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Download Datsun 8110 Specifications
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1 DATSUN 1200 MODEL Bll0 SERIES j t t CHASSIS AND BODY i p ti mf j il INISSANI t l 1 t f NIS AN MOTOR CO TOKYO Rov 2 11 PIN 99999 LTD JAPAN 20019 i i r r J r si r r 7 QUICK REFERENCE INDEX o M fGE Nl A tNIFrO RM A I O N t l I r iEiNJiN lR I N S1l i W E MtANUAL c JU 7 6r j fl r c Itr t 9 VA1 ciiJ i ti W t J I ls ti jM L1AJ IO N r C ib R11NSM IS S10N T i i a o MOIDIEIL O SIEIR IES 1 Oi eOOiO D j RO m@fIDW f Xi f1Ar S USRf N S ON ROiNIJ J elE R lA1XiirEC S E1A 8ijR R U SPENSION y I RIA y t B RAU B r A ND WHEEL I Mfiool J I c r SHERING r f flW INI 1M @il@ 1O TOI @ fNGINE CO M R lJl f Un EXHA1UST SYSUIM FE BODY BF BODY HECTRIC l BE IU Q t JAPAN E EQUIPME NT c SERVI c wY ft I S FOREWORD Thi5 personnels of been has manual senllce di5tributors and dealers our model BllO DATSUN 1200 1 in Explanations but will hand drive for this of utilization of also referred sati5fy our the for customers carefully this manual mainly concerning are be essential to this manual should be read for effective manual easily most the model BllOU left right hand drive models and the version models refer 2 PleUje to both information concerning part and name only this for complete MANUAL 3 All serolce series should be noted followings of assi5ting service and maintenance for effective Since proper maintenance and service are by keeping their can in the best condition The the purpose prepared for the details service A12 the of the chassi5 and in this manual genuine AlO and SERIES because car ENGINE SER VICE this manual describes body only conform parts listed to DATSUN 1200 PARTS CATALOG in this parts catalog should be used for replacements 4 All information based on illustrations the latest and specifications product information contained in available at this manlUll the time are of publication approvaL 5 It is to emphUjized the SER VICE JOURNAL issued 6 that those who by Rights for the factory use this manual revise the contents which carry the latest alteration in acconIing and SER VICE DA TA AND SPECIFlCA TIONS specifications factory approved servicing and others NI55AN at any time are MOTOR TOKYO CO method reseroed LTD JAPAN j em SECTION GI GENERAL INFORMATION DATSUN 1200 MODEL 8110 SERIES CHASSIS I NIS BODY NI NISSAN MOTOR CO TOKYO JAPAN LTD MODEL IDENTIFICATIONS GI 3 IDENTIFICATION NUMBER Gl 3 GENERA L VIEWS GI 5 GENERAL SPECIFICATlo NS GI 9 FINAL TRANSMISSIDN AND SPEEDOMETER RATIOS GI ll RECOMMENDED LUBRICANTS AND PERIDDICAL MAINTENANCE GI ll JACKING UP AND TOWING THE CAR GI l1 GENERAL INFORMATION Fig Fig GI l 4 door Sedan GI 2 2 door Sedan GI l Fig GI Fl J Coupe GI 4 Wagon GI 2 Or Van GENERAL INFORMATION MODEL IDENTIFICATION Vehicle model Transmission Engine model R H drive Item BllOU Q E 0 Remarks Speeds LH drive R3W56 3 BllOTU LBIIOT F4W56 4 BIIOAU LBl10A 3N71A 3 BllOSU R3W56 3 BllOSTU F4W56 4 BIlOSAU 3N7lA 3 BllORU R3W56 3 LBllOTR F4W56 4 LBllOTRU F4W56 4 for CANADA F4W56 4 for CANADA 3N7lA 3 R3W56 3 F4W56 4 R3W56 3 F4W56 4 R3W56 3 LBIIOST J BllOTRU Q LB llOTRN 0 0 Al2 BllOARU BI10SRU j E S J 0 BllOSTRU LBllOSTR VBIIOU l oll LBIlOAR Q VBIIOTU j VBIIOSU J 0 VLBIIOT VBllOSTU VLBIIOST F4W56 4 KBllOU KLB 110 F4W56 4 KLBIIOU F4W56 4 KLBIION F4W56 4 0 u for U S A CANADA Q for CANADA IDENTIFICATION NUMBER The ment identification number is stamped panel The and can be seen from outside on the instru For U S A body number plate identifies the type of engine capacity maximum horse power base SAE engine number and The body number plate cowl top car wheel GI 3 car panel number is attached to the right side I I CHASSIS Fig GI 5 Identification number for U S A Fig i l f 1 fill Y J I C Fig GI 7 Body number plate GI 4 GI 6 Chassis number location GENERAL INFORMATION GENERAL VIEWS E E I Z t c Sl I l N i V 00 l 6 gg 96v L l G1 5 l6 KI l CHASSIS s E E f Z J D j iil 00 l iil ri il o o L gj Q6t 20 u IC N ci e SZI OZL 169 OLI M N lt oi t a M e 0 M N N L il GI 6 inl mm UNIT 61 61 190 300 6251 0 2 3 Coupe IO GI Fig 31 7 1 185146 8 44 48 125 240 1 1 F CHASSIS E E f Z g Bl1 gCl l ill I la BlrIOtrZ L f I I I N J I i IU N tO r 6 S6 nllll l Q It o o 1 GI B GENERAL INFORMATION GENERAL SPECIFICATIONS Four Door Sedln Two Door Sedan Standard BIIOSU Item Overall c I 8110STU Deluxe BIIOSAU BIIOU LBIlOST I Standard BllOTU BllOAU LB I lOT LBllOA length mm in 3 830 l50 S Overall width mm in 1 495 58 9 Owrallheight mm in 1 390 54 7 Wheel base mm in 2 300 90 6 Length mm in 1 690 66 5 Width mm in 1 270 50 0 Height nun in 140 1 44 9 in 1 240 48 8 in 1 245 49 0 70 67 BllOSRU Deluxe I IIOSTRU BllORU LBllOSTR I BllOTRU BllOARU LBllOTR LBllOAR c 8 is E 8 0 Front 1i mm mm Minimum road clearance mm Vchide wright in lb kg 695 1 532 730 715 Naximwn 150 94 peed 145 Naxim wngrade bili ty Jsin 0 398 00418 428 0 700 1 499 1 543 735 1 620 1 653 ISO 94 150 94 145 45 90 90 kmh lIPH 8 680 750 576 1 1 609 0 398 I 0 418 90 0 428 39g 0 10 418 0 398 I OAI8 428 0 MiniwwrR turning radius m 4 ft raodoI 5 persons AI2 a t t OIt al ry 1 Fuel 13 4 4 SeltillB capacity EqiN 1 40AH 12V aty 50AH ity Ynkcapec L U J pi Clutdr 40 Imp pi lhy t diaphrapn lion mil n Tr Final gear type R3W56 dUe COllWirter Dry ingledisc diaphngm spring 3N71A R3W56 Torque 8 pri F4W56 IO I g Torque converter F4W56 R3W56 3N71A I F4W56 Hypoid gear type type circulating ball type Steerilllpar type Re E Drum Two leading type Front Strriee Ro i 0 Leading and trailiftg type lm Dr Mechanically operated PIt Front Independent Ro Risid axle strut rearwheeb type with tension rods nd stabilizer S Front elliptic semi 6 00 124PR Tire 6 00 GI 9 2 PR leaf Torque Dry Jingle disc diaphJIlm spring springl and shock absorbers R3W56 converter I F4W56 3N7lA CHASSIS Wagon and Model For U S A 4Can2da Van Coupe Standard VHllOSU Item YBllOU BlIOSTU I in 3 86S 2 IS1 Overall width mm in 1 495 S8 9 Overall height mm in 390 1 mm in Length mm in 1 4SS SS5 Width mm in 1 230 4 48 815 32 5 length 54 Coupe oedan YBIIOTU VlJlIlOT I VlllllOST mm Overall Two door Deluxe KBllOU LBllOTRU KLBllOU KLBllO IllI HrrRN KLBllON S10 I50 4 3 S30 ISO S 3 1 51S 59 6 3SO I 53 1 7 1 495 39O 1 3 810 SS 9 I SIS 54 7 3S0 I ISO 4 6 S9 53 1 c c Wheel base e u is E 90 6 300 2 0 0 8e IU88 620 63 8 690 66 5 1 610 63 1 270 SO O 1 170 SO O 1 270 50 0 1 075 42 3 44 9 pace luggage sp ce Height mm in Front mm in 1 240 48 8 Re mm in 1 245 49 0 Minimum road clearance mm in 170 67 Vehicle kgOb u weight 730 I 1 609 140 km h MPH Maximum speed Maximum grade ability Minimum turning radius 8PIe space l 7S0 710 1 565 1653 87 1 1 140 Q1S I 1730 720 1 587 145 ISO 94 8 3 42 1 609 90 c I 0 372 sin 8 0 I 417 I 0372 0 0 417 418 E i m 4 1 ft 5 persons Stating apacity Engine 2 or 4 400 kg 880 Ib luggage 12V40AH Battery volt capacity Fuel tank capacity l US 38 SaI Imp gal 10 8 I R3W56 type F4W56 gear Drum F4WS6 Leading and type Disc Annet type or trailing type I Mechanically operated Parking ear Front Independent atrut type with tension Rear Rigid we Suspension Front 6 Re 6 lJO 114PR I24PR S 0 124PR ULT elliptic senti wheels rods and Itabilizer lear springs and shock absorbers 6 I24PR Tire or S lJO GI I0 6PR I2 ULT I type Drum Two leading Drum Rear 8 F4WS6 Service i 10 type ball Two leading type 38 lOll SJO diaphragm spring circulating Re Front 50AH F4W56 Hypoid type e disc I F4W56 R3W56 type gear 5 persons 40 Dry single Transmission or I Clutch type Steering or AI2 model Final gear 4 13 6 00 124PR GENERAL INFORMATION TRANSMISSION AND FINAL SPEEDOMETER RATIOS BIIOS U BIIOS RU VBIIOS U Model BllO S TU BllO S TRU LBllOS LBllO S T TR LBllOTRU LB llOTRN BIlOS AU LBllOA BllOARU TU VLBllO S T KBllOU KLBllO KLBllOU KLBllON VBllO S Item Final gear ratio Type Control system 0 5 E 3 900 3 900 3 900 R3W56 F4W56 3N71A Floor shift Floor shift Steering column shift 1st 3 380 3 757 2 458 2nd 1734 2 169 1458 3rd 1000 1404 1 000 Reverse 3 640 3 640 3 640 gear ratio 17 5 18 5 for Van 17 5 18 5 for Van 17 5 0 e 1000 4th Speedometer LB IIOAR RECOMMENDED LUBRICANTS AND PERIODICAL MAINTENANCE RECOMMENDED SAE VISCOSITY NUMBER ENGINE OIL oils viscosity Multi 5W 20 lOW 30 40 10W 40 2OW Single viscosity oils 20W 20 30 lOW OQ GEAR OIL SAE 80 SAE 90 SAE 140 30 20 10 22 4 I 0 10 32 50 Temperature GI ll J Ran 20 30 0 Oc 68 86 104 OF Anticipated z I 1 oo 1Zo1 1 o rc lDI o Ul S Ul Ul 7 40 20W SHEL 30 IOU 100 X 30 X lOW Shel IOW Shel lOW MOBIL Special Super 30 Mobil J IOW Mobil ENCO Unifo Extril Enco Ruo 30 DP 5W Elso Mot r V lOW costalie DP Mobil lOW 20W 3D IOW lOW Shel Shel 210 MP HD HO Super FlUid Mobil Brlke Super FlUid Mobil Brake Mobil Hydraulic Hydraulic Mobil Gear Ego 40 140 90 Ellu 140EP Oil 90EP Gear BP 80EP 80 Mobilgl CaJe Mul t Glide 140 Enco GP 80 Oil DP Shel 90 Mobilue 80 EP Gear Enco Enerzel lOW ATF ATF Oil 50 80 Don 90 Oil lOW 90 Retinax 90 30 lOW Oil Shel 40 lOW 90 GX 80 Eneo Eneo Euo Euo H u gre pUr Ole GTX20W lOW CastrolHD Culroite Culro Castrol Star Five Oil 40 Oil Custom Mot r Mot r 20W IOW SW 50 40 HypOgClI Unlvca Autnl DP 80 30 lOW Castrol 80 40 30 Unlvea Multiproe 90 80 40 Mot r Suprem 20W40 Oil la Service 3D Lubrlcan Umvenal SpeCial lOW Multi IOW RPM lOW RPM Gell Oil DP 10 80 30 3D MotlOi 20W IOW lOW Mot r 40 20W oline lQ H Hlvoinc 048 srade Multi MI APIMS J 2 ular L L Re a 2104B UmvenalGc Lubncal L PotS MIL API l10S L EP90 EP80 RPM 140 90 EP 80 140 Lubneat 90 80 140 1I Ge 90 EP 80 S L MIL API MIL API iis I 3ll Texamtk Texamtic 0 l G BraOillte frost Anti BP BP CltroGing l purose Purpose FlUid Anti Brake Culro HD Co lan All FlUid Marl k Marf k fre 4 Brake Antl Multi marked oils ute mOl HD 400 and ATF RPM Multi Extu FlUid Atlu Brake fre ze RPM 69 1 FlUid 4571A Texamlic Texamtic Greue purose Purpose tIasPermaGuard A Super Co lant All FlUid Mar k Marf k Fre z Brake Anli Multi BraOike l purose Multi 2108 MIlrG Q 5 Ul 70R3 to Co lant pernuiblc it avilabe e ol F Anti HI TypeF I0924 Clutch MIL Q 3N7IA Grease Brake 70R3 A Ul Brake Atlas Special T 0 Ul z i JZ Ul GPeu rdm Amber frcuc Girtng Castrol Clutch CnmlOn c 4571A HO e 2105B GL 4 GL Ellu FlUid l rol 69 1 FlUid Lubricant Multi Brake BP LM Castrol 80 140 40 Oil 90 Gear 3D Easo 400 Eneo FlUid Brake DP W T Thuban Thuban lO Star lOW Five lOW 3D Casln Eneo Fluid Brake Hypoy 90 HD Fluid 90 Hypoy 400 Free Flul Energre ue B 20W Shelzone L2 140 20 40 XL20W RPM TEXACO 30 Spu 140 AD 140 Mobilue 40 lO Enco ES O SO 90EP SOH j Don GX 140 3D Mot r CHEVRON Mol r 0 20 50 SW 50 HD 50 3D CALTEX Oil 3D Super CASTROL Enca Vis 20W 40 40 IOW ES G ShellSplf l 20 40 IOW 1 140EP 40 be not oill of COLANT brand FREZ the ANTI e abol Should m Zm lC 3 INTERVAL MAINTEC 1 ZI 1 ZloZ o1 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 60 X R X 95 57 X X X 90 54 X X 50 30 X R X 45 85 27 51 X X X 40 80 24 48 X X X 35 75 21 45 X X X 30 70 18 42 X X X 25 65 15 39 X X X 20 60 12 36 X X X 15 55 9 33 X X X 10 6 X X X 5 3 X X X X R X 6 oz z o lC oI lotl I 100 1 r X X X X X X X X X X X X X X X X X X X X X Replacmnt 0 R kilometrs miles t h o u s a n d POINTS of of LUBRICATNG necsary level Number oil oil up gear top diferntal level or if up brake b r a k e fluid disc drum transmio transmio engine check necsary if necsary automic if up Change Change top res voir res voir fluid fluid brake brake Check Refil Refil bushings heel C L L water water eam shaft distrbuo acelrto co ling co ling Change Change Grease Gl w inkage pedal operatd foot Lubricate Lubricate top linkage brake hand level joints oil ball joints grease joints linkage ball box gear ste ring ste ring bearing shaft supenio whel proel r Grease Check Grease Grease Repack Grease nX g X X X X X C X I I X I I I X X X X X J L X X M X X L 30 X 27 M X X X X X X X INTERVAL X X X X X X X I 24 X 21 d X X X X X X X X I 18 g MAINTE C 16 X X X X X X X Replacment 12 X X X X X 9 X X X X X X 6 R X X X X 3 X X X X 6 0 w miles o TS p AOAl dCA SERVICE m ww A GIIlE M w US M oo o 0 cl E o o M A c I II o wreN r m Zm INTERVAL MAINTEC 100 60 R R 95 57 X X 90 54 X X X X X X X X X X X X X 30 X X 45 B5 27 51 X X 40 BO 24 48 R R 35 75 21 45 X X 30 70 18 42 X X 25 65 15 39 X X 20 60 12 36 R R 15 55 9 33 X X 10 6 X X X 5 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 6 X 1 X X X X X X X X X X X X X X X X X 50 X oz Z TI o 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 R 0 kilometrs miles SYTEM POINTS CAND thousand CONTRL leaks of for V nuts points of SERVIC and A S U ENGIE For Number I EMISON elment WITH cleaner air EQUIPD carbueto ENGIE Replace plugs spark strainer distrbuo fuel replace replace or manifold break r or Check Check C etc and timing bolts type head c l e a r n filter c y l i n d e r cartidge valve Replace Replace Retighen Adjust oil G igniton cables tension adjust tension belt idling lo se conetis leaks pi ngs water hoses up P line and for operation for gravity conetis valves specif pi n9 control engine batery hose emis on oil for engine tune fuel Check Check Check Adjust Engine Check Check Check Check Check and high fan 60 95 57 90 54 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 1 100 fl fl 30 45 85 27 40 80 24 48 35 75 21 45 30 70 18 42 25 65 15 39 20 60 12 36 15 55 9 10 6 5 3 X X X X X X X X X X X X X X X X I 50 X X I x INTERVAL MAINTEC 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 X 33 1 X X X X X X X X X X 0 POINTS SERVICE BODY CHASI kilometrs miles thousand of of Number wear pi ngs for hoses discs linkage asembly or play Iree pedal cylinders defcts or operation sy tem leaks brake for brake braKe clutch clutch Check ChecK etc hand foot conetis Check drums pads lin gs brake brake parts caliper liners and bolts disc Check Check absore and box gear ste ring s u p e n i o cylinders shock retighen retighen brake hydraulic pre bearing dam ge for angle flange whe l rotae turni g joint and universal and alignmet whe l discs bal nce whe l and and front whe l whe l front Check Check Check Adiust Check Check Check Overhaul C load positon a shaft proel r Retighen aimng light head test Check Road GENERAL INFORMATION LUBRICANTS CAPACITY U S A Imp measure measure Liter Sedan 40 L 10 38 l 10 with heater 4 9 l 53 16 without heater 4 2 l Oil pan 2 7 Oil filter 0 Fuel tank Cooling gal 8 3 gal 8 3 qts 4 5 47 16qts 3 l 2 7 8 qts 2 l 54 I 1 8 pints I Manual 2 l 1 2 Automatic 5 5 l 5 0 l 75 Coupe Wagon Van system Transmission Differential case 1 I case 2 pints 7 15 I 2 11 3 gal 8 gal 16 qts 16 qts 8 qts pin Is 2 1 8 pints 7 8 quarts 3 8 pints 8 quarts 4 8 pints I JACKING UP AND TOWING THE CAR JACK UP JACKING UP AND POINT TO BE SUPPORTED WITH STAND Pantograph jack Jacking Apply a j8ck to the indicated position where Jange sill Note is embossed for identification B up and point to be supported with stand When operation jacked Do not jack up other position be sure to support the vehicle with s stand b up Carried out with the vehicle s When applying stand s use a piece of cloth or to the body wood between the be sure to body and stand s Front side When J of jacking up the vehicle a garage jack applying the jack jack be sure to use a piece of cloth located JACK UP POINTS behind the front supporting the vehicle with GI IZ JQking or point GI 17 cross rod suspension member When a stand apply front portion of the front side member up wood between the and front suspension member Be careful not to allow the jack coming into contact with the steering JACK Fig apply beneath the front suspension member When the stand to CHASSIS Fig Fig GI tJ Front jacking GI 14 Front point Fig supportable point Fig When jacking up the garage jack beneath the rear side of the vehicle rear axle etc other cases support the apply Rear supportable point a Forward housing removing and installing the spring GI 16 jacking point TOWING Rear side When GI I5 Rear rear rear cross member support both ends of axle housing When towing the vehicle forward with stands In the rear axle apply a rope notched portion of the tension rod bracket In housing should with stands GI IB a rope be applied to the transverse link to no the event GENERAL INFORMATION Fig GI 17 Front Fig towing point GI 18 Rea towing point Rearward When towing the vehicle rearward apply rear shackle of rear a rope to the spring SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE or PAGE BULLETIN No No SUBJECT GI 19 CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or No PAGE No SUBJECT GI 20 SECTION ER a ENGINE REMOVAL INSTAllATION DATSUN 1200 MODEL 8110 SERIES BODY CHASSIS I NISSAN I Nt SSAN MOTOR CO TOKYO JAPAN LTD ENGINE MOUNTING ER 1 ENGINE REMOVAL AND INSTALLATION U4 ENGINE REMOVAL INSTALLATION ENGINE MOUNTING CONTENTS FRONT ENGINE MOUNTING ER l REAR ENGINE MOUNTING ER 2 Removal ER l Removal ER 2 Reinstallation ER 2 Reinstallation ER 3 CO @ Fig This engine adopts the as A IO tion The same ER 1 Structural view engine mounting has been parts changeable used for engine mounting with those for the A 10 and constructions are are not of engine mounting MOUNTING Removal increased in response to the increased engine weight and engine output Consequently the l1J FRONT ENGINE method strength ofoverall engine mounting construe however s t Suspend the 2 Loosen the engine with wire or chain front engine mounting inter although their shapes nuts both sides similar ER l insulator upper CHASSIS 3 Make engine is that the wire or positioned properly SO sure the insulators and 4 remove chain used to suspend that no load is the nuts the applied 2 to Shape of the right the left side bracket completely and side bracket differs from that of Tighten the bolts and nuts correctly securely Lift up the engine and separate the insulators from the engine mounting brackets Tightening Itl kg vf I Bolt l J I 1 IV Nut b 0 o 1 6 to 2 1 @@ 116 to 15 2 Total four each for 0 9 to I 2 both sides 6 5 to 8 7 J A I Total foor each for both sides r r CD@ torque ft Ib m J J I ii j l @ l l @ n H 0 7 Fig ER 2 Removing front mounting f8J Reinstallation Reinstall the engine mounting insulators sequence of removal noting the following @@ in reverse matters @ Both the left and right engine mounting insulators are used attention are commonly on However when installing them pay Fig ER 4 Front mounting installation their upper and lower directions When they installed correctly the positioning pin is projected downward REAR ENGINE MOUNTING Removal Support stand 2 FRONT CROSS MEMBER the 3 so ER 3 InsUlatOT installinR position engine does not a jack or drop down engine The can be mount and separated from the body member is provided installing operations with an opening for Remove the nuts and separate the insulator from the transmission ER 2 other proper Remove the mount member installation bolts Now removing Fig the transmission with that the ENGINE REMOVAL INSTALLATION Tightening torque kg m ft Ib Nut mount 0 6 to 0 8 @ member insulator Nut 1 9 to 2 6 ID@ transmission insula tor 13 Bolt j@ mount member Fig 4 ER 5 Rear Remove four bolts and the engine 43 to 5 8 7 to 18 8 3 2 to 4 0 23 1 to 28 9 body mounting separate the insulator from mount member Reinstallation Reinstall the rear engine mounting in reverse sequence of removal noting the following matters Fig Carefully 2 I Tighten the nuts and bolts correctly and securely rear ER 6 Rear mounting arrange the front and engine mounting when installation rear installing tp Lp FRONT FOR AUTOMATIC TRANSMISSION FOR MANUAL TRANSMISSION Fig ER 7 Rear mounting sp cjfications ER 3 directions of the f CHASSIS ENGINE REMOVAL AND INSTAllATION CONTENTS PRECAUTIONS ERA REMOVAL ER 4 INSTAllATION PRECAUTIONS Be sure to L tor fender use so cover that the body is Cable to the thermal transmitter not Cable to the oil pressure switch damaged 2 When lifting the engine pay attention for engine correctly so that the parts or when jacking up the safety and are not carry out operation Cable to the primary side of the distributor Cable to the starting motor Fuel hose damaged Cable to the alternator Heater hose REMOVAL Removing remove remove four installation bolts Disconnect the 3 Removing battery t1 cable from the terminal radiator easily by removing 1 i 1 lfti t y f dJ remove Ie j f i fI 7 0 I1 I u Fig 4 Removing I k D ER 8 r c t the radiator Fig j l P disconnect two radiator four radiator installation bolts and operation will be the air cleaner IlO CI Drain water from the radiator remove The I and the hood 2 hoses more hood hood Open the for model with heater only Wires for accelerator and choke carried out I ER 6 ER 9 Right 1 side of engine compartment Removing rculiator cables and hoses Disconnect the following cables hoses and wires High voltage cable between ignition coil and distribu Fig 4 ER ER tO Leftsideofenginecompartment 0 ENGINE REMOVAL 5 Disconnecting clutch wire on On left hand drive model the clutch slave hydraulic line from clutch wire at the portion of the See the section covering the clutch withdrawal lever 6 hand drive model cylinder the Disconnect right disconnect INSTALLATION Remove the exhaust front tube Fig ER 12 Removing front tube Model with automatic transmission Remove pins from both ends of the cross shaft and remove the shift rod II Disconnecting clutch ER l1 Fig 7 Disconnect the cable to the back up 8 Disconnect the 9 Remove the Sospend the engine with wire wire lamp switch speedometer cable propeller shaft Remove four bolts used in the differential carrier side and withdraw the propeller shaft Fig 10 ER 13 Removing remote control rod Remove the shift lever Model with remote Disconnect the remote control rod at the transmission outer 12 control shift lever lever and remove the front engine mounting installation nuts portion of the Remove remote control rod 13 Remove the fear engine mounting installation When the engine mounting installation jack beneath the transmission nuts Model with floor shift lever Remove the boot the lever The withdraw the lock pin operation and remove is carried out in the passenger 14 nuts compartment ER 5 removing be sure to apply a CHASSIS 15 Lift up the engine toward the front INSTALLATION Install the en e in reverse sequence of removal Fig BR 14 Lifting up mgiu SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or SUBJECT PAGE No No ER 6 SECTION CL CLUTCH GI DATSUN 1200 MODEL B 110 SERIES BODY CHASSIS INI NI NISSAN MOTOR CO TOKYO JAPAN LTD CLUTCH CL 1 CLUTCH CONTROL CL 5 SERVICE DATA AND SPECIFICATIONS CL 12 TROUBLE DIAGNOSES AND CORRECTIONS CL 13 CLUTCH CLUTCH CONTENTS CL 1 Disc assembly REMOVAL CL 2 Release DISASSEMBL Y CL 2 DESCRIPTION CL 3 CL 3 Release mechanism CL 3 CL 5 REINSTALLATION CL 2 Clutch assembly bearing REASSEMBLY CL 2 INSPECTION AND ADJUSTMENT CL 3 and sleeve DESCRIPTION The clutch is a single dry disc clutch The major components diaphragm spring type are clutch plate diaphragm spring and wire rings provided with riveted springs arranged in a plates link on cover engagement to control clutch The clutch disc is springs are used engagement and disengagement Each part of the clutch assembly is secured with rivets both surfaces and coil The coil and withdrawal lever sleeve Release bearing pressure absorb shock when Therefore while engaging the clutch softening and smoothing clutch a trouble is uncorrectable clutch assembly with a new replace the assembly 93 53 30 03M 0 1810 3 682 O 33 ft b r o o o o g l Ii 00 ci S CDr r to D q N lt o It t 10 If 1 11 TIGHTENING TORQUE 15 to 10 8 2 2 kg m 15 9 ft Ibl to Unit Fig CL 1 Constru ction CL 1 of clutch rnm in CHASSIS REMOVAL The clutch same the engine assembly the clutch mounting Transmission is dismounted assembly as manner primarily Thus in the when dis refer to the Section TM assembly and other relative sections Removal CL 3 Fig 3 by o I I Clutch assembly CL 2 Clutch Fig Clutch di5C assembly and disc Disassembling release mechanism Withdraw the release bearing from the bearing sleeve the use of a bearing puller assembly assembly DISASSEMBLY When flywheel nally Note and clutch the separating loosen and remove assembly from the installation bolts the diago gradually When separating the clutch assembly from flywheel support the clutch cover sufficiently the lIj and loosen the installation bolts gradually and carefully because the diaphragm spring Release Fig tension is always o bearing CL4 Bearing Withd awing sleeve ease b ing applied INSPECTION AND Thoroughly 2 Removing release mechanism I Remove the dust 2 Remove the return cover disc from the clutch spring from the housing wear bearing sleeve Remove the release the front cover and bearing remove and bearing sleeve from I the withdrawal lever from the plate withdrawal lever ball pin all and release bearing except for and check them for assembly Check the clutch etc cover for excessive noise occurs on the clutch CL 2 disassembled parts crack and other defective conditions Clutch and separate the withdrawal lever from the bearing sleeve 3 assembly clean AD USTMENT wear diaphragm spring pressure crack and damage assembly replace When CLUTCH 2 4 Measuring and adjusting height of diaphragm spring 1 on Line up distance piece special diaphragm tool ST20059001 if diaphragm spring by the wrench adjusting spring ST20l05000 clutch assembly base plate special tool ST20101000 of the Adjust height special use of tool required SJ200596o 1 Fig CL5 Base plate and distance piece Disc Place the clutch assembly 2 set the clutch assembly Under this condition the pressure on on the distance piece and I with plate stationarily piece is placed beneath the base the distance CL 7 Fig assembly If the facing is soiled with grease gasoline tetracWoride wire brush plate 2 Adjusting diaphragm spring height Replace surface of the baseplate with vernier caliper Height of diaphragm spring 142 1 to 1220 in at end diameter 62 mm and dress the facing if oil exceeds the clean off facing or to 441 2 in 31 foUowing value mm Upper limit of the deflection 0 5 mm 85 mm 0 0197 in at 3460 3 in radius 29 0 to 31 62 2 441 t BASE PLATE Unit mm in Fig CL 6 Measuring height of diaphragm spring Fig CL 3 replace if the outer circumference of the depth gauge 29 0 CL 8 Checking with a required Check the disc for deflection and repair the deflection at Measure the diaphragm spring height from the upper 3 the or disc for de ction facing CHASSIS Replace the disc assembly if 3 such than an 3 0 facing is worn to bearing that the facing height above rivet is less extent mm the 0 0118 in the facing is worn unevenly sleeve is installed make or sure as shown in Figure CL IO When the turn the completely that the bearing with a bearing finger and bearing operates smoothly rivets are loose 2 Apply multi Bearing purpose grease to the sleeve inside groove Pack this Fig Release CL9 Checking e and sleeve bearing point 2 withdrawal lever When is worn in step replace and bearing the release Fig bearing replace CIA 0 Fitti g release CLl1 Lubricated position bearing or the release Withdrawal noise lever G bearing REASSEMBLY Withdr aI ball 3 on bearing to the place on ball pin and CL12 Position When grease is the the clutch 0 sleeve withdrawal lever 4 CL Withdrawallcwcf tM withdrawal kver to which applied applied housing and install the dust G pin the withdrawal lever Release mechanism TighJly bearing contact surface bearing grease is fit the release the Withdrawal lever and bearing sleeve contact point Fig I on sleeve contact the sleeve When grease leaks from the release occurs on recess tehfacing lOT Fig 1 following places to Ihe necessary release bearing and places install bearing sleeve connect them with return cover on the clutch housing spring CLUTCH A JI A f C U 1 J II J1 ITI 2 Withdrawall I t l L Rei r bearing Return spong CL13 Fig Installing release mechanism REINSTALLATION the Clean clutch pilot bushing and fill it with multi purpose grease 2 Install the disc assembly and clutch assembly the use of flywheel by a tooi clutch special on the 1 Flywheel 2 Clutch 3 Clutch disc as mbly assembly aligning bar ST206l0000 Fig ClrJ4 Installing disc and clutch assembly CLUTCH CONTROL CONTENTS CL DESCRIPTION CLUTCH PEDAL Hydraulic clutch Removal 5 Removal CL 9 CL 9 CL 6 Disassembly CL 6 Inspection CL 9 CL 9 Inspection CL 6 Reassembly Reinstallation CL 6 Reinstallation CL Ad just men CLUTCH PEDAL CLUTCH OPERATING 6 CONTROL CL 10 CYLINDER Hydraulic clutch CL10 Removal CL 10 CL 7 Disassembly CL 10 Removal CL 7 Inspection CL 10 Inspection CL 7 Reassembly CL 10 Rei nstallation CL 7 Reinstallation CL 10 Adjustment CL 7 CABLE Mechanical clutch CLUTCH Hydraulic ADJUSTING WITHDRAWAL LEVER BLEEDING MASTER CYLINDER clutch CL CLUTCH CL 10 SYSTEM CL 11 Hvdraulic clutch 9 DESCRIPTION The B 110 series vehicles with left hand steering The wheel hydraulic type clutch control system clutch master cylinder operating cylinder and right hand steering wheel respectively adopt hydraulic pendent type and mechanical type clutch control systems and withdrawal lever The withdrawal lever is of CL 5 pedal consists of an inner CHASSIS I Pedal head rubber fulcrum type The mechanicai type clutch control system consists of 2 Re turn spring and with 3 Pedal lever bush fulcrum 4 Fulcrum pedal pin etc pendent clutch clutch control cable pedal drawallever The withdrawal lever is of an type which provides required a great lever ratio depressing clutch pedal in outer and thus force Reinstallation is reduced Reinstall Hydraulic CLUTCH PEDAL 2 Remove the return spring push Adjust pedal pad height I Loosen the lock nut of the master cylinder push without stopper The rod applying shim rod end Remove the lock nut and washer of the and remove the pedal shaft pedal s 5 65 mm in by selecting and adjustment having adequate thickness Next adjust the pedal pad height position Thoroughly clean all disassembled carefully check other abnormal conditions if 143 5 having thickness for both same upper and lower Inspection new ones to of sequence lever 2 and reverse is made Be sure to use shims below in Adjustment and disconnect the 3 pedal removal clutch Removal I the clutch Repair or is 141 5 mm 5 57 in so and that the secure the with lock nut indicated parts them for wear pedal stopper properly Nota damage and replace them with Make sure that chassis grease has been the CGI marked portions two applied if Grea placesl required required Adjusting shim Outen 30 peW tree 181 1 n mm @ t Part number Thickness 30611 27260 16 0 0630 3061227260 0 8 0 03 I 5 30613 27260 5 0 0 0197 1 Adjusting shim 2 Pedal lever 3 PedaJ stopper mm in Chassi5gfeee Unit Fig CL 5 Pedal height wj1lStment 6 CL to mm in CLUTCH CLUTCH PEDAL AND CLUTCH CONTROL CABLE Mechanical clutch Removal Loosen the control cable nut and discon adjusting nect the control cable from the withdrawal lever IPn t j I C1 i i j i 0 1 rl 1 f r7ce 5 l IJ i Adjusting Fig nut 0 m pring pedal pin CL 18 J Clutch pedal Removing pedal instaUation bolt Inspection iil 7 r f Fulcrum 4 1 i Return Fig r 1 I 2 3 clean Thoroughly all disassembled parts indicated t and carefully check them for below other abnormal conditions Repair or wear replace damage and as required I Control cable Lock nut CL16 Clutch cantrol cable 2 Pedal head rubber 3 Pedal lever bush 4 Fulcrum 5 Others pedal pin Reinstallation the clutch Reinstall reverse pedal and clutch control cable in sequence of removal Adjustment Withdrawal lever Fig CL 17 Clutch control cable I the Adjust 139 5 range from Disconnecting clutch control cable and secure 2 Next the Unhook the clutch 0 591 in pedal return spring sure 3 Remove the clutch brake remove pedal installation bolts and the clutch pedal and control cable CL 7 that mm position adjust clutch pedal 2 pedal stopper play the 49 5 so in that with lock nut control play completely point of the pedal pad 0 1181 the completely with lock nut so 433 0 to that to and make withdjawallever range from 3 0 to 4 0 mm alignment nut is in range from II to 15 mm P is in 5 65 in mm cable adjust at the center of the clutch at pedal height 143 5 to 0 1575 in is in Secure CHASSIS Note Connect the control cable correcdy cap is faced figure Make upward sure as shown that so in the that chassis grease mark applied following has to places the CG marked three positions Apply urease if required been r A3 r 1 300R I i I I I Lock nut Adjusting 3 Pedal I nut stopper eJ fO fed8 play 11 P 2 1 2 1 1 dal to 0 433 to 0 ChaSSiSgreaSe 2 0 139 5 to 9 to A point 15 5911 end 3 0 to 4 0 O llSl to 0 play 1575 143 5 5 65 L Unit Fig 3 When the clutch pedal is cap from front sure heavy portion of the adjust to use grease remove nut CL 19 Pedal height adjustment grease filler and grease Be containing molybdenum disulfide Fig CL 20 GrNSing to the nippk of clutch control cable 8 Cl in mm I CLUTCH Hydraulic clutch CLUTCH MASTER CYLINDER @L V 9 W aj 1 Snap ring 2 Dust 3 Pushrod 4 Clutch 5 Piston 6 Inlet cover piston spring valve spring 7 Inlet valve 8 Spring 9 Shim Inlet valve release 11 Body Oil re rvoir 12 Oil 13 i retainer 10 L t pin reservoir cap Fig CL 21 Clutch master 1 Removal cylinder Check cylinder the damage Replace Disconnect the push Disconnect the clutch line from the master than 0 15 3 securing bolts and remove the master when cylinder assembly from the vehicle clutch I Remove the filler cap and drain fluid 2 Pull back the dust return spring assembly and the or It must also be deformation due to fatigue or remove line for oil cover damage or the snap is new If abnormal one Reassembly cup and be removed Reassemble The all replaced damage ring Inspection clean the filler cap and reservoir deformation the master cylinder as mbly the following sequence of disassembly noting Thoroughly is cylinder whenever primarily cup condition is found replace with piston assembly primary can replace is disassembled cylinder wear piston Check the dust 4 cover 0 0059 in cylinder and piston found Disassembly push rod between the mm the Replace master The stopper or cylinder and drain fluid Remove the for uneven wear required When clearance more 3 piston rod from the clevis 2 2 if and piston cup should before reassembly parts with brake fluid before it is inspection CL 9 correctly faced in reverse matters be soaked in brake fluid Install the piston cup carefully so that CHASSIS 2 Apply brake fluid sufficiently to the cylinder and Inspection and assemble them pistoo Chedr all pam especially the piston cup and replace if worn or damaged Reinstallation Reinstall sequ nce I the master cylinder assembly of removal and adjust Adjust the as in reverse follows pedal height by changing Reassembly the push rod length 2 Reassemble the operating cylinder in of Bleed air out of the hydraulic syst disassembly noting the following I m Soak the InstaJI the piston r verse in fluid before cup sequence matters piston cup carefully so reassembly that it is faced conectJy OPERATING CYLINDER 2 Apply brake fluid sufficiently mbl them piston and Hydraulic clutch to the cylinder and Removal Reinstallation I Remove the return spring 2 Disconnect the clutch line from the operating cyl ReinstaJI the operating cylinder in reverse sequence of remOV1l inder 3 Disconnect the push rod from the withdrawal lever I Bleed air out of the hydraulic system 4 R 2 Adjust the push rod play is 1 0 to 2 0 mrn two l cylinder to bolts used to mount Ihe operating the clutch housing with the 10 that the withdrawall 0394 0 ver end to 0 0787 in in accordance following instruction Disassembly I 2 Remove the dust cover Remove the soap ring ADJUSTING WITHDRAWAL LEVER All other parts are can be Correct disassembled essential bearing to slip adjustment Insufficient and the while of the clutch withdrawal lever is free travel between diaphragm spring fmge xcessiv the causes release Ihe clutch free lravel affects full dis ngage ment of the clutch The clearance between the release bearing and the diaphragm spring fingers a iU drawallever 1 r can be adjusted at the with nd as follows Hydraulic clutch 1 Loosen the lock nut tighten the adjusting nut and eliminate clearance between the top of the withdrawal lever and release adjusting nul from that turns and set the adjusting nut 2 Fig CLZZ nut Operdtmg cylirrdeT distusembled CLIO bearing Return the position I 1 4 stationarily with the lock CLUTCH When the adjusting nut is returned 1 1 4 turns the wilhdrawal lever end is returned to 10 to 2 0 mm 0 0394 to 00787 and in and clearance between the release bearing diaphragm spring fmgers becomes 0 7 to 3 0 to 4 0 0 1181 to 0 15751 1 4 mm 00276 to 0 0551 in 0 9 to 1 2 0 0354 to 00472 @ D Unit mm t Diaphragm spring 3 Withdnwallever 2 Clutch control cable 4 Release Fig CL24 Adjusting in bearing withdrawal kver play 10 to 2 0 0 0394 to 0 0787 BLEEDING CLUTCH SYSTEM inl mm Unit Hydraulic clutch t Lock nut 2 Adjusting 3 Withdnwallevcr Fig nut CL2J 4 Release 5 Diaphragm spring bearing I Remove the bleed screw d t cap from the operating cylinder Adjusting withdrawal kver play 2 of bleed screw Open the turn a Attach a approximately quarters three tube immersing the open end into clean container which contains a a small amount of brake fluid 3 Fill the master cylinder reservoir with the recom mended fluid 4 Mechanical clutch Depress the clutch pedal quickly down retighten the bleed Adjust the clutch control cable adjust nut at the withdrawal lever end is 3 0 to 4 0 mm 0 1575 in so that play slowly 0 1181 to Repeat this screw and allow it to return action pumping entering the container is free from while keeping it until the fluid air bubbles and securely tighten the lock nut Clearance between the release bearing will become 0 9 to 12 mm and 5 diaphragm spring fingers Screw up the bleed pedal 0 0354 to 0 0472 in CL 11 remove screw on a down stroke of the the bleed tube and replace the dust cap CHASSIS SERVICE DATA AND SPECIFICATIONS Hydraulic Mechanical clutch clutch Clutch release lever Release bearing te withdrawal lever diaphragm spring 0 9 to 1 2 mm 0 7 to I 4 mm clearance 0 0354 to 0 0472 in 0 0276 to 0 0551 in 29 Diaphragm spring te flywheel height to 31 mm I 142 to 1 220 in Outch disc Facing size Outer dia inside dia x x thickness 180 Total friction 264 area 125 x 7 09 7 8 mm x 4 92 x x 3071 0 in 40 92 sq in em Thickness of disc assembly 6 to 8 0 mm Free 0 2992 to 0 3150 in 6 7 to 7 0 Compressed mm 0 2638 to 0 2756 in 6 Number of torsion spring Allowable minimum depth of rivet head from facing surface Allowable facing run out 3 0 mm 0 0118 in 0 5 mm 0 0197 in at radius 85 4 mm 0 Allowable free play of spline Outch rom 346 3 in 0 0157 in pedal Pedal height When not 141 5 mm depressed 57 5 5 139 in 49 5 Free travel of pedal Pressing strength Master cylinder Master at head 30 full stroke 10 8 mm kg 15 87 diameter 23 8Ib mm 5 8 in Allowable maximum clearance 0 15 mm between cylinder and piston C112 143 5 0 0059 in 3 8 mm to 5 65 in 1 181 in clutch cylinder to kg 3lb I8 CLUTCH Operating cylinder clutch 19 05 mm Operating cylinder diameter 0 750 in Tightening torque Clutch assembly securing bolt 5 to 2 2 1 kg m 10 8 to 15 9 ft lb TROUBLE DIAGNOSES AND CORRECTIONS Troubles Noises audible Possible causes on pedal depression Excessively worn cated release damaged or Corrective action lubri poorly the Replace cannot be bearing Seized release bearing and diaphragm spring fmgers greased spring fingers Insufficient pedal free travel Weakened unhooked return and control Weakened or spring broken pedal springs lever return contact faces with felt travel weakened or snapped Replace the spring required Excessive play between clutch disc hub and Replace the clearance drive shaft spline bearing Clean diaphragm Set springs in position unhooked or drive being cased with metal brush and smooth Readjust pedal free broken clutch clutch withdrawal bearing which inside the release Replace out bearing clutch correctly or or it disc and shaft is within 0 50 endwise and 0 20 replace hook hub of between mm polishers them as up ensure if that new clutch and mm 0 0197 in 0 0079 in crosswise When clearances exceed above limits replace the drive shaft also Noises audible pedal release on of clutch disc Misalignment slight causes to of disc movement flywheel hub in Set level of clutch disc with clutch disc in place on drive shaft respect of facings rotation and check for This noise is especially audible with engine scriber idling or at low Broken or set it no under slight out run using a speed weakened clutch disc cushion Replace the clutch disc springs Insufficient pedal free travel Weakened trol and unhooked pedal return or Set pedal free travel correctly broken clutc con Check the springs for correct position and replace prings CL13 them if necessary CHASSIS Weakened broken or unhooked clutch with drawallever return spring Distorted or worn the Replace spring hook or it as up required drive shaft if Replace the drive shaft and clutch disc necessary Excessive of play release bearing on slip Replace the worn parts sleeve The dutch drags Insufficient Excessive push rod length pedal free travel Adjust the Adjust free travel correctly rod length correctly push Set level of clutch disc if pos ible Warped clutch disc Maximum plate 0 25 mm out run 0 0098 in Repolish linings Roughened linings replace I mproperly fitted loose or broken lining with metal a brush or should be them if necessary Replace linings rivets Uning clenched to with protrusion damaging pressure plate and flywheel Incorrect release diaphragrn bearing to spring no avoid Adjust correctly clearance finger Clutch disc hub forcing Damaged drive on shaft drive haft Locate splines prevent the cause Replace the drive shaft also the clutch disc Oil Locate the on linings correct it as Clean Warped or damaged pressure plate or clutch if it Otherwise replace the clutch di if required grease remove possible clutch disc from sliding or of trouble and or cause of oil or grease c leakage and required replace linings Replace defective parts cover Air in the pockets hydraulic system not Bleed out completely bled correctly Dirt or master Air foreign matter cylinder piston pockets in master on sealing faces of replace piston cup if damaged and bleed the system cup cylinder Clean due to loose Replace piston cup and bleed the system piston Replace piston Fluid leakage from cylinder cup if damaged bleed the system Low fluid level in reservoir Top up with brake system if necessary CL14 fluid and bleed the CLUTCH Clogged vent hole in reservoir cap vacuum in master promotes cylinder allowing air to Clean reseIVoir cap unclog the vent hole and bleed the system inflltrate past the seal Abnormal lining wear Insufficient pedal free travel Driver steps unnecessarily causes lining and wear Adjust clutch pedal free on damage pedal to this release bearing travel correctly Advise driver to discoD tinue wrong practice and step clutch on when pedal only ne cessary Weakened or snapped pressure Check pressure springs for tension springs fied and replace if springs as speci they are unserviceable Incorrectly installed linings Replace linings with new ones and install them correctly Check clutch disc for center alignment The clutch grabs Oil or grease on flywheel pressure plate and Remove cause of leakage clean linings pressure Loose disc linings due to poor rivet tightness If linings rivets rivets Qutch disc hub does not slide freely on or not are Otherwise replace linings and clench foreign Remove any dirt deposits matter or When trouble is still shaft splines damaged parts replace present Replace pressure plate cracked pressure plate Locate the defective point Misalignment adjust alignment Stiffened hydraulic control mechanism pedal Install lining or replace tension Check spring down Worn out replace defective worn securely from drive shaft spline Warped flywheel and plate thoroughly reolace linings and if possible distorted parts If necessary take and lubricate components new linings and make sure that the clutch disc pressure plate and flywheel not The clutch slips Insufficient clutch to the control and weak or or pedal due Locate springs being springs return travel return damaged cause of failure and replace defective rnisadjusted Weakened Oil pedal are or grease broken on diaphragm spring Overhaul clutch and replace springs Remove linings cause of leakage and if cleaning is ineffective CL15 replace linings CHASSIS Worn or Replace linings burned disc linings Overloaded master cylinder due to a Overhaul the piston restricted transfer port the master cup if swollen transfer port cylinder replace or damaged and bleed SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or SUBJECT PAGE No No CL 16 the the clean system 1 I i SECTION TM SERVICE MANUAL 1 6 TRANSMISSION I 1 1 1 I J DATSUN 1200 MODEL 8110 SERIES CHASSIS INI BODY I NISSAN MOTOR CO TOKYO JAPAN LTD 1 TRANSMISSION TM TRANSMISSION GEAR CONTROL TM 15 AUTOMATIC TRANSMISSION GEAR CONTROL TM 18 THREE SPEED TRANSMISSION TM 19 SERVICE DATA AN D SPECIFICATION TM 20 TROUBLE DIAGNOSES AND CORRECTIONS TM 22 TRANSMISSION TRANSMISSION CONTENTS DESCRIPTION Specifications REMOVAL Synchro TM l Baulk ring TM 2 Shifting DISASSEMBLY Rear TM 7 Transmission case and rear extension insert Oil seal 4 TM iNSPECTION hub throst washer TM l TM 7 engine mounting insulator REASSEMBl Y AND ADJUSTMENT Bearing 8 TM counter bearing thrust washer Selecting Gear and shaft 8 TM Main shaft TM 8 TM 9 TM 9 TM 9 TM 9 TM 9 TM 9 TM l0 TM 15 REINSTAllATION DESCRIPTION Three transmission speed manual transmission and three speed available for B 110 series repair of the three speed four speed NisSAN FULL AlITOMAT1C TRANSMISSION MODEL manual 3N71 A SERVICE MANUAL under separate automatic transmission are For maintenance service automatic transmission This and chapter cover describes mainly about the four speed manual transmission refer to Specifications BIIO S TV LBIIO tS T Model BIIO S TRV LBllO S TR LBIIO TRV BIIO V tS BIIO tS RV YBllO S V Item BIIO LBllO TRN S AV LBIIO A YBllO S TV BIIO ARV YLBIIO S LBIIO AR T KBIIO V KLBIIO KLBllO V KLBIIO N Final gear ratio Type Control system c 0 3 900 900 3 3 900 R3W56 F4W56 3N71A Steering column shift Floor shift Floor shift 1st 3 380 3 757 2 458 2nd 1734 2 169 1458 3rd 1 000 1404 1 000 3 E 1 c I 1 000 4th Speedometer Oil capaci ty gear ratio 17 5 18 I 2 L 5 for Van 3 US gal 0 TM l 3 640 3 640 3 640 Reverse 17 5 17 5 18 5 for Van 2 t 0 3 US 1 gal 5 t 1 5 5 US gal 1 CHASSIS 31T 32T 3T27T 19 1 31T T 13T 13T 14T 22T 25T 29T 29T 9T 17T Fig Fig TM t R3W56 gear train The transmission assembly consists of transmission which contains gear assembly and The cast main shaft front iron rear case counter shaft and side of the transmission reverse case ends Moreover extension adapter plate supports each end of the idler shaft supports the the rear extension supports the main shaft rear end The gear and other TM 2 F4W56 gear train assembly assembly installed on can the be disassembled with the gear adapter plate V I IHtl I m 0 FiX TM 3 F4W56 transmission REMOVAL the following instructions apply When dismounting the transmission from the vehicle ER TM 2 Engine Removal Refer to the section 1 TRANSMISSION 4 Jack up the vehicle and support it with four stands If available recommend hoist or open hydraulic a back up lamp switch cable from pit be tension utilized 2 Disconnect the front exhaust tube D 5 from the and the transmission ex housing Disconnect the shift rods the removing exhaust manifold @ speedometer drive cable the Disconnect assembly @ and remove from the transmission Speedometer Fig pin cotter from the shift levers by TM 6 G cable the Cotter remote shaft pin Disconnecting speedometer and cross case control cable linkage hydraulic clutch control 6 Remove the clutch the clutch operating cylinder from housing Fig 3 Remove TM 4 the propeller the shaft @ of the companion flange the end of the rear lever by removing four extension gear housing 1 to prevent oil leakage j V V4 f control Disconect the clutch control cable from the withdrawal securing bolts from carrier Seal mechanical clutch 7 Underside of vehicle 1 I dt t v 1J I f Jfi Il I I Y d Withdrawallc I B 8 Fig TM 5 Removing shaft propell pan TM 3 OJ Ii c Crl 4 0 r r 2 vcr t Fig njp clutch control cable Disconnectin TM 7 Support the engine with Do not locate the Clutch control cable a jack placed under the oil jack under the oil pan drain plug 1 t I w 2 i i t 4A i0 J k b CHASSIS To prevent the oil pan from damaging imert a wooden block between the pan and jack 9 used to attach the transmission Remove two nuts to the CID the transmission and remove two bolts rear mounting member to the engine oJ L @ a jack used to O j Pi I engine mounting member Place rear 7 I re L 1 under ft v J fIx the h J body Q I t fp c l O il ii I I 3 r j 2 Fig Raise the II Removing release bearing and three bolts securing the front the front cover cover r r Rear engine mounting installation bolts bolts TM 8 Cross member removal jack supporting the engine to incline the A sufficient space will be rearward direction o for transmission removal provided Remove remove Rear engine mounting a TM 9 withdrawallevef G in spring f i engine Return Fig I 10 Withdrawal lever l I 1 1 2 front Fig Remove the starting motor and the bolts attaching covet TM lO 0 Bolt Removing front COveT the clutch housing to the engine 4 12 Remove the speedometer pinion assembly Lower the jack under the transmission gradually and withdraw the transmission DISASSEMBLY When procedure disassembling should be the adopted transmission the Since the casings following are made of aluminum alloy be careful not to damage any of the castings Drain gear oil from the transmission 2 Remove the dust cover release the withdrawal return lever spring and remove the withdrawal lever and release bearing from the clutch Fig housing 4 TM TM ll Rnnoving speedometer pinion and TRANSMISSION 5 Remove return the and spring plug return remove the 8 spring plunger and bushing from the inside Separate the adapter plate from the transmission case Note a The shaft main assembly b removing When washer installed and assembly installed on the are counter adapter plate be careful not to lose on shaft bearing the front end of the counter shaft Plunger Return Bush Return Fig TM 12 the Removing return spring pin from the striking rod 6 Remove rear end and separate the striking rod from the control striking rod spring spring plug Fig TM 14 Transmission disassembly lever bracket 9 Facing Fig 7 Remove housing TM 13 eight bolts securing the and remove the Lightly tap special upward set it tool ST23820000 on an and them in a vise RertlOlling striking rod rear extension FiR housing 10 Note idler gear reverse setting plate adapter secure the the circumference mallet and withdraw the with a TM 15 S Remove the pin panch special wooden reverse housing n1 5 tting transmission grar asSt mbly retaining pin by the use of tool ST23520000 a fork rod and withdraw the gear shift fork and reverse idler gear l Y if 1 vo ifJi 4 1 C t i ta V q 7 j i4 il CHASSIS Remove the check ball plugs for all fork rods 13 remove and 1st Note the reverse gear fork rod 3rd 2nd gear folk rod from the Be careful not and 4th gear fork rod adapter plate to lose the check ball and check spring o TM 16 Fig II Withdrawing idler gear and reverse Remove the snap ring by the ring pliers and lemo the Reverse idler gear of a pair of snap use washer and shift fork reverse gear O r r J IOfcJo I r y b x Z c r t l T 1 Fig IJ Snap ring I Reverse gear Fig TM 17 Removing 71 14 I and Lightly tap separate the Remove use of a fork rod Fig retaining pin main shaft assembly and counter shaft adapter plate Washer Note snap When from each separating countershaft ring shift fork pin punch special tool TM 18 R check ball the main shaft with a wooden mallet assembly from the them 12 Removing m II 4 1 2 TM 19 ft V t Dl Y j r by They the main assembly be shaft careful mbly and not to may be broken the 000 ST2352 moving retaininR pin Fig TM 6 TM 20 Removing g ar assembly drop M i TRANSMISSION 15 Remove the needle bearing synchronizer hub thrust washer steel ball 4th synchronizer mechanism 3rd baulk ring 3rd gear and main shaft needle bearing toward the front side in that order 1 Thrust washer 5 2 1st gear 6 Coupling sleeve Baulk ring 3 Needle 7 2nd gear 4 Baulk 8 Needle bearing ring 1 Needle bearing 5 2 Thrust washer 6 Baulk ring 3rd gear 3 Steel ball 7 Needle bearing 4 Coupling sleeve 18 Remove the bearing from the counter gear 19 Remove the snap remove Fig the main shaft ring from the main drive gear and bearing Layout of main shaft Remove the main bearing from the main shaft by 16 the use of a TM 2 J Layout of main shaft TM 23 Fig bearing a bearing puller special tool ST22730000 and INSPECTION press Thoroughly clean all and check them for disassembled parts with solvent damage and wear other defective conditions Transmission case and Oean them with solvent crack which may 5122730000 cause rear extension and check for thoroughly oil leaking and other defective conditions When bur pitting and joint repair 2 or or other damage exists on the replace Remove adhesive from the installing surface com pletely Fig TM 22 Removing main drive bearing 3 17 Remove the thrust washer baulk ring ring 1st 1st gear needle bearing 2nd synchronizer mechanism main shaft 2nd gear needle bearing etc Repair damaged replace or bent or the dowel pin knock pin if warped bau1k 4 from the When rear unevenly replace main shaft TM 7 extension bushing interior is worn CHASSIS Bearing 3 Thoroughly clean I with compressed the bearing dry and remove Measure each gear backlash is in range dust 0 0059 in air backlash When backlash exceeds this range bolh driving and driven gears be 2 When the ball sliding surfaces to crack or rough or bearing are worn unevenly and from 0 15 to 0 25 Inspecting baD bearing mm Replace needle bearing if worn Replace rear extension or bushing damaged if worn Me ring gear backlash TM 26 End play of the 1st play 4 set wear 4 3 0 0031 to recommend anew one Fig TM 24 that unsmoolh due or surface replace lhe bearing wilh Fig replaced as a sure inner race and center race ball fround of ball is excessive due to out and make from 0 08 to 0 15 mm mm 2nd gears should be in range 0 0059 to 0 0098 in 0 0059 to 0 0138 in 35 0 When end play is deviated from this range replace with or and end of the 3rd gear should be in range from 0 15 to new gears cracked Gear and shaft I Check Ihe gear for replace 2 damage and or crack and wear and worn if required Check the shaft for spline wear and replace bending crack if required j Fig Synchro TM 27 Me hub thrust washer When bronze oil stay is synchro hub Fig TM 25 Checking main shaft spline fo 2 twisting 8 TM ring gea end play worn thrust washer with When both surfaces are excessively replace the a new one warped or damaged replace TRANSMISSION Baulk 1 ring Check the baulk rings for be with replaced 2 new are Push the ring or detected they must ones Place the baulk ring in position gear chips pitting wear burrs If any abnormal conditions on the cone of each t6 the gear and check the gap between the end face of the baulk ring and the front face of the This gap should be within 1 05 to I 4 mm clutch teeth If it is less than 0 0413 to 0 0551 in in a worn baulk ring 5 0 0 0197 mm may be the cause and a new ring should be fitted Fig Install 2 counter case the 105 to 1 4 ta cone have hearings assembly been fitted on which the to the transmission by the use of a counter gear height gauge mm Note 0 0413 to 0 0551 in ulk ring shaft counter special tool ST23050000 A TM 28 Fitting counter shaft bearing and determine thickness of counter bearing shim to be selected Fig TM 29 Apply the bearing into the groove completely a dimension installing D SHIM HICKHESS insert Shifting if Replace excessively worn de unevenly worn ST23040000 formed or damaged 3 specd ST23050000 4 Oil seal Replace worn or the oil seal with cracked or a new one if lip is deformed Replace rear or engine mounting insulator Selecting thrust washer counter bearing Fit the counter bearings stand rear special shaft case to 0 1 mm 0 to 0 0039 nJ if weakened JUSTMENT AD front and Transmission cracked REASSEMBLY AND I 3 insulator engine mounting deteriorated Counter when the spring is dropped off o Rear speed 2 by to the counter shaft the use of a counter shaft tool ST23030000 and bearing by both press means 1 Transmission 2 Counter shaft 3 Adjusting shim case of pressing FiR TM 9 TM 30 Selecting counter shaft front bearinJ shim CHASSIS b Select lowing shim table is 0 to 2 0 s those shown in the fol 2 that end play of the counter shaft so mm from Install the needle Part number Thickness mm 32224 18001 0 8 0 03 5 18002 0 9 0 0354 32224 18003 10 0 0394 32224 18004 I I 0 0433 32224 18005 2 0 04 72 1 32224 18006 3 0 0512 1 Be c sure to from rear end of the main 0 to 0 0079 in 3 32224 bearing shaft measure at two or more Install the main shaft 2nd gear in positions on end surface of the outer race 3 Remove the counter shaft assembly from the trans Fig mission case Main shaft Note When be assembling sure to apply gear oil rotating and sliding parts sueh as TM 32 Installing main shaft 4 Install the baulk ring 5 Install the synehro hub assembly 2nd g ar to bushing beering etc Note Install the coupling sleeve shifting synchronizer spring on the synchronizer Note a Be careful the b not to hook synchronizer spring Be sure that smoothly and the correctly to hub rear ends of insert and sleeve operates by hand 6 TM 31 insert to groove on the baulk ring and Fig Fig shifting hub front and same insert Line up the Install the TM 33 Installing synchrohub I st gear side needle and main shaft 1st gear in thaI order Installing spring spread TM l0 bearing baulk ring TRANSMISSION 9 Installlhe steel ball synchro hub thrust washer and main shaft Note a pilot bearing Graase slid ing surface of the stael ball and thrust washer b When installing the thrust washer be careful to face the front and rear directions correctly OIL GROOVE SIDE THRUST SIDE FRONT Fig 7 TM 34 Apply the shaft bearing drift special Installing main shaft REARI J st gear liS main shaft thrust washer and fit the main rear side by the use of a main shaft bearing tool ST22350000 DINT FOR OIL Fig 10 TM 37 hub thrust washer Synchro front side Fit the main bearing to the main drive gear and install the main bearing washer and snap ring Note Fig TM 35 Fitting main shaft bearing 8 When to face the web portion b 8 Install the meedle bearing main shafl3rd gear baulk ring and synchronizer hub assembly from front end of Be installing sure securely to to the main fit to bearing the the snap washer be sure baaring side ring correctly the groove the main shaft 5T22350000 yr Fig TM 36 Installing main shaft 3rd gear Pig TM ll TM 38 Fjttin main shaft bearing and CHASSIS I I Install the baulk ring combining on with the main shaft the main drive gear and complete the main shaft assembly 12 14 Install each fork rod together with the check ball plug check ball check ball spring and interlock by the use of a fork rod plunger guide special tool ST23620000 Combine the main shaft assembly with the counter shaft and install them Note Apply on the main bearing front endl approximately 10 1969 inl first line up the 5 mm bearing center assembly counter shaft lighdy tap the main drive gear with wooden mallet a the adapter plate and thus install the main shaft and counter shaft on the adapter plate Note Install the fork rod at a position where the fork rod check ball groove is coincided with the ball b In the standard position upper surface of the plug is flush with upper surface of the adapter c When installing the plug be sure to apply thread locking agent Fig 13 TM 39 Combining gear assembly Install the shift fork on each fork rod Fig Note Pay attention a on the shift fork installing TM 41 InstaGing check ball dire tion b Be sure that there is no gap between the fork rod and shift fork 1st 2nd SHIFT ROD PLUNGER 3rd 4th SHIFT ROD BALL SPRING r J 1st 2 Striking Fig 2nd shift rod rod TM 40 3 3rd 4 Reverse shift rod 4thshift rod REVERSE SHIFT ROD Layout of shift fork andfork rod Fig TM 12 TM 42 Layout of check ball TRANSMISSION Drive shift fork retaining pin IS o Reverse gear shift TM 45 Fig TM 43 Fig 16 and Install the secure Nota When I installing w the Note idler gear snap reverse gear thrust washer ring the thrust washer be sure to face 18 Install the 3rd fork retaining 4th shift fork and drive the shift the pin by use of a special tool ST23520000 to the gear side Reverse gear Install reverse portion reverse Snap ring Fig 17 a Installing Revene idler gear Driving retaining pin main shaft them with o fork TM 44 the Installing reverse reverse idler gear Fig gear together with the In order to insure that the interlock apply plunger is Remove the install it shift fork Drive shift fork retaining pin cracked 19 TM 46 on the Driving retaining pin adapter plate from the attachment and transmis ion case not one fork rod operate the other fork rod and make sure that the gear does not mesh Note 8 Be sure selected TM 13 to install previously the counter bearing shim i6i lU t J2 lco Ii i e j tI A j iiJ i i l Ji tl 1 if iJf CHASSIS Fig TM 47 Instaning counter be4ring 2I Install the return b Remove oil install the c When mallet apply adhesive adapter plate installing on on the joint and with a and ba sure to line up the knock 20 TM 48 Coinciding the Installing striking transmission lever bushing installing apply uar extension plunger return adhesive to the return pin hole I Plunger 3 Return 2 Bush 4 Return TM 50 return Installing spring spring plug spring case instaU the rear ex 22 Install the stopper pin and E ring 23 Install the speedometer pinion 24 Select main drive gear bearing shim Note Measure depth from the front s Be sure to remove oil and apply adhesive on the race surface joined with the adapter plate b select shimCs so as not to tighten g unevenly TM 14 bearing caliper depth depth is 5 g outer gauge and from those shown in the table so that the 0059 in Tighten the installation bolts symmetrically and evenly by the use of vernier installing cover surface to end surface of the main a spring wooden tension Note spring and plug Fig Fig Installing spring plug Note When the transmiuion case lightly tap 49 TM Fig shim following 15 mm 0 1969 TRANSMISSION Install the oil seal on the front 25 Part number Thickness 32208 18000 5 0 0 0197 32208 18001 0 2 0 0079 32208 18002 0 1 0 0039 in mm together r r9 l Pilj i Note r The main shan is not turned synchronously when gear is shifted to neutral and the main drive gear is turned lightly 1 1 Operating 2 I Ie force is not excessive and gears can be shifted smoothly when shifted 10 the individual speeds I REINSTALLATION n J0 D lip Upon completion of the reassembly confmn that I r I it Install the clulch release bearing return spring and 27 C I 1 secure withdrawal lever j I and adjusting shim and O ring Grease the oil seal 26 I Ai with the cover Remount the transmission in reverse sequence of dismounting Main dme sear Fronl Front Shim thick 5 00 5 Fig mm 10 1969 In Selecting TM 51 ccwcr Jjustinalhim mm Shim 0 1868 In th main drive gear shim bearing TRANSMISSION GEAR CONTROL CONTENTS I nspection and repair TM 17 TM 17 Installation TM 18 TM 17 Adjustment TM 18 TM 15 DESCRIPTION COLUMN SHIFT CONTROL SYSTEM Removal DESCRIPTION floor shift control automatic The control forward B I JO series system speed three uses Those vehicles transmission use types of transmission mounted column with system and when collapsible steering option the vehicle uses collapsible three shift control is adopted mounted with four forward speed transmission use direct TM 15 use and those mounted with remote control floor shift systeDL The collapsible together with the occurs control system Those vehicles system transmission transmission control collapsible steering delrine mold located in an rod is used When collision intermediate position of the control rod is cut off the control rod slides toward axial direction and shock is absorbed CHASSIS Y CROSSK SHAFT StWT C VIEW o IiANGE LEVER J ln CHAHGE LEVER 12OO 3rd C r l 1a F nda 3 Jnl SHIFT ROD Pst tfP AVlEW I rw MMlUAL Jm Li3 l llEVER 12fW tJrdl I 2 lst d I Fig TM 52 Control system speed forward 3 transmission COLUMN SHIFT CONTROL SYSTEM Remval I 2 Remove the sleering wheel fig TM 53 Remove the steering column shell and lighting switch assembly Removing steering wheel Fig TM t6 cover turn signal complete TM 54 Rr mol1ing st mrlg column sheU cover TRANSMISSION 5 Remove the 6 Remove the speed change retainer 2 7 Remove the 2nd speed change retainer bolt top change I lever and bush 3 from the control rod 4 8 Lower the control rod so that the control lever comes out from the lower bracket pin and withdraw the 5 control lever pin Note Lower the control rod to control Fig TM 55 Removing turn pin does interfere not the lower bracket signal and lighting switch 9 3 lever l1 en extent that the suc Remove lhe snap ring and control lever pivot pin Wilhdraw 1he control rod from the passenger com partment and withdraw the hand lever 0 10 AI a AI E f 1 i P ei ff l 4 Remove change rods Y J IBI Remove the cotter pins and disconnect the member and withdraw the cross shaft cross shaft from the speed the side assembly J 1 I oJ 4 Of j rn 2 Snap ring Control lever Fig 4 pivot pin TM 56 Remove the l J Withdrawing C washer hand ever washer C Fig TM 58 Cross shaft assembly riJ f i l Inspection Check all and other 0 J 1 Note 1 lJ Fig TM 57 Removing change and repair sliding parts damages Especially and for and component parts for replace as collapsible type TM 17 control rod be careful not to apply direction when delivering and installing When the control rod and slackness exists installing a large load toward the axial toward the axial direction replace lever wear required CHASSIS Installation InslIll the oon1rol leDtonI system in reverse Before instaIIing and assembling srease to all of sequence chasm apply sliding swfacel Acijuatment I Set l1 on m mnn side manual Ie er to the neutral poIition rn 2 2 TemponriIy oonnect the trunion on Neutnlsettinz Lower support Shiftr M ptJ bncbt the lowe Fig support bracket head to each rod 4 TM 59 Adjus Upon completion t of neutral setting of the above adjustmenl operale the hand Ie er to the individual select and shift directions 3 Set the rod grooves for on the lever stationariIy adjustment of neutral poIition so thaI the on the upper surface of the lower support bracket and each 1 and make smoothly are Readjust aligned straight sure that the hand can I be if dragging slackness and or other unusuaI oonditions exist AUTOMATIC TRANSMISSION GEAR CONTROL 8 VlEW TIGHTENING TORQUE 2 0 to 14 5 2 9Irg to A e m 210 ft Ib V1EW I I CROSS SHAfT SHIFT ROD Fig MANUAL BRACKET TNUNMION LEVER TM 60 Control system automatic tTansmission TM 18 operated and lightly TRANSMISSION lever is JUSTMENT AD When the lever drags opetated smoothly or when warped or loose readjust finely until draging warping and or slackness is eliminated completely the lever is I Set tranlllltission side manual lever and hand lever to their neutral positions 2 Adjust length of the shift rod Note at the cross shaft lever a Be sure to parts and fix the shift rod b or apply After individual Make sure that hand laver positions position individual positions THREE SPEED TRANSMISSION TM 61 sliding marks on are the coin con le box indieetor when the gean are shifted to tha adjusting linkage shift change lever to the speed positions and make sure that the shift Fig to the to fill such parts with chassis cided with the 3 chassis R3W56 tTansmission TM 19 CHASSIS Disassembly and speed maintenance service for the thsee transmission are to be conducted in the manner INSPECTION Gear end play mm in identical to the four speed transmission Except for the following transmission is same as the four items the three speed 0 05 to 0 20 Reverse gear 0 0020 to 0 0079 speed transmission 0 05 to 0 15 Reverse gear counter shaft 0 0020 to 0 0059 0 10 Reverse gear to main shaft SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS Type R3W56 No of speeds 3 forward Synchromesh type Warner type F4W56 l reverse 4 forward I reverse Warner type Gear ratio 1st 380 3 3 757 2nd 1 734 2 169 3rd 1 000 1404 4th 1000 Rev 3 640 3 640 Speedometer pinion 17 5 17 5 Oil capacity 2 t 1 3 US gal 0 12 t 3 US 0 gal TIGHTENING TORQUE Transmission proper Engine Engine mount rear installation bolt Speedometer pinion Front kg transmission intallation bolt cover to the m 16 to 2 2 body installation bolt 1 0 to 1 6 TM 20 ft lb I 16 to 15 9 3 2 to 4 0 23 1 to 28 9 5 to 1 0 installation bolt 0 25 0 0039 to 0 0098 3 6 to 8 0 7 2 to 11 6 TRANSMISSION Rear extension installation bolt 16 to 2 2 I 1 6 to 15 9 Drain plug 4 0 to 6 0 28 9 to 4 43 Filler plug 4 0 to 6 0 28 9 to 4 43 Backup lamp switch installation 2 0 to 2 5 5 to 18 1 14 Withdrawal lever ball pin installation 3 1 to 4 2 4 to 22 4 30 Model R3W56 F4W56 Item Each gear standard backlash 0 08 to 0 15 For all gears mm in 0003 I to 0 0059 Each gear standard end play 0 15 to 0 25 1st gear mm in 2nd gear mm in 3rd gear mm in Reverse gear mm in Reverse mm in 0 0059 to 0 0098 0 15 to 0 25 0 0059 100 0098 0 15 to 35 0 0 0059 to 0 0138 0 05 to 0 20 0 0020 to 0 0079 0 05 to 0 15 counter gear 0 0020 to 0 0059 25 Reverse Baulk ring main cone in mm gear 10 to 0 0 0 0039 to 0 0098 clearance 105 to 14 Standard clearance mm in Replacement standard mm in 0 0413 to 0 0551 0 5 0 0197 Counter shaft Adjusting Part number shim TM 21 Thickness mm 32224 18001 0 8 0 03 I 5 32224 18002 0 9 0 0354 32224 18003 1 0 0 0394 32224 18004 1 0 0433 32224 18005 1 2 0 0472 32224 18006 3 0 0512 1 in CHASSIS Front cover Part number Adjusting shim Thickness mm 3220S 18000 5 0 0197 0 32208 18001 0 2 0 0079 32208 18002 0 1 in 0 0039 TROUBLE DIAGNOSES AND CORRECTIONS Symptom and possible Corrective action cause Difficult to intennesh gears Causes for difficult gear shifting gear shift lever is sure heavy and it are classified to troubles concerning the conlroI sys1em and transmission When the is difficult to shift gears clutch disengagement may also be unsmooth First make that lbe clutch operates correctly and inspecl the transmission Worn gean shaft and or Insufficient operating stroke due Defective or Gear slips out of In the most Replace bearing to worn or loose sliding part Repair or replace Replace damaged synchronizer mesh cases this trouble occurs when the interlock when lbe control system is defective In this case plunger check ball and or slips out ofmesh due to vibration Replace weakened or Replace broken spring Worn fork rod ball groove Replace Worn or damaged bearing Replace Worn damaged gear Replace or is worn or weakened or and rear engine mounts Worn interlock plunger Worn check ball and spring the trouble cannot be corrected by replacing gears and lherefore trouble shoaling must be carried out carefully 11 should also be noted that gear generated by weakened front or Noise When noise occurs under gears it may judged engine idling and stops while the clutch that the noise is from lbe transmission TM 22 is disengaged or when noise occurs while shifting TRANSMISSION Insufficient or Add oil or improper lubricant place with designated oil Oil leaking due Wom to defective oil seal and gasket clogged breather etc bearing High humming occurs at a Damaged bearing Cyclic knocking sound or replace Replace high speed occurs Clean also at a low speed Replace Wom each spline Replace Wom each Replace bushing SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL or DATE PAGE BULLETIN No SUBJECT No TM 23 CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or No SUBJECT PAGE No TM 24 SEen ON PD PROPELLER SHAFT DIFFERENTIAL CARRIER DATSUN CD 1200 MODEL 8110 SERIES CHASSIS INI BODY I PROPELLER SHAFT AND UNIVERSAL JOINT NISSAN MOTOR CO TOKYO JAPAN LTD DIFFERENTIAL CARRIER PD 1 PD 4 DIFFERENTIAL CARRIER PROPELLER SHAFT PROPELLER SHAFT AND UNIVERSAL JOINT CONTENTS DESCRIPTION PD 1 SERVICE DATA AND REMOVAL PD 2 SPECI DISASSEMBL Y PD 2 TROUBLE INSPECTION PD 2 AND CORRECTIONS ASSEMBLY PD 2 DIAGNOSES Assembly yoke sleeve Assembly journal with 1 2 PD 3 FICATIONS PD 3 6 Yoke 7 Ring lever race snap bearina race RiD Auembly race bearin Assembly journal with 3 4 5 bearing Fig PD 1 a good riding propeller vehicle gr m propeller Assembly 9 Bolt 10 11 race bearing Washer lock Nut 02 oz in at 4 000 rpm at the factory with the care shaft is very important comfort at high the The assembled in the lapped unbalance of IS bolloming during offroad driving speed shafts in service parts and are best shaft adopt solid tubular sleel construction A correct balance of for 8 Propeller shaft DESCRIPTION Propeller flange snap bearing counterbalanced within ones an Therefore PO l propeller shaft will be unbalanced if erroneously il with a hammer while servicing or occurs flying rocks or CHASSIS Moreover excessive sleeve yoke spline main pline lash and joints to transmission of both front and wear will cause vibrations affecting riding comfort removing and the flange yoke bolts at the rear end of the In this case transmission draw out the sleeve end of the the assembly in out of its a vise Drive the fIrst the lug by tapping projected spider 4 Use 5 Wash and clean the bearing and shaft with cleaning a brass drift with a flat face solvent pinion flange by propeller secure spider bearing back REMOVAL Disconnect the and over rear universal shaft yoke from the end of holding the disconnected rear end of the propeller shaft 0 0 BEARlNG ASSEMIL 0 lRNA1 atn V PD3 Fig INSPECTION Fig PD 2 Check all parts and repair or replace if defective When replacing Before disassembling ponents of shaft that so they former position and that the not match put are mark on all com propeller Replace if 1 shaft balance will do not disassemble the propeller shaft since instructions the journal pin 2 Replace if the yoke hole 3 Replace 4 Replace to replace as an exterior is damaged or is worn or if the nap ring is damaged damaged or defprmed if the bearing needle roller i damaged or worn apply 5 Remove sure assembly When disassembly is unavoidable for necessary repair 1 be scarred it has been balanced as an following unit assembly DISASSEMBLY the journal reassembled in the be deviated Primarily the the yoke and raise snap rings from the Replace both sleeve yoke and yoke and main shaft spline are main shaft if the sleeve damaged or worn propeller shaft 6 2 Remove snap rings bearings in the yoke flange used with If the snap rings cannot be to a secure the a or Slightly opposite bearing is indented ASSEMBLY The journal bearing end until the pushed out of the yoke flange Turn remove if the propeller shaft tube surface is cracked groove wooden mallet slightly This will relieve the pressure from the snap ring 3 Replace pair of pliers snapped out of the tap the end of the bearing with journal the propeller shaft is reassembled in of disassembly Install the PO 2 spider on the yoke flange reverse sequence DIFFERENTIAL CARRIER PROPElLER SHAFT Insert the bearing journal into the into the yoke flange Tap the journal yoke flange using than the hole in the a opposite end of the yoke flange until with the snap With a ring brass drift smaller yoke Tap the other bearing into the the bearing is in line grooves pair of pliers install the snap rings on 37149 18000 52 1 0 0598 Green 37150 18000 S4 0 0606 Blue 37151 18000 S6 0 0614 Brown 3715218000 58 1 0 0622 both end ofthe yoke flange Insert the flange assembly in the sleeve yoke SERVICE Place the other yoke bearing into the opposite end of the bearing snap and yoke i inlo the tap this bearing in line with the snap rings on ring SPECIFICATIONS yoke until the grooves Install the both ends of the yoke When all parts Distance between joints adjust snap rings as mm in Tube outer diameter with over size Sleeve x inner dia x 20 pitch in mm 37146 18000 x Color Permissible unbalance x 0 0630 x 80 0 787 size Thickness 16 Involute spline mm Part number x 2 713 in yoke specification Outer dia over 68 9 thickness x mm follows Snap ring 46 8 1 189 are assembled check the spider and surroundings for tightness When the clearance is excessive DATA AND x x I 3 150 0 0394 15 4 000 cmjrpm gr identification in Check the White 1 46 0 0575 If 37147 18000 1 48 0 0583 Yellow 3714818000 SO 0 0591 Red an is seen adjust joint every 20 000 km abnormal bending replace with snap the a journal play or 12 OOO mile noise occurs bearing and race and ring TROUBLE DIAGNOSES AND CORRECTIONS Trouble Noise and Possible Remedies causes Using exclusively Distorted propeller shaft an arbor press restraighten If distortion is excessive vibration replace propeller shaft Unbalanced propeller Check for balance If unbalance exceeds the shaft limit Worn or Replace spline lash the sleeve yoke Replace the journal damaged journal Replace Incorrect snap rings Loose nuts securing the it Recorrect Incorrectly positioned flange yoke Excessive replace flange yoke to the companion flange PD 3 with correct snap Retighten nuts to the ring specified torque CHASSIS DIFFERENTIAL CARRIER CONTENTS DESCRIPTION PD 4 Adjustin9 preload REMOVAL PO 5 Setting DISASSEMBL Y PD 5 INSTALLATION INSPECTION AND REPAIR PD 7 TROUBLE ASSEMBLY AND ADJUSTMENT PD 8 CORRECTIONS PD 9 SERVICE Assembling differential gear Setting and adjusting case drive pinion and PD l1 adjusting side shims bearing PD 12 PD 15 DIAGNOSES AND PD 16 DATA AND SPECIFICATIONS PD 17 PO 10 DESCRIPTION Apply chassIs grease to oil seal lip when assembling Tightening torque 12 to 17kgm 86 lies correct contact pattern means that it in the range of 213 to 3 4 from the tip of the tooth under no load Backlash is 0 10 to O 15mm 10 0039 to 0 0059 in of drive 8 to pinion 122 9 1t nut Ihl A Tightening 6 0 to 7 0 Q Ug 1 bearing adjust spacer torque of drive gear bolt 43 4 to 50 6 ft lb kg Tighten by tapping a Pinion 4 Ib bolt head with hammer Drive T pinion W N adjusting washer HxO OI Side gear thrust washer T1 T2 Drive gear adjusting left side A TI Right side T2 Fig C B PD 4 Sectional view 4 PD shims O O F Et xO Ol xO Ol of differential 0 200 0 200 carner mm lmm 0 2 mm DIFFERENTIAL CARRIER PROPELLER SHAFT The gear carrier is made of light and strong aluminum metal and alloy drive Adjust hypoid bevel ment with spacer and adjusting pinion the gear carrier remove two rear axle assembly to disconnect the flange yoke shafts Refer to connection REAR AXLE for the work bearing adjust shim on screws drive case with non s still remains for all the DISASSEMBLY threads of this unit Therefore adjustment figures stamped remove drive pinion companion flange and side pinion height standardization Millimeter screw gear is used pinion bearing preload and type spacer To adjusting and shims carrier are I differential washers Attachment millimeters in in Install the gear carrier assembly on the Gear Carrier ST06220000 by engine stand ST06280000 by vise accordance with the millimeter standardization of parts The proper lubrication to the gear cause housing is necessary of the gear and durability otherwise it would shorten the other troubles The lubricant should be checked each 5 000 km 3 000 miles and replenished each 50 000 km 30 000 miles The lubricant should be drained and refilled at the end of the first 1 000 km 600 miles to eliminate any loose material from the sump which results from Differential lubricant should be changed breaking least every at 50 000 km 30 000 miles Considerations should be given the to following matters must be Nominated hypoid gear oil 2 It is prohibited to use any gear Fig used oil 2 3 same brand must always The standard oil capacity Holding differential carrier of different viscosity The PD 6 Inspect be selected is about 0 75 liter 0 198 the following before disassembling I Inspect the 2 Measure tooth contact pattern with gear using REMOVAL 3 Put match mark by the use dial indicator on one side of the side PD5 Differential Fig carrier assembly PD 5 bearing cap of a punch SIDE Fig lead oxide backlash between drive gear and pinion US gal a a PD BEARING CAP Putting mark CHASSIS 4 Remove the side bearing caps and take out the 6 assembly case Remove the hypoid gear strap and loosening the drive by spreading out the lock gear bolts n differential IPIc 1 L JE 0a 1 oI v r Ie I Ii c f r I I I r V j jJ i t f I I 11 f 3 t Fig Removing differential PDB case Fig assembly Note Note Be careful caps and bearing same not to parts PDl0 Removing Loosen the bolts in a drive gear diagonal line confuse the right and left hand bearing outer race so mbled are in the 7 that the Measure backlash between the side gear pinion original mate using a and the dial indicator positions 8 5 Remove the side Side bearing by Drive the pinion shaft lock pin from the left side out from the side of the drive gear the use of a Gear Carrier to the right side by ing u the Fork Rod Pin Punch ST2352oooo Bearing Puller ST33010000 ST23520000 ST330l0000 Fig PD 9 Removing side Fig bearing 9 Note a The puller should be catching the edge of bearing b out Removing lock pin the pinion shaft and take out the mate pinions side gears and thrust washers handled with care in inner race Care should be taken not to confuse the Draw PD ll Note right The gears marked or and left hand parts front and PO 6 as well as thrust washers preserved separately rear as should be left and right DIFFERENTIAL CARRIER PROPELLER SHAFT Measure the initial 10 STJII 90000 Preload Gauge the by using turning torque drive pinion pinion height by using the Drive Pinion inner race of rear gear washer and drive Arrangement Remove the oil seal and take out the front bearing 13 Gauge STJI 120000 innp II Remove the bearing bearing spacer and adjusting drive pinion nut and draw out the race The removed oil seal should not be reuMld Note companion flange assembly Note Flange Use the Drive Pinion 14 Wrench to hold the Draw out the outer races of both front and rear bearings using drift companion flange IST31540000 IS Draw out drive pinion rear bearing inner race using Drive Pinion Rear Inner Race Replacer STJ003Iooo Fig 12 PD12 Removing drive pinion Remove the drive by tapping pinion assembly the front end with The drive pinion can be a unit to the rearward plastic mallet taken out together with the Fig PD 1J Removing bearing INSPECTION AND REPAIR @ O r @ i 8 r Drive pinion washer 3 Companion flange 4 Oil seal Front bearing Gear carrier 7 0 Ol Drive 5 6 pO h lI 1 2 i @ll PD 14 Gear carriJ r and gear PD 7 nut 8 Pinion mate thrust washer Pinion mate 9 Pinion shaft lock pin 10 Pinion mate shaft 11 12 Side gear thrust washer Side gear D Pinion bearing bearing spacer 14 Rear 15 Drive pinion adjusting washer Drive pinion 16 17 18 19 20 2t 22 23 24 25 Fig pinion cap bolt Lock washer Bearing Bearing cap Side bearing Side bearing adjusting Drive gear bolt Lock strap Differential case Drive gear shim CHASSIS so of the clearance between the side gear and thrwt Before inspecting various parts thoroughly wash them case that damage and washer exceeds 0 1 wear can be easily detected Then proceed as follows are Check gear teeth for scoring cracking and chipping and make sure tooth that indicates pattern 5 Note Drive Measure replacement as a as a run out of the drive When the required drive gear are gear at the rear side dial indicator out run is more 0 05 mm the drive gear and pinion gear and pinion parts 0 0039 to 0 0079 in available using replace mm Three kinds of thrust washen correct meshing depth If any defect is evident to 0 2 replace the thrwt washers as a 0 0020 in replace set for supplied set therefore should either part be damaged replace as a set Check the pinion gear shaft and pinion geaJ mating 2 faces for scoring and signs of and wear replace as required Follow the and their seats 3 Inspect chipping or same on all procedure differential bearing for inner faces of side gear case races evidence of excessive and rollers for scoring wear not worn with They should be in tiptop condition mirror like surfaces Replace if there is a doubt on their efficiency since an Fig PD 15 Measuring out run of drive gear incorrect bearing operation may result in noisiness and gear seizure 6 4 can ASSEMBLY be corrected with emery paper TighteninQ torque to differential Replace defective parts In as required JUSTMENT AD AND 5 carrier and distortion Inspect thrust washer faces Small defects Inspect 6kg m 36 2 of side to bearing 4p botlS 43 4 ft Ibl Adjust spacer of adjusting drive pinion without drive gear oil seal Preload for pinion bearing 6 to Skg cm 15 2 to 6 9in lbl s ci E E N Tightening Approximately 45 0 Fig mm 1 PD 16 772 in 12 to Camer section PO s torque of drive pinion nut m 18S S to 122 9 ft Ib 17 kg case for cracks or DIFFERENTIAL CARRIER PROPELLER SHAFT Reassemble the differential carrier in The disassembly instructions for following and usage of special tools reverse are order of bolt by adjustment essential to obtain the bolts Tighten a kg lj4Ib hammer 0 1 The drive gear bolts should be perfect line differential operation The differential gear 1 Assemble the pinion washer in the differential 2 Adjust clearance 6 0 a diagonal to 7 0 kg m lb ft thrust case between washer within 0 01 to 0 20 selecting be in case side gear and mate tightened tightening torque should 4 to 50 6 43 Assembling head of the by striking lightly the the mm side gear and thrust 0 0039 to 0 0079 in by side gear thrust washer PD 18 Fig 5 Press the side case using a Measuring tightening torque bearing inner race on the differential Side Bearing Drift ST3322oooo 33220000 S3 Fig PD17 Measuring clearance Side gear thrust washers Part number Thickness mm in 8000 0 76 to 0 81 0 0299 to 0 0139 3842418001 0 81 to 0 86 0 0319 to 0 0339 38424 18002 0 86 to 0 9 I 0 0339 to 0 0358 38424 Fig 3 Fit the pinion lock pin from opposite side prevent of drive gear the lock the right side of and peen the hole rim pin vibration Note over to It is important behind loose Bolt the drive gear to differential case Only genuine inner Tace the case The drive gear bolts and new lock bolt straps adjusting bearin to obtain proper 15 procedure instruction is PD 9 fit the drive gear shims preload and of gear teeth fourthcoming should be used to the mounting 4 Pressing the side bearing PD19 for page given adjustment in detail here is d ibed and therefore in no CHASSIS Setting Pinion and height behind the drive drive adjusting is pinion adjusted with pinion adjusting washer pinion gear Tolerance from the standard size up to the drive gear center is indicaled on the drive electric pen size it is pinion top by of an means When 10lerance is larger than the standard accompanied with EB mark and with e when smaller The numeI31 following the mark is multiplied by a mark figure 100 Fig Note PD21 Be eereful not to the bearing Ins1all damaged has not Drive a STJII2oooo tighten excessively will be edjusting 5 Measuring pinion preload or otherwise pinion bearing applied Pinion on the fmal sirxe ArrangItlent drive housing and Gauge measure gap with a thickness gauge PD20 Fig I Install the drive pinion outer rear 2 the final drive on on the both front and races housing Install the drive pinion bearing 3 Dri pinion head mark Dummy adjusting washer and rear Shaft STJ I 230000 Install the Dummy Shaft on the fmal drive housing Fig without using drive pinion adjusting spacer and install the pinion front bearing and companion flange 4 Tighten the drive preload by the use of pinion lock a 6 nut Drive Pinion to adjusting the rated Flange Formula PD22 to MetuUrlng pinion g calculate thickness depth of drive pinion washer Wrench T W N HxO OI 0 2 mm ST3l540000 Where Drive pinion bearing preload without oil seal and new 6 to 8 kg cm 5 2 Thickness of washer inserted T Required thickness of justing shim bearing to W N 6 9 inIb Measured menl without oil seal and reused bearing rear mm bearing ad nun clearance Gauge and between Arrange Dummy Shaft face nun 3 to 4 kg m 2 6 to 3 5 inIb H PD 10 Figure marked on the drive pinion head r DIFFERENTIAL CARRIER PROPElLER SHAFT Example W 2 92 N 3mm O housing mm Withdraw the pinion 8 H I Shaft T 2 92 0 3 3 03 Use a 3 04 mm I x Remove the the Dummy Shaft from rear on the above bearing and drive pinion Thickness mm adjusting faced surface of the washer Be sure to face inside toward back of the gear carrier Drive pinion pinion washers Thickness Part number in mm in 381 54 G0400 2 74 0 1079 38154 G0409 3 01 0 1185 38154 G0401 2 77 0 1091 38154 G04IO 3 04 0 1197 38154 G0402 2 80 0 1102 38154G0411 3 07 0 1209 38154 G0403 2 83 0 11 14 38154 G0412 3 10 0 1220 38154 G0404 2 86 0 1126 38154 G0413 3 13 0 1232 38154 G0405 2 89 0 1138 38154 G0414 3 16 0 1244 38154 G0406 2 92 0 1150 38154 G0415 19 3 0 I 256 38154 G0407 2 95 0 1161 38154 G0416 3 22 0 1268 38154 G0408 2 98 0 1173 38154 G0417 3 25 0 1280 Adjusting preload Note When installing the oil seal J based selected together washer Part number bearing from the Dummy rear washer formula and refit the pinion mm Note 7 apply 0 2 0 01 a be sure to grease the seal lip Fit oil seal to 1he final drive housing 2 Inslall the drive pinion been installed on on which the inslall the 1he housing type spacer front bearing and rear bearing has adjusting non companion flange in that order and install the pinion nut Note Apply the gear oil to the bearing and make sure that bearing operates smoothly Adjust the pinion bearing with the adjusting non spacer As the pinion nut is tightened stepped portion of the spacer is deformed Fig PD 23 Pressing the oil seal bearings PD l l is and thus adjusted stepless length between CHASSIS and Setting bearing When be the side mbling re to sure side adjusting shims install a shim without bearing having replacing thickness same as that before disassembly The following instructions apply when the bearing is replaced I Place an 5 Ib weight approximately 2 5 kg side bearing and measure on the bearing thickness Standard side bearing width 5 mm 17 0 689 in Note With the weight paeed on the side the bearing two three to turns bearing and turn measure thickness PDZ4 Fig 3 an Tighten adjusting No spacer the drive pinion nut lemporariIy up to such extenl that slackness is eliminated from front and rear of the drive pinion Note Be that oil and sure grelise removed from thnBled pinion 4 Tighten the pinion portion by the nut and preload gauge When use tightening of the preload whenever measure turned 5 to 10 eompetely of the pinion goer and washer nut rated torque have been degrees that pinion so a torque wrench pinion the nut to the pinion bearing nut is rotation starting torque is the rated value Drive pinion 7 to 9 kg cm 4 to 5 kgm 12 to 17 kg m bearing Turn the drive Figures and fitting to reinspect D E D mate F x x om 100 mm 0 01 are mm dimensional variations in against each standard measurement provide the bearing with preload Spacer should not be reused When preload and Where tightening A adjust the B exceeds the rated preload preload by loosening a new mm 0 200 The figure marked bearing housing with 0 200 side for A B C and D unit of 1 torque Replace C pinion B T2 86 8 to 122 9 ft lb pinion A Right side 3 inIb 4 a Note drive gear side TI 6 1 to 7 8 in Ib 3 5 to Measuring for bearing bearing adjusting shim thickness calculating bearing tightening torque nut Side PD25 formula Left side new with oil seal and reused Pinion 2 bearing preload with oil seal and Fig the C nut spacer D The case PD 12 figure marked figure the left side of gear carrier on bearing housing of gear do not pinion The on marked on the right side carrier the differential DIFFERENTIAL CARRIER PROPELLER SHAFT These F E differences in widlh ofleft are Note or righl side bearing againsl the standard width given 5 17 0 6890 in mm Figwe To measure standen is the width of the side 117 5 gauge indica1Dr on a small in a unil of 1 100 mm Take the left side mm bearing 0 689 use and inl the dial rtaee plate fur bearing example When the measured width is 17 3 mm 10 681 in I II the difference is 2 10079 in against the 0 mm 0 0 standard width and E is C 1 E a i1 20 1 J U 3 02 excllXling the Install the differential case the side bearing outer race Note minus sing 100 x on assembly together the fmaI drive Be careful not to eonfuse the with housing right and left sidllS of the side bearing housing 4 Install the bearing cap bolt to the rated C tightening torque DM Bearing cap tightening 10rque m 36 2 kg 5 to 6 Unit PD 26 Thickness Fig Thickness and tighten the installation mm 4 ftIb 1043 in of shim on kft side of shim on right sUh Example of calculation C A I B 2 E 8 F 10 I D 3 Left side T1 J I 3 8 x om 0 200 33 0 mm Right side 2 Tz Apply a 3 33 0 to the left and 10 mm right x 0 01 0 200 0 29 mm Fig shim and 0 29 mm shim respectively and fit the side PD27 Measuring tightening torque bearing Note Be 18 to matdl mark align put before diSls semblyeorredly Side bearing adjusting shims 5 Part number Thickness mm 38453 HIOOO 0 05 0 0020 38454 HIooO 0 07 0 0028 38455 HlooO 0 10 0 0039 38456 HlooO 0 20 0 0079 38457 HIOOO 50 0 0 0197 in Upon completion of reassembly measure drive pinion drive gear backlash When backlash is less than the rated value move the side bearing left side drive gear side to the adjusting shim from the right side When backlash is more than the rated value side bearing from the Rated backlash right to left contrarily 0 10 to 0 15 mm 0 0039 to 0 0059 in PD 13 move the CHASSIS Limit of deflection Fig PD28 A portion Less than 0 05 mm 0 0020 in S portion Less than 0 05 0 0020 in Measuring hac lash PDJO Fig 6 rom Measuring pa Existence of foreign matter between the drive gear and differential ates case is considered when backlash fluctu considerably Measure drive gear back deflection 8 Apply red lead to both surfaces of three to oily four teeth of the drive gear Limit of deflection lut Run Less than 0 05 mm 0 0020 in turns of drive gear contact is with the following a evenly tum the gear several and check the gear for tooth contact When tooth improper readjust adjust shim in accordance instructions Heel contact Contact surface is insufficient and heel may be damaged Adjust by reducing thickness of shim in right side of the side and increase thickness of shim bearing in left side TOE Fig 7 When PD 29 out run Measuring of flange the gear set deflection of drig gear is normal and fluctuation ive dt of backlash is considerable replacing out ruro be replace sure the gear set Before to measure HEEL DRIVE SIDE HEEL COAST SIDE companion Fluctuation of backlash may be con siderable due to deflection of pinion bearing Fig PD 14 PD Jl Hee contact DIFFERENTIAL CARRIER PROPELLER SHAFT damaged b Toe contact surface is Contact insufficient and toe may to obtain correct tooth replace the drive pinion adjusting be one so thickness of shim in left damaged Adjust by reducing In order washer with contact a thicker that the drive pinion is moved 10 the drive gear side of the side bearing and increase thickness of shim in right side TOE TOE HEEL DRIVE SIDE HEEL SIDE COAST L HEEL SIDE HEEL COAST SIDE DRIVE PD 34 Face contact Fig e PD 32 Toe contact Fig Correct contact When proper tooth contact is obtained lead from gear face A correct wipe off red contaci pattern means that it lies in the range of 2 3 to 3 4 from the tip of c Flank contact the tooth under no load When backlash is too tight flank contact increases tooth and Replace the drive thinner one so edge is easily pinion adjusting that drive pinion occurs worn washer in Noise step with a TOE is moved away from drive gear TOE HEEL COAST SIDE HEEL DRIVE SIDE Fig HEEL DRIVE SIDE HEEL COAST SIDE Note Fig excessive Change in the thickness of shim is accompanied by it when installing adjusting washer or change in backlash Check the gear PD33 FLmk contact INSTALLATION d Face contact In the most PD35 Correct contact cases this trouble occurs when backlash is Installation Noise increases ana tooth edge is easily removal by PD 15 can referring be accomplished in reverse order of REAR AXLEinstallation CHASSIS TROUBLE DIAGNOSES AND CORRECTIONS A problem in trouble and occur However otheJ noises such of noises always exists when the rear axle is great as care univenal noise iOl noise Inuni lr noUc and tire noise joinl must be men not to confuse with Possible Troubles Noise on drive exhaust noUc syptom for trouble engine as Remedies es caw Shortage of oil Supply gear Incorrect tooth contact between drive gear Adjust oil tooth canlact and drive pinion differential Damaged proper coast Worn or adjust between drive gear and Adjust backJash of drive pinion bearing Adjust correctly pinion Incorrect Noise on drive and Replace Replace defective parts geas Incorrect bacldash drive im or adjustment Damaged Noise on coasl side bearing or adjustment damaged drive Incorrect tooth contact pinion bearings Rebuild differential and replace pallern Adjust backlash or replace the as required hypoid geas set side gear Damaged drive gear drive pinion Replace required parts teeth surface Seized drive gear and drive pinion Replace hypoid geas Pinion bearing under inadequate preload Adjust preload Seized damaged Seized damaged or or gear side bearing Noise on tum Side geas jammed or nuts holding drive Retighten them to the Replace defective parts in differential case on their shaft damaged side gear thrust Replace washer as required Replace and pinion thrust washer Excessive backlash Incorrect backlash between drive gear and drive pinion PD 16 Adjust backlash case designaled torque etc Pinion gears too lighl Worn Replace the differential case clamp bolts and Replace the bearing Replace the side bearing broken side bearing Swinging differential Loosen broken pinion bearing set DIFFERENTIAL CARRIER PROPELLER SHAFT Replace Worn differential gears or case of improper oil Breakage of Shortage of oil or use differential Severe service due to excessive an worn parts Rebuild differenlial and replace loading improper use of the clutch After adjusting preload of as bearings backlash and engaging condition of gears fasten parts and apply specified volume of genuine gear Incorrect adjustment of bearings oil Incorrect adjustment of drive gear and drive Avoid abusing of the car pinion Excessive backlash due to defacement of side gear and thrust washer Loosened bolts and nuts such as drive gear bolts SERVICE DATA AND SPECIFICATIONS Final gear type Hypoid Final gear ratio number of teelh Sedan Coupe Wagon Van 3 900 Speedometer Sedan I 39 10 ratio Coupe Wagon Van IS 4 Drive pinion Preload when using new bearings kg em in Ib 6 to 8 5 2 to 6 9 without oil seal Standard distance between drive gear center and top face of drive pinion Thickness of drive pinion mm in Approximately 45 0 mm in From 2 74 to 3 25 1772 adjusting washers 0 1079 to 1280 0 0 0012 Spacing 0 03 Length of drive pinion bearing spacer mm From 5169 in 5I 52 to 2 035 to 2 067 0 0335 Spacing 0 85 Drive gear Backlash between drive gear and pinion out Run mm of rear side of drive gear required in O JO to 0 15 0 0039 to 00059 Less than 0 05 in mm PD l 00020 CHASSIS Side gear and pinion mate of side gear thrust washers Thickn mm in 0 76 to 0 9 I 0 0299 to 0 0358 mm in 0 10 to 0 20 0 0039 to 0 0079 mm in 17 5 mm in 0 05 Clearance between side gear and thrust washer Side bearing Standard width Thickness ofside 0 689 bearing adjusting shims 07 0 10 0 20 0 50 0 0 0020 0 0028 0 0039 0 0078 0 0197 Tightening torque Drive pinion nut kg Drive gear bolts kg m ft lb Side bearing cap bolts kg Differential carrier to axle to propeller 12 to I7 86 8 to 123 6 to 7 43 4 10 ft Ib 5 to 6 36 2 to kgm ft Ib L7 to 5 2 m 50 6 4 43 3 12 to 18 1 shaft ftx nuts Oil filler ft Ib housing ftx nuts Companion flange m plug kgm ft Ib 2 0 to 2 7 kg ft lb 6 to 10 43 4 to 72 3 m 14 5 to 5 19 SERVICE JOURNAL OR BULLETIN REFERENCE DATE JOURNAL or BULLETIN No PAGE No SUBJECT PO 1S SECTION FA FRONT AXLE FRONT SUSPENSION DATSUN 1200 MODEL B 110 SERIES CHASSIS INI BODY I NI55AN MOTOR CO TOKYO JAPAN LTD FRONT AXLE AND FRONT SUSPENSION fA ADJUSTMENT FA 21 SERVICE DATA AND SPECIFICATIONS fA 22 TROUBLE DIAGNOSES AND CORRECTION fA 24 l FRONT SUSPENSION FRONT AXLE FRONT AXLE AND FRONT SUSPENSION CONTENTS DESCRIPTION FA 2 FA 3 Removal FA 3 Reinstallation FA 5 TRANSVERSE FA 6 LOWER Removal FA 6 Removal FA 18 Inspection FA 7 Inspection FA 19 Reinstallation FA 10 Reinstallation FA 19 Wheel bearing adjustment FA 10 FRONT AXLE STRUT ASSEMBLY AND SUSPENSION ASSEMBLY FRONT AXLE FA ll Disassembly FA 12 Inspection FA 14 Reassembly FA 15 LINK AND BALL JOINT FA 17 1 Strut 2 Strut 3 mounting bearing Upper spring scat 4 Bumper rubber 5 Dust 6 Piston rod 7 Front 8 Strut 9 Hub 10 II Fig FA l Front axle and susp nsion FA 1 assembly mounting insulator l ovcr spring assembly scmbly Spindle Ball joint 12 Transverse link 13 Tension rod 14 Stabilizer 15 Suspension member CHASSIS DESCRIPTION The front absorber and spindle is supported by the transverse The outer is suspension casing by is at strut type a combined to the coil link spindle are of at spring a to unit which bearing Moreover the single the upper end and by means on the bottom of the strut through a they are fitted rubber bushing is built in the strut outer between the upper spring the to spindle lower link ball joint and the transverse link connected and bushing with of welding A ball joint is attached to the lower part of the The are the suspension member A coil spring is applied seat fitted to the upper end of piston rod and spring seat welded These components assembled to link supports the overall a to the outer casing single unit Fig are fitted The rubber bushing adopts which the forward The torsion bar changed suspension system by meanS a non and rearward a of the rubber linear shape rigidities are type stabilizer adopted in tl1is is used so that the stIut maintains connection between both side struts this Thus The shock absorber mechanism casing transverse forward and backward strut movements tension rod fitted to the chassis frame through the lower end installed the chassis frame at their upper part through the thrust The shock toward efficiently shocks suspension Drum type brake FA 2 absorbs shocks the tension rod absorbs forward and backward the strut absorbs transverse link absorbs shock FA 2 Cross sectional view mechanism directions into the chassis effectively and all of front axle vertical shock and applied toward sideway the FRONT AXLE FRONT SUSPENSION FRONT AXLE AND 6 SUSPENSION ASSEMBLY Remove cotler pin from the side rod socket ball joint of the steering remove the castle nut side rod socket from the knuckle and separate the arm Removal Jack up the vehicle 1 stands and support the vehicle with See the Section GL 2 Remove the hub nuts and 3 Remove the 4 Loosen the brake tube connecting nut brake hose splash remove the wheel board the remove locking spring withdraw the plate and remove the brake hose from the strut assembly bracket Fig 7 Note 5 FA Detaching brake Be careful not allow dust Removing side socket from knuckle Loosen the tension rod securing bolts and remove Fig FA 5 the tension rod hose entering the brake hose Remove the stabilizer from the body j 7 1i i J I g d r Fig FA 4 tr 0 p 4 Removing stabilizer Fig FA 3 FA 6 Removing temion rod ann nuts and CHASSIS 8 Support the engine baits indicated pension by remove arrow cross member mark the engine mounting and separate the sus from the engine assembly Fig FA 7 Fig Supporting FA l0 Removing suspension cross member gine 10 and Loosen the self locking nut holding the strut on assembly the strut assembly dismount the front suspension assembly FA Fig 9 Apply a suspension the bolts suspen ion Fig R jack cross ving engine mounting bolts to the indicated by cross member FA 9 patch unit in the center of the member to support the member arrow marks loosen and separate the Fig F4 from the body Jack up point of suspensiOfJ cross mber Fig FA 4 FA 12 11 Removing seIf t locking Removing front axle and suspension assembly FRONT SUSPENSION FRONT AXLE Reinstallation First check rubber parts such stabilizer bar ing bushing bushing and other defective crack as tension rod mount for deterioration etc conditions replace and as required Reinstall the front axle and suspension assembly 2 reverse I in 1 Rubber 2 Washer 3 Stabilizer necting sequence of removal noting the following matters the Tighten transverse side stabilizer bar body tightening torque link mounting bolts installation and Fig the rated bolt to 3 under the unladen vehicle Install the tension rod so con rod 4 Transverse link 5 Washer 6 Stabilizer bar Stabiljzer connecting rod FA 14 bush that bushing layout LH mark tension rod is faced to left side of the vehicle and mark is to right 2 Install the stabilizer bar identification mark on so white that the the paint the stabilizer bar is faced to the rod with tightening torque from 0 9 to I 2 through bushings 8 7 ft lb 0 9 to 1 2 kg m The same 6 5 to 8 7 ft Ib also kg shown in body side bushing tighten the from 4 5 to left side of the vehicle Tighten the stabilizer connecting as tension rod 5 kg m Figure FA IS Make in the is correct R H sure position that and securely with tightening torque 32 5 to 39 8 ft lb 5 to 6 m tightening torque applies the on 08 the frame side installation bolt of transverse Two types length below in are neck 35 mm link side installation bolts in and 25 378 1 mm MARK 0 984 used and for both types the tightening torque is 2 2 to 3 0 kg m 15 9 to 7ft lb 21 Fig WHITE PAINT FOR IDENTIFICATION FA 15 Mark on the end of tension rod n 1 0 Fig FA 13 Identification mark on stabilizer Fig FA 5 FA 16 Tension rod body side 1 Washer 2 Rubber bush 3 Frame 4 Collar 5 Tension rod bushing layout CHASSIS Tightening 4 body and torque of front suspension is 3 2 to 4 0 kg m 23 1 cross member 7 28 9 ft Ib to Remove the return spring and brake shoes brake disc assembly installation bolts brake disc assembly from the 5 Tightening torque portion of kg spindle Drum remove the type brake of bolt used to secure the upper assembly the on body is J 6 to 2 1 1 6 to 15 2 ft Ib J m the strut and remove FRONT AXLE Removal Jack up the vehicle nect the remove the brake hose at the strut outer For the details wheel and discon casing bracket unit Removal of front axle and see sus pension assembly 2 Remove remove the Fig brake bolts caliper installation the caliper assembly 8 Remove baffle Remove the brake drum Drum type brake 4 Remove the hub cap with driver or a flat headed other proper tool and hammer Be sure Removingbrakedisc usembly and Disc type brake 3 FA 18 baffle plate set screws and remove the Disc type brake p1ale screw to tap lightly Remove cotter pin from the wheel bearing lock nut 5 and remove the lock nul With the wheel bearing washer and wheel bearing 6 installed the on the wheel hub remove the wheel hub from spindle In the case of a disc type brake the wheel hub may be removed with the disc rotor installed on the wheel hub Fig 9 Utilizing remove Fig FA t7 Removing wheel hub two the wheel Fig FA 6 FA 19 FA 20 Remolling baffle plate grooves inside the wheel hub bearing tap and outer race from the hub Removing wheel beaTing outer race FRONT SUSPENSION FRONT AXLE 10 Remove four brake disc fitting bolts and the brake disc rotor from the wheel hub Inspection remove assembly Disc 1 Grease seal type brake I When grease leakage is detected during disassembly replace 2 Replace the grease seal with a new one if worn or cracked 2 Wheel bearing Remove solvent used grease the wheel bearing with and inspect the bearing for operating condition from the rotation outer from race operating sound and appearance The may be checked for the condition of rolling surface with the race installed on the wheel hub Visual serviceability judgement standard for the wheel Fig Vi ual FA 21 Removing brake disc bearing roto is indicated in the following Serviceability Judgement Standard for Wheel Bearing INNER RACE SURFACE OUTER RACE FITTED SURFACE COLLAR SURFACE OUTER RACE SURFACE INNER RACE FITTED ROLLER ROLLING SURFACE SURFACE INNER RACE SMALL COLLAR LARGE COLLAR ROLLER SUPPORTE R OUTER RACE FA 7 table CHASSIS Judgement x Unserviceable 6 May be used when minor Rust should be removed with 110 emery paper Race and roUer u Cause u l l al U 8 8jiS oo U Flaking Q l ti CIl this However roUing fatigue Service tife due to x before the service life The following causes are symptom occurs considered Abnormal load overload Improper handling Crack Excessive tightening x x x improper installation or is excessive and Gap considerable shock is received from the a outside Rapid heat generation on the race due to creep RaUen bite the supporter due to seizure Abnormal thrust load Tapped Seizure x x x In the 6 6 6 6 6 6 striking Wear seizure occurs the as result of grown flaking foreign mailer Careless installation removal or other handling scar due to striking made by pressing or hammer while removing Shock is given carelessly during installation Bit Recess or wear or a cases most discoloring SClalch with Recess made 6 6 6 by bit foreign Poor lubricant quality or matter deteriorated lubricant Intrusion of dust Fitted surface is worn Wear due Biting 6 6 6 Fretting 6 6 6 to Excessive The fitted excessive preliminary part on preliminary pressure pressure rust on metal contact surface FA B or faulty lubrication is discolored to brown Fretting corrosion remarkably or fitted part black means fine relative slip FRONT SUSPENSION FRONT AXLE 6 Rust during operation Temperature increased 6 6 bearing stops becoming The fine Intrusion drips inside the bearing is the condensed and the grease is moistened has been bearing long period moisture when lowers placed in a highly moistened place for a of time of moisture chemicals touched with bare hand and no etc the or rustproof bearing action is has been taken The Discoloring wheel bearing is iog can be or oxidized oil stain due to grease removed with solvent thinner may become like Slight discoloring serviceable if discolor such In the most this cases occurs when as preliminary pressure is too high by polish ing 0 m 0 Inner RoUer race Cracked roUer Recess bit on foreign inner Cracked inner flaking race made by matter III Recess on bit foreign roller made by matter FA 9 Recess bit on foreign outer race race matter made by CHASSIS Reinstallation I Reinstall the wheel bearing in reverse sequence of removal 2 Install the bearing outer race by the use of a front wheel bearing drift special tool ST353 10000 FA 24 Fig FiT1ing sptICes between wheel with grease 5 Apply multi purpose grease to the bettring spindle threaded Install the wheel 6 hub and install them Note In order to and grease seal bearing on Fig FA 22 InstaIling bearing outer lock nut race matten provide the bearing with 3 that so grease to proper washer dust and no applied a and foreign them Fill the wheel hub and hub cap with multi purpose grease MIL G2l08 or 10924 by asterisk 0 in Figure up to the Wheel portion indicated FA 23 I r FA 2J Creasing points of hub assembly FA 25 Turn the clockwise Fig the wheel 15 9 to 174 Fig 2 bearing adjustment Tighten kg m and lb ft bearing lock 2 2 to nut to 4 2 tightening torque Tightening wheel wheel hub in a bearing few counterclockwise lock turns settle to nut toward down bearing and retighten the wheel bearing lock same 4 on the wheel service life bearing grease seal bearing carefully stick on wheel the spindle prepressure and to extend the install the wheel shaft and and portions wheel bearing washer bearing lock nut surfaces slightly ST353J 0000 krs ro both the nut to the lightening torque Fill the spaces between wheel bearing rollers and grease seal lip pocket with multi purpose grease 3 suf Return the wheel bearing lock to 700 and coincide it with cotter ficien tly FA l0 nut pin in range from hole on the 400 spindle FRONT SUSPENSION FRONT AXLE Correctly starting force toward tangential measure direction agains the hub bolt Fig FA 26 Returning heel bearing lock t Fig 4 Turn the wheel hub in a few turns clockwise and counterclockwise again breaking in apply cotter a measure pin bearing to rotation to secure the nut is within the rated value starting torque allow the Measuring heel bearing starting torque rotation bearing STRUT ASSEMBLY starting torque if the measured The strut assembly and install the with spindle hub cap forms a consisting of a outer strut casing cylinder between the piston rod guide and bottom valve The inner components Wheel bearing rotationstarting torque 9 0 m 7 8 in Ib New bearing dirt and foreign kg 4 0 FA 27 toward both Used bearing in lb 46 lb 3 New bearing At the hub bolt 1 57 kg S4 Ib Used bearing 0 7 kg J No slackness should exist toward the axis direction kgm precisely assembled and no intrusions are 3 47 Be sure to remove the brake pad When replacing components as are handled together them an be sure to assembly 1 Front spring Bound bumper 5 Strut 2 6 Strut 3 Piston rod self locldng nut 7 Oil seal 4 Washer Fig permitted The components such as piston rod piston rod guide cylinder and bottom valve Disc type brake J 1 matter are mounting insulator mounting bearing 8 Upper spring 9 Dust 10 FA 28 Strut assembly components FA ll seat cover Strut assembly as an replace assembly the inner CHASSIS Disassembly Disassemble place clean I the strut that the inner components assembly are in a protected from dirt and other foreign matters r r so and reassemble l I lack up the vehicle ii the wheel and remove link the stabilizer bar and tension rod from the transverse and bolts separate the Loosen the knuckle arm fIxing Loosen the self locking from the ball I I lL strut joint assembly the the upper portion of the strut and remove See the Removal of Front Axle and strut assembly nuts I I remove 5 on Suspension Assembly above for details I I I t EX NSION roIolPAESStON Piston rod 5 Rebound stopper 6 Piston 3 Gland packing Piston rod guide 7 Bottom valve 4 Cylinder Fig f4 29 Cross sectional view of strut assembly Fig and shock absorber operation FA 12 FA 30 Removing knuckle arm fixing bolt FRONT SUSPENSION FRONT AXLE 2 on Removing front FA Jl Fig Install a strut attachment special with the strut outer casing strut a between the strut assembly and of cloth piece outer 4 tool ST356500oo nut Remove the strut mounting insulator strut mounting I bearing oil seal upper spring seat and dust applied casing and Removing piston rod self locking FA JJ Fig assembly cover secure 5 the strut assembly in a vise Remove the spring with the coil spring compressor tool Sn56500oo special installed on the spring from the strut Remove the bound bamper from the piston rod 6 the piston rod down Depress remove special the gland packing with to the bottom and gland packing a wrench tool ST35500000 ST35500000 ST35650000 ST35650000 FA J2 Fig 3 Install such an readily self spring the on strut spring extent that the strut turned locking Note coil a Sn5650000 Securing nut When by hand in assembly a vise tool special compressor compress the spring up to mounting insulator and remove the can piston be Fig FA J4 Remvoing gumd rod packing used to hold down the spring loosening the self driver as a shitter self locking nut locking Moreover used nut when use a screw Note loosening the to hold down the Before removing the gland packing and other spring foreign matters remove mud troin the gland packing and strut assembly install a nut on the bolt used to install the strut on the body and apply 7 the screwdriver to the nut so that the thread of the bolt is not Remove piston damaged FA 13 rod the guide O ring from the upper portion of the CHASSIS Inspection L Be sure damping to replace oil with new D the gland packing ones ring and whenever the strut assembly is disassembled 2 Wash all foreign Fig 8 Separate FA 35 the O Removing rod piston and or matters with thinner and compressed remove dirt and other air Clean the nonmetal parts with 3 except for nonmetal disassembled parts parts with gasoline compressed air ring cylinder assembly upward from the strut tube slowly and carefully Strut outet casing Replace if deformed cracked or damaged Spindle Check the spindle especially carefully for the base and strut damaged assembly if faulty condition Strut on exists mounting insulator Replace if rubber Replace Front hair crack portion Replace the threaded and metal joint i the rubber parts if they melted are or cracked deteriorated spring Replace if weakened Or cracked Specifications for spring FA 36 Fig Removing piston rod and cylinder Free length assembly t10 mffi 338 3t 0 13 394 Note Do not remove the cylinder They are should be handled 9 Drain casing damping piston rod and precisely as an guide assembled Installed from the lheioadght 203 t5 7 and thus mm t 0 1969 in 99 200kg assembly in 441Ib oil from the cylinder and strut outer into a clean container Strut mounting bearing Replace Note This procedure should be shock absorber amount amount of of strictly performance damping damping oil is observed because directly affected by When refilling if unusual sound occurs When installing the strut mounting measure oil correctly fill 924 1 FA 14 during rotation or slackness toward the axis direction is excessive it with multi purpose grease bearing MIL be sure to G 2108 or FRONT SUSPENSION FRONT AXLE 4 Install rubber G ring a guide special tool Sn5550000 lightly Figure FA 37 top of the piston rod guide gland packing by Apply multi Fig on and install the purpose the use of a gland packing MILG 2108 grease 10924 or the lip portion indicated by asterisk to in F A 40 Greasing strut mounting bearing Reassembly Be careful not to drop scratch or part since aU parts are precision finished When reassembling thoroughly clean all component parts foreign and make completely matters are sure that dirt and other removed During reassem bly do not use cloth I Secure the strut attachment of strut outer casing in or gloves Fig vise 2 Strut attachment Insert the strut outer 3 FA 39 Installing gland packing a special tool Sn565oooo piston rod and cylinder assembly into the casing Fill the strut outer casing with correct amount of oil Fig 5 to FA 40 Cross sectional view Tighten 79 5 the ft Ib gland packing by the use of ofgland packing to 8 0 to 110 a gland packing special tool ST35500000 Fig Note FA 38 Pouring shock absorber oil a Correctly to be poured because amount of oil damping measure amount of shock absorber oil 17 1 cu in I for AMPCO 265 16 2 cu in b cc directly affects power 280 CC A TSUGlI make for TOKICO make Use Nissan genuine oil for the shock absorber oil Nisseki Shock Absorber Oil A 2 for Atsugi make Tokico Light Oil No 1 DoS for Tokico make Fig FA 15 FA 41 kg Tightening gland packing m 57 8 wrench CHASSIS Note Before a piston rod will packing 90 approximately This upward the gland tightening 543 3 mm provide the shod system with the best condition for pull the absorber bleeding b Gland packing tightening torque is rated to 11 0 kg m 57 8 to 79 5 ft Ibl shown in the as actually tightening effective length following figure the L l of at 8 0 However length of this tool is extended by 100 in inl mm arm 394 Thus when gland packing measure torque wrench to be l and set up torque wrench value based usa on the a Fig following formula L 10 c L where 100 kg C L Conducting air bkedmg on tM shock absorber system L m C 70 Value read Ikg FA 42 on 3 94 L ft lbJ the torque wrench 7 ft lbl m vise Effective length of torque wrench mm Secure the strut attachment of strut assembly in Strut attachment special tool SB56500oo inl TOROUE WRENCH GLANO PACKING WRENCH 8 C In order to ease raise the operation up most and secure it in that piston rod to the position by inserting bound bumper L 100 6 mm 3 94 in Conduct air bleeding I on the shock absorber system Stand the strut assembly vertically with the spindle side down and pull the piston rod within its stroke Turn over the strut assembly depress the piston with the spindle side up 2 and rod in the full stroke 2 Repeat the above described operations several 3 Make times 3 sure pressure while air that there is depressing a or no feeling variation pulling the piston on rod Thus bleeding completes Fig 9 Place the compress the front seat Bound 3 Strut outer bumper case a on the lower spring seat coil spring compressor special install the dust cover upper spring oil seal strut mounting bearing and strut mounting insulator FA 16 Piston rod 2 Raising piston rod spring spring with tool ST35650000 f FA 43 1 in that order FRONT SUSPENSION FRONT AXLE 10 multi purpose grease MIL G2108 Apply marked to portion shown in or Tightening torque 10924 44 FA Figure Nuts used to install the strut assembly on the 16 to 2 1 body kg m 116 m 3 33 15 2 ft Ib to Bolts used to install the knuckle arm to strut 4 6 to 6 1 kg to 44 1 ft Ib Nut used to install the tension rod on the transverse link 2 2 to 3 0 kg m 15 9 to 217 ft Ib Stabilizer installation bolts Transverse link bracket side 0 9 to 1 2 8 7 ft Ib kg m 6 5 kg m 6 5 to 8 7 ft Ib to Frame bracket side FA 44 Fig Greasing point on strut mounting bearing 0 9 to 1 2 and oil seal Note 8 Be careful not to damage the piston rod when disassembling or reassembling the strut TRANSVERSE LINK AND assembly LOWER BALL JOINT Particularly when raising the piston rod do not use plien b or Pay other tool to hold the rod attention on installing direction the strut See The mounting bearing with the rubber assembly through II lcg Tighten m the piston rod self locking suspension nut to 3 6 to 4 5 The 26 0 to 32 5 ft Ib spring lower Release the compressor the coil spring gradually from and set the the upper and spring to coil the suspension to the inner the lower ball miles lower ball or joint and thus the front link mechanism is formed joint Lubricate the lower ball 12 bushing to sticked the transverse link is also connected to the strut tube 44 FA Figure link is connected transverse member is of a joint every 50 000 krn disas embled non type 30 000 two years spring seats correctly FRONT Fig 13 FA 45 Installing front spring Raise the found bumper to the upper spring 1 Suspension 2 Transverse cross member link 3 Transverse link mounting bolt seat side Fig FA 17 FA 46 Cross sectional view of transverse link bwshing CHASSIS 2 Loosen the separate the Fig FA 47 Cross sectional view Fig remove transverse link link from mounting the bolt and suspension member ofballjoint Removal Jack up the vehicle transverse the wheel and FA 49 Loosening fVerse tran linlt mounting bolt remove the stabilizer bar and tension rod from the transverse link Loosen the knuckle joint from fixing bolts and separate the ball assembly See Removal of front 3 Remove arm the strut axle and suspension assembly knuckle knuckle above for details arm from pin cotter arm loosen the the castle castle nut on the remove the nut and from the ball joint 1 Fig 4 FA 50 Removing knuckle arm Loosen the ball joint installation nut and remove the ball joint from the transverse link 5 Withdraw transverse replacer Fig FA 48 Loosening knuckle fixing arm bolts and FA 18 a link set press the transverse with special a front link bushing transverse tools ST36721000 link from the bushing ST36722000 FRONT SUSPENSION FRONT AXLE 2 the ball Replace with joint a new one when the dust cover is cracked 3 5T36721 000 Lubricate the ball MIL G2108 miles or Install a grease Be grease 50 000 krn eveI 30 000 two years completely 1 with multi purpose grease joint 10924 or nipple sure the plug hole old grease is that so on to reinstall the replaced when plug and grease with new completely greased FA 51 Fig Removing transverse link bushing Note When Inspection a high slowly and Transverse link bushing re p the grease gun grease gun i carefully new so used operate that grease i injected grease does not come out from the clamp portion Rubber and inner tube joints melted or cracked adhered replace the are sticky transverse link as an assembly Reinstallation Ball joint I The ball joint is of therefore Measure the ball joint end play shaking torque i sas embled non a and type be cannot axial reverse disassembled toward the direction and replace when deviated from the link and lower ball joint in Reinstall the transverse and sequence of removal noting the following instruc tions standards When transverse link collar interior 1 Standard end play axial direction transverse 3 to 10 mm 0 0118 to 0 0394 in 0 Shaking torque 35 to 60 kg with 6 6 to 2 pin opening position 3 kg 11 14 6 to is inserted bushing is rusted the remove it emeI paper em 4 to 52 1 in Ib 30 At the colter link along which In order to improve slide make bushing surface and transverse link collar interior wet with soap water when inserting the 24 9Ib 3 transverse link bushing Fit the transverse link bushing to the transverse link collar by the use of a transverse link bushing replacer In order special tool ST36720000 to set unify distances from the transverse link collar end surface to the bushing inner tube for both sides the following instructions apply I When fitting the transverse link bushing tools ST36721000 be sure to face 8 0 ST36722OO0 mm Fig FA 53 Measuring baU joint shaking torque FA 19 special and ST36723000 and 31 SO in side of hol1ow part of 0 the special tool ST36723000 FA 52 use upward as shown in Figure CHASSIS 6 Install the knuckle beneath the strut assembly arm and tighten installation bolt to 4 6 44 1 lb ft Note a to 6 1 3 33 kg m to ST36721 000 Thoroughly lation surface ST36722000 and assembly matter ST36723000 b etc Make dean are sure the knuckle arm and instal the lower portion of the strut on make sure present on Tightening used FA 53 Fig InstaUing tTansverse ink bushing Be sure neck 38 longer one Finely adjust L distances between both bolts to mm inll for the 2 oil no foreign that installation bolt head is correct ly positioned and tighten it c that those parts the rated torque different having shorter one use 1 496 in length to length length are below for the front side and below neck 44 1 732 mm rear side side tiansverse link collar end surfaces and bushing inner lubes so that they are evenly aligned FRONT I SEE NOTE b L L 1 Transverse link 2 Transverse 3 FA 54 Transverse Unk and transverse link Fig bushing 4 Inner tube link bushing 1 Strut assembly 3 Installation bolt Short 2 Knuckle 4 Installation bolt Long installation Install the lower ball joint on to 2 2 to 3 0 kg FA 55 Fig the transverse link and tighten lower ball joint installation bolt 7 Install member Install the knuckle tighten ball 53 5 ft Ib Note a joint Apply Before arm on castle nut to a cotter installing the lower ball joint and 5 to 74 kg m 39 pin and bend it correctly the knuckle arm link 8 to the transverse link and nut 8 assembly on temporarily tighten the suspension cross them with transverse so that the side is faced to the front side of the vehicle Install the tension rod and stabilizer bar connecting rod to the transverse link apply seal agent to circumference of 9 Jack down unloaded rust to 5 0 Occurrence to strut Install the transverse link mounting bolt the ball joint castle nut to protect the nut from preventing ann clean the When the ball joint castle nut is tightened to the rated torque knuckle mounting bolts Note knuckle arm installation hole and ball joint stud b Installing m 15 9 to 21 7 ft Ib 5 arm of rust FA 20 kg tighten m remove the jatk the transverse link 28 9 to 36 2 lb ft and with the vehicle mounting bolt to 4 0 FRONT SUSPENSION FRONT AXLE ADJUSTMENT CONTENTS DATA ADJUSTMENT ALIGNMENT ADJUSTMENT OF WHEEL ADJUSTMENT OF VEHICLE LEVEL 1 alignment Carry air pressure 2 out wheel adjusted Thoroughly steering and on a FA 21 ADJUSTMENT OF TOE IN FA 21 FA 21 ADJUSTMENT OF STEERING ANGLE FA 22 FA 21 flat surface with tire defective parts before starting the wheel alignment to the normal pressure all check JUSTMENT AD parts component suspension systems 3 and repair or of the be The camber and caster adjusted Adjust angles are preset and cannot the toe in and vehicle level only replace DATA Wheel alignment unladen Von WIgOJI Sedan Coupe Comber 35 c Cute 1010 1035 to to 45 to 2010 1005 When 7045 In 430 430 430 Out 360 360 360 psl cm2 5 1 5 22 1 5 1 4to6 le not heated 4PR 12 Ir8 22 JUSTMENT AD ALIGNMENT 1 Use a gauge and alignment gauge for 2 the measurement Carry air pressure out wheel adjusted JUSTMENT AD alignment on a flat surface with tire distance to the normal pressure LEVEL Vehicle level is and adjust L is 296 8 mm OF VEHICLE adjusted by changing springs FA 21 a toe in gauge Loosen the nut indicated by FA 56 2 22 OF TOE IN Measure toe in with turning radius 1040 7045 in OF WHEEL JUSTMENT AD 40 to 7055 King pin incJinatlon 6 00 2005 1045 5to7 0 20 to 0 28 mm 0 16 to 0 24 Normal tire pre to 45 to 5 to 7 0 20 to 0 28 in Toe Steering ongIo 1045 the side arrow mark in Figure rod adjusting bar between both side side rod ball joint 11 7 in so that centers CHASSIS Note a Make rod is 30 b mm Fig FA 56 JUSTMENT AD Side rod adjusting bar Adjusitng toe is less than 30 extending mm height 11 083 inI I in OF STEERING both Adjust indicated by side arrow steering mark angle adjusting and set them at bolts the rated steering angle Fig FA 57 Steering angk adjusting bolt SERVICE DATA AND SPECIFICATIONS WheelllipmeDt unladen Soda w v Coupe Cambe 3S Cutu 1010 T mm in Kin pin iDcUnation Strle qIe In Out to 3 t to 2010 45 to loOj 1045 to 2005 45 10 1045 40 to 1040 4to6 0 16 to 0 24 5 t07 0 20 to 0 28 5 t07 0 20 to 0 28 70SS 7045 7045 30 30 00 360 360 360 Coil spring Wire diameter mmOn Coil outer diameter mm JO in I JO Coil turns Coil effective 77 6 25 turns FA 22 max of the stopper bolt should be 27 5 Place the front wheels on turn table 2 1 181 the stopper ANGLE I tension more Upon completion of the adjustment imum I or increase the clearance by bolt nut 1 181 in mm When the clearance in Q Locking that clearance between tire sure 394 0 33 4 FRONT SUSPENSION FRONT AXLE Free length mm in Installed mm in height load 1 10 338 20315 kg 13 1 3 7 99 1 0 1969 200 Spring kg mm 1b constant in 394 0 441 1 62 90 7 Strut assembly 177 Strut outer diameter mm in 45 Piston rod diameter mm in 18 0 709 Piston diameter mm in 25 Damping force at piston speed 3 0 0984 m sec Expansion 1b kg Compression 1b kg 48 22 106 48 5 Piston rod Bend limit mm Wear limit mm in 0 025 0 0010 Bend limit mm in 0 2 0 0079 Wear limit inside mm in 0 1 0 0039 mm in in 0 1 0 0039 Piston cylinder Stabilizer bar diameter Front wheel 17 0 669 bearing rotation starting 23 torque kg em in lb 18 Ball joint shaking torque kg em in Ib 35 to 60 to 15 6 to 20 0 4 to 52 30 1 Ball joint end play axial direction mm 0 3 to 1 0 in 0 0118 to 0 0394 TIGHTENING TORQUE Front axle kg Brake disc rotor and hub assembly tightening torque m 4 to 6 0 Wheel bearing lock nut 2 2 to Disc brake cali per 4 6 to 6 1 Buffle plate Brake disc fixing bolt installation screw 3 to 0 4 2 4 0 2 7 to 3 7 assembly installation bolt FA 23 ft Ib 31 8 to 4 43 15 9 to 174 33 3 to 44 1 2 1 to 2 9 5 to 26 8 19 CHASSIS Strut assembly Gland packing tightening torque 8 0 to 11 0 57 8 Piston rod self locking 3 6 to 4 5 locking Self on nut nut used to install the strut the to 79 5 26 0 to 32 S assembly body 1 6 to 2 1 11 6 to 15 2 Transverse link and ball joint Bolts used install the knuckle to arm to strut 4 6 to 6 1 Ball joint castle nut 33 3 to 5 to 7 4 39 8 to 1 44 53 5 Bolts used to install the transverse link to ball joint Transverse link mounting bolt 2 2 to 3 0 15 9 to 217 4 0 to 5 0 28 9 to 36 2 Tension rod Transverse link side 2 2 to 3 0 Body side 4 5 to 5 5 32 5 to 39 8 0 9 to 1 2 5 to 8 7 6 0 9 to 1 2 5 to 8 7 6 0 9 to 1 2 5 6 15 9 to 217 Stabilizer bar Connecting rod and transverse link installation nut rod and stabilizer bar installation nut Connecting Stabilizer bar and body installation bolt to 8 7 TROUBLE DIAGNOSES AND CORRECTION Troubles Vibration shock Possible and of shimmying Improper Remedies causes air pressure of tire Adjust steering wheel Unbalance Vibl3tion Loose connection of the ser defective rubber part mitted the to noticeable coupling and wear of of linkage and vibration of wheels front in many cases trans steering wheel This is very are when travelling of road Correct the or unbalance replace Unevenly worn or insufficient Replace worn front wheel Adjust tire When the front wheels bumpy over steering linkage roads is steering wheel This able when the are is travel play of transmitted especially travelling rough road tighten tightening Improperly adjusted or or lighten bearing Faulty wheel alignment Shock or rough over road ling deformation parts and rubber coupling parts ration each and wheel to the the Wom fitting transverse link Insufficiently tightened Adjust bushings steering Replace gear Retighten housing notice Wear of steering FA 24 linkage Replace defective parts FRONT SUSPENSION FRONT AXLE Abnormal vibrations of the Shimmying front suspension which steering linkage specific speed is and the group occur whole when Worn suspension ball Replace joint Excessive backlash due to improper ad a of the retainer justment attained Worn column bearing bearing spring or weakened column loose clamp strut When driving wheel over a swerves Note to with hands off the or steering the vehicle gently left rear also cause and therefore Replace or retighten Correct the unbalance of tire or insuf Adjust or tighten ficient lightening of wheel nuts Difference in height of right and left tire Replace tires treads A defective be the air pressure Improper left or flat road right to right cor loose installation bolts or Unbalance ofvehicle level pulls Check and repair rectly Malfunction ofshock absorber inside the Vehicle Adjust correctly parts see dealing with the suspension may of this trouble also the chapter rear suspension Incorrect adjustment or abrasion of front Adjust or replace wheel bearing Collapsed or twisted front spring Replace Incorrect wheel alignment Adjust Incorrect brake adjustment binding Adjust Worn rubber bushings for transverse link Replace and tension rod Deformed of steering linkage and suspen Replace sionlink Unbalanced vehicle level Instability of vehicle Improper Worn Correct the unbalance air pressure of tire Adjust rubber bushings for transverse link Adjust and tension rod Incorrect wheel Wom or Adjust alignment deformed steering linkage and Replace suspension link Incorrect adjustment of steering Adjust gear Correct Deformed unbalanced wheel Improper Stiff steering wheel checking up procedure Jack up front wheels detach the steering gear and operate the steering wheel and purities worn in lubricants or steering linkage steering linkage FA 25 replace Adjust air pressure of tire Insufficient or mixing or im excessively Replenish place greas the part or re 1 CHASSIS If it is light check steering linkage and Stiff suspension groups lack of grease If it is heavy steering column check steering gear and or damaged suspension ball joint or Replace adjusted wheel Replace Worn damaged steering gear and bearing Replace Worn incorrectly or groups Of adjust bearing Incorrectly adjusted steering Adjust gear Deformed steering linkage Replace Incorrect wheel alignment Adjust Damaged strut Uppef end Replace Damaged or stiff piston bearing or shock absorber Replace rod in the strut Interference of steering colwnn with turn signal Excessive steering wh play Incorrectly adjusted steering Worn Adjust switch gear housing steering linkage Adjust Replace Improperly fitted of gear box Retighten Incorrectly adjusted wheel bearing Adjust Worn transverse link and tension rod Replace fitting bushings Noises Improper air pressure of tire Adjust Insufficient lubricating oil and grease for Replenish suspension ball joint and steering linkage oil or their Loose breakage steering place bolts linkage and absorber inside the gear suspension groups Defective shock Retighten Replace strut Defective wheel Worn steering Worn Replace bearing linkage transverse Replace link and tension rod Replace fitting bushings Broken collapsed coil spring Loose strut mounting insulator tightening nuts FA 26 lubrication and grease Replace Retighten or re FRONT AXLE Grating tire noise FRONT SUSPENSION Improper air pressure of tire Incorrect wheel Adjust alignment Adjust Deformed knuckle spindle and suspension Replace linkage Jumping of disc wheel Excessively or partially Improper Adjust Unbalanced wheels Adjust Defective shock absorber Replace Defective tire Replace Deformed wheel rim Replace Improper worn tire air pressure of tire air pressure of tire Incorrect wheel Adjust alignment Adjust Defective wheel bearing Replace Incorrect brake Adjust Improper Rough tire and adjustment shifting rotation improper driving Adjust manner Drive more SERVICE JOURNAL OR BULLETIN REFERENCE DATE JOURNAL BULLETIN or PAGE No No SUBJECT FA 27 gently CHASSIS SERVICE JOURNAL OR BUllETIN JOURNAL DATE BULLETIN REFERENCE or No PAGE No SUBJECT FA 28 SECTION RA REAR AXLE REAR SUSPENSION DATSUN 1200 MODEL 8110 SERIES BODY CHASSIS a I NISSAN I NISSAN MOTOR CO TOKYO JAPAN LTD REAR AXLE RA 1 REAR SUSPENSID N RA 4 SERVICE DATA AND SPECIFICATIONS RA 7 REAR AXLE REAR AXLE CONTENTS DESCRIPTION RA 1 Inspection RA 3 REAR AXLE SHAFTS RA l Assembly RA 3 Removal RA 1 r 1 r 1fji 1 Axle 2 4 Spacer Wheel bearing Wheel bearing collar 5 Oil seal 6 Bearing adjust 7 Axle 8 BraJce drum 3 shaft shim case i Fig RA 1 Sectional view of rear axle DESCRIPTION reinstallation The axle is of rear housing is a press steel weight and is and bending The fore rear no when shouid fJoating type l sefi Banjo typi housing sufficiently strong is loa wheel bearin be packed with is It axle being careful not to damage the sealing rubber light in t W1thstand all torsional REAR AXLE SHAFTS ar frequent lubricating the rear axle is The a of preseaIed typ s rvice iS required HQ dis embled an approved the wheel g ease There bearj pri9r Removal ever I gs to the 1 RA l Apply wheel chocks on of the vehicle and support it front wheels jack up the on stands rear CHASSIS 2 Remove the wheel cover 6 and nuts Remove the road If either the axle shaft wheel and brake drum If brake linings should hold the replaced drum slacken off the brake deeply shoe adjuster a few notches slide 3 Disconnect cylinder Plug plastic from the up the open end of the brake pipe or cover the brake pipe Xl wooden peg to prevent foreign wheel with remove the remove Be careful not to matters the wheel wheel bearing is to be bearing locking collar by nicking it with a cold chisel in easily the chisel Set the a or rear bearing bearing veral places remover The It will then the axle shaft with damage ST37130000 removed bearing and collar should be discarded and should not be reused from entering the hydraulic line Fig 4 RA 2 Straighten the Disccmnecting brake line cotter pin @ and remove it Remove clevis pin and disconnect the hand brake cable from the hand brake lever Remove the hand brake return Fig RA 4 Removing bearing collar spring CID 5 to Remove the four bolts the axle together housing securing Draw out the axle with the brake back ST36230000 the brake back plate shaft assembly plate using sliding hammer and rear axle stand ST07640oo0 5T37130000 5T07640000 Fig RA 5 Removing wheel bearing 5T36230000 7 It is recommendable that the oil seal be replaced whenever the Fill RA 3 Removinll axle shaft seal RA 2 use a rear axle shaft is suitable bar such replaced as a To remove the oil screwdriver REAR AXLE Fig RA 6 Fig RA 7 Install wheel bearing Removing oil seal 2 Install the oil seal in place on the axle housing flange Inspection 1 Inspect the machined surface of the the axle 2 for housing which affect the rough spots other or Note irregularities sealing used Be sure to the new oil seal apply MP 2 grease damage and distortion The bend amount should be less than 3 3 mm 0 118 in 0 Install the Check Note be is replaced between lips of the oil seal cracks straightness When the axle shaft must action of the oil seal Check the axle shaft for wear axle shaft and Do not attempt to straighten a bend shaft by the clearance shaft into the axle housing between the housing and face If this clearance is o to 0 1 to mm 0 0 0039 in adjusting shim having heating axle rear wheel bearing exceeding adjust it and the limit of by changing the proper thickness Assembly Assemble the rear axle in reverse sequence of removal BEARING ADJUSTING SHIM noting the following points 1 Place the bearing spacer collar a on force of 3 to 5 tons Note A wheel beariAg and bearing the axle shaft and press them new rear using wheel a on press stand bearing the shaft with ST38270000 should be packed with specified MP 2 grease Fig RA 3 RA 8 Wheel aring be tohousing end face clearance CHASSIS 4 Tighten and nuts lb ft the brake back with a Check the Figure RA 9 plate to housing flange torque of IS to 2 0 rear The end kg m axle shaft end play play bolts 10 8 to 14 5 as shown in should be less than 0 1 mm 0 0039 in Fig RA 9 Checking axle shdft end play REAR SUSPENSION CONTENTS DESC R I PTI ON RA 5 REAR SPRING RA 5 Removal I nspection and repair Installation REAR RA 6 SHOCK ABSORBER RA 5 Replacement RA 6 RA 5 Inspection RA 6 1 Leaf spring 5 Axle case 8 Hand brake wire 2 6 Gear curier 9 Brake hose 3 Front mounting Shackle 7 Torque 4 Shock absorber FiR RA 6 arrester RA l0 Rear RA 4 suspension 10 Bound bumper REAR AXLE DESCRIPTION Rear 5 consists of suspension leaf elliptic semi bracket rings s spring toward the front done to reduce while the the center from is ofT set 110 pin the center of the 33 4 mm spring the remove three the fIxing nuts the securing front front bracket from the leaf spring front eye and car body and lower the rear telescopic hydraulic shock absorbers and rubber bumpers The rear Loosen spring in This is wind up and to decrease the 3rc spring wheel swings through Thereby minimizing rear of the possibility rear suspension effecting vehicle stability devices Iso clamp housing to the The leaf are used are for attaching on rubber bushings rear axle housing at each end to minimize noise and vibration of the transmission to the car and passenger axle spring springs shock absorbers and mounted the body compartment REAR SPRING RA 12 Rear Fig spring front bracket Removal 1 are Jack up the center of the clear from the ground rear Support 6 axle until the wheels the rear Remove upper and lower nuts of the rear shackle end of the frame on stands Fig Fig 2 Rear spring bo u ts Inspection Disconnect the shock absorber bottom end from the spring lower 3 RA 11 I or cracks seat Support the rear axle housing Loosen the lock nuts of the remove repair Examine he spring leaves for fractures with a jack spring and compare with the specifications given 2 Test in SelVice Data and Specifications found defective 4 and RA 13 Shackle rear spring replace with a new If the spring is assembly V bolt and the bolts spring seat location plates and seat pads 3 RA 5 Check the front pin shackle V bolts and spring seat CHASSIS for wear cracks defective parts are straightness and damaged threads found Remove the lower end of the 2 from the spring replace with new ones Inspect all rubber parts for 4 If See Figure seat shock absorber rear RA 14 damage separation wear and deformation Replace them if necessary Installation Install the rear spring in reverse sequence of removal noting the following matters 1 Coat the front bracket pin front bracket bushing shackle pin and shackle bushing with to 2 a soap solution prior assembly The front pin securing nut and shock absorber lower end securing nut should be tightened with the vehicle unladen Make sure that the Note clamped evenly on flange of the shackle bushing is both sides Fig 3 REAR SHOCK ABSORBER Removing shock absorber RA 15 Remove the located under the Replacement Jack up the center of the 4 rear Install real shock rear rear upper bracket absorber installing nut seat back shock absorber in reverse sequence of removal axle and support the axle housing with stands Inspection Test the shock specifications given Replace 2 absorber in and compare with the Service Data and Specifications if necessary Check for leakage cracks and the shaft for straightness 3 Inspect excessive necessary Fig M 14 Removing the shodc absorber lower d RA 6 the rubber bushings for damage cracks and deformation Replace the defective parts if REAR AXLE SERVICE DATA AND SPECIFICATIONS Shock absorber Applied Stroke x model max Sedan length 3m O Damping force at Rear in mm 167 506 x Van Coupe 6 57 x 19 9 180 7 09 440 x 3 17 x x 468 180 7 09 4 18 x s Ib Rebound kg Compression kg lb 58 128 68 I SO 90 198 38 83 8 45 99 2 45 99 2 spring Length x width x thickness 1 No of leaves lOx50x constant 1 llOx50x 1 2 1 110 x SO kg in lb mm 1 96 0 2362 I 97xO 2756 43 1 1 2 109 1 96 x 6 7 II in mm 43 7x 1 Spring I 2 2 I I 0 2362 2 43 7x 1 97xO 2756 1 433 0 I 11 97x8 mU 109 3 2 128 8 when unloaded 4 2 235 2 when loaded Camber Free in mm Loaded with specified load 11 Spring 3 4 29 iO 1181 433 0 109 3 4 29 i0 1181 131 is 5 ISiO 1969 11 433 0 I 433 0 192 423 192 423 295 650 in mm kg lb Specified load 109 eye diameter Front mm in 35 378 1 35 378 1 35 Rear mm in 23 0 906 23 0 906 23 378 1 0 906 Rear axle End play in mm Rear axle end shim Wheel bearing 0 1 in mm collar Less than 0 1 0 2 0 5 0 0039 0 0039 0 0078 0 0195 pressing 3 1b ton force to 5 6600 to 11000 Tightening torque kg Axle shaft tohousing flange bolt nuts Differential carrier to housing bolts Spring S J to 2 0 17 to 5 2 3 2 to 4 0 V bolts RA 7 m 10 ft Ib 9 to 14 5 3 12 23 1 to to 18 1 28 9 CHASSIS 8 0 to 9 0 57 8 1 6 to 2 0 116 to 14 5 3 2 to 4 0 23 1 to 28 9 1 6 to 2 0 116 to 14 5 Sedan and Van 3 6 to 4 5 26 0 to 32 5 Coupe 09 Wheel nuts Spring front brake Sedan and to body bolt 65 1 nuts Coupe Van Spring shackle pin to nuts Shock absorber upper nuts to J 2 6 5 to 8 6 Shock absorber lower nuts Sedan and Van 3 6 to 4 5 26 0 to 32 5 Coupe 09 to 1 2 6 5 to 8 6 0 6 to 0 8 3 to 5 8 4 Torque arrester body to bolts SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or No PAGE No SUBJECT RA 8 SECTION BR BRAKE DATSUN 1200 MODEL 8110 SERIES BODY CHASSIS a I NISSAN I NISSAN MOTOR CO TOKYO LTD BRAKE BR SERVICE DATA AND SPECIFICATIONS BR 23 TROUBLE DIAGNOSES AND CORRECTIONS BR 24 JAPAN i 1 BRAKE BRAKE CONTENTS DESCRIPTION BRAKE PEDAL BR 2 Removal and disassembly BR B BR 2 Inspection BR 9 Reassembly and reinstallation BR 9 Removal BR 2 Inspection BR 2 Reinstallation BR 2 Brake pad BR ll BR 3 Caliper assembly BR 12 BR 3 Reassembly BR 14 BR 16 BR 16 TANDEM MASTER CYLINDER Removal FRONT DISC BRAKE Disassembly BR 3 Reinstallation Inspection BR 3 REAR BRAKE BR lO Reassembly BR 4 Removal and disassembly Reinstallation BR 4 Inspection BR 17 BR 4 Reassembly and reinstallation BR 18 BR 5 SINGLE MASTER CYLINDER Removal and disassembly HAND BRAKE BR 17 BR 18 Inspection BR 5 Removal Reassembly and reinstallation BR 5 1 nspection BR 19 BR 5 Reinstallation BR 20 BR 5 BRAKE LINE Removal Inspection BR 6 Reinstallation BR 6 Brake pedal Brake line pressure differential warning light switch BR 7 FRONT DRUM BRAKE BR 8 BR 20 height BR 21 Hand brake BR 21 Bleeding hydraulic system BR 22 1 Brake hose 5 Brake hose 2 Brake master cylinder 3 3 way connector Hand brake lever 6 7 8 3 way connector Hanger strap Turn buckle 4 Fig BR 20 ADJUSTMENT Brake shoe clearance BR 1 Brake system BR l 1 BR 19 CHASSIS Removal DESCRIPTION The Datsun 1200 series brake Disc brake leading two or drum brake is used for the adoption driving range a wheels rear is used cylinder brake There safety high speed at one is 2 Remove the spring pin from the clevis pin which is two specifications cylinder remove the clevis pin and separnte the push arm tandem or types of tandem type Under the standard arm rod from the pedal 3 master for disc brake and the other for drum tandem type master Unhook the relum spring pedal improved are I used to connect the master cylinder push rod to the brake For the mas1er cylinder either single type 1ype hydraulic shoe type leading trai1ing of the disc brake is further adopl shoe type drum brake is used for the front wheels and With models new however Remove the fulcrum pin which is used 10 connect the pedal arm to the brncket and separate the pedal arm from the bracket the is used for disc brake and single 1ype is used for drum brake The tandem masler cylinder provides a dual brake system improving safety The hand brake is of a mechanical type which brakes the rear wheels through the control l The r and s1ee wire control lever is located between the driver and assistant seats and can be operated easily @ BRAKE The The PEDAL steering column bracket supports the brake pedal brake pedal brncket with a is installed fulcrum pin on The brake pedal brake master cylinder push rod pin The stop lamp are joined with switch opposes the brake brackel and opera1es as the pedal t the steering column arm a and Sprina pin Oevis pin 5 Nut 2 6 Spring 3 Washer 7 Nut 4 Spring washer 8 Fulcrum shaft clevis pedal Fig arm BR arm moves 9 washer 10 II Return pring Brake pedal arm Brake master cylinder Brake pedal components tandem type master cylinder Inspection I Check sliding parts for wear and the return spring for weakness 2 Check the brake pedal for bending warping and crack 3 Check other parts for serviceabilities Reinstallation Reinstall the brake removal noting the I Grease 1 Stop lamp switcl1 4 Clem pin 2 Brake pedal stopper Brake pedal arm 5 Push rod 6 Fulcrum pin 3 Fig multipurpose 2 2 9 BR 2 Brake pedal instaUation BR 2 pedal following sliding parts in reverse m and return grease MIL G2I08 15 2 to 21 0 Ib ft of matters or spring hook with GI0924 Tighten the fulcrum pin installation kg sequence nut to 2 to BRAKE TANDEM MASTER CYLINDER The tandem masler cylinder aIIows either front brake trouble displaying occurs or rear sufficient braking effect although The tandem a NABCO in one side of either front or rear brake or TOKICO bling be careful improving driving safety cylinder master lype is manufactured When disassembling and by reassem not to mix the individual manufacturer s parts I t i Fig BR 4 J Cross sectional view master of tandem type cylinder Removal J Remove the clevis pin from the master and separate the brake cylinder push pedal bly and 4 Remove the valve cap rod 2 Disconnect the brake tube from the master cylinder 3 RemOve the master cylinder installation bait cylinder shim and remove and remove the valve as sembly Note the master piston spring remove Disassemble the master the the master cylinder sliding R1rface damaged not assembly from the body piston so that of the piston and piston cup are Do not remove the fluid reservoir unless really necessary the cylinder carefully Moreover cup unless the piston is do not remove replaced Disassembly Inspection Drain brake fluid and remove the stopper bolt Thoroughly clean all wear 2 stopper ring 3 the dust Remov cover and remove the remove the snap ring and check for and replace if necessary Note assembly Do not dean rubb they 1 piston priniill conditions push rod assembly 11 Take dut the piston mechanism components in order of the disassembled parts damage and other defective piston assem secondal are deteriorated When alcohol BR 3 is used parts with mineral oil since Use brake fluid however or alcohol do not immerse CHASSIS rubber parts alcohol und After the parts are longer deaned dry than 30 seconds them with disassembly noting the following matters I Check the uneven wear on cyJinder bore and cylinder the conditions Replace 2 brake Apply com pressed air piston for damage sliding surface as carefully and no and for other defective required Replace if the cylinder and piston clearance is more so fluid to the component pdrts such etc piston that the component parts dust and other foreign are not matters enter the damaged Moreover for rubber parts such piston cup rubber grease slightly apply or cylinder and brake fluid reservoir etc as and carry out the operations as Tightening torque than 0 15 rom 0 006 in Valve cap 3 In principle replace the piston valves with new Be disassembled weakened 4 ones whenever sure to cup packing 5 to 3 5 kg m 2 and the master cylinder is replace if damaged Bleeder orexpanded Check the return springs for 3 6 m lb ft 0 15 to wear as 3 kg 0 m others required Reinstallation if deformed damaged or defective removal After air cylinder bleeding in reverse sequence of make sure that no brake fluid leaks from the circuit For the pedal height adjustment Reassembly Assemble the 1 to 2 2 ft Ib damage and other Reinstall the master Replace lb ft Stopper bolt defective conditions and replace 5 3 25 screw 5 kg 0 worn 1 to 18 master cylinder in reverse refer to the sequence of paragraph pedal adjustment SINGLE MASTER CYLINDER Fig BR 5 Cross sectional view BR 4 of sing master cylinder BRAKE Removal and The in the single same disassembly master cylinder manner as installed cylinder is removed and disassembled the tandem type master cylinder BRAKE LINE Inspection Refer to the section covering type master Inspection of tandem The bl1lke cylinder The single and reinstallation master pipe adopts tubing and with improved Reassembly in the same manner as the tandem type master cylinder is beneath reassembled and the the rigidity has been portion of brake line laid vehicle floor is galvanized improving corrosion resistance re 8 10 Fig double wall construction steel this construction Moreover the a tube 9 Brake hose 1 Bridge 2 Brake tube 10 Bridge 3 Brake hose 11 Brake tube 4 Brake tube 12 Brake hose 5 Brake tube 13 6 7 3 way connector Brake tube 14 Brake tube 3 way connector 15 Brake tube 8 Brake hose tube BR 6 Brake line Removal I Remove flare nuts from both ends of the brake tube steel tube tube on the and remove clips used to panel The brake tube can secure the brake be removed easily Brake master Fig BR 5 BR 7 cylinder 2 Front 3 way connector Brake tubes around master cylinder the CHASSIS Inspection Thoroughly check them for tube and clean the brake tube and brake hose collapsing for weakness crack scar expansion and rust brake brake etc wear and hose if defective Replace 2 Remove mud and dust from the brake tube clip unit md check the G Front 3 way connector Fig 2 BR 8 The brake hose strut assembly 0 Brake master cylinder tom I If the clip covering vinyl coaling is clip repair Front J way connector rubber hose unit and rear axle is used at the front housing Ihe flare nut from Ihe brake tube and unit remove Remove Reinstallation Ihe hose I Provide sufficient space between the brake lines a and other parts so that the brake lines with other paris due to vibration are not interfered during driving BRAKE TUBE PANEL CLIP COATED WITH 3 Fig BR 9 Brak rear Rear axle hoand 3 way connector around axle housing BR ll Brake tube installation Fig 2 the on replace the copper rear Fig assembly BR l0 Brake hose around front strut 4 BR 6 not to or a once be sure to new one twist the brake hose and interfere the brake hose with suspension components Do not forcedly assembly with Be careful not to warp tires and ut axle housing packing particularly be careful Brake hose clip When the brake hose is disconnected from the 3 way connector 3 o VINYL housing or tighten the brake line installation flare nut excessively BRAKE warning light is completed and thus the warning light lights S to 18 kg I 3way connector m In this 10 8 to 13 0 ft b Master S to 1 8 kg I cylinder Brake hose S to 1 8 kg I hydraulic brake problem and light switch assembly for a proper operation Check the switch assembly for fluid leakage m Note Do not attempt to repl8CllIWitl h 0 7 to 0 9 kg 5 1 to correct the Check the warning 10 8 to 13 0 ft Ib Air bleeder case bleed the brakes m 10 8 to 13 0 ft Ib 5 circuit for the ground Tightening torque repair switch for any reason bly completely m 5 ft Ib 6 Fill the master cylinder brake fluid reservoir with brake fluid and Note perform air bleeding a Do not use brake fluid b The completely oththan fi8d brake fluid is used for both end tandem type master single cytindon Upon completion of air bleeding 6 specified make sure that the brake operates correctly and check the brake tube and hose connectors for fluid leaking Fully depress the brake continue to pedal seconds and make 1 To front brake LU 2 From master 3 From master cylinder cylinder Fig BR 12 depress the brake pedal for several sure F 4 To 5 To front rear brake L U R H brake R H R Warning light switch that no brake fluid leaks from any part of the brake line Replace defective parl if required Brake line pressure differential warning A Ii ght Warning light warn rear brake A to a 2421bfsq syslems are When a to in exists belween the fronl and engine compartment Both front and systems panel pressure difference of 13 to 17 hydraulically actuated warning light switch in the 242 is located on the instrument the driver when kgcm2 185 switch is located brake rear 1 connected to this switch assembly pressure difference of 13 to 17 Ibfsq in occurs 2 kg cm2 between the front and Wire terminal Brake tube 3 4 Valve assembty Piston load spring 185 to rear brake sys1ems the valves will shuttle toward the side with the low pressure The valve conlacts with the switch tenninaI Fig BR 7 BR 13 Sectional view of warning light switch CHASSIS FRONT DRUM BRAKE o B J t o o r l Gl e e Fig BR 14 Front drum brake Removal and disassembly I Jack remove up the vehicle support Unhook the retum spring and 4 with a stand the wheel cover and tire Remove the brake drum and remove remove the brake shoe assembly and Disconnect the bridge tube from the fore and after 5 2 components wheel the hub cap cylinders and hub assembly from the spindle 3 unit of the Disconnect the brake tube at the bracket strut assembly Fot the details refer to Section FA 1 A fief wheel 2 Bridge tube Fig cylinder Fig BR 15 BR B bridge wheel cylinder cylinders cylinders tube Remove the installation bolts and after wheel Front drum brake Fore BR 16 Fore and after wheel and 6 3 and remove the fore BRAKE 7 Remove the brake disc installation bolt the brake disc from the 8 and remove 5 Check the brake disc for distortion 6 Check spindle If Inspection Drums and between clearance exceeds 0 15 mm If show they cylinder for wear sign the and cylinder 0 0059 in replace the piston them excessive out of round score reconditioning by machining forth so the bore of the wheel of rust and damage cylinders Disassemble the wheel is required Brake drum inner diameter 203 2 8 00 in mm Drum inside out of roundness Below 0 02 0 0008 in mm Limit of reconditioning drum in diameter 10 2 Linings soiled seated If brake shoe or or heating repair lining is Note greasy or 8 If oil are incompletedly deteriorated due to excessive If the thickness of the 0 0591 in mm replace found is grease or linings them replace 5 1 less than 0 0394 in mm on linings thoroughly with carbon tetrachloride b After installing and lining face to a it or bonding lining clean gasoline grind Fig the 4 Check the adjusting Return replace cams If springs offront Sectional view wheel cylinder diameter equal to the brake drum 7 3 BR 18 for their smooth they are operation When the wheel that cups cylinder be replaced even satisfactory conditions considerably weak is overhauled recommend if apparently they Cups be must replaced in are if de formed due to damage crack corrosion smelling and them or aging Return spring dimension Wire diameter 3 2 x x 118 0 1260 Load x x free length turns Reassembly 20 5 mm 4 65 in 20 5 The rear brake is reassembled and reinstalled in reverse length 55 I2I kg Ib x 127 1 mm 5 00 in sequence of following matters I 13 4 and reinstallation 0 528 disassembly and removal However When assembling the wheel cylinder be note sure to the apply rubber grease to the piston cup and other rubber parts slightly 23 0 906 2 When installing the wheel cylinder apply brake 118 4 65 FREE lENGTH UNIT mm grease to the cylinder plate sliding surfaces and in to fulcrum portion sufficiently Fig BR 17 Return slides smoothly spring 8R 9 the so to disc the brake disc and adjusting wheel cylinder lever that the wheel cylinder CHASSIS 4 Adjust bleeding on brake shoe clearance and perform air the hydraulic system FRONT DISC BRAKE Floating type disc brake Model ANNET 14A 12 is used for some territories as a standard Rigidity worn 3 kg BR 19 Tighten m Greasing point on brake due by elasticity of the piston seal When the pad is the Clip Spring 3 Clevis 4 Shim 5 Ha pin cr piston seal surface 6 Brake 11 Cylinder 7 Air bleeder 12 PisCon A 8 Retaining ring 13 Bias spring 9 Boot 14 Yolee Piston B 15 Yoke to spring Fig increases and thus slipping clearance is Moreover in order to prevent brake squealing inserted behind the pad 19 5 to 26 7 ft Ib 2 piston operating the stroke is adjusted automatically the brake disc installation bolt to 2 7 to 3 7 I is is occurs on Fig caliper high brake pedal feeling pad dragging is minimized The pad adequate retumed of the and the pad BR 20 Front disc brak BR l0 components block spring a shim is BRAKE CYLINDER SIDE PISTON SIDE L COMPRESSION DECOMPRESSION exceeding the elastic displacement is released with slipping on the seal surface Movement Returns in elastic displacement of the seal Note BR 21 Fig Piston seal automatic When the brake brake adjusting operation brapad and shim Withdrawing DR 2l Fig pad is removed do not depress the or otherwise the pedal piston will come out Inspection Brake Clearance between the brake pad automatically Replacement and remove for wear after the 6 000 miles driving and every 5 000 first 10 000 km I Jack up front unit of the vehicle pad adjusted rotor is pad and Check the brake km 3 000 miles thereafter the front wheel I Clean Remove clip from the retaining pin and supporting 2 the brake pad remove the the brake pad with arbon tetrachloride or gasoline retaining pin and coil spring 2 When oil and or grease is or when deteriorated replace the pad with a or heavily sticked on new 0 0630 in than 1 6 mm Replace when total pad deformed due to overheating one When thickness of the friction material 3 the pad pad is less replace thickness is less than 6 1 mm 0 2402 in Recommend pads be replaced Note ment at effect only one position Recommend may rotation as of Replace a set cause uneven pads brake be made periodieally 4 Check the rotor Refer to Rotor inspection Reinstallation I 2 Brake pad Retaining pin Fig 3 J BR 22 I Clip on and shim with a 2 pair of pliers the rotor Depress can BR ll pad installing parts Do not use mineral oil Be eareful not to apply oil Note Removing retaining pin Unhook the hanger spring and withdraw the brake pad Clean the calipers and piston the be installed piston into the cylinder so that new pad CHASSIS Fig Note Note that brake fluid a Ikpression piston BK 24 may overflow from the reservoir Recommend operation be canied out by loosening the The piston can be easily if pushed excessively excessively damaged into the pushed in by hand But the groove of piston goes inside of seal as shown in will be ARROW MARK to release brake fluid breath b seal cylinder A and B into Figure When the piston is cylinder c BR 25 and the remove pushed the brake the assembly disassemble it push out the piston to arrow direction as shown in Figure BR 25 and reassemble BR 26 Arrow Fig Install the shim I rotor forward Apply 2 so mar that the on all shim ow mark points the rotating direction the coil spring to the retaining pin which is distanced from the air bleeder 4 When the pad is installed depress J several times l@ I I as so to settle down the brake pedal the pad in the position I I Caliper assembly RemowI Norrnal Piston seal position I I the Remove brake pad Refer Pad to re placement Fig 3 Install squeal anti with BR 25 Piston pad and anti pushing in squeal shim spring and retaining pin position assemble and secure the 2 Disconnect the brake tube from the wheel 3 Remove the strut lation bolt them so as BR 12 and knuckle to ease removal of the inslaIlation boll clip assembly cylinder arm instal caliper assembly BRAKE Fig BR 27 Removing strut assembly and knuckk ann Fig installation bolt 4 Remove the caliper assembly separate it from the strut installation bolt and 5 Remove the bias 6 Remove BR 28 Removing caliper assembly installation bolt Q Disassembly 1 Loosen the air bleeder and B into the cylinder the piston A and boots from o Retaining ring the BR 30 Boot Cylinder body and piston Depress and remove 8 Remove the piston seal from the cylinder Note cylinder retaining rings 7 Remove mud and other contaminations from the Drain brake fluid from the wheel the Remove the that the 3 ring from A and B Fig caliper assembly before disassembly 2 Tapping yoke head assembly pistons Fig BR 29 the piston piston from seal wall is cylind carefully the cylinder with fingers so not damaged and depress tha pistons A Refer to Pad 9 replacement Remove the yoke spring and yoke bias spring from the yoke 4 Secure the yoke in with a The hammer removed from the body be careful a vise and tap the yoke head cylinder body can then be Inspection and repair yoke When removing the cylinder not to allow the piston A coming Thoroughly clean out all disassembled parts them for the following items from the cylinder BR 13 and check CHASSIS When cl Note fluid lOing rubb parts If rubber parts are use alcohol or brake cleaned with mineral oil they will be deteriorated 1 Calipers If the cylinder wall lated the on emery paper Ifrusted 2 is damaged wall is rusted cylinder or or replace or worn foreign matters are If the accumu cylinder wall carefully polish with fine so that the cylinder wall damaged is not roughened excessively replace Pad See paragraph covering replacement of pad BReJ1 Fig 3 M ring defkction of disc Piston if unevenly Replace worn damaged and rusted or Reassembly Note The piston sliding use emery surface is plated paper aJthough matters are slicked on the Thus do not rusted I foreign or Apply the rubber grease cylinder bore and install the piston seal sliding surface 2 Insert the bias ring to piston A portion of bias ring 4 to comes so that the roundish to the bottom of piston Seals replace both piston and dust Primarily seals whenever overhauling Nota The piston piston seal affects not only rebJm seal even if the For this reason damage leaking replace but also the piston is minor @ 5 Rotor Check the rotor and if it shows round and required so forth score excessive out of reconditioning by machining If any abnormal conditions such distortion and excessive deflection replace as is crack the rotor 1 Yoke 3 Piston A 2 Chamfer 4 Roundish portion Standard rotor thickness 9 5 mm 3740 0 in limit of reconditioning rotor in thickness 4 8 mm 3307 0 Fig in BR J2 Installing bias ring into piston A Deflection of the rotor Below 0 03 mm 0 0012 in Note BR 14 Be careful not to confuse the piston A with B BRAKE J i tu PISTON B P ISTON A Fig 3 Apply rubber piston and too 4 grease insert the lightly piston to the into the When inlllrting the piston Note Fig BR 33 Piston A and B cylinder be careful not to insert much Install the boot and retaining ring 7 Fig BR 34 Inst4Uing boot Install so that the A coincides with the yoke groove of bias ring of piston faces to so ofyoke spring so 2 that the bias spring to the air bleeder side of cylinder Apply the brake grease to the yoke sliding portion of cylinder yoke groove of cylinder 9 Install BR 36 InstaUaticn Install the bias spring to yoke comes 8 6 1 ofyoke spring sliding portion of Fig 5 BR 35 InstaUaticn that the disc as shown in projected portion Figures of yoke spring With lightly the correct yoke spring inserted to position of the bias spring groove of bias spring conincides with yoke BR 35 and 36 BR 15 cylinder groove so that the CHASSIS Fig 10 BR J7 Fig Correcting bias spring position Assemble the cylinder body and yoke by tapping BR 38 Measuring starling torque Starting torque the yoke lightly 9 0 cm 7 80 in Ib kg At the hub bolt II Apply groove of 12 the brake grease fully to the yoke sliding 57 1 kg 3 45 Ib cylinder Tightening torque Install the air bleeder Caliper assembly installation Reinstallation 4 6 to 6 1 Reinstall the caliper assembly in reverse sequence of 5 to 1 8 1 the pad hydraulic line and is installed measure completely REAR BRAKE 00 7 I o i i Q e C 1 4 Fig BR 39 Rear brae construction BR 16 bolt 3 to 44 1 ft lb 33 m 10 8 to 13 0 ft Ib kg bleed the the rotation torque ofdisc e m Brake tube flare nut connected to wheel cylinder removal After kg BRAKE disassembly Removal and Remove the 7 remove the Jack up the 1 side of the vehicle rear support with a removed together stand and remove the wheel from the rear wheel cylinder remove lever with the rear axle shaft Refer to the clevis pin and disconnect the Remove the return hand brake wire axle housing rear Section RA Loosen the hand brake wire 2 flange bolt from the axle shaft The brake disc can then be rear spring pull spring Removing brake disc BR 42 Fig Inspection For the rear brake inspection the instructions for front 1 Return 2 Hand brake wire spring 3 Clevis pin 4 Wheel drum brake apply cylinder lever Return Fig 3 40 BR Removing Remove the brake drum and return spring and remove spring dimensions hand brake wire Remove the shoe retainer the brake shoe Wire dia assembly free length x effective 2 0 x Cylinder 119 2 0 0787 side Load 28 mm 10 6 kg 4 69 in x x length turns 4lb 33 x 132 7 x 5 22 in 28 2 0 Adjuster x 69 5 0 0787 side mm 20 x 2 736 in 20 8 6 kg 19 x 61b 76 7 x mm 3 020 in CYLINDER SIDE 12 472L 0 E Brake shoes Fig spring Adjuster ADJUSTER SIDE BR 41 Rear drum brake 12 4 Disconnect the brake tube from the wheel 5 Remove cylinder 11 The wheel 6 the dust cover cylinder Remove the can adjusting shims I 58 2 283 119 2 4 69 FREE LENGTH Return Shoe retainer and plates 0 433r I42 69 5 UNIT then be removed easily mm in 8R 17 472 0 1 2 736 FREE LENGTH Fig adjuster assembly mm BR 43 r CHASSIS Reassembly Reassemble and reinstallation and reinstall the rear brake in reverse sequence of disassembly and removal noting the follow ing When reassembling matters refer to the notes for front drum brake Measure the wheel cylinder sliding resistance with the brake tube disconnected make 7 sure 409 4 kg Note that the When return 2 2 2 is is in range from 2 to the brake improp kg shoe does not smoothly rn kg 10 8 to 5 14 II6 to 15 9 bolt flange bolt o Sprina lb ft Tighten the adjuster assembly m Figure BR44 and Ib Tighten the brake disc installation 15 to 2 0 3 sliding shown in sliding resistance 432 15 to as installation bolt 1 6 to balancet 44 BR Fig G W Measuring sliding lb ft HAND BRAKE 2 5 3 5 Turn buckle Hand brake 8 Hanger strap Return spring 1 Hand brake lever 2 Cabte 3 Clip 6 Cable 10 Cable shank 4 Lock plate 7 Cable 11 Hand brake fever 9 adjuster Fig BR 45 Hand brake construction BR 1S cover cylinder resistance BRAKE Removal r lr Sf Loosen the I buckle turn adjusting the front cable from the rear nut and septe O cable 0 s 7 fqI 0 l J b 0 1ltL j 0 Y I 1 1 separate the 1 r c 0 1 0 12 Hanger Itn p installation bolt Fig BR 48 o Disconnecting TeaT Lock plate cable rear from axle IwllSing f 5 Loosen the hanger strap unit nut parts into nut hanger strap washer 1 Rear cable 4 Front cable 2 Turn buckle 5 Propeller 3 Lock nut Fig 2 of Removing Remove the lock the turn buckle compartment 3 46 BR side nect the wheel the cylinder lever side brake cable shaft turnbuckle plate located immediately remove and and bracket Discon clip in the in front passenger and disconnect the front cable Remove the hand brake lever cover Remove the lever assembly with the front cable connected toward the passelljlOr compartment side 1 DWlt 2 Hanger strap 3 Bracket BR 49 Fig Note 4 cover washer Hanger strap Hanger strap instal 5 lation bolt Hanger strap mounted on rear axle housing Do not remove the dust cover from the cable but leave it installed on the cable Inspection J cable Fig 4 BR 47 J Remove the hanger strap installation bolt withdraw housing and other defective conditions and replace if required Hand brake lever 2 Replace if sliding part 3 Make Removing hand brake lever the lock plate from the axle Check the cable for damage bracket unit and sure is worn that the hand brake lever smoothly and that the ratchet disconnect the rear cable worn BR 19 excessively unusually or damaged pawl can be operated and teeth are not CHASSIS With 4 hand the pulled lever button and make sure that the push 0 1969 to 0 2362 in Make sure 3 depress the pawl disengages depressed is button push teeth when the 5 brake 5 such the an completely 4 adjusting stud counterclockwise up to that the brake shoe is brake the Turn drum and separated slightly warped if the readjust interferes lhe brake drum damaged pedal depress the brake addition Ot cam extent from the brake drum to 6 mm that the cable dust cover is not Turn the brake shoe the clearance and make sure In that the brake operates effectively and correctly Reinstallation Reinstall hand the brake in reverse Front disc brake sequence of ance twist the dust cover 1 Be careful not to 2 Tighten the hanger strap and kg nut to 0 8 to 10 damage m or adjustment Ordinarily removal noting the following mailers the cable between pad is not and rotor is adjusting When Rear brake brake shoe clearance be 2 MIL G2J08 or brake disc comes GJ0924 the tighten clockwise up to such sliding parts with multi purpose grease the the wheel your hand and tool from reverse side of Applying the Grease remove sure to loosen the inner cable sufficiently 4 adjusted automatically connecting 5 8 to 7 2 ft lb rear because clear by elasticity of the piston seal Jack up the vehicle and 3 required brake adjuster wedge extent that the brake shoe an into contact with the brake drum JUSTMENT AD Brake shoe clearance Front drum brake I Jack up the vehicle and 2 With the brake remove the wheel drum installed adjusting stud clockwise up to such brake shoe comes by applying tighten an the cam extent that the into contact with the brake drum side of your hand and tool from reverse the brake disc Fig 3 BR St Return 4 Turn the rear separated brake press the brake BR 50 Adjtsting front pedal drum and BR 20 that the if the brake readjust In addition shoe de aJ1d make sure that the brake operates effectively and correctly brake shoe clearance so from the brake drum slightly interferes the brake drum Fig brake shoe clearance adjuster wedge properly the brake shoe is Adjusting BRAKE Brake pedal height Ai JI L BRAKE M ASTER CYLINDER r TOP ll Q ci I r ADJUSTING SHIM 0 5 THICKNESS mm 0 8 1 6 mm mm 1 0197 in 0 0315 in 0 0630 in Brake ped4 adjustment Loosen the stopper up to such extent that the brake is pedal stopper separated from the pedal Hand brake arm Turn the turn buclde properly and adjust hand brake 1 2 Measure height of the brake master cylinder and dash 5 143 lever brake pedal head from the panel so that height to is IS 3 091 in kg adjustment 5 65 in rom operating stroke correctly 5 mm 78 and adjust the adjusting shim between the dash panel tJ t 0 BR 52 Fig LAMP SWITCH be 6 notches 3 24 to sure to at Ib 33 1 that so operating operating force lock nut tighten the 0 5 mm 0 0197 in mm 0 0315 in 1 6 mm 0 0630 in Note 3 4 adjusting shims thickness for upper and having master cylinder lower brake installation bolts completion of adjusting shim adjustment the stopper down to such an extent that height of pedal tighten be sure to use adjusting same Upon tighten the When head is 141 5 the lock nut 2 mm 57 5 0 0787 in Free travel of the brake pedal is 6 to IS to 0 590 in and securely and the stroke is 120 mID mm 0 236 4 72 in t Rear cable 4 Front cable 2 Turn buckle 5 Proper 3 Lock nu Fig BR 21 r shaft t BR 53 of I I Upon completion of Adjusting shim thickness for selection 0 8 stroke is Adjusting turn buckle CHASSIS 2 Upon completion of the adjustment release the hand brake lever and make sure that the rear wheels are I not braked r 7 Normal stroke 78 5 I 3 091 in mm 1 1 6 notches I limited stroke 136 0 mm in Stroke The term position 35 5 220 means 8 7 in nun 10 notches O above the hand brake lever Readjust 1 hand brake stroke when it reaches the limited stroke 136 mm 5 35 inll 10 notches 4 Depress Bleeding hydraulic system 5 it is to air bleeder rear the brake pedaI two to three times and keep fully depressed the brake pedal fully depressed loosen the exhaust air and retighten the bleeder screw screw quickly essential factor for regular service an With bleeder the hydraulic brake system deserves much as Connecting vinyl hose BR 54 the pedal Bleeding II Air bleeder Fig attention 1 e fulcrum Note 5i J2 height from the standard brake operation As a likely to matter of fact during the brake service creep into the circuit with the result that the fluid action is altered and the brake 7 becomes spongy pedal will at the travel end Bleeding should be carried cylinder out at clear 8Wi1 V any dirt around master resevoir before removing cover Never d reason pedal the longer comes cover cylinder any Note while brake drums ara a Check the Fluid cylinder with fluid of the c When raplaced inder Thoroughly wipe mud or dust foreign present the bleeder so withdrawn screw and from any that the outlet hole is free from screw some Dip a vinyl d hose to a in again master conduct air is Ordinarily the for bleeding operation refilling eylinder bleeding located most is disaDembled on the wheel or eyl the master performed in the near jar containing e brake fluid Do not tightening BR 22 air bleeding is sequence Rear left the wheel cylinder bleeder the end of the vinyl hose in during blead eylinder matter Attach the which following 3 other wheel cylinders in the ing operation recommended type 2 on oir for fluid level should not be used Top Air When air still exists in brake fluid it out Conducl air bleeding b up the reservoir master above same manner removed unless bleeder valve is open 1 6 through out from the bleeder screw but brake appears white due to air bubble 8 for 4 operations come flrst the master then from the longest line from the master Always Repeat no fluid cylinder and then fmish up with the shortest Note Return the brake pedal slowly 6 air is Rear right return the Front left brake the bleeder saew Front pedal right bef re BRAKE SERVICE DATA AND SPECIFICATIONS 8rab pedal Pedal free height Full stroke of peda head 57 t0D787 5 mm in mm in 120 4 72 rom in 1746 mm in 52 I4I Muter cylinder Inner diameter of maJter cylinder 16 11 Allowable maximum clearance between cylinder and piston 0 13 00051 Wheel cylinder Inner diameter of wheel cylinder Front drum 64 13 16 20 in mm mm in 48 1 894 1 mm in 20 64 13 16 mm in 1746 11 16 mm in 0 18 Drum brab inner diameter mm in 203 2 8 00 Rotor disc outer diameter mm in Rator thickness mm in Drum inside out ofroundness mm in Below 0 02 0 0008 diameter mm in D 0 0394 I Run out of the rotor mm in mm in 84 mm in 35 disc Rear front disc Allowable maximum clearance between cylinder and piston 0071 0 8rab drum and rotor disc 5 212 37 8 5 0 3740 9 Until of reconditioning drum in Below 0 03 00012 Limit of reconditioning rotor in thickness 3307 0 Lining dime1l8ion Front drum brake Lining Tala width braking x thickness x area length cm2 in2 BR 23 x 273 8 4 x 3 42 195 378 1 x 0 1890 x 7 68 CHASSIS B40 Akebono make Lining material Front disc brake Pad width x thickness Total braking x length area mm in cm2 in2 42 5 x 10 3 x 53 1 1673 x 406 0 x 2 091 3 14 0 90 MI12S Pad malerial NBK D864P for A and CANADA s U Rear brake Lining width x Total braking thickness x length mm in 35 cm2 in2 area x 4 8 x 378 1 195 x 0 1890 x 273 42 3 B40 Akebono make Lining material Tightening torque kg m ft Ib 2 1 to 2 9 Master cylinder installation bolt kg m ft Ib 2 1 to 2 9 15 2 to Brake tube installation flare nut kg m ft lb 15 to 18 installation nut kg m ft Ib 17 to 2 0 3 to 12 5 14 Wheel cylinder installation bolt kg m ft lb 1 6 to 2 2 I 16 to 159 kg m ft Ib kg m ft lb 2 7 to 3 7 kg m ft Ib 4 6 to 6 1 kg m ft Ib 1 6 to 2 2 installation bolt kg m ft lb Hand brake lever installation bolt kg m ft Ib 10 to I 4 Rotor and hub installation bolt kg m ft lb 4 4 to 5 9 31 8 to 42 7 Brake pedal fulcrum pin 15 2 to 210 0 21 10 8 to 13 0 Brake hose and connector Brake warning switch installation bolt 32 0 31 to 3 18 2 to 0 44 Front brake disc installation bolt Caliper assembly installation bolt Rear brake adjuster installation bolt 5 to 26 8 19 33 3 to 11 6 to 1 44 15 9 Hand brake cable hanger strap TROUBLE pedal to 0 44 31 to 3 18 2 23 7 to 1 10 DIAGNOSES AND CORRECTIONS Troubles S pon8Y 32 0 Possible Remedies causes Air in brake lines Swollen hose due Bleed thoroughly to deterioration or use poor quality brake fluid BR 24 of Replace hose and bleed the system 7 68 BRAKE Use of a brake fluid boiling point of which is too low a promotes under slight pressure in master vacuum sucks in air through yields specified brake fluid and bleed system Reservoir filler cap vent hole clogged Pedal with the Change This cylinder that Clean reservoir filler and bleed cap the system rear seal Deteriorated check valve Fit External leaks Check master a new check valve and bleed the system cylinder piping and wheel cylinder for leaks and make necessary re pairs Master cylinder leaks through primary cap Excessive pedal System has not been bled Overhaul master cylinder Bleed the system travel Improperly adjusted clearance Adjust shoe Fluid level in master cylinder is too low Full up with to drum clearance specified brake fluid Bleed the system if required Thermal expansion of drums due to over Allow drums to cool off Check brake shoe linings and heating drums Replace damaged parts All brakes drag Insufficient shoe to drum Weak shoe return clearance Adjust clearance Replace springs the springs Brake shoe return no free travel Adjust pedal height Seized master Service cylinder pislon the replace the cylinder master piston and bleed the system One brake drags Loose or damaged wheel bearings broken Weak return or unhooked brake Adjust shoe or replace wheel bearings Replace spring springs Insufficient clearance between brake shoe Adjust brakes and drum Unbalanced brakes Grease or oil on Clean brake mechanism linings correct cause of grease replace lining or oil getting and on lining Seized piston in wheel Service cylinder the wheel cylinder and bleed the system Tires improperly Inflate tires to correct pressure inflated Adjust wheel bearing Loose wheel bearing BR 25 CHASSIS Front suspension Thoroughly faulty check and adjust all front sus pension components Excessive pressure pedal required poor brakes Grease mud or water on Remove linings squeak or Clean and dry Full area of linings not contacting drums Dust on drums or oil soiled Replace or shoes Reface drums and install new linings linings Remove and clean drums thoroughly Eliminate oil leak squeal Weak shoe return springs Check springs and Drum out of round Tum drums Worn inings Replace linings on replace as lathe SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE linings replace Scored brake drums Brake chatter drums or BULLETIN No SUBJECT PAGE No BR 26 required BRAKE SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or No PAGE No SUBJECT BR 27 CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE DATE JOURNAL BULLETIN or PAGE No No SUBJECT BR 2B SECTION WT WHEEL AND TIRE DATSUN 1200 MODEL B 110 SERIES BODY CHASSIS INI NI NISSAN MOTOR CO TOKYO II JAPAN LTD WHEEL AND TIRE WIt TROUBLE DIAGNOSES AN 0 CORRECTIONS WI3 WHEEL AND TIRE WHEEL AND TIRE CONTENTS DESCRIPTION WT PERIODICAL SERVICES WT 2 Tire rotation WT 2 3 WT INSPECTION Inflation of tires WT 2 Wheel balance 3 WT Redial tire WT 2 Wheel 3 WT DESCRIPTION TIRE SIZE in Standard 6 00 4PR I2 Optional 6 00 4PR 12 with tube 6 00 4PR I2 Snow tire 6 00S Tubeless Sports 4PR 12 155SR 12 Tubeless Radial with tube 5 00 4PRULT 12 with tube front 5 00 jPRULT I2 with tube except for Van lor TIRE INFLAnON PRESSURE To be measured when lira are cold Tire size Front Sedan 6 00 Coupe Rear 15 22 15 22 15 22 5 1 22 4PR 12 Wagon 018 26 Sedan Coupe 17 24 17 24 17 24 7 24 1 15 22 155 SR 12 Wagon 5 00 o 4 6PR 12 When the load is ROAD WHEEL SIZE in Van over 2 p ngen with 160 41 12 WT 18 26 02 8 40 kg 350 Ib lu kcm1 Poi rear Van use use CHASSIS Be PERIODICAL SERVICES sure 200 km wheel nuts after retighten to running 100 to 60 to 120 miles Inflation of tires Tires with proper pressure improve riding comfort and steering stability reduce driving sound to the minimum Radial tire and extend the service life When comparing to the The tires should be checked for proper pressure monthly basis or more frequently depending conditions while the tires Ordinarily are on tire pressure rises 10 to 15 accurately first find of that when a wheel constant keeping toein worn See are removed be sure ordinary to reinstall should tire air in the tire in case of a valve leak and excessively rapid tire wear causing Thus the front be carried out care a y and Do not radial tire differ from that of mingle radial tires with an When replacing an ordinary radial tire with a tire due to unavoidable reason use ordinary the valves without fail The valve caps assist in camber power Chapter FA Characteristics of out whether the tire is increase tire and or a1ignment correctly When measuring tire radial tire is lower and cornering power is higher and tire or vice vena When tire valve capo on a consequently hot or cold them of unevenly due to the tire temperature rise tire pressure driving cold the tire is cold during continuous driving under speed on ordinary ordinary an tires for front tires keep dust and water out of the valves When inflation pressure is too high the following Tire rotation troubles will result 1 1 Service life of a tire is indicated Hard ride tires 2 Bruised tire or damaged six immediately inside carcass are limit of 1 6 the tread worn 3 Poor traction at 4 Rapid tread wear at rear wheel resulting in uneven wear In inflation pressure is tuo low on mm with the tread by miles driven The indicator the tire circumference 0 06 in tread depth marks in which indicate When the tire is to the service life the tread wear indicator appean other words when the indicator appears the tire has reached its service life center of tire a When provided positions wear tire i Generally speaking service life of 40 000 km 24 000 miles following troubles will result 1 Tire squeal 2 Hard steering 3 Rapid and uneven 4 Bruised tire rim and various on turns TREAD WEAR INDICATOR 5 Tire cord fatigue wear on or tire tread TIRE TREAD edges types of rupture breakage 6 Tramp and shimmy troubles 7 Unusual tire temperature rise 8 Car roll while turning swerve Fig a comer or making a 2 When it spare tire nuts to a torque of Tread wear indicator sharp in traffic Tighten wheel WT 1 8 0 to 9 0 kg m 58 the tire to 65 ft Ib is intended to use five tires evenly conduct tire shifting order shown in Figure the WT 2 whenever the vehicle is driven 10 000 km 6 000 miles WT 2 including rotation in accordance With WHEEL AND TIRE Check the flange of rim for deformation 2 RIGHT FRONT damage RIGHT REAR dition Yt 3 Deformed and damaged rim will Thoroughly remove rust rubber cause particles air wire brush emery paper and with a LEFT REAR 4 Remove small 5 WT 2 Tire rotation wear leakage mud or pieces of gravel glass nail and other matters from tire tread noticeably When the tire side wall is cracked indicator is exposed replace the tire with or pennissible 35 0 oz unbalance of wheel and tire assembly or 165 less In at the rim circumference oz Balance weights oz Nota no 2 29 event should heavier balance weight be attached or 47 2 cm gr are to sure a to or 35 0 27 4 the wheel 35 0 to interval oz install balance less 70 gr available from 10 to 70 gr with every 10 gr Be inz weight on the flange of inside rim Wheel 1 When the horizontal in Figure axes wheel at the deflections toward vertical and points indicated by the asterisk WT 3 are 1 0 rom 0 04 in or more replace 0 the wheel Fig WT 3 Wheel rim out run check points TROUBLE DIAGNOSES AND CORRECTIONS Possible Troubles Wheel wobbles Remedies causes Improper tire pressure Measure and adjust correctly Damaged tire or distorted wheel rim Repair or replace Unbalanced wheel Balance correctly Loose wheel nuts Retighten WT3 tread a new Wheel balance The sand cloth INSPECTION is 10 gr con I foreign Fig and and other foreign matters from the flange of rim if any J LEFT FRONT tear of welded unit crack other defective one CHASSIS Worn or damaged wheel bearing play ofwheel or excessive damaged Excessive Correct play or replace bearing front wheel alignment Improper Worn or Adjust ball joint and link bushing linkage play steering or worn Replace Adjust replace or steering linkage Loose steering linkage connection Retighten the torque Unevenly or or nuts with the rated replace worn Broken IUSpension spring Replace Defective shock absorber Replace Improper Conduct lire rotation tire rotation excessively worn Standard tightening parts if any periodically every 10 000 km 6 000 miles tire Improper tire pressure Measure and Unbalanced wheel Balance Improperly adjusted brake diitorted or replace Readjust correctly Improper wheel alignment Excessively or adjust correctly Realign improperly installed Repair correctly suspension link reinstall correctly High speed Reduce on curves Sudden start and improper rapid acceleration or speeding due to or replace if squeals Improper Follow correct and proper driving improper brake appli Improper lire pressure Measure and front wheel alignment Distorted knuckle or adjust correctly Realign correctly suspension link Repair or replace if necessary SERVICE JOURNAL OR BULLETIN REFERENCE DATE JOURNAL BULLETIN or No PAGE No SUBJECT 4 WT or speed cation Tire necessary manner WHEEL AND TIRE SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE or BULLETIN No PAGE No SUBJECT WT 5 CHASSIS SERVICE JOURNAL OR BUllETIN REFERENCE JOURNAL DATE or BULLETIN No PAGE No SUBJECT WT 6 SECTION ST STEERING DATSUN 1200 MODEL B 110 SERIES CHASSIS INI BODY I NISSAN MOTOR CO TOKYO JAPAN CD LTD DESCRIPTION ST t STEERING ST t COLLAPSIBLE STEERING ST 1 STEERING LINKAGE ST t3 SERVICE DATA AND SPECIFICATIONS ST l1 TROUBLE DIAGNOSES AND CORRECTIONS ST 18 STEERING DESCRIPTION The steering system consists of recirculating ball type as required The gear box and parallelogram linkage These systems give good response utmost with equipped a the Moreover durability torsion light handling and steering rubber system idler linkage arm bearing is system and are described greased km 30 procedures in the replenish recormnended up with wheel 000 miles for the steering lock ELECTRICAL BODY SECTION of this manual and therefore of gear box should be checked every 10 000 km 6 000 mile should be grease every 50 000 All necessary service which absorbs shock from the wheel The lubricant steering linkage no instruction is given here oil STEERING CONTENTS REMOVAL ST 2 INSPECTION DISASSEMBLY ST 3 ASSEMBL Y ST 4 INSTALLATION Ball nut assembly I 2 3 Steering gear housing Shaft steering sector Screw adjusting roller shaft AND REPAIR AND ADJUSTMENT 4 Cover ectOt shaft 7 5 Shim 8 6 Fig bearing Comp jacket column ST l worm Steering gear components ST 1 4 ST 9 ST 5 ST 7 colAssemblumny steering Assembly bearing steering Assembly nut ball worm CHASSIS Fig ST 2 Steering REMOVAL wheel 3 Remove the turn signal and lighting switch com pletely 1 Remove the horn ring and remove the steering wheel 4 nut rod 5 Remove Note 2 ST 3 Removing steering wheel lock lever assembly from the control assembly by unscrewing the fixing bolts Remove two column Fig the hand to fixing bolts used the instrument to secure the steering panel nut The horn ring can be easily removed by tow bolts Remove the steering column shell Fig ST 2 ST 4 Removing steering column upper side STEERING 6 Remove six bolts used to secure the steering DISASSEMBLY column hole cover to the dash board Remove the I the gear I X I I j gear arm the of by use fIxing nut and Steering Gear a pull out Arm Puller ST27 I 40000 2 I arm steering Remove the drain steering 3 1 10i i gear from the housing Loosen the shaft adjusting the and drain the oil plug adjusting screw a screw nut and turn the sector few turns counterclockwise Remove four sector sector shaft cover shaft cover fIxing bolts and pull with sector shaft from the gear housing 1lJ1Il Fig 7 ST 5 Removing steering column hole cover Remove the shift rod and select rod from the lever and select lever after removing the cotter change pin from the trunnion 8 Disconnect the gear 9 Remove three bolts housing to the arm from the used to cross secure rod the steering gear body Fig 4 Remove four to the gear assembly Fig 10 Pull Removing flXing housing and from the gear sector cover the column jacket out the main column jacket bolts pull shaft securing housing Removing steering geaT assembly ST6 the ST 7 steering gear and transmission control toward the engine compartment II gear Remove the transmission control from the steering assembly as outlined under Fig Transmission control ST 3 ST 8 Removing main column CHASSIS Note Be careful not to a11 the ball nut running d Asoembly and adjustment n to either ond of the worm lbo ends of the ball I lJIides will be until ro stopped I Asoemble the ball nut on the if the nut is oDc I w to the end of the worm at 2 5 Pull the colunm out with the ball 19 baIls into each of two holes on the same Drop side of ball nut mbly from the column Tum the column jacket gradually away from the hole filled Continue until all 38 balls 6 worm guide hole up are being installed Remove the sector shaft oil seal Note In cases where the balls are stopped by the column hold down those baIls the end of already dropped into the ball nut with the blunt end of a direction 7 Take out the jacket by rear outer race from the column bearing The the use of a puller 9 worm races from the front and end holding tho balls down first in one hole then n the balls solidly bearing Place tubes If the rtt the colunm to and fill the circuit completely and 3 Ball nut rod d tho rev of the circuit can then be continued It the other to close up the bearings Remove the colum shaft in column few turns may be Take out the bearing inner rear a filling forth 8 end turn the punch or 22 baIls remarmng in halves of ball guide II each of two halves assembly ball nut assembly recommend the colunm or assembly column to be is 4 defective replaced assembly and adjustment of the column assembly because this half of guide tube with the other half with vaseline are so together and plug each open end that balls will not very drop out while installing difficult However Close Hold the two halves for your reference and adjustment are descnbed as disassembly assembly 5 foUows 6 Disassembly I Remove the clamp Push the guide tubes into the guide holes of the ball nut of the baU guide Assemble the ball guide tube clamp to the ball nut tube and withdraw the ball guide tube out of ball nut 2 Turn the nut upside down and rotate the column back and forth until all 38 balls are nut With the balls removed dropped the nut can INSPECTION AND REPAIR out of ball be puUed Measure axial clearance between the steel balls and 1 endwise off the column ball nut and 0 0031 in Note Bo careful not to 10 the bolls and moke su if the clearance is replace the parts as a more than 0 08 complete rom unit that 2 total number of balls is 60 balls 7 12 in dia l Inspect wear or 3 Inspection as gear teeth of sector shaft and ball nut for damage Ifthere Inspect bearings is any for sign of damage replace wear or chip Replace bearings required Check ball guide tubes for damage at the ends where they pick up the baIls from the helical path Replace 4 guide tubes if damaged wear ST 4 Inspect the serration of sector shaft and column for STEERING ASSEMBLY AND JUSTMENT AD Tightening torque 1 7 ro 2 8kg Standard shim 0 5mm Tightening torque 12 3 ro 20 2 m lbl ft 0 0197 in 1 7 to 2 8 kg Tightening torque 2 0 m to 3 0 14 5 to 12 3 ro 20 2 ft Ib kg m 217 ft Ibl Clearance of adjusting screw to secter shaft 0 05 mm 0 0020 in Apply grease here when assembling Pitman arm Tightening torque 14kg m 101 ft Ib ST 9 Fig I Sectional view Press in oil seal into the housing Note Apply chassis grease to the of steering gear fIxing oil 1 lip bolts Tightening torque before is 7 to 2 8 kg 1 m 3 to 20 2 12 ft Ib assembling 2 Insert the column assembly into the column completely and install rhem with worm to the gear housing by the 3 jacket bearing shims use sary If replacement of column bearing a new ST 5 is nece bearing assembly should be fIlled with bearing grease and then cemented to the column of four flange assembly CHASSIS 4 Adjust the preload the thickness of the to 0 20 mm to bearing of the steering bearing by selecting shim J ST 10 Apply torque oil shim is 2 0 to 5 0 kg m 48130 66000 1 515 to 1 535 4813166000 545 1 48132 66000 575 1 mm in 0 0596 to 0 0604 565 to 1 0 0608 to 0 0616 595 1 0 0620 to 0 0628 to 48133 66000 1 605 to 1 625 0 0632 to 0 0640 48134 66000 1 635 to 1655 0 0644 to 0 0652 Measuring initidl turning torqJAe on the wonn wheel in motion 3 5 to 8 8 screw Thickness Part number that the initial so whee Adjusting lfive kinds 0 05 69 4 inz without sector shaft Fig Note worm worm 0 0020 to 00079 in turning torque 27 8 of the oz at bearings The turning should be 100 to 250 If 20 em 7 874 in of steering wheel A to the standard number bearing shims refto the following Fig radius ofthe Checking ST 11 lash adjuster end clearance worm 6 table Assemble the sector shaft into the gear housing Rotate 1 worm column by hand until baU nut is in the center of its travel so that the center tooth of sector shaft Worm enters into the center tooth space ofbaU nut bearing shim Thickness Part number mm 2 in With cover 0 05 0 0020 48031 18000 0 07 48033 18000 0 08 00031 gasket in push the place After making sure sector shaft that there is some lash between the rack and sector teeth tighten side 0 0028 48032 18000 new with sector shaft in place Tightening torque is cover I 7 to 2 8 bolts 3 12 kg m 20 2 to ft Ib 0 0039 10 0 48034 18000 Note Apply oil on the sector shaft 0 20 0 0079 48035 18000 3 Lock the adjust screw with the adjusting screw nut temporarily 4 5 Sector shaft lash adjuster end clearance Assemble lash adjuster 0 05 rom To obtain this clearance are of the gear with shimin the slot of the sector shaft end Measure clearance 0 0020 Move the sector shaft for several times from the side 5 in five various thickness shims arm and make Connect the gear fitting the gear ann sure arm it turns to the sector shaft the aligning marks and sector shaft should be matched available 51 6 smoothly on correctly Whtn the gear arm STEERING 6 the the backlash at the neutral Adjust adjusting top end screw so radius 127 00039 in that the mm point by screwing movement 5 00 in of the gear is within 0 1 7 Fill oil gear MPS arm US pts 0405 UK pts rom and install a 90 into about 0 23 liter 0 486 assembly through filler hole filler plug and lock temporarily by the nut INSTALLATION Installation removal Pay can be accomplished attention to the in the reverse order of following points I Make 2 Check the alignment of the steering wheel 3 Free travel of steering wheel should be 20 to 25 rom sure that the steering wheel moves smootWy 0 787 to 0 984 in Fig Fig ST 12 ST 13 u C cltitrgb 1dd Adjusting 1sh backlash COLLAPSIBLE STEERING CONTENTS DESCRIPTION ST 8 COLUMN BEARING ST 12 STEERING COLUMN ST 9 DISASSEMBLY ST 12 JACKET ST 10 INSPECTION ST 12 ST 11 REASSEMBL Y ST 13 TUBE STEERING POST CLAMP ST 7 CHASSIS I I Cl o Fig ST 14 CoUapsibk steering DESCRIPTION This column is designed to be impact When an compressed under an cY automobile is being driven the forward split movements of the automobile and the driver constitute a form of energy in a on head or force ment of the car forward is suddenly halted while the this energy is also severe collision generally involves these two forces continues in the forward direction secondary impact When the A column occurs collapsible susceptible no more however column is installed in to to damage and column column is removed from the blow and column is designed to absorb primary required on leaning forces to the extent that the severity of the secondary secondary impact is reduced thereby reducing is the end on than is a an when the column is removed care collapsible partially absorbed contraction characteristics of the column when the driver thrusts forward onto the steering wheel The the secondary the driver The by compartment A s move force primary and secondary rearward into the driver move second later when the driver is thrown forward secondary impact When the automobile is involved collision the primary force to in handling the assembly car the column assembly or or ly the ST 8 the sharp shift levers dropping bellows part which absorbs the energy special as a assembly could bend the steering column jacket the tenden it is ordinary When such actions of the steering shaft car of the especial STEERING 7 CiJ f e e o 1 Lower column shaft 5 Plastic 2 Upper column shaft 6 Column collar 3 Lower column tllbe 7 Column 4 Jacket tube Fig ST 15 pin bush 8 Washer 9 Snap link Steering post clamp 10 Collapsible steering STEERING COLUMN 8 Lower column shaft Plastic 3 Upper column shaft pin Fig ST 16 Steering column ST 9 Lower column tube CHASSIS The construction of the steering column is the as such that lower shaft is fitted into the upper tube when a C compressing force is applied to the lower shaft Steering torque upper tube is transmitted by the lower shaft and The lower shaft adopts circle with two straight cut edges interior is toward special shape a a and the upper tube tightly fitted against the lower shaft exterior the entire area In addition four plastic pins completely eliminate gap between the lower shaft exterior and upper tube interior When a compressing force applied is described plastic pins are into the upper tube When the lower shaft is into the upper tube Jacket tube 3 Shaft 4 the shaft end spreads an once stopper Column coUar Column shaft above Fig cut and the lower shaft is fitted shaft cannot be withdrawn unless is the I 2 ST 17 Shaft ppeT ste fitted Moreover and the lower for reaIW3rd lunm shaft projection collar for steering lock installed extremely high load in three stoppe applied the column shaft places fitting on on the shaft runs the against the jacket tube which allows and thus rearward projection is preven ted NotB In no event should an impact or applied largo The power be to the shaft with a hammer or other matter during disassembly or column shaft lower end supported respectively by two column bushing reassembly JACKET TUBE D CI o Mesh tube Fig ST 18 Jacket ST 10 Jacket tube tube and worm upper end are bearings and a STEERING The is of a mesh jacket tube in rhombus forming an a part of which is of the absorbing part energy that punched function Upper and lower guide tubes poly acetal energy smoothly collapsible steering with an resin are two guide tubes joined inserted into the mesh tube as as a jacket so possible guide and collapsed generated by with a collision can low load be absorbed The for mesh tube while the mesh tube is improve bending rigidity of the tube STEERING POST CLAMP o Plastic 12 Clamp pin Fig The steering post clamp is secured are set stationarily block Steering post clamp the jacket tube on with bolt 08110 81210 and in addition sliding blocks ST 19 2 Sliding two aluminum on the main body with plastic pins Note For the bolt used to install the on the iacket exceeding steering post clamp tube do not use bolt the rated length or Steering post clamp 8 to 1 0 0 as length a trouble follows Jacket tube m 5 8 to 72 it Ibl kg Sing post clamp 1 5 to 1 8 are a otherwise the bolt interferes the column shaft causing Tightening torquas having klt m Steering post 10 8 to bracket 0 it Ibl 13 Fig ST 11 as guide tubes ST 20 Steeriorg post clamp bolts entire CHASSIS The block sliding supported on secured the bracket is installed clamp is on the steering post the half of upper steering column is bracket with bolts on the and thus the Construction of the column shaft upper such that both radial and thrust forces steering post a plastic pins large impact are cut is applied from the disengaged and with this construction and adjust the sector shaft Inspect adjust steering post clamp sliding block does bushing ring from the upper surface of Thereafter general instructions for ordinary steering apply screw unit in accordance front direction of the rearward This construction is called system is the snap remove the column off and leaving the sliding block in the For any force applied from move absorbed DISASSEMBLY the driver side the steering post bracket side the clamp proper downward together with the jacket tube vehicle is as body First When are bearing worm with the worm bearing and other instructions for ball nut unit relative parts ordinary type steering not INSPECTION One way slide projection of the the parts such as column shaft Inspect column shaft toward the driver is prevented completely which following COLUMN BEARING 1 2 used 3re to jacket tube etc absorb energy in accordance with the instructions Check the column shaft plastic pin for breakdown Check the steering lock collar for warping and screw for breakdqwn 3 Measure total length of the jacket tube Replace contracted However when tube collapse is within 3 STEERING 0 1181 in adjustment by WHEEL SIDE of bushing means is if rom also possible 4 t 0 tube 1 2 Washer 3 Snap ring 4 Column bush 5 Column shaft Check heck the column shaft for bending When the A and B portions Fig Column 10 mm bearing JG A steering post clamp sliding block for tightness 5 ST 21 the f t are supported the 0 0394 in at the C 1 B bending should be less than portion tEflEB lL 5 019691 C UNIT Fig ST 22 Measurement of defective of column shaft ST 12 mm in STEERING REASSEMBLY I and install the Adjust alignment jacket tube on the worm shaft and housing 4 0 1575 j 2 Apply bearing grease screw 3 the column Apply bushing washer to the interior sufficiently above the rated 27 5 dia and position and apply the snap ring to the groove correctly and securely UNIT Fig Return the column bushing 4 1083 allowing mm in ST 23 the top surface of the bushing coming into contact with the lower surface of the washer 0 0394 in adjust and the clearance adjust that column shaft to less than 1 0 rom the bushing position correctly turning torque Note Be careful so bushing is the rated value not to crack the tube while If the clearance is too small the steering 6 becomes When caulking column bushing improper after caulking heavy the following shim the Une up the outer two When and that of the column bushing symmetrical positions caulked securely diameter of the dia tube upper end to the groove circumference securely caulk ference jacket jacket tube is make 5 27 length of caulking is 4 on is position is found adjust by or the to use be of s Thickness rom 48932 HI 020 0 05 0 0020 48932 H102l 0 10 in and the circum sure that inner dia 1 083 in rom mrn on jacket tube 1 252 in dia l recaulk Part number 5 defonn the when caulked Morenv make sure that outer diameter of the less than 31 8 mmdia Note or 7 Install the sector shaft adjust in the 0 1575 in manner identical to 0 0039 screw and side cover ordinary steering STEERING LINKAGE CONTENTS REMOVAL ST 14 I NST ALLATION ST 16 DISASSEMBLY ST 14 ACCIDENT st 16 INSPECTION AND REPAIR ST 15 ADJUSTMENT ASSEMBLY ST 15 ST 13 COLLISION ST 16 CHASSIS 1 Steering 2 Pitman gear arm 3 Side rod 5 Idler 4 Cross rod 6 Knuckle Fig ST 24 2 Loosen clamp bolts and Jack up front of the vehicle and support with stands 2 Remove cotter 3 pins and castellated nuts which are arms 3 by backing up boss with a large a 4 the socket Remove the idler arm Remove the baIl studs of cross rod from the gear in step 3 assembly under the same procedure The cross rod and side rods as arm described be removed as Remove the idler assembly from the side member by can assembly taking off two fIXing bolts DISASSEMBLY 1 the Q Disconnect both side rods from the same procedure as described in cross Seal lip wembly TI Bush rod under Removal Fig ST 14 assembly nut and disassemble the idler hammer and idler 5 unscrew the socket from the side rods hammer and striking the opposite side with an remove assembly used to fasten side rod ball studs to knuckle Free the ball studs from knuckle arms ann Steering linkage REMOVAL I arm ST 25 Sectional rMw of idkr arm STEERING INSPECTION AND REPAIR 1 Check the idler rubber bushing for damage wear and play and replace bushing if necessary 2 Check the cross rod and side rods for damage bend and crack and replace them if necessary 3 Check each baIl joints for play due action of the push spring or a to lack of spring damaged ball stud 1 Ball stud 3 2 DustcOYer 4 ST 27 Sectional view fig If any abnormal condition complete 1 Ball stud 2 Dust Clamp Spring cover unit ST 26 Secrional can accomplished be to the r 0 I l jJP 7c C t i rl irf D I J Fig replace as a l Y GT c in the reverse order of j I I I k J W t i 1 t L W 7 c ii s C 1 I 1 r jJ o rod following points I tt s cross is detected C II stud not be disassembled disassembly Pay attention side rod VU W of ball stud ofbaU seat ASSEMBLY seat Assembly Fig They can Clamp Spring rJ r J 7 ST 28 Fronl bottom view 1 of sleering linkage ST 15 1 l l on vehick 1 CHASSIS The 1 foliowing tightening torque of nuts shall be 3 adopted steering system and check it for sliding noise Ball stud nut 30 Gear Idler 5 0 kg m to arm 14 kg lb ft 101 m arm 4 Check the operation for smoothness 5 Check the side rod and 6 Check the gear 7 Check the gear housing tightening bolt for slackness 21 7 to 36 2ft lb cross rod for nut nut 5 7 to 2 the Operate 3 kg 6 Assembly of 2 to 45 6 ft Ib 41 m the idler assembly is arm bending for crack and installation boss for crack accomplished 8 Check the sector shaft serration for twisting as follows 9 I Apply soap outer circumference of water on the bushing Press the bushing into the idler bushing protrudes equally 2 Fit idler the Keep arm body idler arm at arm carefully until Check the sector gear for crack 10 Check the ball 11 Check the screw for pitting the column shaft for bending crack and sliding scar the both sides in the rubber 12 Check the jacket tube for 13 Check bending bushing center line in parallel with the the steering post clamp for existance of column offset chassis center line I4 Check the side member gear housing installation unit for deformation INSTALLATION Installation can be Pay attention removal to the 15 Check in the reverse order of accomplished the installed following points portion of the steering post bracket on the steering post clamp for correct installation I Set the length of both side rods to 296 8 in rom 1169 It should be done between the baIl stud centers Check wheel alingment and if necessary adjust it 2 JUSTMENT AD I ACCIDENT COLLISION When accident vehicle collision especially inspection its front occurs is in accordance with the the Inspect because it is a steering very system important The section unfortunately and the unit damaged following 2 of toe in adjustment is outlined in FRONT AXLE AND FRONT SUSPENSION Steering angle Under the specified load stopper bolt of the knuckle driving has I procedure conduct instruction particularly carefully unit for Toe in an angle 4 passengers arm so adjust the that the inner wheel of 430 Check both side steering angles for correct balance 2 With the tires positioned steering wheel bar for correct at neutral check the Note Specified steering angle of wheel is 43 for inner wheel and position ST 16 3605 for outer wheel STEERING SERVICE DATA AND SPECIFICATIONS Type Recirculating ball type Gear ratio 15 0 I 400 157 0 23 0 486 0 405 Steering wheel diameter mm Oil t US ptsUK pts capacity Steering angle in inner wheel outer 43 wheel 360 Play steering wheel mm in mm in 20 to 25 0 787 to 0 984 Standard thickness of worm bearing shims 5 0 0 0197 Initial turning torque of column assembly kgm Clearance of adjusting screw T 27 8 to 69 4 to sector shaft in mm Length of side 2 0 to 5 0 oz in rod 0 in mm 05 0 0020 296 8 1169 5 21 7 to 25 3 3 teningtorque Steering wheel lock nut kg m ft lb 3 0 to kg m ft lb 0 8 to 1 0 5 8 to 7 2 kg m ft lb 5 to 18 10 8 to 13 1 kg m ft Ib 0 8 to 1 0 5 8 to 7 2 Column to gear housing bolts kg m ft Ib 17 to 2 8 12 3 to 20 2 Side kg m ft Ib 7 to 2 8 1 3 to 20 2 12 kg m ft Ib 2 0 to 3 0 5 to 21 7 14 kg m ft Ib 14 kg m ft Ib 19 to 2 6 kg m ft Ib 5 7 to kg m ft lb 19 to 2 6 13 7 to 18 8 Ball stud nuts kg m ft Ib 3 0 to 5 0 Side rod bar lock nuts kg m ft Ib 8 0 to 10 0 57 8 to Steering post clamp to steering post bracket bolts Collapsible Steering column cover Adjusting hole cover bolts to gear screw Sector shaft to Gear housing housing bolts lock nut pitman to arm nut 101 side main bar bolts and nuts Idler arm nut Idler arm to side main bar bolts and nuts ST 17 13 7 to 18 8 3 412 to 45 6 6 7 to 36 2 21 3 72 CHASSIS TROUBLE DIAGNOSES AND CORRECTIONS Troubles Heavy steering Possible Remedies causes Low tire pressure Inflate tires to recommended pressure Incorrect front wheel alignment Adjust Lack oflubrications Lubricate steering gear and ball joints to replace Firm sticking of the ball joint and strut specifications worn or ball joint Replace bearing and damage of steering Improper adjustment gear Loose steering Adjust housing Hard locking ofcolumn bearing Lubricate with bearing grease Incorrect front wheel bearing adjustment Adjust Loose steering linkage connections Inspect or tighten Pull to one side to instructions replace according or replace replace as required Loose steering gear housing mounting Tighten mounting bolts Incorrect Adjust according adjustment of adjust nut to if any parts worn nuts to recommended torque to proper torque instructions Incorrect tire pressure Inflate to recommended pressure Incorrect front wheel alignment Inspect Incorrect front wheel bearing adjustment Adjust bearings according to Unequal brake adjustment Adjust brakes Weak f ont suspension units Replace Deformation or improper fitting of sus and and correct front wheel alignment Check correct or instructions replace pension Steering shock Incorrect front wheel Loose front wheel alignment Inspect bearings Inspect verse link tighten adjustment of ball nut Adjust replace worn parts if any out of balance steering Inspect and 5T 18 and nuts to proper torque gear according structions Wheels alignment Adjust bearings Loose steering linkage connection and trans Incorrect and correct front wheel correct wheel balance to in SECTION FE ENGINE CONTROL FUEL EXHAUST SYSTEM DATSUN 1200 MODEL B 110 SERIES CHASSIS INI BODY I NISSAN MOTOR CO TOKYO JAPAN LTD t ENGINE CONTROL SYSTEM FE FUEL AND EXHAUST PIPINGS FE 3 ENGINE CONTROL EXHAUST SYSTEM FUEL ENGINE CONTROL SYSTEM CONTENTS ACCELERATOR FE 1 CONTROL FE 2 Adjustment FE 2 Description ACCELERATOR CONTROL e3 I EJ3 I 1 Accelerator pedal 3 Wire outer case 5 Pedal stopper 2 Accelerator arm 4 Inner wire 6 Return Fig FE 1 Accelerator control syst m for spring R H drive L 4 7 1 Accelerator pedal 3 Wire outer 2 Accelerator arm 4 Inner wire Fig case FE 2 Accelerator control FE 1 system for L H 5 Pedal 6 Return drive stopper spring CHASSIS Description The accelerator is that such linkage the is lightweight and construction linkage operates o to 1 is and smoothly mm 0 to 0 0394 inl unaffected by engine vibration Adjustment Play ohceelerator wire I Install the pedal arm side securely with spring a clamp Fig FE 4 Adjusting pedal stopper height 4t 2 a Set the board dash side outer case hand steering stationarily with cap nut Do not set the carburetor side adjusting unit stationariJy T 3 Pull up the carburetor side socket toward direction up to such about to move an extent that the throttle lever is pull down the socket 0 0394 to 0 0590 in Otolmm 0 to 0 0394 in P I to 5 1 mm from that position toward direction and set the socket stationariJy with a Q clamp Lock nut Stopper bolt 3 Accelerator pedal THROTTLE LEVER Fig FE 5 Q Note QClamp I Socket a Do not bend the accelerator b AdiuS Fig Adjusring play of accelerator ire that the throttle lever reverse Apply chassis grease No O or 1 to the sliding fully For model with automatic transmission the pedal to such an extent is opens adjmt stopPer bolt side and stopper bolt head T and secure the is 0 to I rom equipped with kick down switch striker This is arm only difference with the standard model that clearance between the accelerator pedal to 0 0394 in and stopper bolt Model with automatic transmission Depress the accelerator pedal down so play pan of pedal bracket Pedal stopper height accelerator wire pedal orrec c height tly c FEJ Adjusting pedal stopper height right hand sreering Note 0 stopper bolt with lock Note that the kick down switch should not come into nut contact with the pedal accelerator pedal is depressed FE 2 arm striker when the ENGINE CONTROL EXHAUST SYSTEM FUEL R H drive Pedal free KICK DOWN SWITCH play mm in 2 mm in 48 STRIKER Pedal stroke 0 0787 1 890 LH drive 2 50 0 0787 1969 Pedal depressing force when fully 3 8 open kg 4 8 3 3 3 7 lb FE 6 Fig FUEL AND EXHAUST PIPINGS CONTENTS EXHAUST PIPE AND MUFFLER Description FE 3 FUEL TANK 4 FE Description AND PIPINGS 4 FE FE 5 Replacement Precautions for removal and I nspection and FE 4 installation EXHAUST PIPE AND MUFFLER e L v 4 9 Fig FE 7 Exhaust system FE 3 4 FE repair 8 FE CHASSIS Precautions for removal Description For all models sedan wagon and coupe the exhaust system uses pre muffler single a tube front without the using The main muffler is installed beneath the and instaIJation rear seat floor in the left side 1 When there is and floor or no propeller clearance shaft line of tube in the manifold between the front tube turn the tube connecting along center unit and obtain a proper clearance The front component parts tube coupled unit is a separated mainly muffler with and with are clip suspended rear tube and into the they 2 are 60 mm 362 2 approximately in at the muffler inlet The muffler main from the body with hanger bracket and rubber ring and the Muffler front tube inserting depth is rear tube is suspended from 3 the floor ring When suspending line up the hunger of the muffler main against the bracket with strap FUEL TANK AND PIPING Description Fig lJ Fuel system FE 4 FE the muffler main unit with rubber in the body side unit straight EXHAUST SYSTEM ENGINE CONTROL FUEL For all models fuel tank the to response capacity Location and increased engine output mounting strength for improvement of improved are and completely drain fuel has been increased in safety Sedan 40L Wagon 38 L Coupe 38 L 10 gal Imp gal 57 US 8 81 10 04 US Also for safety To 8 37 10 has been the fuel line is protected interferences from road fuel line is laid inside the a rear from In the front tunnel 3 Remove the 4 Remove four bolts used to secure the fuel tank 5 Loosen the hose clamp luggage compartment finishing gal on the coming out given the fuel line specifically from the fuel tank is laid inside the that 04 US Remove the fuel line connector 8 37 Imp gal piping consideration be more gal Imp gal 2 si6e member so gravel and other floor section the and thus fuel line reaches engine compartment In addition the fuel strainer and fuel tank outlet units connect the fuel line with rubber hoses sections bandy tube is and for all other used Fig Replacement Remove the drain plug from the fuel tank bottom Fig plug position 6 Disconnect cable to the unit gauge 7 Dismount the fuel tank FE l0 Fuel tank unit installation FE 5 FE 9 Drain CHASSIS AIR VENTILATION TUBE AIR BREATHER TUBE FIg FE ll u andtu be installations nO VAN SERIES FIg FE12 Fuel mk t FE 6 Un t installation ENGINE CONTROL SEE ARROW FUEL EXHAUST SYSTEM A AIR VENTILATION TUBE Fig FE1J Hose i1Ut4lJations COUPE Fig FE 14 Fel tank FE 7 nit installation CHASSIS I FILLER HOSE Fig and Inspection I repair Check the fuel line for leaking repair Note or replace a When gasoline b as FE 15 Hose installations or other damage and required sold ing is required be sure that no is remained When deaning fuel tank inside use gasoline Do not use water 2 The gauge unit the gauge unit a adopts a bayonet system and thus can be removed and reinstalled simply with screwdriver Fig FE a FE 16 Gauge unit FUEL ENGINE CONTROL EXHAUST SYSTEM VAN ONLY j o e v Fig L e FE 17 Fuel tank unit gauge installation SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE or PAGE BULLETIN No SUBJECT No FE 9 CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE or BULLETIN No PAGE No SUBJECT FE lO SECTI ON BF BODY DATSUN 1200 MODEL B 110 SERIES BODY CHASSIS I NISSAN I NISSAN MOTOR CO TOKYO JAPAN LTD GENERAL DESCRIPTION BF t UNDER BODY ALIGNMENT BF 9 HOOD BF 14 FRONT FENDER AND FRONT END BF t6 TRUNK LID AND REAR BUMPER BF 1 B DOORS BF WINDSHIELD AND REAR WINDOW BF 30 VENTILATOR BF 32 SEAT BF 33 INSTRUMENT PANEL BF 36 ROOM TRIM BF 31 23CD BODY GENERAL DESCRIPTION CONTENTS DESCRIPTION BF 1 BODY CONSTRUCTION AND CROSS SECTIONAL VIEW BF 1 DESCRIPTION The body individual adopt a construction body box is of an unit type The rearward collision absorbing which energy generated from the collision require high strength improving torsional rigidity and components section cross an There the highly rigid structural components are joined under special connecting construction which reduces centralizing coupe are three types of and station wagon section is used body or van construction however sedan the front commonly ohtre Particularly for protection of passenger from side BODY CONSTRUCTION AND collision side section ofthe body is constructed with side member having box and the front and that they are crosssection rear side memben deformed in CROSS SECTIONAL VIEW improving the rigidity are so constructed the event of forward BF 1 Body Seat belt anchorage indicating constTuction 4 door sedan BF 1 crOSHectional body construction sealing points are indicated or t Fig The as follows one side only views and BODY t Fig BF 2 Body Seat belt anchorage indicating one side only construction 2 door seddn Seat belt anchorage indicating both sides Fig Fig BF 4 BF 3 Body Body construction coupe construction station wagon BF 2 or van BODY SEDAN G B H cH C N A 7 A A F F Q J2 DETAILS OF PORTION 4 DOOR Roof 11 Inner 12 3 Cowl top Hood 13 Rear floor Rear fender 4 Lower dash 14 Brace S Front IS 6 Front fender Side dash booud 16 Inner rear pillar Air box panel 11 Outer sill 18 Inner wheel house 19 Outer wheel hQuse BF 5 Cross floor Inner center 9 InnerdOO I sectional BF 3 board 8 10 Fig roof rail 1 2 1 L G vie Outer door I pillar BODY K K lL N N M M J 0 0 SEALING ON CIRCUMFERNCE OF REAR flOOR DETAilS OF PORTION h 1 Rear floor 2 Rear 3 Lugage compartment floor 9 R Seat blCk support Inner lock pillar 11 Lock pillar 12 Roof 13 Rear waist 5 Front pillar Front fender 14 6 Outer door 1S Lugage compartment lid Rear panel 7 Fuel filler cover 16 Outer wheel house 8 Shock absorber mount bracket 4 BF 6 C DETAILS OF PORTION 10 rear Fig cr oss fender side secticmal iew II BF 4 BODY T 2 T V V V V COUPE DETAILS OF PORTION B A A D D DETAILS OF T PORTIONE Fig BF 7 Cross I Roof 6 2 1 Front reDder Inna wheel house 3 Inneuide body Rear fender 8 Rear floor 4 Outer door 9 Innu Iodi S Front pillar 10 sectional BF 5 vieIII pillar Lockpillar 1 BODY STATION WAGON OR VAN A C C 7 4 SEALING ON CIRCUMFERENCE 9 OF REAR FLOOR D D Fig BF 8 Cross sectional view IV BF 6 I Roof 2 Reu 3 SeaIin 4 Rear floor S Side leU fender Sttltion wagon SCIOen Door or van 6 Inner side body 7 Outer back door 8 Inner back door 9 Tail 10 member cross Reupane1 BODY Water drain holes figure Be sure to are located provide all as shown in the following water drain holes grommets with 1 to 6 7 to BF 9 Location of water drain hole hole 14 15 Drain hole cover BF l0 Location oflwater drain hole plug sedan 1 t04 5 6 to 11 12 Fig Rubber plug SClt belt anchorage hole plug Inspection Drain plug 13 Fig 12 Rubber plug Seat belt anchorage hole plug Drain hole cOYer coupe Rubber plug Seat belt anchorage hole plug Fig BF l1 Location of water drain hok BF 7 station wagon or van BODY CD CID CD 4 i @Roof CID Roof drip moulding clip CD Window drip moulding reS5 downward after king moulding op a Windshit1d side Windshield r rnoukJing J moulding Inserted For all four corners Dry U @Body sill moulding l Door cover rubber Nut Used rear in @Radiator one grille shroud Sill @Door Radiator at front and ends two uch side anty outer moulding clip moulding grille shrcul A clip J c Used et four paces except for both ends r each per door Three IUch in one aide xC8pt for front and rur ends Door Radiator upper VRadiator outer panel Clip is assernbMd on the moulding @Rear fendor moulding grille grille side shroud Four are IIch moukling clips used for one This j as a Fig BF 12 Moulding BF 8 insra 14tion side clip also functions sealing BODY UNDER BODY ALIGNMENT CONTENTS UNDERBODY GENERAL SERVICE INFORMATION ALIGNMENT CHECKING PROCEDURE PRINCIPLES OF TRAMMING BF BF 10 BF 9 CAR PREPARATION BF 9 TRAMMING checking alignment of the underbody repairing minor underbody damage or components INFORMATION dimensions it is essential that proper overall strength of the body and following underbody the parts locating replacement underbody component directly affects the Since each BF 10 SEQUENCE assist in To UNDERBODY GENERAL SERVICE 9 checking information alignment are presen ted welding sealing and rust proofing techniques be observed service during operations Whenever the body repaired body parts with In the of case component primer such a repaired is rust rust PRINCIPLES OF TRAMMING provide the All reference locations shown in proof critical proofmg it is essential that as be sure to a 15 underbody air good quality type when example dry directions the mine cross heck of the a Figures measurement diagonal primer surfacers performing dimensions panel corrosion resi tant zinc chromate be used Do not use combination type symmetrical are 14 and Figures BF I3 at the center line of the vehicle BF 13 be should the Cross checking operations relationship between two body floor and 14 used the IS in both same are For to locations deter on the underbody ALIGNMENT CHECKING PROCEDURE in Misalignment fender To the a station It is problems essential within the the points front are body opening alignments wagon particularly affects various affects trunk lid and window alignments and also door the tail gate and rear of underbody the or measure 1 in the case on the the distance between any two reference underbody accurately The horizontal dimension between the two points to be measured 2 suspension system thereby causing that arise from that underbody components be in 13 to be measurement aligned Figures BF The vertical dimension from the datum line to the points suspension misalignment specified dimensions given calculated datum line have necessary alignment realigned external as L if employed frame straightening pulling equipment an a the diagonal plane between rat a 3 606 in 916 rom forward location should be BF 9 mIn 456 0 in rom L 3 150 in at vertical and the dimen lion The vertical pointer used at the machines jacks from the between the forward location of dimension vertical dimension 80 0 116 rom specifications vertical height difference of 116 to correct other standard body example horizontal The rearward location of dimension specified dimensions There are many tools that may be collision damage such 0 456 in important that thoroughly checked and be to the it is on 3 mm 24 8 in 631 BF 13 is damage For measured reference points of dimension line L shown in Figure 14 and 15 underbody specifications required Underbody misalignment van In the event of collision two positioned so as to extend further from the tram bar than the BODY pointer used at the rearward location settings the tram bar will be on a With the proper plane parallel the body The exception to this would be when reference locations is included in the the not parallel plane between prevail misaligned one of the area then the body and the tram bar may After completion of the repairs gauge should be set at the specified TRAMMING SEQUENCE to that of the tram dimension to check the accuracy ofthe repair operation The tramming sequence will vary nature and perfonning reference of the location any points misaligned tramming operation to be determined a damaged underbody alignment checx of body of diamond rear end checking Place the car on a area area level surface The weight of the car should be supported at the can Therefore damage inspection should be eliminate unnecessary measuring Obviously misaligned areas underbody point results condition may often be located made damaged to or visually usually originate from are not suitable for undamaged suspension BF l0 the body floor measuring area one locations should be used a rare or pan are of the as an situation should exist not suitable as reference points repair operations should begin pan the condition underbody alignment with the body floor All other underbody components should be aligned progressively from this area MEMO develops If inspection indicates that these locations have been where all of these locations A visual untrue in the floor pan area as a result of front initial reference pnint If wheel locations 3 reference will produce construction seldom collision disturbed and 2 A must from included in type involves the following I of Unlike the conventional type offrame design the unitized CAR PREPARATION the car for the Prior to the accuracy be used that and confuse the evaluation of the Preparing area upon the originates measurement a depending BODY w Z w E E a w z I Z w U J c c tl al 5 Qj 0 t @ 0 8 0 i5 N il I 0 5 ai ci iii iii N N fr N N iii 0 e zoUIOL 0 05 L 09 Fig BF lJ Body aligrmtDtt lan BF l1 BODY w w Z z i E a w E i I E f Z J 2 w 0 0 0 0 0 m I m 5 ol IOL6 Z S on f 0 2 N Ol 0 J in @ g 0 0 0 8 i 10 10 @iZ on I in ci on 19 10 9t HLl IZ S OL6 J0 0tI PI @ Szz OIS s IIZ os tLZI lOa O on I N 909 9 16 10 g e t o I 10 Z ZI oL r oj i5 Fig BF J4 Body Jignmen BF 12 coupe BODY w C z i e e 1 I e 0 b b 0 0 2 tS LtH tSS s in 0 @ 0 0 e o 5 r It I 11 09 9 09 0 @ ra o Z os ai l LZl H 0 I 1 u I 09 t 9 JS Tr 9909 t l6 I 1 y tZ n 9 OLS e II II OS tlOS H Body alignment Pig BP station BF 13 or i 1o BODY HOOD CONTENTS REMOVAL AND INSTALLATION SF 14 LOCK SF 14 SF 14 Removal BF 14 Installation SF 14 Adjustment BF 15 REMOVAL AND INSTALLATION Installation Install Removal I HOOD Removal carefully Disconnect the windshield washer hose at the so in hood reverse of removal sequence that the hood is flush with the fender top and clearance between the hood and fender is aligned evenly the nozzle toward overall circumference of the hood when the hood 2 In order to protect the hood from rag in both sides of the hood hinge installation rear are end loosen the hood bolts and remove the hood it from both sides as shown in the workers damaging place is closed HOOD LOCK supporting following figure Two required t BF 16 Fig Dovetail bolt 2 Dove tail bolt retaining 3 IS Removing hood hinge I o nut 4 Spring Safety 5 Female lever 6 Spring 7 Hood lock control catch lever lever 8 r Rubber grommet E Fig I l Ii1liI h BF 18 Hood lock mechanism Removal I Remove the radiator grille loosen the installation bolts and remove the male side ofthe hood lock f n r 2 Disconnect the hood lock wire from the female side of the hood lock and Fig BF I 7 R mvoing hood lock BF 14 remove the female side of the hood BODY center correctly 0 u Adjusting hood lock control lever operating force Q When the j t t r f j i j Mf control lever loosen the dove tail bolt dove tail CD bolt securing force of the nut installed length increase and reduce Tightening torque Dove tail bolt retaining d BF 19 @ retaining spring 15 to 2 5 Fig is excessive operating force Removing male side of t ehook lock Adjusting kg m nut 8 to 18 1 ft Ib 10 hood tightness When the hood is closed completely and the slack reduce installed length of and increase CD the hood is dove tail bolt securing force of the spring J o J 0 21 0 r 7r 1 1 Fig 3 BF 20 Remove Removing female side of the hood lock three screws c L and remove the hood lock F control lever 1 i r f ijf2 I i I J j fI D C fI l I Ih Note Removing ood lock k 1 a olle con and b adjusting portion and the spring of the @lfor @ safety catch lever for weakness and break rapidly open Operation the hood may be unlocked during driving of female lever CID Check the female lever for smooth and correction a operation and the spring 3 rom stroke toward front and a 3 mm rear bolts I@ for wkness and breakdown stroke toward left and right sides Loosen the installation following down the hood lock adjusting vehicle the hood lock note the Operation of safety catch lever wea of the vehicle and the female side with in inspecting Check caulked male side hook lock is provided with 0 118 in dove tail bolt matters Adjustment The When I If the spring is broken BF 21 Centering Adjusting 1 ji Fig BF 22 Fig i 1 1 U 1 rj I I 11 j l 01 r If 0 118 the female engaging sides of the stroke lever does with the reduced and it may be and align the BF 15 not move smoothly dove tail bolt will be disengaged BODY FRONT FENDER AND FRONT END CONTENTS FRONT FENDER Removal FRONT BUMPER BF 16 RADIATOR BF 16 OUTSIDE GRILLE BF 17 BF 17 MIRROR BF 17 FRONT FENDER I Front 2 Cowl top 3 Front fender sealer 4 Cowl fender ealer 5 Side dash board 8 Front bumper stay 6 Front 9 Front 7 pillar Front bumper 10 bumper side bracket Bumper side bl8cket shim top Fig BF 23 Fro7lt fend andfr07lt end componenrs Removal Open the hood the sake of safety lamp and side 2 Remove disconnect the battery terminal for and disconnect marker the lamp front at their bumper wirings for the head connecting terminals radiator grille and radiator grille surround 3 Remove the sill moulding and holding the fender remove it Fig BF 16 BF 2 Removi7lg fnmt fend I BODY OUTSIDE MIRROR Indicates outside mirror installing positions Fig BF 25 Removing front fender II FRONT BUMPER Dimen sions A B 817 29 5 161 1 c D E 27 to 6 to 27 8 6 2 dia Item Remove six bolts installed bumper stay to body and remove the front bumper from the body together I with the Round shape movable 32 2 25 0 9843 mirror bumper stay dia 1 063 to 0 2362 t 1094 0 2441 6 to Round shape irror 817 32 2 40 35 378 1 575 1 9 dia 0 3543 6 2 dia 0 2362 to 0 2441 RADIATOR GRILLE Unit Loosen self sedan station remove tapping screws wagon and van five self tapping and ten screws for coupe rom for Fig and BF 27 Fender mirror installing positions the radiator grille from the body The radiator grille for coupe is made of ABS resin Be careful not to allowbrake fluid or oil sticking to it 17Id 3 6 ill o a hO 1 358 t 14 4 1 177 I Unit Fig Fig BF 26 Removing radiator grille coupe BF 17 BF 28 Door mirror installing position for right hand driven vehicle inl mm in BODY 100 13 9 1 In 100 13941 100551 lOOc 3 M 2 100 13 941 3 510 UI00M4 1 131111 87J l i J Q nO i2 104 O 142 diil HOLE 3 DOOO g 11 1021 13 348 450 171 71 78 1 BF 29 Fig Template for door mirror installation for left hand driven vehicle When installing round shape movable outside fender mirror tighten 4 to 0 5 kg 0 movement 174 to the nut to m 2 9 to 3 6 ft lb starting torque 65 1 tightening torque in lb so range from that fender mirror is in range from 20 to 75 When 5 kg tightening torque of 1 the m nut is 10 8 ft lb cm kg tightened higher to the fender mirror stud bolt may be broken NSTAlCATlNG OSrnON SECTION 1 M 2 Mlfror ba se I 1 Fig ror J I stay BF 30 Round shape A A Cap movable outside fender mirror installing unit TRUNK LID AND REAR BUMPER CONTENTS BACK DOOR SEDAN AND COUPE BF 19 Removal Removal BF 19 Adjustment Adjustment BF 19 TRUNK LID TRUNK LOCK LID TORSION BAR LOCK BACK DOOR TORSION BAR BF 20 Installation REAR BUMPER Removal STATION WAGON OR VAN BF 18 BF 20 BF 20 BF 21 BF 23 BF 23 BF 23 BF 23 BODY SEDAN AND COUPE @ 1 CD d @ @ 1 Trunk lid 3 Trunk lid weatherstrip 5 Trunk lid 2 Trunk lid lock assembly 4 Hinge fixing pin 6 Striker Fig BF 31 Trunk lid and hinge hinge assembly construction sedan striker position Adjusting stroke toward left and right TRUNK LID LOCK sides direction is 4 8 rom 0 1890 in and 8 rom 31 SO in toward vertical direction 0 Removal Loosen installation bolts and remove the striker and Coupe lock from the body 2 Remove the leaf clip lock cylinder on the body used to and secure remove the trunk lid When adjusting striker adjust sides the trunk lid lock adjusting engagement between the lock and striker position toward left and right stroke 6 rom 0 2362 in and lock position for vertical direction adjusting stroke cylinder 3150 0 in Adjustment Tightening torque Sedan When striker Lock and striker fIxing bolt adjusting set engagement between the lock and the lock stationarily and properly adjust BF 19 0 12 to 0 2 kg m 0 87 to 45 1 ft Ib 8 mm BODY TRUNK LID TORSION BAR The procedures of installing torsion bar are indicated follows as @ 2 Closed position Rotation center of J trunk lid hinge Trunk lid hinge 4 Trunk lid torsion I m I bar 5 Fig Note When inSUllling the tonion bar use a BF 32 J Rear waist connector torsion baT Installing special tool ST087100001 tonion bar wrench STATION WAGON OR VAN @ Back door hinge torsion bar t s Fig 2 Back door 3 Back door 4 Back door lock rod 5 Lock 6 Striker 7 Striker shim 8 Back door side dove tail 9 Side dove tail shim t 10 Back door 6J 11 Back door BF 32 Back door 1d 4 hinge hinge bumper bumper plate constructions BACK DOOR LOCK 2 Removal Remove the back door trim and sealing Remove the lock free the lock cylinder from the lock screen BF 20 cylindfJ cylinder securing d remove leaf clip so as to the back door lock rod BODY T Il l r I i Adjustment l 1 0 l Striker and lock 7 t O 1 f r The striker and lock engagement is T lJ The lock side is set When 8 adjusting striker shim r I adjusted at stationarity engagement toward vertical direction 1 6 rom the standard condition fa 0 0630 in one is used thick Under striker shim is used Adjusting stroke toward the horizontal direction is 6 rom 0 2362 in a Back door lock rod II Tightening torque Fig BF 34 Remvoing bock door lock rod Lock fIxing machine 0 12 3 Remove the lock 4 Loosen the installation bolts to screw 0 2 kg m 0 87 to I 45 ft Ib Striker fIxing bolt cylinder 1 0 to 1 5 body the striker side for toward horizontal and vertical directions side nd kg m 7 2 to 10 8 ft lb remove 2 the lock and striker Sid and wedge strik A Back door bumper Steel sheet Back door side Rear panel side Tapping plate Steel sheet B Nylon Back door Back door bumper plate Rubber Back door side dove tail Steel sheet AU portion Fig BF 35 Back door BF 21 securing system portion BODY In order the to secure the back door in the position adjust the following instruc in accordance with position plates opening closing force increases although the back door is that the back door @ Install two back door bumpers I on and therefore door no the positioning adjusting stroke is are I inside provided their inside contact surface is contact may be made at the outside Same bumper plates in mm adjusted 0 1575 in Outside Inside Inside bumper bumper plate and correctly the inn shown in as that inside of the back door positions The adjusting stroke is 4 Outside at screw the back door bumper plates the bumper plates 7 2 ft Ib kg m comes into contact with inside of the secure when How Back door hi BF 36 so and closed lightly back door securing effect will be obtained Back door bumper fiXing machine Fugure opened into contact with the come Tightening torque Place be It has been so designed that the back door bumpers Note back worn 2 can so the bottom of the back door Positions of the back door bumpers used for standard positions when plates properly Position the bumper secured tightly tions back door the outside to moved excessively are back door side dove tail adjust both side Now 3 Adjusting BF 37 Fig upper portions of the back door Secure back door side dove tJIiIs temporarily toward the rear in the center for vertical direction direction close the back door and side dove tails properly contact with the adjust positions of the so back door that the dove tail comes into back door hinge arm tightly and the dove tail is bent I to 2 rom 0 0394 to 0 0787 in When there is hinge door Back door bumper 2 Back door bumper plate 0 0630 in dove tail is Fig Adjusring BF 36 When adjusting plasticine plasticine or hinge back door bumper plate positions back door bumper plate positions use arm a gap between the dove tail and back apply arm moved rearward gap is reduced separated from adjusting stroke the hinge rearward adjusting is the beneath thick 2 16 rom dove tJIiI side shim s it dove tail When the approaches toward arm mm Vertical gap increases 0 0787 in and forward stroke is 6 rom 0 2362 in similar material fIll the bumper plates with close adjust properly the so back door that both side contact with both side observe contact bumpers come and Tightening torque into Dove tail fIXing machine bumper plates evenly screw Ikgm 7 2 It should be noted however that when the bumper BF 22 the and when moved forward it is Ib ft BODY BACK DOOR TORSION BAR A D Fig BF 38 Installing torsion bar may be set either from left Installation 1 Fully back door torsion bar open the back door I torsion bar to condition and set the hinge link and or right REAR BUMPER of Figure BF 38 Removal 2 Apply torsion a ST08710000 bar wrench to one end of the torsion bar from position II III to of the tool special Disconnect and hook it wiring bumper installation Figure BF 38 The and remove the for the license bolts from the plate lamp loosen the luggage compartment bumper DOORS CONTENTS DESCRIPTION DOOR CONSTRUCTION Removal BF 23 Front door lock installation BF 27 BF 24 Rear door lock removal BF 28 Rear door lock installation BF 28 BF 25 BF 28 GLASS AND REGULATOR DOOR Adjustment BF 25 DOOR TRIM BF 26 Removal SF 29 BF 26 Installation SF 30 Removal DOOR LOCK MECHANISM BF 26 F rant door lock removal SIDE SF 30 WINDOW SF 30 Removal BF 27 DESCRIPTION The sectional cross door sash rigidity and the door sash is secured means provides on with the door point panel by so applied of welding The door lock is of inside handle bracket is The high a that to the a load is absorbed when inside handle during outside handle is of knob lock type and the inside handle is of a pull rise type BF 23 provided a pull up type an a with a weak large load is accident The BODY DOOR CONSTRUCTION 1 Glass 2 5 Weatherstrip Door panel Weatherstrip Weatherstrip 6 Seal 7 Door 8 Door bumper 9 Door glass stopper 3 4 t5 @ J V finish Drain hole Door rubber cover 12 glass Glazing rubber 13 Bottom 14 Outer channel moulding Door upper hinge Door lower hinge I Glus 2 3 Partition weatherstrip Partitionsaoh 4 Door y @ BF 24 rubber 6 1 Seal 8 Door finish 9 Door comer rubber screen II glass glass Outer moulding 12 Glass 13 Glazing 14 Bottom channel 15 Door upper 16 Door lower 11 Drain hole 18 Door 19 BF 40 Rear door construction run panel Weatherstrip Door bumper 10 Fig screen II 5 @ spacer BF 39 Front door construction is 1 rubber 10 15 16 Fig run Door run rubber rubber hinge hinge cover glass stopper Weatherstrip BODY 3 Removal door It is recommended that the door be removed from the body with the door follow the Hereinafter hinges attached on the door although on f Front door Remove the 2 Remove the door hinge service hole cover from the applying stand a door does not Note Apply a or opened support jack the door piece of rag between the door and stand the body side by the door from the use I so a BF 42 Removingreardoor Adjustment damaging hinge installation bolts of i J r Door Remove I by Fig that the door panel is protected from 4 e1 beneath the door so that the drop off door l I I With the door fully f i 5 package tray dash side trim 3 uri i the door 1 the front 9 the door may be removed from the body with or without the hinges attached instructions for and remove the rear door at the hinge Loosen the bolts used to secure the box wrench and remove the body adjust the door ward position upward to and retighten required as hinge the downward forward body or the rear bolts securely Adjustable 6 mm 0 2362 in range Tightening torque Note Hinge pillar installation bolt 1 6 kg m 11 6 ft lb Hinge door installation bolt 16 kg m 116 ft Ib a When installing the hinge grease the hinge link b Oil top of the hinge while opening or pin when the door squeaks closing Striker Fig BF 41 Removing front door Dash side door hinge trim without Another method service hole fIxing screw to adjust the door loosen the striker and adjust the striker position Rear door Adjustable Remove the kicking plate range 6 mm 0 2362 in Tightening torque 2 Peel off the body side welt and remove Striker installation machine the center 0 12 to 0 2 pillar finish BF 25 screw kg m 0 7 to I 4 ft lb BODY Fig 4J BF Adjruting striker Fig BF 44 DooT trim DOOR TRIM For both the front and rear doon the door trims may be removed and reinstalled in the same method Removal 1 When removing the door regulator handle lock inside handle escutcheon and arm rest remove their installation screws 2 When removing the ash tray outer ash tray and 3 The remove the installation case pull the screws door finish is secured on the door When removing the door finish remove with ill clips Ash tray Fig it toward you BF 45 2 Ouler case Removing ash tray DOOR LOCK MECHANISM 1 Door lock 2 Spring 3 Inside handle 4 6 Loclcing plate Locking plate spring Stopper 1 Outside handle 8 Outside handle rod 9 Nylon nut 10 Escutcheon 11 12 Knob grommet Door lock knob 13 Door lock cylinder 5 Fig BF 46 Front door lock mechanism BF 26 BODY 1 Door lock 2 3 Inside handle Escutcheon 4 Door 5 Knob grommet lock knob BF 47 Rear door lock mechanism Fig Front door lock removal Remove the parts up to the seal screen Remove 2 the door lock knob and then remove the remote control rod used to connect the door lock to the door lock cylinder from the door lock cylinder Remove the inside handle installation screw and the 3 door lock assembly installation the outside handle assembly on remove screws and withdrawing rod from the opening the lock on the lock assembly from the service hole the inside panel Fig Removing front door lock BF 49 Front door lock installation Installing the inside handle and 1 Adjust position and install the stopper the base remote the remote control so that @ of the inside handle @ plate of the door lock control lightly contacts CD If the remote control is installed with the inside handle @ pulled the the ratchet completely @ Lock 4 on BF 48 Door without Detach the leaf the door and clip remove used to at the full catch and the lock knob does not lower assembly 2 Fig does not intermesh with locking plate sealing secure Connecting outside handle Set the locking plate screen insert the rod the lock cylinder @hnto secure the lock cylinder BF 27 nylon the nut @ to the to the locking plate fully ratched position on the end of the outside handle locking plate hole the nylon nut @ with adhesive in and a adjust and position where BODY the outside handle rod 0 0787 to 0 1181 in If the nylon nut @ play @ is is provided positioned plate @ is does not intermesh with the ratchet knob depressed cannot handle rod 0 1967 at be locked is @ in to too low the the full ratch If excessive play 3 lock knob mm 3 locking completely and Hereinafter the screw handle the instructions for removal of the front door lock apply in stroke of the outside outside Remove the bell crank installation the locking plate may be unlocked up to 5 of the stroke with 2 in the stroke mm will be insufficient If the trouble means and nylon occurs Be of adhesive replace as is nut sure the loosened above to secure the nut Check the springs @ described completely by and @ for rust required Tightening torque Door lock installation screw 0 12 to 0 2 kg m 0 9 to I 4 lb ft Door lock remote control installation 0 12 to 0 2 kg Outside handle installation 0 2 to 0 3 Rear door kg m screw 0 9 to I 4 ft Ib m Fig BF 50 Door witlwwr se4ling scr n nut Rear door lock installation I 4 to 2 2 ft Ib Install lock removal the rear door lock in reverse sequence of removal 1 Remove the parts up to the seal 2 Raise the door screen Note DOOR glass to the top and remove the door Except for the precautions for outside handle precautions for the front door lock apply GLASS AND REGULATOR 1 Glass 3 Door 4 window gla u Glazing robber 5 Bottom channel 6 Door 7 Catch handle 9 10 Door ventilator glass Pivot bracket 11 Door ventilator weatherstrip 12 Gins 13 Front 15 BF 51 Front door g14ss and regulator BF 28 ction const ventilator frame VentiJator glass channel 8 14 Fig Front door panel run rubber 2 run rubber window regulator Door handle washer Door window regulator handle 4 door sedmt the BODY 5 1 Rear door 2 Glass 3 Partition run panel rubber rear door weatherstrip 4 Rear door glass 5 Rear door comer 6 Glazing rubber 7 Bottom 8 Door BF 52 Rear door glass and regulator constructiorl channel window tegutator Door handle washer 9 10 Fig glass Door window regulator handle 4 door sedan Removal Remove the door trim and seal screen Remove the door glass to 3 Remove four door ventilator installation screws and glass stopper Pull 5 Remove three and lower the door 2 and upward 4 and the bottom remove Note The the remove the door glass regulator assembly installation regulator assembly from the door regulator may screws service hole be removed without removing the door lock detach the door ventilator l ffL 9 jJl I Q it Jl 3 1 L Fig BF H Removing door f Ii I Fig tilatOl BF 29 BF 54 Removing rear door window regu14tor BODY Installation regulator Insull the door glass and in roverse sequence of removal Reinstall the seal screen aftet correctly door adjusting window closing I C SIDE WINDOW Removal Remove the lock side window handle set pillar moulding and screws and remove the from the body side Loosen the side window 2 remove Side window glass Side window hinge 4 Side window handle 2 5 Handle 3 Side hinge 6 1 hinge installation conr shim Catch handle bracket screws Fig the side window BF 55 sick window construction WINDSHIELD AND REAR WINDOW CONTENTS REMOVAL BF 30 INSTALLATION BF 31 WATERLEAK BF 31 CORRECTION REMOVAL I Place instrument a protective panel cover over the hood front fenders and front seat 2 Remove rear view mirror 3 Remove windshield 4 On inside of body support wiper arm assembly loosen the lip of the rubber channel from spot welded flange along the top and sides of windshield opening With the palm of the hand apply edge near putty knife other suitable tool and or rubber channel over a blunt carefully assist At the same time use pressure to glass spot welded flange Fig 5 BF 56 Removing windshield After windshield rubber channel is free from spot welded flange Note with aid of helper carefully lift windshield assembly from body opening and place it on a The windshield cltrome modlings the protected rubber cltennel and should removing rubber bench BF lO are installed in be removed cltannal from the gI prior to BODY 5 INSTALLATION It is important that the in be body windshield opening glass The be method which may used outlines below procedure the 6 for windshield rubber channel irregu any check entire With ment Note glass body opening flange for the aid of on pulled lips over first across across pressure adhesive type applicator seal inner and channel to glass with as an approved indicated in Figure BF 57 Seal completely around rubber channel irregularities any helper carefully position replace a windshield opening Care should be exercised to make certain glass does strike not chips 4 a of rubber weatherstrip Clean off old sealer around windshield opening and 3 Using outer larities 2 lip of rubber channel Cord should be flange lower at top opening Check properly positioned bottom of windshield then up each side and finally windshield I are opening slowly pull ends of cord starting spot welded check the windshield to glass and channel center of windshield to seat checked thoroughly before installation of the replacement windshield When the With can body metal during installation windshield check body opening Edge lead to future breaks glass supported and centered relationship of glass to in body opening around entire perimeter of glass The inside surface of the I contact the spot welded 2 glass should completely Fig of bber channel flange The curvature of the glass should be uniform to Reinstall all previously removed parts and 7 that remove protective coverings of the body opening 5 BF 57 Sectional view Mark any sections of body to be reformed Remove glass and reform opening as required WATERLEAK CORRECTION 6 Install windshield In Clean I old sealer in glass cavity of windshield out Install rubber channel to glass 3 Insert a strong cord in the channel where the spot welded With the aid of flange Using fits tip glass at by performing around the the following pressure an applicator corking gun with approved weatherstrip adhesive between glass and rubber channel on a narrow black the outside of the glass completely around perimeter of glass a assembly Do not position a apply helper in carefully position and 2 Leak between rubber channel and body body opening Use Note waterleaks Leak between rubber channel and glass bottom center of glass 4 minor operations groove of the rubber Tie ends of cord and tape to inside surface of center windshield instances windshield may be corrected rubber channel and around base of rubber channel 2 many glass by tapping or hammering at a pressure from outside of applicator with body apply a a narrow tip Working sealer under outer lip of rubber channel around entire perimeter of body opening any time BF 31 BODY VENTILATOR CONTENTS DESCRIPTION SF 32 COWL TOP GRILLE SF 33 DESCRIPTION In this body ventilation systeO air intake on the air is taken from the cowl top and ventilator on the front door and exhausted from the slip shape air outlets on rear pillar body side for coupe and side window Thus the passenger compartment is ventilated the J 4 door sedan 2 door sedan I Coupe Station wagon Fig BF 58 Ventilation system BF 32 or V an sufficiently BODY COWL TOP GRILLE Loosen six self tapping screws and remove the cowl top grille from the cowl top panel together with the baffle plate The cowl installing first no and sticking Heater motor 5 Room valve 2 Fan 6 Ventilator valve 3 Heater 4 Shu t valve 7 8 Cowl core tighten four outside self unreasonable force is Moreover 1 top grille is made of ABS tighten inside self tapping screws be careful applied not to tapping to allow When two screws screws so the cowl that top grille brake fluid or oil to it Defroster nozzle top 1 COWL Fig resin BF 59 Cross sectional view offorced ventilation BF 60 Cowl top Fig grille O GRILLE I removal SEAT CONTENTS SEAT Reinstallation BF 33 Description BF 33 HEAD REST Removal BF 34 SEAT BELT BF 35 OPTION BF 35 OPTION BF 35 SEAT Description For available the BIIO one is a series types of front seat two separate bucket seat are and the other is a separate manual reclining seat option The manual reclining seat is operated by a control lever located in the window side of the seat cushion control lever is pulled upward the reclined to any desired position up to seat When the back can be approximately 520 from the normal position Fig BF 33 BF 61 Front seat BODY Unhook the seat back at the 4 Removal rear bulk head upper portion Slide rail of front seat I Slide the lower rail toward remove rear side of the seat Rear seat and the seat frame connecting bolts Remove return spring 3 Slide the lower rail forward and rear Raising I rear side of the cushion stopper and 2 bolts from the coupe remove remove cushion seat pull out the cushion the seat rear seat the fIXing side Rear seat sedan I Remove from both sides of the two screws seat cushion 2 Raising front side of the 3 Remove the seat back seat cushion pull it out attaching screws Fig 2 BF 64 Loosen Removing installation screws cushion and remove the seat back Rear seat Station wagon or Van Turn down the seat cushion forward 1 screws and remove Fig BF 65 remove the seat cushion as shown in four Figure 65 BF Fig BF 62 Remvoing at s cushion fIXing screws 2 Fig BF 63 Removing seat baclc installation Removing BF 34 seat cushion With the seat back turned down from the wheel house and screws rear remove remove two screws the seat back BODY HEAD REST on rest on front installing head When plug OPTION the seat back seat remove and insert the head rest supports into the holes Fig BF 66 Removing rear i I i IJ IJI seat bock r I I f Reinstallation in Reinstall the seat cushions and seat backs I I reverse I Fig sequence of removal SEAT BELT BF 67 Head rest OPTION CO @ Fig BF 68 Seat belt installing positions BF 35 the i Ii i I BODY INSTRUMENT PANEL CONTENTS REMOVAL SF 36 REINSTALLATION SF 37 REMOVAL Note When disconnecting mend to use the wlnng harness tags for identifing recom their relationship i f i 3 Disconnect cables for radio antenna 4 Remove the the shell and speaker I signal 1 ff 1 c II Cll package tray ii Note Work may be carried out steering wheel However without more BF 69 Removing instrument 2 Disconnect the battery cable Disconnect the wiring harness Disconnect the instrument at the be carried out the speedometer cable from 6 manner Disconnect the heater control cable at the heater side battery terminal connector harness from units the engine compartment harness Disconnect the instrument harness from the turn signal switch Disconnect the instrument harness frorn the body harness Disconnect the instrument harness connected to the door switch the unit square However both of them are same can easily Disconnect speedometer There are two types of instrument panel removed and reinstalled in the the panel 5 type and round type removing recommend to remove the steering wheel so that work Note and turn il @ioEl Fig cover switch stop lamp switch flasher unit and passing light relay option Fig BF 36 BF 70 Removing nt instn panel I Remove three screws from 7 one and bottom each installation bolt from both sides of the two together R top of the instrument bolts Note the secure instrument panel with the steering column clamp Raising the rear side used to instrument of the vehicle and panel slightly pull remove Ensuring that all cables 1I e instrument are it toward it disconnected remove panel slowly and carefully REINSTALLATION Reinstall the instrument panel in reverse sequence of Fig removal BF 71 Removing instrument ROOM TRIM INSTALLING HEAD LINING A B A B A Adhesive Detailed view of A FRONT A B A B portion Be sure to hook the clamp securely Fig Note Be sure to install the roof insulator before BF 72 Installing head lining installing the head lining BF 37 panel II BODY For use those vehicles which do not pinar cloth fold at this line I B For A 2 door type vehicles fold pillar cloth at this line FOld and stick this portion B B A A A 0 c 0 The left side opposes the right side 0 00 t symmetrically Fig Note Be sure to apply pal before Installing windshield and center pillar cloth BF 7 J installing dath 4 door type vehicle 2 door type vehicle GG A 0 Detailed view t f BU for 2 door type vehicle First install the rear pillar on the body with screw fold it downward cloth 0oo1 and stick with adhesive Fold Vinyl cloth at this line Fig Note Be sure to apply pad A BF 74 Installing before instaJling cloth BF 38 rear pillar cloth BODY SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or PAGE No SUBJECT No BF 39 BODY SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or SUBJECT PAGE No No BF 4O SECTION BE BODY ELECTRICAL DATSUN 1200 MODEL B110 SERIES BODY CHASSIS I NISSAN I NISSAN MOTOR CO TOKYO JAPAN LTD WIRING BE 1 FUSE BE 6 LIGHTING SYSTEM BE 7 HORN BE 15 METERS AND GAUGES BE 18 WINDSHIELD WIPER AND WASHER BE 26 IGNITION SWITCH AND STEERING LOCK BE 29 CLOCK TACHOMETER BE31G RADIO BE 32 HEATER BE 34 BE 31 BODY ELECTRICAL WIRING CONTENTS WIRING Engine compartment harness I nstrument harness BE 2 Body harness BE 1 HARNESS BE 1 WIRING BE 2 INSPECTION 4 BE DIAGRAM BE 6 WIRING HARNESS The wiring harness is classified into engine compart ment harness instrument harness harness individual positions between indicated as installing and body locating positions the harness and The connecting individual wiring harnesses are follows Moreover for the body harness the positions differ mutually in Sedan Coupe Station wagon and Van Engine compartment harness Fig Fig BE l Engine compartment IuJmess 1 Fig BE 1 BE 2 Engine compartment harness BE 3 Engine compartment harness 2 3 BODY Instrument harness Switch and control J c connecting unit Harness terminal in the engine compartment Fig I 2 Body 4 lnstrvment hamess BE Instrument harness room harness Body 3 harness Engine Fig BE 5 2 Body hamess BE 7 Fig 3 1 Body harness 2 Combination lamp RH Fig Wiring harness connections BE 8 Body harness Body earth sedma harness I j gl r 1 4i i Body To license SS hamc Combination lamp FiX BE 6 Body ham ss Fig I BE 2 BE 9 Un Body harness sedan lamp BODY ELECTRICAL 2 75 3 1 2 Combination lamp To tank unit Fig BE I0 I RH Body 3 3 To license lamp BE II Body Tail harness 2 Wheel house BE 12 o harness Fig 1 Fig harness coupe Combination lamp LH Body Body harness Fig harness coupe BE 3 Body Tolicense BE 13 3 RH 4 Rear seat Body harness harness Station wagon and Van lamp Body o Tail harness harness Station wagon and Van 0 oo 9 D partS t Il i QlIt Indicator t Indicator t nd I 111 1 0 optlO 1 ght t IQ 9 h af beam i OUnd II wet1 teJf es ufe t o 8f ll Q if NeQltivO Ii itrutT UfO ltiO1llO lead Brl e o t ed pl o f q 1 Oi 1 fl 1 t U m iUJ COOE 1 i OR COI H O JE e E tE BLACK GRE N REO w 8 R ll G parte corect d tI J rJ I p IIl vt oc Jl tt n Ii 5 to and D 1 ElEC1R 600 CAl j a io a co 06 t d i S a i f aIll i a t p iJ te i c belil l O ig aO t Ul E t 1 11 g 3 co 3 o O G cr J l a 1 @ d fIIJ B b b IS W fig IIE didI fo os IlE f o l cM s I e BODY INSPECTION Referring for harness 6 check the wiring diagram to connection with electrical the the wiring harness note the following wiring with clamped sharp that so corner they do nol checking 7 matters Cables should be securely in clamped positions sufficiently separated from rotating parts such Connected unit should be not loose come temperature of part or which rises highly equipment and connector for connection and installation When Cables should be into contact rusted or pulley fan belt as fan etc contaminated 8 2 ed Cable insulator or cover should not be insulating material should not crack damaged be deteriorated Cables should be provided with sections length at where vibration stationarily on due to occurs the an optimum body or at extra sections engine operation and others For those parts which 3 are grounded through installation bolts the bolts should be in body completely that so contact continuity is the with the provided Note When 3 nance in inspecting service particularly between the body and bolts Terminals should not of come unit through which current no power supply when it is or may be 4 and performing other mainte or anticipated No part terminal flows b into contact with other metal parts connection should be present erroneous a disconnect the battery circuited short In no should event an unloaded directly connected with ground 5 is required that test lamp or Be circuit be sure to use a circuit tester FUSE DESCRIPTION When flows circuit to an overcurrent circuit a equipment are damaging is equipped the the rated amperage fuse is heated and melted and interrupted is exceeding thus the cables and electrical protected from damaging due to burning or limited to the minimum This vehicle with six fuses and one fusible link The fuses is are located in the fuse box and used to protect illumination signal and other systems and the fusible link is in the cable between the the charging and starting battery and alternator to adopted protect ci cuits Fig BE 17 Fusible link INSPECTION In the most fuse cases However when it is difficult tester may be visually link Fig BE 16 Fuse box can tester BE 6 or used by feeling be inspected The on can to be fusible link finger tip more checked visually check visually can a circuit be inspected However the fusible correctly by using a circuit BODY ELECTRICAL Green color link for model Note When 8 before cause b fuse is blown off be sure to correct the a Be sure installing to use Do not use fuse 3OA new fuse through fuse Moreover the rated having 20A having larger capacity i e d When etc Particularly when the fusible replace with a designated parison with fuse fusible much higher link i link fused ated In com BlIO important to eliminate the II fuse is is loose connected cause inoorrectly and of voltage drops Remove dust or the and heat is gener resulting abnormally operated ment flows current it is blown off fusible link before replacing capacity contact c the fusible link electrical equip when oxidized polish with fine emery paper so that the contact is improved LIGHTING SYSTEM CONTENTS HEAD LAMP BE 7 Description BE 7 Sealed beam replacement BE 7 Aiming adjustment BE 8 FRONT PARKING AND TURN SIGNAL SIDE FLASHER ANO LICENSE MARKER LAMP LAMPS SIGNAL HEAD BE 11 BE 12 LIGHT SWITCH DIAGNOSES AND BE 8 CORRECTIONS BE12 BE 9 Head lamp BE 12 Turn signal lamps AND DIMMER BE 13 Tail and stop lamp BE 10 license lamp back up lamp AMP L BE 15 beam unit 4 Description When installing Top mark All weather type sealed lamps BE 11 PASSING BE 10 COMBINATION SWITCH BE 11 HAZARD WARNING SWITCH TROUBLE BULB SPECIFICATIONS TURN BE 10 Removal LAMP LAMP REAR COMBINATION Removal LIGHTING SWITCH beam 2 light to the a new unit be sure to position the top of ring system front adopted Each lamp of both side head lamps is provided with high beam filament for driving 50W and are low beam filament for dipping 40W Ilunp is of a double filament Sealed beam In other words the type replacement Remove the wiring socket from back of the head lamp 2 Remove the the radiator core screws Coupe only Remove three retaining lamp 3 on rim the front grille to attaching support screws and remove the head All other than coupe Loosen three screws remove Seal d beam unit 3 S al d b 4 am mounting Retaining ring Aimins adjusting ring used to install the retaining ring the sealed beam mounting ring and I 2 Fig the sealed BE 7 BE IS Replacing sealed beam screws BODY Aiming adjustment For aiming adjustment tester screen type tester an passengers except for the standard equipment spare tire aiming machine head light and other instruments are and tools used For the operating instructions of those instruments refer correct to the instruction manual ofthe instrument to be used lamp For the correct aiming the ground remove adjustment all loads such 1126mm Vertical and horizontal directions of the head are adjusted respectively with PASSING BEAM t ff 44 3 in I that pressures of aU tires are two portions of adjusting screws the head lamp mounting ring luggages and DRIVING BEAM I sure located in upper and side level the vehicle to as and make 1126mrn 2 44 3 in 349mm 13 7 in h H m Driving beam Passing beam H h J Sedan 660 mm Coupe 664 26 0 in mm 1 in 26 Van 660 mm 26 0 in 40 116 mm 1010 204 mm Fig BE 19 Head h J in 2010 204 8 03 in 2040 466 mffi 57 4 rom 8 03 in 3 18 in lamp aiming adjustment FRONT PARKING AND TURN SIGNAL LAMP SIDE FLASHER MARKER LAMP AND LICENSE LAMP When pushing removing toward the the bulb socket with the lens turn the bulb removed counter clockwise Fig 8 BE BE 20 Replacing parking and turn signa lamp bulb BODY ELECTRICAL removing When the fear combination remove the socket from the lamp housing nuts and remove the combination Fig BB 21 Replacing side JI uMr p BE 22 Replacing license remove fixing lamp assembly o b Fig Fig lamp assembly BE 24 Removing rear combination lamp sedan lamp bulb REAR COMBINATION LAMPS When remove removing the bulb the socket from the turning lamp housing and remove Tail harness Combination lamp RH Body earth it counterclockwise the bulb from the socket Fig BE 25 w 10 jj rear Removing combination lamp van x 10 if I l t I 1 t1 t Fig BE 2l Replacing rear combination lamp bulb Fig BE 9 j BE 26 Rt moving rear combination lamp coupe BODY BULB SPECIFICATIONS Specifications Item For other than Head s A and Canada U For U S A Canada lamp unit Main Dimmer 12V 50 40W 2 Front parking 12V 21W I Turn signal lamp 12V 5W Side flasher lamp 12V 6W 2 F P 12V 23 SW I T S Side marker lamp License 8W 12V 2 lamp 12V lOW I Sedan Rear combination Tail l2V Van Coupe 12V 5W 7 I 2 5W 7 lamp Stop I 2V 21 5W Turn signal 12V 21W 2 12V 23W 2 Back up 12V 21W 2 12V 23W 2 Room I lamp 12V IOW Figure encircled in 2 12V 23 SW 2 I parentheses indicates number of bulbs used TURN SIGNAL AND DIMMER COMBINATION SWITCH Removal 1 2 Disconnect the combination harness at the connector plug Loosen two bolts used to install the horn steering wheel by applying the switch from the wire the steering wheel and and flasher unit terminal 3 remove ring on the tool from reverse side of the horn Remove the steering wheel fixing ring nut and remove the steering wheel 4 Unscrew two remove 5 Unscrew two steering tube and Fig BI 27 Removing turn sijtnal and hole dimmer combination switch on screws screws used remove the steering tube completely BE 10 fixing and a locating screw and the shell cover to install the switch on the the switch from the locating Now remove the switch unit BODY ELECTRICAL IGNITION SWITCH FUSEM FUSE OIMMEfI IGHTING SWITCH TURN SIGNAL SWITCH SWITCH I UCENSE LAMPS 0 TAIL LAMPS fRONT PARKING 00 0 0 CAM LLUMlNATlON LAMPS LEFTSIDE Z 0 Fig BE 28 Circ it diagram for turn signal and LIGHTING SWITCH dimmer switch system HAZARD WARNING SWITCH 4 way flasher The hazard lamp system Removal consists of hazard warning switch and flasher unit When the hazard 1 Remove the connector from back of the lighting warning switch 2 simultaneously Depressing the lighting switch knob stopped turn it counter on clockwise and switch remove it is turned Loosen the escutcheon and remove When the turn signal the lighting switch from the cluster lid IGNITION SWITCH FUSE H FUSE M TURN SIGNAL SWITCH r OFF L ON HAZARD UNIT FLASHER UNIT HAZARD WARNING SWITCH J o J z in J z Z in Z w J RIGHT SIDE lEFT SIDE Fig BE 29 Circuit diagram for BE 11 all signal lamps flash that the vehicle is lamps flash the pilot lamps the instrument panel also flash telling you of hazard lamp operation 3 on telling other drivers hazard lamp system BODY PASSING LIGHT SWITCH The passing light switch is of the turn signal switch main beams incorporated in the grip end Ie r and cootrob the head With either the lighting switch turned off the head lamp main beams will light while the witch button is pushed in lamp on or USE FUSE P T FUSE L DIMMER SWITCH I 0 2 L UCENSE S lAMl TAil LAIIPS F O PARKING PASSING LIGHT RELAY LIGHTING SWITCH 1 NATlON HEAD LAMP i RIGHT SIDE LEFT SIDE Fig BE 30 Circuit di4gram for passing Ught system TROUBLE DIAGNOSES AND CORRECTIONS Head lamp Troubles A11larnps not do Possible Method of causes inspection Blown off fuse or faulty contact light Remedies Check the fuse block and white Repair as required cable for contact Check faulty the fuse for fusing and When fused and replace Faulty lighting switch terminal detect and repair the contact cause the fuse Check the connector for contact Repair as required Conduct continuity test If the lighting switch connector Defective lighting switch is defective The does for head lamp not light both high Blown off fuse or faulty contact Check faulty the fuse for fusing and contact When replace detect fused and repair the and replace cause the fuse and low beams Improper dimmer switch Defective dimmer switch contact Check the connector for contact Repair Conduct continuity test If the dimmer switch is BE 12 as required defective replace BODY ELECTRICAL Main high beam When Defective dimmer switch red yellow cable red white cannot be switch nected ed to dimmer red black cable beam dimmer beam low beam or to or is con continuity or test and if the dim main mer switch is defec tive replace cable and the Conduct lights the circuit is normal The dinuner vice versa switch is defective Head lamps dim Head lamps when the is or Repair cable being about to break and required faulty contact faulty contact or replace if or check fuse for specific gravity of elec Charge if battery required trolyte op under idling speed Defective battery Head lamps still Faulty sealed beam Replace battery Voltage between head lamp red unit white dim with engine cable and red cable minals is 12 8V above idling run Check the head light circuit for Measure Partly discharged battery engine stopped erated dim Defective light circuit or ter Replace sealed beam units higher speed Voltage Faulty charging system is less through above than l2 8V Check the generator and regulator test light circuit Head light in only one side lights Faulty head lamp termianl Repair con required tact Replace lamp Defective lamp Turn as signal lamps Possible Method of causes inspection Troubles All turn signal lamps do not light Blown fuse or faulty Remedies contact Check the fuse for faulty contact BE 13 fusing and When fused the fuse detect repair the cause replace the fuse is and and BODY Faulty flasher unit terminal con tact or defective flasher unit When unit are flasher the turn and lead two signal the wires connected with switch turned on individual the lamps light of the the connector terminal or replace the flasher unit signal turn flasher Repair unit is defective Defective turn signal switch Conduct continuity test If the turn switch is signal defective replace All signal turn lamp do not Defective flasher unit Replace go the flasher Wlit out Flashing cycle is low too There is a lamp which does not flash Check the mament lamp and for burnt out improper Replace if required socket contact Faulty contact A lamp having the in the circuit Repair wattage less than specified wattage as required Replace is used Defective flasher unit the Replace flasher unit Turn signal lamp flashing cycle too Repair circuit Short required as is A high lamp having wattage larger than Replace the rated wattage is used Defective flasher unit the Replace flasher unit Flashing cycle the left side or turn of Burnt out lamp bulb filament Check aU right Check lamp which does not Iight signal for burnt out filament and defec differs lamp lamps for operation Replace as required tivesocket from that of the right side lamp or turn Faulty connector contact Check both side lamps for Repair as required difference in brightness signal Only right signal left or left side turn operates A lamp other than specified Replace is used dried BE 14 with the spe one BODY ELECTRICAL Flashing cycle varies Faulty contact of power circuit from ignition windshield the When supply wiper Repair as required which uses the ignition for power switch to supply fuse is operated flashing cycle and brightness change Tail and back up stop lamp lamp license lamp Possible Method of causes inspection Troubles Both left right lamps not Remedies and Blown off fuse or faulty contact Check faulty do the fuse for fusing and the When fused detect and contact rect light the replace Defective lamp switch stop backup lamp switch or or faulty Stop lamps and backup contact When two lead wires of the switch are the connected and the lamp lights lamp and fuse circuit are normal cor and the fuse the switch Replace repair cause is or the connector terminal lamp only All Faulty grounding not Only one side lamp 1t BUr out rear combination lamps do light or Faulty side lamp differs minal and or with a new one Repair or lamp replace socket Repair contact of connector ter Brightness of one grounding the Replace lamp bulb mament contact of connector ter minal and the cable contact lights Faulty Repair or replace if required socket from the other HORN CONTENTS DIAGNOSES AND BE 16 TROUBLE Removal BE 16 CORRECTIONS Adjustment BE 16 HORN BE 15 BE 17 BODY FUSE H HORN BUTTON lBGI lHI H B S r 1 Ll I L Fig BE 31 J diagram for it CiTe HORN RELAY tom system HORN Removal Remove the connector loosen the fIXing nut in the horn center and remove the horn unit Adjustmen t I Secure the horn unit in a vise and connect cables as mown in Figure BE 32 Fig Note AMMETER When the Adjtuting BE lJ adjust screw i tom volume turned Clockwise Current increases Counterclockwise Current HORN 4 i VOLTAGE METER 115 to 2OV When a proper sound is obtained adjustment make obtained at voltage generated by sure through that the proper sound Lock the adjust screw the alternator BE 32 Circuit for hom adjusting ON 14 be to and make sure value A Sound adjustment Flat type Set the switch to can with the lock nut Consumed current 2 the above 15V 5 Fig d6 110 to 15A that the Spiral type High H 5 390 2 5 0 440 Low L 5 330 2 5 0 350 voltmeter indicates 12 to 12 5 V 3 Listening adjust the horn for sound level volume and sound properly rated amperage The adjust screw after so tone that the ammeter indicates the adjustment is made loosening the lock by turning the Figures nut Hz BE 16 encircled in parenth sis are basic frequencies BODY ELECTRICAL TROUBLE DIAGNOSES AND CORRECTIONS Troubles The not does horn Possible Method of causes inspection Remedies Excessively discharged battery operate specific gravity Measure of electro Charge if required lyte Check the fuse for Blown off fuse fusing and im Replace fuse Check and proper contact Improper horn button contact The horn sounds relay terminal The Defective horn relay though the horn S is grounded horn sounds though the horn B terminals relay and 11 repair horn button Replace horn relay are circuited short The horn does not sound Defective horn the horn H are horn the relay terminals though 8 Replace horn and and the circuited short still does not sound though terminal is battery con nected to the horn terminal direct ly The horn sounds The horn does not stop though the Defective horn relay horn relay continuously S Replace horn relay terminal is discon nected horn circuited Short and horn relay terminal button S When the horn above stops through the disconnection horn button unit fully Reduced and ty or volume tone Improper check particularly the care horn Repair relay terminal S horn Replace button Correct fuse wire contact quali Repair Broken cable or required Improper horn Repair button contact BE 17 replace if BODY METERS AND GAUGES CONTENTS CLUSTER LID BE lB OIL PRESSURE AND Description BE 18 IGNITION WARNING Removal BE 18 HAND BRAKE BE 19 BULB BE 19 TROUBLE SPEEDOMETER Replacement FUEL GAUGE AND LAMPS BE 20 WARNING LAMP BE 21 BE 21 SPECIFICATIONS DIAGNOSES AND CORRECTIONS TEMPERATURE GAUGE BE 22 BE19 Speedometer BE 22 Description BE19 Thermometer and fuel meter BE 23 Replacement BE 20 Oil pressure and ignition warning lamps BE 25 CLUSTER LID windshield wiper switch lighting switch and choke lever knobs Description The Remove the escutcheon cluster lid holds various meters around the clock located Thus serviced ometer meler as shown in circuit Figure and the printed circuit board is connected with cmulonnectiptolres and indicators and speedometer Printed board is used at the back of the BE 34 turn them counterclockwise to remove the meters extremely easily all meters are can Except operated eleclrically and thermometer are very reliable Inserting disconnect remove the the speed The fuel gauge are equipped with bimetal devices cigarette lighter cigarette lighter outer cable and 4 Remove loosen the 5 6 Pull the screws cover used to secure from the steering tube the meter housing the l2 pole round shape speedometer connector Remove the cluster lid from the instrument panel J terminal depressing the Fig 8E 18 and cable union nut BE 34 Combination meters Disconnect the battery the to and remove the cluster lid panel out the shell Removal I and turn case Remove the radio and heater control knobs remove Fig the cluster lid 3 instrument W tQ into back of the your hand be inspected for and they 2 BE 35 Removing lid dust BODY ELECTRICAL SPEEDOMETER The is speedometer equipped with a FUEL GAUGE AND TEMPE RATURE GAUGE total odometer which records travelled distance Replacement 1 Description When removing the speedometer remove the cluster The fuel gauge consists of lid fIrst Separate the combination meter housing from the cluster lid after removing four recorder reset knob 2 Unscrew two screws and remove the fuel tank and fuel meter The tank unit detects fuel level trip with its float if any screws from the combination converts fuel level variation to of slide resistor installed and meter remove controls current the speedometer The housing flowing Reinstall a new speedometer in reverse sequence of removal resistance The and fuel equipped base resistance and thus the with a thermometer and block engine a The thermistor element water temperature variation to cooling the thus flowing to current the float in located thermaltransmitter is which converts on a to the fuel meter gauge consists of temperature thermal transmitter 3 lank unit located in the a thermaltransmitter a controls the thermometer and thermometer meter provided are with I bimetal and heater coil hen the ignition switch is arm current flows to the heat coil ON set to coil is heated thus the With this heat the bimetal arm is bent connected pointer and the heat to the bimetal and arm is operated The characteristics of both meters A tolerance gauge due regulator to may is used to thermometer and voltage regulator Fig BE 36 Removing combination fuel on opening a same the thermometer fluctuation constant gauge The voltage a the regulator heater coil When the the contact Consequen tly As the bimetal cools repetition of fuel voltage that the correctly operate consists ignition the bimetal arm is heated and bent interrupted so or The is built in the thermometer bimetal arm and turned on voltage supply operating part of The ter occur source are this by of a switch is the coil current to the coil is the contact closes The operation produces a pulsating voltage of 8V which is applied to the temperature and fuel gauges If both thermometer and fuel meters become defective at the the o 0 Fig BE 37 Removing speedometer BE 19 same time this may be attributable to trouble in voltage regulator BODY r REGULATOR FUSE M TEMPE RATURE IGNITION GAUGE SWITCH GAUGE TANK UNIT I FUEL TANK THERMAL TRANSMITTER Fig BE 38 Circuit diagram for frul gauge and I Olt4ge temperature g Replacement pressure warning lamp which glows whenever engine oil pressure falls below 0 4 I Remove the cluster lid first 2 Unscrew two screws and Reinstall a new kg crn2 to 0 6 kg crn2 5 7 to 8 5 Ib sq in remove the thennometer or fuel meter from the combination meter housing 3 regultztor When the engine is stationary ignition switch turned meter in revene sequence of removal on the light glows with the When the engine is running and the oil pressure reaches the circuit is broken and the light goes out J u I i c o Warning light Fuse E Switch c T I J Fig BE 39 R oving thermometer Fig OIL PRESSURE AND IGNITION WARNING LAMPS The engine lubricating system incorporates j without with pressure pressure BE 40 Circuit of oil pressure warning system Ignition warning lamp glows when the ignition switch ON arid the engine is not operated or when the is set to an generator fails to charge with the engine operated oil BE 20 BODY ELECTRICAL When the ignition switch is set to warning circuit ON the ignition is closed and current flows flows from the ignition switch to the warning lamp bulb and ground is started and the through the regulator When the engine comes generator current it the generator output flowing from the warning operation opposes the current in effect lamp into the breaks circuit warning service brake line pressure differential When a warning lamp difference between front and pressures reaches the rated range to 242 Ib sq in the is closed and the 13 rear to 17 ground circuit for the brake line kg cm2 185 warning lamp warning lamp lights ground IGNITION SWITCH connection and the goes out lamp FUSE Ignition r switch WARNING LAMP 8 Cll c Pilot E relay co 0 06 1 110 al HAND SERVICE BRAKE 3 BRAKE LINE WARNING l Alternator PRESSURE SWITCH Regulator OrFFERENTIAL WARNING l 41 BE Fig Circuit of ignition HAND BRAKE This larnp SWITCH L warning system WARNING LAMP function both hand brake warning 42 BE Fig lamp and Circuit diagram for brake warning system BULB SPECIFICATIONS Specifications Item Square type meter Round type meter VW 12 4 3 2 12 1 7 3 V W 12 3 4 2 12 1 7 2 V W 12 3 4 I 12 1 7 I Ignition warning lamp VoW 12 3 4 I 12 1 7 I Oil pressure warning lamp VW 12 4 I 3 12 17 I Hand brake warning lamp V W Meter illumination Turn lamp signal pilot lamp Head lamp main high beam pilot lamp Clock illumination 12 1 7 Figure encircled in VoW lamp Tachometer illumination for U S A lamp parentheses 12 3 4 V W indicates number of bulbs used BE 21 I I CANADA 12 17 2 12 17 2 BODY TROUBLE DIAGNOSES AND CORRECTIONS Speedometer Truubles The Possible and speedometer pointer odometer do not operate Improperly tightened speedometer cable union speedometer pointer de speedometer nut Damaged speedometer drive pinion Replace the drive pinion Defective Replace Rapidly speedometer Correct bent speedometer cable Damaged speedometer drive pinion Replace gear or Improperly tightened speedometer replace the pinion gear cable union Retighten union nut correctly nut Defective speedometer cable Replace sponse to increase of in re driving speed Inaccurate Excessively inner wire indi or speedometer cable Replace the meter cable lack of lubrication speedometer Replace Defective speedometer Replace Defective speedometer bent or twisted the cable Replace Defective speedometer occurs cation Inaccurate odometer operation Improperly worm Replace the meter to deformed odometer and Replace the meter meshed second and third gear gears Faulty feeding due pinion carrier BE 22 gear Replace Defective speedometer Unusual sound cor Replace cable nects widely Unstable speedometer pointer union Retighten rectly nut Broken The Remedies causes BODY ELECTRICAL Thermometer and fuel meter Method of Possible Remedies Troubles inspection causes Both thermometer Blown off fuse and fuel meter do nection not or improper con Check the fuse for fusing and improper contact operate after Replace recting the fused Correct cor if cause con tact Defective voltage regulator Dam aged fused or The voltage regulator operi contact is combined with the thermometer single to a unit When the voltage regulator is defective replace it together with the thermometer Both thermometer Defective voltage regulator Bro and fuel meter ken heat wire oeized contact and indicate inaccu or Meter operates excessively Replace together with thermometer improper grounding rately Improper cable contact Meter operates Check the cable be slightly tween fuse and meter for improper contact and repair if required Thermometer The thermometer Defective thermaItransmitter The pointer deflects when ther maItransmitter does not operate is Defective thermometer yellow white cable The does pointer white cable is cates Defective thermaItransmitter her maltransmitter not deflect The pointer Replace the ther the ther mometer grounded moves limit when the maximum the grounded when thermaItransmitter yellow The pointer indi Replace to the low ignition switch is Replace maltransmitter turned off temperature Defective thermometer The pointer indicates maximum temperature even after the igniton switch is turned off BE 23 Replace mometer the ther BODY The thermome Defective thermometer The thermometer a operate accu plied to rately yellow white cable ter does serviceable is 100 n resistance when not the is Replace if defective ap thermaItransmitter the cable is grounded and the thermometer indicates approximately SOOC 1220 F Defective thermaItransmitter When the thermometer is normal Improper cable contact The transmitter the above inspection through thermometer indicates lower temperature slightly the thermal Replace a than the actual temperature Check the cable from the thennometer the to thermal trans mitter for cable about to contact being break poor and faulty grounding and repair as Fuel required met Fuel meter does Defective tank unit The pointer deflects when the unit tank not operate is cable yellow the Replace tank unit grounded Defective fuel meter The pointer cates Full Defective tank unit The pointer empty p deflect not the above inspection through The pointer indi does limit when ter below lowers the Replace the ignition with Replace the fuel a me one new the tank unit switch is turned off sition Defective fuel meter The pointer still indicates Full above position through the Replace the fuel in me ter spection Fuel meter func tions Defective tank unit The pointer indicates a half level Replace if defective when a 3S n resistance is improperly to the tank unit the cable is Defective fuel meter The applied yellow cable and grounded pointer does not indicate half level through the above spection BE 24 a in Re place meter the fuel BODY ELECTRICAL Improper cable The fuel meter indicates contact slightly lower than level a the actual Check the cable from the fuel meter leveL being about cable to break and contact poor the to for unit tank faulty grounding and repair Oil pressure and as ignition warning lamps Possible Method of causes inspection Troubles Oil pressure required Remedies warn ing lamp The lamp does not mown off fuse or faulty contact light when the Check faulty the fuse for fusing and contact ignition switch is set to ONn Broken faulty lamp bulb fIlament or The warning lamp does not light when oil pressure switch yellow cable contact black cable is grounded Replace after correc fuse ting the cause if fused the Check the light bulb for burnt and ment out ftla replace as required Defective oil pressure switch The warning lamp lights through the above inspection The lamp does not sure Inspect the engine oil Oil pressure is too low go out while the oil pres Replace the switch pressure system engine is being operated Lack of engine oil Check oil level Defective oil pressure switch Continuity sure Add oil exists on the oil pres the engine is switch when Replace the oil pres sure switch being operated Ignition warning lamp The not the lamp light does or faulty contact Check faulty when ignition switch is set to O Blown off fuse Burnt out light bulb filament faulty cable contact or The the fuse for fusing and pilot lamp does not when the voltage regula tor nector is or replace as grounded the ignition switch is set to light Check the bulb for con burnt out mam nt the disconnected white red cable is BE 25 Repair required contact and ON and replace quired as re BODY The not lamp does Inspect the charging system Faulty charging system go out when the is engine started WINDSHIELD WIPER AND WASHER CONTENTS Description BE 26 Wiper washer switch replacement BE 27 Wiper BE 27 Washer nozzle BE 27 motor replacement Wiper blade operating range BE 27 TROUBLE adjustment DIAGNOSES AND CORRECTIONS Description the The windshield wipers consist of wiper motor link arms unit consists of motor and autostop mechanism The wiper motor is of a speed 2 and blades and the wiper motor the windshield pulled wipers operate to the 2nd The nozzles step operate pulled at low at to the Ist step on the fluid tank with windshield washer consists of motor windshield wiper switch to the washer a single twist the switch knob IGNITION SWITCH WASHER MOTOR FUSE P lILR W L WIPER LR OFF IVI IV ILl III 181 181 lLW LW Circuit x 1 SWITCH 2 diagram for windshield wiper washer system BE 26 TWIST X Bll j 43 BE and pump and vinyl tube used to connect BATTERY Fig is washer those compo The windshield washer switch is combined with the the cowl dash in 18L link mechanism nents speed and when high speed The wiper motor unit is located electrically operated washing type When the wiper switch knob is and compartment located behind the instrument panel mechanism wiper a engine BE 2B I unit When operating BODY ELECTRICAL Wiper replacement motor provide the L FiIst of all wiper 2 shaft compartment 3 the connector plug from the motor Remove wheel remove a nut used to connect to wiper connecting rod the side dash Reinstall 4 remove a new arm 434 36 wiper attaching a proper installation blade is angle so positioned correctly nut tightening torque f6 BE Remolling wiper is 60 5 that The cm kg 21i ft motor worm from passenger wiper motor panel Loosen three bolts used to install the the cowl dash wiper with ann the windshield the wiper wiper on motor motor in reverse sequence of removal Fig 27 Fig BE 44 mm 1063 in Wiper motor Fig Wiper 1 BE 47 Wiper arm installation washer switch Remove the connector replacement from back of the wiper washer switch 2 Depressing counterclockwise 3 Fig Wiper When attaching shaft bladc BE 45 operating removing nut Wiper motor li kag the wiper and pull out the wiper When installing the wiper arm arm on wiper switch knob it Loosen the escutcheon and remove the Washer nozzle loosen the turning the remove wiper switch from the cluster lid range arm and wiper adjustment When the washer nozzle is installed arm fluid is not from the pivot the pivot shaft so BE 27 sprayed properly adjust or when washer the nozzle direction that fluid is sprayed in range indicated in Figure 48 BE BODY Caution in Rashed range of washing solvent I use of washer Never operate the washer continuously for 30 seconds causes or without the washer washer should be s the Normally 48 BE Adjusting lI1dSher nozzle TROUBLE DIAGNOSES AND CORRECTIONS Troubles Wiper system does Possible not oper ate Open or Remedies causes short circuit of feed har Repair harness ness Blown off fuse improper fuse or Replace or correct fuse position contact Improper connector contact Defective control Slow rotation of wiper motor switch control switch Defective motor Replace motor Rotating psrt Lubricate rotating part Defective motor Wiper speed does not change Correct contact Replace is out of lubricant Defective switch or improper switch Replace motor Replace or repair switch Replace or repair switch contact Wiper does not stop Improper switch contact Improperly grounded switch Repair Improper adjustment Replace motor Replace motor of autDstop point Noisy wiper motor Defective motor BE 28 the for less than 10 seconds at time Fig than washing liquid This often improper operation operated more BODY ELECTRICAL Improper wiper Improperly positioned of position stop blade and Correct position arm arm Damaged worn or point stop auto Worn rubber blade Improper wiping Inadequate pressing force of Replace motor Replace blade Replace wiper wiper arm arm IGNITION SWITCH AND STEERING LOCK CONTENTS IGNITION SWITCH Rernoval BE 29 Description BE 29 Steering IGNITION SWITCH WITH BE 29 BE 30 lock replacement Warning switch BE 30 and warning buzzer BE 29 STEERING LOCK IGNITION SWITCH This switch position J is installed on the ignition switch bracket which is installed on the instrument with two screws panel and controls the engine ignition system and most ofelectrical equipment Key position OFF ON START Terminal B IG Battery Ignition S Starter R Resistance y 1 Fig 49 BE Removing ignition switch IGNITION SWITCH WITH STEERING LOCK Description Removal The steering lock is built in the ignition switch When Remove the ignition switch connector loosen the ring the key is set the ignition switch from the bracket steering system nut remove BE 29 to is Lock locked position and removed automatically the The locking BODY mechanism is installed the key is set to Lock steering lock spindle which is the steering jacket tube on stationarily When and removed position the is inserted in a notch in the collar set the on sure attaching a screw on the to tighten two a new steering lock hear type self new screws to shear off their heads Warning The ignition switch is installed with be proper to lock the steering shaft steering wheel cylinder steering jacket tube When installing switch and buzzer warning back of key and interchangeable y e Fig 1 I 2 Key cylinder part Steering jacket tube 6 spindle Steering shaft 7 Self shear type Lock collar 8 Attaching screw 3 4 tion switch part 5 BE 51 Warning nuitch Lock The circuit of this warning system is closed when the screw door is opened with the steering unlocked because the door switch and warning switch When the cicuit is closed BE 50 Fig Steering lock OFF Lock When or ON B Battery r S Starter R Resistance cables remove remove the warning switch switch the cap loosen two of the instrument panel with two IG Ignition I FUSE connected in series the buzzer sounds the warning The warning buzzer is installed START GARAGE replacing are disconnect two attaching on screws the back attaching left screws WARNING SWITCH WARNING BUZZER Steering lock replacement For the purpose of tamper proof screws are used and their heads that installed so removed easily the Replace following Loosen two attaching tool Now hear type self sheared off when the steering lock system accordance with the two self shear are the type remove steering lock be proper in instructions when screws screws cannot and break the DOOR SWITCH required remaining with a drill or other proper the steering lock proper from the Fig BE 30 BE 52 Circuit diagram for warning system and side BODY ELECTRICAL CLOCK Installation upper portion of the instrument panel Connect red blue cable I When installing clock first of all remove the cluster nation lid lamp circuit board for illumination Ground the clock Remove the mask and install the clock on the cluster 2 lid in the 3 place meter from the clock ground cable housing installation on on for illumi the In the case of cable 4 along Fig cABlE BE 53 screw Reinstall the cluster lid BLUE CABLE Square type clock BE 54 Round type clock Fig TACHOMETER Installation I When installing tachometer first of all rernove the cluster lid Remove the mask and install the tachometer in 2 place of the mask 3 Connect cables as shown in the Remove the black white cable along the upper portion of the Figure BE 55 plug connect the black white cable of the plug in series 4 Reinstall the cluster lid of the harness laid instrument panel and tachometer to the 1 Black cable 3 Black white cable 2 YeUowfred 4 Red green cable Fig BE 31 cable BE 55 Installing a square together with YELLOW RED CABLE RED BLUE printed the meter housing red cable coming out yellow blue cable of harness laid the to or lamp type clock tighten the ground of mask Connect blue cable red green cable or of the clock to the terminals tachometer the BODY RADIO Removal I Remove the cluster lid 2 Disconnect the lead wires from the radio 3 Remove two nuts used to install the front side of the radio 4 on the instrument and remove the bracket used to install the 5 on 1 0 panel Loosen two screWs as shown in the radio Jtf 0 Figure rear BE 56 I side of the v I r 4 4 r r I I s r panel the instrument e Remove the radio 1 Power 4 e cable 1Otm 6 eS 2 Power 3 Speaker source prevention Run the engine chart raise the antenna Condition I cable BE 56 maximum and set set volume Apparent 7 Radio cable cables Fig Noise tenn Single pole fuse Spare fuse Attaching screws 5 Blue white cable of Removing radio the dial at medium point without a catching broadcasting wave to Repair cause Ignition system Noise occurs when engine is oper High tension code High tension be may dis because noise suppressor regarded ated code is used Ignition coil Apart the ignition coil choke as far from wire as possible F capacitor in primary 0 5 Install a side terminal of ignition coil Notll Be the careful capacitor primary otherwise comes to not in install secondary breaker the side engine or or be improper Connect wire between engine and ignition cOil locating with bond BE 32 area of body BODY ElECTRICAL Secure ground of ignition coil Secure Distributor pole contact of carbon Eliminate excessive tip pole electric and rotor or on the rotor pole by scrubing with cap a screwdriver Check stagger between rotor and stator Charging system Install Alternator Sound of alternating current pre on sents 0 5 lF a capacitor charging terminal A Note not Do use capacitor ex is ex cessively If capacity used the alternator coil cessively will be broken When the accelerator pressed released or noise presents starts noise presents Install Regulator is de pedal a 0 5 lF terminal of the capacitor on voltage regulator A Supplement equipment When engine Noise still presents Operative O stopping the engine Note If ground wire capacitor a between capacitor lF I terminal and mometer and fuel gauge after even Install noise of ther cessive capacity having is used ex indi cation of meter will be devi ated Noise presents when horn is blown Install Horn a 5 IF 0 capacitor horn relay terminal Noise lamps Note a of presents are when Installa Flasher unit signal turn or on the horn switch 5 lF capacitor O operated Be sure to locate capacitor nois6urce and connect in b Cut lead wire as short as c Ground wire should most near completely position parallal possible be placed on tha de Maka installation and connection e Carefully identify marks body BE 33 securely IN or our BODY HEATER CONTENTS Removal and installation BE 35 TROUBLE DIAGNOSES AND BE 35 CORRECTIONS I I to 1 Heater hose 2 Qamp 3 Shut valve Vent valve 4 5 Room valve Defroster hose Defroster nozzle Control wire heater control to room valve Control wire heater control to water cock Control rod heater control to shut valve Heater cock 6 7 8 9 10 11 Fig 57 BE dter H Removal and installation 1 In order to ease the nit wires between water cock and heater control valve operation remove the package and heater control Note Loosen the hose and disconnect two heater clamps 3 Disconnect clamps cables lever to Remove the wire from clamps room Dis control operation upper lever to be sure to set the OEF and lower OFF from the heater hoses the heater unit 5 heater control and main harness 4 When carrying out this heater hoses between the heater unit and engine at the engine side Remove the hose and unit side connect the control rod from the shut valve tray and ash tray 2 the heater at Withdraw two left and right defroster hoses by screws used to install the hand 6 and disconnect two control BE 34 Loosen four attaching BODY ELECTRICAL heater unit on the dash board and remove the heater unit panel carefully 8 Remove two self tapping instrument 7 panel and remove screws from back of the the defroster nozzle When removing the heater control from the instru ment screws panel 9 the control knob and loosen two remove used to install the heater control on the instnunent The heater unit is installed in reverse sequence of removal TROUBLE DIAGNOSES AND CORRECTIONS Troubles Possible Remedies causes Hot air does not come out Motor does not operate Open or short circuit of feed har Check and repair wiring harness ness Defective switch Conduct required Replace Defective motor Fan cannot be rotated Motor journal is out of lubricant smoothly by hand stick Hot air dose out not come fan nevertheless or continuity rep ce switch motor Lubricate journal Replace motor Slow rotation of fan Replace motor Loose fan installation Repair Defective water pump Repair water pump Repair or is rotating Air temperature is low Hot water does not cir culate Bent or Water temperature is too clogged of connecting hose clean piping Defective hot water cock Repair Air is left in the hose Purge Defective thermostat Replace thermostat Defective water hose Replace air out of hose low Water leakage from water hose heater Loose clipping of water hose Improper soldering of heater Defective defroster Disconnected defroster hose Bent or broken defroster hose BE 35 Retighten clip core Solder leaking position Correct connection Correct or replace test and if 10 0 BODY Vibrating noise Loose heater support Tighten completely Loose fixing Retighten screw SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or No PAGE No SUBJECT BE 36 SECTION SE SERVICE EQUIPMENT DATSUN 1200 MODEL B 110 SERIES CHASSIS INI BODY NI NISSAN MOTOR CO TOKYO JAPAN LTD SPECIAL SERVICE TOOL SE 111 SERVICE EQUIPMENT SPECIAL SERVICE TOOL B 110 special service tool set number SetA ST09330000 Set B ST09340000 510 special service tool set number means tool included in Tool Set ST09330000 means tool included both in Tool Sets ST09330000 and ST09340000 ST09IIOOOO II means tool included in Tool Set ST09l10000 Tool number Figure Tool Description 0 0 E t name mm inch l S M refer 0 0 o Applied model on ence page See Fig No lil Clutch tool ST206 I 0000 Clutch aligning For bar centering the clu tch disc BlO B20 Fig CL 14 Fig CL Fig CL 7 ST20 I 01000 For Clutch assembly base @ D pia te measuring the dia phragm spring height Use with the distance BIO B20 5 piece STl005800l 7 Clutch assembly O For measuring the dia 3 distance piece @t phragm spring height Use with the base plate 510 521 130 C30 S30 SE 1 Fig CL 5 CHASSIS go Tool number o Figure Tool name Description rnrn 0 0 M refer S So 00 Applied 0 00 model 00 ot inch l a ence Fig i page See No ST20105000 Diaphragm adjust F or measuring the dia BlO wrench phragm spring height B20 Fig CL7 Transmission tool ST22350000 BlO Main shaft bearing drift For assembly of the main shaft bearings B20 Fig TM 35 Fig TM 29 Fig TM 30 130 A30 ST23030000 Counter shaft bearing press stand For assembly of the BlO counter shaft B20 bearings ST23050000 For measuring the Counter gear height counter gauge from the transmission bearing height case rear SE 2 end BIO B20 SERVICE EQUIPMENT Tool number Figure Tool Description name mm Q inch 5 S M refer 00 g 0 0 l o t il 01 l Applied model t ence page See Fig No ST23S20000 F ark rod pin punch 30IS 21 For removal of the fork BIO rod retaining pins B20 Fig TM 16 Fig TM 18 Fig 4I TM Fig TM lS Fig TM 22 y ST23620000 510 For supporting the inter lock ball when installing F ark rod guide CIO BIO 820 the fork rod 521 C30 ST23820000 270 10 6 Setting plate Adapter setting plate of the transmission gear a BIO B20 assembly ST22730000 For removing the Bearing puller mission main and drive shaft SE 3 trans BIO counter 820 bearings CHASSIS Tool number S M refer 0 gg 0 Applied 0 Description Figure Tool name Differential mm Q model u E inch ence page See Fig No carrier tool ST06220000 50 tting tool of gear 810 carrier Differential gear carrier attachment Fig PD B20 Use with engine stand ST30600000 BlO F or installing Drive pinion bearing pinion drift rear B20 the drive bearing inner 1 417 Page PO II A30 race 36 130 dia S30 SBl120000 Drive pinion armnge ment gauge For height adjustment pinion of BIO Fig PD 22 B20 the drive ST3l230000 For hiehgt Dummy shaft adjustment the drive pinion 4 SE of New Fig PD 22 SERVICE EQUIPMENT i Tool number S M refer iio 0 g Applied Co Description Figure Toolnarne mrn inch u co OIl C l OU I 1 11 model fII ence page See Fig No snl 540000 Drive For removal of the pinion flange drive wrench pinion nut BIO Fig PD 12 B20 ST325oo000 Side bearing adjust weight 84 5 20 0 7871 3 dia r EJ 7 For determining the side 327 LJ IO bearing adjust shim BIO Fig PD25 B20 6891 Sn30lOoo0 BIO F or removing the dif ferential side bearing Differential side bearing puIler assembly B20 CIO Use with adapter 130 ST330l1000 521 Fig PD 9 V5l0 ST33220oo0 Differential side bearing drift uo For assembly of the side bearing BIO Fig PD 19 B20 snl190000 Drive pinion gauge For preload CJIICD measuring the drive pinion SE 5 pre load BIO B20 Fig PD 2l CHASSIS Tool number g Figure Tool name Description mm 0 u 0 sg Q U E o inch S M refer Applied model ence page See Fig No ii ST3003 I 000 O B Drive pinion For removing the drive pinion rear bearing rear bearing inner replacer race inner B20 0 5 Fig PD IJ O C race C30 S30 Front axle and suspension tool ST353IOOOO Front wheel hub For removing and bearing installing outer race drift the front wheel hub bearings O B B20 Fig FA 22 Fig FA 32 Fig FA 34 ST3565ooo0 New 0 5 Coil spring Compressor For set assembly and dis assembly re of the coil O C C30 S30 spring ST35500000 0 5 Gland packing For wrench gland packing tightening the O C C30 S30 width rOD f1ets 55112 7 6 SE SERVICE EQUIPMENT Cii Tool number g S M refer 0 0 0 Figure Tool name Description mm inch Il 0 co Clot Applied model u ence page See Fig No E ST35550DOO Gland For assembly of gland packing packing guide the New Fig FA 39 New Fig FA 53 Fig RA 5 Fig RA 7 ST3672DOOO For Front transverse bushing replacer link the remving and installing transverse link set SUPPORT Rear axle and bushing GUIDE suspension 9 tool ST371300DO Rear axle shaft @ bearing puller ST3827DOOO Rear axle shaft bearing and collar press stand set 41 C For remving the shaft rear axle bearing BID B2D 11 6141 die For installing the rear bearing and axle shaft collar SE 7 BID B2D CHASSIS G Tool number 28 S M refer Go 0 A pplie d ence page c Description Figure Tool name mm inch v ou model o t CC1 I Y See Fig t No ST07640000 BIO For removing the axle shaft Rear axle stand Use with rear sliding hammer ST36230000 pitch 114 3 4 5 510 CIO Fig RA 3 Fig RA 7 C30 S30 di8 ST36230000 I Sliding hammer Steering 1 Use as sliding hammer by All the weight Fig RA 3 tool ST27 140000 Steering gear puller For removing and arm installing gear the steering arm BIO 510 Page 521 ST 3 B20 ST27190000 For assembly and dis Steering linkage joint puller assembly linkage 8 SE ofthe steering BIO Page B20 ST I4 SERVICE EQUIPMENT Tool number Figure Tool name 0 Description mm S M refer O iii 0 8 0 Q in i Applied model ence page See Fig Body tool ST087 I0000 Page For removing and install ing the Torsion bar wrench J e tail gate BF 20 torsion New bar SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or No PAGE No SUBJECT SE 9 BF 23 No tII CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL or DATE BULLETIN No PAGE No SUBJECT SE lO SERVICE EQUIPMENT SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or PAGE No SUBJECT No SE 11 I CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or PAGE No No SUBJECT SE 12 I t t f F r f INISSANI 0 7 1 I j j i sf
