrIcate the cams and apply a small dab of high<br />
meltIng pomt grease to the rubbIng block of the movmg<br />
pOInt<br />
15 AdJust the contact breaker gap as descrIbed m the<br />
sectIon TO CLEAN AND ADJUST BREAKER POINTS<br />
16 Instal the rotor button and check that the<br />
centrIfugal weights are free to operate by turnIng the rotor<br />
button agamst the centrIfugal control sprIng whIle holdIng<br />
the dnve assembly when the rotor button IS released It<br />
should return freely to the fully retarded positIOn<br />
17 If the rotor IS Inchned to stIck or does not return<br />
to the retard pOSItIon the cause should be located and<br />
rectIfied<br />
TO INSTAL<br />
I Check that the engIne has not been rotated after<br />
the distrIbutor was removed by recheckIng the tImIng<br />
pOSItIon as descrIbed m Item I of TO REMOVE sectIon<br />
2 Turn the distrIbutor shaft so that the rotor button<br />
pomts to the posItIon of the high tensIOn termInal for<br />
number one cylInder<br />
3 Instal the distrIbutor mto Its mountmg hole<br />
makmg sure that the drIve assembly IS engaged Instal the<br />
retaInIng set bolts and tighten<br />
4 Check that the contact breaker pomts are Just<br />
startmg to open when the cam assembly IS turned m the<br />
directIOn of rotatIon and tIghten the anchor plate to<br />
distrIbutor body screw<br />
plug leads<br />
5 Instal the distrIbutor cap and connect the spark<br />
6 Instal the low tensIOn lead<br />
7 Check the IgmtlOn tImIng wIth a timIng hght and<br />
check and adJust the dwell angle If necessary<br />
8 Instal the vacuum advance lIne<br />
TO TIME ENGINE AND SET IGNITION<br />
TIMING Static Method<br />
I Ensure that the contact breaker pomts are clean<br />
and adJusted to the specified clearance<br />
2 Rotate the crankshaft unhl No I piston IS at tdc at<br />
the end of the compressIOn stroke<br />
3 Align the pomter on the tlmmg cover with the<br />
extreme left hand mark on the crankshaft pulley when<br />
vlewmg the pulley from the front of the car<br />
4 The positIOn of the rotor should be m alignment<br />
With No I high tensIOn lead termmal of the cap and the<br />
contact breaker pOInts should be Just startIng to open<br />
5 To<br />
adJust loosen the anchor<br />
plate to mountIng<br />
bracket screw and move the distrIbutor body In the<br />
dIrectIOn reqUIred then retIghten the screw<br />
6 Road test the vehIcle and make fInal adJustments<br />
to obtaIn best performance and smoothest operatIOn<br />
TO ADJUST IGNITION TIMING<br />
AND DWELL ANGLE Usmg Instruments<br />
I Connect a tachometer dwell meter and timIng<br />
hght to the engIne accordmg to the manufacturer s<br />
InstructIons<br />
2 Start the engme and brIng to normal operatIng<br />
temperature<br />
IGNITION TIMING MARKS<br />
ShowlIlg Front of Engine with Distributor Mounted III<br />
Position and Ignition Tlmlllg Mark on tdc<br />
188 o
3 AdJust the engme Idle speed to specificatIons<br />
4 Disconnect the vacuum lIne from the vacuum<br />
advance urut and check the advance pOSitIOn with the<br />
tllTung hght each divIsion on the crankshaft pulley equals 5<br />
degrees refer SpecificatIons for the correct settIng<br />
5 AdJust the tImmg posItIon by loosenIng the anchor<br />
bracket screw and move the distrIbutor<br />
plate to mountIng<br />
body m the screw slot If adjustment IS not possible with<br />
this screw It will be necessary to loosen the second screw<br />
holdIng the anchor plate to the distrIbutor body both these<br />
screw slots are elongated for this adJustment<br />
6 After the correct tImmg poslhon has been<br />
deterllUned tIghten both screws<br />
7 Check the contact dwell refer SpeCificatIOns for<br />
the correct settIng adJust by opemng or closmg the contact<br />
TO SERVICE<br />
The spark plugs should be removed for mspectlOn<br />
c1eamng and resettmg at mtervals of 5000 to 6000 km<br />
3000 to 4000 miles<br />
Spark plugs removed from an engme m good condlhon<br />
operatmg under normal conditIOns should have a hght<br />
powdery depOSit rangIng m colour from lIght brown to<br />
greYish tan After conSIderable serYIce the electrodes WIll<br />
show SignS of wear or normal burmng Spark plugs showlllg<br />
a thick black oIly depOSit<br />
IndIcate an engme III poor<br />
mechamcal condItIon or pOSSibly that a plug With too low<br />
a heat range has been fitted<br />
Spark plugs showmg a white or yellOWish depOSit<br />
mdlcate sustamed high speed drIVIng or pOSSibly that plugs<br />
The lugh tensIOn cables between the sparkIng plugs and<br />
the dlstnbutor cap and the centre high tensIOn terllUnal on<br />
the dIstrIbutor cap and the IgnitIon coIl are of speCial<br />
manufacture and have a carbon core Impregnated Instead of<br />
the normal wire core<br />
ThiS IS to ehmmate radiO mterference care must be<br />
exercised when removmg the cables from the sparkmg plugs<br />
to ensure that the cables are not damaged by stretchIng<br />
which Will break the core and render the cable<br />
unserViceable<br />
Always remove the cable from a sparkIng plug by<br />
pulling on the cable termInal Use the same care when<br />
Two types of prImary IgmtIon CUCUltS are used on<br />
these vehicles the Simple CirCUIt and a serIes resistance<br />
CIrCUIt<br />
The prImary CIrCUIt which does not Include<br />
Electrical System 23<br />
breaker pomt gap the engme wIll have to be stopped and<br />
the dlstnbutor cap and rotor button removed to carry out<br />
this operatIOn<br />
8 After settmg the contact dwell at Idle speed<br />
Increase the engIne speed to approXlmately 2500 rpm<br />
checkIng the dwell angle as the speed IS Increased Any<br />
VarIatIOn greater than speCIficatIon Indicate worn parts<br />
wlthm the dlstnbutor m which case the dlstnbutor Will<br />
have to be removed for overhaul<br />
9 After checkmg and adJustmg the dwell angle<br />
recheck the IgnitIon tImIng and adJust If necessary<br />
10 Reconnect the vacuum advance lIne and adJust<br />
the engme Idle to SpeCificatIOns<br />
11 Remove the test Instruments and reconnect any<br />
dIsconnected wiring etc<br />
6 SPAnKING PIUGS<br />
t<br />
of too high heat range have been fitted partIcularly when<br />
these depOSits are accompamed by bhsterIng of the<br />
porcelaIn and burnIng of the electrodes<br />
If the heat range IS correct clean the on a plugs sanding<br />
J<br />
machme and blow clean With compressed aIr<br />
rtIJtM<br />
Set the electrode gap see SpeCificatIons by b ndifiiW<br />
the earthIng electrode s<br />
testIng machIne<br />
7 HIt H TENSIU L AD lI<br />
and test the plugs on a reliable<br />
NOTE Never attempt to set the electrode<br />
gap by<br />
the centre electrode or a cracked msulator WIll result<br />
be<br />
dzng<br />
Clean the spark plug threads and USIng new gaskets fit<br />
the plugs fInger tIght USIng a torque wrench hghten to the<br />
recommended torque Refer SpeCificatIons<br />
connectIng the cable to the plug<br />
If a cable has a broken core It wIll cause IlUsfirIng<br />
Check the cables for penshIng or crackmg and renew as<br />
defectIve cables<br />
requued Never attempt to repair<br />
The cables may be carefully cleaned usmg a cloth<br />
A<br />
mOistened With kerosene then WipIng completely dry<br />
Also check the distrIbutor cap for cracks or trackmg<br />
between the lugh tensIOn terllUnals on both the mSlde and<br />
outSide of the cap Renew the cap If cracks or trackmg IS<br />
eVldent<br />
u IG ITIU COli<br />
a reSIStance<br />
189<br />
Check the carbon brush m the centre of the distrIbutor<br />
cap for eVidence ofarcIng and renew as necessary<br />
between the IgmtlOn SWitch and coIl uses a normal 12 volt<br />
coIl and a SImple prunary CirCUit<br />
When a serIes reSIStance I S mcorporated III the prImary<br />
CIrCUIt a special 12 volt colliS used which IS marked to be<br />
used With a senes resistance<br />
It<br />
t<br />
I<br />
llTt<br />
In<br />
f eil<br />
1
if<br />
24Electrical System<br />
The serIes resistance IS mounted near the coIl and when<br />
used cannot be overlooked or disregarded when the pnmary<br />
CircUit IS beIng checked disconnected or connected<br />
When the serIes reSIStance IS used In conJunctIon with<br />
the specIal cOli a high secondary voltage IS obtaIned<br />
throughout the speed range of the engme resultIng In<br />
better performance of the vehicle The serIes resistance IS<br />
TO REMOVE AND INSTAL<br />
Early Models<br />
I Disconnect the negatIve battery termInal<br />
2 Remove the two wmg nuts holdIng the bottom of<br />
the mstrument cluster to the dash panel from the rear of<br />
the dash panel<br />
3 Disconnect the electrIcal multI connectIon plug<br />
from the prInted CIrCUIt termInal<br />
4 Disconnect the speedo cable from the speedo head<br />
5 Workmg from the front of the mstrument cluster<br />
remove the two screws holdmg the top of the Instrument<br />
cluster to the dash panel<br />
6 TIlt the mstrument cluster away from the dash<br />
panel at the top at the same tIme push the bottom of the<br />
mstrment cluster m to clear the two mountIng studs and<br />
remove the Instrument cluster from the vehicle<br />
Installahon IS a reversal of the removal procedure<br />
Later Models<br />
I Disconnect the negatIve battery termInal<br />
2 Remove the screws holdIng the Instrument trIm<br />
D I STlnJ T<br />
by passed when the IgrutIon sWitch IS moved to the start<br />
posItIon by an Internal brIdge In the IgllltlOn sWitch which<br />
brIngs In a second prunary CIrCUIt ThiS secondary CUCUlt<br />
allows a full 12 volt pressure at the coIl terrlllnal resultIng In<br />
a stronger spark for startmg purposes as any voltage drop<br />
caused by the heavy starter draw IS automatIcally<br />
compensated for by the circUItry<br />
panel with the door open remove two screws at the end of<br />
the panel remove four screws from the bottom of the trIm<br />
panel along the lower dash raIl remove two screws from the<br />
top of the trIm panel<br />
one m each large Instrument recess<br />
and remove the trIm panel takIng care when easIng the<br />
panel over the sWitch knobs and aIr duct outlet<br />
3 To remove the speedometer remove the mountIng<br />
screws disconnect the speedo cable from the speedo head<br />
ease the Instrument forward and remove the globe holders<br />
from the mstrument case remove the speedometer from<br />
the vehicle<br />
4 To remove the combInatIon warlllng hght<br />
assembly remove the mountIng screws ease the mstrument<br />
case forward remove the globe holders from the Instrument<br />
case and remove the warrung lIght assembly from the<br />
vehicle<br />
5 To remove the temperature gauge and fuel gauge<br />
remove the mountIng screws ease the mstrument forward<br />
and remove the wifing connectIOns and Instrument lIght<br />
globe holder from the rear of the Instrument and remove<br />
the Instrument from the vehicle<br />
InstallatIOn IS a reversal of the removal procedure<br />
Instrument Panel and Steermg Wheel With Horn Rmg Removed Later Models<br />
190<br />
r
DESCRIPTION<br />
1<br />
MEDALlON SCREW<br />
SPONGE RUBBER RING<br />
Electrical System 2S<br />
RETAINING SCREWS AND INSULATORS<br />
mOOCONTACT PLATE<br />
MEDALlON SCREW<br />
Exploded View of Horn Ring Assembly<br />
Later Model Separate Medahon<br />
10 TUnN SIGAL ITCH HK DLU IIT I A D HORN Ill<br />
The turn signal sWitch IS a multI purpose Ulllt<br />
comprIsIng sWItch mechalllsm for the turn signal lamps With<br />
automahc cancellIng the headhght dipper SWitch a high<br />
beam flasher contact for overtakmg and the horn wumg<br />
contacts for the horn rIng CirCUIt<br />
HORN RING<br />
To Remove and Instal<br />
1 Disconnect the battery negative terrlllnal<br />
2 Press m on the horn rIng and turn<br />
anh clockwlse directIOn to release It from the retaIner<br />
In an<br />
3 Remove the horn rIng spnng<br />
4 Remove the three screws holdIng the retamer plate<br />
to the steerIng wheel hub and remove the retaIner plate<br />
5 To dismantle the horn rIng remove the two screws<br />
holdmg the medalhon to the horn rmg and separate the two<br />
components<br />
HORN CONTACT<br />
Turn Signal SWitch In Mounted Position With Steering<br />
Column Cover Removed<br />
191<br />
NOTE Early model horn nngs are of one piece<br />
constructIOn<br />
6 Remove the three screws and the non conduchve<br />
retalllmg blocks from the horn rmg<br />
7 Remove the contact plate and sponge rubber rIng<br />
from the horn rIng<br />
8 The assembhng and IIlstallahon procedure IS the<br />
reverse to removal and d1smantllllg operatIOns<br />
TURN SIGNAL SWITCH<br />
To Remove and Instal<br />
1 Disconnect the negahve battery termInal<br />
2 Remove the horn rIng assembly and retaIner<br />
3 Remove the steerIng wheel retammg<br />
r<br />
nut and<br />
washer and a<br />
usmg<br />
SUItable steerIng wheel remove puller the<br />
steerIng wheel<br />
4 Remove the horn contdct rubbIng plate from the<br />
underSide ofthe steerIng and remove the contact sprIng and<br />
plunger<br />
5 Remove the four screws holdlllg the two halves of<br />
HORN WIRE CONNECTOR j<br />
Turn Signal SWitch and Wlrlng CONNECTING BLOCK<br />
l
26Electrical System<br />
the steerIng colunm cover together and remove the top half<br />
of the cover<br />
6 Remove the two screws holdIng the bottom halfof<br />
the cover to the turn signal sWitch and remove the cover<br />
7 Disconnect the wIrIng at the termlllal connectIng<br />
block at the dash panel<br />
I I S ITJ S NitfO TROI S<br />
8 Remove the two screws holdIng the turn signal<br />
sWitch retaInmg clamp and remove the clamp<br />
9 Move the sWitch away from the steerIng colunm<br />
Jacket to disengage the dowel from ItS locatIng hole and<br />
remove the sWitch assembly off the steerIng colunm<br />
InstallatIon IS a reversal of the removal procedure<br />
HEAD LIGHT SWITCH AND 3 Loosen the lock nut of the sWitch and unscrew the<br />
WINDSCREEN WIPER AND WASHER SWITCH<br />
sWitch from ItS mountIng bracket<br />
To Remove and Instal<br />
1 Disconnect the negative battery terrmnal<br />
2 Remove the grub screw holdmg the sWitch knob to<br />
the sWitch operatIng rod<br />
3 Remove the sWitch escutcheon nut and remove the<br />
sWitch from the rearof the dash panel<br />
4 Disconnect the wIrIng from the sWitch and remove<br />
the sWitch from the velucle<br />
InstallatIOn IS a reversal of the removal procedure<br />
STOP LIGHT SWITCH<br />
To Remove<br />
1 DIsconnect the negatIve battery termlllal<br />
2 Remove the Wire connectIOns from the sWitch<br />
To Instal and AdJust<br />
Before Instalhng the stop hght sWitch check the brake<br />
pedal height refer to the BRAKES sectIon for the<br />
specificatIOns and adJust as follows<br />
1 Loosen the lock nut of the master cylInder push<br />
rod<br />
2 Loosen the lock nut of the sWitch and pedal stop<br />
bolt and screw the stop In to clear the sWitch mountIng<br />
bracket<br />
Under Dash EqUipment<br />
192<br />
3 Screw the master cylInder push rod In the dIrectIOn<br />
reqUired to set the pedal height to Speclficahons<br />
4 When the pedal height adjustment IS correct<br />
tIghten the master cylinder push rod lock nut<br />
5 Instal the lock nut to the threaded stem of the<br />
stop bght sWitch<br />
6 Screw the stop light sWitch Into ItS mountIng
bracket untIl ItS threaded stem IS flush with the face ofthe<br />
mountIng bracket on the pedal side then tighten the lock<br />
nut<br />
7 Screw the stop light sWitch pedal stop bolt out<br />
until It pushes the sWitch plunger completely mto the<br />
sWitch mountmg stem and tighten the lock nut<br />
8 Connect the wifing to the stop hght sWitch<br />
9 Reconnect the negatIve battery terrlllnal<br />
10 Operate the brake pedal and check that the stop<br />
hghts operate when the pedal<br />
IS depressed to give a<br />
movement of I 5 mm 0059 m of the sWitch plunger and<br />
that the stop hghts go out when the pedal IS released<br />
11 Operate the pedal several tunes and check that<br />
the sWitch p unger does not stick and that the stop lights<br />
come on each tIme the pedal IS depressed and go off when<br />
the pedal IS released<br />
IGNI ION SWITCH<br />
To Remove and Instal Standard Type<br />
I USIng a sUitable tool remove the sWitch escutcheon<br />
nut and remove the sWitch from the bracket<br />
2 Disconnect the wifing termInal from the sWitch<br />
and remove the SWltch from the vehicle<br />
InstallatIon IS a reversal of the removal procedure<br />
To Remove and Instal SteerIng Lock Type<br />
The spIndle of the steerIng lock protrudes Into the<br />
steerIng Jacket when the sWitch IS turned to the lock<br />
posItion the lock spIndle enters a hole m the steerIng shaft<br />
preventIng the steerIng wheel from beIng turned<br />
The mountmg of the sWitch IS by snap off type set<br />
bolts so that to remove the sWitch It Will be necessary to<br />
drIll out the old bolts or lever off the clamp USIng a sUItable<br />
tool<br />
used<br />
When mstalhng new snap off type set bolts should be<br />
INHIBITOR SWITCH<br />
Refer to the AUTOMATIC TRANSMISSION section<br />
for adjustment and serYIce procedure<br />
DUAL BRAKE SYSTEM WARNING LIGHT SWITCH<br />
Descnption<br />
The sWitch IS located In the engIne compartment and IS<br />
a dIfferenhal type pressure sWitch Should a faIlure occur In<br />
either the front or rear brake system the sWitch piston Will<br />
be forced to the Side With the lowest pressure earthIng the<br />
contact of the electncal connecl1on and completmg the<br />
CirCUit ofthe dash warnmg hght<br />
To Test<br />
Usmg a SUItable Jumper lead earth the terrnmal on the<br />
sWitch the dash warnmg lIght should come on Ifthe CirCUit<br />
193<br />
DUMMY KNOB<br />
NUT @l<br />
HEAT CONTROL LEVER<br />
HEAT CONTROL CABLE<br />
DUCT CONTROL<br />
HEATER PANEL<br />
OEM 1ST AND INTERIOR CONTROL CABLE<br />
Heater Control Umt Removed Later Models<br />
Electrical SYlJtem 27<br />
IS serViceable If the warnIng hght faIls to operate<br />
J<br />
FAN SWITCH<br />
check the<br />
globe and hve CIrCUIt usmg a test light<br />
After testIng the electncal CIrCUIt check the sWitch In<br />
the follOWIng manner Connect a bleeder tube and sUitable<br />
contamer to a front brake bleeder mpple have a second<br />
operator apply pressure to the brake pedal and release the<br />
bleeder IlIpple the warnmg hght should come on repeat<br />
the operatIOn to the rear brake system<br />
NOTE After each test lock off the bleeder mpple and<br />
check the broke flUId level m the reservOIr Top up as<br />
necessary<br />
HEATER CONTROL<br />
To Remove and Instal<br />
I Remove the heater fan control knob<br />
2 Remove the knob from the other end of the heater<br />
panel If thIS knob IS a dummy one remove the nut from the<br />
end of ItS thread from belund the dash panel<br />
3 Remove the heater blower SWitch retaInmg nut and<br />
washer and remove the sWitch from the rear ofthe panel<br />
1
I e<br />
U<br />
T<br />
ll<br />
2d Electrical System<br />
ROOM AND DEMIST LEVER<br />
Heater Control Unit Removed Early Models<br />
4 Remove the heater panel from the dash<br />
5 Remove the radio cover panel screws and cover<br />
6 Remove the radIoIffitted<br />
7 Remove the heater control mountIng screws from<br />
the rear of the dash panel and lower the control umt<br />
assembly<br />
8 Disconnect the cables to the heater controls and<br />
remove the control umt assembly from the vehicle<br />
InstallatIOn IS a reversal of the removal procedure<br />
NOTE For the removal and installatIOn procedure of the<br />
heater umt reference should be made to the COOLING<br />
SYSTEM<br />
TO REMOVE AND INSTAL<br />
I Disconnect the negative battery terrmnal<br />
2 Remove the retalmng nuts of both wiper arms and<br />
remove the wiper arms and blades<br />
3 Remove the plenum cover retaInmg screws and<br />
remove the cover<br />
crank<br />
motor<br />
screws<br />
4 Disconnect the linkage from the wiper motor<br />
5 Disconnect the wifing connector at the wiper<br />
6 Remove the wiper motor to body mountmg<br />
Control Unit ShOWing SWitch and Linkages<br />
CHOKE CONTROL<br />
I Remove the grub screw holdIng the knob to the<br />
Inner cable and remove the knob<br />
valve lever<br />
2 Remove the outer casIng retaInIng nut<br />
3 Disconnect the choke Inner cable from the choke<br />
4 Remove the outer cable from the bracket<br />
5 Remove the choke cable complete towards the<br />
mterIor of the veluc1e<br />
InstallatIOn IS a reversal of the removal procedure<br />
NOTE After mstallmg adJust the choke cable accordmg to<br />
mstructlOns m the FUEL SYSTEM<br />
12 INDSCREEN WIPER<br />
194<br />
7 Remove the Wiper motor from the vehlcLe<br />
8 Remove the piVOt box retaInIng screws and remove<br />
the linkage and piVOt boxes<br />
InstallatIOn IS a reversal of the removal procedure<br />
TO ADJUST THE PARK POSITION<br />
I Loosen both the lock plate screws for the<br />
automatic stop cover<br />
2 Operate the Wiper blades on a wet screen and<br />
sWitch them off If the blades stop before they fmlsh theu<br />
stroke turn the cover m an anh clockwlse dIrechon a small
amount and recheck repeat the operatIon several tImes<br />
makIng the adJustment as necessary<br />
3 If the wiper blades complete theIr full stroke and<br />
stop on the return stroke turn the cover<br />
dIrectIOn and recheck as m operatIOn 2<br />
HEADLAMPS<br />
DescnptIon<br />
In a clockwise<br />
13<br />
The head hght system IS of the four light sealed beam<br />
type The mner sealed beam umts are a sIngle filament umt<br />
winch operates on Igh beam only the outer sealed beam<br />
umts are a doubl filament umt and operate on both high<br />
and low beam When the head lights are on lugh beam all<br />
four lIghts Will operate but on low beam only the two outer<br />
hghts operate<br />
To Remove and Instal<br />
I Disconnect the negahve battery termInal<br />
2 Remove the headlamp rIm<br />
3 Remove the headlamp retammg bezel screws<br />
4 Remove the lamp umt and disconnect the wIrIng<br />
plug InstallatIon IS a reversal of the removal procedure<br />
To AdJust Headlamps<br />
I Make sure the tyres are Inflated to theIr correct<br />
pressures<br />
2 If a head hght 3IffiIng machIne IS used follow the<br />
manufacturer s InstructIons for operatIng procedures<br />
1<br />
LA1UP UNITS<br />
adJustmg<br />
adJustmg<br />
3 To raIse or lower the headlamp beam the top<br />
screw IS used<br />
4 To move the beam to the left or rIght the Side<br />
screws are used<br />
Electrical System 29<br />
make sure the<br />
4 After the adJustment IS completed<br />
lock plate screws arefmnly mpped Do not overtIghten<br />
NOTE WIper tests and adJustments must be made on a wet<br />
wmdscreen<br />
5 When USIng a headlamp 3Iffimg board cover the<br />
lIghts not beIng adJusted With a sUitable cloth so that only<br />
one beam IS proJected onto the board<br />
NOTE Reference should be made to the local regulations<br />
governing headlamp focus and the lamps should befocused<br />
accordmgly<br />
FRONT TURN SIGNAL AND PARK LAMP<br />
To Remove and Instal<br />
the lens<br />
Headlamps With Rim Removed<br />
195<br />
1 Remove the two lens retalllIng screws and remove<br />
2 Remove the bulb or bulbs as necessary accordlllg<br />
to the lamp type<br />
3 Replace the bulb With one ofthe same wattage and<br />
voltage when renewlllg bulbs<br />
4 To remove the lamp umt remove the retammg nuts<br />
workIng from lIlslde the englll bay<br />
InstallatIOn IS a reversal ofthe removal procedure
I<br />
30Electrical System<br />
REAR COMBINATION LAMP<br />
On sedan model vehicles It IS not necessary to remove<br />
the lens or lamp Ulllt to replace a faulty<br />
Exploded View of Front Parking and Turn Signal Lamp<br />
bulb as access to<br />
the bulb holder IS from mSlde the luggage compartment<br />
turn the bulb holder and remove the holder and bulb from<br />
the lamp body<br />
On statIOn wagon models remove the lens retaInIng<br />
screws and remove the lens to gam access to the bulbs<br />
To remove the lamp UllltS remove the retallllng nuts<br />
from mSlde the luggage compartment or cargo<br />
compartment on sedans remove the bulb holders and<br />
bulbs on statIOn wagons remove the wUlng connectJons<br />
from the rear of the lamp and remove the lamp<br />
the vehicle<br />
installatIOn IS a reversal ofthe removal procedure<br />
LICENCE PLATE LAMP<br />
To Remove and Instal<br />
umt from<br />
1 Remove the two screws holdIng the lens and shield<br />
to thelamp urut and remove the shield and lens<br />
2 Remove the bulb from the bulb holder<br />
3 Remove the lamp body retaInmg screws and<br />
remove the lamp<br />
4 Disconnect the wIrIng at the JunctJon and remove<br />
the urut from the velucle<br />
InstallatIOn IS a reversal ofthe removal procedure<br />
NOTE Always replace a damaged orburnt out bulb with a<br />
bulb of the same voltage and wattage as that which has<br />
been removed<br />
196<br />
c<br />
o<br />
e<br />
BEZEL<br />
LENS<br />
o o<br />
fJ i 0<br />
Q<br />
c<br />
RETAININGNUTS AND WASHERS<br />
LENS SCREWS<br />
L<br />
c o<br />
0<br />
Exploded View of Rear CombinatIon Lamp<br />
ob
BATTERY AND ALTERNATOR SYSTEM<br />
a<br />
14 ELECTRICAL FAITLT DIAGNOSIS<br />
Battery undercharged<br />
PossIble cause Remedy<br />
Loose or broken alternator drIve belt<br />
b Defecl1ve or Incorrectly adJusted alternator<br />
regulator umt<br />
c Faulty battery<br />
d Faulty alternator<br />
e Defect In charglllg C1rCwt wIrIng<br />
I Faulty connecllons In charglllg umt<br />
2 Battery overcharged<br />
POSSIble cause<br />
a DefectIve or IIlcorrectly adJusted alternator<br />
regulator umt<br />
b Faulty battery<br />
c Faulty alternator<br />
d Faulty chargIng CirCUit wIrIng or connectIOns<br />
AdJust or renewdrIve belt<br />
Renew or adJust regulator umt<br />
Renew or repau battery<br />
Overhaul or replace umt<br />
Electrical System 31<br />
Check and rep3lr or replace WUIng harness<br />
Check and renew or repau faulty components<br />
Renew or adJust regulator<br />
Renew or rep3lr<br />
Remedy<br />
Overhaul or renew umt<br />
Check and repair or renew defecl1ve components<br />
3 Indicator hght remaInS on<br />
POSSible cause Remedy<br />
a<br />
Loose or broken drIve belt<br />
b Incorrectly adJusted regulator umt<br />
c Faulty alternator regulator<br />
d Low regulator voltage settIng<br />
e Short to earth III warnIng hght CircUIt<br />
Adjust or renew drIve belt<br />
Check and adJust regulator umt<br />
Check and overhaul faulty umt<br />
Check and adJust voltage settIng at regulator<br />
Locate and repair<br />
4 Indicator light does not operate<br />
POSSIble wuse Remedy<br />
a Light globe blown<br />
b Open CirCUit In wUlng or globe socket<br />
c Fuse blown<br />
5 NOise In drive belt oralternator<br />
Check and renew faulty globe<br />
Check and rectIfy open CirCUit<br />
Locate cause and replace fuse<br />
POSSible wuse Remedy<br />
a DrIve belt frayed or out of alignment With pulleys<br />
b Loose alternator mountlllg bolts or worn beanngs<br />
c Loose alternator pulley<br />
d Faulty alternator<br />
e Faulty dIOde or heat slllk<br />
BATTERY AND STARTING SYSTEM<br />
Renew drIve belt and or align pulleys<br />
Tighten mountmg bolts and or renew bearIngs<br />
Tighten pulley retamIng nut<br />
Overhaul faulty umt<br />
Overhaul alternator test diodes<br />
1 Starter lacks power to crank engine<br />
POSSIble cause Remedy<br />
a Battery undercharged<br />
b Battery faulty wIll not hold charge<br />
c Battery terflUnals loose or corroded<br />
d Faulty starter motor<br />
e Faulty starter solenOId SWitch or contacts<br />
197<br />
Check chargIng system and recllfy as necessary<br />
Check and rep3lr or renew battery<br />
Clean and lighten terrnmals<br />
Check and overhaul starter motor<br />
Check and renewsolenOid as necessary<br />
t
1<br />
32 Electrical System<br />
2 Starter wIll not attempt to crank engIne<br />
PossIble cause<br />
a Open CircUit m startmg system<br />
b DIscharged battery<br />
c Battery fully charged but wIll not crank engme<br />
IGNITION SYSTEM<br />
1 Engme wIll not start<br />
PossIble cause<br />
a Fault m Ignition prImary CIrCUIt willng<br />
b Fault In Ignition sWItch<br />
c Fault m coIl prImary wmdmg<br />
d Burnt or duty contact breaker pomts<br />
e Faulty capacitor or capacitor lead<br />
I Fused or broken WIre between breaker arm and<br />
low tensIOn termInal<br />
g Fault m coIllugh tensIOn CIrCUIt<br />
h Cracksm dIStrIbutor cap<br />
I Crack In dlStnbutor rotor<br />
j Faulty lugh tensIOn leads<br />
k Faulty or Incorrectly adJusted spark plugs<br />
2 Engme starts but misfues under load<br />
Possible cause<br />
a Faulty duty or mcorrectly adJusted spark<br />
plug s<br />
b DIrty or Incorrectly adJusted contact breaker<br />
c Uneven wear on distrIbutor cam<br />
d Condensahon mOISture on Inside or outside of<br />
distrIbutor cap<br />
e Cracked spark plug<br />
I Faulty Ignition coIl<br />
3 Engme runs but lacks power<br />
Insulator s<br />
PossIblecause<br />
a IgiutlOn tunmg Incorrectly set or contact pomts<br />
requIre adJustIng<br />
b Vacuum advance mechamsm stickIng or excessively<br />
worn<br />
c Vacuum advance umt moperatlve<br />
d Vacuum advance umt operates but Ineffective<br />
198<br />
Remedy<br />
Check for dirty or loose termmals dIrty com<br />
mutator faulty solenOId faulty sWitch faulty<br />
Ignlhon sWItch<br />
Check for fault or short CUCUlt m system<br />
Check for locked drIve and rIng gears mtemal<br />
starter fault or seized engIne<br />
Remedy<br />
Check CIrCUIt and repair as necessary<br />
Renew IgnitIon sWitch<br />
Renew coIl<br />
Clean and or renew and adJust pOInts<br />
Check and renew capacItor<br />
Renew low tensIOn block and wues<br />
Test and renew coIl as necessary<br />
Renew distrIbutor cap<br />
Renew rotor<br />
Check and renew leads<br />
Renew and or clean and adJust spark plugs<br />
Remedy<br />
Renew and or clean and adJust spark plugs<br />
Clean and adJust pomts<br />
Check and overhaul distrIbutor<br />
Check and dry out and examme for mInute cracks<br />
Renew faulty plug s<br />
Check and renewcoIl<br />
Remedy<br />
Check and readJust Ignition tunmg and orcontact<br />
pomts<br />
Overhaul dlstnbutor<br />
Check for faulty vacuum pipe or faulty<br />
Advance umt link disconnected or requues<br />
adJustment<br />
advance umt
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ZZ<br />
lkf<br />
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Ui<br />
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RV<br />
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Wiring Diagram for <strong>1600</strong> Model Australian Production<br />
m<br />
I<br />
DV<br />
JIFiJ I rtI<br />
r I<br />
rvl v<br />
L<br />
GBt 7<br />
t7<br />
t7<br />
V<br />
t7<br />
V<br />
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IV<br />
B<br />
0<br />
i<br />
AlL<br />
IL c<br />
1<br />
2<br />
Alternator<br />
Regulator<br />
32<br />
33<br />
Od pressure sWitch<br />
Harness<br />
56 RH rear turn signal<br />
WB WhIte black tracer<br />
connector<br />
lamp RY Red yellow tracer<br />
3<br />
4 5<br />
6<br />
Connector<br />
Horns<br />
Horn relay<br />
34<br />
35<br />
Stop lamp sWItch<br />
LH turn signal IOdle<br />
ator lamp<br />
57<br />
58<br />
59<br />
RH tall and stop lamp<br />
RH reversIng I p<br />
CIgar hghter<br />
GB<br />
BW<br />
GY<br />
Green black tracer<br />
Black white tracer<br />
Green yellow tracer<br />
7 Battery 36 RH turn signal die 60 61 Licence plate lamps<br />
WR White red tracer<br />
8 ResIstor ator lamp 62 LH rBVeFSlng lamp<br />
YG Yellow green tracer<br />
9 Ignition call 37 LH turn 10 Distributor<br />
signal<br />
parking lamps<br />
and 63<br />
64<br />
LH stop and tad lamp<br />
LH rear turn signal<br />
RW<br />
GR<br />
Red white tracer<br />
Green red tracer<br />
11<br />
12<br />
Fuse panel<br />
Windscreen washer<br />
38 LH front Side turn<br />
signal lamp<br />
lamp<br />
6566 Courtesy lamp door<br />
YW<br />
BG<br />
Yellow white tracer<br />
Blackgreen tracer<br />
13 Windscreen wiper 39 Harness connector sWitches<br />
YB Yellow black tracer<br />
14 Harness connectors 40 Harness connector 67 Fuel gauge sender Unot<br />
GBL Green blue tracer<br />
15 16 Harness connectors 41 Harness connector 68 Harness connector<br />
BLY Blue yellow tracer<br />
17 Harness connectors 42 Instrument panel con 69 Harness connector BLW Blue white tracer<br />
18 Windscreen WIper nector BBL Blackblue tracer<br />
switch 43 Llghtmg sWItch BLB Blue black tracer<br />
19 Ignition sW1tch 44 Harness connector RBL Red blue tracer<br />
20 Starter solenoid 45 Turn Signal and com BLR Blue red tracer<br />
21 Harness connector blnatlon sWitch COLOR CODE BLG Blue green tracer<br />
22 Reversing lamp sWitch 46 Turn SIgnal relay Unit BYR Blackyellow tracer red<br />
23 Starter motor 47 Intenor lamp and G Green sleeve<br />
24 RH front Side turn sWItch W WhIte RBW Red black tracer whIte<br />
SIgnal lamp 48 Harness connector Y Yellow sleeve<br />
25 RH turn signal and 49 Harness connector R Red WBL White blue tracer<br />
parkmg lamp 50 Heater B Black BLGR Blue green tracer red<br />
26 Headlamp relay 51 52 Harness connector BR Brown sleeve<br />
27 28 RH headlamps 53 Hand brake warmng BL Blue BLGB BlueJgreen tracer black<br />
29 30 LH headlamps lamp SWItch BY Blackyellow tracer sleeve<br />
31 Engine temperature 54 Heater SWitch GW Green white tracer BLGW Bluegreen tracer whIte<br />
sender Unit 55 Harness connector RB Red black tracer sleeve<br />
199
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11<br />
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6<br />
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56<br />
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IA BLRB aJr<br />
SLR<br />
l G21<br />
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IIIII1<br />
WIfing Diagram for <strong>Manual</strong> Pickup with EmissIon Control<br />
J<br />
I<br />
It<br />
IT<br />
JV 1<br />
r<br />
II t1<br />
1 Alternator 28 Engme compartment 52 Instrument con panel GB Green black tracer<br />
2 Rsgulator lamp switch nector BW Blackwh lte tracer<br />
3 Horn relay 29 Stop lamp sWitch 53 Turn Signal and com GY Groen yellow tracer<br />
4 5 Horn 30 Battery banltlon switch WR White red tracer<br />
6 Distributor 31 Starter motor and 54 Hazard signal sWitch YG Yellow green tracer<br />
7 Relay R1 solenoid 55 Hazard signal relay umt RW Red white tracer<br />
T<br />
OR<br />
lItt 1<br />
OR<br />
IiLL I<br />
I<br />
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1L<br />
L<br />
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V J<br />
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Y J<br />
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W<br />
r<br />
J<br />
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W<br />
8 Accelerator switch 32 RH front Side clearance 56 Clock GR Green red tracer<br />
9 Igmtlon cod 10 ROSlStOrs 33<br />
lamp<br />
RH turn signal and<br />
57 58 LH head lamps<br />
59 LH turn signal and<br />
YW<br />
BG<br />
Yellow white tracer<br />
Black green tracer<br />
11 Fuse panel parking lamps parking lamps<br />
YB Yellow black tracer<br />
12 Clutch sWitch 34 35 RH headlamps 60 LH front SIde clearance GBL Green blue tracer<br />
13 Neutral gear sWitch 36 Headlamp relav lamps BLY Blue yellow tracer<br />
14 3rd gear SWItch 37 Engme temperature 61 62 Fog lamps<br />
BLW Blue whitetracer<br />
15 Relay R2 sender unit 63 LH rear Side clearance BBL Black blue tracer<br />
16 Solenoid 38 011 pressure switch lamps BLB Blue black tracer<br />
17 Accessory sWitch 39 Intenor lamp RBL Red blue tracer<br />
18 WIndscreen wiper 40 CIgar lighter COLOR CODE BLR Blue red tracer<br />
motor 41 I ntenor lamp door G Green BLG Blue green tracer<br />
r<br />
19 Windscreen wiper sWitch W White BYR Blackyellow tracer red<br />
SWitch 42 Turn Signa relay umt Y Yellow sleeve<br />
20 Windscreen washer 43 LIghting SWItch R Red RBW Red black tracer whIte<br />
21 Heater motor 44 Reversing lamp sWItch B Black sleeve<br />
22 Heater sWitch 45 Licence plate lamp BR Brown WBL WhIte blue tracer<br />
It<br />
23 RH Side clearance lamp 46 LH turnsignal lamp BL Blue BLG R Blue green tracer red<br />
24 RH reverSIng lamp 47 LH taol and stop lamps BY Blackyellow tracer sleeve<br />
25 RH taol and stop lamps 48 LH reversing lamp GW Green white tracer BLGB Blue green tracer black<br />
26 RH turn SIgnal lamp 49 Fuel gauge sender unit RB Redblack tracer sleeve<br />
27 EngIne compartment 50 RadIO WB White black tracer BLGW Blue green tracer whIte<br />
lamp 51 Igmtlon SWItch RY Red yellow tracer sleeve<br />
200
1<br />
2<br />
3<br />
4<br />
5 6<br />
7<br />
B<br />
9<br />
10<br />
11<br />
12<br />
13<br />
14<br />
15<br />
16<br />
17<br />
18<br />
19<br />
20<br />
21<br />
22<br />
23<br />
24<br />
25<br />
26<br />
2747<br />
coo<br />
4tfJoW<br />
EJ h<br />
Ua uiJ I<br />
n<br />
I<br />
I<br />
1ll9 1tl L<br />
@ m t@I<br />
I<br />
g<br />
I<br />
lld lj<br />
G23<br />
0<br />
C<br />
IIIHI<br />
V V N<br />
Alternator<br />
w<br />
11111<br />
H<br />
i<br />
ro t<br />
tfl<br />
tJ<br />
l<br />
g J I<br />
0<br />
II<br />
I<br />
01 I<br />
l<br />
tt<br />
g<br />
I<br />
11<br />
UL J I<br />
I<br />
E 3<br />
Jf I c<br />
L<br />
r E<br />
t<br />
e<br />
N<br />
F<br />
I<br />
roI I<br />
1 I<br />
P<br />
ili<br />
l<br />
d<br />
8 1<br />
B H<br />
J itJ lJ EEi I<br />
I I L 6<br />
53 Cigar hghter<br />
54 Clock<br />
55 Lighting switch<br />
56 Fuel gauge sender umt<br />
57 LH rear clearance lamp<br />
58 LH reversing lamp<br />
59 LH taol and stop lamps<br />
60 LH rear turn signal<br />
lamp<br />
61 Interior lamp and<br />
switch<br />
62 63 Courtesy lamp door<br />
switches<br />
64 Turn signal Indicator<br />
lamps<br />
G Green<br />
W White<br />
Y Yellow<br />
R Red<br />
B Black<br />
BR Brown<br />
BL Blue<br />
COLOR CODE<br />
BY Black yellow tracer<br />
GW Green white tracer<br />
RB Red blacktracer<br />
WB White blacktracer<br />
I<br />
y<br />
L r<br />
D rb<br />
LIll b<br />
3 J<br />
g<br />
r I<br />
II H<br />
l I HHI<br />
3 1<br />
Wiring Diagram for Sedan and StatIOn Wagon with <strong>Manual</strong> Transmission and EmiSSIOn Control<br />
Regulator<br />
Horn relay<br />
ReverSing lamp sWitch<br />
Horns<br />
Relay R 1<br />
Distributor<br />
Igmtlon coli<br />
Resistor<br />
Third gear switch<br />
ThrottlesWItch<br />
Neutral sWitch<br />
Heater SWitch<br />
Heater<br />
Carburettor solenOid<br />
Windscreen washer<br />
Windscreen wiper<br />
Harness connector<br />
Fuse panel<br />
Engine compartment<br />
lamp and SWitch<br />
Dual brake system<br />
warning lamp SWitch<br />
Battery<br />
Starter motor<br />
R H front clearance<br />
lamps<br />
RH turn Signal and<br />
parkong lamp<br />
RH headlamps<br />
28<br />
29<br />
30<br />
31<br />
32<br />
33<br />
34<br />
35<br />
36<br />
37<br />
38<br />
39<br />
40<br />
41<br />
42<br />
43<br />
44<br />
45<br />
46<br />
48 49<br />
50<br />
51<br />
52<br />
Headlamp relay<br />
Engme temperature<br />
sender umt<br />
ad pressure sWitch<br />
Harness connector<br />
Windscreen wiper<br />
sWitch<br />
RH turnsignal lamp<br />
RH tall and stop lamps<br />
R H reversmg lamps<br />
R H rear clearance lamp<br />
Licence plate lamp<br />
Igmtlon sWitch<br />
I nstrument panel con<br />
nector<br />
Turn signal relay unit<br />
Hand brake warning<br />
lamp switch<br />
Clutch switch<br />
RadiO<br />
Stop lamp sWitch<br />
Hazard signal relay umt<br />
Turn Signal and com<br />
bination switch<br />
LH headlamps<br />
LH turn Signal and<br />
parking lamps<br />
lH front clearance<br />
lamp<br />
Hazard signal sWItch<br />
RY Red yellOW tracer<br />
GB Green black tracer<br />
BW Black white tracer<br />
GY Green yellow tracer<br />
WR White red tracer<br />
YG Yellow green tracer<br />
RW Red white tracer<br />
GR Green red tracer<br />
YW Yellow whitetracer<br />
BG Black green tracer<br />
YB Yellow black tracer<br />
GBL Green blue tracer<br />
BLY Blue yellow tracer<br />
BLW Blue white tracer<br />
BBL Black blue tracer<br />
BLB Blue black tracer<br />
R BL Red blue tracer<br />
BLR Blue red tracer<br />
BLG Blue green tracer<br />
BY R Black yellow tracer red<br />
sleeve<br />
RBW Red black tracer white<br />
sleeve<br />
WBL WhIte blue tracer<br />
BLG R Blue green tracer red<br />
sleeve<br />
BLGB Blue green tracer black<br />
sleeve<br />
BLGW Blue green tracer white<br />
sleeve<br />
E
rlffi<br />
m<br />
Ir iEt<br />
f<br />
G @J G G G @r<br />
I<br />
olIrl<br />
III L<br />
II<br />
iL J<br />
hLAJ<br />
I<br />
Q kD<br />
fl I L<br />
I 1 I<br />
ttS D JLm<br />
I<br />
I Il o L<br />
rTi<br />
1<br />
g<br />
lit<br />
jJ<br />
JIi<br />
L3<br />
tliiCJ OR rf<br />
Lj I IJII h<br />
flo1 rt J<br />
J<br />
B I<br />
I<br />
UHlll<br />
jij1j l II<br />
f<br />
IIIQ<br />
II<br />
I<br />
w<br />
g i<br />
S i<br />
H<br />
r<br />
J<br />
Lo t III fil<br />
IiIlL<br />
gj<br />
IE 3<br />
I III Gr Fj c e<br />
Y i H l G c P<br />
Wifing Diagram for Sedan and Station Wagon with Auto Transmission and EmissIon Control<br />
1 Alternator 28 RH turn Signal and 53 Hazard signal relav umt<br />
2 Regulator park ng lamps 54 Turn s gnal relay unrt<br />
3 Starter Motor 29 46 RH headlamps 55 Turn s gnal and com<br />
4 Battery 30 Headlamp relay blnatoon SWItch<br />
5<br />
6<br />
Reversing lamp sWitch<br />
Reversmg lamp relay<br />
31<br />
32<br />
Harness connector<br />
Engine temperature<br />
56 Hazard signal sWitch<br />
57 58 Automatic transmiSSion<br />
7 InhibitorsWitch sender unit Indicator lamps<br />
8 Starter relay 33 011 pressure SWItch 59 CIgar hghter<br />
9 Engine compartment 34 Harness connector 60 Clock<br />
lamp and SWitch 35 RH rear turn s gnal<br />
61 Llghtong SWItch<br />
10 11 Horns lamps<br />
62 Fuel gauge sender unIt<br />
12 Relay 36 RH tall and stop lamps<br />
63 LH reversing lamp<br />
13 Dlstnbutor 37 RH reverSIng lamp 64 LH tall and stop lamps<br />
14 IgOltlon coil J8 RH rear dearance lamp 65 lH rear clearance lamp<br />
15 ResIstor 39 Licence plate lamp 66 Intenor lamp apd<br />
16 Fuse panel 40 LH rear dearance lamp swotch<br />
17 Throttle SWItch 41 Ignotlon SWitch 67 68 Courtesy lamp door<br />
18 Carburettor solenoid 42 Instrument panel con sWitches<br />
19 Horn relay nector<br />
20 Heater SWItch 43 Hand brake warnong<br />
21 Heater lamp swotch<br />
22 W ndscreen wiper 44 Radoo<br />
23<br />
24<br />
25<br />
26<br />
27<br />
SWItch 45 Stop lamp sWitch<br />
Wondscreen washer 4748 LH headlamps<br />
Wmdscreen wiper 49 LH turn Signal and<br />
Connector parking lamps<br />
Dual brake system 50 LH front dearance<br />
warOlng lamp<br />
5W1tch<br />
RH front clearance 51<br />
lamps<br />
Speed detector<br />
lamp 52 Speed relav<br />
G Green<br />
W WhIte<br />
V Vellow<br />
R Red<br />
B Black<br />
BR Brown<br />
BL Blue<br />
COLOR CODE<br />
EV B ac lyellow racer<br />
GW Green whltetracer<br />
R B Red black tracer<br />
I<br />
I<br />
1 1<br />
r<br />
III<br />
1fti<br />
0 H<br />
IR<br />
r rt ll<br />
1<br />
@<br />
A I<br />
WB Whote black trecer<br />
RV Red yellow tracer<br />
GB Green black tracer<br />
BW Black whIte tracer<br />
GY Green yellow tracer<br />
WR Whote red tracer<br />
YG Yellow green tracer<br />
RW Red whlte tracer<br />
GR Green red tracer<br />
YW Yellow white tracer<br />
BG Black green tracer<br />
VB Vellow black tracer<br />
GBL Green blue tracer<br />
BLV Blue yellow tracer<br />
BLW Blue whlte tracer<br />
BBL Black blue tracer<br />
BLB Blue black tracer<br />
RBL Red blue tracer<br />
BLR Blue red tracer<br />
BLG Blue green tracer<br />
i<br />
BVR Black yellow tracer red<br />
51eeve<br />
RBW Red black tracer whlte<br />
sleeve<br />
WBL Whote blue tracer<br />
BLGR Blue green tracer red<br />
sleeve<br />
BLGB Blue green tracer black<br />
sleeve<br />
BLG B grri ac1 hlte<br />
sleeve<br />
I<br />
8<br />
J
I<br />
I<br />
A<br />
L<br />
l<br />
a<br />
nGt<br />
C L<br />
1<br />
W<br />
OR<br />
1<br />
J f<br />
Y<br />
0fTh LJ<br />
0<br />
I L1 J<br />
y 53<br />
rn<br />
L1 J<br />
m<br />
GR<br />
OR<br />
JL I u<br />
1<br />
2<br />
3<br />
4<br />
5 6<br />
7<br />
8<br />
9<br />
10<br />
11<br />
12<br />
13<br />
14<br />
15<br />
16<br />
17<br />
18<br />
19<br />
20<br />
21<br />
22<br />
23<br />
24<br />
25<br />
26<br />
IlC 1<br />
l<br />
123<br />
111<br />
l<br />
h<br />
r AJr<br />
cUJ 1 1<br />
I<br />
Alternator<br />
Regulator<br />
Igmtlon cOil<br />
Dlstnbutor<br />
Horns<br />
r R<br />
Reversing lamp relay<br />
InhibitorsWitch<br />
Starter relay<br />
Engine compartment<br />
lamp and switch<br />
Relay IR1<br />
Fuse panel<br />
RadiO<br />
Carburettor SWitch<br />
Wmdscreen washer<br />
Horn relay<br />
Heater<br />
Heater sWItch<br />
Windscreen wiper<br />
sWitch<br />
Wmdscreen wiper<br />
Engine temperature<br />
sender unit<br />
Battery<br />
Solenood<br />
Starter motor and<br />
solenoid<br />
RH front SIde turn<br />
sIgnal lamp<br />
RH turn signal and<br />
parkmg lamps<br />
0<br />
33 YG<br />
r<br />
m<br />
t<br />
i<br />
00<br />
Jl<br />
RIlL<br />
l<br />
ow<br />
II<br />
mfJ<br />
I<br />
GR<br />
ilo<br />
I cT<br />
m<br />
l<br />
GR<br />
l<br />
I<br />
I<br />
LII<br />
I<br />
llL<br />
c J<br />
L CJ<br />
1L<br />
I51<br />
1lC I<br />
21<br />
ow<br />
Ji mlJ<br />
w<br />
53 mjlfl<br />
Wlnn Diagram for 1400 Model Sedan with AutomatIc Tranmlsslon North Amenca<br />
27<br />
28 29<br />
30<br />
31<br />
32<br />
33<br />
34<br />
35<br />
36<br />
37<br />
38<br />
39<br />
40<br />
41<br />
42<br />
43<br />
44<br />
45<br />
46<br />
47<br />
Headlamp relay<br />
RH headlamps<br />
011 pressure sWitch<br />
Dual brake warmng<br />
lamp sWItch<br />
Kick downsolenoid<br />
Hand brake warning<br />
lamp swItch<br />
Kick downsWitch<br />
Harness connectors<br />
RH turnstgnallamp<br />
RH tall and stop lamps<br />
RH reversmg lamp<br />
RH Side clearance lamp<br />
Licence plate lamp<br />
LH Side clearance lamp<br />
Resistor<br />
LH reversing lamp<br />
lH taol and stop lamps<br />
lH turnsIgnal lamp<br />
Ignition sWitch<br />
Instrument panel con<br />
nector<br />
48 Turn signal relay umt<br />
49 Turn 51gnal sWitch<br />
50 Hazard signal relay umt<br />
51 Clock<br />
52 53 lH Headlamps<br />
54 lH turn sIgnal and<br />
55<br />
parkIng lamps<br />
LH front Side turn<br />
signal lamp<br />
RBl<br />
56<br />
57<br />
58<br />
59<br />
60 61<br />
62<br />
63<br />
64<br />
f<br />
I 2<br />
7 CJ<br />
Speed mdlcator relay<br />
sWitch<br />
Speed detector<br />
Hazard signal sWitch<br />
Tachometer<br />
Auto transmiSSion m<br />
d cator lamps<br />
Stop lamp sWitch<br />
CIgar lighter<br />
Turn signal mdlcator<br />
lamps<br />
65 lIghting sWItch<br />
66 Fuel gauge sender unot<br />
67 Steering lock sWItch<br />
68 Warning buzzer<br />
69 70 Courtesy lamp SWItches<br />
71 Intenor lamp and<br />
SWitch<br />
G Green<br />
W WhIte<br />
Y Yellow<br />
R Red<br />
8 Black<br />
BR Brown<br />
Bl Blue<br />
COLOR CODE<br />
BY Blackyellow tracer<br />
GW Green whIte tracer<br />
I<br />
I<br />
rll<br />
b<br />
W<br />
IL<br />
1<br />
3<br />
7<br />
i7 fn<br />
lV<br />
r<br />
W<br />
fn<br />
gI<br />
llfo 61<br />
h L7 r<br />
OR<br />
1L Z11<br />
JL<br />
RB Red black tracer<br />
WB WhIte black tracer<br />
RY Red yellow tracer<br />
GB Green black tracer<br />
BW Black wh Ite tracer<br />
I 1<br />
4 1 1 II<br />
GY Green yellow tracer<br />
WR Wh Itelred tracer<br />
YG Yellow green tracer<br />
RW Red whote tracer<br />
GR Green red tracer<br />
YW Yellow whote tracer<br />
BG Blackgreen tracer<br />
YB Yellow black tracer<br />
GBl Green blue tracer<br />
BlY Blue yellow tracer<br />
BlW Blue whIte tracer<br />
BBl Black blue tracer<br />
BlB Blue black tracer<br />
RBl Red blue tracer<br />
BlR Blue red tracer<br />
BLG Blue green tracer<br />
BYR Black yellow tracer red<br />
sleeve<br />
RBW Red black tracer whIte<br />
sleeve<br />
WBl WhIte blue tracer<br />
BlGR Blue green tracer red<br />
sleeve<br />
BlGB Blue green tracer black<br />
sleeve<br />
BlGW Blue green tracer whIte<br />
sleevs
1<br />
2<br />
3<br />
4<br />
5<br />
6<br />
7<br />
8<br />
Alternator<br />
Regulator<br />
Starter motor and<br />
solenoid<br />
Battery<br />
Reversing lamp relay<br />
Inhibitor switch<br />
Igmtlon cOil<br />
Dlstnbutor<br />
9 10 Horns<br />
11<br />
12<br />
13<br />
14<br />
15<br />
16<br />
17<br />
18<br />
19<br />
20<br />
21<br />
22<br />
23<br />
24<br />
25<br />
26<br />
27<br />
28<br />
Relay RlI<br />
Engine compartment<br />
lamp and switch<br />
Starter relay<br />
Engme temperature<br />
sender umt<br />
Fuse panel<br />
Radio<br />
Windscreen washer<br />
Carburettor sWitch<br />
SolenoId<br />
Horn relay<br />
Heater<br />
Heater switch<br />
WI ndscreen wiper<br />
switch<br />
Windscreen WIper<br />
RH tad and turn SIgnal<br />
lamps<br />
RH rear side clearance<br />
lamp<br />
R H reversing and stop<br />
lamp<br />
Licence plate lamp<br />
29<br />
30<br />
31<br />
32<br />
33<br />
34<br />
3536<br />
37<br />
38<br />
39<br />
40<br />
41 42<br />
43<br />
44<br />
45<br />
46<br />
47<br />
48<br />
49<br />
50<br />
51<br />
52<br />
53<br />
Harness connectors<br />
Klckdown solenoid<br />
Dual brake warmng<br />
lamp swItch<br />
Headlamp relay<br />
RH front side turn<br />
s gnallamp<br />
R H tu rn sIgnal and<br />
parking lamps<br />
RH headlamps<br />
Od pressure sWitch<br />
Handbrake warning<br />
lamp SWitch<br />
Klckdown sWitch<br />
Clock<br />
LH headlamps<br />
LH turn sIgnal and<br />
parkmg lamps<br />
LH front side turn<br />
signal lamp<br />
Speed detector<br />
Speed indIcator relay<br />
sWitch<br />
Hazard Signal relay umt<br />
Turn Signal relay umt<br />
Turn signal and com<br />
bination switch<br />
Instrument panel con<br />
nector<br />
Igmtlon switch<br />
LH reversing and stop<br />
lamp<br />
LH rear side clearance<br />
lamp<br />
264<br />
54 LH tall and turn signal<br />
lamps<br />
55 Rear Intenor lamp<br />
56 Tall gate switch<br />
57<br />
58 59<br />
60<br />
61<br />
62<br />
63<br />
64<br />
65<br />
66<br />
67<br />
70<br />
71<br />
72<br />
G<br />
W<br />
Y<br />
R<br />
8<br />
8R<br />
8L<br />
68 69<br />
Front Intenor lamp and<br />
sWitch<br />
Courtesy lamp door<br />
sWitches<br />
Warning buzzer<br />
Steering lock SWItch<br />
Fuel gauge sender umt<br />
Llghtmg SWItch<br />
Turn<br />
lamps<br />
Signal indicator<br />
CIgar hghter<br />
Stop lamp SWItch<br />
Glove box lamp and<br />
sWitch<br />
Auto transmiSSIon In<br />
dicator<br />
Hazard signal SWItch<br />
Tachometer<br />
Resistor<br />
COLOR CODe<br />
Green<br />
WhIte<br />
Yellow<br />
Red<br />
Black<br />
Brown<br />
Blue<br />
1<br />
BY Blackyellow tracer<br />
GW GreenJwh ta tracer<br />
RB Red blacktracer<br />
W8 Whlta blacktracer<br />
RY Red yellow tracer<br />
GB Green black tracer<br />
BW BlackwhIte tracer<br />
GY Green yellow tracer<br />
WR WhIte red tracer<br />
YG Yellow green tracer<br />
RW Red whIte tracer<br />
GR Green red tracer<br />
YW Yellow whIte tracer<br />
BG 8lack green tracer<br />
YB Yellow black tracer<br />
GBL Green blue tracer<br />
BLY Blue yellow tracer<br />
BLW Blue whIte tracer<br />
BBL Black blue tracer<br />
BL8 Blue black tracer<br />
RBL Red blue tracer<br />
BLR Blue red tracer<br />
BLG 8lue green tracer<br />
BY R Black yellow tracer red<br />
sleeve<br />
RBW Red black tracer whlta<br />
sleeve<br />
WBL WhIte blue tracer<br />
BLGR Blue green tracer red<br />
sleeve<br />
BLG8 Blue green tracer black<br />
sleeve<br />
BLGW81ueJgreen tracer whIte<br />
sleeve
F<br />
1<br />
1<br />
p<br />
2 J<br />
I<br />
1 n L f<br />
L iaI<br />
I<br />
G<br />
r 1<br />
1 V<br />
12<br />
rmt<br />
I<br />
Y<br />
fn<br />
V<br />
I rO ffi<br />
ilTJ<br />
fYm r<br />
r<br />
l I<br />
IEiiJr<br />
I<br />
r<br />
J I<br />
IT<br />
L<br />
or<br />
Ir J<br />
l<br />
tn r<br />
la<br />
r<br />
OR<br />
I<br />
BW<br />
Jll IJ<br />
t<br />
1d<br />
lD I<br />
I<br />
1<br />
g<br />
Imr<br />
w<br />
l<br />
I<br />
I<br />
t tOJ<br />
U<br />
1<br />
I<br />
I<br />
n<br />
I<br />
Tll<br />
I<br />
I<br />
I L<br />
1<br />
RL<br />
1fW J<br />
1li L<br />
vw<br />
JL<br />
5<br />
I<br />
c 61<br />
LJ<br />
Ffl f<br />
11<br />
II<br />
LJ<br />
T<br />
ll<br />
o lI1<br />
Wifing DIagram for 1400 Model Station Wagon With AutomatIc TransmiSSIon<br />
1<br />
205<br />
I<br />
LL<br />
I<br />
I<br />
Il ltt<br />
L<br />
gO<br />
rffi<br />
lI r<br />
1f1<br />
I<br />
III<br />
zL<br />
1<br />
2<br />
4<br />
1<br />
Jt<br />
iCTl<br />
I<br />
I<br />
56<br />
I<br />
J I<br />
I<br />
I<br />
y<br />
J<br />
I<br />
lI 1<br />
LJ 1<br />
North America
J<br />
1 Alternator<br />
2 Regulator<br />
3 Reversing lamp relay<br />
4 Reversmg lamp SWitch<br />
5 Inhibitor SWitch<br />
6 7 Horns<br />
S Horn relay<br />
9 Engme compartment<br />
lamp and sWitch<br />
10 Starter relay<br />
11 Od pressure SWitch<br />
12 Dlstrobutor<br />
13 Ignition cOil<br />
14 R stor<br />
15 Fuse panel<br />
16 Wmdscreen washer<br />
17 Wmdscreen wiper<br />
18 Windscreen wiper<br />
SWitch<br />
19 Engine temperature<br />
sender Unit<br />
20 RH rear turn Signal<br />
lamp<br />
21 RH tall and stop lamps<br />
22 RH reversang lamp<br />
23 RH rear clearance lamp<br />
24 Harness connectors<br />
25 Klckdown solenoid<br />
26 Dual brake warnmg<br />
lamp SWitch<br />
Wiring Diagram for <strong>1600</strong> Model Sedan with Automatic Transmission<br />
27<br />
28<br />
29<br />
Battery<br />
Starter motor and<br />
solenoid<br />
RH front side turn<br />
signal lamp<br />
30 RH front turn Signal<br />
and parkmg lamp<br />
31 32 RH headlamps<br />
33 Headlamp relay<br />
34 Klckdown swatch<br />
35 36 LH head lamps<br />
37 LH front turn SIgnal<br />
and parking lamps<br />
38 LH front side turn<br />
39<br />
signal lamps<br />
Radio<br />
40<br />
41<br />
42<br />
43<br />
44<br />
45<br />
46<br />
47<br />
Heatar umt<br />
Hazard Signal SWitch<br />
Heater SWitch<br />
Passing lamp relay<br />
Hazard Signal relay umt<br />
Handbrake warmng<br />
lamp SWitch<br />
Turn Signal relay Unit<br />
Turn Signal and com<br />
bination SWitch<br />
48 49 Automatic transmission<br />
indicator lamps<br />
50 Clock<br />
51 Instrument panel con<br />
nettor<br />
T<br />
52 Turn Signal mdlcator<br />
53<br />
54<br />
55<br />
56<br />
57<br />
58<br />
59<br />
60<br />
61<br />
62<br />
63<br />
lamps<br />
Stop lamp SWitch<br />
Cigar lighter<br />
Igmtlon SWitch<br />
Lighting SWItch<br />
Fuel gauge sender Umt<br />
licence plate lamp<br />
lH rear clearance lamp<br />
LH reversing lamp<br />
LH tall and stop lamp<br />
lHturn Signal lamp<br />
Interior lamp and<br />
SWitch<br />
64 65 Courtesy lamp door<br />
SWitches<br />
G Green<br />
W White<br />
Y Yellow<br />
R Red<br />
B Black<br />
BR Brown<br />
BL Blue<br />
COLOR CODE<br />
BY Black yellow tracer<br />
u<br />
GW Green white tracer<br />
RB Red black traCer<br />
WB White black tracer<br />
RY Red yellow tracer<br />
GB Green black tracer<br />
BW Blackwhite tracer<br />
GY Green yellow tracer<br />
WR WhIte red tracer<br />
YG Yellow green tracer<br />
RW Red white tracer<br />
GR Green red tracer<br />
YW Yellow whitetracer<br />
BG Black green tracer<br />
YB Yellow black tracer<br />
GBL Green blue tracer<br />
BLY Blue yellow tracer<br />
BLW Blue whIte tracer<br />
BBL Black blue tracer<br />
BLB Blue black tracer<br />
RBL Red blue tracer<br />
BLR Blue red tracer<br />
BLG Blue green tracer<br />
BYR Blackyellow tracer red<br />
sleeve<br />
RBW Red black tracer white<br />
sleeve<br />
WBL WhIte blue tracer<br />
BLG R Blue green tracer red<br />
sleeve<br />
BLGB Blue green tracer black<br />
sleeve<br />
BLGW Blue green tracer white<br />
sl
1<br />
2<br />
3<br />
4<br />
5<br />
6<br />
7<br />
8<br />
11<br />
9 10<br />
12<br />
13<br />
14<br />
15<br />
16<br />
17<br />
18<br />
19<br />
20<br />
21<br />
22<br />
23<br />
24<br />
25<br />
26<br />
27<br />
Alternator<br />
Regulator<br />
Starter and solenoid<br />
Reversmg lamp switch<br />
Reversmg lamp relay<br />
Inhibitor sWitch<br />
Starter relay<br />
E ngme compartment<br />
lamp and sWitch<br />
Horns<br />
Horn relay<br />
Engme temperature<br />
sender umt<br />
Fuse panel<br />
Wmdscreen washer<br />
Windscreen wiper<br />
R8Slstor<br />
Igmtlon cOil<br />
Dlstnbutor<br />
Windscreen Wiper<br />
sWitch<br />
RH rear turn 51gnal<br />
lamp<br />
RH taol and stop lamps<br />
RH reversmglamp<br />
RH rear clearance lamp<br />
Glove box lamp and<br />
SWitch<br />
Od pressure sWitch<br />
Harness connectors<br />
Klckdown sWItch<br />
Wmng Diagram for <strong>1600</strong> Model Station Wagon With Automatic Transmlsslon<br />
28<br />
29<br />
30<br />
31<br />
32<br />
33<br />
34 35<br />
36 37<br />
38<br />
39<br />
40<br />
41<br />
42<br />
43<br />
44<br />
45<br />
46<br />
47<br />
48<br />
49<br />
50<br />
51<br />
Klckdown solenoid<br />
Dual brake system<br />
warnmg lamp<br />
Headlamp relay<br />
Battery<br />
RH front side turn<br />
signal lamp<br />
R H tu rn signal and<br />
parkmg lamps<br />
RH headlamps<br />
lHheadlamps<br />
LH turn 51gnal and<br />
parkmg lamps<br />
LH front side turn<br />
signal lamp<br />
Radoo<br />
Hazard signal relay umt<br />
Passong lamp relay<br />
Turn signal relay UOIt<br />
Handbrake warm 9<br />
lamp<br />
Turn signal and com<br />
bination switch<br />
Instrument panel con<br />
nector<br />
IgOltlon switch<br />
LH reversang lamps<br />
LH tall and stop lamps<br />
LH rear turn signal<br />
lamp<br />
Rear anterior lamp<br />
52<br />
53<br />
54 55 Courtesy<br />
sWitches<br />
lamp door<br />
56 Fuel gauge sender umt<br />
57 llghtong swItch<br />
58 Turn<br />
lamps<br />
signal indicator<br />
59 CIgar hghter<br />
60 Clock<br />
61 62 Automatic transmiSSion<br />
63<br />
64<br />
65<br />
66<br />
67<br />
68<br />
G<br />
W<br />
Y<br />
R<br />
B<br />
BR<br />
Bl<br />
BY<br />
GW<br />
RB<br />
Tall gate sWitch<br />
Front interior lamp and<br />
sWitch<br />
andlcator lamps<br />
Heater switch<br />
Hazard signal sWitch<br />
Heater<br />
Stop lamp swotch<br />
Licence plate lamps<br />
LH rear clearance lamp<br />
COLOR CODE<br />
Green<br />
Whote<br />
Yellow<br />
Red<br />
Black<br />
Brown<br />
Blue<br />
Black yellow tracer<br />
Green white tracer<br />
Red black tracer<br />
WB<br />
Whote black tracer<br />
R Y Red yellow tracer<br />
GB Green black tracer<br />
BW Black whote tracer<br />
GY Green yellow tracer<br />
WR Whote red tracer<br />
YG Yellow green tracer<br />
RW Red whote tracer<br />
G R Green red tracer<br />
YW Yellow wtute tracer<br />
BG Black green tracer<br />
YB Yellow black tracer<br />
GBl Green blue tracer<br />
BlY Blue yellow tracer<br />
BlW Blue whIte tracer<br />
BBl Black blue tracer<br />
BlB Blue black tracer<br />
RBl Red blue tracer<br />
BlR Blue red tracer<br />
22<br />
BlG Blue green tracer<br />
BY R Black yellOW tracer red<br />
sleeve<br />
RBW Red black<br />
sleeve<br />
WBl Whote blue tracer<br />
tracer whote<br />
BlGR Blue green tracer red<br />
sleeve<br />
BlGB Blue green tracer black<br />
sleeve<br />
BlGW Blue green tracer whIte<br />
sleeve
1<br />
2<br />
3<br />
45<br />
6<br />
7<br />
8<br />
9<br />
10<br />
11<br />
12<br />
13<br />
14<br />
15<br />
16<br />
17<br />
18<br />
19<br />
20<br />
21<br />
22<br />
Alternator<br />
Regulator<br />
Horn relay<br />
Horns<br />
ReverSing lamp felay<br />
Inhibitor sWitch<br />
Ignition coli<br />
Dlstnbutor<br />
Fuse panel<br />
Wmdscreen washer<br />
Windscreen Wiper<br />
Heater sWitch<br />
Heater<br />
RH turnsignal lamp<br />
RH ta 1 and stop lamp<br />
R H reversmg lamp<br />
Windscreen wiper<br />
sWitch<br />
Engine compartment<br />
lamp and switch<br />
Radio<br />
Starter relay<br />
Passing lamp relay<br />
Wifing Diagram for Model PL<strong>510</strong>A with Automatic Transmission<br />
23<br />
24<br />
25<br />
26<br />
27<br />
28 29<br />
30<br />
31<br />
32<br />
33<br />
34<br />
35<br />
36<br />
37<br />
38<br />
39<br />
40<br />
41 42<br />
Battery<br />
Starter motor and<br />
solenoid<br />
Headlamp relay<br />
RH front Side turn<br />
slynallamp<br />
RH turn signal and<br />
parkong lamp<br />
RH headlamps<br />
Cigar hghter<br />
Engme temperature<br />
sender umt<br />
all pressure switch<br />
Harness connectors<br />
Licence plate lamp<br />
lH reversing lamp<br />
LH tall and stop lamps<br />
LH turnsignal lamp<br />
Lighting sWitch<br />
Intenor lamp<br />
Fuel gauge sender umt<br />
Courtesy lamp door<br />
sWitches<br />
2Q8<br />
43 Igmtlon sWItch<br />
44 Dual brake warning<br />
lamp switch<br />
45 lostrument panel con<br />
nector<br />
46 Stop lamp SWitch<br />
47 Turn signal and com<br />
bination SWItch<br />
48 Turn signal relay umt<br />
49 Glove box lamp<br />
50 Glove box lamp SWItch<br />
51 Clock<br />
52 53 LH headlamps<br />
54 LH stop and tall lamps<br />
55 LH front Side turn<br />
51gnallamp<br />
COLOR CODE<br />
W White<br />
B Black<br />
R Red<br />
G Green<br />
Y Yellow<br />
BL Blue<br />
BR Black red tracer<br />
BY Black yellow tracer<br />
BW Black white tracer<br />
BG Black green tracer<br />
GW Green white tracer<br />
RY Red yellow tracer<br />
WB White black tracer<br />
GB Green blacktracer<br />
YB Yellow black tracer<br />
GR Green red tracer<br />
RW Red whitetracer<br />
GV Green yellow tracer<br />
YW Yellow white tracer<br />
RB Red black tracer<br />
WR WhIte red tracer<br />
GBl Green blue tracer<br />
RBL Red blue tracer<br />
BLW Blue whIte tracer<br />
BLR Blue red tracer<br />
BLY Blue yellow tracer<br />
RBW Red black tracer white<br />
sleeve
1<br />
2<br />
3<br />
4 5<br />
6<br />
7<br />
8<br />
9<br />
10<br />
11<br />
12<br />
13<br />
14<br />
15<br />
16<br />
17<br />
18<br />
19<br />
20<br />
21<br />
22<br />
23<br />
24<br />
Alternator<br />
Regulator<br />
Horn relay<br />
Horns<br />
Ignition cOil<br />
Distributor<br />
Fuse panel<br />
Windscreen washer<br />
Wandscreen wiper<br />
Heater SWItch<br />
Heater<br />
Windscreen wiper<br />
sWitch<br />
RH turn sIgnal lamp<br />
RH stop and la 1 lamp<br />
RH reversmg lamp<br />
Engme compartment<br />
lamp and sWitch<br />
RadIo<br />
Stop lamp sWllch<br />
PasSlOg lamp relay<br />
Battery<br />
Starter motor and<br />
soleno d<br />
Headlamp relay<br />
RH front side turn<br />
signal lamp<br />
25<br />
26 27<br />
28<br />
29<br />
30<br />
31<br />
32<br />
33<br />
34<br />
35<br />
36<br />
37<br />
38<br />
41<br />
42<br />
43<br />
44<br />
45<br />
46<br />
39 40<br />
Wiring Diagram for Model PL<strong>510</strong>A With Passing Lamp<br />
RH turn signal and<br />
pa klng lamps<br />
RH headlamps<br />
Clock<br />
Engme temperature<br />
sender umt<br />
ad pressure sWitch<br />
Harness connectors<br />
llcenee plate amp<br />
LH reversing lamp<br />
LH stop and la lamps<br />
LH rear turn signal<br />
lamp<br />
Fuel gauge sender unit<br />
Intenor lamp<br />
L ghllng SWllch<br />
Courtesy lamp door<br />
sWitches<br />
IgOltlon sWitch<br />
Dual brake syslem<br />
warmng lamp sWitch<br />
Instrument panel con<br />
nectors<br />
Slap lamp sWllch<br />
Turn SIgnal and com<br />
bination sWitch<br />
Turn signal relay Unit<br />
209<br />
47<br />
48<br />
49<br />
SO 51<br />
52<br />
53<br />
G<br />
W<br />
Y<br />
R<br />
B<br />
BR<br />
BL<br />
8Y<br />
GW<br />
RB<br />
W8<br />
RY<br />
G8<br />
8W<br />
Cigar lighter<br />
Glove box lamp<br />
Glove box lamp sWitch<br />
LH head lamps<br />
LH front turn signal<br />
and parkmg lamps<br />
lH front side turn<br />
signal lamp<br />
COLOR CODE<br />
Green<br />
WhIle<br />
Yellow<br />
Red<br />
Black<br />
Brown<br />
Blue<br />
Black yellow tracer<br />
Green wh te tracer<br />
Red black Iracer<br />
White black tracer<br />
Red yellow tracer<br />
Green black tracer<br />
Black whIte Iracer<br />
GY Green yellow tracer<br />
WR White red tracer<br />
YG Yellow green Iracer<br />
RW Red whIle Iracer<br />
GR Green red tracer<br />
YW Yellow whIle tracer<br />
BG Blackgreen tracer<br />
YB Yellow black Iracer<br />
GBL G een blue Iracer<br />
BLY Blue yellow Iracer<br />
BLW Blue whIle Iracer<br />
B8L Black blue Iracer<br />
BLB Blue black Iracer<br />
R8L Red blue tracer<br />
BLR Blue red Iracer<br />
BlG Blue green tracer<br />
BYR Blackyellow tracer red<br />
sleeve<br />
RBW Red black tracer whIte<br />
sleeve<br />
WBL WhIte blue tracer<br />
BLGR 81ueJgreen tracer red<br />
sleeve<br />
BLG8 Blue green tracer black<br />
sleeve<br />
BLGW8lue green tracer whIle<br />
sleeve
tl<br />
Jt<br />
f<br />
I FF<br />
1<br />
L B<br />
I<br />
25<br />
r<br />
t o RUl<br />
E<br />
I G8<br />
I<br />
fy<br />
il<br />
25jl<br />
I o 0<br />
MJ<br />
di<br />
24<br />
5<br />
III<br />
Ifn<br />
l<br />
IDl 1<br />
3<br />
w<br />
I<br />
I<br />
0<br />
V Ill<br />
0<br />
i<br />
m 1 IU I Jw<br />
0 Jf<br />
j<br />
c w 0 0 r<br />
AI IL<br />
DAC mHI l<br />
15<br />
o zz<br />
G<br />
1136<br />
0<br />
J<br />
lD<br />
V<br />
W<br />
DR 0<br />
ow<br />
1 0<br />
l<br />
r<br />
II 1<br />
1<br />
2<br />
3<br />
45<br />
6<br />
7<br />
B<br />
9<br />
10<br />
11<br />
12<br />
13<br />
14<br />
15<br />
16<br />
17<br />
1B<br />
19<br />
20<br />
21<br />
22<br />
23<br />
24<br />
ow<br />
0<br />
If 1S2 1<br />
2 B<br />
t<br />
I j r<br />
Alternator<br />
Regulator<br />
Horn relay<br />
Horns<br />
Reversing lamp sWitch<br />
Inhibitor switch<br />
Dlstnbutor<br />
Igmtlon cOil<br />
Resistor<br />
Fuse panel<br />
Wmdscreen wiper sol<br />
enoid<br />
Windscreen wipers<br />
Heater sWitch<br />
Heater<br />
Wmdscreen washer<br />
RH turn sIgnal lamp<br />
RH taol and stop lamps<br />
RH reversing lamp<br />
RH rear clearance lamp<br />
Windscreen wiper<br />
sWitch<br />
Engme compartment<br />
lamp and swItch<br />
RadIO<br />
Starter relay<br />
I<br />
DR<br />
1 1<br />
I<br />
2<br />
i 59<br />
7<br />
9<br />
m<br />
dol<br />
I I q<br />
55 B<br />
IHL<br />
f<br />
Wiring Diagram for Model PL<strong>510</strong>UA With Hazard Signal Lamps<br />
25<br />
26<br />
27<br />
2B<br />
29<br />
30 31<br />
32<br />
33<br />
34<br />
35<br />
36<br />
37<br />
3B<br />
39<br />
40<br />
41<br />
44<br />
45<br />
46<br />
42 43<br />
Battery<br />
Starter motor and<br />
solenoid<br />
Headlamp relay<br />
RH front Side turn<br />
signal lamp<br />
RH turn signal and<br />
psrkmg lamps<br />
RH headlamps<br />
CIgar hghter<br />
Engine temperature<br />
sender unit<br />
011 pressure sWitch<br />
Dual brake warning<br />
lamp swItch<br />
Harness connectors<br />
licence plate lamp<br />
LH rear clearance lamp<br />
LH reversIng lamp<br />
LH stop and tall lamps<br />
LH turn sIgnal lamp<br />
Auto transmiSSion m<br />
dlcator lamps<br />
LIghting sWItch<br />
Stop lamp sWitch<br />
Turn signal relay Unit<br />
210<br />
47 Turn signal and com<br />
bmatlon sWitch<br />
4B 49<br />
50<br />
51<br />
52<br />
53<br />
54<br />
55<br />
56<br />
57<br />
58<br />
59<br />
60 61<br />
62<br />
63<br />
64<br />
W<br />
B<br />
L Hheadlamps<br />
LH turn s gnal and<br />
parking lamps<br />
LH front Side turn<br />
sIgnal lamp<br />
Hazard signal sWitch<br />
Hazard signal relay Unit<br />
Hand brake warning<br />
lamp sWItch<br />
Glove box lamp<br />
Glove box lamp sWItch<br />
Instrument panel con<br />
nector<br />
Clock<br />
Ignition switch<br />
Courtesy lamp door<br />
SWitches<br />
Fuel gauge sender Unit<br />
Intenor lamp<br />
CIgar hghter<br />
COLOR CODE<br />
WhIte<br />
Black<br />
V<br />
R Red<br />
G Green<br />
Y Yellow<br />
BL Blue<br />
62<br />
BR Black red tracer<br />
BY Blackyellow tracer<br />
BW Black whIte tracer<br />
BG Blackgreen tracer<br />
GW Green whIte tracer<br />
RY Red yellow tracer<br />
WB WhIte black tracer<br />
GB Green black tracer<br />
r<br />
V<br />
f0<br />
r0<br />
fr<br />
V<br />
Bl<br />
YB Yellow black tracer<br />
GR Green red tracer<br />
RW Red whIte tracer<br />
GY Green yellow tracer<br />
YW Yellow whIte tracer<br />
RB Red black tracer<br />
WR White red tracer<br />
GBL Green blue tracer<br />
RBL Red blue tracer<br />
BLW Blue whIte tracer<br />
BLR Blue red tracer<br />
BLY Blue yellow tracer<br />
RBW Red blacktracer white<br />
sleeve<br />
F
Wiring Diagram for Model P l <strong>510</strong> U A with Automatic TransmiSSion<br />
1 Alternator 24 RH front side turn 45 Stop lamp sWItch G Green<br />
2 Regulator<br />
signal lamp 46 Turn signal relay umt Y Yellow<br />
3 Horn 25 RH<br />
relay<br />
turn signal and 47 Turn signal and com Bl Blue<br />
4 5 Horns parking lamps bmatlon sWitch BR Black red tracer<br />
6 26 27 RH<br />
Reversing lamp relay<br />
headlamps 48 BY Black<br />
Cigar hghter<br />
yellow tracer<br />
7 Inhibitor sWitch 28 Headlamp relav 49 Glove box BW Black whItetracer<br />
lamp<br />
8 Igmtlon COil 29 Rear harness connector 50 Glove box lamp sWitch BG Black green tracer<br />
9 Dlstnbutor 30 Temperature sender 51 Clock GW Green white tracer<br />
10 Fuse umt 52 53 Auto transmiSSion<br />
panel<br />
In RY Red yellow tracer<br />
11 Windscreen washer 31 011 pressure sWitch dlcator lamps WB WhIte blacktracer<br />
12 Windscreen wiper 32 Harness connectors 54 55 lH headlamps GB Green black tracer<br />
13 Heater sWitch 33 Licence 56 lH turn<br />
plate lamp<br />
signal and YB Yellow black tracer<br />
14 Heater 34 LH reversmg lamp parking lamps GR Green red tracer<br />
15 RH turnsignal lamp 35 lH ta 1 and 57 lH<br />
stop lamps<br />
front side turn RW Red white tracer<br />
16 RH ta 1 and stop lamps 36 LH turn signal lamp Signal mdlcator lamp GY Green yellow tracer<br />
17 R H reversing lamp 37 Fuel gauge sender umt YW Yellow white tracer<br />
RB Red black<br />
18 Windscreen wiper 38 Intenor lamp<br />
tracer<br />
WR White red<br />
sWitch 39 40 Courtesy lamp door<br />
tracer<br />
19 Ra ho sWitches GBl Green blue tracer<br />
20 Engme compartment 41 lIghting swItch RBl Red blue tracer<br />
lamp and sWitch 42 COLOR CODe BlW Blue whIte<br />
IgOltlon sWitch<br />
tracer<br />
21 Starter relay 43 Handbrake BlR Blue red tracer<br />
warnmg<br />
22 Battery lamp sWitch W White BlY Blue yellow tracer<br />
23 Starter motor and 44 Instrument panel con B Black RBW Red blacktracer whIte<br />
solenoid nector R Red sleeve<br />
211
I<br />
G Green<br />
W Whote<br />
Y Yellow<br />
R Red<br />
B Black<br />
BR Brown<br />
Bl Blue<br />
COLOR CODE<br />
BY Black yellow tracer<br />
GW Green whitetracer<br />
RB Red black tracer<br />
WB Whote black tracer<br />
RY Red yellow tracer<br />
GB Green black tracer<br />
BW Black whote tracer<br />
GY Green yellow tracer<br />
WR Whote red tracer<br />
YG Yellow green tracer<br />
RW Red whote tracer<br />
GR Green red tracer<br />
YW Yellow whote tracer<br />
BG Black green tracer<br />
YB Yellow black tracer<br />
GBl Green blue tracer<br />
BlY Blue yellow tracer<br />
BlW Blue whote tracer<br />
BBl Black blue tracer<br />
BlB Blue black tracer<br />
RBl Red blue tracer<br />
BlR Blue red tracer<br />
BlG Blue green tracer<br />
BYR Black yellow tracer red<br />
sleeve<br />
RBW Red black tracer whote<br />
sleeve<br />
WBl Whote blue tracer<br />
BlGR Blue green tracer red<br />
sleeve<br />
BlGB Blue green tracer black<br />
sleeve<br />
BlGW Blue green tracer whote<br />
sleeve<br />
1 Alternator<br />
2 Regulator<br />
3 Horn relay<br />
4 Reversong lamp sWItch<br />
5 6 Horns<br />
7 Engine compartment<br />
lamp and sWitch<br />
8 Igmtlon COil<br />
9 Distributor<br />
10 Fuse panel<br />
11 Resistor<br />
12 Heater sWitch<br />
13 Heater<br />
14 Windscreen wiper<br />
sWitch<br />
15 Windscreen washer<br />
16 Windscreen WI per<br />
17 Cogar lighter<br />
18 Harness connector<br />
19 Battery<br />
20 Starter motor and<br />
solenoid<br />
21 Headlamp relay<br />
22 RH front SIde turn<br />
signal lamps<br />
21 7<br />
23 RH front turn signal 41 Igmtlon sWItch<br />
and parking lamp 42 loghtong swotch<br />
24 25 RH headlamps 43 Fuel gauge sender Unit<br />
26 Engine temperature 44 Interior lamp and<br />
sender umt SWitch<br />
27 Od pressure SWitch 4546 Courtesy lamp door<br />
28 Dual brake system SWitches<br />
warning lamp sWitch 47 Stop lamp SWItch<br />
29 Harness connectors 48 Instrument panel con<br />
30 RadIO nector<br />
31 Handbrake warning<br />
49 Instrument panel con<br />
lamp swotch<br />
nector<br />
32 RH rear turn signal<br />
50 Turn signal and com<br />
lamp<br />
bmatlon sWitch<br />
33 RH taol and stop lamps<br />
51 Turn signal relay Unit<br />
34 RH reversmg lamp<br />
52 Hazard signal relay Unit<br />
35 RH rear Side clearance 53 Hazard signal sWitch<br />
lamp<br />
54 55 lH headlamps<br />
36 Licence plate lamp 56 lH turn signal and<br />
37 lH rear Side clearance parkong lamps<br />
lamp 57 lH front Side turn<br />
38 lH reversing lamp sognallamp<br />
39 lH taol and stop lamps 58 Passing lamp relay<br />
40 lH rear turn signal<br />
lamp
A rn<br />
p W<br />
E L<br />
r OL<br />
t<br />
T<br />
rrTl<br />
rn H<br />
r<br />
r<br />
ri 1<br />
lliili<br />
I<br />
l<br />
4<br />
0<br />
i<br />
Id<br />
0nJ wur<br />
51<br />
to<br />
I<br />
I<br />
rr1 b<br />
LD<br />
I<br />
L<br />
0<br />
R<br />
r r<br />
l<br />
i1<br />
p<br />
I<br />
V oJr I W<br />
ffiEl<br />
1<br />
01 II<br />
niJL<br />
Qi<br />
Pl<br />
c 12 J<br />
1<br />
ml<br />
rr<br />
G<br />
il<br />
lll Nr<br />
J<br />
II<br />
III<br />
1<br />
II<br />
Iii<br />
w<br />
rot l OW<br />
L r<br />
1<br />
I<br />
R<br />
1<br />
J<br />
1<br />
ru<br />
L<br />
lo<br />
L<br />
In JI<br />
for <strong>1600</strong> Model SSS<br />
Wifing Diagram<br />
OR<br />
213<br />
l<br />
p<br />
iil<br />
l l<br />
r E<br />
It U<br />
i1<br />
r<br />
I<br />
tt ll<br />
Iw JItl<br />
ra v<br />
71f<br />
L<br />
l l<br />
7<br />
17<br />
r<br />
f@ w<br />
l<br />
b<br />
ILl<br />
IIL k<br />
i
1<br />
r<br />
r<br />
1<br />
2<br />
3<br />
4 5<br />
6<br />
7<br />
8<br />
9<br />
10<br />
11<br />
12<br />
13<br />
14<br />
15<br />
16<br />
17<br />
18<br />
19<br />
20<br />
21<br />
22<br />
23<br />
Alternator<br />
Regulator<br />
Horn relay<br />
Horns<br />
Dl51nbutor<br />
Ignition coli<br />
Resistor<br />
Fuse panel<br />
Windscreen washer<br />
Windscreen wiper<br />
Heater sWitch<br />
Heater<br />
RH turnsIgnal lamp<br />
RH tall and stop lamps<br />
RH reversmg lamp<br />
Windscreen wiper<br />
sWitch<br />
Engme compartment<br />
lamp and swItch<br />
Reversmg lamp sWitch<br />
Battery<br />
Starter motor and<br />
solenoid<br />
RH front Side turn<br />
sIgnal lamp<br />
RH front turn sIgnal<br />
and parking lamps<br />
Wrrlllg Diagram for Model PL<strong>510</strong>TK With Passing Lamps<br />
24 25 RH headlamps<br />
26 Headlamp relay<br />
27 PassIng lamp relay<br />
28 Engme<br />
sender umt<br />
temperature<br />
29<br />
30<br />
31<br />
32<br />
33<br />
34<br />
35<br />
36 37<br />
38<br />
39<br />
40<br />
41<br />
42<br />
43<br />
44<br />
45<br />
46<br />
47<br />
Od pressure sWitch<br />
Harness connectors<br />
licence plate lamp<br />
LH reversing lamp<br />
lH tall and stop lamp<br />
lH turn sIgnal lamp<br />
Fuel gauge sender Unit<br />
Courtesy lamp door<br />
sWitches<br />
Intenor lamp<br />
lighting sWItch<br />
gnltlon sWitch<br />
Dual brake<br />
system<br />
warning lamp<br />
Instrument panel con<br />
nectors<br />
Turn signal and com<br />
bination SWitch<br />
Turn signal relay Unit<br />
CIgar hghter<br />
Glove box lamp<br />
Glove box lamp sWItch<br />
21<br />
48 49 lH headlamps<br />
50 lH front turn SIgna<br />
and parkmg lamps<br />
51 LH front side turn<br />
sIgnal lamp<br />
52 Clock<br />
53 Stop lamp swItch<br />
G Green<br />
W WhIte<br />
Y Yellow<br />
R Red<br />
B Black<br />
BR Brown<br />
COLOR CODE<br />
Bl Blue<br />
BY Blackyellow tracer<br />
GW Green whitetracer<br />
RB Red black tracer<br />
WB Whlte black tracer<br />
RY Red yellow tracer<br />
GB Green black tracer<br />
BW Black whlte tracer<br />
GY Green yellow tracer<br />
WR Whlte red tracer<br />
YG Yellow green tracer<br />
RW Red whlte tracer<br />
GR Green red tracer<br />
YW Yellow whlte tracer<br />
BG Black green tracer<br />
YB Yellow black tracer<br />
GBl Green blue tracer<br />
BlY Blue yellow tracer<br />
BlW Blue whlte tracer<br />
BBl Black blue tracer<br />
BlB Blue black tracer<br />
RBl Red blue tracer<br />
BlR Blue red tracer<br />
BlG Blue green tracer<br />
BYR Black yellow tracer red<br />
sleeve<br />
RBW Red black tracer whlte<br />
sleeve<br />
WBl Whlte blue tracer<br />
BlGR Blue green tracer red<br />
sleeve<br />
BlGB Blue green tracer black<br />
sleeve<br />
BlGW Blue green tracer whlte<br />
sleeve
1<br />
2<br />
3<br />
4 5<br />
6<br />
7<br />
8<br />
9<br />
10<br />
11<br />
12<br />
13<br />
14<br />
15<br />
16<br />
17<br />
18<br />
19<br />
20<br />
21<br />
22<br />
23<br />
Alternator<br />
Regulator<br />
Horn relay<br />
Horns<br />
Distributor<br />
Igmtlon call<br />
Resistor for<br />
P L <strong>510</strong> UITK<br />
Fuse panel<br />
Reversmg lamp sWitch<br />
Engine compartment<br />
lamp and sWitch<br />
Wmdscreen washer<br />
Wmdscreen Wiper<br />
Heater switch<br />
Heater<br />
Windscreen Wiper<br />
sWitch<br />
RH turnsignal lamp<br />
RH tall and stop lamp<br />
RH reversing lamps<br />
LIcence plate lamp<br />
RadIO<br />
Battery<br />
Starter motor and<br />
solenoId<br />
WIring DIagram for Model P L<strong>510</strong> U TK with Model PL<strong>510</strong> U T Inset<br />
24<br />
25<br />
26<br />
27 28<br />
29<br />
30<br />
31<br />
32<br />
33<br />
34<br />
35<br />
36<br />
37<br />
38 39<br />
40<br />
41<br />
42<br />
43<br />
44<br />
Headlamp relay<br />
RH front Side turn<br />
signal lamp<br />
RH turn signal and<br />
parking lamp<br />
R H headlamps<br />
CIgar hghter<br />
Engine temperature<br />
sender umt<br />
0 1 pressure<br />
switch<br />
Harness connectors<br />
LH reversing lamp<br />
LH tall and stop lamps<br />
LH turnsIgnal lamp<br />
Fuel gauge sender umt<br />
Interior lamp<br />
Cou rtesy lamp door<br />
sWitches<br />
Igmtlon switch<br />
LIghting SWItch<br />
Handbrake warmng<br />
lamp<br />
Instrument panel con<br />
nector<br />
Turn signal and com<br />
bmatlonsWitch<br />
215<br />
45<br />
46<br />
47<br />
48<br />
49 50<br />
51<br />
52<br />
G<br />
W<br />
Y<br />
R<br />
B<br />
BR<br />
BL<br />
BY<br />
GW<br />
RB<br />
WB<br />
RY<br />
GB<br />
BW<br />
Turn 519081 relay umt<br />
Glove box lamp<br />
Glove box lamp SWitch<br />
Clock<br />
LH head lamps<br />
LH turn signal and<br />
parkmg lamps<br />
LH front Side turn<br />
signal lamp<br />
COLOR CODE<br />
Green<br />
WhIte<br />
Yellow<br />
Red<br />
Black<br />
Brown<br />
Blue<br />
Black yellow tracer<br />
Green white tracer<br />
Red blacktracer<br />
White black tracer<br />
Red yellow tracer<br />
Green black tracer<br />
Black white tracer<br />
GY Green yellow tracer<br />
WR White red tracer<br />
YG Yellow green tracer<br />
RW Red white tracer<br />
GR Green red tracer<br />
YW Yellow white tracer<br />
BG Black green tracer<br />
YB Yellow black tracer<br />
GBL Green blue tracer<br />
BLY Blue vellow tracer<br />
BLW Blue whIte tracer<br />
BBL Black blue tracer<br />
BLB Blue black tracer<br />
RBL Red blue tracer<br />
BLR Blue red tracer<br />
BLG Blue green tracer<br />
BYR Black yellow tracer red<br />
sleeve<br />
RBW Red black tracer whIte<br />
sleeve<br />
WBL WhIte blue tracer<br />
BLG R Blue green tracer red<br />
sleeve<br />
BLGB Blue green tracer black<br />
sleeve<br />
BLGWBlue green tracer whIte<br />
sleeve<br />
r
MAKE<br />
MODEL<br />
BODY TYPE<br />
PRICE<br />
COLOR<br />
MILEAGE START<br />
MILEAGE FINISH<br />
WEIGHT<br />
FUEL CONSUMPTION<br />
Overall<br />
CruISing<br />
TEST CONDITIONS<br />
Weather<br />
Load<br />
Surface<br />
Fuel<br />
SPEEDOMETER ERROR<br />
Indicated 30 40<br />
Actual 28 4 38 1<br />
Piston speed at max bhp<br />
mph<br />
50 60<br />
468 569<br />
PERFORMANCE<br />
Top gear mph at 1000 rpm<br />
E me n9 rpm at max speed<br />
Lbs laden per gross bhp 1 power to weight<br />
MAXIMUM SPEEDS<br />
Fastest run<br />
Average of all runs<br />
Speedometer indication fastest run<br />
IN GEARS<br />
1st<br />
2nd<br />
3rd<br />
4th<br />
50<br />
4<br />
30<br />
Road test figures courtesy Wheels MagaZine<br />
from Its June 1971 Sydney report<br />
<strong>Datsun</strong><br />
<strong>1600</strong><br />
41oor sedan<br />
2363<br />
White<br />
1637<br />
2144<br />
909 8 kg 2006 Ib<br />
70 80<br />
65 7 75 7<br />
25 1 mpg<br />
27 30 mpg<br />
fme warm<br />
2 persons<br />
hot mix<br />
premIum<br />
920m mlot 3018 ft mlot<br />
186<br />
<strong>510</strong>0 rpm<br />
2091b<br />
11544 kph 96 mph<br />
151 2 kph 94 mph<br />
165 7 kph 103 mph<br />
159 5 kph 37 mph 16800 rpm<br />
1014 kph 63 mph 16800 rpm<br />
1148 kph 92 mph 6500 rpm<br />
151 2 kph 94 mph <strong>510</strong>0 rpm<br />
3rd 92mph<br />
TOP SPEED<br />
94mph<br />
ACCELERATION THROUGH<br />
GEARS WITH CHANGE<br />
POINTS<br />
ACCELERATION hhrough gears<br />
030 mph<br />
040 mph<br />
0 50 mph<br />
Q60 mph<br />
o 70 mph<br />
080 mph<br />
2040 mph<br />
30 50 mph<br />
4060 mph<br />
50 70 mph<br />
STANDING QUARTER MILE<br />
Fastest run<br />
Average all runs<br />
BRAKING<br />
From 30 mph to 0<br />
From 60 mph to 0<br />
ENGINE<br />
Cylinders<br />
Bore and stroke<br />
Cubic capacity<br />
Compression ratIo<br />
Valves<br />
Carburettor<br />
Fuel pump<br />
011 filler<br />
Power at rpm<br />
Torque at rpm<br />
TRANSMISSION<br />
Type<br />
Clutch<br />
Gear lever location<br />
RATIOS<br />
1st<br />
2nd<br />
3rd<br />
4th<br />
Final drive<br />
CHASSIS AND RUNNING GEAR<br />
Construction<br />
Suspension front<br />
SuspenSIon rear<br />
Shock absorbers<br />
Steering type<br />
Turns I to I<br />
Turning Circle<br />
Steering wheel diameter<br />
8rakes tvpe<br />
DimenSions<br />
DIMENSIONS<br />
Whee Ibase<br />
Track front<br />
Track rear<br />
Length<br />
Width<br />
Height<br />
Fuel tank capacity<br />
TYRES<br />
Size<br />
Pressures<br />
l<br />
Make on test car<br />
o<br />
MPH<br />
5 10 5 20 a5 30 35<br />
ELAPSED FIME IN SECDNDS<br />
GROUND CLEARANCE<br />
RegJStered<br />
2nd gear<br />
43see<br />
44 see<br />
54 see<br />
3rd gear<br />
67see<br />
65see<br />
69 see<br />
7 7 see<br />
46see<br />
67see<br />
93see<br />
131 see<br />
173see<br />
21 8 see<br />
4th gear<br />
100 see<br />
100 see<br />
103 see<br />
99 see<br />
183 see<br />
185 see<br />
1 8 see<br />
34 see<br />
four In line<br />
83 mm 1327 lot x 733 12 36 lot<br />
1595 ee 973 eu lot<br />
85 to 1<br />
SOHC<br />
Hotaehl2661<br />
mechanical<br />
full flow canridge<br />
96 bhp at 5600 rpm<br />
998 Ib ftat 3600 rpm<br />
four speed manual all syncra<br />
Overall<br />
338<br />
201<br />
131<br />
100<br />
37<br />
SOP<br />
centre floor<br />
Direct<br />
951<br />
742<br />
485<br />
370<br />
unitary<br />
McPherson struts and COil springs<br />
anti roil bar<br />
semi trailing armsand COIl springs<br />
telescopIC<br />
reclrcu lat I og ball<br />
40<br />
315ft<br />
155 lot<br />
disc drum<br />
913 In diSC 9 In drum<br />
95 3 248 9 em<br />
504 lot 11371 em<br />
50 4 lot 1371 em<br />
13ft621ot 411gem<br />
5ft 14 lot 1155 em<br />
4ft71 124 em<br />
99 gallons 449 htres<br />
615 x 13<br />
24 pSI all round<br />
Dunlop LP Guardian<br />
7 5 189 8em
TO REMOVE<br />
I Cover the bonnet and scuttle panel with a SUitable<br />
protectIve cloth to aVOid damage to the paint work<br />
2 Remove the wmdscreen wiper arms and blades<br />
from the front of the wllldscreen<br />
3 Push the weatherstrIp lip under the top and Sides<br />
of the wllldscreen aperture flange Use a SUitable lippmg<br />
tool for thiS purpose<br />
4 ApplYlllg firm pressure from mSlde the car push<br />
the WIndscreen and weatherstrIp assembly forward and out<br />
of the wmdscreen aperture<br />
5 Pnse out the Jomt cover clIp and pull the fimsh<br />
strIp out of the weatherstrIp Remove the weatherstrIp<br />
from the glass<br />
TO INSTAL<br />
1 Clean all old sealIng compound from the glass and<br />
the body flange grooves m the weatherstnp and from the<br />
flange of the body aperture Check the weatherstnp for<br />
deterIoratIOn<br />
2 Place the weatherstnp correctly on the wmdscreen<br />
glass 3 USIng a SUItable pressure gun and sealIng<br />
compound apply the compound to the weatherstrIp rubber<br />
to body groove<br />
4 Insert a length of strong cord In the weatherstrIp<br />
INTERIOR HANDLES AND TRIM PANEL<br />
To Remove<br />
I Usmg a special handle remoVing tool mserted<br />
between the handle flange and thrust washer release the<br />
horse shoe type retainIng clIp and remove the handle and<br />
washer Both the door handle and WIndow wmder handle<br />
are removed m the same manner<br />
2 Remove the two plugs covenng the heads of the<br />
door pull mountIng screws remove the screws and the door<br />
pull 3 Usmg a tlun Wide bladed lever Inserted between the<br />
trIm panel and the door near a retamIng clIp lever the clIp<br />
out of ItS retalnlllg hole talang care not to damage the door<br />
paint work<br />
tnm panel<br />
To Instal<br />
4 Lever each chp free m turn and remove the door<br />
I Check that the dust and splash shields are correctly<br />
fitted andnot tom or damaged<br />
2 Check the trIm panel retammg chps and mserts<br />
replace damaged parts<br />
BODY<br />
I WINDSCREEN AND REAR WINDOW<br />
2 FRONT DOOR<br />
217<br />
rubber to body groove startmg at the lower centre of the<br />
assembly and contInumg around the penphery of the<br />
wmdscreen glass to meet and cross the start of the cord<br />
and tape both ends to the glass on the mSIde<br />
5 With the aid of a second operator position the<br />
wmdscreen and weatherstrIp assembly centrally m the<br />
wmdscreen aperture applymg firm pressure to the outside<br />
of the glass Ensure that the ends of the cord are not<br />
trapped between the weatherstrIp and the body flange<br />
6 From mSlde the velucle carefully pull each end of<br />
the cord from the lower centre ofthe glass assembly across<br />
the bottom of the lower corners of the body aperture to<br />
seat the IIp of the rubber over the body aperture flange<br />
7 Usmg a sUItable pressure gun With swan necked<br />
nozzle and sealIng compound apply the compound to the<br />
rubber to glass groove<br />
8 Replace the fimsh m stnp ItS groove In the<br />
weatherstnp with the use of the IIppmg tool Replace the<br />
jomt cover clIp<br />
9 Clean off any excess seallllg compound with a<br />
cloth soaked m petrol and wipe the assembly clean<br />
10 Replace the wmdscreen wiper arms and blades<br />
TO REMOVE AND INSTAL REAR WINDOW GLASS<br />
3 PosItIon the trun panel mto the top mould and<br />
align the clips WIth the mountmg mserts and the door<br />
recess<br />
The procedures for removmg the rear glass are slllular<br />
to the procedures descrIbed III the preVIous section for<br />
removal and IIlstallatlOn ofthe wllldscreen<br />
4 Check each clip mdlVldually before applYlllg<br />
pressure to the panel and start at the top and work down<br />
5 WInd the WIndow to the closed poslhon fit the<br />
thrust washer over the spllldle fit the handle retamIng clIp<br />
In posItIon and fit the handle to correspond with the<br />
opposite door and push onto the spIndle<br />
6 Fit the thrust washer over the door handle spmdle<br />
fit the retainer chp m posItIon In the handle pOSItIon the<br />
handle to correspond with the opposite door and push It<br />
onto the spmdle<br />
7 Refit the door pull and mstal the plugs to cover the<br />
screw heads<br />
WINDOW REGULATOR<br />
To Remove and Instal<br />
1 Remove the Intenor handles and door trun panel<br />
2 Remove the dust and splash shields from the door<br />
Inner apertures<br />
3 WInd the WIndow to the down pOSItIon
j I<br />
J<br />
2 Body<br />
LIFT CHANNEL SlIDE<br />
InSIde View of the Front Door Window Regulator Removed from the Door<br />
4 Remove the chp from the pivot of the gUide armat<br />
the rear end of the WIndow hft channel<br />
5 Raise the WIndow to the closed poslhon and hold<br />
m this pOSItion with rubber wedges<br />
6 Remove the two nuts and washers holdIng the<br />
gUide armshde to the door panel and remove the slide<br />
7 Remove the four screws holdmg the regulator to<br />
the door panel and lower the regulator down Inside the<br />
door<br />
lOCKIN4<br />
8ARREL<br />
I<br />
a LEt<br />
BARREL RETAINeR<br />
CLIP<br />
1<br />
I E BUTI<br />
LOCKING ROD<br />
LOCK<br />
8 Release the gUIde arm pivOt from ItS hole at the<br />
rearof the WIndow lIft channel<br />
9 Slide the regulator arm from ItS shde on the front<br />
end of the wmdow hft channel<br />
10 Remove the WIndow regulator umt from the door<br />
through the large aperature at the bottom of the door Inner<br />
panel InstallatIon IS a reversal of the removal procedure<br />
NOTE Make sure that the dust and splash shIelds arefitted<br />
correctly over the door panel apertures before fittmg the<br />
trim panel<br />
WINDOW GLASS<br />
To Remove and Instal<br />
1 Remove the mterIor handles and door trIm panel<br />
2 Remove the dust and splash shields from the door<br />
mner apertures<br />
HANDL<br />
H<br />
ETAINING CLIP<br />
Front Door Lock Componenu<br />
218<br />
THRUST WASHER<br />
REMOTECONTROL<br />
o
219<br />
SLIDE<br />
Body 3<br />
Front Door wIth Trim Panel Attached<br />
mM Front Door W l1dow<br />
Glass<br />
Front Door with Trim Panel<br />
Dust and Splash Shields Removed
4 Body<br />
3 Remove the wmdow regulator<br />
4 Ttlt the WIndow glass down at the front and up at<br />
the rear to release It from the glass runchannels<br />
5 Remove the glass through the top of the door at an<br />
angle remoVing the rear top corner first<br />
InstallatIon IS a reversal of the removal procedure<br />
DOOR LOCK AND REMOTE CONTROL<br />
To Remove and Instal<br />
I Remove the mterIor handles and door trIm panel<br />
2 Remove the dust and splash shields from the door<br />
Inner apertures<br />
3 Wmd the wmdow to the fully closed pOSItIon<br />
4 Remove the two screws holdIng the bottom sectIOn<br />
of the rear glass run channel and remove the channel<br />
through the door panel aperture<br />
5 Remove the smpper button from the Inside lockmg<br />
rod<br />
screws<br />
barrel<br />
6 Remove the door lock reiaInIng screws<br />
7 Remove the door lock remote control retalmng<br />
8 Disconnect the lockmg lever from the lockmg<br />
9 Remove the door lock assembly from the door<br />
through the aperture<br />
Installahon IS a reversal of the removal procedure<br />
ShOWing Door Lock Striker RH Front<br />
220<br />
y<br />
PUSH ROD<br />
ADJUSTING BLOCK<br />
r<br />
DOOR HANDLE<br />
FLAT WASHERS<br />
@<br />
@<br />
@<br />
@SHEAS<br />
NUTS<br />
Front Outside Door Handle Assembly shOWing<br />
0<br />
Adjusting POint of Push Rod<br />
OUTSIDE HANDLE AND LOCKING BARREL<br />
To Remove and Instal<br />
lock<br />
washers<br />
I Carry out the operatIOns as for removmg the door<br />
2 Remove the two outside handle retaInIng nuts and<br />
3 Remove the outside handle from ItS mountmg<br />
aperture m the door skIn and manipulate the door lock<br />
operatmg rod through the aperture<br />
Striker Plate Mounted on Door Pillar LH Rear
i<br />
4 Remove the retaIn1l1g chp for the lockIng barrel<br />
lever and remove the lever<br />
5 Remove the lock1l1g barrel<br />
sprIng retaInIng plate by<br />
slidIng It out of the reta1l1111g grooves m the barrel<br />
6 Remove the barrel from the door outer skm<br />
InstallatIon IS a reversal of the removal procedure<br />
talang particular care that the outside handle and loclang<br />
barrel weather seals are serVIceable<br />
TO RENEW AND ADJUST LOCK STRIKER<br />
I Mark the positIOn of the strIker plate With a pencIl<br />
2 Remove the three plullip head set bolts and remove<br />
the stnker plate mspect and replace parts where necessary<br />
3 To Instal the stnker plate the procedure<br />
INTERIOR HANDLES AND TRIM PANEL<br />
To Remove and Instal<br />
IS the<br />
The operatIng procedure IS the same as for the front<br />
door except that the door pull does not have to be<br />
removed<br />
WINDOW REGULATOR<br />
To Remove and Instal<br />
I Remove the InterIor handles and door trIm panel<br />
2 Remove the dust and splash shIelds from the door<br />
Inner apertures<br />
REGULATOR ARM AND SLI<br />
3 RE R DOOR<br />
Body 5<br />
reverse of the removIng operations With attention to the<br />
followmg adJustment pomts<br />
4 Refit the stnker plate accordmg to the pencIl<br />
marks made on remoVing refit the three set bolts but only<br />
tIghten them suffiCiently to hold the strIker plate 111<br />
posItion<br />
5 Close the door and push It firmly shut<br />
6 Lift the outside release lever and carefully open the<br />
door Without movmg the stnker plate<br />
7 TIghten the three mountIng set bolts and aga1l1<br />
close the door checlang the operatIOn of the door lock and<br />
strIker plate If further adJustment IS necessary open the<br />
door and slacken off the three set bolts and move the<br />
strIker plate a small amount In the dIrection reqUIred and<br />
retighten the three set bolts<br />
3 WInd the wmdow to the down pOSItion<br />
4 Remove the clip from the piVOt of the gUIde arm at<br />
the front end of the WIndow lIft channel<br />
5 Wmd the WIndow to the closed pOSItion and hold<br />
m thiS pOSItion With rubber wedges<br />
6 Remove the two nuts and washers holdmg the<br />
gUide armslIde to the door panel and remove the slIde<br />
7 Remove the four screws holdIng the regulator to<br />
the door panel and lower the regulator<br />
8 Remove the gUide arm piVOt from ItS hole In the<br />
frontend of the w1l1dow lift channel<br />
9 Slide the regulator arm from ItS slIde at the rear of<br />
the wmdow lift channel<br />
View of Rear Door With Trim Panel Removed<br />
221<br />
BUTTON<br />
WINDOW REGULATOR<br />
PIVOT<br />
RETURN SPRING<br />
REMOTE CONTROL<br />
GUIDE ARM PIVOT
6 Body<br />
1 11<br />
@<br />
@ NUTS<br />
@ A<br />
OCK WASHE<br />
t<br />
GUIDE ARM SLICE<br />
10 Lower the regulator to the bottom of the door<br />
and wmd the arm to the centre pOSItion align the gUide<br />
arm with the regulator arm and remove the regulator out<br />
through the large aperture<br />
InstallatIOn IS a reversal ofthe removal procedure<br />
NOTE Make sure the dust and splash shields are fitted<br />
correctly over the door panel apertures before fittmg the<br />
trim panel<br />
WINDOW GLASS<br />
To Remove and Instal<br />
I Remove the mtenor handles and door trIm panel<br />
2 Remove the dust and splash sluelds from the door<br />
Inner apertures<br />
3 Remove the WIndow regulator and WIndow stop<br />
and let the glass rest In the bottom of the door<br />
4 Remove the two screws at the top of the diVISion<br />
bar and the screw holdIng the bottom ofthe dIVISIOn bar to<br />
the door Inner panel<br />
5 Ease the quarter WIndow towards the front of the<br />
door with the dIVISIOn bar and rubber seal<br />
6 TIlt the quarter wmdow assembly and remove It<br />
from the door<br />
Jia 7 Lift the WIndow glass from the bottom of the door<br />
J up through the glass opemng and lilt the glass at an angle<br />
With the front top end bemg removed first<br />
8 Ease the glass out through Its opemng workmg<br />
from the outside ofthe door<br />
Installallon IS a reversal of the removal procedure<br />
After mstallIng make sure the glass moves freely In the<br />
slides Without undue side movement A small amount of<br />
adJustment IS obtamed by pOSItIonIng the dIVISIOn bar<br />
RE<br />
GLASS<br />
I<br />
WINDOW STOP<br />
2 2<br />
1<br />
Rear Door Window Regulator Assembly<br />
DOOR LOCK AND REMOTE CONTROL<br />
To Remove and Instal<br />
I Remove the mterIor handles and door trUll panel<br />
2 Remove the dust and splash shlelds from the door<br />
umer apertures<br />
t<br />
t<br />
e<br />
l DOOR PULL<br />
RemOVing the Rear Door Window Glass<br />
v<br />
Ii<br />
pi<br />
WINDOW REGULATOR
Rear Door Lock Removed<br />
TO REMOVE<br />
PIVOT<br />
E CLIP<br />
2LINK<br />
sNIPPER BUTTON<br />
SNIPPER ROD<br />
t SCREW<br />
e WASHERS<br />
oJl<br />
flUSH<br />
Rear Door Lock Components<br />
I Release the bonnet catch and open the bonnet<br />
2 USIng a pencIl mark around the outside edge of<br />
each lunge plate<br />
0<br />
@ WASHER<br />
lOCK WASHER 0<br />
NU<br />
Body 7<br />
Rear Door Outside Handle Removed<br />
3 WInd the WIndow to the closed posItIon<br />
4 Remove the return sprIng from the remote control<br />
5 Remove the two screws holdmg the remote control<br />
to the door Inner panel<br />
6 Remove the<br />
smpper button<br />
7 Remove the smpper<br />
screw washer and nylon bush<br />
rod and lockIng rod piVOt<br />
8 Remove the smpper rod from the door panel<br />
9 Remove the E chp nylon washer and the link<br />
connectIng the outside handle lever to the door lock lever<br />
10 Remove the door lock retaInmg screws and<br />
remove the door lock through the aperture<br />
InstallatIon IS a reversal of the removal procedure<br />
OUTSIDE HANDLE<br />
To Remove and Instal<br />
I Remove the mtenor handJes and door trIm<br />
2 Remove the dust and splash shield from the top<br />
rear door panel aperture<br />
3 Remove the E chp nylon washer and the hnk<br />
connectmg the outside handle lever to the door lock lever<br />
4 Remove the outside handJe retaInmg nuts and<br />
washers and remove the outside handJe from the door<br />
panel<br />
InstallatIon IS a reversal of the removal procedure<br />
takIng partIcular care that the outside handle weather seal IS<br />
serYIceable<br />
LINKAGE<br />
4 ENGINE BONNET<br />
223<br />
SEAL<br />
3 Cover both mudguards with a protectIve cover to<br />
prevent damage to the pamt work<br />
4 With the help of a second operator support the<br />
bonnet and remove the bonnet stay from ItS guide<br />
5 Remove the mountIng bolts holdmg the hInges to<br />
the bonnet and remove the bonnet
8 Body<br />
TO INSTAL AND ADJUST<br />
Engme Bonnet Lock Components<br />
I HoldIng the bonnet m the pOSItIOn prevIOusly<br />
marked fit the bonnet hInge bolts and tighten to Just over<br />
finger tIght<br />
2 Refit the bonnet stay Into ItS gUIde<br />
3 Close the bonnet and by pushmg With the hand<br />
posItIon the bonnet evenly In ItS openIng<br />
4 Open the bonnet carefully and tIghten the<br />
mountIng bolts<br />
TO REMOVE INSTAL AND ADJUST<br />
I Open the lid With a pencIl mark the edges<br />
5 LUGGAf E COMPARTME T LID<br />
of the<br />
mountIng plate to lid pOSItIon on both Sides<br />
2 WhIle supportmg the lId remove the two bolts from<br />
each hInge plate and remove the lid<br />
installatIOn IS the reversal of the removal procedure<br />
with the additIOn of the followmg pOInts<br />
I Tighten the mountIng bolts to Just over finger tIght<br />
and close the lId check for even clearance around the lId<br />
and push Into pOSItIon With the hands<br />
224<br />
Luggage Compartment L d HInge and TOrsion Bars<br />
5 Recheck for correct poslhomng If necessary<br />
loosen one bolt at a tIme to adJust<br />
6 Check the bonnet catch when the catch IS released<br />
the bonnet should pop up suffiCiently to enable the fingers<br />
to release the safety catch and lift the bonnet<br />
7 To adJust first mark the base pOSItIon with a<br />
pencIl then loosen the mountIng bolts and movethe catch<br />
m the deSIred duectIon tIghten the bolts and recheck<br />
Repeat as necessary to obtaIn the correct adJustment<br />
2 When the lid IS correctly pOSItIoned carefully open<br />
and hghten the lunge bolts and recheck<br />
3 To adJust the open pOSItIon of the boot hd mcrease<br />
the tensIOn of the torsIOn sprIngs by sluftIng their mounted<br />
posItIon With the 31d of a stout screwdnver<br />
TO REMOVE AND INSTAL LOCKING BARREL<br />
I Open the hd and lever the retaInmg clip from the<br />
lock and remove the lockIng barrel<br />
InstallatIon IS a reversal to the removal procedure
Luggage Compartment Lock and Striker Components<br />
225<br />
Body 9
Wheel type<br />
Wheel size<br />
WHEELS AND TYRES<br />
Pressed steel<br />
disc<br />
<strong>1600</strong> cc 330 2 mm<br />
With radial tyres<br />
Tyre type<br />
<strong>1600</strong> cc Sedan and StatIon<br />
Wagon<br />
OptIonal<br />
Tyre size<br />
Cross ply<br />
Radial ply<br />
Tyre Pressure Cold<br />
Normal Speed<br />
Under 112654 km 70 mph<br />
272 155 kg 600 lb load<br />
Cross ply front<br />
TO REMOVE<br />
rear<br />
I Apply the hand brake<br />
13 In<br />
330 2 mm<br />
13 In<br />
Cross ply<br />
Radial ply<br />
5 60 x 13<br />
165 SR 13<br />
I 96 kg cm2<br />
28 pSI<br />
2 109 kg cm2<br />
32 pSI<br />
2 Detach the hub cap fwm the wheel to be removed<br />
3 Unscrew the wheel nuts approximately<br />
three quarters of a turn<br />
4 Jack up the vehicle<br />
5 Remove the wheel nuts and Withdraw the wheel<br />
from the vehicle<br />
TO INSTAL<br />
I<br />
InstallatIOn IS a reversal of the removal procedure With<br />
attenhon to the followmg pOInts<br />
TIghten the wheel nuts In the order of I 3 2 and 4 and<br />
do not over tIghten<br />
TO MAINTAIN<br />
Proper tyre and wheel maIntenance IS essentIal for<br />
economical and safe operahon<br />
I Check and adJust tyre pressures when the tyres are<br />
In a cold conditIon Frequent loss of pressure should be<br />
mvestIgated and the leakage rectIfied<br />
NOTE Never adJust tyrepressures when the tyres are warm<br />
otherwISe pressures wIll be mcorrect when the tyres cool<br />
down<br />
SPECIFIC TIONS<br />
Under 112 654 km 70 mph<br />
340 194 kg 750Ib load<br />
Cross ply front<br />
rear<br />
I 69 kg cm2<br />
24 pSI<br />
I 96 kg cm2<br />
28 pSI<br />
General speeds<br />
165 S13 RadIal ply front I 96 kg cm2<br />
28 pSI<br />
I 96 kg cm2<br />
28 pSI<br />
When the vehicle IS operated under full load or at high<br />
sustamed speeds Increase the tyre pressure by the followlllg<br />
amount<br />
rear<br />
Cross ply rear only<br />
Torque Wrench SettIng<br />
Wheel nut<br />
Maxunum tIgh telling torque of wheel<br />
nuts<br />
I HEEl A D TYKE SSEMBL<br />
226<br />
0281 kg cm2<br />
4 pSI<br />
8 98 kg m<br />
65 ft lb<br />
2 Inspect tyres regularly for damage and abnormal<br />
wear Any abnormal wear may be due to one or more of<br />
the faults shown m the illustratIOns or hsted m the FAULT<br />
DIAGNOSIS sechon AttentIOn should be given to<br />
penetratIOns or cuts In the tyre wluch wIll allow the entry<br />
of mOIsture mto the carcass resultmg III premature faIlure<br />
3 Ensure that tyres are kept free of oIl or grease<br />
4 Inspect the wheel studs and nuts for thread damage<br />
and the stud holes m the wheels for elongal1on<br />
5 Check the wheels for rachal and lateral run out and<br />
for damage to the flanges and bead seats<br />
6 TIghten wheel retaInIng nuts to the correct torque<br />
7 Penodlcally rotate wheels and tyres accordIng to<br />
the Illustrahon sequence<br />
8 MaIntam correct wheel balance<br />
t<br />
I<br />
Diagram for Correct Wheel Rotation to Prolong Tyre<br />
Life and Mmlmlse Tyre Wear
TO REMOVE<br />
I Jack up the vehicle and remove the wheel<br />
2 Remove the valve cap and valve core<br />
3 Separate the mSlde bead from the Inside wheel<br />
flange and usmg tyre levers with rounded edges lever the<br />
bead of the tyre overthe Inside edge of the flange<br />
NOTE ExercIse extreme care during operatIOn<br />
2 TUBED TYKES<br />
3 to<br />
ensure that the levers do not damage the tube by forcmg It<br />
against thenm<br />
4 Push the valve of the Inner tube mto the tyre<br />
InterIor and withdraw the mner tube out between the mner<br />
bead of the tyre and the Inner flange of the wheel<br />
5 Separate the outside bead of the tyre from the<br />
outside flange at the wheel and USIng tyre levers With<br />
rounded edges lever the bead of the tyre over the mSlde<br />
flange of the wheel separatmg the two components<br />
TO INSTAL<br />
i Remove any loose or excessive scale or rust from<br />
the wheel flanges and finally clean with a WIre brush or<br />
emery paper<br />
2 PositIOn the mSlde flange of the wheel partJally<br />
Inside one of the tyre beads and USIng tyre levers In good<br />
conditIon lever the remaInder of the tyre bead over the<br />
flange onto the wheel<br />
TO TEST FOR LEAKS<br />
I With the wheel removed from the vehicle Inflate<br />
the tyre to the recommended pressure Immerse the tyre<br />
and wheel In a water tank and check for leaks<br />
2 Place the assembly m the tank so that the valve IS<br />
uppermost then submerge the valve and check for bubbles<br />
3 Release and allow the assembly to float enSUrIng<br />
the channel between the nm flange and the tyre IS filled<br />
With water carefully check for air bubbles emittIng from<br />
thiS area<br />
4 Turn the wheel assembly over and submerge the<br />
wheel rIvets If not already submerged and check for leaks<br />
5 Submerge the assembly and fill the channel<br />
between the flange and the tyre allow to float and check<br />
for leaks IfleakIng wipe area dry and mark the posltJon of<br />
the leak With chalk<br />
TO REPAIR LEAKS<br />
I Repau of a small fracture not exceedIng 2 38 mm<br />
0093 m m the tyre may be repaHed by applymg sealmg<br />
cement or dough WI<br />
h a swtable applicator<br />
2 Mmor repairs to the rIm seat can be effected by<br />
i<br />
Wheels and Tyres 2<br />
NOTE Durmg operatIOn 2 ensure that the pOSltlO1l ofthe<br />
tyre bead opposIte the sIde where the levers are applied IS<br />
seating In the well base of the wheel rim<br />
3 Place the Inner tube InSide the tyre and Insert the<br />
valve through the hole m the wheel<br />
Screw a valve core remoVing tool on the end of the<br />
valve to prevent the valve slippmg back Into the InterIor of<br />
the tyre when the other tyre bead IS bemg placed on the<br />
wheel<br />
4 Fit the second bead of the tyre over the wheel<br />
mner flange usmg the tyre levers or a rubber mallet and<br />
ensurIng that the side ofthe bead adJacent to the tube valve<br />
goes over the wheel flange last<br />
NOTE In the event of a tyre bemg marked With a balance<br />
dot place the dot adJacent to the valve stem to mamtaln<br />
COffect tyre balance<br />
3 TUBELESS TYKES<br />
227<br />
5 Stand the wheel and tyre UprIght fit the valve core<br />
and mflate the tube untIl the tyre beads commence to<br />
posltJon themselves on the wheel bead seats<br />
6 Bounce the tyre on the floor several times to<br />
posltJon the tyre beads agamst the wheel flanges Inflate the<br />
tyre and tube to the recommended pressure and finally<br />
check the valve core for leakage and mstal the valve cap<br />
deflatIng the tyre and holdmg the bead away from the seat<br />
and cleanIng offthe affected area<br />
3 To repair fractures not exceedIng 635 mm 0250<br />
In m dl3meter remove the tyre from the wheel and repau<br />
the fracture by msertIng a rubber plug coated In cement<br />
mto the hole With the needle proVided In the repaH kit<br />
Withdraw the needle after ensurIng It has fully penetrated<br />
the tyre and cut the rubber leaVing approximately 6 35<br />
mm 0 250 In protrudIng<br />
above the tread<br />
NOTE Should the fracture be In excess of 635mm 0250<br />
m the repaIr should be camed out by an authonsed tyre<br />
dealer<br />
4 If the valve stem IS leakIng deflate the tyre and<br />
remove from the wheel Remove the valve from the wheel<br />
and mspect for splittmg cruslung or dut between the wheel<br />
and the valve Clean area or replace If necessary<br />
When fittIng a new valve wet the valve stem and valve<br />
hole With soap and lIlsert from the InSide of the wheel<br />
USIng Schrader tool No 553 pull the valve through untIl<br />
correctly seated on rIm Do not use plIers or Similar hand<br />
tools to fit valve<br />
I
3 Wheels and Tyres<br />
TO REMOVE<br />
1 Remove the wheel from the vehicle remove the<br />
valve cap and core<br />
2 Separate both Inside and outside beads from the<br />
wheel flanges so that the beads arem the base of the rIm<br />
3 USIng tyre levers with rounded edges lever the<br />
beads of the tyre one at a tIme off the Inner flange of the<br />
wheel<br />
PrIor to removal use a soap solutIOn on the beads and<br />
wheel flange and see that the beads diametrIcally opposite<br />
the poInt of leverage are seatIng on the bottom of the<br />
well base<br />
TO INSTAL<br />
I Remove loose or excessive scale or rust from the<br />
wheel takIng care not to damage pamt Repamt the wheel<br />
If necessary<br />
2 Remove any dents from the rIm flanges and wipe<br />
clean With a mOIst rag<br />
3 Clean off the tyre beads mOIsten tyre<br />
surfaces and tyre levers With clean water or soap solutIOn<br />
beads rIm<br />
4 Fit the tyre In the normal way use narrow levers<br />
and takmg small bites to aVOId stram and damage to the<br />
beads AVOId damage at all times as the sealIng quality of<br />
the tyre IS deternuned by the condlhon of the bead<br />
5 Fit the second bead so that the part of the bead<br />
nearest the valve goes over the rImflange last<br />
Spotty or Irregular Wear Due to Misalignment<br />
Wear In Centre of Tread Due to Over Inflation<br />
228<br />
NOTE Do not use hammer or mallet to fit tubeless tyres<br />
Ens re that the balance mark on the tyre IS adJacent to the<br />
valve<br />
TO INFLATE<br />
I Holdmg the assembly UprIght<br />
bounce the tread of<br />
the tyre on the ground at several poInts around ItS<br />
perIphery ThiS wIll help to seat the beads on the tapered<br />
rIm seats and proVide a partIal seal<br />
2 With the valve core removed connect the air hose<br />
and Inflate the tyre untIl the beads have sealed correctly It<br />
may be necessary to bounce the tyre wlule mflatmg<br />
3 Remove the au hose fit the valve core and mflate<br />
the tyre to 2 81 kg cm2 40 pSI Test the tyre for leaks and<br />
deflate to the normal pressure<br />
TO INFLATE USING A TOURNIQUET<br />
1 Inflate the tyre With the assistance of a tourniquet<br />
use Dunlop tool No TT1 or ItS eqUivalent follow the<br />
fittIng mstruchons Included m the kit<br />
2 With the valve core removed Inflate the tyre unhi<br />
the beads are sealed agaInst the flanges Remove the hose<br />
fit the valve core and Inflate the tyre to 2 81 kg cm2 40<br />
pSI Test the tyre for leaks and deflate to normal pressure<br />
NOTE As an alternative method a tourniquet can be made<br />
by uSing a pIece of rope and a sUItable lever e g a bar tyre<br />
lever or a pIece of wood<br />
Wear Due to Incorrect Camber Angle<br />
Wear Due to Under Inflation
Abnormal wear on both sides of tread<br />
a Under InflatIOn of tyres<br />
b Over loadIng<br />
Possible cause<br />
2 Abnormal wear III centre of tread<br />
4 TYR WEAR DIAGNOSIS<br />
Remedy<br />
Wheels and Tyres 4<br />
Check and mflate to recommended pressures<br />
Reduce maxunum loadIng<br />
PossIble cause Remedy<br />
a Over InflatIon of tyres Check and reduce to recommended pressures<br />
3 Abnormal wear on U1Slde of tyres<br />
a Insufficient camber angle<br />
b Saggmg front coIl sprIng s<br />
c Loose or worn front hub bearIngs<br />
d Bent stub axle<br />
Possible cause Remedy<br />
e Loose or worn suspensIOn arm components<br />
4 Abnormal wear on outside of tread<br />
a ExceSSIVe camber angle<br />
b<br />
Incorrect coIl sprIng s fitted<br />
S Spotty or Irregular wear<br />
Check front end alIgnment and adJust as necessary<br />
Check and renew faulty spnng s<br />
Check and adJust or renewhub beanngs<br />
Check and renew faulty components<br />
Check and renewfaulty components AlIgn front end<br />
PossIble cause Remedy<br />
Check front end alignment and adJust as necessary<br />
Check and Instal recommended replacement sprIng s<br />
Possible cause Remedy<br />
a StatIc or dynamiC unbalance of wheel and tyre<br />
assembly<br />
b Lateral runout of wheel<br />
c ExceSSive In play wheel hub beanng<br />
d ExceSSive play m steerIng knuckle ball JOInts<br />
6 Lightly worn spots at centre of tread<br />
Check and balance wheel and tyre assembly<br />
Check and true up or renew wheel<br />
Check and adJust or renewhub bearIng<br />
Check and renew ball JOInts<br />
PossIble cause Remedy<br />
a StatIc unbalance of wheel and tyre assembly<br />
b Radial run out eccentrIcity ofwheel<br />
7 Flat spots at centre of tread<br />
a EccentrIc brake drum<br />
b Repeatedly severe brake applicatIOn<br />
c Lack oftyre rotatIOn<br />
Check and balance wheel and tyre assembly<br />
Check and renew wheel<br />
PossIble cause Remedy<br />
229<br />
Check and renew brake drum<br />
ReVise drIVIng habits<br />
PerIodically change tyres by rotatIon of wheel tyre<br />
assembly
S Wheels and Tyre<br />
8 Heel and toe wear sawtooth effect<br />
a Over loadIng<br />
b High speed drIvmg<br />
c Excessive brakmg<br />
PossIble cause<br />
9 Feathered edge on one Side of tread pattern<br />
PossIble cause<br />
a Sharp InSide edge excessive toe In<br />
b One tyre sharp Inside edge other tyre sharp outside<br />
edge<br />
230<br />
ReVise maximum loadmg<br />
AVOId as far as possible<br />
Revise dnvIng habits<br />
Remedy<br />
Remedy<br />
Check and adJust wheel alignment<br />
Check for bent steerIng arm and renew
LUBRICATION AND MAINTENANCE<br />
LUHUICATION SPE IFI ATIONS<br />
Capacllles and Grade ofLubncant Rear axle<br />
Capacity Sedan o 8 htre<br />
Engme<br />
Sump Without filter 4 0 htre Stahon Wagon<br />
7 Imp pt<br />
84 US pt<br />
Sump mcludIng filter 4 7 htre LubrIcant grade<br />
825 Imp pt SteerIng box<br />
9 9 US pt Capacity<br />
Grade of Lubncant SAE30 IOW 30<br />
<strong>Manual</strong> TransmissIOn<br />
Capacity<br />
LubrIcant grade<br />
AutomatIc transmiSSIOn<br />
Capacity<br />
LubrIcant grade<br />
or MS30<br />
I 7 litre<br />
30 Imp pt<br />
36 USpt SAE 80 HD<br />
7 0 litre<br />
125 Imp pt<br />
15 US pt<br />
AutomatIc<br />
transmiSSIOn<br />
flUid type<br />
A<br />
lubrIcant grade<br />
Rear Axle StatIOn wagon<br />
Capacity<br />
LubrIcan t grade<br />
CoolIng System<br />
Capacity<br />
Fuel tank<br />
Capacity<br />
1 ENGINE<br />
CRANKCASE AND OIL FILTER FUEL SYSTEM<br />
1 Check 011 daily and top up with speCified grade<br />
when necessary<br />
2 Dram and ftll the sump at the first 1000 km 600<br />
mIles agam at 3000 km 2000 nules ContInue to change<br />
011 at every 3000 km 2000 miles untIl the mileage readIng<br />
IS 10 000 km 6000 miles Subsequent changes every 5000<br />
km 3000 miles If vehicle IS operatIng under dusty or<br />
severe conditIons change oIl and filter more frequently<br />
3 Change the oIl filter every 10 000 km 6000 miles<br />
dUrIng 011 change or every SIX mon ths<br />
4 Clean the oIl filler cap filter every 10 000 km<br />
6000 mIles Wash In petrol dry out and re oIl<br />
COOLING SYSTEM<br />
I Check coolant level In radiator daily and top up<br />
with clean water when necessary<br />
2 Drain flush and refill the coolIng system With<br />
clean water every 10 000 km 16 000 km 6000 10 000<br />
miles<br />
231<br />
1 5 Imp pt<br />
1 8 US pt<br />
I 0 litre<br />
I 75 Imp pt<br />
2 I US pt<br />
SAE 80 HD<br />
o 33 litre<br />
05 Imp pt<br />
06 US pt<br />
SAE 80 HD<br />
10 litre<br />
I 75 Imp pt<br />
2 I US pt<br />
SAE 90 HD<br />
6 4 litre<br />
11 41 Imp pt<br />
1380 US pt<br />
45 5 litre<br />
10 Imp gal<br />
12 US gal<br />
I Clean the fuel pump filter every 10000 km 6000<br />
mIles and check fuel pump operatIon every 40 000 km<br />
12 000 mIles Change the fuel pump filter every 40 000<br />
km 24 000 mIles<br />
2 Remove au cleaner element every 5000 km 3000<br />
nules and tap out dust Usmg low pressure au blowout the<br />
remaInder of the dust Clean the air cleaner body and<br />
re Instal element<br />
The air cleaner element should be changed every<br />
40 000 km 24 000 nules or more frequently when<br />
operatmg under dusty conditIons<br />
Do not wash the paper type element m petrol or<br />
solvent of any kmd<br />
3 LubrIcate accelerator lInkage pOInts With a few<br />
drops ofengme oIl every 10 000km 6000 nules<br />
4 LubrIcate the carburettor linkage every 10 000 km<br />
6000 mIles With a few drops of engme oIl
2 Lubrication and Maintenance<br />
GEARBOX<br />
1 Check the oIl level and top up as necessary every<br />
5000 km 3000 nules with correct grade oflubrIcant<br />
2 Dram and refill the gearbox when the vehicle has<br />
completed 1000 km 600 nules and subsequently every<br />
40 000 km 24 000 mIles with the correct grade of<br />
lubrIcant<br />
PROPELLER SHAFT<br />
I Repack the ulllversal Jomts every 50 000 km<br />
30 000 mIles With lithIUm based grease<br />
FRONT SUSPENSION<br />
I Remove clean and repack the hub bearIngs WIth<br />
wheel bearIng grease every 50 000 km 30 000 mIles or<br />
earlier If operatIng under severe conditIons<br />
STEERING<br />
I SteerIng box IS filled on assembly and must not be<br />
over filled<br />
2 Check for leaks and If excessive<br />
BRAKE FLUID RESERVOIR<br />
2 TRANSMISSIO<br />
2 Replace the ulllversal Jomts when found to be<br />
unserViceable<br />
REAR AXLE<br />
I Check the 011 level m the rear axle and top up as<br />
necessary every 5000 km 3000 nuIes With the correct<br />
grade of lubrIcant<br />
2 Drain and refill the rear axJe when the vehicle has<br />
completed 1000 km 600 nuIes and subsequently every<br />
50 000 km 30 000 nuIes With the correct grade of<br />
lubncant<br />
3 SUSPE SION tND STEERING<br />
remove and<br />
I When diSC brakes are fitted flush and change the<br />
hydraulic brake flUid every 20 000 km 12 000 mIles With<br />
clean heavy duty hydraulic brake flUId<br />
ALTERNATOR<br />
I The alternator bearIngs are packed With grease<br />
dUrIng assembly and no further lubrIcatIng IS necessary<br />
dUrIng operatIon<br />
DISTRIBUTOR<br />
I Remove the dlstnbutor cap and rotor and IIlsert a<br />
few drops of 011 III the top of the distrIbutor shaft cam<br />
assembly to lubrIcate the cam bearIng every IO OOO lan<br />
6000 mIles<br />
2 Smear the distrIbutor cam lobes With a lugh<br />
meltIng pomt grease when the contact pOllltS have been<br />
removed for clealllng or renewal<br />
rectIfy refill WIth correct amount and grade of oIl<br />
3 Check 011 level III the steerIng box every 10 000 km<br />
6000 nuIes and top up With correct grade of 011 when<br />
necessary<br />
4 Clean the area surroundIng the suspensIOn ball<br />
Jomt and grease every 20 000 km 12 000 mIles<br />
5 Renew the lubrIcant In the suspensIOn ball JOInt<br />
every 50 000 km 30 000 miles<br />
6 LubrIcate the steerIng linkage every 20 000 km<br />
12 000 mIles<br />
7 Renew the lubrIcant In the steerIng hnkage every<br />
50 000 km 30 000 miles<br />
4 MISCELLtlNEOUS<br />
232<br />
BATTERY<br />
Check and top up electrohte With distIlled water as<br />
requued or at least fortlllghtly<br />
TYRES<br />
I Test and mflate when cold to recommended<br />
pressures as requued or at least fortlllghtly<br />
2 Rotate tyres every 10 000 km 6000 miles<br />
BODY<br />
I Check and lubrIcate the followmg components<br />
every 10 000 km 6000 mIles With dry lubrIcant Door<br />
locks and strIkers bonnet catch luggage lock and strIker<br />
2 Lubncate the followlIlg components With a few<br />
drops of engme 011 door lunges luggage compartment lock<br />
mechanism and lunges LubrIcate the hand brake lInkages<br />
clutch and foot brake lInkages and remote control lever<br />
3 USIng a SUitable rubber grease lubrIcate the brake<br />
shoe lInkages every40 000 Ian 24 000miles
IgllltlOn tImIng<br />
Engllle Idle speed<br />
<strong>Manual</strong> transmission<br />
AutomatIc transmission<br />
DistrIbutor<br />
Make<br />
Model<br />
Capacitor capacity adv<br />
Capacitor capacity ret<br />
Dwell angle<br />
POInt gap<br />
Spark plug<br />
Make<br />
Model<br />
Gap<br />
Alternator<br />
Make<br />
Model<br />
Capacity<br />
Carburettor<br />
Make<br />
Model<br />
Type<br />
Prunary vacuum Jet<br />
Secondary vacuum Jet<br />
Fast Idle settIng<br />
at full choke<br />
PrImary slow au bleed<br />
AIr pump<br />
Make<br />
Model<br />
Capacity<br />
Pulley ratIo<br />
Rehef valve opemng pressure<br />
Flow gUide valve<br />
Make<br />
EMISSION CONTROL<br />
lltPECIFIC TIONS<br />
10 deg btdc Model FGA 2 FGA I<br />
700 rpm<br />
Opelllng pressure<br />
720 rpm In N AntI backfire valve<br />
10 mm Hg<br />
0 4 In Hg<br />
575 In D Make Hitachi<br />
Type Gulp<br />
Hitachi Model I AV54 IB<br />
D41259 DuratIon time 15 19sec<br />
o 22 mfd DuratIon pressure 500 mm Hg<br />
o 05 mfd 19 7 In Hg<br />
49 55 deg<br />
Check valve<br />
o 508 mm Make Hitachi<br />
0020 In Model CV27 2<br />
NGK<br />
Opemng pressure<br />
BP 6E Speed detector and speed sWitch<br />
o 80 0 90 mm Make NIles<br />
015 mm Aq<br />
590 In Aq<br />
0031 0035In Model Slgnex No 57001<br />
Current start<br />
20 km h<br />
Hitachi or 125 mph<br />
Mltsublshl<br />
LT133 04 or<br />
AG2033A TORQUE WRENCH SETTINGS<br />
12 volt<br />
33 amps<br />
Check valve to galley<br />
105 kg m<br />
76 lb ft<br />
Hitachi Air pump to cyhnder block 13 kg m<br />
DAF 328 6<br />
951b ft<br />
DAF 328 8 AIr pump adJustmg bar 2 5 kg m<br />
DAF 328 10 18 Ib ft<br />
Dual th roat AdJustlllg bar to cover I 3 kg m<br />
downdraft<br />
9 5 lb ft<br />
150 Gallery to exhaust malllfold plug 6 0 kg m<br />
130<br />
16 deg<br />
150<br />
InJectIon nozzle to cyhnder<br />
head Sports<br />
Gallery to nozzle flange<br />
435Ib ft<br />
7 6 kg m<br />
55 lb ft<br />
Hitachi screw Sports 6 0 kg m<br />
ECP 140 1<br />
435lb ft<br />
140 cc Rotor rIng retaInmg screws 50 kg m<br />
118103<br />
3 6 lb ft<br />
254 mm Hg Pump coverbolts 130 kg m<br />
10 In Hg<br />
Hitachi<br />
94Ib ft<br />
Air gallery to Injection nozzle 6 0 kg m<br />
DESnUI TIU<br />
To reduce carbon monoxide hydrocarbons and OXides<br />
of IlItrogen which are the three prunary automotIve<br />
emiSSIOns causlllg aIr pollutIOn three distInct types of<br />
emission control systems are used In the <strong>510</strong> SerIes <strong>Datsun</strong><br />
range ofvelucles<br />
Dependmg on pollutIon standards Involved the systems<br />
may be found to be fitted collectIvely or separately to the<br />
velucle<br />
233<br />
43Ib ft
2 Emissiou Control<br />
DESCRIPTION<br />
I CRA KCASE VE TILATIO liiYSIEM<br />
Two types of crankcase venhlatlon systems are used as<br />
standard eqUipment on the <strong>510</strong> serIes engInes<br />
One IS<br />
known as the sealed system and the other as the closed<br />
system<br />
The sealed system IS used on sports cars and the closed<br />
system on sedans statIon wagons and uhhtIes<br />
The Sealed System consists of a hose connectmg the<br />
rocker cover to the au cleaner assembly Pressure drop<br />
created withIn the aIr cleaner au assembly by flow permits<br />
crankcase vapours to flow from the crankcase Via the rocker<br />
cover mto the air cleaner assembly where they are drawn<br />
mto the mlet mamfold and consumed m the cylinders<br />
The engllle 011 dlpstJck and also the 011 filler cap are<br />
sealed to prevent crankcase fumes from escapIng mto the<br />
atmosphere<br />
To prevent au cleaner element 011 contamInatJon<br />
through crankcase vapour<br />
the hose mlet connectIon Into<br />
the au cleaner assembly IS so situated that the vapour<br />
enterIng the assembly does not pass through the element<br />
The Closed System draws clean InductIon au from<br />
withIn the aIr cleaner assembly through a meshed flame<br />
arrester and Into a hose which IS connected to the rocker<br />
cover<br />
The air IS then passed through the engIne and Into the<br />
Inlet mamfold VIa an 011 separator hose and regulatIng<br />
valve Crankcase vapours are thereby fed back mto the<br />
cylinders and consumed<br />
As with the sealed system the oil dlpstJck and filler cap<br />
are sealed from the atmosphere<br />
This system IS most effective at part throttle operatIOn<br />
where a partIcularly high vacuum IS m present the Inlet<br />
mamfold to allow the regulatIng valve to open and for all<br />
crankcase vapours to be scavenged from the crankcase At<br />
full throttle operatJon the manifold vacuum IS Insufficient<br />
to draw all crankcase vapours through the regulatIng valve<br />
and Into the Inlet mamfold Under these condltJons the<br />
crankcase ventIlatIon flow IS reversed With the fumes<br />
draWIng mto the aIr cleaner Instead ofthe IIllet manifold<br />
If the engme IS excessively worn and blow by IS at a<br />
hIgh level then Irrespective of throttle operatJon a certaIn<br />
amount of crankcase vapour will re cycle back through the<br />
rocker cover and Into the au cleaner<br />
A baffle plate and a meshed filter which IS located<br />
withIn the crankcase prevents engllle 011 from beIng drawn<br />
upwards Into the Inlet mamfold<br />
TO CHECK AND TEST OPERATION<br />
Arrangement of Positive Crankcase Ventilation System Components<br />
Sealed System As thiS system IS relatIvely sunple and<br />
does not IIlcorporate a regulatlllg valve It IS only a matter of<br />
perIodically checkIng the follOWIng components at the<br />
234
I<br />
HOSE AIR CLEANER TO VALVECOVER<br />
DIP STICK<br />
t<br />
AIR CLEANER BASE<br />
HOSE pcv<br />
VALVE TO CRANKCASE<br />
PCV VAt<br />
e<br />
OIL FILLER CAP<br />
0 RING<br />
HOSE CLIPS<br />
2<br />
Components of Positive Crankcase VentllatlOl1 System Note Inset PCV Valve DISpOsable type<br />
recommended IIltervals of 12 months or 18000 IGlometres<br />
12 000 miles<br />
I Check the rocker cover to au cleaner assembly<br />
hose for or collapslllg blocklllg deterIoratIon Renew the<br />
hose If after checkIng It IS found to be unserviceable<br />
2 Check the seals on the engme 011 filler cap and the<br />
dipstIck Renew the seals If they are damaged or If their<br />
sealing qualitIes are suspect<br />
Closed System The system should also be serviced at<br />
the recommended Intervals of 12 months or 18000<br />
kilometres 12 000 mIles with particular attentIOn gIVen to<br />
the regulatlllg valve<br />
I Check the conditIOn of the rocker cover to air<br />
cleaner assembly hose and also the crankcase to Inlet<br />
manifold hose Carefully check for blocklllg collapsmg or<br />
deterIoratIon Renew the hoses as found necessary<br />
2 Check the seals on the engme 011 filler cap and the<br />
dipstIck Renew the seals If they are damaged or If theu<br />
seahng qualities are suspect<br />
3 Check the operatIon of the ventIlatIOn regulatIng<br />
valve as follows<br />
With the engIne runnmg at a steady Idle speed<br />
DESCRIPTION<br />
The au InJectIon system In conJunctIon With the engIne<br />
modificatIOns system IS used on the <strong>Datsun</strong> <strong>510</strong> Senes<br />
vehicles to reduce the percentage of pollutant gases beIng<br />
expelled from the engIne exhaust<br />
It has been found that If clean filtered aIr IS mJected<br />
Into the exhaust port of each cylinder where unburnt<br />
hydrocarbons and carbon monoxide gases are present a<br />
chemical reactIon takes place resultmg m a final treatment<br />
r<br />
Emission Control 3<br />
DISPOSABLE PCV VALVE<br />
disconnect the hose from the regulatIng valve<br />
A shrp hlssmg nOIse will be heard at the valve when<br />
the hose IS disconnected<br />
Now place a finger over the valve mlet A strong<br />
vacuum should be Immediately felt as the finger IS placed<br />
over the valve<br />
If the regulatlllg valve IS found to be partIally or fully<br />
moperatIve then renew the valve as a complete assembly<br />
NOTE barly type PCV valves weredemountable and could<br />
be dIsmantled for cleaning Later type valves must be<br />
renewed when faulty<br />
4 A faulty regulatmg valve may give me to anyone<br />
or more of the follOWIng conditions<br />
a Black smoke emergIng from the exhaust<br />
b EngIne huntIng<br />
2 EXHAUST CO TROL S STE I<br />
235<br />
at Idle<br />
c EngIne Idle fluctuates but engIne does not stall<br />
d Loss of power and surgmg at speeds above Idle<br />
e Engllle stalls after stops and runs roughly after<br />
beIng restarted With IIldlcatIons of a lean mIXture<br />
of the exhuast to a level below the standards requued<br />
The carburettor and distrIbutor are specl3lly cahbrated<br />
and modified to assist In brIngIng the pollutant exhaust<br />
gases down to an ahowable level<br />
AIR INJECTION<br />
The baSIC components of the au InJectIon system are<br />
Au Pump Air InJection gallery and nozzle AntI<br />
backfire valve Check valve
4Emission Control<br />
VarIous hoses and clips are connected to these<br />
components See dIagram ofau InJectIOn system<br />
The au pump obtaIns clean air by means of a hose from<br />
the air cleaner assembly<br />
The air IS then compressed by the two vanes of the<br />
pump and delIvered to the air IIlJectlOn gallery and nozzle<br />
assembly at the exhaust manifold<br />
The air IIlJectlOn nozzles protrude down at a shght<br />
angle In to the exhaust manifold ports near the regIOn of<br />
the exhaust valves<br />
Fresh air IS then IIlJected mto the engine at these<br />
pOInts The air InJectIOn gallery and nozzle assembly IS<br />
deSigned m a manner to ensure that an even distrIbutIOn of<br />
air which IS drawn III through the check valve IS supplIed<br />
to each exhaust port<br />
A check valve IS fitted to the air delivery lIne at the<br />
mJectIon gallery The prIme purpose of the valve bemg to<br />
prevent exhaust gases enterIng the au pump when the<br />
exhaust mamfold pressure exceeds the pump InJectIon<br />
pressure<br />
The valve wIll also close agaInst the exhaust mamfold<br />
pressure In the event of complete air pump faIlure<br />
To prevent backfinng In the exhaust system when the<br />
throttle valve IS closed at high speed and a coastIng<br />
conditIOn eXists an antI backfire valve IS Installed between<br />
the Inlet manifold and the air dehvery lIne<br />
It IS known that when a coastlllg condlton eXists an<br />
over rIch mIXture which IS too rIch to completely burn IS<br />
drawn Into the Inlet mamfold and through the engllle Into<br />
the exhaust mamfold where It would Igmte due to the<br />
InstallatIon of the au InJectIon system<br />
The antI backfire valve provides the Inlet mamfold With<br />
the necessary amount of air to obtalll a deSirable leaner<br />
mIXture wluch will burn completely In the combustIOn<br />
chamber and npt In the exhaust malllfold dUrIng coastlllg<br />
The valve IS controlled by a small senSIng hose or brIdge<br />
pipe which relays high manifold vacuum due to<br />
deceleratIon to the antI backfire valve senslllg chamber<br />
The valve dlaphram wluch IS sprIng loaded reacts on thiS<br />
vacuum and IS drawn downwards to open the air valve to<br />
DRIVE PULLEY<br />
AIR PUMP<br />
AIR CLEANER<br />
PUMP SilENCER<br />
INDUCTION MANIFOLD<br />
ANTI BACKFIRE<br />
VALVE<br />
236<br />
supply air pump pressure to the Inlet mamfold The valve<br />
only remaInS open m proportIon to the amount of vacuum<br />
sensed by the dlaphram<br />
AIR PUMP<br />
NOTE The aIr pump which IS a two vane positIve<br />
displacement type IS permanently lubricated and reqUIres<br />
no mamtenance whIle In servIce Do not remove the pump<br />
or assocIated components from the vehIcle unless It IS<br />
absolutely necessary If a malfunctIOn occurs m anypart of<br />
the system ItIS Important that a carefUL test IS camed out<br />
on the suspect component to ensure that It IS m fact<br />
unservIceable before removmg and carrying out the<br />
necessary repairs or replacements<br />
To Remove<br />
I RaIse the engIne bonnet and fit fender covers to<br />
both front fenders<br />
2 Disconnect the hoses from the pump end cover<br />
3 Slacken the pump adJustmg bracket bolt and also<br />
the pump mountIng bolt<br />
4 Push the pump towards the cyhnder<br />
block and<br />
detach the dnve belt from the pump pulley<br />
5 Now completely remove the adJustIng bracket and<br />
mountIng bolts and lIft the au pump assembly from the<br />
engIne compartment<br />
To Dismantle<br />
I Remove the four pump pulley attachIng bolts and<br />
separate the pulley from the pump hub<br />
2 Grasp the pump pulley hub m a vice and USIng a<br />
AIR INJECTION NOZZLES<br />
AIRGAll<br />
AIR SENSING PIPE<br />
J1<br />
CHECK VALVE<br />
Schematic diagram of Air Injection System
HOUSING COVER<br />
SHOE SPRING<br />
ROTOR RING<br />
@<br />
REAR BEARING<br />
DOWEL<br />
CARBON SHOES<br />
ROTOR RING SCReW 61 SHOE SPRING<br />
sUItable sized rIng spanner unscrew the four pump cover<br />
retammg screws<br />
3 With a soft faced hammer carefully tap the end<br />
cover upwards to break ItS seal and then remove It from the<br />
pump body<br />
NOTE Only tap the end cover In the Vlcmlty of the large<br />
dowel<br />
pm to remove Itfrom the pump body Under no<br />
cIrcumstances use screwdnvers or sImIlar probes to prlse<br />
between the matmg surfaces of the end cover and pump<br />
body<br />
4 Inspect the rotor nng and rotor for factory<br />
assembly marks If no marks are vIsible then sUItably mark<br />
the rotor rIng and rotor to ensure correct reassembly<br />
5 Select a sUitable sized Allan key and remove the<br />
rotor rIng attachmg screws<br />
the rotor<br />
PUMP HOUSING<br />
6 Carefully lift the rotor rIng from the end face of<br />
SHOE S1RING<br />
CARBON SHOES<br />
Diagrammatic end view of Ar Pump<br />
237<br />
PUMP HOUSING<br />
DRIVE PULLEY<br />
Emission Control 5<br />
Exploded View of Air Pump Components TYPical<br />
7 Withdraw the vane assembly from the slots In the<br />
rotor<br />
8 Usmg a sharp long nosed paIr of pliers carefully<br />
grasp and then remove the four carbon shoes from the<br />
rotor<br />
9 Remove the two shoe sprIngs from the two deeper<br />
shoe slots m the rotor<br />
10 Further dismantlIng of the au pump assembly IS<br />
unnecessary and therefore should not be attempted<br />
To Clean and Inspect<br />
1 Thoroughly clean the pump rear bed rIng and the<br />
vane hub beanngs m a SUitable clealllng solvent<br />
2 Usmg a stream of compressed<br />
dust from the pump hOUSIng and rotor assembly<br />
aIr remove all carbon<br />
NOTE Do not use cleanmg solvents or any other cleaning<br />
agents on the pump housmg and rotor assembly If<br />
compressed aIr IS unavaIlable use a clean pIece of fluffless<br />
cloth to wipe away the carbon dust from the housmg and<br />
rotor<br />
3 Inspect the varIOUS pump components for<br />
chlppmg scorIng and excessive wear<br />
4 Check the carbon shoe sprIngs for loss of tensIOn<br />
by comparIng wIth a new sprIng<br />
5 Adequately lubrIcate the pump rear bearIng and<br />
the vane hub bearIngs with a high meltIng pomt grease<br />
Work the grease well mto each bearIng with the fingers Just<br />
prIor to assembling the pump<br />
6 Check the aIr pump dnve belt for servlceablhty<br />
Renew the belt IfIt IS 011 soaked cracked orworn<br />
To Assemble<br />
I Support the purnp housmg assembly by the pulley<br />
hub In a vice so that the end cover IS aperture uppermost<br />
faCIng the operator<br />
2 Assemble the vanes onto a dummy shaft made up<br />
out of a sUitable length 01 95 mm 0374 In dIameter<br />
round steel<br />
P
6Emission Control<br />
3 Carefully lower the vanes and dummy shaft as an<br />
assembly Into posItion m the rotor<br />
4 Shde the four carbon shoes down Into the rotor so<br />
that when fitted a carbon shoe IS posItioned at each Side of<br />
each vane<br />
NOTE The chamfered portion of each carbon shoe must<br />
be facmg towards Its respect vane when being Inserted Into<br />
the rotor<br />
5 Fit the two shoe sprIngs to the two deeper slots<br />
behInd the shoes<br />
NOTE When Installed the curved portIOn of the spnngs<br />
must be abutting the shoes They should beflush ora little<br />
below the rotor surface Ifcorrectly Installed<br />
6 Align the marks prevIOusly noted or made dUrIng<br />
dlsmantlmg and posItion the rotor rIng onto the rotor<br />
7 Apply Lockhte or any other sunIlar thread lockmg<br />
materIal to the threads of the rotor rIng attachmg screws<br />
8 Instal the rotor rIng attaclung screws and tighten to<br />
the specified torque See SpeCificatIons for correct torque<br />
settIng<br />
9 Withdraw the dummy shaft from the pump vanes<br />
and carefully posItIon the pump end cover onto the pump<br />
body DUrIng thiS operation align and then ensure that the<br />
vane shaft enters freely through the vane hub bearIngs<br />
10 When satIsfied that the pump end cover IS seated<br />
correctly fit and then hghten the four end cover retaInIng<br />
bolts See SpecificatIons sechon for torque settIng<br />
NOTE When tlghtemng the end cover retainIng bolts start<br />
from the bolt adJacent to the large dowel and then work<br />
around the cover<br />
II Remove the air pump assembly from the vice<br />
To Instal<br />
1 Instal the air pump to the engme and loosely fit<br />
the mountmg and adJustIng bracket bolts<br />
2 Push the pump towards the cyhnder<br />
engage the drIve belt<br />
block and<br />
3 Now pull the air pump away from the cylinder<br />
block suffiCiently to give the belt enough tensIOn to prevent<br />
It slippIng on the pulleys<br />
4 Hold the au In<br />
pump thiS pOSItion and securely<br />
lighten the adJustIng and mountIng bracket bolts<br />
5 Install the three hoses to the pump end cover and<br />
securely tIghten the retaInIng chps<br />
NOTE Do not over tensIOn the drive belt as thIS could<br />
cause rapId wear m the aIr pump beanngs The belt WIll<br />
have sufficIent tensIOn when If can beflexed approxImately<br />
127 mm 050 In with finger and thumb pressure applied<br />
between the pulleys<br />
238<br />
To Test<br />
Non Jf apparent malfunction of the aIr pump has<br />
occurred the follOWing procedure should be camed out to<br />
ensure that the airpump IS Infact at fault<br />
1 Check the drIve belt tensIOn and adJust If<br />
necessary<br />
2 Start and run the engIne untIl It reaches normal<br />
operatmg temperature<br />
3 Check all hoses and hose connectIOns etc for au<br />
leaks Rechfy leaks as found necessary before carrymg on<br />
any further with the pump test<br />
4 Loosen the hose clamp and disconnect the au<br />
supply hose at the check valve<br />
5 Instal the test gauge adaptor to the air supply hose<br />
and tIghten the hose clamp to prevent the adaptor blowmg<br />
out<br />
NOTE Ensure that the open pIpe end of the test gauge<br />
adaptor IS Installed to the supply hose Instal the adaptor In<br />
a manner so that the aIr whIch WIll be emitted through the<br />
dnlledplug WIll beharmlessly expelled<br />
6 Connect a tachometer to the engme distrIbutor<br />
7 Run the engIne at a constant 1500 rpm and note<br />
the pressure which IS produced at the test gauge<br />
8 The au pressure on the test gauge should read at<br />
least 12 mm Hg 047 m Hg for all vehicles except <strong>Datsun</strong><br />
Sports On <strong>Datsun</strong> sports car the readIng should be at least 16<br />
mm Hg 0 63 In Hg<br />
9 If the air pressure readIngs on the test gauge are<br />
lower than those Just mentioned for the model apphcable<br />
then contmue by makIng the followmg tests<br />
10 Disconnect the air supply hose from the<br />
anll backfire valve SUitably plug the hose and repeat the<br />
pressure test with the antI backfire valve Isolated<br />
11 If pressure IS stIli low then check the air cleaner<br />
element for blockIng Renew If necessary<br />
12 Run the engine at 1500 rpm and USIng finger<br />
pressure close the hole In the test gauge adaptor If air<br />
pressure can be felt or heard commg out of the pump relIef<br />
valve then the valve caD be deemed unserviceable m wluch<br />
case It should be renewed or repaued<br />
13 If all abovementioned checks have been carned<br />
out and pump air pressure IS stIll below that recommended<br />
then the air pump assembly<br />
CHECK VALVE<br />
To Test<br />
should be renewed<br />
I Start and run the engIne untIl It reaches normal<br />
operatIng temperature<br />
2 Check all hoses and hose connections etc for air<br />
leaks Recllfy all air leaks as found necessary before<br />
carrYIng out the valve test
3 With the engllle at rest dJsconnect the air supply<br />
hose at the check valve and visually mspect the Inside of the<br />
check valve through the IIllet aperture The valve plate<br />
should be lightly bearIng agaInst the valve seat away from<br />
the Inlet manifold<br />
4 USIng a sUItable probe lift the valve plate and check<br />
to ensure that It returns to ItS orIginal posItIon agamst the<br />
seat<br />
5 With the check valve supply hose still<br />
disconnected start and run the engIne<br />
6 Slowly mcrease engllle speed to 1500 rpm and<br />
visually check for exhaust gas leakage at the check valve<br />
aperture Renew the valve If It IS found to be Ieakmg<br />
exhaust gas<br />
NOTE Due to exhaust manfold pulsatIOns It IS quite<br />
normal for the check valve to flutter or VIbrate at Idle<br />
speed<br />
To Remove and Instal<br />
1 Disconnect the aIr supply hose at the check valve<br />
2 Unscrew the check valve from the air gallery pipe<br />
while holdlllg the au gallery flange with a SUitable pipe<br />
wrench Care should be exercised to<br />
ensure that the air<br />
gallery IS not distorted<br />
3 InstallatIon of the valve IS a reversal of the removal<br />
procedure See SpecificatIOn sectIOn for correct torque<br />
settlllg for valve<br />
ANT BACKFIRE VALVE<br />
To Test<br />
I Start and run the engine untIl it reaches normal<br />
operatIng temperature Check all hoses and hose<br />
connectIons etc for au leaks Rectify all au leaks as found<br />
necessary before carryIng out the valve test<br />
2 Disconnect the air supply hose at the mlet<br />
malllfold Side of the anh backfire valve Plug the hose and<br />
SUItably clamp to prevent the plug from dlslodIng under<br />
pressure<br />
3 With the engIne runnIng place a finger hghtly over<br />
the valve outlet and then rapidly open and close the<br />
throttle valve via the throttle lever<br />
If the valve IS functIonIng correctly au pressure should<br />
be felt With the fingers at the valve outlet for one or two<br />
seconds<br />
If no air flow IS felt With the fingers or If a contInUOUS<br />
air flow IS present then the valve IS unserviceable and m<br />
which case It should be renewed<br />
4 Remove the plug and connect the air hose back to<br />
the Inlet malllfold Side of the valve<br />
5 Now disconnect the air supply hose at the aIr<br />
pump Side of the valve If It IS found that the engIne<br />
Idle<br />
speed changes excessively when the hose IS disconnected<br />
239<br />
Emission Control 7<br />
Sectional VIewof System Check Valve III open position<br />
then the valve IS not functIOnIng correctly and should be<br />
discarded and a new valve IIlstalled<br />
NOTE It IS not abnormal for a backfiring<br />
condition to<br />
eXIst m the exhaust when the valve IS dIsconnected while<br />
testmg<br />
To Remove and Instal<br />
I Disconnect the aIr hoses from the mlet mamfold<br />
and the air pump Sides ofthe valve<br />
hose<br />
2 Disconnect the valve to mlet mamfold sensIng<br />
3 The valve can now be removed from the vehicle<br />
InstallatIon IS a reversal of the removal procedure<br />
Check the valve for correct operatIOn as well as for air<br />
and vacuum leaks<br />
AIR INJECTION GALLERY AND NOZZLES<br />
As the au gallery and InJectIon nozzles are very<br />
difficult to remove from the vehicle Without bendmg or<br />
fractunng pipes It IS the efore recommended that they only<br />
be removed Iffound to be damaged or unserYIceable<br />
To Remove and Instal<br />
Sedan and StatIOn Wagon<br />
I Apply penetratIng oIl to the threaded sectIons of<br />
the InjectIOn nozzles m the exhaust mamfold
J<br />
BEmission Control<br />
Cross section of Cylinder Heed showlIlg<br />
2 Usmg a sUItable pipe wrench loosen the umon nuts<br />
at the InJecllon nozzles<br />
3 Disconnect the air supply hose from the check<br />
valve and then remove the air gallery from the nozzles at<br />
the exhaust mamfold<br />
4 Select a length of hard wire and form a hook on<br />
one end wluch will be small enough to enter the bore ofthe<br />
nozzles<br />
5 Insert the hook end of the wire down the bore of<br />
the nozzle far enough to allow the hook to engage<br />
on the<br />
nozzle lower lip then pull upwards and remove the nozzle<br />
6 Remove the other three nozzles m the same<br />
manner keepIng them In their respectJve order<br />
7 Thoroughly clean all nozzles WIth a wue brush and<br />
check for fractures Of apparent leakage<br />
8 Poslllon each nozzle correctly Into ItS respecllve<br />
In aperture the exhaust mamfold<br />
9 Assemble the air gallery to the InJectJon nozzle and<br />
lighten the umon nuts to the specified torque See<br />
SpeclficatJon sectIOn for correct torque settmg<br />
10 Connect the alf supply hose to the check valve<br />
start and run the engIne and check for exhaust and air<br />
leakage<br />
To Remove and Instal<br />
Sports<br />
1 Apply penetratmg oIl to the JOInmg sectIOns of the<br />
InjectIOn nozzles and air gallery<br />
2 Disconnect the air supply hose at the check valve<br />
3 With a sUltdble sized spanner hold the hexagon<br />
heads 01 the mJectloll nozzles dnd then loosen the flange<br />
screws attachmg the dlr gallery to the nozzles<br />
4 When all screws are loosened suffiCiently detach<br />
the air gallery from the nOZLles<br />
5 Loosen and Ihen remove the mJecllon nozzles from<br />
the cyhnder hedd If necessary keep applYIng penetratmg<br />
011 to the threaded portion of the nozzle<br />
6 Thoroughly clean all nozzles With a wire brush and<br />
check the nozzles and the air gallery for fractures or<br />
damage<br />
240<br />
Au Injection Nozzle In Exhaust Manifold<br />
7 Assemble the nozzle seats to the nozzles and then<br />
mstal the nozzles to the cylInder head See Speclficallons<br />
secllon for correct torque settIng<br />
8 Assemble the air gallery to the InJectIon nozzles<br />
and fit and lighten the gallery to nozzle flange screws See<br />
SpecificatIOns sectIOn for torque settIng<br />
NOTE It Will be necessary to hold the hexagon heads of<br />
the mJectlon nozzles with a flat spanner when tlghtemng<br />
the gallery flange screws<br />
9 Connect the air supply hose to the check valve<br />
start and run the engIne and check for exhaust and air<br />
leakage<br />
ENGINE MODIFICATIONS<br />
The engme modlflcallon system IS deSigned to control<br />
the operatIon of the dual pomt distrIbutor and the<br />
carburettor deceleratIOn deVice when certaIn drIVIng<br />
conditIons eXist to aid In redUCIng hydrocarbon emiSSion<br />
As shown m the dIagrams vanous sWitches are used to<br />
acllvate the carburettor solenOId and the retard Side of the<br />
dual pOInt distrIbutor See dIagram for model apphcable<br />
SWitch on and off positIOns m relatIOn to engIne<br />
operalion are also dIagrammallcally shown for the different<br />
models<br />
As an example on sedan and stallon wagon With<br />
manual transmissIOn the carburettor solenOId sWitch IS<br />
ortly energized dUrIng deceleratIOn when the three<br />
follOWIng condlllons eXist<br />
I The clutch pedal IS at rest In the out poslllon<br />
2 The accelerator pedal IS at rest In the out poslllon<br />
3 The transmiSSion IS engaged m any gear except<br />
neutral<br />
Similarly the retard Side of the dual pOInt distrIbutor IS<br />
only energized to retard Ignlllon tJmmg 10 deg when these<br />
three follOWIng condlllons eXist<br />
I The clutch pedal IS at rest In the out position<br />
2 The transmission IS engaged III the third speed<br />
positIOn<br />
3 The carburettor throttle valve IS opened wlthlll the
ange of 35 deg from Idle and the THI sWitch<br />
plunger see IllustratIon has not been pushed<br />
NOTE By followmg the dlfjerent sWitch posItIOns and<br />
circuits III the diagrams It can be seen that the retard sIde of<br />
the dual pOint dIstributor and the carburettor solenOId<br />
cannot operate at the same tIme ThiS IS applicable for all<br />
models<br />
DUAL POINT DISTRIBUTOR<br />
The two sets of breaker pOllltS In the distrIbutor are<br />
located opposite to one another and are both mounted<br />
Independently on the distrIbutor breaker plate assembly<br />
however a common condensor IS used The capacitor<br />
capacity varIes dependlllg on the breaker pOllltS which are<br />
operatIng<br />
Both sets of breaker are pOllltS situated III parallel the<br />
prImary IgllltlOn CIrCUIt and should be adjusted With the<br />
adJustIng screws available to operate on a phase difference<br />
of5 deg III distrIbutor rotor travel 10 deg flywheel<br />
When the relay for the retard set of breaker pOInts IS<br />
energized the engIne operates on the advanced set of<br />
breaker III pOllltS the distrIbutor to achieve an IIlltIal<br />
ddvance In IgllltlOn tImmg of 10 deg btdc<br />
When drIvlllg conditIOns allow the vanous sWitches to<br />
close and complete the CIrCUIt to energize the relay the<br />
engIne will commence operatIng on the retard set of<br />
breaker pOInts III the distrIbutor The IgllltlOn tImlllg alters<br />
accordIngly and the engllle should now be runnIng WIth an<br />
IgllltlOn tImmg of tdc giVIng a total retard of 10 deg In<br />
flywheel travel between the two sets of breaker pOllltS<br />
To Test Vehicles fitted WIth <strong>Manual</strong> TransmISSIOn<br />
I Disconnect the two low tensIOn lead wires from<br />
the distrIbutor termInals<br />
2 Connect an ammeter between the lead WIre which<br />
was disconnected from the retard contact termInal and<br />
earth<br />
3 Turn the IgmtlOn key to the on posItIon but do<br />
not start the engIne<br />
4 Engage the transmiSSIOn In the thIrd speed posItIon<br />
and partIally open the throttle valve With the transmiSSion<br />
and throttle valve set In these posItIons the ammeter should<br />
be IIldlcatIng approximately 3 ampere<br />
5 Now shift the transmission to any other gear<br />
except third and either fully open or nearly close the<br />
throttle valve The ammeter should now Indicate zero<br />
6 If the ammeter faIled to In<br />
regIster operatIOn 4<br />
then check the relay termmals for looseness<br />
7 If the relay termmals are tIght disconnect the lead<br />
wife from the throttle sWitch Side of the relay and check<br />
the voltage between the lead WIre and earth If<br />
approxunately 12 volts IS registered on the voltmeter then<br />
the relay IS unserYIceable and should be renewed<br />
8 If no voltage was registered on the voltmeter then<br />
check the contInUIty of the CIrCUIt back through the wifing<br />
Emission Control 9<br />
and sWitches m the CIrCUIt Start from the clutch sWitch<br />
See dIagrams for sWitch posItIons and CirCUIt<br />
To Test Vehicles fitted With Automahc TransmissIOn<br />
1 Disconnect the lead<br />
retard contact pOInt termlllal<br />
wue from the distrIbutor<br />
2 Connect an ammeter between the lead wire Just<br />
removed and the dlstnbutor retard LT termmal<br />
3 Start and run the vehicle on a chaSSIS dynamometer<br />
or on the road Operate the vehicle over 13 mph With<br />
partially opened throttle Under these drIVlllg condlhons<br />
the ammeter should be registerIng some amperage<br />
4 Operate the vehicle at varYIng road speed and<br />
throttle pOSItIons other than those descrIbed III operatIon<br />
3 The ammeter should now register zero<br />
5 If It IS found that the system IS not operatIng<br />
correctly then stop the vehicle and check out the varIOUS<br />
SWitches and wifing<br />
TO PHASE DISTRIBUTOR<br />
1 AdJust the two sets ofdlstnbutor breaker pOInts to<br />
a gap of 0 508 mm 0 020 In<br />
2 Connect a tachometer dwell angle meter and<br />
tunIng hght to the engllle<br />
3 Start and run the engIne unhl It reaches normal<br />
operdtIng temperature<br />
4 AdJust the Idle speed to 700 rpm for manual<br />
transmISSIOn or 720 rpm for automatIc<br />
ADVANCED CONTACTS<br />
241<br />
CAPACITOR<br />
1 1<br />
o<br />
2<br />
ADVANCED CONTACT<br />
LT TERMINAL<br />
l<br />
RETARDED CONTACTS<br />
RETARD CONTACT l T TERMINAL<br />
Dual Contact Distributor shOWing phaSing of retarded<br />
contacts<br />
1<br />
f<br />
l
l<br />
10 EmissioR Control<br />
5 USlllg the dwell angle meter check the dwell angle<br />
of the advanced set of distrIbutor breaker pOInts The dwell<br />
angle should be between 49 and 55 deg If necessary alter<br />
the gap on the advanced set ofbreaker pOInt to obtaIn this<br />
angle 6 Now connect a Jumper lead between the<br />
distrIbutor advance breaker pOInt terrmnal and the retard<br />
breaker pomt termmal Then check and adJust If<br />
necessary the dwell angle on the retard set of contact<br />
pOInts Agalll the dwell angle should be between 49 and 55<br />
deg 7 Remove the Jumper lead and with the aid of the<br />
tunmg light set the IgnitIon tImIng at 10 deg btdc<br />
NOTE ThIs reading wIll be for the advanced set of contact<br />
pOIn ts<br />
8 Connect the Jumper lead back between the advance<br />
and retard contact pomt termInals<br />
9 As soon as theJumper lead IS connected the engIne<br />
speed should drop by approxunately 100 rpm<br />
10 Usmg the tmung hght check the 19mtIon tunIng<br />
which wIll now Indicate tunIng for the retard set ofcontact<br />
pOInts<br />
If the contact pOInt phaSIng IS tImIng<br />
correct the IgnitIon<br />
should now be at tdc<br />
11 Ifthe IgmtlOn tImmg IS not at tdc stop the engIne<br />
and<br />
USIng the available adJustmg screws see illustratIon<br />
slightly adJust the posItIon of the retard set of contact<br />
pOllltS<br />
I2 Start the engIne and recheck the IgmtlOn tunIng<br />
If the IgmtlOn tunIng IS still not at tdc repeat the<br />
adJustments as descrIbed In operatIon II until the correct<br />
tdc readIng IS obtaIned<br />
13 When satIsfied that the IgmtIon tunIng IS correct<br />
for the retard set of contact pOInts disconnect theJumper<br />
lead between the distrIbutor termlllals and recheck IgmtlOn<br />
tImIng for the advanced set of pomts<br />
NOTE If the engine Idle mIXture IS being adJusted<br />
dIsconnect and plug the air supply hose at the check valve<br />
Use a carbon monoxIde meter and obtam a readmg of<br />
approxImately 30 per cent by turning the Idle mIXture<br />
screw Reconnect the air supply hose before finally setting<br />
Idle speed See specIficatIOn sectIOn for Idle speeds<br />
CLUTCH SWITCH<br />
To Test<br />
I Check to ensure that the clutch sWitch lead wire<br />
termInals are Insulated from the sWitch body<br />
2 Disconnect the two lead wires from the sWitch<br />
termmals<br />
3 Connect a 12 volt battery and test lamp between<br />
the two sWitCh termInals<br />
242<br />
4 With the clutch pedal at rest m the off pOSItIon<br />
the sWitch contacts should be fully closed and the test lamp<br />
should brIghtly glow<br />
5 When the clutch pedal IS depressed sWitch<br />
contInUity should be broken and the test lamp should go<br />
out<br />
6 Ifthe sWitch IS not funchonIng correctly keep the<br />
clutch pedal depressed and agam carry out tests 4 and 5<br />
but thiS tune sunulate pedal m and out pOSItIons by<br />
operatIng the switch plunger with the fingers<br />
7 If the sWitch IS functIOnIng correctly with thiS test<br />
then the sWitch IS serYIceable and only requires adJustmg<br />
Alternahvely If the sWitch IS still malfunctIOnIng then<br />
I<br />
renew the sWitch and then adJust<br />
8 To adJust the sWitch allow the clutch pedal to<br />
return to the up posItIon Back offthe sWitch adJustIng nut<br />
and then slowly screw the sWitch mwards towards the<br />
clutch pedal until the test lamp glows Screw the sWitch In a<br />
further two complete turns and then tIghten the adJustmg<br />
nut<br />
9 Remove the test eqUipment and connect the lead<br />
wires back to the sWitch termmals<br />
ACCELERATOR SWITCH<br />
To Test<br />
I Check to ensure that the accelerator sWitch<br />
termInals are Insulated from the sWitch body<br />
2 Disconnect the two lead wires from the sWitch<br />
termInals<br />
3 Connect a 12 volt battery and test lamp between<br />
the two sWitch termmals<br />
4 With the accelerator pedal at rest m the up posItIon<br />
the sWitch contacts should be fully closed and the test lamp<br />
should brIghtly glow<br />
5 When the accelerator pedal IS depressed sWitch<br />
contmUlty should be broken and the test lamp should go<br />
out<br />
6 If the sWitch IS not functIonmg correctly keep the<br />
arcelerator pedal depressed and agaIn carry out tests 4<br />
and 5 but tlus tIme sunulate pedal III and out poslhons by<br />
operatIng the sWitch plunger With the fingers<br />
7 If the SWitch IS functlOmng correctly With thiS test<br />
the sWitch IS serViceable and only requires adJustlllg<br />
AlternatIvely If the sWitch IS stIli malfunctlOnmg then<br />
renew the sWitch and adJust<br />
8 To adJust the sWitch allow the accelerator pedal to<br />
return to the up position Back offthe sWitch adJustIng nut<br />
and then slowly screw the sWitch Inwards towards the<br />
pedal untIl the test lamp glows Screw the sWitch In a<br />
further two complete turns and then tighten the adJustlllg<br />
nut<br />
9 Remove the test equipment and connect the lead<br />
wires back to the sWitch termmals
NEUTRAL GEAR SWITCH Tl<br />
To Test<br />
I Check to ensure that the sWitch termInals are<br />
Insulated from the sWitch body<br />
2 Disconnect the two lead wues from the sWitch<br />
termmals<br />
3 Connect a 12 volt battery and test lamp between<br />
the two SWItch termmals<br />
4 With the transmiSSIOn set In the neutral pOSItIon<br />
sWitch contmUlty should be broken and should be so<br />
mdlcated by the test lamp beIng off<br />
5 When the transmission IS engaged III any gear<br />
except neutral the sWitch contacts should be fully closed<br />
and the test lamp should brIghtly glow<br />
6 Renew the sWitch If It does not meet the test<br />
reqUIrements as outhned In operatIons 4 and 5<br />
TRANSMISSION SWITCH T2<br />
To Test<br />
I Check to ensure that the transmiSSion sWitch lead<br />
wire termInals are Insulated from the sWitch body<br />
2 DIsconnect the two lead wires from the sWitch<br />
termInals<br />
3 Connect a 12 volt battery and test lamp between<br />
the two sWitch termInals<br />
4 With the transmission engaged In the tlurd speed<br />
pOSItIon sWItch contacts should be fully closed and the test<br />
lamp should brIghtly glow<br />
5 When the transmiSSion IS engaged m any other gear<br />
pOSItIon IncludIng neutral sWitch contInUity should be<br />
broken and should be so Indicated by the test lamp bemg<br />
off<br />
THROTTLE SWITCH TH1<br />
ADJUSTING SCREW ADJUSTING SCREW<br />
h<br />
TERMINALS 2<br />
3<br />
Throttle SWitch shOWing SWitch adJustment<br />
243<br />
j<br />
Emission Control II<br />
6 Renew the SWitch If It does not meet the test<br />
reqUIrements as outlIned In operatIOns 4 and 5<br />
THROTTLE SWITCH<br />
To Test Sedan and StatIOn Wagon<br />
I Remove the cover from the SWitch<br />
2 Depress the accelerator pedal and ensure that there<br />
IS a functIonal sound heard from the swtIch<br />
3 Ensure that all SWitch termlllals are msulated from<br />
the SWitch base plate<br />
4 With a feeler gauge measure the clearance between<br />
the cam and the micro SWitch bodies<br />
The clearance dimenSIOn recommended<br />
0031 In<br />
IS 0 8 mm<br />
5 If when measured the clearance d menslOn IS over<br />
or under that recommended then loosen the SWitch<br />
adJustmg screws and carefully rotate the complete SWitch<br />
assembly untIl the deSired dunenslOn IS obtaIned<br />
Tighten the SWitch adJustIng screws and recheck the<br />
clearance rnmenslOn to ensure that the SWitch has not<br />
moved<br />
6 Disconnect the SWitch from the termmal<br />
connector<br />
7 Connect a 12 volt battery With test globe between<br />
the No I and No 2 SWitch termInals See dl3gram for<br />
Termmal placement<br />
8 With the accelerator pedal at rest In the up posItIon<br />
the SWitch contacts should be fully closed and should be<br />
IIldlcated by the test lamp bnghtly glOWIng<br />
9 When the accelerator pedal IS shghtly or fully<br />
depressed SWitch contlDUlty should be broken and the test<br />
lamp should go out<br />
10 If It IS found that the SWitch does not meet the<br />
test requuements as outlIned In operatIon 8 and 9 then<br />
renewthe micro SWitch<br />
II Now connect the test eqUipment between the No<br />
I and No 3 SWitch termmals<br />
12 With the accelerator pedal at rest In the up<br />
pOSItIon and also With the accelerator pedal In the fully<br />
depressed posItIon the test lamp should be off<br />
13 When the accelerator IS pedal partIally depressed<br />
the test lamp should glow<br />
14 If the SWitch does not meet the test requirements<br />
as outlIned m operatIon 12 and 13 then renew the micro<br />
SWitch<br />
15 Remove the test eqUipment fit the throttle<br />
SWitch cover and connect the SWitch to the termInal<br />
connector<br />
To Test Pick up<br />
I Ensure that the SWitch termInals are Insulated from<br />
the SWitch body<br />
2 DIsconnect the SWitch lead wues<br />
3 Connect a 12 volt battery WIth test lamp between<br />
the two SWitch termInals<br />
K
I<br />
I<br />
I<br />
12 Emission Cont rol<br />
4 When the carburettor throttle valve IS closed or<br />
partJally open wlthm an angle of 35 deg the sWitch<br />
contacts should be closed and the test lamp should be<br />
brIghtly g10wmg<br />
5 If the carburettor throttle valve IS opened any<br />
further than an angle of 35 deg sWitch contInUity should<br />
be broken and the test lamp should go out<br />
6 Ifthe SWitch IS not functlOmng correctly<br />
then close<br />
the throttle and repeat the test as outhned In operatJon 4<br />
and 5 but thiS tIme sunulate throttle valve openIng by<br />
actuatlllg the sWitch with the finger<br />
If the test uSlllg tlus<br />
method IS satJsfactory then the sWitch IS semceable and<br />
only requires adJustment If however the SWitch test agaIn<br />
proves unsatJsfactory then renew and then adJust the micro<br />
SWitch<br />
7 To adJust the SWitch loosen the two adJustmg<br />
screws and slightly rotate the micro SWitch untIl the SWitch<br />
actuater IS allowed to move 0 5 mm 0020 In after<br />
abuttlllg the cam plate With the SWitch set In thiS posltJon<br />
tIghten the adJustmg screws<br />
SPEED SWITCH<br />
To Test<br />
I Disconnect the lead wues from the speed sWitch<br />
termInals<br />
2 Referrmg to the speed SWitch termmal diagram to<br />
IdentJfy tenrunal numbers connect a 12 volt battery<br />
between SWitch termInals Nos I and 5 and a 3 volt battery<br />
between SWItch termmals Nos 2 and 4<br />
3 Now connect a volt meter between sWitch<br />
termInals Nos 3 and 5 Note the readlllg on the meter wluch<br />
should read 12 volts<br />
4 When the No 2 termmalls disconnected from the<br />
battery the volt meter should mdlcate zero<br />
5 If the SWitch IS found to be unsemceable after<br />
carrYIng out tests 3 and 4 remove the SWitch cover and<br />
check the posItIon of the armature and return sprmg<br />
6 If found necessary adJust the poslton of the SWitch<br />
armature and return sprIng and retest the SWitch as<br />
deSCrIbed m operatIOns 3 and 4<br />
7 Renew the speed SWitch If the tests are stIll<br />
unsatJsfactory<br />
NOTE A new speed detector must always be fitted With a<br />
new speed switch as both components form a kit<br />
3 2<br />
5 4<br />
Speed SWitch Terminal Numbers<br />
24<br />
CARBURETTOR DECELERATION DEVICE<br />
All models use a solenoid valve to control the excess<br />
fuel air miXture wluch IS necessary dUrIng deceleration to<br />
reduce emiSSIOn<br />
On Sedan Stahon Wagon and Pick up where a<br />
conventIOnal down draught type carburettor IS<br />
IIlcorporated the solenoid valve IS mounted directly on the<br />
carburettor The valve needle protrudes mto the secondary<br />
Side slow system air fuel passage<br />
When the solenoid valve IS energized dUrIng<br />
deceleratJon the valve needle retracts from the air fuel<br />
passage and the excess fuel au miXture IS drawn Into the<br />
secondary barrel of the carburettor below the throttle<br />
valve<br />
The Sports car which IS fitted With dual SU type<br />
carburettors also utIlizes the solenOId valve to control<br />
miXture dUrIng deceleratIon but applIcatIOn of the valve IS<br />
shghtly different In thiS case the valve operates on a<br />
by pass system The solenOId valve IS mounted on the Inlet<br />
manifold and the valve needle protrudes mto a by pass tube<br />
wluch transmits air full mixture from the carburettor<br />
ventuns to the Inlet malllfold<br />
When the solenOId valve IS energized dunng<br />
deceleratIon the valve needle retracts and by pass mIXture IS<br />
fed from the carburettors Into the mlet malllfold<br />
SOLENOID VALVE<br />
To Test All Models except AutomatIc<br />
valve<br />
I Disconnect the black earth lead from the solenoid<br />
2 Connect an ammeter between the black lead<br />
wluch was Just disconnected and the velucle earth<br />
3 Turn the IgmtIon key to the ON pOSItIon but do<br />
not start the engme<br />
4 leaVIng the throttle valve In the closed posltJon<br />
engage the transmiSSIOn In any gear except neutral and<br />
check that the ammeter IS registerIng approximately 0 4<br />
amperes In the case of <strong>Datsun</strong> sports engage the<br />
transmiSSion In the thud or fourth gear speed only<br />
5 The ammeter should zero when one of the<br />
follOWIng condltJons eXist<br />
The throttle valve IS parl1ally opened<br />
The clutch pedal IS depressed<br />
The transmission IS shifted to the neutral posltJon<br />
6 If the ammeter does not register In operatJon 4<br />
use a volt meter to check that a 12 volt current IS 1Il fact<br />
reachIng the other Side of the solenOId valve<br />
If voltage IS not mdlcated on the volt meter check<br />
back through the system With the aid of the SWitch<br />
diagrams etc to isolate and rectify the electrIcal or<br />
mechalllcal fault<br />
If the volt meter mdlcates 12 volts at the solenOId valve
then the solenOid valve assembly IS at fault and m winch<br />
case should be renewed<br />
7 If the tests 4 and 5 proved satIsfactory<br />
disconnect the ammeter and reconnect the black lead back<br />
to the solenOId valve<br />
8 Start and run the engme at Idlmg speed<br />
9 Connect a Jumper lead from the posItIve termInal<br />
of the battery to the blue lead In wire ofthe solenoid valve<br />
10 If the solenOId valve IS operatIng correctly the<br />
speed of the engme should Increase to approxunately 1100<br />
rpm<br />
If the engme speed does not Increase then renew the<br />
solenOid valve as an assembly<br />
To Test AutomatIc<br />
1 DIsconnect the black earth lead at the solenOid<br />
valve harness connector<br />
2 Connect an ammeter between the black lead just<br />
dIsconnected and the vehicle earth<br />
3 Start and run the vehicle on the road or on a<br />
chaSSIS dynamometer<br />
4 When the vehicle IS operatIng over 13 mph with the<br />
throttle valve In the closed pOSItIon deceleratIng the<br />
ammeter should register approxImately 04 amperes<br />
5 Under all other drIVIng conditIons the ammeter<br />
should mdlcate zero<br />
6 If the ammeter does not register In operatIon 4<br />
use a volt meter to check that a 12 volt current IS III fact<br />
reachIng the blue lead at the other Side of the solenoid<br />
valve<br />
If voltage IS not mdlcated on the volt meter check<br />
back through system WIth the 31d of the sWItch dlagrams<br />
etc to Isolate and rectify the electrIcal or mechalllcal fault<br />
If the volt meter mdlcates 12 volts at the solenoid blue<br />
lead then the solenoId valve assembly is at fault and III<br />
which case should be renewed<br />
7 If the tests In operatIons 4 and 5 proved<br />
satIsfactory disconnect the anuneter and reconnect the<br />
black solenOId valve lead<br />
8 Start and run the engme at Idlmg speed<br />
9 Connect a Jumper lead from the pOSItIve termmal<br />
of the battery to the blue lead m Wire ofthe solenOId valve<br />
10 If the solenOId valve IS operatmg correctly the<br />
speed of the engIne should Increase to approxunately 1100<br />
rpm<br />
If the engIne speed does not IIlcrease then renew the<br />
solenOId valve as an assembly<br />
OTHER ELECTRICAL EQUIPMENT<br />
To ensure effiCIent burnlllg of the fuel m the engIne<br />
combustIon chamber It IS unportant that aU electrIcal<br />
eqUipment IS perIodically checked for serYIceabIllty as a<br />
245<br />
E mJSSlOn Con<br />
rol 13<br />
FROM SECONDARY MAIN JET AND AIR BLEED<br />
SECONDARY THROTTLE<br />
Diagram showmg Coastmg Enricher Solenoid Valve<br />
fault m anyone piece of electrIcal eqUipment usually has<br />
adverse effects on other related componen ts as well as<br />
effectmg the final result regardlllg emlSSlon control<br />
SPARK PLUGS<br />
Remove and sand blast plugs at the recommended<br />
checklllg mtervals Check each plug thoroughly for<br />
crackmg cluppIng and for excessive wear at the electrodes<br />
Renew the plugs as found necessary<br />
If the spark plugs are stlll servIceable file the centre<br />
electrodes flat prior to settIng gaps With the correct<br />
adJustIng tool See SpeCificatIons for correct electrode gap<br />
HIGH TENSION LEADS<br />
Remove the distrIbutor cap With high<br />
tensIOn leads<br />
from the engllle assembly<br />
Usmg an ohmmeter check the resistance m each high<br />
tensIOn lead<br />
To make the test fit a plug adaptor Into the spark plug<br />
end of the lead and connect the ohmmeter between the<br />
adaptor and the correspondIng termInal m the distrIbutor<br />
cap<br />
If the resistance In any lead IS more than 15 000 ohms<br />
carefully remove the lead from the cap and check the lead<br />
reSIStance separately If resistance IS still over 15 000 ohms<br />
then renew the leads at fault<br />
IMPORTANT Carbon Illed hIgh tensIOn leads must be<br />
handled carefully at all tImes MIshandling of leads WIll<br />
cause a breakdown m lead contmulty<br />
I
I<br />
14Emission Control<br />
3 SWITCH POSITIONS REIATIVE TO ENGINE OPERATION<br />
MANUAL TRANSMISSION EXCEPT PICK UP<br />
Engllle start cold at fast Idle<br />
Clutch sWitch C and Throttle sWitch TH2 ON IgnltJon tunmg advanced Relay RI Solenoid S and all<br />
other sWitches OFF<br />
2 Engllle start hot<br />
As I above plus Throttle sWitch THI ON<br />
3 EngIne Idling hot<br />
As 2 above<br />
4 EngIne revvmg hot<br />
Clutch sWitch C ON Throttle sWitch THI ON OFF ON Throttle sWitch TH2 ON or ON OFF ON<br />
Relay RI SolenOId S and all other sWitches OFF Igmhon tunIng advanced<br />
5 CrUlslIlg or acceleratIng 111 3rd Gear part throttle<br />
Clutch sWitch C Transmission sWitch Tl Throttle sWitch TH2 Transmission sWitch T2 and Relay RI ON<br />
IgmtlOn tunmg retarded SolenOId S and Throttle sWitch THI OFF<br />
6 Crulsmg or acceleratmg through gears part throttle<br />
Clutch sWitch C Transmission sWitch Tl and Throttle sWitch TH2 ON IgmtlOn tunmg Advanced Relay<br />
R SolenOId S and other sWitches OFF<br />
7 CrUIsIng or acceleratIng on full throttle<br />
Clutch sWitch C and TransmISsIOn sWitch Tl ON TransmissIOn sWitch T2 ON for 3rd gear or OFF for 1st<br />
2nd and 4th<br />
gears IgmtJon tunmg advanced throttle sWitches THI TH2 Relay RI and SolenOId S OFF<br />
8 Coastmg<br />
Clutch sWitch C Transmission Tl Throttle sWitches THI TH2 and SolenOId S<br />
advanced TransmiSSion sWitch T2 ON for 3rd gear ON<br />
at ON IgmtIon TunIng<br />
or OFF for 1st 2nd and 4th gear Relay RI OFF<br />
NOTE Clutch sWItch C IS ON only when the pedal IS released TransmIssIOn switch Tl IS OFF only when the lever IS<br />
In neutral position The Throttle sWItch THl IS ON only when the throttle valve IS nearly closed Throttle switch<br />
TH2 IS OFF only when throttle valve IS Wide open TransmissIOn switch T2 IS ON only when the lever IS In 3rd gear<br />
POSitIOn When the Relay Rl IS ON the retarded dlstnbutor contacts P2 are m operatIOn provldmg a retarded<br />
IgmtlOn tlmmg When theSolenoId S IS energized an excessfUel aIr mIXture IS supplied to reduce HC emiSSIOn<br />
A gnltlon SWitch<br />
B Battery<br />
C Clutch sWItch<br />
Ie Ignition call<br />
B<br />
P1<br />
Advance contacts<br />
P2 Retard contacts<br />
Rl Relay<br />
S Solenoid<br />
246<br />
lLJ<br />
I<br />
Ie<br />
T1 TransmiSSIon neutral SWitch<br />
T2 Transmission 3rd gear SWitch<br />
TH 1 Throttle SWitch<br />
TH2 Throttle sWItch<br />
1L<br />
Rl<br />
J v
wl<br />
AUTOMATIC TRANSMISSION EXCEPT PICK UP<br />
J<br />
r<br />
ErnissionControl lS<br />
Engllle start cold at fast Idle<br />
Speed sWitch SP and Throttle sWitch THI OFF Throttle sWitch TH2 ON Relay RI OFF Solenoid<br />
S OFF IgmlIon lImIng advanced<br />
2 EngIne start hot<br />
As I above plus Throttle sWitch THI ON<br />
3 EngIne Idhng hot<br />
As 2 above<br />
4 Engllle revvIng<br />
Speed sWitch SP OFF Throttle sWitch TAl ON OFF ON Throttle sWitch TH2 ON or ON OFF ON<br />
Relay R I and SolenOId S OFF 19mtIon lImIng advanced<br />
5 CruISIng or dcceleratlllg dbove 13 mph on part throttle<br />
Speed sWitch SP ON Throttle sWitch THI OFF Throttle sWItch TH2 and Relay RI ON Solenoid<br />
S OFF IgmtlOn tImlllg retarded<br />
6 CrUlslIlg or acceleratlllg under 13 mph on part throttle<br />
As I above<br />
7 CrUIsIng or acceleratlllg full throttle<br />
Speed swllch SP ON above or OFF below 13 mph All other sWItches Relay and Solenoid OFF IgmtlOn<br />
IIfl1lng advanced<br />
8 CoastIng<br />
Speed sWitch SP ON above or OFF below 13 mph Throttle sWitches THI and TH2 both ON Relay RI<br />
OFF SolenOId S ON above or OFF below 13 mph IgmlIon tlmlllg advanced<br />
NOTE Speed sWItch SP IS ON only at speeds above 13 mph Throttle switch THJ IS ON only when the throttle<br />
valve IS nearly closed Throttle switch TH2 IS OFF only when throttle valve IS WIde open When the Relay R 1 IS ON<br />
the retarded dlstnbutor wl1ta P2 are III operatlOlI proVldmg a retarded IgllltlOll tlmmg Whell the SolenOId S IS<br />
energlsed alld excess fuel airmIXture 1 upplzed to reduce He emlSSlO1l<br />
A IgOltlon sWitch<br />
B Battery<br />
Ie IgOltlon COIl<br />
Pl<br />
Advance contacts<br />
B<br />
P2 Retard contacts<br />
R 1 Relay<br />
S Solenoid<br />
SP Speed SWitch<br />
SP<br />
247<br />
Ji<br />
Ho<br />
TH1<br />
J<br />
K<br />
55 Speed detector<br />
TH 1 Throttle SWitch<br />
TH2 Throttle sWitch
I<br />
I<br />
I<br />
J<br />
I<br />
J<br />
I<br />
16Emission Control<br />
MANUAL TRANSMISSION PICK UP<br />
Engme start cold at fast Idle<br />
Clutch sWitch C ON TransmISsIOn sWitch Tl and Accelerator pedal sWitch AS OFF Relay R2 ON<br />
Transmission sWitch T2 OFF Throttle sWitch TH ON Relay RI and Solenoid S OFF IgnitIon tImIng<br />
advanced<br />
2 EngIne start hot<br />
As I above plus Accelerator pedal sWitch AS ON<br />
3 EngIne Idlmg hot<br />
As 2 above<br />
4 Engme revvmg hot<br />
Clutch sWitch C ON TransrrusslOn sWItch Tl OFF Accelerator pedal sWitch AS ON OFF ON Relay<br />
R2 ON TransmissIOn sWitch T2 OFF Throttle sWitch TH ON or ON OFF ON Relay RI OFF<br />
SolenOId S OFF IgmtlOn tunmg advanced<br />
5 CrUlsmg or AcceleratIng m 3rd gear part throttle<br />
Clutch sWitch C and TransmissIOn switch Tl ON Accelerator pedal sWitch AS OFF Relay R2<br />
Transmission sWitch T2 Throttle sWitch TH and Relay RI ON SolenOId S OFF IgmtlOn tunmg retarded<br />
6 CrUlsmg or acceleratmg through gears part throttle<br />
As 5 above except TransmissIOn sWitch T2 and Relay Rl and SolenOId S OFF and IgmtIon tunIng advanced<br />
7 CrUlsmg or acceleratIng on full throttle<br />
As 6 above except Throttle sWitch TH OFF and TransrrusslOn T2 ON 3rd or OFF other gears<br />
8 Coastmg<br />
Clutch SWitch C Transmission sWitch Tl and Accelerator pedal sWitch AS ON Relay<br />
R2 OFF<br />
TransmissIOn sWitch T2 ON or ON OFF ON Throttle sWitch TH ON Relay RI OFF SolenOId S ON<br />
IgmtIon tunmg advanced<br />
NOTE Clutch switch C IS ON only when pedal IS released TransmIssIOn switch Tl IS OFF only when lever IS m<br />
neutral positIOn Accelerator pedal switch AS IS ON only when IS pedal released Relay Rl IS ON to provIde retarded<br />
IgTIltlon timing<br />
A Ignition switch P1 Advance contacts S SolenoId<br />
AS Accelerator switch P2 Retard contacts T1 Transmission neutral sWitch<br />
B Battery R1 Relay T2 TransmIssion 3rd gear switch<br />
C Clutch swItch R2 Relay TH ThrottlesWItch<br />
IC Ignition coil<br />
B<br />
s<br />
lL<br />
12<br />
248<br />
R2<br />
P2<br />
ITH
Emission Control 17<br />
4 EXHAUST CONTROL SYSTEMF Uf T DIAGNOSIS r<br />
J<br />
I Backfinng m vehicle exhaust<br />
J<br />
PossIble cause Remedy<br />
a AntI backfire valve vacuum lme collapsed<br />
blocked or leakIng<br />
b Defecuve antI backfire valve<br />
c Incorrect Idle mIXture<br />
d DefectIve lugh tensIOn cables or spark plugs<br />
2 Baked aIr supply hose<br />
V<br />
Renew O repair vacuum Ime<br />
Renew antI backfire valve<br />
AdJust Idle mIXture<br />
Renew faulty components<br />
PossIblecause Remedy<br />
a Defective manifold check valve Renew check valve<br />
3 ErratIc engme Idle<br />
a Incorrect Igllltlon tunmg<br />
b Defective antI backfire valve<br />
c Incorrect carburettor adJustment<br />
d leakIng antl backfire valve vacuum<br />
lIne or Inlet hose<br />
4 Engllle surgmg<br />
a Incorrect carburettor adJustments<br />
b Defecuve antI backfire valve<br />
S Engnte stalls<br />
a Incorrect carburettor adJustments<br />
b Incorrect IgnitIOn t1IlUng<br />
c Disconnected orleaklllg antI backfire<br />
valve vacuum hose<br />
6 NOISY aIr pump dnve belt<br />
a Seized or partIally seized au pump<br />
b DefectIve or loose drIve belt<br />
c DefectIve or ffilSallgned dnve pulley<br />
7 System leakmg air<br />
a Leakmg relief valve<br />
POSSible cause Remedy<br />
Reset IgmtlOn tunmg<br />
Renew antI backfire valve<br />
AdJust carburettor<br />
Renew or repaIr hose<br />
POSSible cause Remedy<br />
AdJust carburettor<br />
Renew antI backfire valve<br />
POSSIble cause Remedy<br />
AdJust carburettor<br />
Reset Igmtlon tunmg<br />
Renew or repaIr vacuum hose<br />
POSSible cause Remedy<br />
POSSible cause<br />
b Leakmg hoses and or connectIOns<br />
249<br />
Dismantle and IIlspect air pump<br />
Renew or adJust dnve belt<br />
Renew or align pulley<br />
Renew relief valve<br />
Remedy<br />
Renew or tIghten hoses and or connectIons<br />
l<br />
l<br />
I<br />
t
t<br />
I<br />
I<br />
I<br />
I<br />
18 Emission Control<br />
8 General abnormal noise<br />
PossIble caus<br />
a Faulty au pump<br />
b SlipIlIng pump drIve belt durIng acc etatIon<br />
c AuleakInsystem L<br />
9 Insufficlent au pump delivery<br />
PossIble cause<br />
a Damaged au pump vane hub bearIngs<br />
b Worn au pump carbon shoes<br />
c Worn au pump vane<br />
10 AIC pump moperative<br />
PossIble cause<br />
a DefectJve au pump<br />
jJ SlIppmg or broken drIve belt<br />
DESCRIPTION<br />
The evaporatJon control system IS another approach m<br />
redUCIng the amount of velucle hydro carbon emiSSion It<br />
has been estunated that approxunately 20 percent of all<br />
automotJve Hydrocarbon materIal comes from evaporatJve<br />
loss from the fuel tank<br />
The basiC components of the evaporatIve control<br />
system are<br />
POSltJve sealed fuel tank Vapour hqUld separator<br />
Vapour vent Ime Flow gUide valve<br />
When the engIne IS at rest fuel vapour through<br />
evaporatJon gradually fIlls the air space m the fuel tank<br />
vapour hqUld separator and vapour vent hnes As the fuel<br />
tank IS fitted With a pOSItIve type sealIng cap vapour<br />
pressure buIlds up wlthm the system<br />
The flow gUide valve opens when the<br />
vapour pressure<br />
wlthm the system exceeds 10 mm Hg 04 m hg Excess<br />
vapour IS then by passed Into the crankcase via a connectIng<br />
hose When the engIne starts vacuum created wltlun the<br />
Inlet manifold opens the pOSItIve crankcase ventilatIon valve<br />
and also the crankcase Side of the flow gUide valve Vapour<br />
wluch has been stored In the crankcase vent lllle separator<br />
and fuel tank IS then drawn mto the mlet mamfold and<br />
consumed m the cyllllders<br />
When vapour pressure wltlun the system drops<br />
suffiCiently the air cleaner Side of the flow gUide valve<br />
opens Tills permits atmospherIc au pressure to be routed<br />
from the air cleaner assembly to the fuel tank<br />
Allowlllg air Into the system prevents a lugh vacuum<br />
Repau or renew au pump<br />
AdJu t or renew dnve belt<br />
RectJfy au leak<br />
Renew faulty components<br />
Renew faulty components<br />
Renew faulty components<br />
Renew au pump<br />
Renew or adJust dnve belt<br />
5 EVAPORATIVE CONTROl SYSTEM<br />
250<br />
Remedy<br />
Remedy<br />
Remedy<br />
formmg wltlun the system which could cause techmcal<br />
difficultIes mcludIng a crushed fuel tank<br />
FLOW GUIDE VALVE<br />
The most Important functJon ofthe flow gUide valve IS<br />
to prevent crankcase blow by from enterIng the vapour vent<br />
lme and fuel tank The valve should be removed and<br />
checked for serYIceabIllty at the recommended mtervals It<br />
IS not practIcable to repair the valve If It IS found to be<br />
unserviceable<br />
For easy IdentJficatIon the valve apertures are clearly<br />
marked With A F and C denotIng Air Cleaner Fuel<br />
tank Crankcase<br />
To Test<br />
I Raise the engIne bonnet<br />
2 Disconnect all hoses and then remove the flow<br />
gUide valve from the vehicle<br />
3 Apply a low pressure of au to the fuel tank F<br />
Side aperture of the valve The air should flow through the<br />
valve and out the crankcase C Side aperture<br />
4 If no au pressure IS felt at the fuel tank F<br />
aperture then renew the valve<br />
5 Now apply aupressure to the crankcase C Side of<br />
the valve Renew the valve If au flow IS felt from the<br />
carburettor C and fuel tank F apertures<br />
6 When air pressure IS apphed to the carburettor C<br />
aperture It IS normal for au pressure to be felt at the<br />
crankcase C and fuel tank F Sides of the valve<br />
r
k l<br />
FROM AIR CLEANER<br />
FROM VALVE COVER<br />
L<br />
FROM FUEL TANK<br />
t<br />
FROM CRANKCASE<br />
TO INLET MANIFOLD OR CRANKCASE<br />
FUEL TANK VAPOUR LIQUID SEPARATOR<br />
AND VAPOUR VENT LINE<br />
To Test<br />
1 Check the fuel tank filler cap and all hoses for<br />
serYlceablhty<br />
2 Disconnect the vapour vent lIne from the flow<br />
gUIde valve F aperture<br />
3 Connect a tee piece With manometer and a sUItable<br />
cock Into the vapour vent lIne<br />
4 Slowly apply au pressure to the system via the<br />
cock untIl the manometer Indicates 145 In Aq then close<br />
the cock<br />
ENGINE<br />
5 Leave the system undisturbed for 2 5 mInutes and<br />
I<br />
j<br />
FUEL TANK<br />
Diagram ShowlIlg Evaporation Control System<br />
Emission Control 19<br />
vJ<br />
Engllle runnlllg at slow speed I<br />
then measure the height of the hqUld In the manometer<br />
6 The varIahon of height In the test Instrument<br />
should remam WithIn I 0 m Aq<br />
7 If the test IS satJsfactory remove the tank filler cap<br />
and check that the flUid m the manometer drops qUIckly to<br />
zero<br />
8 If the flUid height In the manometer drops off<br />
slowly a blocked vapour vent lme IS mdlcated The<br />
blockage must be rectJfied to ensure sufficient vapour<br />
delivery to the crankcase<br />
9 Ifthe test Instrument readIng was unsatJsfactory In<br />
operatIon 6 check the tank filler cap and hoses for<br />
leakage Renew or repair defectJve components as found<br />
necessary<br />
RECOMMENDED AI TEN NCE<br />
To ensure effiCient operatIon of the emiSSion control<br />
system It IS Important that the folloWIng service procedure<br />
be carned out on the Items mentJoned at the recommended<br />
mIleage mtervals<br />
I Carry out the followmg serVIce procedure every<br />
5000 km 3000 Miles<br />
Check dlstnbutor pomts for sefvlceabIllty and adJust<br />
dwell angle<br />
Check and adJust IgnltJon t1mmg<br />
Check and adJust engme Idle speed and ffilXture<br />
Remove clean and regap spark plugs<br />
2 Carry out the folloWIng serYIce procedure every<br />
10 000 km 6000 MIles<br />
Check and clean au cleaner element<br />
251<br />
3 Carry out the followmg serYIce procedure every<br />
20 000 km 12 000 Miles<br />
Renew distrIbutor contact pOInts<br />
Spanngly lubrIcate dIStrIbutor cam Wick and shaft<br />
Renew spark plugs<br />
Check high tensIOn leads for serYIceabllity<br />
Tune and test engllle<br />
4 Carry out the folloWing serYIce procedJIre every<br />
40 000 km 24 000 Miles<br />
Renew carburetlor au cleaner element<br />
t i<br />
r<br />
I<br />
l<br />
I<br />
n
l<br />
tr<br />
y<br />
I<br />
I<br />
J<br />
20Emission Control<br />
@ANKCA E<br />
VENTlL Ano SYSTEM<br />
20 000 km 12 000 MIles J<br />
J t Check aIr pump for correct operatIon J<br />
I Carry out the followmg serYIce procedure every Test check valve for correct operatIon<br />
20 000 km 12 000 MIles<br />
Test relief valve for correct operatIon<br />
Check for correct operatIOn ofrcrankcase regulatIng Test antI backfire<br />
v<br />
valve for correct operahon<br />
valve<br />
1 Systemajlcally ch k<br />
complete system for aIr leakage<br />
Check<br />
jail hoses and connectIon for leaks 0all electrIcal sWitches for correct operatIOn<br />
EXHAUS CONTROL SYSTEM EVAPORATION CONTROL SYSTEM<br />
I Carry out the followmg service procedure every<br />
5000 km 3000 lIes<br />
Check and adJust aIr pump drIve belt tensIOn<br />
2 Carry out the followmg serYIce procedure every<br />
0<br />
ENG NE<br />
Specifications<br />
Torque Wrench Settmgs<br />
DescnptlOn<br />
Engme Assembly<br />
Rocker Arms and Plvots<br />
CylInder Head<br />
To AdJust Valve Clearance<br />
ro<br />
Engme Sump<br />
011 Pump<br />
Pistons and Connectmg Rods<br />
CylInder Bores and Pistons<br />
To Check CylInder Bores<br />
Deglazmg Cyhnder Bores<br />
CheckIng Piston Skut Clearance<br />
To Fit new Piston Rmgs<br />
Crankshaft and MaIn Bearmgs<br />
Tmllng Cham TenslOner and Sprocke s<br />
Camshaft<br />
Inlet and Exhaust System<br />
DIstnbutor<br />
Crankcase VentIlatJon<br />
Engme Mountmgs<br />
Engme Fault DiagnOSIs<br />
1 COOliNG SYSTEM<br />
SpeCIficatIons<br />
Descnpl10n<br />
l<br />
J<br />
I<br />
t r<br />
1<br />
1 1<br />
It<br />
f<br />
E I<br />
I<br />
1<br />
r f<br />
j<br />
II jl<br />
1<br />
INDEX<br />
7<br />
11<br />
12<br />
13<br />
14<br />
15<br />
19<br />
19<br />
20<br />
21<br />
23<br />
23<br />
24<br />
24<br />
24<br />
25<br />
27 lt<br />
31<br />
33 Cv<br />
34<br />
35<br />
36<br />
37<br />
40<br />
40<br />
252<br />
I Carry out the followmg serYIce procedure every<br />
20 000 km 12 000 MlIes<br />
Radiator<br />
Checkhoses pipes and connectIons for leakage<br />
Remove and test flow gUide valve for correct operatIon<br />
Thermostat<br />
Water Pump<br />
Fan Belt<br />
Heater Umt<br />
Coohng System Fault DiagnOSIs<br />
FUEL SYSTEM<br />
Speclfical10ns<br />
Carburettor HlIaclu DAF 328<br />
Carburettor Hltaclu OCK 306<br />
Carburettors SU Type HJL38W<br />
Carburettor SerVIce Faults<br />
SU Type Carburettor<br />
Fuel Pump<br />
Fuel Pump Pressure Test<br />
Fuel Pump CapaCity Test<br />
AIr Cleaner<br />
Fuel Tank<br />
fFu 1 System Fault DIagnOSIs<br />
j<br />
0<br />
CLUTCH<br />
Speclllcal10ns<br />
DescnP tlon<br />
Clutch Umt<br />
t<br />
40<br />
41<br />
42<br />
43<br />
43<br />
45<br />
46<br />
47<br />
55<br />
60<br />
64<br />
65<br />
67<br />
67<br />
68<br />
69<br />
69<br />
71<br />
71<br />
72
Mister CylInder<br />
<strong>1600</strong><br />
Series<br />
<strong>1300</strong> Senes<br />
73 FRONT SUSPENSION<br />
73<br />
SpeClflCattons<br />
74 Wheel Hub and BearIng<br />
vJ<br />
0<br />
Drum Type Brakes<br />
126<br />
127<br />
Slave Cybnder 75 Wheel Hub and Wheel Beann<br />
Hydraulic Syste J<br />
76 DISC Type<br />
127<br />
Clutch Throw out BearIng 76 S tabllIser Bar 128<br />
BrakesY<br />
Clutch Pedal 77 RadIUS Rod JV f 128<br />
To adJust Throw out Lever<br />
C<br />
J<br />
SuspensIOn Umt<br />
Free Travel V<br />
v<br />
Nuspen<br />
129<br />
lOrfcontrol Arm Clutch Fault DIagnOSIS 79 Lowy BaIl Jomt<br />
130<br />
131<br />
MANUAL TRANSMISSION<br />
Suspension Crossmember<br />
SuspensIOn<br />
132<br />
and SpeClflcahons 80<br />
Steenng Angles<br />
To Check and AdJust<br />
132<br />
Toe Gearbox 80<br />
m<br />
To Check Camber and Caster<br />
f<br />
132<br />
132<br />
Propeller Shaft 81 Front SuspensIOn Fault DiagnOSIS 1 133<br />
Part 1 Three Speed TransmiSSion 81<br />
DescnptlOn 81 REAR SUSPENSION<br />
Gear Box 81 Part 1 Sedan 135<br />
Gear Change Assembly<br />
88<br />
SuspensIOn Assembly<br />
136<br />
Part 2 Four Speed TransllllSSlon 89 COlI SprIng 37<br />
Descnptton 89 Shock Absorber I 8<br />
Gear Box 90 SuspensIOn Arm 138<br />
Part 3 Propeller Shaft 96 Rear AxJe Shaft and Wheel Bearings 139<br />
Descnptton 96 Shock Absorbers 140<br />
Part 4 <strong>Manual</strong> Transmission Fault DiagnOSIS 97 Part 2 Station Wagon 139 t<br />
DeSCrIptIOn 140 L<br />
AUTOMATIC TRANSMISSION SprIngs 140<br />
SpeCifications 99 Rear SuspensIOn Fault DiagnOSIs 141<br />
Descnptlon<br />
99<br />
Hydraulic FlUid 100 STEERING<br />
Forward Speed Band 101<br />
143<br />
Reverse Band 101<br />
TranSffilSSlon Shift Lmkage<br />
Neutral Safety SWItch<br />
101<br />
102<br />
SpecIfications<br />
Descnptlon<br />
SteerIng Gear Assembly<br />
Steenng LInkage<br />
145<br />
Carburettor and Downsluft Valve Cable 102 To AdJust Wheel AJlgnment 146<br />
TransffilsslOn Assembly<br />
103<br />
Collapsible SteerIng<br />
146<br />
Automatic Transffilsslon Fault DIagnOSIS<br />
REAR AXLE BRAKES<br />
105<br />
Steenng Fault DiagnOSIs<br />
SpecIfications 106 SpecificatIOns 150<br />
Part 1 Rear Axle Sedan 107 DescnptIon<br />
151<br />
DeSCrIptIon 107 SIngle CUcult Master CylInder 151<br />
FInal Dnve Assembly 0 108 Dual CirCUit Master Cylinder 153<br />
To Assemble and AdJust DrIve PInIOn I10 Rear Brake 154<br />
To Assemble and AdJust Differential Front Wheel Drum Brakes 157<br />
Assembly I12 Front Wheel DISC Brakes 159<br />
Dnve PInIOn and Side Retamer To Remove and Instal Brake Caliper 159<br />
011 Seals 115 To Remove and Instal Brake Discs 161<br />
Dnve Shafts I16 Rear Brake Baclong Plate 162<br />
Part 2 Rear Axle Station Sedan I17 Front Brake Baclong Plate 163<br />
DescnptlOn<br />
I17 HandBrake Assembly 163<br />
ee<br />
Differential 0<br />
Carner Assembly 117 Brake AdJustments 164<br />
To Assemble and AdJust DrIve PmlOn I19 Front Brake Shoes Drum type 164<br />
To AdJust Pillion BearIng Pre Load 120 Rear Brake Shoes all models 165<br />
To Assemble and AdJust Differential 121 Hand Brake Cable Sedan 165<br />
Dnve Pillion 011 Seal 122 HydraulIc System 165<br />
Axle Shaft and BearIng 123 To AdJust Hand Brake Cable<br />
Rear Axle Assembly 124 StatIOn Sedan 165<br />
Rear Axle Fault DiagnOSIS 124 Brake Fault DiagnOSIS 166<br />
253<br />
g<br />
r 1<br />
143<br />
143<br />
148<br />
t
d<br />
0<br />
1y<br />
f i<br />
4<br />
J<br />
Specifications<br />
J<br />
r<br />
ELECTRI L SYSTEM<br />
I 167<br />
Battery<br />
Aiternatoy AustrahanProduction<br />
L<br />
i<br />
169<br />
169<br />
169<br />
HItaclu ernator 171<br />
To Check nd Test Alternator on<br />
Vehlcl Lucas 17<br />
I rv<br />
WHtELS AND TYRES<br />
h<br />
Aiternato r Regulator<br />
176<br />
Specifications<br />
To Test on egulator Velucle Wheel and Tyre Assembly<br />
HItachi<br />
175<br />
Tubed Tyres<br />
ElectrIcaD AdJustments HItaclu 177<br />
Tubeless Tyres<br />
To Test Regulator Control Umt<br />
Lucas 178<br />
Starter Motor 178<br />
HItaclu 179<br />
s Luq 181<br />
DIstrIbutor<br />
184<br />
To time Engme and Set<br />
gnltlon Tmung<br />
To AdJust IgrutlOn Tlmmg and<br />
Dwell Angle<br />
Sparkmg Plugs<br />
High TenSIOn Leads<br />
IgnlllOn Coil<br />
Instruments<br />
Turn Signal SWItch Headlight Dipper<br />
and Horn Rmg<br />
SWitches and Controls<br />
Wmdscreen Wiper<br />
Lamp Umts<br />
ElectrIcal Fault DIagnOSIS<br />
Wmng Diagrams<br />
t<br />
I<br />
188<br />
188<br />
189<br />
189<br />
189<br />
190<br />
191<br />
192<br />
194<br />
195<br />
197<br />
198<br />
If<br />
254<br />
BODY<br />
Wmdscreen and Rear WIndow<br />
Front Door<br />
Rear Door<br />
Luggage Compartment Lid<br />
Tyre Wear DiagnosIs<br />
LUBRICATION AND MAINTENANCE<br />
Engme<br />
TransnusslOn<br />
SuspensIOn and Steenng<br />
MlsoeIlaneous<br />
EMISSION CONTROL<br />
SpeCifications<br />
Crankcase VentilatIOn System<br />
Exhaust Control System<br />
SWItch POSitions Relative to<br />
EngIne Operation<br />
Exhaust Control System<br />
Fault DIagnOSIS<br />
Eva poratlve Control System<br />
Recommended Mamtenanoe<br />
J<br />
e<br />
Cl B<br />
j<br />
r 217<br />
221<br />
224<br />
226<br />
226<br />
227<br />
227<br />
229<br />
231<br />
232<br />
232<br />
232<br />
233<br />
234<br />
235<br />
246<br />
249<br />
250<br />
251
GLOSSARY OF<br />
ENGINE<br />
SLAVE CYLINDER<br />
actuatlllg cyllllder<br />
CLutch cyhnder operatI g cyhnder<br />
AIR CLEANER If filter WITHDRAWAL ER Throw out lever clutth fork<br />
BI METAL SPRING Thermostat sprIng release fork f<br />
CAMSHAFT SPROC T OR GEAR Tlmlll ear tImlllg<br />
wheel<br />
j j<br />
T NSMISSION<br />
CRANKSHAFT SPROC fJ<br />
tImlllg<br />
E Tlmlng geaY V<br />
wheel END PLAY End float end dC HdnCe<br />
CIRCLlP Snap rIng sprIng chp<br />
t<br />
GEAR SHIFT LEVER Change speed lever gear selector<br />
ENGINE Motor lever gear change lever<br />
ENGINE INPUT SHAFT Clutch shaft first motIon shaft maIn<br />
TEADY Stablhser support<br />
c<br />
drIve shdft pllnlJlY sh Itt mam drIve gear Spl Ot shdf<br />
MOUNTING Mounts supports LAYGEAR Cluster gear second n gear<br />
FLYWHEEL RING GEAR Starter rIng gear starter drIve lIltermedIate gear<br />
gear LAYSHAFT Cluster gear shaft second motIOnshaft<br />
FUEL PUMP Petrol pump IntermedIate shaft<br />
GUDGEON PIN Piston pIn WrIst pm<br />
INLET MANIFOLD Intake malllfold mductlOn<br />
LOW GEAR<br />
MAJNSHAFT<br />
FIrSt speed first<br />
gear<br />
Tlurd motIon shaft output sh ft<br />
malllfold secondary shaft I<br />
INLET VALVE Intake valve mductIon valve PROPELLER SHAFT Dnve shaft tad shaft<br />
MUFFLER Silencer SELECTOR FORK Shift fork shlltcr fork<br />
NEOPRI NI O RING Rubbcr a ling 011 sedl<br />
SELECTOR SHAFT Selector rod selector rad sluft rad<br />
NEOPRENE SEAL Rubber sCdl 011 sedl shift rod shlfter shaft<br />
OIL PUMP Rotor type SPIGOT BEARING Pilot bearing support bearIng<br />
INNER ROTOR SPRING RING Syncblll spllng enelglsl11g spllng<br />
OUTER ROTOR SYNCHRO HUB Clutch hub<br />
OIL PUMP Gedr type SYNCHRO RING Baulk rIng synchro cone<br />
DRIVE GEAR SYNCHRO SLEEVE Clutch sleeve<br />
DRIVEN GEAR SYNCHRONlSER PLATE Synchro bar synchro key<br />
POWER UNIT Engme and gearbox shd1Jlg key hilt plate<br />
RELIEF VALVE Release valve TOP GEAR High gear ugh speed<br />
ROCKER ARM Rocker tappet UNIVERSAL JOINT DrIve wuphng<br />
SCREEN GduLe type Filter UNIVERSAL JOINT CROSS JOInt trunlllon<br />
SUMP ad pan UNIVERSAL JOINT YOKE UllIversalJomt fork<br />
TAPPET Hydrdulit or sohd Valve hfter Cdm<br />
follower<br />
TIMING CHAIN TENSIONER Chdm tightener<br />
VALVE COTTIR Valve collet valve keep valve key<br />
WATER PUMP IMPELLER Rotor<br />
CLUTCH<br />
CLUTCH HOUSING Clutch cover clutch bell hOUSIng<br />
DRIVEN PLATE Clutch plate drIven diSC clutch diSC<br />
DRIVEN PLATE FACINGS Dnven plate IIllIngs clutch<br />
blllngs<br />
PRESSURE PLATE Clutch drIve plate<br />
1<br />
PRESSURE PLATE COVER Clutch housmg clutch<br />
cover<br />
RELEASE BEARING Throw out bearIng thrust Withdrawal bearIng<br />
bearIng<br />
RELEASE BEARING PLATE<br />
thrust plate<br />
Throw out bearing plate<br />
RELEASE LEVER Clutch finger release flllger<br />
throw out lever<br />
o<br />
NAMES AND TERMS<br />
255<br />
REAR AXLE<br />
AXLE SHAFT Drive shaft half shaft<br />
L<br />
AXLI SHAFT BIARING Redr wheel bearIng rear<br />
axle race<br />
CARRIER BEARING DifferentIal bearing Side bearing<br />
CROWNWHEEL RlIlg gear<br />
DIFFERENTIAL PINION Spider pInIOn DIllion gear<br />
DIFFERENTIAL SIDE GEAR Axle shaft gear spider<br />
gear<br />
DRIVE PINION DifferentIal pInIOn bevel pillion<br />
PINION FLANGE DrIve coupling<br />
FRONT SUSPENSION STEERING<br />
BUMP RUBBER Bumper<br />
CONTROL ARM Wishbone suspensIOn arm Imk<br />
CONTROL ARM SHAFT Fulcrum pIn fulcrum shaft<br />
plVt pm<br />
IDLER ARM Illtermerh te lever 0 1rm<br />
t<br />
Zt<br />
r<br />
r<br />
t
I l<br />
1<br />
I<br />
I<br />
N<br />
k<br />
rr L<br />
Il<br />
j<br />
1I<br />
S<br />
J<br />
r<br />
t<br />
i<br />
KING PIN SWlvel<br />
pm GLOBE Bulb lamp<br />
PITMAN ARM SteerIng arm drop arm sector shaft arm I<br />
SECTOR SHAFT Roller shaft arm pllman shaft drop<br />
TURN SIGNAL LIGHT DIrectIon Indicator light f1asJ1et<br />
bght trafficator lIght<br />
TURN SIGNAL SWITCH DIrectIon IIldlcator sWitch<br />
arm shaft<br />
SHOCKABSORBER Damper flasher wltch trafficator sWitch<br />
STABILlSER BAR Ride stablliser sway bar HEADLAMP Head light maIn lIght<br />
STEERII l G ARM Knuckle arm st erIng lever HIGH TENSION L ADS Plug Wires<br />
STEERING CONNECTING ROD Tlh d relay rod HORN PUSH Horn sWitch horn but on<br />
STEERU<br />
g LINKAGE Track rods t<br />
STEERIN GEAR SteerIng gearbox steenng box<br />
STEERINb SHAFT Worm shaft erIngcolumn<br />
INSTRUMENT LIGHT<br />
U NS l1ss v tdl<br />
Panel light<br />
ERPLATELf6iU<br />
1NUMB<br />
ucen e plate lIght<br />
STUB LE SWIVel axle VY MEDALLION Name<br />
prfre tbver<br />
STUB AXLE SUPPORT SteerIng knuckle support sWivel<br />
PARKING LIGHT SldeJlght side lamp<br />
bnk arm lInk control REGULATOR AltCrIldlOl regulalOr dlte1l1Jtor 1OIltrol<br />
TIE ROD Track rod steerIng link rod<br />
ROTOR ARM Rotor button<br />
T F ROD B LL JOINT Tie rod end<br />
STOP LIGHT Brake lIght<br />
WHEEL ALIGNMENT Toe lIl track ahgnment STARTER Starter motor<br />
J<br />
n<br />
J<br />
t<br />
STARTER DRIVE Bendix gear drIve pInIOn<br />
BRAKES TAIL LIGHT Rear bght<br />
TE PERATURE GAUGE Heat gauge<br />
BArK PLATE Brake plate backmg plate WARNING LIGHT Indicator hght<br />
FrEXlBLE BRAKE PIPE Brake hose flexible connector WINDSCREEN WIPER WIndshield wiper<br />
PISTON Plunger<br />
PRIMARY CUP Mam cup malll rubber seal<br />
RETURN SPRING Pull off sprIng retractor sprIng<br />
SECONDARY CUP Piston seal<br />
WHEEL CYLINDER CUP Wheel cyhnder rubber wheel<br />
cylinder seal<br />
WHEEL CYLINDER BODY<br />
Actuatlllg cylInd r<br />
QOOR GLASS Door Window wlIldow glass<br />
FENDER Mudguard wlIlg<br />
GLASS LIFT CHANNEL WIndow hft channel<br />
GLASS REGULATOR WIndow hft regulator Window<br />
oc<br />
ELECTRICAL<br />
ADJUSTABLE CONTACT Breaker pOInt<br />
ALTERNATOR AC Generator<br />
BREAKER ARM CaNTACT Breaker arm pOInt<br />
CAPACITOR Condensor<br />
COURTESY LIGHT Intenor hght roof light<br />
DIPPER SWITCH Dimmer sWitch<br />
FUEL GAUGE Petrol gauge<br />
GENERATOR Dynamo<br />
GENERATOR REGULATOR Voltage regulator<br />
box<br />
t 1<br />
I<br />
e<br />
Joy<br />
r<br />
F<br />
7 T<br />
oT<br />
J<br />
t<br />
T<br />
l<br />
J<br />
p t r<br />
r<br />
Ii<br />
t<br />
0<br />
control<br />
I<br />
J<br />
i<br />
Winder<br />
GLASS RUN CHANNEL Glass channel glass runner<br />
baIley channel<br />
HEADLINING Roof IImng<br />
HOOD Bonnet engllle compartment lId<br />
LUGGAGE COMPARTMENT Boot<br />
REAR GLASS Back hght back wlIldow<br />
VENTILATOR GLASS No draught ventilator vent glass<br />
ventIlator flipper oIygow quarter glass<br />
WEATHERSTRIP e herslueld<br />
WINDSCREEN Wmdsluel<br />
f<br />
I 0<br />
Pnnted by TlDles PrInters Sdn Bhd Smgapore<br />
I<br />
I<br />
vdp fitf vJ<br />
l<br />
zPi 1<br />
1 r<br />
OJ u fig<br />
f<br />
o<br />
1<br />
c<br />
l Y l<br />
frh<br />
o1<br />
1t
jl<br />
7 I<br />
L<br />
I<br />
J<br />
F<br />
1<br />
S<br />
I<br />
t<br />
I I<br />
I<br />
f<br />
I<br />
j<br />
I<br />
I<br />
I J<br />
I<br />
j<br />
iJ r<br />
I<br />
J<br />
I<br />
t<br />
o T<br />
r<br />
I<br />
I<br />
J<br />
f<br />
i<br />
l<br />
I<br />
d<br />
1<br />
I<br />
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