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Download Datsun 521 Pick up Service manual
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J DAT5U N PICK UP 4 MODEL 521 SERIES r CHASSIS AND B ODY i r I NISSAN I f J J NISSAN MOT TOKYO r ev JJN 20023 99999 R CO JAPAN LTD t f L R v I 41 0 OE Jljl QUI0J OA1 SUN UP p CK SERVICE t ttU MOOE ES 521 SER l lSStS 1001 i j il 1 1 1 It It 11 l t I po to N N SS tAQ10tlJAPAN tOKYO 10 IV 1 r FOREWORD This seroice manual has been of our prepared for distributors and dealers in providing effective seroice and maintenance proper customers this manual should be read for effective 1 utilization Explanations PleaJe refer se1 0e g seroice personnels and maintenance of are The carefully essential absolutely following satisfying our matters should be noted of this manuaL in this manual hand drive but will 2 of aJsisti series DA TSUN PICK PU model 521 Since the purpose easily to both be thi are mainly concerning referred and 13 also to the left the model G N 521 U right hand drive models 15 ENGINE SERVICE MANUAL or LI3 for PL52 1 series for complete details information concerning the chaJsis and L16 and L20 ENGINE SERVICE MANUAL of the car because this manual describes body only 3 All part names in this manual and only the genuine for replacements 4 All on seroice conform parts listed information illustrations and the latest product information the contents according 6 contained in this manual available at the time use are based ofpublication approval this manual are responsible for revising the SER VICE JOURNAL and SER VICE DAT4 AND SPEClflCA 1IONS issued by the servicing DATSUN 521 PARTS CATALOG A LOG must be used in this PAR TS CA l atispeci onsfi 5 It should be emphasized that those who to to the faclory which carry the Intest approved factor methods Rights for alteration of specifications and methods at any time are reserved i NISSAN MOTOR CO JAPAN TOKYO LTD v SECTI ON GI GENERAL INFORMATION DATSUN PICK UP MODEL 521 SERIES CHASSIS BODY I NISSAN I MODEL VARIATION GI 3 IDENTIFICATION NUMBER GI 3 GENERAL VIEWS GI 4 GENERAL SPECIFICATIONS GI a FINAL TRANSMISSION AND SPHDOMETER RATIO GI l0 RECOMMENDED LUBRICANTS AND PERIOD ICAL MAINTENANCE GI l0 I JACKING UP AND TOWING THE CAR GI la t NISSAN MOTOR CO TOKYO LTD JAPAN J r l ll GENERAL INFORMATION I t O Fig Gl l Short body pick up ft Fig 1 GI 2 Long body GI 1 pick up r CHASSIS I I f Fig Gl 3 Double Fig GI 4 GI 2 pick Van up GENERAL INFORMATION MODEL VARIATION Vehicle Engine model Pick up R H drive LH 521U LS2I L 4 R4W63 2 I 2 204 6 5 400 2 3 102 5000 300 6614 OtXl 4 F4W63 LS21T Plck up n 0 Pick up US2JU ULS21 VS21U VLS21 N521U NU21 JI3 5 881 8 4 R4W63 4 R4W63 4 R4W63 2 000 2 1 204 6 NU2lT 5 Rem ITkl drive Double V TIM speed Seating 3Plcity payload kg lb model F4W63 4 R4W63 4 R4W63 4 Double UNLS21 JlS 5 400 8 881 2 SOO 1 5 300 6614 Pick up VN521U V 102 3 NU21 PL521TU ick J for L16 up 454 2 1 000 for CANADA PL52ITN LG521 GS21U 0 GNS21U GNLS21 S The number body engine the plate identifies number and car number The attached to the 113 2 000 2 204 1 JIS 2 000 2 1 6 4 F4W63 4 R4W63 204 6 4 F4W63 GNLS21T maximum hose power engine capacity 4 R4W63 LGS11T Pick up center of cowl top SAE body type uf car wheel base number plate is panel Fig Fig GI 5 Chassis number Upper face of left side frame US A 4 F4W63 GI 6 Body number plate plate near front suspension member Fig GI 3 GI Engine number Ill J IU U I U I en G 1 Z 1a o in mm MDe models 71 40 01 5012 81 I 1 I 1850172 IT Jb 6PR 14 0Q 1035 1 6 91 3 PL521TN PL521TU Indicates I 61 Unit II II II I I II J t f 13 gM 253019 4290168 4325170 j T 1 I 1 if Mark up pick body Short Ii B 0 710 28 iio In In Gl Fill jj r M ci r Z oa or 0M 0 1 o in o II 71 I mm Unit 185146 2 I I oz I I Q m Z ma 88 I I II N I I I I I 2 40 IIII up 0M pick I I I I i I 1 I body Long ii 9 GI Fig Cl U r CHASSIS Ir T 1 c E E 1 c o J 0 o I I 1 S o 9lE I M L 1 B B ii ai C M 0 M O Z9 OZE l N 1 I n r OJ oi 0 IB lS OVEl I I o 11 Q m o o IT q iaio I 00 t o O 00 r iXlOr O N ON NN J 1 11 ll GI 6 m Zm a r ZT1 o a oz r in N o mm Unit J1 0 I 1r e1 f I ON C bN OL N 00 I Oo tN e tC 1 rf I co I I I N I o 1111 Van l1 GI Fig in oN N Gl L CHASSIS GENERAL SPECIFICATIONS 113 ENG lNE 52lU L521 Item L521T U52lU V52lU UL521 VL521 345 4 Ovralllenglh mrn in 4 Overall widlh mm in 1 575 62 0 1 570 Overall height mrn in 1 545 60 8 1 530 60 2 Wheel base mrn in 2 530 99 6 2 530 99 6 mrn in 1 850 72 8 325 3 170 1 171 618 1 c c g E 5 Length 830 32 7 65 0 is 40 9 1 0 0 Width c mrn 1430 in 1 3 56 320 52 0 Height mrn in 0 Front mrn in I 250 49 o f Rear mrn in 1 mrn in Minimum road clearance 400 1 240 49 0 48 8 16 5 2 200 7 87 2 kg Ib 960 Pay load kg Ib 1 000 900 35 4 2 1 250 49 267 49 9 Vehicle weight Maximum speed 420 15 7 1 2 1 245 u u 2 040 1 1 650 267 49 9 187 36 7 1 1 035 4 116 22818 km h MPH 2 125 204 6 400 881 8 soo J 102 1 125 1 78 055 2325 9 300 4 661 78 1 1 E Maximum grade ability sin 8 308 0 0 221 362 0 Minimum turning radius m 5 2 52 17 1 ft 2 382 0 g 380 0 I 17 1 2 Seating capacity Engine model V AH 12 Clutch type 5 J13 12 40 Dry single disc Diaphragm spring Model 2 2 JI3 Battery volt capacity 0 5 R4W63 40 Dry single disc Diaphragm spring F4W63 R4W63 c El Synchro type Hypoid Hypoid Re circulating ball Re circulating ball Final gear type Steering gear type oS Warner Warner Front Uni Rear Duo Servo Uni Servo Duo Servo Service Servo u I Parking ii Front Rear Rear operated Independent Suspension I Mchanically Semi I on rear wheels Mechanically operated torsion bar mmR GI B wheels Independent torsion bar elliptic leaf spring rK on rear Semi LT elliptic leaf spring 5 LI 1 3lb 102 1 loaded 500 kg 2 loaded 300 kg 661 41b GENERAL INFORMATION 115 ENGINE L16 ENGINE N521U NL521 NL521T UNL521 3 170 4 325 1 545 2 530 99 6 VNL52 I 4 345 1 575 62 0 60 8 1 618 530 60 2 2 530 99 6 1 850 728 830 32 7 3 56 400 1 157 320 52 0 420 1 650 1 040 65 0 40 9 GNL52 I LG521T 4 715 185 6 62 8 1 575 1 545 60 8 1 545 60 8 2 530 99 6 2 770 1 850 72 8 2 240 88 2 1 430 3 56 1 430 3 56 400 15 7 400 15 7 1 240 49 0 48 8 900 354 62 0 109 1 1 250 492 1 250 49 2 1250 49 2 I 250 492 1 267 49 9 1 267 49 9 1267 49 9 I 267 49 9 187 200 7 87 960 2 4 116 1 36 7 035 1 000 2 204 6 0 296 5 17 2 00 1023 1 140 253 0 5 1 2 368 0 366 0 2 1 lI5 12 Dry single disc Diaphragm spring R4W63 2 Hypoid Re ciecula ting ball Uni Servo Duo Mechanically operated wheels Independent torsion bar elliptic leaf spring 6 00 12 6 PR LT 14 Hypoid 6 00 14 8 PR LT Duo 115 40 F4W63 R4W63 F4W63 Re circulating ball Uni Servo Duo Servo Servo Mechanically on rear wheels operated on rear Independent torsion bar Independent Semi Semi 50 5 4 18 Hypoid Servo Uni Servo 0 247 Warner Re circulating ball elliptic 0 289 Dry single disc Diaphragm spring R4W63 Hypoid 50 0 215 12 Dry single disc Diaphragm spring Servo 84 4 135 60 Re circulating ball 5 78 1 5 6 112 40 Warner operated 2 204 6 113 Warner Mechanically on rear 1 000 2 F4W63 Duo 2 226 6 2 R4W63 Uni Servo 40 Diaphragm spging Warner 010 17 1 L16 Dry single disc F4W63 125 301 0 2 7 87 5 115 40 5 87 351 0 5 200 1 454 1 000 1 17 5 2 1274 140 2 12 300 MIA 5 87 348 0 1 2 965 2 325 9 400 8818 4 84 135 200 7 87 1 055 2 281 8 GNL52 IT 2 1 245 5 16 GN521 G521 ENGINE U 2 1 I 430 PL521lN 290 168 9 1 595 1 525 60 0 115 G521U PL521TU 4 1 171 1 570 1 Semi 113 ENGINE VN521U leaf spring wheels torsion bar elliptic leaf spring Mechanically operated on rear Independent torsion bar Semi elliptic leaf spring 6 PR LT 14 6 00 14 6 PR LT 6 00 14 6 PR LT 14 6 PR LT 6 00 14 6 PR LT 6 00 14 8 PR LT GI 9 wheels jt r CHASSIS FINAL TRANSMISSION AND SPEEDOMETER RATIO L521T NL521T PL521TU LG521T GNL521T PL52ITN N52lU 52lU NL521 UNL521 L521 UL521 GN52lU VN52lU G521U V52lU GNL521 UNL521 LG521 VL521 Item 4 875 Final gear ratio 4 625 Control system f 4 875 375 4 R4W63 F4W63 Type S 4 625 375 4 4 625 R4W63 Column shift Column shift Floor shift U521 1st 3 657 4 243 5 000 2nd 2 177 2 558 3 014 3rd 1 419 589 1 1 685 4th 1 000 1000 1000 Reverse 3 638 u Speedometer gear ratio 19 5 367 4 18 5 17 5 5 146 18 5 19 5 17 5 RECOMMENDED LUBRICANTS AND PERIODICAL MAINTENANCE RECOMMENDED SAE VISCOSITY NUMBER ENGINE OIL Multi viscosity 5W 20 oil I IOW 30 40 10W 20W 40 Single viscosity oil 20W L 20 30 lOW GEAR OQ 01 L SAE BO SAE 90 30 20 10 0 10 20 30 40 22 4 14 32 50 6B B6 104 Temperature range anticipated GI 10 IOe OF 18 5 CmZm a rJ1 1oo s s 1 ZC1 C rc CD rJ o 3D SHEL SheUXIO MOBILE 3D Oil lOW Enco ES O 20 Supc MobilO BPSuperVl5Coda BP shclpuD 20 ex HD lOW 20W Lube 80 80 90 Lube Mobile Er Eocol u E 30 40 SO 3D MotrOiJ 40 20W 30 40 SO ES O HOEP 140 lOW 20W 30 40 SO Enco 80 90 u Oil E 90 140 RetinlA 1X Don Shel Shel IlD 80 90 140 MobilegrascP 140 GP E Mobile Bukcl 5W l Hydr Mulu 80 90 140 ex HD40 H Enco greas Esso purpo AtluJPcrmaGd Enco FlUid c oIHD Buke Essu lOW 20W BPEne lOW lOW 30 40 SO IJPGcuOil HypogcarOil 1I0Er 90EI 140EP IlrakeFIl lkl I OEP 90EP 140EP UP BP Ill GTX20W IOW 20 ulw D Canroli1 Cutrol Cunol SW lOW 20W 30 40 SO CntrolHyp Hypoy Cntrol 90 HI Brake B 40 XL2QW frost Anu Energ a SO CASTROL Mobile L2 20 3D SO 3Q Frc l lull l ic Gear Enco so v Super Oil Gear 20 80 Mobile Oil Eoca lOW 80Er 90EP SheUSpu Mol r Extra 40 IOW or lOW lOW 40 IOW Oil 5 shclzon Il ShelXIOQ Slo I oz z uI 20W MobiJe Mobile tNeO Uni o z oa O lOW Special r CadwlGirg LM 90 Castwl FlUid fCareezt 5troIAnti v lteh Cll Crl n C purpo MolrOi FivcSI u CALTEX 30 Cunom MotalOn 40 20W 10W 20 lOW 20W Star Five 30 40 UmveualThbn 80 MultproeThban 90 80 140 E AIPurpow Mufaklti Marflk Coflirmecl FludHD Brake Anti marked u CHEVRON RPMSupromctI 30 MOlor 40 20W IOW RPMSpcla Oil Oil ITXACO Mot r VICl 20 lOW 20W Gc Lubn RPMMulli ScI 30 40 Umvers al 80 90 140 RPM Geu Oil 20W O Mol r lOW Havoline 90 140 lOW 20W Havolin 30 40 UmvcnalGer Lubn EPI O EP90 u 80 90 Ge Multi Multi Extu Grease purosc Purposc Lubm 20 HD RPM Jnt Oil 3D Lubneat 80 motive EP 140 AtluPcIl laGl lard HUldoiO and Atlas BTake Anti oils fren to superHD ColanFtre z MurakUi MarfkAl BukeFlJ Anti Colan permisble it avilabe not oils MANUFCTRE gradc 21048 L MulL MIL l1048 L APIMS MS Recu1ar MIL API L210S APIGL 210SB MIL MIL L 10924 GLS API Q 6 Z3z a l G Clutch G MIL puroseG Mul i lkc BT 2108 Q 70R3 COLANT EFijZE G MIL ANTI brand above the case In l I s 1 Zt1 1Z INTERVAL I II I ct 36 72 24 48 X R 33 69 22 46 X X X X 30 66 20 44 X X X X 27 63 18 42 X X X X 24 60 16 40 X X X X 21 57 14 38 X X X X 18 54 gO 12 36 60 X X 15 51 87 10 34 58 X X X X 12 48 84 8 32 56 X X X X 9 45 81 6 30 54 X X X X 6 42 78 4 28 52 X X X X 39 75 50 X X X X X X X MAINTEC 26 2 3 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X 6 X 1 0 Replacmnt R R kilometrs of PL521TN PL521TU except els Allm top miles level of oil POINTS thousand thousand LUBRICATNG of of Number Number jOints necsary gear ball except if diferntal oil e eng up heel earn transmio eck res voir y luid water suthaofrt 9 bushings top parts linkage linkage pedal linkage box ball control supenio grease joint spline oelrato peratd brake gear linkage is ion pIes bearing slhIaerft slIheraft level joints oil of t g 9 I f or Change Change nec s brak cae dist if Refil Change Grease up Cl Lubricate Lubricate han ste ste tra all wt pro pro Grease Check Grease Grease Grease Repack Grease Grease z o0 mz F X r R 24 48 36 72 X r 33 69 X 20 44 30 66 38 14 57 36 60 12 JAI R E 34 58 10 87 51 15 X R 54 90 18 40 16 24 60 21 42 18 63 27 46 22 IN 32 56 8 12 48 134 NANnECE 45 81 9 42 78 I IAI llace Re 28 52 4 6 ent 30 54 6 26 SO 39 75 R X X X 2 3 6 0 1 leak lor eteilors l etc iles I nuts oi oi con ection d TS N l I Jsand too PO lOusand t oi oi CE J SER ber Nu ber Nu Wpe er oos distrbutor cartidge Jgs l1 ele NE ENG eJtcept odels I p larl s cleane llace re air llace Re replace or or Checl coed IiIter cartr oil llace Re Replace a g and Wpe Mad ldge iW ater ling li ti Olt luel leak io9 and tralner breal Wpe li ent PL5 ani1o pointS Iinder c igniton tension clear nce e al Reti9hen t Adju adiust Ioses idling line oil lor lecillc s bat e luel engine e n g i n e and CMck Checl Ch e c l A d j u s t CMc l Checl belt ian J v MAINTEC X 24 48 33 69 22 46 X 30 66 20 44 X 63 18 42 24 60 16 40 X 21 57 14 38 X 18 54 90 12 36 60 15 51 87 10 34 58 X 12 48 84 8 32 56 X g 45 81 6 30 54 6 42 78 4 28 52 X 26 50 X 27 INTERVAL X 36 72 39 75 X X X 2 3 JJ Vi X X X X X X X X X X X PL521TN PL521TU except els Al m X 0 POINTS kilometrs miles of of thousand thousand SERVICE of X X X X X BODY Number AS IS C Number X wear cylinders defcts X X X X X X X X X X X X X X X X X X X X X X X bolts positon angle fjloaninget brake and hand lin gs parts box gear whe l load rotae pre supenio stering bearing damge and turni g and universal alignmet shaft aiming mountigs cracks cylinder ulic atighsn etighten whe l discs balnce whe l ropel r light ody ake Check coneti Check Check Overhaul Check Check Check Adjust Check Check Check Retigher Check Relighte Check Road clu clu Check for or brake brake 11 X nd o p e r a t i o n pedal sy tem leaks liners as embly absor e Iree X linkage hoses play X X X pi ngs of X X 6 1 X X X X X for etc 100 bra shock for for e I t hy an an Ir I wt wt fre he Ir tes I m ZmQ 60 30 INTERVAL MAINTEC R X X X X R X X X X X 52 24 48 X X 21 45 X X 18 42 X X 15 39 X X 12 36 X X g 33 X X 6 X X 3 X X X R 54 Z r1 o Q X 27 57 r oz X X X X X X X r X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Replacmnt X X 6 0 necsary whicevr jf top miles level POINTS thousand of PL521TN PL521TU For LUBRICATNG oil diferntal months Number necsary gear or of A first comes oil transmio if brake drum res voir fluid c h e c k engine brake or Change Change Refil up C L L heel eam water water shaft bushings linkage distrbuo acelrto co ling co ling Change Change Grease U1 pedal operatd foot Lubricate Lubricate top linkage brake hand level joints oil ball box gear linkage parts supenio of ste ring ste ring nip les all grease joint bearing shaft whe l proel r Grease Check Grease Grease Repack Grease r 60 30 27 51 57 X 24 48 INTERVAL MAINTEC R R X X X X X X X X X X R R X X X X X X X X X X X X X X X X 21 45 18 42 15 39 X X 12 36 R R g 33 X X 6 X X X 3 X X X 54 I C I IC C X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Replacmnt X X X 6 X 0 X X X X X X whicevr POINTS SERVIC PL521TN ENGIE 521TU I sy tem I leaks of for thousand nuts months first comes P A conetis leaks air hoses spark distrbuo type head filter ridge I nder clearn igntion cables tension djust tension val an buret r Replace Check Check Replace Replace Retigh n Adjust lace lace 0 or or c elt hig fan e up ine en tu fue oil for e en tion lo se of es oper 5wit for for pi ngs andwater gravity tension idling emison S I elment break r strainer mandanifold cleaner plugs fuel bolts timing c For C etc points or Number control V miles of R conelis operation vcoanlvterosl elctrial of specif belmpt pi ng ry ba air for mp ion peratio em fa ho air Check Check Check AdjuSl Engine Check Check Check Check Check Check Check Check 5z Z n o0 r Cm Z m 10 I X 57 48 21 45 X X X X X 24 X X X X X X X X X 51 X X X X 30 27 X X X X 60 X X X X X X X X X X X X X X X X X INTERVAL MAINTE C X 18 42 15 39 12 9 X X X 54 X X X X X X 36 X X X X X X X X X X X X X 33 X X X X X 6 X X X X X 3 6 X X X X X X X 0 etc whicevr POINTS 8 For thousand of CHAS I wear hoses or BODY months first Number comes bolts pi ngs of SERVICE PL521TN PL521TU coneti s miles play iree pedal for cylinders operation sy tem brake brake brake def cts clutch clutch leaks Check Check for or drums liners and caliper positon linkage asembly parts sbore sshock upenio whe l and load boX pre ste ring bearing damge for c y l i n d e r s lin gs brake retighen retighen whe l discs hydraulic front whe l foot brake Check Check Overhaul Check Check Check Adjust Check hand and and e ooJ angle flange rotate turni g joint and universal alignmet shaft mountigs bal nce whe l aimng whe l front head and Check Check propel r body light Retigh n Retigh n test Check Road CHASSIS LUBRICANTS CAPACITY sA U Liter 41 Fuel tank l I ai Imp measure measure gallon gallon 10 8 9 0 Without heater 6 0 58 1 32 1 With heater 6 6 74 1 45 1 5 MOO c Ul Coolant Without heater c 4 6 1 69 141 6 8 1 80 50 1 3 0 0 79 0 66 1 06 0 88 60 c lUl With heater 113 115 Engine Oil pan Ll6 Engine 4 0 113 0 63 0 17 0 14 0 7 0 19 0 15 20 53 0 0 44 115 Engine Oil filter Ll6 Engine Transmission case 33 0 Steering gear box Differential 0 83 case 0 087 0 073 0 22 0 18 JACKING UP AND TOWING THE CAR JACK UP Screw When jack jacking up Ihe front side apply screw jack 10 screw jack to the the front jacking point beneath lower link When rear jacking up the rear jacking point beneath In no event should side rear screw apply spring jack be applied to other points Fig GI 18 CI 12 FTont jacking point GENERAL INFORMATION Supportable point The front supportable points are two places in frame side member The spring Fig CI 13 Rear rear supportable points are in front of the leaf of frame side member jacking point Garage jack Note When carrying out operations with the car jacked up be sure to support the car with stands When jacking up the front side front cross member or center apply garage jack to of suspension portion member When jacking up the rear side apply the jack to rear axle housing Fig GI t4 Front jacking Fig CI t6 Front Fig CI t7 Rear supporl4bk point point supportable point TOWING When towing forward apply a rope to tension rod bracket When towing rearward apply a rope to leaf spring shackle Fig CI H Rear jacking point Note GI 19 When towing be careful not to apply load rapidly or CHASSIS Fig GI I8 Front towing point Fig GI I9 towing point 4T R SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN t or No PAGE No SUBJECT GI 20 SEen ON ER GI ENGINE REMOVAL INSTAllATION DATSUN PICK UP MODEL 521 SERIES CHASSIS BODY I NISSAN I NISSAN MOTOR CO TOKYO JAPAN LTD ENGINE REMOVAL AND INSTALLATION ER 1 lGIl El lE EtlG1tlE REMOi ll lSl Il l g tlOtl LLA ItlSfA At10 IlEfAOL II ER 3 CON1EN15 ENGINE REAR ENGINE RON ER HI RemoVal nstaHattOn l 110l 2 3 ING MOUN ING MOUN ER H it I I J 6 fig EJI 2 Engin tment comp EA 1 or th L16 ngin 4 CHASSIS Removal 12 Disconnect speedometer cable Disconnect flat attaching plug Scribe alignment marks on hood around hinges and from connector reverse lamp switch remove hood from hinges 2 drain coolant Completely engine and transmission 13 lubricant Disconnect remove 3 Remove blow by hose from cross shift rod and select rod shaft assembly by removing and then cross shaft bracket from side member rocker cover and air cleaner 14 4 Remove radiator 5 Disconnect battery cable and grille Disconnect front exhaust from tube exhaust manifold remove battery offthe car 15 6 Take off both upper and lower radiator hoses loosen fIxing bolts of radiator and take it companion flange Then out Disconnect propeller shaft by disconnecting it from of gear carrier in sequence 16 7 Disconnect fuel tube from fuel pump 8 If equipped with heater Jack up transmission engine mounting cross a little and then member its hoses at engine rear by removing fixing bolts of engine mounting insulator mounting remove remove cross member and hand brake cable clamp attachment 9 Disconnect accelerator control linkage and choke 17 wire at the carburetor side Remove sulators to 10 coil Disconnect wirings for starter alternator bolts securing front engine mounting in cross member ignition oil pressure switch and thermal transmitter 18 II Remove clutch operating cylinder and its Hook with cable are installed on relurn the other spring at Fig Fig ER J Removing clutch operating cylinder ER 2 or chain to stringers engine cylinder head one hooks at the front and the rear 4 ER which Lifting engine for the J 1 J and J15 engine ENGINE At this lifting lower jack gradually REMOVAL INSTAllATION placed under the transmission check draw offjack at adequate stage hoist up engine observing the tension of wire and adjusting the position of chain block so that engine tilts in order off body At this stage take on the care disconnecting parts for before positions actually disconnecting to make it cleared that accessories installed body side do not touch engine and transmission Installation Reverse the removal to parts the engine insulators have been Note 8 Use fender from b protecting cover to protect body is supported by procedure steadily replaced but do not connect any until engine mounting since the power unit weight them damaging When hoisting or operation carefully jacking up engine carry out that component parts so are FRONT ENGINE MOUNTING not damaged The c It should be noted that adopt flange to long body join propeller shaft and mission and others adopt spline d remote When series vehicles disconnecting 1 1 to 1 6 kg m linkages IT I I 8 0 116 1I lb or 1 1 to 1 6 I 1 1 to 1 6 0 11 6 It Ib Crank 2 S g m to 20 2 It Ib Fig kg center m line I ER 5 Sectional view 116 6 to 20 2 I offront engine mounting for theJ13 andJlS engines ER 3 kg S O 11 6 II Ib I 8 however remounting engine J j T noted used for both left and right member installation bolts are removed I T be are that bracket and support for left side differ from those for right side When dismounting control insulators It should sides trans same m support or and reinstalled cross CHASSIS T T 2 6 to 3 2 kg 2 5 to 3 Okg m 181 to 21 7 ft Ib I m 1 O jj l l Fig ER 6 Sectional view for offront engine mounting the L t6 engine REAR ENGINE MOUNTING One type of with long rear extension T engine mounting is used for engine two For engines with short extension types of rear engine mounting for and L series engines are 33 to 3 8 kg m 123 9 to 27 5 ft Ib r T lIto 1 6 kg m 8 0 10 11 6 ft Ib Fig ER 7 Sectional view for of rear engine mounting the GN52t model 4 ER used the J series engines v ENGINE REMOVAL INSTALLATION i to kg m n 4 3 to 5 0 T 31 1 to 36 2 ft Ib I I i T 5 to 2 1 1 10 8 Fig kg m of rear engine mounting the U V N521 models I 3 3 to 3 8 kg 15 2 ft Ibl ER 8 Sectional view for T to lu iLn m 23 9 to 27 5 ft Ib d T j1 5 to 3 1 10 8 T 1 1 to 3 6 kg to J m 8 0 to 11 6 ft Ib Fig ER 9 Sectional view for Note Arrow marks means that engine kg of rear engine mounting the PL521 model removal carries out at this place ER 5 m 15 2 ft Ib CHASSIS t1 lU rF JOURNAL DATE H ll l liR 1 REF or PAGE BULLETIN PH RW No SUBJECT No ER 6 rF REl SECTION CL CLUTCH CD J DATSUN PICK UP MODEL 521 SERIES CHASSIS BODY I NISSAN I NISSAN MOTOR CO TOKYO JAPAN LTD CLUTCH CL 1 CLUTCH CONTROL CL 5 SERVICE DATA AND SPECIFICATIONS CL10 TROUBLE DIAGNOSES AND CORRECTIONS CL 11 CLUTCH L CLUTCH I CONTENTS DESCRIPTION CL 1 Disc assembly CL 4 REMOVAL CL 2 Release bearing and sleeve CL 4 DISASSEMBLY CL 2 INSPECTION AND ADJUSTMENT CL 2 REASSEMBL Y 4 CL REINSTALLATION CL 3 Clutch assembly CL 4 Release mechanism CL 5 DESCRIPTION The clutch is of type a single dry disc diaphragm spring The major components plate diaphragm spring and provided with riveted springs arranged plales are wire on clutch cover engagement rings The clutch disc is to both surfaces and coil in a link The coil and withdrawal lever Release bearing sleeve pressure control clutch Each part Therefore springs absorb shock clutch while engaging the clutch softening and smoothing clutch used engagement and disengagement of the clutch when assembly are a assembly is secured with rivets trouble is uncorrectable with a new replace assembly o 44 44 732 1 732 1 dia o M e Xl 240 9 45 dia g 255 10 04 dia e CX1 Fig CLot Construction CL 1 Unit of clutch mm in the CHASSIS REMOVAL The clutch same 2 ass manner as mounting mbly is dimlounted the engine assembly the clutch assembly efer primarily Thus in the I release mechanism Remove dust cover from clutch housing Remove bearing when dis 2 the Section TM to Removing separate Transmission and other relative sections 3 return Remove release front from spring the withdrawal lever from cover and bearing remove sleeve and bearing sleeve and bearing sleeve from withdrawal lever from withdrawal lever ball pin Fig CL 2 Clutch arsembly DISASSEMBLY When loosen remove Withdrawal lever ball pin 3 Return spring 2 Withdrawal lever 4 Release Fig separating clutch assembly from flywheel and 1 installation bolts diagonally and 3 CL 4 Removing release bearing and withdrdwallever Withdraw release use of a bearing bearing from bearing sleeve by Ihe bearing puller gradually CD Fig CL J Removing clutch Release bearing assembly Fig Note When CL 5 pport clutch cover bolts sufficiendy gradually diaphragm spring tension is and and loosen in carefully always applied because release bearing D IU AfJ separating clutch assemly from flyWheel stallation Withdrawing Thoroughly clean all disassembled parlo except for the disc assembly and release bearing wear I and check them for crack and other defective conditions CLUTCH Clutch 3 assembly Press the master gauge plate down exactly 7 8 307 0 1 etc Check clutch for excessive occurs on 2 cover diaphragm spring presswe plate crack and damage When noise wear clutch assembly replace Measuring and adjusting height of diaphragm spring in this first on Line up distance piece clutch assembly base plate special tool the height gauge plate is plate contacting clutch cover end with cover H from 7 8 nun The result indicates the distance by which in plate is to measure flywheel To do from to pressure pressed against flywheel is mounted diaphragm spring is That is indicated 360 kg 793 71b the by a when clutch initial pressure of gauge when pressure that distance with depressed by the pressure gauge is attached T2005S001 H on Then subtract the value cover 20051000 81 mounting face installed fully loosened 307 0 special tool 8T2oo58001 cover cover mounting face pressure 1 from clutch pressure with clutch mm a press to which If the pressure is less than replace clutch cover as an assembly H 7 8 0 307 H Stroke to be pressed 7 8 0 307 Clutch Tfil facing thickness Fig 2 CL 6 Base plate and distance piece Place clutch assembly clutch assembly on Measure the surface ofbase Height distance piece base plate stationarity condition distance piece is 3 on placed Under this beneath pressure plate diaphragm spring height from plate with vernier caliper depth of diaphragm spring end to 1 772 in at diameter 44 mm and set gauge 43 to 45 mm I 733 Fig the upper CL B 4 Measuring Adjust height diaphragm spring 1 693 in ST20500000 of pressure of diaphragm spring diaphragm spring by adjusting wrench the special if required 43 to 45 91693 to 1 772 BASE PLATE Unit Fig CL 7 Measuring mm lin height of diaphragm spirng Fig G L9 Adjusting CL 3 diaphragm spring height use of tool CHASSIS Disc If facing is soiled with gIease I kerosene and dress facing with Jf a I clean off with oil Replace wire brush facing if required 2 Check disc for deflection and repair 2 or deflection at the outer circumference of replace if the facing withdrawal lever and hearing sleeve contact When point is worn in step When occurs on and sleeve bearing Release assembly grease replace sleeve bearing leaks from release or noise release bearing replace release bearing exceeds the following value Upper limit of the deflection 05 85 rom rom 0 0197 in at 346 3 in radius Fig CL 12 Fitting rekase bearing REASSEMBLY Release mechanism 1 Fig CL10 Checking disc fur deflection Tightly sleeve as Replace disc assembly if facing is extent that the mm facing height above 0 0118 in facing is worn worn unevenly rivets are turn bearing with Apply multi purpose loose Bearing sleeve inside a finger and make grease to the CLot 1 Checking clutch facing for bearing sure that wear Fig CL 4 following places groove Pack this Fig on 3 0 2 or place bearing operates smoothly to such an rivet is less than to the bearing shown in Figure CL 12 When bearing is installed completely 3 fit release CL 13 Lubricated position on recess the bearing sleeve CLUTCH REINSTALLATION Withdrawal lever and bearing sleeve contact point lever Withdrawal ball pin and withdrawal lever Clean clutch pilot bushing contact surface and f1 it with multi purpose grease 2 Install disc assembly and clutch assembly by the of use a clutch aligning bar on flywheel special tool 00 ST20630 1 Withdrawal lever ball pin 3 Return 5pring 2 Withdrawal lever 4 Release bearing Fig CL 14 Position grease is 3 When grease is withdrawal lever on applied to install dust on Apply the necessary release bearing connect Note clutch grease to which applied clutch housing cover the withdrawal lever and places bearing install sleeve them with return spring on and housing compounded with molybdem Fig desulfide to lubricate main drive shaft splines CL J 5 Installing disc and clutch assembly CLUTCH CONTROL CONTENTS DESCRIPTION CL 5 Reassembly CL 8 CLUTCH PEDAL CL 6 Reinstallation CL 8 CL 8 Removal CL 6 Inspection CL 6 Removal CL 8 Reinstallation CL 6 Disassembly CL 8 Adjustment CL 6 Inspection CL 8 CL7 Reassembly CLog CLUTCH MASTER CYLI NDER OPERATING CYLINDER Removal CL 8 Disassembly CL 8 ADJUSTING Reinstallation CLog J nspection CL 8 BLEEDING CLUTCH SYSTEM CLog WITHDRAWAL LEVER CLog DESCRIPTION The 521 series vehicles adopt hydraulic type clutch pendent control system clutch pedal master and withdrawal lever The hydraulic type clutch control system consists of a fulcrum type Cl 5 cylinder operating cylinder The withdrawal lever is of an inner CHASSIS t I I I I I I Fig CL 16 Clutch control CLUTCH PEDAL Removal 1 Adjustment Remove return spring Adjust pedal pad height RH drive Loosen lock 2 nut of master cylinder push rod and selecting disconnect push rod end and applying shim Be sure to use shims s 545 in 138 5 mm to adjustment without stopper The is made for by having adequate thickness having same thickness for both upper and lower 3 Remove lock nut remove pedal and washer of pedal shaft and 153 2 Inspection disassembled and carefully check them for other abnormal conditions new ones 1 2 Repair or parts indicated wear damage replace secure the is 5 135 33 5 mm position with lock and 150 mm 5 91 in in so that the pedal for R H drive and nut for L H drive them with if required Note Pedal head rubber Return spring C t A L a Make sure that chassis grease has been applied to the it 3 Pedal lever bush A adjust pedal stopper properly Next pad height Thoroughly clean all below 6 02 in for L H drive rom lever MG marked portions two required noL JLr W PI U I ll J Do not saew in it more than 3 because pedal Grease t Reinstallation Reinstall clutch places in reverse sequence of removal cylinder CL 6 it may clog the return mm j 0 1181 inl port of master CLUTCH Adjusting Part number 30611 shim Thickness 27260 16 0 0630 30612 27260 0 8 0 0315 30613 27260 0 5 0 0197 Item model R H drive L H drive 8 Fig CL 17 Pedal height adjustment CL18 Sectional view of clutch CL 7 master mm in 126 4 96 117 4 61 Multi purpose grease CLUTCH MASTER CYLINDER Fig 2 1 Applied cylinder in mm mm in 33 s 5 13S 150 0 5 91 r CHASSIS Removal Reinstallation Disconnect 2 Disconnect clutch line from master cylinder pum rod from clutch Reinstall 1 pedal the master cylinder assembly sequence of removal and adjust follo Adjust pedal height by changing push Remove securing bolts and 2 remove rod length Bleed air out of the hydraulic system cylinder master reverse and drain fluid 3 s in assembly from vehicle OPERATING CYLINDER Removal Disassembly Remove return spring 1 Remove riller cap and drain fluid 2 Pull back dust cover and remove snap and return spring cup pusluod piston assembly primary assembly can 2 Di 3 Disconnect push rod from withdrawaHever 4 Release two bolts used to mount nect clutch line from ring Stopper operating cylinder be removed to clutch operating cylinder housing Inspection Thoroughly clean all parts with brake fluid before Disassembly inspection Remove dust 1 Check cylinder and piston for uneven wear cover or 2 damage Replace if required Remove snsp ring All other parts can be dis assembled 2 Replace cylinder wear or 3 piston primarily cup is disassembled It must also be deformation due to Check dust line for damage cover or found replace with whenever fatigue or oil reservoir master replaced when damage is found r fIller cap and clutch deformation If abnormal condition is new one It Reassembly Reassemble the ma5ter sequence of disassembly 1 cylinder assembly noting the following @t in reverse matters The piston cup should be soaked in brake fluid before reassembly Install piston cup carefully so Fig r 2 Apply brake fluid iIlW sufficiently to CL 19 Operating cyUnderdisassembled that it is cylinder and piston J Check all par and assemble them worn or CL 8 damaged especially piston cup and replace if CLUTCH Reassembly Reassemble operating cylinder in reverse sequence of disassem ly noting the following matters Soak piston cup in fluid before reassembly 1 piston cup carefully so that it is faced Apply brake fluid sufficiently 2 to Install correctly cylinder and piston and assemble them Reinstallation Reinstall the operating cylinder in reverse sequence of removal I Bleed air out of the hydraulic system 2 Adjust push 2 0 to 3 0 the following rod so that withdrawal lever end 0 0787 to mm 1181 0 in play is in accordance wilh instructions Unit 1 Lock nut 2 Adjusting 3 Withdrawal Fig CL 20 nut Adjusting mm 4 Release 5 Diaphragm spring in bearing withdrawal lever play WITHDRAWAL LEVER JUSTING AD Correct adjustment of the clutch withdrawal lever is essential Insufficient free bearing and to slip ment the between diaphragm spring fingers the causes BLEEDING CLUTCH SYSTEM release the clutch bleed Remove while excessive free travel affects full disengage dust screw from cap operating cylinder of the clutch The clearance between the diaphragm spring fingers drawallever end I travel as can release bearing and the be adjusted at 2 the with turn follows Loosen lock nut Open bleed Attach a screw tube approximately immersing container which contains tighten adjusting nut and eliminate 3 clearance between the top of withdrawal lever and release Fill master a three quarters of a the open end into a clean small amount cylinder reservoir of brake fluid with recommended fluid bearing 4 2 Return and set adjusting adjusting When nut adjusting nut I 3 4 turns from that stationarily with lock position Depress clutch pedal quickly while keeping retighten nut bleed and screw to return action until the fluid Repeat this pumping nut is returned I 3 4 turns withdrawal allow it it down slowly entering the container is free from air bubbles lever end is returned to 2 0 to 3 0 mm 0 0787 to 0 1181 in and clearance between release bearing and spring fingers is 1 2 to 1 5 mm 5 diaphragm 0 0472 to 0 0591 in Screw up bleed screw remove bleed tube and CLog on replace a down stroke of dust cap pedal CHASSIS SERVICE DATA AND SPECIFICATIONS All 521 series Clutch cover type Diaphragm MF200K Clu tch release lever Withdrawal lever end play mm in 2 0 to 3 0 0 0787 to O 1l81 Diaphragm spring to flywheel height mm in 43 to 45 1 693 to U72 Clutch disc Single dry disc 20OCBL Type Facing size Outer dia x Inside dia x Thickness cm2 Total friction area in 200 sq in 362 mm 130 x x 3 5 7 87 3386 0 to x 5 12 56 I Thickness of disc assembly Free in mm Compressed 6 8 in mm to 9 0 7 6 to 8 0 0 2992 to Numbe of torsion spring 3543 0 3 ISO 0 6 Allowable minimum deplh of rivet head from fscing surface mm in 3 0 O OI18 Allowable facing mm in 0 5 O 0I97 mm in 4 0 0 01 57 run lOt Allowable free play of spline at mdius 85 Clutch pedal Pedal height when not depressed in mm Free travel of pedal head Pressing strength at Master cylinder in mm full stroke for RH drive for LH drive 910 14 kg lb 3543 0 to 0 5512 13 2 29 I for RH drive 14 1 31 I for LH drive Clutch Master cylinder diameter Capacity 33 5 5 91 5 135 150 0 of clutch reservoir Operating cylinder mm cc in 15 87 Imp pts US pts 25 5 8 44 O 52 8 clutch Operating cylinder diameter mm in 19 05 0 750 Tightening torque Clutch assembly securing bolt kg m ft lb 1 5 to 2 2 CL 10 10 8 to 15 9 346 3 x O 1378 CLUTCH TROUBLE DIAGNOSES AND CORRECTIONS Probable Condition damaged Noises audible on Excessively pedal depression cated release bearing worn Corrective action cause or lubri poorly be cannot bearing and diaphragm spring Seized release the Replace out Insufficient pedal or broken clutch return and control springs Weakened broken or drawal lever return Excessive drive shaft pedal Set contact unhooked clutch with in springs weakened faces with felt polishers or the Replace position them replace or if snapped spring or hook it up as required spring between clutch disc hub and play diaphragm Readjust pedal free travel correctly free travel unhooked Weakened bearing Clean bearing with metal brush and smooth spring fingers fingers cased being greased inside the release Replace which bearing the Replace clearance spline drive clutch disc and between hub of shaft is within 0 50 endwise and 0 20 rom ensure that new clutch and rom 0 0197 in 0 0079 in crosswise When clearances exceed above limits replace the drive shaft also Noises audible pedal release on of Misalignment causes slight clutch disc to movement of disc flywheel hub in idling or Broken especially at low audible with place on drive shaft engine it set under run ut slight using a scriber speed weakened clutch or level of clutch disc with clutch disc in rotation and check for no respect of facing This noise is Set disc cushion Replace the clu Ich disc springs Insufficient pedal Weakened unhooked trol and pedal Set free travel return Weakened broken or broken clutch con Check the springs for correct position and replace springs or pedal free travel correctly unhooked clutch with them if necessary Replace the spring or hook it up as required drawallever return spring Distorted or worn Replace drive shaft the drive shaft and clutch disc if necessary Excessive play of release bearing on sleeve CL 11 slip Replace the worn parts CHASSIS Condition C lu1ch drags Probable Corrective action cause Insufficient push rod length Excessive Adjust the push free travel pedal Adjust Warped clutch disc Set level of clutch disc if possible Roughened linings Repolish loose broken or lining diaphragm to spring with linings Replace linings clenched with damaging bearing 5 0 run out a 0 0197 in mm metal brush or them if necessary replace Incorrect release length correctly free travel correctly Maximum plate Improperly filled rod Lining rivets pressure be should to protrusion plate and flywheel no avoid Adjust correctly finger clearance Clutch disc hub forcing on drive shaft Locate cause of trouble and remove it if possible otherwise replace the clutch disc Damaged drive shaft splines prevent the Replace the drive shaft also clutch disc from sliding if required Oil or grease on linings cLcate the mrrect Clean Warped or damaged pressure plate or clutch it or as cause of oil the clutch disc or grea se leakage and required replace linings defective parts Replace cover Air in the pockets hydraulic system not Bleed out completely bled correctly Dirt or master Air foreign matter on sealing faces of pockets in master Clean replace piston cup if damaged and bleed the system cylinder piston cup cylinder due to loose Replace piston cup and bleed the system piston Fluid leakage from cylinder Replace piston cup if damaged bleed the system Low fluid level in reseIVoir Top up with brake fluid and bleed the system if necessary Clogged vent hole in reservoir cap promotes infiltrate past the seal CL 12 Clean reservoir cap unclog the vent hole and CLUTCH Condition Abnormal lining Probable Corrective action cause Insufficient pedal free travel Adjust clutch pedal free travel correctly wear Driver steps unnecessarily lining causes wear on pedal and damage to this release bearing Advise driver to discontinue wrong practice and step clutch pedal only when on ne cessary Weakened or snapped Check pressure springs for tension pressure springs fied and replace springs if they as speci are un serviceable Incorrectly installed linings with new Replace linings them ones and install Check clutch disc for center correctly alignment Clutch drags Oil or grease on flywheel plate pressure and linings Remove cause of plate pressure leakage clean flywheel and and thoroughly replace linings Loose disc linings due to poor rivet tightness If linings rivets rivets disc hub does Clutch drive shaft not slide freely on not Otherwise replace defective worn replace linings and clutch securely Remove any shaft from spline are foreign matter or dirt When splines deposits trouble is still present replace damaged parts Warped or cracked pressure plate Replace Locate Misalignment pressure plate the defective adjust alignment or point and if possible replace distorted parts J Check Stiffened hydraulic control mechanism down Worn out lining Insufficient clutch pedal return travel to the control and pedal return springs being weak or linings cIu tch disc pressure or If necessary take components and make sure that the plate and flywheel are damaged Locate cause of failure and replace defective springs misadjusted Weakened Oil due pedal tension and lubricate Install new not Clutch slips spring or grease broken diaphragm spring on Overhaul clu tch and Remove linings cause replace springs of leakage and ifcleaning is ineffective CL 13 replace linings CHASSIS a Probable Condition Worn ij or Corrective action cause Replace linings burned disc linings Overloaded master cylinder d to a stricted transfer port re Overhaul piston the master cup if swollen cylinder replace the or damaged and clean the transfer port bleed the system SERVICE JOURNAL OR BULLETIN REFERENCE I JOURNAL or PAGE No DATE BULLETIN iO SUBJECT No 1 I J f I i 1 I l I 1 CL 14 I SECTION TM t TRANSMISSION em l DATSUN PICK UP MODEL 521 SERIES CHASSIS I BODY NlsSAN I NISSAN MOTOR CO TOKYO JAPAN LTD 1 TRANSMISSION TM TYPE F4W63 TRANSMISSION TM 12 TRANSMISSION GEAR CONTROL COLUMN SHIFT CONTROL SYSTEM TM 15 SERVICE DATA AND SPE CIFICATlONS TM 18 TROUBLE DIAGNOSES AND CORRECTIO N S TM 21 lr r TRANSMISSION TRANSMISSION CONTENTS DESCRIPTION TM l Gear and shaft TM 8 SPECIFICATIONS TM l Balk TM 8 REMOVAL TM 3 Shifting TM 8 DISASSEMBl Y TM 4 Oil seal TM 9 INSPECTION TM 7 Rear TM 9 9 ring insert engine mounting insulator Transmission case and rear extension TM 7 REASSEMBLY AND ADJUSTMENT TM Bearing TM 7 REINSTAllATION TM 12 DESCRIPTION 521 Datsun forward F4W63 Both series vehicles adopt type column shift I reverse 4 forward I reverse the type R4W63 consist of transmission gear assembly The housing are R4W63 transmission floor shift rear extension housing and unit and transmission and type F4W63 case 4 transmission case case With this construction cover transmission housing The transmission are is combined provided with to a single bottom a maintenance service can be made easily and This chapter mainly describes about the type R4W63 transmission case and rear extension transmission made of aluminum alloy metal The clutch SPECIFICATIONS L521T NL52 IT PL521TU N521U GN521U LG521 T GNL52 IT PL52ITN NL521 GNL52 I Final gear ratio G521U UL521 L521 LG521 V521U 4 875 4 625 375 4 4 625 375 4 VL521 4 875 4 625 Type F4W63 R4W63 R4W63 Control system Floor shift Column shift Column shift 1st 3 657 4 243 5 000 2nd 2 177 2 558 3 014 3rd 1 419 1589 1685 4th 1 000 1 000 1 000 Reverse 3 638 s 6 s os E Speedometer gear ratio 19 5 a b See 18 5 367 4 18 5 17 5 17 L Oil capacity Note VN521U U521U 521U VNL52 I Item os UNL521 Figure 2 0 TM l 17 L 3 6 US pts 3 0 Imp pts 2 0 L 4 2 US pts 5 3 Imp pts TM 1 5 146 17 5 17 L 2 0L 19 5 2 0L 18 5 17 L 2 t 0 CHASSIS l J 1 2 J 3 Extension Applied housing type short model GN521U GN521 G521U LG521 N521U NL521 UNL52l VN521U VNL521 2 long 3 short 521U L521 52IU VL521 L521T Fig TM j LG521T NL521T GNL521T PL521TU PL52lTN R4lV56 and F4lV56 transmissions TM 2 U521U UL521 TRANSMISSION REMOVAL For transmission dismounting applies Refer to Section ER the following procedure Engine Removal of this Manual I Disconnect battery cable from terminal 2 Remove du tch starting housing to motor and bolts used to attach engine Jack up vehicle and support it with four stands 3 Recommend a hydraulic hoist or open pit be utilized Fig if available 4 Disconnect 6 Disconnect front lamp exhaust tube from exhaust mani fold 1M 3 7 Detaching propeller shaft speedometer drive cable and back up switch cable from transmission extension housing Remove cotter and disconnect shift rods from pin Remove shift levers shaft assembly from transmis cross sion case 8 Remove clutch hous operating cylinder from clutch ing 9 Apply oil pan and support jack beneath a engine careful not to apply jack to oil pan drain plug applying jack apply jack a wooden block between oil pan and to protect oil pan from 10 Remove rear Be When engine damaging from transmission and mount cross member rw o hT 0 I V r@ co Q S I Cross shaft 2 Back up J Speedometer Fig 5 switch cable lamp drive Exhaust manifold 5 Propeller I shaft 11 TM 2 Bottom view extensi9n housing prevent oil Pull TM 4 out Removing mounting bolts rear transmission on Rear engine cross to engine rear mount once place rear member and pull it down toward fron t rear Note leakage I portion of extension of vehicle propeller shaft Seal the end of to extension mounting bolts Fig cable Remove four bolts from companion flange of gear carrier and detach with 4 Rear except equipped When dismounting transmission be careful damage flr r shift vehicle TM 3 clutch diaphragm spring hub spline not to CHASSIS 4 Remove 14 bottom cover bottom 5 cover Remove securing bolts and remove from transmission speedometer pinion and remove rear exten sion Note When rear extension cannot lightly tap it with Fig TM 5 Dismounting a plastic be removed easily or wooden mallet transmission DISASSEMBLY For transmission applies The casings careful not to disassembly the following procedure are damage made of aluminum alloy metal Be it 1 Drain gear oil from transmission 2 Remove dust cover spring and remove release withdrawal lever return withdrawal lever and release bearing from clutch housing Fig 6 Removing TNr eXtension CD used to fix crosS shaft rings @ and thrust washers Remove lock pins select link withdraw snap cross withdrawing lip with shaft together cross with outer and and lever When shaft be careful not to damage oil seal groove for snap ring Removing release bearing and withdrawal lever Fig TM 6 3 Remove five front cover front TM 8 securing bolts and remove cover Fig 7 TM Removing cross Double intermesh counter gear and and loosen main shaft lock nut Fig TM 7 Remo11ing front Note co 4 TM sluft Loosen interlock plug previously reverse idler gear I I I i I I I I I I I I I I I I I I I J I I I I I TRANSMISSION p with a drift using a fork rod pin punch Removing ear fork pull ST23510 0 tool special out rod I I I I I fnt I I I I I i r I I I I I II i I I I J I I I I I I I Fig I I 12 I TM 12 Driving out retaining pin Remove main shaft assembly from rear side and main drive gear from front side Note I When main cannot I shaft assembly and be removed easily case with or main drive gear lightly tap transmission asticor wood mallet I Fig 9 Remove front reverse 10 TM l0 Remol1ingcountergear and rear snap rings and withdraw idler gear and shaft Remove plug from interlock hole and take out spring and ball Note Be careful not 10 lose spring and GM check ball 0 ain drive gear Fig TM 13 Removing Main shaft shaft assembly main lvl i l l @ O c ili Fig II TM l1 RemoVing interlock hok assembly V V plug Drive out retaining pin used to fIx fork and rod by Fig TM 5 TM 14 Main shaft gear disassembled CHASSIS 13 and @ 14 Remove snap ring 4th 3rd remove See Figure from main shaft front side @ synchro assembly Remove main shaft lock nut viously and and 3rd gear @ TM 14 for part identification numbers remove reverse @ loosened pre gear and sleeve Fig Fig IS TM 15 Removing map When removing main shaft gear of 1st gear to bearing puller special and withdraw bearing retainer washer @ j Removing bushing ring apply the front end tool ST22130000 j and 1st gear simultaneously by using TM 17 a press See thrust Figure TM IS f@ @ 1 3 8 Snap ring 2 4th 3rd synchronizer special j rIng Mu and with draw synchroassembly together by using a bearing together with ht gear Support this cnd and with 4 1st gear bearing bushing 5 Thrust washer and ball 6 Main shaft iog 7 Main shaft bearing nizcr assembly and 2nd gear TM 18 9 draw 1st gear Cross sectional view bearing bush totethcr with synchro of main shaft gear pm f 2nd gear @ main Removing bearing Ir the front end shaft forward depress synchronizer with ST22130000 ht 2nd Fig TM 16 this end toot asscmbly assembly Fig Support @ 2nd gear and withdraw 1st 2nd @ and bushing @ 17 all To disassemble spread springs press TM 6 synchronizer from both ends assembly remove TRANSMISSION Push out counter shaft from 8 or rear to front with a drift using a fork rod pin punch Removing fork pull other proper tool and take out counter gear Fig 12 jJ special tool ST235IOOOO out rod 1M 12 Dril1ingoutretainingpin Remove main shaft assembly from rear side and main drive gear from front side Note When main shaft assembly and or main drive gear cannot case Fig 9 front Remove e rever 10 TM l0 be removed easily lightly tap transmission with asticor wood mallet Removingcountergear and rear snap rings and withdraw idler gear and shaft Remove plug from interlock hole and take out spring and ball NOlE Be careful notlD lose spring and G check ball Main drive gear Fig lM 13 0 Removing i Main main shaft assembly shaft assembly l c @ d1 I Fig II lM 11 RemoVing interlcck hok pL g Drive out retaining pin used to fix fOlk and rod by Fig TM 5 lM 14 Main shaft gear disassembled r CHASSIS 13 and @ 14 from main shaft fron t side Remove soap ring remove See Figure and and 3rd gear @ TM 14 for part identification numbe Remove viously synchroassembly 4th 3rd main shaft lock nut remove reverse @ loosened pre gear and sleeve Fig Fig 15 TM 15 Removing map When removing main shaft gear of 1st gear to and withdraw washer @ bearing puller special bearing retainer @i Removing bushing ring apply the front end tool ST22130000 1st gear simultaneously by using TM 17 a ill and press See thrust Figure TM IB I Snap ring 2 4th 3rd 8 synchronizer pecial assembly 3 1st ST22 I 30000 2nd synchronizer and with draw together bearing with I st gear 4 1st gear 5 Thrust washer and 6 Main shaft iog 7 Main shaft bearing nizer assembly and 2nd gear Fig TM 16 this end with tool depress main shaff forward assembly Fig Support bearing bushing TM 18 9 ball Support this end draw 1 st gear Cross sectional view and with bearing totether with bush synchrcr of main shaft gear Removing bearing ppot the front end of 2nd gear assembly synchro together by using @ a @ 2nd gear and withdraw 1st 2nd @ and bushing @ all 17 To disassemble synchronizer spread springs from both ends press TM 6 assembly remove TRANSMISSION INSPECTION Thoroughly cJ and check clean all disassembled parts with solvent them for and other defective damage wear conditions @ Transmission o 18 9 1 Coupling 2 Shifting insert Fig sleeve TM J 9 cr case and extension rear Clean them with solvent thoroughly crack which may cause oil leaking and check for and other defective conditions 3 Synchro hub 4 Spread spring When bur joint repair Synchronizer disassembled To disassemble main drive gear remove snap Remove adhesive from 3 Repair or other damage exists on replace 2 ben t or ring or pitting and or replace installing surface completely dowel pin knock pin if damaged warped from front side by using snap ring pliers 4 Replace rear extension if interior is worn bushing unevenly Bearing I compressed 2 When ball bearing inner crack or out are worn race 19 Removing snap ring Remove main drive gear bearing with bearing puller special tool ST30030000 and press and cen ter 3 Replace needle 4 Replace rear bearing if worn extension or bushing if worn ir main drive gear Fig bearing TM 7 TM 22 wear or damaged t Removing ball a new one ii t rig race unsmooth due to unevenly V t TM 21 dust with of round of ball is excessive due to rough surface replace bearing with TM 20 remove air sliding surfaces Fig and Thoroughly clean bearing dry Inspecting baIl bearing or cracked CHASSIS Gear and shaft End 5 plays of I st 2nd range from 005 to 0 15 I Check gear replace 2 as for damage and wear crack or and shaft soap for crack wear and worn 0 0020 to 0 0059 in the end play is deviated from this range required Check and 3rd gears should be in mm When select proper ring again spline Replace if required 3 Check main shaft for straightness Replace main shaft with new one 0 15 mm 0 0059 in end exceeds maximum l Maximum out run if a out run at rear t Fig Balk TM 25 Measuring ge IT end pl4y ring Check balk rings for Replace Fig 4 TM 23 C cking s 1in m ft fOT straightness Measure backlash of each gear When gear is excessively beyond driven gears are limit replaced as recommend a both drive as 2 Place balk ring in position ring to 16 pitting chip on cone of each gear Push gear and check gap between balk worn 0 031 in replace balk and ring end face This gap should be within 1 2 to 0 047 to 0 063 in mm and or bur required clutch tooth front face and wear When gap is less than 0 8 ring with a new one mm It is worn excessively set Standard all gears 0 05 to 0 10 Wear limit all g 0 20 mm 0 0079 in mm 0 0020 to 0 0039 in ars Fig TM 26 Balk ring tcrcone installing dimension i Shifting insert Replace if worn excessively or unevenly deformed Fig TM 24 Measuring gear backlash damaged 8 TM or TRANSMISSION Oil seal Replace snap ring Rear is if lip is deformed dropped worn or cracked or when off engine mounting insulator Replace if weakened deteriorated or cracked REASSEMBLY ADJUSTMENT Reassemble When assembly transmission in reverse sequence reassembling note the following of dis 3 Main shaft and gear When drift to Note 1 Snap ring 4 1st gear 2 4th 3rd 5 Thrust washer and ball assembly 6 Main shaft Ist 2nd synchronizer 7 Main 3 synchronizer 1M 28 Fig matters fitting main shaft ball transmission depress bearing Be to sure Driving bearing bushing bearing adapter special inner race use a hollow tool ST23800000 firmly install thrust and ball wash bearing bushing shaft bearing assembly Fig TM 27 Main shaft assembly Fig 4 1 For both I st 2nd and blies 4th 3rd synchronize install synchronizer hubs toward correct assem For proper 1M 29 4th 3rd snap Fitting main shaft bearing synchronizer hub ring from snap lifec synchronizer hub end play is shaft Part number select ring those listed below so minimum tion 2 When fitting I st gear needle bearing collar use a Note a to brass drift If end of collar is deviated damaged Recommend a piece 1st gear end play is 32263 14600 40 1 to 32263 14601 45 1 to 1 50 45 1 32263 14602 1 50 to 1 55 32263 14603 55 1 32263 14604 1 60 to 1 65 mm in 0 0551 to 0 0571 0 0571 to 0 0591 0 0591 to 0 0610 of mild metal be applied while tapping b Thickness Do not use wooden mallet TM 9 to 1 60 0 0610 to 0 0630 0 0630 to 0 0650 that JfIl CHASSIS 5 disassembly To lock main shaft install main shaft in transmis sion double case with the rated to 79 5 lb ft intermesh gears tightening torque 8 0 tighten lock to 11 0 kg m For shown in the nut proper thrust 57 8 0 05 and fIrmly bend lock washer side tluust washer five types available are Select washer so that counter gear end 0 15 to rear following table mm 0 0020 0 0059 to in play as a is when assembled Note Install thrust washer 132225 A0900 Part number G o Lock washer TM 30 Fig Thickness in front side mm in 32225 A0900 35 2 to 40 2 0 0925 to 0 0945 32225 A090 I 40 2 to 45 2 0 0945 to 0 0965 32225 A0902 45 2 to 2 50 0 0965 to 0 0984 55 2 0 0984 to 0 1004 32225 A0903 2 50 to 32225 A0904 2 55 to 2 60 0 I004to 0 1024 Lock nut Tightening lock nut 6 Main drive gear drive Reassemble main disassembly For those below listed snap so in gear ring that reverse sequence select proper one of Reverse idler gear from Reverse idler gear is reassembled in reverse sequence of drive gear end play is disassembly minimum For snap ring five types following table Select play Part number Thickness mm 149 to 1 55 0 0587 to 0 0610 32204 08001 156 to 1 62 0 0614 to 0 0638 32204 08002 1 62 to 1 68 1 0638 to 0 0661 32204 08003 1 68 to 1 74 0 0661 32204 08004 74 1 0 0685 to 0 0709 32204 16500 1 80 to 1 86 0 0709 to 0 0732 32204 16501 1 86 to 1 92 to 1 80 to are available proper snap ring is 0 05 shown in the so that reverse idler gear end 0 0020 to 0 0059 in to 0 15 mm when assembled in 32204 08000 a as Note Install snap ring 32285 14600 in front side 0 0685 Part number 0 0732 to 0 0756 Thickness mm in 32285 14600 1 15 to 1 25 0 0453 to 0 0492 32285 14601 35 1 0 0531 to 0 0571 to 45 1 o 7 32285 14603 I 45to 1 55 0 0571 to 0 0610 22285 14604 1 05 to 1 15 0 0413 to 0 0453 Counter gear Counter gear is reassembled in reverse sequence of TM 10 TRANSMISSION Shift fork and operating lever i l Rear view o 3 J Forward 1 c 1 @ Operating lever ass 3 y Reverse shift fork 41st Reverse check Fig TM 31 shift rod 2nd shift fork 5 shift rod 6 3rd 4th shift Operating Layout ofshift fork and operating fork ver ass shift rod y lever Install each fork rod and shift fork Note shift fork 8 Pay attention b Be sure that there is to no installing direction gap between fork rod and shift fork 2 Install each fork rod together with check ball plug check ball check ball spring and interlock plunger by using a fork rod guide special tool ST23620000 Fig Note a I nstall fork rod in a position In standard 3 When position upper surface of plug is installing plug be sure to apply Set Insert flush with upper surface of adapter c Layout of check ball where fork rod check ball groove is coincided with ball b TM 32 thread up operating cross lever shaft into case to the correct direction Assemble thrust washer lever in case and set snap ring and operating lever stationarily with lock pin See Figure TM 3 I Lock pin tightening torque 3 0 to 0 2 to locking agent TM 11 4 0 operating cm kg 3 in lb 0 I f I f 0 CHASSiS REINSTALLATION Remount transmission in reverse sequence ofdis mounting Q JwaSherl 2JCross slirlt Fig TM 33 Installing fLockPin cross shaft TYPE F4W63 TRANSMISSI ON CONTENTS DESCRIPTION TM 12 INSPECTION REMOVAL TM 13 ASSEMBLY TM 14 TM 13 Shift fork TM 14 AND INSTALLATION DISASSEMBLY DESCRIPTION The tion is the type F4W63 transmission is used especially for Thus floor shift type vehicle Generally however the construe same as in this TM 34 yp T REPAIR F4W63 TM 12 transmission TM 14 that of the type R4W63 tran chapter description control system and relative matters t Fig AND is made ssion only for the TRANSMISSION REMOVAL AND INSTALLATION Remove speedometer pinion assembly drive procedures for removal and installation of Primarily the F4W63 transmission mission 6 are 7 the same as R4W63 trans For the F4W63 transmission however removal and Remove eight rear extension remove rear extension housing securing housing Disengage s bolts iking rod from fork rod gates and installation of shift lever are required DISASSEMBLY Drain transmission gear oil Remove dust cover 2 spring remove release withdrawal lever withdrawal lever and release return bearing from clutch housing Remove five front 3 front 4 cover securing bolts and remove cover Remove 14 bottom cover bottom cover securing bolts and remove TM 37 Fig from transmission case 8 Removing rear extension Unscrew three check ball plugs and remove springs and balls 9 Drive out rods and 10 gear Move and retaining pins used remove at to secure forks to fork rods and forks Ist 2nd and the same time 4th 3rd coupling sleeves into lock main shaft Release main shaft nul 11 Withdraw counter shaft and together with needle roller bearings Fig TM 35 Removing bottom Remove clevis pin used to secure striking Release reverse rod to remove reverse control lever Fig counter gear and spacers cover 12 5 remove 1M 36 Control arm Fig TM 13 idler gear secu ing snap idler gears and shaft TM 38 Removing reverse idler gear ring and I CH ASSIS 13 Remove bearing four bolts used to secure main shaft retainer to transmiSsion case Fig 15 TM 40 Drawing out main slraft assembly Draw out main drive shaft INSPECTION AND REPAIR Fig 1M 39 RemovingmainslraftbNring retiD For detailed procedure for inspection and repair refer to the section Service covering the type R4W63 data and specifications transmission are shown in page TM 18 14 Draw out main shaft assembly from transmission ASSEMBLY case The transmission is assembled in reverse sequence to disassembly in the section Refer to the instructions and notes described covering the type Shift fork h f t 1 f l 21st Fig 2nd shift fork TM 41 shift rod Layout ofshift fork and operating lever TM 14 R4W63 transmission l TRANSMISSION I Install shift forks 1st 2nd and 4th 3rd on sleeves and apply 1st 2nd fork rod 2 Place 4th 3rd interlock plunger in Place interlock 3 coupling reverse the position and fit plunger in the position and assemble shift fork and fork rod Secure each fork to fork rod with retaininjfpin rp 4 fork rod r TRANSMISSION GEAR CONTROL COLUMN SHIFT CONTROL SYSTEM CONTENTS REMOVAL TM 16 ADJUSTMENT TM 17 INSPECTION AND REPAIR TM 17 Shift linkage TM 17 INSTALLATION TM 17 Select TM 17 linkage 31 To be lSE 1 Control rod 4 Shift lever 1 Select rod 2 Lower 5 Select lever boss 8 Shift lod 3 Cross shaft 6 Select lever bracket and knock Fig TM 42 Control system 4 forward speed TM 15 transmission greased When disassembled r CHASSIS REMOVAL Remove steering wheel assembly o Snap ring 0 Fig 4J TM Fig 2 Remove Removing sleering steering column shell w cover I TM 46 Withdrawing C washer hand lever Remove C washel 4 turn l Controllcver pivot pin signal and lighling switch Fig 44 TM Removing sleering column slrea I Lock 2 Select lever and select rod 3 Lower bracket pin and lock wire co 47 7M Fig 4 Shift lever and shift rod 5 Select lever boss Separating ever and rod lever from shift rod 5 Separate shift 6 Separate 7 Remove lock 8 Withdraw select lever select lever from select rod pin and select lever boss pivot bolt select lever and shift lever 9 Loosen positioning Fig 3 45 TM Removing Remove snap turn signa and lighting ring and control lever switc pivot pin and lower knock TM 16 an extent that pin can be removed 10 Depress control upper support turn control rod and withdraw hand lever bracket up to such rod downward remove it from lower bracket to change direction of remove it toward driver s compartment TRANSMISSION The individual Note joints use small washers and snap When rings Before removing check them for reinstalling apply chassis installing grease to the following parts sequence and direction I Select lever pivot bolt bushing 2 Select lever boss select lever guide unit 3 Reverse check unit 4 Insert and change lever units in upper portion of INSPECTION AND REPAIR Check all sliding parts and other components for and defective other conditions Replace as wear required control shaft INSTALLATION Install control system in reverse sequence of removal Cross shaft both frame and transmission sides 5 ADJUSTMENT J Figure A CD mm nli 10 94 Steering 100 C 24 n J line oc Control rod line center 77 CID center 3 03 in M nnl l @ Ef Figure mm II B II 1 Shift 2 Select 5 Reverse check 6 Trunion 3 Select rod 7 Shift rod 4 Control rod 8 Outer lever shift lever lever Fig Shift ou 9 t TM 48 Transmission control Control rod 11 Beneath steering wheel linkage assembly return linkage Outer lever select 10 spring seat on lower bracket comes into contact with control rod ring 1 Set transmission outer lever to neutral position Note 2 arrives Select 1 trunion nut Adjust A In this arrangement change lever is in B posi tion and tighten it when change lever position linkage Arrange component parts so that reverse 2 Set transmission outer lever to 3 Tighten able force is check TM 17 trunion nut at applied to a neutral position select rod where position no unreason CH ASSIS SERVICE DATA AND SPECIFICATIONS CONTENTS General specifications TM 18 Specifications TM 18 General TIGHTENING TORQUE TM 20 specifications Type Con trol system Synchromesh type F4W63 R4W63 R4W63 Floor shift Column shift Column shift Warner Warner Warner Gear ratio 1st 3 657 4 243 5 000 2nd 2 177 558 2 3 014 3rd 1419 1 587 1 685 4th 000 1 1 000 1 000 Rev Speedometer gear 3 638 ratio 19 5 Final gear ratio Extension 18 5 4 875 4 625 housing Oil capaci ty Note a b See page TM 2 17 5 375 4 5 146 18 5 17 5 19 5 4 625 4 375 4 875 short long long short long 7L I 2 0L 7L I 2 0L 2 0L 71 1 2 0L 3 6 US pis 3 0 Imp pts 2 0 L 4 2 US Imp pts Specifications Model F4W63 R4W63 Item Each gear backlash For all gears Standard backlash 0 05 in mm to 0 10 0 0020 to 0 0039 Replacement standard 4 625 long Extension housing 3 5 18 5 short I 7 L pts 367 4 mm 0 20 in 0 0079 TM IS TRANSMISSION Model F4W63 R4W63 Item Each gear standard end play For aU gears mm 0 05 to 0 15 in 0 0020 to 0 0059 Balk ring cone clearance StMdard clearance mm 2 to 1 6 1 in 0 0472 to 0 0630 Replacement 4th 3rd standard 0 8 mm in 0 0315 adjusting shim Part number 32263 14600 Main drive gear adjusting Reverse idler gear 40 1 shim in 0 0551 to 0 0571 32263 1460 I 1 45 to 1 50 0 0571 to 0 0591 32263 14602 1 50 to 1 55 0 0591 to 0 0610 32263 14603 55 1 0 0610 to 0 0630 32263 14604 1 60 to 165 0 0630 to 0 0650 to to 1 60 Thickness mm in 32204 08000 1 49 to 1 55 32204 08001 56 1 to 1 62 0 0614 to 0 0638 32204 08002 1 62 to 1 68 0 0638 to 0 0661 32204 08003 1 68 to 1 74 0 0661 to 0 0685 32204 08004 I74 to 1 80 0 0685 32204 16500 1 80 to 186 0 0709 to 0 0 32 32204 16501 1 86 to 1 92 0 0732 to 0 0756 Part number 0 0587 to 0 0610 Thickness mm to 00709 in 32285 14600 1 15 to 1 25 0 0453 to 0 0492 32285 14601 35 to 1 45 1 0 0531 to 0 0571 32285 14602 25 1 to 35 1 0 0492 to 0 0531 32285 14603 45 1 to 1 55 0 0571 to 0 0610 22285 14604 TM 19 mm 45 1 Part number shim adjusting Thickness 1 05 to 1 15 0 0413 to 00453 1 i CHASSIS Model R4W63 F4W63 Item Counter gear thrust washer Thickness Part number in mm 32225 A0900 2 35 to 40 2 0 0925 to 0 0945 32225 A090 I 2 40 to 45 2 0 0945 to 0 0965 32225 A0902 45 2 to 2 50 0 0965 to 0 0984 32225 A0903 50 2 to 2 55 0 0984 to 0 1004 2 55 to 2 60 0 1004 to 0 1024 32225 A0904 Tightening torque kg Transmission proper Engine Front 2 4 to 2 8 transmission installation bolt cover 08 transmission installation bolt tightening nut Companion flange tightening to 10 4 to 1 8 1 Rear extension transmission installation bolt Main shaft m nut 174 to 20 2 5 8 to 10 1 7 2 to 13 0 8 to II 57 8 to 5 79 10 to 14 723 to 2 1Ol 3 3 to 3 8 Rear engine mount installation bolt ft lb 1 to 3 25 2 0 to 3 0 14 5 to 7 21 Back up lamp switch 2 0 to 3 0 5 14 to 21 7 Bottom 0 8 to 1 0 5 8 to 7 2 2 2 to 2 9 to 15 2 2 2 to 2 9 Filler plug Drain plug 5 2 cover installation bolt Speedometer pinion Interlock Operating to 3 to 0 installation bolt 5 3 23 9 to 27 5 4 0 18 7 to 2 1 1 plug 3 0 lever for both shift and select to 4 0 Reverse check 2 0 to 3 0 Transmission outer lever 0 8 to 1 0 Trunion nut for both shift and select 2 0 to 2 8 TM 20 3 12 5 t021 7 14 5 8 to 14 7 2 5 to 20 2 TRANSMISSION Select lever pivot bolt 0 5 to 0 8 3 6 to 5 8 Lower support bracket 0 6 to 1 0 3 to 4 7 2 Steering wheel tightening Transmission gear control nut 7 0 to 5 7 50 6 to 54 2 floor shift Control lever installation bolt 1 9 to 2 2 13 7 to 15 9 TROUBLE DIAGNOSES AND CORRECTIONS Condition Probable Corrective action cause Difficult to Causes for difficult gear shifting intermesh gears and transmission are classified to troubles concerning the control system When the gear shift lever is heavy and it is difficult to shift gears clutch disengagement may also be unsmooth First make sure that the clutch operates correctly and inspect the transmission Worn gears shaft and or bearing Insufficient operating stroke due or I ips out of mesh to worn Repair or or damaged synchronizer Replace In the most case this trouble occurs when the interlock is replace loose sliding part Defective Gear Replace worn or In this weakened case shooting the trouble cannot be corrected by replacing gears must be carried out It should also be weakened front and check A rear engine mounts Replace or weakened or Replace broken spring Worn fork rod ball groove Replace Worn damaged bearing Replace Worn or damaged spring and therefore trouble noted that gear slips out of mesh due to vibration ball and or carefully Worn interlock plunger Worn plunger check ball and when the control system is defective or Replace gear TM 21 generated by fI CHASSIS Probable Condition Noise When noise occurs noise occurs while Insufficient or Corrective action cause under engine idling and stops while the clutch is shifting gears it may be judged Add oil or improper lubricant Oil leaking due to defective oil seal and disengaged Clean or at a Replace Damaged bearing Cyclic knocking sound Replace occurs replace high speed occun also at a low speed Worn each spline Replace Worn each bushing Replace SERVICE JOURNAL OR JOURNAL DATE BULLETIN BULLETIN REFERENCE or No PAGE No SUBJECT TM 22 when replace with designated oil gasket clogged breather etc Worn bearing High humming or that the noise is from the transmission SECTION PD PROPELLER SHAFT DIFFERENTIAL CARRIER CI DATSUN PICK UP MODEL 521 SERIES CHASSIS BODY I NISSAN I NISSAN MOTOR CO TOKYO JAPAN LTD PROPELLER SHAFT AND UNIVERSAL JOINT PD 1 DIFFERENTIAL CARRIER PD 5 7 1 C PROPELLER SHAFT DIFFERENTIAL CARRIER PROPELLER SHAFT AND UNIVERSAL JOINT CONTENTS DESCRIPTION PO ASSEMBL Y REMOVAL PD 3 SERVICE PO 4 DISASSEMBL Y PD 3 TROUBLE INSPECTION PD 3 CORRECTIONS PD 4 AND SPECIFICATIONS DATA DIAGNOSES AND PD 5 @ @ Fig PO I Propella shaft for UV N 521 and except Floor Shift vehicles DESCRIPTION Three GN 521 types and 52 IT series vehicles These of are vehicle are counter balanced within propeller shafts for UV N 52l cm gr The used tapped con for a propeller good riding comfort at occurs 36 000 kill high speed Therefore the ones unbalance of IS an factory with the best 9 000 km assembled in the PD may be unbalanced if with a hammer while servicing or erroneously flying rocks or during off road driving Check propeller shaft is very important propeller shafts in service parts and at 4 000 rpm at the propeller shaft bottoming struction A correct balance of lz in care Floor shift vehicles except GN52IT propeller shafts adopt solid tubular steel 0 2 shaft joint and 24 000 miles and center bearing every propeller shaft spline every 6 000 miles for grease CHASSIS f rA 6 u Fig PD 2 Fig Propeller shaft for PD3 G NJ521 series vehicles Propeller shafr for Floor shift vehicles PD 2 DIFFERENTIAL CARRIER PROPELLER SHAFT REMOVAL N UV S21 Remove except propeller transmission side Floor shifl vehicles shaft carefully spline and rear oil G N S21 and Floor shift vehicles Remove so differential gear not to damage seal 3 joint mounting bolts from both and remove case as transmission and bearing mounting brackets DISASSEMBLY Primarily is balanced are required do not disassemble as an When assembly however the propeller shaft because and disassembly it Fig repair following procedures apply S 1 With journal movement installed on When journal does not Lightly Note match propeller shaft can 3 marks on and other be reassembled to the Remove snap ring sleeve parts as yoke required of yoke with a hammer and race smoothly move When removing to Put base tap withdraw bearing check it for propeller shaft disassemble 2 Removing bearing PD5 journal from yoke be careful not damage jau mal flange yoke so that they original condition with an ordinary screw driver CD @ ClO A Fig PD 6 Exploded view INSPECTION Check each part and repair When Fig PD4 Removing snap replacing journal unit or replace replace if defective as an assembly ring 2 When journal pin exterior A yoke hole C or is pitted or cruised replace 4 Remove bearing 3 PD 3 When is worn damaged replace 1 CHASSIS is CD 4 When snap ring 5 When bearing oil seal ring damaged deformed replace or Propeller shaft installation bolt 2 5 to 3 0 is @ 6 damaged or When sleeve damaged 18 5 to 22 m Jb ft yoke and main shaft splined portions replace sleeve yoke and I are main shaft is propeller shaft tube surface dented Direction slackness or replace cracked When center 8 kg and or needle roIler replace worn or worn When 7 @ bearing is worn or damaged replace ASSEMBLY Assemble propeller shaft in sequence reverse to dis assembly Grease is sealed in joint Fill joint with wheel so bearing grease whenever a proper snap ring 0 0008 in so that a shim to side joint less than 10 ring ring having the Install and assemble mm is selected be same Snap ring gap Select over size Selection of snap ring 0 to Color sure Thickness Part number mm in identification thickness for components correctly under bending friction resistance of moves kg cm adjust that slackness is 0 to 0 02 so Moreover when a snap to select another soap opposite as PD 7 propeller shaft is overhauled Snap ring functions also Fig that no greasing is required 37146 14600 2 00 0 0788 White 37147 14600 2 02 0 0795 Yellow 37148 14600 2 04 0 0803 Red 37149 14600 2 06 0 0811 Green 37150 14600 2 08 0 0819 Blue 37151 14600 2 10 0 0827 Brown 37152 14600 2 12 0 0834 No paint 56Ib in Tightening torque Companion flange center G521 and GN521 bearing unit installation nut 10 to 15 kg m 74 to III ft Ib Bearing mounting bracket installation bolt G521 and GN521 4 to 2 7 2 m18 kg to 20 Jb ft SERVICE DATA AND SPECIFICATIONS Vehicle 52IT Floor shift U V N521 Except Distance between joints mm in 1 233 68 9 Spline model Permissible unbalance x 5 48 16 Involute spline gr cm rpm 15 4 000 PD4 GN521 GN52 IT 1st 615 24 2 2nd 743 3 29 5 63 x 16 Involute spline 15 4 000 1st 615 24 2 2nd 983 38 7 5 63 x 16 Involute spline 15 4 000 PROPELLER SHAFT DIFFERENTIAL CARRIER TROUBLE DIAGNOSES AND CORRECTIONS Condition Vibration tion Probable Vibra occurs Worn haft at medium during or the Unbalance due to bent and high speed vibration transmitted needle damaged universal joint Replace bearing on propeller or Corrective action cause or dented propeller Repair or replace shaft i Loose propeller shaft installation to Retighten l body I Worn transmission rear extension t r Damaged Knocking sound during starting noise Worn or on bearing Replace damaged universal joint Replace center or during coasting Replace bushing Worn sleeve yoke and main shaft spline Replace pro peller haft Loose propeller shaft installation Retighten Loose joint installation Adjust snap ring Damaged Replace center bearing DIFFERENTIAL CARRIER CONTENTS DESCRIPTION PD 5 Adjusting REMOVAL PD 6 Adjusting side bearing DI ASSSEMBL Y PD 7 I PD 7 gear tooth contact INSPECTION AND REPAIR PD 8 ASSEMBL Y AND ADJUSTMENT PD 8 SERVICE DATA PD 8 TROUBLE PD 9 CORRECTIONS I nspection before disassembly Assembling differential gear case Adjusting pinion height nspecting drive pinion preload and shim repairing PD lO PD ll drive PD 13 INSTALLATION PD14 AND SPECIFICATIONS PD 14 DIAGNOSES AND PD 15 DESCRIPTION The differential gear carrier is made of light and strong aluminum alloy and uses Shims and washers contact hypoid bevel are Differential gear oil should be replaced at initial I 000 gear km used for adjustments of tooth and preload and backlash of the gear PD 5 600 miles checked every 3 000 km replaced every 36 000 km 24 000 miles 2 000 miles CHASSIS ID @ 1 j I j I @ j @ Qt @ I Companion nange 2 Front 3 Spacer 4 Pinion bearing height adjust shim 8 Side bearing IS Drive gear 9 Bearing 16 Lock 17 Adjust shim 18 Thrust block 19 Side gear 20 Pinion mate shaft cap 10 Differential 1 Oil case 81 5 Pinion mate gear 12 6 Pinion mate gear 13 Drive pinion 7 Side gear thruit washer 14 Rear bearing 8 Cross secaonal view P Fig Adjust washer pin of differential carrier REMOVAL When removing gear carrier pinion companion flange remove two rear to axle shafts assembly disconnect drive flange yoke Refer to connection and REAR AXLE for removal of rear axle 1 Jack up rear axle support it with a stand and drain gear oil 2 Remove 3 Remove companion rear axle stallation bolts remove CD shaft flange and propeller and housing installation nuts shan in @ and differential gear carrier assembly Fig PD 6 PD9 Removing differenti4 gear carrier PROPElLER SHAFT DIFFERENTIAL CARRIER DISASSEMBLY Note Be sure to segregate left lright anc side bearings together with shims Inspectio before 1 In order to obtain the oil assembly for disassembly cause leakage of trouble and measure tooth pinion When tooth contact and backlash are incorrect measure backlash and torque Unbend diagonal drive gear and pinion contact 4 correctly check lock washer loosen installation bolts in and separate drive gear sequence of drive S Pull out lock pin and turn and shaft pinion drive gear hack tiIting also mate gear side gear remove pinion mate block and thrust lst thl washer 1 Secure differential gear carrier assembly special tool tightening t 2 ST07320000 nut and side bearing Remove differential and right side bearing case and remove on side a stand bearing Note Segregate left and right gean and thrust washers cap assembly and segregate 6 eft Hold companion flange tool SB1530000 outer races j and remove Note J remove with a pinion flange wrench special nut withdraw flange drive pinion Be careful not to lose preload adjusting shim I I I j i 1 Fig 3 Withdraw PDl0 side Removing differentidl bearing with puller case special tool Fig P 12 Removing pinion nut SB3010000 7 Remove represser rear bearing inner race by the use special tool SB0030000 t I I I Fig PDl1 R moving side bearing Fig PD 7 PD 13 Removing bearing inner race of a f CHASSIS Be sure to replace it with Note new one when rein Apply bearing seized damaged are adapter an to race s side surface and withdraw O Put removed pinion height adjust oil seal P marily replace 6 Gear carrier Differential replace mate gear thrust washers excessively replace weakened is damaged or replace oil seal whenever disassembled worn or cracked replace worn or cracked case When sliding part is 8 pinion or worn When sliding part is 7 noise occurs seal When outer race shims in order or When side gear and 4 stalling 9 rotation drags during Remove oil seal from differential gear carrier 8 replace Flange When oil seal lip contact surface is damaged replace ASSEMBLY AND JUSTMENT AD Assemble differential carrier in disassembly by noting Fig PD 14 AND REPAIR Drive gear and drive 1 or and repair or pinion positions 2 Clean shim washer and bearing contact surfaces 3 When installing bearing bearing When installing oil seal 4 adjusted correctly replace 2 When tooth seized replace 2 or gears surface is tooth as a contact cannot be carefully cracked or damaged thrust washer replace Repair not to damage oil seal with lip with an surface is oil stone when worn or wear or Install pinion mate gear 1 damaged replace seized differential pin hole case on case thrust Coincide pinion case block and side gear mate shaft with lock and install it seizure is U When Bearing When bearing is seized differential gear Assembling UHUU 3 as lips and install or on When so fIll space between gears as a set When tooth surface is cracked or 2 filling part set Side gear and pinion mate gear 1 When fitting C 21 08 or G I 0924 MIL multi purpose grease When wear is excessive put gear oil however clean off oil from check them for and adjust correctly at the time of reassembly cause on defective When tooth contact is incorrect I to matters Put shims and washers in order and install them the correct Thoroughly clean all disassembled parts replace if worn damaged following sequence rrace outl Removing 1 INSPECTION the reverse thrust exfoliated worn rusted value or 8 PD adjustment is required washer so that clearance select a proper side gear is within the standard PROPELLER SHAFT DIFFERENTIAL CARRIER Side gear thrust washer Thickness Part number mm in ST3321 0000 38424 25660 0 76 to 0 81 0 0299 to 0 0319 38424 32200 0 81 to 0 86 0 0319 to 0 0339 38424 32201 0 86 to 0 91 0 0339 to 0 0358 38424 32202 101 to 1 06 0 0398 to 0 0417 38424 32203 1 06 to l ll 0 0417 to 0 0437 Fig PD 16 Installing side bearing Adjusting pinion height Install pinion on specified preload measure differentia1 7 to 10 carrier temporarily apply 1 to 8 9 in lb 6 and m kg pinion heigh t When installing pinion on differential carrier do not install oil seal Note Do not tighten spacer and shim When PD15 Fig Measuring sjd applied gear back clearance adjustment to pmlon are is nut excessively oot installed required adjust thickness back of rear bearing cup Fit rear bearing 1ltool Speci cone to drive pinion ST30030000 Standard side gear back clearance 002 3 to 0 08 Fit lock pin 0 0008 to 0 0031 in mm caulk circumference of lock pin hole and lock it 4 Install drive gear head with a hammer on differential tighten case bolts in Tapping bolt diagonal sequence bend lock washer to lock bolts Tightening torque 4 8 to 5 5 5 kg m 35 6 to 40 7 ft Ib Fit side bearing together with ferential case by ihe use of a adjust shim drift special to dif tool ST332 10000 r Fig PD 9 PD 17 because Installing pinion bearing of shim CHASSIS 2 drive Apply bearing pinion carrier to and install front Remove drive 6 install shim cone pinion the on from back of differential carrier and bearing rear cup When adjusting preload check pinion height again 3 and tighten companion flange Install 7 to 10 specified preload nut so 6 2 to 8 9 in Ib kgem that can be obtained drive Adjusting 4 Install gauge ferential carrier and and drive tool measure clearance between gauge end pinion end surface ST31100000 dif special with a on thickness gauge I Spacer and rear bearing pinion preload washer to be cones are applied between front and used for adjustment of preload When adjusting oil seal is not installed 2 ST31100000 adjust washer front bearing Install spacer flange on pinion and tighten pinion nut with cone and prescribed tightening torque Note Turn pinion by hand so that nut is not tightened and excessively in thickness of spacer and washer when pinion does not rotate 3 Measure preload of spacer and washer to drive pinion and select proper obtain the prescribed preload Special tool ST3120OO00 Fig 5 PD 18 Measuring clearance Thickness of drive pinion height adjust shim can be obtained by the following equation T N Where H 0 01 x 0 2 T Thickness of shim N Value measured by thickness gauge H Number on drive pinion head Calculation example When N is T 0 5 5 and H is 0 2 x 0 01 Pinion Part number 2 0 2 0 28 heigh t adjust Fig shim Thickness mm 1D 19 Measuring preload in Bearing 38153 10601 0 050 0 0020 38154 10601 0 075 0 0030 Length Part number n 38156 10601 38157 10601 0 250 0 0098 500 0 0 0197 spacer mm o 2 6673 38166 3 2202 6775 38167 3 68 00 2 6772 202 PD lO i in PROPELLER SHAFT DIFFERENTIAL CARRIER i Pinion bearing adjust washer Thickness 38135 09400 2 43 00957 38136 09400 2 41 0 0949 0 1004 38137 09400 2 39 0 0941 53 2 0 0996 38139 09400 37 2 0 0933 51 2 0 0988 38140 09400 35 2 0 0925 2 49 0 0980 38140 09400 2 33 0 0917 38141 09400 31 2 0 0909 Thickness 38127 09400 59 2 38128 09400 57 2 38129 09400 55 2 38130 09400 09400 38131 38132 09400 4 Part number Part number mm 0 1020 1012 0 38133 09400 47 2 0 0972 38134 09400 45 2 0 0965 Remove and install oil seal flange oil seal with a new in Be sure to E F replace width whenever differential carrier is one Tolerance of left against 0 7874 in disassembled and om Install flange and washer and tighten pinion nut with 5 cm torque 14 to 17 kg prescribed tightening is mm or in mm right side assembled standard expressed size 20 rriIi1 in unit of 0 01 0 0004 in is expressed as one 104 to 129 lb in 6 Turn preload side Adjusting I to let flange make sure that of pinion bearing Use the same shim bearing and or pinion bearing breaking again is correct again shim unless differential case side replaced carrier is in and or preload of bearing is abnormal 2 When side bearing replacing approximately 2 5 kg before installing new 5 5 Ib and use weight block of measure bearing width bearing 20 00 mm 0 7874 in Standard width Fig Left side shim thickness Tl Right A C D F x om 0 175 Where Adjusting side shim bearing mm side shim thickness 3 T2 PD 20 B D F x 0 01 A B Mark on C D Mark on 0 150 mm Apply selected shim bearing gear carrier 4 differential mallet and install it case PD ll e to differential case and fit side cone Tap differential case on assembly lightly gear carrier with a rubber F O 3 T 1 I CHASSIS When the width is insufficient 8 Side bearing shim Part number Thickness 38453 61200 0 05 mm in 9 add shim Measure drive gear and drive pinion backlash When backlash is less than standard value it from left to move 0 0020 right Move from right to left when excessive Q7 0 0028 0 38454 61200 38455 61200 0 12 0 0047 38456 61200 0 25 0 0098 38457 61200 50 0 0 0197 Standard backlash 0 13 to 0 18 mm 0 0051 to 0 0071 in 5 Coincide marks on and install bearing cap bearing on cap and bearing housing bearing housing Fig Fig PD21 Installing bearing cap 10 PD23 M When fluctuation of backlash is excessive drive gear back deflection A 6 Tighten bolts in tightening torque 4 diagnal 2 to 4 8 kg sequence m 31 to with prescribed between drive gear and differential case Deflection limit Measure dimension between left and right bearing cap edges by use of a cap measure foreign material may be bit 35 ft Ib 7 the h bacU ring gauge special 0 05 mm 0 002 in tool 00 ST32110 Standard dimension 198 40 to 198 55 mm 7 811 to 7 817 in II Fig PD22 When dirve gear deflection backlash fluctuation is excessive Measuring width PD 12 is replace satisfactory but gears 3S a set DIFFERENTIAL CARRIER PROPELLER SHAFT Inspecting and repairing drive TOE tooth contact gear l I Put red lead Minium evenly three to four teeth of drive gear on both surfaces of turn drive gear to both directions several times by hand and check drive gear for tooth contact 2 When tooth contact is incorrect shim adjust Be sure to wipe completion of adjustment a readjust off red lead HEEL SIDE thickness of completely upon Fig c Heel contact When surface is insufficient contact damaged Adjust by reducing thickness side DRIVE heel may of shim in Flank increases right one so left side d and drive Replace of side bearing and increase thickness of shim in PD 27 Flank contact contact When backlash is be HEEL COAST SIDE too tight tooth edge flank contact occurs Noise is pinion adjusting that drive pinion easily in step worn washer with a thinner is moved away from drive gear Face contact TOE In the most excessive damaged replace one so HEEL DRIVE SIDE Fig b case Noise In this trouble occurs when backlasH is increases and tooth edge is easily order to obtain correct tooth contact drive pinion adjusting that drive pinion washer with a thicker is moved to drive gear HEEL COAST SIDE TOE PD 25 Heel contact Toe contact When contact surface is in sufficient toe may damaged Adjust by reducing thickness of shim be HEEL SIDE HEEL DRIVE SIDE in left COAST side of side bearing and increase thickness of shim in right side Fig PD 28 Face contact TOE HEEL SIDE DRIVE Fig PD 26 TOE HEEL COAST SIDE HEEL DRIVE SIDE Fig Toe contact HEEL COAST SIDE PD29 Correct contact r PD 13 r CHASSIS e Correct contact shim is accompanied by change in backlash Check When proper tooth contact is obtained lead from ilear face A correct contact pattern that it lies in the range of 2 3 when no load is wipe off to 3 4 from it when red installing gear means INSTALLATION tip of tooth applied Install differential in carrier reverse removal Lubricate gears with gear oil upon Note Change in the thickness of adjusting washer sequence completion of installation or SERVICE DATA AND SPECIFI CATIONS Final gear type Hypoid Final gear ratio number of teeth 521 7 36 5 143 V52 I 37 8 4 625 G521 N521 GN512 39 8 4 875 VN521 UN521 35 8 375 4 PL521 35 8 375 4 50 6 to 3 72 Drive pinion Preload when using new bearings without oil seal kg m ft Ib 7 to 10 Standard distance between drive gear center and top face of drive pinion Thickness of drive pinion mm in mm in 61 2 402 adjusting washers 31 2 to 2 59 Spacing Length of drive pinion bearing 0 0909 to 0 1020 02 0 0079 0 mm in 67 56 to 68 00 2 6598 to 2 6772 Backlash between drive gear and pinion mm in 0 13 to 0 18 0 0051 Runout of rear side of drive gear mm in Less than 0 05 0 0020 mm in 0 76 mm in 0 02 to 0 08 0 0008 spacer Drive gear to 0 0071 Side gear and pinion mate Thickness of side gear thrust washers to 11 1 0 0299 to 0 0437 Clearance between side gear and thrust washer Side to 0 0031 bearing Standard width mm in 20 00 0 7874 0 12 0 0047 0 50 0 0197 PD 14 0 25 to 0 0098 PROPELLER SHAFT DIFFERENTIAL CARRIER Tightening torque 122 9 Drive pinion nut kg m ft lb 14 to 17 Drive gear bolts kg m ft Ib 4 8 to 5 34 7 to 39 8 Side bearing cap bolts kg m ft Ib 4 2 to 4 8 4 to 34 7 30 kg m ft Ib kg m ft Ib 2 101 to Differential carrier to axle housing fIx nuts Companion flange to propeller on drive 11 6 to 174 5 to 3 0 18 1 to 2 7 21 DIAGNOSES AND CORRECTIONS Condition Noise 4 2 shaft ftx nuts mOUBLE 16 to Probable Shortage C aerective action cause of oil Incorrect tooth contact between drive gear and drive Supply gear oil Adjust tooth contact pinion side differential Damaged bearing or Replace or adjust improper adjustment Damaged Noise on coast Replace defective parts gear Incorrect backlash between drive gear and Adjust backlash drive pinion Incorrect adjustment of drive pinion bearing Noise on drive Worn or damaged drive pinion bearings Adjust correctly Rebuild differential and replace as required and coast Incorrect tooth contact pattern Damaged side gear drive gear Adjust backlash drive pinion Replace as or replace hypoid required teeth surface Seized drive gear and drive pinion Replace hypoid Pinion bearing under inadequate preload Adjust preload Seized damaged or broken pinion bearing Replace bearing Seized damaged or broken side bearing Replace side bearing Replace differential Swinging defferential case PO 15 gear set case gear set n 7 J CHASSIS Noise on rom Corrective action Probable cause Condition Loosen clamp bolts and nuts holding drive Retighten gear side torque bearing etc Side gear jammed in differential Pinion gears Worn or too Replace side gear thrust washer damaged designated tightening Replace defective parts case their shaft tigh t on them to the as required Replace and pinion thrust washer backlash bwtween drive gear and Excessive Incorrect backlash drive pinion Replace Worn differential gear or case Breakage of Shortage of oil differential Severe selVice due use or to excessive worn parts Rebuild differential and replace of improper oil an Adjust backlash loading After adjusting preload as required of bearings backlash and engaging condition of gears fasten parts Incorrect adjustment of drive gear and drive and apply specified volume of genuine oil pinion Avoid abusing of the Excessive backlash to due car defacement of side gear and thrust washer Loosened bolts and nuts such as drive gear bolts SERV JOURNAL DATE BULLETIN uLri OllAt nl Un tilULLt tE i h i l or PAGE No SUBJECT No PD 16 gear SECTION FA FRONT AXLE FRONT SUSPENSION DATSUN PICK UP MODEL 521 SERIES CHASSIS BODY I NISSAN I NISSAN MOTOR CO TOKYO JAPAN LTD FRONT AXlE FA FRONT SUSPENSION fA 9 SERVICE DATA SPECIFICATION S FA 19 TROUBLE DIAGNOSES AND CORRECTIONS FA 21 1 r lit FRONT AXLE FRONT SUSPENSION FRONT AXLE CONTENTS Inspection FA 3 FA 2 Reinstallation FA 7 FA 2 Wheel DESCRIPTION FA FRONT AXLE Removal 8 FA bearing adjustment DESCRIPTION Fig The knuckle spindle FA l Cross sectional view is installed on the knuckle spindle parts support through the king pin The king pin bushing is placed between the knuckle spindle and of ront king pin sliding arm FA l Knuckle spindle Inner wheel 3 Outer wheel bearing 4 Oil 5 Wheel hub 6 Washer 7 Spindle nut 8 Bearing cap 9 Brake drum bearing seal 10 Wheel nut 11 Knuckle spindle support 12 King pin 13 Thrust bearing 14 Fulcrum bolt 15 Fulcrum pin 16 Spindle shim 17 King pin lock bolt or nu t t8 Collar 19 Knuckle arm 20 King pin bushing axle and the knuckle 1 2 thrust bearing is inserted between the spindle and knuckle spindle support is set stationariIy on the knuckle The knuckle spindle and when CHASSIS knuckle the operated the knuckle secured on supported is with two is lightly wheel bearings spindle and brake drum and wheel are With this the wheel hub with hub bolts construction spindle spindle the knuckle round king pin axis wneel hub The on arm moves wheels lightly rotate round the knuckle axis FRONT AXLE Removal I Jack up vehicle and support it with stands 2 Remove hub nuts and wheeL Fig 11 Remove brake hose from wheel hole cylinder 5 6 Remove brake drum 5 Remove hub cap 6 Remove cotter mean Plug nut M8 screwing a rod or by drilling a plug threading hole may be removed 0 256 in dia mm with a tap 4 Removing lting pin lock Remove plug from the top of king pin with other proper 3 FA 3 a on upper bolt into threaded hole and by pulling boll pin and spindle nut from knuckle spindle 7 Remove wheel hub wheel from knuckle 8 Remove knuckle 9 bearings oil seal and collar spindle brake disc assembly from the flange of spindle Remove knuckle arm from knuckle spindle Fig 12 king Fig 10 FA 2 Removing knuckk Apply FA 4 Removing king pin plug drift to the top of king pin and drive out pin together with lower plug ann Remove king pin lock bolt Fig FA 2 FA 5 Removing king pin FRONT AXLE Tap spindle lightly with 13 a copper FRONT SUSPENSION Clearance limit 0 15 lead hammer or 0 0059 in mm and detach it from knuckle spindle support Be careful not to i Standard dimensions drop thrust bearing King pin r outer diameter 19 979 to 20 000 mm inner diameter Bushing 0 7866 to 0 7874 in when filled 20 010 to 20 035 mm 0 7878 to 0 7888 in if ldf 2 1 tI Fig Lightly tap 14 by applying race a FA 6 brass bar circumference with and remove from wheel hub When tapping a When 2 worn or cracked replace hammer wheel bearing outer outer race 3 circumfer tap evenly ence When grease leakage is detected during disassembly replace Removing spindle support outer race Oil seal Wheel bearing Remove grease from wheel check bearing ness for condition operating Visual indicated as serviceability with solvent and Check it for sound and appearance be checked with bearing hub bearing outer race rotating smooth Rolling surface ca installed standard for wheel on wheel bearing are follows Standard dimensions Outer bearing Fig FA 7 Exploded view of bushing Inspection Replace worn damaged 19 990 diameter 0 7870 to 0 7874 mm in to 52 000 Outer 51987 diameter 2 0467 to 2 04 72 mm in to bearing 31988 to 32 000 2594 1 to 1 2598 64 987 to 65 000 2 5585 to 2 5591 f King pin and bushing when 20 000 Inner Inner l seized rusted or excessively and clearance between king pin and bushing toward diameter direction exceeds limit listed below FA 3 CHASSIS Visual Serviceability Standard for Wheel Bearing INNER RACE SUR FACE OUTER RACE FITTED SURFACE COLLAR SURFACE OUTER RACE SURFACE INNER RACE FITTED SURFACE ROLLER ROLLING SURFACE INNER RACE SMALL COLLAR LARGE COLLAR ROLLER SUPPORTER OUTER RACE Unserviceable x when minor May be used Judgement 0 emery paper Rust should be removed with Race and roller Cause s t O O atU 8 Flaking l l 15o l l ii Service life due to rolling fatigue x before the service life The However this following causes are symptom occurs considered Abnormal load overload Improper handling Crack x x x improper installation or Excessive tightening Gap is excessive and a considerable shock is received from the outside Rapid heat generation on the race due to creep Abnormal thrust load Tapped FA 4 with a hammer while removing FRONT AXLE FRONT SUSPENSION I Race and roller i 1 l g o Cause l a 0 0 0 0 0 Seizure l l ro 00 l u x x In x the most discoloring Scratch 6 6 or wear 6 6 foreign removal of result other handling or Recess made 6 6 by Poor lubricant 6 bit foreign grown scar due to quality matter deteriorated lubricant or Intrusion of dust Fitted surface is Wear due to excessive preliminary pressure 6 6 6 Excessive preliminary pressure Fretting 6 6 6 The fitted part is discolored to brown Fretting on 6 6 6 corrosion remarkably worn Biting Rust the as striking striking Wear occurs matter Careless installation 6 made by pressing or seizure cases flaking Shock is given carelessly during installation 6 Bit Recess or rust on or lubrication faulty or fitted part black fine relative slip means metal contact surface increased Temperature bearing becoming stops during operation moisture inside the lowers bearing is when the condensed fine drips and the grease is moistened The bearing has been placed in a highly moistened place for a long period of time Intrusion of moisture chemicals touched with bare hand and no etc the or rustproof bearing is action has been taken Discoloring The wheel bearing is Slight discoloring may become like oxidized oil stain due to serviceable if discolor grease ing with can be solvent removed by or In the most high polishing l FA 5 cases this Occurs when preliminary pressure is too 17 CHASSIS Inner RoUer race Recess Cracked roller bit flaking Cracked inner inner race made on Recess by foreign matter race on auter race made by bit foreign matter III Recess bit 4 on foreign roller made by matter Spindle Check 5 spindle for exploration or dyeing test When bearing inner spindle with a crack new one by means of a race slips against spindle When thread is Check front hub for crack by magnetic and replace if cracked Fr nt hub exploration or dyeing test and means of a magnetic replace if cracked replace damaged repair or Standard dimensions replace Outer bearing Inner bearing Standard dimensions Wheel hub bore Outer bearing Inner bearing mm in 51 955 to 51 974 2 0455 to 2 0462 64 955 to 64 974 2 5573 to 5580 2 A 19 9721019 985 Spindle diameter mm in 0 7863 to 0 7868 31967 to 31983 2585 1 to 6 2592 1 Thrust bearing Check thrust bearmg FA 6 and replace If damaged rusted FRONT AXLE or it does not rotate smootWy or noise occurs FRONT SUSPENSION U Spindle nut when thread is Repair or replace as side utilize upper side as reaming reaming guide and upper side center damaged both When reaming upper side bushings 7 from Perform reaming lower utilize lower when reaming lower and guide to align the line correctly Bushing inner when fitted diameter 20 010 to 20 035 0 7878 to 0 7888 in mm Reinstallation 2 Reinstall front axle in noting the following reverse matters to removal sequence Moreover I I install thrust by 3 G2108 MIL 10924 to sliding parts When so use support be to face covered side Jack bottom up the clearance by means of Install bushing carefully by the spindle sure to upward Selecting spindle shim I replacing king pin and bushing ST35380000 bearing on when installing front axle lightly apply multi purpose grease or When installing spindle spindle of spindle slightly filler gauge measure and select proper shims to obtain the correct clearance Standard clearance of a special tool a 0 04 mm 0 0016 in or less that grease groove toward circumferen tial direction is in upper side and bushing joint is faced rearward Spindle shim Grease groove Upper Part number Thickness 40032 25660 0 075 0 0030 40033 25660 0 25 0 0098 40034 25660 0 75 0 0295 in mm side Lower side 2 Fig FA 8 King pin bushing When smoothly readjust king pin When shim is turning filled make sure to operate resistance exceeds standard value and check bushing and king pin if neces sary 2 Remove grease bushing through diameter nipple and threaded grease Approximately hole is drilled thoroughly drill grease hole nipple hole 3 mm 0 1181 in remove on King pin turning Drilling resistance 5 1 cm kg 3 in Ib 1 When grease metal particles and bur 4 Install plug after applying seal n its circumference and caulk three positions around spindle by punch 3 use Ream the inside of bushing to standard value by the of king pin bushing reamer special tool HT56802000 5 FA Install bearing outer race CHASSIS 6 Fill wheel hub and hub cap with MIL G2108 Figure 10924 or up to 1lurpose multi grease J Wheel bearing adjustment the described level See I FA 9 Tighten spindle nut to the specified tightening torque Tightening torque 2 to 3 4 3 kg m 1 to 24 6 ft b 23 Fig 7 FA 9 Filling space between heel Fill space between wheel bearing rolle seal lip pocket with multi purpose grease bearing and grease MIL G2108 Fig or FA 11 heel Tightening bearing lock nut 10924 completely 2 Turn wheel hub a few turns toward both clockwise and counterclockwise to settle down bearing tighten spindle 3 nut to the same Turn wheel hub a and counterclockwise and measure starting tightening torque bearing torque is on spindle few turns toward both clockwise again to allow rotation bearing breakingin starting torque If measured deviated from Measuring heel the specified value readjust Fig FiHing FA 10 space between heel bearing rollers with grease 8 shaft Apply grease mentioned to spindle 1lurpose multi threaded portion bearing wheel bearing washer and wheel lock nut exterior Note In order to bearing carefullV on lightly piiivide bearing with grease seal washer that dust and 5 no a proper pressure collar and lock nut foreign material stick Fig grease applied to them FA 12 starting torque FA 8 re Return spindle nut in range from 400 to 700 and cnincide it with cotter pin hole 4 and bearing rotation FRONT SUSPENSION FRONT AXLE Note Wheel bearing rotation starting torque New bearing and seal 15 Used bearing and seal 7 Spring balance indication New bearing and seal Used bearing and seal Correctly measure tiar direction starting against hub force toward tangen bolt 13 0 in Ib orless em kg 1 in Ib 6 em kg or b less No slackness should exist toward axial direc tion at hub bolt 2 1 kg 4 6 Ib 1 0 kg 8 or less 5 2 2Ib or less Apply cotter pin spindle to secure nut and install hub cap FRONT SUSPENSION CONTENTS FA DESCRIPTION FRONT SUSPENSION 9 Reinstallation FA 14 FA 17 ADJUSTMENT FA lO Removal FA 10 Vehicle posture FA 17 Inspection FA 12 Wheel FA 17 alignment DESCRIPTION @ ijI Ql @ @ 1 Upper 2 Lower link link 3 Tension rod 4 Knuckle spindle support 5 Upper link spindle 6 Lower link spindle 7 Fulcrum 8 Fulcrum bolt 9 Cotter pin pin 10 Shock absorber t1 Frame 12 Adjusting shim 13 Lower 14 Upper bump 15 Bracket bumper rubber r rubber f Fig FA J 3 Cross sectional view FA 9 offront suspension 1 CHASSIS The front suspension is double wishbone type in a which uses torsion bar dependent suspension Both the upper and lower links bracket secured on the upper and lower links frame by are means swing through spring installed on the of welding The screw bushing and rubber bushing respectively Top and bottom of installed respectively link and screw the knuckle through bushing on spindle support rubber bushing on are upper lower link The tension rod is installed tension rod receives a force on applied the lower link The to the front and rear directions The front end of the torsion bar the torque is installed the arm on on is installed on the lower link The rear end is connected to anchor spring stationarily by spring means of serration and the torque arm by means the anchor arm The shock absorber is of of serration and is Spring anchor set 3 Anchor bolt Torsion bar spring member a Fig hydraulic double acting Removing anchor bolt FA 14 type The shock absorber installed between the lower link and the bracket to absorb vertical vibration In addition two bamper rubbers are installed on the frame through 6 Spring anchor torsion bar spring and stabilizer the bracket limiting link operating ranges In relation to the above stabilizer is also available as an described standard parts a I Jack down slowly torsion bar optional part 2 spring toward and remove spring anchor and rear When stabilizer is used lizer bracket to frame Then remove remove bolt securing stabi stabilizer from lower link 7 FRONT SUSPENSION Detach shock absorber by removing upper and lower nuts Removal I Jack up vehicle and support it with stands 2 Remove hub nuts and wheel 3 Remove front axle See Section FA Front Axle 5 nuts Remove anchor bolt after loosening lock and adjust using jack under spring anchor a Fig FA 10 FA 15 Shock absorber FRONT AXLE 8 RemOve nuts tension rod D from the front and rear FRONT SUSPENSION ends of Remove bracket bolts @ from the front end of tension rod and then detach tension rod together with bracket Fig Fig FA 16 Tension rod 12 FA 18 Removingcotterpin Drive out fulcrum pin with a drift and detach knuckle spindle support from lower link Remove dust cover Remove fulcrum bolt after 9 detach knuckle loosening spindle support from its nut and upper link Fig J Fulcrum bolt Fig 2 Screw FA 19 Removing fulcrum pin bushing FA 17 Fulcrum bolt 13 Remove upper link bushing from knuckle spindle support 10 Remove screw bushings from both sides offulcrum pin 14 I Remove tightening nut from lower rear side of knuckle spindle support and drive out cotter pin Remove upper link detach upper link camber FA 11 adjusting spindle shim spindle installation bolt and from mounting bracket with CHASSIS Remove lower link 17 arm CD bolt and separate torque torque arm arm @ and torque link from lower f Fig 15 Twist and spindle FA 20 separate upper link and remove dust cover separated upper link on a I Upper link spindk from upper link and dust seal vise and remove screw Secure bushings FA 23 Lower link and torque Fig ann r 18 t Using bushing special a tap it with bushing from a tool to lower link ST36070000 hammer and drive out lower link bracket r J t I I Fig 16 Removing Loosen lower link link spindle on FA 21 spindle screw nut Remove lower link with bushing and remove torque arm lower installed lower link from lower link mounting bracket Fig FA 24 Removing lower link bushing Inspection I or Shock absorber noise ocems replace shock absorber with a new one Check upper and lower rubber bushings for condition Fig FA 22 and Removing lower link FA 12 replace if necessary FRONT SUSPENSION FRONT AXLE replace if necessary Specifications for Shock Absorber Check dust seal for wear and Max Min 12 4 315 mm length 205 mm 8 1 in 110 mm 3 in 4 Stroke and replace damage as in length required Check threaded part of upper link spindle fulcrum pin and screw bushing and repair or replace if necessary force Damping Rebound 110 Compression 55 kg kg 5 Ib 242 3 3lb I21 Lower link bushing upper link bushing I O 3m Check rubber 0 98 ft sec sec bushing for condition and replace as necessary 2 Upper link spindle Apply pin and screw bushing end measure When end upper link fulcrum pin and to play toward play exceeds spindle upper link or 0 35 screw bushing 4 spindle and fulcrum Check torsion bar for distortion and weakness Whim axial direction 0 0138 in mm fulcrum pin together posture of vehicle is adjusted and replace cannot be obtained wIth screw See bushing Check Torsion bar dust Specifications cover for weakness and damage Adjustment vehicle height new one of vehicle posture and for Torsion Bar Spring Diameter Part number L R 54009 10 Short mm 15200 14900 Long 54009 10 Van 54009 10 15200 54009 10 15200 10 54009 Option damaged repair or deg ft lb x 830 2 99 x 32 7 216 219 x 830 3 74 0 862 x 32 7 27 0 20 7 x 830 2 99 0 815 x 32 7 21 6 x 830 2 99 0 815 x 32 7 21 6 219 x 830 3 74 x 32 7 27 0 Bumper deg rubber Replace when weakened threaded part is m 20 7 0 862 6 or kg in 14900 Tension rod When tension rod is distorted and Torsional regidity length x 0 815 20 7 Double cabin 5 replace specified torsion bar with a or damaged replace When cushion rubber is weakened or 7 damaged replace Upper link and When distorted damaged repair FA 13 or lower link cracked replace or damaged or when thread is 1 CHASSIS 1 I Lower link bushing which lower link bushing mounting bracket is inserted and bushing 5 kg 9 m 615 to 68 7Ib ft Upper link 3 When collar interior of lower link along 5 to 8 Tightening torque Reinstallation Tighten I seal and dust bushing screw on upper link Install grease cover exterior are rusted remove rust with emery paper 24 to 25 kg Tightening torque 2 Apply disassembly hammer tool special a to lower link and fit lower ST36070000 bushing link tap bushing it used for evenly with lower to 5 to 180 8Ib ft 173 a 2 MIL G2108 r indicated by asterisk bushing 10924 or Apply in Fig thread grease to interior and thread on upper link bushing r on spindle suffici ently 6 Ie I screw fitted to upper link with multipurpose grease FA 27 0 u Fill link mounting braclwt r m r i t r v 62 5 2 4611 I j I l Fig 2 I FA 25 Fitting IoweT link bushing Lower link 44 6 Install torque arm on lower link Fig T I ghterung torque 2 3 Arm head 2 5 to 3 1 kg Serration boss 0 8 to 12 kg m InStall lower link on 1 to 22 4 Ib ft 18 m 5 8 to 8 7Ib ft Screw front and 1 756 length in lower link mounting bracket 4 so rear links Unk plug mm dimension inl spindle link against upper that opening width standard recommend fIller and tighten lower link spindle nut at the position oflower link shown in Upper link and up FA 2 in the same Unit U561 A spindle is 44 6 When mm screwing be removed Upon installation make sure to operate upper link spindle smoothly Fig FA 26 Operating 5 resistance Remove filler Less than 5 kg 0 install grease plug m 3 6 nipple grease until grease comes out from dust cover lb ft and inject Reinstall filler plug 6 Install upper link bracket Be used before I sure di Apply pin imd thread Fig FA 26 Installing 10 link to use same on upper link mounting camber shims which were embly iurpose grease multi on screw Grease screw bushing FA 14 spindle the bushing sufficiently to thread on fulcrum interior sufficiently FRONT SUSPENSION FRONT AXLE 2 Install dust seal knuckle on 5 spindle support Remove f1ller grease until 3 Coincide of notch direction for cotter pin on plug install grease and nipple inject grease comes out from dust cover Reinstall f1l1er plug fulcrum pin with direction of pin hole of knuckle spindle fulcrum and drive support support with into hole into knuckle pin spindle copper or lead hammer Insert cotter a tighten lock 6 pin Upon installation make sure that fulcrum pin operates smoothly nut Less than 0 5 Operating resistance 0 4 to 0 6 kg Tightening torque kg 3 6 ft Ib m m 2 9 to 43 ft Ib 7 Install knuckle upper link bushing on the upper end of spindle support Install the upper end of knuckle spindle 8 upper link arrange support them to condition shown in on Figure FA 30 and tighten fulcrum bolt Tightening torque 4 7 to 5 2 kg m 34 0 to 37 6 ft Ib 4r t Fig Be sure to install fulcrum bolt from side of vehicle a Installing fulcrum pin FA Z8 rear l Screw bushings in both sides manually and tempora 4 rily that knuckle so spindle lower link and retighten Make torque angle is support be Note sure 76 50 support is in the center of them to the that knuckle Make sure specified tightening and lower link spindle again that knuckle spindle is in the center of lower link TIlls operation can @ j 4 performed easily by removing f1ller plug Tightening torque 24 to 25 kg I73 m 5 to 180 8 ft Ib 54 5 mm 2 146 in Fig FA 30 Assembled posture of knuckle spindle and upper link Tension rod 5 I Unit 9 05 to 11 05 0 3563 to 0 4350 Fig FA Z9 5 1 437 36 Installing mm inl an nut on the rear end of tension rod to obtain extent that rubber mm 9 05 to 1105 4350 0 3563 to 0 screw Tighten 3IS 1 in as bushings shown n are compressed Figure FA 1 3 into and tighten lock f nut 2 bushing fA 15 4 33 Install tension rod bracket on frame bracket r or r CHASSIS 3 Make the distance of rubber bushings to be 36 6 1441 in mm nut on the front eod of by tightening tension rod When adjust rubber bushings are compressed unequally position of adjusting nut the I Lock nut tightening torque 5 to 2 1 kg 1 m 10 8 to 15 2 ft Ib Bracket bolt tightening torque 1 5 to 2 1 10 8 to kg E m E 15 2 ft Ib Fig Bracket bolt 1 5 to 2 1 4 mm 33 FA 32 Stabilizer instJJUation tightening torque kg m 10 8 to 15 8 Torsion bar spring Grease serrations I sufficiently Note Be and install it careful to both ends on on torque select left springs correctly They Right 36 6mm 2 ft Ib 1315 in 2 1441 in and L Left Position lower link so can of torsion bar torsion bar arm and right be identified with R marked on the end surface that no clearance is between lower link and bumper rubber and install spring anchor Fig 6 FA 31 Tension rod installation on Figure Shock absorber Turn nut fully against torsion bar to obtain A dimension shown FA 33 the threaded upper end ofshock absorber and tighten lock nut with specified tightening torque Note Be sure to position suspension as shown in F Figure 30 A Upper lock nut tightening torque 1 5 to 2 1 kg m 10 8 to 15 2 Lower bolt tightening torque 3 6 to 26 0 to 7 3 4 lb ft kg m 1 31 lb ft Stabilizer Tighten nut to arrange the and stabilizer as shown in height between lower link Figure FA 32 Fig FA 16 FA 33 Anchor ann instal1Jtion in FRONT AXLE FRONT SUSPENSIO t 3 Jack up applied spring tighten Figure FA 33 nut anchor which anchor bolt is dimension that so meets the standard dimension Jack up vehi and support it with stands e shown in and secure lock nut A 68 5 dimension mm 2 697 in A dimension Short body 98 3 86 Long body 92 3 62 Van 75 2 95 Double cabin 75 2 95 Option 90 3 54 mm in P @1 t@ fii 4to 5 kg m 28 9 to 36 2 ft Ib 2 Check vehicle for posture and adjust if necessary 4 See Adjustment of Vehicle Posture as near See other defective condition apply when adjustment is dimension mm following ins true 4 dimension with anchor bolt adjust nut dimension changes approximately Figure FA 34 When H nut is turned 5 3 one mm complete dimension is in the following posture of vehicle is correct required ShortfLong Without load Van Double cabin Option 79 to 84 73 to 77 76 t081 3 11 to 3 31 2 87 to 3 03 2 99 to 3 19 54 5 5 54 54 5 2 15 2 15 2 15 With standard load Standard load indicates the following condition lShorongt body 3 passengers and 1 000 Van 3 passengers and 300 Double cabin 2 passengers in front kg 2 204 6Ib kg 661 4Ib I passenger in rear and 250 kg 551 2 Ib Wheel alignment 1 Carry out whee alignment on a so as 3 in 25 turn due to weakened The in anchor bolt of spring anchor spring force vertically when adjust Vehicle posture may be incorrect H H Adjust H Vehicle posture tions part a outlined below 3 or Jack up to release nuts from ADJUSTMENT spring FA 34 Dimmension for standard vehicl posture Fig Lock nut tightening torque flat surface with tire FA 17 air pressure adjusted to the normal pressure range CHASSIS Thoroughly check all 2 componenV parts and repair and suspension systems of steering replace defective OT Short Toein 1 r mm parts before starting wheel alignment v D Cabin Van Long 2 t03 2 t03 2t03 0 0787 to 0 1181 0 0787 to 0 1181 0 0787 to 0 1181 in CambeT 1015 lOIS 1020 Caster 1050 2015 1055 King pin inclination 6015 6015 6010 Inner wheel 360 360 360 Outer wheel 310 310 310 Steering angle Toe in I f Measure ment the 2 in toe and adjust as F OT necessary adjust Loosen stopper bolt lock nut following instructions apply ISc Steering angle adjust stopper bolt to obtain the standard steering angle 0 U c Ji r i 1 I r I 1 IIl l t l r r 0 t L 3 r 7 I e wr so 7 1 t Jj 1 FA J5 Fig Adjusting 1IIIIIIII toein Fig Change the length of Loosen lock nuts hand thread arrow @ CTOSS rod CD and turn cross adjust ID toein right When cross rod is turned to opposite side toe in is increased I m iQ Standard 3 CambeT and CasteT Measure camber and caster and I centers of left and lLmrL right ball joints cross rod Tightening torque length Adjusting steering ang rod to forward direction in is reduced Toe direction to left hand thread and FA J6 516 9 to 12 kg is indicated below mm m UIU Both camber and caster lLlflLIn are adjust if ot necessary in adjusted by increasing or decreasing thickness of adjust shim inserted between 3 in 20 upper link 65 186 8 ft lb FA 18 spindle and upper link mounting bracket FRONT AXLE Adj osting shim FRONT SUSPENSION 1 J I Thi kness Part number 5454204101 1 I li 11 mm in I IAJ t i rr 1 r o 1 rro I J 0 0394 t V 5454304101 2 0 0787 J Standard thickness J 1 54544 04101 0 1575 4 r t r t j 1 1 J II To adjust caster make a difference of front shim and that of thickne increases approximately 33 rear caster per I between thickness shim When front shim reduces mm t Caster changes 0 0394 in of shim Fig FA 37 Adjusting camber and caster thickness Note a Caster adjusted To adjust same valve reduces camber change front and rear changes when shims in the When thickness of shim increases b camber Camber changes approximately 13 per I does 0 0394 in of shim thickness caster camber is adjusted and rear shim thicknesses beyond 2 mm 0 0787 in SERVICE DATA AND SPECIFICATIONS King pin Oearance limit between the Bushing king pin and bushing in mm inner diameter when fitted in mm 15 0 0 0059 20 010 to 20 035 0 7878 to 0 7888 Oearance between the knuckle spindle support and spindle King pin turning resistance kg CJJi in lb mm in 0 04 0 0016 15 3 1 Wheel bearing Tightening torque Spindle nut ft lb kg m 3 2 to 40 to returning angle 4 23 1 to 24 6 3 700 r Wheel bearing rotation starting torque When both bearing and seal are new kg cm in lb FA 19 is however that camber Do not adjust caster with difference between front mm change although not It should be noted less than 13 15 0 r CHASSIS When at readjusted in Ib cm kg r 6 1 7 less than the hub bolt When both bearing and seal When are new readjusted than 2 1 4 6 less than 10 2 2 1b kg less Ib kg resistance kg m ft lb less than 5 0 3 6 sliding resistance kg m ft Ib less than 5 0 3 6 Brake hose connecting nut kg m ft Ib Wheel bearing lock nut kg m ft Ib 3 2 to 3 4 23 1 to 24 6 Brake disc kg m ft Ib 4 0 to 5 4 28 9 to 39 0 Upper link sliding Lower link Tightening torque fixing bolt 7 to 2 0 3 12 1 2 to 13 2 8 to 14 5 0 to 95 4 kg m ft Ib kg m ft lb 2 1 to Arm end kg m ft Ib 2 5 to 3 1 Serration boss kg m ft Ib 0 8 nu t kg m ft Ib 8 5 to 9 5 bushing kg m ft lb 24 to 25 kg m ft lb Cotler pin lock nut kg m ft lb 0 4 to 0 6 Lower link screw kg m ft Ib 24 to 25 173 5 to 180 8 kg m ft Ib 4 7 to 5 2 34 0 to 37 6 Lock nut kg m ft Ib 5 to 2 1 10 8 to 15 2 Bracket bolt kg m ft Ib 5 to 2 1 10 8 to 15 2 kg m ft Ib 1 5 to 2 1 m ft Ib 3 6 to 3 4 kg m ft Ib 5 to 1 2 Lock nut of the anchor bolt kg m ft Ib 4 to 5 Bumper rubber bolt kg m ft Ib 1 to Knuckle arm King pin fixing bolt lock bolt 5 2 15 2 to 1 18 Torque arm w Lower link spindle Upper link screw Upper link spindle bolt fixing to bracket bushing Falcrum bolt to 18 1 4 22 to 2 5 7 to 8 7 1 5 to 68 7 61 173 5 to 180 8 5 to 6 2 39 8 to 44 8 2 9 to 3 4 Tension rod Shock absorber Lock nut of the upper end Lower end kg 10 8 to 15 2 1 31 26 0 to Stabilizer Bracket bolt FA 20 10 8 to 15 2 28 9 to 36 2 6 8 0 tol 6 I r FRONT AXLE FRONT SUSPENSION 1 I TROUBLE DIAGNOSES AND CORRECTIONS V v Condition Probable Corrective action cause shock and shimmying of steer Vibration ing wheel Vibration ing Too much backlash of steer abrasion of each part of linkage gear vibration and of front wheels wheel This is very much noticeable when travelling over air pressure of tire Unbalance ar d Adjust deformation of road in are transmitted to the steering many cases Improper bad roads and at higher wheel Correct the unbalance or Unevenly tire or insufficient worn tight replace Replace or tighten ening speeds Improperly adjusted or worn front wheel Adjust or replace bearing When the front wheels are travel Shock ling steering the bumpy roads over is linkage steering wheel This play of the wheel Worn or alignment loose Adjust suspension link screw Replace bushing the transmitted to is notice especially Faulty Demaged able when travelling rough road idler arm Insufficiently Replace steering tightened gear Tighten housing Shimmying front Abnormal vibrations of the suspension group and the which steering linkage occur whole when Worn Replace steering linkage ball joint a specific speed is attained Improper steering adjustment gear in Adjust sufficient backlash Defective shock absorber or loose installa Replace or tighten tion Unbalanced vehicle posture Vehicle pulls to right or left When driving with hands off the steering Improper wheel ent on swerves Note to a flat road right Adjust the vehicle gently air pressure of tire tightening ofwheel or insuffici Adjust or tighten nuts left or Difference in height of right and left tire A defective rear suspension may Replace tires treads also be the cause of this trouble and therefore see also the with the rear chapter dealing spension Incorrect adjustment or abrasion of front Adjust or wheel bearing su Weakened front torsion spring tion from standard FA 21 specification or devia Replace replace I v CHASSIS Probable Condition 9frective cause action L Worn loose or suspension link screw Replace bushing of Deforrned steering and linkage suspension Correct the unbalance Unbalanced vehicle level Instability of vehicle Improper Worn Replace link Adjust air pressure of tire loose or suspension link screw Replace bushing Adjust Incorrect wheel alignment Worn or deforrned steering linkage and Replace suspension link Incorrect adjustment of steering gear Adjust Correct or replace Deforrned unbalanced wheel Stiff s1llering wheel checking up procedure Jack up front wheels detach the steering wheel and gear and operate the steering If it is light check steering linkage and suspension If it is Improper air pressure of tire Adjust lubricants Insufficient impurities in excessively worn or steering mixing linkage or groups heavy check steering steering coluOUl groups gear and Insufficient Replenish place grease or the part steering linkage in lubricant gear box or Add or or Replace wheel Replace Worn damaged steering gear and bearing Replace Incorrectly adjusted steering Adjust Unsmooth king pin replace gear oil contaminated lubricant damaged part insufficient lubrication Worn or incorrectly adjusted or adjust bearing gear Deformed steering linkage Replace Incorrect wheel alignment Adjust Interference of steering column with turn Adjust r signal switch FA 22 I FRONT AXLE Cfdi e o FRONT SUSPENSION tIOn Excessive steering wheel play Probable Corrective action cause I 7 v Incorrectly adjusted steering Worn steering linkage idler gear housing Worn or loose wheel Retighten bearing suspension I Replace arm Improperly fitted of gear box Incorrectly adjusted Adjust link Adjust screw Replace bushing Noise Improper air pressure of tire Adjust Insufficient lubricating oil and grease for Replenish lubricating suspension ball joint and steering linkage oil or their breakage Loose steering and replace gear bolts linkage and Retigh ten suspension groups Defective shock absorber Replace Defective wheel Replace bearing Worn steering linkage and steering gear Replace Worn Replace of loose suspension link screw bushing Grating tire noise Improper air pressure of tire Adjust Incorrect wheel alignment Adjust Deformed knuckle spindle and suspension Replace linkage Jumping of disc wheel Improper air pressure of tire Adjust Unbalanced wheels Adjust Defective shock absorber Replace Defective tire Replace Deformed wheel rim Replace r FA 23 grease or 1 CHASSIS Probable Condition Excessively or partially Corrective action cause worn tire Improper Adjust air pressure of tire Incorrect wheel Adjust alignment Defective wheel bearing Replace Incorrect brake adjustment Adjust Improper tire shifting Adjust rotation Rough and improper driving manner Drive more SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL or DATE BULLETIN No PAGE No SUBJECT FA 24 gently SECTION RA 1 REAR AXLE REAR SUSPENSION DATSUN PICK UP MODEL 521 SERIES CHASSIS BODY I NISSAN I NI55AN MOTOR CO TOKYO JAPAN LTD REAR AXLE RA 1 REAR SUSPENSION RA 4 REAR AXLE J V 1 J REAR AXLE t CONTENTS DESCRIPTION RA l INSPECTION R 2 REMOVAL RA l INSTALLATION RA 3 J @ 1 12 Axle shaft 3 Wheel bearing 4 Plain washer 5 Lock washer 6 Lock nut 7 Oil sea1 8 Bearing 9 Shim 10 Fig RA l Cross sectionallliew 3 DESCRIPTION The housing in rear is a axle is pressed weight and is any torsional and The rear of a steel semi cage Grease seal 11 Bnkedrum 12 Wheel nut ax Remove brake shoe and disconnect hand brake wire floating type The axle Banjo sufficiently of rear Ax1ccase 2 type housing It is light strong to withstand against bending loads wheel bearings With those bearings the withstands against are rear axle severe use The tapered roller bearings supports heavy load and rear axle receives thrust force through thrust block in the differential housing REMOVAL 1 Jack up vehicle and support it with stands 2 Remove road wheel and brake drum Fig RA l RA 2 Removing bralee CHASSIS 4 Remove four nuts used to install brake end to axle and disconnect brake line Fig RA J 8 p RemoPing A lQck Remove RARemoPing loci nut Withdraw axle shaft 9 Note Be careful notto damage oil seal in axle case side 6 Use axle stand axle on vise special tool ST07630000 and Withdraw axle bearing together with brake disc and bearing cage by using RA 7 Remove oil Seal Fig RA 4 seal again because Secwring axle in cup from Unbend lock washer with a screw a tool puRer special 0 ST371400 secure Fig 7 tool special 1e rNr Fig 5 wrench by nut ST38020000 driver Do not use tap it bearing evenly with as lip required is cage a Remcwing Do not use removed oil damaged remove bearing When removing bearing seal apply rass bar and hammer unbent lock washer again INSPECTION I When axle is cracked replace Repair or replace when bent Bending limit 10 0 039 in mm indicator is placed supported on reading of in center when axle at both end center holes 2 Repair or replace when seal surface and or thrust block side end surface is roughened Fig RA 5 Unbending loci wruher 3 RA 2 Replace when bearing is defective Rough rolling REAR AXLE t i surface rust on roUer or 4 other defective condition Coincide washer tightening 4 Be to sure removed oil seal and lock washer replace lip with nut groove nutand bend washer carefully so correctly by lip that is not maged with new ones Note When no Fit bearing cup and grease seal with a grease 2 MIL G2108 or rubber evenly while fitting brass hammer cone with a to cage Fill Tap 5 lip with on axle Fit oil seal to tube end MIL G2108 and fit or a set a brass Multi purpose grease GI0924 Be careful not to deform seal Note as evenly by applying bar When fitted apply grease to lip G 10924 after fitting seal Install brake disc and bearing cage bearing washer is used beneath lock washer replace lock washer by adding plain washer INSTALLATION 1 plain or I damage lip special tool ST38220000 Fill bearing with grease 6 Note Cone may be fitted by using a brass bar G2108 7 or GI0924 completely Install left or and right shaft adjust direction by applying shim axial MIL greas Multi purpose i clearance toward cated by arrow mark Clearance toward axial direction 3 to 0 9 0 mm 0 012 to 0 035 in Standard shim thickness 5 mm 0 059 in I Fi 3 Tighten lock RA 8 nstaUing bearing nut with a Be careful to place the faced that washer is not special tool ST38020000 side of nut to washer side so damaged Tightening torque 15 to 20 kg 108 to m 145 ft Ib Fig 8 RA tO Adjust shim opposite side and adjust direction by applying shim Install shaft in toward axial clearance Clearance toward axial direction F 6 02 to 0 15 mm 0 0008 to 00059 in Tightel torque ing Fig RA 9 Tightening lock 3 6 to 4 7 kg nut RA 3 m 26 0 to 34 0 ft Ib CHASSIS Install other parts in 1 Fig RA ll reverse sequence to removal MClJSUring clearance toward tDCW direction I REAR SUSPENSION CONTENTS DESCRIPTION RA 5 SUSPENSION ASSEMBLY RA 5 Removal SPRING Removal AXLE CASE RA 5 Removal RA 5 RA 5 INSPECTION RA 5 ASSEMBL Y RA 6 RA 5 SPEC I FICA TIONS RA 6 AND REPAIR RA 6 U YO i c @ Ofr ff l 4 1 2 3 4 5 Spring helper rubber Qiprcar spring Pin rear spring front Pad rear spring lower R H L U Assy shackle rear spring outer 6 7 8 9 Leaf rear spring Kit shock absorber rcar Padrear spring upper Shackle rear spring inner Fig RA 12 Rear 4 RA suspension 10 11 12 13 Assy bush rear spring rear Assy bumper Reinforcement rear axle Bush robber shock absorber mounting REAR AXLE DESCRIPTION The which and rear parallel a Banjo is a suspension rear uses ends of the spring type rigid suspension leaf spring Both front elliptic semi are secured on the frame with rubber bushings and the shock absorber is installed cross the member from the spring lower pad The suspension is an under type on slung type SUSPENSION ASSEMBLY Removal Fig I RA H Removing suspension assembly Jack up vehicle and support it with stands Remove road wheel SPRING 2 Disconnect hand brake separate bracket 3 4 Support remove Note unit axle not r and Removal shock absorber V @ Jack up vehicle and case ID with a jack at the and shackle assembly necessary to remove center and spring seat axle case with Support 3 Remove V bolts and separate remove jack slowly and remove or stand spring from axle case seat from from Note It is not necessary shock absorber Lower jack 2 @ shock absorber unless otherwise required 5 support it with stands and road wheel @ spring pin It is equalizer a CD Remove brake tube propeller shaft wire to remove nless otherwise spring uired suspension assembly 4 Remove manner and and shackle spring pin assembly in the identical with removal of suspension assembly remove leaf spring AXLE CASE Removal 1 Jack up vehicle support it with stands and remove road wheel 2 and Remove hand brake wire brake tube shock absorber propeller shaft Remove U bolts and separate axle case from spring r 3 Fig RA lJ Removing re4r Pass axle case out to the side suspension RA 5 through space above spring and take it 1 I CHASSIS rubber and bushings 4 replace Shock absorber If repl leaking noise or reduced damping force is detected ce ASSEMBLY Rear suspension assembling is carried sequence to I out disassembly by noting the following When installing rubber bushings in reverse items coat soap water on them slightly RA 15 Pig Removing Ie case 2 following Shackle pin Spring When the is spring cracked broken or rubber bushing under no weakened I 1 5 to 13 Spring pin 5 to 13 11 m 83 2 to 94 0 ft Ib kg m 83 2 to 94 0 ft Ib kg ex cessively replace Tightening torque Note When spring sprinilJn 2 in one side is replaced recommend U bolt securing 5 to 61 when threaded part is bruised cracked or broken lb ft wear 3 4 4 to 1 6 1 kg m 26 0 to 31 1 kg lb ft 10 1 to 11 6 lb ft m damaged replace Propeller crac 3 6 to Lower or Rubber and bushings When m kg 3 72 Shock absorber installing nut V bolt Vpper 3 5 to 10 0 8 nut the other side be also replaced When V bolt is bent shaft 5 to 3 0 kg m 2 Securing bolt damage or deterioration exists in Securing bolt 2 3 to 2 8 kg m 18 1 to 21 7 ft Ib 16 6 to 20 2 ft Ib SPECIFICATIONS N 521 PL521 Rearspril18 UrlJth x 55020 20400 width No of leaves nun G521 N 60 On 62 0 2 36 x 60 47 2x 2 36 0 4724 1 0 27562 0 2362 1 0 47242 l f 61 6 RA U N 52t U N 521 Option 55020 20801 55020 20800 63 1 200 60x 12 2 2756 2 02362 2 N 521 7 2 1 200 12 1 47 2 V 55020 20500 72 thickness 1 200 load conditions after jacked down INSPECTioN AND REPAIR I Tighten 51 63 200 1 x 60 12 1 0 2362 3 47 2 x 2 36 x 0 1969 1 0 4724 1 5 1 12 2 0 2362 3 47 2 2 36 0 1969 1 0 4724 2 REAR AXLE N 521 PL52 3 04 Spririg constant kg mm bfin lb kg 170 0 to 20 1 N G 5 2 0 44 292 20 195 0 to 430 1 0 to J V 144 257 to 521 95 9 9 544 than 5 8 1142 U N 521 112 95 to 2 209 to 430 4 5 252 than mo mo U 521 N Option N 52t 277 6 I more 1 112 0 100 to 200 220 to 441 J 5 3 297 than 500 1102 th mo 1 500 1102 Camber Free mm Loaded in 127 5 00 143 5 63 170 in 35 38 1 11 43 0 33 30 650 1433 500 102 70 6 6 69 69 with specified load mm lb kg 698 5 540 5 27 500 108 1102 Spring eye diameter Front 11 Shock in mm 41 161 4 16 4 161 41 161 in mm 33 30 1 33 30 1 3 22 1 31 1 22 absorber Stroke x max GN52 length mm in t90 PL521 475 U V N 521 7 48 x 18 7 195 x 485 7 68 U V N 521 x t9 1 195 x 485 Option 7 68 19 r I 11 Damping force at 0 3 mls Rebound lb k8 97 213 72 158 72 Compression lb kg 29 63 9 21 46 3 21 158 46 3 90 198 28 617 r SERVICE JOURNAL OR BULLETIN REFERENCE DATE JOURNAL BULLETIN or PAGE No SUBJECT No T RA 7 CHASSIS t E JOURNAL UR RViJ JOURNAL DATE BULLETIN 6UL ETli l lRECFEEHEi or No PAGE No SUBJECT f fi 1 B RA SECTION BR BRAKE j i DATSUN PICK UP MODEL 521 SERIES BODY CHASSIS r I NIS J NI l ArJf NISSAN MOTOR CO TOKYO LTD BR BRAKE JAPAN w 1 1 VA tf BRAKE BRAKE CONTENTS DESCRIPTION BR Inspection BRAKE BR Reassembly Removal BR REAR BRAKE BR 8 Inspection BR Removal and BR 9 Reinstallation BR 1 BR 9 BR 2 Reassembly Removal BR 2 HAND BRAKE Disassembly BR 3 I nspecti on BR 3 Inspection Reassembly BR 3 Installation Reinstallation BR 3 BR 4 Bra k BR 4 Brake shoe clearance BR 4 Hand brake BR 4 BR 5 SERVICE BR 6 TROUBLE MASTER BRAKE PEDAL CYLINDER LINES Removal Inspection Reinstallati FRONT m BRAKE Removal and disassembly BR 6 BR 8 t and reinstallation disassembly Inspection and reinstallation BR l1 BR 12 1 Removal BR 12 BR 13 iBR 1 ADJUSTMENT 3 l BR 13 pedal leight BR 13 i i I BR 14 BR 14 Bleeding hydraulic system BR 15 7 DATA AND SPECIFICATIONS DIAGNOS AND CORR BR 15 CTIO BR 17 r DESCRIPTION Removal The Datsun 521 series vehicles The front brake is of a a servo uni adopt type a hydraulic brake I Unhook return spring 2 Remove spring pin and clevis pin and rear brake is of duoservo type The master cylinder is of The hand brake is of a mechanical type a single type which operates push rod from pedal CD @ arid separate arm the rear wheels 3 Remove fulcrum pin @ and remove brake pedal arm BRAKE PEDAL F Inspection Check for sliding parts wear and return pring for weakness 2 Check brake 3 Check other parts for condition pedal for bending warping and crack Reinstallation Reinstall brake pedal in 2 Slightly and evenly G2108 Fig BR l Bra1ee pedal right hand or sequence of removal coat multi purpose grease MIL GI0924 to sliding parts of fulcrum pin and clevis pin and hook P9rtion 1 BR l reverse of return spring ii CHASSIS 3 Tightening torque steering wheels Fulcrum pin For vehicles with both left 3 5 to 4 0 kg m and right hand MASTER CYLINDER 1 Valve cap 2 Valve cap 3 Check valve 4 Check valve 5 Oil reservoir cap 6 gasket spring Reservoir 7 Reservoir band 8 Packing 9 Stopper 15 bolt Primary piston cup 16 Secondary piston cup 17 Stopper ring 10 Piston return tt Spring 18 Snap ring 12 Spring 19 Rubber boot 13 Valve 20 Push rod 14 Piston spring scat Fig BR 2 Master cylinder Removal I 2 nect brake Disc pedal Remove clevis pin master cylinder push rod Disconnect brake tube 4 Remove assembly master to front spring and separate brake pedal from 3 two return bolts CD @ from master retaining dash panel and cylinder master remove cylinder shims and cylinder assembly Fig 4r BR 2 HR 3 Master cylinder 3 to 28 9 ft lb 25 BRAKE Disassembly In I Drain brake fluid 2 Remove stopper bolt 3 Remove rubber boot remove 4 principle replace piston cup gasket and valves with whenever master cylinder is disasSembled new ones 5 Check piston return springs for damage other defective conditions and replace snap ring and stopper ring and 6 Replace others if deformed out piston and other related wear and necessary damaged push rod Take as oLdefective from parts cylinder 5 Remove valve cap and then remove gasket check Reassembly valve and check valve spring I Note Disassemble master cylinder sliding so that the surfaces of piston and piston cup damaged Do absolutely piston carefully not remove necessary fluid Moreover are reservoir Assemble cylinder master in reverse sequence to disassembly not unle 2 do not remove Apply rubber grease to piston cup and other rubber parts slightly Apply brake fluid to other component partS j cup unless piston is replaced and carry out parts not are the operations carefully damaged materials enter 3 cylinder or no that component o dust and oiher foreign and brake fluid reseivoir Tightening torque Valve cap 6 to 9 kg 43 4 to m 1 ft Ib 65 Inspection I or Thoroughly wash all disassembled parts in brake fluid J 0 alcohoL Note Do not wash rubber parts with mineral oil they are When Reinstallation since deteriorated alcohol is used rubber parts in alcohol After parts are however Reinstall do not immerse 2 Fill reservoir with brake fluid and Check cylinder and piston for damage and wear the on conditions 3 Replace than 0 15 mm as if the cylinder and piston clearance is Note 3 more 19 05 mm weakened or cylinder which Make sure that no to is located nearest master brake fluid leaks Do not use brake fluid other than specified cup For pedal height adjustment refer to the paragraph in 4 worn sequence Bleed master cylinder covering pedal adjustment 0 0059 in Replace piston reverse required Master cylinder inner diameter 4 wheel cylinder uneven sliding surface and for other defective Replace in dry them with compressed air 2 cylinder removal longer than 30 seconds cleaned master packing Tightening torque Master cylinder and valves if damaged 2 1 15 expanded BR 3 to 5 kg 2 m 2 to 18 1 ft b CHASSIS BRAKE LINES I Brake 2 Brake tube 3 Brake 4 Front 4 way hose tube connector 5 Brake tube 6 Brake tube 7 Brake hose 8 Connector 9 Brake tube 10 Vinyl 11 Brake tube 12 Brake hose 13 Rear 3 way cover connector Fig BR4 BTaJe 14 Brake tube 15 Brake tube lines Removal 1 Disconnect brake tube both ends and remove by turning flare nuts on the clips used to secure brake tube on the panel Fig BR 6 Rear J WdY ConnectoT Inspection Thoroughly clean brake Fig 2 Disconnect connector BR 5 FTont 4 them for connector collapsing crack scar and rust for weakness expansion ear Replace brake hose from brake tube at 3 way tube and brake hose scar Check brake tube and and crack brake hose if defective by loosening flare nut Reinstallation 3 Disconnect front brake hose by turning flare nuts on 1 the both erids 1l 4 BR Provide a sufficient space between brake lines and BRAKE other parts parts so that brake lines do not interfere with other 4 way connector to 1 7 to 2 brake tube during driving due to vibrati on Connector to brake tube 2 Apply brake fluid to threaded part of brake tube 12 0 3 to 14 5 17 to 2 0 3 12 17 to 2 0 3 to 14 5 12 to 5 14 Wheel cylinder to flare nut correctly engage threads and tighten flare nul brake hose Wheel cylinder to 3 Install brake hose Install front brake hose being sure not to twist particularly carefully so hose load and wheel is set to straight driving position steering wheel from lock and hose In addition wheels are be sure copper packing with 3 to 12 5 14 Brake hose to brake tube io 5 14 3 to 12 5 14 12 17 to 2 0 that hose is not twisted when When brake hose is disconnected from 3 way housing a new 17 to 2 0 brake tube not interfere with brake completely unloaded nector on rear axle 3 to 14 5 2 3 way connector to 6 4 17 to 2 0 brake hose Turn to lock and make sure that tires suspension components do 1 3way connector to twisted when vehicle is in posture with standard is not 7 to 2 0 1 brake tube that hose once be sure to Fill master cylinder reservoir with brake fluid and perform con replace 7 air bleeding completely air Upon completion of one brake make bleeding sure that I operates correctly and no brake fluid leaks from brake tube and hose connectors 5 Tightening torque Fully depress brake pedal kg m ft Ib pedal 4 way connector 10 to 1 5 7 2 to 10 9 3 way connector 10 to 1 5 7 2 to 10 9 If fluid leaks from connector leakage or Master cylinder continue to depress brake and check brake line for fluid for several seconds tigh connector replace if necessaiy to brake tube 17 to 2 0 3 12 to 5 14 Note Do not use brake fluid 1l1an otlll specified FRONT BRAKE 1 Brake di 2 Front brake shoe Fore assembly 3 Front brake shoe assembly After 4 Upper return lower return @@ Fig HR 7 Front brake BR 5 spring spring 5 After shoe return spring 6 Wheel cylinder assembly 7 Adjuster assembly 8 Adjuster housing 9 Adjuster wheel 10 Adjuster screw 11 Adjuste 12 Shim head 13 Lock spring 14 Spring plate 15 Lock plate 16 Shim 17 Rubber boot CHASSIS r Removal and disassembly round lf Out Jack up vehicle and support it with stands I 254 mm Inner diameter 10 00 in Less than 0 02 mm 0 0008 in 2 Remove wheel and brake druOL When brake drum cannot be removed 3 In order to return brake easily operation ease Umit ofrebored drum JD remove hub assembly 2 brake shoe When seated Unhook upper lower and after shoe return springs sive and then remove brake shoe assemblies unevenly heating linings 10 04 in Disconnect brake hose from wheel cracked are incompletely and or deteriorated due worn soiled with grease repair or thickness of brake shoe lining in 5 mm Brake shoe lining from front spindle 4 255 adjuster 6 Loosen securing nut and remove wheel cylinder 7 Remove rubber boot replace If oil a clean or grease is found on brake shoe thoroughly spring plate lock plate and adjuster assembly from lining face shoe brake disc linings with solvent grind b When brake shoe lining is installed remove When is less than 1 0 mm 0 0394 cylinder Note shim and then to exces replace or to diameter equal to brake that of brake drum Lining dimension Width 45 Inspection I x Thickness 5 4 x x Total friction Brake drum 244 area x Length mm 18 x 02 440 cm2 x 9 6 in 68 2 sq in Thoroughly clean and inspect brake drum Replace if cracked or is or excessively damaged When brake drum excessively excessive polish with worn by correct or scratched means or of rebating of out in teri 3 Check adjuster for smooth operation round is When minor 4 fine emery cloth Return springs Ifthey are considerably weakened them tce re Return spring dimension Upper return spring Wire diameter x free length mm mm in in 20 x 136 5 0 079 x Lower return spring 37 5 37 3 2 x 0 091 37 134 5 x 35 5 30 35 After shoe return spring I 4 x 0 055 83 2 x 27 5 3 28 27 5 turns Load kg x Ib length mm 15 in x 0 591 22 159 5 x 0 866 6 28 6 BR 5 159 x x 6 28 4 5 0 177 x x 99 3 90 i BRAKE 1 1 12 4488 dla 810 5039 die u 11 4 11 1111 II IU ENGTH FR 136 r r 515 371 F Unit Fig BR 8 mm H 134 515 301 Unit in Upper return spring BR 9 Lower return Fig 5 Check brake disc for distortion 6 Wheel cylinder mm in spring f fl @ @ 1 Wheel cylinder housing 2 Piston 3 Piston cup 4 Dust 5 Snap ring 6 Connector 7 Packing 8 Connector bolt 9 Bleeder BR I0 Front wheel cylinder I 1 Wheel cylinder can following procedure be disassembled simply by the Remove snap ring and dust from wheel cylinder Chec the cover Thoroughly Be careful not to damage sliding part they O Qo Wheel t Sup X cr ck are min1 oil since rubber parts in alcohol After parIS are cleaned r r c6rroSign be and piston exceeds 0 15 pla c ithem if1il i tde Cy must piston eiJp diameter 64 20 mm replaced if deformed and or replaced aging even 13 due 16 in to damage It is recommended that if they are apparently in satisfactory condition dotsriorated When alcohol is used JA i mm wash all disassembled parts in brake fluid Do not wash rubber parIS with Qf wheel cylinder for scratches and beiew n cylinder Ifclelirimc alcohol Note it t and take out piston of piston and piston cup or ore J corrosion described below screw Bleeder cap 10 Fig cover however longer dry Assemble wheel cylinder in do not immerse than 30 seconds tham with sembly Carry comprassed parts air are not out sequence to disas operations carefully so that component damaged materials enter cylinder BR 7 reverse or no dust and other foreign CHASSIS Apply rubber grease to piston cup and other rubber parts slightly and brake lIuid Reassembly Reassemble sequence to to piston and cylinder bore and reinstallation and reinstall brake front in Note the disassembly and removal reverse following matters I When to grease adjuster assembling adjuster adjuster housing assembly bore adjuster apply brake wheel and screw When installing adjuster assembly to brake disc Fig apply BR l1 Greasing points on ront brake brake grease to disc surfaces to slide adjuster and spring plate sliding adjuster smoothly Measure adjuster when sIding resistance sliding resistance Adjust by 3 Tightening shim Whee is incorrect torque 17 to 2 0 bolt Connector kg I 10 to 26 5Ib 12 Before installing grease to wheel brake shoe assemblies cylinder and adjuster brake shoe installing grooves and brake disc and brake shoe faces stick two on apply brake places assembly contact 4 Be careful not to allow brake grease to brake shoe surface rn kg 3 to 4 0 to Brake disc 2 rn kg 30 4 to 37 6 ft Ib Adjuster sliding resistance 5 to 12 4 2 to 5 2 cylinder 5 4 4 5 lb ft rn kg 28 9 to 39 0 lb ft Adjust brake shoe clearance and bleed brake system Upon completion of the above that brake operates correctly and no brake fluid leaks adjustments make REAR BRAKE 1f1 1 Brake disc 11 Adjuster 2 Rear brake shoe 12 Shim assemblies 3 4 5 6 8 BR Lock spring After 14 Spring plate Upper return 15 Lock spring t6 Shim Lower return 17 Rubber boot spring 18 AntiI1lttle After shoe 19 Spring return 20 Anti rattle spring plate pin seat spring Wheel cylindet 21 Retainer 7 Adjuster assemblY 22 Extension link 8 Adjuster housing 23 Toggle Adjuster wheel 24 Retumspring 9 BR 12 Rear brake 13 Fore assembly 10 Fig head Adjuster screw lever sure k BRAKE if 8 disassembly Remov al and Disconnect brake tube at wheel cylinder by loosening flare nut J Jack up vehicle and support with stands 2 Remove wheel and brake drum 9 Remove wheel cylinder from brake disc by loosening installation nuts 10 spring plate lock plate and from brake disc assembly adjuster Remove rubber boot shim and remove 1 Inspection For the rear brake inspection refer to the instructions for front brake I Fig BR tJ Rear b ake Brake drum Refer to the paragraph covering brake drum of front brake 3 4 Remove anti rattle Open brake shoe spring and remove 5 pin assemblies outward against return extension link Remove return Remove brake shoe assemblies shoe assembly 254 Out of round 0 02 mm 0 Limit of rebored drum LD 255 mm mm 00 in 0008 in 10 04 in springs 2 6 10 Inner diameter must be separated Note that after brake from toggle Refer lever When 7 Lining paragraph covering the to front brake shoe lining separating after brake shoe assembly from toggle lever I withdraw clevis pin 7 Disconnect toggle lever from hand brake rear cable lining dimension Width 45 x x Thickness 4 5 x Total friction Tpgg e lever rJ BR 14 Removing toggk leve adjuster area Length mm 18 440 for smooth x 02 em x 9 6 in 68 2 sq in operation r 4 r Fig Check 3 I 244 x Return Ifthey r 9 BA springs are considerably weakened replace them CHASSIS 1 J Upper Wire diameter x free length in mm mm 2 0 in return x 0 079 175 x spring 2 3 32 5 6 89 spring Lower return 0 091 32 5 6 22 x 14 x 83 2 30 158 x After shoe return spring 0 055 30 5 27 3 28 x 27 5 turns 12 Load kg lb x length mm x 473 0 in FREE LENGTH 19 184 x 0 748 7 24 x LENGTH 1010 L 3941dia Unit mm 99 x 0 188 6 93 FREE 1U BR 15 5 4 176 17516 69 ll 1 Fig x x 3 90 56 I 111 12 610 504 Unit in Upper return spring Fig BR 16 Lower return 5 Check brake disc for distortion 6 Wheel cylinder mm in spring 1 @ @J @ CD @ I Wheel 2 Piston 3 Piston cup 4 Piston head 5 Dust 6 Connector 7 Connector 6 Packing 9 10 r Fig BR 17 Rear wheel BR l0 cylinder cylinder housing caver Bleeder bolt screw Bleeder cap i 1 c v d Wheel cylinder 64 20 3 ifUler diameter mm 13116 cover For piston assembly Wheel cylinder and pull piston out head and inspection and reassembly refer apply Before installing brake shoe assemblies grease to the following in 1 Remove dust t BRAKE brake places Brake shoe installing grooves of adjuster and wheel cylinder to 2 Extension link installing grooves 3 Lower surface of spring seat 4 Contact surfaces between brake disc and brake shoe offront brake assembly Six places Reassembly At this time and reinstallation surface of brake Reassemble and reinstall rear sure not to coat brake grease to the brake in reverse sequence disassembly and removal noting of be shoe the following 1 mailers Refer to the notes for front brake Rear adjuster assembly is the 1 the same as front Refer to ng front adjuster assembly covel paragraph Adjuster sliding resistance 5 to 12 kg 2 When assembly brake shoe a n o to 26 5Ib assembling toggle lever and after brake shoe adjust clearance between toggle lever and after assembly to 0 to properly selected toggle pin 3 mm 0 to 0 Ql18 0 in with washer Fig Part No Thickness 44034 32200 2 0 44034 14800 3 2 44034 14801 2 6 0 102 44034 14802 2 9 0 114 44034 14803 3 2 0 126 mm in 4 BR 18 Tightening Greasing points Connector bolt 0 091 Brake disc 5 brake torque Wheel cylinder 0 079 on rear 1 5 to 18 kg m 12 m 17 to 2 0 kg 4 0 to 4 5 kg IO 8to 13 0 ft Ib m 3to 14 5 ft Ib 28 9 to 39 0 ft Ib Adjust brake shoe clearance and bleed brake system Upon completion of the above adjustments make that brake operates correctly and Itaks no r BR ll l brake fluid sure r I CHASSIS HAND BRAKE @ I Control bracket 6 Set spring 11 Inner lever 15 Equalizer 2 Control lever 7 Front lever 12 Arm spring 16 Rear cable Lock plate Cable spring 3 Control stem 8 Front cable 13 Center link rod 17 4 Control guide 9 Outer lever 14 Equalizer link 18 5 Control yoke 10 Center cable Fig BR 19 Hand brake construction Front cable center cable Removal Completely loosen hand Control stem 2 1 Completely 2 Remove loosen hand brake clevis pins D and @ and brake Remove clevis pin and separate cable from lever separate control steOL Fig BR 20 Control stem Fig BR 12 BR 21 Cable and lever 1 BRAKE Rear cable 2 Replace if ratchet pawl ly or unusually I Completely 2 Remove clevis pin and disconnect equalizer from loosen hand brake 3 or and teeth are worn excessive damaged Check springs for weakness and replace if required link equalizer Installation 3 Remove lock plate CD and cable spring @ Reinstall hand brake in reverse sequence of removal Grease G2108 or sliding parts with multi purpose grease MIL GI0924 JUSTMENT AD Brake pedal height Loosen stopper up to such separated from pedal Fig HR 22 Lock Fig 4 5 extent that stopper is arm and cable spring HR 23 Rear cable Remove both side rear cable p an rear Unit brake drums and disconnect from toggle lever mm On @ Separate cable connecting flange @ Fig from brake BR 24 Brake pedal adjustment disc 2 With Inspection pedal I Check cable for master cylinder push adjust thickness of adjusting shim damage other defective conditions and elongation replace if required ices ive e head is 138 5 mm 45 5 rod so fully pulled that height of brake in from dash panel and Standard shim thickness BR 13 1 6 mm out 0 0630 in r CHASSIS i Rear drum brake Part No Thickness mm in With hand brake fully released For clearance 3061 I 27260 16 00630 30612 27260 0 8 0 0315 30613 27260 5 0 0 0197 Note When having the Screw in 5 135 mm sure to refer rear brake brake shoe Front drum upper and shim lower installation bolts stopper so that height of brake pedal head 5 33 in procedure rear to brake adjusting use for thickn same cylinder m 3 be adjusting the adjust is and tighten lock from dash panel nut Brake shoe clearance Front drum brake Fig Jack up vehicle to lift up wheel Remove rubber boot from brake disc 3 tightly tap adjuster housing and rrtove brake adjuster wheel with shoes on and spread when a adjust in rear screw cable stretched A portion so adjust equalizer link L that dimension with shown Figure BR 27 is standard dimension Lock adjust screw with lock nut brake drum For both left and right brakes when adjuster wheel i 4 screwdriver With it forward Stop turning adjuster wheel considerable drag is felt Note a Adjusting Hand brake 2 Turn BR 26 brake shoes Equalizer link spread L dimension 5 29 turned downward 161 1 mm in Return adjuster wheel 12 ratches to obtain correct clearance between brake drum and brake shoes Turn brake drum and make without dragging brake drum 5 when sure brake that brake drum turns shoes interfere with readjust clearance Install rubber boot e f I Fig BR 27 Hand brake adjustment F Adjust front cable adjust Fig BR 25 Adjusting front Inake screw control stem stroke is 80 to 100 BR 14 B mm portion so that 3 15 to 3 94 in BRAKE when control stem is 44 1 to 66 llb pulled Lock with adjust force of 20 to 30 kg a screw other end of hose in container a containing some brake fluid with lock nut Normal stroke 80 to 100 3 3 15 to 3 94 in mm Limited stroke Less than 144 Note mm 5 67 in 4 H nd brake must operate smoothly pulled and released noise Depress brake pedal Make dragging twisting sure that while being or With brake pedal screw 5 when stroke exceed 7 Bleeding hydraulic system essential factor for matter of fact regular during operation the brake service 8 air is the Allow brake pedal brake pedal is on down to return slowly with bleeder closed Repeat these Conduct air same Note operations until no air bubbles emerge bleeding on remaining wheel cylinders in manner Check l 1lS8IVoir b reservoir cap and top up reseIVoir with the recommended Thoroughly clean materials that the any mud outlet ho1e then attach a vinyl Fluid c Ordinarily Rear is free pl ced foreign the When master conduct which i located again the for bleeding Rear left d Dip ir sequence dust from bleeder hose to bleeder during following or from drained should not be used brake fluid so for fluid level during bleeding operation Clean any dirt around master cylinder reseIVoir and screw as to creep into the circuit with the result that the the travel end 2 quickly screw much attention as service brake fluid action is altered and brake pedal becomes spongy at 1 open the bleeder in hose Bleeding hydraulic system deserves likely fully depressed to exhaust air Close bleed screw a and keep limit 6 As three times stroke Readiust an or abnorm 1 no othf ulty condition occurs it is two pedal fully depressed right i performed Front left bleeding most near option refilling cylinder i air bleeding Front right diSassembled to master cylinder Specifications Brake type servo Uni Rear servo Duo Hand brake Mechanical operating Brake drum Front Rear mm in in mm BR 15 254 10 00 254 10 00 or re on wheel cylinder SERVICE DATA AND SPECIFICATIONS Front in the on rear wheels CHASSIS Brake lining Dimension width x front thickness Total friction rear x length 4 5 x x 244 18 x 0 2 440 68 2 sq in em area 45 in rom Wheel cylinder Front rom in 20 64 13 16 Rear rom in 20 64 13 16 Master cylinder diameter rom 19 05 3 4 in Service data Master Cylinder push At brake rod pedal height rom in rom in 138 5 545 Brake pedal Brake pedal height 5 135 33 5 Wheel cylinder Allowable maximum clearance between cylinder and piston Master rom in 0 15 0 0059 0 15 0 0059 cylinder Allowable maximum clearance between cylinder and piston rom in Brake drum Allowable maximum fround out rom 0 02 0 0008 in Allowable maximum inner diameter of rebored drum Brake rom in 255 10 04 rom in 10 0 0394 rom in lining Allowable minimum thickness Hand brake Equalizer link L dimension 29 5 161 1 Normal stroke rom in 80 to 100 3 15 Allowable maximum stroke rom in 144 BA 16 5 67 to 3 94 x 9 6 BRAKE Tightening torque Fulcrum pin kg m lb ft 5 to 4 0 3 Master cylinder kg m lb ft 2 1 to 2 5 m kg lb ft 6t09 Master cylinder valve cap 3 to 28 9 25 15 2 to 18 1 4 to 65 1 43 4 way connector kg m ftIb 10 to 15 7 23 to 10 85 3way connector kg m ft lb 10 to 15 7 23 to 10 85 Front brake Wheel cylinder kg m lb ft 4 2 to 5 2 Connector bolt kg m lb ft 1 7 to 2 0 Brake disc kgm lb ft 4 0 to 5 4 kg lb ft 5 to 18 1 10 1 7 to 2 0 123 30 4 to 37 6 3 12 5 14 to 28 9 to 39 0 Rear brake Wheel cylinder m Connector bolt kg m ft Ib Brake disc 8 to 13 0 5 14 to kg m ftIb 4 0 to Master cylinder to brake tubO kg m ft Ib 7 to 2 0 I 3 to 12 5 14 4way connector to brake tube kg m lb ft Ito 2 0 7 12 3 to 5 14 Connector to brake tube kg m ft lb 17 to 2 0 3 12 Wheel cylinder to brake hose kg m ft Ib 7 to 2 0 1 Wheel cylinder tolbrake tube kgm ft Ib 1 7 to 2 0 12 3 to 14 5 3way connector kg m ft Ib 17 to 2 0 3 to 14 5 12 Brake hose to brake tube kg m lb ft 17 to 2 0 3 to 14 5 12 3 way connector to brake tube kg m ft Ib Ito 2 0 7 3 12 4 5 28 9 to 39 0 Brake lines to brake hose 12 to 14 5 3 to 14 5 to 14 5 TROUBLE DIAGNOSES AND CORRECTIONS Condition Probable cause Corrective action Lack of braking power Excessive pressure pedal required Grease mud or water on brake shoe linings Remove drums Clean and dry brake shoe linings or replace poor brakes Full area of linings does not contact Scored brake drums Replace brake shoes Reface drums and install linings BA 17 new brake shoe CHASSIS Condition Spongy pedal Probable Deteriorated brake shoe lining face Replace Worn brake shoe lining Replace Oogged brake line Inspect and clean Air in brake lines Bleed Swollen hose due to deterioration use of Replace hose and bleed system Use prescribed brake fluid Use of a brake fluid boiling poin t of which is Change too low bleed system reservoir filler cap vent hole This promotes a vacuum that sucks in air through slight or thoroughly poor quality brake fluid Oogged Pedal yields under Corrective action cause in master rear with prescribed brake fluid and Clean reservoir filler cap and bleed system cylinder seal Deteriorated check valve Fit External leaks Check master cylinder a new check valve and bleed system pressure piping and wheel cylinder for leaks and make necessary repair Leakage from master cylinder through pri Overhaul master cylinder mary cap Unbalanced brakes Insufficient brake fluid level Check and add Tires Inflate tires improperly Improper Water Mud or or brake oil sand on on inflated adjustment brake shoe to correct pressure Readjust linings brake drum Oean or replace Clean Deteriorated brake shoe lining face Repair by means of polishing Improper brake shoe lining contact Repair by means of polishing Improper brake shoe Rearrange or lining angle Worn brake shoe linings Replace Deformed brake shoe Replace BA IB replace or replace BRAKE Condition Probable Worn or damaged Corrective action cause rust other than brake Repair or replace Repair or replace Adjust and Apply brake grease drum Defective wheel Faulty cylinder operation brake shoe sliding Faulty adjuster sliding plate installation bolt Loose back Deformed back plate Replace Improperly adjusted wheel bearing Readjust wheel Improper Brake drags or replace Readjust alignment Inspect and clean Loose leaf spring U oolt Retighten Insufficient brake shoe drum clearance Adjust No cylinder brake pedal master play on Faulty brake shoe return port or replace Clean and adjust brake pedal height Adjust and apply brake cylinder operation Repair or replace broken return spring Replace Defective hand brake return Inspect and correct Oogged brake Inspect and clean Improper grease Replace Expanded piston cap Weakened or Adjust and apply brake grease sliding Faulty adjuster sliding Defective wheel grease replace or Clogged brake lines Clogged Squeak Retighten apply brake lines wheel bearing adjustment Readjust replace Brake drags Dragging See Worn brake shoe lining Replace Bfl 19 or above CHASSIS Condition Squeal Probable Corrective action cause Deteriorated brake shoe lining face Correct by means of polishing or replace Deteriorated brake shoe lining face Correct by means of polishing or replace Worn brake shoe lining Replace Improper brake shoe and lining contact Replace Excessive friction between brake shoe and Oean and apply brake grease brake disc Foreign brake drum sliding sur Oean deflection of drum sliding sur Rebore or replace matter on face Damaged or face Chatter Deformed or improperly installed brake shoe Correct or Loose back Retighten plate installation bolt replace Worn anchor contact part Replace Improper brake shoe lining contact Correct or replace Roughened brake drum sliding surface Rebore or replace Rebore or replace Correct by means Excessively distorted or deviated drum out of round Roughened Excessive pedal brake shoe Improperly adjusted lining surface brake of polishing or Readjust travel Air intrusion into Brake fluid hydraulic system leakage Bleed system from hydraulic system or Check repair insufficient lluid level Worn brake shoe Tilted brake shoe lining or faulty Replace return RR Correct O or add brake fluid replace BRAKE SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or No PAGE No SUBJECT BA 21 CHASSIS E JOURI l SERVi JOURNAL DATE OR ET j k3UU I EFEI1E Il E or PAGE BULLETIN L No SUBJECT No BA 22 SECTION WT WHEEL AND TIRE DATSUN PICK UP MODEL 521 SERIES CHASSIS BODY I NISSAN I 1 Jc NI SSANMOTOR CO TOKYO JAPAN LTD WHEEL AND TIRE WIl TROUBLE DIAGNOSES AND CORRECTIONS WT 5 WHEEl AND TIRE WHEEL AND TIRE CONTENTS DESCRIPTION WT 2 Tire rotation WT2 TIRE SIZE INSPECTION WT2 I nflation of tires WT 2 Wheel WT 2 CHECKING WHEELS AND JACKING UP WT3 in Front 6 00 Rear 6 00 146PR LT Front 6 00 146PR L T Rear 6 00 14 8PR 6PR 14 LT PL52l G N 521 Series LT 6 00 146PR LT L521 TU Only U N V Front 50 5 Rear 50 5 t 146PR LT 521 TIRE INFLATION PRESSURE To be measured when tires are 6PR 14 LT cold Unit Under 100 km h 60 MPH Over 100 km h kg lb cm2 in 60 MPH Tire size Front Series 21 75 1 25 1 8 26 21 3 0 42 18 26 15 21 2 75 39 18 26 15 21 4 25 60 18 26 15 21 N 52I V Series Rear 2 05 29 3 46 3 05 43 55 4 64 1 75 25 1 8 26 5 21 1 3 0 42 18 26 3 46 15 21 1 75 25 18 26 2 05 29 15 21 3 25 46 18 26 3 55 50 L52lTU U Front 15 15 PL52 I G N 52I Rear The upper column indicates moderate load and the lower column indicates WTl for both Front and Rear 6 0014 6PR LT Front 6 00 Rear 6 00 6PR 14 8PR 14 LT LT 2 05 29 heavy load Rear 6 00 146PR LT for both Front and Rear 5 50146PR LT CflASSIS Tighten DESCRIPTION wheel nuts to a torque of 5 to 10 0 kg 8 m 61 5 to 72 3 ft Ib Inflation of tires Tire rotation improve riding comfort and Tires with proper pressure the steering stability reduce driving sound and extend To equalize the service life in the checked for proper pressure The tires should be monthly bassis conditions 5 0 rises pressure frequently depending or more while the tires 7 Ib kg cm in2 tires should be rotated as shown diagram on driving on Ordinarily cold are wear PL521 tire G of that when tire is U 10 000 km 6 000 miles 5 500 miles N 52I 9 000km N V 52I 9 000 km 5 500 miles cold during continuous driving under a constant speed due to the tire rise When temperature When tire valve caps are removed be sure to or r cold AIGHT FAONT install AIGHT AEAA the valves with out fail The valve caps assist in on air in the tire in case of keeping tire pressure first find out whether the tire is hot accurately them measuring a valve leak and keep When is inflation pressure too high tit tl dust and water out of the valves the following SPAAE troubles will result Hard ride 2 LEFT FAONT Bruised tire or damaged carcass LEFT AEAA iromeadiately inside the tread Fig 3 Poor traction at 4 Rapid tread wear at in flation When rear wheel resulting in uneven WT Tire rotation GN 521 v N 521 U wear center of tire is pressure too low AIGHT FAONT the following AIGHT AEAA troubles will result I Ti 2 s squeal on turns SPAAE Q Hard steering J l 3 Rapid and uneven wear on tire tread edges LEFT 4 Bruised tire rim and various type of rupture 5 Tie cord 6 Tramp fatigue and or FAONT Fig breakage LEFT AEAA WT 2 Tire rotation PL521U shimmy troubles INSPECTION 7 Unusual tire temperature rise 8 Car roll while turning Wheel swerve a corner or making a sharp in traffic I WT 2 When wheel deflections toward vertical and hor WHEEL AND TIRE izontal axes Figure WT 3 the at 15 are the points indicated by mm 0 06 in or more asterisk in replace wheel Fig 2 Fig WT 3 Wheel rim run out Jacking WT 4 Place jack under rear spring added car is jacked up damage tear condition of flange of rim welded deformed and for deformation unit and damaged other Front seat Rear apply parking brakes and as precaution against moving place block under the front Check the spare tire up Place jack under lower link check points Before 2 Removing an rear of l one a large wheel crack defective rim will cause air leakage 3 Thoroughly and other remove foreign rubber particles mud sand flange of rim a 4 Remove small foreign pieces of gravel glass nail and other matters from tire tread Fig When the tire side wall is cracked wear if any wire brush emery paper and for cloth with 5 rust matters from the indicator is exposed replace the noticeably tire with a or WT 5 Jacking up front side tread new one CHECKING WHEELS AND JACKING UP Remove the sp Insert jack re rod tire to guide and then turn it counterclockwise When installing tighten a little strong after lifting up and lock Fig WT3 WT 6 Jacking up rear side stone an or CHASSIS 3 5 Remove wheel cap Change when Fig 4 WT 7 Removing wheel 6 Loosen wheel nuts When loosening turn nuts counterclockwise WT B Loos ing wheel Remove sure to WT 9 jack wheel by wheel a 4 WT temporarily nuts follow the order shown in figure ing Tighl order of wheel and tightening wheel following the above mentioned order nut wrench Fig tighling be Fig cap and tighten tire nul nut properly WHEEL AND TIRE TROUBLE DIAGNOSES AND CORRECTIONS Possible Condition Wheel wobbles Corrective actions causes Improper tire pressure Measure and Damaged tire Repair or distorted wheel rim or Unbalanced wheel Balance Loosen wheel n ills Retighten or damaged wheel bearing cessive play of wheel bearing Worn or ex Improper front wheel alignment Worn or link damaged steering ball Correct adjust correctly replace correctly play or replace Adjust joint and Replace bushing Excessive steering linkage play or worn Adjust or replace steering linkage Loosen steering linkage connection nuts with the rated Retighten torque or Broken suspension spring Replace Defective shock absorber Replace replace worn tightening parts if any i Unevenly exces sively worn tire Improper tire rotation Conduct tire rotation periodically in stan dard every 10 000 km 6 000 miles Unbalanced wheel Improperly adjusted Balance brake or replace Readjust correctly Improper wheel alignment Excessively distorted or Realign improperly in Repair correctly stalled suspension link reinstall High speed Reduce speed Sudden to on curves start and improper speeding due rapid acceleration or J improper brake application WT 5 Follow manner or replace if necessary or correctly correct and proper driving I CHASSIS Condition Tire Possible squeals Improper tire pressure Improper front wheel Distorted knuckle C DATE or Measure and adjust correctly alignment y BULLETIN Realign correctly suspension pnV CE JOURN AL yn JOURNAL Corrective actions causes link Repair 01 UU 1 J lE P J or replace if nesessary n i n t RI lr t or PAGE No No SUBJECT WT 6 SECTION ST STEERING DATSUN PICK UP MODEL 521 SERIES CHASSIS BODY I NISSAN I NISSAN MOTOR CO TOKYO JAPAN I LTD STEERING ST STEERING LINKAGE ST 6 SERVICE DATA AND SPECIfiCATION ST 8 TROUBLE DIAGNOSES AND CORRECTIONS ST 9 I STEERING STEERING CONTENTS DESCAIPTION ST 1 INSPECTION AND REPAI A REMOVAL ST 2 ASSEMBLY AND ADJUSTMENT DISASSEMBL Y ST 3 INSTALLATION 4 ST 4 ST ST 6 fr DESCRIPTION 1 J Steering column 7 Cross rod Steering column jacket 8 Cross rod socket 3 Steering wheel 9 Idler arm assembly 4 Column clamp 10 5 Post grommet 11 6 Steering gear 1 2 Side rod Steering gear assembly ann P g ST l Structural view CT 1 of steering r1Jechanism v CHASSIS The steering gear is of gear ratio is 19 8 IThe rod tie rods one on link as the front recirculating ball type a steering linkage each side of the wishbone type These side rods pitman the and idler arm left and wheel Steering motion in arm side At the same through is remove steering post control is attached to steering colunan jacket even gear I Detach gear lever 2 Disconnect shift lever from shift rod and select lever and from select rod at the steering column base arm the gear ratio by the steering motion operates the side rod same time the cross rod and gear arm vertically converted to When transmission 8 connected through ball moves bolts fixing grommet independent arms Unscrew drag be safely maintained can to an rod With this construction rotation proportion The gear arm of cross steering right wheel or independently steering gear are to both the knuckle arms joints if is suspension 7 and has two side the idler arm on the is moved and the opposite side rod is also moved REMOVAL I Remove horn ring by depressing and turning it counterclockwise 2 Remove steering wheel 3 Remove steering wheel 4 Remove steering column shell 5 Remove turn signal and dimmer combination switch nut Fig 9 assembly Remove nut Unscrew two fIxing bolts and remove column ST 2 Column arm secure by gear arm to sector shaft the use of a gear arm puller tool ST2714oo00 clamp Note Fig Transmission control used to and withdraw gear special 6 ST J cLunp Marl gear arm Fig ST 2 ST4 installing position before Removing gear arm removal if STEERING Remove 10 steering 12 housing installation bolts gear Detach transmission control parts from steering column jacket 11 Remove steering gear assembly toward engine com partment DISASSEMBLY JID @ I @ 6 D 1 3 1 Sector shaft 2 Filler 3 Sector shaft 4 Sector shaft adjusting Gear housing 5 adjusting screw plug cover screw shim Fig 6 Sector 11 Column jacket 7 Oil seal 12 Steering column 8 Gear housing bushing 13 Column jacket bushing 9 Worm 14 10 Worm 0 ring Worm bearing shaft assembly ball nut assembly bearing adjusting shim ST 5 Cross sectional view 15 of steering gear b I Drain steering gear oil 2 Loosen lock nut and turn sector shaft adjusting screw a Jew turns counterclockwise Remove sector shaft Cover fIXing bolts I it Fi ST3 ST 6 Sector raft s cOlleT CHASSIS Pull sector shaft 3 from gear screw with sector shaft together cover sector shaft housing Disassemble Remove column 7 jacket bushing adjusting INSPECTION AND REPAIR and shims from the cover Wash all in parts solvent clean and dry them thoroughly I Sector shaft Check sector shaft tooth surface for pitting exfoliation or c other damage and replace sector shaft and or necessary contact surface is gear housing bushing Yhen replace as bushing as damaged Check necessary sector shaft and sector shaft bushing for bushing and shaft fitting Replace It outsector Remove fixing bolts used to 4 gear and housing pull secure out column shaft smoothly on assembly vertically column jacket to column worn by steering worm its own weight condition is if ball nut is turned until it In this test the end of reaches Raise worm when it nut and observe ball nut When ball nut rotates and comes down satisfactory jacket excessively when disassemble ball to is not necessary rotates Pulling ST 7 together Steering worm assembly 2 Fig them worm ball guide may be thread damaged Do not allow ball nut to turn down to the end of thread worm When steering live be sure to 3 Worm bearing 1 Check and replace worm replace as as an worm assembly is defec other damage assembly bearing for pitting wear or necessary r ASSEMBLY AND ADJUSTMENT 3 Worm bearing Worm bearing adjusting shim 4 SY 8 Fig Apply genuine gear oil MP 90 parts Removing column jacket Fit column jacket bushing 5 Remove steering and detach wonn worm bearings assembly wonn from gear all disassembled to housing bearing adjusting Note shims When fitting apply to column jacket adhesive to bushing exterior and grease to interior and Oring 2 Note Be careful not to allow ball nut to worm end worm end If ball nut rotates ends of ball guides rundown suddenly may be to to the Fill space between sector shaft oil grease and fit it to gear 6 Pry discard it sector shaft oil seal from lips with housing the damaged 3 Place steering housing together out seal gear housing and jacket on gear and Oring worm assembly with worm in the position in gear bearings and install column housing together with worm bearing shims STEERING 1 6 to 18 Tightening torque 116 Standard Install sector haft adjusitng 5 kg m and selected shim in the slot of sector shaft to 13 0 ft Ib bearing shim thickness worm lj Measure end clearance 1 5 mm 0 0591 in adjusting mm Worm bearing adjusting Part No 4 screw mm 48029 71200 0 762 0 0300 48030 71200 0 254 0 0100 48031 71200 0 127 0 0050 48032 71200 0 050 0 0020 of worm t shim so a proper sector shaft that end clearance is 0 01 to 0 03 0 0004 to 0 0012 in shim Thickness Adjust preload screw and select in lecting aring by worm bearing shims to obtain steering colUJ nn initial turning torque of 4 0 6 0 to kg m 28 9 to 434 ft lb Fig ST J 0 Measuring end deamce Initial turning torque of steering column New worm bearing 4 0 to 6 0 Used worm 4 to 2 kg m Sector shaft bearing 4 kg m adjusting screw shim 3 5 to 5 2 in Ib Thickness Part No 2 1 to 3 8 lb in At steering wheel New 0 2 to Used 0 12 to 0 22 3 kg 0 nrn in 48213 BOIOO 1 575 0 0620 48214 BOIOO 1 550 0 0610 0 4 to O 7lb 525 1 48215 BOlOO kg 3 to 0 0 0600 5 lb 0 6 I 48216 BOIOO 1 500 0 0591 48217 BOIOO 1475 48218 80100 1450 0 0571 a 0 0580 Install sector shaft in gear housing Turn steering column by hand until ball nut travel center so is in its that sector shaft center tooth enters baU nut center looth space 2 Install adjusting side 1 so sector screw shaft cover and turn sector shaft to raise sector shaft to sector shaft cover that 2 t03 mm 0 0787 toO 1181 in lash is made r between sector shaft teeth and ball nut II ball nut Fig ST 9 Measuring initidl turning torque sure and sector shaft intermeshing position deviated from center ST 5 Make is that not CHASSIS Sector shaft cover 9 tightening torque m 116 to 13 0 kg 1 6 to 1 8 adjusting lb ft lock Note Be sure to use preventing agent surface of surface of 3 on steering gasket and apply oil the sector shaft cover gear housing and nut and leak nut sector shaft tighten when temporarily slowly shaft Connect gear several times 8 to ensure Set gear arm to sector shaft it turns to neutral move Pour gear oil position and with ball measure nut Approximately liter 0 70 US pts 0 58 UK pts Installation may be backlash mm 0 to 0 004 in prescribed assembly upto level into gear INSTALLATION 0 1 screw m sector shaft When backlash is deviated from adjusting MP 90 Volume of oil into arm sector shaft kg with comes at the end of gear range of 0 to and tighten of nner plug hole and install filler plug lower to smoothly and sector shaft intermeshed at center 3 2 to 3 7 tightening torque 33 0 arm turn shaft 231 t026 8ft lb contact with ball nut 7 full one sector the upper adjusting screw sector retighten finally Lock nut 10 screw 1 8 to 1 6 of screw installing gasket Turn sector shaft adjusting sector shaft lock new gear arm several times Operate further in reverse sequence accomplished of removal Pay attention to the following matters Tightening torque tighten and adjust backlash to the Steering gear housing value 3 2 to 3 7 kg m 1 to 26 8 ft lb 23 Gear arm 14 Steering wheel 2 With make sure kg 7 to front wheels to 2 ft lb 101 m 5 kg 7 m directed punch mark on 50 6 to 54 2 lb ft correctly forward to the top end of steering column 3 When installing steering wheel apply grease to sliding part lightly Check steering wheel for smooth operation 4 Fig ST 11 Metuuring backl4sh STEERING LINKAGE CONTENTS AEMOVAl AND DISASSEMBLY INSPECTION AND AEPAIA ASSEMBLY AND INSTAllATION ST 7 Idler arm ST 7 ST 6 assembly l ST 7 8 ST STEERING REMOVAL AND DISASSEMBLY I Jack up the front 7 of vehicle and support it with pins and Remove cotter ends of cross and idler arm rod nuts from ball studs in both and separate cross rod from gear arm stands 2 pins and Remove cotter ball studs from knuckle nuts and detach side rod INSPECTION AND REPAIR in both sides arms I Side rod ball joint and When ball cross rod stud is wo n and direction is excesSive replace with Fig 3 Remove shaft and used nut remove puller special 4 ST tZ Side rod and gear to secure gear arm by When dust a new one joint 0 1 to 0 5 mm clea r cross is cover Clearance toward ball sock t ce toward axi rod socket or side rod damaged replace axial direction 0 004 to 0 020 in arm gear arm the use of a on sector gear arm tool ST27140000 Remove idler arm assembly from frame i ST 14 Cross sectional view Fig afball joint 1 2 Idler arm Remove old assembly for 3 replace Remove side rod them gear arm as an r od idl r m arm ly an arm for bending arm damage steering linkage in disassembly by noting the following and crack and reverse of sequence matters assembly I 6 and check idler ASSEMBLY AND INSTALLATION ST 13 Idler arm cross dirt deformation and damage if necessary Assemble S grease and wear Cross rod side rod and gear Check Fig assernbly Tightening torque Remove cotter pin and nut from side rod ball stud and separate side rod from gear arm or idler Cross rod ball stud arm ST 7 6 to 7 kg m 4 to 50 6 43 lb ft CHASSIS Side rod ball stud Knuckle Gear arm arm or 6 to 7 side idler kg 6 to 7 kg side arm 4 to 50 6 43 m lb ft m o 434 to 50 6 ft Ib @ Idler assembly arm 3 2 to 3 7 kg I m 1 to 26 8 ft b 23 A Cross rod lock nut 9 to 12 kg m 1 to 86 8 ft lb 65 ST 15 Cross sectional view Fig When 2 adjust cross cross rod socket an cross ro are rod length correctly I multi purpose grease Apply to threaded Standard cross rod length 516 mm 20 3 in Adjust toe in and 2 outlined in section Steering 3 lgle arm Install bushing tightening torque is 12 When idler arm nipple 0 0787 to 0 1181 in Inner wheel 360 Outer wheel 310 grease on grease filler arm removal by noting the kg m MIL G2108 assembly is installed install grease plug hole and inject multi purpose 10924 until grease comes out from or lower end dust seal lip Remove grease nipple and reinstall filler plug When idler arm assembly the standard dimension A Standard dimension A is is installed make sure that adjusted correctly assembly idler assembly following in reverse sequence of 137 8 to 139 8 mm 5 425 to matters 1 SERVICE DATA AND SPECIFICATIONS SPECIFICATIONS Gear type Recirculating ball type Gear ratio 19 8 Steering 10924 FRONT AXLE AND SUS 4 Idler or arm Threaded 3 2 to 3 ffim G210S 86 8 ft Ib PENSION Toe in bushing MIL interior plain bushing interior dust steering angle The procedure of toe in and steering angle adjustments are arm a ssembly seal inside and threaded part and bushing sliding surface of idler 3 of idler parated se wheel diameter mm in 400 8 ST I 157 504 5 in STEERING SERVICE DATA Standard thickness of Worm shims bearing adjusting in mm 15 0 059 t Initial turning torque of steering column New worm bearing kgm Used bearing kgm in Ib worm in Ib 4 0 to 6 0 3 5 to 5 2 2 4 to 2 1 to 3 8 4 End clearance of sector shaft adjusting screw Backlash at the gear arm top end Oil capacity ann mm in 0 01 to 0 03 o to 0 1 mm in mm in mm in 33 0 0 0004 to 0 0012 0 to 0 004 0 70 0 58 0 1 to 5 0 0 004 to 0 020 dimension A 8 ST Refer to page Standard in L US pts UK pis Ball joint axial end play Idler mm cross rod length Toe in 8 to 139 8 5 425 to 137 516 in mm 504 5 3 20 2 to 3 mm 0 0787 to 0 1181 in Steering angle Inner wheel 360 Outer wheel 310 Tightening torque Steering column jacket to housing m ft Ib 16 to 1 8 116 to 13 0 kg m ft Ib 1 6 to 1 8 11 6 Sector shaft lock nut kg m ft Ib 3 2 to 3 7 23 I to 26 8 Gear housing kg m ft Ib 3 2 to 3 7 23 1 to 26 8 Gear arm kg m ft Ib 14 Steering wheel kg m ft lb 7 to 7 5 Ball studs of cross rod kg m ft Ib 6 to 7 gear Sector shaft kg 0 cover to 3 l 0 1012 50 6 to 54 2 4 to 50 6 43 Ball stud of side rod Knuckle Gear or arm idler side arm side kg m ft Ib 6 to 7 43 4 to 50 6 kg m ft Ib 6 to 7 4 to 50 6 43 f TROUBLE DIAGNOSES AND CORRECTIONS In regard of this matter refer to the same subject described in the section ST 9 FRONT AXLE AND SUSPENSION CHASSIS SERViCE JOURNAL OR BUllETIN REFERENCE JOURNAL DATE BULLETIN or No PAGE No SUBJECT r J ST 10 SECTION FE ENGINE CONTROL FUEL EXHAUST SYSTEM DATSUN PICK UP MODEL 521 SERIES BODY CHASSIS I NISSAN I GI t i t NISSAN MOTOR CO TOKYO JAPAN LTD ENGINE CONTROL SYSTEM FE 1 FUEL AND EXHAUST PIPINGS FE 5 EN GINE CONTROL FUEL EXHAUST SYSTEM ENGINE CONTROL SYSTEM 1 CONTENTS DESCRIPTION FE 3 Play of accelerator wire ADJUSTMENT FE 3 Pedal stopper FE 3 4 FE height f L1 I Open Angle Operating I Close Hitach 81 Nikki 82 C A Nut B Adjust C Lock nut B A nut Unit Fig FE 1 Accelerator contTol syst fE for RH drive mm in CHASSIS GP l Clearance 0 to 1 0 to 0 0394 Unit Fig FE 2 Accelerator control system for LH drive rnm in mm in except model PL521 it E3 Unit Fig FE 3 Accelerator control system FE 2 for LH drive PL521 model ENGINE CONTROL EXHAUST SYSTEM FUEL half turns DESCRIPTION so to 0 08 in The accelerator is system light The constructed so and the smootWy is linkage is system Tighten accelerator control the that in part linkage A nut C B to lock nut mm Nut 0 04 B is of carburetor side outer case operates affected by engine not that accelerator wire play is I to 2 Throttle Valve Operating Angle vibration 0 AD USTMENT RH drive I I FE I Fully screw nut bracket and adjust can A 830 Nikki LH be turned I Close lock nut C is With nut adjust wire provided B clockwise with sufficient slackness and play extent that throttle lever is about to move I I turn it up to such tighten Operating angle ABC loose 2 PL521 wire turn Make sure that freely and except PL52I shown in as against accelerator complete unscrew one B nut RH 790 Hitachi Assemble accelerator control system Figure Nikki 830 of accelerator wire Play MODEL Open 2 an is zero at Hitachi 81 Nikki 83 T 5 3 0 1181 this time A 3 B Unscrew adjust nut Play will tighten be I nuts to A 2 mm and one to two 0 04 to 0 08 in e complete Now turns securing bracket completely 8 to secure nut Accelerator wire B Nut C Lock nut Fig FE 5 Unit Adjusting play of accele fo 3 ato mm in wire LH drive PL521U vehicles mounted with L16 engine Adjusting method Note that throttle is the valve exactly same as for LH drive completely closed position differs C 8 A A Nut B Adjust C Lock nut nut 200 Fig FE 4 Adjusting play of accele fo ato wire RH drive 18 2 709 0 LH drive Install accelerator wire throttle valve to sufficiently such an as completely shown in Figure FE 2 slackened tighten nut 8 in part A extent that throttle lever is about to move is zero at this time Set Unit mm closed position and with wire Unscrew nut 8 one Fig up to Play to IDe and a FE 3 FE 6 Adjusting play of accele ato wi e fo PL521 vehicles mounted with L6 engine in CHASSIS Pedal stopper height RH drive wire Upon completion of accelerator accelerator pedal and adjust stopper plate between ance pedal I mm proximately arm and 0 04 in stopper play so depress that clear is plate when throttle valve is opened Secure stopper plate with a lock ap fully screw Unit Fig 18St FE 8 Adjusting ped41 hight for LH drive PL521U method is the Adjusting ever Unit FE 7 in 83 3 Fig stopper mm mm same as for lR drive How pedal stroke differs in Adjusting ped J stopper height for RH drive Unit 2 LH drive accelerator pedal that clearance T Depress height so Fig bolt head is 0 to I is fully opened mm and adjust between pedal stopper bolt and pad bolt with a lock nut Pedal free play Pedal stroke Pedal depressing force when fully mm in rom in kg Qb alignment should be less than center of stopper bolt RH drive LH drive 10 to 2 0 1 0 to 2 0 0 0394 to 0 0787 0 0394 to 0 0787 46 1 811 50 3 7 8 2 1969 3 7 82 open 4 FE in Adjusting ped41 stopper sheight for PL521U Note Deviation in center stopper 0 to 004 in when throttle valve Secure stopper FE 9 mm of accelerator pedal 2 mm LH drive 0 08 in against only PL521 10 to 2 0 0 0394 to 0 0787 48 1 890 3 7 8 2 ENGINE CONTROL FUEl EXHAUST SYSTEM FUEL AND EXHAUST PIPINGS CONTENTS EXHAUST PIPE AND MUFFLEA FE 5 FUEL TANK Description FE 7 Difference of part by model FE 7 Precautions for removal and installation FE 9 AND PIPINGS FE 9 Description FE 9 Removal FE 11 I nspection and repair FE 11 EXHAUST PIPE AND MUFFER N521 Model Series l GN521 Model Series t Note Front and are Fig FE tO Exhaust construction rear tubes of the GN521 model series longer than those of the N521 model series for N52t andGN52t models FE 5 1 i u I I CHASSIS VN521 Model Series UN521 Model Series Note Aear tube of the UN521 model series diffen from that of the VN521 model Fig ies FE l1 Exhaust constructi01l for VN521 and UN521 models G521 Model Series 521 Model Series Note L Rear tube of the V521 model series diffen from that of the 521 model b ies of the G521 model Muffl that of the 521 model series Fig FE 12 Exhaust construction FE 6 for 521 a11d V521 models ies is than long ENGINE CONTROL FUEL EXHAUST SYSTEM e i 1 i l11l I Fig FE 13 Exhaust constTUction Description fOT tube Exhaust piping consists of front tube muffler and Difference of part by PL521 model These components are clamped clips rear model Front tube Muffler Rear tube 52tU 20010 14800 20100 00100 2040t N52tU 20010 83000 20100 B2000 20401 B2000 521 1 20010 20600 20100 00 100 2040t 00301 52 IT 1 20010 t 4800 20100 BOIOO 20401 NL521 20010 B3600 20100 B2000 20401 B2000 52IT N1 20010 B3000 20tOO B2000 20401 82000 20010 B2OO9 20100 B2000 2040 I B2000 200 10 B2000 20100 B200D 20401 B2000 G521U 20010 14800 20100 B0200 2040 t GN521U 20010 B3200 20100 B200D 2040 t B3200 LG52t 20010 20600 20100 00200 20401 t4800 LG52tT 20010 t4800 20100 B0200 20401 t4800 PL52ITU 52ITN P1 with U bolts or 14800 14800 c 14800 521 GN1 20010 B3700 20100 B2000 20401 83200 GNL52IT 20010 B3200 20tOO B2000 20401 B3200 V521U 200 10 t4800 20100 BOtOO 20401 t5200 VN521 20010 14800 20 t 00 B3000 20401 t5200 VL521 20010 20600 20tOO BOtOO 20401 15200 20010 20600 20100 B3llOO 20401 15200 U52tU 20010 t4800 20tOo 2040 t 28300 UL521 20010 20600 20too BOtOO 2040t 20010 20100 B3llOO 20401 28300 521 VN1 521 UN1 20600 A FE BOtOO f V 28300 CH ASSIS PL521 N521 521 SERISE EXHAUST PIPINGS 1887 74 3 N521 serise CD 1193147 01 A 2127183 71 0 @ b GN521 serise N L521 serise @ A A A 5 @ b GNL521 serise A B 3 1638 5 164 51 206147 3 JiS 3P c @ 511 521 serise G521 serise @ 37tI54 0 1653165 11 @ c A A @ 15e21 1 59 L521 serise 9 1 GL521 serise 1973 3 77 71 PL521 serise D Unit FE S mm in FUEL ENGINE CONTROL EXHAUST SYSTEM Precaution for removal and installation I Remove mount bolts A B and C See through muffler are embossed FE1O FEB 2 Remove 3 Remove installation tube FigUres Muffler side of front tube and rear tube side of on clamps manifold L E J J B and D bolts used to secure and disconnect exhaust exhaust tube from EMBOSSMENT manifold Fig b FE 15 Clearance should be 55 FE 14 Fig NOlll a When connecting tube to muffler cenlllr Removing of Muffler and between mm side 2 165 in frame See and Figure muffler FE 16 mount A muffler to front tube or rear Front Unit be sure to apply it complelllly to embossed portion See Figure FE 15 Fig FE 16 Clearance between side rame and FUEL TANK AND PIPINGS Description Fig tube connection FE 17 Fuel system for the J13 and J15 Engine models fE 9 mm in muffler C CHASSIS Three types of fuel tank fuel tank for the 521 G521 N521 and GN521 UN521 fuel tank for the V521 and fuel tank for the PL521 U are Tank capacity is 41 liters VN521 and all fuel tanks available e Fig Fig FE 18 F l tank FE 19 Fuel tank for VN521 for 521 FE 19 r V521 and UN521 G521 G521 and GN521 10 8 US gal 9 0 Imp gal for ENGINE CONTROL FUEL EXHAUST SYSTEM rY To CAANK CASE V A i Fig FE 20 F 1 tank FE ll rfoT PL521 U CFlASSIS Removal I 521 and GN521 models I Remove drain 2 Loosen hand brake 3 Remove plug and drain fuel hole inspection completely cover from body rear Through inspection hole disconnect unit gauge wiring and disconnect outlet tube and breather tube 4 Loosen filler hose 5 Remove front and and then 2 remove clips clip rear tank support bracket bolts fuel tank UVN521model Procedures for the 521 However and GN521 that breather tube position and note Fig models apply support Vapor liquid separator FE 22 er COI bracket differ 3 PL521 model Fuel tank is installed along with the liquid vapor and Inspection repair separator A cover has been provided just wheel to protect vapor view fuel tank and piping for leakage and other damages Repair liquid separator against damage Photograph below shows an exploded Inspect I in front of left rear or replace as required Check rubber hose and fuel line joint particularly carefully for crack and lofiqvaporuid leakage separator Note a When soldering make sure that no gasoline is remained b When cleaning inside of tank use gasoline Do not use water 2 Unit gauge and therefore it Fig 21 FE Vapor liquid separator a screw FE 12 driver adopts bayonet can system for installation be removed and installed simply with ENGINE CONTROL FUEL EXHAUST SYSTEM SERVICE JOURNAL OR BUllETIN REFERENCE JOURNAL DATE BULLETIN or No PAGE No SUBJECT y 11 3 CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL or DATE BULLETIN No PAGE No SUBJECT CJ FE 14 SECTION BF BODY DATSUN PICK UP MODEL 521 SEPIES CHASSIS BODY I NISSAN I NISSAN MOTOR CO TOKYO JAPAN LTD FRAME BF 1 BODY BF 3 HOOD BF 1 FRONT END AND FRONT FENDER BF 8 DOOR BF 13 DOUBLE PICK UP AND VAN BF 18 WINDSHIELD AND REAR WINDOW BF 21 INSTRUMENT PANEL BF 23 SEAT BF 25 ROOM TRIM BF 26 a BODY fRAME DESCRIPTioN The ladder shape frame members and six cross consists of left and members right the frame as side This frame with in condition long as the vehicle is used under the standard When the vehicle comes into a hard collision or creased bending stress and torsional strength sufficiently is driven with an excessive load on withstands against heavy load and high speed however broken and or The engine springs are cab mounted body on rear severe use body shock absorbers and the frame may be bent frame for REPAIR partially The frame is rigid and normally no trouble occurs damage or a cracked twisted When the vehicle is driven this frame rough road under a hard thoroughly inspect the and damaged parts Remove the frame entirely depending on the condition of damage and repair on 5 n tll lI tJ OI IDI hila 10 I I E E U ClI 1011 I i l i 5 B O i ii J C llI aOl 9 2 oS 1 0 5 II aj i cu l Cl 1 n ta iS II d fi 0 i 1 IJC llne 01 tU 1II d BF l r a p BODY 5 ts stlOIOI 6 h E E lOS IlII os I n Uh c I iJ c J m Q r I Q Tg Ig COVlill l EO It all o j Il II m t o uml r u E llOtoS rtl I c 3 u 21 10 iE9 Q o I E ij r E l I s 20 IO ill E tLlSl IE l1 2 Q it u l b ijo f 1M t alii BF 2 a BODY BODY CONTENTS MAIN CAB CAOSS SECTIONS BODY AEAA OF CAB BODY MOUNTING BODY MOUNTING BF 3 DETACHING BFA DETACHING CAB BODY AEAA BODY BF 5 BF 6 BFA MAIN CROSS SECTIONS OF CAB BODY Fig BF J Crosssecticm of cab body 1 li Fig 4 Cross secticm BF BF 3 of cab body 2 I 10 BODY CAB BODY MOUNTING Jute 0 LA S O C c lif S C 0 Body mounting jute Body mounting bracket Aubber washe Body mountmg b 0 I t 3rd b Plain washer y mountmg rubber r A bber washu et o Washe is 1st body mounting Body mounting bolt J Plain washer rubber Special I washer Body mounting bottom rubber ock nut Plain washer Mounting bolt Unless otherwi details are MCtion Crosssection A A Cross section B B Fig BF 5 Cab the specially notBd same as those in 8J B Cross section CC body mounting REAR BODY MOUNTING I I Center of body E r c 0 0 F I L E LO S1 Co a l 0 lit F E 3l I nstallation bolt Plain washer Installation bolt Shim Shim Plain washe lock Cross section O D nut Cross section E E Fig BF 6 Rear body mounting 4 BF Shim Plain W3lher lock Cross section F F nut the aosa BODY DETACHING CAB BODY I Disconnect battery terminal from battery 2 Disconnect speedometer cable 3 Remove steering mechanism steering wheel steering post assembly and remote control system BF 9 Disconnect brake tube Fig 5 6 Disconnect hand brake partment linkage harness body and engine Fig 4 BF 7 7 Removing steering post clamp bolts front lever and cable joint engine controls Disconnect accelerator at such choke wire as heater hose etc rear engine com instrument harness and others between or chassis Remove six cab body mounting bolts Disconnect front brake tube at hose and brake tube joint and rear brake tube at 4 way connector Fig 8 Apply rope wire body by the Fig BF 8 Disconnect brake tube cab body front RJ BF 10 Cab use or body mounting hanger of a hoist or to cab body lift up cab chain block and dismount BODY Fig 4 Apply Fig BF ll up cab Taking kg body since radiator radiator grille before core or to rear body lift chain block up rear and dismount support or lifting not to scar or body while scratch cab lifting and be body Slightly body weight long body Approximately 140 309lb cab portion near rear rear body rearward while lifting Aear to detach hqist Carefully baiance pull sure hanger body Lifting careful Be body mounting body Note 9 wire or rope the use of a body by rear BF 12 Rear is suspended Note Carefully balance dismount carefully or cab so body while lifting and that cab body is not scarred scratched Cab body weight standanl 200 kg model Approximately 441Ib Fig DETACHING REAR BODY Note a BF 13 Rear Lifting rear body Taking body mountings No 1 up through 5 use shims Be careful to select conect shim Disconnect battery terminal from battery b 2 Disconnect rear combination 15 lamp wiring Clearance between rear to 30 mm toward the left 3 Remove rear 0 591 or body to RF fl in body is Deviation right should be within 5 0 1969 in at the center line body mounting bolts and cab 1 181 n1m BODY HOOD CONTENTS Adjusting SF 7 ADJUSTMENT Centering hood lock Adjusting hood lock control lever operating force hood tightness AEMOVAl AND SF 7 SF S SF S INSTAllATION SF S Removal SF S Installation SF S ADJUSTMENT CD 2 9 I r 0 0 t 1 @ f I 1 Fig @ in 5 Dove 4 Safety catch 2 Dove tail bolt retaining nut 5 Female 3 Spring 6 Spring tail bolt Fig Adjusting The female hood lock is 4 I BF 15 adjusting stroke toward mal hood locks with provided the front or a 3 mm 0 118 rear side of the vehicle lever lever BF 14 Male and female hood locks Centering hood lock The male hood lock is provided toward the left adjusting stroke with or a 3 mm 0 118 in right side of the vehicle Fig BF 7 BP 16 Adjusting female hood locks I i BODY Loosen installation bolts and align the correctly center Disconnect windshield washer hose at nozzle 3 Cover hood lock control lever Adjusting operating force to When the hood Jock control lever cannot be operated lightly 2 loosen dove tail bolt retaining nut protect cowl area with cloth or other proper material them from dama ng increase dove tail bolt installation length and reduce securing force of spring hood Adjusting tightness When the hood is closed and is slack reduce installation tightly and increase Note securing When length of force of the inspecting cannot be closed the dove tail bolt spring the hood lock note the following matters a Safety catdllever Check caulked portion of the wear and the spring b catch lever for for weakness and breakdown Fig If the spring is broken and rapidly open safety the aid of a operation down female lever for smooth move Installation smoothly Position hood engaging stroke with the dove tail bolt will be Removal Open hood and prop it in the open to hood hinges and install attaching screws and it may disengage REMOVAL AND INSTALLATION I helper upward and correct and the spring for weakness and break If the female lever does not reduced Coveringcowlarea Remove hinge bolts and detach it from hinges with 4 during driving Female lever Check BF 17 the hood may be unlocked 2 Adjust hood position and tighten attaching 3 Install hood latch striker on screws hood and adjust hood latch position FRONT END AND FRONT FENDER Q CONTENTS BF BUMPER Removal BF Installation BF 10 RADIATDA GRILLE AND HEADLAMP Removal FRONT APRON 9 Removal 9 FRONT GRILLE SURROUNDINGS RIM BF 10 BF 10 Ri A FENDEAS BF 11 BF 11 BF 11 Removal BF 11 Installation BF 12 BODY BUMPER @ Fig SF 1 Front bumper 2 Bumper day 18 Front 3 Front member bumper Removal I 2 Remove installation bolts from both ends of bumper Front bumper Fig BF 19 bumper stays Bumper stays both ends of front apron G Detach G Front are installed at on engine compartment side frame with four bolts apron Removing bumper bolt Fig BF 9 BF 20 Removing bumper bolt BODY 3 Pull forward and remove bumper together Installation with bumper stays 4 Install front Remove four installation bolts When installing and separate bumper that stays from bumper GRItE GRILLE SURROUNDINGS L are Radiator grille and headlamp sequence of removal so and clearance between bumper and AND HEADLAMP RIM @ BF 2J reverse uniform 1 Fig in align position carefully and correctly bumper height front apron RADIATOR bumper Upper radiator grille surrounding 2 Radiator grille 3 Headlamp rim 4 Side radiator grille mrroundings 5 Lower radiator grille surrounding grille surroundings im Removal I Unscrew upper screws and remove four and front two First 2 installation radiator grille toward front next detach lower radiator grille surroundings and remove Note both side radiator grille surroundings Both ends of lower surroundings are overlapped on side and surroundings the above de therefore scribed removing sequence must be regarded of five lower surrounding installation screw s three side left or rightl installation screws either roundings 3 Fig BF 22 Removing radiator griu one BF 10 left one or In other words out of radiator grille surrounding in the bottom is used right end of lower to sur also Unscrew three self tapping screws in front two in both ends are used to secure both side surrounding bottoms also secure screws Out and detach head lamp rim two on top and BODY FRONT APRON 1 3 Fig Front 3 Front apron bumper BF 23 Front apron Removal Detach front Bumper stay 2 Removal bumper See Figure BF 18 Remove apron to fender attaching bolts and I remove Clean fender attaching removing screws bolts and nuts by dirt from them apron downward 2 Disconnect side marker FRONT FENDERS 3 lamp wirings for headlamp and lamp at their Remove radiator BF 24 Front fender assemblies from the vehicle Fig BF l1 flasher grille grille surroundings and head III Fig side connecting terminals BF 25 Headlamp assembly t ODY 8 front side attaching bolts from headlamp Remove 4 Remove front fender 7 rear side attaching bolts installing parL Pig BF26 lt 7 Pr ft j 4 Jchf rg att boJts Pig 5 Remove apron to BP 29 Fender rear side attaching bolts fender attaching bolts from both sides 8 Remove attaching bolt from bottom of front rear fender 9 Pull left or right front fender toward front left right direction and detach Pig 6 BF 27 Apron to fender attaching or it bolt Remove front fender top attaching bolts Fig BP 30 Detaching front fender Installation Install front fender in Note Fig BF 28 Pender top Aeplace reverse lender rubber with a new one when attaching bolts BF 12 sequence of removal used in rear reinstalling side of fender fender BODY DOOR CONTENTS ADJUSTMENT SF 13 DOOR LOCK MECHANISM Door lock striker SF 13 Removal Door SF 14 Installation hinge REMOVAL SF 14 Fig DOOR SF 15 SF 15 SF GLASS AND AEGULATOA 1 Door 2 Door window ventilator 3 Door window 4 Glass run 5 Door window weather 6 Door ou tside handle 7 Door lock 8 Door lock and remote control Ass y 9 Door panel assem bly strip key cylinder window regulator I nside 11 Regulator 12 Door 13 Scaling screen 14 Sealing screen 15 Sealing screen 16 Support cushion handle handle finish BF 31 Door construction ADJUSTMENT Door lock striker Door lock striker direction as can be adjusted freely toward any required Fig BF 13 BF 32 Adjusting assembly glass 10 16 SF 16 door striker I BODY 2 Align door position correctly before adjusting door by adjusting Loosen gently 3 to align striker against Open Door attaching striker door and door and apply a jack or rigid rack door striker Note 2 open beneath door to support it striker It should be noted however that door sag cannot be corrected Fully and close screws When applying jack or cloth between door and door latch mechanism tighten striker attaching a rigid rack apply piece of jaek or rack to protect door from scratching screws hinge Door hinges are adjusted top bottom front place door in the position right and l Visually inspect door from outside and make or left toward rear that accent stripe is to positioned straight I sure with front fender and door exterior is flush with body exte ior When door is not placed in the position correctly 2 detach dash side trim 3 front When adjusting door position toward top bottom and when adjusting or rear adjust body side hinge door position toward eft or Fig sure Supporting door right adjust door side hinge 3 4 BF 34 When door position is adjusted that door can be closed and at hinge side Remove upper and lower hinges at the body side and separate door from body make opened smoothly and that door lock operates correctly REMOVAL I Remove package tray and remove dash side trim Fig Note When BF 35 Separating door from body reinstalling clearance door position it correctly Fig BF 3J Removing d4sh Adjust striker side trim BF 14 that between door and body is even Adjust door position with hinge installation bolts side so body door lock engagement at door lock BODY DOOR LOCK MECHANISM Door lock is provided with a lock knob and is of door is open an unlock type in which lock knob does not lower while 6 D @ o l @ @ Fig I 2 Detach inside handle and regulator handle an ordinary Be careful not to scar or remove screw scratch panel and Detach damaged driver Lock 3 Bell crank 4 Door lock remote control 5 Door lock 6 Outside handle lever 7 Inside lock knob installation bolt installation bolt installation bolt assembly assembly sealing remove screen carefully so that it is crank installation bolts and inside lock knob installation sealing screen w I Lock installation bolts 4 Knob lock 2 Inside lock knob installation 5 Glass 3 13 Door f1nish Fig BF 37 Bell crank Fig Cloth 3 Detaching door finish BF 15 run instaiIation bolts CD not lock installation bolts lock knob bell bolts and remove lock knob and separate door fmish from door Note Lock knob BF 36 Door lock mechanism Removal door finish installation clips with 1 2 installation bolts BF J 8 Removing lock assembly Separate key cylipder and lock joint bolts BODY 4 Remove door lock with remote control together DOOR GLASS AND REGULATOR assembly through work opening Detach door lock assembly door finish and sealing screen I 2 Remove installation bults and remove door window support cushion I a 1 I I Do i I r Fig BF J9 b Removing door lock 1 c Installa tion 1 Install door lock mechanism in reverse Fig sequence of BF 41 Sealing screen and bolts removal 2 Upon completion of installation make A sure between outside handle lever and lock side lever end is I to 3 mm 3 that play roller Remove on end of regulator locking Recommend that glass be suspended with of string beforehand L so 1 11 Q I I I 71 c 40 BF Fig 3 J When play A Adjusting door lock is insufficient adjust outside handle installing position When door panel is deformed e g hollow etc repair panel Fig BF 16 42 BF a piece that glass can be taken out easily I t from glass 0 0394 to 0 1181 in Note I arm channel and lower window glass to the bottom Take out glass BODY 4 Remove four installation screws from upper portion of door sash Fig Fig 5 Removing fouT installation Detach side window weather screw driver carefully so as not to strip with Removing door ventilator 8 Pull door glass upward and 9 Remove four door window regulator assembly in stallation BF 43 BF 45 remove it screws SCTewS an ordinary damage it Fig BF 46 Door window regulator instaLtion screws 10 Remove service Fig 6 opening weatherstrip Remove two door window ventilator center side sash instaJlation 7 BF 44 Del4ch door window regulator assembly through Pull screws door window ventilator toward upper rear direction and separate it from door Fig BF 17 47 BF Removing window egulatoT flSsembly BODY DOUBLE PICK UP AND VAN CONTENTS BF18 SIDE WINDOW TAIL GATE AND Double pick up BF 18 Double pick up Van BF 18 Van SIDE BF 19 LIFT GATE BF 19 BF 20 WINDOW Double pick up CROSS SECTION A A Fig When installing be sure to BF 48 Side window double pick up apply sealing agent between body panel and weather strip Van Fig BF lB BF 49 Side window van BODY Remove set weather strip remove screws toward side window sash detach luggage compartment side and side window assembly toward outside When installing be weather from sure to apply sealing agen t between strip and panel G Roof Side window sash Fig BF 50 Removing side window TAIL GATE AND LIFT GATE Double pick up Tail gate lock r ll 1 Side lock T G RH assembly 4 Clip 2 Side lock T G LH assembly 5 Thrust 3 Remote control assembly Fig and Remove tail gate inside cover lock installation from both sides screws BF 51 remove screw Tailgate cross headed lock doubk tail gate side 2 tail gate lock assembly through Spring 7 Striker washer up correctly Remove tail gate remote control installation bolts Remove pick 6 When strokes of claws in both sides adjust at remote control service adjuster locks are balanced opening Upon completion of reinstallation I Make sure 3 that both left and right locks operate Bf 19 Apply grease to slinding parts so are unbalanced that both side I I J B Van Tail gate lock @ II 1 Tail gate lock body assembly 2 Shaft 3 Lock lever 4 8 j Fig Detach tail gate inside cover and remove right tail gate side lock installation BF 52 Tail gate lock both left and screws CD r Strike spring assembly 5 Lift gate side lock assembly 7 Push lever 8 Lock lever 9 Stopper A 10 Pull lever 11 Keylcrer 12 Tail gate 13 Lift gate lock ide lock assembly 14 Striker assembly 15 Clip 16 Key cylinder 17 Outside 18 Pull handle lever handle van Disconnect key cylinder and lock joint key cylinder jl rod through @ 1 Sld c I k iri t tion screws 2 Lift gakdock installation Fig 3 jen Ob inst btion 4 Lock screw body installation Fig BF 54 Removing key cylind rod screws screws BF 53 Remove Removing tailgate installation bolts lock installation screws assembly from service opening RF 7n and remove lock BODY 3 When lock does not operate check grease lightly and smoothly lever sliding parts for lubrication as and apply required Uft gate Remove lift gate support installation Fig BF 55 screws Removing lock Upon completion of reinstallation I Make sure that both side locks and two locks on tail gate top operate correctly 2 When both side claw strokes are unbalanced at remote control adjuster so adjust that both claws engage evenly Fig Apply a piece BF 57 Lift gate of cloth between roof and lift gate to protect body from scratching Remove hinge installation bolts and separate lift gate from body Lift gate is installed in When sides l Fig BF 56 Adjusting lock stroke installing 3re reverse lift gate sequence of removal position ocrrectly that both aligned evenly Upon completion of installation make operates correctly and smoothly When required so move sure that lock adjustment is striker side WINDSHIELD AND REAR WINDOW CONTENTS AEMOVAl BF 22 INSTAllATION BF 22 BF 21 WATEAlEAK COARECTION BF 23 BODY windshield REMOVAL Place protective a panel instrument cover over and front front fenders hood The glass method which below procedure may be used to check ou the tlines the windshield opening seat I Check 2 Remove rear view mirror support ularities 3 Remove windshield wiper 2 t On inside of body loosen the lip of rubber channel arm assembly channel rubber windshield for Cle n off old sealer around windshield anyirreg and opening check entire b dy opening flange for any irregularities from spot welded flange windshield opening pressure to glass putty knif or near edge other rubber channel over 5 With s along the the palm top and sides of the hand 3 apply a blunt and carefully tQol assist At the same time itable of With l1entgl31 spot welded flange Note ith ail of helper ca fully lift assembly from body opening and place it on a Care should be exercised to make certain strike body chips windshield helper Carefully position replace a nAshi I t openip g on not After windshield rubber channel is free from spotI welded flange the aid of can glass during installation metal does Edge lead to future breaks protected bench 6 glass and Clean either is to be or weatherstrip of all old sealer if used re With 4 ndshield glass supported body opening check relationship of glass peririleier around entire Inside I and to centered in body opening of glass surface of glass should completely contact spot welded flange 2 Curvature of glass should be uniform that of to body opening Mark any sections of body 5 glass Fig Note BF 58 The windshield Removing windshield chrome moldings are 6 the rubber channel and shoo Id be removed removing rubber channel from the prior important that as Remove required Clean out old sealer in glass cavity of windshield rubber channel and around base of rubber channel to glass INSTALLATION It is opening be reformed Install windshield I installed in and reform to 2 Install rubber channel to 3 Insert a glass strong cord in the groove of rubber channel where spot welded flange fits the Tie ends of cord and tape to inside surface of glass at body windshield opening be checked thoroughly before installation of the replacement upper center of g at ss BCJDY r t CD Weather With the aid of center windshield Note Do Glass BF 59 Draw cord installed Fig 4 2 strip a assembly notposition helper in Fig carefully position and 7 body opening glass by tapping or BF 60 Sectional view of rubber channel Reinstall all previously removed parts and remove protective coverings hammering any time t l f WATERLEAK CORRECTION at H11 iH t l In many instances minor waterleaks around windshield may be corrected by performing the the following operations 5 When glass and channel are properly positioned in opening slowly pull ends of cord starting at upper center of windshield to seat lip of rubber channel welded flange Cord should be pulled first wIndshield then upj e ch side and over Using spot tip top of across finally across outer Using a lips of weatherstrip completely pressure rubber adhesive type channel as applicator to glass sJ r irt with er apply pressure an cor of Leak between rubber 2 Use indicated in Figure BF 60 Seal a pressure from outside of around rubber channel apply J with a lt 9J j e fSojw black qf gla body cli i i iel and applicator bbdy a na glass j ed wit ng gun weatherstrip adhesive approved a i b narrow q tip Working sealer under outer iip of rubber channel around entire perimeter of body opening INSTRUMENT PAN EL CONTENTS REMOVAL applicator completely around perimeter ana ri appio a between glass and rubber chann l ofjthe wind shield bottom 6 Leak between rubber channel and glass 1 BF24 RF 3 BODY Fig BF 61 Removing instrument panel REMOVAL I Disconnect battery terminal 2 Disconnect heater control strun1mtharnessfengine wirings for 3 jwishienld BF 62 wire from compartment harness wP Remove steering pOst Fig 4 lever screws from the top of instrument panel and two from both sides in connector 5 panel instrument PulJ rearward and separate it from body toward left rietc clamp Remove four set insiallation bolts Removing steerifJg post clamp bolts Fig RF 4 BF 63 Remolling instrurTlent panel BODY SEAT square shape pipe frame and Sshape and and vinyl leather are used for and urethane springs Rear seat Seat uses steel van seat cover REMOVAL Front seat and pick up double pick up van J@ a Fig Fig Remove four riser Seat can be Rear seat BF 64 Front seat installation nuts Remove screwed against seat double pick front side hinge installation remove rear seat as Seat cushion Fig G screws separate an assembly up SEAT BELT Q an seat back from brackets in both side wheel housing units and separated BF 66 Rear seat OPTION Seat back BF 65 Rear seat double pick Fig up BF 25 8F 67 Seat belt Jling inst positions BODY ROOM TRIM OVERHEAD LINING Removal o Insert a spatula and withdraw o between roof panel and roof rail end of overhead lining one Peel off overhead lining from roof panel from the t withdrawn end to the other end eAi e j Installa tion o Thoroughly remove lining remained foreign matter o Adhere overhead apply adhesive is and to roof other panel front side to rear side completely Providing circumference with a OVERHEAD LINING stretched sufficient space so folded into roof rail cut off unnecessary that it i extra dust panel lining from carefully so that it o roof on and pieces of overhead old adhesive space with a knife fold circumference in or o roof other proper tool and SERVICE JOURNAL DATE Fig rail or Al OR JpURi PAGE BF 68 overhedd lining BUllETIN REFERENCE No SUBJECT BULLETIN No I Bf 26 SECTION BE BODY ELECTRICAL DATSUN PICK UP MODEL 521 SERIES BODY CHASSIS INI NI NISSAN MOTOR CO TOKYO JAPAN LTD WIRING BE 1 FUSE BE 7 LIGHTING SYSTEM BE 8 HORN BE 15 METER AND GAUGES BE l B WINDSHIELD WIPER AND WASHER BE 26 IGNITION SWITCH AND STEERING LOCK BE 3D RADIO BE 32 CLOCK BE 35 HEATER BE 36 a BODY ELECTRICAL WIRING CONTENTS WIRING Engine HAANESS BE 1 compartment harness BE 1 WIRING BE 2 INSPECTION Instrument harness Body harness DIAGRAM BE 2 BE 4 BE 7 WIRING HARNESS Engine compartment harness t Fig BE 1 E gi compartment harness BE 1 BODY Instrument harness Body harness Fig BE 2 Instrument hamess Fig BE 3 B09Y BE 2 ham s 521 600 BodY l EtECJR C t n J 4 t I 1 JN harness C bt j S DC C f L t 1 j i r 1 4 BE fi codY rness lO V521 h f f t lt l rne55 Fg BE 5 Bod BE 3 0521 BODY WIRING DIAGRAM w g r c s c a ta m CI i c m o 0 a J OCO t lI I i I 8 i cO 03 g i eT if f n J r r I I 01 4 o o o g 0 o g a i c IIl 8 8 l I l I l J 3 3 1 r eve Fig I 6 Wiring BE dillgram BE 4 common countms 3i J C1 BODY ELECTRICAL w c o0 U OE a o 6m J lQOII J t3S lJi i 0 i j io a H i II u lRi Jj Q LJ w G O 0j I 1 Ji J i f l1 a 5d a j d diagram Fig BE 7 Wiring BE 5 U S A Canada 8 lP o l ct Q3 a a l c J BOPY w 9 a r CD c og I CD iL M i 5 V Ii t C I 1 CD U J n i c J Ii 1 i i t J Q J i 6 i Ifi I i i ii Iil I 1 j I I I 8 11 1 1 E t 1t ii l l 2 gf t I f tit Fig 8 Wiring diagram BE 6 BE Van Double cabin Q 12 tl CI Ca a o I i lP 0 IJ CC J O BOOYELE TRICAL INSPECTION Cables 6 should be into contact with Referring to wiring diagram check wiring harness for connection with electrical connection and harness note the Connected equipment and installation following When f i connector checking wiring matters unit should not be loose rusted ed or cover should not be tion bolts pletely so are bolts should be or that Cables 7 continuity is body should be at sections of unit where vibration which current Note When 8 IToneous connection should be with fan 1 optumim an on body due occurs to at or extra sections engine operation and inspecting other main performing or tenance service without power when or it is pply from battery s anticipated that part a may be disconnect battery I I terminal flows b In no directly No as com should not come into contact with othermetal parts 5 positions such others provided jn between body through in rotating parts irily station circuited short Terminals securely clamped from and bolts 4 not come part temperature of or Cables should be provided length crack grounded through installa in contact with corner they do pulley fan belt etc insulating material should not be deteriorated For those parts which 3 damaged that so wplFh rises highly 8 Cable insulator sharp sufficiently spearated contaminated 2 clamped present test event should an unloaded connected with ground lamp or circuit Be circuit be to use sure a tester r c 1 FUSE j DESCRiPtiON l ov When to a rcurrent circuit the interrupted and fuse t us INSPECTION exceeding the rated amperage flows is heated and melted s bles and protected from damage due to electric tequipment burning In the circuit is or most cases fuse can be checked visually when it is difficult to check visually However a l tester may be used are damage the circuit u is limited to the minimtim Note o a When fuse is blown off be sUre to correct the cause before Be sure i installing new fuse I b to use fuse having the specified C Do not use fuse having larger capaeity e 7 Q ie r i j c When the contact surface is dirty or rusts or the eontact is loose fuses ment and BE 9 Fuse box BE voltage drops resulting in heated abnormally operated Remove dust paper to Fig capacity 20A 30A etc improve or polish the contact electrical with a equip fine emery I BODY LIGHTING SYSTEM CONTENTS SIGNAL AND DIMMEA BE 8 TUAN Sealed beam unit replacement BE 8 COMBINATION SWITCH Headlamp adjustment BE 8 HEADLAMP SIGNAL AEAA SIDE BE COMBINATION LAMPS LICENSE PLATE LAMPS MAAKEA 9 BE 11 SWITCH LIGHTING LAMP FLASHEA BE 11 Removal PAAKING AND TUAN FAONT BE 11 Removal DIAGNOSES AND BE 10 TROUBLE BE 10 COAAECTIONS BE 12 BE 12 Headlamp ILLUMINATION LAMP BE 10 BULB SPECIFICATIONS BE 10 Turn BE 13 signal lamps Tail lamp stop lamp license lamp BE 15 backup lamp HEADLAMP Sealed beam unit replacement I Remove wiring socket from the back of sealed beam unit 2 Remove head 3 Remove retaining ring by unscrewing three screws Note lamp fmisher Do not disturb two aiming adjusting screws 5 10 Fig Remove sealed beam unit 4 Reinstafl sealed beam unit in reverse Remooing head Lmtp finUher sequence to removal Headlamp adjustment For correct aiming adjustment floor correct pressures of all tires such as luggages equipment and passengers place and vehicle to level remove except all loads for standard spare lire and tools Adjust vertical and horizontaI directions of head lamp respectively with adjusting screws and side portions of headlight moun located at the upper ting ring Fig BE B BE 11 BE II Removing head Lmtp BODY ELECTRICAL When adjusting low beam adjust aiming of low beam head lamps at the outside adjusting high beam cover at the outside with cover and then beam head lamps High adjust aiming of high at the inside Vertical adjusting 1 low beam head lamps 1 screw Horizontal adjusting screw Fig Aiming head lamp BE 12 Low beam beam t f I r r c i J 1 n When t 10m 32 lIftl i J r I f in Hmm 521 N521 741 G521 GN521 738 U521 UN521 715 V521 720 VN521 M 132 I Gfll h mm llftl f in h mm 29 2 50 145 571 1040 291 1 29 50 145 5 71 1040 291 115 10 175 6 89 1050 320 12 6 1010 204 8 03 20 349 13 7 28 1 3 28 Fig BE 13 Head lamp aiming adjustment data FRONT PARKING AND TURN SIGNAL LAMP I When removing bulb with lens removed push bulb toward socket turn bulb counterclockwise and withdraw bulb When removing lamp 2 I Remove mud cover in housing used to cover lamp from the inside of wheel house Fig BE 9 BE 14 Mud coveT 11 5 BODY 2 Remove connector from wire harness 3 Remove lamp housing installation REAR COMBINATION LAMP nuts and remove When removing bulb toward socket lamp assembly turn with lens removed push bulb bulb counterclockwise and withdraw bulb When 2 removing lamp housing I Remove connector from wire harness 2 Loosen lamp installation nuts and remove lamp assembly 1 SIDE FLASHER MARKER Remove if i 1 i side flasher lamp installation nut from the inside of fender Of and and lamp housing Fig BE 15 Front p Dking and tvm signal lamp LAMP can rem ve lens be separated packing and bulb Lens from body LICENSE PLATE ILLUMINATION LAMP When removing bulb remove lens and then remove bulb BULB SPECIFICATIONS All countries except For U S A and Canada for U S A and Canada Item Wattage Candela power High beam Lowbeam unit Front parking turn j rr License number 37 5 50 4002 5 50 37 4002 23 32 cp 1073 8 4 cp 67 6 5 cp 4 7 5 6 cp 1034 lamp 32 33 cp tail 89 7 5 6cp 23 8 23 8 Stop Rear combination 23 8 8 4 cp illumination lamp number 4001 signal lamp r power trade 5 37 lamp plate Candela SAE 4001 Side flasher lamp Side maker trade Wattage 5 37 unit Head lamp SAE 6 67 89 1034 1034 32 33 cp 32 33 cp Turn signal 23 32 cp 1073 23 32 cp 1073 Back up 23 32 cp 1073 23 32 cp 1073 Passenger compartment 6 Engine compartment lamp 6 BE lO 4 5 cp 5 cp 4 6 4 5 cp 6 4 5 cp BODY ELECTRICAL TURN SIGNAL AND DIMMER ring and steering wheel 2 Remove horn 3 Remove shell cover 4 Unscrew two screws used to secure switch on COMBINATION SWITCH Removal Disconnect combination switch from wire harness at connector column plug steering jucket and column remOve jacket steering switch from locating hole Now remove switch on completely LIGHTING SWITCH Removal Fig BE 16 Removing turn I Remove connector from the back of lighting switch 2 Remove 3 Remove nut 4 Remove lighting switch screw and knob plain washer and spacer sigMl and diameter combination switch A CLOCKIL M SW 8 TO FUSE FLA Fig tER 3l F UNIT BE 17 Circuit diagram forlighting system BE ll v BODY T LIGHT TCH CUXK IL iz It I TO USf r TO rUSE H Fig BE iS Circuit diagram for lighting system CtUUJdU S A TROUBLE DIAGNOSES AND CORRECTIONS Headlamp Condition The not headlamp does light Probable Blown off fuse or Corrective action cause faulty contact for both Check fuse for When fused Faulty lighting switch or light relay or vice versa is defective Conduct Defective dimmer switch cause then or replace continuity switch is defective be switched to lower beam detect and repair Check continuity test and if the switch relay cannot and faulty contact replace fuse upper and lower beams Upper beam fusing test and if dimmer replace Check the operation if dimmer switch is Defective light relay defective replace ne BODY ELECTRICAL Condition Headlamps dim Probable Corrective action cause Defective light circuit Check the headlight circuit for cable being about to break and faulty contact or check fuse for faulty contact Repair Headlamps dim Partly discharged battery or with engine Charge battery if required operated under idling speed Headlamps replace if required Measure specific gravity of electrolyte when the engine is stopped or still dim Defective battery Replace battery beam unit Faulty sealed Voltage between headlamp red white cable and black cable terminals is or black red run above idling speed 12 8V or higher Replace sealed beam units Faulty charging system Voltage is less than 12 8V through above test Check generator regulator and light circuit Headlamp ip only one Faulty headlamp terminal contact Repair as required side lights Defective lamp Turn signal lamps Condition All turn signal lamps Replace lamp Probable Blown offfuse or Corrective action cause faulty Check fuse for fusing and contact do not ligh t Faulty flasher unit terminal contact defective flasher unit or When fuse is fused cause and replace fuse faulty contact detect and repair the When two lead wires of flasher unit are connected with turn signal switch turned on and individual turn signal lamps light her unit is defective fla Repair connector terminal if necessary Replace flasher unit Defective turn signal Conduct continuity test switch If the replace tF BE 13 turn signal switch is defective BODY Condition All turn Probable Corrective actions causes Defective flasher unit signal Replace the flasher unit lainps do not go out Flashing cycle is A to low lamp having wattage specified wattage more than the flashing cycle Faulty contact one is used Defective flasher unit Turn signal lamp Replace with the specified Replace flasher in circuit Repair as unit necessary is too A high lamp having wattage less than the spe Replace with the specified one cified wattage is used Defective flasher unit There is Flashing cycle or right side ofteft turn a Burnt out Replace flasher lamp which does not flash lamp bulb fIlament right Replace Check all lamps for operation Check lamp which does not light for burnt signal lamp differs from that of or unit out fIlament and defective socket left side turn Replace if necessary signal lamp Only left or right side turn Faulty Check both side lamps for difference in connector contact brightness signal operates Repair A When windshield wiper lamp other than specified is used is necessary Replace with Measure Partly discharged battery which uses ignition for power supply as the specified specific gravity one of electrolyte Charge battery if necessary operated flashing cycle and brigh tness change Faulty contact of power supply circuit BE 14 Improper contact of power supply circuit ELECTRICAL BODY Tail license lamp stop lamp back up lamp lamp Condition Probable Both left and right lamps do not Blown offfuse or Corrective action cause faulty Check fuse for fusing and faulty contact contact When fuse is blown off detect and correct light cause Defective stop lamp switch or backup lamp switch or faulty Stop lamps and and replace fuse When two lead wires of switch are contact neeted and the backup lamp only circuit are normal Replace switch or lamp lights repair con lamp and connector termi nal Only one side lamp Faulty grounding Repair grounding cable contact Burnt out lamp bulb filament Replace lamp lights Faulty or Brigh tness of one side lamp differs from the a new one Repair socket Faulty or contact of connector terminal and with contact of connector terminal and Repair if required socket other tI HORN CONTENTS AEPLACEMENT BE 15 TROUBLE DIAGNOSES AND ADJUSTMENT BE 16 CORAECTIONS BElT REPLACEMENT 1 Disconnect wire from horn 2 Remove bolts retaining horn to bracket 3 Install horn in reverse sequence to removal Test horn operation when installed Low and located in upper and lower sides BE 15 high tone horns are respectively BODY JUSTMENT AD Note When adjust screw Clockwise I Secure horn in power 2 a vise and connect horn cables to is turned Current decreases Counterclockwise Current increases supply See Figure BE 19 Set power supply switch to and make ON sure 4 that voltmeter indicates 12 to 12 5V Upon completion of above adjustment make sure that horn sounds correctly with 14 to 15V generated by alternator AMMETER 110 to 15Al HORN Sound VOLTAGE METER 115 to 20VI Fig 3 for hum adjustment BE 19 Circuit Consumed current adjusting value High 5 440 Low 5 350 Figure encircled in parenthesis are basic A frequencies Hz Listen horn sound for level volume and tone Adjust sound as ammeter required to obtain When adjustment is and turn adjust screw sepecified required amperage by loosen lock nut 5 adequately Secure lock nut of adjust screw HOR N BUTTON IHI III Fig BE 20 Adjusting hum Fig BE 16 HE ll Circuit diagram for horn system BODY ELECTRICAL TROUBLE DIAGNOSES AND CORRECTIONS Probable cause Condition Horn does not Excessively discharged battery operate Corrective action Measure specific gravity of Charge Blown off fuse if required Check fuse for fusing and improper contact Replace Improper electrolyte horn button contact or repair if required In this case the horn sounds relay terminal S is though horn grounded Check and repair horn button Defective horn relay Horn sounds though the horn relay termi nals B and Replace Defective horn Horn B horn terminal Replace Defective horn relay circuited short relay and H still does are not circuited short sound directly horn Horn does not stop though horn relay continuously Short ircuited horn button and horn relay When terminal S nection relay horn horn stops through above discon check horn button unit particu larly carefully Repair horn relay Replace tone S terminal is disconnected Replace Reduced volume and though terminal is connected to horn battery Horn sound are does not sound though horn relay terminals and H horn or Improper fuse wire contact terminal S horn button Correct quality Broken cable Improper horn button Repair or replace contact BE 17 Repair if required I BODY METERS AND GAUGES CONTENTS COMBINATION METEA BE lB OIL PAESSUAE WAANING Description BE 1B IGNHlON WARNING LAMP BE 21 Replacement BE 19 BULB SPECIFICATION BE 21 BE 19 TAOUBLE BE 19 COAAECTIONS SPEEDOMETEA Replacement FUEL METEA AND THERMOMETEA LAMP BE 21 DIAGNOSES AND BE 22 BE 19 Speedometer BE 22 Description BE 19 Thermometer and fuel meter BE 23 Replacement BE 20 Oil pressure and ignition BE 25 warning lamps COMBINATION METER Description The combination fuel speedometer indicator lamps meter oil consists meter and of three meters thermometer and five indicator lamp ignition warning lamp head lamp high beam pilot lamp and turn signal pilot lamps left and right For illumination of the pressure combination meter four meter uses meter for a wiring meter can be the 12 printed pole lamps are used The combination circuit board located behind the With this construction the combination simply connected connector See 1 Speedometer 2 Meter illumination to power supply through Figure BE22 6 Oil pressure warning lamp lamp 7 Ignition warning lamp 3 Fuel meter 8 Head lamp upper beam 4 Thermometer 5 Tum lamp signal pilot pilot tamp 9 to Regulator 12 pole connector Fig BE lB BE 22 Combination met 1 BODY ELECTRICAL The illumination board with clips lamp sockets they can are secured on the back be removed and reinstallation 4 Loosen speedometer cable cable from speedometer union nut and remove speedometer head easily The fuel meter and thermometer The regulator use meter regulator minimize indication error due to fluctuation and therefore the meters are voltage Install combination meter in s reverse sequence to removal very reliable SPEEDOMETER Replacement I Replacement Disconnect negative battery cable I With combination meter removed screws 2 Unscrew two set screws from lower part of combi 2 Loosen two screws combination nation meter loosen attaching and separate combination meter from meter meter used to secure cover speedometer on and detach speedometer housing from combination meter 3 Install speedometer Fig Fig BE 23 Removing combination meter BE 24 in reverse sequence to removal Removing speedometer FUEL METER AND THERMOMETER Description The fuel meter consists of a tank unit located in the fuel tank and fuel meter The tank unit detects fuel level with its float converts fuel level variation to 3 Pull out 12 pole connector from the back of combi of slide resistor installed nation meter controls current BE 19 flowing on the float to the fuel meter base a resistance and thus J BODY The consists thermometer thermaltransmitter of in located thermometer and a the thermaltransmitter is equipped with engine a block The current bimetal arm ON the provided current flows to the heat coil pointer connected the to with tolerance may occur on are ann and arm on a voltage fluctuation supply a constant If both Consequently defective the thermometer of fuel applied the at trouble in the the a to the time coil the contact closes The a pulsating voltage temperature and fuel gauges thermometer same by the current to the coil is repetition of this operation produces is voltage that the heater coil When the ignition switch is As the bimetal cools of8Y which is so meter the bimetal arm is heated and bent interrupted same The voltage operate correctly part of the regulator consists of opening the contact and the heat bimetal is used to operating bimetal the bimetal ann is bent and operated The characteristics ofboth meters A controls and healer coil When the ignition switch is coil is heated With this heat thus The a turned are source thermometer and fuel thermometer flowing to the fuel meter and thermometer The set to thermaltransmitler the and thus due to regulator thermistor element which converts cooling water temperature variation to resistance meter and fuel meter become this may be attributable to voltage regulator r AEGULATOA FUSE M TEMPE AATUAE IGNITION GAUGE SWITCH GAUGE TANK UNIT T I FUEL TANK THEAMAL TAANSMITTEA Fig di4gram for fuel meter temperature meter and voltage regulator BE 25 Circuit Replacement 1 With screws combination meter removed used to secure combination meter fuel meter housing and or remove two set thermometer remove fuel meter 2 Install fuel meter or thermometer in reverse sequence to removal on or thermometer from combination meter BE 20 BODY ElECTRICAL When the ignition switch is circuit is closed warning ignition switch through the generator current to ON the ignition the warning lamp bulb and to ground regulator When the engine is started and the comes opposes in lamp set and current flows from the into effect it the generator output operation flowing from the warning the current breaks the warning circuit ground connection and the lamp goes out Ignition switch r Fig BE 26 8 Removing thermometer c 0 5 co Pilot OIL PRESSURE WARNING LAMP The engine lubricating system incorporates an relay oil stationary the the light glows with When the engine is kg Alternator Regulator 5 7 to 8 5 em when the Under normal operation Ib sq in on to 0 6 em 1 I a L pressure waming lamp which glows whenever engine oil pressure falls below OA kg a 3 Ql te lD J 2 engine is ignition switch turned Fig BE 28 Circuit of ignition warning system running and oil pressure reaches the above range the circuit opens and the light goes out u I i c o Warning light BULB SPECIFICATIONS Fuse 0 Wattage Switch en Item Candela T I power J without with pressure pressure Meter illumination signal lamp BE 27 Circuit of oil pressure 34 2cp 158 7 1 cp 1 161 17 lcp 161 17 lcp 161 I 7 I cp 161 indicator lamp warning system High beam indicator lamp Ignition warning lamp IGNITION WARNING LAMP Ignition warning lamp glows is set to ON generator fails trade number J Turn Fig SAE and the engine to charge when the is not with the ignition switch operated or Oil pressure warning when the lamp engine operated BE 21 rr BODY mOUBLE DIAGNOSES AND CORRECTIONS Speedometer Condition Probable Corrective action cause Speedometer pointer and Improperly tightened speedometer odometer do not operate union nut cable Broken speedometer cable union nut correctly Replace Damaged speedometer drive pinion Speedometer pointer Retighten gear Replace Defective speedometer Replace Rapidly bent speedometer cable Correct drive or pinion gear replace deflects widely Damaged speedometer drive pinion gear Defective speedometer Improperly tightened speedometer pointer union nut occurs in response to increase cable Retighten Defective speedometer cable Replace Defective speedometer Replace Excessively Replace bent cable inner wire or or gear Replace Unstable speedometer Unusual sound Replace pinion twisted speedometer union nut cable meter cable lack of lubrication of driving speed Defective speedometer Replace Defective speedometer Replace Inaccurate odometer Improperly Replace speedometer operation worm Inaccurate speedometer indication meshed second and third gear gears Faulty feeding due to deformed odometer and pinion carrier BE 22 correctly Replace speedometer or lubricate BODY ElECTRICAL Thermometer and fuel meter Probable Condition Both thermometer and Blown off fuse or Corrective action cause improper connection Check fuse for fusing and improper contact fuel meter do not Replace after correcting operate Correct contact Defective fused or voltage regulator Damaged cause if fused Replace open contact Both thentlometer and Defective voltage fuel meter indicate wire inaccurately grounding seized regulator contact and Broken heat or improper In this case meter operates excessively Replace In this case meter operates Improper cable contact for Check cable repair if slightly improper contact and required ThennometeJ Thermometer does not Defective thermal transmitter thermal transmitter Replace white cable is Defective thermometer Replace deflect Pointer indicates Defective thermal transmitter Pointer when does not pointer thermaltransmitter yellow grounded moves to low limit when ignition switch is turned off temperature Pointer Defective thermometer even indicates replace Thermometer 40 n resistance accurately transmitter grounded thermometer is applied when a thermal cable is and thermometer indicates ap 800C If thermometer Replace to wihite cable I760F is normal above inspection BE 23 temperature seIViceable is yellow proximately Defective thermal transmitter maximum after ignition switch is turned off In this case Defective thermometer thermaltransmitter replace In this case Thermometer does grounded thermometer if white cable is not operate pointer deflects when thermaltransmitter yellow operate maximum if thermaltransmitter through the v BODY Condition Probable Improper cable Corrective action cause If thermometer indicates contact a temperature slightly lower than the actual temperature check cable from thermometer transmitter for cable poor contact and to thermal being about to break faulty grounding and repair if necessary Fud meter Fuel meter does not Defective tank unit Replace tank yellow tank unit operate Defective fuel meter unit if Replace fuel pointer does pointer deflects when cable is grounded with a new meter not deflect one if through the above inspection Pointer indicates F Defective tank unit Replace tank unit if empty limit when position pointer lowers below ignition switch is turned off Defective fuel meter F Fuel meter functions fuel meter if pointer still indicates position through the above inspection Replace Defective tank unit Replace tank level when improperly tank unit unit if pointer indicates a half 35 n resistance is applied to a yellow cable and then cable is grounded Defective fuel meter Replace fuel indicate a meter if pointer does half level through the not above inspection Improper cable contact If fuel meter indicates than actual level a level slightly lower check cable from meter to tank unit for cable break poor contact and and repair BE 24 as necessary being fuel about to faulty grounding BODY ElECTRICAL Oil pressure and ignition warning lamps Condition Probable Corrective action cause Oil pressure warning lamp Lamp does light not Blown offfuse or faulty Check fuse for contact fusing and faulty contact when ignition switch Replace after correcting is set to necessary ON Broken lamp bulb filament or faulty cable contact cause or repair as If oil pressure switch yellow black cable is grounded and warning lamp does not light check bulb for burnt out fIlament and replace Defective oil pressure switch as necessary If warning lamp ligh Is through the above inspection replace oil Lamp does not go out while engine is pressure switch Lack of engine oil Check oil level and add oil Oil pressure is too low Inspect engine oil Defective oil pressure switch Continuity as required being operated pressure system exists on oil pressure switch men engine is being operated Replace oil pressure swi tch Ignition warning lamp Lamp does not light Blown off fuse or faulty contact Check fuse for fusing and when ignition switch is set to Repair or faulty contact replace if necessary ON Bumt out lamp bulb ftlament or cable contact faulty Pilot lamp does not light when voltage regulator connector is disconnected white red cable is grounded and ignition switch is set to NO Check bulb for burnt out fIlament and replace if necessary Lamp does out when not go engine Faulty charging system Inspect charging system is started BE 25 rl BODY WINDSHIELD WIPER AND WASHER CONTENTS DESCRIPTION AEMOVAl AND INSTAllATION Wiper motor Wiper motor linkage BE 26 Wiper switch BE 27 Washer nozzle BE 27 BE 27 Caution for windshield washer BE 27 Specifications BE 28 adjustment operation BE 28 BE 28 DESCRIPTION The windshield mechanism wiper wiper arms consists of wiper motor and blades The wiper motor unit consists of a motor and auto stop mechanism motor is of a The the 2 wiper engine electrically operated windshield washer consists of washing fluid tank pump washer nozzles and vinyl tube The link used to connect those components The wiper The ed type motor unit is located on the cowl compartment and the link dash in windshield washer switch is combined with the windshield wiper switch to a single the washer twist the switch knob mechanism is located behind the instrument panel BATTERY IGNITION SWITCH WASHER MOTOR FUSE W LR IBL L WIPER SWITCH 1 llAI OFF IVI lVl ILl ILl IBI IBI lLWI ILW j BE 29 Circuit diagram for windshield wiper system BE 26 2 lWlST X lBll Fig 1 JSher UJ Z I unit When operating BODY ELECTRICAL REMOVAL AND INSTALLATION Wiper motor linkage Removing wiper I arm from pivot shaft Raise wiper blade from windshield glass of wiper 2 ann and remove Separate wiper wiper motor ann raise the base from pivot shaft drive shaft arm from con 25mm 0 984 in necting rod Fig Wiper BE J 1 Wiper arm installation motor Disconnect connector from wire harness 2 Separate wiper drive shaft motor arm from con necting rod Fig BE 30 Wiper motor linkage Fig 3 and 4 Loosen set remove screws used to secure both sequence of removal linkage in noting the following matter reverse 3 Loosen three bolts and 4 Reinstall wiper motor in Wiper Install windshield wiper arm for correct remove reverse motor sequence of removal switch I Disconnect connector from the back of wiper switch 2 Loosen switch knob set in correct installation angle to obtain correct sweeping angle See Figure 31 BE Wiper motor pivot shaft connecting rod assembly Reinstall windshield wiper motor Note BE 32 pivot shafts installing dimensions knob BE 27 screw and remove switch J BODY Caution for windshield washer 3 Remove installation nut 4 Remove wiper switch from the back of instrument plain washer and spacer operation panel Do not operate windshield washer continuously Washer nozzle than 30 seconds adjustment often When washer nozzle is installed not is sprayed properly adjust sprayed or when washer fluid is without improper windshield Norrnally nozzle direction so that fluid in proper range See causes or applying windshield more washer fluid This washer washer should be operation operated 10 seconds or less at one time Figure BE33 Specifications Type Interlocked Angle 87 to 930 Driver side parallel type 96 to 1020 Assistant side 100mm 3 94 in Fig Operating speed BE 33 Washer nozzle High 59 to 73 rpm Low 41 to 51 rpm adjustment TROUBLE DIAGNOSES AND CORRECTIONS Condition Windshield wiper does not operate Probable Motor Corrective action cause No current flows to motor due to Broken armature Replace motor Worn motor brush Replace motor brush Replace motor Motor is minutes are overheated when elapsed due 4 to or armature 5 to Seized motor shaft Windshield wiper circuit fuse 15A is easily fused due to circuit Short rare circuit short burning of motor inside component BE 2B or Replace part motor or repair circuited short BODY ElECTRICAL Probable Condition Corrective action cause Power supply Blown off fuse due to trouble of other Check and cable part in windshield wiper circuit correct trouble Loose open Check wiring or broken wiring for other part near operation and motor and terminal for connection connector I Correct if necessary Erroneous wiring Check each connecting cord for cord color and correct Switch Improper grounding Correct Improper switch Connect L Blue B Black and contact motor Link Wire harness of other part is hooked on as uy necess LW Blue white or to if motor operates If switch replace operates see Correct link Windshield wiper Motor Disconnected link rod Correct Seized Lubricate With or rusted arm arm raised shaft or replace arm shaft still excessive current flows 3 to 5A due to operating speed is too slow Rare of motor armature circuit short Windshield wiper stops only by holding with hand due arm motor armature lightly to Worn motor brush With Replace Replace brush still excessive current raised flows 3 to 5A due to Seized motor shaft Replace motor or lubricate earing I with engine oil Power sup ply Dropped source voltage and parts for operation cable Link Measure voltage check other electrical action for power Hununing occurs on and take corrective supply if necessary motor in arm op erating cycle due to Seized a9 shaft Switch Improper switch Lubricate grease contact replace Conduct continuity test and necessary BE 29 or replace if 5 r BODY Condition Probable Corrective action causes Windshield Windshield wiper blade sticks wiper blade shield on wind Raise arm without glass and operate applying windshield wiper load Oean windshield glass and or replace wiper blade Windshield wiper speed Motor Low high speed differs from I cannot be considerably ratio 14 Windshield wiper is operated under the changed correctly same or speed at both low and high speeds windshield wiper does not operate at either low or high speed due to Motor brush for either low speed is Motor high improper relay stop auto contact due contact foreign to brush Remove au clean device stop to carefully contact cover so as not and to deform relay plate matter 0 Replace worn Contaminated or or connection Cable and Improper switch 2nd switch steps between 1st and Remove switch and make and 2nd steps 0 are sure that 1st not connected at OFF position i If connected replace switch i 0 ii 0 0 Motor E Contaminated autostop relay contact 0 or 0 matter 0 Incomplete Cl improper Contact is not con tact due to foreign Remove clean autostop contact deform relay operation stop auto interrupted Remove correct device carefully so cover as not and to plate au to stop device relay plate bending cover and J IGNITION SWITCH AND STEERING LOCK CONTENTS BE 31 IGNITION SWITCH WITH STEEAING Description BE 31 LOCK Removal BE 31 IGNITION SWITCH BE 30 BE 31 Description BE 31 Steering lock replacement BE 31 BODY ELECTRICAL Removal IGNITION SWITCH Remove ring nut from ignition switch I Description plain The ignition switch controls the engine ignition system and most of electrical The terminal 2 Terminal equipment is for power I to ON is connected to 3 magnetic switch on switch is set to START switch supply power The terminal S terminal of the by STEERING LOCK the stater motor When the ignition current flows to the pass line so resistor of is for radio magnetic 5 only Description The steering lock is built in the ignition switch When is lS used for vehicle equipped with with resistor In order to increase while connector IGNITION SWITCH WITH the key is 4 ignition switch from the back of instrument is and the magnetic switch operates to start the The terminal voltage Remove When starter motor ignition coil washer and spacer panel and disconnect prepared for electrical equipment and ignition circuit The terminal remove supply from the battery is connected upto the fuse block the ignition switch is set 2 and cranking engine this ignition terminal forms a that current does not flow through the set Lock and removed the steering system locked automatically stalled The locking mechanism jacket is in tube When the key and removed the steering lock spindle is Lock inserted in on the The the steering column on is set to ignition coil to notch in the collar which is stationarily set a steering column ignition cylinder with to lock the attaching a steering wheel switch is installed screw the on back of key and interchangeable Key position Lock Terminal Ace Garage On Start B On Off Start II IG S 1 2 A R 3 IGNITION SWITCH I on Ace Off On Steering Start Terminal lock replacement For the purpose of tamper t screws 2 3 4 I r are installed so used that removed easily are the self shear type sheared off when the steering lock system cannot Replace the be steerfug lock proper in accordance with the followiitg instructions when required 0 5 I Loosen two attaching two self shear IGNITION SWITCH proof and their heads II tool BE 31 type screws screws and break remaining with drill a or other proper r BODY 2 Now remove steering lock proper from sleering jackel tube 3 When tighten installing a new lwo new self ear steering lock type screws be sure to proper 10 shear off their heads I Ignition 2 5 Lock spindle Key cylinder part 6 S leering 3 Steering jactet tube 7 Self shear type 4 Lock collar 8 Attaching switch put rb haft screw SCJeW Fig BE 34 Steering lock RADIO CONTENTS INSTAllATION BE 32 ADJUSTING BE 33 ANTENNA TRIMMER Noise prevention INSTALLATION Fig BE 35 Instolling BE 32 ado chart BE 34 l BODY ELECTRICAL L InslaII mounting brackel on InslaII anlenna 7 radio proper and lead anlenna cable to Ihe back of instrument panel 2 Remove mask for radio from instrument 3 Fit radio inlo inslrument panel by applying il from panel 8 the back of inslrumenl 4 panel Tighten plain washer Connect anlenna cable and speaker cable 10 lead cables from radio Connecl radio power source cable 10 blue cable of inslrumenl harness spring washer and nul on adjusl shaft Note Blue cable of instrument harness is used not only for radio but also for clock 5 Tighlen strumenl screw securing brackel of radio 10 in panel JUSTING AD ANTENNA TRIMMER When radio is installed newly replaced anlenna trimmer adjusl or when adjusI antenna is screw on the bottom of radio in accordance with the following inslruc tion Fig 6 C EI 1400 kc BE 36 Ins tolling radio InslaII speaker See Figure BE37 Fig BE 38 Adjusting antenna timmer L Exlend antenna complelely 2 Sel frequency 10 I 400 KC Noise may be generaled bul disregard it t 3 Fig BE 37 Installing speaker Turn anlenna trimmer 10 left and righl slowly and sel il al a BE 33 position where receiving sensitivily is highest f BODY Noise prevention chart Run engine raise antenna set volume to maximum and sel dial al medium point withoul catching a Condition casting wave broad Probable Corrective action cause Ignition system Noise occurs when is engine High tension code tension High operaled code may be disregarded because noise suppressor is used coil Ignitio wire from Apart choke as ignilion coil as far possible Install 5 fJ F capacilor in primary side 0 a lerminal of ignition coil Note Be careful not to install capacitor in secondary primary or breaker side otherwise engine becomes improper Connecl wire belween engine and ignition coil locating Secure area of body with adhesive ground of ignition coil Secure contact of carbon electric Dislributor poIe and rotor Elirninale excessive tip on pole by scrubbing with a Check slagger belween rotor rolor pole or cap screwdriver and slator Charging system Sound of allemating current AIlemalor Inslall presents Note If depressed or F Do not use capacity tor When acceleralor pedal is 5fJ O a capacitor on charging lerminal A Regulator Inslall released capacitor excessively is used excessively altema coil will be broken a 0 5 fJ F capacitor on A lerminal ofvoItage regulalor noise preseo ts Supplement equipmenl When engine slarts Operative noise gauge presents noise of thermomeler and fuel and ground wire Noise still presents even inslaII 0 1 fJ F capacitor between lerminal Note after stopping If a capacity engine is used be deviated BE 34 capacitor having excessive indication of meter will BODY ElECTRICAL Condition Probable Noise presenls when Corrective action cause Horn Noise presents when turn signallarnps a 0 terminal or Inslall horn is blown Flasher unit InslaII lF capacilor 5 5 pF 0 a on horn relay horn switch capacitor are operated Note a Be sure to locate capacitor most near position completely of noise source and connect in parallel b Cut lead wire as short as possible c Ground wire should be placed d e on the body Make installation and connection securely Carefully IN identify or OUT marks CLOCK Installation I I Apply rubber seal and sland 10 inslalIation screw of clock and instaII them inlo located hole al the center of inslrumenl panel v insta1Ialion Tighten 3 Connect lead cables of clock 10 inslrumenl harness with nut K Black cable is for illumination lamp j 9 i@ p grounding red blue cable is for it and blue cable is for clock power supply Note Fil o J i i Blue cable of instrument harness is used not po only for clock but also for radio Fig BE 35 BE 39 Instolling clock I I II 2 screw 1 JLIJllttlll 41 111lIl rr BODY HEATER @ CD J @ Fig I Inlet hose 2 Outlet 3 Air duct 4 Defroster hose hose 5 Hose connector 6 Defroster 7 Heater control lever 8 Air control 9 Clamp nozzle lever 10 Room healer unit 11 Heater control cable BE 40 Heatl T unit Installation I Remove instrumenl panel 2 Install heater unil proper on dash panel Connecl to blue cable wire harness of blue cable from molor healer unil Secure black cable on heater unil with 10 screw ground Fil heater hoses 10 hol waler inlet and outIel of 3 healer unil and secure them with clamps Connect the other ends of healer hose Yfhen connecting use connector as 10 engine side required t Inlet hose 3 Connector 2 Outlet hose 4 Connector Fig BE J6 41 BE Installing heater hose BODY ELECTRICAL 4 Install air intake duct G Air intake duct Fig 5 42 BE on dash G Installing InslaII defroster nozzle on panei and heater unit 1 Defroster nozzle 2 Heater control lever Heater unit Fig BE 43 3 Defroster Air control lever nozzle and heater and air control levers heater unit 9 the back of inslrumenl Connecl healer conlrol cable 10 healer conlrollever panel 6 InslaII healer switch on inslrumenl panel 7 Install heater conlrol lever and air control lever on 10 Install rod of air conlroI lever adjusl lever on air intake ducl II Connecl defroster hoses 12 Connecl heater swilch to instrument harness inslrumenl panel 8 and heater unit to instrument harness ReinslaII inslrumenl panel Motor speed L B L ill High Resistor DMediUmw YR II YB Body Low 11 J i21 YG earth t Fig BE 44 Circuit diagram BE 37 for heater JI BODY TROUBLE DIAGNOSES AND CORRECTIONS Condition Probable Corrective cause actiQp Hol air does nol come out Molor does nol Open or shorl circuil of feed harness Check and repair wiring harness operate Defective swilch Conducl continuity tesl and replace switch if necessary Defective motor Fan cannol be rotaled smoothly by Replace Molor journal is out oflubricant or hand Hot air does Dol come stick motor Lubricatejoumal Replace motor Slow rolation offan Replace molor Loose fan installation Repair Defective water pump Repair waler pump Benl or clogged of connecting hose Repair or Defective hol waler cock Repair Air is left in hose Purge Defective thermoslal Replace thermostat Defective water hose Replace Loose Retighten clip JIll nevertheless fan is rotating Air temperature is low Hol waler does nol circulate Water temperature is clean piping air oul of hose 100 low Water leakage from waler hose heater clipping of waler hose Improper soldering of healer Defective defrosler Vibrating noise core Solder leaking position Disconnecled defroster hose Correct connection Benl Correct or broken defroster hose or replace Loose heater supporl Tighlen completely Loose Retighlen fixing screw BE 38 SECTION SE SERVICE EQUIPMENT DATSUN PICK UP MODEL 521 SERIES BODY CHASSIS INI NI NISSAN MOTOR CO TOKYO JAPAN LTD SPECIAL SERVICE TOOL SE 18 SERVICE EQUIPMENT SPECIAL SERVICE TOOL Tool number Tool M reference S Figure name mm Applied Description in model page See Fig No Clutch tool For centering lhe c1ulch disc ST20630000 521 Fig CIA 5 130 Clulch aligning PA30 bar G l J S30 j ST20051000 Clutch base For measuring the diaphragm 521 spring height 130 Use with the distance assembly @ plale piece Sf20058001 Fig CL6 C30 S30 510 41 C24 C80 For measuring the ST20058001 q diaphragm 521 Fig CL6 130 spring height Clutch assembly Use with the base distance piece S20051000 pIale C30 S30 510 Q BHO ST2050000 For adjusting spring height the diaphragm 521 Page 130 CL3 Diaphragm adjusI C30 wrench S30 510 BHO SE 1 r CHASSfS M reference S Applied Figure Tool number Description Toolnarne mm in page model See Fig No Transmission tool For ST23620000 supporting the inter lock ball when inslalling Ihe fork Fork rod page TM II rod guide ST23510000 Fork rod All For removing Ibe fork rod 521 Page relaining pins CIO TM 5 510 pin punch C30 n I ST22 I 30000 For removing the main shaft 521 bearing 780 For removing the drive shaft 521 bearing C30 Fig TM 16 Bearing replacer 0 ST30030000 Bearing puller II S30 @ SE 2 Fig TM 21 2 E EQUIPMENL SERVI jl 1 j L j Tool number tl Applied Tl r9 Lnarrie mm Description page model in See No Fig H r S M reference 1 Figure 1 ST23g00000 I l Ie l n For inslalling the main shaft 521 bearing 130 1 Transmission If q 0 r1 d Uifferen tial carrier tool 3tl 1 t l Setting Iool of Ihe ST07320000 I gear carrier 521 s 4L PD IO J stand e J lfl nj 1r jn in lJtbs rlgf Hi tt li1 ST33010000 Fig 130 Differential carrier dl Cl 1 ijL adapter J Fig iM 29 JUJJ t For removing the differenlial nIt Lm bearing puller 1 I side Differential side 2 I vn t n AIl lbearing r k r Fig PD n 1 i r 1 I L @ t 1I I ST3fs30000 I i q 1HIU J f i1nwn J 1 t r l t l1q ll Drive pinion flange V For removing Ihe drive pinion 521 nul 130 A30 t ll wrench C30 1 7 S30 lo CIO 510 i I i SE 3 VV Fig 1 11 111 i Ir PD 12 3 l 2U ll CHASSIS S M reference Figure Tool number Tool Descriplion mm name For removing the drive pinion rear pinion model in ST3003000ll Drive Applied bearing Fig PD 16 PO I7 S30 inner race C30 rear bearing inner 521 page See Fig No CIO II race replacer 510 @ ST33210000 For assembling the side 521 bearing CIO PD 16 Fig PO 18 V510 Differential side bearing drift Fig V For ST31IOOOO heighl adjustmenl of the drive 521 130 pinion V510 Drive pinion arrangemenl gauge For measuring the drive ST3 I 200000 preload Drive pinion preload gauge SE 4 pinion All Fig PD 19 SERVICE EQUIPMENT S M reference Tool number Tool Figure name Applied Description mm See For measuring the distance ST321 10000 belween side bearing caps Front axle and 521 Fig No Fig PD 22 130 V510 DifferenliaI side bearing cap gauge page model in n suspension tool For removing the ST35380000 king pin bush New Page 521 FA 7 King pin bush drift r For correcling the king pin HT56802000 521 Page FA 7 bush King pin bush reamer ST36070000 Lower link bush drift SE 5 For removing Ihe lower link New bush 521 Fig FA 24 f e CHASSIS Tool number M referenc S Figure Tool name mm Description in Applied model page See Fig No Rear axle and suspension tool ST38020000 Rear axle For loosening the rear axle and tighlening bearing 521 Fig 6 RA lock nul bearing lock nul wrench ST07630000 Fig RA4 For removing the rear axle sbafl Rear axle stand Use with sliding hammer ST36230000 C r II ST3623WQO Use as hammer by sliding the weighl Sliding All Fig 4 RA hammer I f ST37 I 40000 For removing the shaft bearing Rear axle shaft bearing puller SE 6 rear axle 521 130 Fig RA 7 n SERVICr EtlJJPMENT S M reference Figure Tool number Tool name mm Appjied Descriplion in IfV 10 1 page model I v See Fig i 1 J l Il I I No I u I ST38220000 for inslalling the 521 raft bearing and collar u Jl ear axle axle rear i Fig RA 8 I 130 shaft bearing collar insert l f 1 I u 1 to I I Steering I tool t ST27140000 r gear Steering gear 521 For removing the sleering arm 130 arm 510 I l p L Fig T4 i i BIIO 1 J k o L f I r r q I J I u i r I SERVICEJOURNALOR BULLETlN REEERENCE I 1 I JOURNAL DATE r or BUltETIWNo I PAGE No 1 SUBJECT 1 I I I I 1 i r r r o t 1 t 1 n u i r J i i I I T n 0 1 r I 4 7 SE r V CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE or BULLETIN No SUBJECT PAGE No E R INISSANl Issuro Date 25th August 1970 U105501 Publication No 10E s 0521GO
