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Download Service Manual Datsun Model 410 Series
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1 h r SERVICE MANUAL r f to DATSUN J 44 410 SERIES MODEL I w 1 rf A H t I ff A r l 1 1 4 1 ty f t f NISSANI l ir r 1 fr l J t 1 r r jo cr 11 t1f r I i NISSAN MOTOR CO OTEMACHI BLDG OTEMACHI TOKYO CAIUS ADDRtSS PHONES CHIYODA JAPAN NISMO LTD TOKYO 211 5281 9 KU MODEL DlTSUI BLUEBlRD P L 41 0 INTRODUCTION Thls manual has been DA TSUN dlstnbutors and mamtenance dealers for effective IS descnbed In Each detaIl In addltlOn mstructJOns are glven assemblmg and mspectlOn of these assembhes IS emphaslsed shuu ld be used as that only for complete genume DA TSUN replacements serVlCe assembly prehenslve It i for purpose of asslstmg of the Model P L 410 major components j comphes and of the com dl manrlmg Spare Parts l I t t I CONTENTS Page SPECIFICATION l 7 ENGINE 1 General SpeclfIcatlons 1 COOLING SYSTEM 3 LubrIcatlon ServIce 10 OperatIons WIth Engme m PosltlOn 16 Rocker Mechamsm 20 Removmg OperatlOn 34 Reflttmg WIth the Engme Removed BRAKER POINT AND IGNITION TIMING 37 ADJUSlMENT 42 DistrIbutor 42 the AdJustmg IgmtlOn Tlmmg r Jf 44 FUEL SYSTEM 48 Carburetor 48 1 r i The 1 Gasohne Tank 55 Fuel Stramer 59 Fuel Pump Adjustment ijf 60 and Inspectlon of Engme 65 4 CLUTCH r 1 170 i t TRANSMISSION h 8I 82 DIsassemble the TransmIssIon Case DIsassemble the TransmIssIon Case For 4 r Stage Floor Slnft 100c l b 4 FRONT AXLE 1 t no 1 Dlsassemblmg the Front Hub Independent Front SUSpenSIon ll lq I I l i J PROPELLER SHAFT UNIVERSAL JOINTS f 125 REAR AXLE 129 STEERING 152 Steermg BRAKE 153 158 i Front Brake 159 Rear Brake 166 169 Hand Brake 1 lf Page ELECTRICAL SYSTEM 172 Alternator l74 Generator l76 l86 190 Regulator 14 Items on Handhng Trouble Shootmg LIst Starter Motor 192 194 1 1 nl t 7 I 1 I J t 5 P ICIFICA ION MAJOR SPECIFICATION Name and Model of VehIcle Datsun P410 Name of Manufacturer ClassIfIcation S NISSAN MOTOR CO LTD Passenger Name of ChaSSIS and Model Datsun P410 VehIcle 885 Name of VehIcle Datsun 5 SerIes of VehIcle P410 I 160 Engme Weight kg Seating CapacIty VehIcle Gross Overall WeIght Length Overall WIdth kg mm 3 990 mm I 490 Kmd of VehIcle Model Total PIston 4 wheel d EI Olsplace Itr ment Fuel I 189 Gasolme i Overall HeIght mm c I 415 r InterIor of Length I 685 Wheel Base WIdth I 240 Overhang to Rear Body HeIght I 130 Cargo Space mm 2 380 sIze room Space the end of 950 mm of set mm DIstrIbutIOn of VehIcle Front 505 Front 5 60 134P Rear 5 60 13 4P Front 95 2 Rear 88 9 Front 460 Rear 460 TIre SIze WeIght WIthout Load Rear 380 Front 600 Rear 560 kg DIstrIbution of VehIcle PrOpOl tlOn of TIre WeIght WIth Load WIth Load kg ProportIOn of Front TIre wIth Load Max 51 7 nation Front I 206 Rear I 198 Tread mm Inch 1 Angle i COMPARlBON WITH MAJOR SPECIFICATION OF MODEL P410 MODEL ITEM P410 F VehIcle Overall E E VehIcle Overall WIdth 1 490 VehIcle Overall 1 415 HeIght Overall Length l 685 Overall WIdth 1 240 Overall I 130 Intenor SIze of Cargo Space tI Z a 3 995 Length HeIght I 206 Front Tread 1 Rear CI Z w Mm Cl Road Clearance Floor 198 2 380 Wheel Base 175 HeIght Overhang to the Front End WIthout 605 Bumoer Overhand to the Rear End WIthout 950 Bumper Frame Overhand to the Front End Frame Overhang to the Rear End Ww rN tI 5 60 13 4P Front 60 13 4P Rear VehIcle 915 WeIght 5 Seatmg CapacIty Max 6 Payload I VehIcle Gross WeIght IOU 1 190 llIl ol I 0 W a O1stnbutlon of Verncle Wel ht WIthout Loa Front 505 525 Rear 380 390 O1stnbutlon of Front 610 615 Rear 560 575 Verncle WeIght Wlth Load ChassIs WeIght Front DIstnbutlon Dlstnbutlon HeIght Max of Rear Gravlty Center mm krn h Speed m jh rw au z r c E W Flat Road W2 Max Grade AbIlity krn t Load Sm 565 128 80 18 0 34 2 mfh t 1 I MODEL P410 ITEM rw au z r w Turnm Mm RadIus Stoppmg Brake 5 0 m DIstance 50 lcm h 13 7 p El Model Nlssan Manufacturer Gasohne ClassIflCatlon Coohng System No of Cylmder 4 m Lme Arrang Cycle 4 Combustlon Chamber Wedge Type Valve Over Head Bore Arrangement Stroke x i 0 Z w I 189 i 8 2 CompressIOn Ratlo CompressIOn Pressure 11 5 358 cm r p kg cm r pm kg cm r p kg m Pressure Explodmg Max 73 x 71 mm DIsplacement W Engme Water Forced Clrculatlon Max Mean Effectlve lV1ax Power B H P Max Torque r p m m 48 3 600 9 3 3 600 m 60 5 000 SAE kg r p 9 3 3 m 210 2 000 Full Road SR PS h Length x WIdth x HeIght Type mm 589x582 x690 kg 138 y Weight Position of of PIston of PIston Rmg Tlmmg If SpIlt Slart La EX Pressure 2 all I Inlet Valve t 0 It Front Engme Matenal of PIston No 63 7 ft lb SAE 6oo 140B Open T D C Inlet Close 500 A B D C Qutlet Open 520B T D C Outlet Close 120 A B D C Intake 0 35 Valve Clearance 0 35 Exhaust I z QUJ z 2 Startmg Method Ignition itI Magnetlc Startmg System Battery Method 3 Coli Type i MODEL P410 ITEM Igmtlon Tlmmg FIring B T D C r p 100 600 m 1 Order C14 S0 Type IgllltIOn Coll 0 409 Type I Hltacln I Vacuum Advance Hanshm l ea TVB 4BL Manufacturer Tlmmg 12F HN Hitachi Manufacturer D1stnbutlOn 3 4 2 MltsublsW Governor or ystem Type L45 B 6E Hitachi Manufacturer Spark Plug Nlhontokushutob Thread W Z J Gap 0 Z W m 14 mm O 7 No Type 2D 30CE 28 30 mm 21 8 25 14 7 mm 96 115 mm 48 48 Pump Jet mm 60 Power mm 55 p Ventun SIze Carburetor if Malll Jet Slow Jet AIr l Fuel A rOW G 1 hJ J UCIl Lubncatmg Chl Jet Down W JI 8 Type DIaphragm Manufacturer Showa Capacity of Fuel Tank UCIl Kyosan 8 U S TrocOld Paper eU S CapacIty gallon Type Type Teth FIlter 2 9 0 8 gal Water Coohng Closed Type Maccord Closed Type Radiator Type 41t lO ea Forced Pressure Method 011 Filter CapaCIty 1 Tsuchlya Type E O FIlter Manufacturer Pump Type 011 Pan DoWV Paper No Pump Fuel Tank E z 1 mm Draught Type AIr Cleaner lea Nlhonlokakl Manufacturer Throttle Valve Bore II 0 8 of Coohng of Water Water e 4 7 Centnfugal Type Bellet Type Pump Thermostat 4 MODEL P4l0 ITEM f o Type of No 25MB 14M2 w Voltage V CapacIty 12 A H 40 Type 0 E AC300 Manufacturer GeneratIng w Z w 0 Voltage MItsublShl Method Alternator V 12 CapacIty kw 0 3 Voltage Regulator w E E U RL A2 Type 5114 72 Manufacturer HItachI Power V HP Voltage i 12AIR l2 1 4 Ow u Z z w O Engme TransmlsslOn Mechamsm EngIne Type W U Smgle Dry Dlsc Operatlon Number of Plate Clutch Outd18 x IndIa ThIckness w 0 Clutch TransmIssIon I x 0 Z Total Fnctlon Area E Type factlng 200 mm x 363 Svnchromeshetl on E Top Operatmg en Z TransmlsslOn E Method o 2 em 2hd SynC 3n I Reverse I Remote Control p r J WU p Length Type x Outdla Floor ShIft 3 518 3 945 2nd 1 725 2 402 3rd 1 000 r 490 x 1 000 of Umversal 4 125 IndIa mm 1 237 JOInt Type rr rr hed un 2nd hrane 4th forward 410 Un 5 159 x 68 9 x 65 3 SpIcer of Gear L J f1f tf 1 HypOld Fmal Gear z i reverqe 1st Reverse wwrr J l 130x3 5 4th E Gear Ratio o 4 375 Housmg Type w 00 Type r Hydrauhc BanjO of Numberof Gear StraIght 5 Bevel PInion 2 I l MODEL P410 ITEM E O 1 W Type of Gear 1 Gear Ratlo W Steermg Angle Cam 14 8 WCJt 1 CIl Lever Out 28036 CIl Steering Wheel Ola 405 mm Wheel Arrangement W U W Cl 0 2 Front Front Axle WIsh Bone Ball Toe In 2 Rear Jomt Type 3 mm Camller 1030 Caster 1030 Z 5 Inclmatlon of Angle Kmg 6030 Pm I Type of Rear Axle Seml 2 Leadm Type Leadmg Lmmg Master Brake E Area Rear em 25 40 IndIa of Drum Rear 23 81 India of Master of Wheel India I Cyl Max of Wheel Cyl 011 Pressure US em Meehameal for Rear Wheel Type Lmmg India Z 0 DlmenslOn Brakmg 4Ox4 5x215 351 em of Drum 228 6 mm Independent SuspenslOn Double WIsh Bones Pront WIth COlI Sprmgs Z CIl mm Area CIl CIl 23 81 mm kg Total 25 40 mm Rear c 22 22 mm Front Brake 1hI Front CIl Parkmg l of Drum CIl 011 Brake 228 6 India Cyl SprIn Length x Call Size Idth 14 x 94 x 325 x Rear 40 x4 5x215 Rear Brakmg Inner Dla W 1 W DlmenslOn Ftont rallmg 40 x 4 5 x 215 DlmenslOn Front Lmmg Total Floatmg Type TIuekness No 6 5 8 r MODEL P410 ITEM Parallel Seml Rear Z Q tIl Z W p 6 Sprmg SIze Length x WIdth x Thickness 1200x60x5 No Elhptlc 2 2 mm Helpmg Spnng Shock Absorber Front Telescopic Double Action Shock Absorber Rear TelescopIc Double Action tIl J tIl Stabilizer Front Stabilizer Rear W Type Section I i O1menslOn Height x Width x l111ckness mm 7 TorSlOn Bar Type TorslOn Bar Type MODEl WP4 10 RUNNING PERFORMANCE CURVE F mal gear ratio 1st speed ratIO 4 375 2nd ratIO 1 725 ratio 1 000 1235 kg Sm 6 0 32 3rd speed speed 51S Gross vehicle Max 500 weight grade abIlIty Effective radIUS of tire 40 Max Max o 287 m 9 3 kg m 3600 torque BHP 60 HP 5000 r p r p m m 5000 t t bO 8 t J co U l E aJ 00 ri aJo Cc p b bllbll t t t t l 0 0 fT c p o 30 40 Car SO 60 speed 70 80 km h QO 100 110 150 MODel P410 RUNNING PERFORMANCE CURVE Fmal gear 4 rano speed ratlO 2nd speed ratIo 3rd speed ratio Gross vehicle weight Max grade ablhty 1st 500 Effective radlUs of 40 Max Max tIre torque BHP 375 3 518 1 725 1 000 1190 leg 0 34 Sm 0 287 m 9 3 kg m 3600 60 B H P r 5000 r p m p m 35 5lOO J I 1 CIl CJbO C loi 6 3000 I 0 CIl CJl I 8m bObO c M M l c M l I lX O CIl I 3Ro CIl c M bO J U 10 20 30 80 Car speed km h 90 100 110 120 130 140 o ISO ENGINE I ENGINE The engme IS of monobloc construcnon and IS fItted wIth overhead valves 011 seals are fitted to the rockers and push rods from the camshaft valves Three steel backed beanngs support the camshaft whIch IS cham dnven operated by The OIl pump and dlstnbutor are dnven from the camshaft each component havmg ItS own dnve shaft The pIstons are each fItted wIth two compresslOn rmgs and a slotted OIl control nng Beanngs of the thm shell preformed type are fItted to the connect A counter blanced crankshaft IS fItted rod ends and to the mam beanngs mg bIg The end thrust beanng The on thIS component centnfugal water IS taken pump and by specIal washers at the center mam coohng fan are dnven by the dynamo belt GENERAL No of SPECIFICATIONS 4 Cyhnder Bore 73 025 Stroke 71 Volume I l89 2 2 796 mm 875 m m fr cc 60 HP at 5000 r p m Torque 9 3 m at F Inng order 1 Valve arrangement Overhead valve CompresslOn 163 Ibs Max brake horse power mm pressure 3 at Compression 8 2 rano 1 kg 4 350 I 3600 r p m 2 per sq r p m push m rod type 11 5 kg cm EMGIME ilft t l x cc JJ L E7j 0 1 Y t SlOE RIG c 1 c li t JF 1 I r t EMGIME lt c J Ic r l v LEf 2 SlOE Jt J r I vI e it COOLING SYSTEM An effICIent runrung of the engme and lts of major Importance to ensure the sausfactory therefore necessary to pay paucular attentlOn to coohng system It IS IS mamtance Description The coolmg system IS mamtamed by water pump clrculatlon combmed wIth efficient fan cooled radIator and thermostat The system IS pressunsed and the rehef valve mcorporated m the radIator Do not fIller cap controls the pressure at approximately 0 4 kg per sq cm remove the fIller cap If the temperature of the coolant IS above bOlhng pomt or If the engme IS runmng Toppmg up should only be reqUIred occaslOnally to re the overflow pIpe water lost Top up when the engme IS cold and an place If pOSSible through use clean soft water r 1l t l f t 0 t 1 I f f I Fig Fill to wlthm 1 2 1 Radiator of the bottom of the fIller through engme IS cold may of the system IS approxImately 5 2 htres cause water to flow 3 plug well Overfllhng the overflow pipe when the The capacity Thermostat effIcIency It IS essentlal to keep the engme ope wIthm certam hmlts To asslst thIS a bellows type thermostat ratlng temperatures The de located m the water outlet at the front of the cyhnd r head IS fitted bemg filled wlth a volatlle hquled whIch controls a VIce consIsts of metallIc bellows In order to ensure maXlmum When the engme IS cold thIS valve IS closed and restncted engme the flow of water to the radiator IS temporarIly Due to thlS the temperature of the water m the cyhnder head and cyhnder Jackets wIll qUlckly mushroom valve so generated w1l1 startmg the The heat warmmg up the bellows so rapId thus ensunng nse on gradually expand openIng the valve full flow of water and ultlmatelly permIttmg a the radiator The thermostat Itself IS detachable therefore should the occaSlOn anse It can be removed from ItS and the hose reconnected to avoid to housmg Should the thermostat be tlght up the car la lng there are two capped holes on the top WhICh may When the sys be utlhzed to ease It from castmg It IS essennal tern has been completely emptled to allow air to escape the thermostat valve The thermostat up opening the manufacturer and cannot be altered Fig 2 Pellet Thermostat It open at a temperature of 76 SO IISoC thIS open Durmg decarbomsmg It IS pohcy to test the m water raIsed to thermostat mg by Immersmg The valve should open under these condmons but 1f It the IS M through fmally top and then set by requlslte temperature falls to open a new unIt should be fltted Overheating m the Overheatlng may be caused by a slack fan belt exceSSIve carbon deposlt retarded mcorrect carburetor WIth the too far adJust 19mtlOn cyhnders runnmg ment falhre of the water to cIrculate or loss of water I Fan Belt Adjustment r The fan shaft by a IS V dnven belt from the crank thIS also dnvmg the alternator A New belt can be fItted by fIrst clamp bolts Fig 3 which hold the dynamo m posmon and the engme movmg the dynamo towards loosenIng the Shde the belt fan over pulley Adjustment IS the fan and onto the then made by bnng the en mg the alternator away from gme The belt should be sufflclently yet the belt tlght should have 10 to IS mm slack be tween the generator and crankshaft to prevent shp Fig 4 3 Fan Belt Adjustment pulley when the midspan IS pushed fIrmly After the correct tenslOn has been obtamed securely lock It m pOSItlOn agam Front Precausions Freezmg occur may fIrst at the bottom of the radIator or m the lower hose connectlons Ice m the hose wlll stop water clrculatlOn and ma cause bollmg be used to advantage but care must be taken not to run with the muff A muff can closed fully expected or when the car IS to be used m a very low temperature make sure that the strength of the solUtion IS m fact up to the strength advised by the manufacturers The strength of the solutlon must be mamtamed by toppmg up WIth antl freeze solutlon as necessary ExceSSive toppmg Solutlon must be made up up WIth water reduces the degree of protection afforded m accordance WIth mstruCtlons supphed WIth the contamer Top up when the system IS cold If the coohng system has to be dramed run the mIxture mto a clear co ltamer or bollmg and use WIll result IS agam Protection On When frost cars by Draining where anti freeze IS not used the followmg precautlons must be taken dUring frosty weather to obVIate any damage due to freezmg of the coohng system When heavy frost IS Immment the coohng system must be completely dramed It IS not suffICIent There other tern merely are two dram to cover the radiator and engme WIth rugs and musks one on the left hand Side of the cyhnder block and the cocks Both taps must be while dram mg the base of the radIator block at and the car must be on level ground tested at frequent The dram taps should be to ensure that they are cleare WIre opened dram the sys by msertmg a piece of Immediately the taps are be flushed out by the water mtervals This should be done opened so that any obstructlOn freed by the wire may The drammg should be carried out when the engme IS hot When completely dramed the engme should be run for that all water has been cleaned from the system A suitable notIce should be then affIxed to the radIator water to a tlmed mmute to mdlcatmg ensure that the has been dramed Flushing the Radiator To effICient clrculatlon of the coolant and to reduce the formation of flushed With the system should be m the radIator hcalperlolyc water before putting m anti freeze m the winter and agam ensure scale and sediment clear runnmg when takmg It out preferably the spring The It comes out clear from the dram taps m mto the taps dUring sediment WIth ThIS method of radIator mserted drammg water should be allowed to run through until At mtervals a Stlff piece of WIre should be to ensure that they are not becommg clogged flushmg may serve well but m cases where the fur the WIll fmd It more effICient practice to remove the operator ring up turn the radiator up the reverse way to the flow radiator completely and flush m hose the bottom connectlon and out of flow m Side down and let the water through IS exceSSIve the top connectlOn 5 I I Gasket o II rt v l seat F10atng f l tilT I puley Sea pUMP pumP 6 an rOT ub H 1080 type 5 belt 1060 zMB Fan Z1061 Zl061 foT J r WATER bateTY f Fig used dt3 dta m m p3ltn 3m lo 1060 1080 lock ZlO ZlO l l i puley 0 II PUMP WATER After drammg the water from the radiator remove the pump umt cyhnder by takmg off the fan belt and releasmg the setbolts with washers and hmge bolts to dynamo block from the spnng Removing the Pump Shaft Assembly Dlsconnect the fan blades The shaft and ball Put the pulley First press beanngs and cover combmed with pulley IS one umt hub on the bench or knock the shaft end with a dnft hard bar hub on the U type bench Take out the set pm from the sht which locked the shaft and draw out the pulley See body Next vane Fig turn side on assembly to the pump 1 the body upside down and press out the shaft assembly from the the U type bench Fig The shaft and ball Thus take out the 4 beanng assembly can be drewout from the body floatmg seal and seal WhICh remamed the pump lxxly vane Reassembly The r but a care for a sht said nng of the pump IS a reversal of the dlsassembIy procedure should be taken to ensure that the shaft assembly IS fmed correctly a hole of set nng with a groove of shaft so as to msert and set the assembhng correctly 7 1 Set crew lley Pu Pulley 1mb I frontl 21035 K Set 0 000 rUle p1n Waaher Cover ll f Secnon Vlew Flg 6 of the FIg 8 7 Water Pump Adjusting the Clearance the Vane End and Body press down the shaft fItting WIth a groove line to Insert the set pin inserting thIckness gauge fhlckness O 4 O 5 mm between the vane end on the U block bench Take out the thIckness gauge and find out good condmon Screw up FIrst WIth the cover and cork washer screT Shaft o bear1ngs assembly Float1ng 1 I 1 4 Vane f Set p1n sea l r I J Insert here th1ckness i 4r gauge 0 0 5 4 ii Fig mm 8 f 1 9 LUBRICATION Circulation throughout the umt and IS provided by an ecentnc 011 011 pump The pump IS bolted mto the left hand side of the crank driven from the camshaft gear by a short verucal shaft Pressure lubncauon non drammg case and IS IS used mto the pump via the fIlter and IS dehvered through mternal oil ways to the non adjustable rehef valve which IS situated at the rear left hand side of the crankcase From the rellef valve the 011 passes OllIS drawn mto the mam 011 on the right hand The flow then passes gallery sIde of the engme via connecung 011ways end and mgs ends the m cam shaft to the mam bearings through big dnll The connectmg the crankshaft dnlhng m the cyhnder block and are rear rocker shaft bracket cate the rockers to lubri and then drams back sump via the push rod all from the center camshaft mto the engme apertures enters a gallery on the left hand Side of the engme and lubncates the tappa As the pets through mdlvldual dnlhngs bearmg two grooves m the front a small hole m the WIth Journal regIster camshaft thrust plate thus allowmg a camshaft rotates small amount of OIl to pass mto the tlmmg case twice durmg case revolutIOn of the camshaft to provide lubncatlon for the ummg cham and gears case the 011 returns VIa From the tlmmg a dram hole back The filter therefore forms part of the mam OIl gallery and as such IS filled WIth 011 under pressure to the engme sump A proportion of the 011 enters the through holes m the casmg and element Fg 1 the an passes through the element mto nular space round the center bolt This space IS sealed top and bottom so that the 011 can only from thiS pomt back escape through the sump a small hole mto the hollow center bolt and Into Draining Oil Pan The 011 pan IS a metal pressIng With the draIn plug On new and recondmoned engmes the sump must be draIned and refilled with and subsequently at Intervals of 5 000 Ian new 011 after the first I 000 Ian and takes with Dram the 011 when the engme IS hot SInce warm OIl flows freely have accumulated It any sludge or sedIment whIch may Such cleamng medIUms or paraffIn for flushIng purposes Never use are never petrol completely dispersed from the engIne lubricatIOn system and wIll remaIn 10 II I to contammate any fresh 011 This may cause bearmg premature faIlure Oil Pressure The normal operatmg 011 pressure IS 60 lb per sq m The warnIng hght whIch IS embodied m the mstrument panel hght If the 011 pressure drops below 8 Ib sq m under these cIrcumstances do not attempt to the engme or serIOUS damage may result run Refilling When reflllIng the sump do not pour the 011 from the fIller onflce and mIslead the operdtor the engme too In as qUickly to the as It may overflow quantity of lubncant m Before testing the level of the 011 ensure that the vehicle IS as near level as Always wIpe the dIp stick clean WIth a non fluffy cloth before takmg the readmg It should be remembered that time must be allowed for new 011 to pOSSIble reach to sump before readmg the dIpstick Check for Low Oil Pressure Check the level of 011 of the the engme stick and top In sump by dIp If the warnmg lIght IS up If necessary still on after refIllmg the sump SWItch off and ascertam that the gauge stramer means 0 at the stramer unIOn on the suction of the 011 pump bemg defectIve the unIt and rectify the fault j 1 the sump IS clean and not choked with sludge sale that no aIr leakage eXIsts m c c c c r SIde j I remove 3 I r r Oil Release Valve 2 4 The 011 release valve should be j ex ammed If the engme beanngs are worn the 011 pressure WIll be reduced A complete bearmg overhaul and the fIttmg of replace ment parts IS the tatmg I 0 tb C only remedy j necessl the removal of the engme from the i 3 classls f I Removing the By pass Filter FJg A new fIlter element should be fItted every 15 000 km The fIlter torms part of the mam 011 gallery of the engme To remove the fllter It IS only necessary 2 OJl Release Valve DScatmg @Spnng @Screw Plug @ Washer to unscrew the center bolt when the bowl can be removeed from 11 11 GASKET fllter body top ASS Y ELEMENT 011 fllter With gasket ASS Y SHAFT center 1 r RING C PRING element ASS Y SEAT element settIng c O GASKET element seat GASKET 011 filter body RlNG retainer RETAlNER VALVE safety BRACKET steel ball 011 filter GASKET 011 fllter to cyhnder o k I o RING snap SPRINGI 011 fllter cyhnder 3 01 L FILTER 12 ent safety STUD to fix Fig ele see block sechon snap the crankcase ring dry complete with the element Take care not to lose the rubber Remove the element and note the assembly of the components Wash out the bowl with pettol so that It IS clean It IS Important to the bowl to obviate any contammaUon Replacing of the sealing thorough lubrIcatmg 011 the Filter With the center bolt tIOn In the bowl with the the washer and the spring together with the collar m POSI element Place the dIstance pIece over the center bolt end towards the element The bowl of filter must now be filled with msert a new flanged 011 Offer up the of the center bolt Removing complete assembly to the engme and secure mto posItion by means the Oil Pan The sump capacity IS 3 I Inres Dram the 011 and replace the dram plug Remove the set screw bolts which are mserted from the underSIde of the se cUring flange and the lower bolts from the bottom edge of the bell housmg Lower the 011 pan from the engme takmg care not to damage the Jomt wahsers In the pro cess Removing the Strainer WIth the snup lowered It IS possIble to remove the 011 stramer through which drawn mto the 011 pump To remove the straIner unto the unIOn connecung the 011 pIck up to the pump and unscrew 011 IS the securmg bolts The stramer may be dIsmantled for cleanmg purpose by removmg the delivery pipe flange bolts NotIce that there are the dowel pms to the cover whIch must be rectly when Removing posItIOned cor refItung the Oil Pump Remove the Oil pan and pick up Three of the fIve bolts securing the 011 pump bottom cover are long enough straIner to secure the pump to the crankcase FIg 4 Illustrates the pump m explosed form Unscrew the long bolts and the pump With ItS drive shaft remove Dismantling the Oil Pump Remove the setscrews and spring washers WhICh secure the cover to the body and take off the cover On ultmg the body upSIde down the mner rotor WIth Its drive shaft and the outer Ftg rotor WIth slide out 13 4 Refitting the Sump Clean out the sump by washing It 10 paraffm the care to remove any traces paraffm before refIttmg the 011 pan to the engme Pay patlcular attentlon to the 011 pan and crank case lomt faces and remove any traces of old Jomnng materIal Examme the Jomt washer and renew It 1f necessary The old Jomt of the washer can be used agam If It IS sound but adVIsable to fIt a new one Smear LIft the 011 pan mto poSl tlghtmg them up evenly It IS the faces of the Jomt WIth grease and fIt the Jomt washer non and msert the setscrews mto the Reassembling the Oil flange Pump The outer rotor Fig 4 has a chamfered edge It IS of great Important that thIS chamfer be towards the base of the body fIlure to assemble m thiS way WIll result 10 the cover IS tlghtened down Insert the slotted end of the drIve shaft mto the body and brIng the rotors mto mesh t r1 y n o l fuo f 0 P i Fzg 5 OJl Pump 14 GASKET 011 pump to cyhnder bloc k ASS Y SPINDLE drlVlng 011 pump ilx pump to WASHER O k cover BOLT I i Stud 0 u 0 U o 0 0 0 D ASS Y SHAFT 0 1 pump D p Cover Washer Washer Bolt oll pump @ tft Washer @ Washer Bolt 1 ASS Y GASKET ot stramer to SCREW to ilx 0 WASHER pump lock 1 stralner Fig 6 OIL 15 PUMP STRAINER 011 i r OPERATIONS SERVICE ENGINEi Removing Starting Nut and Remove the radIator N WITH POSITION Pulley Slacken the dynamo attachment bolts and remove the fan belt dog Bend back the tab on the starting dog nut by USing H eavy duty Shock type A few sharp blows Removing the The tlmIng washer and a locking washer Unscrew the starting spanner clockwIse dlrecnon will slacken the In an ann Pull off the crankshaft nut nut pulley Timing Cover cover IS secured specIal plam by set washer screw bolts Note that the each specIal having washer a shakeproof of elongated IS and IS fItted next to the nmIng cover flange The sprIng washers are ImmedIately below the bolt heads Take out the set screw bolts remove the cover and ItS JOint washer Care should be taken not to damage the washer when If damage does breaking the Jomt occur flt a new washer cleaning of the faces of the JOint surfaces beforehand shape Removing 1 Timing Gear The tlmIng chain IS endless and It IS necessary to remove both the crankshaft and camshaft gears together Before dOing thIS notlce the tlmIng marks on both gears and theIr relatlonshlp to each other Draw off both the gears retamIng of the a lIttle at a tlme fIrst removing the crankshaftt gear nut As the gears are withdrawn care must be taken not to lose the paclang washers from behmd the crankshaft gear Between the camshaft g ar teeth IS a rubber and ensures silent operatIon of the chain drIve rmg wInch acts as a tens lOner l Examme the felt washer and renew It If 011 has been lost he seepage Refitting Timing Gear the Replacmg the jl1anthng process components of the nmmg gear is largely a reversal of the dlS but specIal attentlon should be pal to the follOWing pOints FIt the crankshaft and camshaft gears Into theIr respectlve shaftes Ensure the tlmIng marks are opposlte and m lIne Turn the engme crankshaft untll the IS at T D C and the c m shaft keyway wlth Its keyway approxImately the clock posltlOn Place the gears mto pOSltIon ensunpg that the keys are present In vays key on the shafts Ensure that the tlmmg marks on the gears are opposlte to each other and m lIne DrIve the gears home The same number of packing washers from talCeil behind the crankshaft gear must be replaced unless a new crank or camshaft has been fmed In thIS case the ahgnment of the gear fac s and measurn g the alIgnment With a feeler gauge To adjust the alIgnment It wlll be necessary to vary the number of packmg washers In one o C 16 l ct r 4 T r T l t a Fit the 011 thrower behmd the crankshaft gear so that wards the front of the car and check that the felt washer ltS concave IS m face It to positIOn Valve Rocker Cover Removal Remove the brackets air cleaner Unscrew the cap nuts secunng the engme hfung Remove the rocker cover and the cork Jomt washer Removing the Rocker Assembly Dram the coohng system If anlt freeze IS m use use a clean contamer for be used agam It IS necessary to dram the system and slacken the cyhnder head nuts four of the rocker shaft flxmg nuts also secure the cyhnder head the flUid If It If the IS to cylmder head nuts are water to fmd Its way from the NotIce that under the nght not slackened dlstonatIon may result and allow coolmg systefIl hand rear mto the cyhnders and pump IS a speclallockmg rocker stud nut plate Completely unscrew the rocker shaft blacket assembly Complete wIth brackets and rockers Dismantling the Assembl becaust nuts and remove the rocker y To dIsmantle the rocker shaft assembly fIrst loclung plate from the rear rocker bracket remove the grub screw and f tr 1 FIg 1 Cylinder 1 t l7 JII Head J Remove the splIt pms flat washers and sprmg washers from each end of the shaft Shde the rockers brackets and Unscrew the plug sprmgs from the shaft from the end of the shaft and clean out the 011 way The two end rockers may be dIsmantled WIthout the whole rocker assembly bemg dr awn out ThIS may be achlVed by turnmg the engme by hand untIl No I push rod reacher ItS lowest pOSItlOn Unlock the tappet adjustrng screw and screw It back as far as It wIll go WIthdraw the splIt pm flat and sprIng washers and slIde the rocker off the shaft SometImes the valve sprIng WIll have to be slIghtly compressed by leverIng screwdrIver under No 2 rocker thus allowing the end rocker to slIde off the shaft easIly Repeat the procedure for No 8 rocker a Reassembling the Rocker On reassembly tIghten the pedestal bracket securmg nuts a lIttle at a tIme worlang dIagonally from nut to nut left nut of No I pedestal bracket rIght nut of No 2 left of No 3 and so on completely strIpped the left nut of No 4 bracket and If the rocker assembly has been the 011 holes wIll have to be redrIlled returnmg from repeatmg the process untIl they are all tight down and rebushed and the bushes reamed down to size before The rockers and sprIng must Remember to lock plate ends of the shaft h assembly on the shaft be replaced m theIr orIgmal posltlOn On the replace the rocker shaft locatmg screw and Replace the Replace sprIng and flat washers WIth the splIt pms on the ends of the the rocker cover and gasket The vent pipe should be at the front of the engme Secure the cover by means of the tWo cap nuts ensurIng that the rubber bushed and engme lIftmg plates are m poSItIon If the rocker cover gasket or the rubber bushes are found to be faulty they must be renewed otherwIse 011 leaks WIll result shaft Jt Push Rod Removal If the valve rocker assembly has already push rods to be lIfted out They may detachmg the rocker assembly for the out Remove the aIr claner and rocker been removed all that remains IS on the other hand be taken t i cover out y Slacken all the tappet adjustmg screws to theIr full extent then usmg a WIth the rocker shaft as a fulcrum depress the valve sprmg the rocker SIde ways and lIft out the pusod screwdrIver All but the end push WIth slIde r m thIS way These w1l1 have to be wIthdrawn after the removal of the two end rockers from the shaft When re placmg push rods ensure that the ball ends regIster m the tappet cups From here onwards reassembly IS a straIght forward reversal of the rods can be WIthdrawn dlsmantlmg process A djusti ng Valve Rocker Clearances Remove the aIr There should be cleaner and rocker a rocker and the base of the valve stem portant to mamtam cover clearance of 0 014 pressure WIth m 0 3S WhIlst a screw 18 mm checkmg drIver on between the face of the the clearances It the tappet adjustmg IS Im screw push rod cup will result m a wrong readmg bemg taken Turn the engme over by hand Startmg handle the valve IS fully closed to dIsperse Fallure the film of 011 from the Ftg 2 Adjusting to untll the follow this procedure rod stops push fallmg the Rocker Clearance screw slot and slaken adjust FIg 2 msert a screw dnver m the ad ustmg face of the rocker and between the insert 014 m feeler lock nut Then gauge the Raise or lower the adJustmg screw untll the correct clearance IS the valve stem To obtamed Tighten It valve IS the lock nut and recheck the clearance to note that whlle the clearance Important bemg adjusted IS must be on the back of the cam bemg the tappet of the set OpposIte to Its I f14 J 19 peak ROCKER MECHANISM Rocker shaft Length 355 63 Outer dIameter l5 850 14 1 32 mm m l5 875 mm 0 624 O 625 m Rocker arm bush WhIte metal wIth Type steellmmg Outer diameter before mountmg 19075 19 101 15 888 15 0 751 mm 0 752 m Inner dIameter Reamer fmlshed dImensIon after mountmg 90l 0 625 l 2 mm 0 626 m l1llckness before reamer fmishmg Clearance Rocker l 644 1 727 mm 0 013 0 051 mm 0 065 0 INDER 0 002 m m arm 19 37 mm 0 748 1 2 0 749 1 2 Bore 19 012 Lever ratlO 25 003 to 35 7l9mm 63 64 to 1 13 32 CY 1 2 0 068 0001 2 m m HEAD Removing the Cylinder Head f Dram the cooling system by openmg the radlator and cyhnder block dram taps sItuated inlet tube at the backSIde of the radlator and other at the rear If amt freeze mixture IS m use It should be dramed nght hand SIde of the engme mto a sUitable contamer and retamed for future use cable from the battery be extractmg the term mal screw DIsconnect the One IS negatlve and removmg the lug from the battery term mal post Slacken both the retammg chps on the hose connectmg the radIator mostat housing and remove the hose Extract the termostat housmg secunng nuts and remove the to housmg the ther and ther mostat Remove the alrcleaner carburetor rocker cover and the mlet and exhaust mamfolds Detach the hIgh tenslOn cables and remove the sparkmg plugs also dIsconnect the water temperature gauge connectlon from the thermostat housmg Take off the rocker assembly not forgettmg to slacken the external cyhnder head nuts at the same tlTpe WIthdraw the push rods head The cyhnder breadmg the cylmder head pIece of wood mterposed to them m the order of removal To facilItate be hfted off the cyhnder block a hammer usmg each Side of the head WIth OInt tap keepmg can now take the blow Do not 20 use exceSSIve force a When hftmg the head up the studs a dIrect Remove the pull should be gIven cyhnder head gasket so that the head IS pulled evenly Decarbonising Remove the cylmder head With the valves stlll m pOSltlon remove the carbon from the combustlon chambers and the valve faces Leavmg the valves m POSI tion for tlus operatlon ensures that damage cannot be caused to the seats by the wire brush Wh1Ch should be used for the removal of carbon If the exhsust valve heads are coated WIth a very hard moved by usmg a ch1sel shaped p1ece of hardwood Remove the valves and usmg the wire deposit thIS may be re brush clean out the carbon from the mlet and exhaust ports Blowout all traces of carbon dust with compressed aIr or type pump and fmally clean the ports with gasohne and dry them out The carbon should now be removed Rotate the engIne untll the PIston to be worked on 1S at from the piSton crowns Protect the other cyhnder bore from the entry of carbon partlcles by push T D C a non fluffy rag mto them mg Usmg a clusel shaped pIece of hardwood Carefully remove the carbon from A rmg of carbon should be left round the penphery of each the pIston crowns pIston and the depoSIt round the top of the cyhnder bore should not be touched An mdlCatlOn as to when decarbomsanon IS reqUlre IS generally gIven by an all Cars used mamly on short runs w1l1 reqUIre thiS attentlon round loss of power more often than those used for Removal and a Valve long runs Replacement of Whllst the cyhnder head IS moved the valves can be taken re out To do thiS compress the valve spnng with the special valve spnng com pressor as shown m F1g 1 Removal Remove the two cap retammg Release the valve spnng collets valve sprmg cap valve 011 seal valve only and Its retamer Withdraw the valve from the Keep the valves m the Inlet gUlde thell relanve poSltlons when removed from the engme to ensure replacement m theIr ongmal valve guides Fg 21 1 Valve Spnng Compressor Replacement Note that the dIameter of the exhaust valve heads are smaller than the mlet To replace the valves Insert each valve Into Its guIde and replace the spnng 011 seal and retamer FIt 011 seal chamfered sIde down wards The 011 valve seals easIly fItted If they have been soaked m engme 011 for a short The 011 seal IS used for the Intake valve penod before use only Replace the valve spnng and compress the valve spnng RefIt the cap retamers and secure them by means of the valve cotters are more Remove the compressor Inner Free length Length m use Turnnmg Nos Effectlve turn of coil kg of coil of coil 36 9 13 l 0 7 6 5 mm 24mm SPRING 7 y Ct r V L r J f 7 t h fro r i o j j l j c f FIg 2 Valve Spring 22 8 1O 2 5 33 7 7 f f 38 9 29 1 1 5 6 5 4 5 r T Sp 52mm 8 5 5 6 LO 2 WIre DIameter of coIl VALVE Outer and loaded mm Dla Sp 50mm mm Valve Ass y mm mm 7 Valve Grinding Before replacement of the cyhnder head the valves and theIr seats should be exammed for SIgnS of pIttIng or burnt patches and distortIon If these condItIOns are present the valve seats must be recut before attempt mg to gnnd m the valves whllst dIstorted valve heads should be trued or the valve renewed Only the mmlmum amount of metal should be removed m the turnmg process When gnndmg a valve onto ItS seahng the valve face should be smeared hght WIth gnndmg paste and then lapped m With a suctIon type gnndmg tool The valve must be ground to us seat WIth a semI rotary motIron A hght COlI spnng mterposed between the valve head and the port WIll assist conSIderably when hftmg the valve m order to rotate the face to a dIfferent pOSItIOn ThIS should be done ly frequently to spread the gnndmg compound evenly It IS necessary to contmue the gnndmg process untIl an even matt surface IS produced on the seatmg and the valve face On completIon gasohne soaked rag the valve seats and ports should be throughly cleaned With and dned and the subjected to a compressed aIr blast The valves should be washed m gasohne and all traces of gnndmg compound removed VALVES Valve head dIameter Intake valve Exhaust valve Valve seat Valve stem both WIdth 34 798 34 30 023 30 1 935 mm ISO mm iO 015 63 1 370 1 375 1 182 1 187 m m mm outer dIameter mtake and ex 8 6805 8 6932 0 341 3 4 mm 0 342 1 4 Overall length Intake valve 109 54 mm 4 5 16 m Ex valve 108 74 mm 4 9 32 m Intake valve 47 63 mm 1 57 mm 2 9 32 VAL VE GUIDE Length Exhaust valve Outer dIameter both mtake and exhaust Inner dIameter both mtake and exhaust 94 14 313 7 8 14 440 8 733 8 860 m m mm mm 0 5635 0 5685 m 0 3438 0 3443m Inner dIameter at gUlde mlet to msert both mtake and exhaust Clearance of valve stem and guIde both mtake and exhaust 14 3 mm 0 5634 O 0394 0 0648 23 m mm 0 0015 0 0025 m m J Refitting Cylinder Bead the Ensure that the cyhnder head and cyhnder block Jomt faces are clean The cyhnder head gasket IS mar ed Top so that It w1l1 be placed head m Place the gasket mto posltlon and correctly cyhnder head securIng nuts fmger tlght Insert the push rods replacmg them m the lower the cyhnder head mto place FIt the posltlons from WhICh they were taken Screw back all the tappet adJustmg screws down the securIng nuts fmger tlght and screw head nuts WIth a a httle at a torque wrench tlme the order glven m set to 4S Ibs Replace the rocker assembly Evenly tlghten the eleven cyhnder m FIg 3 fmally pulhng them down 1ft 10 8 Flg 3 4 The Order of Tighting the Cylinder Head Nuts Reset the valve clearances hot or cold and fmally check them when the engme IS not cyhnder head huts may pull down shghtly more after the engme nonnal workmg temperature m WhIch case the valve clearances The has attamed ItS w1l1 have to be checked agam and reset If necessary RefIt the mlet and exhaust manifolds FIt the craburetor and reconnect the control hnkage Refit the igrutlon advance suctIon pIpe to the connectlon on the carburetter aIr cleaner or place it Vlll have the rocker cover to but do not at tlus stage refIt the be removed later to check the valve clearances Re takmg care Place the thennostat and ItS to fIt the cork housmg gasket correctly posltlon and secure WIth the three nuts ire and fIt the radIator hose to the ther m Reconnect the water temperature gauge mostat housmg Connect the cables to the battery Ensure that the ramator and block dram tapes are closed and refIll the radIator Clean and adjust the sparking plugs and refIt them chppmg cyhnder on the lughtenslon order of the englne IS 1 3 4 2 Replace the chp wluch se cures part of the electncal whlnng harness to the SIde of the head When the normal The 19n1tlon can now be SWItched on and the engme started leads The flnng operatmg temperature has been reached swItch off and remove the rocker that the valve clearances may be rechecked Replace the rocker the lllr cleaner when the fmal check has been made so hne Wlulst the engme IS unlOns do not leak running Tighten check that the water them If necessary 24 cover co er and fIt hose connectlons and fuel and Removing Remove the Refitting Valve Guides cylmder head Remove the appropnate valve and spnng Rest the cyhnder head wIth Its machmed face downwards on a clean surface and dnve the gUIde downward mto the combustion space wIth a dnft Tlus should take the form of ened steel When punch fItting should be dnven cyhnder See FIg a hard 5 valve guIdes these from the top of the new m head o FIg 5 Hardened Steel Punch j Ftg Renewing In head to a an Valve emergency a When domg tlus ehrnmate any Remove the Spring new the POSSlblhty spark plug 4 Renewing a Valve Glade in Position can be fItted without removmg the cylmder piston must be brought to Its T D C posltlon of the valve falhng mto the cyhnder Hold the valve onto ItS from the cyhnder concerned valve spnng apphcable seahng with the aId of a sUItable tool such as a bent screwdnver WhICh will pass through the sparkmg plug onflce and locate on the valve head By usmg the rocker shaft as a fulcrum pomt the spnng can be compressed with two screwdnvers or a fork ended bar WIthdraw the valve cotters and renew 25 the valve spnng dU rod lrlng S push in er Nut Call Loestlni asheI Plate Vi shaft GEMl JE 1 i 16 J j 8 if ln eht nut sere roeker Bush J B Adjust Valve ni ng Colet r 1 lIl lllI f Pr s Rub er Outer S C 6 shaft Fig roeker Valve her as Bolt e l 0 t t r 1 o flller Iv 011 J ffj sf Packlng NUT @ lil l l l WASHER Outlet elbow Cover val 132b4 l cker bO Rocker cover packing JOint washer Nut Thermostat Wa iJ4 U Jt her Slinger GUlde Gulde Stud exh ex 1n rear valve valve mamfold Slinger front @ Washer ea Nut e o eO jaO Gasket 11044 cyl h ead 30004 11044 0720 0 4 0 4000 10 F Ig 7 CYLI NDE R 27 e HEAD for com onom for com ratio 8 Z ratio 8 0 ratlO 7 b and Removing Replacing the Tappets Remove the carburetor and the rocker then take off the cover mamfolds DIsconnect the high tension sprong plugs remove the rocker assembly and wIthdraw the push rods keepmg leads frDm the them so m that theIr respectIve pOSltIOnS they Will be replaced onto the same tappets Remove the tappet covers and the tappets also keepmg them m same locatIOns FIg 8 hft out New tappet should be htted by assembly so that they fall selectIve the gulds under theIr own wdlght when lubncated Assembly IS a reversal of the above procedure but car should be mto taken are are to see 011 tIght adJusted that tappet cover Jomts and that the rockers give the to correct valve clearance Fig Piston and Dram the 8 Removing a Tappet Connecting Rod Removal coohng water from the engme and radIator Dram and remove the sump from the engme then dIsconnect and remove the 011 stramer Take out the set screws and rock washers from the bIg ends and WIthdraw the caps When used are r placed after It will be noted that the caps are off set lrts P It IS essentIal are fltted mto theIr ongmal pOSltlOns To en dlsmanthng they sure correct refIttIng mark the caps and connectIng rods on the SIdes to Iden tIfy them wards together The pIston and through the cyhnder bores connectIng rods must be with drawn up Release the connectmg rod from the crankshaft and through the cyhnder bore slowly push the pIston and rod upwa ds NOTE It may be necessary to remove the nng of carbon or hp from the top of the cyhn er bore With a hand scraper to aVOld nsk of pIston nng breakage Remove the assembly from the top of the cyhnder block Check the cranlcpms for ovahty wlth a paIr of mIcro meter calIpers and examme the beanng surface for scormg either defect w1l1 neces sltate the removal of the crankshaft for 28 regnndmg CONNECTING ROD DIstance between center of large end and small end Large end tO 03 mm 144 bearmg Type ClevIte Overall length FSOO 25 T7 3 25 527 mm 0 995 0 005 m 1 8288 1 8352 mm 0 072 0 0725 m 51 346 mm 2 015 m Tluckness Outer dIameter WIdth of large end 26 8 End O 203 0 305 of large end play mm 1 055 m mm 0 008 0 012 m dlmenslOn of mner mameter of small end bush Fmishmg Standard 17 450 17 462 rom 0 6870 0 6875 m CRANKSHAFT Clearance of phery to bearmg pen cyhnder block hole Matenal Clearance of beanng mam ter and crank Olameier of End play mam of mner Journal Journal 0 Ol3 0 050 White metal Block Side Clevlt metal Cap SIde O 0127 0 OS08 mm 0 0005 0 0020 183 50 825 mm 2 0005 2 001 SO shaft cranlc mm 0 051 0 076 mm m m 0 002 0 003 ID Crank pm dIameter Standard 47 640 47 652 Olfference of crank pm dIameter End play when flywheel mm Less than 0 012 mm I 875 1 876 0 00048 m m was mstalled Less than 0 05 mm 0 002 In The shell bearmg are removable by hand The bearmgs are requIre no beddmg m It IS bemg only necessary to ensure that the housmgs are scrupu lously clean and dry and to place the bearmgs mto pOSltlOn WIth the tangs located m theIr correspondmg slots Always renew beanngs If they are scored or dam aged m any way or foll9wiqg the regnndmg of the crankshaft beanng surfaces In the latter case undersIze bearmgs wlll be required and the kmds of sizes avai lable are 0 010 O 020 Q Q and 0 040 etc l N ttto 29 I t J washer gear ng Lock R ng BuSh F1 n NUt SHA P NK CRA A 8t Crankshaft ON S1 P 9 t Fig I r Flg 10 Crank Shaft PISTON Replacing Pistons Insert each and Connecting Rods pIston and connectIng It IS essennal that the taken wards the camshaft was split rod 111 assembly mto the cylmder from which IS positIOned to It the skIrt of the piston and gently tool FIg 11 the pIston nngs With msernng piston usmg untIl the pIston handle a hammer end of ot the piston With the wooden tap the crown IS clear of the piston nng clamp Compress Flg 11 Piston 31 Adapter push the piston down the cyhnder block untll the bIg end of the connectmg rod Just protrudes through the bottom of the cyhnder bore then posltlon upper half beaTIng shells Now NOTE Each upper lower beanng has two 011 holes there by ensuTlng suffIcIent and It IS of the greatest Importance that the correspondmg OIl bole m the beaTIng shell regIsters wlth the 011 way to provIde an unobstructed passage Pull the connectmg rod onto the crankpln talang care not to mJure the beanng lock surface Insert the shell mto the connectlng rod cap posltlon the cap and the 21 24 6 7 Insert the setscrews and ughten with a torque wrench to mg washers Ibs ft Fmally knock back the lock washers and see that Check the connectmg rod bIg end for Side clearance l lOoo m when rotatlng the crankshaft are not on the the shell beaTIngs If It or IS gTlt difficult to turn bmdmg bIg undo the crankpm end and examme the shell and seat for dIrt reassembhng always apply a httle clean 011 to the pISton surfaces and surfaces cyhnder bore Never file the connectmg rod caps or thelT matmg creates ovahty m the bearmg Before mto the as tms Removing a Piston clampmg bolt from the small end of the connecung tod amI push out 21 lOC gudgeon pm The gudgeon pm IS a push flt m pIston at 700F When reassembhng ensure the gadgeon pm IS posltloned m tJ le connectmg rod Check that the spnng washer so that lts groove IS m hne Wlth the clamp screw hole IS not fItted under the head of the pItch bolt damaged Remove the the PISTON PIN 17 DLameter 447 17 452 mm 0 6869 0 687l Over SIze 5 1000 l7 m 574 l7 579 m mm 0 6919 0 6921 m 17 706 mm 0 6969 0 697l m 10 1000 m 17 701 15 looo m 17 828 17 833 mm 0 7019 0 7021 64 20 64 45 Length mm 2 568 2 578 Clearance of pm and pm hole Degree fmger m to be able to at 2OoC 0 003 0 010 Clearance of pm and connectlng rod bush hole mm 0 0001 0 0004 32 m m push It by PISTON AND There should be PISTON BORES a clearance of 0 0010 0 0016 m 0 025 0 040 mm RINGS The pIston nng gap should be 0 008 0 013 m 0 203 0 330 mm when checked bore The clearance of the cyhnder compressIOn nngs m theIr grooves should amount to 0 0015 0 0035 m 0 038 0 089 mm and the 011 control nng 0 041 0 092 mm 0 0016 0 0036 m m IS the Because tl1e piston nngs 00 not travel to the end of the eventually formed due to wear cyhnder bores a hp ThIS may be checked wIth a dial gauge and must be removed If thIS IS not there will be a tendency to nOISY operauon or a fractured rmg caused by the top pIston nng stnkmg the hp done PIston and nngs In D 762 mm are D 030 avallable and D 04O Ftg should over always the slurt be fitted from the Before fittIng 0 010 m 1 Ol6 m m 0 254 mm mm overSlzes D 02D m mm 12 of the pIston and never pushed upwards remove any carbon deposIt from the note that the second compression IS tapered crown the nngs When flttmg grooves m the piston type and od control nng IS slat type 0 508 The pIston nngs processed by 33 chromlUm plaung REMOVING Expenence has smgle mISSIon as a shown that It IS REFITTING much eaSIer umt than to detach the to remove the englne and trans engme by Itself the engme and transmIssIon upwars proceed as follows Completely dram the coohng system and the transmIssIon dIsconnect and To remove the battery and ItS supportmg tray Remove the upper and lower radIator hoses by undonng the retammg chps DIsconnect the capacItor lead at the dIstributor also the hIgh tenslOn and remove swItch WIres at the COIL Take off the dynamo lead and dIsconnect the starter motor cable at the motor end on Remove the OIl gauge and water temperature gauge leads from theIr termmals the engme The throttle and choke controls must be dIsconnected from the carburetor DIsconnect the fuel pipe from the tuel pump Next remove the exhaust pIpe from the mamfold From below the vehicle remove the gear change selector rod from on the tranSmIssion cas mg O1sconnect the earth strap from the starter motor the lever Remove the hand brake control rod supporting from transmIssIon O1sconnect the speed meter cable from the transmIssIon Uncouple the pro of the transmlSSlOn draw the shaft out shaft I1 rear axle and at pml fraqges peller be To allow the engme and transmIssIon to be drawn forward removed by undomg the four securjng bolts 34 the radIator must Ftg 1 Ftg 2 35 7 i f t l i l self lock t Nut rJWasher lii Bolt r Insulator W II i1 Washer I H L NG Washer MOUNT 1 tut Bolt Nut Washer e Bolt rBolt NE lock ENG self er Nut a fSpacer bushing g 0 3 Fig OPERA TION The the folloWIng WITH operatIons are THE best ENGINE performed REMOVED WIth the engIne removed from car Although engIne m It may be found possIble to carry out certam attentlons wIth the It IS more convement to do the work on the bench pOSIuon Withdrawing Camshaft The camshaft IS poSItIOned by a locatmg plate held by three screws and Note the pOSItIOn of the small lubrIcatIng 011 hole In the shakeproof washers locatmg plate when replaCIng should be to the nght of the engIne End play of O 003 0 007 m 0 076 0 178 mm IS controlled by the thIckness of the locatIng plate and can be checked wIth a dIal millcator set agamst the cam shaft gear Before wlthdrawmg the camshaft the dIstrIbutor and Its drIVIng spIndle push and tappet WIll have to be removed Remove the 011 pump and ItS dnve shaft and take off the tImmg cover and gears The engIne front mountmg plate IS now accessIble and may be removed by wlthdrawmg the setscrew and lockIng rods plates The dynamo Take out the shaft can swmgmg lInk must be removed securmg the camshaft locatmg setscrews be WIthdrawn from the CAMSHAFT cylInder plate when the cam block BEARINGS WJnte metal bearmgs WIth steel be taken out renewed when necessary block IS bemg reconilluoned lImng are used It bemg usual for the camshaft to do thIS when the They can cylInder The beanngs can be removed by dnftIng them out of theIr housmgs fIttIng new beanngs care must be taken to lIne up the 011 holes WIth the corresponillng holes m the cylInder block Tap the new bearIngs mto posluon and ream them to gIve a runnmg clearance When of O 001 0 002 m 0 025 0 051 mm Refitting the Camshaft reversal of the Introducuons for removal Cate should be taKen to alIgn and engage the dnve pm m the rear end of the camshaft WIth the slot m the 011 pump dnve shaft TJns IS a however 37 tap SCREW lel Ipt1n1 011 lY plate DOUDI1 I tu boos SPRINV teln lock WASlER fu to d sCJlEW VMHER Y u it l yb c dd ll stlJI II PI ott OISl qld er A uPt I1ll htt 1 to Y b IoSS d S11l1l ca IoSS 1 p b I u fuel fll b l5 P j 1 pUJG Y S te cop in SnJD wASKER P uAStT OCKBl INCYlDER nt h SlAl 1 b Fig a GAUGE level dram Y l ASS o COCK lower slze up er metal metal scrantkandr half welch cyhnder block caP beang b bl thrust mam front thrust front cap hx to otl 2OCk WASHER BEARINGshaft WASHER CAP beang WASHER SEALbeang PLUG 6 B BLOCK T BOL ddle 5fCAP maln bean g Washer Bolt m NOCYlER rear slde I oll SEALbearmg 2 rear l Fig J m shaft Slze case galery ass PLUGcrank 1 0 per ta PLUG brasS crank brasS relief hole crankstand r I o taper hole 1 PLUG 0 se PLUG vent ca D BEARING half sldreaer Yl 10Ck BOLT W A S H E R SEAL bean g beang oll fix to Main Bearing Caps Remove the flywheel and clutch Take off the tImmg cham the sump and stramer and the engIne rear mountmg plate Unlock and remove the bolts securmg the main bearmg caps to the cylInder block also the two bolts securmg the front cap to the engme front bearer plate a thrust washer IS fItted on each sIde of the centre mam bearmg to take the crankshaft end thrust These thrust washers each consist of two semI Note tha cIrcular vRlves one half havmg a lug whIch IS located m a recess m the detach bearmg the other bemg plam flttmg new bearIngs no scrapmg IS reqUIred as they are machmed to tve able half of the When the correct runmng clearance of 0 0005 0 002 m 0 0127 0 0508 mm Ensure that the locatmg tangs are properly engaged m theIr recesses Handle the new beaTings carefully so as not to damage the fme surface fmlsh Remove all traces of dIrt and OIl from the housmgs and throughly dry them WIth a non fluffy rag Make sure that the 011 ways are clear When the fIttmg bearmg caps marked Each cap way round and the marks should face the camshaft SIde of the engIne ensure that they are replaced the rIght 1 I o I I I FIg 3 Engine 40 Rear Sule IS punch Cant i on Never fIle the bearIng caps to take up exceSSIve playas thIS wIll cause ovahty Always beanng surfaces WIth engIne 011 when they are replaced The maIn bearIng caps are held In poSItIOn by set screws and lock washers Pull the set screws up tIght WIth a torque wrench set to a loadmg of 75 80 lb 1ft 10 36 11 05 kgm When refIttIng the maIn beanng caps tIghten the center one fIrst after each cap IS tIghten rotate the crankshaft to ascertaIn that It revolues freely If It IS tIght remove the last cap tIghtened and examIne the bearIng and Its seatIng for foreIgn matter Check the crankshaft end play by means of a dIal gauge ThIS should be 0 002 cover m 0 051 If the mm run It IS essentIal to clean out all OIl ways In the crank Wash out the engIne sump and the straIner Ensure that no partIcles of The OIl pump should be dIsmantled and cleaned metal are left WIthIn the engIne lubncatIon bearIng system a bearIng has shaft and block Fig 4 Removmg a Maln 41 Beanng Cap Extractor I BRAKER POINT AND IGNITION TIMING ADJUSTMENT DISTRIBUTOR b HItachI 0406 01 Type IgnItIon tImIng standard 10 at Apparatus of automatIc advance Advance startIng vacuum before top dead 600 r c m p mt r Y Governor type pressure 100 120 Hg mm 1 F Advance angle by pressure of 340 vacuum mm Number of revolutIon start of advance Max advance angle at 9 Crankshaft DIstnbutor p m the 450 crankshaft r 11 IS at 2400 1 3 4 0 45 0 55 Dowel 50 angle arm sprIng pressure IS a m Q QS O 20 braker pOInt as mID g O 24 mfd shown m FIg and brakes contact several thousand tImes In one mmute brakes contact a spark IS generated In one of the maIntenance of thIS braker must not be tre ted 0 018 0 022 tn 55 9 Condenser capacIty InSIde the dlstnbutor p 2 POInt gap Contact r CounterclockwIse cam order FIrIng r at l8 6 angle dIreCtIOn of RotatIng 120 Hg 2TJns braker makes Each tIme thIS braker spark plugs lIghtly Also Therefore the because the tIme durIng whIch the IgnItIOn coIl current flows varIes WIth the gap between these braker pOInts see that thIS gap IS maIntaIned at the standard value wJnch IS 0 45 mm 0 018 to G 022 In The lker brJ pOInts must be kept free of grease and OIL If the pOInts sl10uld become burnt or blackened they are cleaned WIth a fIne hOnIng stone or croucus cloth after WhICh they should be wIped clean WIth a pIece of cloth WhICh has been dampened WIth gasolIne If the pOInts are badly burnt always be replaced as sets they must be replaced Braker poInts must rI Adjusting the Braker Points To adjust the braker pomts turn the engIne crankshaft WIth the crank handle untIl the braker IS fully open Then loosen the braKer poInt fIXIng screw Next the screw move the ilate untIl a feeler gauge of O 45 to O 55 by turnmg adjustIng w 42 M Fig I DISTRIBUTOR 43 I 0 018 mm to Then tIghten FInllly screw Id the s wIped areas between the braker pOInts easIly securely check the gap once more xteng5i zfto Ig p thIckness slIdes InS FIXIng the cap e b 0 022 the clean wIt between th thel1 reInstall the rotor as oft The Intenor and pIece of cloth extra attentIon Clean the center electrode on the dry Inals insloe of the cap also 11 not the vacuum tY advancer IS functIOnIng Wheth i be determIned by the InspectIon pOInter located at the dIaphragm If R Sr rifnIng J IS beIng run advancer IS tJns pOInter moves when the engIne speed IS suddenly properly can the engIne changed the as satIsfactory 1 I Fig 2 ADJUSTING The IgmtIOn tImIng IS Adjusting THE the Pomt Gap IGNITION TIMING adjusted to 10 degrees before top dead center wIth the FIg 3 WIth thIS adjustment the automatIc tImIng advances the Ignmon tImIng even further at the tIme engIne stopped as shown In advancer of the dlstnbutor the engIne starts to rotate SUItable for the rotatIonal and the tImIng IS maIntaIned constantly at valves speed WIth the engIne stopped adjust so that the dlstnbutor breaker pOInt Just breaks when the pIston of the No 1 cylInder IS In It 10 degrees before top dead center pOSItIOn for If a tImIng lamp IS used the standard IgnItIon compreSSIOn fIf 1 t 44 1 tImIng IS 15 degress before top dead center at In the case of marks wJnch are not 15 deg the and 20 folowmg deg poSItIons procedure 1 FIrst 2 Turn the crankshaft the adjust 600 rpm IdlIng evenly spaced before top dead center speed pOInters IndIcate 10 deg Adjustment IS made by the dlstnbuter to the correct gap as descrIbed pulley penfery prevIously gradually untIl the top dead center mark FIg 3 on cOIncIdes WIth the mark for 10 deg before top dead center the tImmg gear cover as the crankshaft approaches Its posItIons somewhat be fore that correspondIng to the end of the compreSSIOn stroke of the No 1 pIston on Stop can the crankshaft In thIS pOSItIOn be determIned If the plugged vIOusly WIth a fInger spark plug The compreSSIOn stroke of the No of the No 1 cylInder and the crankshaft turned mentIoned pOSItIOn the No top dead center of compreSSIOn Fg 3 1 pIston IS Checktng the In IS removed WIth the crankshaft Its posItIon of 10 1 pIston the hole ill deg the pre before Igmhon 1imuzg 3 Next InsertIng the dnvIng shaft of the dIstrIbutor at aI1 angle to the engIne engage the gear on ItS lower and WIth the gear on the camshaft DurIng thIS assembly place the slot of the dlstnbutor dnve of the upper end of the shaft some what to the left as shown In FIg 5 At thIS tIme the smaller of the semI CIrcles IS placed toward the front 45 i l Frg 4 t 1 Gear Mark Setting of Timing 4 AdjustIng the dIreCtIOn of the rotor so that It engages the dnve shaft slot mount the dlstnbutor to the engIne Dunng tJns assembly the dIreCtIOns of the dlstnbutor and rotor must be as shown In FIg 5 At the same tIme the breaker must be In Its pOSItIOn when It IS Just COInCIde they are made to do so begInIng to open by slIghtly turnIQg the If these conmtIons do dlstnbutor not body only To determIne the posItIOn when the breaker pOInt IS Just begmIng to open turn on the IgnItIon key hold the end of the No 1 spar sord about 1 4 Inch away from the tcylInder head and turn the body untIl spark Jumps across the gap The off set slot posmon of the dnve shaft when the No pressIOn top dead center pOSItIon IS shown here S 6 Next put the dlstnbutor cap on and 1p It securely WIth the clIp c1al To the No 1 spark plug connect the cord from the termInal to WhICh the J of the rotor Ithe J 7 1 pIston I S In Its com IS lter cou c1ock wlse Upon completIon engIne should Thereafter pOIntIng now order so as to ofthe wlrmg start connect the terIJIInal obtaIn a 1 7 3 cover 4 cords 2 to fIrIng the dIstnbutor WIth a theIr a rm spark plugs order rubber cap The preyperly OrdInarIly the pOInter of the octane selec 9r If set at ItS zero readIng dUrIng the Ignmon tImIng adjustment If the octane nmber of the fuel beIng used IS low and the engIne knocks the poInter IS adjusted to the nght R to the optImum advance angle 46 tl I t FIg 5 Assembly Angle of Drive Shaft Dlllstnbutor shaft C DIstnblltor III Ive shaft @Dlstnhutor fIxing plate Conversely If the octane number IS hIgh the poInter IS adjusted to the left A One UnIt of calIbratIOn of the selector corresponds to 2 deg of the dlstnbutor angle and to 4 deg of the crankshaft angle When a tImIng lamp IS used the standard settIng IS 15 deg before top dead center WIth the engIne IdlIng 600 620 In any case the optImum ad Justment IS that In whIch a slIght mockIng IS heard when WIth the car runnIng at low speed In HIGH TOP gear acceleratIon 47 IS applIed suddenly c 48 SPECIFICA TIONS 20 30CE Type PrImary Secondary Bore dIameter 28mm 30mm Ventun dIameter 21 8 25 Mam Jet 96 Mam aIr breed Slow Jet Slow aIr FIrst Slow aIr Second EmulsIOn hole Slow mm 14 7 mm l1S 80 60 48 48 100 l20 220 er 60 x 10 econcrnlzer 20 x 2 Power Jet 60 x 14 55 Power valve BegInS to open when the prImary throttle valve IS at 480 opemng Float level 19 mm below the upper surface of the float chamber body The carburetor has the functIon of atomlzmg the fuel mlxmg It In SUItable supplymg the mIxture to the engIne It IS therefore an Important part WhIch can Influence the performance of the raUo to aIr and engme The Model 20 30C carburetor IS a hIghly effICIent carburetor of two barrel two step and down draft type haVIng the follOWIng specIal features y Construction and Operation J FJg 49 1 a Secondary SIde D @ @ @ @ @ Pnmary SIde Secondary Flg 2 Flg 3 Body assembly SIde @ AuxIlIarv throttle valve @ Throttle valve Ventury Float chamber Throttle shaft MaID jer @By pass hole Q Slow let @VenturI @ AusIlIary valve shaft @ MaID jet @Mam aIr bleed @ Pump mjector @ Out let valve @ Inlet check valve @ Power valve @ Pump p ston MaID jet carner Float chamber cover @Float @ MaID aIr bleed @ Air bent pIpe @Choke valve @ Choke control hnk @ ConnectlDg rod G Choke wire blacket @ Throttle Wire blacker @ Lower body AIr vent hole @ Pump p ston return spnng @ Connect 109 rod 50 Main Carburetting System The fuel of the passage at the bottom of the float chamber passes wIth the aIr commIng from the maIn Jet and then mIXed drops and Inject Into the ventun through the maIn nozzle out flOWIng the pnmary bleed to be mInute When the throttle valve maIn through aIr gas Into the acceletIng mIxture IS wIdely open and the engIne reqUIres dense where the fuel also flows Its valve from opens power pump the maIn system The power valve begIns to operate when the throttle valve opens 48 from full closed posltlon Slow Speed System from maIn lIne and PassIng through the maIn Jet the fuel passage separate fIrst slow economIzer through the slow Jet slow aIr bleed flows slow aIr bleed second and Inject from the by pass holes and Idle holes Accelerating System Mechamcal acceleratIng pump synchronIzed wIth the throttle valve IS adapted the pIston rod IS pushed up WIth the lInkage wJnch IS open When the the IS pIston commIng dumper sprIng pushed up the pIston through down the Inlet check valve closes the out let check valve opens and the fuel WIthIn the pump IS blown out from the pump Jet by the compressed dumper sprIng and hItS agaInst the SIde wall of the small ventun to be mInute drops compensatIng A JettIng amount of the fuel can be vaned WIth tranclent sparseness of the fuel the two holes provIded on the pump arm that IS the InsertIng poSItIOnS of the When throttle valve connectIng rod Starting System The choke valve IS normal carburettIng choke IS fully closed provIded wIth the spnng and Installed eccentncally on the synchrOnIzed wIth the throttle valve When the deVIce and full the throttle valve opens about 14 from a close ThIS The synchrOnIzatIon of the choke valve the best CondItIOn to start operatIon and the throttle valve can be exactly maIntaIned often the engIne has started flnng IS Fig 51 4 @ Choke control Itnk @Connectmg rod @Choke wIre blacket @Throttle WIre b1acket cgStartmg coo rod 8Auxlltary lever @StartIng 8 SprIng throttle lever @ Throttle adjustIng screw @ Con rod 8 Throttle wire clamp @ Throttle lever o Scale @ Idle adlust screw POWER Main Q O CJ FIg CA RBURETTING 6 5 FUNCTION Carburetting System the normal carburettmg functIon the fuel flOWIng out of the passage at the bottom of the float chamber passes through the secondary maIn Jet and be the maIn aIr bleed and IS come minute drops mIxmg wIth the aIr comIng from Same as blown Into the ventun through Fig 6 the maIn nozzle Carburetor Model Nikki 2D 30C and the When the throttle valve of the normal carburetor IS wIdely opened the carburetor throttle valve of begIns power engIne produces hIgh power the the sunchronIzed lInkage an aUlulIary at the top of the power carburetor throttle valve IS load of the valve wJnch IS not open at a slow speed WIth a heavy load due to the to open by However 52 the valve shaft even when the throttle valve IS open When the engIne change to stIll hIgher revolutIons the aUlohary valve open and the power carburetor starts operatIon the loat of the counter counter weIght connected to weIght agaInst for Jngh power When the normal carburetor throttle valve IS In a full open the power craburetor throttle valve IS also to be In a full open Float Chamber of WhICh IS made of glass of facIlItate marked lIne of cover of It Adjustment for InspectIng InSIde valve from outSIde by addIng or subtractIng the needle of the float level can be done valve Installed at the Inlet connector the float needle carner gasket after removIng and pressure As ventIlatIon WIthIn the float chamber IS of a aIr vent method how suctIonal constant no matter WltIDn the ventun and the float chamber IS always be fuel can economIcally vanes always consumptIon of the aIr cleaner prOVIded cover condItIOn through the The float chamber IS reglstance mamtaIned @ Pump arm @l Float valve sheet gasket @ Float valve sheet @ Umon bolt @ Banjo umoo valve 8 Needle o SprIng retamer o Needle valve sprIng wIre clamp @l Choke FIg Adjusting 7 Fuel Level Float level the Float Chamber IS shown on the float chamber cover WIth the lIne top to WhICh fuel IS to be body addmg or subtractIng AddItIOn down about 1 or adjusted AdjustIng 19 the float level mm IS below done of float valve seat needle valve carner subtractIon of 2 numbers gasket make the float level up or the gasket mm 53 by Accelerating Linkages l 8 PIg rDJ IS adjusted to 86 5 tIghten surly after fIXIng DImensIOns of The nut must DROll by rod and adjustIng the dImensIon of J rD mm @AdJustmg plate PIg 54 9 @Nut plate FUEL SYSTEM The fuel tank has luggage a capacIty of 41 0 htres and The fuel pump supply operated Draining of the the Fuel Tank large and effIcIent aIr cleaner fIlters the GASOLINE SItuated IS draIned Gauge on screws TANK Fuel by turnIng the wrench operated Fuel Tank 1 Securing the top face of the tank IS the gauge WhICh secure the UnIt to the tank not electncallead beforehand thIS may also applIes when dram cock Unit Fig as A to the carburetor The fuel tank lever rear off the camshaft draws fuel from the tank and forces THE the set SItuated at the compartment It Into the carburetor float chamber aIr IS Care must be taken effect serously refIttIng the subsequent UnIt not gauge To forgettIng remove wlthraw to dIsconnect the to straIn or bend the float readmgs Remember thIS UnIt ExamIne the JOInt washer to ensure that It IS In pOSItIOn and undamage IS essentIal as the JOInt between the tank and gauge unIt must be fuel tIght ThIS 55 cap a y Breather tube Band front Band Fuel tank for sedan rear 1 Conne tor Gauge ass Screw y NUT Gasket Tube to gauge tube Washer Grommet strainer Plug e Grommet Tube to strainer Screw aSher WAGON Gauge Gas ket j Bolt Gi Washer Jolnt washer e raln Fue tank for wagon Fig 2 FUEL TANK 56 MOUNTI NG plug Troubles and A Repairs of Gasoline Tank When Fuel Leaks from Gasoline Tank or damage IS found In the tank repaIr or replace It chalk at the marks WIth To make repaIrs put leakIng poInts and even after the fuel in the tank has been draIned out blow WIth compressed aIr through the tank to force out vapor completely RepaIrs should be done only When a crack dIstortIOn stagnant gasolIne completely dry the Leakage IS ordInarIly mended by soldenng When weldIng IS necessary OtherwIse there wIll be danger of above precautIon must be strIctly observed explosIOn when the tank B IS When Gasoline Fails to Reach Gasoline Strainer if the fuel falls to reach the gasolIne straIner when there IS some fuel left In the gasolIne tank and the operatIOn of fuel pump IS known to be satIsfactory check the follOWIng pOInts When It IS dIffIcult to confIrm the delIvery of fuel at the straIner connector at the fuel Intake of the carburetor loosen the Check to see If gasolIne pIpe IS clogged WIth dust and dIrt ThIS can be eaSIly checked by dIsconnectIng 1 the connector of the pIpe and blow Ing wIth compressed aIr toward the Then from the dIreCtIOn of the tank tank end blow the pIpe agaIn and clean the pIpe in many cases the tIp of gasolIne Intake pIpe of tank UnIt IS clogged WIth dust and water Therefore together WIth cleanIng of the pIpe the Intenor of the tank should be cleaned by removIng the at the bottom of the tank draIn plug Check to see If the gasolIne of the tank unIt IS so bent to reach the fuel surface as pIpe to fall The standard pOSItIOn of the bottom end of pIpe IS about 3 4 In apart from the bottom suckIng In order to prevent Its on the tank bot up sedIments tom normal remove tank unIt adjust the bend of the pIpe if and Fg 3 jllnlt gauge Z Fuse @Fuel gauge Wiring of Fuel Gauge not Check too seelf the vent hole of the IS clogged wIth dust and mrt fIller cap @ IgnltJOO switch supplymg AccordIng not Ammeter @ Battery aIr lO the tank to the degree of vacuum WIthIn the tank fuel cannot be drawn fuel pump up even by the operatIon of 57 So be sure to clean the aIr vent of the cap If you should lose the cap and substItute a wooden plug for It a measure whIch IS sometImes wItnessed the COndItIOn mSlde of the tank becomes the same as though It were sealed up Always use only the standard cap Operation and As shown The dash cross of a Gauge FIg In UnIt each other keeper of Fuel Repairs at 3 the fuel gauge consIsts of the dash UnIt and tank unIt wmch IS Installed on the Instrument panel has two cOIls that nght angles whose magnetIc forces control the movement pIece WIth a hand IndIcator On the tank UnIt a contact arm slIdes over float level Iron As shown electnc then In current through CoIl A FIg 3 If the IgnItIOn SWItch IS a resIstance In response to the turned wIll flow from the battery through the ground the contact arm to then magnetIzed attracts the IS Iron the pIece on when the tank ammeter Into IS empty coIl A and and the IndIcator pOInts to E As the float IS raIsed and the tank UnIt Increases reSIS contact arm moves tance In the CIrCUIt and thus the current wmch traveled through COIl A then flows tms tIme both contact arm and coIl B and fInally to the ground As both A and B cIls are so wound as to have theIr magnetIc poles In the same dIrectIOn the Iron pIece wIll rotate to the dIrectIon where the magnetIc power of the two COIls can be balanced wIth the IndIcator deflectIng In the dIrectIOn of F That IS thIS IS a gauge of electnc resIstance control E Empty level and F Troubles with Fuel When somethIng SIgnIfIes type Full level IS Gauge and their Remedies wrong WIth the readIngs of he fuel gauge IgnItIOn SWItch connect the wlnng at the UnIt and turnIng on the ground the termInal end of the saId wlnng to the If the IndIcator of the dash UnIt SWIngs fIrst dIS ground and un body of the car actIvely between E and F the wlrmg between the dash UnIt and the saId termInal end IS In good condItIon WIth the de fect eXIstIng either In tank unIt Itself or In poor ground of thIS UnIt In the test mentIOned In the preceedIng sectIon If the IndIcator does not SWIng but IS moves to E when the dash UnIt end of the wlnng from the tank the wlnng between the dash UnIt and tank UnIt IS defectIve Therefore reWIrIng or repalnng IS It moves UnIt grounded requIred If when IndIcator flals to swmg but sparkIng IS observed when the WIrIng connectIng the battery wIth the termInal on the dash UnIt IS dIsconnected at the dash UnIt end and grounded It proves the wirIng IS satIsfactory and the trouble IS In the dash UnIt Itself If order sparkIng does not should be occur repaIred or the WIrIng case adjust the Troubles with the UnIt IS thus IndIcated to be out of replaced Incorrect readIngs of the IndIcator of the tank UnIt IS m error In thIS wmch heIght are probably of the float dIffIcult to S8 that the by bendIng repaIr unIt means so It heIght of the float the rod should be replaced by a new In checkIng the battery between the tank unIt and the be sure to Insert a fuel gauge In the CIrcUIt unIt FUEL STRAINER Instruction for Disassembly To remove the bowl from the body sIde Take off the bolt nut WIre to a gasket and The Pay are nut and remove the screen straIner threads of each bowl loosen the straIner and washer from the wire and remove bowl body IS made of alumInum alloy Take good care not to break connectIOn attentIon not to tIghten the straIner nut so excessIvely that the gasket and broken InstallIng the straIner assembly the stramer bracket should be cleaned suffICIently Dust and dIrt on the bracket surface prevent plug from keepIng aIr tIght When V l 4 13 1 12 e CD Plug @Gasket @CheLk valve @ Packmg @ Stramer @Ilody @Washer screen Glass Flg 4 @ Bracket @ WIre @Nut @ Bolt @ PIpe term mal Fuel Strainer 59 Assembly FUEL PUMP screw Angle washer connector Rocker arm side spacer Rocker arm pin Hand pnmer lever rod Rocker arm ass Rocker Rocker Fig 5 COMPONENT OF 60 FUEL arm arm PUMP y r pln side spacer FUEL PUMP Type DIaphragm Method dnven Dnven DIaphragm legnth Length In use Free camshaft spnng Free Rocker by pump arm and 36 5 18 mm tensIOn O 1 16 mm o 1 kg spnng 30mm length Valve spnng Free length 95 ThIckness of valve mm 1 6mm Performance Max quanuty 1 300 cu cm dIscharged per mInute at 1000 r p 500 mm In suctIon heIght of cam Max pressure Max degree dIscharged llO l30 mm In m mercury column of suctIon vacuum More than 400 mm 80 20 strokes m mercury column Hand pnmer quanty dJscharged The fuel pump whIch JS of the cu cm at dIaphragm type IS dnven mechamcally by the eccentnc pan of the camshaft of the engIne It draws gasolme from the tank and delIvers It under pressure to the carbure tor Even when the engIne IS not runmng fuel can be delIvered under pressure by moVIng the hand pnmer up and down By the rotatIon of camshaft rocker arm IS pushed and pull rod of dIaphragm IS pulled down At the same ome pushed By dIaphragm goes down agamst up agam by ItS spnng the movements of the dIaphragm and and outlet of the pump chamber gasolIne IS dJaphragm functIonIng spnng and then of the valves drawn up from the tank at to IS the mlet the carbu retor If the float chamber of the carburetor contams enough gasolme and the needle IS closed gasolme IS not allowed Into the carburetor Thus gasolme IS stored In the pump chamber and due to ItS pressure the dIaphragm IS kept down and cannot return Under thIS COndItIOn the rocker arm works In vaIn as the rod remaInS low valve The rocker pushed agamst drm spnng serves to prevent nOIse the eccentric of the camshaft 61 keepmg the rocker arm Disassembling Inspection wIth fuel pump Installed on engme SWItch off and stop the engIne DIsconnect the fuel pIpe at the mlet unIOn of the carburetor and then turn the engIne wIth the crank handle Now the gasolIne should be ejected vlgorounsly from the tIp of the pIpe once Checkmg every two rotatIOns of the crankshaft To test the functIon of the pump alone checkmg the fuel eleCtIon IS enough Removal from engIne Fuel pump can be easIly removed and loosenIng operatIon of the hand prImer and by dIsconnectIng the mlet and outlet UnIons the 2 attachment nuts 1 the 1 InspectIOn prIor to dIsassemblIng Pnor to dIsassemblIng of the removed pump measure the dIstance between rocker arm and flange of the lower body by means of a scale and see If the rocker rocker lInk and pms arm Method of are worn dIsassemblIng FIrst WIpe dIrt off the outer surface of the pump and put marks on both the upper and lower bodIes to make theIr reassembling easy It IS easIly separated Into two when the fIVe screws around the upper body are loosened Take great care not to damage Wash the dIsassembled Replace Replace the a dIaphragm dUrIng thIS dIsassembly of Parts Repaues Checking the parts well In gasolIne then Inspect them ImpregnatIon by gasolIne faulty operatIOn IS detected unavOIdably reqUIred the lImIt for repaIrs of warp dIaphragm If any damage valve assembly If any wear Even If repaIrs are wear of the valve IS 0 001 or In When the surface of the valve seat or valve IS found Irregular valve seat of the outlet and dress the surface WIth a fIne OIlstone In case be taken off of Irregulanty from the body or remove the of the seat surface of the Inlet valve whIch cannot recondItIon It wIth a cutter and grIndIng tool When the surface of the valve IS faulty pound on the surface of a flat pIece of glass place some very fIne gnndIng com plate and gnnd It lIghtly wIth the tIp The standard thIckness of the valve IS 1 6 mm The hole of the JOInt parts of dIaphragm shaft and lInk may be worn to some extent ThIS IS not serIous but when serIOUS eccentrIC wear crack or break the part must be replaced IS found age of As a remedIal measure such wear can be compensated for at the tIme thIck made of of the and InsertIng a packIng of a fInger dIsmantlIng reassemblIng body by paper between the lower body and dIaphragm to dIaphragm shaft wIth respect to the lower body raIse the relatIve posItIon The rocker arm should be replace when ItS contact face wIth the that WIth the lInk and Its pIn hole are senously worn 62 cam of and When ItS re employment by recondltIOmng IS unavOIdable the rocker arm and lInk by weldIng and fInISh them WIth a fIle last long and IS no more Renew the arm than a pIn when It temporary measure IS found worn excessIvely The dIaphragm spnng arm spnng seldom become faulty always with standard ones If the dIaphragm spnng IS too stron It results In overflow replace add matenal to but tms cannot but when weakened them of the float cham ber of the carburetor The tenSIOn of the spnng must not be strengthened or weakened arbItranly hand by Check and after to see If there dIsassemblIng Reassembling IS any warp IS over the JOInt surfaces of the cap and the gasket to keep ItS alr on body tIghteness renew Installing standard sprIngs for the varIOUS uses as stated before Install valves precIsely for close contact wIth theIr respectIve seats In screwIng In of upper and lower bodIes and dIaphragm fIt them together accordmg to the marks WhClh were put before the dIsassemblIng and alIgn one Employ screwmg hole IS fully pulled mate and then down WIth the rocker to Its screw In at pushed arm the pOSItIOn where the dIaphragm towards the SIde of the body by and pressure Do not screw the In tIght one by one SInce It causes warpIng lnstead clamp all loosely and umformly tIghten them dIagonally and lastly re tIghten all of them In order to make screws Then round sure As a general InstallatIon Be rule on sure to set properly not gaskets the engIne the rocker IS should be done arm so In replaced by the that It IS the rear SIde or to one SIde block and pump WIth a new standard reverse new ones order to that for contactIng Replace the dIsassembly the eccentrIC of camshaft gasket between the cylInder one Checking Function When repaIrs of the pump a check to see IS over or before It IS Installed on the engIne make When mounted a vacuum on a revolVIng tester gauge IS connected to the pump Inlet port and the pump IS the rocker arm IS actIvated by the eccentnc of the camshaft 1000 rpm at of mercury column mm rema1l1 tt should more Then the gauge pressure should nse to and even If operatIon IS dIscontInued mgher than 400 thIS condItIOn than 3 seconds not avaIlable test In the follOWIng way Clost the Inlet port and outlet port wIth fInger tIps Then after operatIng the rocker arm several tImes suddenly release the fIngers The pump IS 11good When a gauge COndItIOnS If 3 to or tester IS 5 seconds thence there can be heard strong Inlet and outlet respectIvely The pump IS mechanIcally fIt for use when by connectIng a hose port It IS able to draw up gasolIne from a heIght of more than O 5 m InstallIng the pump test ItS functIOns dunng operatIon nOIse 63 to the Inlet After A Connect the gasolIne pIpe on the Inlet post sIde only Leave that on the outlet port sIde as It IS and turn the engIne 6 to 7 rotatIons by means of the crank handle and make sure that there IS sure outflow of gasohne from the outlet port B JOIntS of aIr Connect the Then or turn gasolIne gasohne pIpe to the outlet port SIde and ughten all the pIpIng the engme agaIn several tImes to see If there IS any leakage from each connectIon v 64 f INSPECTION AND ADJUSTMENT OF ENGINE and for The engIne must always be operated In the best possIble condmon tms purpose penochc InspectIon and adjustment must be maIntaIned In a certaJD order whIle In use as well as after overhaul Order of Check the 1 2 of 3 Inspection and Adjustment water coohng all Inspect the battery electrolyte and voltage Inspect the OIl amount 4 CleanIng of spark plugs water level and connectIons fIlthIness and of Engine extent level of of fIlthIness electrolyte specIfIC gravIty classlflcanon and VISCOSIty adjustment of theIr gaps The standard com 5 Measurement of compresssIOn pressure of cylInders 163 lbs per sq In at 350 r p m preSSIOn pressure of the engIne IS approx see FIg 1 FIrst Measurement of pressure IS made In the follOWIng manner remove all of water 800C then 70 warm up the engIne temperature coolIng and out the throttle knob all the way that IS In the carburetor spark pull plugs the throttle valve and choke valve fully opened press a compres gauge agaInst each spark plug hole and runnIng the starter motor WIth a fully charged battery are SIOn read the motor be made pressure ob 8 rotatIons of the maXImum tamed WIthIn 5 Tms measurement must as qUICkly as pOSSIble It the compreSSIOn pressure of anyone cyhnder dIffers by 10 lb sq In or more from that of another the cause must be m vestIgated 6 Check and adjust the dlstn butor If the breaker contact pOIntS have defectIve contact surfaces dress them and adjust the gap to O 45 0 55 mm Fig 1 CompressHm Gauge Also turn the cam of the dIS tnbutor clockwIse and check to see If the governor can carry out advanCIng functIon Adjust Ignmon tImIng correctly can be checked By unhzmg a power tImIng lIght the functIon of the governor WIll enable to m of carnk IllumInatIOn pulley together wIth the IgnItIOn tImIng T D C 2 of the and tImlllg 8 condItIOnS of runnIng advancmg spect the 7 0 8 9 InspectIon Adjust the of fuel pump and gasolIne straIner slow settIng of carburetor 65 10 Checkmg operatIon of generator Check the generatIng condmon and of IndIcatIOns of the ammeter 11 AdJu 12 Adjustment l3 Road ment of slack In functIonIng of the cut out relay by means fan belt of valve tappet clearance test WhIle dnvIng In 3rd speed at about 25 km fhr suddenly step on the If only a slIght knockIng results the IgnItIOn tImIng IS correct Slow speed adjustment IS made so that the when speed IS about 15 krn Ihr dn VIng In 3rd speed accelerator Diagnosing of Engine by means Gauge and Combustion Tester of Vacuum In dIagnOSIng the engIne the COndItIOn of each cylInder can be assumed by measunng ItS com preSSIOn For employment of a vacuum gauge It to the engIne Intake manIfold and refer connect to FIg 2 The In use 2 IS FIg When a of a master motor tester as shown convement combustlOn tester IS used Install a speCIal Intake pIck up In the exhaust tube and after the engIne has been started analyze by means of a speCIal gauge the combustIon gas WhICh flows tester and through the connectIng hose Into the Judge the combustIOn COndItIon ac to the mIxture ratIo of fuel and aIr When measurement IS to be made In raInyor cold cordIng weather use an aUXIlIary condenser between the and the meter otherwIse the exceSSIve pIck up mOIsture m the exhaust gas WIll damage the func tIonIng of the meter If permItted to enter It FIg 2 Motor Master Tester Available for 4 6 and 8 Cylmder EngJne When a tester IS to be used make adjustments accordIng to the follOWIng table Condmons Low WIthout load SUItable Speed RunnIng 600 r p 70 r p RatIo of MIxture i 2 m HIgh Speed RunnIng 2 000 WeIght 85 m 66 5 2 Engine Trouble Shooting FIg 3 IS Intended be of to aSSIstance In the systematIc and Isola analysIs tIon of symptoms of engIne troubles so that the defectIve pOInts may be traced and accurately economIcally repaIred 6 1 When Indicator drops by several IDches at certain Normal condition Settles between 1820 In time valves are burnt 7 2 When Indicator Normal condItion When Indicator behveen as a fluctuates range of 0 engine and 19 valves raced are 2 about In 25 Faulty In drops by valves leak seatIDg of valves In rings good conditions 8 3 When Even If IndIcator settles If readIDg IS low nngs or OIl are nfaulty cond tlon Indicator OSCillates 14 actively between 18 In worn end valve stem gUide is out 9 4 When above 3 condition eXists IDdlcator w1I1 sWIDg to 0 In If engIne IS raced Wben With tng Up between With a 11122 IDcrease range shght speed IndIcator end of speed becomes valve springs moves ID are the larger weak 10 5 When Ind cator sometimes drops by 4 In or so valve stlckIDg eXists 67 When mdlcator remaIns stllJ between 8 15 ill it IS because eIther valve bmmg IS retarded or vslve clearances are notcorrect 14 11 When When Indicator settles bet ween 14 timing IS 17 Indicator oscillates regularly between Ignition 10 519 In there Is leakage at cylm der head gasket Faulty retarded c1ampmg 12 of gasket 15 When Indicator moves When Indicator first rises slowly between 1416 m high drops down zero to It Is because eIther elect and tben returns to 16 i1l rode gaps of plugs are too narrow or breaker pomt mufller IS clogged defective 16 13 When md cator 5 IS 111 or leskage at below points to there is When mdlcator slowly between carburetor intake manifold is moves I3 171n poorly ad justed gasket of carburetor Faulty clampmg of gas or ket FIg 3 Dlagnosmg EngIne by means of a Vacuum Battery discharged Gauge or CODDectloDS poor T mmg poorly adjusted AIr bplDg sucked l 1 o a Cl i to 0 1 Il spark rPIug Plugs do not spark In Plug sparkmg weak Wlrtng SpBrklngat termmals t Tlmmg Sbort mcorrect In CIrcuit IgnItion coil Nosperk or condenser defective pomt dllty mg at ter mllll ls Incorrect Plugs dirty Breaker defectIve Econtact Pomt contact poor Breaker j arm insulatIOn defectIve Rotor shorted l r N mOD Stramer defective Pipe clogged No gasobne in carburetor Float valve sllckmg No air can enter tank Fuel pump not operatIng 68 No 0 Compres 8 sion l l LLubr gasohne supply stopped or cat on Ulsufficlent A Ir beIng sucked good Plugs spark gasoline Engine seIZed Carburetor free of trouble Jet or 10 clogged sunk Eloat Carburetor defective p pe Float In high pOSItIOn wIll arburetor attachment not l Piston nng f l COmpressIOn o t poor Plston r Breaker I spark 109 from cOIl hne valve or arm 80ntact IgDlhon coli good 8lstr ap IOsulatlOn defect Cord shorted or Wiring shorted I COIl hne Trouble condenser or defective butor wet do Plugs not spark A defectIve spring Rotor shorted LBreaker form sticky connecting rod broken point poor arm LSparklng descend secure Valve seating poor I No or not Plugs Shooting dIrt or ve connectIOn poor or cut broken Chart COmpressIon weak Valve clearance Incorrect Valve sprIng weak Valve deformed Muffler clogged ContmuoUB lack of Valve tlmlOg Incorrect JIOwer Igtlltlon retarded too much buretor adjustment poor sohne supphed insulIiciently bon deposIts excesstve aaohne of poor grade IntermIttent Isck of power 1 uus1De open tlOft defective during rumllng I I buretor defectIve Valves stIcking Pre Igtlltlon EngIne gives off abnormal noIse J erheat ng I BearIng worn Plugs dIrty Breaker poInt defectIve IntermIttent shorltng Ml8finDg Mllrture too rIch IllSulliclent gaaoline supply to carburetor Water In gasohne Nozzle clogged B Trouble Shooting 69 Chart CLUTCH GENERAL DATA dISC Type SIngle dry ConstructIon of dISC WIth coIl sprIng Outer dla of faCIng 200 mm Inner dla of faCIng 130 mm ThIckness of faCIng 3 Smm Gross fnctwn 363 area ThIckness of dISC DIsc run ass y Backlash Inner dla PRESSURE when O 15 releaSIng depreSSIng mm 0 002 mm 0 006 In of master 15 85 5 8 mm In of operatIng 19 05 3 4 mm In GenuIne super brake 011 WIthdrawal Return spnng WIre dla 1 6mm 87 length In when mm all pressure Operatmg lIqUld Length mm 8 1 method cylmder Free 9 1 0 05 cylmder Inner dla 8 6 7 3 sphnes part at Operating cm Less than O 5 out plate used tensIOn mm 136 mmlS kg SPRING Free 49 mm l 1 5 length Compressed length Less than 25 Turn numbers 7 8 Power of compo In full Length kg 3 3mm WIre dIameter In use About 300 mm and load 29 2 37 l2 S kg RELEASE BEARING Ball Constru tIon HeIght of release plate beanng type From flywheel SO 5 l O 2 Release If SO use plate run master dISC l8 lO 2 S out face to rear end of plate mm Less than 0 03 0 0012 m l O 5 mm mm heIght mm 70 heIght of release lever IS DRIVEN PLATE ASSEMBLY ThIS IS the flexIble type In WhICh the splIned hub WhICh transmIts the power and the over run through In pOSItIOn by retaInIng Two fnctIon lInIngs COVER The IndIrectly attached number of coIl IS a dISC sprIngs held WIres are rIveted to the dISC ASSEMBLY assembly conSIsts of pressed steel cover and plate by SIX pressure spnngs Mounted on the pressure plate are three release levers Adjustmg nuts are screwed on the bolts of pressure plate cover a cast Iron located spnng msert to the clutch RELEASE cover holes and antI pressure RetaIners of pressure rattle Sp 1Dgs load release levers BEARING The release the cup to a bearIng bearIng located ConSIstS by of a carbon shrunk mto a beanng the operatIng fork and the release beanng cup bearmg retaIner sprIng RUNNING OwIng to ADJUSTMENT of the clutch controls no to the the clutch hydrauhc deSIgn pedal adjustment IS necessary Removing the Clutch To gam access to the clutch from the engme It IS fIrst necessary to remove the transmISSIOn complete Once the transmISSIOn UnIt IS free a turn at a time by the sprIng pressIng IS reh ved Then remove the screws completely and hft the clutch flywheel FInally remove The release levers unless new parts have are to the drIven assembly selectIon until away from the plate assembly correctly be fItted Dismantling Assembling By usmg serVIce tool adjusted to a hIgh degree dIagonal set on assembly Interference WIth thIS settmg wIll throw the pressure plate out causIng judder Gauging the clutch can be qUIckly dIsmantled reassembled and of accuracy The tool compnses the followmg parts base plate centre pIllar spacIng washers dIstance pIeces hlght fInger actuating mechamsm setscrews speed brace and metal box As thIS tool IS unIversal a chart mdlcatIng the parts to be used for the box patIcular patIcular types of clutch Will be found on the InSIde of the hd of 7l s tod on lTrunn sh plJ ocl t l a dfa lla dra i th tb n q p evet l 10 0 10 0 1010 1020Q lO lo rl rt ns spr pp bly bIY UiC r ell h C Co t C 2 rig boll 1 l pr EY S re 11 S J II ni IPt pr net PrCIUYC reta IF wa6net c oc t 0 t ll 0 E Dismantling Place the clutch cover assembly on the three spnng so that the holes the cover cOIncIde wIth the tapped holes In the plate Insert the set screws provIded and tighten them a lIttle at a time by diagonal selectIon untIl the cover In I IS fIrmly attached to the base If the best results are plate at all possIble pOInts ThIS IS most Important to be achIeved Mark the cover pressure plate lugs and release levers WIth a centre punch so that the parts can be reassembled In theIr relative poSItion In order to maIntaID the balance of the clutch Detach the release lever and adJustIng plate from the eye bolts and 6 nut I 73 remove the three lock nuts t Fzg 4 Dzsassemblzng 74 Slowly spnngs the set base release the pressure unscrewIng by dIagonal on the selectIon the securIng the cover to can be lIfted The clutch then screws plate to expose all components for InspectIon The release levers and spnngs should l111t be examIned for wear and dlstorbIOn Renew these parts If necessary beanng In mInd that the pressure sprIngs must only be renewed In sets lubrIcate the spanngly bearIng t Clean all parts and surfaces of the levers t q 51 7J 8 Inii WIth grease Flg 5 AssemblinK Press the pIn Into the eye bolt hole through shown 75 the lug on the pressure plate as Place the pressure plate on the base plate WIth the pressure spnngs In posItlon and plate put the pressure spnng retaIners on It Cover and set the dutch cover assembly on the base plate on the pressure Compress the pressure spnngs by screwIng down the cover to the base plate by specIal set screw placed through each hole In the cover TIghten the screws a lIttle at a ume by dIagonal selectIon to prevent dIstortIOn to the cover Set the release lever on the eye bolt with lock nuts InsertIng for lug at the edge of pressure plate USIng the 76 J Gauging Screw the nuts Into the bolts and and plate shaped heIght fInger the base Into proceed as follows Screw the centre pIllar shp the dIstance pIece over the pIllar followed by the cam Adjust the heIght of the release levers by screwIng or un untIl the heIght fInger when roted Just contact the helghest screwmg the bolt nuts poInt on the tIp of the release levers Replace the heIght fInger and pIllar the clutch actuatIng mechanIsm See by operatIng the handle FIg TJns wIll enable the parts to settle down on theIr lallfe edges the and dIstance pIece and readjust the heIght of the re 5 and Inset Replace actuate by the clutch several tImes heIght fInger lease levers checked for run out as near the edge as possIble as If the error press hIgh spots untIl It IS true WIthIn thIS figure It IS Important to keep fnctIon faCIngs free from OIl or grease FInally repeat the procedure to make qUIte sure the release levers are seat Secure the lock nuts and fIX the release lever Ing properly and gauge agam Release the setscrews and remove the clutch assembly from the base plate IS more than O 02 lD over the Refacing the Driven Plate fItted If a new complete clutch dnven plate IS not avaIlable new lInIngs may be manner dnven In the the old to plate follOWIng be punched Each nvet should be removed by USIng dnll The nvets should not avaIlable use If correct tool IS not then the out RIvet one new facmg In pOSItIOn The to roll the nvet shanks securely agaInst the plate bluntended center punch a should then be nveted on the opposIte SIde of the plate WIth the clear The plate the fIrst faCIng holes over the heads already formed In fIttIng and run out as centers checked for a mandrel between should then be mounted on second faCIng 0 02 In press over mgh edge as pOSSIble If the wabbmg IS more than lt IS Important to keep fnctIon faCIngs free It IS true WIthIn thIS fIgure untIl spots from OIl or grease near the Refitting the Clutch end of Place the dnven plate on the flywheel wIth the longer chamfered splIned transmISSIOn hub towards the the dnven plate fIts the The dnven plate should be centrahsed by a dummmy dnve shaft WhICh the flywheel sphned bore of the dnven plate hub and the pIlot beanng of 77 assembly can now be se cured to the flywheel by means of the tIghtenIng them a turn at a tIme by dIagonal selectIon Remove a There are two dowels In the flywheel to locate m the clutch cover 35 lb ft 4 84 kg m shaft after these screws are fully tIghtened dummy The weIght avoid stram on the RefIt the release bearing and transmISSIOn case drIve shaft and dIstortIon of the drIven plate assembly The clutch holdmg cover screws DESCRIPTION The clutch IS A mounted cylinder CLUTCH OF from operated a CONTROL master the clutch bell on cylmder by means of a suspended pedal hOUSIng IS coupled to the clutch operatIng shaft Gcit 9 f 1 Fig CD @ @ @ 6 Push rod Master assembly cylmder rubber Stopper rIng Piston secondary Secondary cup the Master Components of boots cup rIng @ PrImary cup lMaster cylinder p ston @ Let m valve as sembiv @ Let m valve sprIng @ Return spnng seat l CylJnder @ Piston return sprIng @ Clutch master cylinder lxxIy @ Let m valve release pm Oi Rmg @ Gasket @ Filler cap gasket @Cap @ End plug gasket @ End plug ass y When pressure to the clutch pedal IS applied the pIston of the master cylInder lIne In turn moves the pISton of dIsplaces the flUId m the cylInder and VIa a pIpe the cylmder pushmg agamst the lever of the clutch shaft The Master Cylinder The master cylInder reserVOIr WIth cap alloy body WIth a polIshed fInIsh bore and assembly IS made up of the push rod rIng stopper conSIsts of an The mner valve and valve spnng cups spnng seat sprIng rmg pISton The end of cylInder IS protected by a rubber boot 78 Dismantling the Clutch Master Cylinder DIsconnect the pressure pIpe UnIon from the cylmder and remove the secunng then the master cyhnder and may be wIthdrawn complete from the car Pull back the rubber boot and re Remove the fIller cap and draIn out the flUId bolts The push rod and nng can the stopper rIng WIth a paIr of long nosed plIers then be removed and unscrew the release pIn When the push rod has been removed the pIston WIth caps attached wIll be ex posed remove the pIston assembly complete The assembly can be separated by hftIng the spnng seat edge over the shouldered move end of the pIston slIde through the Depress the pIston return sprmg allOWIng the valve assembly elongated hole of the spnng seat thus releaSIng the tensIOn on spnng ExamIne all parts wear or dIstortIon and especIally the gasket cylInder bore and pIston replace the new parts where necessary cups to the for Assembling Smear the sembly assembly well WIth the recommended brake flUId and msert the as cyhnder end fIrst easIng the pIston cups hps m the mto the bore of the bore Replace by push the rod WIth the secondary cup nng Into the cylInder followed the stopper rIng WhICh engages Into the groove machIned In the cylmder body Replace the rubber boot and secure the UnIt by means of the two bolts on the flange The and refIt the rpessure pIpe UnIon mto the cylInder Operating Cylinder PIston pIston ThIS cylmder IS of sImple constructIon consIstIng of the body WIth cup spnng and bleed screw the open end of the cylInder beIng protected by a rubber dust cover The cylInder IS mounted under SIde of the startIng motor Di smantling the Remove the rubber dust cap from the bleed screw attach a bleed tube open untIl all the flUId the clutch bleed screw three quarters of a turn and pump pedal has been draIned Into a clean container The operatIng cyhnder Unscrew the fleXIble pIpe UnIon and adjustable push rod now be removed Removed the rubber cover and If compressed aIr lIne IS can avaIlable blowout the pISton from the SIde UnIon especIally the seal and replace If ExamIne all parts worn or damaged Assembling the Place the seal IntO the stem of the pISton with the back of the seal agaInst well WIth the with small end on the stem smear the the sprmgs pIston replace flUId and Insert Into the cylInder Replace the dust cover and mount recommended the cyhnder boot push In Secure the rod by makmg sure the push rod enters cylInder WIth the bolt and screw In the pOSItIon the screw the hole m the rubber pIpe unIOn Adjust the drLver at top of wIthdrawal lever WIth the adjustable rod of 79 operatIng cylmder to gIve the end play 2 5 3 0 mm Bleeding the Clutch System screw dust cap at the operatIng cylInder open the bleed a turn and attach a tube Immersmg the three of quaters apprOlumately FIll open end Into a clean receptacle contaInIng a small amount of brake flUId WIth the recommended flUId and slow the master cylInder reserVOIr by usmg full strokes pump the clutch pedal untIl the flUId entenng the contamer IS free Remove the bleed screw pedal screw up the bleed screw re replace the dust cap When the clutch pedal IS depressed the force IS transmItted to the ball beanng and the surface pushed the release plate Effectual stroke of the pedal 95 mm untIl the IS 128 mm leavmg 30 mm surplus In stroke ltch cl dIsengages When there IS undue surplus or shortness mstroke readJust the pedal poSItIOn WIth the adjust shrm from move aIr bubbles On a down stroke of the the bleed tube and Jg F 7 80 TRANSMISSION 1 Frg Model 3 stage for forward for reverse 1 stage 4 stage for forward mesh on for speed Remote control Full synchromesh on for ward gears Type of gear Synchro meshed helIcal 2nd gear type RatIo 1 3 Sl8 RatIo 2 1 725 3 94 2 40 RatIo 3 1 000 1 49 RatIo 4 4 125 5 lS9 Reverse 1 00 81 3rd 4th gear synchro DISASSEMBLE THE TRANSMISSION CASE FIrst dram the OIl from the draIn plug IS transmIssIon sItuated beneath the DIsconnect the propeller Shift Lever Remote by removIng the dram plug The case shaft startIng motor clutch lever and ShIft levers Control The sJnft lever IS posItIOned on the nght hand sIde of the case of transmIssIon If the car has rIght hand steenng wheel and on the left hand sIde If It has left hand steenng wheel Shift Lever Floor Gear Shift Lever The sJnft lever IS located on the nght hand F g 82 2 or left hand sIde of dnver s seat T J V r If I TRANSMISSION Flg 3 83 CASE ol1 I SEAL I llNG BUS locI BREATHR Y EXTNSIO y ASS TEMSIOM EX cover bot m WASHER REAR fpt to WASHERlock shaft ASS SEAL e1t nSlo rear rear CROS Oll 6 COVERbot m lnter hole lock PLUG CASE BOLT PLUG aln y ASS dr TRAMsISloN 4 FIG front On COVERtransmlS If l Ow @ U U i iilt l t so tr n 18 i I l e e 85 U o J i 1t 6 It 0 DISASSEMBLY Front Bearing Retainer Release the front bearIng retaIner sItuated wIthIn the clutch the nuts c Fig 6 Beanng 86 Retmner housmg by removmg Cover of Transmission HoldIng when the the pOSItion be taken off cover In cover can FJg FJg are 14 set nuts all of WhICh must be removed Bottom Cover 7 8 Vlew of lnslde of 87 Tnmsmlsslon Fig 9 Take out the RIng FIg 88 u 10 the Take off pm Nut Counter Shaft Gear USIng a soft and long metal dnft dnve out the counter shaft forward When the counter gear cluster and two thrust washers will drop In the case These gear cluster can only be hfted from the case Hg 11 Counter Shaft Removal 89 FIg 12 Ftg Pull Out the 13 A Retaimng Fork Pm Pull Out the Fork Rods 90 3 i Fig s 13 B Pull Out the Fork Rods Revers Gear A the lug maIn of the shaft wmch IS an Integral castIng locates part of the forward end To secure the gear shaft pOSItIOn a set bolt IS screwed the lug locatIng In the shaft of reverse In through reverse gear Release the lock washer out LIft out the reverse then screw gear shaft Fig 14 A Pull Out the Reverse Gear Shaft 91 j J FIg 14 B Pull Out the Reverse Gear Shaft Main Drive Shaft Tapped out the mam dnve gear assembly r f k f f q J t FIg i J e 15 A Removal 92 t 1 t of Mam ff t yr DrIve Gear Shaft F g 15 B moval of Ma n Shaft Dnve Gear Fig 16 A 93 Matn Shaft moval Fig 16 B Main Snafl Removal Main Shaft Pull out the from the maIn rear shaft beanng rear and the speed sIde Fig 17 94 gear sleeve by the beanng puller 1 Reverse Gear A part of the maIn castIng locates the forward end of the shaft In poSltlon a set pm IS screwed through the lug locatmg m the shaft The set key IS locked out sIde of the case Release the set pm then tap fOrWard and remove the reverse LIft out gear shaft the reverse gear the lug wJnch reverse IS aD mtegral gear shaft To secure Rear Oil Seal ThIS 011 seal IS sItuated In the end of the be dIsmantled unless seal WIthout suspected of leakIng damage It consequently a new rear It IS bearIDg retaIner and should not ImpossIble to take off the almost OIl seal should be fitted If the old one has been removed ThIS can be removed by usmg a punch and hammer Main Shaft Counter cluster gear In the case Insert the fIrst gear to the maID shaft together rear hole and fIt the fIrst and reverse wIth second and tJnrd gear assembly from fork shIfter over the fIrst gear Fu the sJnft fork of the second and thIrd gears assembly on nIzer Depress the maID shaft bearIng to the end of the case Change the dummy shaft to counter gear WIth the saId 95 shaft the hub of synchro lever ge fll lNUT HER Change Znd ci@ i f1I I ER to @ WASHER change 3rd Nu WASHER ICk lnter BAL I l m mI d SPRING mIl BOL 1 PLUNGER retaln g RING cros @ SPRING chekmg BAL heCklng WASthrust shaft 7 P1aln ball 1st ER i EVER Znd sHAFT L J fL t cros rev s WASHER RING y SHAFT 3r cro nd l i NI FO g 13 fi t L LE ope lock mg to I IN I I fork e va 8 ROO revet 1st fork 3rd RoO Znd C J tII Il I o 00 oD lI II8 WASHER WASHER PIN k loc lever shaft r 1 C F 9 t FIg I 9 OF ASSEMBLY ORDER CASE TRANSMISSION GEAR 97 IOCk coMTRO WASHER e on locasutp ort l L up ebrracket BO hand LEVER SS P C1 REMOTE 20 FIG e Hand one eft h use lfo Of l I tat ft h ROO GE IMKI T COl TE ENlO 21 G t c tOd l Ol h I Jl R eh 1 0R tOdh 1 lh t e ISUl Il DD DISASSEMBLE THE TRANSMISSION CASE FOR 4 STAGE FLOOR SHIFT Removal of Control Lever TWIst the cap on the lower portIon of the control lever counterclockwIse WIth sbght downward pressure Removal of ShIft Rod Remove the a Slnft Fork cOYer from the transmISSIon by detachIng SIX bolts Reverse Gear A lug WhICh IS an mtergral part of the maIn casmg locates the forward end of To secure the shaft In pOSItIOn a gear shaft settIng screw IS locked a tab washer screw StraIghten the tab washer release the then the by reverse settmg forward and the remove Counter Shaft reverse gear shaft Set out the tap reverse gear Gear USIng soft metal dnft dnve out the counter shaft forward and out of case wben the counter gear cluster and two thrust washers wIll drop to the bottom of the case These gears can only be hfted from the casmg when the maIn and drive shafts together WIth theIr respectIve gears have been removed the needle roller bearmg witlun the counter gear cluster It IS neces sary to break the retamIng clrchps before dnvmg out the bearIng wIth a sUltabl e pIece of metal tubmg To remove Main Shaft The maIn shaft can now be wIthdrawn from the transmIssIon To remove casmg the gears from the mam shaft fIrst slide off the tJnrd and forth speed synchrallzer assembly then WIth a pIece of wire Inserted through the hole m the cone de gear press the small spnng loaded plunger WhICh locates the sphned washer at the for ward end of the maIn shaft turnmg the washer moo lme WIth the splmes The tJnrd and second speed constant mesh WIth theIr common gears together phosphor bronze sleeve can now be pulled over the steel and so clear of the mam shaft As plunger the bronze sleeves and theIr common dnvIng washer are a tIght fIt on the the shaft should be Immersed m warm OIl In order to expand the sleeves so phosphor shaft that wIll slIde off the shaft when the second they speed gear can be removed Talce out the steel Next plunger and spnng splmed washer separatmg the the second speed constant mesh gear from the fIrst gear umt and then slIde the fIrst gear assembly free of the shaft remove assembly maIn To release the and unscrew ItS speedometer securmg nut wheel from the then shde the Do not lose the maIn shaft speedometer straIghten the tab washer wheel off the shaft key Take off the dIstance pIece and the mam shaft beanng can hOUSIng after the nut has been pnsed from the shaft If It IS deSIred to dIsmantle the fourth and thIrd speed couplIng sleeve or the fIrst speed gear these can be pressed clear of theIr spUned synchromzers but care must be taken to retneve the three balls and spnngs In each assembly Take out be separated from Its 100 the maIn shaft front needle roller beanngs from the end of the dnve gear shaft Rear Oil Seal TJns OIl seal IS of suspected unless sItuated In leakmg the end of the It IS almost rear cover ImpOSSIble to and should not be dismantled take off the seal WIthout dam agIng It consequently a new OIl seal should be fItted If the old one has been moved ThIS can be re It wIll be seen that the 011 seal housmg IS pInched Into pOSItIon moved by USIng a punch and hammer ASSEMBLING THE TRANSMISSION The 2nd speed gear the 3rd and 4th speed couplIng sleeves are each paIred WIth synchronIzers Only mated paIrs of these parts should therefore theIr respectIve fItted Reverse Gear RefIt the reverse gear Into the gear case WIth the large gear to the rear all the reverse gear shaft before InsertIng and secure the shIft WIth locatIng screw and lock washer Counter Shaft Gears FIrst put the two thrust washers to the counter gears ensunng that the larger IS at the front and then place the gear cluster In the gear case Check that there IS end play for the cluster gears between 0 04 mm and 0 12mm and remedy If necessary by fIttIng a tJncker or thInner rear 0 0015 0 0046 washer washer TJnckness of front thrust washer TJnckness of Part No ThIckness 32224 26760 3 91 rear 3 96T thrust washer Part No ThIckness 32226 26760 32227 26760 3 9T 32228 26760 4 32229 26760 4 2T 4 0T 1T the counter shaft WIth a thm temporary rod WhICh wIll permIt the gear cluster to remaIn out of mesh WIth the maIn and dnve shaft gears Replace 101 Drive Gear Shaft The ball Journal beanng should now be dnfted on to the shaft WIth Its spnng geared end POSItIOn the geared end of the dnve shaft In a speed couplIng sleeve put the washer over the bearmg tIghten rIng away from the dummy 3rd and 4th the nut and lock It In pOSItIOn the end of the shaft where the maIn shaft locates then load the needle rollers so that they adhere In pOSlUon Turn the by means of the grease gear casIng to ensure that the counter teeth are below the dnve shaft bearIng housmg FaIlure to do tJns wIll result In damage to both the counter gear and dnve shaft Smear geared grease In ends The dnve shaft can now be dnfted Into poslUon from the clutch Ensure that the sprIng nng reSIsters properly In the race on hOUSIng the gear end case Main Shaft Press the the mam shaft center beanng complete WIth hOUSIng on to the shaft from rear The bearIng must be pressed fIrmly agaInst the shoulder of the center splIned Lightly smear OIl the shaft forward of the beanng and refIt assembly WIth the ynchromzer pomtmg forward washer on to the shaft followed by the baulkmg nng The phos whIch carnes the second speed IS a tIght fIt on the shaft there portIon of the shaft the fIrst speed wheel RefIt the thrust phor It bronze sleeve must be fIrst Immersed In warm OIl and then slId Into pOSItIOn on the shaft second speed wheel over the sleeve then the FIt dnvIng washer and the secood bronze The two sleeves are locked together sleeve WhICh carnes the tJnrd speed wheel by the dnvIng washer Now poSlUon the thIrd gear over Its sleeve Place the sprmg and plunger Into the hole In the maIn shaft and slIde the splmed washer Depress the plunger WIth a pIece of WIre through the hole m the thIrd Then turn the washer for speed and slIde the splIned washer over the plunger the plunger to engage WIth a groove In the washer The gear are now assembled on the maIn 102 shaft TRANSMISSION CASE SPEED 4 l 22 7 111 U 40 16 f1 fIT 26 1 Case transrmSSlOn 2 S y Af 3 BushIng 4 Seal mI 5 lsh1ng speedometer 6 Ass y breather 7 Gasket 8 Washer lock 9 Washer lam extensIOn rear extensIOn rear extension pInion Stud 17 Washer loel 18 Nut 19 Bolt 20 Bolt 21 Washer lock 22 Nut rear extenSlQn 10 Bolt 11 Bolt rubber to Bracket spnng Spnng rear 16 fix rear extenslOD return return 12 Ass Y SlICk 13 Ass y 14 Cover 15 Gasket front plug cover fiX transrmsslon case speedometer 18T speedometer 22 Ass y sleeve speedometer 23 Rmg 24 Reramer 25 plmon sleeve Rmg 0 Plug speedometer plmon 0 Screw 1ST plOwn speedometer pmlOD 0 nng set to dram front to cover Ass y plmon dIp transnusSlon case fix frOIl Ass y pmlOn 26 011 level to fix reverse shaft Washer lock 27 Gasket 28 Bolt 29 Washer lock 103 cover transnusslOn case TRANSMISSION 17 8 ROD FORK 4 SPEED 6 17 Il Ass Ass 1 2 3 y y Cover Rmg cover cover tranSIlUSBIOn 13 tranSlTUB810D 14 15 transnusSlOJl shIft roo O Rod fork 3rd 8 4th speed 4th speed Fork 3rd 25 26 Bracke rod 3rd Ball checlang T 28 4 16 SCrew 5 6 Fork 1st 2nd speed Bracket rod 1st Pi 2nd 17 18 WIre lock Ball checbng 7 8 Rod fork reverse Fork reverse 19 20 Spring poppe Pm mterlock 9 10 reverse Bracket rod Pm fort reverse 21 22 Ball lDterloct Plug weld 11 12 Pm 23 24 Plug weld Plare dua cottel reverse fork speed set sh ft Plug 29 ABs y lever control conrrollever lCnob rollever coo 30 31 Sprmg lever control Cap cover transausluon Boot Sprmg poppe pin Pm control lever pivot Rod fork 1st 8 2nd speed Spnng pln 4th Washer lock Bol rod case 32 Boot rubber 33 Seat lever sprIng Screw stop reverse fork Nut 104 a1n pl TRANSMISSION GEAR 4 SPEED 16 I 16 2021 19 34 11 1817 1 38 I J 35 33 37 5 I 4l 3a 3 I 2 3b 1 2 Ass 18 19 Ball synchronIzer hub Gear mamehaft 3 Shaft reverse gear Screw set reverse geal Washer lock 20 Rmg baulk 21 Washer thrust 22 4 23 Gear 2nd speed Iahmg 9 2nd speed gear Washer thrust malO shaft 3rd Bushmg speed gear Gear 3rd speed reverse y gear Bushmg Gear reverse gear counter 5 Shaft counter 6 Roller needle 4 2 7 Countershaft spacer 8 RIDg retamer needle 9 Washer thrust 10 Washer thrust 25 26 roller 27 cOWlter front counter rear 3 9T Washer thrust counter rear 4 Washer thrust counter rear 4 Washer thrust counter rear 4 On In 28 29 2T 30 31 11 Gear 12 Bearmg mam dnve gear Spacer bearmg 1 6D Rmg snap malO dnve gear 1 6T Rmg snap mam drive gear 1 6Sn Rmg snap mam dnve gear 1 74T Rmg snap malO drive gear 1 77T 32 33 Shaft 37 38 13 4 1 15 16 Hub mam drIve mam synchronizer 17 SprIng synchronIzer hub 34 35 36 2nd speed malO shaft Washer thrust malO 3 mam shaft shaft front Washer thrust froot 4 Washer thrust malO shaft front 4 Peg locklD Spnng Iockmg peg Hub synchro 3rd I 4th speed Rmg baull 3rd I 4th apeed Sleeve synchro 3rd 8r 4th speed Beanng main shaft Ass y retamer mam shaft bearmg Peg Ioclung Gear dnve speedometer 5T Gear drIve speedometer 4T Piece dIstance Key woodruff mam shaft 39 Washer lock 40 Nut malO shaft 41 105 rear BeaTing malO shaft pilot m on IT 36 39 40 iO i a a l 1 H g li III ii iU III n i 1Il 0 hi II IB oe ii a si 1 a t l D4 l a B i 3 I nlll1 e e GO se i flh i tl O s i i i si llo e I 106 Keep for tbe of Oil depth gage fixed level FIG 4 B TRANSMISSION Speed shift gear type 107 FRONT AXLE 109 NUT lock o NUT lt o 0 NUT ASHER speC1al outer ASHER shock f vlt Oe ASS Y e MEMBER f o front suspension PAD rubber front W54466 10600 absurber speClal iii l b OLT BUSHING rubber It e mner rear 54467 1060 0 Ul g a fm NUT WASHER USHING rubbe shock absorber WASHER 0 speclal outer outer speclal SEA T rubbe r 1ront 54468 10600 rear 54469 10600 for front BUSHING rubber suspension member @ WASHER special SEA T front upper spring front 54464 10600 rear 54465 10600 mounbng BAR tenslon front stablhzer NUT WAHER @ speC1al SPRING front SPACER front BUSHING rubber WASHER stablhzer BRACKET special mner stablhzer @ BUSHING stablhzer mounhng eWASHER WASHER Iock rubber WASHER specl outer BUSHING BOLT rubber WASHER @ plam WASHER outer BUSHING rubber special Iock outter BOLT R i o 0 connectlng front stablhzer C EAT Iower front spring FRONT SUSPENSION MEMBER SHOCK ABSORBER 110 DISASSEMBLING THE FRONT HUB DISmantlIng of the front hub fIrst Jack the car untIl the wheel IS clear of the Lower ground and then place blocks under Independent suspensIOn spnng plate the to the blocks the brake shoes Remove the wheel and the screw If the drum appears to The shoe adjusters should be slackened car on bInd on Lever off the hub cap and then extract the splIt pIn from the spIndle nut USIng a box spanner remove the spIndle nut and ease flat washer under the nut clear of the axle thread by carefully USIng a narrow rod lI1to small holes In turn In each SIde of the spIndle and WIth the hub removed outer tappIng the race lIghtly bearIng can tappIng the The be dIsmantled Inner and beanng clear bearIng and 011 out by InsertIng a dnft through the Inner beanng and of the hub seal can then be removed the dnft from by InsertIng the opposIte SIde of the hub When assemblIng the hub the Inner beanng race should first be Inserted Into Pack the hub WIth recommended grease Replace the hub Oil seal over the bearIng Renew the seal If It IS damaged any way the hub Inner The hub be the spmdle Gently tap the hub Into posItIon ehe shoulder the spmdle on agamst Place the spIndle flat washer Into posItIon and screw the nut down fInger tight Spin the whell and examIne the reSIstance TIghten the nut untIl the can now Inner race replaced on bear A slIghtly Increased resistance to the SpInnIng of the wheel WIll then be notIced beanngs are now preloaded and the splIt pIn should be Inserted to lock the nut Tap the hub cap to the hub after packIng the cap WIth grease It IS Important that Replace the brake drum and secure WIth machIne screws the drum IS fully home before thiS screws IS tIghtened and If necessary the drum should be pressed In poslt1on by tIghtenIng two wheel nut RefIt the wheel and nuts are best fInally tIghtened when the car IS off the blocks but readjust the fackIng brake shoes If necessary before the car IS lowered to the ground The o lAND t TYI CAP oad m ltl I N1JT COLLAR froDt OJ pmd1 lSEAIlINC SOL T bub r d beel WA5HER frollt wheel frOl1t wbeel beanlli u FRONT HUB III DRUM kl Q I 0 8 2 0 C 10 ASS V frone JOINT pen ball uprel lon T fu knude NUT J S USHING lower 1 SEAL dUll hnl lower hnlr bu h H FRONT SUSPENSION LINK f 112 INDEPENDENT FRONT The dependent front suspensIOn upper and lower bottom lInkages Between these two WIshbones tween the upper and lower whIch IS known roughly as SUSPENSION the WIshbone type SInce the top to the shape of a WIshbone conform the COIl spnng held under compressIOn be secured to the lower suspensIOn member by four bolts At the sWIvel axle end the upper and lower Imkages are JOInted by the ball JOInts The upper spIndle bracket IS bolted to the front suspenSIon IS IS member WIth caster shIms and the lower of the suspenslon member Change for spIndle the number of Shlms Front SIde only Camber to the lower bracket Caster 0001 029 0016 003l 002 003l 1 0004 0029 1 1 0015 2 2 1 1 2 2 1 Both Camber Camber connected Back SIde 1 Caster IS 1 113 0027 00 l5 027 thIckness of each shIm a Camber adjustIng sJnms Parts No 54542 04100 54543 04100 Standard adjustment 1 m m 54544 04100 Camber 1030 Caster 1030 lmm 2mm 4mm R L dIfference R L dIfference WIthIn 40 WIthIn 40 BALL JOINTS AND BUSHES OF THE SWIVEL AXLE Wear If the sWIvel ball JOInt or wear of the screw bushes of lInks or both by JackIng the front of the car and endeavounng to rock the wheel may be checked by graspIng can opposIte poInts of the tyre In a honzontal posItIon If any movement be detected between the upper and lower sWIvel JOInts and the sWIvel axle as sembly the ball JOInts or the screw bushed mInatIon Front C oil are worn and must be stnpped for exa Spring J Between the upper and lower lInks IS the coIl spnng held under compressIOn IS secured by nuts of the lower and upper ball JOInts of It wJnch Through the center of coIl spnng the telescorp type shock absorber WhICh IS connected to the top sprIng seat and lower lInk wIth nuts of the lower and upper 114 FRONT SUSPENSION us The rubber bearmg bushes or screw bushes may renewmg ExcessIve sIde ways movement m eIther of these of the rubber bushes or screw bushes The screwed bushes or the ball JOInts may of eIther of these parts has been dIsmantled Disassembling ThIS assembly can Remove shock absorber 2 Compress 3 DIsconnect lower ball JOInt and rebound 4 Release the COIl spnng by loosing 5 When the cOIl sprmg fully 6 DIsconnect upper Imk for Removing the Coil bearmgs would denote softemng develop excess free play due to wear best be checked when the suspensIOn 1 IS detenorate and need Suspension Order of Front the coIl sprmg tIme In tool by from lower lInk the nut of tool extended spmdle bumper take out It from suspensloo member If need to mspect Spring A METHOD 1 Unscrew nut ot the shock absorber at the top and take out It from down sIde after unscrew lower flange of It from lower lmk FIt the service tool and screw up the sprIng compressor nut In the absence of the serVIce tool a sUItable tool wIll be reqUIred to release the compressIOn from the coil sprmg Compressmg located under the the COlI sprIng unscrew the 3 nuts of lower ball Jomt WhICh edge of lower lInk Remove these nuts and release the compressIOn from the coIl sprmg loosmg of nut of tool When lf the coIl sprIng IS fully extended 116 take out It by I l t 4 Front Suspens on Assembly Detachment of Shock Suspens Absorber from Detachment of Shock Absorber from Suspens on 117 on vetachment Rebound Bumper Shock Absorber Remove ReleasUag of the Ban Joints LoWer of NutS 118 119 r MeTHOD B Unscrew the four bolts of lower spmdle wJnch IS secured to the suspensIOn member Remove these bolts and release the compressIOn from the coIl sprIng When the lower lmk WIth spIndle can be drIven out Refitnng the COIl Spnng Screw up the screw Use the coIl compressor or Jack against the lower lmk bolts of the lower lInk spindle to the front suspensIOn member and then secure the bolts of the lower spmdle nut or the down Jack screw Set up the shock absorber lower sIde METHOD ReplaCIng Release the compressIon by by loosmg the compresso the double nut of upper sIde and the bolts of C Order of Upper LInk 1 Prepare 2 Jack 3 Remove wheel 4 DIsconnect upper ball JOInt and rebound 5 Detach upper lInk and 6 DIsassemble upper lInk 7 Reassemble upper lInk spIndle and bushIngs to upper lInk of Inforced part carefully follOWIng undermenuoned InstructIon 8 Reassemble whole parts back agaIn 9 Check and to remove front wheel up and support front suspensIOn lower lInk adjust link from suspensIOn member spIndle spmdle front wheel from upper bumper from upper lInk complete to by unscrewIng lInk busJnngs replaCIng re unIt alIgnment InstructIon 1 Don t hold pItch are spIndle tIght agaInst lInk when screwIng In busJnngs Because the spIndle Inner and outer screw of bushIng and lInk sleeve of threads of all same 2 Apply ample 3 Pay careful attensIOn not to damage the ghread when TIghten up busJnng agaInst lInk sleeve by the torque 137 4 grease on to the Inner screw of busJnng and spIndle screwIng 20 of 19 In the kg m busJnng 145 ft lbs Fncuon reSIstance torque between spIndle and kg m 3 6 ft Ibs when assembled busJnng should be WIthIn o 5 5 Adjust the relatIve poslUon of le spmd and lInk 120 as shown In the figure by turnIng ll the spmdle 6 AlIgn 7 Lubncate the dlrectlOn of grease bushIngs mpples wIth grease as shown completely the In unul fIgure extra dust seal grease wIll come out from Center of ball JOint Center of ball JOint i J TIghtenIng Torque Nuts fIXIng upper ball JOInt and rebound l7 4 l8 8 lb ft Bolt Nut flXlng upper lInk spIndle fIXIng lower lInk spIndle Front Wheel 4 7 5 0 4 5 4 0 bumper kgm kgm to 34 the upper lInk IS 2 4 36 2 lb ft 32 5 lb ft 29 AlIgnment DQO I Toe 3 In 1030 Camber 103Q pm mclInatlon camber WIth adjustIng shIm at Caster Onl y of upper 1 8 In 6030 angle caster WIth the same sJnm or TurnIng upper bush by turnIng spIndle fIxmg portlCtl spIndle only upper lInk 1 2 one turn spIndle 3600 One turn 0032 1800 Half turn 0018 l800 00 13 3600 0027 clockwIse 0 mm Caster Kmg Adjust Adjust 2 6 kgm See from back SIde CounterclockwIse See from back SIde 1 f 121 s r A S ON rRONT SUSpEN 122 c l r c1 7 I l II j i I I J c I U o FRONT SUSPENSION B 123 I I torque n btefl f l 1g 2I1 e to PROPELLER SHAFT UNIVERSAL JOINTS JOURNAL PROPELLER SHAFT UNIVERSAL JOINTS a Fore and aft movement of the rear axle and other components IS allowed for by between the front end of the propeller shaft and the rear of the trans slIdIng splIne mISSIOn case beanngs Each unIversal JOInt and tow consIsts yokes 125 of a center spIder four needle roller Back lash of sleeve yoke splIne O 1 mm 0 004 O 5 mm 0 02 In Amendment lImIt of dIttoed backlash In Outer dIameter of unIversal 14 728 Jomt Journal Inner dla of bearIng lace 14 72Smm 0 S80 0 S79m 19 SlS l9 S30mm 0 768 0 769m Number of roller of bearIng 22 for each needle I DIameter x length on dIttoed bearIng needle roller bearIng 2 38 mm x 1O 3mm Less than 0 4 mm O OlS Run out of shaft In torque of companIon TlghtIng flange nuts 15 68 9 65 3 Outer dla Inner dla l8 ft lbs mm Parts No 37000 11600 mm Comp shaft WIth JOInt Length front between 1237 rear mm JOInt Lubrication nIpple Is fItted spIder for the lubncatmg bearIngs An 011 to each center The central 011 cham ber IS connected to the four 011 reserVOIrs the needle roller assemblIes and to bearmgs FIg The needle roller bear are fIlled WIth OIl on mgs OIl from the assembly transmISSIOn LubrIcates the slIdIng splmed JOInt between pro peller shaft and the trans mISSIon Before propeller refIttIng transmISSIon case the the shaft to the splInes smear WIth the 011 1 Propeller shaft 2 UnIversal JOInt nIpple Lubncahng a unwersal Jotnt oj propeller shajt l26 the Rem oval Remove the by takIng rear propeller out the secunng nuts shaft flange from the pInIOn bolts and lock washers flange of the rear axle Place a clean tray under the rear end of the gear box to collect any surplus OIl that may draIn off The operator should now take the weIght of the propeller shaft and then draw the splIned end out of the transmISSIon Dismantling Clean away the paInts from all the snap rIngs and bearmg faces to ensure easy extractIon of the beanngs Remove the snap nngs by pressIng these ends together and pnse out wIth screw drIver If the nng done not come out tap the bearIng face lIghtly to relIeve the pressure agaInst the rIng Hold the splIned end of the shaft a lead or copper hammer when the hand and tap the radIus of the beanng WIll begIn to emerge In one yoke WIth lf dIffIculty IS expenenced use a small bar to tap the beanng from the InsIde takIng care not to damage the race Itself belllg careful not to lose any of the needles Repeat tJns operatIon the other beanng and the splIned yoke can be removed from the spIder The same procedure can be utIlIzed to detach the other spIder from Its yoke 127 EXAMINATION tIE CHECKING FOR WEAR When the In use for a propeller shaft has been long tIme the parts most lIkely to show SIgnS of wear are the bearIng races and the spIder Journals The complete assembly should be renewed If looseness are or observed beanngs or stress marks as no overSIze provIded are that bearIng races are In the yoke trUnIons Any ovahty a It Journals IS lIght essentIal drIve fIt the trunIon bearIng fIttIng of new yokes The straIghtness of the shaft IS determIned by measurIng the offcenter In holes IndIcates the deflectIon of the shaft In rotatIon WIth a dIal gauge applIed both ends If the deflectIon exceeds clearance lImIt Less than 0 4 rom correct or replace the shaft Reassembling See that the drIlled holes In the Journals are cleaned out and fIlled WIth 011 Assemble the needle rollers In the bearIng races and fIll WIth the OIL Should dIffI culty be experIenced In assembly to retaIn the needle rollers tap the In lng beaI 22 pOSItIOn WIth smear Nos a In the walls of the place races Insert the foot nosed dnft smaller In WIth spIder In petroleum Jelly the yoke and dIameter than the hole yoke It IS essentIal that the bearIng races are a lIght dnve fIt In the yoke trun nIons Repeat tJns operatIOn for the other bearIngs The spIder Journal shoulder should be coated wIth shellac pnor to fIttIng the re tamers to ensure a good seal If the JOInt appears to bInd tap lIghtly wIth a wooden mallet wJnch WIll relIve It IS adVIsable to renew any pressure of the beanngs on the end of the Journals cork washers and washer retaIners on speeder Journals usmg a tublar dnft In the Replacing the Shaft Smear the propeller those of transmISSIOn Assembling shaft mam splInes WIth OIl and slIde the splInes WIpe the rear companIon flange and flange yoke faces clean pIlot flange regIsters properly and the Jomt faces bed evenly all lock them In posltlon It IS Into mesh WIth shaft adVIsable to use new to use new lock washers 128 lock In pOSItIOn to ensure that the around and It IS securely adVIsable REAR AXLE G PL tap SPACER oil r SEAL 30loI06OOCOMP CA SEo u 43010 10800 CO Mp CASE STUD ul tOLLER u1 oear p ASS Y PLUG be BEARING er dram ASS V BREATHER REAR AXL E CASE 129 a SHAFT J ule ear u1 u1 boa shalt I b I CJ @ T T ghtenlng torque FUl up grease suffleienUy on the surface of bearing race except other space Press thIS collar by metr The to 5 tons 3 pressure T Ttghtemng c collar change s requued new one when daassembled J FIG 2 COMPONENT 130 OF REAR AXLE torque Axle Shaft Removal Choke all the wheels not bemg operated upon Jack up the car Lower the axle on to the blocks and remove the wheel USIng a screw driver un screw the drum locating screws release the hand brake and tap the drum off WIth tbe mallet If the brake lInIngs should hold the drum when the hand brake leased slack off the brake shoe adjuster a few notches Take off the fIX bolts of the brake dISC and remove the axle shaft as IS re shown WIth SWIng hammer holdIng the wheel studs bolt WIth the rear axle shaft stand draw out the shaft and dISC assembly by gnppIng It outSIde of the dISC FIg Tap To rear axle case FJg 3 Remove of Axle Shaft l31 and Disc Assembly SERVICE SPECIAL TOOLS j DT 4679 SpeCUll Disassembly When FIg Stand and As Hummer the dIfferentIal axle shaft do not replacIng flange forget the aJustIng washer be assembly so as to keep the end and the brake dISC of the axle shafts play Order of Rear Axle Shaft The ratIon rear axle bearIng WIth by pressing Into place the shoulder oLthe Into SWJng of Axle Shaft embly tween the top of the axle hub DT 4678 4 case Brake Di the brake dISC When NomInated In 2 It warner IS ly em assembly IS the axle shaft end replaceable It In one ope should be compressed slum Jetween Its flange and taken Into consIderatIon HYPOId gear 011 No MP90 must be used dlstnct than 320C use MPlt140 prohIbIted VISCOClty As end after InsertIng the part No 43036 04100 The follOWIng poInts must be 1 fIttIng c The to use any other kInds of gear 011 or any OIl of dIfferent same brand must always be selected The standard capacIty of OIl IS about OIl O 93 i The method of feedIng 011 by takmg off the feeler plug at the rear cover of the housmg and sh08ld be done fIll In full up to the Dismounting 1 2 feedIng hole Disassembling of Differential Take off and dram out the gear 011 At the tIme of dIsmountIng the gear Gear Carrier pull out the assembly SIde of propeller shaft carner both left and nght axle shaft WIth the dISC of the brake 3 4 5 Take off the JOInt flange from the Pull off the nuts of the hOUSIng and dIsmount forward the Take off the SIde gear 6 case and bearIng cap the bearmg DIsmount the dIfferentIal SIde As illustrated In FIg 5 of carner and pry with a carner ass y lever the dIfferentIal bearIng wIth the aid of SIde 132 bearIng puller pull out the The beanng bearIng Inner should be 7 puller should be handled WIth care m catchmg the lace WhICh IS hard to hook Both the left and nght arranged separagely DIsmount the dIfferentIal dnve gear screws on the dIfferentIal gear case Loosen them In a 9 dIagonal RIng gear by loosenIng the 8 VIXIng spreadIng out the lock washer consIderIng to keep from the gear bendIng lIne and Usmg of Slde Beanng 5 Flg 8 hedge of beanng Take out the dIfferentIal pInIOn shaft should fIrst be pulled out the Side gear The pInIOn mate by stnkmg out the pInIOn mate shaft lockIng pIn WhICh IS fIxed on the dIfferentIal case from left SIde from the SIde of rIng gear fIxed to the nght before pullIng out the pInIOn SIde gear and the thrust washer The gear as well as the thrust washer should be as well Puller DT 4686 as arranged separately as left and nght front and rear After takIng the out nut of the carner pull out the companIon flange The dnve pInIOn flange wrench should be employed settmg Its four poInts m the holes of flange to keep It from movIng take off the nuts WIth the box wrench 10 11 Take out the dnve pInIOn of gear carner by stnkIng out lIghtly to the back wards the front end at the Side of companIon flange of dnve pInIOn WIth the dnft of soft metal Thus the pInIOn would be taken out together WIth the Inner lace of rear bearIng and roller dIstance pIece and the smm and the 011 seal outer lace and pInIon of front and well as the pmIOn adJustmg smm left In the carner Pull out the rear bearIng Inner race of the dnve pInIon As Illustrated place and the In FIg adaptor the round form WIth the 12 TakIng VIce IS for flxmg out the rear No 6 rear the dnve pInIOn rear beanng mner lace re employed m thIS case The adapter In the should be fIXmg one and the other for takIng off It IS easy to handle In FIg as to make the end of replacer beanng outer race of gear carner The dnve pmlon beanng outer race replacer as Illustrated should be employed In tms case In other upon the stud so screw adJustmg beanng as at the center of carner and set the adapter 6 at the lower fnm of the race Supportmg the tommy bar 1 and screw up tIll the corn 7 closely touches the adapter then screw the WIng nut to take out the rear outer race 133 Too No DT4782 DT4631 ii89 DT Fig 6 134 pull out T 13 To pull body 3 out as the front beanng In FIg Illustrated rear race outer race from the gear carner set the tool 7 pull It out WIth adapter B In the way of 1 2 3 Tommy bar Wmg nut Tool body 4 Cone Adaptor Beanng Fig Dnve for Front Outer Race 7 nlon Outer Race Front and Rear Bearing Replacer 5 Fig 8 Inner Race 135 Replacer FIG 9 SECTION OF Tlghten DIFFERENTIAL torque 01 pinion 14001680 kg CIII 100 AdJuet 120 ft driv CASE 1 nntdrive IIhl1D8 01 jul tl 1i ad pInIon bearilli without ear drive oll lIeal hypold a 1be Pre 10ad for pinion 7 10 kg CIII Q Tightenilli torque nutdill 60 q ca bra cap 490 3 40 It 254 Gear ratio TransmissIon 3 gear Change 4 375 35 8 change Optional 4 III 37 9 4 625 37 8 4 gear 136 1be bearilli Fig 10 137 AX11 RIAl I it o ii Jj i C C C go b t 1 II 1 o i i t l rg REAR 138 AXL E INSPECTION REPAIRING OF DISASSEMBLED PARTS Every parts compressed aIr I Each after they are dIsassembled makmg an InSpectIon before bearIng should be should be cleaned and cleaned and by the adjustment Inspected In every UnIt of ass deCIdIng to re use them y regard wIth the defect and defacement before 2 The axle should be Inspected In of the crack and the defacement of respect The dIf measunng the shake wIth the gauge by holdIng the both end ference over 0 4 mm should be adjusted wIth O 8 m m or replaced The clearance between the end of rear axle case and brake dIsc should be splIne adjusted 3 WIth the Every gear end shIm adjustIng should be Inspected any defects on the surface to suffICIent standard back lash as to If see Part No the they 43036 04100 lockIng can deformatIOn be or condItIon defacement re used damage In found case of or m replacement IS necessary SpecIally the dnve pInIOn and dnve gear should be replaced ever the lockIng condItIon gets worse and the defacement IS because progress fIcult to adjust The perfect about from 2 3 even dnvIng mm to It would WIth proper COndItIon 3 4 cause mm In at the nOIse adjustment In a set when already In later operatIon and be dIf IS made In the surface of dnve pInIOn gear should be dnvIng whIle the gear surface should unloaded to touch from tIp to full surface In an ordInary loaded dnvIng The InspectIon of thIS condItIOn can be made as It IS If It IS hard to Inspect them as It IS do otherWIse by cleamng the both surface WIth the rugs before dIsassemblIng and paInt thInly and evenly WIth the mIxed WIth start the gear surface dnve SIde then turn the pInIon WIth hand to pnnt the on the gear WhIch shows the SItuatIons of conSIderably worn out gear In case of unloaded test It IS perfect that the gears contact for about three quarter at the center of 1 4 of whole gear length from too Intenor up end of the thIn 011 on track of It gear 4 on the pItch lIne Lock the SIde gear WIth pInIOn together WIth respectIve thrust In the gear case of the back lash over O 2 mm and the clearance between the SIde and thrust washer exceeds O 5 mm replace the thrust washer gear The else worn out parts should also be replaced In case The contact when nng gear IS too close to pInIon center lash should be adjusted closely or It gIves much nOIse 5 In case of back Put the dnve gear nng gear on the buoy block as It IS fIxed In the dIf ferentIal gear case and measure WIth the dIal IndIcator Revolve the dnve gear to turn around the dIfferentIal gear case as the block Measure the shake at the rear do not move on the bearIng buoy In SIde of gear by the scale and the shake should be wIthm O 5 mm measured the face and rear face the clean well gear fIttIng mountIng face of It and fIX correctly then there should not be any shakmg 139 ASSEMBLING JUSTMENT AD Assembling Differential Gear 1 Assemble the pInIOn and sIde gear In the dIfferentIal case Every parts should be cleaned and OIled WIth new gear oIl then the pInIOn mate sIde gear and the thrust washer should be assembled by the mentIoned inspectIon InspectIon llnd selectIon before pushIng In the pInIon mate to shaft should be made agaIn m the clearance of between the washer or the backlash AdJustment must be made In case any abnormal IS found Stnke In the pInIOn shaft lockIng pm from the rIght SIde of the case opposIte SIde of dnve gear and must be fIxed by settIng well the stnkmg hole of It after puttIng It to the reqUIred pISton so as the pIn should not loosen 2 FIX the dove gear RIng gear WIth the dIfferentIal case The drIve gear as well as the dnve pInIon should be well Inspected ot they must be replaced as a set whenever the replacement IS reqUIred OtherwIse they would not properly lock after assemblIng IS complected lP mountIng In the case the fIttIng surface must speCIally be cleaned and fIxed WIth 8 set screws as well as lock washer bend the washer WIth sure ness after the dove In tIghtenIng up the screw It gear shake IS adJusted should be damage set and supported by VIce or any other settIng dIagonal lIne WIth a wrench It and screw up In a tools so as whIch fIt not to correctly WIth the head of the screws The standard screwIng torque for thIs IS 25 ft lbs to 30 ft lbs Screw In for sure stnkmg lIghtly the head of screw by one quarter pound hammer 3 Mount the SIde beanng In the dIfferentIal case Press In the both SIde of the USIng the dnft It IS Important m thIs by puttmg the SIde to gIve the bearmg fIXIng WIth the case beaong by to assemble bearIng adJustIng a proper preload shrrn In carner Ftg 140 12 ASSEMBLING JUSTMENT AD BY GEAR CARRIER It IS to decIde the by assemblIng of gear whIch IS very Important accordance wIth the exact sample adJustment y and should be carned the manufacturer In an rear shown axle ASS Y ass In The constructIon and mechanIsm must well be comprehended refernng to 21 and the adJustment repaInng exactly accordmg to the condItIon of practIcal use based on the adJustment by exact calculatIOn FIg A 19 The Preparation for Mounting the Drive Pinion in the Gear Carrier I If the dnve gear dnve pInIon and bearIng are are as a result of dIsassemblIng and InspectIOn to the reused they as they should be assembled order of dIsassemblIng at the prevIOus CondItIOn of adjustIng shIm any Item should be replaced or reqUIred to reuse even If any Item IS worn out prepare the varIOUS shIm as mentIoned later because the po SItIon of dnve pInIon to be fIxed WIth carner must be adJusted by the ad m on In case Justmg shIm between the 2 There an are carner and pInIOn rear beanng outer race few numbers wIth 0 or beSIdes set number marked on the tIp head surface of drIve pInIOn electrIC pen Peg 13 Adjustment of 141 mon Height by They show the 0 025 mm manufacturIng error In a to decIde the thIckness of standard posltlon center as shown In The standard FIg 13 17 at the UnIt of 0 001 In fIgure adjustIng pInIOn heIght shIm for IS 51 0 adJustment mm If the fIgure IS dIffIcult to dISCrImInate due to the corrOSIon the oXIdIze substance on the surface by a some what narrow wIth care not to scrape off even the mark AdJust 3 of from axle scrape off grInd stone to the dIreCtIOn of on arrow In accordance wIth the PInIon mark The thIckness of dnve pInIon adJustIng shIm are arranged as follOWIng The use of the adJustIng shIm wIll be explaIned In the follOWIng paragraph adJustment SUPPOSIng the dnve gear and the dnve pInIOn were re placed as a new set and the heIght of dnve pInIOn prevIOusly used was nght prepare the shIm of thIckness WhICh equals to the dIfference of fIgures on the new and thIs pInIOn Deduct the prevIOusly used shIm In case It IS plus Increase In case of mInUS and have the gen ral Idea of reqUIred thIckness of the shIm for assemblIng to prepare of Parts Name Dnve pInIon shIm Part No ThIckness 38153 25660 adJustIng 0 75 1 0 In 1 0 38154 25660 O 25 mm 0 010 In 2 38155 25660 0 125 2 1 2 1 mm 0 030 0 005 38156 25660 0 075 0 003 It IS In the measurement of pInIOn tIon of defacement on the carner conSIderatIon Fixing 1 mm In mm In convenIent to Inspect the condItIon before mentIoned later B Standard Leaf No and though It wIll be adjustment Dnve pInIOn In thIS case dIsassemblIng In a way as BeSIdes the condI heIght beanng must be taken Into the pInIon explaIned In detaIl later of Drive Pinion bearIng outer race should be mounted In the carner after InsertIng the properly selected adjustIng shIm as pre VIOusly mentIOned between the carner and bearIng race mount the outer race by the outer race re speCIal tool of drIve pInICIl front rear rear beanng placer For adjustment of preVIously mentIoned pInIOn heIght the shIm at the SIde of thIS outer race IS Increased or decreased and the race also must be taken off In each tIme for thIS adJustment therefore the tools must be handled properly to aVOId such a SItuatIon as to make the bearIng hole of carner In on oval Refernng to FIg 8 for handlmg method of rear tool set the adaptor the small hole of bearIng nng A on the coni 7 to guIde the body of tool at put the rear outer race on the com 8 surfaces InSIde at the tIp end of screw and put the splIt carner 142 as the adaptor mSIde race At the same tIll the tIme 2 and supportmg It by the bar twIst up the to the setted pOSItIOn then screw 7 adaptor up the WIng the 2 so as the race be housed properly at the setted pOSI tIon corn race come Mount the front beanng outer race m the carner For mountIng the front outer race take off at fIrst the adapter A from the front end of the carner and fIX the tool at the side of stud m oppo SIte SIde tIghten the screw as to be the center of carner as shown FIg 14 then mount It by USIng as In a adaptor C way of mountmg the rear outer race The 3 race IS Mount the rear to be taken off unless scarcely necessary bearIng mner damaged race and roller to the dnve pInIOn By usmg the round adapter attached to the dnve pInIOn rear beanng Inner race replacer whIch was employed at dIsassemblmg press In the dnve pInIon ThIS mIght SIng m dnft 4 as by the well be done use of a In pres certaIn Mount the dnve pInIOn In the carner and adJust by measunng the pOSItIOn The pInIOn heIght must be adjusted the preVIOUS para FIg 14 graph by mountmg temperarIly the pInIon In the carner and the bearIng On the other hand the beanng of dnve pInIon be gIven a regular preload should be newly OIled after the pInIOn IS Inserted from the InSIde of the as mentIoned In the Inserted end of pInIOn should be locked WIth front bearIng corn tIghtened up by the pillIon nut fIXIng WIth the companIon flange ull the regular revolVIng torque IS requIred As thIS IS not yet at the fInal as the spacer dIstance pIece bearIng adJustIng shIm and carner and semblIng 011 seal beanng are not mounted At the tIme of InsertIng the front beanng as pushIng In the mner race by pullIng out the dnve pInIOn from the rear SIde of the carner Put the rear SIde of the carner downward and set the tool under It then the end surface of dnve pInIon press In the beanng by USIng supportIng The operatIon would be eaSIer Inserter as shown In the dnft beanng TIghten preload 7 10 kg by USIng the dnve pInIon front Inner race use of up the pInIOn nut by turnIng It slowly WIth hands WIth the the bearIng preload at gauge as FIg 15 to the degree that support cm When the dnve pInIon IS mounted IS necessary to measure the IS hIgher or the In heIght of lower than the standard prevIously mentIQIled arrangement gauge The standard beanng heIght of the pInIOn fIxed WIth the IS 51 0 carner 143 condItIon It surface of the pInIOn whether It Make use of the specIal dnve pInIon rear mm from the bottom of the SIde The fIXIng pOSItIOn can be measured by settIng an arc of cIrcle on both SIdes of arrangement gauge at the posmon of SIde beanng and Insert the thIckness gauge m the clearance between the tIp of gauge bar and the pInIon such as to push m by scrapmg of the carner m dIagonal otherwIse preload and the pmIon heIght of the beanng would come out of order and tend to cause an unexpected trouble In future i r Fg 5 15 The formal adJustment of the dnve After pInIon bearIng and preload the fIXIng pOSItIon of dnve pInIon IS deCIded as mentIoned In the pre VIOUS paragraph take off the pmIoo nut companIon flange to mount agaIn the dnve pInIOn bearIng spacer dIstance pIece and nut up the nut as FIg 16 by USIng the torque wrench at the re gular torque of 100 120 ft per Ibs The preload supportedly the bear TIghten Ing In thIS case IS dIfferent accord Ing to the condmon of the bearIng adJustIng shIm Inserted Flg 16 144 The more axle of the shIm Inserted much the play of pInIon to the dIreCtIOn of Increased IS The less of the shIm Inserted the more the beanng tIghtened by the pre mentIoned nuts and cause It to be burned If left and turned as It IS Therefore for readjustment of the bearIng preload In thIS case It must vIOusly be adJusted by decreaSIng the number of four kInds of ad follOWIng hst and measunng WIth the use of dnve pInIon bearIng preload gauge as FIg 15 so as to make the revolv torque of pInIon at 7 10 kg cm If there should not by any error In the JustIng shIm the IncreasIng or shown In the as Ing pInIOn WIth the head mark at 0 and the clearance should be sealed at 0 2mm 0 008 In by the feeler gauge thus pInIOn IS regarded as at the correct posltlon because the heIght of the gauge the standard SIze 51 0 mm Ftg IS made shorter for O 2 mm than 17 Remarks When measunng the heIght of the pInIOn head set the semI CIrcular SIde portIons of the gauge on the SIde bearIng seats Insert a feeler gauge Into the clearance between the tIp of the gauge center rod and the pInIOn head and adJust the pInIOn The gauge rod IS made O 2 mm 8 1000 In shorter than the standard measurement 5 I mm Therefore adJustment IS made by selectIng a feeler gauge In accord ance WIth the plus or mInUS valve marked on the pInIon head adjust the pInIOn heIght take off the dnve pInIOn as well as pInIOn rear beanng outer race from the carner to adJust by In creasing or decreaSIng the number of the adjustIng shIm In other words read the mark on the head of the dnve pInIOn before adJustmg by In 110 5093 creasIng or decreaSIng the number of dnve pInIon adJustmg shIm If It IS necessary to 6 to Insert the feeler gauge whIch 145 IS deducted for the number of mark from O 008 in O 008 m m case of mmus sIde added for the number of mark to of plus mark shows m case For mstance the 2 adJust the pOSItIon of dnve pInIon by the number of shIm so as to make the clearance at O 008 m 0 002 m 0 001 m It IS necessary to give the bearIng a rIght pre load At the tIme of pushIng the outer race mto the carner It must be deductmg done m a way otherwIse when the old bearmg rIght IS to be used agaIn In assemblIng the should be made at the lower torque than standard In accord wIth the COndItIOnS of practIcal use so as not to gIVe It an over pre SpeCIally adjustment ance load 6 When the former adjustment of preload of the beanng IS completed as the preVIOUS paragraph Inspect the pInIOO heIght agaIn Unless any thIng wrong IS found loosen the pInIon nut take off the flange Insert the new 011 seal In the rear of the carner and formerly fIX the flange In washer and pInIOO nut The nut should be tIghtened up at the standard In case the cotter pIn hole fItted the adjustment should be torque made not C by tIghtenIng the nut but by fIllIng Mounting the Differential Gear Ass y in 1 gear Mount the complete UnIt of dIfferentIal There IS a engrayed mark cap be fItted WIth mark on the leg of bearmg bearmg Important to note that the fIXIng part the washer Carrier In the carner and fIX the the SIde of cap WhICh should housmg when mountmg It IS on of the cap of each beanng housmg fInIshed up The dIfferentIal gear case IS machInerly IS Inserted by the beanng adJustmg shIm WIth bearmg as explamed m 3 of A and by hOUSIng m the beanng The regular preload housmg of carner the bearIng must be gIven ths screwmg torque of the fIXIng nut of the SIde bearmg cap IS at 3S 40ft lbs and should be equally locked WIth fIXIng cotter pIn So far only the dIfferentIal UnIt IS mounted and the dnve gear IS locked WIth the drive pInIon therefore the followmg adjustment must be made the gear back lash to acqUIre the regular SIde beanng preload the SIde 2 back lash bearIng preload nght preload on the SIde bearIng of dIfferentIal gear case and In pressIng the beanng In the dIfferentIal case adjust by InsertIng InSIde the bearIng adJustIng shIm of thIckness calculated In accordance WIth the follOWIng method of computatIon There IS a marked numberal of adjustIng baSIS on the beanng hOUSIng of The numberalIs the manufacturmg the gear carner and dIfferentIal case Adjustment of SIde To gIve the erro D In in a unIt of 1 1000 In agamst each standard measurement of A B C FIg the WIdth of the SIde beanng on left and nght use the stand In thIS case ard gauge 20 0 mm thIckness and dial gauge on a flat board WIth the aId of block for about 2 5 kg weIght place the load on the bearIng To measure to acqUIre the steady fIgures minus SIde agaInst the each standard measurement F XlO and assume each of them as E the unIt baSIS of l l for the measured WIdth IS When Take the left side bearmg example 0 008 m 19 8 mm It IS 0 2 mm agaInst the standard measurement and the E IS by excludmg the mInUS sign 0 008 In Calculate the of 20 0 error on mm on 146 The thIckness of the shIm IS acquIred by applYIng the numerals to the folloWIng method of computanon It may as well be assembled by USIng the shIm of thIckness whIch IS In accord WIth above method of computanon The left and nght beanng must be well pressed In otherw1se the preload changes ance Measure the backlash of the dnve pIMon nng gear as FIg IndIcator to make sure that It IS WIthIn 0 1 mm 0 2 mm 0 004 much move to left by takIng off the nght shIm for adjustment 20 by USIng the dIal 0 008 If It 1S I I fl J I 0 il J I 8 J l I I I X l I i i I I D c I L FIg TIuckness of ShIm Left SIde Tl Example A 8 on Left SIde lCght l 2 E 8 0 2 F lO T1 A 0 0 001 0 008 C O 07 0002 C 1 B mmjO 0 1 D 3 0 02S mm 0 25 2 A ThIckness of ShIm SIde RIght on T2 B 0 B 0 F S1de 6 0 lS0 of ca1culanon RIght T2 1 I 18 A 0tDE 7 Left T I E 3 F 10 6 10 mm x 20 0 5 mm 7 0 02S mm xIS 0 375 mm 6 E 0 002 mm 0 025 7 8 8 mm 02S T 2 0 007 B 0 O 002 0 015 O 016 TIuckness of left SIde shIm 0 006 TIuckness of 147 F 0 003 0 006 nght O OlO SIde shIm The numeral marked by the electnc pen on the sIde of the dnve gear shows that For example b 6 means of the recommended back lash besIded the set number the back lash of 0 006 In 0 025 mm x 6 O 15 mm Fig After the 1 DIal gauge 2 S T D 3 WeIght 4 The gauge thIckness 20 mm block beanng measured 19 Operauon Fig 20 Measurement of 148 h for the Dnve Backla mon RIng Gear ne If ne of each of 80 ol ae 6 Y JI a or calculated f ro ae we left k alu of n ngb d ron prnlOOd oun beeau from above he duck pro nroe of we he on a ron 0 00 bean non 0 001 c cred be h he nu duc m accordh we lum of prelo beaT he 0 pracncal ven method of computatlon I t tl t 0 iI 4 J t fI tJt J 1 1 p 1 r I 1tt t r Flg 21 UStng the Dtfferenttal 149 Stde Beanng Cap Gauge Saae ar to the Chaa lip ll of A 350 25 torque T1ghteni q 420 30 ft lb Back laab 0 1 0 2 17 1 FIG 22 55 CARRIER 150 Thus the meter of the FIg 21 o 002 adjustment IS completed By way of precaunon measure Wlth rmchro large SIze the L measurement whIch IS wIthIn 173 40 173 55 mm as SerVIce No 0 05 In mm tool DT 468S If It IS left and InSUfficIent nght In thIs case employed for scalIng add an addInonal shIm of the saId rmchrometer gauge should be The shake of the back of dnve gear whIch has been fixed WIth the be measured by dIal IndIcator to confirm that IS wIthIn 0 05 mm specIal Mountin the Gear Carrier Ass InterIor of the axle The carner hOUSIng packIng should y on the Rear Axle should be cleaned well also be replaced WIth new Mount the gear carner ass y WIthout mIstakIng and through 8 studs then fix WIth the lock washer In a dIagonal lIne so as not to cause the OIl leaks It IS mounted on the vehIcle 151 carner 21 or should Housing one upper SIde WIth down slde The nut must be tIghtened nut feed the gear 011 ImmedIately be feed 011 No 90 should deslgnated hypoId gear Feed the 011 nllIt comes up to the down SIde of the feedIng hole When the Its FIg The 011 of It 11 a z i nng ring 10610 hornb1ac 1 510horn k yelow horn 4842 AD 4842 AD P P WHE L b1ackl ste ring bhloacrnk yheolronwl STERING WHE L RING RING Y Y Y ASS ASS ASS 1060 1060 1 50 48 0 4842 4842 0 0 shel signal shel SCREW SCREW turn sW1tch to fix SHEL SHEL SHEL 1 yelow SET black SET SET black rmg to 1 10610 30614 3 steng steng 10651 1 5 0 tee 10851 4832 48327 48327 s 7 CJ1 fix to 3 STEERING STEERING Type of gear Cam and Lever Gear RatIo 14 8 Adjustment AdJusung DIameter of steerIng wheel 405 Tunung screw and nut mm 5 000 cIrcle 1 mm The steermg tube revolves a cam whIch engages In turn WIth a taper peg fIt to a rocker shaft WIthIn roller bearIng ThIs assembly IS enclosed In an 011 tIght caSIng whIch carnes two ball beanngs at eIther end of the cam ted When the steenng wheelIS turned the tube revolves the cam the taper peg to remove over a predeternuned arc thus causes shaft Its deSIred motIon connected to the rocker shaft IS a WhICh gIving In turn the rocker steenng IS a steerIng The steermg IS of the that lInks up WIth the steenng lInkage cross rod lever three cross rod connectIng the SIde and cross rod lever to the gear arm on the Idler shaft Two shorter SIde rod one on eIther SIde connect the steenng gear arm to the steenng gear and Idler arms respectIvely SIde Side Cross Rods The SIde and cross rods are held In poslUon by a castllated nut and spht pIn at each end To removt the rod the rod and then spht pIn and release the nut at each end of the rods clear of the levers to whIch they are con tap WIthdraw the carefully nected Removing These the are Steering Gear Arm secured to the steenng gear rocker shaft and Idler shaft respec Normaly these levers need not be removed for tIvely by a nut and splIt pIn each The only occaSIOn reqUIrIng theIr removal would be any general maIntenance when damage has occurred under WhICh CIrcumstances the steerIng box or Idler should also be remove for InspectIon when the arm concerned can be wIthdrawn the steerIng gear box or Idler has been removed to the work bench The gear arm should be WIth drawn from the shaft concerned USIng a SUItable once extractor The gear arm must not be hammered from Its shaft 153 Flg 1 1 Steenng Gear Flg Removing the Idler 1 2 Steenng Gear After the sIde and cross rods dIsconnected the Idler can be detached from the It IS secured by two bolts to the front body suspentIOn member HoldIng the Idler body on the bench and take off rubber cover Unscrew the Idler shaft out of the body Steering Gear Housing Removal RemOVIng lock the horn nng then dIsconnect assembly from the steenng wheel unscrew hIgher up the column Jacket from the hOUSIng the column FIrst dIsconnect ball stud nut and draw out from the end of steenng gear arm Unscrew the bolts secured to front suspensIOn member Thus the steerrng 154 w I 5 J q in J U ct 4O 0 1 J l u 0 J lJ gg go 0 2 U cz 6 1 o aill o w U 5 1 rn 1 t 4O Z 1 II U 1 lI ol J Sl tIl 0 d 00 00 00 ci r 00 l 2 2 1 J f u 0 J J 0 U in 155 Steenng Gear HOUSIng Removal RemovIng the horn rIng assembly from the steerIng wheel unscrew the column then dIsconnect hIgher up the column Jacket from the housmg FIrst dIsconnect ball stud nut and draw out from the end of steerIng gear arm Unscrew the bolts secured to front member Thus the steerIng suspensIOn lock NUT COLLAR WIRE ns wbeel I WASHER Jock 0480S0 10600 COMP COLUMN S050 10800 COMP COLUMN eket Jacket 48052 10650 ARM III rk 80S2 enns lurC yellow I lane 48052 10651 ARM 6J kM S sure yell 108S0 ARM Il 48052 80 U l DS seal ycllow 1 48052 10852 ARM n seal yellow lhoe o fu 1111 WASHER t ASS Y BEARING m ASS Y ASS y STUD HOUSING HOUSING hOVIIDS te front front I 1 Fig 3 STEERING GEAR 156 2 ItDC DO r tie 0 front y hae L R hOUSIng assembly gear should be removed from poslUon Disassembly SupportIng the housmg on the sUItable bench leavmg the rocker shaft free Remove the rocker shaft cover after extracllng the four setscrews Tapped out the rocker shaft usmg a soft metal dnft A ball roller IS sItuated WIthIn needle rollers fitted m the ball plug of the shaft and care should be exercIsed that the rollers do not fall out It a ball roller IS removed moved If showmg an apprecIable It should only be re DIsconnect the three nuts of the WIth shIms amount of wear front cover m posIuon and release thIs Take off column Jacket way cover The complete unIt should now be up ended wIth the steenng housmg uppermost By bumpmg the end of the worm gear agaInst a wooden block tap out on the floor the worm gear WIth rear beanng WIll be dIsplaced The complete Inner assembly can then be WIthdrawn from the housmg through the open end of It Then WIth the steenng wheel held to prevent If from turnIng endeavour to turn the SIde rod and gear arm Should the steenng wheel have a tendency to 11ft It may be assumed that there IS excess end play In the worm gear Assembling housmg IS merely a reversal of the dIsmantlmg pro shIms should be fitted behInd the front cover so that adjustIng end play on the column but at the same tIme they should not be pre Reassembly of the gear cedure however there IS no loaded otherwIse damage to the ball races may ensue When the rocker shaft IS dropped Into posIuon ensure that It IS a good fIt m ItS hOUSIng and that the OIl seal at the rear cover of the housmg IS makIng good contact Before refitung the rear and front Ensure that all Jomt are 011 ught Adjusting The cover screw back the adjustmg nut the Gear adjustIng screw m the cover should be slackened and unscrewIng the screw a few turns Then the adJustmg screw should be down untIl there by releasmg IS no the lock nut free movement m the straIght ahead pOSItIon of the gear and adJustment secured by lock nut Fmal adjustment should be made once the gear has been reassembled to the housmg It should be noted that as wear In use IS normally greater In the straIght ahead pOSItIOn than on lock prOVISIOn IS made for thIs In the deSIgn of the cam and It WIll be found that there IS a slIght end play towards each lock The steenng gear hOUSIng should be filled WIth recommended gear OIl through the filler plug SItuated at the rocker shaft cover and then a final test made to en sure that the movement IS free from lock Steering Faults Loose steerIng IS Invariably attributed end play of the worm gear through steenng column whIch can be rectIfied by the removal of shImes located behInd To check for thIs end play the gear hOUSIng front cover as already mentIoned dIsconnect ball JOInt stud at the end of cross rod from gear steenng partly to the nght or left lock 157 arm and turn the BRAKE GENERAL DATA Type Foot brake HydraulIc Hand brake MechanIcal expansion 2 shoes for 4 wheels mternal expansIOn rear wheels braked Lmmg Width x TIuckness x 40 Length x 4 5 x 215 Same for Front mm Rear Area of surface Brake drum dIa Master cm2 Front cylInder 35 Rear cylInder 228 6 cm 2 22 mm Same for Front bore Inner dIa Wheel Rear Front 22 bore Inner dIa Front wheels 25 40 Rear wheels 23 81 Fig 1 Front Brake brake dJsc 158 Flange mm mm Rear 2 Fzg 2 Front Brake Out Szde are hydraulIcally operated by foot pedal applIcauon cylInder In WhICh the hydraulIc pressure of the brake operaung flUId IS ongmated As supply tank cast Integrally WIth the master cylInder provIdes a reserVOIr by WhICh the flUId IS replemshed and a pIpe lIne consIsung of tube fleXlble hose and umon Inter connected the master cylInder and wheel cylIn The brake all four wheels on d1recdy coupled to a master ders IS The pressure generated In the master cylInder by applIcatIon WIth the foot pedal transrmtted WIth the equal and undImImshed force to all wheel cylInders SImul taneously ThIS moves dUCIng pl1ed at the pIstons out wards WhICh equalIsatIOn and effiCIency automauc the pedal When the pedal IS In In turn expand the brake shoe thus pro to the effort sup dIrect proporuon released the brake shoe spnng return the shoe whIch then re cylmder pIstons and therefore the flUId back Into the pIpe lInes and An mdependent mechamcal lInkage actuated by a hand brake master cylInder mounted dnvers seat SIde ThIS IS posItIOned on the nght hand SIde of seat If the car has nght hand steermg and on the left hand SIde If It has left hand steenng Operated the rear wheels by mechamcal expanders attached to rear wheel cylInder turn the wheel bodIes FRONT BRAKE The front brakes are constructed by the two leadIng system WIth each two wheel cylInder allowed to slIde and centralIze automatIcally dunng the actual whIch dIstnbutes the brakIng force strongly over the lImng area brakIng operauon the fnc ensunng hIgh effiCIency the brake d1sc caused by adJuster hOUSIng agaInst The shoes are uon of the brake lImngs of front and rear shoes ana 159 even lInmg wear i l p z q x O d fItJ Ul 0 nt if ilL o c 3 x Sj 2 ct U 0 o s u 1l Z u f r to III @ 2 t t u c n ui tJ fO J J Ii u o V z 0 P c 0 VJ 0 l 100 u FIG 4 ADJUSTI NG OF 161 FRONT BRAKE L lJ Q IOSe 140 1 Ot lo 1050 41020 OJO Pio ii wsi 1 t cyl 51 Fore f L 0n 5ect1 BRAKE FRONT 5 on FIG EeSt1 Q SL ectOn 3 dll ng Rotau UOl B dl of 0 l op l PiN rod pull SPRiNG cros off LlNKAGE C l j to BRAKE HAND 6 FlG C1CJ o 0 SectIon A B B SectIon 1055 AdJustment of brake shoe ThIS precaution should be taken to elIminate the possIbIlIty of brake shoe drag due to mlB adJusted parking bolt to screw screw 2 brakes dIrection tightly 3 notches until the wheel drum turns Just free from the shoe FIG 7 Turn the and then turn back REAR BRAKE NO 164 I as IJf 23a N I A FIG S REAR BRAKE NO 2 165 Adjustment for the front brake shoe IS by means of the teeth of the gear WhICh located at the lower posItton of the brake dIsc Remove the dust cover of the urn servo housmg Tap the adjuster hOUSIng and Insert a screw drIver through adJusttng hole and engage the teeth on the wheel Turn the drum adJusttng nut down dIrectIon untIl the shoe becomes locked on the brake then turn back It upward dIrectIon unttll the shoes becomes Just free notches RJ AR BRAKES The the brake shoe are not fixed but are allowed to slIde and centrallse WIth effect as In the front brake They are hydrauhcally operated by wheel and Independent hand brake mechamsm rear same cyhnder WASHER ASS Y nYIotn BRACKET SPRING hand brake contro retainer WASHER lOCk to BOLT SPRING fn hand brake bracket retainer ASS Y LEVER hand brake control SPRING nalI tr fake NAIL ratchet hand brake control WASHER nyIon PIr clev18 YOKE hand brake WASHER control nylon p Fig 9 Hand Brake Control 166 COMP hand rEM S brake control Flg Adjustment for the 10 AdJudhng Brake Shoe brake shoes IS by means of the screw bolt whIch TIns precauuon should be t lken to ehrm nate the possIbIhty of brake shoe lg drl due to rms adJusted parkIng brakes Turn the bolt to screw dIrecuon ughtly and then turn back screw 2 3 notches located at rear the outsIde of brake dIsc untIl the wheel drum turns Just free from the shoe 167 tlABCO B tlABCOl ng t TOK1C01 SlUM dlu ble d A d Ung SCREW T01 CO ungSIUM tel l B ung b1e de dlu y ASS CAP SIIlM u d H hoe tet lte l bt u r SIUM INOCYER weDGe OUSING Ildlu A wbe l TAP ET b U d dlu u N d TAP ET lr b BRAKE her OE Sl blake yG REAR Y ASS teat y ASS shoe lo bte l t1 de feto tlABCO ICO SPRlt4G adlu ng B TO tetutn t B du G t du COVER de SPRn cyhnder COvER 10 CO Ir NABCO T01 b e e EVER EVER y S AS y b OE Sl ntlG u y ASS ASS a G f HAND BRAKE The hand brake operates on the rear wheels only and IS applIed by a pull up The cable from the control IS type of lever sItuated along sIde the drIver s seat The hand brake attached to the toggle lever connected WIth the rear brake dIsc IS set when leaVIng the works and should not requIre any attennon under normal mamtenance Only when a complete overhaul IS necessary should the hand brake lInkage requIre resetting lmkage When thIs IS correct the rear shoes should be locked to the drums the hand brake control Just slIghtly applIed and the WIre rope set WIth the slackness Just removed by means of a nut at the center rod of the equalIzer drag lInk Ftg 12 AdJusttng Nut MASTER CYLINDER ThIs IS conSIsts of an WIth cap The Inner ondery cap assembly alloy body IS return spnng WIth made of the a push polIshed rod fimshed bore reserVOIr stoper plate nng pIston let out valve and check valve seat 169 and sec The open end of tlle cylInder the Brake Master dIsassemblIng protected by CylInder IS rubber boot a shown as FIg Olsconnect the pressure pIpe umon from the cylInder and remove the secunng bolts when the master cylInder and flUId reservOIr may withdrawn complete from Pull back the rubber boot and the car Remove the filler cap and dram out flUid The push rod assembly remove the stopper nng WIth a paIr of long nosed plIers can then be removed When the push rod has been removed the pIston WIth the the pIston assembly complete secondary cap WIll be exposed therefore remove small parts other can be out The assembly separated by takIng Exarmne all parts especIally the rubber prImary cap for wear or dIstortIon and replace WIth new parts where necessary l s CLUTCH BRAKE GASKET bller SET CAP cap f1llet s SPRING return brake SPACER plstOll cup pedal 11 PISTON brake CUP pIston NlUJASHER I ASS 0 1 Y imaal1erl ASS Y VALVE l S secondary COVER dust us ROD Q t s aJP l SPRING valve plStOll prnnary SEAT valve 1 i 1 NUT WASHER lock BOLT RING snap NU llUSHING pedal fulcrum STOPPER e pedal bral f 0 PIN cleVIS brake PIN fulcrum SLEEVE pedal shaft master cyl ASS Y PEDAL brake FIg 13 Brake Master Cyltnder BleedlDg the Hydraulic System BleedIng IS dIsconnected of the hydraulIc system has been necessary any time a portIon If the level of the brake flUId has been allowed to fall so low that or 170 i jl or r 17 I rr WaSh Puley Nut N Termlna Washer l Termlna Washer bolt J Sethng t r waSh l 1 G Ir l fTI02 l00 3 J UJ c D fI Beartng L Jt r ALTERNATOR I Alternator MItsubIShI OenkI Co Model AC300 12AIR NomInal output 12V Constant SuccessiVe 300W SIde Pole ground Constant revolutIon 2 500 r p m No load 1 000 r p m down 14V 2 500 r p m 14V 24 SA up normal temp 2 500 r p m 14V 21 SA up Output Pulley mInlmum revolutlon current MItsubIShI DenkI Co Regulator 23500 RL Type TIrnll type leaf spnng Element Constant Constant 3 contact pOInt type PrImary Adjust valve 14 voltage relay 14 15V 4000rp Load Battery Pilot lamp relay battery charged 3 contact Put off 4 2 In full Put voltage on o 5 5 2V tl 2c 1 174 lamp relay SIde 15V Battery reSIStIng point type 1 12200 4000rp m load 21 SA approx Use PIlot Secondary SIde Dynamo revolutIon NOTE temp A2 Model voltage relay hIgh 1 73 1 ratIo normal temp voltage 3V m JOR MA COMPONENTS OF ALTERNATOR 1 2310061200 23500 12200 Q ty Part Name Part No Alternator ass Regulator Nut 17rjJ Pulley Through bolt ass 1 y 1 y I 2 23153 12210 23151 12210 3 23131 12210 4 23118 12210 5 6 23102 12210 23120 12210 7 8 23108 12210 23129 12210 9 23230 12210 10 23183 12210 23133 12210 Rear Brush holder 1 23135 12210 23127 12211 Brush 2 I 11 12 Front cover Stator ass y 1 4 ass y ass I 1 y set slIp nng 1 I cover cover WIth 1 Ball beanng DIode set Rear 1 1 Ball beanng Rotor Remarks ode wIth dIode brush brush sprIng ball beanng each holder etc termInal 21067 10800 I Fun belt 175 GENERATOR Construction and Feature DIfferent from the DC generator the AC generator turns the magnetIc pole and fixes the armature makIng it generates 3 phase alternate current and rectI fies all waves WIth the sIlIcon dIOde each three that are buIlt wIthIn and takes out as dIrect current F Terminal A 1 Fig D Rotor 1 ass Sectwnal VteW @ DIOde @ Front y 00 Pulley WIth fan @ Starter @ Rear of Dynamo set @Brush cover @Beanng Brush holder armature I cover cover @ Diode @ Brush cover The sealed ball beanngs @ @ are used to support the rotor Clearance between the brush and brush holder IS also made so as to prevent It from dust Thus the AC generatOr WIll Increase rmlage WIthout maIntenance Each 3 dIodes are pressed In the rear cover and the dIode base respectIvely iJ Field core jField segment @Fleld @ Shaft Fig 1 1 Sechanal V ew of Rotor 176 r COli The clIp rIng pressed In the shaft is soldered at both ends of the field COIl to pass magneuc current The pole of rotor makes out the magneuc CIrCUIt as shown In FIg 1 3 and all the poles are magnetIzed by doughnut COIL sw I I 1 QlI 8 Ql tll t 01 t AI J I 1 I 1 ffil I J FIg 1 3 Magnettc CIrCUIt The armature fIes all It IS of a three FIg phase 1 4 ConnectIon wlthm Dynamo type and the SIlIcon dIode Y connectIon reCtI the neutral pOInt and adds voltage haVIng conducted 3 rectIficatIon In the CIrCUIt of relay and controls the voltage COIl of waves pulls out phase half wave the pIlot lamp relay Regulator 17 IG CJ 7 e I j I 01ll U I I I I l I I I 0 I a I lco I tlIl L Dynamo Ftg 1 1 5 Regulator L Q j 1 I I oj 18 Charge pllot lamp J Chnrglng System FIg 1 6 OutSIde Connection In the arrow When the IgnItIOn SWItch IS put on the battery current flows brush slIp nng field marked dIrecOon passIng through the dynamo E termInal and lG termInal F termInal F termInal relay COIL slIp nng brush dynamo stand up only the to In dIfficult for filed CIrCUIt It dynamo and the completes IS necessary reSIdual magnetIsm of the field core so that magneozatIon started unol voltage nses to SUIt charging after the engine has add to It IS so ThIs IS because the dIode IS used and when the voltage to does not flow through shows and current up low large proporuonal reSIstanCe revoluoon the makes field COIl unless hIgh the dynamo very by 177 DISASSEMBL Y AND ASSEM BLY A Disassembl The dynamo 18 wsassembled In the folloWIng order a completed 23100 61200 parenthesIZed IS the part The The number for SP31O 2 1 Flg b i t 1 1 jI itu ll I l 1 r J j l 1t Flg Remove the brush 23107 12210 brush 2 ea and cover pull 23135 off the 0 612 2 2 c J llIl j t v o i 1 1 l 1 t c I I J Remove the cover 23130 12210 of bearIng 23129 12210 lIS 62022 ZZCa and take off the o Flg hex 2 3 178 bolt of shaft Remove the hex d pulley the pulley of nut 23153 12210 23151 61200 and and the half moon pull off key Be careful not to m 23195 12210 jure the fan when the nut IS removed 00 2 FJg 4 Remove the through bolt 23131 12210 front cover 23118 12210 bolt ughtemng and rear cover 23183 12210 pull off e 1 I FJg the front Use I a cover and rotor 23108 12210 hammer of wood or plastIc If necessary 2 5 Remove the ball f beanng from Front Remove the bolt 23352 09610 cover tIghtenIng the beanng plate or pull off 23123 12210 and Slacken N terrmnal bolt cover sIde and then the be FJg the such as a hand press bearIng WIth remove rear cover on the the clIp rear terrmnal and the stator can separated 2 6 g Remove the rear cover 23102 12210 dIode 3ea from the stator cOli lead 3ea WIre electnc on the clIp by meltIng soldenng Iron rear cover terrmnaI NOTE 2 WIth SIde and then the remove rear cover separated 7 When temperature wIthIn dIode gear up over lS0 C the dIode wIll lose functIomng so that use the electnc Iron 100 200W for around 2 seconds at the soldered portIons 179 an Slacken N terrmnal bolt the stator can be FJg and stator the sIlIcon Separate the and h Remove the dIode set and brush k t yr 1i holder cover small parts such and bushIngs l J L j d f c 23133 12210 from the rear when be careful not to lose as screws washers 1 i p 2 8 Frg B AssemblY Assembly IS done INSPECTION OF A InspectIon of In the reverse sequence of dIsassembly TROUBLES Output For inspectIon of output WIrIng as shown In FIg 3 1 remove the dynamo from the vehIcle and connect For inspectIon of output WIth motor of dynamo WIthout removIng It from the vehIcle refer to inspectIon of AC generator to be publIshed later and dnve It NOTE Use the In capacIty 2 3 Fg battery charged full up to the normal 3 1 magnetIc current flows from the Through the WIrIng shown In FIg 3 1 raIse revolutIon of dynamo slowly thIs state In battery to the field COli of dynamo flow 2A to the field COli and where there IS no reverse approx up to the speed read the revolutIon Next Increase Correct revolutIon load reSIstance to the IS approx maxImum 000 rpm WIthout load and almost stop flOWIng of load 1 Then raIsmg the load current slowly Increase and put off the SWItch Observe thus revolutIon of dynamo IncreasIng output current as revoluoon of dy current namo Increases 180 If there IS IS no large dIffer nce from the It IS specIficatIon correct No matter how the battery IS over charged or dIscharged If the chargIng current small first make sure eIther the dynamo or the relay IS In dIsorder See the chargIng current DIsconnect by InsertIng the ammeter between A termInal of relay and the battery paSSIng from the dynamo F tenmnal to the relay F termInal at the relay F termInal and make the removed lead WIre short CIrCUIts at the relay A terrmnal when If the chargIng current hIghly Increases the relay IS In dIsorder B WIre Short CIrCUItS on DIOde SIde Judged as the pIlot lamp does not flare even If the key SWItch IS turned Actually a trouble such as dIode open IS very rare and short CIrCUIts at the SIde short CIr polar lIne are also rare OrdInanly there are many cases of It can be on CUIts C InspectIon 1ode of D WIth Tester a Check between the terrmnals as shown A N Set the dIal FIg 3 2 for conductIVIty and put the In of tester tester needles at both terrmnals alternately When one shows low reSIstance and the other shows pretty hIgh reSIst ance the 3 dIodes In the dIode set are all rIght Check between the terrmnals same as A E above When the same result IS obtaIned 3 dIodes are also all nght Hg 3 2 However found In when there thIS SImple dynamo output IS IS no d1sorder test and the somewhat lower 1 2 dIod s are opemng when one by one checkIng Will be necessary than the standard often In T Fig 3 3 f b Separate InspectIon Check reSIstance wIth the tester between the dIode base commonly used 2 tImes changIng the poles for 2 dIodes and lead WIre on the rear cover When one SIde shows low reSIstance and the other shows hIgh reSIstance 1 181 o There IS no both sIdes dIsorder are hIgh Fig D InspectIon a If both sIdes are low there wIll be short CIrcUlt and there wIll be open 3 4 5 3 Fig of DIOdeJ wIth Lamp Slmple InspectIon 3 6 FIg Check between the termInals A N as shown lamp 12V In FIg In straIght and put both On one SIde the lamp flares and on the alternately 3 dIodes of the dIode set are all nght Connect WIth the ends 3 6 at A and N termInals other the lamp IS off when When the same re N E same step IS taken between the termInals However If the obtaIned 3 dIodes pressed In the cover are all nght SImple test IS all nght but when the dynamo output IS lower than the standard The sult 1 lS 2 dIodes may often be openIng so that o 182 one by one check WIll be necessary 3 Fig b 7 Separate InspectIon r FIfJ Flg 3 8 Check between the lead 2 dIodes or the rear cover SIde flares and the other and both SIdes E InspectIon are off WIre and the dIode set common 3 9 WIth the other lamp and battery It IS all nght If one If both SIdes flare there IS short CIrCuIt WIth the IS off there IS open of FIeld CoIl 11 1 r FIg 3 10 183 i As shown If there are the rotor F Ball FIg In shp 3 7 n 6 nght tester between the Make sure there shp IS no nng of rotor and conducnon between BearIng InspectIon a put the nng and the shaft Both sIdes sealed ball G 10 It IS all of Stator beanng IS used so lubncanon IS not necessary Armature Conducnon Test If the terrmnal connected to the dIode IS not conductIve WIth the stator core Fg that IS all nght 3 11 If each terrmnal of the COli and the terrmnal connected to N terrmnal are not conducnve that IS all nght FJg b Layer 3 12 Test Connect the tester cord to loov WIre put the stator on the test stand and one turn readIng the ammeter If there IS short CIrcUIt on make the tester the coIl SWIngs of the ammeter there WIll be no change abruptly 184 Increase and If there IS no trouble Fg H InspectIOn and WIpe WIth slIp rmg Same to the of Brush clean cloth when 011 as In case wear 3 13 or of DC generator dust IS on replace the contact surface of the brush the brush when wear of It reached hnut t 185 REGULATOR 1 Constution and operation 1 ConstructIon F g 2 OperatIon of Constant 4 1 Voltage Relay When the 19I1ltIOn swItch IS on battery passes the dynamo E termInal fIeld carrent from the through I I cOlI I I I I I pomts P2 magneuzed contact dynamo I IS WhIle It also frows the I I It r L l Dynamo Fg 1 Pi E termInal N J L Regulator the o lamp contact and the regulator pOInts Ps p and flares t f 4 2 When the engine starts and the dynamo IS dnven three phase alternate current three phase all wave rectIfier generates on the stator coIl passIng through the the ternunal A E for chargIng dIode and changes to dIrect current between A that E generates and passes ternunal half of between At the N voltage COIl E termInal and WIth actIon of the VC the CIrCUIt N ternunal through VC1 WIth P6 so the movable contact pOInt Ps leaves from p and makes contact E ternunal contact pOInts thaCtlie la l1p IS off and It passes through the CIrCUIt and Ps P6 reSIstance R2 VC2 COIl and A ternunal then the VC2 coIl anImated COlI 186 prepares to VIbrate the movable contact pOInt P2 of the constant voltage relay When the dynamo revolutIon gets hIgher the contact pOInt Pa separates from PI WIth electnc magnetIsm of the e VCa COli and the field l lilT o U CIrcuIt cd l1 c OIel l all ll It dynamo j L of dynamo termInal E termInal 4 3 contact pOInt F field call contact poInts Pa repeated accordIng Fzg current from the E termInal field cOIl F termInal and resIstance R I and when the contact pOInt Pa contacts WIth PI the current flows through the CIrCUIt 0 M of the PI ThIs to VIbratIon of IS the Pa and the dynamo termInal voltage IS kept evenly chargIng and contInues u S e I s t m 8 1 s oIell a o all ll 00 Dynamo o Re ulator o E Eo 4 4 Ftg Fzg 4 5 When the dynamo revolutIon gets stIll hIgher the movable pIece IS drawn and the movable contact pOInt P z stIcks to P3 so that current almost does not flow the field and the generated voltage of dynamo goes down As the result the cont act poInt Pz separates from P3 and the current from through the dynamo E terrmnal fIeld COli speed voltage F terrmnal reSIstance WIth open and close of the IS At such a hIgh Rl and voltage goes up agaIn and the P3 dynamo termInal pOInts Pa contact always kept evenly S The operatIon of thIS tlme IS called a hIgh speed operatIon and the adjust voltage IS colled a secondary voltage When the dynamo revolutIon goes down and chargIng capacIty reduces the voltage e jri lIDi between the terrmnals o I e u Oll III N E also lowers As the result the electnc magnetIsm of VCI COIl weakens and the contact pOInt Ps llll fixed WIth the movable pIece can not con tInue contact WIth P 6 and changes to P 4 SIde o and E lIghts the lamp IndICatIng non generatIon When the IgnItIOn swItch IS turned off to stop the engIne the lamp goes out and the Fig 4 6 current to the fIeld COli IS 187 e suspended 3 Operauon of PIlot Lamp Relay As shown In FIg 4 2 thIs IS made up WIth the contact pOInts p Ps and P6 The contact pOInt Ps IS on the movable SIde and usually makes contact wlth P Between the termInals N E the movable pIece lS drawn when voltage half of the battery IS added and Ps fixed to the movable pIece separates from p and makes When the voltage between N E termInals IS conspIcuously reducted contact to P 6 makes contact WIth P agaIn The voltage between N E termInals necessary for Ps to make contact WIth P 6 Put off voltage and that Ps changes from P 6 to p IS Put on voltage Ps 2 IS Adjustment 1 Check Adjust Voltage Relay Value of Constant Connect the full battery almost charged shown and make the dynamo revolutIon WIth 4 000 rpm When the voltage of thIs tlme IS In 14 Fig 2 Check Voltage 4 as ISV of Put off Put on PIlot Lamp Relay lamp WIth con FIg 4 8 and read the voltage between N E by puttlng off the lamp mOVIng the volt splIt pOInt of ThlS IS a put off the rubbIng resIstance voltage move the rubbmg From thIS state resIstance volt splIt pomt and lower the voltage and read the voltage Whl m the lamp frares If the ThIS IS a put on voltage 4 2 2V the off IS 5 and put voltage all on IS O S 3V It IS put voltage nght FIrst r I I I I I I P h P vc RI I n A Fig 3 Adjustment The must of nght 7 nectlon as 1 It IS all f jj 4 8 Gap Constant Voltage voltage adjust values of the be as shown m FIg 4 9 PIlot constant 188 put on shown the In Lamp Relay voltage relay and the pIlot lamp relay Gap G1 Constant P110t Voltage Relay Lamp Relay Flg 4 AdJustment G2 G3 o 8 1 0 0 7 09 0 3 04 o 8 I 2 08 11 0 8 I I 4 9 of Voltage voltage of the constant voltage relay and pIlot lamp relay AdJust voltage by bendIng the stopper up and down Bend upward heIghten adjust value and bend downward to lower adJust value Put off the 189 to 14 ITEMS ON HANDLING Reason ProhImUon 1 When mountIng pOint 2 Make vehIcle polIsh the both sIdes removing pOInts rust or 011 the engine sIde pItch and pItch of the front cover sure sIde dynamo are on on contact well fitted 3 Be attentIve 4 Regulator the belt to tenSIOn sealed WIth lead IS If the seal together IS claIm perIod rE moved dunng the the claIm WIll In valId 5 If the earth IS not correctly set the adjust value WIll change 6 Connect the dynamo and battery WIth full attennon When the battery poles are con nected In reverse large current flows from resultmg lead 7 Make sure the whole CIrCUIt In battery to dynamo damages of dIode or WIre IS com pletely composed 8 When after the engine started the dynamo IS magnetIzed from wInng WIth full attentIOn Change the IgnItIOn SWItch so that In correct wIrmg wIll result In hampenng magnenzanon and then generatIon 9 Do not such 10 use as EngIne the As dIode tester hIgh voltage be megger room must be kept In IS bUIlt WIth damaged Because there the detenorate condItIon of standard usage 11 Do not separate the battery termInal dynamo A termInal durIng dnvIng vehIcle 190 the dIode WIll hIgh voltage dIode whIch wlll damaged WIth hIgher than the normal or temperature IS In be SeparatIon of the termmal causes and serge voltage wIthm battery damages dIode 12 When cleamng If the dIode WIth steam cleaner do not expose dynamo dIrectly When washmg WIth IS performance to steam the mOIstened wIll be lowered water must be free from reckless dynamo pour of water 13 battery is qUIckly charged qUIck charger the lead WIre regulator A termmal dynamo A When the WIth the or terrmnal 14 Serge voltage of the quIck charger damage dIode WIll also should be dIsconnected swItch off when the engIne Put the key IS m a stop except when portIcularly needed key magnetIc current on 191 swItch When the the field coIl IS on always flows and rmght dam age the and often over of battery dynamo dIscharge cause TROUBLE SHOOTING LIST Trouble 5 1 Cause dIs Overcharge of Remedy battery 1 Slackness of fan belt Adjust 2 Earth RepaIr 3 Breakage 4 Mal contact of brush and breakage or of stator coIl of rotor cOIl or replace Replace slIp nng Replace brush clean holder 5 Mal funcnon of dIode 6 Adjust voltage relay IS low 7 of constant 10 a set voltage Readjust constant Adherence of speed SIde contact voltage ready hIgh speed SIde Polish contact poInt contact Replace pOInt 9 as Mal contact of low pOInt of 8 Replace Shortage or unfItness of Mal funcnon of electrolyte Add dIsnlled water check S G battery pole short CIrCUIt Replace 11 Mal contact of 12 Mal contact or breakage between IgnitIOn swItch and relay IG battery termInal Clean or repaIr retIghten termInal RepaIr termInal 13 Mal contact regulator or breakage F termInal and F termInal 14 5 2 Over 1 charge of Check power consumed battery voltage relay adJust voltage hIgh Constant or rare 3 I Constant too Constant RepaIr dynamo ExcessIve electnc load IS 2 between voltage relay Readjust coIl breakage Replace voltage relay breakage COli straIght Replace voltage relay low speed Replace short reSIstance 4 Constant SIde contact pOInt adherence 192 5 Constant voltage relay hIgh speed Pobsh contact poInt sIde contact poInt mal contact 6 Breakage relay 7 Mal contact of or rare short of pIlot lamp pIlot lamp relay Replace PolIsh contact poInt contact poInt S Mal functIon of regulator 9 Mal contact or breakage regulator N ternunal and earth between dynamo N terrmnal 5 3 NOIses of Adjust Repalr Dynamo 1 Mal functIOn of 2 Mal functIon of dIode Replace 3 Earth Replace or rare beanng Replace short of stator coIl dIode as a set J 193 STARTER MOTOR Type S1l4 72 Voltage 12 volts 1 0 HP Output StartIng Less than 500 amps voltage current Over 0 9 Lock torque Type kg 9 5 volts m Bendextype of pImon gear Number of tooth on pIffion gear 9 Number of tooth on nng gear 120 Amendment lIrmt of short dImensIOn on shaft dIa pIffion SIde 0 1 mm 0 004 In 0 1 mm 0 004 In Amendment lIrmt of short dImensIOn of shaft dIa Gap rear end between shaft and bush pIffion 0 038 0 095 SIde Amendment lIrmt dIttoed gap Gap between shaft and bush 0 02 rear end Amendment lIrmt dIttoed gap Amendment lIrmt of deflectIon In 0 0012 0 0030 mm 0 2 mm 0 008 10 0 1 mm 0004 10 In of commutator Outer dIa Amendment lIrmt of short dImensIOn degree 2 of real clrcle DIttoed lIrmt of Bush 0 008 In on shaft DIttoed mm o 03 0 006 0 0015 0 0038 mm polanzed mm 0 05 4 0 wear 0 08 mm mm m 0 002 m 0 016 length Amendment lIrmt 9 Brush spnng pressure 0 9 mm kg 0 36 m O 1 Construction and Operation IS a 1 0 horsepower slIdIng InertIa type electrIC motor The motor when mounted on the engine IS on the front slde of the transrmSSlOn WIth ItS pIffion gear dIrectly opposite to the rIng The constructIon of the starter motor IS sIrmlar to that of the generator The starter motor for use 10 rIght startIng gear but dIffers only 10 that ItS armature shaft extends out backwards WIth a pIffion 1 2 Installed on the end as shown 10 FIg group 3 The connectIon dIagram for the starter IS shown In FIg The starter switch IS a key type combmed WIth the 19nitIOn sWltch By switch to the dIrectIon the relay on the magnetIc SWItch move to turnIng perrmt current rIght to flow to the starter and cause the armature to start suddenly 194 turnIng 4 r MagnetIc sWItch Plunger Contacter Armature r ShIft lever Brush f PInIon stopper I Hg 1 Magnehc Sh ft Type the pInIOn completes the meshIng Into the nng gear The dIrectIon In whIch the pInIOn moves IS torque towards the starter bracket thus reductIng the bendIng from the end of the shaft and ItS speed becomes greater than the no load After the starts torque engIne to ItS former speed of the starter the pInIOn IS kIcked back to unmesh and return After advancIng and dnves about 14 It WIth a mm powerful poSItIOn Contactor Series coIl Shuntcoll Rerum sprmg ShIft lever i P Armature Fg 2 Rmg gear PInIon sleeve spnng PinIon sleeve Spnng 2 A V ew I of Starter System Operational Precautions The InstruCtIons to be observed when startIng the engine securely mounted 1 The starter should be 2 any looseness The starter SWItch should be operated Immechately when the engine starts 195 on are as follows the engme and should not show properly and should be release I e o Ul UZ lo Me brush COVER Y ASS SWITCH core pole Y set ASS dust SCREW Ccoter OVER I PIN shIft plQon shIft LEV R LPIEVNR held e COlL Y Y ASS ASS BOLT en t 0 t111 0 TI G 0 t0 0 l er J t 0J ExceptIng extremely In cold weather the engIne should normally start wIthIn 10 seconds 3 The starter sWItch should not be 4 When n the engIne IS runmng If the operated whc falls to allow for the come rest before start tIme to to engme pImon turnIng the starter swItch agaIn the engIne falls to start after turnIng the starter key for over 10 seconds do not contInue turmng the key tIme after tIme but try to save the In thIS battery case check for the cause of the trouble and correct so that the engIne WIll start Operation While in Checking 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 but for some 1 WIth a reason the armature IS not a trouble usually caused Careful check should be made turmng starter pImon may be locked In the by turmng SInce the nng gear and unable to return the starter whIle the engIne is sull flywheel on runIng I l 2 When the starter sWItch turned up and the starter motor falls to turn although the lIghts remaIn bnght the SWItch should first be checked If the swItch IS In satIsfactory condItIon then the condItIon of all the terrmnal t I and ground connectIons of the If the starter so that In starter SWItch and starter are checked slUggIsh are case badly dIs corrected and the starter falls to operate It IS due to Internal defects and shows defectIve thIS It IndIcates eIther a to loose connectIon In the starter CIrCUIt or a If after the above troubles occasIonally battery motor runs but ItS movement IS hIgh reSIstance due charged battery 3 IS performance It should be dIsmantled and checked Dismantling and Disassembling The starter 1 the starter can be dIsmantled eaSIly by the engIne The two stay bolts on the starter engIne are removed 2 removIng the two stud nuts mountIng on rear cover front end when mounted on the After removIng the band cover the brushes and lead WIres are removed shaft IS By properly protectIng and holdIng the starter body the armature 3 4 pulled out cover are taken out together the cotter pIn on the end the pInIOn group from the armature shaft of the shaft IS pulled out and by removIng the pImon nut the pImon group IS 5 The armature and the front 6 To remove removed Inspecting and Repairing Parts fit 1 Inl can procedure as that for the generator parts IS followed the parts be InSpected after WhICh deterrmnatIons are made as to whether they reused or If repairs or replacements are necessary The same cleaned and be 197 The pimon IS Inspected for defects and If the tooth face is worn or the tooth edge is damaged the pImon should be replaced Worn or broken teeth Will not only make the gear mesh poorly but WIll hasten the wear on the oppoSing gear and also poorly meshIng gears WIll cause bendmg In the armature I For thIs last sh aft reason care should be taken when inspectIng to also flywheel and take remedIal measures if the nng gear IS found worn damaged When the pimon is found defectIve replaced the entIre pinIOn check the or group 2 When inspectIng the armature check the armature to core gap In the same manner bushIng clearance bendIng In shaft etc shaft to as that for the generator and are corrected to the specIfied lIrmts or the armature IS replaced SpecIal attentIon should be gIven to the clearance between the and corrOSIOn armature and the core to see that they are not contactIng found on the outside surface of the armature or the Inner surface of the core should be removed and the surfaces by polIshIng paInted with rust preven tIve OIL 3 The armature IS InSpected and repaIred In accordance WIth the procedures outlIned for the generator ESpecIally to improve or correct the brusl the brushes are reseated At the same tIme the condItIon contactIng brush sprIng are checked and are corrected or replaced The InsulatIon on the Wires are carefully Inspected and WIres found With 4 weak 5 or damaged InsulatIon should br An armature found WIth StrICtly tested by one replaced part especIally damaged by bunng should be the InsulatIon test Assembling and Testi ng Starter ReassemblIng IS performed by follOWIng the reverse procedure for dlsassemblIng All frIctIonal parts are lubncated With mobIle OIl 5AE 30 whIle the beanngs are coated WIth a small amount of grease CirCUit In the magnetIc SWItch and causes the main Circuit Sg In the magnetIc CIrcuit to close ReleaSIng the starter switch opens the magnetIc CirCUIt whIch also opens Causes for magnetIc switch and mechamcal sources 1 Sg faIlling to operate can be dlvided Into electncal Causes for electncal troubles A Current faIlure In magnetIc When the starter SWitch CirCUit In Circuit pressed and the current falls to pass through most of the trouble is due to broken soldered connec the magnetIc termInal tIon between the magnetIc coIl WIre add the magnetIc sWItch and defectIve ground connectIon from the coIl WIre to the magnetIc SWItch body B DefectIve contact In maIn CIrCUIt Sg When the magnetIc CIrCUIt is satIsfactory and 5g IS clOSIng but only a small current flOWing due to hIgh contact reSIstance and the oppOSite case of In eIther case the trouble switch Sl openmg but Sg remalnes closed lIes In come faulty movIng of the core or roughness of the contactIng poInt then the operatIon Will be Therefore polIshed the surface well the surface satIsfactory 198 Causes for mechanIcal troubles IS caused In many FaIlure to by the guIde shaft on the movIng maIn CIrCUIt 52 stIckIng agaInst the cover hole can made In thIs case by loosenIng the cover screws 4 pIeces CorrectIon be and retIghtenmg them so that the shaft moves freely operate core of the magnetIc SWItch 2 cases PrecautIon In removIng nuts from the magnetIc swItch maIn CIrcuIt termInals when In stallIng or removIng cables the lower nut of the double nuts should be kept state whIle unscrewIng If the lower nut IS loose the terrmnal In a tIghtened bolt may turn Starter Troubles The starter 1 follOWIng IS together ground the terrmnal to the cover and cause damage Their Causes and Remedies IS a Installed anrl on lIst of troubles WhICh can be deterrmned from the state the the engIne Starter falls to turn The engIne IS checked to see If It can be cranked by hand If It If It cannot be cranked the engIne IS at fault and should be checked the wInng should be checked the starter be cranked IncludIng eaSIly can and correctIons made accordIngly Check the Is the battery run down see If It IS over 1 240 and recharge speCIfIC gravIty of the battery flUId to or replace the battery as found necessary All loose battery and ground cables should be cleaned and properly tIghtened Magneto grease or Gargoyle BRB All cord connectIons are carefully tIghtened and speCIal No 1 attentIon gIven to the condItIon of The assembly check InsulatIon IS made by testIng the starter as a SIngle UnIt USIng a fully charged Tests are made WIth a FIg 4 Torque Teshng Apparatu battery starter motor tester or WIth the apparatus shown case In FIg 4 WhICh by the normal value should be 0 9 Construction of brakIng m kg otrque IS measured In thIs Magnetic Switch and Instructions The magnetIc SWItch IS an apparatus when the engIne IS bemg started by ShIft and serves to close the CIrCUIt between the battery and the starter motor lever perrmts a large current to flow and actuate the starter motor when the engIne IS stopped the swItch pies of operatIon can be seen from FIg the current to flow through 5 the magnetIc 199 After startIng or The prInco keep the CIrCUIt open Closmg the starter SWItch serves to S I allows Igllltion sWItch Connect to others Battery FIg If there MagnetJc Starter CJrCUJt the magnetIc CIrcUIt It should be corrected Improperly contactIng starter brushed the brushes together WIth the ar mature should be checked and correctIons or replacement made as found neces IS trouble 5 In For sary If all of the above checks WIth theIr correspondIng repaIrs have been made and the starter stIll falls to operate the trouble can be assumed to be m the starter Itself so that It should be removed from the engIne and checked ThIs IS exceedIngly rare but care should be taken to see that the starter pImon not locked mto the Cases lIke thIS are usually caused by flywheel nng gear 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 and forth to free the gears If thIS trouble IS frequently repeated the starter should be dIsmanted from the enjp ne for checkIng and repaIrs IS badly 1 worn gears Starter turns but Its turmng power IS weak and falls to start the engIne If the trouble IS due to a run down battery loose termInals troubles m magnetIc ShIft swItch worn and stIckIng brushes dIrty and damaged com checkIng and repaIrs are made In the same manner as descnbed In the precedIng chapters If the outer surface of the armature IS rubbing agaInst the core the starter should be dIsmantled illsassembled and repaIred BeSIdes the above there IS the case of the pImon meshIng Improperly If the trouble IS due to the gear teeth beIng badly worn the gears should be replaced but If It IS due to the screw gUIde on the pInIOn shaft beIng dIrty and not allOWIng the pImon to advance smoothly and causIng Improper meshIng the shaft should be cleaned and OIled mutator 2 Starter etc the exceedIng nOISY when In operatIon The flywheel nng gear IS checked and If the teeth are deformed they should repaIred or the gear replaced RattlIng nOIse caused by loose starter mountIng bolts are corrected by re tIghtemng the bolts NOIse caused by brushes Improperly contactIng the armature requIred cor rectIng as thIs conilltIon not only produces nOIse but WIll hasten wear on be both parts 200 rubbIng agaInst the core whIle In operatIon IS clearance between the armature shaft and the bushIng by Wear between the shaft and bushmg so the worn parts should be replaced be gIven to proper lubrIcatIon IS due to lack of OIl so that attentIon should Lubncate once every half year USIng good grade of machIne or mobIle OIl The amount of 011 requIred and lubncate the parts through the 011 nIpples IS about 0 5 cc for each bracket NOIses made caused by the large too armature a 201
