1
Download Datsun 411 Series Service manual
Transcript
Or 1 XJ o r t I u Z i r V A 1 t 1 1 I 1 t r C 0 l MODEL 411 SERIES A 1 j 1t k t r DATSUN MODEL 411 SERIES SERVICE MANUAL INISSANI NISSAN MOTOR CO OTEMACHI BLDG OTEMACHI TOKYO CABLE ADDRESS PHONES LTD CHIYODA KU JAPAN llNISMOll TOKYO 216 2311 INTR ODUCTION This manual has been complies for purpose of assisting DATSUN distributors and dealers for effective service and maintenance major of the Model components comprehensive ing detaiL in given assembly for of the In addition complete dismantl and inspection of these assemblies emphasised should be used described instructions are assembling It is is Each P L 411 as that only genuine DATSUN Spare Parts replacements DATSUN MODEL 1 411 U CONTENTS Page MAJOR SPECIFICATIONS ENGINE 1 Cooling System 3 Lubrication 8 SERVICE OPERATIONS 11 Rocker Mechanism 12 REMOVING REFITTING Operation with the 25 Engine Removed 26 IGNITION TIMING 31 Distributor 31 Adjusting the Ignition Timing 31 FUEL SYSTEM 34 Carburetor 34 The Gasoline Tank 37 Fuel Strainer 40 Adjustment and Inspection of Engine 43 CLUTCH 48 TRANSMISSION 57 Cover of Transmission Case 58 Transmission Case 59 Extension of TransmiBBion Case DiBaBSembly the Transmission Case CHASSIS 65 For 4 Stage Floor Shift 72 85 FRONT AXLE 85 DiBaBSembling the Front Hub Indipendent Front Suspension REAR AXLE 86 88 98 STEERING 112 BRAKE 119 Front Brake 120 Rear Brake 123 Hand Brake 126 ELECTRICAL SYSTEM 129 Alternator 130 Generator 132 Regulator 139 14 ItemB Trouble on Handling Shooting Starter Motor List 142 143 144 SPECIFICATION OF MA JOR MODEL 41 1 SERIES MODEL ITEM P L 411 U WP L 411 U P L 4 1 1 oUT WP L 411 UT Overall Length 3 995 mm Overall Width 1 490 Overall Height 1 440 Wheel Base 157 3 in 3 995 mm 58 7 in 1 490 mm 58 7 in mm 56 7 in 1 430 mm 56 3 in 2 380 mm 93 7 in 2 380 mm 93 7 in 1 710 mm 67 3 in 1 704 mm 67 1 in Inner Width 1 240 mm 48 8 in 1 240 mm 48 8 in Inner 1 130 mm 44 5 in 1 130 mm 44 5 in 1 206 mm 47 5 in 1 206 mm 47 5 in 47 2 in 1 198 mm 47 2 in L Room Space Height rront Tread A Rear Min 1 Road Clearance Overhang mm 175 mm 6 157 6 3 in 9 in 175 mm 9 in 605 mm 23 8 in 605 mm 23 8 in 950 37 4 in 947 mm 37 3 in to the Front End without bumper Overhang 198 mm to the Rear End without bumper Vehicle Weight mm 885 kg 1951 Ib 960 Front 505 kg 1113 lb Rear 380 kg 838 lb 160 kg 2557 lb Front 600 kg 1323 lb 595 kg 1312 Ib Rear 560 1234 lb 640 1411 lb kg 2116 lb 500 kg 1102 Ib 460 kg 1014 lb 235 kg 2723 lb Distribution Vehicle Gross Weight I 1 1 Distribution 9 Height of Gravity Center 580 Proportion of Front Tire Angle Inclination 22 8 in mm kg 580 mm 22 8 in 51 7 48 2 Right 46 46 Left 46 46 with load Max kg I r DATSUN MODEl ITEM Speed Max P l 411 U WP l U 411 P l WP l UT 411 UT 411 140 km H 87 MPH 140 km H 87 MPH l Fuel Consumption p 0 r p Grade Min Ability sinO 0 375 Turning Radius l 5 18 5 0 P km 0 417 18 5 km UT o 334 164ft m 5 o t 391 UT 0 m 164ft 135m 443ft Po Brake Distance Stopping 50 h km 44 3 ft 135m Model J Make NISSAN MOTOR CO Classification GASOLINE ENGINE Cooling System No of WATER FORCED CIRCULATION Arrang Cylinder 4 IN LINE Cycle 4 Combustion Chamer BATHTUB TYPE Valve Arrangement l LTD OVER HEAD VALVE Bore x Stroke 73 x 77 6 mm DiBplacement 1299 c 2 874 x 3 055 in 7927cu in c Compression Ratio 8 2 as lE Compression PreBsure 350 kg cm2 r p m 48 3600 kg cm2 r p m 11 5 l Max Exploding Max Mean Effective PreBB Max B Max Torque SAE Length x H P PresBure 9 7 28000 SAE Width x kg cm2 r p m 67 5200 HP r p m 76 7 2800 ft Ib Height 597 Weight x 575 x r p m 690 mm 10 6 2800 kg 23 1 x 22 SPLIT SKIRT TYPE PiBton Material LO EX 2 r p m 6x26 5 in 139 kg 306 Ib PiBton Type m MAJOR SPECIFICATION MODEL ITEM No of WP L 411 U P L 411 UT WP L 411 UT 2 PreBsure PiBton Ring riI I i P L 411 U 011 1 Inlet Open 14 B T D C Inlet Close 50 A B D C Exh Open 52 B B D C Exh CloBe 12 A T D C Valve Timing @ f riI Intake 0 35 mm 0 014 in ExhauBt 0 35 0 014 in Valve Clearance p riI Eo Starting Method MAGNETIC STARTING SYSTEM Type N41 p riI Z N50 14MZ 40 Ground Polarity NEGATIVE Type AC300 12WR Make MITSUBISHI ALTERNATOR Generating Method 12V Voltage 300 W Capacity Voltage Regulator RL 2Bl Type S114 92 Make HITACHI Eo on I l z Zl l 12 1 Power 4V HP BATTERY COIL TYPE Ignition Method t 9 Voltage 1 each 50 A H riI p riI 2SMB 12V Voltage Capacity p 0 Eo mm 8 Ignition Timing 600 B T D C 1 Firing Order 3 4 2 3 r p m r DATSUN MODEL ITEM P l 411 U P l UT 411 C1Z Type WP l U 411 WP l UT 411 18 Ignition Coil Make HITACHI 0411 Type 53 Distributor Make Distributor HITACHI Ign Timing Advance System VACUUM AND GOVERNOR B Type Make 6E NGK Spark Plug Thread 14 mm Gap 0 7 08 mm Type l 0 Make E Carburetor 0 0315 in NllIONKIKAKI Throttle Z 0 00275 D2630A 5A Q iI I Eo 0 551 in P S Valve Bore 26 Venturi Size 20mm 30mm mm 27 mm Main Jet 192 1140 Slow Jet 148 I 48 Z 0 Pump 145 Jet Power Jet 140 Air Draught Type DOWN No PAPER TYPE 1 each Air Cleaner Make TSUCHIYA Type DIAPHRAGM Fuel Pump Make Capacity z 0 SHOWA of Fuel Tank 41f Lubrication Method r KYOSAN 10 8 U S gal FORCED PRESSURE TYPE 9t2E 4 MAJOR SPECIFICATION MODEL a ITE C p L 411 U WP L 4 1 1 U P L 411 UT WP L 411 UT TROCHOID TYPE Oil Pump Type E 0 l f CARTRIDGE TYPE FULL FLOW TYPE Oil Filter p Q I 2 Oil Pan Capacity 9 fr 0 76 U S gal H WATER CUULING CLOSED TYPE Type l riI E Radiator l t Cooling CORRUGATED FIN AND TUBE TYPE Water 5 4 fr Capacity 1 43 U S gal as H 0 0 U Water CENTRIFUGAL TYPE Pump Type PELLET TYPE Thermostat SINGLE DRY DISC HYDRAULIC OPERATION Type No U E H U 1 of Plate Out dia x dia In x 200 Thickness x dia of In dia of Master x 181 Total Friction Area In 130 3 5 mm x 2 cm2 19 05 Operating Cylinder 7 87 x 5 28 06 mm 15 87 mm Cylinder 3 FORWARD Type FACING 2 1 REVERSE x 12 x 0 138 in 2 sq in 3 4 in 5 8 in 4 FOREARD 1 REVERSE ALL SYNCHROMESHED SYNCHROMESHED ON ON FORWARD GEARS 2ND Gear Shift Method REMOTE CONTROL Oil Capacity 1 3RD 4TH FLOOR SHIFT Z 9 f l l p E Gear Ratio 2 45 U S gal 7 fO 2 0 1st 3 197 3 945 2nd 1 725 2 402 3rd 1 000 1 490 4th 4 Reverse 125 1 000 5 159 0 I 1st Length Out x dia x In 1222 x 71 dia 0 0 Type x 67 8 mm SPICER TYPE of Universal Joint 0 5 58 U HYPOID Gear Type o 5 S gal r DATSUN MODEL P L 0 i 1 1 L 411 U P ITEM P L 41l Gear Ratio WP L 411 U UT 411 WP L U 4 375 WP L 41l 4 U Housing Type P L 41l OP 3889 111 UT 411 UT WP L 411 UT BANJO J r No Type is of Gear STRAIGHT BEVEL PINION 2 each Oil Capacity 1 fO Type 26 U S gal RECIRCULATING BALL TYPE Gear Ratio 15 0 Eo ES Steering Angle r Out I Eo 360 Steering Wheel 280 Dia 405 mm Oil Capacity 0 33 f Wheel Arrangement Front Axle Toe 0 D p 1 45 0 Inclination Angle of King Pin 6 Width x 15 SEMI FLOATING TYPE Type FRONT 2 LEADING Lining Dimension p l 2 REAR 3 mm Type j f 087 UoS gal Caster p l 95 in WISHBONE BALL JOINT TYPE Type in Rear Axle Eo 15 2 FRONT Camber ES 36 x REAR LEADING AND TRAILING 40 x 4 5 x 215 mm 1 575 x 0 177 x 8 465 in 40 x 4 1 575 x 0 177 Thickness Length 5 x 215 mm 351 cm2 54 4 in2 351 cm2 54 4 Total Braking Area U in2 p In dia of Brake F 228 6 R 228 6 mm mm 9 0 in Drum q 6 9 o in x 8 465 in MAJOR SPECIFICATION MODEL ITEM In dla I r WP L 411 UT of Master 22 22 mm 0 8748 in F 25 40 mm 1 000 In R 23 81 mm 0 9374 In 115 kg cm2 j In dla II Q I r I 0 of Wheel Cylinder H n WP L 411 U P L 411 UT Cylinder II Q I I r P L 411 U 0 II I r Max Oil PreSBure 1636 Ib ln2 MECHANICAL FOR REAR WHEEL I r I r Type II Q I II Q I Lining Dimension 40 x 4 5x215mm 1 575xO 177 x 8 465 In t 351 Total Braking Area cm2 54 4 sq in II In of Drum dla 228 6 mm 9 0 In Po Front INDEPENDENT SUSPENTION WITH COIL SPRING Suspension Type R H Coil Wire dia x Free Length Z 9 Z I r Po Rear Coil dla No x of Coils 14 2 Size Length Thickness x CAR x 94 x 8 5 14 2 325 L x 94 x Width 6 2 x 1200 x 60 x No 6 1200 x 60 5 2 P ShOck Absorber F TELESCOPIC DOUBLE ACTION Shock Absorber R TELESCOPIC DOUBLE ACTION Stabilizer F TORSION BAR TYPE Tire Size e F 5 60 13 4P R 5 60 13 4P 12V 37 5 50W Head Lamp Sealed beam Po H x Width Indicators 12V 8Wx2 Tail Lamps 12V 8W x2 12V 8W x2 LlcenBe Plate 325 8 5 LONGITUDINAL SEMI ELLIPTING SPRING Suspension Type Spring L H CAR 336 R LampB Stop Lamps 12V 25W x 2 Reverse LampB 12V 25W xl Room 12V Lamps 7 5W x 1 2 x 3 5 2 r DATSUN MODEL ITEM P L U 411 WP L 411 U P l UT 411 WP L Fog Lamps 12V 35W x 2 Inspection Lamps 12V 8Wx 1 Parking Lamps 12V 8Wx4 Turn Signal Lamps 12V 25W Dash LampB 12V x 4 3W x 4 p 32 Reflection 50 x 2 l Warning Lamps Turn 12V 15W Signal x 2 Main Beam 12V l Ignition 12V 1 5W xl Oil Pres sure 12V l 8 5W xl 5W xl UT 411 oc EJ l 10 11 c l 0f o 9 8 zor 0E 300 7 z8 g 200 100 a CENGI E URVE J MODEL m p 40 102 x PERFOMANC A SPE D ENGIE W U 8 SO 70 0 I 0 I I 357 SO O CURVE 375 197 725 000 4 3 1 1 160 1 382 lanD O d I t r 0 40 0 20 0 30 0 p 280 T 8 kg S I rn sin8 O 35 Oc I 1 I 0 10 I 60 m kg 287 6rn O 10 m 0 3 p le l 0 5 52o r 67HP 5 U PMODEL ERFOMANC L P RUNIG 100 1 3 411 ratio ratio ratio ratio ratio geal spe d spe d Final 1st weight abilty radius SAE spe d spe d vehicle grade ef ctive torque 2nd 3td 4th 160 ISO 140 130 120 110 90 30 80 SAE BHP 70 40 Gron Max Tire Max Max SOO 400 f bii 200 300 u I 2 VI Z 100 1il Ian 60 SPE O 50 CAR 40 600 h I t Iici 417 CURVE kg 111 945 403 490 000 160 4 3 2 UT PMODEL ERFOMANC 411 Pil RUNIG 1 1 1 0 tan 280 r m kg Crol foo 287 6m O lSO 52o r 40 102 31 67HP 10 P 2nd 3rd 4th 10 0 J2000 P joo 90 80 40 p 1st 30 0 m weight radius SAE SAE ratio ratio ratio ratio ratio abil ty gear eed spe d spe d spe d vetlc1e rade ef ctive torque BHP Final 40 U t5 P sinO O 4S9 SO O m r SO 70 45 sil 3040 s 1st o I 400 3oo S g 111 CURVE 945 403 490 4 3 2 1 1000 UT 411 L WP DEL MO PERFOMANC ratio ratio tio ra ratio ratio gear spe d spe d spe d Final 1st cd spl 2nd 3rd 4th 425 tan8 Ii 0 j p 280 r m kg 287 6m O 10 50 0 m P 200 0 u l S j OI01 z r 40 0 30 0 20 0 160 ISO 520 1 67HP 102 3 4 weight abilty radius SAE SAE vehicle llde gt Car 10 soo m Spe d 21 I O dn8 kg 60 Max Tire Max Max 391 h 100 ef ctive torque BHP Gros Max Tire IMaxMu 90 80 h 70 45 SO RUNIG 60 50 40 30 lat 20 10 o 600 100 f I 0 II5 n J km Spe d Car ENGINE ENGINE ENGINE The engine is of monobloc construction the valve are set in line in the are operated by camshaft in the and cylinder head and push rods from left hand side of the engine rockers and running in three steel backed is chain driven and has a whitemetal bearings and oil pump are driven pistons piston are the split skirt type of pins two carry in bolted are compression ring connecting steel backed lead and copper which have changeable big end bearings The A counter balanced crankshaft is fitted on this ust thr washers at centrifugal from the camshaft The alloy and alloy and a slotted oil control The rods end rubber chain tenssioner distributor rings the The camshaft The aluminum component the center water is taken main and pump by special bearing cooling The fan are driven by the generator belt GENERAL SPECIFICA TlONS J Engine type No of Bore 4 73 mm 1 Volume brake horse power 10 Torque Firing order 67 HP at 5200 r 6 at 2800 r kg m 1 Valve arrangement Compression Compression mm 77 6 mm Stroke Max type Cylinder pressure ratio Overhead valve 163 lbs per sq in 11 5 kg cm2 299 p m p 3 m 4 2 push rod type at 350 r p m 821 DATSUN j f St J ENGINE RIGHT SIDE ENGINE LEFT SIDE 2 ENGINE COOLING SYSTEM f I I J cooling BYBtem is of major enBure the satisfactory running efficient An importance to of the engine and it iB therefore necessary pay particular attention to its maintenance to Description The cooling system iB maintained by water pump circulation combined with an efficient fan cooled radiator and thermostat system is pressurised and the relief valve incorporated in the radiator filler cap controls the pressure at approximately 0 4 kg The per cm sq Do not remove the filler cap if the temperature of the coolant is above boiling point or should if Topping Fig the 1 Radiator up Fill to within 1 2 be required occasionally to replace through the overflow pipe Top up is cold and if use possible engine only water lost when the engine iB running plug well may cause pipe clean soft water mately 3 of the bottom of the filler Overfilling when the engine is cold through the overflow water to flow The capacity of the system is approxi 5 2 litres DATSUN housing and the hose reconnected to avoid laying up the car is The set thennostat opening by the Thermostat from In order to ensure maximum essential is keep to the efficiency engine temperatures within certain limit this pellet tyep thermostat a located in the cylinder head outlet water is at it manufacturer and operating To being front of the can not be altered During decabonising it is policy to test this opening by immersing the thennostat in water The valve raised to requisite temperature assist fitted its should Pellet type thermostat works by the principle of rapid variation of solution of wax open fails to open under these conditions but if it unit should be fitted a new Overheating belt Overheating may be caused by a slack fan excessive carbon deposit in the cylinders with running the far too ignition carburetor incorrect adjustment retarded failure of the water to circulate or loss of water Fan Belt The a V A Adjustment fan belt is belt new driven this from the crankshaft also driving can by the alternator by first loosening be fitted which hold the dynamo 3 the clamp bolts Fig in position and moving the dynamo towards the Slide the belt engine 2 Pellet Fig Thermostat Type The devise consists of metalic pellet with the which controls a mash wax by solution of on starting the radiator is Due this the fan and onto the pulley filled valve wax When the engine and room fan over the is cold this valve is closed engine the flow of temporarily water to restricted the temperature of the water in the cylinder jackets will quickly thus ensuring rapid warming up The heat so generated will gradually press cylinder head and rise up the piston by shrinkage of synthetic rubber so opening the valve and ultimately pennitting a full flow of water to the radiator sleeve The thennostat itself is should be occasion detachable arise it can therefore be removed Fig Part No Standard Optional for cold district 21200 21200 61001 61001 3 Fall Belt Rated Temperature Open at 76 5 Open fully at Open at 82 Open fully 4 AdjustmeTlt t1 C 5 C t1 90 5 C t1 C 5 at 95 t 1 C 5 C ENGINE Adjustment is then made by bringing the The belt away engine Bhould be sufficiently tight to prevent slip yet alternator the from belt should have 10 to 15 the generator and midspan When completely drained the engine the mm crankshaft be when minute to ensure the should that all system suitable notice should be then affixed to A the radiator indicating that the water has been drained pushed firmly is timed a water has been cleaned from the slack between pulley for run After the correct tension has been obtained securely lock it in position again the Radiator Flushing To ensure efficient circulation of the coolant Frost Precautions Freezing may the radiator and may advantage must care closed fully expected used in low temperature a very or it up to the up with anti freeze solution as the degree be made of in up when the where weather to frosty of the freezing must sufficient anti freeze mUBt engine drian completely merely with rugs cocks one and on not used the is taken be cylinder block and radiator block remove during setbolts the cooling the masks the It is not radiator and There are left hand two side of the other at the base of the Both taps must drain the system and the ground while draining car be must opened be on to level The drain taps should be tested at frequent intervals that they by inserting are immediately clear the taps a piece This are of wire to enBure should opened so be done that any obstruction freed by the wire may be flushed out The draining should be carried by the water out when the engine completely and to the the bottom hose connection and out of Pump the pump unit from by taking off to drained cover the reverse again any damage due to obviate to the radiator remove run cooling system be to After draining the water from the radiator When heavy frost is imminent system At the top connection Water precautions through until the drain taps flow turn the way radiator upside down and let the water flow in by Draining cars following not through the mixture into a clear container and use On from stiff piece of wire should be inserted flush in the instructions If the cooling system has to be drained Protection a clear during draining to ensure that they becoming clogged with sediment practice is cold system in the excessive the operator will find it more efficient neces with the container supplied Top with accordance in anti freeze This method of radiator flushing may serve well but in cases where the urring up is topping up with water reduces protection afforded Solution must up out comes are Excessive sary and into the taps strength advised by the manufacturers The strength of the solution must be maintained by topping scale and again when taking it out in the spring intervals make sure that in fact of the The water should be allowed to run when the car is to be of the solution is the strength winter boiling will result When frost is formation periodically flushed preferably before putting connections be taken not to run or the system should be with clear running water will stop water circulation A muff can be used to boiling but reduce to sediment in the radiator hose cause with the muff first at the bottom of occur in the lower hOBe or Ice in the and is hot 5 with dynamo the fan belt spring the and washers cylinder block releasing the and hinge bolts r DATSUN Seat set Sn v r n h Boh Pulley 21051 10600 131 m m db 21051 10800 143 m m dla Beanng k WA twi j 1lj lL Bolt I L Hub for fan pump pullf long v Gasket FOlD Screw belt 21067 10600 21067 10800 Used for 2MB type battery 4 Fig the Removing Pump Shaft Disconnect the fan blades The shaft and ball one bearings Water Pump Assembly pulley and 5Jtj cover is combined with unit Put the pulley First press or knock the shaft end drift hard bar bub on the bench and draw out the pulley with hub a on Fig the U type bench Take locked out the See Fig Next the shaft set pin from assembly to the Example of the Pump Body Bench for slit which the pump body The shaft and ball bearing 6 drew out from the turn the out the shaft 5 body upside down and press assembly from the vane side on the Thus take out the vane which remained the pump U type bench 6 aBsembly can be body floating seal and seal body ENGINE The Reassembly of the 905 0 2 21 O Front be 3 reassembling of the taken to ensure fitted correctly for Set a screw pump is a reversal but disassembly procedure that the a slit a a care should shaft assembly is hole of set ring with groove of shaft so as to insert and set the said ring correctly Shaft with bearings Adjusting Clearnace End and Body First 0 4 mm O 5 Inserting thiclmess pin Insert here bench thickness out gauge good between 6 7 the gauge vane fitting with condition Thiclmess end Take out the thiclmess cork washer Fig shaft a pin mm o 5 mm a down the groove line to insert the set Clearance Set press the Van on 0 4 the U block gauge Screw up with the and find cover and r DATSUN LUBRICATION Circulatiol Pressure unit and is oil The full of the oil enters the element lubrication is used throughout the provided by an ecentric and is driven from relief valve which is oilways situated at the is This space the oil to the cover the pipe the camshaft gear by a short vertical shaft The oil is drawn into the pump via the filter and is delivered through internal through through element into the annular space round the center The oil pump is bolted into the left pump hand side of the crankcase and passes cartridge holes in the draining non only can sealed top and bottom through escape so that small hole into a the hollow center pipe and from this point back into the oil pan of oil pump the Oil Draining The must oil be on and new drained and reconditioned engines then filled with after first 2000 mileB 3000 Lan of every 3000 miles 5000 Lan is at The oil the oil pan when the new oil and at intervals The drain plug should be drained is hot as the oil will flow more engine readilY Before filling the oil connect and pan with new oil dis change the oil cartridge Oil Pressure The oil lb Fig 1 main oil gallery on oilways the to the right hand side of the and the rear lubricate the rockers are drilling rocker in the shaft from the center camshaft a to b ings c on As the camshaft rotates case two grooves in timing case forms part of the main oil and as at will noticeable drop in pressure a good supply a sludge bearings to That the have twice This gauge as bearings the excessive of the correct will sides when more which oil correct the oil the from becomes the of oil the is more bearings warm and fluid cause in clear will escape a drop in preBsure on the compared with that are is fed under working good order shown when the The relief valve in the lubrication system deals with any excessive oil pressure when starting from cold When hot The filter therefore gallery readings engine is give low speeds oil new in the oil pan particularly lubric ation for the timing chain and gears From the timing case the oil returns via a drain pan sq in when the That the strainer in the oil pan is clean and readily revolution of the camshaft to provide hole back to the oil with engines there is ances register with a small hole in the camshaft thrust plate thus allowing a small amount of oil to pass into the That pressure the front journal during New 10 lb approximately not choked with enters a the left hand side of the engine and lubricates the tappets through individual drill gallery the gauge at normal kg cm2 should be shown grade of oil The oil bearing on the following points should be checked and then drains back into the oil pan via the push rod apertures whilst should there be cylinder bracket kg cm2 1 considerably higher big end and camshaft drillings in the crankshaft The connecting ends 7 idling main bearings through block 0 The flow then passes via connecting engine 2 road speeds From the relief valve the oil passes into the should not drop below 30 pressure sq in such is the pressure filled with oil under pressure fluid 8 drops as the oil becomes more ENGINE Check for Low Oil Pressure resistance opened with with the air no leakage existB Removing after new unit and the remove should cartridge Take by hand sealing ring care is cylinder block it can not in oil sent to to locker element of the paasage delivered to all the the If the temperature journal filter in of lublicant oil oil viscosity is high or oil alve which are the securing bottom edge is Notice cover pan refitting low at embly idge I Fig pump through which oil to is To remove the strainer connecting 2 Oil Filter 9 that there which must if the filtration filter strainer pOBsible iB the oil pick up to the Becuring bolts bolts cylinder and chain blode Relief bolts The Btrainer may be dismantled for cleaning purpose by removing the delivery pipe flange Flemfilt Cyl oil lowered it pump and unscrew the the with a relief valve provided Element To snup drawn into the oil the lubrication crank pin camshaft arm The oil filter is starting remove the rubber and finally returned to the oil tensioner With removed easily lose the oil system crankshaft journal bore screw underside of the Strainer Removing of unto the union filtered cartridge gallery part of the main oil in the container as a unit The the washers in the process The element of oil filter is sealed the engine Drain the and then every 3000 kIn miles changed be 000 km after this The forms 1 litres flange and the lower bolts from the Lower the oil pan from the of the bell housing not to damage the care taking joint engine the Filter first 2000 set the Remove inserted from filter large oil and replace the drain plug the fault rectify A defective being is difference to bypass oil pressure The sump capacity is 3 at strainer union on the suction side of the oil pump 10 sale that sludge up element the relief valve will be the Oil Pan Removing clean and not chocked strainer in the sump is filter after refilling the on switch off and ascertain that the gauge sump oil the choke caused by its Check the level of oil in the engine sump by of the dip stick and top up if necessary means If the warning light is still of be the dowel pins to the positioned correctly when are r DATsUN Removing Remove the Oil the oil Pump the and pick up strainer securing the oil pump long enough to Becure the inner pan Three of the five bolts bottom cover pump to pump in and are the crankcaBe remove Unscrew the long tilting rotor with its the body upside down drive shaft the and the outer rotor with slide out 3 illustrates the Fig explosed form On cover Refitting bolts the pump With its drive Bhaft the Pump Clean out the sump by washing it in paraffin care to remove any traces of the paraffin before refitting the oil pan to the engine Pay the particular attention to the oil pan and crankcase joint faces and remove any traces nf oil jointing material it if Examine used again if fit a new one it the joint washer and renew The necessary is oil joint washer can be but it iB advisable to sound Smear the faces of the joint With grease and fit the joint washer Lift the oil pan into position and insert flange tighting them up Reassembling the setscrews into the evenly the Oil Pump The outer rotor haB a chamfered 3 Fig the base of the Dismantling Remove which the Oil the secure Pump I cover to the Insert spring body washers n i f j11 j 1 o It is failure to assemble in this Jl r l Fig 4 Oil Pump 10 cover is tightened down the slotted end of the drive Bhatt into the body and bring the and take off I r body way will result in the setscrews and the edge of great important that this chamber be towards rotors into meBh ENGINE SERVICE OPERATION WITH ENGINE IN POSITION Removing Starting Nut and The Pulley washers spring are immediately below the bolt heads Remove the radiator attachment bolts and 1 Slacken the remove Take dynamo the fan belt Bend back the tab on the starting dog nut Unscrew the starting dog nut locking washer by using Heavy duty Shock type spanner A few sharp blows in an anti clockwise not out the set to the damage If joint cleaning does of faces remove the Care should be taken washer damage the bolts screw and its joint washer cover when breaking the occur fit the of a new washer surfaces joint beforehand direction will slackent the nut Pull off the crankshaft Fig Removing The bolts Removing Timing cover having special plain a is secured by set washer Note that the screw and is endless bOth the remove relationship next is to each other Draw off both the gears a little at a time first removing the crankshaft gear retaining nut As the gears are withdrawn care must be taken J not to lose the packing behind the crankshaft gear shaft gear teeth is a rubber a tensioner chain renew is drive Examine the special Timing attention following points 11 ensures from ring which acts as silent operation of the the felt washer and Gear Replacing the componentB of the timing gear largely a reversal of the dismantling process but 2 and washers Between the cam it if oil has been lost be seepage Refitting Fig it and crankshaft and camshaft gears together Before doing this notice the timing marks on both gears and their a special washer is of elongated shape and is fitted to the timing cover flange chain timing necessary to Gear 3 Fig Cover shakeproof washer Timing the 1 The the timing each pulley should be paid to the DATSUN Fit the crankshaft and camshaft gears into Ensure respective shafts are opposite and in line their marks in at and the camshaft with its T D C the one o clock approximately the keys ensuring that Ensure opposite keyways in present are on the shafts If the unless a new In been fitted gear faces and this the the measuring To feeler gauge be neceBsary crank caBe to adjust vary the alignment of the alignment with a alignment it will gear that front of the is in thrower behind its car Concave and pump stud nut is the rocker remove rear special locking plate a rocker Completely blacket the rocker shaft unscrew and nuts Complete with assembly brackets and rockers the face it the Rocker Dismantling Assembly To first packing the remove rear Shaft rocker the dismantle from the so the not siackened are Notice that under the righi hand wash Fit the oil secure camshaft has or number of the also nuts head nust cylinder cylinders the gears are that the timing marks Drive the in line to each other and replaced fixing system and because four of distonation may result and allow water to find its Bystem into the way from the cooling on gears home The Bame number of packing washers taken be behind the crankshaft gear must from head nuts cylinder shaft drain the to necessary head cylinder keyway poBition Place the gears into position is rocker the crankshaft until the keyway Turn the engine is the timing It slacken the grob shaft assembly and screw locking plate rocker bracket crankshaft towards the and check that the felt waBher pOBition ROCKER MECHANISM Valve Rocker Cover Removal Remove the air cleaner Unscrew the cap securing the engine lifting brackets Remove the rocker cover and the cork joint nuts washer Removing the Rocker Drain the in use UBe Assembly cooling sYBtem Fig Cylinder 5 Head If anti freeze is clean container for the fluid Remove the Bplit washers spring Slide the rockers the shaft pins from brackets Unscrew the flat washers each end of plug and the shaft and Bprings from from the end of the shaft and clean out the oil way The two end rockers may be dismantled without the whole rocker out This may be by hand until No assembly being drawn achived by turning the engine 1 push rod reacher its lowest pos ition Unlock the tappet adjuBting screw and screw it back as far as it will go Withdraw waBher and the Bplit slide the pin rocker flat and Bpring off the shaft Sometimes the valve spring will have to be compressed by levering a Bcrewdriver Fig slightly 4 underNo 2 rocker 12 thus allowing the end rocker ENGINE to slide off procedure for the shaft No Repeat the easily and lock plate Replace the spring and flat washers with the split pins on the ends of the shaft Replace the screw 8 rocker the Rocker Reassembling rocker cover and gasket o s 0 Fig On reassembly tighten nuts securing diagonally from bracket pedestal little a nut the at to pedestal time a nut 3 and No 4 bracket and repeating the they been are on all tight completely stripped holes will have bushes reamed down on No down to be to size The 2 process should pipe Secure the the Cylinder be at the front by cover Head of the of the two means ensuring that the rubber bushed and If the lifting plates are in position rocker cover gasket or the rubber bushes are found to be faulty they must be renewed other 1 cap nuts left of engine until assembly Reassembling vent engine the left nut of If the rocker the oil bracket working left nut of No right nut of returning from No so 8 Fig 6 wise oil leaks will result has and rebushed redrilled and the before assembly the shaft Push Rod Removal If the valve rocker has assembly already been removed all that remainB iB for the push rods to be lifted out They may hand be taken out without on detaching the other the rocker aBsembly Remove the Slacken all air cleaner and the then their full extent the rocker shaft spring slide the push rod as a the using a cover screws screwdriver to with fulcrum depress the valve rocker side ways and lift out All but the end push rods in this way rocker adjusting tappet can be withdrawn These will have to be withdrawn after the removal of the two end rockerB from Fig 7 the shaft The rockers and spring must be replaced in their original pOBition on Remember to replace the the Ocker l When replacing push rodB ensure the ball ends register in the tappet cups ends of the shaft here onwards shaft locating reassembly is a straight forward reversal of the dismantling process 13 that From DATSUN Valve Rocker Clearances Adjusting the air cleaner and rocker Remove should There 0 be a clearance the a rod cup result in Turn or a screw driver in lower the adjusting screw until the correct driver on tappet adjusting disperse the film of oil from the push Failure to follow this procedure will clearance is obtained wrong reading being taken hand the engine over by important to note that while the clearance is being set the tappet of the valve the screw to screw insert slot and slaken the lock nut Then insert 0 Whilst checking the clearances it is important to maintain pressure with 9 Fig screw 014 in feeler gauge between the Raise face of the rocker and the valve Btem between the face of the rocker and 35 mm the base of the valve stem adjust adjusting To cover of 0 014 in It a handle until the valve is fully push starting the StopB falling rod 9 Adjusting nut and recheck the is being adjusted must be opposite to itB peak closed Fig lock the Tighten clearance on the back of the cam the Rocker Clearance CYLINDER HEAD Rocker shaft Length OUter diameter Removing 15 85 One 19 01 19 04 mmo is situated inlet tube at the backside of the radiator and other side of the engine Inner diameter 15 89 dimension after 15 90 use mmo at the rear right hand If anti freeze mixture is in it should be drained into a suitable container and retained for future use the Disconnect the negative cahle from battery he extracting the tenninal screw and removing the lug from the hattery terminal post Slacken both the retaining clips on the hose mounting Rocker Head cocks before mounting Clearance Cylinder Drain water from the cooling sYBtem by opening the radiator and cylinder hlock drain 15 88 mm Rocker inn bush Outer diameter Reamer finished the 356 4 o 01 0 05 mm arm Bore 19 012 19 037 Lever ratio 1 mm connecting the radiator 43 ing and 14 remove the hose to the thennostat hous ENGINE Extract nuts and thermostat the the remove aircleaner Remove the securing housing and housing used for long Detach the high tension cables and also the sparking plugs temperature thermostat gauge Removal and Whilst valves the from rocker assembly slacken the external cylinder spring is head cylinder removed tbe To do this compress be taken out with the compressor as shown in forgetting not the can the vaive housing Take off the of the Valves Replacement remove disconnect the water connection often than those more runs rocker carburetor and the inlet and exhaust manifolds cover to will require this attention thermostat special valve spring Fig 1 head nuts at the time same push rods keeping them in the Withdraw the order of removal The cylinder head block cylinder cylinder with to hammer a using When lifting the given so the of the head piece of wood interposed head a head is the Remove the studs a breading side Do not use excessive force blow that be lifted off the now facilitate tap each head joint take the can To should be direct puil puiled evenly cylinder up the head gasket Decarbonising the Remove still in position remove Fig i With the valves cylinder head the carbon combustion chambers and the valve faces Leaving ensures seats the valves in damage that by the position cannot for this be retaining coilets Release spring the valve spring cap Inlet valve oil seal valve only and its retainer valve from the guide Withdraw the Keep the valves in their relative positions to ensure when removed from the enigne replacement in their original valve guides Remove the two cap caused to the wire brush which should are the valve be used coated with a deposit this may be removed by using chisel shaped piece of hardwood very hard a Remove the valves and using clean out the carbon from brush spring Compressor Removal operation for the removal of carbon If the exhaust valve heads Valve from the the wire the inlet and exhaust ports Blowout all compressed the ports with carbon should crowns worked cylinder traces type pump gasoline and dry is now at and dust engine until T D C them out the with Replacement finally clean be removed from the Rotate the on of carbon air or the heads piston piston Protect Note that the diameter of the exhaust valve The smailer are to be replace other guide the and retainer bore from the entry of carbon particles Fit The fluffy rag into them chisel a shaped piece of hardwood Using the remove carbon from the piston Carefuily wards ring of carbon should be left round and the deposit the periphery of each piston round the top of the cylinder bore should not be intake valve by pushing crowns touched tion is a non Replace loss of power the oil spring seal charrifered seals are more seal side easily and down fitted if only the valve spring and compress the Refit the cap retainers and an ail round generally given by Cars used mainly on oil valve into its valve spring An indication as to when decarbonisa is oil To inlet valve insert each they have been soaked in engine oil for a short period before use The oil seal is used for the A require valves replace than the means short runs of compressor 15 the valve cotters secure them by Remove the r DATSUN Inner Free length Length in use 50mm mm loaded and 36 9 mill kg t0 of coil Turning Nos Effective turn of coil Dia of coil wire Diameter of coil Outer Sp 13 1 7 cylinder head the valves and their seats should be examined for i1 signs of pitting 5 6 5 6 5 4 5 mml i l mm Grinding Before replacement of the 38 9 29 5 24 Valve 52mm 8 28 Sp 25 2 or burnt patches and distortion If these conditions seats i 4mml i mml mUBt the valves in should the be present are the valve be recut before attemoting to grind whilst distorted valve heads trued mimmum the valve renewed or amount of metal Only should be removed in the turning process When grinding a valve onto its sealing valve face be should type grinding tool The its seat with a semi coil lightly paste and then lapped in with grinding to smeared valve must rotary a the with suction be ground A motiron light spring interposed between the valve head and the port will assist considerably when lifting the valve in order to rotate the face to a different This position should be done frequently to spread the grinding compound evenly It is process on necessary to continue the grinding until an even matt surface is produced the seating and the valve face On the completion should be throughly rag and dried and the air valve seats subjected to a The valves should gasoline and all traces of blast and ports cleaned with gasoline soaked be compressed washed removed Fig 2 Checking Spring Tension i t tJ20 OI KI l 1 O Oi J U lOO tRl bU1 Fig 3 Valve Spring g l Valve Ass y Fig 16 4 Turning in grinding compound the Value Seating ENGINE VAL VES Valve head diameter Intake valve 34 Exhaust valve 30 I 63 t0 Valve seat width and mm 015 8 7 Valve stem outer diameter both intake 9 mm 01 0 ex mm mm0 0 02 Overall length Intake valve Ex 109 54 mm 108 74 mm valve Fig 5 Cylinder Head Distortion Measurement o Dimensions Place mmq A 40 Intake 34 5 mmdl c 32 2 mmth B 2 DO the securing nuts positions 29 4 C 26 8 B D1 0 the tappet rocker Replace the securing 1 2mm eleven the with nuts given a adjusting assembly and head nuts in 6 Fig screws down screw Evenly tighten finger tight cylinder in the order down head in the push rods replacing them they were taken the the mmq lower the cylinder from which Screw back all mmq Exhaust Fit the finger tight mm mmq A 3S and position cylinder Insert O 4 into gasket head into place little at a a time finally pulling them set torque wrench to 45 lbs 1ft VALVE GUIDE 9 7 3 1 47 6 mm Length Intake valve 56 Exhaust valve Outer diameter 5 both intake 14 mm 14 33 mm 74 8 76 mm 31 10 and exhaust Inner diameter both intake 8 and exhaust Inner diameter at guide 8 inlet to insert both intake 14 Fig and exhaust both intake and 004 007 15 5 15 guide spring from them when the 9 mm seat the Ensure that The BO Cylinder the Head cylinder head and will that it will be head gasket is marked placed finally not hot or cold check The have to in which case the valve clearances be checked again and reset if necessary cylinder Refit the inlet and exhaust manifolds faces are clean cylinder engine is cylinder head nuts may pull down slightly more after the engine has attained its normal working temperature block joint Tightening Head Nuts Reset the valve clearances and valve face of the Refitting Cylinder mm exhaust Height of 6 2 The Order ot 6 the Clearance of valve stem and guide 4 3 mm Fit the craburetor and reconnect the control Top linkage head in correctly 17 Refit the ignition advance suction pipe JN DATSl connection the at this stage refit the air cleaner it will have or later to check the valve clear to be removed the rocker cover Replace ances on but do not the carburetter to taking care to fit the cork gasket correctly Place and thermostat the its housing in and secure with the three nuts position Reconnect the water gauge wire temperature and fit the radiator hose to the thermostat hous Connect the cables to the ing that the radiator and are Clean and adjust clipping the sparking plugs and refit The the hightension leads on the firing order of the clip which wiring block drain tapes and refill the radiator closed them cylinder Ensure battery 4 2 3 1 engine is of part secures Replace Fig the electrical Location of Valve Guide to be Fixed 9 harness to the side of the head The ignition can started engine temperature been has the rocker remove now When be switched on and the the normal reached cover so that Remove the operating switch the Remove off and Rest valve Whilst the engine water hose not leak is a punch connections and fuel line unions do When Tighten them if necessary clean valve with its and spring machined face surface and drive the drift This running check that the head downward into the combustion space with gnide final check has been made a on head appropriate cylinder downwards Replace the may be rechecked air cover and fit the cleaner when the clearances rocker the cylinder the should take the from of hardened steel See Fig fitting 8 new valve guides these should be driven in from the top of the cylinder head Removing and Refitting Valve Guides Removing a Valve Spring in Position I Fig 7 Fitting o Fig Position of a Valve Guide l 8 Hardened Steel Punch Fig 8 10 Checking Spring Tension ENGINE In an emergency a new fitted without removing the doing to this its T D C driver which will pass through the sparking plug orifice and locate on the valve head By using be When head position to eliminate the can any Withdraw Hold the valve onto its sealing with concerned a suitable tool such as a bent as a fork ended bar cylinder the cylinder spark plug from fulcrum point the spring be compressed with two screwdrivers or a the rocker shaft of the valve falling into the Remove aid of cylinder can the applic able piston must be brought possibility the valve spring the valve and cotters renew valve spring screw Cotter Nut Adjust tr screw nut Valve rocker Spdng Locating plate out 11 i tJ smcke j d C@l s I Bush Valve rocker shaft Pin VVaSher VVasher Valve Valve rocker shaft Rocker shaft bracket 8 COllet Spring etainer G Rubb dng Outer tension Bolt Lock w jChaiD hec II spring Intake valve Inner lock washer Bolt Timing Chain Camshaft Valve Gear 19 od spring Valve hfter earn Locating plate 11 Push Exhaust valve e Fig Tappet adjwting II G maft screw the r DATSUN Oil sherI Washer i Nut fix to Screw i is iller outlet elbow e Cover valve rocker I I nCgaver p r Jorntwash at Thennost @ waSher Heater outlet I Cy a Stud Cover j @ Nut I i plate 6 Q I 1 bolt J3Slinger Guide Q Slinger CyI manioHd froIit Nut Fig Remove the the valve oo 12 Cylinder t ey head Head Tappets and carburetor valve in head Washer e e Gasket Replacing ex Guide Ilil Stud exh and rear I I Removing Nut Washer the rocker then take off the manifolds cover Disconnect the high tension leads from sprking plugs the the rocker assembly and withdraw the push rods keeping them in their remove respective positions so that they will be replaced onto the same tappets Remove tappets tappet covers them and lift out the in same locations 13 jFig New tappet assembly their the also keeping own Assembly cedure tappet should be fitted by Belective that they fall into the guides under weigbt when lubricated so but cover is car a reversal of the above pro sbould joints are be taken oil tight to see that and that the Fig 20 13 Removing a Tappet ENGINE rockers to adjusted are CONNECTING ROD the correct valve give clearance i mm 22 49 of tappet 22 48 of cyl side hole 22 50 Dia Dia Clearance of the hole 0 01 Piston and Drain Connecting cooling the large 04 mm Rod Removal water from and then disconnect remove Outer End from 87 2 parts are replaced after dismantling it is essential they are fitted into their original To ensure correct refitting mark the positions and caps connecting rods on the sides to identify F500 1 mm 34 mm 51 35 diameter large end play of large end mm 31 mm o Finishing dimension of inner diameter of When used them 1 Width of and rock Take out the setscrews the big ends and withdraw the It will be noted that the caps are off set caps 22 0 t Thickness the oil 03 mm Clevite Overall width engine the strainer washers t0 150 end and small end Large end bearing Type Drain and remove the sump from and radiator the engine 0 Distance between center of i mm 22 52 20 0 31 17 450 mm 17 462 mm small end bush Standard CRANKSHAFT connecting rods upwards through the cylinder The piston and together must be with drawn Clearance of bearing bores peripbery to 0 cylinder 013 0 050 mm block hole White metal Material Block side Clevit metal Cap side Clearance of bearing inner diameter and crank o 0127 0 0508 mm 813 50 825 mm journal Diameter of main t 50 journal End play of crankshaft o 051 0 076 mm 47 640 47 652 mm Crank pin diameter Standard Difference of crank pin Less than 0 012 mm diameter Fig 14 Removing Connecting Rod flywheel End play with Pis ton Release the connecting rod from the crank is Less than 0 05 mm installed shaft and slowly push the piston and rod upwards the through cylinder hore NOTE shell bearing are removable by hand bearings are require no bedding in it is being only necessary to ensure that the housings and to place tbe are scrupulously clean and dry The The It may be necessary to remove the ring of carbon or lip from the top of the cylinder bore with a hand scraper to avoid risk of piston ring bearings into position with the tangs located in their corresponding slots Always renew bear bre akage Remove cylinder the assembly from the top of the oval Check the crankpins for of micro meter calipers ing ings if they are scored or damaged in any way the regrinding of the crankshaft or following In tbe latter case undersize bearing surfaces bearings will be required and the kinds of sizes block surface necessitate for the scoring removal with a pair and examine the bear either of the defect will available crankshaft for are 8 with punched mark regrindin g 21 12 25 50 75 and 100 f DATSUN P on P f og ton et 1 Bol Key Packing Thrower oil 1 Starting nut Bushing 1st motion shaft Jrgl i Fig Fig 16 wNut Pal C nk shaft 15 Piston Fly wheel assembly Budling 4 nut Crankshaft Crankshaft PISTON Replacing Insert assembly taken Pistons and each into Connecting and connecting cylinder from which it piston the Rods it is essential that the split rod was in the skirt of the piston is positioned towards the camshaft Fig Compress the piston rings with inserting and gently tap the piston using tool Fig 18 crown of the piston with the wooden end of a hammer handle 17 Inserting the Piston untt the piston is clear of the Fig piston ring clamp 22 18 Piston Adapter ENGINE push the piston down the cylinder block until big end of the connecting rod just protrudes through the bottom of the cylinder bore then position upper half bearing shells The gudgeon pin Now piston the at 700 F gudgeon pin 21 1 is a push fit in C reassembling ensure the gudgeon pin positioned in the connecting rod so that its groove is in line with the clamp screw hole When is NOTE spring washer fitted under pitch bolt is not damaged Check that the head of the lower bearing has two oil by ensuring sufficient and it is of the greatest importance that the corresponding oil hole in the bearing shell registers with the oilway to provide an unobstructed passage Pull the connecting rod onto the crankpin Each upper the there holes taking Insert not care the position to the bearing surface injure connecting rod cap locking washers and setscrews tighten with a torque 21 7 24 6lbs 1ft shell into the the cap and the Insert the wrench t Fig 20 Re assembling Pistons Connecting Rods and PISTON PIN 17 41 Diameter Over size Fig 19 Thrust Clearance Measuring of Connecting o 125 2 o 250 3 o 375 65 3 mm Length Rod mmli 1 Degree to he able push it by finger Clearance of pin and pin hole to at 200 C knock back the lock washers Finally clearance bearings are rotating the turn Clearance of pin and the connecting rod hig end for side 7 1000 in and see that the shell Check not binding on If it crankshaft is difficult to undo the big end and examine the shell and seat for dirt or grit reassembling always Before clean oil cylinder caps 01 mm hole crankpin when the o connecting rod bush or the to bore piston Never Piston and Bores apply surfaces a little Insert and into the between file the connecting rod their mating surfaces as this cylinder at the lower creates angle oval in the bearing 0 04 mm thick gauge bore and piston and measure Feeler to the portion of piston pin the cylinder bore There should be a clearance of 0 at right 015 0 030 the spring mm Removing Remove end of the a Piston Pull out the clamping connecting bolt rod and push out with feeler gauge scale and then inspect if from the small regulations the 23 0 5 1 5 kg by the reading is within or not DATSUN Because end of the the piston rings do not travel to the bores a 1ip is eventually cylinder formed due to wear This may be be a a dial gauge and If this is not done there will checked with be removed must tendency to noisy operation ring lip Piston and rings 0 0 or a fractured caused by the top piston ring striking the 254 762 mm mm 0 020 are in available in 0 010 in 0 508 0 030 in and 0 040 in 1 mm 016 mm over piston rings should always be fitted from the crown of the piston and never pushed Before fitting the upwards over the skirt carbon remove deposit from the any rings the When in fitting note that piston grooves sizes Fig 21 Removing Piston Ring The the second compression is tapered type and oil control ring is slat type processed by chromium Piston plating Rings The piston ring gap should be 0 008 0 013 in 0 330 mm when checked in the cylinder 0 203 bore clearance of the compression rings The in their grooves should amount to 0 in o 0 038 0 089 0016 0 0036 in Fig 22 mm 0 0015 0 0035 and the oil control 041 0 092 ring mm Clearance Between and Groove Ring Fig 24 23 Measuring Clearance of Ring Joint ENGINE TROUBLES REMEDIES Excessive Oil Consumption Lack of Burning oil Ignition system improperly adjusted 1 Rings correctly seated not to cylinder wall 1 Give Bufficient time for rings to seat 2 Piston rings worn excessively or stuck in Fit new 4 due wall cylinder fitting between to wear and piston improper or walls scored tapered or out of 1 Recondition cylinders and fit ring oil Piston return holes new pistons clogged 2 3 Replace rings 7 rings broken Replace ring S stem Replace Leaking 1 2 Rocker oil 4 or leaking 5 cover gasket or tightening tappet cover damaged or loose Tighten covers or replace gasket 1 Dirt in gasoline tank Air leaks in gasoline line Fuel pump not functioning properly or repair fuel pump Oil pan drain plug loose 2 drain plug Oil pan retainer boltB loose Carburetor choke partly closed Adjust or replace choke mechanism Over heat oil pan bolts Oil pan gasket damaged 3 or oil into clutch main bearing or main replace Fan belt worn or oil Water pump Replace flywheel housing Adjust or replace bearing oil seal or 5 inoperative water pump Thermostat sticking Replace thermostat 24 soaked Replace belt 4 leaking Fan belt loose Adj ust Fuel pump loose or gasket damaged Tighten fuel pump bolts or replace gasket Rear main bearing Lack of water Refill BYBtem Timing gear cover loose or gasket damaged Tighten cover bolts or replace gasket housing Air cleaner dirty Clean air cleaner 2 7 Dirt or water in carburetor Carburetor air inlet restricted Replace gasket 6 partly plugged Replace 1 5 Gas line Check gasoline lines and tighten seals missing check for sealing seals arm Tighten 4 Ignition not properly timed Set ignition by the instruction under correct Bpecification of engine oil Tighten 3 points and timing engine Clean the tank Piston Valve Distributor points not set correctly Clean carburetor and fuel pump with carbon 6 and seat Bpark Clean gas lineB round 5 adjust Lack of fuel pistons Cylinder 2 3 clearance Excessive Spark plug faulty Replace or clean Set distributor ring grooves Replace ring 3 Power plugs if neceBsary Replace Engine closed r DATSUN 6 Cooling system clogged Clean and 7 reverse Incorrect ignition 4 flush or Improper and 9 viscosity oil being 6 to correct oil or Loose connections in primary circult Series resistance in condenser circuit Clean all connectiOnB in condenser circuit Fuel mixture too lean Overhaul in Tighten all connections in primary circuit used Change corroded Clean code and cap terminals valve timing 5 grade loose and distributor cap Retime engine 8 codes Spark plug 7 adjust carburetor Low capacity condenser Install proper condenBer 10 Valve improperly adjusted Adjust valves 11 Engine condition 1 ExhanBt system partly restricted Clean or Grind valveB replace 2 Over cooling holding 3 open Replace thermostat 2 3 5 Faulty pistonB 1 Partially diBcharged battery Change battery undercapacity battery connections Clean and tighten 5 6 or replace motor or 2 starting switch or LooBe wiring connectionB Faulty wiring Replace faulty wiring 3 Faulty Bpark plugs Clean or replace and adjust plug gap replace points Spark plugs improperly gapped Set plug gap correctly 08 mm and Detonation 2 corroded Points improperly adjusted 07 Carburetor dirty and passageB restricted Ignition trouble Readjust points correctly 3 repair choke mechaniBm Tighten all code connections Distributor points burned or working properly or Throttle not Bet properly Spitting Ignition troubles Clean Choke not Overhaul carburetor 1 1 cylinderB connections Faulty starter switch Replace switch Faulty starting or Set throttle 3 battery ringB Lack of power AdjuBt 2 Poor replace gasket Carburetion Replace battery 4 or mounting Tighten carburetor mounting boltB See Heavy engine oil Change to lighter oil or Leaking manifold gasket Tighten manifold bolts Loose carburetor Starting Faulty change ValveB holding open 4 Slow cranking 1 or Adjust valves Thermostat Hard Valves burned 00275 0 0315 in 24 2 rl ENGINE REMOVING Experience to remove single the engine unit than to To remove upwards Completely drain transmission and detach engine the proceed battery iliat has shown as REFITTING The it is much easier the Next remove and remove change selector rod transmission casing the at the coil transmission from and water Remove Disconnect pinion franges starter motor cable at the motor end ature gauge leads from the the gear lever on the the hand brake control rod the speed meter cable from the Uncouple the propeller shaft at rear axle and draw the shaft out of the transmission To temper their terminals on the allow the drawn forward engine engine and transmission to be the radiator must be removed 1 i t Fig 25 f remove the by undoing the four securing bolts Fig from supporting from transmission dynamo lead and disconnect the gauge pipe Disconnect the earth strap from the starter upper and lower radiator hoses the oil the exhaust From below the vehicle cooling system and the by undoing the retaining clips Disconnect the capacitor lead at the dis tributor also the high tension and switch wires Remove must be Disconnect manifold motor Take off the controls the fuel pipe from the fuel pump the engine by itself and transmission and its supporting tray Remove the choke and disconnected from the carburetor transmission as a follows disconnect throttle 2 r DATSUN OPERA nON WITH THE ENGINE REMOVED @ L a Iosulator engme Bolt mounting Front J InRUib l Bolt I Nut Bolt Nut lo fllii W I6fl I Washe Nut self lock rfj Washer 1 118 I Bolt f Washer Bolt Washer R H r Cross member mounting Bushing engine rear f f i f spacer Nut self lock bushing Fig The following operations are 3 Bolt mounting F rW 4 Removing Washer Bolt Engine Mounting best performed Crank Gear engine ont ri he out certain attentions with the with the engine removed from the car Although it may be found possible to carry Fig Insulator it is more convenient to engine do the in position work on bench Carn Gear and Chain Fig 26 5 Checking Thrust Clearance the ENGINE Camshaft Withdrawing The plate is camshaft held positioned three by screws by mounting plate is now accessible and may be removed by withdrawing the setscrew and lock The dynamo swinging link must be ing plates locating shakeproof a and position of the small lubricat ing oil hole in the locating plate when replacing should be to the right of the engine washers Note the End mm of 0 003 is controlled plate set play and can by 007 0 in 0 076 the thickness of the 0 the camshaft gear Before withdrawing will have pump timing and its to the camshaft be removed drive and cover withdrawn from the cam when the camshaft can be shaft locating plate locating the trihutor and its driving spindle push rods oil Take out the setscrews securing the 178 cylinder block be checked with a dial indicator against tappet removed shaft gears Camshaft dis with steel lining are They can be taken out renewed when necessary it being usual to do this when the cylinder block is being reconditioned The bearings can be removed by drifting and White metal bearings used for the camshafL Remove the and take off the The engine Bearings front them out of their housings bearings care must be taken oil holes with the corresponding When fitting new to line up the holes in the cylinder block Tap the new bearings into position and ream them to give a running clearance of 0 001 0 002 in 0 025 0 015 mm Refitting the Camshaft This is removal align and the Fig 6 Pulling out 27 reversal of the introductions for Care should be engage the drive taken however pin to in the rear end of camshaft with the slot in the oil pump drive shafL Camshaft a r DATSUN fix xm bo gear QUIlting 1 I II1I I Au Y pan Ass y tube Stud to Fig Cylinder 7 Adapter it it breather ap lnk cr Block p cDUre fix fuel pump to switch care A An bI ock th Wl cylinder plug Plug welch cylinder 6 block Au y Washer Jock oil gauge level Bolt Plug chain tI Q r ensione oil eed br us Cock drain if l Y Bearing crank Ih aft half Washer t Cap tand st Waiher Seal to k Seal fiJ bearing iI rear bunngo side Fig 8 Cylinder 28 Block B hI m2in b rd eanng thrust il I e met a frant bl 1 upper frent metal l ower bearing cap plate ENGINE Main Bearing Caps Remove the off Take strainer and Unlock and flywheel and clutch timing chain the the the engine remove bearing caps to the the sump and mounting plate bolts securing the main cylinder rear also the block two holts securing the front cap to the engine front bearer plate Note that side of the thrust a centre washer is main fitted on to take bearing These thrust crankshaft end thrust each consist of two semicircular valves having a each the washers one half which is located in a recess in the lug detachable half of the bearing the other being plain When required correct 0 0127 fitting new bearings no scraping is they are machined to give the running clearance of 0 0005 0 002 in 0508 0 Ensure engaged Main Bearing Cap locating tangs are properly new all rag traces of dirt and oil throughly dry them Make sure that the and housings bearings carefully so as not the fine surface finish Remove clear Removing in their recesses damage fluffy 10 mm that the Handle the to Fig as When fitting from the with a non oilways are the bearing caps ensure that they are replaced the right way round Each cap is punch marked and the marks should race the camshaft side of the engine Removing Crankshaft 11 Fig i ii r JL 0 0 0 fJ 0 0 O L l 0 r01 Or j 10 0 0 O Fig 9 Removing Fly Wheel Fig 29 12 Engine Rear Side r DATSUN Check the crankshaft end play dial I If L block 1 I q a 1 by means 002 in 0 of a 051 run oilwayB out the in it the is essential to crankBhaft engine sump and and the strainer 1 I If has bearing Wash The II I a clean out all I I I gauge should be 0 mm l l This oil cleaned metal pump Ensure are left should be dism antled and particles of bearing the engine lubrication that no within system I i J 13 Fig Bend Measuring of Crankshaft Fig 14 Fig Measuring Crankshaft 15 Measuring End Plav of Crankshaft Pin and Journal Caution file the Never excessive playas Always bearing this will cover the engine oil when they The by main setscrews screws up loading of When refitting one the freely is tight examine foreign 10 the main held in position Pull the set wrench 36 11 05 bearing set caps remove BBcertain the the bearing its tighten tighten that it last cap and to a kgm after each cap iB crankBhaft to rotate and torque 1ft firBt up bearing surfaces with replaced caps are with a take to ovality and lock washers tight volveB If it bearing 75 80 lb the center are caps cause re tightened seating for matter Fig 30 16 Removilzg Crankshaft ENGINE IGNITION TIMING DISTRIBUTOR the Braker Points Adjusting Hitachi D411 53 Type Ignition timing standard To is Governor type screw advance 100 Advance starting vacuum 120 120 is 60 90 the 01S to 0 022 ins 0 between the braker of the cap is wiped clean with Hg of cloth extra attention at the start of between the advance angle electrode on 450 r pm Number of revolution 11 advance angle at Max advancer soft Clean terminals dry piece to the areas the center the inside of the cap also or not the type timing can be properly vacuum is 01S 0 022 in suddenly changed 1 0 a being paid o 45 0 55 mm r m p determined Counterclockwise cam Point gap 3 4 2 500 Dowel angle arm Whether at then more functioning the inspection painter located at as the engine is being run the diaphragm if this painter moves when the engine speed is 2400 crankshaft Rotating direction of Firing order Contact 15 Then The interior and exterior reinstall the rotor Distributor thickness points tighten the Fixing screw Becurely check the gap once Finally Cranksbaft vacuum pressure of 340 mm by turning adjusting plate until a feeler gauge of the 55 mm slides easily pressure Advance angle by engine braker point the Next move o 45 to 0 H mm turn the points Then loosen fully open fixing screw center at 600 r p m Apparatus of automatic the braker adjust crankshaft with the crank handle until the braker So before top dead o 5 spring by the advancer is satisfactory 55 0 65 kg pressure o 20 0 24 mfd Condenser capacity Inside shown in the distributor is Fig 1 a braker point several thousand times in one minute contact Each time this braker brakes contact is as This braker makes and brakes generated a spark There spark plugs in one of the tbe maintenance of this braker must not be fore treated lightly because the time Also during which the ignition coil current flows varies with see that the gap between these braker points is this maintained gap which is 0 45 The grease burnt honing or Fig points must be blackened they stone or croucus are cleaned with cloth after should be wiped clean with a replaced replaced are Braker as badly points the Point Gap before top dead center with the engine stopped 2 With this adjustment the as shown in Fig a fine which they timing advancer of the distributor advances the ignition timing even further at the time the engine starts to rotate and the timing automatic piece of cloth which has been dampened with gasoline If the points Adjusting ADJUSTING THE IGNITION TIMING The ignition timing is adjusted to 10 degrees kept free of If the points should become oil 1 standard value 0 01S to 0 022 in mm braker and the at burnt must they must be always be maintained constantly the rotational Bpeed is sets 31 at valveB suitable for DATSUN slot of the distributor drive of the upper end of engine stopped adjust so that the distributor breaker point just breaks when the piston of the No 1 cylinder is in its 10 degrees With the the 4 is before top dead center position for compression the standard ignition If a timing lamp is used timing idling In is the case of marks 2 First is the front which are not evenly adjust distributor to the correct the described as center dead and made by the following procedure previously Turn the crankshaft the gradually until mark Fig 2 on the top pulley perifery coincides with the mark for 10 deg before top dead center on the timing gear the crankshaft cover as approaches i tB that somewhat before corresponding positions to the end No Fig center at 15 deg pointers indicate 10 deg center before dead top positions Adjustment gap placed toward shown in as the smaller of the semicircle At this time 600 rpm spaced 20 deg 1 degreBs before top dead speed 15 shaft somewhat to the left 1 of the compression stroke Stop the crankshaft compression stroke piston in With the crankshaft in the 1 4 Gear Mark engages distributor the No position of 10 deg before top dead center of drive shaft the to the assembly same when engine do During of the directions is just begining distributor 4 Fig At the position to open If these they made to conditions do not coincide compression the this the breaker must be in its time it mount slot and rotor must be as shown in is in its mentioned position the direction of the rotor so that it Adjusting the previously piston Setting of Timing this of the The position No 1 piston can be determined if the spark the plug of the No 1 cylinder is removed hole plugged with a finger and the crankshaft turned 3 Fig of the are by slightly turning the distributor body so only To determine the position when the breaker point is just begining to open ignition key hold the end of the turn on the No cord about 1 4 inch away from the head and across turn the body 1 spark cylinder until spark jumpB the gap The off set slot position of the drive shaft when the No I piston is in its compression top dead center position is shown here Fig 2 Checking the Ignition Timing 5 Next 6 To the No l put the distributor securely with the clip spark plug cap on and clamp it connect the cord from the terminal to which the arm of the rotor is 3 Next inserting distributor at an the driving shaft angle to the engine of the Thereafter connect the terminal pointing cords engage to their spark clockwise order the gear on its lower and with the gear on the camshaft During this assembly place the firing 32 order so plugs as in the counter to obtain a 1 3 4 2 iINE EN 7 distributor with should now Ordinarily is set its at start the pointer is a The rubber cap pointer the engine properly pointer of the octane selector reading during the ignition If the octane number of the low adjusted and engine knocks right R to the the to the optimum advance angle if the octane number Conversely adjusted is cover wlrmg zero timing adjustment fuel being used is the of the Upon completion to the left A is high the One unit of calibration of the selector corresponds to 2 deg of the distributor angle crankshaft When and to 4 deg of the angle a timing lamp is used the standard Fig center with setting is 15 dge before top dead the In any case the engine idling 600 620 a slight optimum adjustment is that in which knocking is heard when with the car running at HIGH TOP gear acceleration low speed in is applied suddenly 33 4 Assembly Angle of Orive Shaft CD 2 @ Distributor shaft Distributor drive shaft Distributor fixing plate DA UN FUEL SYSTEM I CARBURETOR Starting con SP ECIFICA TlONS Primary D2630A 5A Bore diameter Secondary 26 mm 30 mm 20mm 27 Venturi diameter Pump planger large 8 small Pump 8 1192 11140 Main air bleed 1160 1160 1148 1148 Slow air bleed first 100 Slow air bleed second valve strainer kit Small venturi Main jet Slow jet Pump mm Throttle shaft arm Fig 1 11120 11240 Emulsion hole 1160 low economizer x 12 1160 x 20 Body gasket 11145 Power jet Power valve 1140 Begins to open whe the primary throttle valve is at 48 opening Float level 21 5 upper float mm below the Burface of the chamber body The carburetor has the function of automizing the fuel mixing it supplying the mixture to the in suitable ratio to air and engine important part which influence the performance of the engine It is therefore an The carburetor is two the a highly efficient Flange gasket Secondary can one Bide Primary side of barrel two step and down draft type having following special Construction and features Operation Main air bleed Pum p valve Small venturi l55embly 1 Power jet sheet gasket Power Jet Secondary Fig 34 2 side ENGINE amount of the holes provided fuel be varied with the two can the pump on inserting pOBitions of the that is arm the rod Connecting Starting System The choke and installed carburetting close adjust valve and normal When the choke is is the best closed fully from condition a The synchronization of the choke the throttle valve can be exactly Carburetting System The fuel flowing out of the passage at the bottom of the float chamber passes through the primary main jet coming from the drops and inject and then mixed with main the venturi Slow jet embly the air air bleed to be into minute through the main nozzle When the throttle valve the engine requires acceleting where the The pump fuel dense opens its is widely open beings Throttle and adjust screw mixture power gas valve also flows into the main power valve the from system to operate when the throttle valveopens480from full closed position Slow Con Speed System through Passing passage separate the from main main jet line the and fuel flows the slow jet slow air bleed first slow slow air bleed second and inject from the by pass holes and idle holes through economizer Accelerating System Mechanical accelerating pump with the throttle valve is adapted valve is open ihe linkage the dumper down the synchronized When throttle the piston rod is pushed up with which pUBhed up the piston spring full to start maintained often the engine has started firing 3 Fig Main screw the on valve opens about 140 This operation Idle eccentrically device and synchronized with the throttle valve the throttle valve is provided with the spring When the through piston is coming inlet check valve closes the out let I check valve opens and the fuel within the pump is blown out from the pump jet by the compressed Throttle lever dumper spring and hits against the side wall of the small venturi to be minute drops compensat A jetting ing trancient sparseness of the fuel Fig 35 4 assembly rod spring f DATSUN Float Chamber 4 of the Adjustment from outside valve 4 As a 5 by adding subtracting the needle gasket after removing the float air valve at installed vent method matter and within pressure the constant always registance of the air fuel consumption can be always suctional how cleaner varies maintained econmically Carburetting System Main Same the as the fuel flowing of the float secondary normal carbUretting function Adjusting out of the passage at the bottom chamber passes through the jet and become minute drops main mixing with the air coming from the main 1 Take off the Raise L i1 JI 3 l q fl float upper surface must the float level is done by adding or the gasket of float valve seat throttle valve fT of and the throttle power to open at the is an subtraction of 2 numbers gasket When the tions The accelerator must be adjusting plate at to adjusted by normal and of slight gap with pedal off this tighten up surely After the nuts of the for high carburetor throttle the normal the engine valve of the by c the syn 5 1 p valve which is not is i1 l J Z open When power is 01 J I l t y the in a full 0 the power carburetor throttle valve is also to be in a full open open Fig 36 7 1 J I c still higher revolu valve on adjusting adjusting plate auxiliary operation the the carburetor side that the throttle valve may be full open with full pedal throttle valve engine change so valve open against the loat of the counter weight and the power carburetor starts the the mm mm 0 5 of accelerator speed with aheavy load due to the load of the counter weight connected to the valve when down about 1 or is thickness gasket Adjustment J top of the power carburetor auxiliary or J 11 opened widely Addition open at a slow even hanger lip r chronized linkage throttle valve its until and parallel with the chamber top Adjusting one 6 Nikki Carburetor carburetor begins However the stage make the float level up 1 i71 IIi fl Fig 5 ll u cl IJr v power slowly needle valve carrier J U U c produces high At this be level J jAYd Lc jll ffi p the of float chamber subtracting g When cover the float contact with the valve retainer 4 carburetor is Fuel Level 2 air bleed and is blown into the venturi through the Il ain nozzle shaft the inlet connector ventilation within the float chamber is of venturi and the float chamber is no be done can carrier needle Fig float level or 0 ENGINE i D Fig Dimensions of rod and The D is adjusted to 86 5 mm 8 THE by GASOLINE TANK adjusting plate nut must tighten surly after fixing the The dimension of D and is fuel tank has situated a at capacity of the rear 41 Olitres of the luggage compartment The fuel operated off pump draws fuel from the carburetor float chamber air fillers cleaner the camshaft tank and forces it into the A large and efficient supply to the air the carburetor Draining The wrench the Fuel fuel to must float lever gauge when 37 as top face of the tank is the the unit to the tank not forgetting disconnect the Care plate the To remove withdraw the set screws which secure 9 CD Rod o Adjusting @Nut on by turning the Unit Gauge Situated gauge unit drained cock operated drain Fuel Tank Fig is tank be electrical this may readings refitting not taken to lead beforehand strain or bend the serously effect subsequent Remember this also applies the unit r DATSUN Examine the joint washer to is as in position and the joint must be fuel undamage between ensure that it This is essential the tank and gauge unit I J tight J Fig 1 Fuel Tank j r r Securing i I 1 Ii 1 1 C capass J y Filler lube Clamp Fuel tank for sedan Breather tube Band ear Grommet For SEDAN Tube to S crew strainer washer Ventilation tube E Gauge Gas ket Bolt1 j Washer Fue tank for wagon For WAGON Fig 2 Fuel Tank 38 Mounting E Gl 3 E S l 40 ENGINE FUEL PUMP By the rotation of camshaft rocker arm is pushed and pull rod of diaphragm is pulled down At the same time diaphragm goes down against diaphragm spring and then is pushed up its again by spring By the movements functioning of the valves the pump chamber of and diaphragm the at the inlet and outlet of drawn up from is gasoline the tank to the carburetor If the chamber float of the carburetor enough gasoline and the needle valve is not allowed into the gasoline is contains closed carburetor Thus and gasoline due to its is stored in the pump chamber the pressure is diaphragm kept down and cannot return the rocker arm works Under this condition 5 Fig in vain The FUEL PUMP spring 18 mm in use and l 0 6 1 mm 0 1 Checking kg on tension Rocker 95 length 1 Thickness of valve mm 6 mm rom at 1000 500 mm I p m 110 height 130 mm in the tip of the pipe Fuel once very two rotations function mercury column at 20 strokes ing the 80 cu cm pump is of the diaphragm pump mechanically driven by the eccentric arm scale part of the camshaft of the engine it under pressure to the carburetor engine running fuel can by moving the hand is not be delivered under pressure alone can be easily removed by dis primer up and down 41 to to disassembling disassembling of the removed measure the distance between the rocker and flange of the lower and and pins gasoline from the tank and delivers Even when the pump 2 attachment nuts Prior which the engine Inspection prior The fuel pump of connecting the inlet and outlet unions and loosen scharged It draws the test Removal from More than 400 mm in suction vacuum type Disconnect at the inlet union of the carburetor operation of the hand primer and checking the fuel ejection is enough I ercury column Hand primer quanty is installed engine To of cam in suction pressure discharged Max degree of di pushed against of the crankshaft 1300 cu cm per minute quantity dis charged Max arm prevent and then turn the engine with the crank handle N ow the gasoline should be ejected vigorously Performance Max fuel pump with the fuel pipe 30 mm spring Free to serves Switch off and stop the engine spring length arm Free Valve Io spring Inspection Disassembling 36 5 legnth Length arm the eccentric of the camshaft Driven by camshaft Method driven Free pump rocker keeping the rocker noise Diaphragm Type IDiaghragm as the rod remains see if the rocker are worn body by arm means of a rocker link DATSUN Method of disassembling First pump and to make their oodies It is screws wipe dirt off the outer surface of the put marks on both the upper and lower reassembling easily separated around the upper body care notto Take great during this disassembly are Wasbthe disassembled parts weU in gasoline then inspect them diaphragm if any damage impregnation by gasoline Replace a valve assembly if any wear or the Replace easy into two when the five loosened of Parts Repaires Checking damage the diaphragm is detected faulty operation Even if repairs the limit for unavoidably required are repairs of of the or wear warp valve is 0 001 in When the Burface of th is found irregular valve Beat outlet and dress the surface with In of case irregularity the inlet valve the body or valve the valve Beat of the remove a fine oilBtone of the seat surface of be taken off from which cannot recondition it with cutter and a grind ing tool When the surface of the valve is faulty place some of a very fine grinding compound flat piece of glass plate and with the tip of a finger of the valve is 1 6 mm on the surface grind it lightly The standard thickness The hole ofthe joint parts of diaphragm shaft Fig and link may be 6 crack or worn This is to some extent but when serious eccentric not serious breakage is wear the part must be found replaced As a remedial compensated for reassembling such wear can be measure at the time of of the dismantling and a packing body by inBerting made of thick paper between the lower body and diaphragm to raise the relative position of shaft with respect to the lower body arm should be replace when its diaphragm The rocker contact face with the carn and that with the link and its pin hole When its Fig 7 this worn by reconditioning and finish them with by welding cannot temporary seriously add material to the rocker unavidable link are employment re last long and is no arm a file is and but than a more measure Renew the arm pin when It is found worn excessively arm spring seldom The diaphragm spring become faulty but when weakened replace them always with standard ones o If the diaphragm spring is to strong it results in overflow of the float chamber of the carburetor The tension strengthened Fig 8 42 or of the weakened spring must not arbitrarily by be hand ENGINE disassembling its air is over renew there can be heard thence the gasket to keep 3 to 5 seconds good conditions if The pump is in Check to see if there is any warp on the joint and after surfaces of the cap and body strong inlet and outlet noise respectively The pump is mechanically fit for tighteness by connecting to draw up gasoline from o 5 m After installing Installing Reassembling functions Employ standard springs for the various A stated before uses as valves precisely Install for contact close with their respective seats screwing in of upper and lower bodies and diaphragm fit them together according to the marks which were put before the disassembling In and align it is able screwing screw position where the diaphragm is with the rocker arm pushed down fully pulled the body by and pressure the side of towards Do not screw in tight one by one since it causes warping Instead clamp all the screws tighten As of them in order to make all a the to set the contacting is engine gasket standard a new and turn the by means of the crank handle there is 6 to 7 rotations engine and make sure outflow of gasoline from sure Connect the gasoline pipe to the outlet port Then any leakage of air or Bee gasoline if from ADJUSTMENT AND INSPECTION OF ENGINE re must always be operated in the possible condition and for this purpose periodic inspection and adjuBtment must be The engine done in the in a certain maintained well rocker arm so that it is eccentric between the is sure as order while in use as after overhaul of camshaft properly the rear side or to one side not it each connection order to that for disassembly sure as best the on its during operation there iB should be re gaskets test side and tighten all the piping joints again several timeB to new ones Installation Be rule general placed by reverse diagonally and lastly them the pump turn the eI gine round loosely and uniformly tighten than more the outlet port B in at the Then height of Connect the gasoline pipe on the inlet post side only Leave that on the outlet port side that and then hole to its mate one a when use a hose to the inlet port Replace Order of Inspection and of Engine the block and pump with cylinder 1 one Check the cooling Adjustment water water level and extent of fillthiness When it is the pump is over repairs of installed the on make engine or a InBpect the 3 Inspect the oil before check to battery all connections level of specific gravity of electrolyte electrolyte and voltage 2 Function Checking amount classifi filthiness cation and see 4 When a vacuum is gauge connected to the pump inlet port and the pump is mounted the tester rocker arm is activated by eccentric of the camshaft revolving their gaps 5 on a the at 1000 rpm is discontinued remain for When in the a gauge see finger tips the inlet Then several times of the tester is not available test remove 1 operating suddenly the 163 lbs approx Measurement of p m First all warm cooling spark water plugs manner up the and engine 70 80oC pull is throttle out then the in the knob all the way that carburetor the throttle valve and choke valve port and outlet port with after r made in the follOWing is Fig is engine at 350 temperature of than 3 seconds or cylinder The pressure following way Close arm more of per sq in this condition should compression pressure of standard compression Measurement pressure Then the gauge pressure should rise to higher than 400 mm of mercury column and even if operation viscosity Cleaning of spark plugs and adjustment of rocker are release the fingers fully opened against 43 each press a compression gauge and spark plug hole running RUN DA the starter motor with a fully read 5 8 the maximum pressure obtained within This measure rotations of the motor ment It must be made quickly as the compression pressure cylinder differs by 10 lb Isq form Diagnosing of Engine by means Vacuum Gauge and Combustion charged battery that the of another as of in cause In each possible diagnosing cylinder call be assumed or more compression For employment of must it to the any one be the condition of engine the of Tester by measuring a vacuum gauge connect intake manifold and refer to engine its Fig 2 The in of use a master motor tester as shown 2 is convenient Fig When combustion tester is used a install a special intake pick up in the exhaust tube and after the engine has been started analyze by the combustion gas special gauge the which flows through connecting hose into the of a means and tester according When to pick up excessive Fig Compression Gauge 1 combustion the mixture measurement is to cold weather the the judge damage the use be made auxiliary an and ratio of fuel moisture in functioning the and air rainy or condenser between meter the in condition otherwise exhaust gas the will of the meter if permitted to enter it 6 Check and adjust the distributor If the breaker contact points have defective contact surfaces gap to 0 45 0 Also turn the and dress them and adjust the 55 mm cam check to see of the distributor clockwise if the governor can carry advancing function Adjust ignition timing correctly By utilizing a power timing light the function of the governor can be checked together with out 7 the ignition pulley illumination timing of crank will enable to inspect the conditions of running and advancing of the timing DC 8 9 B T 200 Inspection of fuel pump and gasoline strainer the slow setting of carburetor Adjust 10 Cbecking operation of generator Check the generating condition and functioning of the cut out relay by means of indications of the ammeter 11 Adjustment of slack in fan belt 12 Adjustment of valve tappet clearance 13 Road test While driving in 3rd speed at about 25 lanl If hr on the accelerator step suddenly the ignition only a slight knocking results is Slow correct speed timing adjustment is made so that the speed is about 15 Ian hr when driving in 3rd speed Fig 2 Motor Master Tester Available 4 6 and 8 44 Cylinder Engine for ENGINE When a tester ments according conditions to be used is to the Without Speed Running 2 indicator times drops by 4 in valve sticking so exists 1 85 5 2 m 6 Trouble indicator drops When several by Engine some 12 70 Speed Running 000 r p When or of Mixture 600 r pm IEligh 5 Suitable Weight Ratio load Low adjust make following table certain time Shooting inches valve at are burnt Fig 3 is intended to be of assistance in the systematic analysis and isolation of symptoms of engine may be troubles so accurately that the traced defective points and economically repaired Normal Condition 1 Settles 7 indicator drops When between 18 by 20 in about leak 2 in valve Faulty seating of valves 2 8 Normal condition When fluct indicator When indicator oscil lates 14 of 0 stem is 25 in raced valves are engine as and rings in actively between and 18 in uates between a range guide valve is worn out good conditions 3 Even if indicator set tles if is low reading rings or oil faulty condition 9 are When with speeding in moves in a slight up indicator between 10 22 and with increase of s peed the range becomes larger valve springs 4 When above dition exists will 3 10 con mains indicator swing to 0 engine is reaced in When 8 if are indicator still 15 in cause timing weak re between it either is valve is retarded or valve clearances not correct 45 be are DATSUN 11 tles 14 between ignition timing in 14 set indicator When indicator When lates 17 5 is regularly 19 in clamping 12 slowly between 14 in it is When 15 When indicator moves rises 16 row or are first bigh and then re muffler clogged is too nar Faulty gasket drops down turns to 16 in either electrode gaps of plugs of cylinder indicator to zero because is there at leakage head gasket retarded oscil between breaker point is defective 13 When indicator 5 in there is to or points leakage intake manifold gasket Faulty Whenindicator 16 below moves slowly between at 17 in 13 carburetor is poorly adjusted or of carburetor clamping of gas ket Fig 3 Diagnosing Engine bv Means Sparking B g o c Plugs not Gauge at terminals Timing incorrect Short in circuit Ignition coil spark No sparking at terminals or condenser defective Contact point dirty Breaker defective Point contact poor Breaker arm insulation defective Rotor shorted 1 c No 6D c gasoline in tank Strainer defective Pipe clogged Float valve sticking No gasoline poor Wiring incorrect Plugs dirty do Q Vacuum Battery discharged or connections Timing poorly adjusted Air being sucked in Plug sparking weak Plug spark 5 of a in carburetor No air can enter tank Fuel pump not operating 46 ENGINE No trouble Air Carburetor Plugs spark gasoline supply stopped free of good a a o or Engine seized Lubrication insufficient carbureto Compression gasoline defective Jet r being sucked in or pipe clogged Float sunk Float in high poSition t will not descend Carburetor attachment not secure ring or valve sticky Piston or connecting rod broken Valve seating poor Piston l r Compression E poor Breaker No ing from foe o Plugs do not spark arm spring defective Contact point poor Rotor shorted spark Ignition coil or condenser defective Breaker coil line arm Distributor wet good Cap insulation defective 5 Cord shorted S parki ng form COI 11 me A Trouble or connection poor Wiring shorted or cut PIugs dlrty or broIre n Shooting Chart Compression weak Valve clearance incorrect Valve spring weak Valve deformed Muffler clogged Continuous lack Valve timing incorrect Ignition retarded too much of power Carburetor adjustment poor Gasoline supplied insufficiently Power weak Carbon deposits excessive Gasoline of poor Intermittent lack of power Engine operation defective during renning t grade Carburetor defective Valves sticking Pre ignition Engine gives off abnormal noise f Overheating Bearing worn Plugs dirty MIS fIrIng Sparking Breaker point defective irregular Intermittent shorting Mixture too rich Sparking normal Insufficient gasoline Water in Nozzle B Trouble 47 Shooting gasoline clogged Chart supply to carburetor r DATSUN CLUTCH GENERAL DATA DISASSEBLY LEVER Single Type Construction of disc Outer dia Inner dia dis ry With coil of facing Clutch i pl OF CLUTCH SIDFT Housing spring 200 mm of facing 130 Thickness of facing 3 Gross friction area 5 86 when 7 9 mm cm2 363 Thickness of disc ass y mm 1 mm releasing 3 8 1 mm when depressing Disc run out Less than 0 Backlash at splines part o 05 0 0 002 Operating method Inner dia 0 5 mm 15 mm 006 in Oil pressure of master 15 85 mm 5 8 in of operating 19 05 mm 3 cylinder Inner dia cylinder Operating liquid Fig 4 in Genuine super brake oil Return spring with 3 16 mm drawal wire dia Free length Length 87 mm in used 1 tension 136 5 rmn j d r J kg t I PRESSURE SPRING Free X length 49 ompreBsed length urn mmct 1 7 8 of comp in full About 300 kg ire diameter ength c Less than 25 mm numbers ower L 5 Fig 2 Fig 3 33 mm in used and load 29 2 37 t2 5 kg RELEASE BEARING Construction Ball Height of release plate From bearing type flywheel face to rear end of elease plate run out height use master mm Less than 0 03 0 If plate 10 2 5 50 disc 7 height of release lever 8 mm is 50 0012 in I 05 t0 2 5 rom mm 48 CLUTCH Driver Plate attached to indirectly is number disc a the power and the over run transmi ts of coil To held springs in through Two friction a are access to the clutch time by diagonal pressing riveted to the disc the Assembly The cover Finally and a six pressure Mounted the are the flywheel plate plate are Interference with this set on unless setting will parts have to be fitted pressure plate out causing judder three assembly correctly new the pressure turn at and lift completely from driven levers release assembly springs on assembly away remove The assembly consists of pressed steel cast iron pressure plate located by a is relived clutch cover first complete until the spring selection Then remove the screws Cover is it Once the transmission unit is free position by a linings gain necessary to remove the transmission from the engine which wires retaining the Clutch Removing is the flexible type in which the splined This hub Assembly throw the release levers Adjusting nuts are screwed on the bolts of Retainers of pressure pressure plate insert to the clutch spring holes and anti rattle cover springB load release levers By using Release The Bearing release bearing consists of a quickly a high degree carbon plate the Running Adjustment no clutch is speed brace universal parts to and metal a to chart box As thiB indicating the be used for particular types the box clutch pedal IF 0 adjusted of accuracy of clutch will be found on the inside of the lid of hydraulic design of the clutch adjustment is necessary to the o be can comprises the following parts base pillar spacing washers distance hight finger actuating mechaniBm Bet particular the Fig the centre pieces tool controls tool The tool cup screws to service dismantled reassembled and the bearing shrunk into a bearing cup bearing located by the operating fork and release bearing retainer spring Owing Gauging Dismantling Assembling 0 4 Fig 49 5 r DAmUN Ey Clutch bolt caver Pin with drawa 1 Preuure spring etalner Sleeve bearing Clutch release bearing cav i Nut lock Dutch disc Cover Pressure @ F assembly part assembly Part No 30100 10600 No 30209 10600 Tnmnicm bush red spring S37kg I I Lock washer Bolt Fig 6 Clutch Dismantling Place the clutch spring with the screws on the three time by diagonal cover coincide firmly attached to the base plate at all possible tapped holes in the plate insert the set prOVided and tighten them a little at a pointB so cover aBsembly that the holes In the This reBults are Mark IB selection until the mOBt parts the can position In is important if the best to be achieved cover release leverB with CD cover be plate lugs and punch so that the pressure a centre reassembled in their order to maintain the relative balance of the clutch Detach the release lever plate from the eye and remove the three lock nuts and bolts adjusting nutB @ r f e I 0 or L r r o N o 50 l b OLUTOH @ @ 8 e fa j @ M @ I Fig 7 Disassembling 5 r DATSUN Slowly release the pressure on selection unscrewing by diagonal screws securing the coyer The clutch can then to the springs the Place the pressure set with the base plate be lifted to expose all The release levers wear man sprin should c Renew these down the parts if necessary bearing in mind that the springs must only be renewed in sets Clean all parts and lubricate the bearing special the pressure sparingly G qB nfn on poSition preBsure on the spring Cover and set the clutch cover sprlngB screwing plate by using fhe placed through each hole In sBure pr omp Bsthe El cover to the base set screw cove r screw a little at a time by diagonal Belection to prevent distortion to the cover Set the release lever with lock nuts s1mm the the base plate the base plate Tighten the with grease put on in springs and plate assembly and diatorsion surfaces of the levers pressure retainers on it components for inspection examined for the pressure plate pressure on the eye bolt inserting for lug at the edge of plate 7j8mm E CD Fig 8 Assembling Press the pin into the eye bolt hole through the lug on the pressure plate as shown I Fig 9 52 @ O U OH I @ @ @ @ @ Fig 10 53 r DATSUN Gauging Refitting Screw the nuts into the boltB and proceed Screw the centre follows Place the driven plate as into the when roted contact the just heighest point flywheel with longer chamfered splined end of the driven plate hub towards the transmission The driven plate Bhould be centralished by a dummy drive shaft which fits the spi ined bore of or bolt nuts until the height finger the unscrewing the on the base pillar plate and slip the distance piece over the pillar followed by the camshaped height finger Adjust the height or the release levers by screwing the Clutch the driven plate hub and the pilot bearing of the flywheel on the tip of the release leverB Replace the height finger and pillar by the clutch actuating mechanism S e insert Fig 5 and actuate the clutch several times by operating the handle This will enable their knife the partB to settle down on edges Replace the height finger and distance piece and readjust the height of the release levers checked for possible as out run if the press over the as error near the edge is more than 0 high spots until as 02 in it is true within It is important to keep friction figure facings free from oil or grease Finally repeat the procedure to make quite this the release levers sure and gauge again the release lever Release clutch assembly a new available seating properly and setscrews remove Fig the The complete clutch driven plate is new driven plate in linings may be fitted the following manner to one rivets new should not be punched out facing the old tool is not available use a on shaft bluntended center over the heads fitting the first facing be mounted checked possible press figure on a for already out be at a time by dowels in the after these 4 84 screws kg flywheel to a dummy fully tightened Remove cover are m The weight avoid strain on the drive shaft assembly formed in The plate should then as near the edge Description as The of Clutch Control clutch is of operated from a master suspended pedal cylinder by A cylinder mounted on the clutch bell houBing is coupled to the clutch operating shaft means It IB important to keep friction facings or turn and diBtortion of the driven plate high spots until it Is true within thiB free from oil now Refit the release bearing and transmission case if the wabbing is more than 0 02 in over two are mandrel between centers and run can of the holding selection 35 Ibs ft the opposite side of the plate with the clear holes a flywheel by tightening them locate in the clutch Rivet sembly screws There punch to roll the rivet shanks securely against the plate The second facing should then be riveted cover means diagonal then if the correct positiOn in clutch secured to the not Each rivet Bhould be removed by using drill The 11 from the base plate the Driven Plate Refacing If the are Secure the lock nuts and fix grease 54 a CLUTCH Pull back the rubber boot and remove the stopper ring with pair of long nosed pliers a rod and ring can then be removed the release pin When The 12 Components of Cylinder can be separated by lifting the edge over the shouldered end of the Depress the piston return spring assembly the valve of the the tension the Bpring Examine Push rod Master assembly cylinder rubber boots @ Stopper ring @ Piston secondary cup cylinder @ Secondary cup @ Primary cup Z Master cylinder @ Let in valve release mended brake pin Ring into the bore Return spring spring se at Piston return in valve assembly body fluid in the moves the of the lips Gasket Replace the Filler cap gasket cup Cap stopper End plug gasket machined In the End plug into ring ring Replace meanB the pipe line in turn cylinder pushing against The body with cap push a push rod the with the which engages boot and of the two bolts on the cylinder is cylinder of consists bore assembly of an The alloy and reservoir cylinder starting is mounted motor is made up of the ring boot the Clutch Master Disconnect the pressure cylinder the and master remove cylinder complete from the groove secure the unit flange and refit cylinder simple piston seat Dismantling by the into cylinder body the rubber stopper ring piston cups spring valve and valve spring The end of cylinder is protected by a rubber spring secondary followed cylinder spring and bleed screw cylinder being protected by polished finish The inner rod easing Operating Cylinder This Cylinder master with end first cylinder recom assembly in the bore consisting of the body The insert the the pressure pipe union into the pedal is applied cylinder displaces the the lever of the clutch shaft The Master well with the and and via a cylinder piston of fluid the piston cups by piston of the master gasket for wear or piston cups replace the new parts where Smear the assembly y When pressure to the clutch the the Assembling cyl ass especially parts necessary spring Clutch master @ @ @ @ @I @ piston @Let @ @ @ @ spring through the releasing seat thus and and Let in valve inder ring all bore distortion 1 @ on to slide assembly elongated hole the Master exposed Beat allowing Fig will be the piston assembly complete remove spring piston attached caps unscrew rod has been removed the the push with piston The push and pipe Cylinder union from the the securing bolts and may o then be withdrawn the car Fig Remove the filler cap and drain out the fluid 55 13 the a construction piston with cup open end rubber dust under side of the cover of the r DATSUN Dismantling Remove the rubber dust cap from the bleed attach screw a bleed tube three quarters of a stem and pump cover turn the clutch Bure clean container Unscrew adjustable push can now cover be and mount the the boot the flexible The rod removed well with the recommended fluid and insert into the cylinder the fluid has been drained into a pedal until all smear open the bleed screw union pipe and in the the and if compressed air line is available position making enterB the hole in the ruhber pipe union and Adjust the pUBh rod hy driver at top of withdrawal level with the screw rubber in Secure the cylinder with the bolt Bcrew operating cylinder Removed the puBh rod Replace the dust cylinder rod of operating adjustable play 2 the end 5 3 cylinder to give 0 mm blowout the piston from the side union Examine all replace if especially damaged parts worn or the seal and the Clutch Bleading System J Fig 14 16 Fig Assembling Remove Place the seal into the stem of the piston with the back of the Beal against the piston operating replace the springs with the a small end on the bleed dust Bcrew open cylinder approximately three quaterB the of at cap bleed a turn the screw and attach immersing the open end into a clean receptacle containing a Bmall amount of brake the tube fluid Fill the master cylinder reservoir by using slow with the recommended fluid and I Btrokes I pump entering the II v On a bleed down full the clutch pedal until the fluid container is free from air bubbles stroke screw of the pedal remove screw up the the bleed tube and replace the dust cap When the clutch pedal depressed is force is transmitted to the ball p surface i a o stroke i1 pushed in stroke disengages shorness Fig 15 with the 56 release of the pedal is surplus c the bearing mm mm Effectual plate leaving until the 30 shim readjust the pedal mm clutch When there is undue Burplus Instroke adjust 95 128 the and the or position o ob ntkg places 2 0 32 0 ces place46485 3QO O 0410 46482 46460 v S 3 pl 2 10602 46520 0870 46123 4 1 tOrque Tightenig 2 1 J Vlc t Pe stOP pad Brake uteh up Cl lock with lon pedal dimeuS adjustmen sa1d pl places 0870 1 the the 1 465W 345 U 9 stroke stroke pedal pedal Clutch Brake lb 9 30614 304 4 18 14 14 t7 145 1 28 kl to 5 15215 1 145 h2 9 9 h plateslower ting 2 3 eacn up er dl r uu t side 6t height ed 1 l U k St a 1 3 05mIl v kg kg 58 45 16 3 15 17 m1ll nun 143 120 foot fun Y bl OL sUlt end iert ke trC l 1 strOKe at level 1y iu uU oke sb strength pedal stroKe pedal pedal pedalBu uM t e n c e pedal 27260 rele tull full Ilt h d r a w l e v r C l u t c h 46182760 Clutch Withdrawl Clutch presing 0 prdS1ng e the I 8t 5t hy strokee1lcestopendl top Ces pushedped3for1 n stroke of 0 27260 ndQtd 461 7 461 9 ped M4 95 32 mtn kt ntm ntm kg place place at 25 32 2 pl contaced pedal GJ 1 2 ce arm the ce j point stop er lodung nut tandhe height Adjust Stop er After end without The of 0410 4648 of mark the the t Wi For e Brake kg 60 DATSUN 56 2 TRANSMISSION TRANSMISSION i Fig Model 3 stage for forward for f 1 1 stage reverse 4 stage for forward mesh on for speed Remote control Full synchromesh on forward gears t Type of ge ar Synchro meshed helical gear 2nd 3rd 4th gear type Ratio 1 3 197 3 94 Ratio 2 1 725 2 40 Ratio 3 1 000 Ratio 4 ReverBe 1 49 4 125 57 1 00 5 159 synchro r DATSUN COVER CASE OF TRANSMISSION Drain out the gear oil from the ing case the cover in position are 14 set which must be removed when nuts cover can DlSASSEBL Y Hold Front all of be taken COURSE Bearing Retainer Release the front off within the clutch Fig 1 bearing retainer situated housing by removing the nuts 1 Fig I i u Ii iV p j 1 i f Fig Fig 3 2 View Bottom Cover of Inside of Transmission 58 Fig 2 Fig 3 TRANSMISSION TRANSMISSION CASE CROSS SHAFT IL SEAL GJ G l1 I r 101 3 n Q 1 1 1 1 Fig Fig 4 Plug 1 Cross Shaft PLUG CROSS SHAFT Fig Fig 5 2 fIIIIIIM 1 SPRING CHACK BALL PLUG INTER LOOK HOLE Fig CRACK BALL Fig 6 59 3 DATSUN j o 1 n i J I Ii 1 C j Ii I l I o ul 1 co f C f c f c L tS G 8 7 t I it 1 b 4 k I i Fig f D i i I 1 r Press out the Fig 6 Fig 7 pin from fork shaft Disassembly Insert the pin and tap into the shaft and hole fork hole setting Take out the cross shaft from the case F 6 j J r 1 Q n II I 1 0 J I 1 3 I rf CO S I H I t I I L I j 4 III I I iI H ii j ot Ii i J Ii 1 N il I d U c Fig 5 Fig 60 8 Take off the Pin Nut of Cross Shaft TRANSMISSION Fig Fork 9 Pull out the Cross Shaft Fig 12 Shaft 1V LF R O llh 1 111 I t i O lO O i J I II J J I 0 0 I 1 I r4 I 1 h I 1 J I 1 r u Fig 10 Fig 11 Fig 13 Fig 61 zt Detach the Fork 14 from Take out the Fork I the Gear Shaft r DATSUN front and small one cluster gears in the Fig Fig 15 Pull out the place the Assembly Course Shaft J I I Counter Shaft 17 at the rear then case Gear J I J t 1 u I bc j s ja I f 1 I J v I j r J c 0 3 D THFW r 9 T FRON ER r Fig it j r M Ii 3IfI E J c Fig iJ 18 Disassemblv Course I o 16 Disassembly Using a soft and long metal drift out the counter shaft forward pushing When the counter gear cluster and two thrust washer will the drop in case Assembling First locate the two washers to the counter gearB ensuring that the larger washer is at the Fig 62 19 TRANSMISSION Main Shaft Pull out the sleeve by the rear Fig bearing and the speed gear bearing puller from the main shaft rear side 20 Fig 23 of Main Shaft Assembly Removal I trmIC lJ I l J Fig 21 Pull Out the Reverse Gear 8 Shaft I ffJ C E 0 t Main Drive Shaft 4 I 1 r Fig 24 Take olll the Main Drive Gear Fig 22 63 0 DATSUN Caver fcoat tnmmhl10ll Glldu tfront covel o fi1 ft Oil Aa y breather l G Plug IlIion d PlugCI OQ ri go AD y enelJlilXl Caver botoom An y d Fig 25 x bottom fi rear cover plug Transmission Case Rear Extension 5 AI Aa y pinion speedomete Y hev speedometer OD in Sleeve Gear 3 rd coupling Per tfvun Spring for peg speed Piece 6 washer din i CeardrivinS eedometer Gear reverst mailld1aft I r w counter 1 mg Gm count ring It Washer ft An y gear n erseidler I Bushing 1 Walber lock 0 Jd fix revent fevet1 t gUf shaft Scre Fig 26 Components of 64 duwt CCIWlter C frOUt Sbaft pee Transmission Gear TRANSMISSION Reverse Gear A lug which iB an integral part of the main casting locateB the forward end of the reverse To Becure the Bhaft in pOBition a gear Bhaft set pin is screwed through the lug locating in the rl The Bet key is locked out side of the shaft F case Release the set pin f then tap forward and remove the reverBe gear reverse gear shaft Lift out the If seal is oil ThiB bearing rear and should not dismantled unleBs suspected of leaking almoBt impossible damage it fitted if the old This to take consequently can 1 1 be i li I J L It is Q off the seal without a new J R2 C situated in the end of the retainer l Ilr r I Rear Oil Seal I I r oil seal should be has been removed one removed by uBing a punch and hammer Main Shaft Counter cluster gear in the Insert the case Fig first gear to the main shaft together with second and third gear assembly from rear hole and fit the first and reverse fork shifter over 2 Detatchment of the first gear Fit the shift fork of the second and third assembly on the hub of synchronizer DepreBs the main shaft bearing to the end of gears the case Change the dummy shaft the B to counter gear with aid shaft EXTENSION OF TRANSMISSION CASE r r r 5 oJ l Fig II I 0 Fig 1 c 1 0 Speedometer L 1 Pinion Gear 65 3 Rear Extension r QATSUN Fig 4 Fig 1ever 5 change 2nd 1 3 to cha Fork 2nd 3rd Fork Roo frok 1st 10 Rod fork 2nd reverse 1 3 I Lever change 1st PI Pin 6 NU Was DDg r Pm loC k operatmg lever to maft Lever operating D Washer lock Nut I tJ 6 Transmission Fork 66 reverse Spring checking 1G Jm ta r Fig at checking inter lock Ball Leve ClOSS Ball Spring Rod 2pd Shaft ball fix ver TRANSMISSION i I e I 0 n 01 trf 0 T CD IJ ell Fig u@ 7 Components of Transmission WaSher lock Bolt location upper support bracket co J S Pin pivot control lever Fig 8 Remote Control 6 e DATSUN o o 11 o e MAIN SHAFT Fig 9 Assembling order through Disassembly Fig 10 Main 11 Shaft of Main Shaft Front Side Shaft ComPlete Assembly Disassembling Fig the Main Taking 1 Course out by the Sliap Ring Plier Fig 68 13 TRANSMISSION Disassembly of Main Shafti Fig Fig 14 Fig Main Shaft Bearing Fig 18 Fig Tapping out Retainer 69 Take out 16 the Spacer @ 3 @ 17 Press out the Fig 15 19 Fig 20 S l setnb ing k tUng the Bau Qoo nO Fig 21 w Fig j 22 Fig Fig 23 10 24 TRANSMISSION I Fig 25 Fig 29 Fig 26 Fig 30 Fig Fig 27 I Jo Fig 31 Jli f Fig 28 1 32 Oil Seal F Ollt COlier r DATSlffl Insulator rod gearshift Ass y lever 2nd 3M Truman gear shift rod change speed Washer asher W r Pin cotter J i j Nut Tn spechtl Wa e@ @ S Washer plain Washer plain 2 Ot 1 6t I we t f lone cJD a il n l t Bolt rOd lock Wa h tf Ass y bracket supPort low er Seat Retainer Ch nge change speed lever upper Clamp lower support bracket syeed lever Rod shift Fig DISASSEMBLE 33 Remote Control the cap lever the on with a slight These casing Removal of Shift Rod detaching cover To Shift Fork from the transmission lug which is an integral part of casing locates the forward end of the To Straighten screw can be only respective gears remove lifted from the and drive shafts together the needle have been removed roller bearing within a suitable piece of metal tubing Main Shaft A screw gears when the main bearing with Reverse Gear setting when the counter the counter gear cluster itis necessary to break the retaining circlips before driving out the by six bolts gear shaft drive out the counter case gear cluster and two thrust washers will drop to the bottom of the case lower portion of the counterclockwise Gear Using soft metal drift with their the Handle Left shaft forward and out of downward pressure Remove For gear Counter Shaft of Control Lever Twist control Linkage reverse THE TRANSMISSION CASE For 4 Stage Floor Shift Removal 1st secure is locked the main the shaft in position by the tab washer a The main from a tab washer can now be withdrawn from To remove the gears the main shaft first slide off the third and forth speed synchronizer assembly then with a piece of wire inserted through the hole in the release the setting then tap forward and remove the Set out the reverse gear shaft the transmission casing reverse reverse cone deprese the small spring loaded plunger which locates the splined washer at the gear gear shaft 72 TRANSMISSION forward end shaft main of the The be now pulled the steel As the clear of the main shaft sleeves and their tight fit immersed in sleeves the Oil the and should First counter is the release the shaft unscrew speedometer o inserting screw and and washer gears between 0 thicker end play for the cluster 04 mm and 0 12 mm and remedy 0046 or to the thrust washers if necessary thinner rear washer 0 0015 by fitting a its securing nut then slide the speedo Thickness of front thrust washer meter wheel off the shaft Do not lose the piece locating ensuring that the larger washer and then place the gear cluster at the front gears wheel from the tab the straighten two the put in the gear case Check that there is from the first gear unit and then slide the first gear assembly free of the main shaft main the shift with secure Counter Shaft Gears splined washer separating the second speed constant mesh gear assembly To rear gear shaft before will slide off the shaft when they remove reverse into the gear case be expand the the second speed gear can be removed Take out the steel plunger and spring Next gear lock washer washer are shaft reverse with the large gear to the so phosphor bronze in order to oil warm that so shaft Refit the can plunger and driving common the on bronze sleeve phosphor over Reverse Gear third together and second speed constant mesh gears with their common the turning into line with the splines washer and key shaft main the its separated from been prised from Take off the distance bearing after housing can the Thic knes s Part No be nut has 32224 the shaft 3 26760 3 91 96T is desired to dismantle the fourth and If it Thickness of or the first speed third speed coupling sleeve gear these can be pressed clear of their splined but synchronizers must care be taken rear thrust washer Thickness Part No to the three balls and springs in each Take out the main shaft front needle assembly roller bearings from the end of the drive gear retrieve shaft oil seal and rear cover situated is take off consequently the old one the It is seal can in the end of the a new oil 4 1T 32229 26760 4 2T It will be pinched by using the counter shaft with a thin impossible damaging It Drive Gear Shaft The seen ball journal into drifted on to the shaft a from position punch and the geared end bearing should now be with its spring ring away Position the geared end dummy 3rd and 4th speed coupling sleeve put the washer over the bearing tighten the nut and lock it in position of the drive shaft in hammer Assembling sleeves are the 3rd and 4th each p aired with a Smear grease in the end of the shaft where the main shaft locates then load the needle the Transmission The 2nd speed gear coupling 32228 26760 shaft gears seal should be fitted if has been moved be removed almost without that the oil seal housing is This 32227 26760 temporary rod which will permit the gear cluster to remain out of mesh with the main and drive should not be dismantled unless suspected of leaking to 3 9T 40T Replace Rear Oil Seal This 32226 26760 rollers speed so that they adhere in pOSition by means of the grease Turn the gear casing to ensure the counter teeth are below the drive shaft that their respective synchronizers Only mated pairs of these parts should therefore fitted bearing housing 3 DATSUN the counter both gear and drive shaft bronze drive position from can the clutch that Ensure properly shaft the now be drifted housing end spring ring into is tight a on warm th main shaft on oil and then slid into position bearing Place to the shaft from the main Lightly assembly and with refit the the first speed synchronizer with a the hole in the third speed washer over the oil the shaft forward of position the third gear spring and plunger into the hole in shaft and sUde the spUned washer Depress the plunger bearing Now the the the the its sleeve over The bearing must be pressed firmly against the shoulder of the center splined portion of the smear over then the rear shaft the second speed Fit second speed wheel the driving washer complete with housing shaft driving washer and the second bronze sleeve which carries the third speed wheel The two sleeves are locked together by sleeve Main Shaft center the The phosphor there it must be first fit on the shaft the shaft to on baulking ring sleeve which carries immersed in resisters in the rece on the gear case Press thrus t washer followed by the geared ends The the Refit Failure to do this will result in damage to plunger wire through and the slide spUned piece of Then turn the washer for the plunger to engage with wheel a groove in the washer pointing The forward shaft 4 gear are now assembled on the main TRANSMISSION l 1 22 1 7 25 t fl 16 11 5 lO 2i 2i f1 fIT 13 Case transmission Ass y extension rear @ Stud @ Washer lock @ Nut @ Bolt @ Bushing @ Seal @ Bushing speedometer pinion @ Bolt @ Ass y breather @ Wa8her Gasket @ Nut oil rear extension rear rear extension extension lock to fix transmission case Washer lock @ Washer plain @ Bolt @ Ass y sleeve @ Bolt rubber @ Ring Bracket spring return @ Retainer @ Ring @ Plug speedometer pinion to fix rear extension return @Ass y stick @Ass y plug @Cover @Gasket front front oil level dip pinion speedometer 18T Ass y pinion speedometer 15T O ring Oft pinion sleeve Washer lock transmission case @ Gasket @ Bolt @ Washer Transmission Case 5 4 speedometer pinion speedometer pinion Screw set drain cover Ass y 0 s to fix front cover @ Spring ff 8910 26 CD b cover lock Speed 1 to fIx reverse shaft transmission case DATSUN 28 t 29 14 15 9 8 Ass y cover Ass y cover transmission transmission Cover transmission Ring O shift rod Pin control lever @ @ @ Rod fork Fork 1st @ @ @ @ @ @ t3 @ 2nd speed Fork 2nd 1st Bracket rod Rod fork pivot 2nd speed 1st reverse reverse Bracket rod Pin fork reverse reverse Boot control lever Pin cotter Spring pin Rod fork reverse 3rd Fork 3rd fork 4th speed 4th speed Bracket rod 3rd 4th speed Ball checking @ @ Wire lock checking Ball @ Spring poppet shift rod @ Pin interlock @ @ Ball interlock @ Plug weld @ Plug weld @ Plate dust @ Washer lock @ Bolt @ Plug @ Ass y Iever control @ @ @ @ @ Knob control lever Spring Cap Boot lever cover rubber Seat lever spring Spring poppet pin Screw stop Screw set Nut 6 reverse plain Rod 4 Transmission Fork control transmission SpeedJ fork case TRANSMISSION 16 13 12 34 3S L 38 IS d 1c JL 33373639 0 l S ll CD @ Ass y Bushing Shaft reverse reverse Screw set @ @ @ @ @ @ @ @ @ reverse gear gear gear reverse gear Washer lock 8 @ @ Gear counter Shaft counter Roller needle Counter shaft spacer @ @ @I @ @ @ @ @ @ @ @ Ring retainer Washer thrust needle roller counter front 9T Washer thrust counter rear 3 Washer thrust counter rear 4 Washer thrust counter rear 4 1T Washer thrust counter rear 4 2T @ @J @ @ @ @ @ @ @ @ @ @ @ @ @ OT Gear main drive main drive gear Bearing Spacer bearing 1 6T Ring snap main drive gear 1 Ring Ring snap main drive gear 1 65T snap main drive gear 1 74T Ring snap main drive gear 1 77T Shaft Hub 6T main synchronizer Spring synchronizer Ball synchronizer l I hub hub Transmission Gear 4 Gear main shaft Ring 2nd speed main shaft rear Gear 2nd speed Bushing 2nd speed gear main shaft Washer thrust Bushing 3rd speed gear Gear 3rd speed Washer thrust main shaft front 3 Washer thrust main shaft front 4 OT Washer thrust main shaft front 4 Peg locking Spring locking peg Hub synchro 3rd Ring baulk 3rd Sleeve synchro Bearing Ass y 4th speed 4th speed 3rd 4th speed main shaft retainer main shaft bearing Peg locking Gear drive Gear drive Piece speedometer 5T speedometer 4T distance main shaft Key woodruff Washer lock Nut main shaft Bearing main shaft pilot Speed for n baulk Washer thrust 1200 cc Engine 9T 1T ii with seal mficently oil control lever 08 0 32841 Ass of lip the on 4T spedomtr 0720 greas drive l NCS O 0 Gear 32701 y Smear 32 64 267 0 mm No 12 26761 C 0 smal 26761 3posible 2647 9 as part the by Dime on play End Adjurt B cc Dimenso Selct 26762 32 64 32 64 120 by play s end No 6 Engine 6 part by No Adjust Part play for 26761 lit le 26762 32 64 water 32 64 end 6 l Transmio NCS A gre Pack 0 2 No here As by Pa tight Dimenso pOSlibe the m as the and before aplay djuster spring 5 1 rod return Adjust Bearing push fit ing by em I grease 3010 brake 4 0 3 the No Smear Part J ex kg 280 240 T TRANSMISSION Transmission 4 forward i type Ii Fig 1 Fig 2 3 Rear extension Gear ratio New Floor shift Former rod setting through extension is set in rear extension 1 1 3 657 3 2 2 177 2 402 3 1 419 1 490 4 1 000 1 000 Rev 3 638 5 159 Transmission The cover bottom of 945 case of transmission is attached to the case Fig 4 oo ro 0 QO Fig Fig 2 9 5 the rear DATSUN 3 Reverse It is 4 lamp switch placed Speedometer pinion sleeve at the side of rear extension and directly operated reverse shift fork Fig LAMP Fig SW 7 TCH 6 @ 80 Revene Lamp Switch TRANSMISSION 81 DATSUN SECTIONAL OF VIEWS TRANSMISSION I I SECTION C SECTION C B SECTION A B A IE 3F T 2 I IAkg m T A B 9 11 kg m C i J DIMENSION SELECT AND ADJUST THE END PLAY OF REVERSE GEAR IDLER SO AS TO FIT J 0 05 0 15 H DIMENSION ADJUST THE mm END PLAY OF COUNTER GEAR SO AS TO FIT 0 05 352 32225 14600 665 HZ 2 3 BY PART No 32285 14600 1 1 2 3 4 0 15 mm BY PART No 4 TRANSMISSION II o i F SEer ON 1ST 2ND N 45 17lo IllS REV D 4 T 27 37 kg m GEAR RATIO 7 1ST 2177 2ND 9 4TH Tol7 23 kg m SECTION E 83 E D D S l A 84 CHASSIS ASSIS CFI FRONT AXLE Fig 1 85 r DATSUN NUT lock 10 e NUT o UTj ASHER JSpecial rubber shock absorber ASHER inner ear Z o front PAD rubber ront special o oi ASS Y MEMBER LT BUSHING outer fJv suspension 10600 466 V54 S44b7 1060 o g li NUT WASHER @special e USHING ruhber 8hock ab SOl ber SEA T WASHER specla I hb er ru iront 54468 t ear 54469 l tfi l lii 10600 10600 or outer WASHER front SEA T u front er iPring p rea r 54464 10600 10600 front suspension member mounting special 54465 outer BUSHING rubber BAR n front stab1l1zer tens NUT WAHER o @ special outer BUSHING rubber BUSHING rubber tabilizer WASHER pecia I BRACKET tabili er llSl WASHER outer I BUSHING rubber BOLT WASHER special lock uutter BO LT C DISASSEMBLING THE of the front hub Dismantling car until the wheel is clear OD connecting front stabilizer EAT lower front spring Suspension 2 Front Fig Remove FRONT HUB and first jack the appears to bind adjusters Lever on screw the brake shoes out bearing clear of the hub seal then be can removed by inseriing the drift from the opposite side of the hub If the drum When The shoe race and then extract the bearing inner assembling the hub the should first be inserted into the hub hub oil seal over the inner Pack Replace the the hub with recommended grease should be slackened off the hub cap tapping the The inner bearing and oil of the Lower the car on to the blocks the wheel and the Shock Absorber Member ground and then place blocks under independent suspension spring plate BUSHING rubber specia WASHER lock ClrWASHER C t Inner mountIng WASHER e plain SPACER front stabilizer Renew the bearing split pin from the spindle nut Using a box spanner remove the spindle nut seal if it is damaged any way and Gently tap the hub into position until the inner race bear against the shoulder on the spindle ease flat washer under the nut axle thread by carefully using small boles in turn and the The hub clear of the a narrow rod into in each side of the be replaced on the spindle Place the spindle flat washer into position spindle and With the hub lightly removed outer bearing can be dismantled and by inserting a drift through the inner bearing tapping can now race screw wheel l Ild nut 86 the nut down finger tight examine the resistance Spin the Tighten the CHASSIS A the slightly increased resistance to The spinning of the wheel will then be noticed bearings are now preloaded and the split pin should be inserted to lock the nut Tap the hub cap to the hub after packing the cap with grease Replace the brake drum and secure with machine It is screws is home before this sc rews is fully the drum if necessary position by tightening wheel and nuts important that the drum car the brake shoes is lowered to the NUT two wheel nut if necessary before the ground knuckle WASHER front wheel ASS V WHEEL Learing Fig Front Hub 1 0 Drum n NIP PL E T 8 ASS BUS O 4Jt Y HING in NUT r Hl 04101 be ca SHIM rr 154 5 NIP 1 2 0 Ul J 04101 10 lr Ji 11 o 2 i 3 ri 1 SS Y fro JOI T b lI pp pennon opp b n JOin BOLT upper front pe LJl UT on CLAMP o ASS Y STOPPER bnuId BOLT WASHER CO dUll ER up bdl DIll NUT PIN Nlf SS tr BUSHING 10 link J SEAL dua lowe hnk buoh aOLT SPINDLE I NUT lInke Fig 2 Front 8 Refit the best pindle runt and finally tightened when off the backing blocks but readjust are the CQLLAR tightened should be pressed in Suspension Link colte car is DATSUN INDEPENDENT FRONT SUSPENSION The dependent front suspension is known the wishbone since the as Fig type top bottom linkages roughly conform to the shape of CD a wishbone are two wishbones under compression is member axle end jointed by @ Front coil spring @ Front suspension between the by four the upper and the ball joints bolts Ai caster shims and the lower linkages spindle Oil pan @ Front Exhaust front tube swpension memb r @ Lower link @ @ Stabilizer spindle Outch operating cylinder The upper spindle the lower CD @ lower link bracket is bolted to the front suspension member with suspension the coil and lower which is secured to the lower suspension swivel these held spring Front upper link Between upper 1 upper and lower @Speedometer cable @Trommhsion is connected to the lower bracket of the suspension Cross rod member Change Adjust for the number of Shims 0001 0029 0016 0 31 0002 0 31 1 0 04 0029 1 1 0 15 2 2 0 Zl 1 1 0 15 2 2 0 Zl 1 Caster 1 Camber only Caster Back side Front side 1 Both Camber Camber 88 CHASSIS a thickness of each shim 1 m m Camber adjusting shims Parts No Standard adjustment BALL JOINTS AXLE BUSHES OF 54542 04100 1 mm 54543 04100 2mm 54544 04100 4mm Camber 1 30 R L difference within 40 Caster 30 R L difference within 40 1 THE SWIVEL Wear screw if the swivel ball bushes of links by jacking the front of to rock the the tyre joint both or wear movement of the may be checked and the car and endeavouring wheel by grasping opposite points of in Front Coil or a horizontal the ball assembly are be detected between the upper can lower swivel worn and must joints and the swivel axle joints or the screw bushed be stripped for examination If any position Spring UPPER LINK SPiNDLE 1J PER l BALL 0 rOINT CeJ 0 It O UPPER t LINK I a J o LOWER LOWER Fig Between the upper and lower links is the coil spring held under secured by nuts compression of it of the lower and LINK I SPINDLE 2 Through the center of coil spring the shock absorber whcih is connected which is upper LINK telescorp type to the top spring ball joints seat and lower link with nuts of the lower and upper 89 r DATSUN Fig 3 FRONT SUSPENSION Fig The rubber may in time 4 bearing bushes deteriorate and or screw need bushes The screwed bushes develop renewing Excessive side ways movement in either of these bearings robber bushes would or screw denote softening of these checked of the bushes excess parts when dismantled 90 or the ball joints may free play due to wear of either This assembly can best be the suspension has been CHASSIS Disassembling Front METHOD A Order of Suspension 1 1 Remove shock absorber 2 Compress the coil spring by 3 Disconnect lower tool 4 5 When tbe coil too is fully extended take out it 6 Disconnect upper link spindle from sion member if need to inspect for flange Fit the lower ball joint and rebound bumper from lower link Release the coil spring by loosing the nut of spring Unscrew nut of the shock absorber at the top and take out if from down side after unscrew compressor nut In the absence of the service tool a suitable tool will be release required to the compression from the coil spring Compressing the coil spring unscrew the 3 nuts of lower ball joint which located under the suspen of it from lower link serVice tool and screw up the spring edge of lower link Remove these nuts and release the compres sion from the coil spring by loosing of nut Removing the Coil Spring too When the coil Spring is fully extended take out it Fig 5 Front Suspension Assembly Fig 6 Detachmellt of Shock Absorber from Suspension Fig 91 7 Detachment of Shock from Suspension Absorber DATSUN E I I Fig 8 Remove Shock Absorber Fig 9 Detachment of Rebound Bumper Assembling Tightening torque 4 04 5 kgm A Fig 10 Releasillg the Nuts 92 of Lower Ball JOillts CHASSIS METHOD B Unscrew which is the four bolts of lower spindle the suspension member secured to Remove these bolts and release the compression from the coil spring spindle can Refitting When the lower link with be driven out the Coil Spring Use the coil compressor or lower link member Fig the to the bolts of the front suspension the bolts of the lower Release the compression by loosing jack screw down shock absorber by the double nut nut compressor Set 11 spindle and then secure spindle the jack against Screw up the screw lower link up the or the of upper side and the bolts of lower side METHOD Replacing @ C Order of Upper Link 1 Prepare 2 Jack up and support front suspension lower to remove front wheel link 3 Remove wheel 4 Disconnect 5 ball upper bumper from and joint rebound upper link Detach upper link and spindle from suspension member 6 Fig 12 Disassemble upper link spindle from upper link by unscrewing link bushings 7 Reassemble upper link spindle and bushings to @ link upper of replacing reinforced part carefully following undermentioned instruc tion 8 Reassemble complete 9 whole parts back again to unit Check and adjust fron wheel alignment Instruction 1 Don t hold screwing in spindle tight against link when Because the pitch of bushings threads of spindle inner and outer screw of bushing and link sleeve Fig 13 93 are all same r DATSUN 2 Apply sufficiently grease on of bushing and spindle screw 3 careful Pay attension not to the Assemble inner damage to to 4 ue 5 resistance bushing when assembled Adjust the spindle reiative shown as so as lower link to the 9 5 12 5 3 m nut kgm Connect with upper link to the suspension 5 0 kg m tightening torque 4 7 forget to insert the adjusting shims member by torque between spindle should be within 0 5 kg ft 1bs link Lower bushing against link sleeve by the 20 kg m of 19 137 145 ft ibs up Friction and and upper Tightening torque for ball joint 7 kgm Upper 6 the thread when screwing in the bushing Tighten the knuckle spindle Do not 6 of chamber position of spindle and in the figure by turning the to the link and the spindle to bave dimension of it 6 Align the direction of nipples grease as shown in the figure 7 Lubricate bushings with grease completely until the grease will out from dust seal come Center of ball joint Center of ball joint S5 sj 5 15 Fig til0 rS4 Front Wheel sS 189 Fig Nuts 174 Assembling of Upper ball joint and rebound 2 link 4 2 6 link spindle 4 7 kgm 4 kgm r30 1 6030 camber with bush spindle ing fixing fixing lower link spindle 4 0 5 upper link 30 shim at upper portion spindle Turning of install the screw bush sufficient grease shall screw Pay be applied in the inside of the bush threads of the spindle carefull attension threads when screwing in the 24 adjusting caster with the same shim or 360 up 8 in only 1 2 by one turn turn upper spindle 32 5Ib ft Prior to and 1 King pin inclination angle Adjust kgm 5 0 mm Camber Adjust upper 3 36 2 Ib ft Nut 29 upper the upper fixing Alignment Caster Link 188Ib ft Bolt 34 fixing to Lower Link Toe in 14 Tightening Torque bumper Assembling of not to damage bushing bushing against link sleeve by 25 kgm One turn 0032 Caster 180 Only 180 0013 360 027 Half turn 0018 the Tighten the torque of Clockwise See fro n back side Counterclockwise 94 See from back side CHASSIS s t I 0 0 CJ t or1 I D o i r 1f 1J I I I J J o 0 1U013 oq O n U 3 11 Front suspension 95 A I i DATSUN c 0 C o c r di rl II JJ C 0 Q I I 1 ji i c 2 0 c U o 0 C I lC C c l C U @ @ @ 0 I Q 41 It 2 I Q Front Suspension 96 B o ww w body of line BaISe torque Tightenig T N 0 0 C0 1g 0 lu of of HJ r ente C limo spIndle spIndle Bue up er up er I spindle lower of front line condit loading Center SIde embl r under M Tight cs of 5 1 l standr r DATSUN REAR AXLE 4 I 6 Hand brake 11 Rear trunk drain hole 2 Muffler Rear 7 Hand brake cable 12 Rear shock absorber 3 Pre muller 8 Rear 13 Rear axle 4 Side rod 9 Hand brake balance lever 14 Exhaust 5 Propeller Rear IS Rear spring seat 10 shaft Plu 43010 10600 43010 10800 Camp Camp swing arm spring U bolt spring shackle pin per axle Stud gear carrier Ass y plug drai Ass y breather Drum brake 43235 04101 Ass y catcher 43234 04101 Ass y catcher Fig 1 tube spring axle ia1 aXI case case case grease L H grease R Rear Axle Case 98 H I Shaft CHASSIS r8 D Smear grease on a little the surface of shaft Fill up grease on UK91ft the raCe suffieiently bearing surface of excpet other space Press this collar by pressure 3 v 5 tons T metric Tightening torque The collar is required to change new one when disassembled Fig 2 Axle Component of Rear Axle Shaft Removal Choke all the wheels not jack Lower the axle the being operated brake upon up the car is adjuster on to the blocks and remove release a slack off the brake shoe few notches Take off the fix bolts of the brake disc and wheel using a screw driver unscrew the drum locating screws release the hand brake and tap the drum off with the mallet If the brake linings should hold the drum when the hand remove the axle shaft swing hammer the disc 99 rear holding as shown Fig Tap with the wheel studs bolt with axle shaft stand draw out the shaft and assembly by gripping it outside of the disc DATSUN Order of Rear Axle Shaft Disc Brake Assembl The axle bearing with the brake disc replaceable in one operation by When fitting the axle shaft pressing into place it should be compressed inlo the shoulder of the rear assemblv is end after case flange its The inserting the end hub and following Part points shim between No must 43036 04100 be taken into consideration 1 Nominated used oo Hypoid In gear oil No district warner MP90 must be than 32 C use MPII 140 o 2 It is oil to use any other kinds of gear The any oil of different viscocity brand must always be selected prohibited or same The standard capacity of oil is about oil 93 The method of feeding oil should be done by taking off the feeler plug at the rear cover of the bousing and fill in full up to the L o feeding hole Dismounting of Disassembling Differential Gear Carrier Fig 3 Remolle of Axle Shaft and 1 Take off and drain oul the gear oU 2 At the carrier Disc Assemblv axle ti me of pull with shaft dismounting out the the the gear both left and right disc of the brake assembly 3 propeller G Fig DT Axle 5 of so Pull off the nuts Take case the side of of the housing and dis off the side bearing cap of carrier pry with a lever the differential gear and the bearing DT 4678 6 Swing Assembly Hammer Dismount of Shaft the side bearing Fig 5 with the aid of side bearing puller pull oul the bearing The puller should be handled wilh care in catching the hedge of bearing inner lace As differential illustrated which is in to hook hard right bearing separately When not joint flange from shaft mount forward the carrier ass y and 4679 and 4 4 Special Stand Disassembly Take off the replacing the differential axle shaft do forget the adjusting washer between the top the axle flange and the brake disc assembly as to keep the end play of the axle shafts 7 Dismount Ring 100 gear the by Both the left and should be differential loosening arranged drive the 8 gear fixing CHASSIS screws the on spreading differential gear and case 11 out the lock washer illustrated Fig in bearing pinion the adapter should rear Loosen them in to As adiagonal line considering from the keep gear bending The case for No adapter be drive the employed in the round and the other for fixing 6 inner race replace and taking in this form is off easy to handle with the vice fixing end of replacer is 12 Taking out the rear gear carrier The drive pinion replacer as bearing outer stud to make the screw at the center up so as till the adapter and the set In other upon the the adapter at 1 and screw tommy bar 7 closely touches the corn then screw the wing nut to take DT 4686 8 Take the out the differential side gear Tbe pinion well as as shaft mate pinion should first be pulled out by striking out the mate shaft pinion the fixed on side from the from case side of ring gear fixed to before pulling out the pinion right well front and 9 the as arranged left the side gear and the thrust washer as which is locking pin differential thrust separately The gear washer left as should be and right rear After taking out the nut of the carrier pull out the companion flange The pinion flange wrench should be drIve employed Tool No setting its four points in the holes of flange to keep it from moving take off the Fig nuts with the box wrench 10 Take out the drive by striking front end pinion of gear carrier out lightly to the backwards the at the side of companion flange of drive pinion with the drift of soft metal Thus the pinion ing and roller adjusting and well would taken distance piece shim and the oil seal pinion of front and as be out with the inner lace of rear bear together the bearing as shim left in rear pinion adjusting and the outer lace the carrier 11 Pull out the rear bearing inner race of the drive pinion 101 6 the race out the rear outer race Puller race 6 should be in this case Supporting Using of Side Bearing outer race of illustrated in Fig lower frim of the 5 one employed of carrier Fig bearing It DT4782 DT4631 Pull out the DT4689 Bearing Race r j UN DAT 13 To pull from 3 out lhe front hearing the gear carrier as adapter set illustrated in Fig B 7 When the drive outer race Drive the tool body pull pinion Tightening it out with 14 t7 100 in the way of rear race kg ion torque nut with kg 120 ft lbs M m hypoid drive adjust the irk tion of rotation so the torque is be 19 kg to em Tightening torque Drive Pinion Front and Rear Bearing Outer Race Replacer Fig 8 Inner Race 4 2 4 8 kg m 30 35 ft lb Replacer Fig 102 10 the washer of drive pacer Fig by pinion bearing and 0 7 17 without the oil adjust C tightened al of 7 0 is torque 14 m gear Fig pin nut 9 Section of Differential Case CHASSIS 38440 04100 Gear drive 38101 04101 137Tl 38120 04100 38189 027 38210 25660 INSPECTION REPAIRING OF DISASSEMBLED PARTS Every parts after they are locking condition defacement or on the surface to see if they disassembled should be cleaned and cleaned by the compressed air before making an inspection and adjustment 1 Each should bearing every unit of ass y be back lash in The re use axle should be inspected in respect of the crack and cause spline of the defacement 0 4 mm m or m The axle adjusted with 0 between clearance case Part No and with brake the the disc adjusting or be re standard damage found would 8 cause the noise be difficult to adjustment in later adjust even is made perfect driving condition at the surface pinion gear should be about from 2 3 to while the gear 4 in unloaded driving 3 mm from tip to full should start to touch surface The end of end of drive rear should be shim surface in 43036 04100 Every gear should be inspected it with proper replaced adjusted 3 should be insufficient deformation operation and measuring the shake with the gauge by The difference houlding the both end over of replacement Specially the drive pinion and drive gear should be replaced in a set whenever the locking condition gets worse and the be defacement is already in progress them 2 case is necessary inspected regard with the defect and defacement before deciding to In used any defects can an ordinary loaded driving The inspection of this condition as to the as 103 it is can be made r DATSUN is If it hard to inspect them as it is do by cleaning the both surface with the rugs before disassembling and paint thinly and evenly with the mixed wi th thin oil on the gear Strike in the pinion shaft locking pin from right side of the case opposite side of otherwise drive side surface then the situations of drive gear on the gear considerably the gears 4 of whole gear interior tip end of the gear 4 Lock the with In is perfect that contact for about three center of 1 quarter length drive Fix the differential at the the pin should Ring gear gear with the well as as the drive pinion should be well inspected to they must be replaced as a set whenever the replace ment is required Otherwise they would not properly lock side gear with pinion together respective thrust in the gear case of the back lash over 0 2 mm and after assembling is complected case In mounting in the case the fitting surface the clearance between the side gear and thrust washer exceeds 0 5 mm replace the must thrust washer washer with sureness after the drive gear The else out worn be cleaned and fixed with 8 set screws as well as lock washer bend the should also be parts specially shake adjusted is replaced screw The contact when ring gear is too close to pinion center in case of back lash should vice or any other be with adjusted closely or it gives damage much noise a Put the drive gear ring gear on the buoy block as it is fixed in the differential gear and case measure In and it setting tools so as not to up in a diagonal line screw wrench which fit Screw in for sure of one screw by correctly with the The standard screw screws ing torque for this with the dial indicator tightening up the and supported by should be set it head of the 5 as case The drive gear from tooth the Pitch line on so out 2 it by setting not loosen gear In case of unloaded test required piston to lhe Which worn and must be fixed well the striking hole of it after putting it turn the pinion with hand to print the track of it shows the is 25 it lbs to 30 ft lbs striking lightly the head quarter pound hammer Revolve the drive gear to turn around the differential gear not move on the case as the bearing do buoy block 3 Measure the In rear side of gear by the scale the shake should be within 0 5 mm mounting the gear clean well the fitting face and and fix rear face correctly measured face side bearing in the differential case shake at the and Mount the of it Press in the both side of the bearing the drift by It is important in this by the putting give the bearing then there should not be any shaking a proper with the carrier ASSEMBLING ADJUSTMENT Asseinbling 1 Differential Gear Assemble the pinion and differential side gear in the case Every parts should be cleaned with new gear oil and oiled then the pinion mate side gear and the thrust washer should be assembled by the mentioned inspection and selection before pushing in the pinion mate to shaft Inspection should be made again in the washer or clearance the back lash be made in case of between Adjustment any abnormal the must Fig Is found 104 case side bearing 12 to assemble adjusting preload shim to in fixing CHASSIS ASSEMBLING ADJUSTMENT BY GEAR CARRIER ASS Y It is to decide the assembling They adjustment of gear which is very important in an rear axle ass y and should be carried in accordance with the be the the exact sample in 0 by the manufacturer shown a show the figure at standard 21 and comprehended referring to Fig 19 to repairing according adjustment exactly condition of practical use based on the center adjustment by shim for exact calculation shown as figure for Preparation 1 drive gear bearing as a drive Adjust they are disassembling and of 3 because later of drive shim right the which pinion adjusted by between rear bearing the to be fixed with carrier must be the carrier outer There are race besides few numbers with 0 set electric pen drive on number the tip marked by pinion adjusting arranged as following of the adjusting shim will be prepare the equals figures on Deduct the it case 2 narrow explained in the following paragraph of adjustment Supposing the drive gear and the drive pinion were re placed as a new set and the height of drive pinion previously used was Qut prepare the various shim mentioned adjusting off the scrape the surface by a grind stone with on The thickness of drive The use previous condition of adjusting shim In case any item should be replaced or required to reuse even if any item and pinion 17 is difficult to discriminate to the direction of on arrow in in on they should be assembled order of disassembling at the position axle 13 to the reused as are result worn from accordance with the Pinion mark inspection as standard not to scrape off even the mark care and pinion what some the Mounting shim are is Fig due to the corrosion Drive Pinion in the Gear Carrier If the 0 mm in oxidize substance A The of adjustment The position pinion height is 51 If the error of 0 001 in to decide the thickness of 025 mm adjusting The construction and mechanism must well manufacturing the unit the difference and new have the general idea of required thickness assembling to prepare head surface of shim in increase in case of of an of this pinion used previously plus and minus or is shim of thickness the to the pinion shim for Standard Part No Thickness Leaf No Drive 0 75 pinion adjusting mm 1 0 38153 25660 shim 0 030 in O 25 1 0 mm 2 3815425660 0 010 in O 125 0 005 in 0 075 is 1 0 003 in inspect the condi disassembling in a way as convenient tion before mm 2 38156 25660 It rnm 2 1 3815525660 to mentioned later in the measurement of pinion height Besides the condi tion of defacement on the carrier pinion bearing consideration Fig 13 Adjustment of Pinion explained Height must be taken though it will the into be in detail later 105 e r DATSUN B and Adjustment of Drive Pinion Fixing 1 Drive pinion rear bearing outer race in the carrier in should be mounted this case after inserting the selected adjusting mentioned bearing shim as between the carrier mount the race properly previously and outer race the special tool of drive pinion rear outer bearing race replacer by front For of adjustment previously mentioned pinion height the shim at the rear side of this outer race is increased decreased or and the race also must be taken offln each time for this adjustment must be such therefore handled properly to ing hole of Referring the This might in to 8 Fig for handling the adaptor set guide the body corn to 4 as use well be done In pressing a certain drift of Mount the drive pinion in the carrier and ring of 1001 at adjust by measuring the position The pinion height must be adjusted mentioned in the previous paragraph outer race on the corn as the by mounting temporarily the pinion in the carrier and the bearing be given a regular preload On the other hand the bearing of drive pinion should be At the same bearing lwist up race come be 10 up the housed race supporting it by the the corn till the adaptor and screw screw lime bar then the setted position wing properly so as at the the setted bearing outer race in is mounting the fronl ouler race off at first the adapter from front end of the 1001 at side the carrier side of tighten the center the inside of the carrier of Ihe and fix the as at the final assembling At the time bearing as of as the rear Put the side of the carrier rear side of the carrier down ward and set the tool under it the rear bearing inner and roller to the drive pinion the using round adapter By attached to pinion rear bearing inner replacer which was employed at disassembling press in then supporting the end surface of drive pinion press in the bearing by using the drift The operation would be easier by using the drive pinion front bearing inner race inserter as shown race the drive race the inserting the front pushing in the inner race out the drive pinion from by pulling to be the shown Fig 14 as in a adaptor by using of outer the rear race way mounting carrier yet not mounted stud in opposite screw not bearing spacer distance piece bear ing adjusting shim and oil seal are then mount it Mount the by the pinion nut fixing with the companion flange till the regular revolving torque is required As this the carrier take oiled after the pinion is inserted from up Mounl the front For newly inserted end of pinion should be locked with front bearing corn and tightened race position 3 as the small hole of carrier put the rear surfaces inside at the tip end of and put the split adaptor inside 2 by the carrier in on oval method of tool on avoid situation as to make the bear a 14 Fig the tools the drive in pinion Tighten 106 up the pinion nut by turning it CHASSIS slowly preload with with hands the use of The preload that the 7 kg shim inserted 10 When the is cm the drive pinion case is the bearing different according to condition of the bearing adjusting mounted in is previously mentioned condition it necessary to measure the height of rear is in this supportedly Fig 15 to the degree support the bearing preload at gauge as surface of the higher or pinion whether in than the standard lower special drive pinion Make use of the arrangement gauge The standard height of the the bottom from 51 0 mm pinion is of the side bearing fixed with the carrier The fixing position can be measured by setting an arc of circle on both sides of arrangement guage at the position of side bearing and insert the thickness in gauge between the pinion such as to of the carrier in preload and the bearing would the clearance of gauge bar tip come tend to cause an and the The out of order and unexpected trouble 16 Fig push in by scraping diagonal otherwise pinion height of the the more of the shim inserted to the play of pinion much direction of axle is increased in fulure The less the more previously it of shim inserted the tightened by bearing mentioned nuts and the the cause to be burned if left and turned as it is Therefore for readjustment of bearing preload in this case it must be adjusted by increasing or decreasing the number of four kinds the of adjusting shim as shown following list and measuring use ofthe drive pinion gauge Fig 5 The formal the and bearing fixing position decided as paragraph 15 of the drive After preload mentioned in pinion is the previous of drive take off the pinion companion flange to drive pinion bearing and nut Fig 15 adjustment pinion as nut mount again the spacer distance up the nut as piece Tighten Fig 16 by using the torque wrench at the regular torque of 100 120 ft per Fig lbs IO 17 so in the with the bearing preload as to make the DATSUN revolving torque of pinion at by any if there should not cm 7 10 kg error practical use over preload in so as not to it an give the pinion with the head mark at 0 and the clearance should be sealed at 0 2 0 mm thus 008 in 6 pinion is position because lhe height correct When the former the previous paragraph of wrong the pLnLOn head set the semi circular side portions of the gauge on the side bearing insert seats a feeler The guage rod is made 0 2 mm 8 shorter than the standard measurement Is made by selectlug feeler gauge in accordance with the plus minus valve marked on the pinion head a If it is necessary to take height well as adjust off the pinion rear bearing on of head the increas insert 110 50936 o 008 in feeler for and to So 2 shows make o 002 in to At 0 001 in 0 used It is necessary again in adjustment lower should torque accordance with only 2 fi lbs and the differential unit is and the drive gear is locked therefore the of side bearing preload Adjustment back lash bearing is to To give the bearing be at the in standard in the of the side the gear back lash assembling than at pin far load it must be done in a when the old nut 35 40 fixing is follOWing adjustment must be made to acquire the regular side bearing pre otherwise right way Specially of A in the with the drive pinion in 008 give the bearing a right preload the time of pushing the outer race into the carrier be at the cap mounted the number of shim so as to the clearance with the 3 should be equally locked with fixing cotter the mark of bearing 008 in adjust the position of drive pinion by deducting by housing torque in case of minus side added instance is inserted bearing housing of carrier the bearing must be given The screwing the regular preload in case of plus For case by the bearing adjusting shim side bearing as explained in which the number of mark to 0 Mount the complete unit of differential The differential gear drive is gauge deducted for the number of mark from the the washer finished up pinion before adjusting by increasing or decreasing the number of drive pinion adjusting shim by filling but It is important ing when mounting to note that the fixing part of the cap of each bearing housing is machinerly as outer race the adjustment the side of cap which should be fitted with mark on the leg of bearing hous ing or decreaSing the number of the In other words read adjusting shim the mark In case the the gear in the carrier and fix the bearing There is a engrayed mark on cap the pinion adjust by form the carrier to 1 or drive pinion up at the standard torque CMounting the Differential Gear Ass y in Carrier 51 mm adjustment insert the new oil of the carrier and cotter pin hole fitted nut the pinion Therefore rear should be made not by tightening the gauge into the clearance between the tip of the gauge center rod and the pinion head and adjust 1000 In the thing formerly fix the flange washer and pinion nut The nut should be tightened Remarks height of in inspect in the loosen the pinion nut take off the flange seal measuring the is found as Unless any pinion height again the gauge is made shorter for 0 2 mm than the standard size 51 0 mm When of pre adjustment load of the bearing is completed by the feeler gauge regarded as at the made conditions the pressing differential of inside the 108 right preload of differential the on gear the side case bearing in and the adjust hy inserting bearing adjusting shim of case CHASSIS calculated thickness with the 0 accordance in 0 008 004 off the If it is much following method of taking marked numberal of Thickness of Shim of bearing housing Left Side right move to left by for adjustment shim computation There is adjusting of a basis on the carrier and differential the gear case manufacturing in the erro in a unit of 1 1000 ment of A B C D and place case kg 5 to acquire and 1000 the applying the E 8 F 10 D E 0 0 A C 1 mm bearing Right on A side measure o the unit basis of o each of them as E B D F 6 T2 0 025 O 07 E C D 001 0 002 002 0 007 008 Thickness for bearing mm by excluding of the shim ring to as 0 1 3 8 7 15 0 375mm 0 002 o 3 10 6 006 0 006 F 003 0 016 010 0 015 Thickness of left of right side shim The numeral marked by the electric pen the side of the drive For example in 0 025 mm shows which is b 6 x 6 means 0 in 20 make sure that it by using right otherwise the pinion the dial indicator is within 0 1 mm O 2 on of the the back lash of 0 15 mm using the The left and that gear recommended back lash besided the set number sign is the back lash of the drive Fig 8 10 20 0 5 mm B D 0 in accordance with bearing must be well pressed preload changes gear x T2 acquired by the following method above method of computation Measure mm side shim 0 008 in the minus well be assembled by shim of thickness x 2 0 0 2 is numerals to as 025 mm O 025 mm mm 0 025 mm 7 of computation It may O 2 mm 25 1 o 008 in thickness T Left against the standard measurement and The 2 In this minus on error assume mm it the E is 1 B When the measured width example 18 3 the A the steady figures Take the left side F is on each standard the ment of 18 5 1 load the the Calculate against flat board on a 7 aid of weight block for about with the 2 side use F 6 Right Side T2 B D Example of calculation 18 5 mm thickness standard guage and dial gauge right Pinion mate side C E measure of the A on Right Side Ring gear side Left Side T 1 18 Fig width left on in the measure bearing standard each against To is numberal The Thickness of shim mm Fig 19 Fig 109 006 DATSUN After the Operation JJ I I Fig 20 Measurement of Back Lash for the Drive Pinion Ring Gear If it is necessary to use the bearing again at of each shim the time of repairing the thickness 001 of left right must be reducted for 0 against with the practical in accordance preload standard becuase over preload is given condition of use o 003 to the on the basis bearing calculated from with of 80 the or shim 60 of Fig thickness above method of computation 110 21 Using the Differential Bearing Cap Gauge Side CHASSIS 3 11 DJ4 1 l Wl Jl J OJ4 JO J JI3IDH Jill OJ4 JIm UJ4 Select from J J J IJ bJ4 1J QJ411D IIHOII 7 J8 Ok D94M J8 M4011 IJ J81 1 O 3 1 40 3 10 15132 38166131011 MOO O 3 167 1410 400 J6153 Impact chassis the lip of oil in grease al pinion and 1001 361541061 361551U6UI O 18 36157 10 I shims by adjusting mesh good of drive to 161561001 the hack lash O 19 Adjust IJ2 bearing cap H 38 Ca1culwes Thickness of shim for Left side 11 32 03 38101 A Tl C D ide preload E 0 025 0 1 0 hearings 0 175 8 D F x 0 025 O 150 Right side TZ To tight this head of bolt tapping slightly with 4 1 0 1 pound kg hammer Tightening torque 3 5 4 2 klOm 25 30 ft lhs JIJIJ 13700 Contact wide of tooth must he more Back lash O Give with by than three 1 O 3B453 10500 3BJj S410 forth t 2 Refer ential dirnension Q fS51050 n 384561050Q J 3 457 IT3Sf 050 preload for side berings adjusting him gained alculuses Fig 22 Carrier the Gear Carrier Ass y the Rear Axle Housing Mounting Thus the of precaution large 173 measure 55 DT 4685 is Interior of the axle housing should be cleaned well L measurement which is within size the 40 173 completed By way with michrometer of the adjustment mm as Fig 21 If it is insufficient shim of 0 002 in Tbe has 05 mm Service No add an The carrier packing should also be replaced tool additional with new one Mountthe gear carrier ass y withoutmistak ing its upper side with down side and through 8 The studs then fix with the lock washer nut In right 21 or the said michrometer this case Fig special gauge should be employed for scaling 0 left and shake of the back of drive gear which fixed with the carrier should be nut must be dial indicator to confirm that is When it by within 0 05 tightened to cause the oil been measured on is mounted gear oil immediately hypoid gear oil No 90 mm Feed the oil till it of the feeding hole III in a diagonal line so as not leaks on the vehicle The oil of the feed the designated should be feed comes up to the down side I DATSUN STEERING 48400 10600 Ass y wheel steering black 48420 10600 Ass horn black y iug 48420 11500 Ass y ing born yellow 48422 10610 Pad horn ring black 48327 10651 Set shell rteering black 48327 11550 Set shell 48422 11510 Pad horn steering yellow 48327 10851 Set shell steering black ring Plate yellow clamp Bushing horn l4 jthion f bwhing Bushing horn A y contact horn at 3 10610 1 Screw to fix shell 3 30614 1 Screw to fix turn signal switch to shell Fig 1 Steering Wheel Type Recirculating ball type Gear 15 0 steering Rotational numbers 2 the connected to the rocker shaft is 96 Distance between sector shaft steering linkage three rod worm shaft 45 mm 0ear oil capacity Two o 3L side cross rod lever cross lever to the The worm ing and stable functioning gear with and lower supported upper angular contact ball bearings to the housing is meshed with the through the circulating steel ball and ball nut This assembly is enclosed in an oil tight casing which carries two ball bearings at sector arm either end of the earn When the steering wheel is turned the tube revolves the taper peg to earn which in remove over a turn causes predetermined the arc thus giving the rocker shaft its desired motion 112 The the gear arm side rod steering gear and idler arms Steering system consist of the recirculating ball type robust structure and gives light handl steering steering is rod connecting the side and shorter connect a gear is a that links up with on one the on arm respectively to of the cross idler shaft either side the steering CHASSIS Side Cross Rods The by side and To rods cross castllated a Steering and nut held in position split pin the rod remove are withdraw the split pin carefully tap the rods clear they are connected of the levers to from the end of steering Unscrew the These the are Steering secured to the split pin not be removed The nance only steering for any casion o removal would be when general position STEERING GEAR mainte requiring damage its gear respectively by a Normally these levers shaft and idler shaft each member gear arm bolts secured to front suspen Thus the steering gear housing assembly should be removed from nut need sion Gear Arm rocker and Removal First disconnect ball stud nut and draw out which Removing Housing Removing the horn ring assembly from the steering wheel unscrew the column lock then disconnect higher up the column jacket from the housing at each end and release the nut at each end of the rod and then Gear Adjuster their screw has occurred under which circumstances the steering box or idler should also be remove for inspection when the arm concerned steering gear box can or be withdrawn once the idler has been removed to the work bench The gear arm should be with drawn from shaft concerned using gear arm a suitable extractor must not be hammered from its the Recirculating The ball nut shaft Removing the Idler Referential Figure of Recirculating Ball Type Ball Nut After the side and the idler can secured by cross rods disconnected be detached from the two bolts to Assembly body It is the front suspention member Holding off rubber the idler body on the bench and take Slip the cover Unscrew the idler shaft out of the body nut over the worm with the ball holes up and the shallow end of the 113 rack guide teeth DATSUN Align the grooves in the worm and ing through the ball guide holes Count This is 58 balls into a nut suitable Assemble by sight being container screw the proper number of balls for this ball the nut see Drop balls side of nut this operation either side of nut same side must be used Shake the nut being filled ball guide clamp to the nut then tighten the screw assembly by rotating that it moves freely clamp Check securely the nut on the worm to into each of two holes on the same from end the sure to use a lock washer under the may be perfonned but two holes on the not two holes on same away from hole until all 42 balls are gradually Continue installed Place remaining 16 balls in ball guides 8 o in each of two halves 9 o ASSEMBLING 1 2 Fix the completed gear housing with needle roller beearings and oil on the vice Set the 0 3 easily guides into the guide holes of the If the guides do not push all the way down tap lightly into the wonn @ correctly adjust the shims and bearing to the housing Push the nut Insert column unit to the gear main @ housing with @ o ring 4 place 0 Tight 5 6 To carry after of 7 finding 8 1 on oiling 2 5 the kg surely 13 m adjustment for the CD correct position the bOlts 0 Retighten ing torque the bolts with temporarily washer after wonn witli tighten 18 lbs feet of main column bearing by rotation steering wheel Motive power shims 2 3 cm should 4 be with 200 adjusted 450 by @ grams at 20 R on the circumference of steering handle ADJUSTING a Adjust fixing 114 for rotation the main of steering gear after column and coltJ inh gasket CHASSIS Roller shaft adjust shim c2 @ Bearing @ C 1 ing c3 1 575 Roller shaft 1 @801t 550 525 1 500 1 Sector shaft gasket 1 48204 16500 e Sector shaft 1 48201 16500 Bolt 5 16 cover 24 x g Lock washer 5 h Lock nut 3 18 3 1 24518 16 3 9 15115 1 9 11346 8 24 Filler plug 48029 71200 1 o 48030 71200 2 48031 71200 1 o 48032 71200 1 o 050 Parts Name a Q ty Steering column assembly bl Worm b2 Worm b3 Worm b4 Worm bearing bearing bearing bearing 48064 16500 127 Part No 1 48024 16500 shim 1 48029 71200 shim 2 48030 71200 shim 1 48031 81200 shim 1 48032 71200 1 48035 71200 1 48025 16500 0 d ring Steering worm e Bolt 3 1 24520 Lock washer 3 9 15115 c 1 762 o 254 Signs 48132 71200 525 mm d f No s 1 48131 71200 adjust shim 550 mm 1 Roller shaft adjust shim c4 iWasher Part No 48130 71200 mm bearing f b Insert ing sector shaft and then attach hous cover Part Name Signs a the Steering Q ty sector shaft Arm sector shaft b Roller shaft screw Roller shaft adjust 48103 16500 1 48502 16500 I 1 48502 1 1 575r l 600 mm 1 shim 1 @CD 1 for LH cl y Part No for RH Arm sector shaft CD @ 170001 Set with the selected 4 numbers shims C3 C4 after fitting the adjusting Cl C2 screw to the sector shaft 48135 32200 o 48129 71200 Gap at adjust should be 0 liS E 01 screw 0 03 to the direction of shaft mm r DATSUN ADJUSTING 2 Correct the position of ball nut to the center 1 Attach with and insert oiled sector shaft to the housing temporary sector gear arm Rotating slowly the sector shaft find and Stick the gasket center of meshed point of the clearance adjust 3 the housing with sealing on 0 at cover 4 screw Fitting with @ adjust screw temporarily the bolt and washer with G l housing 5 Pull the direction of m 13 Fix 3 Make sure smooth rotation of gears 4 The @the lock nut the cover up housing 2 up 2 sector shaft cover retighten 3 mm the bolts with the torque 1 8 cover to 2 5 the by of k lash of gear arm should be bi the screw 0 0 1 mm at adjusted the kg 18 lbs ft 5 After finishing adjustment repeatedly then lock @ the retightening adjust 9 11246 rotate screw more Tightening torque 2 the gears surely nut 1 8 5kg m Select and adjust with the shim by part No 48204 16500 as to 48129 30 31 3271200 the clearance is to be 0 01 Type Distance between 4Smm Gear ratio sector 15 0 and column 450 Locking angle Ge oil 45 IX N Impact Grease NCS 17112 tl 1 at assem bling I Tightening torque l4kg m neutral position 9 1l252 116 MP90 0 33L so 0 03 1 after 6 up CHASSIS 0 49 0 4 r 19 18 17 3 4 CD Steering gear housing @ Steering 2 Needle bearing complete @ Steering column assembly 0 Expantion plug @ Steering G Secter shaft oil seal @ Secter shaft adjusting screw @ Secter shaft cover @ Secter shaft shim @ Secter shaft @J Lock nut J Plug @ Bolt @ Bolt @ Lock washer @ Lock washer @ Nut @ Washer @ Steering gear @ Lock washer @ Nut @ @ Worm 0 bearing y gasket shim ring @ Steering @ cover ass column jacket complete Steering column bearing assembly Fig 2 Components of steering II worm bearing sector shaft adjusting arm Gears D TSUN i Bolt to fix idler Nut to body Nut to lock ball to bar joint Ass y Ass y socket ide rod inner R H Ass y socket ride rod inner s1y As rod side Fig 3 R H Ass y rod R H side t H Steering Linkage Steering Faults Loose steering is play of the worm gear which can be rectified invariably attributed end already through steering column by the removal of shimes located behind the gear housing front cover mentioned To check for this end play disconnect ball joint stud at the end of cross rod from gear arm and turn the steering partly to the right as 118 or left lock CHASSIS BRAKE GENERAL DA TA Type Hydraulic expansion Foot brake Mechanical Hand brake internal expansion 2 shoes for 4 wheels rear 2 wheels braked Lining Width x Thickness Area of surface Brake drum dia Master cylinder x 40 x 4 Length 5 x 215 mm Same for Front Rear 35 Front Rear for Front Rear cm2 Front 228 Rear 6 cm2 Same bore 22 22 mm Inner dia Wheel cylinder bore Front wheels 25 40 mm Inner dia Rear wheels 23 Fig 1 Front Brake Brake Disc 119 Flange 81 mm DATSUN i 00 o B on f y o o lI P ll Fig The brake all four wheels on hydrauli are cally operated by foot pedal application directly which the cylinder hydraulic pressure of the brake operating fluid is originated As supply tank cast integrally the with master cylinder provides a reservoir coupled to a master in is by which the fluid replenished line consisting of tube inter connected and a pipe flexible hose and union the master cylinder Out Side 2 Front Brake and wheel This turn moves the the expand pistons brake proportion to shoe thus which in producing and efficiency in direct equalisation automatic out wards the effort supplied at the pedal When the pedal is released the brake spring wheel return the shoe cylinder pistons shoe which then return the and therefore the fluid and master cylinder the pipe mechanical An independent linkage actuated by a back lines into mounted drivers seat side This is cylinders hand brake generated in the master by application with the foot pedal is transmitted with the equal and undiminished force to all wheel cylinders simultaneously positioned on the right hand side of seat if the car has right hand steering and on the left The pressure cylinder FRONT The front by mechanical Operated the rear wheels expanders attached to rear wheel cylinder bodies BRAKE brakes leading system The shoes hand side if it has left hand steering with are are each two by the two wheel cylinder over allowed to slide and centralize automatically druing the which distributes ensuring high efficiency the brake disc caused by adjuster housing against the friction of the brake linings of front and rear constrocted force lining shoes and actual braking operation the braking the strongly 120 even area lining wear CHASSIS 55 Y TUBE f oftt I J It L r O BL NG tI r p S ao ft t T l RET INER plln h CYLlND H S Y Fig Fig Adjustment 3 4 for the front brake shoes of the bolts of adjuster Turn Adjusting of Front is H Brake direction until the shoe becomes by locked on the the shoe dru then turn back it until becomes just free form the brake drum which located at adjusting bolt I Frollt Brake L H brake the lower and upper position of the out side of the brake disc BCOl A I l means i to the left III SuN l IA o o c w pll Fig 5 Front Brake l22 L B ELECTffiCAL SYSTEM BRAKES REAR The allowed effect hrake rear shoe are not fixed but to slide and centralize with the in as front the They hrake hydraulically operated by are wheel and cylinder independent hand brake mechanism same are WASHER nylon ASS Y BRACKET hand brake control lSPR1rtaiNnGer loe k WASHER WASHER to fix BOLT hand brake bracket nylon PIN cl hand brake control SPRING nail hand brake control NAIL ratchet hand brake control COMP hand STEM brake control I WASHER nylon PIN clevis YOKE hand brake control Fig WASHER nylon 6 Halld Brake COlltrol Adjustment means of the for the screw outside of brake disc 0 rear brake shoes bolt which This located is by at the precaution should taken to eliminate the possibility of brake shoe drag due to mis adjusted parking brakes be I n I i 0 fl If I Turn r I turn JJ IJ II J A ttt J 7 Adjusting screw 2 3 notches tightly Brake Shoe 123 and then until the wheel drum turns just free from the shoe I Fig the bolt to screw direction back DATSUN o 0 Section A B I Dl ci 44060 10500 Upper side Sett1l 44118 JOOO I g jl of Feq Isio 4 eCt10I A Jrle 21 5 Fq 4407 44 00 JOOO 10600 f o I 41128 JOOOI j B B Section 41129 LI055 Adjustment JOOOI of brake shoe This precaution should be taken to eliminate the possibility of brake shoe drag due to adjusted parking brakes Turn the bolt to Screw direction tightly and then turn mis screw Fig 8 Rear Brake No 1 2 3 notches just free from 124 the back until the wheel drum turns shoe CHASSIS 85 A A Section 44118 30001 44030 10600ML H 44020 10600 4414131700 44142 31700 4414931700 I C SectiDn 31700 44145 31700 S 44205 10500 44081 04100 c J 44144 44084 30000 Fig 8 Rear Brake 125 No 2 R H Fitting Df wheel cyl DATSUN 55 COVER A SS Y LEVER tTOKICO B dust COVER duH LEVER htel TOKICO 8 PL BCO S SABCO TE TOKlCO PL HE i S 5 iDER CYLl SHIM A8CO 8 TOKlCO SHlM adJuumg adJuuln B NASCa J adjatlng A TOKICO SHIM oa SHIM SCREW bl ASS Y bral SHOE e SPRING fOle bralshoe return yhnder Ide CAP bleeder COVER dun COVER A TOK S A du BCO brake CUP r RI PISTON HOUSIN G e W SHER TAPPET bral hoe ASS e rerun V adJuulU adjuSI r bral WEDGE adjuster SHOE bral after e de ung TAPPET J SUT adJu adjuster locl Fig 9 Rear Brake L H BRAKE HAND The hand brake only and situated is operates on the rear wheels applied by a pull up type of lever along side the driver s seat l r I The cable tk j the control is attached to the toggle lever connected with the rear brake disc brake linkage is set when leaving the should not require any attention maintenance Only is should necessary when a c The hand under normal r Jf complete overhaul the hand brake linkage require resetting When this is correct be locked to the drums the i 5 works and rear shoes should t J f 0 the hand brake control just slightly applied and the wire rope set with the slackness just removed by means of a nut at the center rod of the equalizer drag link Fig 126 10 cyhnder wheel snap bra shoe SPRING PISTO l TOKICO RING snap NASCa G ASS Y LINING u p cylinder heel TOKICO from d e I LIISG NASCO adjuulng Adjusting Nut ABCO CHASSIS MASTER CYLINDER This is consists polished The inner The a with alloy body an filler cap and drain out fluid a rubber boot and and reservoir with cap assembly stoper plate ring spring of finished bore is made of the secondery piston pair of long nosed assembly can then be removed push rod return cap let out valve and check valve seat open end of the rubber boot as shown Fig pipe union from the securing bolts when cylinder the cylinder master the withdrawn complete from the with piston the cap will be all Examine Remove the ar the other small parts fluid reservoir may and removed When the push xposed therefore remove the piston assembly complete The assembly can be separated by taking out Disconnect the pressure remove been secondary is Brake Master Cylinder and has rod protected by disassembling the cylinder Pull back the the stopper ring with a The push rod pliers remove of distortion and replace cap with parts where necessary new the rubber especially parts for primary wear GASKET filler SET CAP ap s fille s SPRING eturn brake pedal SPACER piston up r 1 PISTON brake aJP piston secondary NUJASHER lJ i COVER dos ASS y ROD P J 1sterj ru s 1 Y VALVE i l AS s f T orWASHER NUT SPRING alve SEAT n alve BOLT I I IOCk i RING soap NUT BUSHING pedal 1 PIN fulcrum fulcrum PlN SLEEVE pedal shaft clevis brake master cyl STOPPER brake pedal ASS Y PEDAL brake Fig Bleeding the necessary any time a portion of system has been disconnected or hydraulic so low that air has entered the brake and the remove a to seat remove This process must all the supply hydraulic tank topped connections up with the fluid the cap from the bleed valve bleed tube over the bleed valve free end of the tube in of the other wheel secure a clean and Always keep immersing the jar containing a that quarters of pedal with a turn and a slow a screw cap bleed tube be repeated for each cylinder a careful check on the supply full level is maintained supply tank tion must be valve cap about three the brake then operate full stroke until the now bleed Should air reach the master the the bleed air the free tank during bleeding since it is most important fit the liltle brake fluid Unscrew of downstroke of completely during tighten the pedal sufficiently master is jar Then bubbles cylinder With the entering if the level of the brake fluid has been allowed to fall Cylinder Hydraulic System is Bleeding the Brake Master 11 correct full l2 cylinder from bleeding opera repeated bieeding top up the supply tank to its level of approximately three quarters After fluid the whole of the r DATSUN Never fluid use that has bleed been from the a brake system for topping up the supply tank as this brake fluid may be to some extent aerated Such one fluid must day be allowed to stand for before it is used again fluid lime to disperse in the and especially any part of the hydraulic system so where the brake fluid is concerned at least This well bubbles air Great cleanliness is essencial when dealing with allow fluid Dirly must be never added to the system to l ASS Y CABLE front RE TAINER fix rn a to l llg acket spring I SPRING j ARM Eo 1 PLATE LU 0 PIN ck clevlS f h nr to PIN cleVis t 6q c PIN den f to hx ablepIN b a1 ance lever NUT hand brake cable rSCRE brackeUWASHER plaln If to fix to wheel rod cylinder f leverl BRACKET hanger i W 1oss PIN BRACKET@ PIN PIN cotter djll Nul NU to flXbracket ROD cross hand brake cotter WASHER Fig 12 Hand Brake 128 fix cable to balance Linkage fa rod ROD cross hand brake short rod balance lever FELT ng CARRIER balanct lever to leverl long to cottoc to hanger PIN clevis 1I T PIN e CI rod d v tI co er rosa II 0 clevis LEVEK RING balance felt ra e tH e handk lock SPRING pull off TOSS rod A If N1PPLE grease 0 FERRULE cross BOLT Gl adjustlllg NltT hx od 0 ASS i CABLE hand brake after TO TRUNNION pIn hand brake cable to lever pull U PIN de brak lac k COMP SUPPORT balance lever o IrP P IoI u oJ r J ComblfOt rD el o tr1ttr1 o tr1 JIP I3 Il Combhun lamp lamp lamp lamp lamp lamp pilot pilol warm I lamp g O l1ll lompv r itch RighI Sid unit Tank lW 0 1 auQe itc Lamp Door InJl1me TUrn Mom Ignitu prul Wi3 TS IL OIL IG i 1 womlng Ilgnal beam Left u b I r d or lamp 2 n OIo 0 th nUl n DIm er tM B Combuled L I OJ ICSJ urn Hl swi r C igniton llr 1 k toc GII l i i col ur line c Block Whu B f w Red Gr R G Blu Yelow Y l Elet wneh witch lIghting Wiper i 1k r ll ll twitc lamp 1I SlOp l Bt j lff lH b molar nlLJJ 1 I Aldrm l Wiper r Speak AI 100 111 t plug I i ij 1Irl linn t Conectd Head ight R Hight Horn HClrn lo r u J llp lol Igmp Bolery lo alall lp RightlParun Onel turn IF Fog OO Right hl Porhng ligtIC omp l ft l 12t t ND o to C COnCl 1 Spark H rt F lomp H ft L 10mp C DATSUN 1 SCREW WASHER TI BRUSH cove d COVER BEARING over DIODE 1 set WASHER BEARING ball W ASHERl WASHERl BEARING K WASHER l BEARING washer Fig Alternator Mitsubishi 1 AL TERNA TOR Altemator Mitsubishi Denki Co Model 12V 300W Nominal output Constant side ground 2 Constant revolution No load minimum revolution current 000 1 500 r r p m 14V normal 2 500 24 5A up r 21 5A up 1 1 Note resisting Battery battery charged in full 73 Mitsubishi Denki Co Model Use Pilot lamp relay 3 contact point type RL 2BI Tirrill type Type Element leaf spring Put off voltage Constant voltage Pilot voltage relay relay lamp relay 3 contact 4 5 point type 130 5 2V Put 15V 4 000r p m m 14V 23500 12200 Constant 14 load 21 5A approx 14V high temp ratio Regulator Battery Load side 15V 4 OOOr p revolution p down Secondary side normal temp 2 500 r p m Pulley 14 Dynamo m temp p m valve djust Successive Pole Output Primary AC300 12WR on o 5 voltage 3V ELECTRICAL SYSTEM COMPONENTS OF AL TERNA TOR FOR 41 1 MAJOR 8 0 0 10 9 12 14 11 2 3 19 0 ljG L I j 181716 Part Name Part No Il 1817 Fig ey 0 1700 @ 13 lf0 1 Major Components Q ty Key 23100 14600 As s y alternator Ass y alternator Mitsubishi 12V 300W 1 2 23108 14610 23116 14610 Ass y 1 rotor 1 seal Washer 1 23159 14610 Grommet 23233 14610 Clip 22 23118 14610 Ass y 23 23121 14610 Washer seal 1 24 23120 14611 Bearing ball 1 25 23123 14610 Retainer 21 1 Mitsubishi 12V 300W 23100 14602 Q ty Part Name Part No No No 1 front cover 1 1 bearing 3 3 23120 14610 Bearing ball 1 26 23352 12210 Screw 4 23102 14610 Ass y 1 27 22203 32210 Wasber 3 23151 14610 Ass y 1 5 23131 14610 stator through Iy cover 6 23127 14610 Ass 7 23230 14610 Ass y diode 8 23133 14610 Ass y holder brusb 9 23135 14610 Ass y brush rear set 1 29 23152 12210 Wasber 1 30 23162 12210 Wasber 1 31 23153 35010 Nut 2 32 23139 12900 Bolt 9 15115 1 Washer lock 34 9 11245 1 Nut spring 2 23352 09160 Screw 4 ti 12 22156 01302 Washer 13 23156 14610 Ass y 14 23158 14610 Screw 1 15 23161 14610 Insulator 1 16 23157 14610 Insulator 1 17 22213 71311 Washer 1 19 20 Washer 23139 12210 Bolt terminal Washer spring spring to bracket fix 1 1 1 1 teminal 22203 22210 22203 32210 fltema 33 11 18 to 2 brush 1 1 1 Cover 1 spring plain X 10 23107 14610 10 28 4 Bolt spring puUey E Part No 23500 14602 Remarks Part Name Regulator ass y The con nectar was 1 23100 14602 Alternator 1 24299 14801 Connector regulator enlarged 1 24299 14800 Connector alternator in this l31 ass y type r DATSUN GENERA TOR Construction and Feature Different from generator turns armature making the DC generator the AC magnetic pole and fixes generates 3 phase alternate current and rectifies all waves each three diode it and takes out as direct current tn S A Tenn T l i Ito bolt ra k cet lon l It tn bn h n ulot A 8ail 8 11 N o a IocoW 10 M p e 0 It n l l Au U 2 1 Fig 1 Sectional View of Dynamo r @ sealed ball bearing The with the silicon that are built within the @ are r used to Clearance between the brush support the rotor and brush holder is also made so as to prevent from it dust Thus the AC generator will I increase Each 3 milage without maintenance diodes are pressed in the rear cover and the diode base respectively @ I @ Fig 2 1 3 Magnetic Circuit f sw C Relay i r R CD Field core I 0 I o o 0 s Field segment e I h Fig 2 1 2 Sectional View The at of Rotor clip ring pressed Field coil o Shaft I s I I L in tbe shaft is soldered both ends of the field coil to pass magnetic Fig current The pole circuit as are of rotor shown in makes out the Fig 1 3 and all magnetized by doughnut coil magnetic poles the J 2 1 4 Connection within Dynamo The armature is of a three type 132 and phase Y connection the silicon diode rectifies all waves ELECTRICAL SYSTEM It pulls out the neutral point and adds voltage Disassembly having conducted 3 phase half wave rectification in the circuit of relay and controls the voltage coil of the A pilot lamp relay and Assembly Disassembly The is disassembled in the dynamo following order r r I I 0 a l E j 1l SC o U 9 i Hi FC Dynamo t lePl I 2 1 Fig i O Charging System 5 Regulator 2 2 Fig 1 The completed is rhe parenthesized the part number for SP311 b l 1 ji 1 0 I f I r I I Charge pilot lamp Fig When battery the 2 1 Outside Connection 6 switch ignition current flows in the direction passing through the is put on arrow dynamo a t the marked E termInal brush field coil slip ring slip ring brush dynamo F terminal relay F terminal and IG terminal and completes the field circuit It in difficult for the dynamo to stand up only by Fig Remove brush residual magnetism of the field core so that magnetization is necessary until voltage rises to suit charging after the engine has started This is the voltage proportional the brush cover pull off 1 because the diode is used and when to add to resistance it is shows so low large to add to resistance it is shows so low t r up and current 0 t makes very high revolution This is because the diode is used and when large 0 c f 1 0 j 0 up and current does not flow through the field coil unless the dynamo and c dynamo voltage proportional 2 2 ea does not flow through the field coil unless the the 2 2 makes very high revolution Fig 133 2 2 3 the DATSUN Remove the the hex cover of bearing and take off bearing from the front or tightening the bearing plate and or pull off the bearing the Remove bol t of shaft d ball Remove cover with such as a the bolt hand press Slacken N terminal bolt side and the rear the and cover the on rear cover clip terminal the remove stator then be can separated g r oQ 2 2 Fig 4 pulley and pull off Be the pulley and the half moon key Remove nut of the hex careful not to injure the fan when the nut is removed 2 2 Fig e the Remove 7 and stator rear cover Separate the silicon diode 3 stator coil lead wire soldering I the P 0 2 2 Remove front the cover front cover Use a and and cover 5 functioning rear of tightening bolt cover pull off the wood or plastic iron seconds so 100 the at for then can be h y 6 i A Fig 134 2 2 the electric around 2 soldered portions if f 2 2 terminal that use 200W necessary Fig rear cover the stator and rotor hammer the When temperature within diode gear up over 150 C the diode will lose holt through by melting separated NOTE Fig on the clip remove rear from the ea ea with an electric iron Slacken N terminal bolt side and 3 8 ELECTRICAL SYSTEM the diode Remove and brush holder set Installation from the rear cover When be careful such B as not to lose small washers screws parts Assembly the heat sink or end Support and bushings which fits over Press down Assembly is done in the reverse sequence of disassembly Always make sure the polarity of alternator I case positive the i the or regulator shows coloured diode Fig or Black 2 2 AI n J k m Black Red k m mark 9 2 2 Fig Inspection 12 of Troubles Inspection of Output A For inspection of output Diode 2 2 10 ExPloded inspection removing it from View of AC remove a diode use support the end of the frame a generator of output of the as dynamo shown in dynamo the vehicle refer to to be without Inspection published later lAe suitable tool to or heat sink wiring 1 and drive it with motor For Removal To 3 Fig remove the vehicle and connect from Fig @ I l should be mounted in the frame of slip ring end and the black coloured diode in the heat sink Red i ff i red alternator ground of B I j lable which is attached to each model In the diode in the mount ing bore of C portion to the lower edge portion of the diode Checking the replaced diodes regulator before replacing the diode either The polarity of alternator positive or negative or regulator is usually marked on the name plate the a the outer diode edge A portion perfectly or or frame with suitable tool and then press the diode in the heat sink and end frame by using the tool shaped @ and l Ammeter Q push s the diode own out by using an arbor press as I le II Volt the below meter 0 Fig NOTE Press so 1 Use the battery charged in full up to the normal out 2 3 not to capacity injure the mounting bore of the frame Through the heat sink magnetic field Fig 2 2 11 the coil of revolution of 135 wiring shown current flows from the In this dynamo dynamo slowly up in Fig 3 1 battery to the state raise to the speed DATSUN where there is 2 A approx flow no reverse the field coil and read the revolution revolution is approx Next and the load current to resistance stop the Then shows one load of flowing and put off the switch current dynamo load almost alternately low resistance and the other shows pretty high resistance the 3 3 diodes in the diode set are all right When Without load 1000 rpm increase maximum at both terminals to Correct raising increase revolution of slowly Observe thus increasing output current U there is as revolution of no large difference from the specification increases dynamo it is correct No matter or bow the if the discbarged first make sure is in disorder inserting the battery charging either the is over charged current is small dynamo or the relay See the charging current by ammeter between A terminal of rei ay and the battery Disconnect Wire passing from the terminal to the F terminal at relay dynamo the relay A terminal relay charging current highly the at increases as When the the are is in disorder However Short Circuits on Diode Side flare a rare and also rare C judged if even Actually of be the the pilot lamp does not as short switch key trouble such as at the circuits there Ordinarily is turned diode open one result is obtained simple test and the many are often in opening checking will a b Separate Inspection are caseS Diode with Tester Simple Inspection 2 3 Fig Check shown for between in Fig the 3 2 conductivity Fig 2 3 4 Fig 2 3 5 2 terminals dynamo output A N as Set the dial of tester and put the tester needles 136 1 when one be necessary side short circuits Inspection of 3diodes when there is no disorder found on is very polar line are same is somewhat lower than the standard diodes It can same also all right in this B A E above when if the relay 3 Check between the terminals F terminal and make the removed lead wire short circuits 2 3 Fig F 2 by ELECTRICAL SYSTEM Check resistance with the tester between When the diode base the other shows high resistance commonly and lead wire on used for 2 diodes the rear cover 2 times no disorder will changing the poles side shows one be If both sides lnspectioll of there is low there are open Diode with Lamp Simple Inspection a Check pOSitive diodes negative diodes Method Lamp Test Lamp Method Connection Lamp Result Light Good Test Method Connection Should be Connect conductive to to Check Test Test @ are short circuit and both sides high there will be D low resistance and @ to@ @ EEl 8 Lamp Result Light Good Method Should be and non No Defective Light @ @ ductive 8 to to @ Connect con and No Defective Light to@ Should be Connect non to con @ 8 No Light and 8 to @ ductive Defective Light @to@ Should be Good con duc tive @ 8 to @andEjjto@ Connect to @ The soldering for the lead wires should be performed in less than 20 seconds as the excessive heat may Defective Light No Good Light damage the diodes J I C I o rii i 1 l Fig Check between shown in Fig Connect with and 3 the A N terminals 2 3 alternately as and 6 the lamp put both ends 6 12V at A and N in on diodes straight terminals l3 the of On one side the lamp flares other the lamp is off the diode set are all when 3 right DATSUN Fig 2 3 9 Check between the lead wire and lhe diode set common wilh lhe olher 2 diodes or lhe with lhe lamp and rear cover is all right is off If bolh sides flare circuit battery It if one side flares and the olher and bolh sides lhere is short are off lhere is open E Fig The same terminals is step N all right is all right is E taken between lhe result in lhe cover if lhe simple test but when the lower lhan lhe standard so same pressed However often be opening Field Coil 7 When lhe 3 diodes obtained are 2 3 Inspection dynamo output 1 that one is 2 diodes may by one check will be necessary b Separate Inspection Fig As shown in Fig Fig 2 3 8 tween 6 7 j the slip it is all ring 2 3 3 of right 10 10 put lhe tester be rotor and Make sure conduction between lhe rotor slip shaft 138 if lhere there is ring and are no lhe ELECTRICAL SYSTEM F Ball Both Connect the tester cord to IOOV wire Bearing sides sealed ball the stator bearing is used tester so lubrication is not necessary G Inspection of stator the turn of the ammeter Armature there is If the ammeter reading abruptly trouble no put test stand and make the short circuit on the coil there is Conduction Test a one on swings increase and there will be if no change If the terminal connected to the diode is not conductive with the is all stator core that H Inspection of Brush right Wipe with clean cloth when oil or dust is on the contact Same as surface of the brush and slip ring in case of DC generator replace the brush when wear of it reaoohed to the wear limit REGULA TOR L Construction and 1 Operation Construction Fig 2 3 11 Fig 2 3 12 If each terminal terminal connected conductive b of the coil and Fig the to N terminal are not Operation of 2 that is all right 3 1 Constant 1 Voltage Relay r Layer Test I 0 I e Isc o I I s Fe Dynamo 3 1 ignition switch is through battery passes terminal the 139 field coil dynamo LEecril 2 When the 13 c J Fig 2 3 S E I Fig O o I II c T J a I the III R is contact magnetized on current from the points dynamo P2 PI E and DATSUN While it alBa flowB the contact pOints regulator E terminai iB kept and continueB charging evenly and the lamp flares PS P4 r I r r I I I c I 0 I I I sc Cl U r I I I I l I Dynamo I L II In I I I I I I I I I I I o I L RegulatornJ lbn J 3 1 Fig 3 iB When the the movable piece on three phaBe alternate current generates the stator coil pas Bing through the three contact point Pz phase all direct wave current Btarts and the rectifier diode dynamo and changeB the terminal A E for between between A E terminal generates and N terminal circuit voltage pasBes coil VCI with action of the VC coil half of voltage RZ VCZ through the the movable contact I I I I I I field I Dynamo Regulator J L I c tl a S Fe Jr I N namo Dy contact point flows through Pz secondary voltage When the dynamo the terminalB As 3 1 VCI 4 revolution goeB down and the coil N E result weakep s the circuit of PI dynamo voltage between the electric magnetiBm of and the contact point can Ps fixed not continue contact and changes to P side and lights the 4 the current With E terminal lamp indicating P6 the alBo lowers with the movable piece contactB With 6 charging capacity reduces J Fig 3 1 J The operation of this time is called a high Bpeed operation and the adjuBt voltage iB called t 0 always kept evenly Fe u I voltage I and when the IL R is voltage Fig ISC and lsc r I I RI and the terminal I dynamo revolution getB higher the point Pz BeparateB from PI With electric magnetiBm of the VCZ coil and the field current I reBiBtance P3 E I contact HI dynamo I I When the F terminal and reBiBtance BeparateB from the generated AB the reBult r then voltage relay coil that current BO P3 I E terminal P2 through terminal dynamo VCZ coil animated and prepares to vibrate the movable contact point Pz of the conBtant dynamo P3 At such a high speed with open goes up again and close of the contact pilints the P2 and the from the circuit of the and the movable drawn goeB down F terminal field coil E terminal and coil and A terminal iB BtickB to dynamo current from of that point Ps leaves from P 4 and makeB contact With P6 BO that the lamp iB off and it paBBeB through the circuit E terminal contact pointB PS P6 reBistance still higher dynamo revolutiongetB the contact point the N 5 almOBt does not flow the field and the to charging At re I driven When the engine l I I n 3 1 Fig n 1 I Regulator I J gr I S Fe I o I tl J I t ISC t 8 aT II j I l a I non generation ThiB iB repeated vibration of the When the ignition SWitch is turned off to stop the engine the lamp goes out and the current to contact terminal the field coil is field coil F terminal contact according to and the dynamo point Pz pointB Pz PI voltage 140 Buspended ELECTRICAL SYSTEM 3 Operation of As Pilot Lamp shown in Fig 3 1 with the contact points contact point is P5 2 N terminals E the First put on the lamp with connection shown in Fig 2 2 and read the voltage this is made up The P5 and P4 P6 N Between the 4 movable piece is drawn when voltage half of the battery is added and From this state volt split point the between N E terminals is conspicuously reduced makes contact with P 4 voltage to make contact with sary for P5 voltage and Put 2 on that P5 is P6 changes from P6 P4 is 3 voltage Check a is 4 2 the rubbing resistance put lamp flares voltage on 5 2V it is all If the and the put on Adjust of Constant is right Adjustment of Gap Constant Voltage Pilot Lamp Relay voltage adjust values of the voltage relay and the pilot lamp relay 2 3 as shown in Fig The Value put off voltage Put off to Adjustment 1 is 5 0 3V o neces move and lower the voltage and read when the voltage This again The voltage between N E terminals betweel E P5 fixed to the movable piece separates from P 4 and makes contact to When the voltage P6 P5 as by putting off the lamp moving the volt split This is a put point of the rubbing resistance off voltage the movable side and on makes contact with P usually Relay Voltage constant must be Relny Gap 0 1 g u 3 2 Fig Connect the shown battery and make the G2 Gl J Constant 0 8 1 0 0 o 8 1 2 o 8 Voltage Relay 1 almost charged in full revolution dynamo Pilot Lamp as 7 G3 0 9 o 3 0 4 1 o 1 1 8 1 Relay with 4000 rpm When the is all 2 voltage of this time is 14 15V it right Check Voltage of Put off Put on Auxiliary leaf spring Pilot Lamp Relay r I L I I I I Thrusting I I J esistance I I I I I Fig I N r 3 2 3 I I p l I 1 p I p I 4 I I Put off voltage of the constant voltage I E VC2 R2 I I I I I and pilot lamp Adjust I I L n Adjustment of Voltage E and donw the relay voltage by bending 3 2 2 141 the stopper up adjust value Bend upward to heighten and bend downward to lower Fig relay adjust value r DATSUN 14 ITEMS ON HANDLING Prohibition Reason 1 When mounting on vehicle polish the contact pOints on both sides removing point rust or oil 2 Make sure pitch of the engine side pitch and dynamo side cover are well fitted together the front 3 Be attentive to the belt tension 4 Regulator removed sealed is during the lead with seal If the claim period the claim is will invalid 5 If the earth is not correctly set will change 6 Connect the the adjust value and battery with full attention dynamo When the battery poles battery dynamo to ages of diode 7 Make the whole sure circuit is completely or are connected in current flows large reverse from in dam resulting lead wire com posed 8 Change wiring with full attention When after dynamo is switch the engine started the magnetized from the ignition that so incorrect wiring will result in hampering magnetization and then generation I 9 Do not use the high voltage tester such as megger I As diode is built in damaged 10 Engine room must be kept in the condition of stand ard usage Because 11 Do not the battery terminal during driving vehicle separate terminal there deteriorate ature dynamo the diode will be with high voltage or higher is diode will be damaged with temper than the normal Separation ofthe terminal voltage which within battery causes and serge dam ages diode 12 When cleaning with steam cleaner do not expose When washing with dynamo to steam directly water dynamo must be free from reckless pour of If the diode is mance moistened the perfor will be lowered water 13 When the battery charger the dynamo 14 Put the is lead A terminal key quicklv charged with the quick regulator A terminal wire or Serge voltage also damage of the quick charger will diode should be disconnected switch off when the engine in a stop except when particularly needed When the key switch is on magnetic always flows on the field coil and might damage the dynamo and often causes over discharge of battery current 142 ELECTRICAL SYSTEM TROUBLE SHOOTING LIST Trouble 5 1 Over Cause Remedy discharge of battery 1 Slackness of fan belt 2 Earth or 3 Breakage of 4 Mal contact of brush and slip ring Mal function of diode 5 Adjust breakage of stator coil Repair or replace Replace Replace blUsh clean holder Replace as a set rotor coil 6 Adjust voltage 7 Mal contact of low speed side contact point of constant of constant voltage relay is low voltage relay Polish contact point 8 Adherence 9 unfitness of electrolyte Mal function of battery pole short circuit Add distilled water 11 Mal contact of battery Clean 12 Mal contact or breakage between ignition switch 10 Shortage and of Readjust high point relay terminal IG terminal Mal contact 14 Excessive electric load or terminal and Over contact or 13 5 2 side speed 1 Constant voltage Constant 3 Constant between regulator 4 Constant F terminal Repair Check power consumed 5 Constant voltage relay adjust voltage voltage relay coil is too breakage or high Replace voltage relay coil straight resistance Replace voltage relay low speed side contact point adherence 9 Replace relay high speed side contact point mal contact Breakage or rare short of pilot lamp relay Mal contact of pilot lamp relay contact point Mal function of regulator earth Mal contact or breakage between regulator N terminal and 5 3 Noises Readjust rare breakage 8 repair retighten terminal F short 7 check S G or charge of battery 2 6 Replace Repair breakage dynamo Replace dynamo N terminal Polish contact point Replace Polish contact point Adjust Repair of Dynamo 1 Mal function of 2 Mal function of diode 3 Earth or rare bearing Replace Replace diode Replace short of stator coil 143 as a set r DATSUN STARTER MOTOR with the the right switch direction to move and starter switch ignition By turning the permit relay the switch to magnetic current to flow to the the armature cause on to start turning suddenly CONTACTOR ARMATURE BRUSH Fig Type S1l4 92 Make Hitachi After Weight 4 6 completes kg S114 Type Rated Output V Kw 12 92 1 No Load Rev rpm Brush Normal Height mm Brush Wear Limig mm 4 5 kg o 8 Spring Tension Commutator Above 7 mm 14 33 Dia rom 2 bending torque reducting After the engine starts and speed becomes greater than the no load speed of the starter the pinion is kicked back to unmesh and return to its former position 000 rom pmlOn its 60 Dia the shaft towards the starter bracket thus Magnetic V Under 12 14 the 0 No Load Current A about advancing meshing into the ring gear and drives it with a powerful torque The direction in whicll the pinion moves is from the end of the the Meshing Device Brush Magnetic Shift Type 1 Motor Starting STARTING SWITCH CONTACTOR Commutator Wear Limig Pinion Operating Voltage Gap V Pinion Under 8 3 5 mm RING GEAR PINION SLEEVE SPRING Construction and The starter sliding inertia on the The similar to in that its with in a Fig The 0 horsepower motor for directly opposite that of the Fig in 2 A View of Starter System engine to the ring Operational generator but differs only Precautions armature shaft extends out backwards pinion group installed 1 use construction of the starter motor is on The instructions to be observed when the end as show the engine 2 connection shown in Fig The 1 a front right side of the transmission with its pinion gear gear is The motor when mounted on the starting is motor type electric 1 PINION SLEEVE SPRING 2 Operation diagram for the starter 1 switch is a key type starting follows is 3 starter are as combined The the 144 starter should be securely engine and should not mounted on show any looseness ELECTRICAL SYSTEM PIN ASS y lever PIN lever ASS y ASSrY switch I cotter pinion shift magnetic shift case gear n o SCREW Fig 3 set pole core Hitachi starter Motor Checking 2 The starter switch should be and should be release properly operated 1 immediately should engine normally switch starter engine fails to start come to switch rest is weather start within the engine does through the 10 should not be operated running gear allow time for the pinion to before turning the starter engine fails the starter continue key for turning to save the for the starter is used when the the current is flowing motor coil but for some the armature is not turning Careful should be made since the starter in the and unable to return a flywheel ring trouble caused by turning on the starter engine is still running usually while the again When the try not start pinion may be locked If the engine 2 4 and with the starter switch lamps lighted lamps become dim especially reason when the fully charged battery a check The Operation If the seconds 3 in the when the engine starts Excepting in extremely cold With While cause the to over key battery When the starter switch is turned up and the start after turning 10 seconds do not remain lime after time but checked If the switch In this case condition then starter motor fails to turn check of the trouble and correct terminal so that the engine will start battery 145 bright and the the should first be is in condilion ground starter although the lights switch satisfactory of all the connections of the switch and starter are r DATSUN checked If the starter motor movement is sluggish resistance high the starter it runs taken but its indicates either when inspecting to flywheel and take remedial a to loose connection in due circuit or the badly discharged a If after the above troubles are corrected and the starter fails to operate internal defects that in this so 2 occasionally and shows defective performance it is due to same are Dismantling and starter starter on the to be two dismantled stud nuts core the check the armature shaft in bushing etc that for the as to shaft gap bending manner in the generator and corrected to the specified limits is not easily by mounting the replaced the or attention Special and corrosion found contacting outside surface of the armature surface of the engine The two stay bolls on the starter rear cover front end when mounted on the engine are removed core should the on the inner or be removed by and the surfaces painted with rost polishing 2 replaced should be given to the clearance between the armature and the core to see that they are Disassembling can the removing the inspecting clearance it should case When armature The if the When damaged pinion is found defective pinion group armature be dismantled and checked 1 check the entire battery 3 gear is found worn or ring also measures preventive oil 3 The armature inspected is and repaired in accordance with the procedures outlined for 3 After removing the band cover and lead wires are removed the broshes the broshes 4 By properly body starter and protecting the armature holding the Especially generator correct the are brosh brush The insulation At the same checked spring are corrected or replaced shaft is pulled improve contacting condition reseated the to or the time and are out 4 5 The out 6 and the front armature taken cover are the remove shaft armature pinIOn group from the 5 the cotter pin on the end of the nut and Inspection The same inspected after or group Repairing procedure parts is followed as pinion the as is which determinations they can be reused replacements are necessary pinion tooth face damaged the generator a or are if shaft will weak or cause especially strictly tested part one by buring should be test only L dimension For this last reason between the pinion in Fig 4 must be following L 0 3 5 mm adjust plunger gap of the magnetic switch by following paragraph b Pay attention that theLdimension must be measured when the pinion is pushed wear on out by the shift lever of the atmostly plunger and the back lash ofthe pinion is eliminated by pUSh ing gear inward with finger as Fig 3 shows poorly meshing in the armature care clearance In case that the Ldimension is incorrect make the but will hasten the bending correct stopper and pushed out pinion which is shown by inspected for defects and if the the worn or tooth edge is the pinion should be replaced poorly found with Meshed Pinion Position by Magnetic Switch The made repairs is opposing gear and also gears carefully are with ADJUSTMENT is Worn or broken teeth will not gear mesh wires found parts being cleaned and to whether The armature by the insulation 1 1 the wires removed Parts that for lhe An damaged the shaft is pulled out and by removing the pinion on damaged insulation should be replaced together To and inspected If the L dimension is incorrect should be 146 It wll1 be the ELECTRICAL SYSTEM possible cause wear and of large meshing noises or of the pinion damage and early ring gear 7 Y I 10 1O 3 1 Slltllt 1 Fig Fig 4 Checking 6 Measurement of Plunger Cap Dimension l 1 t r Battery 1 CH I r J Fig 5 I of Adjust Cable Connection Dimension Adjustment of Plunger Gap of I r T Magnetic Switch The o dimension when the plunger gap is L compressed L 31 7 This to 0 must be following in t I 00 b i Fig Fig 6 a o Removing Magnetic Switch 32 3 mm adjustment is carried out at the adjuster and the adjusting nut DISASSEMBLING AND ASSEMBLY OPERATION 5 1 Disassembling the Armature Gear Case and Pinion Disassembling Fig order is shown by Fig a to c o Disassembly is operated by removing magnetic switch fixing bolts through bolts and the armature shaft clip Before disassembling main fixing body remove screws as brushes by unscrewing brush Fig 0 Q 0 I Fig b Drawing out Brushes After removing fixing screw 6 14 rj DATSUN ARMATURE PINION STOPPER o Fig c Drawing Out Yoke Fig f Disassembling o Armature GEAR CASE SHIFT d Fig Disassembling LEVER Armature and Fig g Gear Case Removing Pinion Clip SL EEVE PINION SLEEVE SPRINC3 PINION seREVV Fig e STOPPER CLIP Id DRIVER Removing Pinion Fig Stopper 148 h Disassembling Subassembly Pinion ELECTRICAL SYSTEM L 0 8 oo 01 1 o 0 o 0 r r e M OIV Q MJJ i Fig DisPlay of all Component Disassembling Pinion the current magnetic Disassembling is carried pinion clip as Fig g will Assembling of sequence be out by removing in magnetic B and Testing R oassembling is reverse frictional 8AE 30 parts are Starter disassembling are All coated with 82 switch opens the opens Releasing magnetic the wire coil to the body 8 case of switch lies in the 81 opening but In either case faulty moving the of the roughness ofthe contacting point Therefore polished the surface then the operation will become surface the starter well circuit which also satisfactory Causes for mechnical troubles for operate can mechanical magnetic be switch failing to cases divided into electrical and core sources 82 Causes for electrical troubles to the starter can freely 149 caused in cover many hole be made in this the cover screws retightening them switch in pressed and is sticking against the Correction Current failure in magnetic circuit operate by the guide shaft on the moving of the magnetic switch main clrcuit loosening When magnetic and defective ground or core 82 Causes A from switch opposite Failure 1 wire add the remaines closed trouble a 82 to close coil Defective contact in main circuit the small amount of grease circuit in the magnetic switch and causes the main circuit in the magnetic circuit trouble is magnetic circuit is satisfactory and 82 is closing but only a small current flowing due to high contact resistance and lubricated with mobile oil while the bearings of the the When the performed by following the for procedure through pass most terminal connection At assembly check each dimension and major specification standard Assembling magnetic switch reverse disassembling operation circuit to due to broken soldered connection between the done falls so 4 case pieces that the shaft by and moves DATSUN 2 Construction of Magnetic Switch Precaution and Instructions In removing nuts from the magnetic switch main circuit terminals when installing or magnetic switch is the engine is being started by removing cables the lower nul of the double nuts should be kept in a tightened state while to If the lower unscrewing nut the is loose terminal bolt may turn together and ground the terminal to the cover and cause damage Remedies The following is a from installed on the engine 1 is engine cranked by state starter flow starting actuate the when the or switch serves to a large starter keep the current to motor is engine After the stopped circuit open the starter The is m CONNECT TO OlHERS to see if checked it can be hand the engine is at fault If it can be cranked and should be checked starter the be should and permits motor and IGNITION SWITCH If it cannot be cranked easily serves close the circuit between the battery and the Starter fails to turn The apparatus when shift lever list of troubles which can the be determined an principles of operation can be seen from Fig 7 Closing the starter switch 81 allows the current to flow through the magnetic and Then Causes Starter Troubles The checked the including and BATTERY wiring correclion made accordingly Is the battery gravity 1 over battery of the battery and 240 as Check the specific down run fluid to recharge see If there is trouble in the magnelic circuit found necessary tightened Magneto grease or Gargoyle BRB No 1 All cord connections are carefully tightened given to the condition The assembly check is made attention of insulation by testing the starter as a fully charged battery with a starter motor apparatus shown in Fig torque is measured a single unit 4 be 9 this m checked made case all the assumed the ce l I 7ffiVolt Startu the to see with their itself so that it usually improperly 15v Gl can 500A forth motor Torque Testing Apparatus to repairs 150 wt care should be ring gear by badly Cases like this worn are gears meshing and if the defect is not too severe it by placing the gear shift lever be remedied into fourth Battory 12v rare that the starter pinion is not locked speed and rocking the free the the car back and If this trouble is gears repeated dismantled from 7 should replacement checks starter exceedingly flywheel frequently Fig above in the be caused Ammeter dynamometer of This is into the Bai or should be removed from the engine and checked kg mot corrections corresponding repairs have been made and the starter still fails to operate the trouble can be taken to Starter whe and found necessary as If using with starter broshed the broshes together with the armature by which braking In normal value should be 0 or improperly contacting For Tests are made tester it should be corrected cleaned and properly special Starter Circuit Magnetic replace the or All loose battery and ground cables should be and 8 Fig if it is starter the engine for should be checking and ELEOTRIOAL SYSTEM 1 Starter turns but its and fails to start the turning engine If the trouble is due to worn damaged are described in the If the outer etc made in the or the dirty and checking same manner as preceding chapters surface of the armature is the starter should rubbing against be dismantled disassembled and repaired the deformed are noise Rattling mounting bolts there is the case of the loose starter by brushes improperly contact required correcting as this ing condition not only produces noise but will hasten wear on the by the large a and the bushing rubbing against the worn parts should be between the shaft and replaced bushing is due to lack of oil so that attention should be given to proper lubrication so Wear grade once every half year using good of machine or mobile oil and lubricate through the oil nipples required is about 0 5 amount of oil each bracket 151 armature while in operation is caused by too clearance between the armature shaft Lubricate when operation both parts core shaft should be cleaned and oiled screw exceeding noisy by corrected by retightening Noise caused guide on the pinion shaft being dirty and not allowing the pinion to advance smoothly and causing improper meshing the Starter caused are the bolts the parts 2 they should be repaired the gear replaced Noises made If the trouble pinion meshing improperly is due to the gear teeth being badly worn the gears should be replaced but if it is due to gear is checked and if the the armature the core Besides the above flywheel ring The teeth down battery and sticking brushes commutator and repairs run troubles in magnetic shift loose terminals switch a power is weak The cc for r DATSUN BODY DISMOUNTING ASSEMBLING Parts Body Mechanism of Hood Bonnet top the Hood Lock Disassembling To completely remove the hood Bonnet top simply a matter of detatching the bolts of the hood and hinge at each side visible when the hood is remove after disconnecting the support is Detach the grill of radiator from the front of body Disconnect the relurn spring of the hood lock lever from back of the radi r top frame of it Assemhling of the dismantling process hood is a reversal of Hood Lock To adjust the position of the hood lock bolt for the hole of the radiator top frame To remove up or down way By removing the nut at the top of the center bolt of the spring unit the spring center bolt etc can be separli d from the hracket to the bonnet top To remove left or right side way By removing the position of the hood and hood hinge to left or bolts can he adjusted Disconnect the Return right side Adjusting Remove the hood lock lever working clamp Detach the loose through assemhly of female from the front panel the lever the hood lock cannot he hold the hood tightly Adjust by removing the position lock lever as showing the figure Adjust the Position of Hood from its lever the Hood Lock Lever In the event of the hook Spring the direction of the hood Disconnect the Hood Lock Male Assembly from the Hood Lock Lever 152 BODY Assembling of the hood lock reversal of disassembling routine system Front Fender is a Detatch the front bumper Jack up the front wheels and take out the Disassemble the head tire lamps and parking lamps from front the Remove the body antena assembly Detatch the fender milar and side emblem Disconnect the bolts and the Disconnect the Hood Lock Female Adjusting the Position for Upper or Lower Direction 153 figures screws as showing r DATSUN moulds inside and out must be removed also the door glass must be removed from upwards through the main aperature the door Front Dopr Front door trim 1 Take out the door inside regurator handle shown the figure as handle I I T3 panel lO I J J T3 261 2 Assembling of the front the disassembly routine fender is a reversal of Front Door Window To a front change the door trim the drive door window first then lower the window screws that secure remove Extract the window rear channel to the door frame Rear Door Window The window routine same is door window instance front bracket and for removing a rear as that outlined for namely removal of trim adopted window regulator channel In a door front in this window stop addion the window 154 Take out the moulding garnish inside and wind BODY Remove the the front door finish as showing in Remove the figure Springing fixing bolts and screws as show ing figure Door Trim Clips from Assembling of the front door the disassembling routine is a Remove the Front Door Ventirator Door Shell reversal of Front Door Glass Take out the panel of front strip the vinyl Loosing the cover on the screws door trim and operation hole remove the door regulator Unscrew the Bolts Detaching Door Screws Regulator T3 245 Remove the Velltilator Glass Frame 155 r DATSUN The door glass be removed from must the door upwards through the main aperture 1 Remove the nut 2 Detach the of pivot pin and the spring rivet and then remove the venti lator window Remove the Door Glass 3 Take off the lock of ventilator 4 Removing the front door glass from the Change bezel of channel 1 Remove slightly the glass of channel the the front glass as same as glass replacement method the of Door Lock Mechanism by tapping with wooden hammer Removing 1 Detach body the door trim panel from front and strip the vinyl cover the of the operation hole 2 Take off the 2 numbers set screws and detach out side handle from the door I tt J i 0 I To fixing for the channel insert the v 7I r 8 i I 2J glass with the weather strip in the bezel and tap b 18 with wooden hammer slightly Detaching r 156 Outer Handle J I I BODY Loosing the of front door in the detach screws the lock remote control assembling as the shown figures e i T3 257 Remollal the 3 Remove cylinder the and Retaining retaining plate of detach the Plate the door lock cylinder assembly Front door 1 Removing the pin of the door check linkage detash the check link l3 56 Extract the Door Lock Cylinder 2 Detach pillar the bolts of door hinge at the front take off the door assembly Wind Shield Glass Removing the wind glass Unscrew the Front Door Lock IS 1 Extract the 2 Detach the shield 3 Strip out contact portion between the weather strip and the body with a spatula wipper arms molding if used DATSUN 4 Detach the front wind strip carefully as glass with the showing the figure weather 4 Offer the window to the car 5 Remove the weather wind maintains pressure the detached strip from glass assembly on aperture frame of the from the outside and whilst on the inside of the the car glass 1 Assembling material glass gloove erture outer rubber to the wind sheild insert sheild front Iass body the above assembly the edge over which will the scuttle bring the side and Finally peel out the cord so that the rubber lip settles over the fascia side fillets and headlining Pushing or tapping the front wind ghl sS assembly from the outside of it assemble the glass as pulling out the cotton string to a right angle slowly the prepared wind to lip over top window frame insert the strong cotton cord to the of the weather strip inside around of it 2 Then the ap operator then The outside arrange the outer the weather strip with the sealing cemendine 366E frame operator the operator should peel out the cord of the inner lip which fits Fixing the wind glass assembly one frame of the where the bezel is to fit t 3 To assemble to fix for the frame Two operators wind First glass are essential when fitting the 5 glass the rubber must be sprung over the which fits into the deep square groove whilst the large portion of the bead bulges 6 and bead on sealing compound between up to between Clean and spatula Fixing glass 158 sealing the wipe around the of the front the outside face the 366E material the inside of the curvature Next insert Filling material weather off the the excess weather wind glass glass fixing rear cemendine strip and body strip sealing by a is a same method m
