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Download Datsun 510 series Specifications
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l 0 p1ffj i 1 l i t V 10 Ji f t f jrtcJcr Ii I t t If it1fi 1 1p 1 H kt 1 u 1I 1 L a Ep p 7 l 1 MODI r tq v t t t i J 1 VV I J J e r fiE P j f Af f7 f y 0 in V c Y j o 6 C J l f o ro rJa 0 e c r 7 @ J @ m U @l @loa 1o 1J Jf J n l o If 2 NISSAN MOTOR CO 6 171 G1NZA CHUOKU TOKYO CABLE ADDRESS PHONES JAPAN NISMD TOKYO 5431 5523 L TD i j i 5 t JW f i a 1l t 1if I 3 manual This h 1 o i J W lti has been 1 complies for purpose i assisting DATSUN 1000 distributors and dealers for effective service and maintenance major of the Model B10 Series components comprehensive assembling It is is described instructions are in Each assembly detail In given for complete dismantling emphasised that only genuine DATSUN MODEL VB10 1000 Spare replacements DATSUN 1000 addition and inspection of these assemblies Parts should be used as DATSUN of the 1000 MODEL Bl0 e t l ir Jl fi CONTENTS Page I GENERAL SPECIFICATIONS IX SERVICE DATA 1 ENGINE Cooling System 3 Lubrication 9 SERVICE OPERATIONS WITH ENGINE IN POSITION Rocker Mechanism REMOVING 17 18 REFITTING 27 Operation with the Engine Removed 28 IGNITION TIMING 47 Distributor 47 Adjusting the Ignition Timing 48 Troubles 50 Remedies FUEL SYSTEM 53 Carburetor 53 The Gasoline Tank 57 Adjustment and Inspection of Engine 62 CLUTCH 67 TRANSMISSION 73 CHASSIS 95 STEERING steering 95 Gear Housing 99 FRONT AXLE Dismantling the Front Spring 103 Front Hub 105 106 Upper Link 108 Lower Link 108 REAR AXLE Inspection Repairing of Disassembled Assembling Adjustment 109 Parts 115 116 BRAKE SYSTEM 125 PROPELLER SHAFT 131 REAR SUSPENSION 133 r DATSUN 1000 ELECTRICAL SYSTEM Alternator Generator Handling Shooting List 140 140 14 Items on 149 Trouble 150 Starter Motor BODY 137 151 159 DATSUN 1000 GENERAL VIEWS OF BID 1 180 1 I i 1 l o II i l 1 LL f n 1 1 I i 1 1 I I 0 in 1 I i Ii I 1 385 II c I I b 1 190 llf O Full width 1 280 t62S s 445 Full length Full without the ider 3 800 dude the ider 3 820 length GENERAL VIEWS OF VBID r i Ai 0 t i Of j n n 180 1 in I 0 0 N 0 1 LN L 1 1 I I 8 I I I n 1 h 1 2 Full These specifications are subject to 280 length 3 800 change without notice 28 5 DATSUN 1000 o GENERAL SPECIFICATIONS B10 ITEM VB10 S T D Deluxe 3 800 mm Overall length 149 3 6 in 1 Overall width 820 mm 150 4 in S T D 3 Deluxe 800 mm 149 445 mm 1 345 1 2 1 mm 280 89 1 LL 8 in 93 7 in 1 1 255 mm 100 1 1 1 Rear 1 1 mm 160 road clea 6 O H to the F E w o 22 O H to the R E w o 3 625 Vehicle weight Max Max 6 23 0 in 850 4 in kg 7 in 585 mm 8 in 3 645 kg 1422 lb 1378 lb mm 170 mm mm 3 in 875 mm B 180 46 6 in 580 mm B 190 mm 46 9 in 46 6 in Min mm 32 7 in 190 mm 180 160 830 mm mm 46 9 in Tread mm 45 7 in 43 3 in Front 285 50 6 in 48 2 in LH 385 mm 2 280 mm mm 630 mm 1 LW mm 54 5 in 64 2 in Room space 445 4 in 56 9 in 53 0 in Wheel base 820 mm 150 56 9 in Overall height 3 6 in 645 mm 3 in kg 665 1422 lb kg 1466 lb Right 49 49 Left 49 49 LA speed 135 km 135 km 100 MPH 100 MPH 130 km 130 km 97 MPH 97 MPH I d r DATSUN 1000 Grade ability sin I o 387 8 o 379 o turning radius 13 131ft Model A10 Manufacturer NISSAN MOTOR CO Classification Gasoline Cooling system Water cooled No of cylinder 0 40 40m Min I 306 m 1 ft LTD 4 in line arrangement Cycle 4 Combustion cbamber Wedge Valve arrangment o H V Bore x Stroke mm 73 x 59 Displacement l o 988 8 5 2 87 x 2 32 in 60 3 cu in 1 Z Compression ratio Compression pressure 0 Z kg cm r p m r p 12 0 350 48 4 000 975 3 600 1 01 t Max exploding Max mean Max power HP Max torque SAE Length x pressure kg cm effective pressure kg Width r x kg Height Weight r p m 62 6 000 SAE p m m cm m r p 8 5 4 000 m mm 547 x 553 x 590 kg 91 5 Position Front Type of piston T Slot Material of piston LoEX No of Piston ring 61 5 ft lb 4000 r p Pressure 2 Oil 1 II m 301 1 GENERAL SPECIFICATIONS C Intake open 12 B T D Intake close 48 A B D C Exhaust open 50 B T D C Z Exhaust close 10 A T D C C Z Intake mm 0 35 Exhaust mm 0 35 Valve timing Valve Clearance Starting method Starter Motor Firing Method Battery coil type Ignition timing E Ignition order Z 0 Ignition coil B T D C r p m 8 600 1 3 4 2 Type C14 51 Manufacturer HITACHI Type D412 Manufacturer HITACHI Type L45 Manufacturer HITACHI E 1 Z C Distributor Z 0 E Spark Plug Z C Thread mm 14 Cap mm o 7 0 1 8 Type DCG286 Manufacturer HITACHI Throttle vlve E 53 3 26 28 bore mm Venturi size mm 20 x 7 Main jet mm o 95 1 Slow jet mm o 0 Power mm 24 x 7 Carburetor p Air jet o Down Draught 1II 80 60 40 oA TSUN 1 l r 1000 Type Paper element Manufacturer T8UCHIYA Type Diaphragm Manufacturer 8HOWASEIKI Fuel Tank 35 for B10 Air cleaner f ell ell l l r Fuel pump Capacity 30 Lubrication method Forced fuH flow Oil pump type Trochoid type Oil filter Paper filter Oil pan 2 for VB10 Lubricating system Cooling system Generator arter 5 Type Pressure feed water cooled Radiator Corugated fin Capacity of cooling water Type of Battery capacity water pump 4 5 Centrifngal type Thermostat Pellet type Type N40L Voltage V Capacity A 12 H 40 Type LT125 Manufacturer lllTAClll Generating method 0J Alternator Voltage V 12 Capacity W 250 Voltage regulator TL1Z 10A Type 8114 87 Manufacturer lllTAClll Voltage 12V 1 power V HP IV tube type 0 J GENERAL SPECIFICATIONS Type Single dry disc u E Number of place 1 1 U Out riI dia In dia Total friction area x x Thickness Facing 2 mm 160 x 110 x 3 cm2 212 2 U riI 0 4 Forward 1 re all synchro mesh on forward verse gears gears Remote control Floor shift verse Type Z 0 Z 0 3 Forward 1 re Operating method mesh all synchro on 1st 3 38 3 76 2nd 173 2 17 3rd 1 00 1 40 Z p Z E p E Gear ratio 4th 1 00 Reverse Propeller shaft Length x 3 64 Out dia Xln dia mm Type of universal joint 3 64 1 178 x 63 5 x 60 3 Spicer Type of gear Hypoid Gear ratio 4 111 Housing type Banjo type Final gear BI0 4 375 VBI0 Differential gear Type 0 Z p number of gear Straight bevel pinion Type of gear Recirculating Gear ratio 15 2 each ball type 1 riI riI E riI U riI 0 Steering angle Inner 45 Outer 36 36 Steering wheel diameter Wheel arrangement mm 400 Front 2 wheels Rear 2 wheels 0 Z Z Z Front axle Wishbone ball joint type p Toe in unloaded 2 v 3 mm forward r r DATSUN 1000 l 0 w 0 0 Z Camber unloaded unloaded C1ster 1 45 2 15 6030 Inclination angle of king pin Z Z p Type of rear Semi axle floating type Rear 2 leading leading and trailing Front Type dimension front mm 35 x 4 8 x 195 Lining dimension rear mm 35 x 4 8 x 195 Lining p g p w E Cll Cll E Total braking area front cm2 273 Total braking area rear cm2 273 mm 203 2 mm 17 46 mm 20 64 mm 20 64 kg cm2 175 Cll g w Inner dia of drum front l Inner dia of master cylinder p Inner dia of wheel Inner dia of wheel cylinder p rear cylinder front rear 0 Max Mechanical for Type w ii1 p oil pressure Lining 0 Z dimension Total braking area mm 35 x 4 cm2 273 mm 203 ear wheels 8 x 195 e Inner dia of drum 2 Po Transverse leaf Front Spring size Out dia x Length mm Semi Rear Z 0 Cll Z 976 x 50 x 4 Spring Length Width x Thickness No mm 1 7 2 50 x 7 2 1 x BI0 150 x size x 6 elliptic leaf spring 50 1 spring 150 x 50 x 5 50 x 11 VB10 1 Po Cll Helper spring mm Shock absorber Front Telescopic type double action Shock absorber Rear Telescopic type double action VI DATSUN 1000 MODEL BID ENGINE PERFORMANCE CURVE 60 50 40 r 8 E V e 30 7 is o 0 6 0 E a 20 5 to o 300 100 1 i E o U 8 12 16 24 28 32 Engine Speed VII 36 rpm 40 44 48 52 56 60 x 102 oo o 2 o io4 E 8 0 1 11 0 0 OOIl l 000 c 1 2 60 4 150 m 140 p p g ill 380 i 000 H 7 130 OOO 3 6 920 1 1 oOO 3 s oI S6PS 17 raO f m 110 100 So RUNIG ratio latio tatlo Ie al0 Find ltlO drl IbiHty H 3tdl Mu znd Jj f Car SO 0 MODEL Spe d 0 MIX MIL troth 70 P l tOfClU Stade lpe d spe d b 80 0 51 0 I to 0 ICO 00 soo 400 il o 0 JlQ 000 r ceu 1J Q 1 3 4 m 1 140 p 600 I 3 375 380 134 ooo 115 t 1 m W r 000 6 1 3 4 160 150 I 561 7 120 y if 5 g l 110 J t I 7 100 90 RUNIG YBIO MODEL h If 0 abiUty O j gt final il pe edrl t peed 1d Zl rd de l I ue torq D MOl rM Spe d 70 RO H i 60 C I SO Ma 0 0 I 0 I I 10 0 I oo 500 400 t gj 0 CO SERVICE DATA Tightening torque Tightening torque kg ENGINE Cylinder head bolt 4 5 4 8 Main bearing 5 0 5 3 Con rod 3 4 3 6 Fly wheel bolt 2 5 3 0 Camshaft sprocket 4 0 4 5 Rocker shaft bolt 2 2 3 Water pump nut 12 13 Oil pump bolt 13 15 Oil pan 05 06 Front cover 05 06 Front cover 10 14 Rear extension 1 6 2 2 Hub nut Without lubrication 2 3 2 5 Hub nut Coating 16 Hub nut Begining cap bolt bearing cap bolt 0 TRANSMISSION FRONT SUSPENSION with grease to turn motion Under 9 18 kg cm Front shock absorber bolt 2 2 2 8 Tension rod 4 0 4 5 4 2 5 3 4 0 4 5 Upper ball joint 3 5 4 9 Upper ball fixing bolt 1 6 2 2 Lower ball 55 76 2 0 2 4 2 5 3 4 2 5 3 Tension rod Suspension Front side Rear side member fixing bolt joint LQwer ball joint fixing bolt 8 r Upper link Lower link spindle fixing bolt pin IX m DATSUN 1000 REAR SUSPENSION fixing bolt 1 5 2 0 Rear shock absorber 2 0 2 5 U bolt 3 5 4 0 Rear shaft Rear spring front pin 3 5 4 0 Rear spring shacle pin 2 0 2 5 GEAR CARRIER 20 Gear carrier 15 Pinion nut 14 Drive gear 3 0 3 5 Side bearing cap 4 2 4 9 2 5 16 8 STEERING Gear box 6 fixing bolt Gear box side 1 cover 18 Gear rear cover 25 14 0 Gear arm nut Gear arm cross Idler arm rod bracket Tie rod end Steering wheel 8 0 nut 3 5 4 9 1 9 2 6 35 49 4 4 5 0 ENGINE SERVICE DATA 3 04 L Oil content include oil filter 0 54L distinct Min 0 6 L between level gauge mark Max Cooling 3 8 water 1 L 8 L Transmission 0 8 L Idling 600 r p m r with heater 4 5 L Radiator side p m Fan belt slack 13 15 rum Compression More than 10 x 2 L Engine side kg cm2 350 r p m SERVICE DATA Spark plug Point gap 07 gap o distributor 08mm 45 0 55 600 r p mm Ignition timing 8 Vacuum More than 400 m mmHg 600 r p m CYLINDER HEAD Limit strain Under 0 10 Thickness of gasket Free 1 Allowable difference of each cyl An eliptic 0 015 Taper within 0 020 mm 10 Used 1 05 inner dia bore Wear limit of inner dia 02 Clearance between piston and o mm PISTON 03 0 at 200 04 C bore cyl Fixing F mark to front side Con direction rod oil hole to camshaft side Piston oversize S T D Measure with feeler gauge between Pullout measuring 0 5 1 5 kg with 0 03 piston cyl bore 0 25 0 50 0 75 1 00 1 25 1 50 mm thickness feeler Clearance between piston groove Within 0 20 mm ring Piston ring end gap Within 1 0 Piston ring S over size Method of inserting piston and pin T D 0 mm 25 0 50 0 75 Press fit to piston and con 1 1 1 00 1 25 150 rod small end 5t CONNECTING ROD Within 5 gram for each weight diff Allowable difference of gross weight with Alignment connecting on a con rod piston o rod 05 mm Allowable limit with pin on 100 mm length Material of big end bushing Connecting rod side F 500 Within 0 4 clearance Clearance big end bearing Con rod side clearance Connecting bushing thrust under size o 01 0 05 o 20 0 30 limit 0 40 S T D Xl mm 0 008 0 12 0 25 C 0 50 0 75 1 00 r DATSUN 1000 CRANK SHAFT 0 03 mm Wear limit at pin portion of elliptic or taper crank shaft journal Limit crank shaft Not to exceed 0 alignment Side clearance of crank shaft Within 0 3 Crank shaft journal oil clearance 0 02 Portion of crank shaft thrust 2nd Bushing over journal bushing size of crank shaft 0 05 mm mm 06 mm side S T D 0 25 0 50 Dimension of crank shaft jorunal 49 951 49 964 mm Dimension of crank shaft pin 44 961 44 974 mm 0 75 1 00 CAM SHAFT Wear limit of eam shaft Limit of alignment Height of of jornal o shaft cam 36 45 Wear limit of cam Clearance bushing Bushing under o cam 36 55 at all 5 01 0 shaft cam or taper 05 mm cam End play of elliptic 03 mm shaft o size 03 Inlet Exhaust height 2mm 0 S T D 07 mm 0 25 same 0 50 0 journal for all 75 VALVE 45 30 Angle of valve face Exhaust 1 3 mm Inlet Exhaust Limit valve head thickness o 5 Inlet mm lxhaust Dia 8 0 mm Diameter valve stem Inlet of stem Wear limit valve stem Clearance to guide Tappet clearance Clearance valve guide and guide o 35 mm Inlet o 02 04 mm 0 inserting hole Clearance for valve seat inserting 006 Limit of valve seat depresion o 2mm Valve seat S T D 0 S TD 050 over Valve guide size over Valve spring size Free 45 7 III 009mm mm 50 Less than 0 Exhaust at hot 10 mm 7 SERVICE DATA Limit valve Fix load spring Free length 44 7 fixed length Clearance valve lifter Clearance valve locker mm No 1 30 0 Within 0 15 guide arm 38 5 No shaft o 02 0 2 61 2 31 0 mm 05 mm FL Y WHEEL Limit shake on the frictional face 02 mm Nos 105 of teeth ring gear THERMOSTAT to operate Temp Max 82 C of valve lift More than 9 mm at 95 C WATER PUMP fi Rotation ratio water pump pulley 1 05 for crank l 85 Current quantity pulley 400 r p m OIL PUMP r Oil pump Trocoid gear Oil pressure 3 5 Thickness of adjusting shims o 5mm 4 0 type kg cm2 for oil regulator Quantity of oil pumping L nnn r 19 5 3000 p m FUEL PUMP Perlormance 750cc 3000 min r p m 1 xm t r DA TSUN 1000 A MANUFACTURER MITSUBISHI HITACHI STARTER MOTOR f SS114 Type MW 87 V1R 30 30tl 12 11 Less than 60 Less than 60 Constant NO LOAD Terminal voltage V A Ampere Rotation r p More than 7 m More than 4 000 800 LOADED Terminal voltage V Ampere A Torque Voltage for kg pinion 6 6 Less than 470 Less than 420 More than 0 m More than 0 68 9 Less than 9 Less than 8 out Front Clearance shaft 3 Medium Less than 0 2 mm Less than 0 2 mm Less than 0 2 Less than 0 45 mm bushing Rear Alignment of shaft Out dia Less than 0 03 0 2 mm Less than 0 05 mm More than 0 Depth mica height Wear limit tension 2 0 mm Less than 0 Amendable accuracy of commutator Spring 32 Less than out limit of commutator Brush 1 mm 33 standard Diameter wear limit of commutator Run mm Less than 0 Limit of commutator 1 9 2mm 16mm 15 mm 5 mm 7 mm 800 g Standard Weakness limit Up XlV 1 to 15 700 g mm SERVICE DATA NGK HITACHI MANUFACTURER ALTERNATOR Alternator LT125 B 02 U sed rotation 1 5 Constant revolution 14 h revolution Voltage Out dia of Wear limit 31 Dia Rotor coil Rotor shaft Brush run height Less than 1 050 33 mm 0 5 4 07 n 0 mm mm mm 7 n 13 mm 7 mm mm 300 spring 100 mm 19 mm 7 6 6 Under 0 10 St of brush 000 2 500 out Wear limit of brush Strength 12 000 Less than 1 spring 050 6E 380 g 300 400 g REGULATOR No load RL2220B5 TLIZI0A Type 14 0 regulated O 5V GAP Voltage regulator Pilot lamp realy Air o 8 1 2 12 Back 0 8 1 1 0 Point 0 3 0 4 Air 0 9 1 2 Yoke o 9 1 Core 08 Point o 4 Yoke 0 5 o 2 Core 0 5 0 6 Back 0 8 1 1 Point o 4 0 5 Point 0 8 11 i tt l t J I t h xv t 1 DATSUN 1000 lllTAClll MANUFACTURER MITSUBlSlll DISTRIBUTOR D412 53 Type TVA 8 Ignition timing Point contact 49 angle Point gap Contact arm 600 r p tension m 55 0 45 spring 4FIL 0 500 55 mm 10 650 g fifS ADVANCE CHARACTERISTIC Governor type Commerce 450 r p Max 12 1 300 r p o m 6 m 11 Vacuum type Commerce 150 mmHg Max 305 mmHg 9 5 18 7 9 0 0 17 5 5 at 1 at 8 7 10 5 at C14 l HP5 1 51 160 mmHg at 250 350 mmHg More than 6 mm Secondary voltage 3 ways spark gap Primary coil resistance Secondary coil resistance E 12V Primary voltage 3 2 Below 20 XVI 000 n 4 In Below 17 m 440 r p m IGNITION COIL Type m at 1 028 r p 13 0 5 8 7 at 500 r p 000 n SERVICE DATA MANUFACTURER HITACHI NGK L45 NGK B 6E SPARK PLUG Type Screw x Reach x Hexagonal Length 14 x 19 x 20 6 mm 7 Gap o 7 0 31 lfrK 8 iil m BATTERY Type NS40L C20 Capacity S ecific h 32A H gravity Discharge Voltage hour 150 C 150A 5 second 1 260 2 5L More than 2 150 C 150A 5 minute More than B 4 V CLUTCH i Setting height of diaphragm spring 31 5 mm Wear limit of cJutch o Disc facing run facing out 5 mm Less than 0 Play of with drawal lever Height of clutch by the head of 5 rivet r mm 15 2 0 pedal 144 Play of clutch pedal 15 5 mm 20 mm TRANSMISSION Type Synchromeshed Reverse one on 2nd 3rd gear stage Gear ratio 1st 3 380 Gear type Helical gear type XVI the 1st 2nd 1 734 3rd 1 000 Rev 3 640 r DATSUN 1000 driven gear Main drive gear Back lash of each meshing gear second gears first gear Gear ratio of MAIN speed 4 meter 00 16 4 DRIVE GEAR 19 Main drive gear Nos MAIN SHAFT Second gear teeth Nos 25 First gear teeth Nos 31 Reverse gear teeth Nos 31 Reverse gear thrust clearance 0 15 0 25mm First gear thrust clearance 0 15 0 25mm Second gear thrust clearance 0 1 0 3rnm Front gear thrust clearance 0 1 0 35 0 8 1 45 rnm 0 5 Clearance between boulk ring Cover adjusting each gear shim 0 2 1 mm Ball bearing Rear Front Bearing type of spline 0 Bushing COUNTER GEAR SHAFT Driven 29 gear teeth Nos Counter gear teeth Nos 22 First gear teeth Nos 14 Reverse teeth gear 13 Clearance of front thrust 0 02 Thrust washer size 0 8 Bearing type of spline Front 0 Q 08 mm 9 10 rear 1 17 Clearance between shaft bushing 0 032 Clearance between gear adapter plate 0 1 0 5 0 1 0 4 Clearance to snap ring 0 077 FORK SHIFT Length of 16 4 locking ball spring xvm rum 1 2 balt bearing REVERSE IDLER Gear teeth Nos 1 at 7 kg 1 3 mm SERVICE DATA PROPELLER SHAFT Play at pin of universal joint Adjust by 1 Thickness of snap ring 58 1 ring snap 56 1 54 1 52 1 50 1 48 1 46 DIFFERENTIAL GEAR CARRIER CAR MODEL Bl0 V010 9 8 37 35 SPECIFICATION Teeth Nos of drive pinion Teeth Nos of drive gear 4111 Final gear ratio 4 375 ADJUSTMENT Back lash between drive pinion drive gear Less than 0 10 08 Run out of drive gear back side Less than 0 Pre load of drive pinion bearing 6 8 kg Standard dimension of drive pinion 45mm Back lash of side gear o Standard width of side bearing 17 1 0 0 15 mm mm cm 2mm 50 mm ADJUST WASHER OF DRIVE PINION Thickness Parts No 38125 18000 2 30 2 32 mm 38126 18000 2 32 2 34 mm 38127 18000 2 34 2 36mm 38128 18000 2 36 2 38mm 38129 18000 2 38 2 40 mm 38130 18000 2 40 2 42 mm 38131 18000 2 42 2 44 mm 38132 18000 2 44 2 46 mm 38133 18000 2 46 2 48 mm 38134 18000 2 48 2 50 mm 38135 18000 2 50 2 52 mm 38136 18000 2 52 2 54 mm XIX J r DA TSUN 1000 38137 18000 2 54 2 56 mm 38138 18000 2 56 2 58 mm 38139 18000 2 2 60 58 mm ADJUSTING SHIM OF DRIVE PINION Parts No Thickness 38153 18000 050mm 38154 18000 0 075 mm 38155 18000 0 125 mm 38156 18000 0 250 mm 38157 18000 0 SPACER OF DRIVE 500 mm PINION Parts No Thickness 38165 18000 5 75 mm 38166 18000 6 OOmm 38167 18000 6 25 mm THRUST WASHER OF SI DE GEAR Parts No Thickness 38424 18000 0 76 0 81 38424 18001 0 81 0 86 mm 38424 18002 0 86 0 91 mm mm ADJUSTING SHIM OF SIDE BEARING Parts No Thickness 38453 18000 0 050 mm 38454 18000 0 075 mm 38455 18000 0 125 mm 38456 18000 0 250 mm 38457 18000 0 500 mm SUSPENSION FRONT SPRING Dimension L x W x T Nos 976 Free chamber Spring x 120 constant 2 05 xx 50 x 4 mm kgmm 6 SERVICE DATA FRONT SHOCK ABSORBER Stroke 130 Absorbability 0 3 sec extensile side Contractile side mm 58 kg 20 kg REAR SPRING B10 VB10 50 x Length x width x thickness Nos 1150 x 50 x 7 Free chamber Spring 2 156 mm constant 1 45 Span kg 7 x 2 150 x 50 x 5 1 50X11 1 161 3 95 mm 1150 mm 5 mm kg mm 115mm REAR SHOCK ABSORBER Stroke 160 Absorbability 0 3 sec extensile side Contractile side 160 mm mm 70 kg 25 kg 105 kg 35 kg STEERING SPECIFICATION Steering gear Steering gear ratio Max type Recirculating ball type 15 turning angle of front wheels 3 4 Inside 45 Outside Steering 1 36 gear oil 36 MP 90 O 24L Steering wheel dia 400 mm Play of steering wheel At the top of around of wheelless than 20 25 mm WORM BEARING ADJUSTING SHIMS Parts No Thickness 48031 18000 0 05 mm 48032 18000 0 07 rum 48033 18000 0 08 mm 48034 18000 0 10 XXI mm DA TSUN 1000 48035 18000 o 20 mm SECTOR SHAFT ADJUSTING SHIMS Thickness Parts No 48131 18000 1 52 1 53 mm 48132 18000 1 55 1 56 mm 48133 18000 1 58 1 59 48134 18000 1 61 1 62 mm 48135 18000 1 64 1 65 mm mm CLEARANCE Clearance of ball nut to direction of shaft Less than 0 02 mm Clearance between of shaft T groove Less than 0 1 mID shim Clearance of sector shaft Less than 0 bnshing 12 mm FRONT WHEEL ALIGNMENT SPECIFICATION Toe 2 in 3mm Camber 1 45 Caster 2 15 King pin angle 6 30 Side slip Less than 3 mm with each lmm Turning angle 45 Inside 36036 Outside kg Rotation torque front hub Motive Less than 9 Clearance of front hub to direction along Less than 0 08 mm cm the shaft Clearance of ball joint to direction along Less than 0 9 mm the shaft XXII running distance SERVICE DATA BRAKE F FRONT R REAR ITEM FOOT BRAKE Type Two Drum inner dia 203 2 Leading trailing mm Leading trailing Less than 1 mm Leading trailing elliptic Within 0 02 mm Leading trailing cylindericallimit Within 0 02 mm Leading trailing Drum over size Drum inner dia Drum leading at 35 mm from Drum surface cylinder roughness Honing by paper less than 1 Leading trailing 6 RETURN SPRING Wire dia x x Free length 3 211 x 118 mm x 20 5 rolls Cy side 2 011 119 x 2 mm x 28 rolls Rolls Adjuster side x Fixed load x 55 Fixed length kg x 127 1 mm 2 011 x 69 5 mm 20 rolls Cy side Adjuster 10 6 side kg 8 6 x 132 kg x 7 76 mm 7 WHEEL CYLINDER Inner dia 20 64 mm Clearance between cylinder 0 02 0 20 64 mm 105 mm 0 02 0 105 mm piston Limit of clearance Piston spring Free fixed length x length fixing load o x 15 mm 0 28 mm x 16 mm XLI 0 1kg 15 mm 28mm x 16mm Xl 10 1kg LINING Length x width x thickness Wear limit Thickness 35 mm x 195 mm 4 x 8 mm size 5 3 mm 0 5 3 mm 5 mm for service use PE DAl Height of pedal 144 Remained stroke More than 25 mm Play of pedal 10 Adjusting shim for pedal height 16 xxm 5 2 mm 15 mm mm 8 More than 1 mm More than 1 mm over 35 mm x 195 mm X 4 Part No 30611 27260 0 5 mm mm DATSUN 1000 o 8 rom o 5 rom Part No part No MASTER CYLINDER Inner dia 17 Remained pressure 03 07 Oil pressure 175 kg cm2 100 kg by foot Clearance between cylinder 46 002 piston Limit of clearance o XXN 15 mm 0 rom kg cm2 105 mm 30612 27260 30613 27260 1 NISSAN MOTOR CO I L TO l i g C y T 1 TG 1l 131 TI 7 1 ENGINE This engine has three main bearings and The use the mounted individually rocker arms seats A lubrication for portion of the engine The main oil gallery along valve lifter The areas passes oil through drilled passages to each carn and main bearings through the valve lifters and hollow push rods to the rocker are the and carry skirt type split two of compression rings and a oil control ring The piston pin is pressed in small end of connecting rods which have steel backed lead and copper alloy changeable big end bearings which trocoid gear type oil pivot driven camshaft pump by provides full pressure ball on pistons alloy aluminum the valve lifters and hollow push rods to operate counter The end throst balanced on crankshaft is fitted this component is taken by the second main The arms are bearing with flange centrifugal water pump and cooling fan ddven by the generator belt GENERAL SPECIFICATIONS 4 Design cylinder Bore x stroke Displacement Compression Max B 73 in line 4 59 mm cycle 87 x 2 2 988 cc 61 ratio H P torque Ignition timing ax x O H 32iJ cu 8 SAE 62 HP at 6 61 5 Jt Sff lb at 4 000 r p 8 m 8 C in 5 1 000 r p m Kgiat fi g oO i 5m B T D V r p i m at 600 r p m 1 1l g J 1 DATSUN 1000 2 to ENGINE COOLING SYSTEM Cylinder head Thermostat I Water pump Manifold aG B oal Cylinder Fan Cooling System An efficient imporatnce of the engine pay particular cooling ensure to and it is is system controls of major the satisfactory running therefore per necessary to is maintained by water combined with an Fill to efficient fan valve system is incorporated within filler plug well cooled radiator and thermostat The at approximately 0 4 kg Do not remove the filler cap if the water cooling system pump circulation pressure temperature of the coolant is above boiling point or if the engine is running Topping up should only be required occasionally to replace water lost through the overflow pipe Top up when the engine is cold and if possible use clean soft attention to its maintenance Description The the sq cm cold may pressurised and the relief flow cause 1 2 in Overfilling water to flow The pipe capacity approximately 4 5 liters in the radiator filler cap 3 of the bottom of tl ie when the through of the engine is the over system is DA TSUN 1000 21 J 1 1 11 9 6 10 tf 3 o Radiator 1 Ass y radiator for cooler 5 BoIt 2 Ass y cap pressure valve 6 Nut 7 Washer 8 Waiher Iock 3 4 drain Handle Packing drain cock cock plain 4 9 Hose cylinder 10 Hose radiator 11 Clamp hose head to to water radiator pump ENGINE its from Thermostat avoid In is order to ensure maximum essential to keep the efficiency it engine operating tem peratures within certain limit a pellet type thermostat To is fitted in the water outlet at front of the Pellet type thermostat ciple of rapid works up the car thermostat is opening set by the manufacturer and can not be altered assist this During decabonising it is policy to test this opening by immersing the thermostat in water raised to requisite temperature The valve located being laying The and the hose reconnected to housing cylinder head by the prin should variation of solution of wax under these open fails to open a but if conditions it unit should be fitted new Overheating may be caused Overheating belt excessive running the with water to circulate Fan Belt A the Pellet which controls wax by solution of slack fan far retarded failure of the 108s of water or driven this also belt from driving the carnkshaft by by first loosening dynamo in and moving the dynamo towards tl e which hold the the belt over the fan and onto the filled pellet mash room valve a wax Fan p ey When the engine is cold this valve is closed and on starting the engine the flow of water to the radiator is temporarily restricted Due this cylinder rise the temperature of the water in the head and cylinder jackets will quickly thus ensuring rapid warming up The heat so Alternator generated will gradually press up the piston by shrinkage of synthetic rubber and so ultim tely opening the valve permitting a full flow of water to the radiator sleeve The thermostat itself is detachable should be occasion arise it can Crank shaft Standard Fan Belt Adjustment 21200 61001 Rated Temperature Open at 76 Open fully Optional for cold district pulley therefore be removed Part No 21200 61001 Open 50C 1 at 900 C at 820 C Open fully 5 a the alternator be fitted can bolts clamp position Slide engine fan pulley Thermostat consists of metalic The device with the Type new a Adjustment The fan is belt too ignition carburetor adjustment incorrect V by carbon deposit in the cylinders 15 at 95 C 5 C 1 50C C 1 5 C DATSUN 1000 by bringing the The belt alternator away engine be to should sufficiently tight prevent slip yet is Adjustment then be the belt should have 10 to 15 the mm generator and crankshaft pulley when midspan is pushed firmly run for timed minute to a water has been cleaned from the A slack between the should When completely drained the engine made from the the suitable notice that all system should be then affixed to that the water has been indicating radiator ensure drained After the correct tension has been obtained securely lock position again it in Flushing the Radiator To ensure efficient circulation of the coolant Frost Precautions Freezing the in the or Ice in the hose and may but with the muff lower hose will A care fully closed When frost is expected used in winter boiling of the solution is make sure in fact that mixture the into and in anti freeze in the it taking out in the should be allowed to run comes out clear from the drain a into the are in cases the efficeient stiff piece of wire should taps during draining to becoming clogged with not turn the where the operator practice completely and flush flow clear but excessive to will up is it more find remove in the radiator serve furring the radiator reverse way to the upside down and let the water flow in through the bottom hose connection is cold a scale This method of radiator flushing may well with the container system cooling system has it of the sediment must be made up in accordance with instructions up when the when water that they ensure sary topping up with water reduces the degree of protection afforded Solution If the until be inserted up to the Excessive Top again The At intervals taps strength The strength advised by the manufacturers the must be maintained of solution by strength anti neces with freeze solution as topping up supplied and spring through will result when the car is to be low temperature a very the preferably before putting muff can be used to or or formation system should be with clear running water periodically flushed circulation be taken not to run must the reduce to sediment in the radiator connections water stop boiling cause advantage first at the bottom of occur may radiator and to be drained container and out of the top connection run and use Water again Pump After draining the water from the radiator Draining Protection by remove cars where anti freeze is On not used must be taken druing following precautions frosty weather to obviate any damage due to freezing of the cooling system When heavy frost is imminent the cooling sufficient engine drain to merely with one the and masks rugs cocks cover the on alternator It is not be completely drained must system radiator and There are two left hand side of the cylinder block and the other at the base of the radiator block Both taps must drain the and the system ground while draining be opened to car must be on level The drain taps should be tested at frequent intervals by inserting that they are clear a piece of This wire to ensure should be done the so that any taps are opened obstruction freed by the wire may be flushed out immediately by the water out when the The engine draining should the pump unit from the cylinder block by taking off the fan belt and releasing the set bolts with spring washers and hinge bolts to the the be carried is hot 6 ENGINE 15 3 7 5 CD Seal @ Valve body @ Shaft @ Seal Portion embly CW contact surface Sectiollal Components of 1 Vane water 2 Ass y seal 3 Ass y seat 4 Bearing 5 Wire 6 Hub 7 Cask watcr lock 9 pump water pUmp pump 11 Blade fan front 12 Blade fan rear l3 Bolt bearing watcr Washer lock to Pulley f m l4 Washer lock pulley t Water Pump pump 15 cover 8 Nut 7 Be It fan ate pump View of Seal DATSUN 1000 Adjusting Clearance and Body Removing the Pump Shaft Assembly pulley and cover and ball bearings are combined the fan blades Disconnect The shaft First First pulley hub o a out locked the Next 5 out the pin from set assembly shaft to the mm bench on type bench Take the shaft fitting with between the vane end good condition the pump body Water pump hub a C the Bench A for Pump Body Adj The shaft and ball bearing assembly drew out from the take with correctly for a groove of Water Pump A 74 0 mm B 19 5 mm 05 mm floating seal and pump body but a reversal a care should that the shaft assembly is a ment B vane of the disassembly procedure ensure us C the The reassembling of the pump is fitted be body out seal which remained the be taken to can slit a hole of set ring of shaft so as to insert and set the said ring correctly 8 0 4 Take out the thickness gauge and find body upside down and press assembly from the vane side on the Example of a the U block slit wbich type bench Thus on turn the out the shaft U be nch and draw out the pulley hub drift hard bar the U the knock the shaft end with or press On down insert the set pin groove line to thickness Inserting gauge Thickness with one unit Put the press the Vane End Hub 21054 18000 Bearing shaft 21035 13201 Seal y 21026 73000 Seat ass y 21027 73000 ass ENGINE LUBRICA TION To oil p m through push rod holes Oil capacity 3 04 0 t foroil filter 54 Oil Passages From the relief valve the oil passes into the the oil on the right hand side of Circulation of Oil Pressure unit and is oil pump lubrication is provided by an used throughout the hand side of the cylinder block from the camshaft gear The flow then passes via connecting engine oilways draining into the right ecentric non The oil pump is bolted gallery main big end and camshaft bearings throUgh drillings in the crankshaft The connecting ends are drilling in the cylinder and is driven by the drive gear block oil is drawn into the pump via the filter and is delivered through oil regulator which is The the oil from the and lubricate situated at the lower body of oil pump the to main rear the rockers pan via the center the rocker shaft bracket to and then drains back into push rod apertures camshaft bearing The oil enters a gallery on the left hand side of the engine and individual the lubricates tappets through drillings As in the front the camshaft rotates journal register two grooves with a small hole in the camshaft thrust plate thus allowing amount a small of oil to pass into the timing case twice of the camshaft to case revolution during provide lubrication for the timing chain and gears From the drain hole timing back to case the the oil returns via oil pan The a filter therefore forms part of the main oil gallery and as 9 such is filled with oil under pressure DATSUN 1000 The full of the oil enters the element through holes in the cartridge and passes Check for Low Oil Pressure through the Check the level of oil in the engine sump by element into the annular space round the center means pipe if This the oil is ad bottom so that l only escape through a small hole into space can sealed top the hollow center The must pipe and from this point back on then and the oil when the filled with The oil pan new strainer union on the suction side of the oil connect and defective pump being rectify the fault The drain the oil pan with new oil dis filter new change the oil cartridge lb sq in 2 road speeds part of The engine removed kg cm2 on the gauge at normal whilst approximately 10 lb sq in 1 hand by a That there is a The filtered cartridge is bore in oil c readily from particularly becomes correct to the the of the caused by its oil is passage all crank pin correct the oil the sides the working high or choke up of oil the is if the filtration to bypass oil and Removing the Oil Pan in flange a in pressure on the Remove the inserted from system deals with any oil pressure when starting from cold When hot the pressure drops as the oil becomes lubrication edge excessive more large bearings warm as the pan f more drop compared with that shown when the The relief aJ ve v bearings are in good order gauge chain the relief valve will be pressure difference clear will escape fluid cause the cylinder and The sump capacity is 3 1 liters will in the lubrication filter element is oil and replace the drain This easily element of filter oil camshaft journal arm starting oil viscosity opened with when more can to which oil is fed under have the excessive ances it not to lose the The oil filter is provided with a relief valve if the temperature of lubricant oil is low at sludge bearings pressure gallery filter is and finally returned to the oil tensioner That the strainer in the oil pan is clean and That the sent locker resistance not choked with care cylinder block system crankshaft journal grade of oil in the oil pan b oil unit a delivered to be checked good supply of the as Take of rubber sealing ring kg cm2 should be shown when the engine is New engines with new oil will give idling consideral ly higher readings at low speeds should there be a noticeable drop in pressure following points should be changed and then every the main oil element selaed in the container should not drop below 30 0 7 the 3 000 kIn 10 000 kIn after this of the pressure should cartridge after first 2 000 miles Oil Pressure oil unit and the Filter Removing The filter forms The the remove plug A filling chocked exists at leakage should be drained readily Before air oil is hot as the oil will flow more engine no 3 000 kIn and at intervals of every 3 000 miles 5 000 kIn at sale that and reconditioned engines new after first 2 000 miles is sump is clean and not in the with sludge the drained switch off and ascertain that the gauge strainer the Oil oil be of the dip stick and top up if necessary warning light is still on after refilling the sump into the oil pan Draining the bolts ngine t which underside of the ld the lower bolts from joint washers 10 the plug screw of the bell housing from the fluid set Drain the ng in the process the bottom Lower the oil care not to are securing pan damage the ENGINE the Oil Removing the Strainer Removing Remove bottom pick up strainer five bolts securing the oil pump oil the of the Three Pump cover and pan enouth long are pump to the crankcase and remove secure the Oil the On cover inner long bolts Pump the setscrews and Remove the the secure the pump with its drive shaft Dismantling which to Unscrew the the tilting with its rotor spring washers body and take off body upside down the cover to the drive shaft and the outer rotor with slide out Refitting the sump lowered With the oil into the remove drawn strainer oil it is through pump To possible to the cover are engine Pay particular attention to the oil pan and crankcase joint faces and remove any traces of oil jointing Examine the joint washer and renew material The oil joint washer can be it if necessary bolts that there pan to the before refitting the oil connecting the oil pick up to the pump and unscrew the securing bolts The strainer may be dismantled for cleaning purpose by removing the delivery pipe flange strainer unto the union Notice Pump Clean out the sump by washing it in paraffin the care to remove any traces of the paraffin which oil is remove the used again if it is the dowel pins to the fit which must be positioned correctly when but it is advisable to sound Smear the faces of the a new one joint with Lift the oil pan grease and fit the joint washer into position and insert the setscrews into the refitting flange tighting them Reassembling up evenly the Oil The outer rotor has is of great towards the important base of Pump a chamfered edge that the this body It chamfer be Failure to assemble in this way will result in the cover is tightened down Insert the Oil Filter 11 the slotted body and bring the end of the drive shaft into rotors into mesh r DA TSUN 1000 15 3 13 5 t8 Oil Pump I Ass y shaft 2 Gear drive 3 Gasket oil pump 4 Gear S Oil Filter il pump Oil Strainer 13 drive Gasket oil pump to 14 Washer lock IS Bolt Plug welch 16 Bolt 6 Bolt 17 Ass y strainer 7 Washer IB Gasket oil strainer B Valve oil 19 Bolt 9 Spring 20 Washer lock cover drive lock oil 10 oil Plug tt Washer 12 Pin slotted egulator egulator 21 egulator oil cylinder block regulator 12 oil Bolt 22 Ass y oil filter 23 Ass y switch atridge oil pressure ENGINE ENGINE LEFT SIDE ENGINE RIGHT SIDE Tightening torque i m kg Cylinder head bolts Main bearing cap bolts Connecting rod bolts nuts Flywheel bolts Cam shaft sprocket 45 48 50 53 3 4 3 6 2 5 3 0 4 0 4 5 Rocker shaft bolts 2 0 2 3 Water pump nuts 12 13 Oil pump bolts 13 1 5 Oil pan bolts 05 06 Front cover bolts 05 06 13 r DATSUN 1000 SECTIONAL VIEWS OF B10 TYPE ENGINE 14 ENGINE CYLINDER BLOCK CYLINDER HEAD M II IIlH I h 1m GAUUU IJ I rt m i r lHE @ r mtlltt r liiUWh n I jD k to fI I ttcnhrttllr r all I 11 Ill II fi rA w IUTLIT I r lc Hfl UlR i1llfll IASIU 1I1 hr U I I ITa SDPPUrleISI f ltISIIlSI I e In lt i1pulr i UnIll PO UI 15 t 11 u DATSUN 1000 18 7 1 Manifold intake 2 Plug 9 3 Stud 2 4 Manifold exhaust 5 5md 6 Casket intake 7 Bolt 8 Stud 9 Washer plain 10 Washer lock 11 Nut 12 Nut to 13 Washer plain 14 Washer lock 15 Yoke manifold 16 Gasket 17 Stud 18 lnsu1ator carb ex 3 s ha us t manifold 1 f Id mam 0 10 to cylinder head 8 6 I tor 16 4 Manifold Transmission Axle Exhaust manifold case Rear tube D I Exhaust Tube 16 Muffler ENGINE SERVICE OPERATIONS WITH ENGINE IN Removing Starting Remove Nut and POSITION the Removing Pulley Gear Timing Slacken the dynamo the radiator attachment bolts and remove the fan belt Bend washer locking on the starting dog nut Unscrew the starting dog nut back the tab by using Heavy duty Shock type in an A few sharp blows direction will slacken spanner anti clockwise the nut Pull off the crankshaft pulley The chain timing necessary to remove endless is both Before together camshaft gears and it is crankshaft and the doing this marks on both gears and their notice the timing relationship to each other gears a little at a time crankshaft gear retaining Draw off both the first removing the nut As taken the gears not to are withdrawn lose the packing Removing The the timing Timing cover is Cover secured by set each having a shakeproof washer and a Note that the special special plain washer washer is of elongated shape and is fitted next timing The cover spring ensures Examine the drive renew it if oil has been lost felt by washer and seepage the Timing Gear Replacing the components of the timing gear is largely a reversal ofthe dismantling process should be paid to the but speica1 attention immediately below following points the bolt heads Take out the set ring which acts as silent operation of the is a rubber chain Refitting flange washers are be from screw bolts to the must Between the cam behind the crankshaft gear shaft gear teeth and a tentioqer care washers screw bolts remove Fit the cranksahft and camshaft gears into the should joint taken not to damage the washer when breaking If damage does occur fit a new the joint washer cleaning of the faces of the joint sur their is Ensure the timing respective shafts are opposite and in line Turn the engine crankshaft until the keyway at T D C and the camshaft with its keyway faces beforehand in approximately cover and its washer Care be marks 17 the one 0 clock position DATSUN 1000 Place the gears into position the keys that Ensure that ensuring keyways the timing marks to opposite in present are on the gears on each other and in line the snart the shafts Unscrew the plug from the end of the shaft and clean out the oil way The are Drive the two end rockers out This gears home The same number of packing washers taken engine by hand until from lowest position behind the replaced unless been fitted a crank new and feeler gauge be necessary must be To alignment of the number Fit thrower the oil is in the behind concave it face dismantled 1 by push turning the rod reaches its screw flat and and screw spring washer and slide the rocker off the shaft of packing Sometimes the valve spring will have to be slightly compressed by levering a screwdriver crankshaft under No 2 rocker thus washers gear so that its front of the car No it back as far as it will go Withdraw the split pin the the vary be achieved may Unlock the tappet adjusting camshaft has alignment with a adjust the alignment it will measure to gear or In this case the faces gear crankshaft be may without the whole rocker assembly being drawn towards the slide to and check that the felt washer off the No procedure for allowing shaft the end rocker easily Repeat the 8 rocker position ROCKER MECHANISM Valve Rocker Covet Removal Remove the air cleaner nuts the securing Unscrew the cap Reassembling engine lifting brackets Remove the rocker cover and the cork the Rocker joint washer the Rocker Removing Drain the in use It If anti freeze is cooling system use is Assembly clean container for the a to necessary the drain slacken the cylinder head bolts the rocker cylinder fixing shaft nuts and because four of also secure the head If the cylinder head bolts distortion its fluid system may the from way are not slackened result and allow water to cooling system find into the cylinder and pump Notice that under the right hand rear rocker special locking plate Completely stud nut is a the unscrew remove rocker shaft the rocker bracket nuts and Complete with assembly On nuts To first dismantle remove from the rear Remove spring Slide the Rocker Shaft the grub rocker screw Assembly shaft assembly and locking plate flat washers from end of the rockers 3 No 4 bracket been split pins each No they rocker bracket the washers the the and and pedestal bracket bushes brackets and springs from on 18 so at on returning from and repeating the the left nut of process unitl all If the rocker assembly has tight completely stripped down and rebushed are the oil shaft I the a little a time securing working left nut of No 1 diagonally from nut to nut pedestal bracket right nut of No 2 left of brackets and rockers Dismantling reassembly tighten holes will have to be redrilled and the reamed the shaft down to size before assembly ENGINE Push Rod Removal If the TIGHTENING 2 0 valve been removed TORQUE rocker assembly has already all that remains is for the push rods to be lifted out 2 3kgm They may on the other hand be taken out without detaching the rocker assembly Remove the Slacken all air cleaner and rocker cover the tappet adjusting screws to their full extent then using a screwdriver with the rocker shaft as a fulcrum TIGHTENING ORDER FROM INSIDE TO OUTSIDE rocker the spring slide the push rod All but the end WAY in this way push depress side the valve ways and lift out rods can be withdrawn These will have to be withdrawn after the removal of the two end rockers from the shaft The rocker and spring must their original position on be the ends replaced replacing push rods ensure register in the tappet cups From here onwards reassembly is a straight forward reversal of the dismantling process in of the shaft Remember to replace the rocker shaft locating screw and lock plate Replace the spring and flat washers with split pins on the ends of the shaft Replace rocker cover and gasket When the ball ends that the the Valve Rocker Clearances Adjusting Remove the air cleaner and rocker should There 0 35 mm the base the adjusting the push procedure Turn with the the Cvlinder Head ing The vent pipe should be at the front of the engine rocker cover by found to be faulty are or they in means of the two position to important on checking mai ntain the tappet disperse the film of oil from Failure cup result in a to wrong follow this reading being the adjust insert screw a screwdriver in the adjust slot and slacken the lock nut in rocker Then feeler gauge between the face and the valve stem Raise or adjusting screw until the correct Tighten the lock nut and recheck the clearance If the the rubber bushes must Whilst clearance is obtained ensuring that the rubber bushed and lifting plates cover gasket stem engine over by hand starting push rod stops falling the until handle of the the to rod is screwdriver a will lower the Secure it screw insert 0 014 cap nuts valve the valve is fully closed To engine cOver 014 in taken oAUlm Reassembling of 0 clearance a between the face of the rocker and of clearances pressure be It is important clearance is being set are be renewed other being adjusted wise oil leaks will result opposite 19 to its to note the that while the tappet of the valve must be on the back of the cam peak r I DATSUN 1000 Adjusting the Rocker Clearance CYLINDER HEAD the Removing Drain the opening Cylinder water from and radiator Head cooling the other at and the rear If anti freeze mixture is in side of the engine into a suitable container it should be drained use When lifting given so and retained for future studs use cable Disconnect from R Extract and the still the housing securing housing and thermostat carburetor Detach the high tension cables and temperature stat housing a direct pull should be Remove the cylinder head gasket rocker to rocker assembly the position remove the seats by the With the valves carbon from the wire brush which should be If the exhaust valve heads very a not cylinder head used for the removal of carbon remove gauge connection from the thenno off the in Leaving the valves in position for this operation ensure that damage cannot be caused also disconnect the water slacken the external cylinder same head combustion chambers and the valve faces thermostat remove the sparking plugs to interposed that the head is pulled evenly up the Remove the and the inlet and exhaust manifolds Take wood Decarbonising to the thermostat hous Remove the airc1eaner cover piece of fiug connecting the radiator ing and remove the hose nuts a Do not use excessive force the the negative tracting the terminal screw and from the battery terminal post 1i removiriir H Slacken both the retaining clips on the hose battery using the facilitate detaching the tap each side of the head head joint to take the blow right hand be lifted off the can now To with a hammer situated inlet tube at the backside of One is block cylinder cylinder cylinder block drain cocks the radiator cylinder head The system by forgetting coated with chisel shaped piece of hardwood Remove the valves and using brush head nuts at the are a hard deposit this may be removed by using clean out the carbon from the wire the inlet and exhaust ports time Withdraw the push rods keeping them in the Blowout compressedI order of removal 20 all air traces of carbon dust witb and finally clean the ports with ENGINE and gasoline dry them The carbon should Replacement now be removed from the Rotate the piston crowns Note that the diameter of the exhaust valve engine until the piston to be worked on is at heads are smaller than the inlet valve To T D C Protect the other cylinder bore from the valves insert each valve into its replace the entry of carbon particles by pushing a non oil seal and guide and replace the spring fluffy rag into them retainer Fit oil seal chamfered side down harctwood Using a chisel shaped piece of wards The oil seals are more easily fitted if the the remove carbon from Carefully piston have been soaked in engine oil for a short they A ring of carbon should be left round crowns The oil seal is used for the period before use the periphery of each piston and the deposit intake valve only round the top of the cylinder bpre should not be Replace the valve spring and compress the touched indication when An tion is as require is loss of power will require this attention used for long decarbonisa to valve spring generally given by an all round Cars used mainly on short runs more Refit the of means often than those cap retainers the valve and cotters secure them by Remove the compressor runs Spring Specification Removal and Replacement Whilst cylinder head valves the the be taken out can valve spring with VVire diameter mm of the Valves In mm 22 0 is Free mm 45 7 removed the To do this compress the compressor as shown in speical valve spring Figure dia length 4 276 Coil turns 6 5 Effective coil turns 4 5 4 2 Spring constant kg mm Pressed length 1st mm Pressed mm length 2nd kg kg I 0 r oi N r 38 5 30 0 31 0 61 2 I 0 I 45 Valve r 7 Spring Compressor Removal Remove the two cap retaining collets Release the valve spring the valve spring valve oil seal Inlet valve only and its cap retainer Witlidraw the valve from the guide Keep the valves when removed replacement in their relative from in their the engine original to positions ensure Checking Spring valve guide s 21 Tension r DATSUN 1000 I ST 4356 0 0 0 r Valve Valve Valve Spring Turning the Valve Seating Grinding Before replacement of the cylinder head the Exhaust valves and their seats should be examined for sings of pitting If these seats must the in or burnt conditions valves whilst minimum 18 mm valve heads Only metal C s u he shonld Intake 34 removed in the When valve turning process grinding a valve onto face smeared be should grinding paste and then lapped too The valve type grinding to its seat with a semi rotary and the port will assist valve in order process on the On must be the necessary to A when the face should be grinding light continue tbe seating and the valve face the valve seats completion lifting to VALVES a done Valve head diameter compound until an even mat surface is and dried essed air blast in i and mmltt ground grinding produced and the subjected to Intake valve 35 0 mm Exhaust valve 29 0 mm In Ex Valve seat width Valve stem outer diameter ports both intake and should be throughly cleaned with gasoline soaked rad 6 with lightly mortion rotate This position freque ntly to spread evenly is the 6 mmq in with a suction considerably to different It sealing Exhaust 28 between the valve head coil spring interposed the its only S grind valve renewed of amount Ex 1 3mm the valve present distorted the or In patches and distortion are be recut before attemoting to should be trued the Cutter a com Overall The valves should be washed soline and all traces of grinding compound removed 22 ex 1 3mm 1 8 mm 8 7 0 6 mrn 01 0 length Intake valve 109 54 Exhaust valve 108 74 mm mm 02 ENGINE unit 13 I IR l r Standard Clearance accuracy limit 2Oo t 9R l 5R Clearance 5R In between S IljJ 2 5 6 0 040 Exh o 045 0 065 guide S 0 2 5 I Reamer for guide of cylinder head 2 6 5 SST No Exhaust Valve ST 4355 Finishing 12p S T D dimension 0 0 0 011 O S and 011 H6 GUIDE Removing 10 8 5 Intake Valve 0 020 0 valve stem 84 N 4LVE V mm Refitting 12 Valve Guide 5p H6 0 Valve Guide Service Parts Standard tight 0 mm ST 4354 025 0 040 Reamer Part No SST NO 13212 18010 O S ST 4355 13212 18000 S ST 4355 13213 18010 O S ST 4355 13213 18000 S T D ST 4355 In T D Ex Fitting warning up position of a valve guide cylinder head 2000 C after the Pressing direction In Ex Remove the D cylinder head Remove the appropriate valve and spring Reset the cylinder head with its machined face o downwards on a clean surface and guide downward into the combustion a drive the space with drift This should take the from of hardened steel In Ex punch D When fitting new valve guides these hourCl cylinder head be driven in from the top of the Location of Valve Guide to be Fixed 23 r DATSUN 1000 Remoying Valye a In an ernergency When its T aid of plug a 4 down orifice spring drivers the plug from or as a shaft as a 1ft 5 Ibs screw valve the cotters and the point two 4 8 the renew of Tightening The Order the the Cylinder Head Nuts Cylinder Ensure that the block joint faces t 6 2 screw valve spring are cylinder head and cylinder clean cylinder head gasket is marked that it will be head in correctly The finally pulling Figure torque wrench set to cylinder cylinder bent fulcrum be compr essed with a fork ended bar Withdraw so a will pass through the sparking and locate on the valve head By rocker can Refitting in given with to eliminate any into the suitable tool such which using the falling the order them Hold the valve onto its sealing with concerned driver in be head Deposition of the valve Remove the spark the can removing cylinder the applicable piston must be doing this brought to possibility valve spring a new the without fitted in Position Spring placed Top Reset the valve clearances check them when the engine is The cylInder more head bolts may and pull down clearances will have to be checked reset if necessary TIGHTENING Cylinder Measurement gasket into position and lower the Fit the cylinder head cylinder place nuts securing finger tight Insert the push rods replacing them in the Place the head into positions from which they were taken Screw back all the tappet adjusting Replace e rocker the securing nuts the ten cylinder assembly and finger tight head bolts a screws screw down Evenly tighten little at a time 24 slightly the engine has attained its normal in which case the valve temperature after working Head Distortion finally not hot or cold TORQUE I I I 3kgm again and ENGINE Clean and adjust the Refit the inlet and exhaust manifolds Fit the carburetor and reconnect the control Refit the ignition linkage advance suction at to this stage be removed later to check the valve position and thermostat secure and its housing engine temperature in remove Reconnect the water temperature gauge wire and fit the radiator hose to the thermostat housing Ensure that drain tapes the are cables radiator and closed to the part of the electrical When been rocker The Replace the normal reached cover so on and the operating switch off and that the valve final check has been made Whilst the engine is running check that the and fuel line unions do battery cylinder the has and refit clearances may be rechecked Replace the rocker cover and fit the air cleaner when the with the three nuts Connect the engine secures started Replace the rocker cover taking gasket correctly the clip which is 1 3 4 2 wiring harness to the side of the head The ignition can now be switched to fit the cork Place firing the refit the air cleaner or it will have clearances care pipe but do not to the connection on the carburetor clipping order of the on sparking plugs the high tension leads them block water hose connections not leak and refill the radiator Tighten them if necessary 1 25 DATSUN 1000 26 ENGINE REFITTING REMOVING O tt i pj Il zl j q I f C J J Y 1 i I h I I oF I Disconnect the speedometer cable from the transmission Experience has to the remove single To shown that it is much easier engine unit than to and transmission detach the engine as a by itself the engine and transmission proceed as follows Completely drain the cooling system and the remove upwards transmission battery and its disconnect Remove the upper by undoing and and lower radiator hoses the retaining clips the capacitor lead also the high tension and Disconnect tributor the remove supporting tray the at dis switch wires at the coil Take off the dynamo lead and disconnect the starter motor cable at the motor end Remove the oil gange and water Uncouple the propeller shaft pinion franges temper ature gauge leads from their terminals on at rear axle and draw the shaft out of the trans the mission engine The throttle and choke controls disconnected from the carburetor the fuel pipe from Next must be Disconnect the fuel pump remove the exhaust pipe from the manifold From change below selector the rod vehicle from remove the lever the gear on the transmission casing DisconneCt the earth strap from the starter motor Remove the hand brake control rod supporting from transmission 27 r DATSUN 1000 l 1 Jr 1 1 r Ii 1 ii d Jy i r r 1 I I f ds OPERATION I l i I WITH THE ENGINE REMOVED 3 151 6 16 17 8 13 12 11 I t4 9 A Engine Mounting 1 Insulator 7 Ass y insulator 2 Bracket engine mounting engine mounting front front R H 8 Member 3 Bracket engine mounting front L H 9 4 Washer plain 5 Washer lock 6 Nut 13 Washer lock 14 Washer plain Balt 15 Bolt 10 Washer lock 16 Washer lock 11 Nut 17 Nut 12 Bolt 28 engine mounting engine mounting eo ENGINE v 0 Bracket rocker shaft a 0 a 5 5 c 0 i f 0 Spacer rocker valve 0 go ii lifter valve a Camshaft c 0 o tj 0 e u o J g Camshaft Valve Mechanism LIMIT o 15mm ACCURACY Intake valve 4BO Bottom dead 500 center 29 0 03 0 07mm DATSUN 1000 2 12 IS 28 I 7 9 I l 15 13 I 18 37 3S I I 20 32 Block Cylinder I AA 2 801 3 Washer lock 17 Seal oil Ptug 18 Pipe mcti Plug taper 1 Plug water Plug taper 20 Auty S block y cylwdn 15 16 taper 7 Plug craukC2SIf 8 Plllg oil gallery blind Dowd titnina chain cover 10 Dowel timing chain locatiDg 11 Set 12 Slll 13 S bushins canuhUt S Jet oil tirningchain crank Seal 22 Temiaaer oil 23 Support cbain OOlnI er l tendCQ watu 80 Z7 uher W lock Block sufficient rigidity light despite its compact and construction The flange is provided at the rear h2in c temion Bolt The cylinder block made of special cast iron has timing Galket timing 29 Gauge oil level 30 Slinger engine 31 801 32 Au y oil 33 Plug cl2J1kshaftfront 21 25 w drain cover Slll Cylinder shaft 28 side of the cylinder block to connect with the transmission directly 30 pump side ensiCl l ide cbain covel fmnt an p drain Guket in 35 Seal oil oil pan fn mt 3 Seal oil 37 Gasket 38 Gasket oil pan t H 3 Bolt 0 Washerlock plug oil pan rear oil pan R H 5 ENGINE Camshaft Clearance o 03 Limit of bent o 05 mm out of Camshaft bore in crankcase 0 07 mm Less than 0 03 mm roundness End o play Cam height Intake and exhaust Wear limit of earn No 1 43 No front 43 793 806 S T D 43 S o 25 US o 50 US o 75 13005 43 543 43 Lapped 2 43 283 556 296 43 033 43 046 13006 18002 18002 43 293 43 306 42 783 42 796 13006 18003 13005 18003 43 043 43 056 13005 18004 42 533 42 546 13006 Dimension No 13006 18001 13005 18001 U o height Camshaft Size 18004 0 02 36 45 42 3 783 13007 42 533 08 mm 36 55 mm 5mm mm No center 42 796 42 546 42 033 L fflT 1516 Cvlinder Head 31 42 246 41 783 40 968 40 981 13009 18002 41 796 40 718 40 731 18003 13009 18003 41546 40 468 40 481 18004 13009 18004 13008 42 046 rear 13009 18001 13008 18002 42 296 5 41 218 41 231 41 533 13007 18004 1 J No 13008 18001 13007 18003 42 033 4 42 283 42 296 18001 13007 18002 42 283 Part No Bushing 13008 1 Ass y head 2 Guide valve intake 3 Guide valve exhaust 4 Insert valve 5 Plug taper 6 Plug taper 7 Stud water 8 1ci Sb cylinder intake at manifold outlet manifold 9 Plug blind 10 Plug heater outlet hole head 11 Gasket 12 Bolt 13 Washer lock cylinder cylinder 14 Slinger engine 15 Outlet 16 Washer joint 17 Washer lock 18 Nut 19 Ass y 20 Gauge 21 Nut 22 Clamp tube 23 Clamp vacuum 24 Ais y 25 Washer head front w2ter water outlet thermostat unit water temperatUre ground fuel pump valve rocker cover lock 26 Screw 27 filler 28 Cap oil Packing 29 Packing rocker oil to carburetor control tube filler cap cover DA TSUN 1000 Removing and Replacing the Tappets Remove the carburetor and the rocker cover washers then take off the maoifolds and the caps withdraw push rods it is essential keeping To remove side so that they fall into the guides weight Assembly is cedure rockers original mark the bores Release the connecting rod from the crank shaft and slowly push the piston and rod upwards under through when lubricated a refitting connecting rods on the sides to identify The piston and connecting rods together must be with drawn upwards through the cylinder the tappet of camshaft when drawing out the their own fitted into their them pullout the tappets camshaft also keeping them in same locations New tappet should be fitted by selective assembly replaced after dismantling are caps and their respective positions from the are they To ensure correct positions them in withdraw the and It will be noted that the caps are off set When used parts high tension leads remove the rocker assembly Disconnect the sparking plugs the big ends from the cylinder bore reversal of the above pro but care should be taken to see that the are adjusted to give the correct valve clearance NOTE Piston and Drain the radiator engine strainer Connecting cooling Rod Removal water from the It engine and with Drain and remove the sump from the then disconnect Take out and remove the setscrews the and may be carbon a necessary to remove the ring of lip from the top of the cylinder bore or hand scraper to avoid risk of piston ring breakage oil Remove rock the assembly the from top of the cylinder block Check the crankpins for oval with a pair of calipers and examine the bearing either for defect scoring will micro meter surface necessitate the removal of the crankshaft for regrinding CONNECTING ROD Difference in weights of connecting rods engine in one Less than 5 gr Limit of bent or twist 0 05 mm Side clearance 0 2 0 01 0 3 mm Connecting rod bearing clearance Removing Connecting 0 05 mm Crank pin bore Rod with Piston diameter 32 44 961 44 974 mm ENGINE Rod Connecting Part No Bushing for rePlacement Bushing Thickness Size mm 44 961 44 1 540 1 548 mm 44 881 44 984 mm 1 560 1 568 mm 44 841 44 854 mm 1 625 1 633 mm 44 711 44 724 750 1 758 mm 44 461 44 473 mm 875 1 883 mm 44 211 44 224 2 008 mm 43 961 43 874 mm 1 500 1 508 12111 18000 S T D 12111 18001 US o 08 12111 18002 US o 18003 US 0 25 12111 18004 U S o 50 1 12111 18005 US o 75 1 1 00 2 000 12111 12111 18006 US 12 of Crankpin dia Lapped 974 mm mm mm CRANKSHAFT USABLE ST LIMIT ACCURACY Main O 30mm 0 05 0 15mm bearing journal Less than 0 03 mm round Less than 0 03 mm Limit of bent Less than 0 05 mm out of round out of Crankpin Crankshaft main end bearing play 05 0 0 15 mm Bearing clearance 0 limit Main Part No front 12247 18000 center 12215 18001 front 12247 18001 center 12215 18002 front 12247 18002 center 12215 18003 front 12247 18003 center 12215 18004 12247 18004 The Bearing Bushing for replacement front rear rear S T D rear 961 mm 49 95h49 mm 49 701 49 714 mm 952 1 960 mm S 0 25 1 U S 0 50 2 077 2 085 mm 49 451 49 464 mm U S 0 75 2 202 2 210 mm 49 201 U S 1 00 2 327 2 335 49 214 mm 48 951 48 964 mm mm center shell bearing are ings if they or following removable by hand bearings are require no bending in it is being only necessary to ensure that the housings and to place the are scrupulously Clean and dry the into with position tangs located in bearings corresponding of Journal 1 827 1 835 The their Dia U rear rear Lapped Bushing Thickness Size 12215 18000 1 mm slots Always renew are the bearings will be available with bear 33 are punched damaged in any way regrinding of the crankshaft required and the kinds of sizes scored 8 mark 12 or 25 50 75 and 100 DATSUN 1000 1 a l 3 17 18 19 1 7 13 10 12 20 14 45 6 8 5 6 11 Piston 1 Set piston 2 Set ring piston 3 Ass y rod 4 Bolt with pistoD Crank pin connecting connecting rod Shaft 12 Thrower oil 13 Pulley 14 Washer 15 Bolt crank crank shaft crank shah lock pulley 5 Nut 16 Set 6 Bushing connecting rod 17 Ass y flywheel 7 Ass y crank shaft 18 Gear 8 Bushing pilot 19 Dowel ring flywheel flywheel 9 bushing Key woodruff 20 Washer 10 Sprocket 21 Bolt 11 Washer crank shaft packing crank shaft 34 bolt pulley main flywheel flywheel bearing ENGIN PISTON Replacing Insert assembly taken the Pistons and into Connecting piston ng and it is essential that the is Rods rod piston connecting the cylinder from which it was each in the skirt of split positioned towards the camshaft with Compress inserting piston rings piston using tool and gently tap the crown of the piston with the wooden end of a hammer handle until the piston is clear of the piston ring clamp the Direction of Ring Gap push the piston down the cylinder block end of the connecting rod just of the cylinder the bottom protrudes through N ow until the big bore then position upper half bearing shells the Piston Inserting i l x Piston Adaptor Bushing of Connecting Rod service parts Finished Dimension Part No Size 12111 18000 S T D 12111 12111 12111 12111 18001 18002 18003 18004 Thickness of Bushing of C rankpin mm 44 961 44 974 mm US o 08 1 540 1 548 mm 44 881 44 894 mm US o 12 1 560 1 568 mm 44 841 44 854 mm 25 1 625 1 633 mm 44 711 44 724 mm o 50 1 750 1 758 mm 44 461 mm US US 1 500 1 508 o 44 474 18005 US 0 75 1 875 1 883 mm 44 211 44 224 mm 12111 18006 US 1 2 000 2 008 mm 43 961 43 974 mm 12111 00 35 DATSUN 1000 Remove NOTE bearing has two oil by ensuring sufficient and it is of and Each upper there holes lower connecting The and the small end of the from the pin rod press out the is press fit in gudegeon pin the greatest importance that the corresponding oil hole in the bearing shell registers witll the oilway to unit provide an unobstructed passage connecting rod onto the crankpin into Wear accuracy limit shell rod the cap connecting locking washers the Insert setscrews and tighten with a 3 6 kg m torque wrench to 3 4 taking 0 o 2 0 Allowable error TIGHTENING 05 Inner dia cap and the position the mm Correctional Pull the the gudgeon pin piston cyl TORQUE 0 Elips of within inner Taper dia 0 Difference of inner dL 015 020 within 0 each cyl 05 Piston Over Size Part No Over Size S T D Measuring Thnlst Clearance of Connecting Rod Finally knock back 0 clearance bearings and 4 mm rod big the the OS 0 25 12013 18000 OS 0 50 12014 18000 OS 0 75 12015 18000 OS 1 00 12016 18000 OS 1 25 12017 18000 OS 1 50 12018 18000 Insert 0 03 mm thick Feeler gauge between cylinder bore and piston and measure end for side that see at the lower shell crankpin when to the binding If it is difficult to rotating the crankshaft turn undo the big end and examine the shell and angle seat for dirt or regulations are not on or their mating surfaces portion of piston pin Pullout scale grit Before reassembling always apply a little clean oil to the piston surfaces and into the Never file the connecting rod cylinder bore caps 18000 Piston and Bores the lock washers Check the connecting 12012 the cylinder bore with and then 0 5 15 kg or not oval in the bearing Removing a Piston Measuring isuring Me A J I b g Measuring for B direction A 1 co CD Bore Siz e Removing 36 right feeler gauge by the spring inspect if the reading is within this creates as at Piston Ring ENGINE Piston Rings The when unit piston ring in checked of clearance grooves gap should be within 1 the the should amount to 0 20 control ring 0 041 0 bore cylinder compression 0 in rings mm mm The Standard Clearance their accuracy limit and ihe oii mm Clearance 092 mm between 07 o 20 04 007 o 20 04 0 Top o 04 Second 0 Oil 0 0 Groove ring r r 08 Clearance between 0 003T Pin hole 0 pin o 20 0 02 009L Clearance Between Ring and Groove Because end of the the piston rings do not travel to the cylinder bores a lip is eventually formed due to wear a dial gauge and If this is not done there will operation or a fractured checked with This may be must be removed tendency to noisy caused by the top piston ring striking ring lip be a Pis ton Pis ton Ring side clearance Compression rings Oil ring side clearance End gap of both piston the compression and oil rings o o S S S 12012 0 25 0 0 50 75 07 mm 0 08 mID o 2 12013 0 3 mm 15t Piston Ring Set Piston with Piston pin o 0 04 10 S S T D 04 o press fit piston pin with set o o Upper Lower Oil 18000 12041 13200 12043 30000 12046 30800 18000 12042 13200 12044 30000 12047 30801 12042 13201 12044 30001 12047 30802 12042 13202 12044 30002 12047 30803 12047 30804 12014 18000 12015 18000 OS 1 00 12016 18000 12042 13203 12044 30003 OS 125 12017 18000 12042 13204 12044 30004 12047 30805 o 1 50 12018 18000 12042 13205 12044 30005 12047 30806 S 37 DATSUN 1000 Piston and 0 50 mm oversizes fitted from rings 0 75 available in O 25 are 1 00 mm and 1 mm 50 mm The piston rings should always be the crown of the piston and never pushed upwards over the skirt Before fitting deposit from the fitting note that grooves in the piston is the second compression tapered type and oil control ring is slat type processed by chromium the rings remove any carbon When plating Measuring Clearance of Ring Joint 38 ENGINE The following operations with the engine Although it out certain it is more Remove best performed are drive removed from the car may be found possible to carry the shaft valve lifter Take the off the oil pump timing and its cover and gears attentions with the engine in position convenient to do the work on the bench M 371 Removing Crank Gear BENT Cam Gear LIMIT O 05mm CORRECTED ACCURACY 0 015 UNDER and Chain Withdrawing The plate Camshaft camshaft washers the Note lubricating oil hole replacing should be End the play positioned by is three held by of 0 1 screws and position of the small locating plate when to the right of the engine 0 2 mm is controiled by in the thickness of the locating plate checked with a a locating shakeproof dial indicator set and can against be the Take out the camshaft gear Before the withdrawing tributor driving pindlewill camshaft have setscrews shaft locating piate the dis securing the when the camshaft withdrawn from the cylinder block to be removed 39 cam can be DATSUN 1000 Camshaft Bearings White metal lining PLAY LIMIT are O I mm can be taken out used for the camshaft renewed when necessary this when the with steel bearings They it being usual cylinder block is to do being recondi tioned The bearings can be removed by drifting them out of their housings t When fitting new bearings care taken to line up the oil holes with the ponding holes Tap in the the lew them to give a must be corres cylinder block bearings into position and running clearance of 0 1 ream 0 2 mm Setting position for dowel on key the straight line Key guide STANDARD CLEARANCE O I 0 2mm Assembling l ili direction O i J o Refitting This is the Camshaft a reversal of the introductions for Sprocket removal 40 l Cr nk shaft ENGINE 24 25 17 14 19 13 3S 20 18 G 3 rF 1 I U liS earn Camshaft 13 Spring 2 Dowel 14 Support camshaft gear profile Valve Mechanism Camshaft 1 chain tensioner chain tensioner spring 25 Plug expansion 26 Spring inside rocker 3 Plate camshaft 15 Bolt 27 Bracket rocker shaft Bolt 16 Washer lock 28 Rocker vaive No 1 5 Washer lock 17 Valve intake 29 Rocker lve va No 2 6 Sprocket camshaft 18 Valve exhaust 30 Bolt rocker shaft 7 Bolt camshaft 19 Spring valve 31 8 Washer camshaft 20 Seat valve Washer plain Spacer rocker valve 9 spring 32 Washer lock 21 Retainer 33 SCrew 10 Chain 22 Collet valve 34 Nut 11 Tensioner chain 23 Seal 35 Rod 12 Bolt chain tensioner 24 Assly 36 Lifter valve cam haft oil valve spring valve shaft valve rocker 41 push haft rocker shaft 4 sprocket 6R DATSUN 1000 2 I 1 3 1 t 18 j 13 10 12 14 15 I 6 I 8 5 6 11 16 Piston 1 Set piston 2 Set ring with piston pin pistor 3 Ass y rod 4 Bolhconnecting 5 Nut 6 Bushing connecting 7 Ass y crank shaft connecting rod rod Crank Shaft 8 Bushing pilot 15 Bolt crank 9 16 Set 10 Ker woodruff Sprocket crank 17 Ass y flywheel 11 Washer 18 Gear ring 12 Thrower oil 19 Dowel 13 Pulley 20 Washer 14 Washer lock 21 Bolt shaft packing crank shaft crank shoi ft crank shaft pulley bolt pulley bushing main bearing flywheel flywheel flywheel flywheel CRANKSHAFT Wear limit at pin portion of o 03 mm elliptic or taper crank shaft journal Limit crank shaft alignment Not to exceed 0 Side clearance of crank shaft Within 0 3 mm Crank shaft journal oil clearance o Portion of crank shaft thrust 2nd side Bushing bushing 02 05 mm 0 06 mm size of crank shaft S T D Dimension of crank shaft journal Dimension of crank shaft pin 49 951 49 964 mm 44 961 44 974 mm over 0 25 0 50 journal 42 0 75 1 00 ENGINE Main Bearing Caps Remove the Take the and strainer Unlock and bearing flywheel and clutch off the timing the chain engine sump and mounting plate rear the bolts securing the main cylinder block also the two front cap to the engine front remove caps to the bolts securing the bearer plate Note that thrust a of the side center washer is fitted main consist half having the of lug a detachable two each the semicircular valves which is located in half on take These thrust washers crankshaft end thrust each bearing to one a recess of the bearing in the other being plain When fitting new bearings no scraping is required as they are machined to give the correct 0 0127 running clearance of 0 005 0 Removing Flywheel 002 in 0 0508 mm TIGHTENING 5 0 5 TORQUE 3kgm Main Bearing Ensure engaged that the locating tangs properly in their recesses Handle the to are Cap new bearings carefully so as not damage the fine surface finish Remove all and housings fluffy clear rag traces of dirt and oil thoroughly dry Make sure that from the them with the a oilways non are When fitting the bearing caps esnure repiaced the right way round Each cap is punch marked and the marks should race the camshaft side of the engine that they are Removing Crankshaft 43 DATSUN 1000 I I I Wear limit o 7 03mm Measuring Crankshaft n Pin and Journal Caution Never file the bearing caps to take up sive playas Always cause the cover engine oil when they TIGHTENING ORDER FOR THE MAIN BEARING CAP I this will are exces ovality surfaces bearing with replaced caps are held in position Pull the set by setscrews and lock washers The main I bearing tight with screws up loading of 5 0 When refitting the center rotate 5 3 one a kg torque wrench the main first bearing caps tigbten after each cap is tighten crankshaft the set to a m to ascertain that it revolves freely If it is tigbt and foreign the last cap tightened bearing and its seating for remove the examine matter Check the crankshaft bent gauge by means This should be within 0 05 If a bearing has clean out all oilways run it is of a dial mm essntial to in the crankshaft and block Wash out the engine sump and the strainer The oil metal Accuracy to less than 0 015 system mm correcting measuring bend of crank shaft allowable limit 0 05 mm 44 pump sshould Ensure cleaned are left be dismantled and particles of bearing within the engine lubrication that no ENGINE Measuring Side Clearance of Crankshaft within 0 3 4S Play mm DATSUN 1000 46 ENGINE IGNITION TIMING DISTRIBUTOR 1 12 11 8 10 13 9 i 5 I 6 1 Jt @9 25 t 25 Q 2 Ass1y clamp Ass y clamp 3 Ass y shaft 4 Ass y 5 Screw 6 Ass y 7 Spring 6 3 cap cam weight governor governor 8 Ass y 9 Washer 10 2 cap head rotor thrust Ass y braker 11 Set 12 Ass y wire lead 13 Ass y wire lead 14 Screw 15 Assly 16 Ass y control 17 Screw 18 Ass y cap 19 Ass y 20 21 Cap high tension Plate fixing 22 Bolt 23 Ass y pinioD 2 Ass y condemer 25 Screw contact 6 1 @ 23 i Vis tributor Hitachi fi 47 point terminal vacuum distributor point thon set able DATSUN 1000 Inside the distributor is shown in brakes This Figure braker electrode as and makes thousand times several contact braker point a spark not be treated which the ignition see a spark plugs vacuum type timing flows current coil etween these braker varies with the gap the because the time Also lightly not be can functioning properly determined by the inspection pointer located at the diaphragm if as the engine is being run this pointer moves when the engine speed is suddenly changed the advancer is satisfactory the maintenance of this braker must Therefore during in one of the or is advancer in one contact this braker brakes generated is the inside of the cap also Whether minute Each time on ADJUSTING points IGNITION THE TIMING this gap is maintained at the standard which is 0 45 mm The braker points must be kept free of that value The ignition timing is before top dead If the points should become grease burnt of blackened they are cleaned with a fine and honing oil stone or croucus should be wiped has been dampened with If the points replaced replaced as A djusting To a which they piece of cloth which Braker points slides turn the the 55 mm easily Finally 0 018 to 0 screw check Then the gap once The interior terminals with a positions before top dead center wing foll Adjustment is made by the deg procedure securely extra attention the 2 thickness 022 ins between the braker points cap is wiped clean between engine the braker by turning the adjusting plate until a feeler gauge of reinstall the rotor of cloth intil Next tighten the fixing of the piston of the No 1 cylinder is in its 8 degrees before top dead center position for compression the standard ignition If a timing lamp is used 15 before is top dead center at timing degrees 600 rpm speed idling In the case of marks which are not evenly 15 deg and spaced pointers indicate 10 deg Then loosen the braker point is move further at the With the engine stopped adjust so that the distributor breaker point just breaks when the the Braker Points fully open fixing screw even the rotational speed be sets crankshaft with the crank handle o 45 to 0 they always degrees engine stopped adjustment the time the engine starts to rotate and the timing is maintained constantly at valves suitable for must be must adjust the braker points screw advances the ignition timing gasoline badly burnt are to 10 With this shown in Figure automatic timing advancer of the distributor as cloth after clean with adjusted center with the more Clean First 1 and exterior soft being paid then dry piece gap as adjust the distributor to the correct described previously to the areas the center t A Adjusting th e4Foillt Cheekiiig Gap 1Joo 1M J i efIgnition Timing fh of g i l Jr t 48 I 1 i ENGINE 2 Turn the crankshaft gradually If these conditions do not coincide they are by slightly turning the dis tributor body only To determine the position when the breaker until the top made to do dead pulley perifery for 10 with the mark coincides degrees the before top dead center on timing gear its the crankshaft cover as approaches somewhat that before correspond positions mark center 4 ing cylinder body until spark jumps the gap across The spark 1 4 inch away from the and turn the head slot position of the drive off set shaft piston is in its compression top dead center position is shown here when the the crankshaft in With 1 cord about 1 crankshaft turned turn on the hold the end of the No ignition key piston Stop the crankshaft in this position The compression stroke of 1 piston can be determined if the the No spark plug of the No 1 cylinder is removed with a finger and the the hole plugged the No so point is just beginning to open compression stroke of ned of the to the the on previously mentioned position the No 1 piston is in its position of 10 degrees before top dead center of compression No 1 the 3 Next the gear the the inserting distributor at an driving shaft to the engine camshaft During this Next 6 To on of the assembly place somewhat to the left shaft shown in Figure At this time on and the No 1 spark plug connect from the terminal to which the rotor the siot of the distributor drive of the upper end cap clamp it of the engage lower and with the gear its on angle put the distributor securely with the clip 5 is Thereafter pointing as clockwise order counter 1 3 4 2 of the semicircle is placed toward the front 7 arm so to botain as distributor with a rubber cap start now is a set cover The the engine properly the Ordianrily selector the in the firing order Upon completion of the wiring should cord of the connect park plugs terminal cords to their the smaller the at its octane pointer of the zero reading during the If the octane adjustment number of the fuel being used is low and the the pointer is adjusted to the engine knocks right R to the optimum advance angle if the octane number is high Conversely the pointer is adjusted to the left A One unit f of calibration of the selector corresponds to 2 ignition Setting of Timing 4 Adjusting the assembly shaft slot the to same engine the directions of the and rotor must be the as mount the setting it is degrees before top dead 600 620 center In any case the distributor just beginning 15 idling optimum adjustment is that in which a slight knocking is heard when with the car running at acceleration TOP gear low speed in HIGH is applied suddenly During this shown in Figure is with the engine At the breaker must be in its time position when degrees of the distributor angle and to 4 degrees of the crankshaft angle the standard When a timing lamp is used direction of the rotor so that it engages the drive distributor Gear timing to open I 49 j fh J r J1 DATSUN 1000 REMEDIES TROUBLES Excessive Oil Consumption Lack of Burning Oil 1 Ignition System Improperly Adjusted not Rings Give to correctly seated time sufficient 1 cylinder wall for rings to seat Replace IT necessary 2 Piston rings worn Excessive excessively or stuck in 2 cylinder fitting between to piston 3 and improper or wear spark points correctly and timing engine properly timed ignition by the instruction under specllication of engine pistons scored Cylinder walls tapered or out lack of Fuel of 1 Recondition cylinders fit and ring 2 oil return hoies clogged Gas line partly plugged Clean gas lines new pistons Piston seat not Set round 5 Ignition correct Fit new 4 due adjust and Distributor points not set Set distributor clearance wall Spark plug faulty Replace or dean pings Replace ring 3 Power Engine Dirt or water in carburetor Clean carburetor and fuel pump with carbon 3 Replace rings 6 7 Piston ring broken Repiace rings 2 r 4 leaking sealing or check for 5 Rocker arm cover gasket or 6 tappet cover damaged or loose Tighten covers or replace gasket 1 Oil pan drain plug loose 2 dirty Carburetor choke partly closed Adjust or replace choke mechanism Over Heat Oil pan gasket damaged 1 Fuel pump loose or Rear 2 pump bolts or Fan belt ioose Adjust gasket damaged 3 replace or replace Fan belt worn or oil soaked Replace belt 4 main bearing leaking oil into clutch housing or flywheel housing Adjust or replace main bearing or bearing Lack of water Refii system Timing cover loose or gaskei damaged Tighten cover bolts or replace gasket main Water pump Replace 5 oil seal inoperative water pump Thermostat sticking closed Replace thermostat so f Air cleaner Clean air cleaner gasket I pump Oil pan retainer bolts loose Tighten fuel 7 epair fuel Corburetor Air Inlet Restricted tightening Replace gasket 5 functioning properly or Oil Tighten oil pan bolts 4 gasoline line Fuel pump not Replace Tighten drain plug 3 Air leaks in Check gasoline lines and tighten Valve stem oil seals missing leaking 1 gasoline tank Clean the tank Replace seals 1 Dirt in ENGINE 6 Cooling system clogged Clean and reverse 4 flush ignition or valve timing Retime engine 5 9 10 6 adjust carburetor 7 Low Engine 1 Cooling all connections 2 Replace thermostat Condition Valves burned Hard Storti ng cranking oil Leaking manifold gasket manifold 4 Loose carburetor 5 Faulty pistons Partially discharged battery Change battery 3 Faulty or undercapacity battery Replace battery 4 Poor or replace rings or cylinders Lack of power Carburetion 1 connections or bolts mounting Tighten carburetor mounting bolts See 2 Clean and tighten change Valves holding open Tighten gasket battery condenser Adjust valves 3 Heavy engine oil Change to lighter in capacity condenser Grind valves or Thermostat holding open 1 primary Install proper condenser Exhaust system partly restricted Clean or replace Slow in connections circuit Adjust valves Over in Series resistance in condenser circuit Clean Valve improperly adjusted 11 corroded circuit Fuel mixture too lean or all Tighen to correct oil Overhaul and Loose connections in primary circuit Improper grade and viscosity oil being used Change loose Clean code and cap terminals Incorrect 8 codes distribotor cap J 7 Spark plug Choke not working properly Adjust replace 2 connections or repair choke mechanism Throttle not set properly Set throttle 5 Faulty starter switch 6 3 switch Replace Fflulty starting motor or starting Carburetor dirty and passages restricted Overhaul carburetor switch Spitting and Ignition 1 Ignition trouble Distributor points burned or corroded Clean 2 or replace points Spark plugs improperly gapped Set plug gap correctly o 7 0 8 mm 0 0275 0 0315 in Loose 2 Faulty wiring Replace faulty wiring 3 Faulty spark plugs wiring connections Tighten all code connections Clean 51 o 1 Points improperly adjusted Readjust points correctly 3 Detonation Troubles or replace and adjust piug gap l DATSUN 1000 f t l 52 ENGINE FUEL SYSTEM Air clea ner Fuel strainer Fuel tank A Quantity BlO 35 1 VBlD 30 L Carubretor Fuel pump CARBURETOR Secondary vent vent Primary pipe Primary main nozzle bleed Primary pipe zzle Secondary main Secondary main bleed illn m Primary slow bleed Primary slow jet Needle alve Float Secondary emulsion tube Sectmdary maUl jet AuxiliaiY valve Counter lever Primary emulsiQll tube I Primary By main jet pass hale Secondary ttl Idle hole Iv 1 f counterT t weight Constructure Model Hitachi DCG 286 3 Type Down draft 2 barrel Primary Throttle valve bore Main jet 95 Main air bleed 80 210 18 j 1 mm Fuel pressure o secondary degrees 120 60 Float level at 48 160 15 mm Needle valve dia begin 7 mm x 140 220 Power jet when the 24 40 Slow jet Slow air bleed The 28 mm 20 x 7 mm Venturi size Secondary 26 mm 16 kg cm2 throttle valve is open to primary throttle valve is open The carburetor has the function of automiz ing the fuel mixing it in suitable ratio to and supplying the mixture to the engine It is therefore an important part which influence the performance of the engine The carburetor is a highly efficient air can one of barrel two step and down draft type having the following special features two DATSUN 1000 ti 4O c 1 e f1 57 155 43 1 8 j r 35 tl 28 et27 29 29 9 30 12 @ 21 Bleeder 26 DIeNer slow air It 27 Jet main 95 28 Jet main 160 29 Washer 30 Plug 31 Ass y 32 Shaft float 33 Ass y 34 Washer 35 Ball 36 Spring 37 Piston 38 Gasket float 39 Screw 1 1 3 1 r Plate adjusting throttle 2 Washer 10 3 Lever 11 4 Sleeve starting 12 throttie 13 Spring adjusting Spring throttle Rod connecting JSher W 5 Lever 6 Nut 14 Screw idle adjwing 7 Wasber 15 Spring idle adjusting 8 Screw 16 Ass y holder spring adjusting throttle throttle wue valve J needle urn ret Screw 41 Wasber 42 Spring 43 Iever choke pistoD chamber spring choke 44 Spring choke valve 45 Bleedu slow air 46 Ass y bolder 47 Hanger spring 1220 choke wire throttle throttle chamber Lever pump 49 Shaft pump lever 50 Washer 51 Washer 52 Cover pump spring Gasket S3 Rod pump 18 Screw S4 Rod 19 Screw 55 Pin 20 W 56 FilteT 57 Packing 22 screw lt flo 17 21 cotter pil1 S turn 9 screw 120 P drain 40 48 2 slow air BO P 2S her lpring lsber Weight injector 23 ro Tube ermusion P 24 Tube Carburetl r S4 e bion Hitachi S connecting choke cotter 58 Bolt filter 59 Jet slow 140 60 Spring throttle return ENGINE Main Primary Carburetting System of Primary Primary le z oz main main the venturi small to minute be drops compensating sparseness of the fuel A jetting amount of the fuel can be varied with the two holes provided on the pump arm that is bleed tracient the inserting positions of the connecting rod Pump lever Pump nozzle I Piston Primary main jet By pass hole Idle hole Primary throttle valve PBton Partially Loading The fuel Outlet valve out of the passage at the float chamber passes through the flowing bottom of the spring eturn Inlet valve primary main jet and then mixed with the air coming from the main air bleed to be minute drops and inject into the venturi through the At Accelerating v main nozzle When the throttle valve engine the accelerating requires dense where The power widely mixture open and gas its power valve pump opens the fuel is also flows into the main valve Starting System the from The and system beings operate degrees from full to when the throttle valve opens 48 choke valve is provided with the spring installed eccentrically device carburetting throttle valve closed a full close operation Speed System valve Passing through the from passage separate through the slow jet main main jet the line and slow air bleed first and the on When the cho e is 14 fully closed degrees from This is the best condition to start The the synchronization of throttle valve can the choke be maintained often the engine has started fuel normal and synchronized with the the throttle valve opens about position Slow rod Pump connecting Primary throttle valve exactly firing flows slow air bleed second and inject from the by pass holes and idle holes economizer slow Accelerating System Mechanical accelerating pump synchronized with the throttle valve is valve is closed the linkage the piston which the dumper spring down adapted rod is When throttle pushed up with up the piston through When the piston is coming pushed the inlet check t valve closes the outlet check valve opens and the fuel within the pump is the pump jet by the compressed spring and hits agairist the side wall blown out from dumper 55 fJ DATSUN 1000 Carburetting System Main Same as the fuel the Secondary carburetting function normal When flowing load of the float chamber passes through the second the into blown venturi engine change still to the au xiliary valve open the weight counter starts operation and for higher against the the high power power When the normal carburetor throttle valve is in the main through of carburetor main jet and become minute drops mixing with the air coming from the main air bleed and ary is the revolutions out of the passage at the bottom a full open the power carburetor throttle valve is also to be in a full open nozzle I lmary r I Adjustment main nozzle Primary for Cormection of air bleed Connecting J It g Counter Auxiliary Weig Jht At Full the valve speed of opened to begins an Speed the and normal the engine the throttle valve of the power throttle valve is open at a slow Slow widely at the r throttle valve C Open power carburetor chronized linkage However imary main jet Primary E 8 throttle is produces high c top of sun the power carburetor auxiliary with a open by the Choke lever lever Secondary connecting valve which is not Choke valve n throttle valve When p heavy load due to the load of the counter weight connected to the valve shaft 0 when the throttle valve is open even Secondary main no2Zle Pnmaty bleed mam i J cl Counter lever Secondary main Counter rod valve Seccndary carburetor Primary and Secondary Valves m un ule Do weight Choke lThrottle lever connecting lever 14 Secondary main jet Auxiliary valve Secondary It throttle valve Primacy maiu Gl 261t1 jet F Primary throttle valve g Throttle chamber Primary throttle valve 0 4t Full Open High Speed Opening Degree S6 1 1 to Begin Starting i i ENGINE Float Chamber The accelerator must be Adjustment of the float level can be done by adding or subtracting the needle valve carrier gasket after removing the float needle valve installed at the inlet connector ventilation within the float chamber As method vent and iof of within the no suctional resistance of the air how matter cleaner varies fuel consumption economically maintained can be always THE Fuel Level Adjusting stage the float upper surface must parallel with the chamber top Dimension 10 5 mm height Adjust by bending At the be level GASOLINE TANK The fuel tank has and and is situated at a capacity of rear the 41 0 liters of the luggage compartment the float seat The fuel pump operated off the camshaft draws fuel from the tank and forces it intO the A carburetor float chamber Float air fillers cleaner the large and efficient supply to the air rburetor ca Float stopper Float adjusted by the adjusting plate air pressure venturi and the float chamber is always constant a so adjusting plate at the carburetor side that the t1irottle valve may be full open with full pedal on 3ld of slight gap with pedal off After adjust ing this tighten up surely the nuts of the from outside seat f t The a J the Fuel Draining fuel tank is drained by turning the wrench operated drain cock 0 t Adjusting i the Float Level is Done of Accelerator Pedal Adjusting Fuel Tank Situated gauge on unit screws I i or l play 1S m B l is as bend I II 1J1 l i secure the unit to the tank not disconnect Care the electrical must be taken the float lever lead not to strain 57 as Examine the joint washer to ensure that it in position and undamage This is essential the joint between must be fuel I the top face of the tank is the remove withdraw the set this may seriously Remember effeGt subsequent gauge readings unit this also applies when refitting the X y Throttle lever to beforehand Stroke Unit To which forgetting Cbmp f Gauge N Carburetor t C tight the tank and gauge unit r DATSUN 1000 8 151 11 0 14 0 12 @ 13 yr 16 10 18 Contents Fuel Tank Sedan fud tank 1 Ass y fuel 11 Unit gauge 2 Hose filleT tube 12 Ring 3 Clamp hose 13 Washer plain 4 Ass y 14 Wash lock 5 Packing 15 Screw 6 Ass y 16 Ass y tube 7 Grommet rubber 8 Tube breather 9 10 tank cap filler filler cap tube Clamp hose Grommet drain r 0 fuel gauge unit fuel tank to fuel strainer fuel tube 17 Connector 18 Ass y 19 Grommet fuel tank tube 58 tube fuel tank to onnector 35 L ENGINE 4 14 18 l t 19 20 Contents Fuel Tank fuel 1 Ass y 2 VVasher drain tank 3 Plug drain 4 Ass y cap 5 Tube plug filler fuel tank breather 6 hose Clamp 7 Grommet 8 Unit gauge 9 fuel tank Van 12 Washer lock 13 Screw 14 Covcr 15 Grommet 16 Cover fuel gauge fuel filler 17 Screw 18 Washer 19 Cover fuel tank plain Packing fuel tank 20 Welt 10 Seat fuel tank 21 Ass y tube 11 Washer mounting rear strainer plain 59 ck floor fuel tank to 30 L DATSUN 1000 FUEL PUMP 7 20 tor carb To 5 6 13 14 2 3 I fuel pump valvl 1 Ass y 2 Packing valve 3 Retainer 4 Screw 5 Packing cap tainer 6 Screen 7 Illt 8 Packing 9 Spring r P 4 12 10 l cap bolt oc k Ass y 11 Washer seal 12 13 Spring diaphragm Screw body et 14 Washer 15 Elbow 16 Washer 17 Nut 18 Washer 19 Spacer fuel pump 20 Ass y tube 18 II Fuel Pump 60 with seal lock joint carburetor 17 urn diapmagm 10 fuel pump to ENGINE The Cam r p m Outlet Outlet Pressure Quantity mm Hg noise rocker arm spring serves to prevent keeping the rocker arm pushed against the eccentric of the camshaft min cc 300 130 450 1 000 130 450 3 000 130 750 Disassembling with Fuel Pump Installed Checking Engine Disassembly Switch off and the fuel Disconnect the tube 2 Take off the attached bolts of body on the Disconnect at the inlet union of the carburetor pipe Now Mark stop the engine on and then turn the engine with the crank handle 1 3 Inspection the should gasoline tip of the pipe be from the vigorously ejected once very two rotations of the crankshaft edge of body for preparation of assembly again 4 Detach the cap 5 Separate packing and the upper and lower from Engine Removal screen Fuel body can pump 6 out Take the two valves from connecting loosening the the upper body 7 Hook out the diaphragm with the seal from the rocker arm Turn it about 90 Prior horizontal way 8 pin to separate the rocker arm assembling of components is the rever sal procedure in this order Pull out the The fuel pump is scale mechanically the rotation of camshaft At By same of the arm is It is screws contains closed chamber of is the drawn is not allowed into Replace body are not to loosened damage the this disassembly Repaires the arm disassembled the the parts if Replace a valve assembly faulty operation is detected The rocker the rocker of Parts diaphragm impregnation by gasoline is down and cannot return as care well in gasoline then inspect them carburetor is stored in the pump chamber and due to its pressure the diaphragm is kept in vain great Wash gasoline Under this condition around the upper Checkiilg carburetor Thus of a Disassembling aiaphragm during up enough gasoline and the needle valve gasoline means rocker link arm diaphragm and of the pump chamber gasoline from the tank to the carburetor float if the rocker see removed the distance between the rocker reassembling easy easily separated into two when the five Take functioning of the valves at the inlet and outlet If the the to make their bodies rocker time the movements of First wipe dirt off the outer surface of the pump and put marks on both the upper and lower and pull rod of the Disassembling are worn Method of diaphragm is pulled down diaphragm goes down against diaphragm spring and then is pushed up again by its spring pushed and diaphragm driven it under pressure to the carburetor By and and pins by the eccentric the camshaft of the engine draws gasoline from the tank and delivers type part of It of the which is unions and flange of the lower body by arm the outlet disassembling to measure pump removed by dis easily and 2 attachment nuts Prior to Inspection degrees be inlet the arm any if any damage wear or should be replace when its contact face with the earn and that with the works link and its pin hole the rod remains low 61 are seriously worn DATSUN 1000 Rene the arm when pin it is found it worn excessively installed is the engine on make a check to inspect When a vacuum gauge is connect d to the inlei port and the pump is mounted on a tester the rocker arm is activated by the diaphragm spring arm spring seldom become faulty but when weakened replace them always with standard ones The pump of the eccentric If camshaft the diaphragm spri ng is to strong it results in overflow of the float chamber of rpm the carburetor even than 400 higher if tension of the strengthened or weakened spring must be not is discontinued operation When arbitrarily by in the hand see if there is any warp joint surfaces of the after disassembling to gasket keep its air cap is on and body over and renew Reassembling The tighteness o Install valves o In the various o 5 seats A lower bodies the not screw in Then tight since on sure to set if arm so in the is by the inlet the outlet port port and turn the engine 6 to 7 of the crank handle and means that there is sure outflow of engine again several times to see any leakage of air or gasoline ENGI NE engine best possible that it is periodic of camshaft properly inspection maintained well as must in always be operated condition a in the and for this purpose and adjustment must certain order while in be use as after overhaul one Order of of Checking on on there is The the rear side or to one side Replace the gasket between the cylinder block and pump with standard its ADJUSTMENT AND INSPECTION re not a new than test from each connection disassembly the rocker the eccentric done gasoline pipe sure turn the it OF is pump more sure gaskets should be the engine order to that for the when it is able Connect the gasoline pipe to the outlet port side and tighten all the piping joints Then all all of them in order to make Installation contacting B warping the loosely and uniformly tighten them diagonally and lastly general rule placed by new one Be by one clamp port height of use gasoline from the outlet port round a reverse one as make and pressure Instead retighten As one from a Leave that it rotations screws o Connect according fit for during operation side causes mechanically gasoline assembling and align Do to 5 strong inlet hose to the inlet a side only put before the dis screwing hole to its mate in at the position and then screw the where diaphragm is fully pulled down with the rocker arm pushed towards the o the conditions if 3 good in After installing m functions fit them together body hy release suddenly there can be heard is pump to the marks which were side of the is by connecting for close contact in of upper and diaphragm times thence to draw up respective screwing and for springs precisely test and outlet noise respectively stated before wi th their is not available Then pump The uses as tester fingers the Installing Employ standard this condition than 3 seconds way several arm and inlet port and outlet port with after operating the rocker finger tips the more or gauge following seconds o a Close the Check to 000 of mercury column mm should remain for The at 1 revolving Then the gauge pressure should rise to Function When repairs of the pump is 1 over or and Inspection Engine Check the cooling water extent of fillthiness before 62 Adjustment water level and ENGINE 2 the Inspect all battery connections of electro yte specific electrolyte and voltage 3 the Inspect of gravity amount oil Also turn the level filthiness 7 classification and viscosity 4 cylinder pressure 12 0 350 r Measurement of following p see if the governor can function Adjust ignition timing correctly By utilizing a power timing light the the B T D timing C advancing of 80 approximately is engine kg cm2 advancing the conditions of running and of compression pressure of The standard compression of the carry out of the governor can be checked together with the ignition timing illumina tion of crank pulley will enable to inspect Cleaning of spark plugs and adjustment of Measurement check to function their gaps 5 of the distributor clock cam wise and m pressure is made in the manner First warm up the engine temperature of 700 800 C then remove all cooiing water spark plugs and pull out the throttle knob all the way throttle opened each that is in the carburetor valve and choke press a spark valve compression plug against running the fully charged battery gauge and hole starter motor with a the fully are read the maximum pressure obtained within 5 8 rotations of the motor ment must be made as This measure quickly as possible 8 Inspection of fuel pump and gasoline strainer 9 10 Adjust the slow setting of carburetor Checking operation of generator heck the generating condition and function ing of the cut out relay by means of ind a tions of the ammeter Compression Gauge It the compression pressure of anyone inder differs by 10 lb sq in that the of another or more cause cyl from must 12 Adjustment of valve tappet clearance 13 Road test in in fan belt 3rd speed at about 25 suddenly step on the accelerator the If only a slight knocking results Slow is correct speed ignition timing adjustment is made so that the speed is about 15 km hr when driving in 3rd km hr Check and adjust the distributor If the breaker contact points have defective contact surfaces dress them and adjust the gap to 0 45 0 55 Adjustment of slack While driving be investigated 6 11 speed mm 63 DATSUN 1000 Trouble Shooting Chart Battery discharged or connections Timing poorly adjusted Air being sucked in Plug sparking weak PlUg spark Sparking S B o Wiring incorrect Plugs dirty at terminals Timing Ignition coil No c incorrect Short in circuit Plugs do not spark ell poor sparking Breaker at terminals or condenser defective Contact point dirty Point contact poor defective Breaker arm insulation defective Rotor shorted 0 6 No in tank gasoline Strainer defective l r Pipe clogged Float valve sticking No gasoline in carburetor No air can enter tank Fuel pump not operating No carbureto gasoline or gasoline supply stopped Engine seized free of Lubrication insufficient presslOn 1trOUble c o Plugs spark ell defective Air being sucked in Jet or pipe clogged carburetor Float sunk t Float in high position Piston l r Compression E poor ring or valve sticky connecting rod broken seating poor Piston or Valve Breaker No ing from bllo Plugs do o not bll spark spring defective Rotor shorted Breaker arm ell arm Contact point poor spark coil line will not descend Carburetor attachment not secure good Ignition coil or condenser defective Distributor wet Cap insulation defective ell Cord shorted Sparking form coil line Plugs dirty 64 or Wiring shorted or connection poor or cut broken ENGINE Compression weak Valve clearance incorrect Valve spring weak Valve deformed Muffler Continuous lack of power Ignition retarded too much Carburetor adjustment poor Gasoline supplied insufficiently Carbon deposits excessive Gasoline of poor grade Power weak Intermittent lack of power Engine operation E defective during running Engine gives off abnormal noise 0 MoIS firIng clogged Valve timing incorrect E Carburetor defective Valves sticking Pre ignition Overheating Bearing worn Plugs dirty Breaker point defective Sparking irregular Intermittent shorting Mixture too rich Sparking normal Insufficient gasoline supply to carburetor Water in gasoline Nozzle clogged 65 DATSUN 1000 66 CLUTCH CLUTCH Construction The clutch is mechanism for ieft handle drive and mechanically operated for right handle drive plate a disc plate diaphragm spring assembly The cover is bolted to the flywheel with a disc plate and pressure plate hydraulically operated a and consists of 31 5 mm at a Spring height Thickness position diaphragm spring distance piece Wear limit of clutch Run out Play Less than 0 facing of withdrawal lever 0 on the 20mm 144 pedal 15 out dia by the head of mm 15 Facing thickness Facing 5 mm Less than 0 5 facing of clutch 41 72 mm Height clutch pedal Play pressure and cover 5 mm 20 mm 32 mm 160 mm 1l0mm Facing inside dia 67 rivet DATSUN 1000 The exploded view in following figure shows each of the parts DIAPHRAGM SPRING CLUTCH COVER Poa PRESSURE TH PLATE UST RING DRIVING STRAP The Thrust ring cover is bolted to disc plate encloses a Clutch Cover The disc Diaphragm spring to plate comprises flexible a and pressure plate Thrust rivet nected flywheel the a splined hub steel plate by a con spring mounted The annular friction facings the plate and around the damper hub to springs absorb are rivetied to are assembled power shocks and torsional vibration diaphragm spring is interposed between two annular rings whi ch provide fulcrum points for the diaphragm when it is fixed The rings and the diaphragm are located and secured to the cover by six equally spaced The rivets 68 CLUTCH 15 18 17 4 t Clutch 12 Washer lock 13 Bolt Spring diaphragm 14 Washer Cover clutch 15 Ass y sbaft pressure 16 Pin thrust 17 Yeke 18 Spring 1 Ass y disc 2 A 3 4 sly clutch clutch cover lock clutch elease 5 ate Pl 6 Ring 7 Rivet thrust 8 Plate hanger 19 Spring holder 9 ring taper clutch elease return Strap driving 20 Sleeve 10 Rivet 21 Bearing clutch 11 Bolt driving strap 69 elease yoke bearing clutch yoke clutch e1ease elease I I I DATSUN 1000 ST 4360 ST 4360 PLATE BAR DISTANCE PIECE To adjust for clutch diaphragm spring place the distance pieces on the base plate and set the clutch assembly on the base plate by bolts Screw the center bar the through ST 4360 height gauge DISTANCE PLATE CENTER ADJUST BAR WRENCH PIECE HEIGHT GAUGE Adjustment for operating clutch operating cylinder left bandle driving Correct and adjust the height of the diaphragm spring by adjust wrench Do not disassemble the pressure plate and cover body which balanced as one set Master cyl inside dia Piston stroke Operating cyi Piston stroke 70 inside dia wire master type system cylinder for 15 87 mm 31 5 mm 19 05 mm 23 mm 5 5 8 in 3 4 in CLUTCH 2 9 pedal 1 Ass y 2 Push fulcrum clutch clutch pedal pedal pad 3 Cover 4 Pin fulcrum 5 Washer 6 Washer lock 7 Nut clutch pedal spring 8 Pin clevis 9 15 Spring return 10 Stopper pedal 11 Ass y 12 Bolt clutch cable 13 Nut 14 Bracket clutch 15 Bolt 16 Washer 17 Ass y shaft cable clutch operating able lower lock clutch elease 3 l Jr 17 13 1 12 oP r f Dampe l D h panel Stopper om 1 b t o Withdrawal lever p Ad wt end play 1 5 2 0 mm at pomt and then tighten the lock Clutch Pedal 71 Linkage thiV Dut for pedal DATSUN 1000 f r I r 1 J I I LI 1 I 0 I I i L LJ I lJ r tJ 204 Clutch op eratulg C1 linder Master C1 linder 72 fior Left Handle TRANSMISSION TRANSMISSION o Components of Transmission Sectional View of 73 Transmission DATSUN 1000 Model 3 stage for forward 1 4 stage for reverse stage for forward for speed synchromesh on Remote control Full synchromesh Type of on forward gears Synchromeshed helical gear type gear i2nd 3rd 4th gear Ratio ill 3 38 3 76 Ratio i2 1 73 2 17 Ratio i3 1 00 1 40 Ratio iI4 Reverse 3 Final gear ratio 4 64 11 1 4 Back lash of each meshing gear o 05 0 4 00 00 3 64 375 1 van 1 Main drive gear counter driven second gear and first gear gear Gear ratio of speed meter 1 16 4 MAIN DRIVE GEAR Main drive gear Nos 19 MAIN SHAFf Second gear Nos 25 First gear Nos 31 Reverse gear Nos 31 Reverse gear thrust clearance o 15 0 25mm First gear thrust clearance o 15 0 25 Second gear thrust clearance 01 03mm o 0 Front gear thrust clearance Clearance between boulk ring each gear Cover adjusting shim Bearing type of spline 1 08 mm 35 1 45mm 05 O Front 2 Olmm Ball bearing Rear Bushing COUNTER GEAR SHAFf Driven gear teeth Nos Counter gear teeth Nos 29 First gear teeth Nos 14 22 Reverse gear 13 Clearance of front thrust o 02 Thrust washer size 0 8 Bearing type of spline 0 0 Front 08 mm 9 10 rear 11 ball REVERSE IDLER Gear teeth Nos Clearance between shaft Clearance between gear Clearance to snap ring 17 bushing adapter plate 0032 0 01 05 01 04 077 FORK SIDFf Length of locking ball spring 16 4 mm at 7 74 kg 1 2 bearing 1 3 mm TRANSMISSION Assembling Order of Main 12 13 20 27 11 10 Shaft 1 23 24 20 17 26 22 29 25 20 17 24 1617 18 18 9 12 11 15 13 14 4 9 8 7 6 5 2 5 3 4 7 Transmission Gear 1 Ass y 2 Bushing 3 Shaft 4 Ring 5 W uher 6 Ass y everse gear gear reverse map idler everse idler counter gear 7 Bearing ball 8 Washer adjusting 9 Ring map 10 Ass y gear 11 Bearing ball 12 Washer 13 Ring 14 Shaft main counter shaft counter counter bearing bearing main drive main tp sn idler idler reverse thrust idler reverse main shaft bearing main drive gear main shaft 75 19 15 Washer thrust 16 Bwhing 17 Spacer main shaft main shaft needle 18 Bearing 19 A 20 Ring 21 Imert 22 Spring synchronizer 23 Huh 24 Sleeve 25 Ass y 26 Ass y 27 Washer thrust 28 Ball steel 29 Bearing pivot s needle y gear main shaft everse I feverse gear bearing main shaft baulk shifting synchronizer coupling gear ar ge 1st speed 2nd speed synchronizer main shaft hub DATSUN 1000 Assembling Assemble the Synchro hub SHIFTING Coupling Order Through Sleeve to theMain Shaft Assemble the needle bearing and bearing sleeve to rear side of the main shaft INSERT SYNCHRO HUB t o SYNCHRONIZER SPRING COUPLING SLEEVE To Set Apply up the main Gear Oil shaft gear baulk ring shown SURFACE BACK SIDE To 76 Apply Cup Grease as TRANSMISSION Insert the synchro hub fitting shifting insert ring Insert the reverse gear and thrust washer to groove of baulk Insert the main shaft bush of reverse speed Press the main bearing from rear side of the main shaft and then insert washer and snap ring Back Lash Abhut Assembled One Inspect First gear and main shaft and thrust washer Put the needle bearing spacer and bearing by order To Somer Gear Oil for Needle Bearing 77 Reverse gear DATSUN 1000 synchro the Insert Set up the needle bearing and needle bearing spacer from front of main shaft hub Thrust Oil groove side side Rear Front APPly fitting the shifting insert for groove of baulk ring Gear Oil Put the second gear and baulk ring on the shaft To Smear Inside Cup Greasefor Baulk Ring of Insert steel ball thrust washer of synchro mesh hub and and then pilot bearing To smear grease for dint of washer Press front the main and snap ring 78 bearing to the main drive gear Put the washer of main bearing washer TRANSMISSION If I Tap and after inserting of plate jf the main set hammer fitting the main with wooden center of counter shaft bearing bearing rear into the hole JJ I 0 Assembling Hold the adapter plate on the bench ST 4361 Fix the shift fork for each rod T ansmission case 1st Rev speed fork rod Adopter plate Rear extension 2nd 3rd sl eed Shift fork Set the shaft fitting main with shaft gears assembly each and other as counter shown 79 k food DATSUN 1000 5 2 9 8 4 6 0 7 I n 2 18 3 19 8 13 12 16 14 12 10 Transmission Gear 11 Compo 12 Ring 13 Washer thruSt 14 Ring E Ring stopper 15 Lever ope Ball checking 16 lever 7 Plunger inter lock 17 Pin 8 Spring checking Plug checking 18 Nut 19 Washer lock 1 Rod rk fo 2 Fork shift 3 Pin 4 Rod 5 6 9 10 reverse retaining fork Compo fork 2nd shaft bt Shifting 3rd ball cross lst everse 80 ha 10 t cross cross cross cross rating operating retaining 2nd 300 shaft shaft shaft 2nd ist 3rd speed everse speed 15 17 TRANSMISSION To fix the second setting third check balls and speed fork rod after springs Inserting the reverse idler gear and thrust washer and set them up by tapping with a brass bar these gears should be neutral position in this Set stopper link and the Fix the first Insert the into the reverse inter lock planger and speed fork rod check ball and check ball spring plug hole and set it Screw the plug up to level against the plate edge Tapping the retain pin of shift fork and fix as finding the hole of reverse the adopter plate idler shaft as upper side 81 procedure DATSUN 1000 Fix the reverse washer and snap Back idler shaft ring for front and lash of idler gear and with thrust rear washer 0 1 order of aide 0 tightening Tightening 16 torque 2 2 kg 111 1 5 mm Put the case of transmission back side up To use washer Fix the washer of counter bearing and plane Complete with set up by fix bolts the adopter plate to the gear box 82 rear extention to the gear box TRANSMISSION Select the shims for front Assemble the cover return spring and clutch re lease yoke n r I 1 J 1 J Ji A III J t rl I Jt o r I z I 1 vI w fE IT I 0 1 I Front cover Fix the tappe r pin to the yoke adjusting shims Depth from fixed face of the front race of main bearing cover to 1 end face of outer Thickness Pari No 32208 18000 o 5 0 32208 18001 0 2 32208 18002 0 1 5 15 l mm o I Set the oil shim to front seal with apply ring and adjusting 14 kg 1 cover Tightening torque To 0 1 0 cup grease for m lip of oil seal Press the release bearing into the sleeve and complete holder 83 the release bearing assembly with DATSUN 1000 Fix the sleeve to front cover the Transmission Assembly the Car Dismounting from o Disconnect the front tube of muffler o Drain gear oil from the case of transmission o Disconnect o Detach the propeller shaft o Disconnect speedometer cable remote control linkage and side lever of transmission Insert the pinion gear assembly of speed meter o Separate clutch operating wire and drawal lever To about smear o Take off the starting motor o Disconnect the plate of dust sealed o Jack up the body of transmission o Unscrew cup grease on the teeth to confirm condition of main drive gear and main shaft 84 fixing bolts to the engine block with TRANSMISSION o Unscrew rear the rear engine extenssion bolt and Mounting of transmission dismounting way mounting bolts cross member is a reversal of Disassembly A Pullout gradually The Case of Transmission to rear way ofter detach ing the mounting Extension Take off the plUton sleeve of Rear insulator speedometer and pullout the pinion sleeve assembly 85 l DATSUN 1000 Detach the rear extension assembly from the adapter plate Separate the adapter plate with main shaft assembly and counter shaft complete from the transmission case To confirm the numbers of used washers at the front of counter shaft for reassembling Disconnect sleeve the at the holder spring release yoke and of bearing take out the sleeve with spring Knock out the release shaft after pulling the tapper pin Take out the adjusting shims and front To 0 ring of cover confirm numbers of used shims for sembling reas case 86 case TRANSMISSION B Main adapter plate assembly on the bench figure and knock out the retainning boss by tool from the ST 4363 pins Fix the Shaft as Fix the adapter plate with the counter shaft assembly and the main shaft assembly as shown shown the the figure ST 4361 Take pIng Detach the snap ring shaft and tap out the 2 at the reverse idler shaft by the brass bar reverse idler gear aod thrust from shaft at neutral position Detach the washer 2 87 out check ball and spring from the DATSUN Detach 1000 low reverse and speed fork rod by Separate the main drive gear and main shaft ihe brass bar Detach the pilot bearing washer sleeve steel ball baulk ring needle bearing etc synchro hub synchro hub with thrust cup ring main shaft second gear and from the main shaft Take out main bearing washer main bearing rear side from main shaft after detaching snap ring Draw out main shaft thrust washer reverse needle speed gear main reverse shaft speed bearing spacer hub with sleeve baulk bush cup ring synchro ring main shaft low gear needle bearing spacer from rear and main shaft needle bearing etc main shaft needle bearing side C Disassemble the second inter lock Rear Extension planger and pullout Disconnect the cotter third and speed fork second pin of operating lever by pulling Detach the main shaft assembly and shaft complete from the adapter plate counter 88 low reverse and third speed operating lever and take out the cross shaft out TRANSMISSION Setting a Counter Press the Bearing Counter Washer ball bearings into front and Part No Thickness 32224 18001 o 8 32224 18002 o 9 32224 18003 1 0 32224 18004 1 1 32224 18005 1 2 32224 18006 1 3 rear of the counter gear claster bearing washer mm ST 4367 b Assemble the snap ring for the transmission case and set temporalily the claster to the transmission counter gear case d Take out the counter gear transmission case after this Assembling a Insert ring c The outer race should be inserted surely to ring and gauge the clearance for the bearing by a service tool close for snap 89 from the Rear Extention the to claster desfsion the E ring second thrust third washer and cross 0 rod shaft 1000 DATSUN b Assemble the lever to the c Put the cross 0 second cross third d speed operating shaft and lock with pin ring for the first reverse Assemble the first reverse speed operating lever to this shaft speed Knock and set the oil e shaft seal for end of extension Rear Extension Transmission Case 1 Bolt 2 Washer lock 3 Compo case 4 5 Bushing clutch Plug welch 6 Ass y 7 Seal oil front cover 8 Seal oil front cover 9 Shim 10 Bolt cover transmusioD haft s transmission adjusting front case cover 11 Washer 12 Ass y lock 21 Ass y extension 22 Pin 13 Bush 23 Plug rear Seal 24 Cover 15 Ass y breather 25 Bolt 16 Bolt 26 Washer lock 17 Washer lock 27 Ass y 18 Washer plain 28 Ass y sleeve 19 Plug Plug rear extension adapter rear 14 20 oil extension plate dowel welch extension lamp reveI e 90 switch 29 0 dust pinion extemion clutch housing speedometer speedometer ing speedometer pinion rear TRANSMISSION 5 1 I 2 9 8 4 6 7 8 13 I 1 2 3 n 11 18 19 12 16 14 12 10 Transmission Gear 1 Rod fork 2 Fork shift 3 Pin 4 Rod fork 5 6 Ring stopper Ball checking 7 Plunger 8 Spring checking Plug checking 9 10 everse retaining Compo 1st 11 fork 2nd 3rd inter lock shaft ball cross 1st evene 91 Shifting 12 Compo shaft cross 2nd cross shaft Ring a 13 Washer tluust 14 Ring E cross shaft 15 Lever operating 2nd 16 Lever operating 1st 17 Pin 18 Nut 19 Washer lock retaining crou 3rd shaft 3rd speed 5e evel speed 15 17 DATSUN 1000 12 27 20 23 24 20 17 26 25 17 20 I I 9 8 6 7 7 Transmission Gears 1 Ass y gearJ 2 Bushing gear 3 Shaft 4 Ring map 5 6 7 reverse revene hrust t Wasber Wa Ring idler revelSe idler counter shaft adjurting her map 17 cronter Bearing b111 9 idler idler everse Au y gear 8 16 idler reverse counter counter bearing bearing main drive Bwhing Spacer main shaft needle 18 Bearing needle 19 Ass y gear eve main shaft baulk 20 Ring 21 Imert 22 Spring synchronizer 23 Hub 24 Sleeve 25 Ass y gear 1st 2nd shifting synchronizer coupling speed Ass y gear 11 Bearing ball main sbaft 26 Ass y gear 12 Washer 27 Washer tluust 28 Ball 29 Bearing pivot main shaft 13 Ring 14 Shaft main 15 Washer snap main drive ge2r throst main shaft main shaft 92 gear main shaft everse 10 main bearing e bearing speed synchronizer steel hub TRANSMISSION Cl i Cl i i s 8 1 0 Q 0 0 0 0 N or or 1 c 1 or j I r U I B i E E E I 8 lriw i t N 0 a 01 0 c 93 a DATSUN 1000 94 DATSUN TRANSMISSION 1000 OF VIEWS SECTIONAL TRANSMISSION r i JY 10 A 5 ADJJST G 32208 18XlO l12 JG ART lrE 00 5 15 A I a SECTION B B SECTlON c C SECTION D D E SECTION E SECTION nvn AY BY R EN 32208laoool A A 1 C 2 SHM I 0 E I GEAR r st 2nd J 32224 IsoOt 31415 2 0 2 rrm BY A l 6 ST e ADJ DPlAY so AS 0 o 3 TO SHIM 12 295 d Rev laD 670 F VIEW RATIO 3 380 I 734 1 000 3 640 j1 l 1 NISSAN MOTOR CO L TO l ilj f jf9 t H Ni S i i1b c f r iO STEERING Washer lock internal tooth Nut Ass y bushing column jacket Clamp steering post upper Clamp steering post Bolt I lower P1ug I Nut W h olumn ew ting adju Bearing worm Cover Washer 0 sector Shaft Bolt Gasket Shim sec cover Shim adjusting r Screw adjustiDR fill ectn Ass y housm Bolt adjusting worm shaft O Ass y column steering OSt i W gear e Bolt Washer plam Nut self lock Ann steering gear f1Washer Seal oil plain Washer lock sector shaft lock Nut Components of Steering 95 Gear Box DATSUN 1000 1 3 7 12 Steering 1 Ass y 2 Insert 3 Assly Wheel ring slip bar I Iiom 8 Seat horn 9 Spring horn 10 Button horn 4 Bar horn 11 Lock horn buttoo 5 Insulator hornbar 12 AIS y shell 13 Screw 14 Screw 6A 8S y 7 plat contact RIDg lmulator 96 I teenng colwnn CHASSIS 18 6 17 7 6 14 15 13 19 1 23 24 26 27 Steering Linkage 1 Arm 2 Ass y rod steering gear 00 Bushing rubber 12 Cover dust idler shaft idler shaft 13 Cover dwt idler shaft lower 21 Ass y socket 22 Ass y rocket 23 Cover du Cover dust 4 Clamp 14 Washer 24 Clamp dust 5 PlUg filler 15 Nut self lock 25 Plug filler 6 Nut 16 Bolt 26 Nut 7 Pin cotter 17 Bolt 27 Pin 8 Ass y 18 Nut 28 Bar side roo 9 Ann idler 19 Ass y socket ide rod inner R H 29 Nut lock 20 Ass y socket ide rod inner R H 30 Nut 10 cover idler Bushing idler shaft idler shaft 97 lower outer LH side rod inner ide roo LH side rod t 3 dust ide rod 11 cover cotter side rod 1H P lII 1000 DATSUN and release the nut at each Recirculating ball type Steering type then slighUy tap which 15 Gear ratio The In steering angle 45 Out o Gear oil capacity by these levers MP general 90 The steering circulating light robust structure and ball type and stable supported gear contact ball angular meshed circulating steel sector balls two ball bearings lower housing is through the numbers and idler respec arms split not pin be each Normally for removed any only be occation when requiring damage circumstances the arm concerned steering box remove can the removal has occurred or under under for inspection when be withdrawn one the steering gear box or idler has been removed to the gear arm should be the service bench with drawn front the shaft convemed using a to the arm 60 the The upper and is enclosed in an oil assembly caries the with with bearings need idler should also be gives functioning handling worm which mechanism consist of the re gear maintenance The would a the rods clear of the levers to connected nut and tively 36036 24 are steering 3 4 Rotational numbers Max 1 they end of the rod and suitable extractor This tight casing which at either end of the cam When the steering wheel is turned the tube revolves the carn which in turn causes the taper peg to remove over a predetermined arc thus giving the rocker shaft its desired motion connected to the rocker shaft is a steering side steering that links up with the cross rod lever linkage The is the steering linkage system and connected to the parallelogram rear side of the front axl e Two shorter side rod one on either side the steering gear arm to the steering and idler arms respectively gear connect The gear arm must its shaft Side Rods The side rods castilated nut and To remove not be hammered from are held split pin the rod in position by a at each end withdraw the split pin After the side and the idler 98 can cross rods disconnected be detached from the body CHASSIS It is secured by suspension member Holding the idler the rubber bolts two body on to the front the bench take off cover Pull out the idler shaft out of the body STEERING GEAR HOUSING Removal Take off the plug and drain out gear oil Separate cover the Unscrew the Unscrew the lock nut and then take off the side of adjusting screw cover 99 adjusting screw and the side and detach the sector shaft from body fixing bolts of rear cover DATSUN 1000 Draw out the baU nut assembly e 0 iP Components of Steering Assembling of steering gear reversal order of housing is Gear Housing sighting through a baUs disassembly into a the suitable baU guide holes count 60 container proper number of baUs for Drop balls Assembling Slip the guide teeth side of nut nut over holes up and the Align the worm with ihe baU shaUow end of the rack the grooves in the worm and nut by 100 into each of two holes This operation from either same side must be used end side of nut This is the this baU nut on may be the same performed but two holes on the not two holes on same CHASSIS Shake being the gradually nut Continue filled away until the from hole balls Tightening torque are Place remaining balls in ball installed in full Front rear cover 18 2 5 kg m in each of two halves guides Push the guide into holes of the nut If the push all the way down easily tap Assemble the ball guide lightly into place clamp to the nut being sure to use a lock washer under the clamp screw then tighten the guides do screw not securely Check the assembly by rotating the nut the worm to see that it moves Insert the ball nut assembly with the bearing at rear side into the gear smear the oil to the worm on freely worm housing and bearing CLEARANCE BETWEEN SECTER SHAFT GROOVE Select the disassembling same thickness of shims at the time and connect the Fitting column the side with it to the gear housing Tight the rear cover bolts assemhly way 101 AND ADJUST SCREW O 05mm the side cover with cover to gear box adjust screw by turning fix it for left DATSUN 1000 After then lock by nut surely and tighten the oil plug Tightening torque Conneciing bolt 1 Set np the gear arm Adjust 0 the 1 mm and play 8 2 temporarily 5 49 Nut steering wheel 4 4 Nut idler arm bracket 19 26 35 49 m to the shaft at the gear arm then lock temporarily kg top within by the nut Rotating the gear arm several times for right and left way to find and correct center without any variation about back lash l 1 V 102 6 35 Tightening torque cover gear box m Ball stud Tie rod end Side kg 5 j CHASSIS FRONT AXLE i r1i 39 010 53 52 50 t1 42 3S 36 111 rftt 78r 47 I 16 10 01 15 @ 13 12 11 58 81 33 r 46 4S 20 Q 62 18 0 63 64 Jl Suspension Front Axle 1 Ass y 2 Collar front 3 Arm knuckle 4 Catcher grease front 5 Plate lock 6 Bolt 7 Nut 8 Bolt 9 Nut 10 spindle knuckle spindle joint Seat 29 Ass y member knuckle ann ball upper front suspension Bracket 61 Bolt 62 33 Washer tasher y 67 Nut 40 Washer 41 Washer 15 Bolt 42 16 Nut 43 19 Clamp 20 Nut 21 Pin 22 23 24 25 Ass Y Spr Bolt center 26 27 joint inner Pin lowerlink Bolt Pin lower ball Nut 65 37 Nut dust 64 66 14 suspension Washer lock Nut lock mpp 63 36 13 Cover pacer Shim Nut 18 Support robber Washer mounting lovier mbi er Bushing 35 Washer front mounting bolt umper rebound Ass y link 34 39 lower ball R H engine mounting front LH mounting suspension member 38 cotter ounting front engine Nut 60 32 Clamp dust cover 59 31 12 y joint 58 suspension Bracket Cover dust upper i AS 57 spring front 30 11 17 front member steering stopper Ass y 28 pivot 17 Rod tension 70 Bushing 71 Nut self lock Shim mounting Bumper bound 72 Nut 73 Washer 44 Washer 74 Collar tension rod 45 Washer 75 Washer special tension rod 46 Nut 76 Washer sp eci al tensiop 77 Bolt lock lock tension 78 Shock absorber 49 lUbber 79 Washer 801t 50 Washer upper link outer 80 Bwhing fIbber Nut 51 Washer upper link inner 81 Nut 52 Washer lock 82 Washer lock 53 Nut 83 Bolt Seat 54 Bolt 84 Washer lock Clip 55 Shim 85 Washer 56 Washer tooth lock upper link upper link spindle camber 103 suspension d rc plain upper link upper front plain Spindle Bushing suspension spring Washer Compo front spring front 68 48 cotter front 69 plain link cover suspension lock 47 dust front lower link plain front roo 1000 DATSUN 5 13 4 1 2 7 10 3 911 12 8 6 tI wheel 7 Ass y front road Ass y Nut road wheel 3 Cap road wheel B 4 Ass y hub 9 Nut front wheel 5 Bolt hub 6 Ass y road bearing 1 2 wheel front road wheel road wheel bearing front ad wheel inner Seal outer grease 10 Washer 11 Pin front hub bearing front wheel hearing cotter 12 Cap hub 13 Drum front brake Fronl Wheel Toe Alignment Data in 2 3mm Camber 1045 Caster 2015 i King pin angle j Side 6CIJO slip Less than 3 i mm with mnning di5tance 1 Turning angle InSide ch mm 450 Outside 36 Rotation torque front hub less than 9 Motive kg em Clearance of front hub to direction long l Less than 0 08 mm the shaft Clearance of ball to direction joint along Le the shaft Toe in Camber Caster 104 than 0 9 mm CHASSIS DISMANTLING THE FRONT HUB dismantle the front hub To first until the wheel is clear of the car then place a hold on car on the wheel the brake If the drum appears to the lever spindle nut U sing a box spanner the the the puller adjusters the bearing from as spindle extract shown the the a the split pin from remove and the flat washer under it hub with shoe Take off the hub cap by and then extract spindle by and ground the stand shoes should be slackened wheel up the stand under the side member Jack down the Remove jack nut road the knuckle figure the bearings can be bearing and oil seal can by inserting the drift from the After the hub removed dismantled The inner then be removed opposite side of Assembling When the hub the hub the Wheel Hub assembling the inner bearing sufficiently the grease smear corn to to the inner face of wheel hub Assemble the wheel bearing to the wheel hub as 105 shown the figure 1000 DATSUN FRONT SPRING Removal Take out the wheel cap and loose slightly the wheel nut Jack up the front suspension member and set on the stands with the side member Remove the wheeis and attached bolts 2 at the lower side of front shock absorber Pack the hub with recommended grease the hub oil Replace seal Renew the seal if it is Adjusting Wheel for 6 the inner bearing damaged load Pre of Bearings Tightening torque 1 over 18 kg m of spindle nut in the case of lubricated on face the of screw and washer somewhat 2 3 2 5 kg m without lubrication any Screw out the bolts hub times 2 at the side of lower link on the tension rod several for Rotating the wheel and then again tight the nut setting smoothly with the aforesaid torque Torque for rotation of beginning 25 30 kg em pin hole With the spindle nut within 700 degree turning back around the nut 400 Again rotating the wheel hub make sure as to beginning torque for rotation and end play for horizontai way along the spindle Fit the a Torque of beginning for Less than 9 b kg rotation em End play for horizontal spindle Under 0 08 way along the cotter pin mm Lock the spindle nut by the new Screw out the attached nut at a front side of and lock washer after final adjustment for pre tension rod load 106 Leave alone other side nut CHASSIS Jack up the end of lower link on the side of removed tension rod l C I F I Remove pulling the nut out the cotter Remove of lower ball joint after i pin the jack at the end of lower link then iake off the lower link b pin t 5 I 1f t Fixing the Front Fitting the remained Supporting lower link pin the at front spring remove the the unscrewed side of tension so upon weakness Free camber crack and faults etc spring without to the lower removing link and set at it temporarily To fix the rod Inspect side Spring as to spring correcily for the pivot seat fit the center pin for the center hole of suspension member Jack up the end of spring at the tension rod removed side and fix it temporarily by the 120 mm special tool 107 ST 4369 Front Spring Clamp 1000 DATSUN Remove screw screen of the hood the bolt of upper iink Fixing of and then ledge un spindle the upper link is reversal for a removement of it t Lower the jack and fix the of lower link pin temporarily Tightening torque Lower ball Lower link kg m joint 55 76 pin 4 2 5 3 2 4 5 53 Tension rod Front side 4 Rear side 42 Tightening torque Connect the lower ball joint to swivel axle kg Upper ball joint Fixing nut of upper spindle m 3 5 4 9 4 2 5 3 link and then attach the wheels Tighting up the lower link pin and wheel nut correctly UPPER LINK LOWER Removal Disassembling Jack up the front of car and hold by side cross LINK on the stand a member Remove the fixing Jack side nut at the upper of swivel b axle up the cross Take front of member on out the lower car and keep the the stands fixing nuts of front shock absorbers c d Dismount the tension rod Screw out the fixing nut of swivel axle and then pull out the pin of lower link Assembling Order of assembling is a reversal of dis assembling Tightening torque Lower ball Lower link 108 joint pin kg m 55 76 4 5 3 2 J I f H 0 C J 4 II P I Z E I O o Z 0 f r j I f r ad uJ t I 5 a z o t f 2 1 I 4 t lOB 1 u E 0 i uJ I 0J i o 0 o I o Z I I 108 2 CHASSIS REAR AXLE i 11 6 Rear 4xle Case 1 Comp 2 Stud gear 3 Pl ug case ca rear axle rler taper 4 1 Ass y pug 5 Ass v breather rubber drain 6 Ass v shaft 7 Spacer 8 Bearing 9 Collar 10 Shim rea r xle 11 Pack mg grease catch er 12 C atcherl 13 S eal oll axle sha ft 14 Bolt end 15 W aJ her Iock 16 Nut lock axle beating rear axle be arlng rear Shaft xle 109 grea rear lH e xle shaft a DATSUN 1000 Component of Rear Axle Shaft Removal Axle Choke all the wheels not being operated upon jack J up the car Lower the axle on to the blocks and remove the wheel using drum locating a screw screws driver unscrew and tap the drum off with the mallet brake linings juster If the should hold the drum when the hand brake is release a few the release the hand brake slack off the brake shoe ad notches Take off the fix bolts of the brake disc and remove the axle shaft as shown swing hammer holding Figure Tap with the wheel studs bolt with the rear axle shaft stand draw out the shaft and disc assembly by gripping it outside of the disc Remove Disc 110 of Axle Shaft and Assembly CHASSIS The following points into be taken must consideration DT 4678 DT 4679 Special Stand Swing Hammer 1 and of Axle Shaft Disassembly When not forgeCthe adjusting as to keep the Nominated Hypoid gear oil No MP90 must be used In warmer district than 320C use MPiI 140 replacing the differential axle shaft do of the axle flange so Assembly 2 washer between the top oil and the brake disc assembly prohibited It is or same end play of the axle shafts The cover of different kings of gear The viscocity brand must always be selected capacity of oil is about oil of feeding oil should be standard method The by taking off the feeler plug at the rear of the housing and fill in full up to the feeding Cut off with oil any o 75 t done to use any other hole chisel Disassembling Dismounting of Differential Gear Carrier 1 Take off and drain out the gear oil 2 At the time carrier axle of shaft the dismounting out the both left and pull with the disc of the gear right brake assembly 3 propeller shaft Order of Rear Axle Shaft Brake Disc The rear axle bearing 4 with should be compressed the bearing and collar into the shoulder of the inserting case the end shim between its Pull off the nuts of the housing and dis mount forward the carrier ass y the brake disc assembly if replaceable in one operation by When fitting the axle shaft pressing into place it Take off the joint flange from the side of 5 Take off the side bearing cap of carrier and pry with a lever the differential gear case and the bearing new end after 6 flange and Dismount the differential side illustrated in hub 111 Figure bearing with the Ae aid of sid DATSUN 1000 Thus The bearing puller pullout ihe bearing handled with in should be care puller of the inner race catching hedge bearing is which to hard hook and Both be should right bearing separately the the pinion would be taken out to gether with the inner race of rear distance and roller piece bearing and the adjust ing shim and the oil seal outer race and pinion of front and rear bearing as well as the pinion adjusting shim left in the left arranged carrier 7 Dismount Ring differential the gear by drive loosening the gear 8 fixing differential gear case out the lock washer spreading screws on the Loosen them in a to diagonal line and 11 Pullout the rear bearing inner race of the drive pinion As illustrated in Figure the drive pinion considering keep from the gear bending rear inner race bearing replace and the adapter should be employed in this case The adapter in ihe round from is for fix ing and the other for taking oIf It is easy to handle with the vice fixing one end of replacer DT 4686 12 out the rear Taking bearing outer race of f gear carrier j The drive pinion bearing outer race re placer as illustrated in Figure should be In other upon the employed in this case stud of so as to make the screw at the center carrier and lower trim of the Supporting Using of Side Bearing Puller up till DT 4686 the adapter the set the adapter at the race tommy bar 1 and screw 1 closely touches the screw the wing nut to take corn then out the rear outer race 8 Take out the differential pinion the side gear The pinion should first be pulled out by the pinion fixed side the on mate the shaft well as shaft striking out locking pin which differential from the side as mate case from is left of ring gear fixed to right before pulling out the pinion side gear and the thrust washer well as the thrust arranged separately and 9 The gear as washer should be as left and right front rear After taking out the nut of the carrier pull out the companion flange The drive pinion flange wrench should be employed setting its four points in the holes of flange to keep it from moving take off the nuts with the box wrench 10 Take out the drive pinion of gear carrier by striking front end out lightly to the backwards the at the side of Tool No DT4782 DT4631 DT4689 companion flange of drive pinion with the prift of soft metal Pull out the 112 Bearing Race CliASSIS Inner Race 13 To pullout the from the gear front bearing carrier set outer race the tool body illustrated in Figure pull it out with adapter B in the way of rear race 3 Replacer as When the drive pin Drivepini llt ian Tightening torque 14 17 kg 1 14 17 otq1le without the oil m 120 ft 100 kg Ibs m d of UOD of the 6 the 8 kg to be by em Wa r am 1 Tight 4 2 ing torque 4 8 kg m 30 3S ft Ib Drive Pinion Front and Rear Bearing Outer Race Replacer Section 113 of Differential the of drive plniOD bearing S ic rotatlCll1 torque adjult drive hypoid adjQ st gear N tighteDed gut with Case DATSUN 1000 10 9 12 9 1 10 I 8 I Ql 8 I @ 11 e @ oo 26 17 28 T 21 18 22 25 24 23 Gear Carrier Gear 1 Compo 15 Ass y bearing 2 Stud 16 Shim adjusting 3 Washer 17 Ass y bearing drive pinion 4 Nut 18 Ass y bearing drive pinion bearing 5 Set gear 19 Washer 6 Bolt drive gear 20 Spacer 7 Strap lock bolt 21 8 Case differential gear 22 Seal oil 9 Gear side 23 Ass y 24 Washer 25 Nut drin 26 Gasket gear catTier 27 Washer lock 28 Nut carrier gear hypoid with pinion differential bevel 10 Washer thrust 11 Mate 12 Washer thrust 13 Shaft 14 Pin lock differential bevel pinion Iinian side gear pinion mate mate pinion shaft 114 differential side drive gear adjwting drive rear pinion bearing drive pinion bearing Shim adjusting drive pinion drive flange pinion companion plain pinion dust shield CHASSIS with the end shim adjusting I SIDE GEAR THRUST Every gear should be inspected as to the locking condition defacement or any de 3 WASHER SIDE GEAR PINION MATE fects SHAFT 1 L In they can be of insufficient standard case back lash deformation or damage found replacement is necessary Specially the drive pinion and drive gear should be replaced in a set whenever the e9 PleN locking MATE MATE GEAR THRUST WASHER PINION the surface to see if on reused condition gets and the de worse facement is already in progress because it would cause the noise in later operation and be difficult to adjust even with proper is made adjustment The perfect driving condition at the surface pinion gear should be about from 2 3 to of drive 3 4 in unloaded mm surface should surface in an start driving while the gear touch from tip to full to ordinary loaded driving The inspection of this condition can be made as it is inspect them as it is do by cleaning the both surface with the before disassembling and paint thinly and If it is hard to otherwise rugs evenly with the mixed with thin oil surface drive side on then turn the the gear pinion with hand to Which print the track of it on the gear shows the situations of considerably worn out PINION MATE SHAFT gear In INSPECTION REPAIRING OF DISASSEMBLED PARTS parts after they Every are 1 making an 4 disassembled In inspection and adjustment before deciding to re the it perfect that is gear with pinion together thrust in the gear of the back lash over 0 case 2 mm and clearance between the side gear and 5 mm replace the thrust washer The use else worn out parts should also be replaced crack and the measuring holding the the 0 4 mm mm or of defacement shake both over end with the The contact when ring gear is too close to pinion center in case of back lash should The spline be gauge by difference 5 and should be adjusted with 0 8 brake adjusted closely Put the drive gear case disc rear or it gives much ring gear on noise the buoy block as it is fixed in the differential gear replaced The clearance between the end of case test thrust washer exceeds 0 axle should be inspected in respect of The side respective case the them 2 Lock the with Each bearing should be inspected in every unit of ass y regard with the defect and defacement of unloaded contact for about three gears should be cleaned and cleaned by the compressed air before case quarter at the center of 1 4 of whole gear length from tooth interior tip end of the gear on the pitch line the and measure with the dial indicator Revolve the drive gear to turn around the differential gear case as the bearing do axle should be adjusted 115 DATSUN 1000 not move on shake at the the buoy rear block Measure the side of gear the scale by and the shake should be within 0 08 In mounting the face and rear and fix any correctly shaking set of it measured face then there should not be ASSEMBLING ADJUSTMENT Assembling 1 screws as be cleaned and fixed with 8 well lock washer bend gear in the after the drive is the screw it should be set and by vice to damage adjusted In tightening up supported line setting tools so as not up in a diagonal with a wrench which fit correctly with the head or any other it oI and screw the screws for this is Screw in for sure differential as gear shake screwing torque Differential Gear Assemble the pinion and side of screw by one The standard 3 3 5 striking lightly kg m the head quarter pound hammer case Every parts with specially the washer with sureness mm clean well the fitting gear face must should be cleaned and oiled TORQUE 3 3 5kg m pinion mate gear side gear and the thrust washer should be assembled by the mentioned inspection and oil new then the selection before pushing mate to shaft again in washer the or be made Inspection clearance the back lash in the pinion should be made of between Adjustment in case any abnormal the must is found Strike in the pinion shaft locking pin from the right side of the case opposite side of drive gear and must be fixed by setting well the striking hole of it after putting it to the required piston so as the pin should not loosen 3 Mount the side bearing in the differential case Press in the both side of the bearing by the drift It is important in this case to assemble by putting the side bearing adjusting shim to give the bearing a proper preload in fixing with the carrier 2 Fix the drive differential gear Ring gear with the case The drive gear as well as the drive pinion should be well inspected to they must be replaced as a set whenever ment is required Overwise after In they would assembling mounting is not the replace properly lock completed in the case the fitting surface 116 CHASSIS BY ADJUSTMENT ASSEMBLING GEAR CARRIER ASS Y It is to decide the assembling important in of gear which is very ass the y and exact The adjustment an rear axle should be carried in accordance with sample shown by construction the manufacturer and mechanism must well comprehended referring to Figure and the adjustment repairing exactly according to the condition of practical use based on the adjust be ment by A exact calculation The Preparation for Mounting the Drive Pinion in the Gear Carrier Adjustment of They in 0 show the Height manufacturing variation at figure a Pinion unit of 0 the 001 in to decide the thickness of 025 mm for shim adjusting adjustiment of u position pinion height is 45 Ii f center shown as due to the Standard dimension 45 0 0 mm care bearing as a drive pllllOn to the reused as they is worn as a stone with not to scrape off even the mark to the direction of on arrow in with the Pinion SET mark NO LETTERS FOR VARIATION OF DRIVE PINION I r @I 4 I pinion be must to be fixed with adjusted the by electric pen outer race number marked by on the carrier There are few numbers with 0 besides set VARIA TION OF DRIVE GEAR later because the posi adjusting shim between and pinion rear bearing 2 off the out prepare the various shim of drive carrier scrape to reuse even if any item mentioned tion axle the surface by grind are result of disassembling and in required from Figure and spection they should be assembled in on order of disassembling at the previous condition of adjusting shim In case any item should be replaced or on narrow accordance are mm corrosion oxidize substance Adjust If the drive gear in standard Ifthe figure is difficult to discriminate somewhat 1 The standard 1 or an the tip head surface of 3 The thickness of drive pinion adjusting shim are The drive pinion use explained 117 arranged as following of the adjusting shim will be in the following paragraph DATSUN 1000 situation Supposing the drive drive pinion were re new set and the height of of adjustment and gear placed as a previously drive pinion right prepare the which figures Deduct it case used equals difference on of corn to on race and put the screw side and have the general idea of required thickness of the shim for assembling to prepare minus adapter ring guide the body of iool At the race it porting Thickness corn as by split adaPter time same the in suIr the bar twist up the corn till the adapter and setted position so the as the surfaces inside at the tip end bearing of handling the set small hole of carrier put the outer rear increase in case of Part No the at the new plus bearing hoie for Figure method of tool and this pinion the previously used shim in is io make the to Referring was shim of thickness the to the on as of carrier in on oval the race come to the then screw up the be housed race wing properly at the setted post ion Drive pinion adjisting shim It 38153 18000 0 050 mm 38154 18000 0 075 mm 38155 18000 0 125 mm 38156 18000 0 250 mm 38157 18000 0 500 mm is convenient tion ST 4374 inspect the condi before disassembling in a way as to mentioned later in the measurement Besides the condi of pinion height tion of defacement on the carrier the pinion bearing must be taken into consideration though it will be explain ed in detail later 2 Fixing and Adjustmenl of B Drive pinion rear bearing outer race case mentioned as between the ed pinion height or decreased be taken off adjustmeni race and the in way 3 each therefore the as to be the Fig 24 as in a adapter by using of mounting the rear outer race roller as shown the inner race the drive pinion By to round adaPter a 118 attached to pinion rear bearing replacer which was oyed empl pinion This might the tools must bearing rear disassembling for this be handled properly to avoid such screw carrier the drive race also must time tighten the using mention is increased race carrier and fix the side of stud in opposite Mount the and the shim at the rear side of this outer end of the at then mount it mount the outer race bearing race the by special tool of drive pinion outer race front rear bearing replacer For adjustment of previously off at first the adapter from the center of carrier and outer race mounting the side previously front For tool after inserting the properly selected adjusting shim outer race in take front should be mounted in the carrier in this bearing the carrier Drive Pinion 1 Mount the front in by the as use press in inner at the drive well be done in pressing of a certain drift CHASSIS bearing as pushing in the inner race by pulling out the drive pinion from the of the carrier side rear Put the rear side of the carrier down ward and set the tool under it 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 ST 4377 bearing inner race inserter as shown in Tighten up the pinion nut by turning it slowly with hands with the use of pre load gauge that support 6 kg 8 Figure as the to the degree bearing preload at em When the drive pinion is mounted in the previously mentioned condition it is necessary to measure the rear is ST 4377 higher Make height of surface of the pinion whether in use or lower than the standard of the special drive pinion arrangement gauge The standard height of 45 mm from bearing the pinion is the bottom of the side fixed with the carrier The fixing position by setting an arc can be measured of circle on both sides of arrangement gauge at the position of side bearing and insert the thickness gauge in the clearance be tween the tip of gauge bar and the pinion such as to push in by scraping 4 Mount the drive and adjust by pinion in Lng the carrier position thi adjusted as mentioned in the previous paragraph by mounting temporarily the pinion in the carrier and the bearing be given The pinion measUl height must be regular preload On the other hand the bearing of drive pinion should be newly oiled after the pinion is inserted of the carrier in the inside of the carrier tend to cause an future TIGHTENING TOROUE the inserted end of pinion should be locked with front bearing corn and tightened by the pinion nut fixing with the companion flange till the regular re As this volving torque is required is not yet at the final assembling the bearing spacer distance piece bear up ing adjusting shim and oil seal are not mounted At the time of inserting the front 119 otherwise the pinion height of the preload would come out of order and bearing a from diagonal and ST 4375 unexpected trouble in DATSUN 1000 Drive Pinion Part No SPacer Thickness 38165 18000 5 75 38166 18000 6 00 38167 18000 6 25 Drive Pinion Part No mm 38125 18000 2 30 2 32 38126 18000 232 2 34 38127 18000 234 2 36 38128 18000 2 36 2 38 38129 18000 2 38 2 40 38130 18000 2 40 2 42 38131 18000 242 the 18000 244 2 46 18000 2 46 2 48 38134 18000 2 48 2 50 38135 18000 2 50 2 52 38137 18000 38138 38139 2 52 2 following use 54 2 56 18000 256 2 58 18000 2 2 60 in this case it be adjusted by increasing or decreasing the number of four kinds of adjusting shim as shown in the u 2 54 58 bearing preload must 38132 18000 B E 244 38133 38136 Washer Adjust Thickness mm list and measuring with the of the load gauge drive pinion bearing pre Figure so as to make revolving torque of pinion at 6 8 kg em if there should not by an error in as the pinion with the head mark at 0 and the clearance should be sealed at O 2 mm 0 008 in by the feeler gauge thus pinion is regarded 5 The formal pinion the adjustment of bearing and the drive rect After preload gauge is of drive pinion is mentioned in the previous fixing position decided as paragraph take off the pinion nut drive pinion bearing spacer distance piece and nut Tighten up the nut as Figure by using the torque wrench at the regular torque of 14 16 8 kg m The preload supportedly the bearing the case id different according to condition of the bearing adjusting shim inserted The more of the shim inserted the play of pinion much to the direction of axle is increased The more less the of the shim inserted bearing tightened by previously mentioned it is nuts and the the cause to be burned if left and turned as it Therefore made shorter for readjustment of 120 at the cor for than the standard size 45 companion flange to mount agaia the in this as position because the height of the 0 mm 2 mm CHASSIS For ST 4376 instance the mark shows adjust the position of drive pinion deducting c s the number of shim clearance at 0 008 in o 0 it is n 001 in to so as make the 002 2 b necessary to give the bearing a right preload At thE time of pushing the outer race into the carrier it must be done in a right way otherwise Specially when the old bearing is to be used again in assembling the adjust ment should be made than torque standard with the conditions of not to as 6 give at the lower in accordance practical use preload so it an over When the former adjustment of pre load of the bearing is completed as in the previous paragraph inspect the pinion height again Unless anything wrong is found loosen the pinion nut take off the flange insert the new oil Tightening torque 6 8 kg em seal in the formerly pinion Remarks When head gauge measuring the set the semi circular side on the side bearing seats portions of nut flange The nut the insert a feeler the nut but by washer and hould be tighten filling gauge into the clearance between the tip of the gauge center rod and the pinion head and adjust the of the carrier and ed up at the standard torque In case the cotter pin hole fitted the adjust ment should be made not by tightening of the pllllOn height rear fix the The gauge rod is made 0 2 mm 8 shorter than the standard measurement the washer pinion 1000 in C Mounting the Gear Differential Ass y in Carrier 45 mm adjustment Therefore is made by selecting feeler gauge in accordance with the plus minus valve marked on the pinion head a 1 or Mountthe is necessary to take height well as pinion off the rear pinion pinion as drive bearing outer to race the number of the other words read the head mark on the case of minus side added number of mark to 0 008 in for the leg of bearing hous important It is part of the cap fixing bearing housing is machinery The differential gear case is inserted by the side and bearing adjusting shim with the bearing as explained in 3 of A by housing of carrier the feeler gauge which is deducted for the number of mark from on finished up pinion before adjusting by increasing the number of drive or decreasing pinion adjusting shim to insert the 008 in of cap which should be fitted note that the of each of the drive 0 bearing engrayed mark on a ing when mounting form the carrier to adjust by increas ing or decreasing adjusting shim In side with mark the adjust There is cap the If it unit of differential complete gear in the carrier and fix the of the fixing bearing the cap is should be in case cotter of plus 121 pin bearing housing the bearing must be given regular preload torque in in the at4 2 equally The nut 4 screwing of the side 9kg mand locked with fixing 1000 DATSUN width is 17 3mmit is 0 2mm 0008 against the standard measurement and the E is by excluding the minus in sign The applying TIGHTENING 4 2 4 of the shim thickness the numerals to the is acquired by following method of computation TOROUE 9kg 0 008 in It m may as well be assembled shim of thickness which is by using the in accordance with above method of computation The left and right right bearing must be well pressed in otherwise the So only far the preload changes differential unit is mounted and the drive gear is locked therefore the with the drive pinion must be made to following adjustment acquire the the gear back lash load 2 regular side bearing pre Adjustment of side bearing preload back lash To give right preload the on the side bearing of differential gear case and in pressing the bearing in the differ ential case the bearing adjust by inserting insdie adjusting shim of thick calculated ness in accordance Measure the back lash of the drive with There is a marked numeral of ing basis on The numeral is adjust To in 1000 in against A B Figure measure bearing case manufacturing measurment of each standard C D the in a unit of 1 error 0 the bearing housing of the gear carrier and differential on the left width and 5 of the right use side the thickness standard gauge and dial gauge 17 this the load on the bear on a mm flat board In place ing with the aid of weight block for about 2 2 5 kg to acquire the steady case figures Calculate the error on side against the each standard urement of 17 of 1 1000 and E F each of them Take the left side for example minus meas 5 mm on the unit basis assume When the ring gear to the following method of computation as bearing measured 122 make 004 as sure that if is within 0 1 0 008 taking off the right If it is much shim mm move pinion indicator Figure by using the dial O to for adjustment 2 mm left by CHASSIS A example of calculation A 1 E I B 2 0 gr F 1 T1 I I 11 0 2 C 0 15 1 3 1 2 D 8 x 3 0 N 025 0 2 T2 p 32 8 xO 025 0 15 Thickness of the shim The numeral 4 2 C 0 on 0 IO O the side marked by the electric pen of the drive O gear If it is on Thickness of shim the left side the Ring gear side Pinion mate side x 0 025 8 E mID T2 x 0 on of left right side B D N 025 F set number o 003 are Operation nece ssary the time of Thickness of shim to the mm be on the basis of 80 preload bearing again in use bearing B Letters on the C D Letters on the diff E F Difference the standard width between Remarks N Side flange of gear carrier A reducted for 0 001 or accordance 60 against stand the practical preload is given with because over with the shim of thickness cal plas means standard width Bearing Adjusting Shim case Part No F the valve 17 Letters on the drive gear less than 50 mm variation 123 at the thickness of each shim repairing right must condition of 8 to use the culated from above method of computation E on shows that of the ISmm After the T1 375 the R side recommended back lash besided the N the L r J D on side J C 2 Thickness of the shim 475 mm I 0 u A 2 Thickness 38453 18000 o 050 38454 18000 o 075 38455 18000 o 125 38456 18000 o 250 38457 18000 o 500 mm ATSUN D 1000 the Gear Caarrier Ass y the Rear Axle H using Mounting on Interior of the axle housing should be clean nut ed well The carrier packing should aiso be replaced with new one ing studs then fix with the lock washer be tightened in When it gear oil Mount the gear carrter ass y without mistak it supper side with down side and must a diagonal line so as not to cause the oil leaks throngh nut hypoid 8 The 124 is mounted on the vehicle feed the The oil of the designated 90 should be feed immediately gear oil No Feed the oil till it of the feeding hole comes up to the down side CHASSIS BRAKE SYST EM 9 14 1O 5 1 llil b brakerflolt rcyli d r 1 21 t lJ 534 Brake A hydraulic brake system 1 Ass y tube to 5 way brake master on four wheels and cylinder 8 9 connector brake tube 5 way a Connector 10 Spring Bolt 11 Tube brake 4 Washer lock 12 Assly hosc front brake 6 Ass y tube front brake 7 Ass y hose brake R H LH 13 14 Piping mechanical hand brake Plate lock 3 Ass y tube 11 lock Spring Connector 17 Bolt 18 Washer 19 Ass y tube brake 20 Ass y brake 21 Ass y switch brake lock 125 wheels 16 Gasket brake tube Plate on rear 15 Gasket brake tube 2 5 I lock brake tube 3 way lock tube ear stop lamp R H L H DATSUN 1000 Front Rear Leading trailing leading Type 2 Drum diameter 203 2 rom 203 2 17 cylinder dia cylinder dia Master Wheel Max 175 kg cm2 Lining Th x 0 7 foot kg cm2 Akebono B40 Akebono B40 35 x 195 x 4 8 mm 35 cm2 273 area cm2 by 100 kg 0 3 Lining material Lining dimension xW mm mm 20 64 mm oil pressure Remained pressure L 46 195 x 4 8 mm x 283 cm2 Mechanical for Hand brake type rear wheels 32 28 22 23 f 27 T 4 cL 56 O 3 I 21 l 11 T 20 t r rru 14 9 f 191 18 16 15 Front Brake disc front brake 14 Ass 27 Cover dust shoe front brake 15 Spring piston 28 Packing 16 Seat spring 29 Connector 17 Cup piston 30 BoltMconnector Piston 31 Screw bleeder 2 ASlly Assly 3 Lining brake 1 Pin anti shoe attle cylinder y front wheel fore 6 spring Spring anti shoe attle 18 19 Cover dust 32 Cap bleeder 7 Retainer shoe rattle 20 Screw bleeder 33 Nut 8 Spring return 21 Cap bleeder 34 Washer lock 9 earn adjusting 22 Ass y 35 Bolt 10 Stud adjusting 23 Spring piston 36 Washer lock 11 Spring adjusting 24 Seat 37 Nut 12 Baffle front brake disc 25 38 Ass y tubC 13 Spacer adjusting 26 Cup piston Piston cylinder 5 Seat am am am cylinder cylinder spring 126 front wheel after J bridge front 3S CHASSIS Front Brake Drum Raise the the floor and body until the wheel remove and tire clean the wheel and tire from Detach the return the hub Disconnect Remove the brake drum from the hub Check the drum for defects spring and wheel bridge tube flexible cylinder Remove the disc from spindle or wear f o r o o crl ll 1 g J1 Component of Rear 127 remove brake shoes Brake tube and DATSUN 1000 J 21 r l 4 I I 18 2 I I I I 4 1 er J 12 13 5 L L 24 r I I 1 I 1 Rear Brake 1 Ass y disc 2 Ass y shoe 3 Aa y sboe 4 Lining 5 Pin ear Seat 7 Spring spring Spring Ring snap 15 Ass y lever brake after 16 Caver 17 Screw bleeder brake anti shoe rattle return nI brake shoe cylinder 10 Spring Ass y 12 Cup 128 brake 5hoe adjusting cylinder 11 13 retum piston Piston cylind er rear dust A 18 Cap bleeder 2ttle 1 anti shoe rattle 8 Retainer shoe 9 14 brake fore ear anti shoe 6 brake wheel 19 Shim 20 Shim 21 Cover dw 22 Plate A 23 Plate B 24 Ass y adjuster 25 Wedge adjusting adjusting t A B B rear adjuster 26 Tappet adjuster 27 Washer 28 Nut lock brake i Disassembling CHASSIS the Rear Brake To the wheel cylinder remove at side brake cross rod and spring pin of cross rod end detach the pull out the L E A o I N G S I o E Take off the wheel and brake drum on the stand or Detach the return spring by plier and take off anti rattle a spring plier Disconnect the brake tube from back of flange Push out the Removing Detach the Return shoes and plate Spring adjuster from the flange Assembling is a The Brake Pedal reversal of tdjustment Thickness 1 Adjusting master cylinder Part No 6mm 30611 27260 0 8mm 30612 22760 0 30613 32760 shim for disassembling 5mm When the brake pedal free travel the movement of the brake rod 129 touches the master which is pedal before the push the cylinder piston DATSUN 1000 hole is free from Connect a foreign matter vinyl hose to the wheel cylinder bleed valve Dip the end of the vinyl containing some brake fluid hose in a jar o S @ pedal i s should be To check adjusted by the adjusting shims pedal free travel check push the Push out the bleeder valve several turns and brake pedal down by hand pressure and check the free travel Select adjusting shim from 16 mm the brake 0 is free from the 8 mm and 0 5 mm pedal height 0146 size 5 mm when work and Adjust bubbles stopper of brake are evacuated from the bleeder valve Keeping pedal pressed lock nut dimension the pedal depressing it quickly releasing slowly repeatedly until no air on and then lock stopper at distance 144 5 i 2 mm as bleeder valve and remove Repeat the above shown in the figure down retighten the the vinyl hose said procedure When bleeding the hydraulic lines Bleeding the Hydraulic Bleeding should Fill up brake fluid in the reservoir Brake System be carried out at first the nearest wheel from the master never let the fluid level in the reservoir tank drop below the plate contained in the tank by Fluid cylinder with drawn in the bleeding operation should not be reused Thoroughly wipe the bleeder connection end from any mud or dust present so that the outlet Full up the reservoir with 130 new one CHASSIS PROPELLER SHAFT Washer lock Bolt @ Ring snap race f ftltAss1y Assly journal bearing bearing A i Ring soap bearing i J T Ass y ace bearing Propeller Shaft Distance between 1178 mm joints Tube outer diameter x 63 5mmx1 6mm thickness Involute spline Sleeve yoke y specification Out dia x inner dia x CO I 20 x 80 x 1 mm pitch The allowance of 15 g cm 4000 r p o m 1 unbalance Check the joint every 40 000 km mile If noise race an is abnormal bending such as seen replace the journal and make an adjustment by SNAP RING 24 000 G BEARING ASSEMBLY a play or V bearing the snap 0 OJOURNAL ring 131 DATSUN 1000 Remoyal Disconnect the flange yoke and the pinion flange by removing bolts at the rear end of the propeller shaft In this the end nected Parts with any of 1hese re worn of transmission rear end of the be must Inspect the sleeve yoke for worn splines bearing surfaces and bearings and plugged lubricant fittings draw out the sleeve yoke from case faults placed holding the discon propeller shaft Assembling Assemb1in operation is a reversal of dis assembly Install spider in yoke flange Insert the the a journal into the yoke flange journal bearing into the yoke flange brass drift smaller than the hole in the Tap using yoke Tap the other bearing into the opposi e end of the yoke flange until the bearing is in line with the snap ring grooves With pair of pliers install yoke flange the flange assembly a the snap rings on both ends of the Insert in the sleeve yoke Before of shaft so to as and position balance disassembling Place the other yoke bearing into the oppo mark all components site end of the yoke and tap this bearing into yoke until the bearing is in line with the snap Install the snap rings on both ring grooves ends of the yoke After assembling all parts assemble them in the former avoid that the propeller the shaft may be some how affected make sure In the over about case size snap Uniyersal Joint Remove snap propeller shaft Remove bearings the rings from excess rings as rings yoke flange with snap ring does not a spider adjus1 Over Size journal snap out of the Part No Thickness ring Distinguished painted colour 37146 18000 1 46 White bearing until the opposite bearing is pushed out of the yoke flange Turn 1he assembly over in 37147 18000 1 48 Yellow the vise and drive the first 37148 18000 1 50 Red 37149 18000 1 52 Green and shaft with 37150 18000 1 54 Blue dive shaft about cracks broken 37151 18000 1 56 Brown 37152 18000 1 58 Remove out of its snap slightly on lug by driving the end of the journal spider bearing back on the exposed end of the spider Use a brass drift with a flat face Wash and clean the cleaning solvent Inspect the welds scored journal shaft bearing bearing with pair of pliers groove tap the end of the bearing with wooden hammer slightly This will relieve the pressure against the the around follows Snap Ring secured the sna on clearance the in a rise in the If the yoke place tightness of surfaces or bent 132 I CHASSIS REAR SUSPENSION 14 i VA lA 15 19 llJ rri r Constructure 1 Ass y 2 Pin 3 lp C of Rear Suspension 14 Clip spring front 15 Ass y bracket 16 Nut spring rear l 20 6 13 front rubber spring rear spring axle bumper 4 Bushing 17 Washer 5 Nut 18 Pad 6 Washer lock 19 Plate 7 Ass y shackJe spring 20 Kit shock absorber 8 Plate spring inner 21 Bushing rubber 9 Washer shock absorber Washer shock absorber spring ear shackle Bushing spring upper 22 10 Bushing rear spring lower 23 11 Nut 24 Nut 12 Washer lock 25 Washer 13 Seat 26 Bracket spring lower 133 spring ear Iocation rear rear lock seat ear J ear spring shock lock shock absorber DATSUN 1000 Body Disconnect From Disconnect the shackle pin and then separate the figure Fixing to the rear Side spring front spring the rear as showing Member member Jack up the hody and hold at the side on the stand Attach the bushing rear to the spring and rear spring bracket Connect the front side of rear spring to rear spring bracket Front pin Tightening torque Take seat load plate off the shock Jack up the rear absorber from le housing U bolt bumper seat pad and spring seat etc Disconnect 3 5 4 0 kg m spring to release location Connect the rear side of spring to bracket Shackle pin Tightening 134 torque 2 0 2 5 kg m the CHASSIS Set up the seat bumper U bolt pad location plate rear axle and spring seat U bolt Tightening torque 3 5 4 0 kg m 1 IS DATSUN 1000 136 ELECTRICAL SYSTEM ELECTRICAL SYSTEM Wiring Harness egulator Parking turn ignal Head Type Wiring BiD ignal lamp Head Bod arth Altemator nun Type Wiring 137 LH ParkiQ8 turn VBiD lamp mp Harness egulator Parking l Harness bmp L H o oo lamP it icence Un I nr 1 ht bt 1 ht l1 ht 1 tot hi atn lot P ht t cato lrnlng nst ndiU furn V ut bea tOr l ldol Oil flegu1Q i M l C lte tlul Red de P dioW colOW 61a Wb N n GRP f Wif JJY 8 p O YI R NG co ler conector R V4 fat H Y m tel I Horu he n W rI 1 ght indcatOr 1 t ingj l n Side t tor rI iudica 1 1 in t turn lamp P turn a p P P tn Side 1 dI He it fl 9 L ELECTRICAL SYSTEM 24 30 I 32 Q @ @ @ 9 11 Alternator 1 Ass y 2 Bearing ball 3 4 5 Hitachi 17 otor 8 h 18 Spring brush Bearing ball 19 Screw Retainer 20 Cover brush Ass y stator 21 Screw 6 Ass y 22 Bolt terminal 7 Set diode 23 Ass y wire 8 Ass 24 Cover front 9 Assly y bearing cover diode et 25 Retainer 10 Screw 26 Screw 11 Bushing insulator 27 Spacer 12 Holder brush 28 Ass y 29 Key terminal lead bearing pulley 13 asher iD5ulator 14 Washer insulator 30 Nut 15 Bushing insulating 31 Bolt set 16 Screw 32 Bolt through 139 pulley D ATSUN 1000 ALTERNATOR The sealed ball the rotor brush holder Alternator Hitachi Model LT125 Nominal 12V 250W output Constant from dust 02 AC300 milage 12WR Pole is also made so without maintenance the pressed respectively used to support to as prevent it Each 3 diodes are and the diode base rear cover side ground Constant revolution 2 500 r p m No load minimum 1 000 r p m revolution Output 14V normal current 2 500 2 r temp 14V normal 500 r p 21 5A up @ down m p 5A up 24 temp Type Tirrill type ieaf spring Constant voltage relay Pilot Constant voltage The Secondary Primary side clip side 15V 14 15V 4 OOOr Battery Load 4 m p revolution resisting r p pressed in the shaft The rotor magnetized by doughnut coil m r r in full battery charged t Pilot lamp relav Put 4 off voltage 5 point type 3 contact 5 Put 2V on o f I I voltage 5 Magnetic 3V Circuit W Relay r R GENERATOR I I I I I generator armature current the DC the making it generator the AC magnetic pole and fixes generates and rectifies all diode and takes out each three as 3 I 1 01 I I I S I phase alterna1e waves that 1 I I I L I l with the silicon are built within direct current Connection within Dvnamo 140 i T 1 0 1 I 1 turns EB v t I 3 Construction and Feature Different from is makes out the magnetic shown in Figure and all the poles are pole of Battery load 21 5A approx Use 000 ring of Rotor current circuit as Dynamo Shaft egment Field coil soldered at both ends of the field coil to pass magnetic 14 J core point type Sectional View Adjust valve Field lamp relay 3 contact relay Field @ @ high temp TLIZI0A Element CD l4V m Regulator Note are Thus the AC generator will increase in SUccessive bearings Clearance between the brush and e I ELECTRICAL SYSTEM tion and type flow three phase Y connec the silicon diode rectifies all The armature is of a the through field coil unless the dynamo makes very high revolution pulls out the neutral point and adds voltage having conducted 3 phase half wave rectification in the circuit of relay and controls It waves and Disassembly Assembly the voltage coil of the pilot lamp relay A Disassembly n The n r f I I S l o II jl t 9 f u I J 3 FC following a e I SC is disassembled in the B 0 1 I dynamo order Oli1e a gu1ator Dynamo Charging Svstem Regulator b Remove brush the brush and cover pull off the 2 ea Charge pilot lamp J When the ignition current battery direction terminal brush flows in dynamo the put arrow fN1flJ f cr 1 marked c j E l J and IG terminal and completes the field circuit residual magnetism magnetization to suit dynamo to stand up of the field is necessary until core I only by so voltage V l through dynamo slip ring field coil slip ring F terminal relay F terminal It in difficult for the 1 1 iA I the on the passing brush is switch l 1 11 Outside Connection that o rises charging after the engine has started This is because the diode is used and when the voltage to add to it is so low large propor c tional resistance shows up and current does not 141 of bearing and take off Remove the the hex bolt of shaft cover DATSUN 1000 e Remove front front Use the COver cover a through and rear Remove the hex nut the pulley and the half ful no1 to of pulley moon of injure the fan and pull off key when Be care the nut is removed f d9 142 tightening bolt pull off the cover and rotor hammer necessary d bolt wood or plaslic if ELECTRICAL SYSTEM Remove the ball from bearing cover Remove the bolt bearing plate and or the front tightening the pull off the bearing or v with such as hand press Slacken N terminal bolt on the rear cover side and the remove rear the clip terminal and COVer the stator l then can be separated t g Remove the diode and set brush holder from the rear cover When be careful such as sc rewa B Separate stator rear cover coil soldering lead wire the and rear from the ea the remQve cover 3 by melting ea the rear cover on clip the and terminal stator then can be When up Always make sure the polarity of alternator regulator before replacing the diode either The polarity of alternator positive or negative or regulator is usually marked on the name plate or label which is attached to each model In case the alternator or over 100 1500C so the that 200W at the soldered diode diode use the will gear lose regulator colo 1r the red be mounted in the frame of within temperature functioning iron is done in the reverse sequence of positive ground separated NOTE bushings or with an electric iron Slacken N terminal bolt side 3 lose small parts disassembly and stator the silicon diode to Assembly Assembly Remove the not washers and slip ring portions h a a Red Or Black Red Black mark DiOde ExPloded 143 the end and the black coloured diode in the heat sink electric for around 2 seconds shows diode should View muk mark H DATSUN 1000 Removal To Figure remove a diode and drive it with motor For use a support the end of the frame or heat push the diode out by using an arbor sink inspection of output of dynamo without the from vehicle refer to removing it AC Generator of 10 be Inspec1ion published to suiiable tool and press as later shown the below l Ammeter u I Ie T Volt meter 0 Press out 50 not t injure the mounting bore of the frame the heat Support NOTE or Use the ink normal Throngh Tool battery charged the shown in wiring netic current flows from the coil Figure mag ba1tery to the field In this state dynamo raise revolution of dynamo slowly up to 1he speed where there is Installation no Support of in full up to the capacity the heat sink end frame with or a suitable tool and then press the diode in the heat sink and end frame by using the tool which fits over the outer diode edge A Next Press down perfectly the diode in the mount ing bore of C portion to the lower edge of B portion of the diode Checking the replaced diodes current load almost and Observe current as revolution of or i i AI oncreasing dynamo output If increases from the how the battery is if the specifica discbarged in charging either sure disorder the See the over charged current is small dynamo or the relay charging current by inserting the ammeter between relay and the battery j raising it is correct first make is thus large difference No matter @ i V Then the load increase revolution of dynamo tion of flowing and put off the switch no to resistance stop the load current slowly there is l Correct revolution is without load increase maximum 10 the field coil approx the revolution 1000 rpm approx shaped Al portion 2 A flow reverse and read A terminal of Disconnect wire passing from the dynamo F terminal to the relay F terminal at the relay F terminal and make the removed lead wire short circuits at the relay current charging A terminal highly increases when if the the relay is in disorder B Inspection A Short Circuits It of Troubles flare rare from inspection of output remove the dynamo also the vehicle and connect wiring as shown in of 144 be even Actually Inspection of Output For can a and rare judged if the on Diode as the key trouble such short Side pilot lamp switch as circuits Ordinarily side short circuits at is does not turned diode open the polar line there are on is very many are cases ELECTRICAL SYSTEM C Inspection of somewhat Diode with Tester diodes one a the standard lower than are often in opening 1 2 when one by checking will be necessary Simple Inspection b Check between the terminals A Separate Inspection N as shown Set the dial of tester for con in Figure ductivity and put the terminals alternately When shows one low tester needles at both resistance and shows pretty high resistance diodes in the diode set are all right other the the 3 Check resistance with the diode and lead wire Check between the terminals above When the are same also all However in this result is obtained the other shows 3 diodes right when there is simple no no test and the between rear cover disorder high If low times resistance and resistance both sides 2 are there is low there will be short circuit and both sides are disorder found dynamo output the on charging the poles When one side shows A E same as the tester base commonly used for 2 diodes there will be open is I I 145 high 1000 DATSUN Inspection of Diode with Lamp D a Simple Inspection Check positive diodes Check negative diodes Test Test Method Connection Should be Connect conductive to @ to @ to @ @ non EB ductive to 8 and @ to Result Light Good Test Test Method Connection Should be non @ No Light Defective Light Good Light to in less than Defective 20 seconds as @ 8 to @and10@ Connect ductive @to @ Lamp Method Lamp Result Light Good No @ Should be co The soldering for the lead wires should be performed con ductive Connect @ Lamp No to @ Method and Should be con E8 e Lamp Connect A to lID Check and Light Light No between the Light terminals iitt j 1 A N as lamp 12V in straigh1 and put both ends at A and N terminals alter On one side the lamp flares and on nately the diode set f Good Connect with the the other the lamp is off M rJI Defective E8 to@ shown in Figure the excessive heat may damage the diodes li Defective oiil j 146 are all right when 3 diodes of ELECTRICAL SYSTEM The same nals N obtained all all step E is taken between the termi When 3 diodes However right right but the when in the cover are if the simple test is dynamo output the lower then the standard 1 often be opening one so is result same pressed that is 2 diodes may by one check will be necessary b Separate Inspection F Ball Bearing Both sides sealed ball bearing is used lubrication is not necessary Inspection of G a Stator so i Armature Conduction Test If the terminal connected to the diode is not conductive with the stator right Check set between the lead wire and the diode common rear cover is all is off right with the other 2 diodes with the if both It side flares and the other one If both sides flare circuit and the or lamp and battery sides are there is short off there is open Inspection Field Coil E As shown in Figure the it is slip ring of all right rotor Make tion between the rotor put the tester between and if there sure slip there is are no 6 7 n conduc ring and the shaft 147 core that is all DAiSUN 1000 If each terminal of the coil and the terminal connected to N terminal that is all b Layer not conductive are right Test H Connect the tester cord on tester turn reading the there is short circuit the ammeter is no trouble 100V wire put abruptly on ammeter the coil If there will be no change when oil or dust is on the contact surface of the brush and slip ring Same as swings of increase and if there Inspection of Brush Wipe with clean cloth the test stand and make the the stator one to in case of DC the brush when limit 148 wear generator replace of it reached to the wear ELECTRICAL SYSTEM 14 ITEMS ON HANDLING REASON PROHIBITION 1 2 mounting points on Make the contact vehicle polish both sides removing point When sure on rust or oil engine side pitch and dynamo side cover are well fitted together the of the front pitch 3 Be attentive to the belt tension 4 Regulator is removed sealed during with the claim If the seal is lead the claim will period invalid 5 If the earth is not correctly set the adjust value will change 6 Connect and dynamo the with battery full attention 7 Make circuit whole the sure is hattery poles are connected in reverse large current flows from resulting in battery to dynamo When the lead wire damages of diode or When engine completely composed 8 Change wiring with full attention the after switch will wiring Do not the use high voltage tester such as 10 Engine room be kept in the condition of must Because with In the incorrect hampering generation the diode will be high voltage there deteriorate standard usage in and then As diode is built damaged megger from that so result magnetization 9 started the magnetized is dynamo ignition or which will diode is be damaged with tem perature higher than the normal 11 separate the battery terminal terminal during driving vehicle Do not dynamo Separation serge of voltage the terminal within causes battery and damages diode 12 When cleaning with to dynamo dynamo water steam cleaner do not expose washing with directly must be free from reckless pour When steam If the diode is moistened the per formance will be lowered of water 13 When quick the battery is the charger dynamo terminal A quickly charged with the lead wire or regulator A terminal should be engine in a Serge voltage of the quick will also damage diode charger dis connected 14 Put the except key switch off when when the particularly stop When the key switch is current needed and often on magnetic the field coil might damage the dynamo and over causes discharge of battery 149 always flows on DATSUN 1000 TROUBLE SHOOTING TROUBLE of lOver discharge 1 Slackness of fan belt 2 Earth or CAUSE REMEDY batterv breakage of Adjust stator coil Repair of rotor coil 3 Breakage 4 Mal contact of brush and slip ring 5 Mal function of diode 6 Adjust voltage 7 Mal contact 8 or side contact point of Polish contact point Adherence of high speed side contact point Shortage or unfitness of electrolyte Replace 10 Mal function of battery pole Replace 11 Mal contact of battery terminal 12 Mal contact 13 Mal contact 14 Excessive electric load 9 or Add distilled water short circuit Clean Over 2 Constant 2 Constant retighten terminal Repair breakage between regulator dynamo F terminal or F Repair Check power consumed 3 Constant 4 Constant 5 Constant relay voltage adjust is voltage too high Readjust voltage relay coil voltage relay coil straight breakage or rara short Replace resistance breakage Replace voltage relay low speed side contact point adherence point Replace voltage relay high speed side contact mal contact Polish contact point 6 Breakage 7 Mal contact of pilot lamp 8 Mal function of regulator earth 9 Mal contact or rare short of pilot lamp relay relay contact of Replace Polish contact point point Adjust breakage between regulator terminal and dynamo N terminal Noises check S G repair charge of battery 1 3 or breakage between ignition switch and relay IG terminal terminal and replace Replace Replace brush clean holder Replace as a set Readjust of constant voltage relay is low of low speed voltage relay constant LIST or N Repair dvnamo 1 Mal function of bearing Replace 2 Mal function of diode Replace diode 3 Earth or rare shor1 of stator coil Replace 150 as a set ELECTRICAL SYSTEM STARTER MOTOR switch move starter and to permit cause current to flow to the the armature to start turning suddenly CONTACTER MAGNETIC 5W1TCH PLUNGER ARMATURE Magnetic Shift TyPe After advancing about 14 mm the pinion completes the meshing into the ring gear and drives it with a powerful torque The direction in which the pinion moves is from the end of the shaft towards the starter bracket TyPe S1l4 87 Motor Starting Type Rated output Meshing device V Kw No load current Hitachi 8114 87 12 to unmesh and return to its former 1 0 V A Under 12 60 rpm Above 7 000 Brush normal height mm 16 mm 9 5 wear limit Commutator 33 mm SWITCH CONTACTOR SERIES COIL RETURN SPRING 800 t15 Dta STARTING SHUNT COIL Brush spring tension gram Commutator position Magnetic No load rev Brush thus reduct After the engine starts ing the bending torque and its speed becomes greater than the no load speed of the starter the pinion is kicked back 5H1FT LEVER PINION wear limit dia mm Under 2 Under 8 Pinion operating RING V voltage AR GF P1N10N SLEEVE SPRING P1NlON SLEEVE SPRING Construction and Operation The sliding starter inertia starting The engine is motor is a electric type motor oil the front when right 1 A View 0 to that of the for mounted use on in Operational Precautions the side of the trans generator but differs ing only 1 in that its armature shaft extends out backwards with in a pinion group installed Figure The shown in connection diagram on The instructions to be observed when start the engine are as follows The starter should be securely mounted on the engine and should not show any looseness the end as show 2 for the starter is The starter switch should be operated pro perly Figure and should be release immediately when the engine starts The starter switch is with the ignition switch the right direction the of Starter System horsepower motor mission with its pinion gear directly to the ring The construction of the starter motor is gear similar 1 2 a key type combined Expecting By turning relay on the magnetic switch to engine seconds 151 in should extremely normally cold weather start within the 10 DATSUN 1000 15 16 654 20 f 11 12 22 Starter Motor Hitachi 1 Ass y 13 Lever shift 2 Washer ttuust 14 Pin lever 3 Ass y 15 Pin 4 16 Ass y switch 5 Stopper pinion Clip stopper 17 Cover dust i Washer stoppe 18 Packing 7 Bearing cent er 19 Bolt 8 A5S y 20 As 9 Brush 21 Screw 10 Snuh 22 Ass V coil 11 Screw 3 23 Screw 12 Bolt annature pinion I cover rear through 152 cotter ly cover magnetic brush field 10 fi 9 11 ELECTRICAL SYSTEM 3 The starter switch should net be operated is when the engine fails to start allow time for rest to come 2 If the running engine pinion to the removed starter before turning the 3 After removing the hand cover and lead wires are removed the brushes 4 By and holding the switch again 4 fails to start after turning When the engine the starter continue try to check do not for over 10 seconds key the of cause correct so that the the trouble engine will properly body 5 in out With start To the remove pmlOn sbaft the shaft is pulled out and Operation fully charged battery and with the lamps lighted the starter switch is used If the lamps become dim especially when the engine does not start the current is flowing through the starter motor coil rot some since the armature check should reason Careful turning is The procedure same cleaned and be made are made inspected as to whether repairs 1 or refnoving the is removed The pinion When the starter remain the bright switch factory condition then the condition of all battery ground switch starter checked If the starter motor movement is sluggish resistance due starter starter runs armature are care parts being be reused or if necessary for defects and if edge is replaced the tooth be should will but its shaft also check the it indicates either a cause For should be taken measures to loose connection in damaged badly discharged defective circuit or a can worn or pinion meshing gears connections of the and the the for only make the will hasten the wear gear mesh poorly hut the on poorly opposing gear and also should If the switch is in satis the Worn or broken teeth will not although the first be checked the terminal and damaged turned up and motor fails to turn starter lights switch is are inspected is that as they replacements the tooth face is the by after which determinations in flywheel ring gear and unable to return a trouble usually caused by turning on the starter while the engine is still running high pin Parts followed is generator parts not the starter pinion may be locked Repairing and Inspection the the the the end of on group the pinion nut from group the cotter a for 2 pulled together pinion 1 shaft is armature and the front cover are taken The and armature while the armature out 6 Checking protecting starter turning the key time after time but In this case the battery save for The two stay bolts on the starter rear cover front end when mounted on the engine are this last the to and take remedial if the ring gear is found replaced reason when inspecting flywheel When in the bending the entire worn or is pinion found pinion group battery 2 3 If after the above troubles are corrected clearance operate occasionally and shows defective performance it is due internal defects so that in this case same and to core bending manner as armature gap in shaft shaft The starter are removing the starter on the two be dismantled in the corrected to the armature Disassembling can bushing etc that for the generator and not contacting and corrosion found outside surface of the armature 1 check the to specified limits or the is replaced Special attention to should be given the clearance j the letwe n armature and the core to see that they are it should be dismantled and checked Dismantling the inspecting armature and the starter fails to to When surface of the easily by core engine 153 the the inner should be removed by and the surfaces polishing rust preventive oil stud nuts mounting the or on painted with DATSUN 1000 3 The armature is inspected accordance with and repaired in the procedures outlined for the generator Especially to improve brush contacting condition correct the or the brushes time reseated are the brush spring corrected or are At the Sa ttery same checked and are replaced Cable Connection 4 The insulation and inspected damaged on the wires wires found carefully are with weak of Dimension Adjust or b insulation should be replaced of lstment Adjl Plunger Gap of Magnetic Switch 5 found with An armature one part especially buring should be damaged by by the insulation strictly The tested L compressed test L 31 7 dimension when the plunger gap is to 0 must be following in Figure 32 3 mm adjustment is adjuster and the adjusting This ADJUSTMENT a Meshed Pinion Position The correct stopper and pushed L dimension in L 0 In 3 clearance out Fignre by Magnetic between case the pinion by following that the L dimension is incorrect of the magnetic switch by b Pay attention that the L dimension must be measured when the atmostly pushed out and back plunger the by pinion meshing Disassembling Operation and Disassembling the Armature Disassembling the shift lever of the lash of the pinion Assembly it will be the possible noises or early wear and main of large cause damage order is shown by Figure is Disassemhly operated hy removing magnetic switch fixing bolts throngh bolts and the armature shaft clip Before disassembling is by pushing gear inward with finger If the L dimension is in Fignre shows correct the Gear Case and Pinion eliminated as at 15 mm adjust plunger gap following paragraph is out Switch pinion which is shown must be carried nut brush of body remove fixing screws as brushes by unscrewing Figure the pinion and ring gear 1 Checking 3 1 5mm Measurement Dimension 154 of Plunger Gap ELECTRICAL SYSTEM GEAR CASE ARMATURE ii jv J t 1r I lu I 00 IA r 1 o Removing Magnetic SHIFT LEVER 0 Switch Disassembling Armature and Gear Case o 0 SCREW DRIVER 0 J Removing Drawing out Brushes After removing fixing screw Pinion Stopper ARMATURE PINION STOPPER O PINION ASSEMBLY Drawing Disassembling out Yoke 155 Armature DATSUN 1000 PINION SLEEVE PINION SLEEVE SPRING CLIP id Removing Pinion Clip Pinion Disassembling Subassembly 01 A 00 oO QU 4 l ooo o r ta1m 1 AA J 0 c Display of all Component Disassembling pinion clip as starter switch opens the magnetic circuit which also opens 82 Pinion Disassembling is carried out by removing Figure 1 Assembling and Reassembling reverse frictional SAE 30 Testing for are while the by following disassembling lubricated bearings the magnetic to close can coated with Relea sing switch failing to and sources All with mobile oil are magnetic be divided into electrical Causes for electrical troubles A Current failure in magnetic circuit When the starter switch in pressed and the current falls to pass through the a small amount of grease circuit in the magnetic switch and causes the main circuit 82 in the circuit for operate mechanical is performed procedure parts Starter Causes magnetic the due 156 to circuit broken most of the trouble is soldered connection ELECTRICAL SYSTEM Check the battery run down fluid to see if specific gravity of the battery is 1 240 it over and recharge or replace the Is between the magnetic coil wire and the terminal and defec magnetic switch ground connection from magnetic switch body tive the coil wire as found necessary All loose battery and ground cables should battery to the B Defective contact in main circuit 82 closing but only flowing due to high is Sz current and resistance the be cleaned and satisfactory When the magnetic circuit is and the Magneto small a and special attention given to the condition contact opposite of case properly tightened Gargoyle BRB No 1 are carefully tightened grease or All cord connections of insulation The assembly check is made a single unit using switch 81 opening but 82 remains closed In either case the trouble lies in the by testing the starter as a fully charged battery faulty moving of the with core or roughness of contacting point surface the polished the surface operation will become Therefore starter in shown Figure by measured is torque Tests are made tester motor apparatus the then well a In normal value should be 0 9 satisfactory this m with or which the braking case the kg Causes for mechanical troubles to operate is caused in many by the guide shaft on the moving of the magnetic switch main circuit Failure cases core 82 sticking against Correction can loosening the and 2 cover cover 4 screws them so case Starter pieces nuts from the or The following be determined installed on motor magnetic switch is an apparatus when engine is being started by shift lever sefves to close the circuit between the battery The terminal to the cover the and the starter current to and motor and permits or when the engine Their Causes is to flow through the magnetic is a list of troubles which can the state the starter is IGNITlON SWITCH the engine CONNECT TO OTHERS 1 Starter fails to turn The engine is checked to see if it can be cranked by hand If it cannot be cranked the and should be checked easily should the be starter checked engine is at fault BATTERY If it can be cranked including and large stopped The keep the circuit open be from seen Fig 8 principles of operation can allows the current Closing the starter switch 81 the switch serves to from a flow and actuate the starter motor After starting cause Starter Troubles and Remedies 12v Construction of Magnetic and Switch Instructions magnetic switch circuit terminals when installing ground the damage Battery Torque Testing Apparatus removing cables the lower nut of the double state nuts should be kept in a tightened If while unscrewing the lower nut is loose the terminal bolt may turn together and IlAmmeter SOOA that the shaft freely removing main I ce dynamometer by Precaution In l5v voltmete l B hole be made in this retightening moves the Starter wheel the wiring correction made Magnetic accordingly 157 Starter Circuit DATSUN 1000 If there is trouble in the circuit magnetic Besides the above it pinion meshing improperly is due to the gear teeth being badly worn 1he gears should be replaced bill if it is due to the Be rew guide on the pinion shaft being brushes be checked made starter brushed improperly contacting the as together the armature with corrections and or should replacement dirty and not allowing the pinion to advance smoothly and causing improper meshing found necessary of If all responding the above checks with their been have repairs starter still fails to operate assumed be to the If the trouble shouid be corrected For there is the case of made and the trouble in the starter itself cor so can the shaft should be cleaned and oiled the be that it should be removed from the engine and checked This is exceedingly rare taken to see that the starter into the flywheel ring but care should be pinion 2 is not locked The Cases like this are gear exceeding noisy when operation flywheel ring gear is checked and if the Starter teeth usually caused by badly gears meshing improperly and if the defect is not too severe it can be remedied by placing the gear shift lever into fourth speed and rocking the car back they should be repaired deformed are worn the gear replaced Rattling ilOise caused or mounting bolts ing the bolts If this trouble is and forth to free the gears the starter should be frequently repeated dismantled from as repairs this Starter turns but its against power is weak turning and worn and damaged ing and manner sticking commutator repairs as run down are brushes in the shaft and the check etc in made described the outer the surface of the rubbing against be dismantled the core not the that be bushing so the worn Wear between replaced bushing attention should is due to lack of oil be given to so proper Lubricate once every half year using grade of macline or mobile oil preceding lubricate the is The amount the starter should disassem bled and clearance between the lubrication same armature a shaft and the parts should dirty chapter s If only produces noise both parts made the armature by rubbing the while in operation is core armature battery troubles in magnetic shift loose terminals switch a improperly wear on caused by too large and fails to start the engine If the trouble is due to brushes by condition but will hasten Noises 1 caused starter contacting the armature required correcting checking and for the engine Noise loose by corrected by retighten are parts through of oil required for each bracket repaired 158 the oil i good and nipples about 0 5 cc r i s NISSAN MOTOR CO L TD H BODy i j t L h 5 BODY @ waSher ain Washer lock I Fix bolt @ 19 21 JU 15 @ 25 33 22 3 11 3 12 10 1 Ass y 2 Panel front apron 3 Ass y fender front R An y fender front LH ruppon 5 Screw 6 Bolt 7 Nut 8 Washer lock 9 radiator Washer plain 10 Bumper hood front 11 Bumper hood 12 A 13 14 ly panel Ass y panel Ass y panel 15 Rod hood 16 Spring 17 uher W 18 Pin 19 Ass y 20 Pin hood ledge R H hood ledge LH hood support hood support plain cotter hinge hood hood hinge 21 Bolt 22 Washer lock 23 Waiher 24 Seal hood 25 Grille cowl 26 Screw 27 Any 28 Grommet heater hose 29 Grommet 30 Grommet washer tube 31 Crommet brak plain hinge top grommet steering post antenna able tub tub l BOlt 32 Cromm 33 As y l nel p 34 Ass y l nd p IIO Tn Washer lock @ @ Washer 789 6 2 ain @ Front Panel Hood Lock Control 159 H t chok wire cowl lSh d op fud DATSUN 1000 HOOD LOCK CONTROL Removal o Remove the radiator o Disconnect from Assembling grille the female hood reversal of disassembling procedure support of radiator grille and separate Adjustment o To disconnect the control wire the release lever a lock assembly from the cable cable from is at edge the position of male lock by sliding fix hole by loosing the fix bolts separate the the Adjust of o Adjust the position of male by turning the bolt to the left way cable 160 BODY 34 T@ 15 27 10 17 View oj Front 27 Bol 28 Bolt 29 Washer lock 30 Washer plain 31 M 32 Moul 33 Clip lodrside sill moulding Bolt 34 Ass y ba k mirror outside R H Ass back mirror outside 1H 1 Grille radiator 14 Washer 2 Screw 15 Nut 3 Rim head 16 Overrider front bumper R 17 Overrider front bumper LH 18 Bracket licence plate plain 19 Bracket front bumper lock 20 Washei 21 4 Screw 5 Set 6 Washer tapping lamp Washer 8 Nut Bumper front 10 Bumper front 11 Connector 12 Bolt 13 Washer 1H tapping adiator TI emblc 7 9 griH lock Remove o Take from ill Washer plain L H 23 Washer lock 36 y Mud guard front fender 24 Nut 37 Emblem plain 25 Stay front bumpe 26 Stay frnt bumper moulding and mud guard 38 Clip LH 39 Badge the attaching bolts of fender of o Disconnect hpening o Deluxe the front door bolts from front side flasher lamp and head lalllP front fender DATSUN tubular R H o the side from hood ng b oQY side 22 front bumper the lding roof drip R H front fender o ide B 35 bumper B Remove H rubber Front Fender o Side front fender take out the attaching piller Detach the fender from the body ledge off the Assembling side bracket of front bumper the fender and disassembly bumper 161 is a reversal procedure of DATSUN 1000 Disconnect o o Take off the Remove wiper the arm of windshield outside o it so as to over around moulding windshield o Separate weatherstrip from body spatula at the outside and inside o Disconnect the wind glass with Hold ends of it with o In this tapping the surface of glass by closely between the weatherstrip flange of body by giving vibration case hand to fix and the the Glass to o Set the wea1herstrip o Insert a of cotton rubber Strip to the on rope channel o in pinch o Tie glass at o bottom center of glass o Fit the glass Using an ends of it to inside surface of for fixing a the glass pressure in by a spatula position type applicator seal inner and outer lips of rubber channel to glass with around windshield o Correct the lip of weatherstrip after glass strong cord completely pulling body Holding the inside edge of it pull it from right and left side so as 10 over the flange of body frame Assembling flange worker and of the o a strip from by inside approved weatherstrip adhesive Seal to extend are completely around rubber channel correct position on the o frame Clean of excess sealer from windshield glass with mineral spirits 7 6 1 3 1 C 5 4 4 2 Windshield Front Window 1 Glass windshield 2 Weatherstdp windshield 3 Set moulding windshield 4 41 5 ss f y fack mirror Fitting inside Arm back mirror imide Screw 162 6 Ass y 7 Screw sun visor BODY 22 21 25 26 rIo f DELUXE Sectional View window of Rear Side 1 Weatherstrip side 24 Emblem 2 Glass side window 25 3 Rubber 26 Clip tubular Mark Oeluxe 4 Ass y sash 27 Hinge 28 Hinge trunk lid 29 Pin hi ge 51 30 Screw 52 B olt Washer side window side window 5 Ass y bandle 6 Pin handle 7 Screw 8 Washer 9 Weatherstrip 10 Glass 11 Set 12 Ass y lid rear ide window side window rear window window moulding ear window trunk DATSUN 1000 trunk lid 46 Nut 47 Overrider rear bumper R H 48 Overrider rear bumper L H R H 49 Rubber overrider L H 50 Stay 31 Washer plain 53 32 Washer lock 54 33 Spring stay 34 Stoppu stay 35 Ass y sta y trunk lid tnmk lid trunk lid J St y rear bumper R H rear bumper 1 H plain r lock Washe 55 Bolt 56 Washer bumper 8 57 Washer lock Nut plain 13 Striker trunk lid lock 36 Screw 58 14 Washer plain 37 Washer lock 59 Ass y lid fuel filler 15 Washer lock 38 Board 60 Ass y lid fuel filler 16 Screw 39 Holder 61 Spring 17 Ass y lock 40 Ass y 62 Bumper 18 Washer plain 41 Bumper 63 Screw 19 Washer lock 42 Connector 64 Washer lock 20 Screw 43 Bolt 65 Washer plain 21 Ass y 44 Washer plain 66 Ass y Iock 22 Ass y handle 45 Wash Iock 67 Clip 23 Weatherstrip tnlnk lid cylinder trunk lid lock trunk lid finish trunk room jack lever bumper rear rear bwnper bumper r filler lid robber fill r fuel filler lid lid lock trunk lid I Removal o Opening of Trunk Lid Lock trunk remove o the lock bolt of it 163 Disconnect retaining clip and the lock remove for lock cylinder cylinder panel from lid DATSUN 1000 bt 1 Cl liDp door v nrila ar lI1ilatar door fr Dlila ftllbO a J A u dI a Ultn door WaobupbiD yfinithd A Wa herpb I hulock Wa 01 1 aJherpb I Wubetlodil II I Boll Components of Door Fitting loc1 N 1 k 100 rp t0 w be l r uincr o lo k Aa wl doo yloudl at c Construction of Door Door Finish Lock o Regulator Take off the screw at the lower side of door sash center pillar Removal o o Remove the door finisher from inside of door Drop the regulator out it from the inside by screwdriver disconnecting clips o Window o regulator sealing screen regulator Disconnect the groove of After removing the door to the bottom of door panel top of regulator glass take hole arID from the channel finisher and inside remove screw of the window 164 Assembling disassembling is a reversal procedure of a Jj fL r f q If c 4 ir tioa f 73 J 5 f Ii 711 s I I ffr l l fi i t f o 4 p f tr l 4 r p t t1 d r I it r 2 t or I t r JJ iI r 1 4r y Zc r r L r z t r r7 f r 1 0 1 i I r i 1 r 1 Cf 7 f J f t t ff J 1i f r jp 0 s v r Cu r t 1J J J ffi r i t 1t T r f if i r l 2 5 V v ij tt L Pr f r t t i 0 T tr r r f t 0t t lJitild J i Jl f T r i b l t PUbJi I l o l I fir ii rft N 29111 h iJ i 090 4093 J I I Il l 1 J ItlJ r 7n I J r t
