-教學資源-Datsun 1000 and 1200 A10 A12

SCIENTIFIC PUBLICATIONS
WORKSHOP MANUAL SE
IES No 87
rl
1000
Z1
WITH SPECIFICATIONS
REPAIR AND
MAINTENANCE
DATA
COVERING
AIO AI2 ENGINE
STATION WAGON
SEDAN
PICKUP
SCIENTIFIC PU LICATIONS
WORKSHOP MANUAL SERIES No
DATSITN 14M
00
87
seIE
FIe PUBLICATIONS
WORKSHOP MANUAL SERIES
No
87
DATSUN 1000 1200

SERIES OIO 0110
SEDAN
WAGON
PICK UP
AUTOMATIC and MANtJAL TRANSMISSIONS
With
Repair
SCIIL
and
Speelfieations
Maintenanee Data
PUBUCADONS
MELBOURNE
Published
by Scientific Publications Ply
142 Oarence Street

Printed
Sydney
Ltd
2000 New South Wales
by Kenmure
Press Ply Ltd
New South Wales
Copyright by Scientific Publications Pty Ltd

Registered at GPO Sydney for transmission by post as a book
First Edition
National
January 1972
of Australia Registry Number

SBN 85566 038 4
Library
CK
OWLt UC E IE
thank Nissan Motor

Scientific Publications
Fairfield
for help in
USA
Lid
and
Warner
Borg
Corp
aspects of preparing this manual
wishes
to
EXGIXE
COOLING SYSTEM
FUEL SYSTEM
28
14
CLUTCH
47
MANUAL TRANS1UISSION
57
AUTOMATIC TIlANSMISSION
73
REAR
85
AXLE
103
STEERING
FRONT SUSPENSION
RE
R SUSPENSION
BRAKES
126
131
ELECTRIC
L SYSTE
148
184
BODY
WHEEL
ll
I
AXD TYRES
LUHIUCATION AND MAINTENANCE

EMISSIOX CONTROL SYSTI MS
195
200
1
20
IXDEX
211
GLOSSARY OF TERMS
lIlt
ROAD TEST
217
OTHER TITLES IN THE SCIENTIFIC
PUBUCATIONS
Bool
No
Car
Austin A40 Devon
00
Austin A40 Somerset

A utoServ I
Complete BMC Mini
1
50
1100
1800
Datsun
1000 1200
Datsun 510 1300
1400
1600
Dodge ASM 106

Ford Capri 1600
and 1600 GT
Ford ConsulZephyr
Mk I 1951 55
Ford
7L
87
Pag
IDo
Indiom
of Text
106
99
294
431
224
BNUAI SERIES
Book
No
Price
Aus
Car
89
120
84
48
2 30
7 00
Lawn Mowers Vieta 2 Stroke

100
Kirby 4 Stroke
23
Morris Minor MM II
24
Morris Minor 1000
315
208
9 00
Morris Austin Mini
6 25
and S
Mini 1100 Moke
Morris Austin 1100
88
6
256
464
241
517
6 50
82
173
108
5 75
2 80
153
85
184
124
50
3
Zephyr
Consul
Mk II 1956 62
Ford Cortina 1200
1500 1600
68
288
192
6 25
Ford Customline
Custom
1949 54
10
193
107
120
3 50
Morris Austin 1800

Mk I
Morris Austin 1800
MG Midget Series TO
MG Series TC TD
V8 and 6 cyt
Holden HK HT HG
V8 Engine
Holden HK HT HG
121
3 75
40
41
81
51
147
134
100
175
125
184
149
3 00
5 75
73
93
176
107
5 75
83
44
224
167
175
130
6 00
5 25
69
174
95
6 25
cyl Engine
78
279
145
6 25
Holden Torana S SL
1969 Brabham
76
200
140
5 75
HC Trucks AR AL
IHC Trucks AS line
IHC Trucks AA line
Jaguar Mks VII VIII
47
224
160
6 25
46
224
204
6 25
IX XK
150
48
49
256
202
66
6 25
100
Jaguar
4
2
Standard
Space
master Series
Standard
11
42
III
Vanguard
128
82
7 00
185
75
287
197
7 00
Valiant AP 6
VE VF V8
86
224
188
6 25
72
191
120
6 25
17
437
657
18
19
173
595
245
1040
3 50
40
1
3 50
43
105
VC
Engine
AP5
Valiant R S
AP6 VC VE
VF 6 cy
Engine
Vauxhall Viva HA
HB 90
Volkswagen
1500
1600
Volkswagen
1200A
1100
1200
1300 1500
Volkswagen
20 140
21
274
237
22
77
274
202
281
124
7 00
4 Mks I
3
and II 3 8 Mk II
Jaguar 3 8 4 2 E
Standard 10 1955 58
286
80
7 00
2 30
90
113
67
16
215
106
29
37
Corolla 11 00
Toyota Corolla 1200
Toyota Corona
Triumph TR2 3 4
272
6 25
Elysee
Toyota
85
174
7 00
6 25
FE FC FB EK
EH EJ HD HR
Holden FE FC FB
Holden HI Series
224
399
Standard 8 14
1939 46
5 75
66a
390
Simca Aronde
1200 1300
121
5 75
5 75
7 00
188
95
97
188
79
138
133
164
750f760
290
3 50
66
34
Dauphine
74
Renault R8 and RIO
Rootes Group Hillman
Humber Husky Cob
36
1958 66
Renault
Renault
62
132
6 25
5 75
3 75
100
4 00
Peugeot
5 75
122
187
106
7 00
172
11
236
145
171
98
158
184
Hillman Hunler
Arrow HB HC
Holden 1948 53 FJ
64
65
204
81
155
50
3
121
79
404
Ford Falcon XK to
XW 6 cyl
238
96
304
403
63
40
1
2 30
31
33
MGA MGB
Ford Customline OHV

Ford Escort I 100
BOO 1300 GT
Ford V8 and
Mercury 1932 48
89
161
AusLt
70
TF
166
121
Ford Falcon XR to
XW V8
80
142
96
Price
s
Dlu
trntiollS
Cooper
Mk I Mk II
120
Pages
of Text
7 00
6 25
Transporter
Wolseley 1500
100
In Production
t Recommended retail price in Australia
OVERSFAS REPRESENTATIVES
South Africa Central News Agency Ltd Laub Street New Centre Johannesburg 10799
United Kingdom Alltech Distributors 15 High St Hampton Middlesex
North America
Autobooks
Repco
Burbank California 91503

Magnolia
Blvd
Doylestown Penn Ios Angeles Calif Toronto
2900 W
Auto Parts
Ontario Vancouver
Be
ENGINE
SPECIFIC
4
Type
Replacement guide
in
cylinder
TIO
12 211
12 200
4807
0
4800
0
line OHV
Valve seat
73mm
Bore
30
1
Inlet
Stroke
59mm
A 12
70mm
323
2
p709 in
Valve seat insert outer diameter
standard
cm3
60 3 in3
engine
1171
em
71 5
in3
37 080
Inlet
988
engine
37 096 mm
1 460 iri
459
33 080
Exhaust
33 096
302
1
mm
in
303
1
Valve seat insert inner diameter
Compression ratio
AIO engine
A 12 engine
Bhp Maximum
AIO engine
A 12 engine
30 to 1O
Inlet
8 5 I
1181
90 1
1 023 in
56 at 6000 rpm
68 at 6000 rpm
Valve seat insert
depth
6 0
Inlet and exhaust

8 50
kg
5 90
mm
0 2362
Insert interference fit in head
@ 4000 rpm
5 ft lb
61
0 2323 in
0 096 mm
0 064
0 0038 in
0 0025
@4000 rpm
9 70 kg m
engine
mm
to 004in
26mm
Exhaust
Maximum torque
A I 0 engine
A 12
1 80mm
Exhaust
in
2 756 in
Capacity
A 12
mm
0 0512 in
AIO engine
A I0
in
450
angle
Valve seat width
2 874 in
engine
mm
VALVES
GUIDES AND SPRINGS
@ 3600 rpm
70
Valves
1 ft lb
Head diameter
@ 3600 rpm
1
Firing order
Idling speed
600
378
1
0
Stem diameter
distortion limit
Overall length
O IOmm
Stem to
Valve seat material

bronze
recess
diameter
14573
replacement
insert
37 516
14770
Exhaust
standard insert
33 016
1 2998
Exhaust
replacement
insert
33 516
3195
1
Cylinder
4 0984 in
Exhaust
0 040 0 070 mm
0 0016 0 0028 in
14567 in
A 12
engine
14763 in
Valve
3190
1
12 00
4728
0
4724
0
in
mm
8 015
8 000 mm
0 3155
mm
Outside diameter
12 044
Interference fit in head
0 022
Length
53mm
3150
0
12 033
4740
0
in
guide
12 011
50
7
guide
Inner diameter
mm
1 2992 in
50
33
mm
0 2953 in
37 50 mm
33 00
7 80
3071
0
37 00 mm
head bore diameter for valve
tandard guide
mm
0 015 0 045 mm
0 0006 0 0018 in
A10 engine
37 016
standard insert
104 1
Valve lift
in head
Inlet
guide
in
3430
0
103 5
Inlet
Cast iron
Valve seat insert
8 69 mm
clearance
Aluminium
Exhaust
142 in
8 70
4 0750
0 004 in
Inlet
in
3426
0
Aluminium alloy
Type
Inlet
35mm
29mm
exhaust
rp
CYLINDER HEAD
Gasket face
inlet
mm
in
0 044 mm
0 0009 0 0017 in
2 087 in
in
4737
0
in
mm
Engine
Fitted height above spring
seat
18mm
0 006
Clearance in piston
0 709 in
Valve
Interference fit in connecting rod
spring
45 7
Free length
65 23
Length
6548
@ 30 0 kg
With pistolJ
at
mm
2 5779 in
2 5681
38 5 mm
mm
0 0013 in
0 0007
mm
I 7992 in
Fitted length and load
0 008
10 0002 0 0003 in
0 017 0 034 mm
temperature of 200C 680F
1 516 in
CRAN
SHAFT AND MAIN BEARINGS
@66 llb
Number of effective coils
4 5
Wire diameter
4 276 mm
Crankshaft
0 1693 in
26 224
Coil diameter
Main
arm
diamet
49 964
Journal taper
ovality wear
or
limit
35
0
Main
mm
ring clear
be
0 020
ce
Clearance
0 25 mm
wear l
it
CrankShaft
Slipper skirt
cast aluqlinium
alloy
standard
diameter
25
mm
4th oversize
100
73 517
73 967
125
oversize
mm
150 nun
bore clearance
Piston rings
Width
compression
Lergth
74 297 nun
2 92 19 2 9239 in
74
467
74 517 nun
Big
2 9337 in
0 023
0 043 nun
0 0009 0 0017 in
ance
in grpove
0 07
0 20
gap
0 0079
wear
Big end bearing

crankpin
mm
clearance
on
0 020 0 050
or
misalignment
6869
mm
0 0020 in
1 0 mrn
0
0 05
00020
0039
in
mm
0 0ll8 in
CAMSHAFT AND BEARINGS
journal
diameter
43
I
0
mm
0 0012 in
40 mm
0
0016 in
limit
Connec ing rod bent
Camshaft bearing
No
17447
0 0594 in
30
0
0 0008
Gudgeon pin
er
0 20
0 0079
GUDGEON PIN
Diame
0 0591
Big end end float
0 0027 in
30
0
1 508 mm
1 500
mm
0 0016
4 6188 in
9051
12147 12153 mm
4 7822 4 7846 in
end bearing thickness
End float
0 04
117 3 mm
116 97
engine
AI2 engine
0 1575 in
Side clea
A 10
4 00 mm
trol
1 7701 in
0 03 mm
Connecting rod
0 0787 in
con
limit
CONNECTING ROD AND BIG END BEARING
74 217
2 00
wear
0 0012 in
2 9140 in
2 9318
cylinder
0 0719 in
44 961 mm
974
mm
74 017 riun
2 9121
44
Crankpin taper or ovality
2 8944 in
2 8924
nun
1 827 mm
I 7706
73 217 73267 nun

2 8826 2 8845 in
73 717 73 767 nun

2 9022 2 9042 in
75
1 835
bearing thickness
rankpin diameter
2 8747 in
mm
3rd oversize
5 th oversize
nun
73 467
50
0 0059 in
mm
0 0722
73 0 7
72967
30
0
wear limit
0 0118 in
Main
mm
2nd oversize
Piston to
End float
Selective
I t oversize
Ung
0 15 mm
0 0020
2 8727
oil
0 050 nun
0006 0 0020 in
0 05
End float
Piston fit
in
5mm
10
Pistons
Type
nun
0024
0 015
run out
PISTONS PISTON RINGS AND GUDGEON PINS
6th
0 0059 in
0 0098 in
Skirt
0062
0 0008
0 0138 in
Cold
0 03 mm
00012 in
to valve stem clearance
Hot
49 957 mm
1 9668 in
I 9671
0 0324 in
Rocker
journal
mm
17452mm
No 2
0 6871 in
8
43
793
7241
806
mm
1 7246 in
43 283
43 296 mm
7040
1
1 7046 in
3
Engine
42
No 3
42
783
1 6844
2 75
1 6652 in
37
3
1 6228
1 6233 in
No 5
61
231
41
bearing
37
2
mm
TORQUE
inner diameter
43
No 1
843
43
323
43
333
43
I 7060
42 846
No 3
Comiecting
1 6667
323
3 6
nuts
Flywheel bolts
A10 engine
nim
Full
7 50
Al2 engine
mm
kg
30
5
tt lb
20
54
1 6243 in
kg
sprocket
4 50
bolt
Eccentric
Filter type
Full flow
Camshaft locating
motor
plate
0 50
bolts
lb
ft
0 60
Sump bol ts
30
4
Clearance outer rotor and body
0 15
0 12
0 0020
0 21
0 0059
end cover
kg
in
Oil strainer bolts
mm
0 0083 in
ft lb
kg m
I0 80 ft lb
1 40 kg in
10 10 ft tb
16kg m
mm
6047
kg in
1 50
Oil pump attachment bolis
outer
0 65
kg
3 60 ft lb
trochoid
rotors
3250 ft lb
pressure
Oil pump type
Crankshaft pulley bolt
116 ft lb
0 12mm
0 0492 in
Timing
0 80
chain tensioner bolts
klilm
5 80 ft lb
Relief valve
spring
leilgth
49
43
I
Fitted
kg in
30
38
Type
Free
7 50 ft lb
Camshaft
rotor to
kg
3 00
LUBRICATION
Clearance
34 70 ft lb
Main bearing cap bolts
Oil pump
Side clearance inner and
kg
4 80
Cylinder head bolts
mm
1 6663 in
258
41
1 6247
rod
26 ft lb
1 6865 in
41268
No 5
MAXIMUM
mm
1 7050 in
42
333
42
WRENCH SETTING
mm
42 836
1 6868
No 4
833
17257 in
17261
No 2
Imp qts
2 87 US qts
0 0026 in
0 0009
Bearing
US qts
0 0039 in
0 065
0 024
clearance
Imp qts
2 70 litre
Less filter
mm
0 IOmm
0 0004
Journal to
3 20 litre
With new filter
I 6647
41 218
42 283
run out
Capacity
IiI
42 296 rom
No 4
Camshaft
796 mm
16849
30
length
I
pedestal
2 50 kg m
I 8 10 ft lb
1 40 kg ni
10 10 ft lb
5 00 kg in
36 20 ft lb
bolts
Mainfolct
mm
bolts
19 in
4 26 kg cm2
3 80
Relief pressure
Rocker
mm
71 in
54 0
59 70
Pump release valve plug
psi
t
DESRIP
i
lON
the comi cting rod and this is the only means of retaining the
gudgeon pin in the assembly
four cylinder
overhead valve engine has a cast iron

alloy cylinder block and crankcase The cylinder head is of
cast aluminium alloy with
replaceable valve guides Each
The
valve has its individual port and is operated by

rod and rocker arm from the camshaft
The crankshaft is counter balanced and funs in three

AI2
AIO
or five
steel backed copper lead split shell
tappet push
bearings Crankshaft end float is taken at the centre

bearing
Connectirig rod big end bearings are split steel backed
copper lead replaceable shells
main
main
Pistons are slipper skirt aluminium alloy type with two

compression rings and orie oil ring The lower compression
ring is taper faced and t e oil ring comprises an upper and
lower chrome faced steel segment with

The gudgeon pin is
an
Pistons
spacer in between
interference fit in the
smail end
the
cylinder
engine
of
9
are
marked
bore size
on
a code number of
be to the front of the
the crown with
which
must
4l Engine
Driven Side View of 1000 Series Engine and Automatic Transmission

Typical Also of 1200 Series
to
Connecting rods and big end bearing caps are numbered

The big ends of the connecting rods are bored with an oil
squirt hole
on
Oil pressure is maintained
the thrust side
The
engine
Oil passes
through
drilling
to
moun ted
the centre rocker pedestal
Drain the
cooling system and the gearbox

Disconnect the battery leads at the battery and
remove the battery and battery Hay
speedometer
13
Release the retaining clips and remove the upper and

lower radiator hoses Remove the air cleaner
release
disconnect the heater hoses

5
Disconnect
the
at
the
retaining
the engine
high and low tension leads
and distributor
6
Disconnect the alternator leads
at
clips
14
and
eng
cable
assembly
at
the
gearbox
rear
Disconnect the earth
strap
at
the starter motor
Disconnect
the handbrake rod support
on
the
15 Take out the four bolts disconnect the rear

universal joint flange from the pinion flange at the rear and
withuraw the pC0peller shaft from the rear ufthc gearbox
t 16 1000 model Slacken the lock nut at the adjuster
the alternator and
con
drive
gearbox
at the coil
end of the clutch control cable and unscrew the cable adjuster
bolt from the end of the cable 1200 model Slacken the
adjustment at the upper end ofth cable case and unhook the
ne
Disconnect the choke and throttle

the carburettor
8
full flow oil filter
mounting bolt
the starter leads at the starter solenoid

7 Disconnect the oil gauge and temperature gauge
wires at the
extension
fitted
lubricating oil passes through

externally on the oil pump
and disconnect the gear change links at the levers on the side
of the gearbox
the
and
the
ferrule
disconnect
12 Unscrew
Where
pre detennined maximum

the pump
mNE AND TRANSMISSION
TO REMOVE AND INSTAL
at a
by a spring loaded relief valve situated within

body
The oil pump is the trocoid gear or internal rotor type

and is driven by the camshaft to provide full pressure to the
provide lubrication to the rocker armS and shaft
rrollinkage at
lower end of the cable off the clutch release throwout lever
17 Remove clutch cable casing bracket attaching bolt
and withdraw the cable and bracket clear of the engine and
9
Disconnect the fuel inlet pipe at the fuel pump
10 Remove the flange nuts and disconnect the exhaust
outlet pipe at the manifold
11 Raise the car sufficiently take out the split pins
gearbox assembly
18
10
On
models
with
hvdraulic
clutch
operation
5
Engine
the slave
cylinder
and
at
both the hose and the
connection to prevent entry of
cylinder
bolts attaching the mounting bracket

remove the rear mounting assemble
plug
disconnect the flexible hose
Take out the four
securing
bolts and
radiator
Using suitable lifting tackle attached to the lifting

the engine tighten the lifting gear to take the
weight of the engine assembly
21
Remove
the nuts securing the front engine
out
the two bolts attaching the rear engine
take
mountings
mounting to the rear extension housing take out the two
20
brackets
Raise the
front and lift it from the
the
remove
the underframe and
engine tilting it upwards sharplv at the

car through the bonnet opening
Installation is a reversal of the removal procedure with
attention to the following points
the weight of the engine to settle on the front
Ow
AIl
1ts
engine mounting before tightening the mounting n1
Fill the gearbox with the correct grade and quantity of
22
dirt
19
to
on
oil
frEnsure
that there
are no
water leaks
ROCKER
inMS AND SHAFI
1
I
TO REMOVE AND DISMANTLE
Continue to reassemble the remaining components

rear pedestal has been installed and retained in
i
tilthe
Remove the air cleaner and the
1
cleaner
2
to
Take out the
remove
position by inserting the securing bolt
pipe from the air
the rocker cover
the cork
screws
and lift off the rocker cover and

NOTE If the rocker shaft is correctly assembled each rocker
arm v
fiu be offset with the adjuster screw end of the rocker
gasket
Unscrew the five rocker pedestal bolts progressively

loosening eacn bolt a few turns at a time until they are all free
3
and lift offthe rocker

4
towards the adjacent pedestal
assembly
Remove the bolts from the rocker
pedestals starting
pedestal rocker armspring
rocker arm pedestal in that order noting any spacer washers
interposed between the rocker arms and the adjacent
pedestaL
at
the
rear
and withdraw the
NOTE Keep each component in the order

that it
can
important
screw
rear
original position This is

offset with the adjusting
adjacen t pedestal
the rocker arms
end towards the
are
TO ASSEMBLE AND INSTAL
Check each rocker
arm and
sludge
or
adjust
the rocker shaft for wear
Check that the oil holes and passages in the rocker

clean and free of any
arms
followed by the
washer and the second
pedestal push the pedestal along the shaft compressing the
spring unttl the pedestal bolt can be inserted to hold the
Instal
ann
spacer washer
spring rocker
if fitted
ann
Check the rocker

if necessary
as
head and
arm to
valve stem clearance and
described in TO ADJUST VALVE
the rocker cover
assembly in position
t
r
i
V
cylinder
9
Using a new gasket place the rocker cover on the
cylinder head with the oil filler cap to the front instal the six
securing screws firmly but do not over tighten or the cover
flange will become distorted
10 Position the air cleaner on the carbureltor and
secure with clamp and wing nut Using suitable pliers to
expand the clips connect the pipe between the air cleaner and
Position the front rocker pedestal on the front end

of the shaft and insert the pedestal bol t to hold it in position
3
the
CLEARANCE
are
scale
front rocker
on
6 Using a suitable spanner

tighten each pedestal
securing bolt progressively a few turns ach until the five
pedestals are seating securely on the cytlnder head Use care
to ensure that the centre pedestal is located correctly on the
oil passage in the cylinder head
7 Tighten the rocker pedestal securing bolts to the
specified torque
of dismantling so
be assembled in the
as
Place the rocker assembly
the securing bolts into the head until they are finger
that the ball end of each rocker adjusting screw
Ensure
tight
is seated correctly in the socket end ofits push rod
screw
i
U
Rocker and Shaft Assembly Note Offset of Rocker Screws
11
Engine
6
4
Cl LI
DER
carburettor and distributor and
TO REMOVE
I
D
UK
Remove the air cleaner and the pipe from the air
the
cleaner to the rocker cover
spark plugs
8
Drain the cooling system at the two drain cocks one

the rear ofthe lower radiator tank and the other on the left
2
on
hand side of the engine towards the
bolts
few turns at
with the
4 Slacken both hose clips and remove the upper

radiator hose between the radiator and the thermostat
on
advance
pipe from
Do not
and
remove
the
remove
the bolts from the pedestals
to retain the rocker components

Remove the rocker and shaft assembly from the
they will serve
Withdraw the push rods keeping them in order of

ensure installation in the original positions
12
the
13
and remove the inlet
Remove the nuts and washe
and exhaust manifold assembly

manifold gasket
reverse
RINGSE
U
screws
from the cylinder head

loosen the rocker pedestal securing
time until they can be fully unscrewed
removal to
engine
vacuum
as
the shaft
II
Disconnect the fuel feed pipe at the carburettor and

the fuel pump release the fuel pipe from the steady clip on
the front of the cylinder head and remove the pipe from the
5
Disconnect the
securing
the
cylinder head
housing
fingers
and shaft
the battery tenninal
and
wire at
gauge
cylinder head
temperature
gasket
Progressively
cover
10
NOTE If anti freeze mixture is being used drain into a dean

container to be used again
at
the
rake out the six
rear
Disconnect the earth cable
from the engine
from the cylinder head
Disconnect
connection on the front of the
rocker
remove
7 Disconnect the high tension leads at the spark plugs

and coil and remove the distributor cap and leads Remove
Remove and discard the
Unscrew and remove the cylinder head bolts in the

see illustration
Note that the
order of tightening
bolt removed from the centre hole on the right

T on the bolt head
hand side is marked with a
the
Lift
off
cylinder head and gasket Discard the
14
cylinder head
b
COTTERS
gasket
COTTERS
TO DISMANTLE
SPRING eN
INLET VALVE
SEAL
cylinder head on its edge on a bench and

spring compressor compress each valve
remove the O ring seal and split retaining
Place the
using a suitable
spring in turn
valve
wllets
2
Release the
spring compressor
3
caused
and remove the valve
spring seat washer if fitted

Check the end ofthe valves for bur and upsetting
by slack adjustment and if necessary clean up with a
spring retaining cap spring
and
smooth file
4
Withdraw the valves keeping them in order

EXHAUST VALVES
sEAT
O
WASHERS
LLJI J
JL
q
4HLET VALVE
EXHAUST VALVE
INLET
VALVES
Combustion Chamber Side of
Valve and Valve Spring Companenu

12
Cylinder
Head
so
that
Engine 7
Sequence fr Tightening Cylinder Head

Jlt
be reassembled in the original positions
off
the
seal
end
ofthe
type neoprene
inlet valve guide and discard if they have been in service for a
they
Loosen in Reverse Order
surface ground
condition
can
Pull the shroud
Its
the used
TO CHECK AND INSPECT
or
burnt
to the recommended angle
as
guides
shown in the specifications and each valve stem flat and true
t
on a suitable valve eefacing machine Discard any valve tha
be excessively bent
valve head has been reduced
after the grinding operation

should be renewed
Valve stem ends may only be
less
to
0 50
mm
0 020 in
Measure
guide
guide
guides
and
or
up to 0 50 mm
se
recut
the seats with
valves should be
valve seat
cutter to
If
excessively
the
then
seats
new
in
the
worn
or
and
of
the
exhaust valve guide
Check the fit of the valve in the
the
tool
to
ensure
concentric with bore
recessed
important
inserts will have to be installed It is
installation of new valve inserts

be entmsted to an
valve guides if necessary
reconditioner
who has the necessarv
automotive engine
recommended that
The internal bore
suitable
head are
guide position in
clean
is
new
valve guide and
if necessary ream the guide to the specified diameter

5
After the new guide has been fitted and if necessary
reamed to size reface the valve seat using a vibro centric or
recommended angle and wid tho

NOTE
in and around the
counter bored at its combustion chamber end Ensure that

this end of the guide enters the cvlinder head first
ts
If necessary
area
Warm the
NOTE
4
Remove the carbon deposits from the cylinder head
face and the valve throats and check the conditions of the
valve
spring
springs for squareness
new
drive the worn valve

a suitable pilot drift
of the cylinder head towards the combustion
Clean the
the valve stem outer diameter and the valve
0 004 in then the valve

renewed
serviceable
wipe
cylinder head up to a temperature of
2000C 3920F lightly oil the lower end of the new guide
and using the shouldered drift drive the new guide into
position so that it stands proud of the valve spring seat by the
specified amount See Specifications
or
inner diameter to calculate the actual valve stem to

clearance If clearance is in excess of the limit of 0 1
mm
Using
out
0 020 in
3
the cylinder head and
then the valve concerned
reduced
to
chamber
to
If a
back
TO RENEW V ALVEGUIDES
Clean the valves thoroughly of carbon deposit and
proves
springs with
Also check the valve
discard any valve that is cracked

2
Reface each valve face
the head
7
With a valve spring tester check the valve spring
If a valve spring
tensions and lengths see Specifications
tester is unavailable then the test can be made by comparing
considerable time Note that the shroud type seal is retained

on the end of the guide by a spring ring
bring
to
that
the valve
axis of the valve
seat is true and
guide
This is most
to ensure that the valve seats correctly
the
TO CHECK VALVE SPRING
or
specialised equipment to
carry out these
Check the valve spring free length and length under
operations
load
Lap the valves to the valve seats with a lapping

compound Apply a smear of Pruss ion blue to the valves after
lapping and check the valves on their respective seats to
been gained
ens ure that a true and concentric seating has
6 With a steel straight edge and feeler gauge check the
cylinder head face for warping If the cylinder head is found
see
to
be warped in excess of the limit specified
will
have
the
head
then
it
be
to
necessary
Specifications
5
Check that the springs
are
not
bent or distorted from
heat
spring tester is not available check the springs by

comparison with new springs This can be done by using a
surface plate and straight edge for checking free length and by
using a new spring and a used spring loaded in a vice end on
end with a plate in between Measure from the plate to the
vice jaw adjacent to both the new and used springs
If
13
sEngine
in the location from
spring is serviceable if1t does not show collapse in

aftive percent when subjected to this comparison test
A used
excess
rod
on
seats and ports and

seats and the valve guides
apply
valv
light coating
Oil the valve items and instal all eight valves ensuring
position from which it was
spritig
in the
the
spring retaining cap above

remaining valves in a similar
the
split
spring retaining
collets
few
turns at
see
the
the direction of
in
engine crankshaft
the valve stem
gasket
11
Connect
fuel delivery pipe between the

fuel pump and the vacuum advance
between the distributot and the catbureltor
the
12 Clean adjust and instal the spark plugs fit the

distributor cap and connect the high tension leads to the
spark plugs and the ignition coil
13 Connect the wire to the tempetature gauge sender
with the end of

cap y tapping on the end of the valve stem
a hammer handle
6 Oil a new O ring seal and instal it in the receSS in
the
specified torque
Refit the inlet and exhaust manifolds using a new

gasket and temporarily fit the r ket cover and
pipe
Hold the collets in position and

spring compressor Ensure
correctly seated
the
catbureltot and the
release and remove the

are
to
manifold
10
that the collets
pedestal bolts
progressively
temperature
suitable spring compressor compress the

and fit the split retaining collets in the recess in the
carefully
the rocker
See Specifications
This is a
should
for
valve
and
the
c1eatance
adjustment
starting point
be ch cked wheQ the engine is at normal opetating
retaining cap
end of the valve stem
Turn
and
arm
3 On inlet valves instal a new shroud type seal on

each valve stem and secure on the valve guide upper end by
fitting the spring ring
4
Instal a valve spring seat washer valve spring and
Using
removed and that each
normal totation until each valve tappet is exactly on the

heel of its cam and adjust the clearance between the tocket
remQved
g
5
was
Specifications
of oil to the
that each valve is installed in the
spri
Tighten
of emery dust
which it
in its tappet
7
Position the rocker shaft and tocker ann assembly
the cylinder head and instal the rocker pedestal securing
time evenly and
Before assembling the cylinder head ensUre that all

or grinding paste are removed from the
correctly
bolts finger tight
TO ASSEMBLE
traces
seats
unit on the front of the cylinder head

14 Instal the upper tadiator hose and secure with the
Assemble
two hose
manner
clips
15
Fill the
cooling system
with
clean
water
if
TO INSTAL
necessary using the water and anti freeze mixture drained

from the engine previously
Ensure that the gasket faces of the cylinder block

and the cylinder head are perfectly clean and free of any
start
I6
at
Connect the earth lead to the battery tenninal

engine and bring it to nonnal operating
temperature switch off the engine remove the rocker cover

and check and if necessary adjust the rocker to valve stem
cleatance see Specifications
burrs or pieces of the old gasket

2 Place the new gasket in position on the cylinder
block face and ensure that all bolt and water circulation
holes register If available screw a guide pin into one of the
hold down bolts holes
the
17 Re instal
screws securely
each end of the cylinder block
18
face
the rocker
cylinder head gasket is marked TOP

assembly
The
NOTE
acilftate
3
co
cylinder
remmnder
of
the
cyli
rhe cylinder head bolts is marked wirh
the ait cleaner and pipe from the cleaner to

Inst
start the engine and run to check for oil
One of
the bolt head This bolt must be installed at the
hole position on the right hand side of rhe engine
Using
suitable
torque
wrench
tightening figure
See
progressively
Specifications in the
Instal the push rods
ensuring
tighten the
specified
anns
the compression
give the specified
on
to
and check the clearance for this valve

remaining valves in the same manner
6 Refit the rocker cover and air cleaner
order shown
that each is
is at tde
Using the same procedure fot the remaining three

cylinders adjust the other six tockers
5 To check the adjustment turn the crankshaft until
one valve is fully open then turn a fUtther one complete
turn
in the illustration
cylinder
to the
det head bolts evenly and
stroke and adjust both rocker

rocker to valve stem clearance
on
centre
six
cover
rotation until No
NOTE
tighten the
it has
I Run the engine at a fast idle speed until
attained the normal operating temperature
2 Remove the air cleaner and rocker covet
3 Turn the crankshaft in the normal direction of
head into position and instal
finger tight
guide pins if used and instal
the cylinder head bolts finger tight
cylinder
and
cover
TO ADJUST VALVE CLEARANCE
head bolts
Remove the two
rocker
leaks
to
ect
Lower the
seveal of the
the
replaced
14
Check the
Engin
d
ENGINE
SUMP
NOTE With
or
have
new
shrunk
cork gaskets that appear to be too small

few minutes immersed in water will
engine removed from the vehicle remove

plug and drain the oil into a suitable container
Replace and tighten the plug
2 Progressively loosen and remove all the bolts and
spring washers securing the slimp to the crankcase
3 Remove the sump lifting it clear of the oil intake
strainer Remove the side gasket and the end seals around
the rear bearing cap and the lower edge of the timing cover
restore them to their norma
and discard
J
4
Clean the sump thoroughly ensuring that all traces
of the old gasket are removed
5
Clean the gasket face of the crankcase and the end
position
the
With the
length
drain
7
Place the end seals in position and ensure that the
ends of the seals mate with the ends of the side gasket to
form
TIMiNG
sump in position on the gaskets

three
two or
sump retaining bolts to hold it in
Carefully place the
and instal
Instal the remainder of the bolts and
10
Using a suitable sockei wrench tighten the bolts
evenly and progressively a few tums each to pull the sump
up firmly against the gasket Do not over tighten the bolts
or the flange on the sump will be distorted Ensure that the
drain plug is tight before filling with oil
HAIN
ieUV
AND
4
TO REMOVE
Remove
K
the
the
washers and
front of the
slinger if fitted from
the front end
remaining
the timing chain

withdra
the engine rerrloved from the vehicle remove

the water pump and fan assembly
2 Take out
the retaining bolt and washer and
withdraw the crankshaft pulley
3
ihe
Remove
sump drain plug drain the oil into a
1
tighten finger
tight
cylinder block
6
oil tight joint
an
seals ensuring that all traces o the old gasket are removed
a
small
6 Using
quaniity of suitable sealing
compound position a new gasket on the crankcase face of
the
vlith
engine
Remove the oil
cover
bol ts
from
and
of the crankshafi
Unscrew the two bolts
securing
to the front of the cylinder block and
the chain tensioner

remove
the chain
B
tehsioner
suitable container and remove the sump

and
stem
spring
removing the tensioneras the pad

forced out of the tensioner body by the
Use care when
NOTE
will be
when the bolts
are moved
Rotate the crankshaft until the sprocket key is at 4

the crankshaft sprocket is
o clock and the timing mark on
the
link
to
marked
plate on the chain The other
6
adjacent
marked link plate on the chain will be at approximately

clock and adjacent to the timing mark dimple on
12 15
the camshaft sprocket
7
Remove the camshaft sprocket retaining bolt and
washers and using a suitable lever prise the sprocket off
the camshaft from the top and remove the sprocket and
disengaging the chain from around ihe crankshaft
chain
sprocket
TO INSTAL
1 Clean all components and remove all traces of the

old gasket from the timing cover waier pump body and
sump
Check and if necessary rotate the camshaft until

the sprocket locating dowel is at the 4 0 clock position in
2
relation
the centre of the camshaft

Check and if necessary rotate the crankshaft until
the sprocket drive key in the shaft is at 4 0 clock position
Timing
Cover
showing Timing
Chain Damper Pad
15
to
SPROCKET
lQEngine
RETAINING
WASHER
BOLT
t
RETAIDlER
SPRING WASHER
TIMING
CHAIN
PLATE
WASHER
TENSIONER
BODY
fENSIONER
SPRING
SUPPER HEAD
Camshaft and Timing Chain Components

NOTE The liming clwill lillk plale marks circles are rell
plates apart on the shortest chain run This includes the
marked plates
Grasp the camshaft sprocker engaged in the chain

it on the camshaft looping the chain around
the crankshaft sprocket so that the second mark circle on
the chain link is adjacent to the timing mark dimple on
the crankshaft sprocket see illustration
8
Push the camshaft sprocket on to fully engage the
locating dowel lnstal the securing bolt and washers and
tighten to the specified torque see Specifications
9 Check that both sprocket and chain timing minks
register for correct valve timing
10 Instal the chairi tensioner on the front face of the
cylinder block ensuring that the long end of the slipper pad
7
and
Showing
Wear
Limit
for
Timing Chain
Wear
Stretch
and
Tensioner Pad
in relation to the centre of the crankshaft
With the camshaft and crankshaft positioned as in

above a line drawn through the centre of each
shaft will also pass through the centre of the camshaft
dowei and the crankshaft key
4
is to the camshaft
i and 3
uy
the camshaft
sprocket
flat
sprocket
Check that the side tensioner pad in the timing

is serviceable and renew if excessively worn
II
cover
bench with the

The locating
to
the
arid
mark
top
facing
up
dimple
timing
dowel hole will be at 4 0 clock
6 Loop the timing chain on the camshaft sprocket so
5
position
Instal a new oil seal in the timing cover with the

of the seal towards the timing sprocket Instal
face
lipped
the oil slinger if fitted with the concave face towards the
12
on a
crankshaft pulley
of the two marked link plates of the chain engages
i 3 Further installation is a reversal of the removal
dimple procedure with attention to the following
the sprocket adjacen t to the sprocket timing mark
Fit new gaskets where necessary
The second marked chain link plate must be to the right on
Do not over tighten the sump retaining bolts
the short chain run
that
one
ND
C AMSHAFT
TAI
PETS
2
Evenly and progressively loosen the rocker pedestal
securing bolts and remove the rocker arm and shaft
assembly
3
Take out the retaining bolt and withdraw the
TO REMOVE
I With the engine removed from the vehicle remove

the water pump and fan assembly and take off the rocker
crankshaft
cover
16
pulley
ll
Engine
uppermost
and press each tappet down well clear
of the
camshaft
9 Disconnect the fuel delivery pipe at the fuel pump
take out the two bolts and remove the fuel pump from the
right hand side of the engine
10
the
Remove
distributor cap
disconnect the vacuum
leads
pipe
at
and high
the
vacuum
tension
advance
unit
Checking
4
5
engine oil and remove

oui the remaining bolts
the sump
Take
and withdraw the
Slinger
of the cylinder block and
remove
spring
sprocket retaining bolt and

and using a suitable lever prise the sprocket off
the camshaft from the top and remove the sprocket and
chain disengaging the chain from around the crankshaft
excess
sprocket
the
TIMING
engine
so
that
the
A
SPROCKET
is
Check
using
the
MARKS
CAMSHAFT
crankshaft
not to
camshaft bearings and if worn to

special screw press remove the worn
bearings and press ne bearings into position Line bore the
new
bearing to the cor ect size and fit a new expansion
plug using a small quantity of sealing compound in the
end of the rear camshaft bearing bore
5
Remove the eamshaft
Turn
Withdraw the camshaft from the
care
washers
the
cylinder block
with the
the
camshaft
damage
bearings
using
sharp sides of the cams Remove the tappets keeping them
in their correct order for reassembly
14
removing the tensioner as the pad

will be forced out of the tensioner bodv bv the
when the bolts are removed
iwo bolts from
withdraw the distributor
13 Remove the two retaining bolts and washers and

slide the camshaft retaining plate clear of the groove in the
camshaft and remove the plate
the chain
Use care when
and stem
the
from the crankcase
tensioner
NOTE
and
Remove the oil pump and tilter as an assembly by

unscrewing the three bolts and withdrawing the assembly
the chain tensioner
securing
remove
12
Remove
from the front end of the crankshaft
Unscrew the two bolts
to the front
engine
and
Unscrew
oistributor retaining plate

from the cylinder block
Drain the
chain cover from the front of the
timing
tlie oil
II
Camshaft End Float
tr
17
1
wf
12Engine
TO INSTAL
marked link
plate
must
be
to
the right
the short chain
on
run
Check
tha t
have
been
bearings
the
bearings
clean and
are
if
new
installed
check that the oil holes

register with the oil passages in the block casing
2 Biow out all oil ways to remove any dirt or metal
NOTE The timing chain link plate maries circles are ten
plates apart on the shortest chain roll This includes the
marked
cuttings Apply engine oil to the tappets and fit them in

their cortect positions
3
Apply engine oil to the bearing bores and the
cainshaft jOlJ rnals and insert the camshaft into position
taking care not to damage the bearings with the edges of
10
Grasp the camshaft sprocket engaged in the chairi
and position it on the camshaft looping ine chain around
the crankshaft sprocket so that the secdnd mark on the
chain link circle is adjacent io ihe timing mark
dimple
the cams
4
plates
the crankshaft sprocket See illustration

11
Push the camshaft sprocket on to fully engage the
locating dowel instal the securing bolt and washers and
on
Che k the camshaft
serviceable
apply
retaining plate for wear and if

coating of oil and position it in the
groove in the camshaft line

the holes and instal tlie two
securing bolts and tighten firmly If a small lubrication hole
tighten io the specified torque see Specifications

t2 Check that both sprocket and chain timing marks
register for correct valve timi1Jg
13
Instlil the chain tensioner ensuring that ille
long
end of the slipper pad is to the camshaft sprocket
14 Check the side tensioner in the timing cover is
up
is
preSent in the camshaft retaining plate it should be to

the right of the engine when the plate is correctly installed
5
Rotate the camshaft until the sprocket locating
dowel i s at the 4 u clock position in relation io the centre of
the camsHaft
6 Rotate the crankshaft until the sprocket drive key
ii1 tl e shaft is at 4 o clock position in relation to the centre
lipped
Instal a new oil seal in the timing

face of the seal towards the timing
of the crankshaft
the oil
slinger
crankShaft
Witli die camshafi aM
7
5
and 6
above
line drawn
serviceable and renew if excessively
positioned as in
8 Lay the cainsh ft sprocket flat on a bench With

the timing mark dimple to the top and facing
up The
locating dowel hole will be at 4 0 clock
9
that
Loop the timing chain
one
adjacent
on
of the two marked link

to the
sprocket timing
plates engages
mark
8
TO
REMOVE
AND
the camshaft
dimple
sprocket
pulley
a
reversal of the removal
procedure with attention to the following

Fit n w gaskets where ne
essary
Instal the distributor and time the ignition
DISTRIBUTOR
clea
as
described
ELECTRICAL SYSTEM
ance
after the engine has been brought to operating
temperature
CONNECTING
the
lJ With the engine removed from ihe vehiCle drain

the engine oil aridJemove the sump
2
Remove the cylinder
as previously described
RODS
This will prevent the metal
of the enginc
cvlinder bore
shavings
into the crankcase area
Push the
and piston up the bore of

the top of the engine
Remove the other piston and connecting rod assemblies in a
like manner
pead
the
iftmkstf
ntil iwd of the pistons are at
3j Turn the cr
the top of theicylinder bores The two other connecting
rods will be ai the lo esipoinls ih the engine
4
Check that the big end bearing caps and connecting
rods are numbered with the number of the corresponding
engine adjacen t
Instal
with the concave face towards the
Ensure that the push rods are installed in the positions

which they were removed and adjust the valve
DISMANTLE
and note the side of the
if fitted
Further installation is
from getting
cylinder bore
with the
from
so
AND
16
in
tlce sprocket
The second
PISTONS
cover
sprocket
crankshaft
ihrOligh
eac
the centre of
shaft will also pass through the centres of the camshaft
dowel and the crankshaft key
a
worn
15
cylinder
Replace
assembly
as
connecting rod
and
remove
the
big
from
eno
liearing
shells and cap in each

retaining nuts
it is removed arid instal the
8
If new piston rings are being installed remove the
old piston rings from the pistons using care not to damage
the piston skirt or ring lands
to
the numbers
5
Release and remove the big end bearing nuts on

of the connecting rods and withdraw the big end
bearing cap and lower half shell bearing
one
Clean all carbon deposits from the bottoms of the

taking care not to damage the sides of the
ring grooves
lands
or
base
of the grooves A broken piston ring of the

used carefully makes a satisfactory
Correct section width
NOTE
If
the
piston iings
are to
be reneWed
it is
good
scraper
remove any ridge around the upper end of the

cylinder bore using a suitable ridge removing tool before
policy
to
removing
the
piston
and
connecting
Remove the carbon deposits from the piston

using care not to score the top ofthe piston
II Do not press the gudgeon pin out of the piston
10
crown
rod assemblies from

18
13
Engine
and small end of the connecting rod unless
the components are to be renewed
one or
TOP RING
other of
The gudgeon pin is an interference fit in the small

of the connecting rod and this is the sole means of
retaining the assembly together The gudgeon pin is a
thumb push fit in the piston at normal room temperature
NOTE
SECOND RING
end
OIL RING SEGMENT
TO FIT NEW PISTON RINGS

1
Wipe the cylinder bores clean and ensure that there

or other foreign matter present
2 Place a new piston ring in the bore of the cylinder
and using the piston inverted push the piston ring down to
a relatively unworn part of the cylinder bore
3 Using a feeler gauge of the correct thickness check
the gap If necessary adjust the gap by filing to increase the
gap width If the gap is too wide select another ring from
the set If the rings are a matched set adjustment will not
are
no
traces of carbon
OIL RING EXPANOER
OIL RING SEGMENT
PISTON
be necessary
4
Treat
all
piston rings in the same manner and

ring side clearance in the piston groove is
within the specified limits and that the rings are installed on
the piston for the cylinder to which the rings have been
ensure
that the
CONNECTING ROD
fitted
ring expanding tool to fit the rings on the

rings from the top ofthe piston never over
NOTE
USe
pistons
Fit the
BOLT
the skirt
Lubricate the piston and ring assemblies with

fitting in the cylinder bores
6
If the compression rings are taper faced they will
be marked Top and this mark must be uppermost when ihe
rings are installed on the pistons
engine
oil before
BEARING CAP
TO REASSEMBLE AND INSTAL
1
and
With the rings fi tted to the pistons and the piston

rod assembly adequately lubricated with
connecting
clean engine oil
arrange the piston rings so that the top ring

gap will be to the side of the piston directly away from the
exhaust valve position
Fit the
second compression ring with the gap
NUT
Piston and
the bore
Insert the connecting rod into the cylinder bore

was originally removed and using
suitable
ring
compressor to compress the
end of the
Ensure that the number of the bearing cap is

adjacent to the number on the connecting rod and that the
squirt hole in the big end of the connecting rod is to the
right hand side ofthe engine
rings
size code number and the
letter F if shown should be to iheTront
ensure
big
NOTE
tap the
clean hammer handle until
assembly iilto the bore using a

the ring compressor is free The
until the
with the
from which the assembly

a
Rod Components
connecting rod engages

squarely
crankpin
7 Oil the lower half bearing shell and bearing cap and
fit it to the connecting rod Instal the big end nuts finger
tight
1800 to the top ring gap

3
Fit the oil ring spacer with the gap to the right side
of the engine and the upper and lower oil ring segments
with their gaps 1200 either side of the spacer gap
4
Connecting
at
Oil the upper half of the big end bearing shell and
correctly seated in the connecting rod with
Instal
the
other
piston
assemblies using the same procedure

9 J Tighten the big end bearing
torque See Specifications
that it is
tang oUhe bearing shell locating with the recess in the rod
6 Pull the connecting rod and piston assembly down
19
and
nuts
connecting
to the
rod
specified
14
Engine
9
LlNDER
BOllES
TO CHECK CYLINDER BORES

NOTE
wear
it
DEGlAZING CYLINDER BORES
To accurately check cvUnder bore condition alld

is essential that all pistons and connecting rod
assemblies be removed from the cylinder block also that

accurate measuring equipment be available to determine the
actual
ovality
clean with
or
overall wear including taper and

cylinder boTf s should be wiped thoroughly
clean rag before checking
I Visually
scoring
and
check the bores for cracks flaws
NOTE
Cl
bores that
lder
li
original pistons
with
cvlinder bore
The
AND PISTONS
but
require
are
fit for further service with

nOnging should be deglazed
re
hone
1 Position plenty of clean rag over the crankshaft

and under each cylinder bore to keep abrasive materials
from entering the crankcase area
2 De glazing of the cylinder walls may be done by
scuffing
using
cylinder surfacing hone equipped
with 280
grit
stones
2 Check each cylinder bore for wear including

taper
ovality
3 Cylinder bores that
upon checking prove to be
out
by moving the hone
walls fast
seating of piston rings

NOTE When deglazing it is important t
wt only enough
strokes of the hone are made to eliminate the
glazing
NOTE If it is found that the cylinders leed boring select

the cylinder with the most wear to detennine what oversize
pistons aTe to be used Bore all cylinders to that oversize
See Specifications for available oversize pistons
condition of the cylinder Excessive honing will increase

bore size and thus increase piston skirt clearance
4
Use honing oil which is available from all major
distributors Do not use engine or transmission oil mineral
spirits or kerosene
Engines that have been bored to their extreme limit can

be filted with cylinder sleeves which are available in three
sizes on outer
New pistons and rings should still
diameter
be filted with sleeves
Grade Numbers
cylinder
enough to achieve a
hatch pattern When hone marks
ect at 60 deg
inter
the Cross hatch angle is most satisfactory for the correct
filted
Cylinder
should be carried
cross
unserviceable should be rebored and honed to the smallest

immediate oversize and new oversize pistons and rings
Piston and
Honing
up and down the
Stamped
20
After
honing
it is necessary that the cylinder block

remove all traces of abrasive
be
thoroughly
on
Pistons and Top of Cylinder Block
cleaned to
EngineIS
CA UTlON Be
sure
that all abrasives
are
thickness and approximately 12 mm 0 50 in in width The

strip should be long enough to extend the full length of the
removed from the
It is recommended that
engine after honing
solution of
soap and water be used with a brush and the affected

components thorough y dried
The cylinder bores can be cf msidered clean when they
can
be
wiped clean
with
piston
3
Insert the feeler strip into the cylinder bore Invert
piston and position it into the cylinder bore so that the
feeler strip is located lengthwise between the cylinder wall
and the full length of the piston at 90 degrees to the
gudgeon pin axis
4
Attach a spring scale to the top end of the feeler
strip and withdraw the feeler strip in a plane parallel to the
centre line of the cylinder bore noting the reading on the
spring scale
5 The correct spring scale reading should be within
30
3
0 2 and 15 kg 0 44 and
Ibs
If the reading is not
the
within these specifications then check
original
measurements of the piston and bore and also check the
piston skirt for high spots If necessary select measure and
check another piston to obtain the required fit
6 Follow the same procedure to fit the remaining
pistons as required
the
white cloth and the cloth remains
clean Smear the bores with engine oil after cleaning
to
prevent rusting
CHECKING PISTON
SKIRT CLEARANCE
NOTE
Cylinders that haye been rebored and honed to take

appropriate oversize pistons should have each piston
measured and then tried in its respective bore with a feeler
strip and spring scale to ensure that correct skirt clearance
the
is obtained
1 Measure the outside diameter of the piston skirt at

right angles to the gudgeon pin axis and IS 6 mll 0 732 in
down from the gudgeon pin centres
The piston temperature when measuring should be
approximately 200C 6S0F
2 Select a feeler strip 0 04 mm
0 0016 in in
fi
o
Q
r l
SPACER
h
fi
0
0
If
iiI
11
Il I
Engine
with
Sump
Removed
Showing
Crankshaft Sprocket
lO
II
Arrow
CRANKSHAFT
NU
1200 has five Main
MAIN
bolts and
position
the
With the
rocker
engine removed from
mechanism
the vehicle remove
manifold and cylinder head
bench
as
previously described
2
Remove the sump timing

as previously described
cover
timing
Bearings
Bearings
and Shims behind
HEAIIINGS
remove
the
flywheel
in relation to the crankshaft
marking the flywheel
flange
With
on
the engine inverted and resting on a clean

the cylinder block top gasket surface release the
big end bearing cap nuts and remove the caps and lower
half of the bearing shells Keep each cap and shell together
chain and
for
sprockets
3
7Q
Front and Intermediate Main
on
1000 Series shown
1ll
of
if
x
s
Underside
ff
0 t
Il
1
EP
eo
SHIMSfU
Remove the oil pick up tube and strainer

Release the lock plates take out the six securing
correct
installation and note the number
on
the side of
each cap
6
21
Push the
connecting
rod and
piston assemblies
16
Engine
INNER PLATE
t
FLANGE PLATE
SECURING
Torque
Converter Drive Plate to Crankshaft Attachment
down the bores towards the top of the block well clear of
the crankshaft but do not push the pistons out through the
top of the bores Ensure that the upper half of each big end
bearing shell has remained

sticking to the crankpin
7
On the
AIO
in the
connecting rod
cap bolts and remove the five main bearing caps and lower
half bearing shells Keep each cap and shell together for
and is not
the main
bearing
caps
bearing
andlower
cap
half
NOTE
Number
already
numbered
the
main
With
tJ
Checking Crankshaft End
Bearing
bearing shells Keep each cap and shell together for

reassembly On the A 12 engine release the main bearing
F ii
Rear Main
131
161
reassembly
engine release
bolts and lift off the three main
LOCK PLAn
1000 Series Automatic
BOLTS
Oil Seal with
Bearing Cap
float at Centre Main

Bearing on 1000 Model
Removed
22
bearing caps if they are not

exception of the rear main
the
EngineI 7
bearing there is an arrow cast in the cap of ail
bearings which must point to the front of the engine
One damaged journal will
other
journills
directly upwards
8 Lift the ctankshaft

from the qankcaSe
9
Remove the upper half of the main

in pairs with each
row
cap
NOTE The centre main bearing shells have

side to fake crankshaft end thrust
bearing
shells should be
011
PUMP
new
torque
Irtstal
filter
body
main
new
filter
body
USing
on
NOTE
the
original
unit
is
DiJ not remove the inner rotor from the shaft

shaft and inner rotor as an assembly if either are
worn
0
Unscrew and
remove
the screwed
Using
sharp
centre
punch
driven
ASSEMBLE
PLUo
bolts and withdraw the pump

Discard the gasket
2
Unscrew and
take out
assembly
remove
the
fi
the tiuee securing
GASKET
from the crankcase
single
bolt
attaching
VALVE SPRIN
the
PRESSURE REGULATOR
ALVE
l
GASKET
PUMP
DRI
BODV
E GEAR
lA
J
aja
iifJ
11
RETAINER PIN
Exploded
View of Oil
and
gasket
and the cs
plug
rewed
6 Unscrew and remove the pressure gauge sending
unit being careful to avoid damage io the sender element
7
1 Remove the oil filter
plug
and withdraw the pressure relief valve and spring 00 not

lose the adjusting shim between the outer end of the spring
not
comparatively ne
Tighten the filter to the pump by hand only Do not
over tighten or leaking may result
Ensure that gasket faces are dean and free of any burrs
TO DISMANTLE AND
pump
the
Renew the
if
suitable pin punch
drive out the pin

diive gear 0 the shaft and tap the shaft
and inner rotor out fthe gear and the pump body
securing
cover imd the
pump
the bench
following points
gasket 1 etween the
and refl10ve it by tapping the end of the
trochoid rotor
Specifications
a
two revolutions to check
to the main body of the pump separate the two

assemblies and discard the gasket
3
Mark the outer end face of the pump outer
pump body and the body and crankcase

Tighten the three pump securing bolts to the specified
see
or
body cover
turn
it
firmly
If
the
body
pump
a special
tool is
available to fit the lower end of t1ie filter body
Take out the three securing screws and withdraw
the oil pump from the right hand side of the crankcase
Installation is a eversa1 ofthe removal procedure vitti
Use
one
AND FILTER
anti clockwise and upscrew it off the oil

filter is too tight to rotate by hand
attention to the
Jhe crankshaft
It will be necessarY to resei the valve timing on the

timing chain and sprockets check the ignition timing and
adjust rocker to valve stem clearance with the engine
installed and at working temperature

oil
cap points to the frorit of the engine

the cap coincides with the number on
throughout
checked fat
JI
the
on
It will be good policy to renew the rear main bearing

d the seal in the timing cover Instal new
oil se l
gaskets
wear
taper or sc ring
Bearings that are
unserviceable should be replaced with the appropriate
undersize shells and the journal ground to fit
Grasp
bearing
forbindirtg
excessive
the
by rotatil g
each
Ins allation is a reversal of the removal procedure with

attention to the following points
Journals and
grinding of all
Connect up the connecting rod big ends to the

crankpins before tightening the main bearing bolts and then
tighten one main bearing to the specified torque followed
for correct
flange on
on
and the number

the crarikcase
bearings and
keep them together

reassembly
necessitate the
fitting new
undersize hearing shells or fitting a

crankshaft and standard bearings Ensure that the
new
and remove
and
rrch
I
iitl
SY
O
INNER ROTOR AND SHAFT
d
Pump Components
23
EXPANSION
PLUG
PASS VALVE
SPRING
through
the
18Engine
0p
1
1 the
tj
Ii
fj
fJ
Jr
Checking
Clearance Between Outer Rotor and Body
Cftlecking
Thoroughly clean all components of the pump and

all traces ofthe old gaskets from the gasket faces of
the pump and crankcase

9 Insert the inner rotor and shaft in the pump
fit the drive gear and temporarily fit the retaining pin
10
J 8 Place the body cover in position on the main

body to locate on the dowels and instal and tighten the
small securing bolt
19 Place the filter by pass valve ball in position
followed by the spring small end first and instal a new
plug Use a small amount of sealing compound
ixopans
on the plug to prevent oil leaks
body
Check the end float of the shaft and rotor in the
body TItis should be a minimUm free fit

I Apply engine oil to the outer
1
trochoid
with the mark made
top
on
dismantling
to the
rotor
and slide it
into the pump body to mesh with the inner rotor

12 Check the clearance between the outer rotor and
the pump body and also between the highest point of the
rotor lobe
20
in the
that
the
highest point on the outer rotor

lobe using feeler gauges of the specified thickness see
If clearance at these points is in excess
Specifications
of wear limits renew the pump assembly
13 Using a straight edge placed across the ends of the
rotors and the pump body use a feeler gauge to measure
rotor to cover end clearance see Specifications
inner
14
to
f end float of the rotor shaft is excessive
the drive gear and instal a suitable spacer shim

J 5 Instal the drive gear and peen the retaining
Clearance Between Inner and Outer Rotor lobes
16 Apply engine oil to the inner and outer rotor and

instal the outer rotor
J 7 POsition a new gasket on the cover face of the
pump body and locate it on the cover dowels
expansion plug remove the plug and withdraw the filtet

by pass valve spring and ball Disc t the expansign Ilug
remove
Insert the relief valve
plain
pump body followed by
are
the
end first in the bore
spring ana
any shims
fitted Place the shims in the hollow bure of the
retaining plug
21
Instal the
plug
and gasket and tighten securely
Screw the pressure light sender unit into position

in the cover and tighten just sufficiently to prevent any oil
l22
leaks
23
Using
the crankcase and
remove
gasket instal the pump assembly

tighten the three securing bolts to
new
on
the
specified torque
24
pin
Instal the oil
tighten by hand only
24
filter unit
on
the pump cover and
19
fJngi
12
EN
INE
MOUNTINGS
Place a jack under the transmission to take the
of the engi e and transmission assembly
3 Remove the two transmission rear crossmember to
FRONT
weight
I
Raise
the
of the
front
vehicle and support on
chassis stands
2
mounting securing
Remove the bolt nuts
fixing
brackets to the front crossmember

3
Interpose a wooden block between
sump
and
jack
and
jack up
the crossmember
5
assembly
4
the
engif e
securing
brackets
ounting
each
and
engine mounting
the
bolts
from
remove
to
is
reversal
the
of
the
Instal tion
is
bolts
connecting
transmission
that the
the
extension
engine
rear
housing
and
reversal of the removal procedure

mounting i centralized and that eflgine
and tiansm sion weight is
finally tigjItening
procedure
removal
the
the
mounting
E nsure
Remove both front mountings from the brackets
Installation
to
the
bracket to the crossmemher

5
Undo
mounting
Remove the nuts
the
bolts which attach
the rear
crossmember to the uf derbody an remove
transmission
the engine
front of the engine
the
bolts
Remove
the engine mounting
the
aken
the
on
mounting bef9re
mounting securingbolis
Allow the full weight of the engine assembly to bear on the

mountings before tightening the securing bolts and nuts
REAR
NOTE
Raise
the
front
of the vehicle
and
support
chassis stands
IJ
I
Engine wm
not
start
by
normal
Possible
a
b
c
Dirty
or
ENGINE FA1JLT
Carburettor nooding
Moisture on high tension
wires
Clean
and
or
inside
Dry
Engine
or
out
high
tension wires and cap
Reset
spark plug gaps to specification

faulty components
Test and renew faulty wires
source of vapo
lock and insulate
Test and overhaul fuel pump
Check and retime ignition
low
tension
lead
Test and
to
renew
inst heat
lead
points
weak
Possible
or renew
Test and renew
timing
circuited
short
wm not start
or
erratic
cranking
Remedv
cause
faulty battery
Weak
Fault in starter lead
Faulty
or
NOSIS
Check
pump
set ignition
ensure a
Clean out carburettor and fuel system
Fuel vapor lock
distributo
oil soaked should be
and adjust points

Check needle valve and noat clean out fuel system
distributor cap
Dirt or water in carburettor and fuel system
Broken
are
Remedv
points
Incorrectly set spark plug gaps

t Faulty coil or capacitor
g
Faulty low or high tension wires
that
cranking
corroded distributor
i Faulty fuel
0 Incorrectly
DIA
cause
Engine mountings
renewed and the cause of the oil lea rectified to

normq l working flfe for the mounting concerned
on
or
Recharge
Test and
solenoid
battery
faulty components
or renew
renew
Test and overhaul starter
starter
Engine stalls
Possible
a
Idling speed set
Idling
Carburettor
Remedy
Readjust idling speed stop screw
Readjust idling mixtur s rew and idling speed
cause
too slow
mixture too lean or rich
nooding
or
noat level incorrectly set
Check needle valve
Continued neXl
25
1ge
p
reset noat level
screw
2QEngine
d
ault in coil or apacitor

Valve clearance out of adjustment
Air leak at inlet manifold or carburettor flange
Carbon tracking or cracked distributor cap
Weak
fa lty battery and
or
or
Test and
1 lleW faulty cOlllpollelll

Adjust valve clearance
Tighten securing bolts or renew gaskets
Clean
corroded terminals
or
renew
Recharge
or
cap
battery and
renew
or
clean
or
renew
terminals
i Carburettor
setting
0
k
Fauty coil
Excessive
b
c
or
incorrect
or
breaker
earn
Burned
warped
or
Loose
Check needle valve
or
reset float level
Test and renew faulty component

eriew
worn components
pitted valves
C rry
top overhaul
spark plugs
Clean
or
renew
and set
points
Clean
or
renew
and
on
engine
at
idling speed
Possible cause
Dirty defectiJe or incorrectly
or
level
in distributor shaft and bushes or
contact
Burned
float
capaci tor
wear
Engine missing
a
flooding
pitted
distributor contact
broken
or
Remedy
set
low
high tension wires
or
spark plugs
adjust contacts
Tighten or renew defective
in
components
ignition system
d
Carburettor idling
Burned
or
t Moisture on tigh
Engine
mis
tension
on
accelerati
Possible
b
Spark pluilfs dirty faulty
Dirt
Carburettor
or
Coil
Incorrect
Burned
or
gap set too wide
warped
misses at
pump
t Dirt
or
Clean out carburettor
jet
component
Check and reset ignition timing

Carty out top overhaul on engine
pitted valves
high speed
or
Remedv
Clean and readjust points
Clean or renew and reset faulty
cause
or
incorrectly adjusted
too
wide
Clean
Renew
in cluburettor power
Incorrect
ignition timing
Excessive
wear
incorrectly
faulty component
faulty component
teck
C
and reset
Renew f ulty
or carn
ignition timing
components
Remedy
cause
gap to specific tions

Drain and clean out fuel system and carburettor
Clean and
spark ptugs
reset
Dirty
Dirt
Incorrect
Incorrect carburettor float level

Checkand reset float level
Faulty fuel
Check and
I
g
h
or
or
set
water in carburettor and fuel system
ignition timing
pump
Incorrect valve clearance
automatic advance
Restricted muffler
or
overhaul fuel pump

valve clearance
Check and readjust
Faulty distributor
tail
plug s
carburettor and fuel pump fil ter
Clean and blowout carburettor
jet
in distributor shaft
lacks power
Possib
out
Renew
capacitor
Engine
discharge
Renew defective
Spark plug s dirty faulty or gap set

Dirt or water in carburettor
Burned or cracked distributor rotor
Faulty coil
pump defective
plug
Clean and blowout carburettor and fuel pump filter
Distributor points dirty
and cap
Remedy
faulty component
high tension system
out
Clean and readjust points

Clean or renew and reset faulty
accelerator
Possible
or
capacjtor faulty
ignition timing
Engine
Dry
or
water in carburettor
blocked
spark plug
Distributor points dirty
or
wires
mixture screw
cause
or
Renew
cap
1rdistribut
S
Adjust idling
mixture out of adjustment
cracked distributor rotor
Check and rectify or renew

Iean as ne essarv
Check a
1d
pipe
26
Engine 21
i
Faulty
0
k
or
Renew
capacitor
faulty component
faulty component
Renew faulty components
Renew
Incorrect valve
Check and
Burned warped
Carry
timing
or pitted valves
Blown cylinder head gasket
loss of compression
m
n
0
So
coil
Burned or cracked distributor rotor

Excessive wear in distributor shaft or earn
Noisy
valve
reset as
necessary
out top overhaul

Renew gasket
Cnrrv
compression
out
b
c
Big
test
and rectify
Remedy
Incorrectly adjusted clearance

Weak or broken valve springs
Worn valve guides
end
engine
operation
Possible cause
on
bearing
Check and adjust to

Check and
Renew
or
renew
specifications
faulty components
reallJ and fit oversize valve
noise
Possible cause
Remedy
Lack of adequate oil
Excessive bearing clearance
Check oil level in sump condition of oil pump and

relief valve Renew oil fiI teT element
supply
Renew bearing shells
check and regrind
journals
if
oval
c
Thin oil
or
crankcase dilution
oil
Check operating
grade
cooling system thermostat
Check pressure relief valve and spring oil filter by pass
Change
to
correct
conditions and
d
Low oil pressure
Misaligned big end bearings
valve
10
Apparent
main
Align connecting rods and
Possible cause
Remedy
Tighten securing bolts to specified torque
Renew or tighten pulley
Check bearing to journal clearance check condition of
flywheel
Loose
Loose crankshaft
Low oil pressure
pulley
oil
Regrind journals
journal clearance
f Insufficient oil supplv
II
relief valve
pump and pressure
necessary
Renew centre main
Excessive crankshaft end play

Crankshaft journals ou t of round and excessive
bearing
if necessary
bearings
bearing noise
renew
bearing
Recondition
as
thrust washers
and fit undersize
bearings
to
Replenish
oil in sump to correct level
Excessive oil consumption

Possible cause
a
Oil leaks
Damaged
Excessive clearance
Remedy
Check and renew
or worn
valve stem oil seals
valve
stem to
valve
gaskets
as
necessaI
Renew
damaged or worn components

Renew valve guides bushes and valves
guide
or ream
and fit
oversize valves
d
Worn or broken
Rings
Excessive
12
tight
Renew rings
Renew rings and clean
rings
or
stuck in groves
in
cylinders pistons and rings

Compression rings incorrectly installed oil rings
ged or hroken
c1og
Drop
a
too
wear
Recondition
out
cylinders and
ring grooves
renew pistons and rings
Renew rings
in oil pressure
Possible
Oil level low in sump
Thin or diluted oil
Remedy
cause
Check and replenish to full mark
Change
to
correct
oil
grade and rectify
source
of
dilution
c
Oil pump relief valve stuck

Excessive bearing clearance
Excessive
Air leak in
or
spring
broken
Free valve
Renew
renew
broken spring
or
recondition
shells
necessary
Renew or recondition oil pump
wear of
oiling
or
bearing
oil pump components

system
Rectify
27
as
necessary
journals
as
COOLING SYSTEM
SPIlCIFICATIONS
Water pump
Radiator cap
Type
Centrifugal
impeller
Bearing rype
Double
row
bearing
and
shaft
Impeller
to
Type
Working
Pressure
0 9 kg cm2
pressure
ball
12 8 psi
Corrugated fin
Radiator type
assembly
Cooling
body
capacity
system
With heater
clearance
4 9 litre
0 5mm
9 Imp pt
10 5 US pt
0 019 in
Thermostat
Without heater
pellet
82 deg C
180 deg F
Maximum valve lift
mm
315
0
203
The
deg
Fan belt deflection
394
0
0 590 in
DESCH
The fan belt and water pump
assistance
Two dra ning poin ts are
pump
incorporated in the system one at the lower radiator tank
at
The system
the left hand side of the engine assembly

pressurised in order to raise the
the system
and
crankshaft
cap
of
an
Remove the radiator cap and drain the cooling

via the tap on the lower radiator tank
2
Disconnect and remove the upper and lower
radiator hoses
the
with
radiator tank
to prevent entry of dirt
if fitted
cooling pipes
lower
plug
Unscrew the
bolts and
Remove the four radiator
fixing
transmission
automatic
the
pipes and
cooling system is controlled by

cylinder head water outlet pipe
any
length of time
tank of
The radiator should be immersed in
otherwise kept fUll Failure to observe

this precaution may result in overheating when the engine is
put back into sef1Jice This is caused by internal deposits in
converter
the
RADIATOR
system
torque
V belt
in the system to allow limited

circulation of the coolant when the thermostat is closed
for
On vehicles
within the
thermostat located in the
the
drives
housing
A by pass is incorporated
that is at nonnal
TO REMOVE
by
also
lubrication in service
so
caution when
use
engine
connect
driven
belt
The water pump seal is a spring loaded carbon thrust

washer and rubber bellows assembly
avoid accidental scalding
releasing the radiator

operating temperature
are
The water pump is fitted with a shaft and ball bearing

is pre lubricated and requires no further
Temperature
To
This
assembly which
NOTE
pulley
alternator
is also
boiling point of the coolant within

increase the efficiency of the engine
the
from
water
and the other
ON
system is the thermo syphon type with fan
cooling
Imp pI
9 US pt
10 15 nun
@ 95 deg C
in @
and
4 2 litre
Wax
Type
Opening temperature
water
or
the radiator drying and flaking and

circulation of the coolant in the system
so
obstmcting the
dis
at
unions
lower
Securely plug the

r adiatof
tanks and
water outlets in the upper and
fill the radiator assembly with
clean water
remove
the radiator
grille
retaining
TO CHECK
bolts and lift
out the radiator
With the radiator removed from the vehicle turn it

and apply a hose to the lower tank outlet and
down
upside
reverse flush the unit
NOTE
When
is removed
out to
the
radiator that has been in
from the
engine it
vehicle to enable
should not be
use for some time

repairs to be carried
alloweq
to
stand empty
or
28
Stand the radiator upright and using
jet of water
air pressure to the rear side of the core remove any dirt
Cooling System
or
matter that may have accumulated on the front
foreign
side of the
3
down
tubes
NOTE
Inspect all hoses before installing for cracking or

perishing and renew any hose that upon impection proves
core
With
the aid
through the
If
of
flash light make
radiator
fill
point
onto
visual check
the
to
it
thoroughly
operation be carried
necessary
be unserviceable
radiator
is apparent that the tubes are severely

with
flakes of rust it will be necessary to have
impregnated
the upper and lower tanks un sweated from the core and
the tubes
cleaned
where
pipes
radiator
to
specialist
On vehicles fitted with automatic transmission and
cooling
Close the radiator drain tap and instal the drain

cylinder block Fill the system with clean water
at the
plug
who has the
connect up the torque converter

the lower radiator tank
applicable
at
It is recommended that this
by
specialised equipment
out
and instal the pressure cap

5
Start the engine and check that the water level in
carry out this type of
work
the radiator is approximately within 12 7

the bottom of the filler neck
TO INSTAL
mm
0 50 in
of
NOTE Use
care to avoid the risk of scalding If the engine

operating temperature remuve the radiator cap slowly
allow pressure to escape before removing the cap
is at
assembly in the front panel

the four securing bolts
Position the radiator
opening and
instal and
tighten
2 Connect the upper and lower

between the radiator and the engine Use
grease between the hoses and
radiator
a
light
to
hoses
smear
of
temperature
that neither the

sides
or
the radiator pressure cap and drain the

water from the cooling system via the tap on the lower
Remove
remove
and
Remove the
elbow to the front portion of the cylinder head
4 Detach the water outlet elbow and gasket and
withdraw the thermostat from the recess in the cylinder
then
on
the
water
the
noting
the thermometer as the thermostat
measure
the
thermostat with its
Ensure that
unit fitted
valve
Fill
the
approximately
procedure
gasket is fitted when assembling
cooling system with clean water
a
a new
12 7
mm
to
0 50 in below the radiator filler
neck and check for water leaks
TO CHECK
Gleck that the thermostat is closed when it is cold
Suspend
and immerse the thermostat
reliable thermometer in
together
open
thermostat
Specification section fo maximum valve lift

opening temperature
A thermostat with opening temperature and maximum
valve lift not within specifications should be discarded and
See
open when removed from a cold engine is obviously faultv

and should be discarded and a new unit fitted
Installation is
completely
maximum lift of the
and valve
a new
instance
or
heat
Progressively
NOTE A visual examination of the thermostat will often

determine its serviceability and obviate the necessity for
Fur
and
valve
head
further testing
operating
at
water
or thermometer is touching the

thermosta
valve commences to open

4
Continue heating until the valve is
the top radiator hose

two bolts securing the water outlet
and
for
bottom of the vessel
temperature reading
radiator tank
Disconnect and
engine running
thoroughly
check
T ERMOSTAT
the
transmission fluid leaks
pipes
With
with
essel of cold water ensuring
Thermostat and
29
Housing Compartments
Cooling
3
System
4
TER
TO REMOVE
Remove
the
radiator
cap and drain
the
and
Disconnect
the
remove
at
and
upper
the ball bearing has becume noisv Once dismantled it is a

good policy to instal a complete water pump kit which
consists of seal as emb y bearing and shaft assemb v and
impeller
When the pump is removed from the vehicle make a
visual check of the pump body If it is apparent that the
pump body is corroded or cracked then it can be assumed
cooling
system via the tap on the lower radiator tank and

plug on the left hand side of the cylinder block
the
lower
radiator hoses
On vehicles fitted with automatic transmission and
3
where
pipes
to
disconnect the torque
applicable
the lower radiator tank
at
plug
converter
the
prevent entry of dirt

4
Unscrew the fixing bolts and
remove
that the pump
complete
new unit fitted
water
coolIng
pipes and
unions
1
damage
the radiator
grille
Remove the four radiator
retaining bolts and lift
bodv is unserviceable
pump
assembly
in which case the
should be discarded and
Check the pump body for corrosion
cracks
or
Check the bearing for looseness in the pump body

roughness when rotated
Check that the water by pass hole in the
pump
bore and for
out the radiator
PU IP
Slacken the fan belt adjusting bracket bolt and the

attaching the alternator to the mounting bracket
two bolts
body
the cylinder block

7
Push the alternator towards the cylinder block and
remove the fan belt
NOTE
and
timing
cover
are
free ofobstruction
on
Bend back the lock tabs
8
remove
the four bolts
securing
where applicable
the fan and fan
pulley
cleaning the pump components do not

shaft and bearing assembly in cleaning soh ent
if rhe assembly is to be used again
and
to the
pump and withdraw the fan and

Unscrew the water pump to
water
bolts and detach the water pump
When
immerse the
pulley
timing case securing
and gasket Discard the
Q 5mm
020In
0
gasket
Installation is
attention
reversal of the removal procedure with
following
gasket between the water pump and timing
cover when installing the pump
Apply a smear of jointing compound to both sides of
the new gasket
Use
given
to the
a new
Adjust
the fan belt as described under FAN BELT
TO ADJUST
Ensure that the cooling system drain points are closed
and that the system is replenished with clean water
TO DISMANTLE
Drain the
I
pump
2
as
cooling
system and remove the water

described
previously
Using a suitable puller withdraw the pump pulley
flange from
the
fOlWard end of the
shaft and
bearing
assembly
3
bearing
impeller
4
Remove the bearing retaining clip and press the

and shaft assembly
together with the seal and
out of the pump body
Press the impeller off the end of the shaft and
bearing assembly
5
and withdraw the seal
Remove the seal
the recess in the
rubbing
assembly
block and shaft seal from
impeller
TO CHECK
NOTE
pump
It is generally
assembly unless
74
unnecessary to dismantle the water
it is leaking water past the seal or if
Assembly Dimensions f
30
mm
913In
2
Vater Pump
Cooling
TO ASSEMBLE
assembly
and press
clearance of 0 5
1 With a small amount of waterproof sealing

compound applied to the large end of the new seal
assembly press the new seal assembly into position in the
pump body so that the carbon face of the seal will be facing
towards the pump impeller
2 Applying pressure to the outer portion of the
bearing press the bearing and shaft assembly into the pump
bo y
the
from
NOTE
body
On
to
3
4
recess
apgn
bearing far enough into

retaining clip grooves
7 With
the pump
the
on
Oli O the
shaft until
is obtained between
the
body
it on the
support
impeller end
the bossed side

press the
of the
pulley flange facing
the front end of

the pump bearing shaft until a measurement of 74 mm
2 913 in is obtained between the gasket face of the
Plj11P
body and the outer face of the flange
NOTE
the pump
When
detailed
in
pressing
the
operatiqn
flange
onto
pullev flange
ensure
onto
the
shaft
as
that the assemblv is
supported directlv on the end of the shaft and not on the

impeller o herwise t e clearance qetween the impeller and
the re r face of the pump as given in operation 5
mav be
decreased with possible
e
to
the
and
setil
dama
impeller
assemP v
impeller
Support
pump
impeller
019 in
the pump and
towards the pump
Instal the bearing retaining clip

Position the shaft seal and rubbing block into the
in the
the
Inver
of the shaft
of the pump
ffont side
press the
the
lring
be
impeller and
the
mm
4
System
front end of the shaft
RETAINER CU
PULLEY FLANGE
iD
SEAL
4
w
ASSY
BEARING AND SHAFT ASSY
ER
d
IMPELlER
Exploded View of Water Pump Components

5
FAN
TO ADJUST
TO RENEW
Loosen
the
two alternator
mounting bracket
to
Loosen the two alternator
mounting bracket bolts

alternator adjusting bracket bolts and
pull the alternator away from the cyli der block
sufficiently to give the belt enol gh ten ion to prevent it
slipping on the pulleys
3
Hold the alternator in this posi
jon and tighten the
bracket and mounting bracket bolts securely
adjus
ing
1
bolts
io
2
3
Loosen the alternator adjusting bracket bolts

Push the alternator as far as possible towards the
cylinder block assembly

4
Slip
the old belt off the alternator pulley and hen

pulleys and remove
manoeuvre
it off the fari and crankshaft
it from the
engine
Manoeuvre the new belt
fan pulleys and

6 Adjust
the
BELT
position it
on
he tension
adjusting pracket
7
over
NOTE
the crankshaft and
the fan belt
on
ard
bolts
Securely tighten
bracket securing bolts
two
alternator
to
Tq REMOVE
I
2
system
AND INSTAL
DEATER
engine
4
Raise the engine bonnet

Remove
the
plug
cooling
harness
situated at
the left hand side of the engine assemb ly
unit
31
over
lter
w
tenJioned
and
pump
be
pulleys
Disconnect
both
comp rtment and re

To gain access to
box and
radiator cap and drain the
An
in the
T
3
I 000
at the lower radiator tank and at the
pump
fan belt
bearings
can
0 590 in
water
the
wear
be deemed to have sufficient tension

flexed between 10 and 15 mm 0 394 and
with finger and thumb between the alternator nd
when it
engine
tighten
rapid
belt will
The
the
will cause
alternator
retighten
the
Do not over
fan belt
the alternator
sen
heater
ove
hoses
from
the hos
clips
ihe heater
within
unit the radio
gl
the
ve
parcel
tray where fitted should be renioyed

Disconnect the hea ter fan electrical wires at the
connector
which is located at the
ar
of the he ter
Cooling
5
6
SY3tem
Detach
the
uemisting
wo
tubes by hand 3t each
side of the unit
l7J
Remove the four heater
and carefully
two
remove
the heater
assembly mounting bolts

from the vehicle
assembly
NOTf
The heater assemblv is moullted to the pellicle bv
bolts at the engine bulkhead and by two bolts at the
dash
panel
Installation is
Ensure

cooling system is refilled after heater
that the
unit installation
Start
and
run
engine until
the
functioning correctly
Allow the engine
and check
to
cool
that
it
reaches normal
the heater unit is
off and check the coolan t
level
TO REMOVE AND INSTAL 1200

I
2
Raise the
engine
Remove
the
bonnet
radiator cap and drain the
cooling
Heater
system
at
Demister Assembly
the lower radiator tank and at the
situated on the left hand side of the

3
1000 Series
Disconnect
both
plug
which is
engine assembly
heater hoses
from
within the
engine compartmen t and remove the hose clips

4
To gain access to the heater unit remove
the
parcel
tray and the ash tray

5
Disconnect the heater control wires and rod at the
heater unit
NOTE
Before carrying out operation 5

demisting position and
offposition
control lever to the

to
the
6
harness
set
the
the upper
lever
lower
Disconnect the heater fan electrical wires

connection
which is located at the
rear
at
the
of the
heater unit
7
Detach the two demisting tubes by hand which
located at each side of the heater room valve
S
are
Remove the four heater assembly mounting bolts

remove the heater assembly from the vehicle
and carefully
NOTE
The heater assembly is mounted
two
bolts at the
dash
panel
engine bulkhead
to
the vehicle
by
and by two bolts at the
staYs
Installation is

cooling system is refilled after heater
Ensure that the

unit installation
Start and run the engine until it reaches normal

operating temperature and check that the heater is
functioning correctly Allow the engine to cool off and
Heater
Oemister
Assembly
1200 Series
check the coolant leveL

32
Cooling
7
L
Coolant
leakage
S
STIl 1
OOLlNt
Possible
Remedy
calise
Lpose hose clips or faulty hoses

b Leaking radiator core or tanks
e Worn or damaged water pump seal assembly
d Worn or damaged water pump bearing assembly
Loos or rusted expansion plugs
e
I External crack in cylinder block or head
Faulty cylinder head gasket or loose holding down
g
Tighten hose clips or renew faulty components

Repair or renew r diator
Renew seal assembly
Renew water pump bearing and shaft assembly
Renew gasket and correctly tighten cylinder
bolts
Leaks
IUAt
NOSIS
external
AULT
Y3tem
head
bolts
thermostat
at
and
cover
or
water pump
Rectify leaks
joint gaskets
2
f oolant leakage internal

Possible
b
c
Cylinder head cracked
and
leaking
rocker compartment
Crackeq cylinder block water
engine tappet compartment

Cylinder head gasket leak due
into
warped
Renew
or
valve
jacket leaking
to
Renew
Remedy
cylinder block
ylinder head
l enew cylinder
into
Renew
head
cylinder bloc
Reface cylinder head and reney gasket
head
Coolani loss by overflow

a
Possible
Over full system
Faulty pressurised
Blocked radiator
core
Coolani
due to poor
foaming
corrosion inhi
4
cause
Crack in cylinder bore wall

Crack in cylinder head combustion chambers
valve ports
Remedy
below filler
cause
Drain and refill to l
neck
Renew faulty
radiator cap
cap
Clean Of renew radiator
tubes
quality
anti freeze or
Drai
systemartd
from
Blow
o t
c re
reneW coolant and additive
itor
Engine overheating
Possible
a
frout
b
c
d
e
to
Remedy
cause
Obstructed air passage
through
radiator
core
from rear to front of radiator

with compressed airor water pressure
Check and res t valve timing
rear
Incorrect
obstruction
core
ignition timing
Incorrect valve timing

Low engine oil level
Stop engine immediately and replenish oil in sump

Check and if satisfactory stop erigineandallow to
Engine tight after overhaul
cool
out
I
g
h
Poor circulation
Loss of coolani due to overflow
Faulty thermostat
Check and rectify
as
under item 5
Check and rectify
as
under ite
i Restricted muffler
or
tail pipe accompanied by
Remove
or
dragging brakes
Check
restrictions
or
renew
loss of power
j
5
Incorrectly
Renew thermostat
djusted
rectify
by
adjustIl
e nt
or
renewal
of
components
Coolant circnlation faulty

Possible
and
compone t
Remedy
radtator core
Clean and flusl engine water jacket and add
cause
radiator
Partial blockage of
Water
Fan belt broken
Faulty water pump
Coll psing lower radiator hose
core
sludge deposits in engine
tubes
water
Clean out
jacket
or
renew
rust
inhibitor to cool nt
or
Renew
slipping
or
or
Overhaul
tltermostat
Check
adjust fan bell

ren w water pump
Qr
and
radiator core
I Insufficient coobnt
in
Repleni r
systelT
33
renew
tllbes
coola
ll
lower
tpe
mostat
hose
and
renew
nidiator
check
FUEL
SYSTEM
SPECIFIC
CARBURETTOR
130
125
1000
1200
13300 ft
Dual barrel
26mm
30mm
130
2000
1200
125
3000 m
120
4oo0m
20mm
Float level
1000
24mm
1200
26mm
Metric
1000
95
1200
98
1200
135
in
472
0
tFlo
t seat
1000
140
mm
I2 0mm
1200
mm
jet
1000
10 5
413
0
100ths
1000
main
ft
13300 ft
venturi diameter
jet
10000
venturi diameter
main
6600 ft
28mm
Secondary
1000
throttle barrel diameter
1200
Secondary
130
3300 ft
1000
Primary
135
diameter
1200
Secondary
ft
Secondary main jet with altitude

compensation jetting 1200
Hitachi DCG306
Primary throttle barrel
1000
4000
Hitachi DCG286
Dual barrel
Primary
3000 m
10000
Make and model
1000
TIO
S
in
clearance
1200
3
1
1 7
0 051
nun
0 066 in
Primary slow jet

1000
40
1200
43
Secondary
slow
Distance between carburettor top cover gasket surface

upper edge of float with float in the raised position
and
jet
1200
t Distance between float seat

float in the lowered position
50
Primary
1000
and needle valve stem with
main air bleed
1200
Secondary
80
1000
120
1200
80
Primary slow
Type
Delivery
1000
210
220
pressure
kg cm2
psi
0 18 kg cm2
Z 56 psi
1000
0 16
2 Z8
slow air bleed
1200
Mechanical
diaphragm
air bleed
1200
Secondary
FUEL PUMP
main air bleed
I ZOO
100
Power jet
1000
Delivery rate
1200
60
1000 1 ZOO
450
per min
pI per mini
0 8 US pt per min
Primary main jet with altitude

compensation jetting 1000 1200
98
96
3300 ft
2000
90
3000 m
86
4000
AIR CLEANER
6600 ft
Type
10000 ft
13300
135
FUEL TANK
ft
Capacity
main
Sedan
40 litre
8 81
1000 m
2000
Imp gal
gal
10 57 US
3300 ft
135
Paper element
jet with altitude

compensation jetting 1000
140
Imp
1000 m
92
Secondary
cc
0 7
Wagon and coupe
38 litre
37
8
Imp gal
Q4 US gal
l0
6600 ft
34
Fuel
The
Hitachi
DCG286 and DCG306 carbureltors
the Datsun
to
1000 and 1200
are
major difference between the two carburettors is

the power valve mechanism which was introduced to the
As
both
procedure
applicable
The
to
improve high speed driving

carburettors
are
quite similar
attention
overhaul
manifold
as
making
to
from the
engine Discard the gasket

procedure with
the full owing
If necessary
sure that
manifold
gasket
new
and washer
ecuring the
and withdraw the
nuts
no
between the carburettor and irilet

scrape
foreign
the
matter
is
gasket surfaces
dropped
clean
into the inlet
manifold orifice
carburettor is of the twin barrel type with each
barrel
incorporating a multiple venturi system

The barrels provide a primary and secondary system
and
given
Use
four
inlet
gasket
Installation is
outlined in the carhurettor section will be

both models unless otherwise stated
etc
the
to
carburettor and
The
the
Remove
carburettor
engines respectively
and
are almost identical in construction
1200 version to
Ct RBIJRETTOR
filted
System
each barrel shares
common
air
NOTE It is good practice to cover the inlet manifold with

rag when the carburetfor is removed for overhaul Extensive
engine damage mav result if objects are accidentally
horn and separate
main nozzle and throttle valve
dropped
primary system provides suitable mixtures for low

speed moderate speed and acceleration It also provides
adequate mixtures for starting when the choke plate is
into the induction
Orifice
The
closed
paneL
secondary bore provides mixtures for high speed

and also for full throttle openings at low speed
A high speed valve which is incorporated in the
secondary system opens against a counterweighted lever to
enable the secondary system to maintain full mixture for
high power operation
The
Check the carburettor for fuel and
adjust
Raise the
engine
bonnet
and fit fender covers to
the
vacuum
specified rpm after
leaks and
warm
up
and channels
assembly
feed pipe
Remove the air cleaner
Disconnect the fuel
Disconnect
Disconnect the choke control cable
Detach the
the distributor
tluottle cable
vacuum
from
Replace faulty parts with new ones When checking

from the carburettor it is at times v ry
removed
parts
difficult to be sure whether they are satisfactory for further
3
advance
pipe
service
the carburettor
It is therefore recommended that in such cases new

parts be installed
4
Always use a new gasket kit when overhauling the
throttle lever
PRIMARY THROTTLE VALVE
carburettor
5
SPRING
lir
THROTTLE
SCREW
SCREW
HIGH SPEED VALVE
Flange
idling speed
to
When overhauling the carburettor several items of

importance should be observed to ensure a thorough job
i All parts should be carefully cleaned in a suitable
solvent and then inspected for damage or wear
2 Use air pressure 9nly to clear the various oritlces
both front fenders
Carnurettor
the
TO SERVICE
that the choke valve is fully open when the

control knob is in the full off position at the dash
Ensure
choke
and Main
Body with Main Jets Throttle

Typical of Both Models
and Idle Screws Removed
35
It
is
most
important
that
the
correct
fitting
Sy
Fuel
tem
CHOKE VALVE
CHOKE
LEVER
PUMP
HIGH
SPEED VALVE
LEYEA
Rear
screwdrivers
and
spanners
be
1200 Series
Carburettor
View
of
used
when seTvicing the
Also
2
Typical of
Disengage and
carburettQf
spring
TO DISMANTLE
accelerator pump
Remove
previously
1000 Series
remove
primary throttle
the
return
retaining screw and detach the

actuating lever from the top cover On
1200 models remove the actuating lever return spring with
3
ACnJATING LEVER
the
carburetlor
from
the
engine
Unscrew
the
the lever
as
described
Take out the five
screws
Right Hand
FLANGE
36
and washers and detach
Side View of 1000 Series

Typical of 1200 Series
Carburettor
Fuel
4
System
the carburettor top cover assembly Disconnect the choke

link during this operation
5
Remove the three retaining screws and separate the
carburettor flange from the main body
6
The carburettor has now been dismantled into its
three major components namely main body flange and top
sLOWJET
cover
TO CLEAN PARTS
1 Clean all carburettor components in petrol or

cleaning solvent and place in a suitable container
2
If compressed
air is
available
blow
each
component clean when assembling
Du
NOTE
not
clean
jets with
wire
drills
or
other
mechanical means as
too
rich
orifices may become enlarged causing

mixture for proper perfomzance
Clean
away
carbon
any
deposits
that may have
accumulated around the throttle valves

4
Discard all used
Before
gaskets and packings

assembling check all fuel passages
blowing through with compressed air
by
TO SERVICE MAIN BODY
Remove
the
primary
and
secondary
main
air
Remove
the
primary
and
secondary
emulsion
bleeds
2
tubes
primary slow jet

models only remove
Remove the
On
Unscrew the
1200
Slow
the
Jets
secondary slow
13
jet
Air
Bleeds
Dismantled
from
or
for cracks and all
gasket surfaces
burrs
Check the power valve for smooth operation and

proper seating If necessary blow against the power valve to
ensure that it does not leak
15
Check the accelerator pump plunger for wear and
for smooth operation in the plunger bore Check the spring
for rust or weakness
and then remove the
jets
access
Main
Inspect the body
for nicks
to the main
plugs to gain
primary and secondary main jets
two
and
Carburettor Main Body 1000 Series
14
On 1200 models
remove the power valve

Withdraw the accelerator pump plunger invert the
carburettor body and remove the plunger spring and check
ball
With the carburettor
body still inverted allow
accelerator pump outlet weight to become

its bore
dislodged
the
play
10
speed
Instal all
Peen
assembly
With
in the
17 Reassembly is a reversal of the dismantling

procedure with attention given to the following
9 Using a small file remove the peening from the

ends of the high speed valve retaining screws and mark the
valve
in relation to the carburettor body to facilitate
correct
Check the high speed valve shaft for excessive

body and also for bend
16
from
suitable screwdriver
valve retaining
screws
screws
the two
high
and withdraw the high speed
remove
to
new
gaskets
when
reassembling
the ends of the throttle and choke valve

ensure
that
they will
not
comc
retaining
dislodged
in
service
valve
11
NOTE
Remove the
Onlv
remove
the carburettor bodv
TO SERVICE TOP COVER
high speed valve shaft from the body

the
if it
high speed valve
and
The carburettor top cover assembly which houses the

choke valve and shaft normally requires very little service
Do not remove the choke valve and shaft unless it is
shaft from
is unserviceable
absolutely
12 Now that the carburettor main body is

dismantled check all components for serviceability and
make replacements as found necessary
necessary
Remove the primary and secondary slow air bleeds

On 1000 models the primary side only
1
37
SY6tem
Fuel
MAIN
TOP COVER
POWER
BODY
VALVE
ti
SECONOARY
MAIN AIR 8
SECQNOARY
SLOW JET
PRIMARY
to
SlOW JET
O
SECONOARV
PRIMARY
SLOW AIR
OLEED
It
POWER VALVE PISTON
SLOW AIR BLEED
Internal View of Carburettor Top Cover and Main Body Assemblies
7 Inspect the flange

surfaces for nicks or burrs
Mark the choke valve in relation to the cover to
facilitate
3
correct
a
Using
assembly
small me
ends of the choke valve

valve retaining
screws
the peening from the
screwdriver remove the two choke
and withdraw the choke valve
Remove the choke valve shaft from the cover
Lay
straight edge
across
Lay
straight edge
the gasket face of the
into their
to check for warpage File the cover gasket face back

true condilion if ex cessive warpage is eviden t
excessive clearance
to
necessary
I I Assemble
TO SERVICE FLANGE
appruximately
adjusting screw and spring
adjusting Screw and spring
primary and secondary throttle valve
the flange body If wear is not evident
Check
shafts for
wear
the
in
the
throttle
NOTE
The abovementioned
and
remove
primary
the
both
throttle
valves
engine
at
are
adjustments
on
the rhraule
must
be
procedure
screws
disconnect
secondary connecting link and
both throttle shafts from the
TO ASSEMBLE
the
then remove
I
Assemble the flange with a new gasket onto the
carburettor main body and instal and tighten the three
flange
6 If necessary unscrew the retaining nut and remove

the throttle lever etc from the end of the primary throttle
a re
Note
how
situated before
shaft
components
dismantling
three
screws
Withdraw
to
in two or
Engine
adjusted correct v with the
operating temperature See adjustment section for
idle mixture and speed
plate retaining
screw
olllv preliminarY adjustments
Mark the primary and secondary throttle valves in

conjunction with their respective bores File the peening
4
throttle
adjusting
turns
and idle screw
from the ends of the
surfaces and
in the flange and check for

Renew the shafts or flange as found
then do not dismantle the shaft assemblies
away
gasket
gasket
3 turns
Screw the
Screw out the idle
Remove the throttle
the
the
with attention
into the inlet manifold
across
and
flange in the reverse order of

given to the following
dismantling
the
and
primary
secondary throttle valves to
Adjust
close fully
Check both primary and secondary throttle valve and
shafts for smooth operation and peen over the ends of the
valve retaining screws
Turn the idle adjusting screw and spring in gently with
the fingers until it just seats and then back it off
7 Reassemble by carrying out the dismantling

procedure in reverse with attention given to the foBowing
points
Check the choke valve for proper operation Instal the
of
two new choke valve retaining screws and peen the ends
loose
fall
will
not
work
and
to
ensure
that
the screws
they
cracks
respective bores
cover
a
for
check for warping

9 Check the seating surface and the thread of the idle
adjusting screw for damage
IO Place both primary and secondary throttle shafts
retaining screws
suitable
With a
remove
1200 Series
to ensure correct
retaining
assembly
new
38
screws
Assemble the top cover to the main body with a

gasket and instal and tighten the five retaining screWS
2
Fuel
6
Syatem
LINK
PRIMARY THROTTLE LEVER
I
I
1200 Series
Throttle and Idle Screws Installed
rburettor
Flange Typical of 1000 Serie

Connect
3
PLUNGER
up
the
choke
link
the
during
above
operation
Fit the accelerator pump
where fitted
SPRING
the top
to
securing
screw
connect
the
to
retain
cover
actuating lever and spring

and instal and tighten the
the lever
During
this
operation
primary throttle lever
actuating lever
to accelerator pump
link into the inner hole on t e actuating
lever
5
Attach the
Actuate all throttle and
ensure
return
linkage
chok
spring
by hand
to
that all mechanism is operating smoothly
TO CHECK AND ADJUST FLOAT LEVEL

Remove the air cleaner and carburettor top cover
described
assembly as
1
previously
Invert the carburettor top cover and allow the float

seat to rest against the needle valve
Measure
the distance from
the upper
edge
FLOAT
Pump
Components
Dismantled
From
Carburettor Main
Body Typical Both Model
i
G4SKET
Float
and
Needle
Valve
Carburettor Top Cover
Assembly
Removed
of the
P7
l
PIN
Typical of Both Models
Fuel
7
floal
System
the
to
carburet tor
top
cover
should be
10 5
mm
measurement
models and 12 0
4
If
472
0
mm
adjustment
gently with
is
413
0
in
for
000
in for 1200 models
required bend
nosed
pair of long
gasket surface This
pliers
the float seat

until
tab
the desired
pleasurement is obtained
With the carbureltor top cover still inverted raise
the float with the fingers until the float
stopper tab
contacts its stop
6
Now measure the distance between the needle
valve stem and the float seat tab
This measurement should be within the limits as set out
Specificatio section un4er F oat Seat Clearance
in the
If found
cessary
pair of long nosed

clearance is obtained
a
bend the float stopper tab with

until the Correct float seat
pliers
CHOKE INTERLOCK ADJUSTMENT

NOTE When the choke valve is in the fully closed position
the primary throttle valve should be opened 1 22 mm
wili obtain a throttle valve opening angle vf

degrees from the fully closed position
0 048
14
in This
1 Remove the carburettor from the vehicle as

2 Actuate the choke operating lever by hand until
the choice valye is in the fully closed position
0048 iiI diameter rod as a
3
22
mm
Using a 1
the
check
clearance
gauge
the primary throttle
feen
bet
valye and the valve bore
4 If the throttle valve clearance is larger or smaller
1 22
Method
10 048 nl
GAUGE ROO
mm
PRI
ARY THROTTLE VA VE
OIA
Checking
Cho
e Interlock
Adjustment
Models
Both
than
then carefully bend the choke

the gauge rod
connecting rod with a pair of suitable pliers until the gauge
will just slide neatly between the throttle valve and bore
ti
FLOAT
FLOAT S AT
1 31 7
mm
CLEA
Method of
o 066
Ei
PRIMARY ANp SECONDARY THROTTLE

INTERLOCK
ADJUSTME
IT
v
1
The secondary throttle valve should begin to open

when the primary throttle valve is opened 48 degreesIrom
the fully closed position This angle can be assessed by
CE
ED LE VALVE STE
Checking Float Seat Clearance Float Must

Stop to Simulate its lowered pOsltio
be
Raised Against
40
Fuel
B
Syatem
Ensure that the secondary throttle valve is fully
closed
connecting rod with a pair of pliers until

5
Check the adjustment by withdrawing the gauge
rod closing both throttle valves and then gradually open
the primary throttle valve via the throttle iever until the
secondary throttle valve just commences to open In this
position the gauge rod should just slide neatly between the
primary throttle valve and the primary throttle bore
4
it
just
Bend the
comes
into contact with the
to ADJUST IDLING SPEED

I
Remove the
MiXTURE
AND
vacuum
access
the
plug from
inlet
manifold
2
Connect
vacuum
with suitable
gauge
adaptors
into the inlet manifold

3
Connect
Start anti
tachometer to the
run
the
coil
ignition
it reaches riormal
until
erigine
5
SECONDARY THROTTLE VALVE
PRIMARY
I
5
MethOd
of
1
831T1f
0 230
Checking
CIA
nl
GAUGE
Primary
ROO
and
Interlock Opening Typical
vacuum
Secondary
Position
shown in
the
5 83
0 230 in
mm
illustration
Throttle
screw
reading
on
vehicle
as
the vacuum
an
idle
speed
screw
gauge
until the highesl
is obtained
it
may be
adjust the jdle speed during this operation

Stop the engine and discorinect the vacul m gauge
re
diameter rod
as
NOTE An exhaust gasanalyser

rture
mL
or to check
adjust the
ifavaiiable
gauge readings
reading is desired on the gas
the idling mixture screw in
rture
mL
vser
anal
a
at
and anti clockwise
10 5
rill
U13
idle
richer mixture
MODEL
1200MDOEl
41
engine
Turning
clockwise direction gives
Float level
be used to
as
TAB
Carburettor TQp C ver with Float in the Raised Position
can
a comparison with the

An uptimum mixture strength
vacuum
lealler
Showing Correct
until
between the
valve and ihe throttle bore
STOPPER
idling
the tachometer
and tachometer
between the primary throttle
FLOAT
on
Adjust the idling mixture
necessary to
of Both Models
positioning a 5 83 mm 0 230 in diameter rod

primary throttle valve and valve bore
Remove
I
the carburettor from the
the throttle
Adjust
of 600 rpm is obtained
THROTTLE VALVE
Fuel Syatem
2
lIP
DESCRIPTION
Remove
the
two nuts and
spring
washers which
the fuet pump to the cylinder block and withdraw

the fuel pump with spacer and gaskets
secure
type
The fuel pump is a mechanically operated diaphragm

actuated by a rocker arm assembly which in turn is
operated by
an eeCCll tTic on the

engine camshaft
the carhurettor floar chamber is full and the
carburettor needle valve is closed pressure in the pump
NOTL During operation 3 lousen the luts progressiFeh

until pressure nf the diaphragm and rocker aml
spring is
reUelled
When
will hold the pump diaphragm downwards

the pressure of the diaphragm
spring
At this time the rocker arm assembly will run freely on
outlet pipe
against
the
diaphragm
stem
until the pressure in the outlet
pipe
is
JtiInstoanl
attention
is
Instal
relieved
given
to
new
the
following
gaskets
to
both sides of the fuel pump
spacer
When the outlet pipe pressure is relieved the pump

diaphragm again rises under pressure from the diaphragm
spring and into operation by the rocker ann assembly
A small compression spring holds the rocker ann in
constant contact with the
minimise
operating
eccentric
on
the
camshaft
PUMP
OUTLET
RETAINING SCREW
to
noise
A seal which runs
on the
diaphragm stem and which is
retained in the fuel pump lower body by the
diaphragm
spring prevents engine oil from entering the upper section
of the pump lower body
The rubber fuel pump diaphragm is held together

by
metal discs and is specially treated so that it is not
affected by gasoline
two
Raise the
engirie bonnet
both front fenders

2
Disconnect the fuel inlet and outlet pipes
at
the
fuel pump connections
OUTLET
VALVE
Assembled View of Fuel

RETAINER
DIAPHRAGM MOUNTING FACE
FUEL
NLET
INLET VALVE
Valves Mounted in Fuel Pump Upper Body
42
Pump
Fuel
UTR
GAS KET
COVER
BOOY
ES
GbASKETAVALV
@f
iJ
SPRING
SPRIN
SCREW
DIAPHRAGM
kF
10
System
o
i
I ft
g
LOWER BOOY
SCREW
RETAINER AND SCREWS
ROCKER ARM
GAS
Ensure that all traces of old

the new
A
the
gaskets
smear
of
will
gasket
gasket
are
removed before
fitted and the pump installed

jointing compound applied to both sides of
are
help sealing
SPAeER
TO DISMANTLE
Remove
previously
2
the
fuel
the
from
pump
engine
the
Actuate the rocker
arm
by
hand and
With
the
of
corner
file mark
screws
of the upper and lower body section of the pump

to facilitate correct assembly
5
Remove the screws from the pump upper body and
separate the two pump body section
Mark
or
the
note
position of
If a fuel pump
two
or
surface plate check
main
sections
of the
repair
has seen considerable service and is
inspection it is advisable tv fit a

diaphragm seal valves and gasket
thorough job and further trouble free
dismantled for repair
assembled
position
of the
and
NOTE
the
suitable flat surface

surface
pump for distortion Rectify by filing if necessary

5
Renew faulty components as found necessary
expel residual
fuel out of the pump into a suitable container

3
Remove the pump top cover retaining
detach the top
ef and gasket
CO
Using a
diaphragm
4
as
described
Exploded view of Fuel Pump Components
or
kit which includes
This
i ensure
wi
service
from
the unit
the inlet and outlet
valves in relation to the pump upper body section

7 Remove the two screws from the valve retainer and
take
the
out
retainer
valves
and
Discard
gaskets
the
gaskets
diaphragm and by using a probe
the
arm aperture
in the pump
rocker
through
working
lower body unhook the diaphragm stem from the end of
8
Press down on the
the rocker
arm
Withdraw the
take
spring
diaphragm
out
diaphragm
the
seal
and lift off the
retainer
and
diaphragm
withdraw
the
oil seal from the pump lower body

Relieve the staking on one end of the rocker arm
10
stern
pivot pin and with the pump suitably supported on the

pivot pin boss tap in one end of the rocker arm pivot pin
with a pin punch to remove it from the opposite end of the
pump body
II
Withdraw the pin punch and lift out the rocker
arm and rocker arm spring
TO CLEAN AND CHECK
J Wash
all
components
thoroughly
in
cleaning
solvent
Check the pump diaphragm and

perforation and or deterioration
2
stem
oil seal for
Check the valve assemblies and mechanical linkage
for undue
Mounting
Position
of
Disposable
Assembly
wear
43
Type
Fuel
Filter
II
Fuel
System
TO ASSEMBLE
Excessivelv high pressure usualv mdicati that

diaphragm spring has been Jitted to he pump
NOTE
incorrecr
reversal of the dismantling procedure

Assembly
with attention given to the following
Ensure that valve assemblies are installed correctly in
is
their respective
hat he
seats and
that each valve is fitted with
gaske t
Lubricate the mechanical linkage
stem with engine oil when assembling
diaphragm
is
pulled
pressures could
Low
lOa
right
be
caused
perforated diaphragm gummed valves
bv
or a
worn
weak
an
or
linkage
ur
broken
diaphragm spring
new
and the
NOTE This test should be carried out if the pump pressure

was checked and found to be within specifications
FUEL PUMP PRESSURE TEST
junction
the carburettor
connect
pipe back
Connect
suitable pressure gauge
junction of the T piece

4
Start and run
observing
the
to
the
engine
pump
delivery pipe
the remaining
at
varying
that has
on
wi th
pressure above
NUT
measuring beaker under the pipe and

engine at 1000 rpm for one ffilnute
capacity of fuel delivered in the beaker is
a
fun the
If the
specified see Specitkations then either a

partial blockage in the system may be evident or the pump
is unserviceable
or
blowout the
below that recommended is unserviceable and should be

removed and dismantled for inspection
WlJlG
the carburettor
below that
pressure readings
delivery
at
Position
start and
speeds
the
pressure gauge
in the front of the section to
specifications
comparereconutlcnded pressures
fuel
to
pressure readings
Check the
A
I
Run the engine for a few minutes to ensure that
fue
the carburettor float chamber is full of
2
Stop the engine and disconnect the fuel pump
Disconnect the fuel feed pipe at the carburettor

fit a T fitting to the fuel feed pipe and from one
FUEL PUMP CAPACITY TEST
diaphragm
Check the condition of the fuel filter and

lines before removing the pump for
fuel
inspection
eo
IfEFlBODY
LO
r
View of 1000 Inlet and Exhaust Manifold
TypicaJ of 1200
Dismantled View of Air Cleaner Assembly

Models
44
Typical
of Both
Assembly
Also
Fuel
1
AIR CI HANER
which is secured
DESCRIPTION
on
the two models covered
Remove
in this manual are fitted with viscous paper type elements

The elements should not be cleaned in service but
carburettor
should be renewed at the recommended mileage of 40 000

kilometres 24 000 miles
from
to
cylinder head
Unscrew the
the
air
the
cleaner
wing
nut
air cleaner main
and remove the
body and
the
from
assembly
top
cover
withdraw the paper

t
element
This mileage is only a guide for nonnal operating

conditions and should be reduced accordingly if the vehicle
is
the inlet manifold
on
stud
retaining
The air cleaner assemblies
12
rem
Sy
TO INSTAL
operating under extremely dusty conditions
NOTE Paper air cleaner elements should
petrol
been
or
other type
any
washed in
of so
so vent or
should be discarded and
1 With a piece of clean fluffless cloth thoroughly

wipe accumulated dust away from both portions of the air
cleaner assembly
2 Place the paper element into he air cleaner body
be washed in
Elements that have
vent
that have
a new
not
element
become oil soaked
and centre it
fitted
on
its seat
the air cleaner top cover onto the main

and
instal
and
body
tighten the wing nut
Instal the air cleaner assembly to the carburetlor
4
5
TO REMOVE
cleaner
Detach tire rocker
cover
to
Remove the two bolts which
On 1200 models
Engine will not
disconnect the additional bracket
Lack of fuel in bowl
Engine flooded with fuel
Engine
Incorrect
and
or
SYSTEM FAULT
the
DIA
rocker
cover
air
to
Remedy
when cold
at idle
or
Hold accelerator flat until
by
engine
starting procedure
accelerator pedal flat until engine
starts and revise

Hold
starts
speed
adjustment
Remedv
cause
of idling speed
Check and
adjust control
screws
mixture control screws
Carburettor float bowl flooding
Check float level and for sticking needle valve

or punctured float Clean and blowout carburettor
Carburettor starving for fuel
Check fuel delivery at needle valve Clean

and blowout carburetlor Check fuel pump
Blocked idling jet or idle air bleed

Carburettor to manifold attachment bolts lopse

Check and tighten bolts
Leaking
Check and
d
e
carburettor
flange or intake
renew
faulty gaskets
manifold gaskets
g
or
loose attachment
carburettor main
to air horn
Faulty gasket
body
air
cleaner
NOSIS
cause
use
Possible
to
ventilation hose
of choke or accelerator
flooded when hot as in b above
Engine stalls
inlet manifold
Check fuel pump delivery sticking

clogged needle valve
excessive
FUEl
two
start
Possible
retaining stud
7 Reconnect
the air cleaner
to the inlet manifold bracket
4
1
secure
Fit and tighten the

assembly bracket bolts
6 On 1200 models connect the additional bracket

which is secured to the inlet manifold to cylinder head
air cleaner ventilation
hose
assembly
Position
Renew
screws
assembly
45
faulty gaskets
and
tighten securing
screws
13
3
Fuel
Flat spot
System
on
acceleration
Possible
a
b
c
Remedr
cause
Blocked accelerator pump
discharge
jet or sticking check valve

Faulty accelerator pump plunger
Faulty accelerator pump linkage
Renew pump
plunger assembly
Check and rectify pump linkage Check that

pump connecting link is in correct position
in the pump lever
Engine misfires
or
cuts out at
Possible
a
high speed
Remedv
cause
Obstruction in main
or power jets
Low fuel level in float chamber or
float chamber starving for fuel
Dismantle and blowout
Failure of fuel pump to

deliver sufficien t fuel
Overhaul fuel pump
Blockage
in fuel tank pipe

Restriction in fuel filter
Remove
blockage
Clean or
renew
Air leak between fuel pump and filter

or between filter and tank
Rectify
Air leak between carburettor air horn

and main body assemblies or main body
jets
Check float level setting check fuel pump

filter and supply lines
securing
Water in carburettor
pipe
air leak
Check and renew
flange
and clean
filter
gasket
and
tighten
screws
Drain and clean fuel system
5 Excessive fuel consumption

Possible
cause
Float level too
Choke butterfly partially closed

Air cleaner element dirty or
Remedy
high
Check and
Check and
adjust float level

rectify
re
Clean element
or renew
requires renewal
d
Accelerator pump requires an adjustment

or in wrong hole in
pump connecting link
Re
Fuel pump
Check and fit
delivery
fuel pump
pressure too
adjust accelerator pump stroke

with link in other hole oflever
high
Faulty
Leaks between fuel pump and fuel tank

or fuel pump and carburettor
Gleck and
Power jet
Free
in release
i
j
k
vacuum
diaphragm
or
damaged
Excessive
diaphragm spring adjust
plunger stuck
rectify
plunger or
leaks
renew
lower position
Faulty power jet

Worn
correct
fuel pressure with pump base gasket

Overhaul fuel pump and renew as necessary
use
Check and renew

main
or
of choke
or
power
Check and
jets
Revise
accelerator pump
46
renew
faulty jet
faulty components
driving habits
CLUTCH
SPE
IFltATIONS
1000 SERIES
Type ofdriven plate

Driven plate
Spring
hub
cushion
Type
Single dry
plate
Outside diameter
180mm
Operation
Hydraulic or
mechanical
Spring tushion
Facing thickness
7 8mm
Inside diameter
125mm
160 mm
Total friction
264
Type
of driven
Driven
plate hiIb
7 09 in
307
0
4 92 in
plate
Outside diameter
30
6
Facing
15 87
Master cylinder dl meter
llOmm
Total friction
area
2i2 cm2
diameter
15 87 mm
in
aut
bearing
free
travei
0 9
Mechanical
0 7mm
0 027 in
Clutch pedal free travel
31 5mm
bearing free travel
15
110
Mechanical
1 240 in
Clutch throw out
078 in
0
Piston stroke
23 5
30mm
Hydraulic
Pedal height
Mechanical
mm
139 5
143 5
0 925 in
height
Chitch pedal
free travel
in
1181
mm
0 750 in
Pedal
rum
144 5 mm
5492
5 689 in
5 65 in
15
mm
0 591 in
0 059
19 05
15 0
433
0
2 0mm
Slave cylinder diameter
mm
0 0472 in
Hydraulic
0 625 in
Piston stroke
1 2
0 0354
in2
32 860
cylinder
in2
mm
0 625 in
Clutch throw
Inside diameter
330
4
cm
40 92
in
3 2mm
thickness
area
0 126 in
Master
in
20mm
141 5mm
Hydraulic
5 57 in
590
0
0 787 in
I ioo
SERIES
TORQUE
Single dry
plate
Hydraulic or
mechanical
Type
Operation
Pressure
plate
to
WRENCH SEITINGS
flywheel bolts
2 2
kg
5 9 ft lb
RIPTION
DES
I
1000 SERIES
fork and release uf the bearing when the

pedal is returned from the depressed position
Operation of the release fork on the mechanical clutch
by means of a cable which is connected to the arm of the
return of the
The clutch
of the
driven
design as
following exceptions
same
The
throw
out
plate
and pressure
by
the clutch
is
that fitted to the 1200 Series with the

is
bearing
in
release shaft
shaft which extends
end
release me chanism differs
that the release fork is mounted on
through
plate assembly
clutch
opposite
The release fork is mounted on the centre of the shaft

means of two tapered
pins with the fork
sleeve
extending
bearing
sleeve thus
return
spring
is fitted
are
end and
removed first
withdraw the shaft
engaging
to
the
clutch
pedal
at
the
tap out the
sufficiently
tapered
to remove
dowels and
the return
spring
and fork then withdraw the shaft
and disengaging the bearing

A
one
Removal of the throw out bearing and release shaft

differs in that with the gearbox removed the bearing and
housing
down to contact the throw out
at
to the shaft
to
assist in the
Throw out
47
bearing adjustment
is achieved
by adjusting
Clutch
2
the bolt connecting the cable to the release shaft arm
the distance between the lower faces of the cable
bracket and the release shaft arm The correct
measurement oetween the

4 881 in
two
faces is to read 114
plate
pressure
Measure
support
and cover
on
its
pressure
between ihe top of the pedal

floor
shaft
flvwheel
The driven plate has
the
same
type mounted on the bearing sleeve which slides on the

clutch shaft bearing retainer
a
Where
hydraulically operated clutch release
mechanism is fitted the push rod on the slave cylinder is
adjusiable to provide clearance between the throw out
that of ihe 1200 Series
bearing
and
diaphragm fingers
in the released
1200 SERIES
Where
fitted
The single dry plate clutch comprises

cover
assembly and a driven plate
press ure
assembly
2
TO
REMOVE
AND
throw out
INSTAL
bearing and the diaphragm lingers

bearing in the released position
section
Mark the pressure plate cover in relation to the

flywheel so that they may be assembled in their original
the pressure
3
Take out the six bolts and spiing washers securing
the pressure plate assembly to the t1ywheel releasing theni
evenly and progressively and remove the dutch pressure
Diaphragm
and the clutch driven
Spring Type Pressure Plate
Align
of the
driven
plate
Driven Plate Assemblies

48
hub must face
plate
the
marks
on
the
pressure
flywheel made on dismantling

Tighten the six securing bolts evenly
plate
and
revers
attention to the
NOTJ
The raised section
positions
assembly
with the
1 9f the removal procedure with

following points
Use the special aligning tool or used gearbox
input
shaft to align the centre of the driven plate hob with the
spigot bearing in the rear end ofthe crankshaft
Raise the vehicle and remove the propeller shaft

as
described
in
the
MANUAL
and cover
mechanically operated release mechanism is

adjustable to provide clearance between
JnstaHation is a
plate
bearing
UT
U UNIT
gearbox
TRANSMISSION
out
position
the cable is
particular
and
with the throw
the throw out
plate
the
to
single
hydraulic clutCh is fitted LH drive vehicles

iype df master cylinder and siave cylindet as fitted
a
the 1200 Series is utilised

of the throw out bea ing and clutch pedal
Adju t
f1ent
and bleeding procedute for the hydraulic system is the same
and
spiined
the clutch shaft gearbox

input
located in he end of the engine crankshaft is a
porous bronze bush
The clutch throw out bearing is a
row ball thrust
to
as
a spring cushioned hub

gearbox input shaft
the spigot bearing for
centre line to the
Secondly to obtain correct pedal free travel adjust the

cable at the cable lower end
Where
diaphragm
eigllteen tapered levers which are

diaphragm and maintain constant pressure
plate thus holding the driven plate to the
slide on the c10tch shaft
the
integral with
mm
Pedal height adjustment is obtained by

adjusting the
pedal stop and cable
First adjust the pedal stop and measure the distance
through
assembly incorporates
type spring
The assembly has
Release
Bearing
plate
and
cover
and
progressively
Side of Pressure Plate
3
Clutch
COVER
I
L
DIAPHRAGM SPRING
W
0
PRESSURE PLATE
Diaphragm
the specified torque
fitting the securing bolts
to
If the
flexible
Fit
new
Pressure
Spring Type
spring
washers
prior
Plate Assembly FlyWheel Side

spigot bearirig
to
hydraulic pipe has been discoimected
froni the slave cylinder
it will be necessary to bleed
This beacing is
the
the
flywheei
the gearbox with the recommended od and ensure

that the propeller shafi fear universal joint flange and
pinion flange are connected to the marks made on
ismantling in order to maintain the original baiance of the
FiJI
serviceable
sinterect bronze bush and requires nb
Check
iIuow out
the
NOn
bearing
for
ise
or
the clutch parts do not immerse ihe

the
fluid This beanng is
cleaning
bearing in
When
th ow out
luqricated
when
cieaning
assemblea
and
requires
no
further
lubrication ih service
CHECK AND INSPECT
If the driven
plate
is stilI
any cleaning fluid oil or grease

8
or
Check the hub of the
wear in the hub
splines Check
plate hob cushion springs
4
Check
that
the
exceed 0 050 nim

5
Check
input
reamth
Do not
Check
shaft spigot bearing Apply
high
melting point grease

assembling the clutch
coating of
the
flywheel
to
the bore of
and pressure plate for
high
driven plate for looseness or

effective action of the driven
spots glazing and cracking

If gIaz g and high spots are in evidenr e remove the
flywheel from the crankshaft Machine ihe surfa e
does
removing only sufficient material to restore the flywheel

face
Renew both the driven plate and pressure plate
assembly
run
out of the
ooi
in
that the clutch shaft
flywheel face
gearbox input
shaft
MASTER
VUNDER
3
Remove the two attaching bolts and

cylinder
assembly and spacer shims
master
iight
the biIsh before
coring
3
serviceabie do not allow

to contaminate the plate
facings
Check that the driven plate facings are not highly

gummed with burned oil
2 If the driven plate facings are worn down to the
rivets check the flywheel and pressure plate faces for wear
glazed
not
in
roughness
shaft
and
flange Is
luorication in service
hydraulic system
TO
in
condition
Remove
the split pin and clevis pin to release the

master cylinder push rod from the clutch pedal
2
Disconnect the pressure pipe at
the master
installation
bleed the system Ensure that

any painted surface
49
the renioval procedure

hyctratilic brake fluid and
is a reversal of
Refill the reservoir with clean
cylinder
withdraw the
hydraulic
fluid is not
spilt
on
clutch
4
TO DISMANTLE
I
Place the inlet valve seal
Remove the tiller

cap from the reservoir and drain
cylinder and reservoir
the nuid from the master
Pull back the robber boot and remove the

circlip
Withdraw the push rod and stop washer
4 Remove the inlet valve stop bolt from the master
cylinder and withdraw the piston assembly and return
2
3
and
retainer from the
end of the
spigot
spring and inlet valve

Take care not to lose the inlet
piston
remove
the
bolt
and take
out the
Insert the push rod push in and instal the retaining

circlip and rubber boot
washer
valve
the
Place
piston return spring over the spring

dip
piston in hydraulic fluid and instal the
spring and piston assembly Screw in the inlet valve stop
Remove the spring from the spring retainer lift the
spring
Partially fill the

push rod
Remove the inlet valve seal from he inleLvalve and
and pUmP the
the
outlet
primary
and
secondary
from the
cup
the inlet valve with the
secure
retainer
spring
spring
un
lip facing the piston assembly

3
Place the inlet valve spring with the tapered end on
the face of the inlet valve flange and press the spring
retainer down over the splined end of the piston assembly
piston
assembly
Fit the master
that the
TO CLEAN AND INSPECT
reservoir with clean
hydraulic fluid
cylinder
until fluid emits from the
cylinder
to the vehicle arid ensure
number of spacer shims are fitted between

master cylinder
retaining flange and the fire wall to
the
Correct
achieve correct
I
pedal clearance
hydraulic pipe
the master cylinder replace
clean the master cylinder components

and the inside of the master cyIind
in methylated spiritS
2
Check the inside of the bore for wear and or
the filler cap and bleed

top up
the air from the system as described in TO BLEED in the
pitting If necessary
HYDRAULIC SYSTEM
Thoroughly
hone the bore

Check the piston groove and piston body for
to
the
master
up the master
Top
cylinder
cylinder
on
completion
wear
and renew the piston cups

4
Check the tension of the piston return spring
5
Renew the rubber boot if it shows signs
Connect the
of
eM
deterioration
6
Check the breather
hoie
in the reservoir
cap
FLU D R
to
ensure that it is clear

7
Remove any sediments that may have accumulated
in the bottom of the reservoir
PUSH HOO
RUBBER BOOT
CYLlNDE R BODY
PISTON AND SEAL ASSV

VALVE SPRING
CIRCL
RETA N R WASH
VALV
TJ
the
lip
is
facing
the
OJWASH
RS
VALVE RELEASE BOLT
spigot end of
SH7
I
Dip the master cylinder components in a container
of clean hydraulic fluid and instal the new
primary and
secondary cup on the piston enSuring that the cups are
that the
IDtf
O
SPRING R TAIN
TO ASSEMBLE
correctly and
piston
SPRING
It
4ljl l l
I
seated
CLIP
Clutch Master Cylinder

Exploded View
Left Hand DriveModels
SI A VI
UNDER
3
Unscrew the two lock nuts and withdraw the
push
rod from the withdrawal lever
Unhook and
spring
cylinder
return
Disco
cylinder
ingress
and
remove
the clutch withdrawal lever
connected to the lever and the
lug
on
the slave
Remove the two bolts
to the clutch
housing
and
attaching
remove
the slave
the slave
cylinder
cylinder from
the vehicle
ect the flexible hydraulic pipe at the slave
plug the pipe to prevent loss of fluid and
Draw back the slave
cylinder rubber boot
remove
the retaining clip and withdraw the piston and push rod
from the slave cylinder Remove the seal from the piston
of dirt
50
5
Clutch
the
piston
tIrst
to bend back
1
not
use
Check the bore of the
as
necessary
Check the
deterioration and
cylinder for
cups
Check the piston for
3
renew
on
wear
scoring and pitting and
cup and rubber boot for
piston
renew as
worn in the
pitting
or
wear
reassembly
wear
and
necessary
Check the cylinder retaining clip and
5
or
new
if weak
renew
cylinder groove
lever
appropriate headings
fluid
piston and piston cup in clean hydraulic

instal the cup on the piston easing it into the
that the lip of the seal faces the spigot end of the
and
groove so
travel
free
as
detailed
in this section
the
Dip
RUBBER COVER
piston
Ensure that the cup is correctly seated in the groove
Screw in the bleeder valve but do not tighten past finger
to
tight
BLEED VA LVE
Insert the
piston and
cup
end of
assembly spigot
CYLINDER BODY
ADJUSTING NUT
DT
PUSH ROD
LOCK NUT
fJJ i
PISTON
iIi
rr
if
SEA L
I
tAo
Exploded View of Clutch Slave Cylinder Components Left

HVDRAIJI U
TO BLEED
I
clean
hydraulic
of the reservoir
2
slave
Attach
and fill the fluid reservoir with
approximately
half an inch
top
a
bleeder tube to the bleeder valve on the

end of the tube in a
glass container
three quarters
approximately
Open
turn and apply pressure to the clutch pedal Close the
amount
of fluid in a clean
cap
fluid to within
and immerse the free
cylinder
small
of
the
Remove
bleed
the bleed screw
screw
at the end of the
pedal
down stroke before the
pedal is allowed to return to the off position

4
Repeat the above operation until clean fluid
from air bubbles is
It is
slowly
being pumped
free
into the container
important that the pedal be allowed to return

drawing air into the system and to maintain
to avoid
the fluid level at leasthalf way in the fluid reservoir

5
Close the bleeder valve remove the bleeder tube
and
top
up
approximately
the
cylinder
master
12 70 mm
reservoir
to
within
0 500 in of the filler orifice
Clutch Operating Cable
Adjusting
care
not
If the slave
withdrawal
cylinder taking
of the seal
damage the lip

cylinder is not to be fitted to the
vehicle immediately fit the rubber boot to open end of the
cylinder as a guard against the piston falling out of position
or the ingress of dirt
particular attention to the following points
Ensure that the slave cylinder retaining clip is seated
correctly in the groove on the cylinder body and that the
rubber boot is correctly fitted over the open end of the
cylinder body
Bleed the clutch hydraulic system and adjust the
3
Clean all parts and wash in methylated spirits do

petrol or mineral solvents for this purpose
Hone if necessary and fit
in the bore of the
or
Point 1200 Models
51
Hand Drive 1200 Model Shown
SVSTIlM
under
the
Clutch
6
6
1 tJTCH
THROW OUT
MECHANICAllY OPERATED CLUTCH

TO RENEW 1000 SERIES
hub
1 Remove the gearbox and clutch bell housing

assembly as described in the TRANSMISSION SECTION of
NUTE
this manual
when
2 Unhook and remove the bearing return spring from

the release shaft fork
3
Slide the throw out bearing and hub assembly
housing
forward
the
along
gearbox input
shaft
bearing
the release shaft and fork
for
Check the release shaft bushes in the
Using a suitable puller or

bearing from the bearing
out
throw
and
beUhousing
bearing
hub for
Replace
remove
press
hub and check
the
the
wear
all
worn
or
damaged
components
bearing on the bearing

bearing is facing away
Insert the
race
vf
the
bearing
release shaft sufficiently into the

spring and release shaft fork
Posh the release shaft fully home and check the
to
bearing
instal the
return
tIld alignment in the bellhousing

II Centre the fork on the shaf and tap in the two
tapered pins and check that they are secure
12 Lightly lubricate the input shaft and sleeve with
melting
high
poin t grease
13 Instal the bearing and hub assembly on the input
shaft bearing retaining sleeve and position the fork on the
bearing hub
14 Instal the bearing return spring on the bearing hub
and locate the end of the spring on the fork
IS Check the operation of the clutch release
mechanism and instal the gearbox and bellhousing assembly
wear
throw out
movement
distortion
6
new
Applv pressure to the inner

insta
ingon the bearing hub
IO
retainer
wear
fork and return spring from the shaft and

withdraw the shaft from the bellhousing
for
the
that the
thrust face of the

from the end of the hub
to remove the
Inspect
Instal
sleeve and withdraw from the bellhousing

4 Tap out the two tapered pins
securing the release
shaft fork to the shaft and withdraw the shaft sufficiently
BEARING
in the vehicle
where
described in the TRANSMISSION section
as
of this manual
necessary
the clutch release shaft free travel to

detailed in under ADJUSTMENTS in this
16 Adjust
specifications as
section
MECHANICALLY OPERATED CLUTCH

TO RENEW 1200 SERIES
Remove
assembly
as
the gearbox
and clutch bellhousing
described in the TRANSMISSION section of
this manual
2
Remove the rubber dust excluder from the end of
the withdrawal lever and the aperture in the bellhousing
3 Separate the withdrawal lever return spring from
the
lever
and throw out bearing and

bearing and bearing hub out over
bearing retaining sleeve
throw
pin
EL
RE
RN
SP
pin
AFT
r
BEAAING RETAINER
Components
input shaft
from the
puller
bearing
bellhousing
or
press
Inspect
the
spring
Renew
bearing
hub
withdrawal
and dust excluder for wear

worn
remove
the
hub
bearing
in
lever pivot
damage
and
where
damaged components
necessary
8 Instal the new throw out bearing on the
bearing
hub so that the thrust face of the bearing is
facing away
from the lever end of the hub
SPRING
JI
f
J
View of Clutch Release
bearing
return
fatique
BEARING AHDstEEVE
Exploded
suitable
6 Clean the components excluding the

suitable solvent and allow to dry
7
Using
throw out
LEVE
witlldraw the
the
Disengage the withdrawal lever from the lever pivot
and withdraw the lever from the

5
NS
out
NOTE
1000 Models
When installing
or
the
bearing
ofl the
pressure must be applied to the inner
52
bearing hub the

of the bearing
race
Clutch
Unless
this
is adhered
procedure
to
the
bearing
Position the end of the withdrawal lever in the
sparingly
the throw
out
with a
bearing
high melting point
and
bearing
hub
on
grease and instal

the sleeve
Locate the ends of the withdrawal lever return

spring in the holes in the lever and the throw out bearing
hub
Ensure that the
prior to
assembly
installation
spring ends are correctly lucated

of the gearbox and bel housing
Instal the rubber dust excluder
12
the withdrawal lever and ensure that it is

the clutch bellhousing aperture
over
the end of
correctly seated
in
Position
14 Adjust
specifications as
14 Adjust the clutch withdrawal lever free travel to

specifications as detailed under ADJUSTMENTS in this
the
bearing hub
the
section
HYDRAULIC CLUTCH
RENEW
1200 SERIES
Remove
as
end of the withdrawal lever in the
the clutch withdrawal lever free travel to

detailed under ADJUSTMENTS in this
section
the
this manual
this manual
assembly
on
the vehicle as described in the TRANSMISSION section of
Instal the gearbox and bellhousing assembly in

the vehicle as described in the TRANSMISSION section of
13
TO
bearing
bellhousing aperture and locate the lever on the lever pivot

pin
10 Lobricate the gearbox input shaft bearing retainer
sleeve sparingly with high melting point grease and instal
the throw out bearing and hub assembly on the gearbox
input shaft sleeve
11
Position the throw out bearing return spring on
the throw out bearing ensuring that it is correctly seated
on the bearing and in the bellhousing
12 Instal the rubber dust excluder over the end of
the withdrawal lever and ensure that it is correctly seated in
the clutch bellhousing aperture
13
Instal the gearbox and bellhousing assembly in
11
NOTE
the
damaged
aperture of the bellhousing and locate the opposite end of

the lever on the lever pivot pin
10
Lubricate the gearbox input shaft bearing retainer
sleeve
installing
pressure must be applied to the inner section of the bean ng

Unless this procedure is adhered tu the bearing will be
damaged
9
When
Non
will be
the
gearbox and clutch bellhousing
described in the TRANSMISSION section of
BEARING SLEEVE
I
this manual
2
Remove the rubber dust excluder from the end of
the withdrawal lever and the aperture in the bellhousing
LEVER
Remove the return spring from the throw out

bearing hub and withdraw the bearing and hub assembly
4
Remove the withdrawal lever from the lever pivot
and
withdraw
the lever from the clutch bellhousing
pin
5
Using a suitable puller or press remove the
throw out bearing from the bearing hub

6 Clean the components excluding the bearing in
suitable solvent and allow to
RETAINER SPRING
dry
PIVOT
bearing hub withdrawal lever pivot

pin bearing return spring and dust excluder fof wear
damage and fatigue Renew worn parts and damaged
7
Inspect
the
components where necessary

8 Instal the new throw
hub
so
out
that the thrust face of the
bearing
bearing
on
is
the
BOLT
bearing
facing
away
from the lever end of the hub
Clutch Withdrawal
Lever and Bearing

Drive Models
53
Typical
Left Hand
Clutch
8
7
TB
PIlD 4 L
HYDRAULIC CLUTCH
piVOI bolt
To
9 Align the holes in the clevis with the hole in the

clutch pedal instal the clevis pin and secure with the flat
washer and new split pin
Remove
I
fit the waved washer and flat washer and

with the self locking nut
Instal
and
Disconnect
and
the clutch pedal
femove
return
spring
secure
10
Instal the clutch pedal return spring and check
the operation of the pedal
Withdraw the split pin and washer take out the

clevis pin and disconnect the clutch pedal from the master
cylinder push rod

3
Unscrew
PEDAL AND CONTROL CABLE
the
self locking nut remove the flat

washer waved washer and withdraw the clutch pedal pivot
bolt and lift oot the clutch pedal Remove the two nylon
flanged
4
5
bushes from the metal spacer

Check the pedal bushes and pivot bolt for
Check the clevis and cleviS pin for wear
To
and
Instal
1000 Series
Removal and installation
wear
induding
components
of the
clutch
pedal on the 1000 Series is the same as for the

hydraulic system with the exception that the clutch control
clevis coupling is connected to the top of the clutch pedaL
I To remove the control cable from the clutch pedal
remove the split pin and flat washer withdraw the clevis
pin from the clevis thus disconnecting the clutch control
cable from the slot at the top of the clutch pedal
Replace all components where necessary

lightly apply high melting point grease to the
pedal bush and pivot bolt and instal the nylon bushes in the
7
metal spacer
8
Place the clutch pedal in position and insert the
ADJUSTING
Remove
Withdraw the clevis and the
outer
cable from the
firewall at the upper end
NUT
3
Working at the clutch release shaft end disconnect
the lower end of the control cable from the release shaft
LOCK
SCREWED CABLE END
I
jJ
Loosen the two lock nuts
INNER CABLE
the inner and
engine
5
Withdraw the control cable from the vehicle and
it
check the
CABLE BRACKET
connecting
cable to the cable support bracket attached to the

and separate the cables from the support bracket
outer
outer
cable for damage or fatigue

nuts for thread damage and the rubber
Check lock
insulators for
7
fatigue
Replace all
worn
or
damaged components
where
necessary
Installation is the reverse
with attention to the
Lobricate
the
procedure to that ofremoval

following
cable with molybdenum disulphide
grease
SPRING
Adjust the pedal height and release shaft free travel to

specifications as detailed under ADJUSTMENTS in this
section
Tn
Remove
and
Instal
1200
Series
Removal and installation including cnmponents of the

on the 1200 series is the same as for the
dotch pedal
hydraulic system with the exception that the clutch control

clevis coupling is cnnnected to the top of the clutch pedal
I
To remove the control cable from the clutch pedal
unhook the clutch cable from the slot at the top of the
clutch
pedal
Remove the three

cable flange to the fire wall
Exploded View of Clutch and Brake Pedal Fulcrum Bushes

Pin and Clutch Cable
1000 Models
Working
at
the
screws
attaching the control
lower end of the control cable
disconnect the cable from the withdrawal lever
54
Clutch
Installation is the reverse
4
Release the lock nuts at the upper end of the outer
cable and withdraw the cable assembly
5
Inspect
Replace
damaged components
or
worn
where
height
necessary
to that of removal
following
Instal the control cable with the grease nipple

uppeqnost to facilitate lubrication and lubricate the cable
Adjust the clutch release lever free travel and pedal
the inner and ooter cable for fr aying and
external damage
6
procedure
to
specifications
as
detailed in this section
AD JlJSTMENTS
HYDRAULIC CLUTCH
To
Adjust Pedal
Height
Pedal
height adjustment is carried out in two stages

the pedal height by measuring in a straight
Check
1
line with a steel rule the distance from he floor to the top
of the
pedal pad
The correct measurement shoold be 143 5
5 65 in
mm
If adjustment is necessary
loosen the two bolts
attaching
fire wall and add
or remove
obtain the correct
pedal height
back off the pedal stop

the master
adjusting
cylinder to the
required to
shims as
Ensure that the upper and lower adjusting shims are of

equal thickness and that the two bolts attaching the master
cylinder to the fire

of this adjustment
2
wall have been secured
on
completion
Measure the distance between the floor and the top
of the
pedal pad and adjust the pedal stop so that the pedal
pad height is 141 5 mm 5 57 in
Tighten the pedal stop lock not and recheck the
measurements
Clutch
To
Lever
Withdrawal
Adjust
Free
of the
Travel
mm
vehicle and sopport on

on a hoist
vehicle
complete
support
Apply clutch pedal and allow to return to the off
1
stands
the
Raise
front
of
the
the
or
nut
Check the
lever from
the
when
thrust
adjustment by measuring
the
the free travel
full off position and the position
bearing
contacts the clutch
specified
Specification
5
mm
with the
15
free travel of the withdrawal lever See
1000
adjusting
nut
and push rod and tighten
To
reading
2 0
mm
the lock nut and recheck both measurements
the
I 200
Series
the top of the pedal pad

The correct measurement
is obtained
by adjusting
pedal height by measuring
steel rule
Adjust
Pedal height adjustment is carried out in two stages

I Check the pedal pad height by measuring in a
straight line with a steel rule the distance from the floor to
Series
height adjostment
pedal stop
i Check
line with
travel
078 in
0
Tighten
PEDAL AND CONTROL CABLE
Pedal
release shaft free
0 059
correct
4 881 in
section
Hold the
Adjust
If adjustment is necessary back off the pedal stop lock

and adjust the stop to obtain the correct pedal height
measorement between the two faces is 124
the lock nut Recheck the free travel
To
correct measurement should be 144 5
5728 in
under side of the cablc lower support bracket The
If adjustment is required slacken the lock nut on

cylinder push rod and turn the adjustment nut to
achieve the
1200 Models
between the lower face of the release shaft lever and the
diaphragm
fingers
the slave
pedal pad The
Cable Operated
Tighten the lock nut and recheck the pedal pad height
2
Working at the lower end of the cable release the
lock nut on the adjusting bolt and measuring the distance
position
of the
Release Mechanism
in
the
143 5 mm
straight
the
the distance from the floor to the top
should be from
139 5 to
5 65 in
Shoold pedal height adjustment be necessary back off

pedal stop lock nut and adjust the pedal stop to obtain
the correct
55
49
5
pedal height
iUtch
Secure the lock
nut
and recheck
the
Check
pedal pad heigllt
Release the lock nut at the

upper end of the outer
cable and adjust the pedal free travel
Adju
rum
t the cable
433
0
has been
0 591 in
uhtil
from the original
bearing release lever free
within this tolerance
pedal height setting
readjust
the cable
Tighten
ohtairiect
pedal
the
adjusting
LUTf
U FAIJI T
lock nut and recheck
DIAGNOSIS
slipping
Remedy
cause
Check and adjust
Clutch
W eak
Worn driven plate facings

Worn or scored flywheel face
bleadjustfnent
or
broken
diaphragm spring
Check and
to
spepifications
assembly
Check arid renew driven plate
Renew flywheel and ring gear
renew
2 Gutch shudder
Possible
Oil
or gummy driven
Scor d pressure plate
Remedv
cause
Check and renew driven
plate facings
or
Jeriew pressure plate
flywheel
assembly
Loole
or
renew
damaged
Check and
renew
Loose or
Loose driven plate facings

Cracked pressure plate face
3 Gutch
driven
plate hub
Gummy
Cracked pressure piate face

Loose or broken engine mountings
4 Throw out
driven
Renew pressure
driven
driven
plate
bearing
Renew driven
and
cover
Incorrect
Faulty
or
plate
noise
Remedy
cause
clutch cable
adjustment
broken diaphragm spring
Checkand
renew
Check and
readjust
bearing
to
specification
plate assembly
Check and renew pressure
Insufficient clutch release

Possible cause
Remedv
Excessive free travel of clutch pedal

Excessive play of release lever
Adjust correctly
Adju
siicking
correctly
Pilot bushing
Clutch
Replace
clutch disc
cylinder cup
Leaking
Leaking shive cylinder cup
Air in hydraulic system
Replace
Repl ce
cup
Low fluid levei in reservoir
Top up
assembly
Renew pressure plate and cover assembly

Check and renew engine mountings as
necessaiy
Dry or seized bearing
g
h
plate
plate
Remedv
plate facings
Possible
a
check
and ring gear

mountings as riecessary
cause
Renew or
plate
and cover
grab
Possible
el
Yheel
flY
Check arid
or
damaged engine mounting
disc
eplace pilot bearing
warped
master
Bleed
56
cup
system
with brake fluid
travel not be
free travel
free travel
Possible
the
Should
free travel of between II 15
9
I Clutch
reading
the bearing release lever free travel and this

4 0 rum 0 1 i81
0 1575 in
should be 3 0
the
MANUi
TIL NSMJSSION
ATlQNS
SPEClFl
GEARBOX
Minimum
0 5mm
020
0
3
SPEED
Gear backlash
Type
speed with
rem9te control
15 mm
003
0 006 in
colunID cljange
Synchromesh
in
0 08
Laygea
On all forward
End float
O I
gears
Ratios
Thrust washer sizes for adjustment
0 8
mm
004 in
3 mm
1
Top
1 00
incremeQts of
Interme iate
173
O lmm
in increments
Dw
I
38
3
Reverse
0 031
3 61
0 051
of 0 004 in
4
SPEED
Fron
Type
speed
with
Adjustin
g cov r
bearif
shim size
0 1
flogr change
qn all
Synchromesh
0 2
0 5 mm
forward
0 004
ears
0 008
0 020 in
Ratios
Detent
spring
Length at lo
Top
100
Thir
140
Second
2 17
Fir t
Reverse
3 76
at
4111m
16
at
7kg
7 in
645
4lb
15
3 64
and 4 SPEED
LER SHAFT
PROPE
Gear end float

I st and 2nd
gears all
0 15
0 25
mm
0 006
0 01 0 in
3rd gear
speed
0 15
35
0
rum
Type
Oper
Number of universal joints

Type 0 univ rsal j ints
2
Needle roller
be ring
0 006
ear
10
0
speed
and
trunnion
0 014 in
Reverse
tubular
0 25
mm
0 004
p1O
0
Reverse idler 3 speed
in
0 05
1 mm
TORQUE
002
l
W
EN
fSEITINGS
0 006 in
Baul
ring to gear clearance
Main drive
105
Standar
40
1
0 040 CO
0 055 in
PAQ T
Extension housing
speed gearbox
has
kg
1 6
2 2
12
16
kg
f Ib
THREE SPEED TRANSMISSION

ARBOX
The laygear operates on two ball type bearings which
locate in tile carrier plate and ge lbox casing Laygear
end float is adjusted by a washef which can be obtained in
DESCRIffION
three
I 4
10 ft lb
The
10
bearing retainer
mm
synchrqme
ori
all
differ
gears are helical cut and run in con taryt

mesh with the laygear Revefse gear funs in mesh with a
which i constan tly m shed with the
everse i ler
ainshaft laygear and reverse idler are attached to the

carrieipl te whicll is interposed between the ge case and
Iaygear
reaf
forwar
gears The
gear
nt thickness s for this
purpose
57
lsi9n
exte
The
in
raft operate
on
two ball
type
I
2
lUtmual
Transmission
which also locate in the
bearings
arrier
plate
and
TO DISMANTLE
gearbox
casing
Front bearing end float is adjusted by shims which are
ill different thicknesses for this purpose
All
tI
Disconnect
release
the
bearing retaining spring
available
from the release fork and withdraw the
mainshaft
gears run on needle roHef bearings A needle

roller bearing is also used to mount the input shaft tn the
assembly
mainshaft
The gear change is the remote control type mounted on
the steering column
Rods transfer the gear change lever
movement to operating levers located in the gearbox case
to the release shaft and lever Withdraw the shaft from the
and throogh
ring
adjustment
selector forks
case
Knock out the taper
and fork
3
Take
front bearing
the
synchro sleeves Rod

the steering box end of the
to
is carried out at
1000 model
out
pins securing
the release fork
retaining the mainshaft
to the case and withdraw the cover
and shims
NOTE Check the number of adjusting

facilitate adjustment at reassembly
rods
and sleeve
only
the three bolts
cover
bearing
shims
fitted
to

4
Jack up the front of the vehicle and support
axle stands
Disconnect the exhaust
Disconnect
5
and
at the manifold and
pipe
brackets
extension
the
cable
speedometer
the
at
rear
housing
Mark across the
axle pinion
flanges
of the
edges
to
ensure
universal
rear
joint
in their
reassembly
original positions
6
Disconnect
pinion flange
rear
of the
7
change
the
universal joint
and withdraw the
flange
from
the
the spring
out
rods from the
Detach the
clips
and
detach
clutch
housing
J0
slave
operating levers and relay shaft

relay shaft from between the gearbox
cylinder
where
fitted
Remove the bolts
the carrier plate and
NOTE Check the number of adjusting shims at the front of

the aygear to facilitate adjustment at reassemblv
the gear
and side plate

9 Disconnect the clutch cable from the clutch lever
or
bolts retaining the speedo driven

housing and withdraw the
from the
propeller shaft
gearbox
Take
two
the extension
securing the extension housing

gearbox casing
6 Withdraw the extension housing from the rear face
of the carrier plate It may be necessary to ease the housing
off the plate dowels this can be best accomplished by
exerting upward pressure on the housing while tapping the
ends of the dowels with a punch and hammer
7 Hold the mainshaft and using a soft faced hammer
gently tap the gearbox casing to separate the carrier plate
and gear assembly from the casing
to
gearbox
holding
to
assembly
Remove the drain plug and drain the oil from the
Remove the
gear assembly
on
from
the
jaws
of
9
Mount the carrier

a
vice fitted with
Remove the
plate and gear assembly

protective covers
circlip
in the
and thrust washer at the front
bell
SYNCHRO ASSY
Loosen off and remove the starter motor
11
Take out the bolts and remove the dust shield
from the lower half of the bell housing
12
Support
the
engine and
transmission
mounting
housing
14
Remove
cross
jack
13
on a
the
bolts
member
Unscrew and
to
remove
attaching
the
the
chassis
rear
and
gearbox
extension
the bolts securing the clutch
bell housing to the rear of the engine

15 Carefully draw the gearbox rearward lower it to
the floor and
remove
Installation is
from beneath the vehicle
procedure
Lay
58
Gear and Main haft Assembly
Manual Tra
3
smission
1ST REVERSE SELECTOR ROD AND FORK

2ND
TOP SELECTOR ROO AND FORK
INPUT
SHAFT
View of Gearbox with Gear Case

Removed to Show Internal Assembly
1ST REVERSE SELECTOR FORK
REVERSE LIGHT SWITCH
of reverse idler gear shaft and also at the rear carrier

face end of the shaft
10
Knock out the idler shaft
the carrier
plate
and detach
from the
the idler gear and
rear
plate
face of
thrust
rear
washer
I I Support the selector forks and knock out the

spring pin attaching each fork to each selector rod
12 Unscrew the plug retaining the detent spring and
ball in the end of the carrier plate
13 Tap the 1st reverse selector rod out of the carrier
plate allowing the rod to move through the fork
14 Repeat the operation for the 2nd top selector rod
and remove the interlock plunger located in the carrier
plate between the selector rod holes
1ST REVERSE SELECTOR ROD
NOTE A n additional detent ball and spring are located in a

blank ended hole in the carrier plate and should lie removed
when
practicable
Using a soft faced hammer tap the rear end of the

to dislodge the
bearing from the carrier plate It
be
also
may
necessary to tap the Jaygear rear bearing to
enable the laygear and mainshaft assembly to be withdrawn
together from the carrier plate
16 Pull the input shaft from the end of the mainshaft
assembly remove the needle roller bearing if attached to
the mainshaft spigot
15
mainshaft
10
TH
i 9 bQO
WASHE
BAULK
RING
Exploded
View of
Input Shaft Components

59
SHIMS
4111anual Trammission
IoJoo ir
ltjr
REVE
oJ
BEARING
CIRCLlP
EGEAR
BAUL
Exploded
View of M inshaft
Remove the thrust washer and ball
rear
bearing
and
Withdraw the
119
needle roller
remove
thrust
the
cones
reverse
gear
section
narrow
of a bearing spacer Note the

dismantling to facilitate reassembly
Before
spacer
the extension
dismantling
of the levers in relation to the
the position
22 Remove the
cotter
pin retaining
nut
the
position
when
housing
mark
kIiock
out the
low reverse selector lever to the
cross
shaft from the
Repeat the operation

cross shaft and selector lever
the
to
remove
replacement of
remove the circlip
the
input shaft bearing
and washer and press
Position the baulk
or
The svnchro
viewed from
is
draw
Clean all components in
solvent and blow
cleaning
7
onto
air
Check ball bearings for roughness or excessive side

rotate the bearings at high speed with
compressed air particularly when the bearings

damage will result
3
Check
needle
roller
Examine the teeth
5
or
on
on
the gear cone
plates
side
springs must be installed so that when

they travel in opposite directions
the ends of the
Lubricate and instal the needle roller

reverse
bearing
and
gear
Position the
reverne gear on the mainshaft with the

the synchro hub assembly
facing
bearings
for
are
wear
dry
or
on
all
gears
for
wear
Instal the thrust washer and press the
rear
bearing
the mainshaft
that the
Position
concave
Instal
the tension washer
on
the mainshaft so
face of the washer faces the bearing
the
circlip
and check that it is correctly
and
or
seated in the groove of the mainshaft

10 Check the end float between the reverse gear and
thrust washer and the first gear and mainshaft flange
See
and
or
specifications
pitting
pitting also burring
ring
NOTE Instal the bearing spacer if originally fitted
Do not
play
one
mainshaft bush for
from the shaft
compressed
as
synchro hub assembly on the mainshaft

synchro plates in the notches of
the baulk ring and the hub splines on the mainshaft splines
TO CLEAN AND INSPECf
damaged components
Instal the
engaging
gear cone
dry with
or
at each side to tension the
NOTE
the second top
the extension housing
If
bearing
worn
and
housing
25 If replacement of the oil seal and or the main

shaft bush is necessary knock out the components from
necessary
all
or
If the synchro hub has been dismantled instal the

synchro plates in the hub slots and slide the sleeve over the
hub splines Fit the synchro springs under the synchro plate
housing
and washer and
24
26
wear
the selector
forksfo
springs for breakage
lugs
Withdraw the
rear of
gear
NOTE Instal the bearing spacer if originally fitted and oil

components during assembly
selector lever
the
Renew
corresponding
I
Instal the low gear and needle roller bearing on the
main shaft with the gear cone facing to the rear of the shaft
cross shaft
23
their
TO ASSEMBLE
may have the gears

roller bearing with the
addition
21
on
specifications
see
and mainshaft bush
bearing
on
O ASSEMBLY
necessary
Some mainshaft assemblies
mounted
wear
Check the selector
8
with
20 Remove the synchro hub assembly followed by

the bau1k ring and low gear with needle roller bearing
NOTE
Check the baulk rings
for
detent balls for wear and the detent

loss of tension see specifications
bearing
washer
SYNC
Component
6
17
bearing from
the end of the mainshaft followed by the baulk ring
synchro hub assembly second baulk ring and second gear
complete with needle roller bearing
18 Remove the circlip and washer retaining the
NG
LOCATINGBALL
I
MAINSHAFT
mainshaft
BL
TtGEA
NG
for end float clearance
the teeth ends
Check the synchronising teeth
on
the gear for
NOTE
wear
washer
chipping
60
If end float exceeds the limit
renew
the thrust
Manrtal
11
Instal the second gear needle roller bearing
front of the mainshaft
12
Instal
13
bearing with
14 If
bearing
Position
the
the gear
on
the
LEVER
cone
originally fitted
gear on the needle roller
facing
COTTER
forward
LEVER
Q RINGSEALS
THRUST
NorrOP
bearing
in the
mainshaft
Exploded
the notch in the thrust washer over the ball
bearing
the synchro plate
17 Position the baulk ring so that

ends engage the baulk ring notches
18 Lubricate and instal the needle roller bearing on
19 If the input shaft has been dismantled press on
the bearing and secure with the washer and circlip
20 Position the input shaft on the mainshaft needle
23
laygear
ST4367 position the tool
rear
pen end of the gear case with the

located immediately below the cutaway
bearing
25 Using feeler gauges check the remaining gap

between the washer and gauge Measure the thickness of the
washer and add the thickness of the feeler
gauges used
Deduct from the total measurement 0 03 mm 0 001 in for
be installed to the
end float
The
balance
remaining
washer necessary for correct
is the
adjustment
thickness of the
See
specifications
for washer thicknesses and end float tolerance

26 Alternatively if the special toolJis not available
the Plastigage method can be used as follows
Ensure that the circlip is correctly located in the

at the front of the gear case
Instal the laygear in the case so that the bearing
27
fit
an
Cut three pieces of
the
Plastigage
or
soft lead wire to
bearing
aperture flange in the carrier plate space

them equidistant around the flange
circ1ip
NOTE
in
SYNCHRC
tool No
Insert the thrust washer originally removed on

dismantling between the top face of the bearing and the
lower edge of the gauge cutaway
bearing aperture
abuts the
Using special
24
mainshaft assembly it will be necessary to check the

laygear end float in the gear case This is essential
particularly if any parts of the assembly have been renewed
22
View of Selector Cross Shaft Components
in the tool
bearing and engage the gear cone in the baulk ring

Mainshaft assembly is now completed ready for installation
21
CROSS SHAFT
the faces of the
across
roller
can
E ClIP
recess
grease bnth faces of the thrust washer and instal so that the
oil groove side of the washer abuts the synchro hub Locate
NOTE Before the laygear assembly
t
WASHER
iIiI
r
splines
Instal the ball
lo
P1N
Ir
dismantled assemble the synchro hub as

15 Position the synchro hub assembly on the
mainshaft so that the synchro plate ends engage the baulk
ring notches and the hub splines engage the mainshaft
16
ST REVERSE CROSS SHAFT
spacer if
second
Tranamiaaion
5
ASS
To hold the three pieces
position
THRUST WASHER
28
ND GEAR
With
operations
over
the
of Plastigage or lead
a smear ofgrease
wire
it may be necessary to use
the
21 and
laygear rear
installed
laygear
as
described
in
22
fit the carrier plate into position

bearing and onto the gear case
Instal the carrier plate retaining bolts and tighten

them evenly and diagonally to a torque of 12 16 ft lb
30 Remove the carrier plate and carefully detach the
29
pieces of Plastigage
or
lead wire from the
NOTE Provided the Plastigage

thickness it should
now
be in
flange
or lead wire was of adequate

flattened condition
31 Using a micrometer check the thickness of each

piece of compressed Plastigage or soft lead wire and arrive
at
mean
end float
figure
Deduct from this

25
operation
thickness of the washer
Thrust Washer Must be Fitted with
Dumpled
61
required
laygear assembly from the gear case
carrier plate in the jaws of a vice fitted
32
Remove the
33
Mount the
with protective
Face Forward
figure the necessary

and the balance represents the
covers
6Manual
Transmission
GEAR SHAFT
t
THRUST WASHER
that
both
bearings
NOTE
Ensure
squarely
and do not allow the gear
the
enter
apertures
teeth to come out
Exploded View of Reverse Idler Components
of
fork and into the carrier plate with the three

facing the detent ball
selector
mesh
detents on the selector rod

37
Instal the selector forks to the
38
Instal a detent
synchro
spring
plate and using a piece
ball and spring and hold in this position
hole in the carrier

the
40
sleeves
of rod
rod until the ball engages in the centre detent
depress
Instal the first
42
II
PLUo
detent
the rod
on
43
Drop
the hole
facing
the
reverse
the shaft
selector rod with the
the interlock
detent ball and
remaining
single
plunger
the edge of the carrier plate and

plug until it is flush with the plate edge
DETENT
on
Instal the stop circlip at the rear end of the selector rod
41 Insert the interlock plunger into the hole located
at right angles to and between the selector rod holes
Insert the second top selector rod through the
39
When the selector rod engages over the depressed

remove the holding rod and push in the selector
detent ball
and ball to the blank end
on
spring
screw
into
in the
The position of the detent plug regulates the

of tension on the detent ball and spring Normalv
correct when set as described in operation 43
NOTE
8ALL
amount
it is
INTERLOCK PLUNGER
BALL
oETENT
@
Firmly support the
44
selector rods and forks
the hole in each rod and fork and
SPRING
tap
in the
align
retaining spring
pins
CARRIER
45
With the gears in neutral position instal the

idler gear with front and rear thrust washers
46 Tap the idler shaft into position and secure with
PLATE
reverse
circlips
the front and rear of the shaft

Check the end float on the reverse idler gear and
the thrust washers if the clearance exceeds
at
47
renew
slecifications
48 Instal
the selected laygear end float adjusting

abut the circlip in the front bearing aperture
Smear with a little grease to hold in position
washer
as
emblies
50
hammer
Selector
Fi
to
Road
Detent
Components
51
are
plate assembly into the gear case

bearings of the mainshaft and laygear
enter the
bearing apertures squarely
that the front
aligned
in which
Instal the carrier
49
so
Order
to
Check
that
62
dowel
holes and dowels
are
plate and gear case Use a soft faced

and gently tap the carrier plate down into position
If the extension housing components have been
dismantled assemble
the Carrier Plate
the
in the carrier
as
follows
Manual
52
Instal the E clip if removed

thrust washer and a
0 ring to the second top speed cross shaft
53 Hold the selector lever in position and insert the
new
cross
55
shaft through the housing and lever Secure the lever

the cross shaft with the cotter pin nut and washer
NOTE
To
facilitate assemblv align
the marks made
on
and
Position
rear
of the extension
diagonally
extension housing on the carrier

retaining bolts Tighten the bolts evenly
a
2 kg m i 2
i6
torque of 1 6
the
and instal the

to
ft lb
57
Fit
described for the second top speed
as
Instal a new oil seal in the
56
plate
dismantling
54
ion
housing
cross
t
shaft and instal

shaft and lever
cross
Tra n mi
new
0 ring seal to the fiI treverse speed
Using
epth gauge check the dimension from

bearing outer race to th gear case
the face of the front

front
cover
inm
0 20
face
Deduct from the dimension 5 00
0 206
in
to
The balance
adjustment
retainer boss
for
58
smear
allow
th
thicklles
is the
Instal the selected shim
on
the
cover
of sni
bearing
5 15
bearing
requir d
outer race
seal with grease anq fit to the front cover

Position the front
over with gasket ring on the
new
59
oil
gear case instal nd tighten the ret inlng bo1ts to a torque

I 4 kg m 7
of 1 0
10 ft l
60 Insert the clutch release shaft through the case
return
spring and
61
release fork
Instal the
taper pins to secure the shaft and fork

Position tne return spring so that one leg engages over the
front of the fork leg and the other spring leg against the
case
62 Instal the release bearing and sleeve

attach to the release fork by the spring legs
63
apd
Lubricate the
bolts
64
Check that
change speed levers

65
Selector Cross Shafts and levers Correc
Assemb ed
2 GE
DANGE
grade
h8using
tran
and
with
gears engage
at the side
Instal the
the correct
driven
speedpinete
in tar in t e extension
pf
the
tpe
assem
ly and
gear assembly
wo r
taining
by operatiPg
the
casing
mission to the vehicle and fin with

of oil
quantity
ASSE1UBLY

3
1 Take out the retaining screws frm the column

cover assembly and detach both halves of t
le cover
2 Remove the circlip at the control rod top support
Remove the
lever to the
clange
circlip and
control rod
clevis pin retaining the gear

and
with
raw the lever and
rubber bush
4
bracket
support
Lapsen
r
off and
remove
the steeri g column upper
cket
r
R LAY SHAfT
63
Gear
Charge Linkage
rfange
ents
Manu l Tran
lfliuion
5
Remove the
attaching
screws
the rubber dust seal
the floor boards and work the seal up the column

6
at the steering box disconnect both gear
change rods from the control rod levers
to
Working
CIRCLlP f
WASHER
7
BUSH
INSERT
j8
Ji
0
SPRI
J
L
rl
PIN
to
of
Remove
the
the lever
two
set
bolts
from
the
assembly
to
the upper end of the control rod

9 Ease the control assembly down and
GEAR C ANGE LEVER
vehicle
from the
out
rod
working the
Jnstallation is
cLlP
e
bracket
the steering column

Move the control rod assembly down the column
facilitate rerpoval of the spring swivel pin and bush from
retaining
through the rubber dust seal

reversal of the remava procedure
TO DISMANTLE AM ASSEMBLE
I
co
2
CONTROL ROD
Remove the
trol rod lever
groove
3
From
the
retainer op
Extract the
and remoVe
set
bolt retaining the
bearing boss
the
dd1e to the
nd remove the saddle
end of the control rod remove the

rating lever and be ring boss
pin from the hole in tIie control rod

remaining operating lever llnd grooved
retainer
1ST
4
Clean all components and examine tlje
bushes for wear Re e
V al1Y components which are
AND REVERSE LEVER
RETAINER
CLAMP
iif Y
TQ
BOLT
B ARING BOSS
AND SUPPORT
ADJUST GEAR CHANGE RODS
I
2
it
2ND AND TOP LEVER
position all three marks will be aligned

3 If adjustment is required lengthen
Iumn
RpAINER
Gear
Contro
al1ge
PAnT
ge rods as necessary at the

gear ch
above and below the trunnions
Comp9nents
SPEED
tlJR
F
I
four
speed gearbox
The
constant mesh with the
gears
has synchromesh
helical cut a d
are
on
all
run
in
laygear
a
sses
gears
are
reverse
attached
to
locateq
assembly
to the mainshaft
selectecl
are
locaied
reverse
gear and idler when
All components of the revers gear

at the rear face of the carrier plale
The floor type gear
change
is
accidental election of reverse gear

64
extension
Reverse gear is splined to the mainshaft and secured by

circlip The reverse idler gear is plinecl to the laygear and
cured by a circlip A reverse sliding gear operat d by the
reverse is
gear and reverse sliding and

the carrier plate which is
rear
gears run on needle roller

A needle roller bearing is also used to mount the
forward
selector fork meshes with both
for this purpose
M insh ft laygear
the gear case and
mairishaft
bearings
inpu sjIaft
TjIe laygear qperates o two ball type bearings which

locate in the carrier plate and
gearbox casi g Laygear
end f1qat is adjusted by a washer which can be obtairied in
different thi9ki1
adjustihg
shorten the
nu
ANSMISSION
interposed between
All
speeds
or
GEARBOX
DESCRIPTION
idler
are
Y
t
The
forward
Ch ck that the tra smission is in neutral

l
pte that the control rod operating levers
marked with a groove on their top edge and the bearitg

boss with a ridge When correctly adjusted in the neutral
PIN
BOLT
bearing
worn or
damaged Lubricate components during assembly

Assembly is a reversal of the dismantling procedure
3Jfl
SADDLE
BRACKET
spring
loadeq
to
prevent
Mannal
fransmission
o
REVERSE
1
LAYGEAR
SHIM
L y Gear and
IDLER GEAR
C1RCLlP
BEARING
Components
12
Take
out
the bolts and
from the lower half of the bell

I
Jack up the front of the vehicle and support
13
coverings to gain
the gear lever
the gear lever knob and move the floor

access to the rubber boot at the base of
15
plug
Disconnect the
reverse
ilOd drain the oil from the
TO DISMANTLE
Disconnect
the exhaust
pipe
at the manifold and
support brackets
7
8
and
re
speedometer
cable
at
the
from the
rear
housing
edges
of the rear universal

e
sur
reassembly
joint
in their
or
clutch slave
cylinder
where
3
front
bearing retaining spring
tg
eari
d sleeve
IOOOmoael only
fork
TaKe out the three bolts retaining the mainshaft

earing cover to he case and withdraw the cover seal
and shims
fitted
Check
NOTE
from the bell housing
rhe number
facilitate adjustment
Loosen offand remove the starter
4
SELECTOR ROD AND FORK
TOP
RD
at
of adjusring shims fitted

reassembly
to
motqr
Remove
driven
2ND
lST
release
Knock out the taper pins securing the release fork

Withdraw die shaft from the
case and
the universal joint flange from the

pinion flange and withdraw the propeller shaft from the
rear of the gearbox
10 Disconnect the clutch cable from the clutch
11
the
lease fork and withdraw tHe
to the release shaft and lever
Disconnect
withdrawal lever
assembly
axle pinion flanges to
original positio
9
the
Mark across the

r
Disconnect
Disconnect
extension
to the rear of the
switch wires at the side of
gearbox
6
Unscrew and remove the bolts
bell
gearbox
5
x rear
gearb
extension
securing the clutch

engine
housing
I6 Lower the assembly and draw it rearward until
clear of the engine and remove from beneath the vehicle
Installatio is a reversal of the removal procedure
Remove the E clip and pin retaining the gea lever

to the control assembly and detach the lever
Remove the drain
jack
housing
the
14
Unscrew
the dust shield
Support the engine and transmission on

Remove the bolts attaching the
mounting crossmember to the c assis and
on
axle stands
2
remove
housing
as
gear
withdraw the
the two bolts retaining the speedometer

to
the extension ho sing and
embly
assemhly
5 Remove the bolts securing the extension housing

to the carrier plate and gearbox casing
SELECTOR ROO AND FORK
Remove
mainshaft and
the
laygear
extensi
as a
n housing
carrier plate
complete assembly from the gear
case
NOTE Remove and check the
adjusti
1g
ofthe laygear
to
facilitate adjustment
shims
ar
the fronr
reassembly
7
Support the selector forks and knock out
spring pin attaching each fork to each selector rod
8 Unscrew the plug retaining the detent spring
ball for the I st 2nd selector rod and remove the spring
the
and
and
ball
9
move
it
Instal the gear lever to the control assembly and

through neutral until it contacts the spring
resistance for reverse selection Do not

10
Gear Case Removed to Show Mainshaft
Poll the I st 2nd selector rod t
fork until it is clear of the carrier plate
Assembly
6S
ngage reverse gear
ugh the selector
10lI1anual
Transnri33ion
NUT
1 nsure that the IIlterluck
plunger
is
rec
Jlered
20 Slide both gears from the splines of their

respective shafts
21
Using a soft faced hammer tap the rear end of the
mainshaft to dislodge the bearing from the carrier plate It
may be necessary to tap the laygear shaft also to allow the
laygear and mainshaft assemblies to be withdrawn together
from the carrier plate
22 Separate the laygear from the mainshaft and pull
the input shaft from the top of the mainshaft assembly
If it
should be dislodged from the carrier plate
11
Move the gear lever across to what is normally the

position and retain in this position
2
Carefully tap the extension housing with a
soft faced hammer to disengag i from the carrier plate
dowels and separate the hous ng from the carrier plate
assembly
13 Unscrew the plug retaining the detent spring and
ball for the 3rd 4th selector rod and remove the spring and
1 st 2nd
remove
roller
the needle
if still attached to the
bearing
mainshaft spigot
23
Remove the thrust washer and ball bearing from
the end of the mainshaft followed by the baulk ring
ball
14 Unscrew the blanking plug for the reverse selector

rod but note that the detent ball and spring cannot be
synchro hub assembly third gear baulk ring and

complete with needle roller bearing
removed until the rod is withdrawn

15
Tap the 3rdj4th selector rod through the selector
fork and out ofthe carrier plate detach the fork
24
16 Tap the reverse selector rod through the carrier

plate and out of the selector fork detach the fork
17 Remove reverse selector detent spring and ball
from the blank ended hole in the carrier plate also
interlock plungers from their respective positions
18 Withdraw the reverse sliding gear from its shaft
19 Remove the circlips retaining reverse gear to the
mainshaft and reverse idler gear to the layshaft
Remove the mainshaft
SPR1NG
bearing
rear
third gear
and
thrust
PIN
Cf
1ST lND SELECTOR
1ST
ROD
2ND SELECTOR FO
srRIH
IN
3R
fTOf SELECTOR
ROD
I
TOP
3RO
SELECTOR FORK
REVERSE SELECTOR
SHAFT
GEAR lEVER
BUSH
CLEVIS PIN
REVERSE SlIOING GEAR
BOSH
Gear Selector Rods and Forks
CllP
SEAl
O
SELECTOR
r
CLEVIS PIN
LEVER
CONTRtOl
1ra
ROD
WELCH PLUG
cLIP
E
BOLT
EXTENSION HOUSING
Exploded
66
View of Gear
Change
Control Components
ll
Transmission
Manual
MAINSHAFT
o
G
I
t
Exploded
BEAR1NG
GEAR
View of Mainshaft C mponents
BUSH
by first speed gear complete with needle

roller bearing spacer and mainshaft bush
25 Withdraw from the mainshaft the first gear baulk
mark one face of the hub and sleeve to
27
correct
the
necessary
circlip
the bearing from the shaft
29
32
To
remove
the gear
ensure
bearing
and washer and press
change
control rod
BEARING
or
Unscrew the
retaining plug
and
withdraw
the
circlip and clevis pin retaining the

assembly to the extension housing and
withdraw the assembly from the housing sleeve
33
To separate the control rod from the pivot
assembly it will be necessary Jo remove the expansion plug
and push out the control rod
If replacement
34
of the oil seal and or the
control
Remove the synchro springs from each end of the
remove
Ii
BAULK RING
30
order
hubs and press out the hubs from the sleeves

28 If replacement of the input shaft
t
SYNCHRQ AS
double spring and plunger for reverse selector loading

31
Remove the gear lever if not already removed
ring synchro hub assembly second gear baulk ring and

second gear complete with needle roller bearing
26 If dismantling the synchro hub assemblies is
reassembly in the
II
washer followed
necessary
2ND GEAR
SVNCHRO ASSY
SPACER
RoIGEAR
THRUST WASHER
BAULK RING
o4
VJ o
fA
THRUST WASHER
REVERSE
idl
i
Remove the
rod
mainshaft bush is necessary
is
from the
draw
rear
knock out the components
of the extension hous ng
assembly
from the extension housing remove the wire locking the

control rod selector lever retaining bolt and remove the bolt
CUG
and lever
OUTER
t
f
SPRING
PLUNGER
i
Extension Housing Removed to Show Revene Gear Assembly
67
Components for Reverse Selector Loading
4h
II
f
t
aris
is ion
J2Manual
lugs
l Clean all components in cleaning solvent and blow
dry
compressed air
Check ball bearings for roughness or excessive side
play Do not rotate the bearings at high speed with
compressed air particularly when thebearings are dry or
damage will result
3
Check needle
roller bearings for wear imd or
pitting
with
Examine the
teeth
pitting also for burring

5
wear
Check
or
6
cones
the
on all
gears
the teeth ends
synchronising
for
teeth
on
wear
the
and
gears
Check the baulk
for
wear
see
rings on
specific tions
Check ihe selector

wear
loss of tensjon
see
Renew
all
their
corresponding
forks for
viewed from
5
engaging
or
gear
wear
the selector
springs for breakage
damaged
components
I Ir stal second gea nd ne le roller bearing on the

mainshaft with the gear cone facing to the rear of the shaft
If the
hub
splines
so
thal when
so
directions
Instal the thrust washer and press the
rear
bearing
For the purpose of checking first gear to thrust

instal the reverse gear and secure with the
specifications
NOTE
opposite
Instal the synchro hub assembly on themainshaft

the ends of the synchro plates in the notches of
the gear
l0
synchro hub has een dismantl ed instal the

ihel ub slots and slide the sleeve over the
on
dismantliitg
exceeds
the limit
renew
the thrust
recheck
Remove reverse gear and
Circlip
on
completion of
cone
11 Lubricat and instal third gear complete with

needle roller bearing to the front of the mainshaft with gear
cone facing forwaro
in
thaI the marks made
for end float Clearance
If end float
washer and
syrichrci plates
be installed
must
side thev travel in
circlip Check the end float between first gear and thrust
w h er also between second
gear and the mainshaft flange
as
TO ASSEMBLE
on
one
washer end float
or
See
Position the baulk ring
synchru plate
7 Engage the not hes of a baulk ring on the synchro

hub plate ends and instal the first gear entering the cone
into the baulk ring
for
necessary
the
the baulk ring and the hub splines on the mainshaft splines
6 Lubricate and instal the mainshaft bush needle
roller bearing and spacer for first gear
specifications
or
synchro spring under

tension the plates
to
onto the mainshaft
and the detent
worn
Fit the
each side
NOTE The svnchrn springs
chipping
detent balls for
on
4
at
are
at
the same side
12
Instal a baulk
13
If dismantled
ring
to the
thrd gear
assemble
the
cone
synchro
hub
as
4
Position
the
synchro
hub
assembly
the
on
mainshaft SQ that the synchro plate ends engage the baulk

ring notches and the hub splines engage the mainshaft
splines
5
lnstalthe ball bearing in the mainshaft
recess
grease both faces of the thrust washer and instal so that the
oil gronve side of the washer abuts the synchro hub Locate
the notch in the tliIust washer over the ball bearing

16
Position the remaining baulk ring so that the
synchro plate ends engage the baulk ring notches
17
Lubricate and iris tal the needle roller bearing
18 If the input shaft has been dismantled press
the
bearing
19
SH
FT PLATES
roller
Ex
loded View
ofSvnchrolii
Position the
bearing
Mainshaft
NOTE
and secure with the washer and
input
shaft
and erigage the gear
assembly
is
on
on
on
circlip
the mainshaft needle
cone
in the baulk
ow completed ready
ring
for installation
Before installation of the laygear and mainshaft

to check
assemblies to the carrier platdi Will be
sary
neces
the laygear end float This is essential particularly if
any
parts of the assemb v have beei renewed
As in the three speed gearbox the end float figure is
nomul v found bv use of a special tool for this purpose
omponents
68
Manual Tran mi
N
BAU
19
i Oyd
VI
Exploded
SHIMS
if available Alternative v if the tool is

available the Plastigage method can be used as follows
34
Instal the reverse
35
Instal the selector forks
and the
20
abuts the
reverse
36
in the case so that the
laygear
bearing
hold in
circlip
piece of metal rod depress

this position
37
Insert the
and carrier
To hold the three

it may
pieces of Plastigage or lead

be necessary to use a smear ofgrease
wire
Fit the carrier
into
plate
position
over
the
and onto the gear case

Instal the carrier plate retaining bolts and
25
to
Remove the carrier
pieces of Plastigage
or
torque of 12
plate
and
plug
laygear
selector rod through the fork
with the two detents on the selector rod
plate
When the selector rod engages
over
the
depressed
in the detent hole
Align the holes

spring pin to
39
knock in the
tighten
Instal
40
16 ft lb
carefully detach
flange
plate
spring and
detent ball remove the holding rod and push in the selector
rod until the ball engages the first detent on the rod Instal
bearing
them diagonally and evenly
reverse
the ball and
reverse
the detent ball
facing
the
24
synchro sleeves
sliding gear
Using
position
rear
the
its shaft
the
Insert the detent spring and ball for the
38
23
on
on
Instal the
Cut three pieces of Plastigage or soft lead wire to

fit on the bearing aperture flange in he carrier plate space
them equidistant around the flange
in
selector fork
on
selector rod in the blank ended hole in the carrier
22
NOTE
sliding gear
Ensure that the citc1ip is correctly located in the

at the front of the gear case
bearing aperture
21
CIRCLIP
View of Input Shaft Components
which should be used

not
1l
OTRlNG
u
ion
the
in the selector rod and fork and

secure
interlock
plunger
for
reverse
and
third top selector rods

the
Insert
41
lead wire from the
carrier
plate
the third top selector rod through the

and selector fork with the three detents on the
rod facing the hole in the carrier plate for the detent ball
NOTE Provided the Plastigage or lead wire was of adequate
thickness it should now be in a flattened comjitiolL
and
spring
42 Align the centre detent on the rod with the
carrier plate hole and instal the detent ball and spring
Screw in the retaining plug until it is flush with the plate
edge
43 Align the holes in the selector rod and fork and
knock in the spring pin to secure
Using a micrometer check the thickness of each

piece of compressed Plastigage or soft lead wire and arrive
at a mean figure Deduct fr9m this figure the necessary
end float of 0 03 rum 0 001 in and the balance represents
the thickness of the washer required
27 Remove the laygear assembly from the gear case
28
Mount the carrier plate in the jaws of a vice fitted
with protective covers
29
Bring together the laygear and mainshaft
assembly so that the teeth on both are meshed in the
running position
30 Insert the mainshaft through the appropriate hole
in the carrier plate and enter the rear bearings of the
mainshaft and laygear in their respective carrier plate
apertures
31 Using a soft faced hammer or press seat the
bearings in their apertures
26
that
both
bearings
enter
Ensure
squarely
and do not allow the gear teeth to unmesh
44
extension
Instal the
reverse
with the circlip

33 Instal reverse gear
with the circlip
idler gear to the
housing
the control
rod components to
in the reverse order of re moval
Instal
the
a
oil seal and expansion plug to the pivot assembly and

locking wire to the control rod selector lever retaining bolt
45 Fit the gear lever to the control rod assembly and
move
the gear
lever to what is normally the first second
position andretain
in this
position
46
Offer the extension housing up to the carrier

plate and engage it on the dowels Use a soft faced hammer
and gently tap the housing into position on the carrier
plate
47
layshaft
Assemble
new
but do
32
rod should not be installed
until the extension housing has been fitted
the apertures
NOTE
First second selector
NOTE
and
Move the gear lever across to the reverse position

attempt to engage the gear hold in this position
not
48
Insert the interlock
plunger for third tnp and
first second selector rods
secure
on
the mainshaft and
49 Push the selector rod through the first second

selector fork and into the carrier plate with the three
secure
69
14MaJlUal
detents
Transmission
the shaft
on
the detent ball and
50
facing
Align the holes

spring pin to
knock in the
51
the hole in the carrier
plate
for
spring
in the selector rod and fork and
secure
Insert the detent ball and spring into the carrier

in the retaining plug until it is flush with
plate and screw

the plate edge
NOTE
position of the detent retaining plugs regulates

of rension on the detent balls and springs
selector
except reverse
Normally the tension is correct
when the plugs are screwed in flush with the carrier plate
edge
the
The
amount
Instal
52
washer
the
selected
laygear
end float
adjusting
to abut the
circlip in the front bearing aperture

Smear with a little grease to hold in position
53
Instal the carrier plate assembly into the gear case
so that the front bearings of the mainshaft and laygear
assemblies enter the bearing apertures squarely Ensure that
the selector rods enter the support holes in the gearcase
54 Check that the dowel holes and dowels
aligned
in the carrier
hammer and
55
2 2
56
and gear
case
Use
are
soft faced
gently
Instal
tap the carrier plate down into position

the retaining bolts and tighten evenly
working diagonally
16
plate
kg m
Using
from
12
one bolt to another to

16 ft lb
torque of
a depth gauge
check the dimension from
face of the front bearing outer race to the gear
front cover face Deduct from the dimension 5 00
the front
case
15
5
mm
0 20
0 206 in
to
allow for the
bearing
cover
retainer boss
The
balance is the
thickness of shim required
for
adjustment
57
smear a
58
61
Instal the selected shim on the

new
bearing
outer race
oil seal with grease and fit to the front cover

cover with gasket ring on the
62
and instal in
Position the front
gear case instal and tighten the retaining bolts to

1 4 kg m 7
10 ft lb
of 10
63
plug
housing
with the two retaining
Instal
for the
64
leg
reverse
Check that aU
geari
engage by operating the gear
change lever
front of the fork leg and the other spring leg against the
65
Instal the transmission to the vehicle and fIll with
the correct grade and quantity of oil
case
extension
the plunger double spring and retaining

selector loading Refit the reverse light
switch if it has been removed
case
60 Instal the taper pins to secure the shaft and fork

Position the return spring so that one
engages over the
PART
the
bolts
torque
Insert the clutch release shaft through the

return spring and release fork
59
Instal the release bearing and sleeve assembly and

by the spring legs
Lubricate the speedometer driven gear assembly
attach to the release fork
PROPELLER
SHAFT
DESCRIPTION
The
joint has internal splines which slide on mating splines on

the rear end of the gearbox mainshaft
which is supported
on its outer circumference by a bush with an oil seal in the
piece tubular propeller shaft is fItted with two

needle roller and trunnion type universal joints
The rear yoke of the rear universal joint is flanged and
bolted to the rear axle pinion shaft flange
The sleeve on the front yoke of the front universal
one
gearbox
rear extension
Oversize circlips are available to compensate for any

end float in the bearing cups
70
Ianllal
to
Jack up the rear of the vehicle and support on axle

Mark
and
the
across
edges of the
axle
pinion flanges
original positions
rear
to ensure
Remove the four universal
pinion attaching
4
universal
reassembly
joint flanges
joint
in thei
to rear
axle
bolts and nuts

the
Withdraw
the
disengage
rear
propeller shaft to
yoke sleeve from
front
the
rear
the
and
gearbox
mainshaft
Insert
sliding
spare
sleeve in the
transmission
rear
prevent loss of oil

Installation is a reversal of the removal procedure
cover
Again
bearing out of the yoke and again carefully remove to avoid

dislodging the needle rollers
4 Manoeuvre the yoke over the ends of the trunnion
and withdraw from the shaft assembly
5
Treat the other two bearings of the front universal
joint and the bearings of the rear universal joint in a similar
manner to completely dismantle the propeller shaft
6 Check the needle roller bearings and trunnions for
wear
I f wear is apparent renew the trunnions and bearings
a
kit
Never renew individual needle roller bearing
as
or
assemblies
fit old bearings to a new trunnion Always use
new bearing retaining circlips and bearing seal washers
Reassembly is a reversal of the dismantling procedure
stands
2
15
avoid dislodging the needle rollers

using a soft drift tap on the end of the
trunnion of the bearing just removed to drive the other
fingers
Transmission
to
TO DISMANTLE AND ASSEMBLE
Knock out and remove the two securing
circ1ips
When dismantling or reassembling do lIor hold the

machined section of the front u niversal joint yoke in the
NOTE
on
of the front
niversal joint
and using a soft metal
opposed needle roller bearings

2
Holding the joint in a vice
drift tap on the end of one of the bearing cups to drive the
other bearing out of the yoke Lift the bearing out with the
PART
MANUAL
or the seal surface of the yoke

damaged Where necessary reduce any bearing cup
end float bv installing oversize circlips
unprot cred jaws of a vice

will be
NSMISSION
TR1
FAUI T
DIAGNOSIS
GEARBOX
IDifficult
gear change
Possible cause
b
c
d
e
Remedv
Maladjustment ofselector mechanism

Faulty gear synchroniser mechanism
Faulty clutch or clutch release mechanism
Check and overhaul clutch and
gear teeth
Distorted transmission shaft splines
Damaged
2 Gear clash
on
changing
me
Renew
damaged components
Renew
damaged
Faulty clutch or clutch release mechanism

Faulty synchro rings and cones
Broken
Remedy
Overhaul clutch and
Check and overhaul
as
incorrect
positioning ofsynchro
retaining springs
Gearbox lubricating oil
as
too
Slipping
nut of
gear
Weak
Worn mainshaft
or
renew
components
required
Drain gear case and refill with correct
heavy
grade
of oil
1st and 2nd
Possible
adjust release mechanism

renew components
required
and
3
or
gearbox
Check and overhaul gearbox
bar
d
adjust
component
cause
or
or
hanism
release
down
Possible
Check and adjust selector mechanism

Overhaul gearbox
Remedy
cause
broken selector shaft detent spring
sliding gear
or
Renew
faulty components
renew faulty
components
Check and
laygear
71
quantity
16
Manual Tran3miuion
end float of laygear
or mainshaft ball
fxcessive
Worn main drive gear
Incorrectly adjusted
Slipping
out of gear
b
c
d
e
re
adjust
as
necessary
Remedy
Worn ball
Check and
renew worn
Check and
re
renew
Check and
Check and
bearings on main drive gear or mainshaft

Incorrectly adjusted gear change mechanism
1ew
re
faulty
worn
renew worn
adjust
as
components
components
thrust washers
bearings
necessary
in neutral
cause
Remedy
Worn main drive ball bearing
Overhaul and
Overp aul and
Chipped or pitted constan t mesh gears

laygear main drive gear or 2nd and 3rd
Excessive
thrust washero
components
Check and
renew
bearing
renew
components
as
necessary
gearo
speep mainshaft
c
Check llfld
faulty
or broken selector shaft detent spring

Worn synchro teeth on third or top speeds
Excessive end float of lay gear
Possible
a
renew worn
cause
Weak
5 Gearbox noise
mechanism
renew
Check and
3rd and Top

Possible
change
gear
bearings
Check and
laygear end
float
Lack of sufficient lubricant
Check and
Drain and
renew
refill
and grade of
laygear
thrust washers
gear case with correct
quantity
pi
PROPELLER SHAFT
I Shaft vibration
Possible
a
Bent
Excessive
and
propeller
Renew
complete univeroal joint trunnion

bearings
Renew complete propeller shaft
Rrnew exteJlsion housing bush assembly
and
Piopeller shaft out

wear of
exterision bush
of balance
front joint sleeve in
Rear universal joint to pinion
lxcessive
rear
hearing
flange
bolts loose
Renew and
tighten
loose bolts
backlash
Possible
joint trunnion
bearings
Excessive
Renew shaft
universal
Remedy
shaft
wear in
cause
cause
Remedy
Worn univeroal joint trunnion and bearings

Worn mainshaft and universal joint sleeve
Renew joint trunnion and

Renew worn components
splines
72
bearings
as
assembly
AUTOMATIC
TRAN MISSION
SPE IFITlONS
Intermediate
Three forward
Type
low
to
34
speeds
39 kph
24
21
and
Downshift speeds
nil tlirottle
Intermediate to low
reverse
epicyclic
gear
train with torque
mph
kph
13
8 inph
cooveTte f
Model
Nissan 3N71A
Operation
Automatic
Shift
Speeds
Upshift speeds
3 900 1 Axle ratio
light
throttle
Low to iri termediate
hydraulic
1O
IOdo Series
Intermediate
Column change
Floor change
1200 Series
T bar
to
14
high
Low to intermediate
2 458
Intermediate
1458
High
IdOO
Reverse
2 182
Intermediate to
on
88
78
48
Type F
Intermediate to low
equivalent
Imp pis
tJl750USpts
24
Downshift speeds
nil throttle
Intermediate to low
25
13
Speeds
Upshift speeds
4 111
I Axle ratio
TORQUE
12
8
29
high
18
Upshift speeds
Intermediate to high
55
21
34
on
Intermediate to high
77
27
48
High
to
on
intermediaie
with
71
Drive
reverse
a
plate
to
torque converter
1 0kg m
7Ib ft
kph
24 mph
plug
5
4
kg
in
32Ib fl
Inhibitor switch io
60
transmission case
kg
38 kph
8Ib ft
4 5
48kph
kg
32lb ft
30 mpli
Oil
cooling pipe
II
flare nut
kg
81b ft
82
kph
51 mph
Oil
76 kph
47
3 0
cooling pipe connecting nut
fluid
2 5
Converter housing to engine
mph
kg
kg
18Ib
ft
DES
iUPTION
Fiuid level in the transmission is checked by a dipstick

type indicator locaied in the oil filler tube The 1200 Series
T bar and quadrant
gear selector is it floor mounted
The speed selector quadritnt adjacent to the base of
coupling
fully
automatic three speed

epicyclic gear system The torque converter housing arid the
transmission case are separate casings
The transmission provides three forward ratios and one
a
kg
21 lb ft
The automatic transmission combines

converter
60
39
torque
crankshaft
kickdown
44
or
to
Manual shift lock nut

43
Downshift speeds
plate
43Ib ft
kickdown
intermediate
to
Drive
17kph
mph
34 kph
21 mph
Oil pan drain

34
Low
WRENCH SEITINGS
II
full throtile
Low to intermediate
Upshift speeds
kph
light throttle
Low to intermediate
Intermediate to
mph
8mph
Shift
kph
55mph
40 kph
I5
9750
mph
96 kph
60 mph
kickdown
551itres
capacity
30
80
iniermediate
to
mph
48kph
50
High
or
35
high
Downshift speeds
3N71A
type
15
22
Lubricant
inph
24kph
quadrant
Low
11
kickdown
Upshift speeds
Gear ratios
Total
18kph
Gear control
the floor mounted selector lever is marked L
The hydraulic system consists of a single pump and
or
valve arrangement
low
neutral
73
2
R
drive
reveIe
in
and 2
and P
park
drive
lock
or
in first
direct
Automatic Transmission
TRUNNION
The
following
gear selections cannot be made without
depressing the spring loaded button on

T shaped gear selector lever P to R R to
the
side
P D to 2
WASHER
of the
2 to I
and N to R
n
not
addition
possible
the P
or
to
starter inhibitor switch ensures that it is
start the
engine unless the selector lever
is in
position
The
1000 Series gear selector differs from the 1200

gear selection lever is mounted on the
steering column
series
in that the
IJ
If
ENGINE TUNING
When tuning
be
firmly applied
SELECTOR
or
changing
KEY
CIRCUP
position otherwise the vehicle will

move forward or backward as the engine speed is increased
When adjusting the idling speed move the selector lever
to the D position in order that the correct idling speed
adjustmen t may be obtained
If idling speed is too slow the engine will not operate
smoothly If it is too high a shock or crunch develops when
park
testing the engine the handbrake must

and the selector lever must be in the P
or
neutral
from N to D
or
View of the Automatic Transmission Selector Components

Lower End of Steering Column 1000 Models
An alternative method is to tow the vehicle
from the
The vehicle may be towed for a short distance without

the propeller shaft provided the towing speed
TOWING
disconnecting
docs not exceed 48 kmh
For long distance towing the propeller shaft should be

disconnected at the rear universal flange and removed from
the vehicle and
transmission
suspended
rear
case
suitable
to
plug applied
prevent loss of fluid
to
the
or
rear
ingress
the vehicle is being

the rear axle
of the
It is not
of dirt
or
pushing
practicable
30
J is
tow
mph
nut
and the cause for which
within the trausmissiull
to start the
ur
engine by either towing
the vehicle
HYDRAULI
FLUID
Only a recommended Automatic Transmission Fluid

should be used in the transmission when topping up or
changing
The
checked
the fluid in the system See Specification section

fluid level in the transmission case should be
regular intervals of no greater than 6 500 km

and it is good policy to check the fluid level
at
4 000 miles
at
each lubrication service
Every
48 000 km
30 000 miles
the fluid should be
drained off while the transmission assembly is
at
operating
temperature
TO CHECK AND TOP UP

1
Place
the vehicle
on
level
t100r and open the
engine bonnet
2
Carefully clean around the top of the transmission
case filler tube and dipstick
to ensure that no dirt or
matter
can
enter
the
filler
tube as the dipstick is
foreign
withdrawn
3
Check the transmission thoroughly for damp areas
and determine the type of oil present Transmission oil is
readily identified by its reddish colour
Gear Selector level Pivot and Quadrant with Turn Signal

Switch and Top Column Covers Removed 1000 Models
74
is difficult
to
detemline the
exact
area
from
A utomatic Transmission
ASSV
CROSS
DUST BOOT
STn
BUSH
SPRING
I
12QlD
Jl
SUPPORT
RACKET
a
WASHER
II
DISHED WASHER
DISHED WASHER
STEERING COLUMN TUBE

TRANSMISSION LINK
BRACKET
INSERT
CONTROL TUBE
WASHER
BRACKET
fLJ
Lj
t11lIIIIlIIlIII
SCREW
CI
PIN
SPRING
ADJUSTING NUTS
ADJUSTING THREAD
LAMP ASSV
I
QUADRANT INDICATOR
E CLIP
a
BUSH
View
of
Cross
Shaft
and
linkage
Assembly
Components Automatic Transmission 1000 Models
Exploded
which the fluid
is
escaping
sequence it
following
the oil is escaping
can
However
by checking
WIRING
in the
be determined from what aveoue
Should oil be leaking from the converter housing the

oil could be emitting from the pump housing holes in the
pump external wall or the oil seal of the engine crankshaft
If the rubber ring fitted to the oil pump housing is
defective it will allow the oil to seep out onto the external
walls of the converter housing

5 To determine accurately the
areas
from which the
oil is escaping wipe the transmission assembly thoroughly

and remove the dust cover from the converter housing
Having removed the dust cover wash the area clean

6 Bring the oil to normal operaiing temperature
then select D
or
Replace
9
R to increase the oil pressure and examine
the torque converter housing for leakage

7
Clean the area where the transmission body is
coupled to the extension housing Select the D or R
position and
with the
manner
10
engine
fluid under pressure

oil pressure inspection hole
the transmission body and
of
Steering Column
the defective vacuum
1000 Models
diaphragm immediately
Check and top up the fluid in the following

Place the selector lever in the P position and firmly
the handbrake
apply
transmission
Exploded View of Automatic Trans

mission Selector Components Upper End
Start the engine and
run
at a fast idle to
and transmission to normal
bring the
examine the elbow connector
and
the
extension
gasket between
housing for leakage
NOTE
Alternatively run
approximately five miles
8 Should the vacuum diaphragm be damaged this

be
can
readily detached by checking the emission of smoke
at the rear end of the exhaust pipe
If white smoke is emitting from the exhaust pipe this
indicates
fluid to be
through
damaged diaphragm allowing

drawn
up into the
the
vehicle
on
the
road
for
II Return the engine to the correct idling speed

withdraw the dipstick and check the level of the hydraulic
fluid If necessary add sufficient fluid to the transmission
case via the filler rube to bring the level to the FULL mark
the transmission
manifold and dispensed
on
the
dipstick
the exhaust system
Use a recommended automatic transmission fluid

only do not overfill or foaming and unsatisfactory
operation of the assemblv will result
A
damaged diaphragm will result in excessive
consumption of transmission fluid and premature engine
NOTE
wear
75
4Automatic Transmission
1
that
no
Replace
dirt
or
the
dust
dipstick
can
enter
in thc
tiller tube
rOTE
ensuring
the transmission case
after
TO DRAIN AND FILL
and drain the hydraulic fluid into
plug
H
tzen
llie
Jrallling
fluid
could result
and tighten
Replace
suitable
TRANSMISSION
scalding
as
the oil pan drain
plug
to
the
Refill the transmission case with the correct
grade
and quantity of fluid as recommended start the engine and

bring it to the normal operating temperature
5
Check the fluid level on the dipstick and top up if
necessary
container
nm
specified torque
I
Bring the transmission to the nonnal operating
tempera LUre and raise the vehicle on a hoist or place it over
a pit so that the transmission case is
reasonably level
2
Unscrew and remove the transmission case oil pan
drain
Excn ise extreme cauriun
long
as
detailed in TO CHECK AND TOP UP
SELECTOR LlNKA4 E
TO ADJUST
Raise
the
front
of the vehicle
and support on
stands
2
Check the position of the gear indicator in relation
to the actual selected or detent
by selec ing either

3
When
park
or
position
on
the transmission
L low
of the gears are selected a slight

experienced during the change pattern
this indicates that the manual valve is correctly positioned
in the detent position in the valve body and that the lever is
correctly aligned
4 Check position of the gear indicator when released
in relation to the relevant position on the plate
either
perceptible drag
LEVER
5
and
adjustment
mounted
ic
NOTE
lE
Should
working
Models only
SELECTORQU ADRA NT
r
AND PARK BL
LEVER BRACKET
is
on
all
adjustment be necessary raise the bonnet

from inside the engine compartment 1000
adjust the linkage Prior to carrying out
select
1200 Models
adjustment point
the eizicIe
PIN
dI
Adjust
WIRE
corresponds
quadrant
position
on
the
indicator
gear
the steering column
the
on
linkage
with
with
T bar
floor shift the

from below
the link rod is accessible
so
position
View of Selector Lever
that
the
on
detent position D
indicator plate
the
Showing Reverse
and Park
Blocking
Pin and Method of Locking the Lever Bracket Grub Screw
A
I
Floor Change
NEUTRAL
SAFETY
The
neutral safety switch incorporating the reverse

is attached to the right hand side of the
transmission case The black yellow wires of the switch are
connected with the starter inhibitor switch to

the
engine
can
either the N
only
neutral
be started with the

or
ensure
with the
when
the R
reverse
the transmission
safety
switch
linkage
should be
adjustment
that
transmission in
TO ADJUST
park positions
are connected in
which should only operate
position is selected 011 the selector
reverse
to
followed by the neutral
The two red black wires of the switch

series
1200 Models
SWIT
R
Any adjustment
switch
light
Systell
1
With the engine stopped disconnect the remote
control lower rod and position the gear selecting lever at N
neutral un the side of the transmission case
It will be noted that the
parallel flats on the switch
light
quadrant
76
Automatic Trallsmission
WIRING CONNECTORS
Neutral Safety Switch

3
Showing Adjustment
Move the selector lever to the P
The lamp connected
to
the black
yellow
Points
park position
wires should be
extinguished as the indicator moves to the R reverse

position This lamp should light again as the P park
position is selected
The reverse light test lamp must light only when the R
reverse position is select d
If adjustment is necessary unscrew the nut on the
4
selector
lever and loosen the two bolts securing the
gear
switch body then remove the machined screw from the
body of the swi tch
5 Move the manual shaft to the N ncutral position
noting that the selection of the N neutral position can be
determined by a pronounced click
6 Move the switch sufficiently to
alig the screw hole
1
with the pin hole of the internal rotor and manual shaft
Check this alignment by inserting aU m 0 0591 in
View of Neutral Safety Switch Removed from the Selector
Shaft
shaft will be in the vertical position with the

lever in N neutral position
2
Disconnect
safety switch
the black
and connect
yellow
lf
gC
diameter pin to align the holes

7
Should the alignment
retighten the switch body bolts
selector
prove satisfactory
the pin and replace
the machined screw
8 Recheck the continuity with the test lamps

Should the switch prove inoperable replace the complete
wires to the neutral
12 volt test
lamp in series with

these wires and the battery and earth Similarly eOJmeet a
second test lamp across the red black reverse light wires and
a
check
remove
safety
9
switch
Remove
the
test
lamps and
restore
connections
the switch
View of Under
Body
Automatic Transmission Selector linkage Column
77
Change System
1000 Models
the
original
6Automatic Tran mission

o
View of the Under Body Automatic Transmission Selector
KI
KDOWN
Floor
Linkage
Change System
SWIT
II AND DOWNSHIFT
1200 Models
SOLENOID
TO CHECK AND TEST
Turn the ignition key
to the ON position and press

pedal fully
During the pressing of the pedal the electrical
the accelerator
2
circuit between the kickdown switch and the solenoid is

completed When the circuit is completed a click is emitted
from the solenoid

3
Should the solenoid fail

the gear
operation
or
check the
following
to
change speed
emit a click
be
during this
higher than specified
components with suitable electrical test
equipmen t
out
Test the kickdown switch for internal
Test
and
shorting out
shorting
the downshift solenoid for internal
faulty connections
Check the wiring connecting the kickdown switch
to the downshift solenoid for

7
continuity
Replace defective components where
the solenoid is to be
have to be
8
replaced
necessary If
the torque converter shall
partially drained
off approximately
Drain
I litre I 750 Imp pts

US pts fit the new solenoid and replace the same
amount of oil as drained from the
torque converter
2 125
View
of
Brake
location of
78
Pedal
and
Accelerator
Pedal
Showing
Automatic Transmission Kick Down Switch

1000 Models
Aittomatic Tran mi
6
The stall
D
engine
test
and R
drive
is
performed in
reverse range
low
STALL
C7
ion
TEST
engine speed will become constant and this speed is called

the stall point at which the engine speed should be noted
The speed should be ihe same in all ranges and shoold be
intermediate
at full throttle to check
clutch operation
or
converter
performance
the holding ability of the forward clutch
between 1950 and 2000 rpm
installation and
reverse clutch and low band
Having tested one range and prior to testing the

place the transmission in Nand nm at
approximately 1200 rpm for one or two minutes to cool
NOTE
NOTE
at full
While perfonning this test do not hoid the throttle

op
ning for more than ten seconds at a time
next
range
the torque converter oil
Prior to carrying out the tests bring the engine and

transmission to nonnal operating temperature by placing
the
in
transmission
arid
park
If the stall point is the same in each range but

below the specified rpm the following defects may be
a
The engine output is inadequate Check the
present
6
running for several
minutes
Check the transmission oil
throttle
the
apply
brake
parking
firmly
3
Connect the tachometer to the
tre tachometer
engine
plainly visible
where it is
and
or clutch slippage is apparent

selected
8 Excessive engine speed in I
band
moun t
from the driver 5
seat
Mark the tachometer at 1700 rpm 1 100 rpm on
the
the foot brake and shift the selector lever to
in 1
the dial
5
I
Apply
D and R
the accelerator
successively and at
pedal gradually and note
ach range press
ges
valve in the carburettor for full throttle
opening in
pedal movement b The stator one
way clutch may be slipping in the converter
7
When the stall point exceeds the specified figure
oil and radiator
engine
relation to accelerator
Top up where necessary

2
Chock all wheels and
the
the
engine speed
depending
on
the range
2 and D indicate that
slipping
9
Excessive engine speed in 2 and D and normal
the one way clutch is slipping
10 Excessive engine speed in R only indicates
front clutch or low and reverse brake is slipping
rear
clutch is
rpm
that
rpm
When
pedal
the accelerator
is fully
compressed
the
SELECTOR
E
l 6 iIt
WR
R
PIN
j
BOSH
tf
t
DISHED
fi
1iil
WASHER
PIN
LEVER BRACKET
PIN
SCREW
CLlP
E
l
I
SPRING
I
I
LINK
OISHEO
BUSH
PlN
Oa
@
j
ASHE
I
1
SPRING
LEVER
BUSH
o@
BUSH
Wi
@ amll
i
l
u
WASHER
WASHER
WASHER
BOOT
PIN
@
O
BlitH I
@G
T Co
0
Gj
TRUNNION
DISHED WASHER
Exploded
View of the Automatic Gear
79
Change linkage
1200 Model
TBAR
CLlP
E
8Automatic TrarumilJlJion
II
When the stall test speeds are the same in every

above 2100 rpm and discharge pressure from the
but
range
oil pump is normal and there is no slippage of clutch or
level in the torque converter

b Oil circulation to the
converter has ceased thus
allowing the generation of steam
band
fluid due to
the
following
defects
mav
be present
and air inside the converter
Low oil
LINE PRESSURE
overheating
Air in the transmission
of the oil
TEST
TO CHECK AND TEST
reading
I
Should
the
transmission performance indicate

of the clutch band and brake or incorrect speeds
slipping
during gear change

2
connect
the
rear
rear
check the line pressure
To cheCK the line pressure remove the plugs and

the line pressure gauge to the measuring points In
on
Commence the line pressure
measurement at
idle
transmission
9 High idling line pressures are caused by increased

line pressures due to sticking regulator valve and increased
throttle pressure due to vacuum tube or diaphragm
leakage
10
performance
oil pump
Select
or
ranges
and D
the
vacuum
the transmission via the manifold

12
Checking of line pressure
insufficient power due

sticking regulator valve or oil pressure
leak in the valve body or case or an oil pressure leakage in
the oil pump
worn
measure
leakage
remove
the
the
pipe and measure
negative pressure
immediately the pipe is removed
d 1 A defective or punctured diaphragm can be
determined by the emission of white smoke from the
If the diaphragm is
exhaust pipe
damaged replace
Immediately as a damaged diaphragm will drain the oil from
Should low idling pressures exist in all ranges namely

P I 2 and D this condition can be caused by a
defective pressure supply system
To
vacuum
lilll gear range
it can be determined that the loss of

pressure in R
leakage in the low and reverse brake
circuit
6
With
the line pressure gauge titted to the
transmission carry out a slow idling line pressure test for the
to
positions R and P and check the line

If the pressure reading is below that specified and
selecting I 2 and D and finding that the pressures are as
and P is due to oil
and check by stages through to throttle range

4
High throttle pressure results in excessive speeds
and a sharp thump or shock during the chariging up process
5 Leaking spool valve or gear trains result in slipping
the governor and
Select
specified
flange
faulty
leakage in
pressure
speed
or
be attributed to oil
can
clutch
and
check
carried
the line
Should the readings in the three respective ranges be

those readings specified and pressure reading in R is
within the specified range the cause of the lo
pressure
Vacuum
conjunction
iitcrease
should be
with the STALL TEST
Using
300 rum Hg
gauge with a range from 0 rum Hg
carry out the necessary tests
13 Should the line pressures fail to increase with the
vacuum
14
below
Pan
in
vacoum
pressure a t low i le
View of Automatic Transmission with Oil
out
pressure
decreasing
Diaphragm Assembly
80
then check the
vacuum
rod connection
Faulty line pressures are due mainly to a defective

regulator valve plug or pressure regulating valve
and Down Shift Solenoid Removed
Automatic Tran3mi33ion
LINE PRESSURE
Gear
SPECIFICATIONS
Range
kg cm2
kg cm2
5 kR cm2
i421b in2
991b in2
49 Ib in2
6 kg cm2
kg cm2
l42lb in2
6 kg cm2
10
Half throttle
Minimum throttle
Full throttle
Half to
10
minimum throttle
Full throttle
kg cm2
io kg cm2
Half throttle
Minimum throttle
Full throttle
15
Half throttle
10 7
8
TO
kg cm2
5 kg cm2
Raise the vehicle and support on stands disconnect

the earth lead at the battery terminal and the lead at the
terminal on the starter solenoid switch
the
carbu ret
accelerator
linkage
at
cross
Disconnect
the
exhaust
outlet
pipe
at
bolts and
securing
the
remove
the
rotate
crankshaft
as
necessary
and mark the
the
Ensure that the transmission is supported on alld

secured to a suitable jack so that it cannot become
NOTE
manifold
shaft at the rear
Disconnect the propeller
withdraw
the
propeller shaft from the rear
flange
of the transmission and remove the shaft assembly from the
vehicle Plug the rear end of the transmission to prevent
10
dislodged as it is withdrawn from the vehicle Ensure

the jack does notdamage the transmission oil pan
universal
remove
in the
With
suitable
protection
the
the
Ijack
to
assembly slightly and

Carefully withdraw the
transmission
dipstick assembly
Exercise
clear the converter from the
plate
extreme
ensure
to
on
the
cautioil when withdrawing the

the torque converter does not
that
assembly
become dislodged from rhe front of the transmission
NOTE
original positions
retaining strap to the converter

housing cover halts so that it
retains the converter in position when the transmission is
withdrawn from rhe rear of the engine
head
Attach
transmission case and remove the

support
transmission supporting crossmember from the und rbody
under
Lower
assembly rearwards
To preserve the original balance of the propeller

mark across the joint and pinion flange to ensure
shaft
replacement
rhat
18
ingress of dirt
II
the
out
16 Sopport the engine with a suitable jack using care

damage the sump
17 Progressively slacken off and remove the eight
bolts connecting the torque converter housing to the
engine
arid outlet oil cooling pipes
NOTE
noting
safety switch
position
the correct
not to
Disconnect the vacuum tube and remove the inlet
the wires to the starter
conveiter bolts
clean container for further use

8
ASSEMBLV
drive plate in relation to the torque converter plate then

progressively slacken off and remove the drive plate t
shaft from the transmission
Unscrew and withdraw the speedometer cable

Take out the drain plug and drain off the oil into
49lb in2
76lb in2
motor
assembly
6
in2
681b in2
starter
or
Disconnect the
851b
kg cm2
kg cm2
motor then remove the torque converter dust cover

15 Working through the aperture for the starter
the
control lever
5
811b in2
2131b in2
152 Ib in2
housing bolt
14 Take
Discoitnect the lower shift rod from the manual
in2
13 If installed disconnect the reversing light earth

froin under the appropriate gearcase to extension
Disconnect the wiring connecting the kickdown

the downshift solenoid
Disconnect
851b
wire
to
3 5
in2
491b in2
on the side of the transmission

of the wires for reassembly
switch
491b in2
4 8
85 Ib
681b in2
kg cm2
6 kg cm2
12 Disconnect
REMOVE
5 7
Eriglish
kg cm2
kg cm2
1421b in2
991b in2
kg cm2
kg cm2
4 kg cm2
5
TRANSMISSION
3 5
in
132Ib
3
9
4 8
kph
mph and above
Metric
Full throttle
Minimum throttle
21 7
English
Metric
35
High speed
Speed 15 kph
3 mph and below
9
Low
Throttle Opening
housing
the
and from the gearbox

81
suitable
bolting
ir ro
the
1 tiA utomalic
fran
mission
Lower the
jack supporting the
it from the vehicle
and
withdraw
assembly
19
free of any burrs

Instal the bolts securing the converter to the drive
perfectly dean and
transmission
tighten evenly to the specified torque

Tighten the bolts securing the converter housing to
the rear of the engine to the specified torque
5 Fill the transmission with the specified grade and
quantity of the recommended hydr ulic fluid
plate
and
TO INSTAL
Installation is
particular
I
attention
Ensure

the following points
with
to
that the converter is
fully engaged
in the
switch Replace if necessary

8 Road test the vehicle and recheck the hydraulic
TO
fluid level as described in HYDRAULIC FLUID
front of the transmission and in the spigot in the rear of the

crankshaft
2 Ensore that the attachment faces of the torque
converter
housing and the
stari in
Incorrect selector
bj
CHECK AND TOP UP
are
TRANSMISSION
FAUI T
Remedy
cause
Check and
linkage
adjustment
Defective inhibitor switch or wiring
Faulty ignition switch
Engine
starts in D
or
or
as
Check and repair
starter motor
or renew
necessary
or
renew
switch
or
starter
R range
Possible
adjost linkage
Check switch and wires adjust

switch
DIAGNOSIS
P or N
Possible
of the engine crankcase
AUTOMATIC
9
I Engine will not
rear
Check and if necessary adjust the selector linkage

Check the neutral safety switch and kickdown
Remedy
couse
Check and adjust linkage

Check switch and wires adjust
switch as necessary
Incorrect selector linkage adjustment

Defective inhibitor switch or wiring
or renew
3 Harsh engllgement N to D
Possible
too
Check and adjust idling speed

Check and renew faulty components
Check throttle pressure and regulator
valve and plug
high
Engine idling speed
Faulty vacuum diaphragm
Throttle pressure too
Contrf 1
valve
Remedy
cause
or
pipe
high
Free up
sticking or faulty
or
renew control valve
No drive in D operates in other ranges
Possible
Remedy
cause
Incorrect selector linkage adjustment
Check and
Throttle
Control valve
Check throttle pressure regolator valve

and plug
Free up or renew control valve
pressure
too
sticking
high
or
faulty
82
adjust linkage
Automatic Tranllmullion
5
No drive in R operates in other ranges

poor acceleration
Remedy
Possible cause
Selector linkage requires adjustment

Low thr tt1e pressure
Check and top up fluid level

Check and adjust selector linkage
Low fluid level in transmission
Control valve sticking
Slipping
or
Check pressure and regulator valve and plug

Free up or renew control valve
faulty
in all ranges
Possible
Remedy
cause
Low throttle pressure
Check fluid level and top up

Check pressure regulator valve and
Transmission fluid
Change
Control valve sticking
Low fluid level in transmission
Selectorlinkage requires adjustment
7 No
upshift
foaming
or
Free up or
faulty
renew
control valve
in D range
Possible
Remedy
cause
Incorrectly adjusted selector linkage

Faulty vacuum diaphragm or piping
Fault in shift solenoid and kickdown
plug
to recommended brand of fluid

Check and renew diaphragm or piping
Check and renew or repair wiring
switch wiring
d
Faulty governor valve
Fluid level low
or
servo
or
Renew governor valve overhaul servo
control valve
Drain and refill with recommended

quantity of fluid
fluid foaming
83
grade
and
ll
REAR
AXLE
SPECIFI
ATIONS
1000 MODELS
Side gears
Thickness range of thrust washers
Type
0 76
0 91
mm
increments of
Hypoid
0 05 mm
Ratio
4 111
Sedan
375
4
Station Sedan
0 030
I
I
of 0 002 in
Number of crown wheel and
Gear to thrust washer clearance
pinion teeth
4 111
1 ratio
37 9
375
4
I ratio
35 8
0 2
0 1
mm
0 004
0 008 in
Tapered roller
Bearing type
Drive pinion
Dimension
0 036
in increments
TORQUE
pinion head
WRENCH SETTINGS
to
crownwheel centre
45 0
I
6
Bearing pre load
kg
5 2
Thickness range of selective fit
shims pinion height adjustment
Maximum Settings
mm
Differential carrier to axle housing
772 in
Propeller shaft flange nuts
2kg m
14 5 ft lb
2 5 kg m
Pinion nut
14
cm
6 9Ib in
18 ft lb
0 05
0 50
mm
3 5
Crown wheel bolts
Carrier bearings cap nuts

2 60
kg
25 5 ft lb
increments
30
2
kg
123
ft lb
0 002
0 020 in

washers bearing preload adjustment
17
101
increments
kg
36 ft lb
mm
increments of
0 02
1200 MODELS
mm
0 09
0 10 in
increments of
Type
0 0008
Ratio
in

spacers
bearing preload adjustment
5 75
Sedan and coupe

Station se an and
mm
0 226 in
6 00
mm
0 246 in
3 900
I ratio
39
10
4 III
ratio
37
crownwheel
Dimension
0 15
Tapered roller
Bearing type
Drive pinion
Crownwheel
0 10
4 111
pinion teeth
6 25 mm
and pinion
3 900
van
Number of crownwheel and
0 236 in
Backlash between
Hypoid
pinion head
to
crownwheel centre approx
mm
45 0
0 004
0 006 in
Preload
Maximum run out at crownwheel
with new
and oil seal

0 08
face
bearings
7
initial
17 5mm
0 05
cm
7 8
and oil seal
bearings
4
initial
0 69 in
Thickness range of adjusting shims
kg
lb in
Preload with used
earings
Standard width
6 1
mm
0 003 in
Carrier
mm
I 772 in
kg
3 5
0 50 mm
em
3
4
lb in
increments
Preload with
0 002
new
bearings
but without oil seal
0 020 in
initial
5 2
incremen 1s
lb in
85
kg
cm
6 9
1c
Rear
2
A sk
Preload with used bearings but

without oil seal initial
2 6
kg
Side gears
Thickness range of thrust washers
em
3 5
0 76
0 91
Ib in
0 05
mm
0 030

wash rs
height adjustment
mm
increments of
0 036
increments
2
trinio
3 25 mm
74
of 0 002 in
increments o f
Gear to thrust washer clearance
0 03 mm
02
mm
0 004
0 128
0 108
0 1
0 008 in
in increments
of 0 0012 in
TORQUE
Crownwheel
l acklash between
rownwheel and
pinion
0 10
15
Maximuin settings
Differential carrier
mm
0 004
0 006 in
Maximum
run
out
at crownwheel
face
housing
nuts
Oil filler
plug
0 05 mm
Propeller
bearings
Standard width
axle
5 kg m
2
18 ft lb
10 kg m
72 ft lb
0 002 in
Carrier
to
WRENCH SETTINGS
17 5mm
Pinion
shaft
flange nuts
2 7
nut
0 69 in
TIrickness range of
adjusting
shims
0 05
0 50 mm
Crownwheel bolts
0 002
0 020
Carrier
REAR AXLE
7kg
means
tapered
carrier
rear
lder
sllO
DIFFERENTIAl
are the pre lubricated ball

type
lubrication in service and are retained to
means
of collars
adjusted by
assembly
can
End float in the axle shaft
shims located at the brake
backing
of the axle shafts the differential

be detached from the axle without
adjustments
ASSEMBI Y
Remove the nuts retaining the brake

backing plates
to the axle casing through the holes provided in the axle
of the vehicle and support
on
shaft
axle
flange
5
rear
Withdraw each axle shaft
assembly from the axle

slide hammer and adaptor if necessary
6 Take out the oil drain plug and drain the
differential oil into a suitable container
casing using
wheels and brake
3 pisconnect the handbrake

cables and hydraulic
brake pipes at the rear of the brake
backing plates Plug the
pipes to prevent the loss of fluid and entry of dirt
7 Mark across the flanges of the pinion and rear

universal joint take out the four securing bolts and nuts to
release the propeller shaft
86
to
bearings
no
the removal
ARRIER
Irunis
6kg
the various differential and pinion
stands
Loosen off and remove the
cap bolts
removing the axle casing from the vehicle

It is important to note thatadjustritent figures stamped
on the fin al
rive c
9mpOn n s are ir nits of O opl j ch
which must be taken into consideration
l1 when calculatIng
is
With
drive pinion is supported in the carrier by two

roller bearings which are adjusted for pre load by a
Raise the
require
assembly
plate
Pinion height in relation to the crown wheel is

controlled by shims located between the rear
bearing outer
cone and the carrier
shaft
the shafts by
assembly
bearing
Axle
adjusted by
JSher and spacer installed between the linion

w
and the front bearing inner cone
IOOO MODELS
which
of shims
The
and crownwheel backlash is
123 ft lb
DESCRIPTION
The rear axle is a semi floating type with hypoid final

drive gears mounted in a detachable carrier
The crownwheel and differential case assembly is
supported in the carrier by two tapered roller bearings the
bearing preload
17kg
43 ft lb
if
12
50 ft lb
increments
ft ID
87
increments
PART
kg
19
DIFFERENTIAL CASE
CROWNWHEEL
LDCK PIN
SHAFT
DRIVE PINION
rj
SIDE GEAR
HIM
THRU
TWASHER
Remove the nuts
assembly
will be necessary to
casing and withdraw the assembly

procedure but
bleed the brake hydraulic system
NG
fIt1
t
OUTER CONE
Wij
91
NUT
Oil SEAL
to the axle
Installation is
TO
BEAI
R CONE
the differential carrier
retaining
WASHER
FLANGE
EA
3
xle
CONE
00
PINION
OUTER
Rear A
THRUST WASHER
it
Exploded
DISMANTLE
but
NOTE
Before dismantling the assembly carry out the

following checks The information gained from the checks
will prove helpful when assembling the unit
View of Differential Final Drive Componen
Lift out
respective
differential
bearing
assembly
from the carrier
kept with
outer cones are
their
bearings
To
NOTE
the
th at the
ensure
facilitate assembly
carry
aut
the
following
check
Check
to
contaci
the tooth
th
of
ctownwheel and
thin coating of red lead and engine oil

both sides ofSix or eight of the crownwheej teeth
pinion by applying
1tihmiets
the flange end Torque required should be within
5 kg cm 3 5
4 jn lb Note the reading
3
of 4
3 wiih the pinion fl ange held to prevent it from
hef
turning re ove the flange retaining nut 3
ld wa
the
4
a
withdraw
fl nge
suitable
pinion
USing
puller
b Roiate the pinion both ways placing a bar

between the differential case and the carrier tn apply a load
gear
to the
teeth and so obtain
pinion height bearing

area
pre load
of contact should be
as
good marking If the
d backlash
are
correct the
shown in the teeth
marking
from the end of the pinion shaft

5
Using a soft metal drift
illustration
ve and below the area of contaci

ab6
The margin
should be the same and the contact margin should run
c
three quarters of the

patterps on both sides of the tooth
approximately
d
carrier
tooth
length
to
the heel of
crownwheel tooth
check the
then
Hold the
the
backlash
NOTE
aftwith
Unless replacement of the pinion taper bearings is

intended do not remove the taper bearing outer cones from
and rock the crownwheel
at
0 15
on
approximately
around the crownwheel Backlash is

the imits of0 1 0
inner con e
NOTE
pinion firmly
back and forth to check the backlash

Check
bearing
zero
the dial gaoge

e
tap the pinion
assembly wash r and bearing

space
r
out of the differential carrier housing
6 Workirig through the rear bearing outer tp drift
out the front bearing inner cone and rollers and the pinion
flange oil seal
rear
Moont a dial indicator gauge on to the differential

housing so that the plunger is in contact with and at
right angles
pre load measuring

or spring scale
gauge
check the torque required to rotate the pi
1 at
iO
Using a
and cord
mm
0 004
the dial gauge

three
correct
the carrier
positions
Provided replacement of the pinion is not required do
when within
bearing inner cone assembly from the

pinion
If however replacement ofone or both of the above is
required continue dismantling as follows
not remove the rear
0 006 in
Having completed the foregoing checks dismantle

follows
the assemblv as
1
caps
Remove the carrier
Check that the caps
are
carrier to ensure installation in their
Using
suitable puller
or a
press
remove
the
rear
assembly from the pinion

8 Draw or press the taper bearing outer cones from
the carrier takirig particular note of the pinion height
taper bearing
cap nuts and detach the

marked in relation to he
bearing
original positions
87
inner
cone
Rear
4
Axle
BEARING
WASHER
O
OUTER
DRIVE PINION
shims located between the
WASHER
OIL SEAL
Components
damage
Replace parts listed in

serTiceable condition
and
carrier
Beiore dismantling
the differential check the camer

bearings at each end of the differential case Provided the
bearings are fit for further service do not remove from
their position
NOTE
OUTER CONE
View of Drive Pinion
rear outer cone
SPACER
CONE
Examine the differential
distortion
and
NUT
Expldded
adjusting
FlANGE
and
side gear
and
case
for
if
damage
not
in
and or
if necessary Check also the pinion

thrust faces in the case for wear and or
renew
pitting
8
Ensure
that
all
shims and spacers
free
are
of
damage
the
9 Mark the position of the crownwheej in relation to

differential case
10 Release the locks from the crownwheel retaining
TO ASSEMBLE AND ADJUST DRIVE PINION
Where the old
pinion and bearings are serviceable and

tooth contact turning torque and backlash checks
made on dismantling are satisfactory then assembly is a
bolts and remoVe the bolts and crownwheel
the
II Knock out the differeniial shaft lock pin from the

crownwlieel side of the differential case
12 knock out the differential shaft and remove
pinions iuid side gears together with the thrust washers
reversal of the
the
dismantling procedure
If any of the above factors proved incorrect on the

check it will be necessary to carry out the appropriate
adjustment as described in this section
It is important that each pinion and siLle

gear
together with its thrUst washer is marked in relat on to the
differential case to ensure original installation on assembly
NOTE
This is
not
crownwheel
Adjustment
the
case
however when
is to be installed and
of the
or
new
the
and
pinion
bearings
pinion positiori and bearing
renewed
pre load
then becomes essential
13
If necessary for
There
bearing replacement or bearing

setting use a suitable puller and draw
b arings rbro each side of the differential case
pre load or backlash
he carrier
Noie ihe adjusting shims between the bearing and

TO CLEAN AND
I
Wash all
2
or
case
INSPECT
components in
blow dry Vith compressed
solvent and
cleaning
air
Check the crownwheel and pinion for
wear
are
two methods of
obtaining
the correct
pinion
position which is regulated by the shims located between

the rear bearing outer cup and the carrier One method
requires the use of an arbor and gauge kit to calculate the
thickness of shim required The second method entails the
alteration of the existing shims thickness to comperisate for
the new pinion head variation using the old pinion head
variation as a guide
Note that the pinion head variation from standard
figures is given in units of 0 00 I in
pitting
damage
Adjust Pinion Position
Method I With special tools
To
NOTE Crownwheel and pinion

sets o ly therefore damage to
are
supplied
one
item
as
matched
requires
the
replacement of both
3
Check the differential carrier
pitting or damage
bearing c9rnprisi
4
Check
desciibed in 3
5
If a
g
the
is
faulty
bearings
renew
difTerential pinion and
foi wear pitting
thrust washers are in

Check
bearing
the
for wear
or
complete
er cone rollers and outer

cup
inI
pinion taper bearings and renew
Examine the
and thrust faces

6
1 Instal the front and

original shims to the carrier
Instal ihe
rear
rear
bearing
bearing
outer
inner cone
cones
with
assembly to
the
dummy pinion
3
as
Fit the
front taper
side gear teeth

the
NOTE
damage Check that
washer
dummy pinion to the carrier

and the pinion flange
Do not instal
at
and instal the
bearing
this
the
bearing
pre load
spacer
alld
point
serviceable condition
the differential shaft
for
wear
pitting
l4
or
88
Instal and
tighten
the
flange retaining nut until the
Rear A
CrQWnw heel and Pinion Mating Numben and Pinion Head

Variation from
correct initial
Standait
turning torque of
should
This
specifications
To
Units of 0 001 in
the
be
pinion
checked
is obtained
with
pre
see
In
load
gauge or spring scale arid cord

Mount the arbor into the differential case carrier
bearing bores
pinion head
so
that
the gauge
rod is
directly
over
case
the
measurement
Calculate the thickness of shims
ion
pi
positIon
from
001
H x0
required
tfte following
0 008
to obtain
equ tion
inches
Definition
W
thickness of adjusting shims fitted
N
clearance figures obtained in 6 with feeler gauges
Ii pinion head variation figure on the pinion head
T
thickness of shims
required
to
0 004
I x 0
required
001
to
0 008
the
or
minus
new
the
as
pinion
as
pinion
marking is
mustbe ADDED
0 007 in
correctly position pini9D
correct
are
marking
2
or
zero
the original
is 0 or zero and the new

0 002 in must be
then
Remove the
lg
beari
adjusting shims from the carrier

9 Instal the shims as calculated
rear
bearing
outer cone and o
to
original shim
thickne
s to
ive
the
Where the old pinion marking is 2 and the new pipion

marking i 2 the p ositiqn is slightly mqre complica ed
As 0 002 in was added to the shim thickness for a zero
marked pinion to compensate for the
2 mark on the olq
dummy pinion assembly from the
ier and withdraw the rear
to the
pinion position
Example
0 007 in 0 178 mm
refit the
plus
on
SUBTRACTED from the original shim thickness

Again if the new pinion mark is 2 then 0 002 in
Thickness of shims
8
cone
the figure etched
If the old
pinion
Therefore
car
may be
If both pinion markings

shims will be correct
pion
0 010
the event of the arbor and gauge kit not being

use the shims removed fom
Example
0 004 in
tools
correctly position
Example
w 0 010 in
N
Position
Without pecial
starting point foi pinion position adjustment This method

of adjus ment entails asseini ling the pinion and adjusting
pillion bearing pre load fitting crownwheel and differential
a sembly
and adjusting the backlash and iaking t th
markings with red lead or engineers blue This is it trial and
erro metho d unt
sat sfactory
arking is o tained
If a new crownwheel and pinion are to be fitted with
r to
the old pinion bearing it is a relatively simple
maU
the thickness of the pinion positioning shinis if
culate
ca
t e shim
from the old pinion are kept intact and used
the markings on the lId
considerati
ln
agairi taking into
and new pinions
6 Using feeler gauge check the clearance between

the pinion head and the tip of the gauge rod and note th
correct
PiniQn
avai1 ble it will be necessary tQ

behind the re r bearing o ter
measuring
5
Adjust
Method 2
5
le
the carrier and
pinion head then 0 002
outer cone
89
in must now be subtracted from
Rear Axle
DRIVE
OVERDRIVE
VI
CENTR
l
TOO
TOE OF
C6 NTRE
MARKING
TOE
Crownwheel Tooth Marking for
Correctly Adjusted Crownwheel and Pinion Marking will be slightly Closer to Toe
Overdrive or Concave Side Changes in Thickness of Pinion
Positioning Shims will Affect Tooth Marlcing
0
on Overdrive to Greater Exteiit than
Drive or Conve Side of T oath Changes in Backlash have a more Pronounced
Effect on Drive Side Markings IAII models J
of
Tooth
on
TOE OF
TOE
low Profile
Marlcing
on
Profile
Marlcing
on
HEEL LOW
Rectify by Reducing Thickness of Pinion Positioning Shims and

BacHash All models
I
EEl
High
LOW
Both Sides of Tooth
Both Sides
TOOT
TOE
OF TOOT
HIGH
TOE
Tooth Rectify
by
Backlash IA 1 models
of Crownwheel
TOE
OF
TOE CENTRE
Toe
Increasing
HIGH
of Pinion
Positioning
Shims and Reset
i
TOOT
TOE SLIGHTLY LOW
on Drive
Side and low Profile Marlcing on Overdrive Side of Crownwheel Tooth To
Rectify
It may be Necessary to Increase Thickness of Pinion Positioning hims to Maintain Backlash within
limit All
dels
Marlcing
Backlash
Reset
Increase
Specified
TOE OF TOO
HEEL
CENTRE
HEEL SLIGHTLY HIGH
Heel Marki g on Drive Side and High Profile Marlcing on Overdrlve Side of Crownwheel Tooth To
tify
Re
Backlash It may be Nec ary to Decrea e Thickness of Phiion Positioning Shims to Maintain acklash within
limit All models
Reduce
Specified
90
Hi
Rear
becomes
before
the
nut
maximum
substitute
the
washer
to
relieve
the
If rhe
pre load
Axle7
excessive
tightening torque is reached

and or spacer for thicker ones
pre load
4
With
the retaining nut tightened to the correct

the torque required to rotate the pinion
check
torque
assembly with a pre load measuring gauge
5
If necessary
adjust the bearing pre load to obtain a

figure within the specified limits by
turning
torque
replacing
the washer and
or
spacer from the available sizes
Reducing the overall length of the spacer and

washer will increase the tuming torque Increasing the
will reduce rhe turning torque When used
length
overal
bearings are taken back into service the preload should be
NOTE
adjusted
6
to
the lower limit
Recheck the pinion position to
ensure
that there
has been no alteration in
height
7 On final assembly instal a new oil seal tighten the
retaining nut to the specified torque and secure with a new
split pin
Differential Case Variation from Standard
Units of 0 001
TO ASSEMBLE AND ADJUST DIFFERENTIAL
in
the present
shim thickness
and a further 0 002 in
2 marking on the new pinion head
subtracted for the
Thus
0 004 in should be subtracted from the shint
thickness when
new
pinion
replacing
marked
an
old pinion marked
2 with
differential
as calculated in the previous

starting point for pinion position
adjustment but fmal assessment will be influenced by the
crownwheel tooth contact markings taken after the
crownwheel to pinion backlash adjustment has been made
is
an
With the
the
spacer
and
not instal
NOTE Do
the oil seal at this
during
the
to seat the
tightening
to the marks made on dismantling

Instal the crownwheel retaining bolts with new
lock plates Tighten the bolts progressively a little at a time
in a diagonal pattern to the specified torque Secure the
washer to the
bolts
point but lubricate
by turning
NOTE
the lock
plate tabs against the bolt heads
During the tightening procedure lightly tap each

to assist seating ofthe crownwheel on the case
bolt head
rfier
Provided the original differential case and carrier

are to be used mount the differential
bearings assemblies
case assembly with
carrier bearing inner
of the retaining nut rotate the pinion
bearings
Tighten the retaining nut a little ar a time checking

bearing preload frequently to avoid exceeding the
specified bearing preload and retaining nut torque See
specifications for permissible limits on bearing preload and
NOTE
the
original pre load shims between the
cone and case
into the carrier
Operations 7 and 8 are only practical when the

dismanrling check on tooth contact pattern backlash and
pre load proved satisfactory
However if the differential case or carrier bearings
NOTE
rhe
nu t
the thrust washers to obtain the correct
and
the pmlOn assembly into the c
the front taper bearing
Fit the pinion flange washer and retaining nut
Insert
replace
according
the bearings
through
in the
4 Instal the differential shaft lock piit from the right

side of the case and secure in position by peening the hole
5
Position the crownwheel on the differential case
LOAD
original adjusting
positions
case
clearance
selected pinion positioning shims fitted

outer cone and the carrier instal
rear
bearing
pinion
necessary
bearing
between the
gears and pinions together with

into their former
side gears and thrust washers Clearance should be within

If
0 20 mm 0 004
0 008 in
the limits of 0 10
accurate
TO ADJUST PINION BEARING PRE
side
2 Instal the differential shaft aligning the hole in the

shaft with the hole in the case for the lock pin
3
Check the clearance by feeler gauge between the
The pinion head thickness
paragraph
Instal the
mating thrust washers
torque
91
8Rear A de
replaced ur the differential checks prored
unsarisfactory it will be necessary to adjust the differential
as follows
been
have
the shim thickness aJreadr calculated bl O OJ
J
Instal the carrier bearing caps and nuts according
mating marks on the cap and housing Tighten the
retaining nuts to the specified totque
the
9
Using a surface plate and dial indicator measure
8
to
the
standard width 17 5 mm
2 5 kg
0 689 in of each carrier bearing when subject to a
0
in
be
in
units
of
001
5 5Ib load Variation should
10 Calculate the thickness of shims required for each
variation from
carrier
standard width
bearing by the following equations

A
Left side Tl
Right side T2
Definition
C D
D
N E
N
location of
0 001
0 001
letters and
0 008
0 008
variation from
standard figures
A
left side carrier bearing housing
B
right side carrier bearing housing
differential
D
F
crownwheel
case
bearing width variation from standard for each

carrier bearing in units of 0 001 in
Instal the selected shims nn their
of the differential case and fit the carrier
required
respective ends
bearing inner cone
assemblies
12
With the carrier bearing outer cones mated with

assemply instal the differential in the
the correct inner cone

carrier
osing
soft faced hammer to tap the assembly in to
the bearing seats

13
Instal the carrier bearing caps and nuts according
to the mating marks on the cap and housing Tighten the
to the specified torque
Check the crownwheel backlash as previously
described in TO DISMANTLE If necessary adjust the
backlash by transferring the appropriate thickness of carrier
retaining nuts
bearing shims from

requirement
15
Check the
for
side
to
the other
crownwheel
according
run out
if the
to the
run out
the differential assembly

specifications
detach the crownwheeJ from the case and check the contact
faces of the case and crown wheel for dirt or burrs During
assembly
remove
crownwheel
that the
ensure
squarely
specifications
the
case
If
the
a new crown wheel
is
run out
pulled down
still
exceeds
and pinion set will have to
be installed
the tooth contact pattern check as
in TO DISMANTLE Provided pinion
height backlash and pre loads are correct the desired tooth
patterns will be obtained
16
described
NOTE If the old carrier bearings are to be taken back into

service the pre load required will be slightly less than that
for new bearing To compensate for the old bearings reduce
one
exceeds
on
each carrier bearing

calculated by the equation will be in thousandths of an inch
0 001 in
Thickness of shims
in
14
in units of 0 001 in
0 003
0 001
0 07 mm
17
Carry
out
previously
Instal the assembly in the vehicle in the reverse

quantity and grade of oil
order of removal fill with correct
Carrier Bearing Housing Variation From Standard

92
Units of 0 001 in
Rear A
3
AXLE SHAFT
AND BEARINGS
2
TO REMOVE
Place
collar i
Raise the
rear
chisel make
of the vehicle and support on stands

remove the rear wheel and brake
the axle
resting
a
on
cut
Use
bearing retaining
using a hammer and cold
top of the retaining collar
in the
It may be necessary to release the brake adjusrer

notches if the brake drum proves difficult to
damage the axle shaft with the

completely through the collar
it
will
be
Usually
necessary to make shallow cuts only in
order to expand the collar sufficiently for it to be removed
Disconnect
on
NOTE
drum
care
not to
chisel if it is necessary
several
shaft so that the

anvil and
an
Loosen off and
NOTE
9
rle
to cut
remove
3
3
brake pipe
pipe
to
at
the
the
rear
handbrake
of the
cable
and
hydraulic
brake backing plate Plug the
prevent the loss of fluid or entry of dirt

Remove the nuts retaining the brake backing
plate
the axle casing through the holes provided in the axle

shaft flange
5
Withdraw the axle shaft from the axle casing using
slide hammer and adaptor if necessary
NOTE
Keep intact the end float adjustment shims fitted

backing plate and casing
between the
TO RENEW AXLE SHAFT BEARING
press and press
plates support the bearing

and press the axle shaft out of the
special tool No ST37130000 to pull the
race
bearing or use
bearing from the shaft
4
Detach the bearing spacer brake backing plate and
grease trap
5
Clean all parts and check the condition of the axle
shaft for wear damage or distortion
6
If necessary remove the old oil seal from the axle
casing grease the seal lips of the new seal and instal into the
casing
7 Position the grease trap brake backing plate
bearing spacer and bearing on the axle shaft
8 Press a new bearing retaining collar onto the shaft
to secure the bearing a load of 4 5 tons will be necessary
to
Using
the inner
Remove the axle shaft as described above
for collar installation

TO INSTAL
ri
the outer face of the
s
f
t
and
bearing with suitable gre
retaining collar with greafe
the shims originally removed on the brake
Pack the axle shaft
I
smear
Position
backing plate
3
the axle shaft assembly into the rear axle

casing engaging the splines of the shaft and differential side
Insert
gear
NOTE Ensure that the oil seal lip is
shaft
I y
T
is passed
4
not
to the axle
as
the
nuts
to secure the
casing flange
dial gauge to the brake backing plate with

plunger bearing on the axle shaft flange and zero
Check the end float on the axle shaft which
Mount
the gauge
the gauge
damaged
it
Instal and tighten the retaining
assembly
5
through
0 004 in
0 1 mm 0
should be within the limits of 0
6
If adjustment to the shaft end float is necessary
add to
or
subtract
from
brake backing plate

end float is obtained
and
the shims located between the
axle casing until the correct
7 Connect the brake cable and hydraulic brake pipe

and refit the brake drum
8
Adjust
the
braking
system and bleed
as
described
in the BRAKES section
Method of Removing Rear Axle Shaft
Bearing
9 Ensure that the rear axle oil level is correct

the road wheel and lower the vehicle to the ground
Retainer
93
refit
10
Rear
Ade
4
REAR
AXLE ASSEMRL1f

Jack up the
ll
stands
2
rear
the
placed under
three way connector on the axle casing and plug the

flexible hose to prevent loss of fluid and or entry of dirt
of the vehicle and support it
on
jacking points
Raise the axle housing and remove the road wheels

Disconnect the handbrake cable at the equaliser
of the
4
Mark across the
5
universal
assembly
pinion
in the
and universal
brake hose
from
E
AXL
pre load
bearing
means
and
1200
Axle shaft
assembly
plate
two
of shims
carrier
bearing
on
removing
It is
relation
to
the crownwheel is
controlled by a washer loc ted between the rear bearing
inner cone and the pinion head
IFFER
AL
Raise the
rear
securing nuts from each

spring seats and pads
assembly
MODELS
on
is
are the pre lubricated ball

type
lubrication in service and are retained to
bearings
no
means
of collars End float in the axle shaft
adjusted by
shims located at the brake backing
the axle
casing from the vehicle

important to note that adjustment figures stamped
ARRIER ASSEMBLY
the
the final drive components are in units of 0 01 mm

which must be taken into consideration when calculating
the various differential and pinion adjustments
inner cone assemblies

in
remove
With the removal of the axle shafts the differential

assembly can be detached from the axle without
drive pinion is supported in the carrier by two

tapered roller bearings which are adjusted for pre load by a
compressible spacer installed between the front and rear
height
maunting
V bolts and detach the
ee
which require
the shafts by
The
Pinion
lower
DESCRIPI ION
tapered roller bearings the

crownwheel backlash is adjusted by
by
absorber
shock absorber and detach them
will be necessary to bleed the hydraulic brake system and

check the handbrake adjustment
The rear axle is a semi floating type with hypoid final

drive gears mounted in a detachable carrier
The crownwheel and differential case
assembly is
in the carrier
spring
shock
rear
tift the axle assembly and withdraw it from one

or alternatively disconnect the rear
spring shackles and lower the assembly to the ground
Installation is a reversal of the removal procedure but it
the
BEAR
I
supported
the
each
side clear of the vehicle
Remove the four nuts and bolts connecting the

joint flange to the pinion flange tie the shaft to
PART 2
on
joint flanges
original position
the underbody out of the way

6
Disconnect the hydraulic
nut
from the sprillg seats

8 Unscrew and
lever
to ensure
Remove
retaining
to
the axle
casing
and withdraw the
assembly
Installation is a reversal of the removal procedure but it

will be necessary to bleed the brake hydraulic system
axle
stands
2
Loosen off and
remove
the
rear
TO DISMANTLE
wheels and brake
drums
3
Disconnect the
handbrake cables and
Before dismantling the assembly carry out the

following check The information gained from the checks
will prove helpful when assembling the unit
NOTE
hydraulic
brake pipes at the rear of the brake backing plates

pipes to prevent the loss of fluid and entry of dirt
Plug
the
Remove the nuts retaining the brake backing plates

casing tIuough the holes provided in the axle
to the axle
Take
out
the
oil
drain
plug
and
drain
Mark
across
Remove
and
b Rotate the pinion both ways placing

between the differential case and the carrier to apply
the
to the gear
teeth and
so
obtain
bar
load
good marking If the
pre load and backlash are correct the

area of contact should be as shown in the teeth
marking
pinion height bearing
flanges of the pinion and rear

the four securing bolts and nuts to
the
universal joint take out

release the propeller shaft
8
crown wheel
thin coating of red lead and engine oil

to both sides of six or eight of the crown wheel teeth
differential oil into a suitable container

7
Check the tooth contact of the
pinion by applying
shaft flange
5
Withdraw each axle shaft assembly from the axle
casing using a slide hammer and adaptor if necessary
illustration
the nuts retaining the differential carrier
94
The margin above and below the
area
of contact
R
the
should be
same
and the
contact
margin should
approximately three quarters of tpe tooth

patterns on both sides of the tooth
length
run
check the
rear
the heel of
crownwheel
tooth
then
Hold the
back and
Check
and rock
pinion firmly
the
housing
out the
flange oil seal
wheel
crown
t check the backlash on the dial gauge

three positions
backlash at approximately
forth
the
around the crownwheel

the limits of 0 10
IS mm 0
004
Unless
NOTE
replacement of the pinion taper bearings is

from
intended do not remove the taper bearing outer cones

the carrier
Backlash is correct when within

0 006 in
Provided
t of the
pinion not required do
is
bearing inner cone assemblv rom t e
replace
le
the rear
NOTE Having completed the foregoing checks dismantle
not remove
the assembly as follows
pinion
If
bearing cap bolts and detach

the caps Check that the caps are marked in relation io the
carrier tq ensure installation in their original position
2
Lift out the differential assembly from the carriei
required continue dismantling
but
Take out the carrier
nsure
that the
pearing
outer cones are
kept
with thei
the
To
facilitate
assembly
carry
out
rhe
however
replacement ofone or both of the

as follows
above is
7
Using a suitable puller or a press remove the rear
taper bearing inner cone assembly and adjusting washer
from the pinion
8
Draw or press the taper bearing outer cones from
respective bearings
NOTE
pinion flange
Working through tpr rear bearing outer cup drift

front bearing i ner cqne and rollers and the pinion
zero
the dial gauge

e
the
ll
Using a soft metal drift tap the pinion shaft with

bearing inner cone anq rollers and bearing spacer out of
the differential carrier
plunger
to
suitable puller withdraw

ihe pinion shaft
Ax
d
Mount a dial indicator gauge on to th differential
is in contact with and at
carrier housing so that the
right angles
Using
from the end of
ar
following
arrier
J carrier
Before dismlUltIing the differeniial check th
at
each
end
Provided
the
the
bearings
of
differimtiatcase
do
not remove them
are
service
fit
for
further
bearings
from position
NOTE
check
Using a pre load measuring gauge or spring scale
check the torque required to rotate the pinion at
the flange end Torque required should be within the limits
3 in lb Not the reading
4
5 kg cm 3 5
of 4
3 With the pinion flange held to prevent it from
turning remove the flange retaining nut and vasher
a
and cor
Mark the
the differential
10
position of the
Release
bolts and
wheel in relation to
crown
case
remove
the locks from the crownwheel
itaining
the bolts and crownwheel
II Knock out the differential shaft lock

crownwh el side of the differential case
pin
from the
12 Knock out the differential shaft and remove

pinions and side gea s togetlier with the thru t washers
CROWNWHEEL BOLTS
It is important that each pinion and side gear

together with its thrust washer is marked in relation to the
differential case to ensure original installation on assembly
NOTE
DIFFERENTIAL CASE
AND BEARINGS
t
LOCK PLATE
BEARING CA
CONE
a
r
1
CAPBOLTS
CROWNWHEEL
SPACER
OOTER CONE
t
ORIVE PINION
ot9
I
BEARING
COMPRESSIBLE
BEARING
FLANGE
SPACER
BEARING
CAP
m
G
I
OUTER CONE
CAP BOLTS
Exploded
the
View of Differential Final Drive Components
9S
0I
Nr
OilSeAL
SHER
12
Rear 4 le
Exploded View of Differential Case Components

LOCK PIN
SIDE
UST
ER
DIFFERENTIAL
GEAR
THRUST WASHER
THRUST
HE
CARRIER
BEARING
I
0
DIFFERENTIAL SHAFT
13 If necessary for bearing replacement or bearing

pre load or backlash setting use a suitable puller and draw
the carrier bearings from each side of the differential case
Note the adjusting shims between the bearings and
OR
case

I
blow
dry
2
or
Wash
with
all
in a
components
compressed
7
Examine the differential case for damage and or
distortion and renew if necessary Check alsn the pinion
and side gear thrust faces in the case for wear and or
solvent and
cleaning
air
Check the crownwheel and pinion for
wear
pitting
pitting
damage
8
NOTE
Crownwheel and pinion
damage
only therefore
replacement ofboth
sets
are
to
supplied as matched
item requires the
bearings
for
Examine the differential
and thrust faces for wear
damage
shims
Where the old pinion and
wear
and
spacers
are
free
of
pitting
damage
as
Replace parts
listed in
This is
wear
and
pitting
or
if not
in
not
crownwheel
the
case
however when
is to be installed and or the
of the pinion position and

then becomes essential
Adjustment
There
CARRIER
serviceable and
check it will be necessary to carry out the

adjustment as described in this section
Check that the
Check the differential shaft for
are
turning torque and backlash checks

made on dismantling are satisfactory then assembly is a
If any of the above factors proved incorrect on the
pinion and side gear teeth

or
bearings
the tooth contact
described in 3
in
all
TO ASSEMBLE AND ADJUST DRIVE PINION
pitting
damage If a bearing is faulty renew the
lplete
cOf
bearing comprising inner cone rollers and outer cup
4 Check the pinion taper bearings and renew
are
that
one
Check the differential carrier
thmst washers
Ensure
dam ge
or
E
THRUST
are
two methods of
position which
li
is
regulated by
obtaining
new
appropriate
piniqn
bearings
bearing
and
renewed
pre load
the correct pinion
the washer located between
the xear bearing inner cup and pinion head One method
r
tlires the use of an arbor and gauge kit to calcuiate the
Exploded View of Drive Pinion Components
OUTER CO
BEARING
DRIVE PINION
ES
EAl
JIl 1 iO
COMPRESSIBLE
SPACER
96
RING
tt j
FLANGE
Rear
Crown wheel and Pinion
Mating
Numbers and Pinion Head
of washer requ rcd The secund method entails

alteration of the
existing washer thickness to
compensate for the
Figure
Units of 0 01
Definition
thickness
the
Variation from Stand rd
41e13
thickness of adjusting washer fitted
pinion head variation using the old

pinion head variation as a guide
Note that the pinion head variation from standard
figure is given in units of 0 0 mm
new
figure
clearance
pinion
obtained in 6
head variation
figure
on
thickness of washer reR uired to
with feeler gauges

pinion head
the
correctly position
pinion
Example
To
Adjust
Pinion Position
Method I With special tools
Instal the front and
bearing
rear
outer
cones
to
the
4mm
O
2 95
assembly and
bearing
original adjusting washer to the dummy pinion
3
Fit the dummy pinion to the carrier and instal the
t
fron taper bearing and the pinion flange
NOTH
2 95
Instal the
inner cone
rear
Do not instal
the
bearing
pinion
is 3 16
tighten the flange retaining nut until

turning torque of the pinion is ohtained
This
specifications
carrier
over
the
Calculate
correct
the
pinion
thickness
position
of washer
from
H xO OI
0 2
Adjust
In
the
required to
following
orrectly
positiqn
0 1244 in
the
bearjng
inner
pinioll
the
old
and
cone
on
the
adjusting
washer is
head
Pinion Position
the
Without special tools

event
of the arbor and gauge kit not
being
starting point for pinion position adjustment This method

of adjustment entails assembling the pinion and adjusting
pinion bearing pre load fitting crown wheel and differentia
assembly and adjusting the backlash and taking teeth
the
equation
W
required
3 16 mm
to
available it will be necessary to use the washer removed

from behind the rear bearing inner cone plus or minus as
the case may be the figure etched on the new pinion as a
measurement
obtain
rear
Method 2
between
note
Remove
towards the
Tu
bearing bores so that the gauge rod is directly

pinion head
6
Using feeler gauges check the clearance
the pinion head and the tip of the gauge rod and
mm
0 2
NOTE Ensure that the chamfer
see
pre load
case
0 01
the
scale and cord
gauge
spring
Mount the arbor into the differential
measuring
5
should be checked with
or
dummy pinion assembly from

rear bearing inner cone and
washer
from
the
adjusting
dummy pinion
9
Instal the washer as calculated to the pinion
pre load spacer at this
Instal and
of washer
carrier and withdraw the
refit the
4
0
Thickness
point
correct initial
mm
Therefore
carrier
2
in mm
97
14
Rear Axle
with red lead
markings
or engineers
blue This is a trial and
satisfactory marking is obtained
If a new crown wheel and pinion are to be fitted with
the old pinion bearing it is a relatively simple matter to
calculate the thickness of the pinion positioning washer if
the washer from the old pinion is kept intact and used
again taking into consideration the markings on the old
and new pinions
error
method until
If both pinion markings

washer will be
are
or
zero
the
if the
Again
the correct
is
As 0 02
original
pinion marking
the position is
mm
then 0 02
washer thickness
to
differential
mm
2 and the
is
slightly
more
new pinion
complicated
new
should be
replacing
an
an
subtracted from the washer

2 with a
old pinion marked
crown wheel
to the marks made
on
on
the differential
case
dismantling
6 Instal the crownwheel retaining bolts with new

lock plates Tighten the bolts progressively a little at a time
in a diagonal pattern to the specified torque Secure the
bolts by turning the lock plate tabs against the bolt heads
accurate
TO ADJUST PINION BEARING PRE
Position the
according
as calculated in the previous

starting point for pinion position
adjustment but final assessment will be influenced by the
crownwheel tooth contact markings taken after the
crownwheel to pinion backlash has been made
is
Instal the differential shaft lock pin from the right

case and secure in
position by peening the hole
side of the
pinion marked t2
The pinion head thickness
paragrap
the thrust washers to obtain the correct
clearance
present washer thickness and a further 0 02 mm

subtracted for the
2 marking on the new pinion head
mm
case
replace
necessary
the
0 04
Ihat there
3
Check the clearance by feeler gauge between the
side gears and thrust washers Clearance should be within
the limits of
10
0
0 20 mm 0 004
0 008 in
If
piflion to compensate for the 2 mark on the

head the 0 02 mm must now be subtracted from
thickness when
ensure
Instal the differential shaft aligning the hole in he

shaft with the hole in the case for the lock
pin
marked
Thus
to
give
added to the washer thickness fur
was
Recheck the pinion positiun

no alteration in height
1 Instal the side gears and pinions together wi th

mating thrust washers into their former positions in the
be
pjnion
new
pinion position
Where the old
old
is
pinion mark
oe
must be ADDED to the
zero
back the flange retaining nut if the

speCified bearing pre load is exceeded il is essenlia ill this
case In renew the compressible bearing
spacer
TO ASSEMBLE AND ADJUST DIFFERENTIAL
old pinion marking is 0 or zero and the

2
0 02
must
pinion marking is
then
mm
SUBTRACTED from the original washer thickness
marking
Do not slacken
original
correct
If the
Example
rorque
nut
has been
Example
bean
specified
zg pre uad and rewillillg Ill
wrque f see
specifications for permissable limits on bearing pre load and
IDENTIFICATION LETTER AND VARIATION
FIGURE
LOAD
With the selected pinion positioning washer fitted

bearing inner cone and pinion head instal
etween the rear

a
ncloY
bearing
spacer
to
the
NOTE Ensure that the

awards the
pinion head
a new
Instal
pinion assembly
bearing
pinion
chamfer
on
the adjusting washer is
oil seal in the carrier and insert the
into the carrier and
through
the front
taper
and oil seal
NOTE Lubricate the oil seal lips and bearings bur ensure
that the pinion thread nut and washer are free of oil or
grease
Fit the plOlOn flange washer and retaining nut

tightening of the retaining nut rotate the pinion
to seat the beariitgs
during
the
NOTE Tighten the retaining nut a little at a time checking

the bearing pre load frequently to avoid exceeding the
Carrier
Bearing Housing Variation

Units of
98
01
from Standard
mm
Figures
Rear
side
Right
T2
IDENTIFICATION
LETTER AND
location
Definition
F x 0 01
0 2
of letters and variation from
standard figures in units of 0 01 mm

left side carrier bearing housing
right
side carrier
dif erenti
ll
15
4de
bearing housing
case
width variation from standard for each
bearing
carrier bearing in units of 0 01
mm
Thickness of shims required for each carrier bearing

calcolated by the equation will be in hundredths of a
millimetre 0 01
mm
NOTE If the old carrier bearings are to be taken back into

sel1Jice the preload required will be slightly less than that
for
new
To compensate for the old bearings reduce

thickness alreadv calculated by 0 03
bearing
the overall shim
0 003
0 07 mm 0 001
Instal the selected shims
II
Differential Case Variation from Standard
Units of
Figures
of the differential
0 01 mml
NOTE
bolt head
to
assist
12
tightening procedure lightly tap each

seating of the crownwheel on the case
With
the carrier
in to he
0 689 in
surface plate and dial indicator
standard width
of each carrier
standard
bearing
when
measure
width
subject
17 5
to
5 5Ib load Variation should be in units of 0 01

10
carrier
Calculate the thickness of shims
bearing by
Left side
Tl
the
the
case
DRIVE
kg
assembly
ensure
squarely
to
Raise the
rear
that
the
a
new
the
case
tap
the assembly
and check the contact
out
burrs During
pulled down
still exceeds
pinion
set will have to
crownwheel
If
case
the
run
crownwheel and
16 Carry out
previously
the
and
pre
height backlash
or
is
tooth contact
in TO DISMANTLE
loads
are
correct
pattern check as
Provided pinion
the desired tooth
patterns will be obtained

17 Instal the assembly in the vehicle in the reverse
order of removal fill with correct quantity and grade of oil
each
PINION
on SEt I
position of the pinion llange and

shaft
if
not
flange
previously marked and remove
propeller
the retaining bolts support the propeller shaft to the
underbody clear of the pinion flange
shaft and bearing assemblies

described under AXLE SHAFT
NOTE As the tension of the lip of a new pinion oil seal on

the seal surface of the pinion flange will be greater than
TO RENEW OIL SEAL AND OR PINION FLANGE
under the axle housing
the differential in
to
and crownwheel for dirt
described
0 2
0 01
soft faced hammer
be installed
following equations
A
cone
outer cones mated with

instal
using
bearing seats
faces of the
mm
required for
bearing
assembly
detach the crownwheel from the
mm
2 5
cone
specifications
from
respective ends
13 Instal the carrier bearing caps and bolts according

mating marks on the cap and housing Tighten the
retaining bolts to the specified torque
14 Check the crownwheel backlash as previously
described in TO DISMANTLE If necessary adjust the
backlash by transferring the appropriate thickness of carrier
bearing shims from one side to the other according to the
requirement
15 Check the crownwheel run out if the run out
exceeds specifications
remove the differential assembly
7 and 8 are only practical when the

dismantling check on tooth contact pattern backlash and
pre load proved satisfactory
However if the differential case or carrier bearings
have been replaced
or
the differential checks proved
unsatisfactory it will be necessary to adjust the differential
as follows
Using
their
to the
NOTE Operations
on
and fit the carrier bearing inner
the carrier
the correct inner
7
Provided the original differential case and carrier
bearing assemblies are to be used mount the differential
case assembly
with the original pre load shims between the
carrier bearing inner cones and case into the carrier
8
Instal the carrier bearing caps and bolts according
to the mating marks on the cap and housing
Tighten the
retaining bolts to the specified torque
variation
case
assemblies
the
During
in

raise the
or
complete
on
stands
vehicle
on
Mark the relative
hoist
Remove
from the axle
both axle
housing
AND BEARING
as
that of the original component
TO REMOVE
99
particuiarly if a new flange
16
Rear A rle
is alsv
being
instaled it will be
lleceS
Jf
ru
cuk ulate the
overall preload to ensure that
after reassemb v the actual

pinioll bearing pre load is the same as originally This
calculation is ca ied out dun ng the following op rations
he slwJi or iJ the seal surJ n of the jlange is grovl ed ur

rough A new jlange should be a reasonably right fit on the
shaft splines
UIl
11
Using
suitable pre load measuring gauge measure

the overall tOlque
torotat the drive pinion at the
requi
red
flange before loosening the flange securing nut and make a
record of the
5
I1gure
Undo
obtained
the
pinion
flange
nut
retaining
approximately three complete turns and using a suitable
poller draw the flange along the pinion shaft to abut the
retaining nut
6 Tighten the flange retaining nut until there is a
slight end float in the pinion shaft bearings
NOTE This will relieve the assemb
ofallY pillioll bearillg
pre load but will maintain the side bearing pre Joad and the
llec
J saf IV fum lhe piniull assemblJ
e
turque
against the
retardillg effect of the
old oil seal
7 Again using a pre Iuad measuring gauge measure

torque required to rotate the pinion at the flange end
with negative pinion bearing p e Ioad as in
operation 4
and record the ligure obtained
8
Undo and completely remove the pinion flange
retaining nut and washer and again using a suitable puller
withdraw the flange from the pinion shaft
9 Prise the defective seal assembly out of the
the
differential carrier bore and discard

10 Clean the recess for the new seal in the end of the
carrier bore and the splines on the end of the pinion shafe
the tlange against rotation and

carefully
pinion retaining nut until there is just a slight
end float in the pinion shaft and
bearings
14
Using a pre load measuring gauge measure the
torque required at the flange end to rotate the pinion with
negative pinion bearing pre load but with the original
pre load on the carrier side bearings plus the retarding
effect of the new pinion seal and if fitted the new
pinion
flange Record the figure obtained
15 Subtract the figure obtained in operation 7
from that obtained in operation 14 and add the result to
the tlgure obtained in operation 4
16 The result calculated in operation 15 will be
the overall pre load required at the pinion flange when the
assembly is correctly adjusted
17 To apply the overall pre load see operations 15
and
16hold the pinion flange against rotation and very
carefully lighten the flange retaining nut to just remove the
bearing end float Rotate the assembly to correctly seat the
pinion bearings
18 Continue to tighten the flange retaining nut
carefully a fraction of a turn at a time alternatively
checking the overall pre load at the pinion tlange until the
pre load gauge reading is as detailed in operation 16
tighten
NOTE It is
most important
to adhere strictly to the
instructions given in operation i8 to avoid exceeding the
calculated overall preload bv tightening the retaining nut
beyond
NOTE
Ensure that
foreign matter finds its way infO the

front pinion bearing or a false pre load setting will be
110
obtained
II
Apply a light coating of suitable sealing

compound to the outer surface of a new pinion oil seal
position it in the bore of the differential carrier so that the
lip of the seal faces the pinion bearing and tap it fully into
place
NOTE
in
The
new
seal should be allowed to stand immersed
light engine oil for
12 Apply a
compound to the
position the flange
the washer and
at
least one hour
coating of
splines
inner
before installing
non
of
hardening
sealing
the
pinion flange
on the end of the
pinion shaft and tit
new nut on the threaded end of the pinion
point
and over compressing the
special spacer
of the pinion bearings In the event
of the pinion bearing preload figure being exceeded by
overtightening the flange nUl it will be necessary to remOle
the pinion flange and oil seal again and withdraw the front
pinion bearing inner cone instal a new collapsible spacer
and re instal the bearing cont oil seal pinion flange with
washer ilnd a new nut and carry out operations 17 and
IS again
cones
19 When the calculated pre load has been correctly

applied to the assembly connect the rear universal joint
flange to the pinion flange then instal and tighten the bolts
and self locking nuts
20 Instal both rear axle shaft and bearing assemblies
in the axle housing and fit the brake drums and road wheels
the brake shoes
21
Check the lubricant level in the rear axle and top
up with the correct grade if necessary

22 Check the differential housing
sure
NOTE Renew the pinioll jlallge if the splilles dre
this
between the inner
Adjust
shaft
Hold
the
loose fit
it is clear
23
100
Lower the vehicle to the floor
breather to make
Rear
4
AXI
S U
AXD
AIIIl
4
Clean all parts and check the condition of the axle
TO REMOVE
shaft for wear
drum
NOTE
bearing
several
It may be necessary to release the brake adjuster

notches if the brake drum proves difficult to
to
remove
Position
or
distortion
remove
grease the seal
casing
casing
damage
If necessary
Raise the rear of the vehicle and support on stands

Loosen off and remove the rear wheel and brake
17
Axle
lips
the old oil seal from the axle
of
e new
seal and instal into the
brake backing plate

grease trap
bearing on the axle shaft
8 Press a new bearing retaining collar onto the shaft
secure the bearing
5 tons will be necessary
a load of 4
the
spacer and
for collar installation

3
brake
the
Disconnect
handbrake
and hydraulic
backing plate Plug the
at the rear of the brake
pipe
cable
TO INSTAL
to prevent the loss of fluid or entry of dirt

4
Remove the nuts retaining the brake backing plate
to the axle casing through the holes provided in the axle
pipe
shaft
adaptor
Position the shims
if necessary
Insert
shims
bearing with suitable grease

retaining collar with grease
originally
the axle shaft

the
casing engaging
Keep intact the end float adjustment

backing plate and casing
NOTE
face of the
ou er
removed
on
and
the brake
backing plate
Withdraw the axle shaft from the axle casing using
slide hammer and
the
flange
5
Pack the axle shaft
1
smear
splines
into the
assembly
axle
rear
of the shaft and differential side
gear
fitted
between the
NOTE
shaft
TO RENEW AXLE SHAFT BEARING
Remove the axle shaft
I
2
Place
collar is
the axle shaft
NOTE
Use
chisel if it is
it
Usually
order to
described above
that the
on an
care
not to
necessary to
expand
make
sufficlentlv
shallow
cu
ts
lip
is not
as
the
secure
the
damaged
it
casing flange
dial gauge to the brake backing plate with

plunger bearing on the axle shaft flange and zero
Mount
Check
end float
the
on
should be within the limits of 0
shaft with the

damage
cut completely through the colar
the collar
the axle
to
the gauge
the gauge
the axle
that the oiLseal
Instal and tighten the retaining nuts to
assembly
bearing retaining
anvil and using a hammer and cold

cut in the top of the retaining collar
resting
chisel make
as
so
Ensure
passed through
is
the
0 1
axle shaft which
mm
0 004 in
adjustment to the shaft end float is necessary

add to or subtract from the shims located between the
brake backing plate and axle casing until the correct
6
only in
for it to be removed
If
end float is obtained
on
Using
the
inner
bearing
bearing
or
press and press
race
use
plates support
the
7
Connect the brake cable and hydraulic brake pipe
and refit the brake drum
bearing

tool No ST37130000 to pull the
special
ll
AH
the road wheel and lower the vehicle to the
XI
SS
three
way connector
7
retaining
Jack up the rear of the vehicle and support it on

placed under the jacking points
2
Raise the axle housing and remove the road wheels
3
Disconnect the handbrake cable at the equaliser
lever
pinion and universal joint flanges

to ensure assembly in the original position
5
Remove the four nuts and bolts connecting the
universal joint flange to the pinion flange tie the shaft to
the underbody out of the way
Disconnect
the
the
hydraulic
brake hose
from
the
nut
to
on
each
from the spring seats

8 Unscrew and
of the
on
refit
ground
axle casing and plug the

or entry of dirt
prevent loss of fluid and

Remove
the
shock absorber
stands
across
described
flU
flexible hose
Mark
as
Ensure that the rear axle oil level is correct
Detach the bearing spacer brake backing plate and

grease trap
4
the braking system and bleed
Adjust
in the BRAKES section
from the shaft
spring
rear
lower
mounting
shock absorber and detach them
remove
the
securing nuts from each

spring seats and pads
U bolts and detach the
Lift the axle assembly and withdraw it from

the vehicle or alternatively disconnect the
side clear of
spring shackles
and lower the
Installation is
assembly
to the
one
rear
ground
reversal of the removal procedure but it
will be necessary to bleed the hydraulic brake system and

check the handbrake adjustment
the
101
18Rear
Ale
f
IlEAR
XI I
FAUI T
IUAf NOSIS
Rear wheel noise
Possible cause
Wheel loose
on
axle
Remedv
flange
Check condition of axle and wheel and tighten

renew component
Defective brake components
shoes
or
wheel
Renew
or
faulty components
cylinder
e
Worn
or
defective axle shaft
bearing
lack of
lubrication
d
Bent axle tube or shaft
Wheel out of balance
Renew axle housing and or shaft

Check and rectify wheel balitnce or
bent
or
renew
or
true up
2 Final drive gear noise
Possible
cause
Remedy
Faulty inion bearings

Faulty differential carrier bearings
Renew pinion
b
c
Lack oflubrication
Check condition of
bearings
and readjust gears
Renew carrier bearings and
readjust
gears
assembly flush and
renew
lubricant
dl
Incorrectly adjusted
crownwheel and pininn
Check condition of gears and readjust
or renew as
mated pair
Incorrectly
adjusted bearing
carrier
pre load
Check condition of assembly
or
adjust bearing pre load

faulty components
Overhaul assembly and renew faulty components
Overhaul assembly and renew faulty components
Faulty final drive gears and adjustment Renew and
readjust
Renew housing and faulty components
bearings
or renew
Excessive noise or grind under load
Excessive noise
Excessive noise
Bent axle housing
pinion
or
grind
on
on
overdrive
coast
Excessive backlash in differential

Possible cause
Remedy
Looseness between axle shaft and differential
Check and
renew
axle and
or
side gears
side gear
b
c
splines
Worn dtfferential side gear thrust washers
Worn differential pinion thrust washers
Check and
renew differential side

gear thrust washers
Check and renew differential pinion thrust washers
Check condition of gear and pinion teeth and renew
Excessive backlash between differential side gears

and pinions
gear and or
Excessive
Check and
between differential shaft and

pinions and or shaft bore in carrier housing
wear
pi
ion thrust washers
renew
faulty components
Repeated axle shaft breakage

Possible cause
Remedy
Bent axle housing
Check and
RepeatJd
Abnormal clutch operation

Incorrectly torqued axle shaft bearing
Revise load capacity

Revise driving habits
over
retaining plate
loading
renew
housing
or
check condition of clutch
Tighten axle shaft bearing retaining nuts

tightening torque
nuts
102
to
specified
STEERING
E FIC
Ball nut balls
Recirculating
Type
ball nut
ard
worm
15 0
Ratio
N umber
38
Size
5 556 mm
new
0 218 in
0 23 litre
Oil capacity
Preload adjustment
Steering worm shaft
Sector shaft end
TlONS
405
0
Steel shims
and
Steel sh
tltrust
Imp pts
USpts
486
0
SAE 90 EP
Oil grade
screw
Shim thickness
Five sizes for
worm
shaft
0 05
0 20
TORgUE WRENCH SEITINGS
mm
0 002
Column
0 008 in
Four sizes for sector shaft
2 8
bolts
flange fixing
Ball stud
0 059
nut
Sect9f shaft
steering column
0 05
bush
0
0
Sector shaft end
0 10
Idler
3
6
nut
arm
kg
45 ft lb
in
Gear housing fixing
o ooi in
Idler
Stee ing wheel turning torque

minus sectQr shaft
14 0 kg
nut
pitman arm
101 ft lb
0 05 mm
play
to
mm
002
004
36 ft lb
0 065 in
Collapsible
kg
20 ftjlb
5 0 kg m
1655mm
515
1
arm
fixing
2 6
bolls
bolts
kg
I9
ft lb
2 6
kg in
19 ft lb
5 0
kg cm
69 injoz
Steering wheel lock
5
3
nut
kg
25 ft lb
DES
RIPTION
The
steering
gear
is the
and
worm
re
and lock nut in the top cover

d attached
recessed slot in the upper end of the sector shaft
circulati g ball
screw
type
bush
The sector shaft operates in bronze bushes and has an
oil seal at its lqwer end
A three toothed sector on the upper end of the sector
underbody
An
mm
steqing worm shaft bearing adjustment is

controlled by shims between the steering box and the
s eering column flange
Sector shaft end thrust is controlled by an adjusting
TO REMOVE
Column Gear
toe
in
box
Unscrew
the
GEAR
Remove
withdraw the
the
steering
horn
two
ring emblem retaining
column
wheel
retaining
nut
outee end to the
centre
and
to
wheel
103
same
steering
length
to
arm
maintain the
whefl the front wheels
Remove the column shell
are
in
retaining bolts
and shell
disc nnect
e
trafficator clamp screws
plug arid slide the trafficator switch off the
the
electrical
ring
steering
either side of the steering

at its inner end to the
joints
ASSEMIILY
4
positive terminal of the
on
steering column complete
screws and lift off the horn
its
steering
straight ahead position
Change
the lead at the
on
ball
and must both be the
oosen
1 Disconnect
battery
tie rod
attached to the brake backing plate These tie rods are a

for setting the alignment for the front wheels
means
The
STEERING
frame
adjustable
linkage is attached by
connecting ro and at
0 218 in in dial1eter
The
steering gear li kage
omprises a steeriI1g
connecting rod connected by a ball join at oe end to the
steering gear pitman arm and at the other end to the idler
arm which in turn pivots on a bracket attached to the
steering shaft at the worm end operates in two ball

and at the steering wheel end in a plastic
thrust bearin
The
shaft engage a sector on the side of the ball nut

There are 60 steel balls in the ball nut 5 556
to
Remove
to
the
with the column shell cover
two
bolts connecting the
steering
the facia
Remove the dust
the floor
cover screws conne
tjng thC cover
Steering
2
7
the
Release
rod
shift control
car
drclip
at
change lever
to
Remove the
the
the gear
the control rod and detach the lever and
bush
Working
at
the
hox end of the
steering
10 Before dismantling ball nut and worm shaft

check for correct alignment and excessive wear
I
Remove the clamp fitted to the ball guide tubes
10
Take out the lower support bracket retainer bolt
and detach the control rod lever retainer
and withdraw the ball guide tube from the ball nut Empty
the b ls into a suitable container
2
Invert the nut and rotate the column left to right
Place all linkages to one side and secure

p emove the lower change speed lever and bush by
sliding off the lower end of the contrbl

Poll down
13
the control
on
until all 38 Qalls have been removed from the nut Having
removed the balls the nut can be withdrawn from the
rod
rod and
remove
the
column
control lever actuating pin

14 Press down on
the
control
rod
insert
and
the bracket on the upper end of the steering

column Withdraw the insert bush and spring frqm the end
of the control rod
15 Withdraw the control rod from the drivers
disengage from
Check the steering
wear or
wear
box removed from
fjller plug
the
or
already described remove

upside down and draiIl off the
the
wear and
box
ensure
sector
that the pitman

faci
will
shaj This
wear
the steering
worm
for
pitting
the
sector
Check
the
ball
Check
the
Check
shaft
for
wear
and
teeth for
wear
and
shim
for
pushes
nut
sector
damage
9 Replace
bolt
adjusting
head
and
or
all
worn
or
faulty components
as
found
necessary
is
ann
on
chipping
oil
Remove tf1e pitman ann retaining nut and spring

washer Using a suitable puller remove the pitman arm
Prior to removal
marked in relation to the
the ball tracks
alignment
NOTE
and balls for
t ing
pi
Chec
the vehicle as
turn
guides
Check the ball nut and track
steering
cleaning solvent and dry
worm shaft bearing inner cones

pitting
3 Cpeck the outer cups and balls of the steering
worm shaft bearings for wear and pitting
for
TO DISMANTLE
the
in
I Wash all components

off
compartment of the vehicle

16 Disconnect the steering linkage connecting rod at
the steeri g gear pitman arm ball joint
17 Remove the three retaining bolts securing the
steering box to the body
18
Withdraw the steering box from the engine
compartment
l With
the
box
trunnions
II
suitable puller
Remove the sector shaft oil seal from the steering
linkage
disconnect the gear change rods from the control levers by

removing the split pin and nat washer on each of the rod
I2
tubt
the
upper bearing outer cup from

olumn tube tlange with a suitable puller
8 Remove the lower bearing outer cup from
steering box with

9
shaft frum the column
worm
the
Remove
support bracket at the lOp of the control rod

t8
Remove the E dip and pin retaining
itate
TO ASSEMBLE
assemMv
I
3
Loosen the
back Off the
sector
adjusting
shaft adjusting bolt lock nut and
bolt
the hoosing
sector shaft from
the four retaining bolts attaching the cover to the
housing and remove the cover and sector shaft Unscrew the
bolt out of the cover and lock nut and slide the
4
To
remove
the
remove
adjusting
adjusiing
bolt and shim
out
shaft
of the upper end of the sector
NOTE The
the
cover
cover
plate
plate
shim
Ensure tho
during dismantling procedure

safe place for reassembly
are
situated with a
the shims
are
not
gasket
worm
with the ball
guide
gradually
away
from the holes until the 38 balls
are
passage is clear
Add remainder of the balls filling the circuit fully
3 Instal the remaining 22 balls in the guide tubes
11 to each
Hold the guides together and plug with
lube
dahlaged
Store shims and gasket in
the
NOTE If the balls are Slopped bv the end of the wonn use
a clean punch or rod
to hold down the balls previous v
and
tum
in the opposite direction until the
the
shaft
jitted
t the
four retaining bolts securing the
tube
flange to the housing Withdraw the
steering column
column assembly Do not allow the ball nut to rotate on
the worm as damage will be incurred to the ball guides
Take
nut to
installed
shaft
5
Fit the ball
holes uppermost
2 Place 19 balls in each of the two holes on the same
side Qf the nut As the balls are being fitted turn the worm
for installation
Fit the guide tubes to the guide holes of the ball
petroleum jelly ready
4
nut
3
Steering
TS
LotNUT
Exploded View of Steering Gear Components 1200 Model Shown

Typical also of 1000 Models Except for Collapsible Column
5
guide retaining clamp
Fit the ball
and secure with two

6
When
to
the ball nut
screws
the
replacing
sector
shaft
bushes
in
the
steering box press the new bushes into position so that the
plain end of the bush is flush with the oil seal shoulder in
the bore
7
housing
Pross the oil seal into the
oil seal is lightly lubricated with
Ensure that the
housing
suitable
grease
column
Fit the bearing cups to the

tube and
the
and
i
b
ll
nut assembly into
box
Fit
worm
shaft
steering
the steering box with the ball nut sector facing the sector
8
shaft side of the box Fit the column tube
over
the
worm
gasket and
shims as removed Instal the foor bolts and adjust the
or removing shims
worm shaft bearing pre load by adding
See Specifications
shaft and attach
To
adjustment
the
the
to
steering
the sector shaft
the
slot and check
are
Specifications
available
for
fit the lash
clearance
Clearance should be 0 01
Shim sizes
with
new
the correct end clearance and lash
determine
on
box
0 03
in
the purpose
mm
with
adjuster bolt
a
0 0004
different
to
feeler gauge
0 0012 in
thicknesses
of obtaining the
see
correct
end tloat
IU
Rotate the
worm
is located in the centre
shaft by hand ontil the ball nut

to allow the centre tooth of
posit ion
the sector shaft to engage the centre tooth of the ball nut
Prior to installing the sector shaft smear the shaft with oil
nsert the sector shaft and cover into place and check
that
back lash exists between
teeth before
II
lock
tightening
Temporarily
ball
nut
and sector shaft
the side cover bolts
secure
the adjusting
screw
with the
Check Sector Shaft End Float
nut
105
Seeeriiag
4
12
turns
Rotate the
shaft several times ensuring it
sector
until the mOVement of the pitman

10 0039 in
smoothly
13
Fit the
that the
marking
pitman
on
14
Select
release the
the sector shaft and
arm to
the pitman
the sector shaft
marking
on
the
adjusting
central
SCrew
arm
instal the
in
nut
the
and
steering
adjust
the
box
COLLAPSIBLI
steering
box
10
the vehicle
procedure
liiX6
to
shaft
the
steering wheel forces the upper shaft down

nylon pin S connecting the upper and lower
the
shearing
the
allowing
upper shaft
to
move
down
over
the
lower shaft
downward pressure to or on
in the shearing of the nylon pins
connecting the upper and
lower shafts causing the column to collapse
The jacket is constructed of a fibre glass material and is

of the convoluted design This
design allows the jacket to
absorb initial shock then collapse when the upper shaft is
forced down over the lower shaft
SHAFT
LOWER
PLASTIC PINS
COLUMN SHAFT
BALL NUT
assembly
ST
applied
Severe bumping or
the steering wheel could result
COLUMN
90 EP oil and
The column assembly is comprised of an upper and

lower shaft lower column tube jac et tube column bush
and collar steering post clamp snap link and washer
The column is so designed so that on impact the force
the column when in situ
UPPER
with SAE
steering box
rnm
I7 Finally check the steering wheel aligitment gear

shift mechanism and lubricate all applicable points
screw
The principle of the steering column is to compress on

impact of a pre determined force
The
operation of a collapsible steering column
assembly is the same as that of the conveniional type The
only variance is that caution must be exercised when
on
Instal the
Installation is
DESCRIPTION
working
the
is within 0 01
plug
16
point
lock
Refill
15
ensure
is in line with the
arm
SNAP RING GROOVE
LOCK
BOm
COllAR
LOWER COLUMN TUBE

BEARING
t
COLUMN
BUSH
COLLAPSIBLE
OLT
COLUMN TUBE ASSY
COLUMN FLANGE
SLIDING
BLOCK
Exploded View of Collap ible Steering Column
COLUMN CLAMP
Components
4
TO
REMOVE
I
AND INSPECT
Remove
as
the
the
steering
conventional
and
gear assembly in the same

assembly but firstly remove
the washer
Carry
out an
inspection
componen ts in the normal

3
meaSUre
mm
on
the
the shaft
If the end clearance is not

the jacket can be put back into
thicker thrust washer at the top of
0 118 in
service
the snap ring from the upper face of the column bush Do
not bump the steering wheel or convoluted section of the
assembly during removal
2
fitted to 1200 Models
JA
KET TUDf
within 3
manner
STEERING BOX ASSY
SHIMS
BOLTS
by means of a
jacket
4
Inspect the plastic pins conoecting the column
shafts for
fatigue
Inspect the steering
column lock collar for
fatigue
and looseness
of the steering box and
manner
worm
the steering jacket iristalled on the shaft

the end clearance between the jacket bush flange
With
Support the column shaft on two V blocks at the

end and check the shaft for distortion If distortion
exceeds
correct
i06
1 0
or
0 039 in
mm
replace
as
necessary
at
the steering wheel end
CIRCU
eering
previous adjustments completed and
the
With
the
ball nut fitted to the worm shaft lubricate where necessary

and fit the worm shaft and column to the steering box
the
Tigh ten
steering
2
washer
seating
3
four
bol ts connecting the column
box and check the
to
the
adjustment
Fit the upper bush to the column and apply the

and snap ring
Check the snap ring for correct
in the groove
Raise the bush
until the top of the bush contacts
the lower surface of the washer Back off the bush until
clearance of less than 1 0 mm 0 039 in is obtained
Check for free turning of the column sh ft and adjust

the bush accordingly Shoold the clearance between the
washer and the bush be insufficient binding will result
4
Align the upper end of the jacket lube with the
groove
in
positions
the
on
jacket
two posi tions
Caulk the
mm
coh mn bush
twq symmetrical
and chalk
the
0 157 in
to
depth
not
and ensure that the inner
exceeding
periphery
tube measurement is less than 31 8 mm 1 252 in

Re check the clearance of the bush and should
clearance be incorrect
adjust by adding
5
COLUMN
Fit and
fe
caulk
the
or
shims
adjust
TUBE
cover
it
4 0
of the
bolts to the
the sector shaft and
specified
tighten
the side
torque
Upper End of Steering Worm Shaft and Column Tube

a
OLUMl
4
LAMP
jack lock collar ensuring that the bolts do not contact

steering shaft
4 Fit the steering assembly to the vehicle with the
wheel It
open end of the spacer blocks facing the steering
is imperative that the spacer blocks be fitted in this manner
to ensure that on impact the nylon pins yill shear off
allowing the column to move forward away from the driver
Replace parts where necessary
the
TO INSPECT AND INSTAL
the
I
damage
Check the colomn
2
3
jacket
Inspect the two aluminium spacer blocks for

particular attention to the nylon pins
with
Check that the

lock collar
are
clamp
for
damage
and
cracking
bolts connecting the clamp to the
of the correct
length
Fit the
clamp
to
4 I
STIlIlHIl
1l
KA4
extractor press the tapered ball

a suitable
in each steering ann
of
the
hole
tapered
joint
4
Repeat operations 1 and 2 to detach the inner
end of each tie rod from the steering conne cting rod and
withdraw the tie rods from the vehicle
Using
out
Jack
up the
front of the vehicle
wheels and lower the vehicle

2
nut
on
Take out the
split pin
to
jack
block the
rear
stands
and remove the castellated
the tie rod outer ball
securing
suspension
each
on
joint
to the
steering
arm
unit
IDLER ARM ASS

TIE ROD BALL JOINT
TIE ROD BALL JOINT
PITMAN
fl
fI
ARM BALL JOINT

TIE ROD
CONNECTING ROD
TI
TIE ROD BAll JOI
View of
Steering linkage Components
IDLER ARM BALL JOINT
Removed from Vehicle
107
1000 Models
Steering
6
5
Take out the split pin and remuve the
steering connecting rod joint bolt on the pitman
6
Using
nut
un
the
eye in the
rod
arm
suitable extractor press the bolt out of the
forward end of the pitman arm

7
Using similar procedure
idler
as in operations
4
and
steering connecting rod from the
forward end of the idler arm and withdraw the connecting
disconnect
replaced
as
complete
unserviceable
are
unit not
they must
serviced separately
rod
tighten
the castellated nut and secure with
Attach
the
ball joint of each tie rod to its

tighten the castellated nut and fit a
respective steering
new
split pin
be
the uther end of the
JIl
split pin
a new
If tie rods ends
Repeat
Position the connecting rod on the pitman arm and

Fit castellated nuts and split pins
Attach the inner ball join t of each tie rod to the
connecting
rod from the vehicle

8
rod
arm
the
uIlnccting
outer
arm
Measure the length of tie rods between the ball
stud centres Distance between Centres should be 296 8

11 69 in
I If the steering connecting rod ends are to be

renewed press the new bolt and bush into the rod until the
end of the outer sleeve of bush is flush with the end of the
6 Centre the steering box with the wheels in the

straight ahead position and check the wheel alignment
toe
in
Kl
BALL
r
described under LINKAGE ADJUSTMENT
as
SPLIT PIN
mm
SPLrTPIN
CONNECTING
ROD
NU
NUT
AlL JOINT
SPLIT PIN
o
NUT
SPLIT PIN
T1E
oo
NUT
T1EIROO
IE ROD BALL JOINT
Dismantled View of
TIE ROD BAllJOIHT
7
TO
REMOVE
solution and instal them in the idler housing Ensure that

the lip of the bushes is protruding
equally at either end
Remove the split pin and castellated

arm
to
the connecting rod and
connecting rod
idler
2
Remove the two
nut
The wetting procedure is unnecessary where

bush is fitted
securing
detach
the
and bolts securing the idler

the body side member and remove the
nuts
2 Instal the idler arm pivot bolt

and tighten to the specified torque
nut
bracket assembly to
assembly from the vehicle
3
1000 Models
AIUI
AND DISMANTLE
the
IOU
Steering Linkage Components
section
Fit
a new
nylon
fit the castellated

See Specification
split pin
Position the bracket assembly on the body side

member and secure with the two retaining bolts and nuts
4
Connect the steering connecting rod to the idler
Remove the split pin and castellated nut and press

pivot bolt out of the bracket body
the idler arm
and instal the castellated
arm
5
When the idler
arm
nut
new
assembly
the centre line of the idler
body
and
arm
split pin
is mounted
on
the
should be parallel
to
the chassis
With the idler assembly removed check the bushes
I
for
wear
If
and
new
bushes
arc
Check
fatigue
required
wet
the bushes with
II
UKAf F
o UST
the
IF
angle
as
adjust
the
described
in
front
wheel
LINKAGE
TS
the
specified degree reading and tighten the

Specifications
3
Turn the front wheels to the right hand lock and
check the degree angle of the wheel Adjust the stop bolt
setting the angle to the specified degree reading and tighten
lock nut
1 Set the vehicle up with turn tables under the front

wheels and slacken the lock nuts and
stop adjusting bolts
2
if necessary
toe in
ADJUSTMENT
soapy
TO ADJUST STEERING LOCK STOPS
he
and
alignment
Turn the front wheels to the left lock and check

of the wheel Adjust the stop bolt setting
the
degree angle
k nut See
4
108
to
See
Specifications
Recheck both locks and
section
remove
the
turn
tables
Steerirrg
NUT
FLAT WASHER
lASTrC
BlAH
iii
LASTIC BUSH
fi
FLAT WASHE
NUT
e
o
Exploded
ORING
View af Idler Arm Campanenn
Exploded
TO CHECK AND ADJUST TOE
View af Idler Arm Campanents
the
roll
IN
1000 Madels
vehicle
lurwanJ until
distance above the floor at the

I
With
the vehicle
on
level floor
2
a
Spin
centre as
3
each wheel in turn and
line around the
periphery
using
piece
of each tyre
of chalk
as near
to the
be
possible
centre
chalk line
203
the floor and in front of the

5
Using
suitable
distance between the
in
lock
two
254
both tyres
on
mm
suspension
telescopic gauge
marks
on
10 in
at
measure
the tyre
Maintain the wheels in the
straight
een tees
ahead
the
same
t0
24
mm
Station
t0
2
04 in
Wagon
Sedan
less
and
than
t1
6
the
nuts
on
each
tie rod
and
turn
the toe in is Correct
each
Tighten
rod by eq al
the four lock
nuts
above
NOTE II is importall
the
make equal adjustmen ts
t to
tie rod to maintain the central
and
If all oplical
manufacturers
record the measurements

6
t1
5
04
aITounts until
position approximately
are
measurement taken at the rear of the wheels

8 If adjustment of the toe in is required loosen the
bouncc the front
and rear of the vehicle up and down several times and let it
find its own height Set the front wheels in the straight
ahead position
4
Mark the
approximately
mm
Lower the vehicle to the floor
marks
of the front suspension
of the vehicle
mark
the
rear
Again use the telescopic gauge to measure and

the
distance between the maries on the tyres
record
ust
The distance measured at the front of the wheels
up the front
jack
1200 Madels
position
109
or
other
on
each
pusition ufthe steering gear

tvpe gauge is used follow the
instmctions
Steering
B
ft
Excessive play
or
Steering
worn or
gear
ER
T D
FA U I
OS S
looseness in steering gear

Possible
ST
cause
out
Remedv
of adjustment
Overhaul
steering
gear
renew
faulty
components and
b
Steering linkage
ball joints
Pitman
Idler lever bush and bolt
Steering
arm
loose on
gear loose
worn or
sector
on
adjust
Tighten or renew faulty
loose
shaft
worn
sub frame
mounting bolts
Heavy steering
Possible cause
Low or uneven tyre
Steering
Remedy
pressures
gear incorrectly adjusted

Lack of lubricant in steering linkage
Front suspension
Chech tyres and inflate to recommended pressures

Check and readjust steering gear
Ascertain
joints
t
3
cause
worn or out
of
alignment
Check front end for

Check and
mountings
Soft or sagging front springs
Renew
to
one
wear
align steering
springs
gear and
cause
Incorrect front end
Dragging brakes
Check and
Broken
Renew
faulty springs
Renew
faulty componen ts
renew
damaged
wear or
adjustment
sagging rear spring so

Broken rear spring mounting bolts
Damaged front suspension or front sub frame members
Faultv or damaged front crossmember
or
d
e
I
g
h
S
b
c
d
e
Check and
Check and
renew
components
front crossmember
causes
Remedv
Looseness in steering gear

Uneven tyre wear or incorrect tyre pressures
Rectify
Tyre and
or wheel unbalance
Front end damaged or out of alignment
Worn or badly adjusted front wheel bearing
Wheel alignment incorrectly adjusted
Check and balance as necessary

Check and rectify front end damage and
Check condition and adjust wheel
Check and
Loose
adjust
Check and
faulty components
renew as a pair
or worn
Faulty
Steering
or
adjust
alignment
bearings
shock absorbers
erratic
and
Check condition of tyres and inflate

to recommended pressures
tie rod ends
Check and
front wheel
toe
in
alignment
renew
wandering
Possible
brake shoes
adjust
shimmy
Possible
Check conditions of tyres and inflate

to recommended pressures
Check front end alignment
pressure
or
Front wheel wobble
alignment
Remedy
Uneven tyre
components
olumn mountings
and check front end
renew worn
side
Possible
and lubricate
lbricant
ofl
front end
align
Mis alignment between steering gear and column
Steering pulls
of loss
steering linkage where applicable

and fe
components
Tighten pitman ann retainingnut

Renew and adjust idler lever bush and bolt
Tighten mounting bolts and check alignment
of steering gear mounting
Remedv
cause
Incorrect or uneven camber andjorc3stor setting

Smooth front lyres
Check and renew components to
Check and
renew
tyres
Excessive play in steering gear and or linkage

Excessively high or low tyre pressures
Check and
renew
faulty components readjust
Loose
or
incorrectly adjusted front
wheel
as
rectify
necessary
Check and inflate to recommended

pressures
Check and adjust front wheel bearings
bearings
llU
FRONT SUSPENSION
pAnT
1000
T
SPE
FI
NS
Radius rod
Transverse leaf
Type
SERIES
4 5
front
Radius rod
3
5
rear
shock absorbel1
976 mm
36 925 in
Stub axle
Thickness
Number of leaves
3
5
nut
Shock absorber bolt
2 8
front
Upper
kg
Lower ball to control
120mm
2 2
kg m
16lb ft
2 8 kg m
ball to control arm bolts
arm
bolts
20Ib ft
4 724 in
Wheel
kg
20Ib ft
0 157 in
Free camber
i8lb fi
968 in
4mm
kg
38Ib ft
2 5 kg in
50mm
35lb ft
Retaining Ilut fulcrum
Width
kg
4 9
Upper ball joint
and radius rods
Spring dimensions
Length
38Ib ft
tubular
arms
kg
32lb ft
spring with upper

and lower control
alignment
2
Toe in
3mm
0 0787
Caster
0 118 in
20 15 min
angle
angle
King pin inclination
Toe out
Toe out
15 min
Camber
60 30 min
on
turn
inner wheel
450
on
turn
Quter wheel
360 36 min
TORQUE WRENCH SEITINGS

7 6
Lower ball nut
kg
RETAINING
55Ib ft
Lower control
arm
5 3
connecting bolt
kg
RING
DUST
38Ib ft
SE
i
SPRING SUppORT
NOT
@
SPRING AND
LOWER
RM
LOCK
WASHER
BALL JOINT BOLTS
ONTIlOI
tt
sHER
W
LOWER
CONTROL
AF M
TO REMOVE AND INSPECT
I Jack up the front of the vehicle block the rear

wheels and support the vehicle on jack stands
2
Remove the road wheels
3
Remove the two bolts attaching the shock absorber
to
the radius rod and lower control

4
Remove the bolts
lower control
5
and
WASHER
ann
attaching the radius rod
to
the
NUT
VOTOO
arm
the lower control
Sopport
remove
SPACER
the
split pin
arm
and castellated
with
nut
Working
the
nut
at the
lowering
the
BAll JOINT
NUTS
opposite
remove
floor jack
and
the floor jack to withdraw the lower ball joint from the
stub axle swivel
unscrew
v
t
end of the control arm

washers and withdraw the
Exploded
111
View of Lower Control Arm with Stub Axle and

Swivel Arm Components 1000 Models
Front
Suspension
MOUNTING
ft
BOLT
MOUNTING
WASHERS
80LT1
WASHERS
NUT
ENGINE SUPPORTS
lOCK WASHER
CROSS MEMBER
MOUNTING BRACKET
WASHER
NUT
SPRING SEAT
CUSHION
t
BUMP RUBBER
BUSH
NUT
DISC
WASHER
CAOll
1
8JSH
WASHER
RADIUS ROD
10
I
SPACER
DISC
NUT
View of Front Cross Member and
control
control
7
out
the
arm
to
crossmembcr pivot
bolt and lift
out
Spring Component
the
TO INSTAL
arm
Supporl
same
the transverse
procedure
to
spring with
jack
and carry
Installation procedure is the reversal
dismantle the opposing side

I
With
crossmember
NOTE
If spring
lower control
Oll V
arm
is to
Oil lu
be removed
withdraw the
discoIJnect
With
spring
left and right hand lower control arms

removed the spring can now be lowered and removed from
the
llld
9
Remove the two swivel rubber insulators from the
crossmember and the two spring support rubbers from the
cornrol arms
II
Inspect
i Inspect
the rubbers for
fatigue
the spring for sag
and
lower
1 0l1tl 01
elasticity
for
fatigue
and
14
Disconnect
the
the
same
procedure
when
assembling
the
Fit the
road
Ensure
wheels and lower the vehicle to the
Finally tighten thc control arm inner pivot bolts

Replace all worn or damaged components
lubricate where necessary and tighten all nuts and bolts to
the specified torque as described
in the
catSpeciionfi
8
shock absorber from its

the vehicle
arm
Ilum
distortion and check the rubber bushes fur wear

13
Check the lower ball join t for wear
mounting and remove it from

leaks damage and recoil action
uut
he upposite ide of thL vehicle

suspension
5
Fit the shock absorbers and radius rods
that the radius rods are of equal length
distorted and broken

arm
fit the support rubber to the lower control
on
Check the
the two swivel insulator rubbers fitted to the

offer the spring to the crossmember and
attach
Carry
leaves
12
that of removal
the arm to the crossmember by inserting the

bolt
from
the rear
pivot
4
Cunnect the lower ball joint to the stub axle swivel
and tighten to the specified
torque Remove the clamp
the vehicle
10
to
following points
support the spring

2 Jack up one end of the spring and retain it with the
front spring clamp tool ST
4369 then lower the jack
one
3
8
1000 Models
upper
Check for oil
section
112
Front
BACKING
NT
PLATE
RADIUS ROD
LOWER BALL JOINT
Rear View of the Left Hand Side
Suspension arid Steering
UPPER 4 ONTROJ

0 Raise the front of the vehicle block the
wheels and support the vehicle on jack stands
2
3
Withdraw the split pin
and disconnect the arm from
unscrew
rear
the castellated nut
the stub axle swivel
at
the
upper ball joint

4
the opposite end of the control arm

retaining nuts and bolts and lift off the
control arm assembly noting the position and number of
shims between the pivot shaft and the body frame
5
Clean the arm assembly and inspect for fatigue or
remove
Working
the
at
two
distortion
6
for
Inspect the bushes
wear
If
replacement
is
necessary press t e bushes out from the opposite ends and

remove the pivot shaft
To fit new bushes place the pivot
shaft in the upper control
that the
ensuring
wi th the
7
splines
splines
and press the bushes home

the bush are correctly
aligned
arm
on
in the control
arm
Inspect rebound rubbers for fatigue and cracking

Check the upper ball joint for wear
Replace all worn or damaged components where
8
9
necessary
View
of
Upper Inner Control Arm in Mounted Position

1000 Model
113
AIlM
Compone
lts
1000 Models
SlIspension
3
4Ifront
8ion
SU5pe
NUT
LOCI WASHER
UPPER CONTROL ARM
WASHER
BOSH
fULCRUM SHAfT
CAMBER
ADJUSTING
SHIMS
WASHER
0
WSHER
OCK
NUT
i
e
Dismantled View of Upper Control Arm Components 1000 Models
in the positions from which they
TO INSTAL
rnstallation procedure is tne reverse

with attention to the following points
II As
fit the camber
starting point
to
STUB AXLE
SWn EL
6
7
support
Raise
the
vehicle
the vehicle on
jack
block the
Tear
Remove the hydraulic brake line retaining clamp

plug the line to avoid loss of
ingress of dirt
Remove
the brake
in
1200
described
the
Installation is the reversal of the removal procedure
drum and hub assembly as

FRONT SUSPENSION
Series
I Bleed
cylinder
2
Carry
section in this manual
Disconnect the stub axle swivel from the upper and

lower control arms and withdraw the assembly from the
vehicle
5
4
I
up
RE
K AND AD1UST
TO
Specification
ASTOR
Check and
with the
adjust tyre pressures and set the vehicle

alignment equipment being used according to
tJle manufacturer
instructions
down and let it find its

2
described in the 1200 Series
TO INSTAL
disconnect the brake line and
as
stands
fluid and
Check the swivel and stub axle for distortion

Remove and inspect the wheel bearings cups and
seals and assembly
wheels and
required
Lubricate all points where necessary
shims
removed
adjust front end alignment

3 Carry
out
to
tightening
torque
specifications See Specification section
that of removal
adjusting
were
Check and
own
Check the castor
rear
Bounce the vehicle up and
angle
tightening procedure
as
op the master
specified
in the
CAMBER
the
to
front
bolt
ANGUlS
will decrease
castor
and
shims from the front bolt to the rear bolt will
increase castor
level
and if necessary
bolt
out
following points
hydraulic system and top
section
ND
transferring
the
adjust by
Check the camber
installing
transferring shims from one upper suspension pivot shaft

mounting bolt to the other Transferring shims from the
an
equal
angle and adjust by removing or

number of shims at each of the two
upper suspension pivot shaft mounting bolts
114
5
Suapenawn
Front
SHO
K ABSORBERS
Mount the shock absorber
lower eye
Raise
the front
Remove
the
bolts
two
connecting
absorber to the lower control arm and radius rod

3
Remove the nut and washer connecting the upper
end of the shock absorber to the sub frame and withdraw
the shock absorber from the vehicle
Installation is
rever
al of the removal
vice
by the
stem
Grasp the upper half of the shock absorber pull up

to the fully extended position and then slowly push down
until the shock absorber is fully compressed
3
Repeat operation 2 six or eight times to remove
If slack spots
slack
spots caused by air in the system
any
exist and cannot be removed by this method the shock
absorber is evidently defective and should be renewed
shock
the
in
on
stands
2
or
upright
procedure
test and bleed the shock absorber as described

under TO TEST AND BLEED
Check
NOTE
The resistance will be greater
on
upward stroke of
the shock absorber than on the downward stroke

TO TEST AND BLEED
The
to which
extent
testing
special
without
shock absorber
is
equipment
can
Check the body of the shock absorber for dents or

for fluid leakage The shock absorbers cannot
in
service and should be renewed if defective
be repaired
4
be tested
limited
damage and
the
to
following
BALL JOINTS
NOTE
Use care not to
damage
the
hydraulic brake pipe
by stretching
I
Raise
the front of the vehicle
support
on
stands
3
and remove the road wheel
connecting the ball joint to the

and withdraw the ball joint
Remove the bolts
upper control
arm
Sopport the lower control arm with a jack and

remove the split pin and nut from the lower ball joint
Using a suitable spreader press the lower ball joint
tapered spindle out of the stub axle swivel
5
Remove the bolts connecting the lower ball joint
lower
control arm and withdraw the ball joint
to the
6 Place the ball joint in the vice and check the dust
whichever is fitted to the
cover metal circlip or 0 ring
dust cap
for damage or fatigue
4
NOTE
control
It
will also
arm
on
be
jack
to
support the lower
necessarv
to
relieve the
spring pressure
on
the
upper rebound rubber
To
upper and lower bali joints

split pin and nut from the upper ball
the
remove
the
separately
joint and using a suitable spreader press
tapered spindle oot of the stub axle swivel
remove
the
ball joint
Installation is
SIOX
SUSPE
FRONT
AIJLT
rev
DIAt NOSIS
rsal of the removal
1000
SERIES
1 Front end noise
Possible
a
Remedy
cause
Tighten mounting
Tighten or renew lower ball joint
Loose upper suspension mounting

Loose or worn suspension unit lower
ball
joint
Noise in shock absorber unit
Worn
Mal
steering linkage
components
adjusted
or
idler
Renew shock absorber unit
Renew defective components
arm
Readjust
front hub bearings
Continued
next page
115
or
renew
hub bearings
procedure
Front
6
2
Poor
Suspension
or
holding ability
erratic road
Possible
Remedy
cause
Low or uneven tyre pressure

Defective shock absorber operation
Inflate tyres to recommended pressures

Check and renew faulty onit
Incorrect front end
Check and
Loose or defective front crossmember
Weak or broken front spring leaf or leaves

Broken leaf in or weak rear spring
Loose or defective front hub bearings
I
g
h
alignment
Mal adjusted or defective steering gear

or idler
Defective tyres or front wheel balance
Worn
Check and
as
necessary
renew
leaf
or
complete
rear
Adjust
or renew
hub bearings
Adjust
or
faulty components
renew
spring
Renew defective tyres and balance

front wheels
sagging spring pivot rubber
or
adjust alignment
Check and tighten or renew member

Check and renew spring
Renew
spring pivot rubbers
Heavy steering
Possible
Remedy
cause
Check and inflate tyres
Incorrect front end
pressures
Check and
Lack of lubricant in steering gear
Check oil level in steering gear and apply
and components
Worn or damaged front suspension
grease gun to any grease nipples

Check and renew worn or damaged components
and adjust front end alignment
Sagging
Incorrect
4 Front
or
wbeeI
aligrunent
broken transverse
adjustment
w
bble
or
recommended
adjust aLignment
Renew spring
Check and adjust steering gear
spring
of steering gear
shimmy
Possible
Remedy
cause
Check and balance tyre and wheel as a uni t

Check front end alignment see Wheels and
Tyre and or wheel unbalance

Rapid and uneven tyre wear
Worn
or
loose hob bearings
Check and
Worn
or
damaged steering linkage
Check
Incorrect front end
Mal
to
Tyres
alignment
adjusted or worn steering gear

Steering gear loose on frame mounting
or
off centre
5 Vehicle
pulls
to one side
Possible
adjust hub bearings

faolty components and adjust
Adjust and or renew suspension components
to restore alignment
Renew and or adjust steering gear components
Check and tighten mounting and or centre
steering gear
Low or
renew or
renew
uneven
Incorrect or
Remedv
cause
Check and inflate tyres
tyre pressure
unequal front
end
pressures
Check and
alignment
adjust
to
to
recommended
restore correct
alignment
side to side
c
High road camber
Avoid
Renew
Weak or broken rear spring

Front brake dragging
far as possible
faulty spring
Adjust or rectify cause
Check and re centre steering
Steering gear off centre

116
as
Front
PART
II
Suspension
1200 SERIES
SPE
IFICiTIONS
Suspension and
Type
shock absorber
unit with coil
I 10
Gland packing
spring and lower

control arm
kg
79Ib ft
6 5 kg m
Piston rod nut
47lb ft
Coil spring
Free
338 tlO mm
length
Stabiliser bar link
3t 0
13
4 in
Loaded
2 1 kg m
IS Ib ft
Upper mounting bolts
203 tS
length
2kg
1
retaining nuts
mm
7 99 t0 2 in
Load at loaded length
200
Total number of coils
77
Wire diameter
IOmm
2
1
Stabiliser bar bracket bolts
kg
2 4
xle nut
Stub
aster
le
an
in
Camber angle
kg
Radius rod to frame
6 5 kg m
47Ib ft
Radius rod to control ann
3 0
1040
t 30
1005
kg
21Ib ft
1010 t30
Station wagon
17lb ft
Wheel
alignment
Caster angle Sedan models
kg
8Ib ft
44llb
394
0
8Ib ft
Lower ball joint
to
6 1 kg m
44 lb ft
strut
30
Lower ball
7 4
joint retaining nut
kg
53 Ib ft
2 kg m
1
Engine mounting bracket nut
King pin inclination

7055
7045 t 30
Sedan models
Station wagon
Disc brake
8 Ib ft
6 1 kg m
caliper bolts
44 lb ft
Toe out
Disc to hub
turns
on
6 0
assembly
kg m
43Ibfft
430 t 1
Inner wheel
Outer wheel
t
360
Backing plate installation
3 7 kgfm
261b ft
bolts
Toe in
5
Sedan models
Lower ball
lmm
control
2 t 04 in
Station wagon
McPherson
a
strut
type
front
RIPTION
DES
unit
suspension
to
vertical tubular shOCk absorber surrounded at

by a coil on top of which is the upper spring
mounting attached
housing
The piston rod
of the front
shock absorber is in
to
A ball
the lower end of the shock absorber
joint incorporating the steering
foot by
two
bolts and spring
on
the ball joint attaches the suspension

suspension control arm which pivots at its inner
bolt
and
rubber
bush
attaching
it
to
the
A radius rod is attached at its rear end by tW9 bolts to

the outer end of the lower control arm and at its forward
end to a bracket on the under frame by a rubber bush
mounting arrangement
A stabiliser bar attached to the body sub frame
forward of the suspension and connected between the outer
tube
arm
unit
suspension crossmember
turn
to
axle is attached
suspension
unit to the
wheel
end
of the
the
washers
The ball bolt of
the upper centre of the spring upper mounting

by a rubber mounted thrust bearing assembly
The suspension unit foot integral with the wheel stub
attached
Back off to nearest castellation
the upper end
to the underside
kg
21Ib ft
comprises
3 0
6tlmm
24 t 04 in
Each
joint to
arm
is attached
117
BFronl
Srupenaion
end of each suspension unit control

link
Caster
camber
and
arm
by
If the coil spring is to be removed from the unit special

must be used to hold the spring in a compressed
condition to assist in the removal and installation of the
rubber bushed
clips
swivel
inclination
are
set
in
production and cannot be adjusted Any variations in these

angles will be caused by worn or damaged components
WBEELBlJB AND BEARING
2
Drum
Place blocks at
rear
unit
wheel bearing grease apply grease to the rollers of the inner

cone and place it in position in the hub
3
Place a new grease retaining seal on the inner end
Type Brakes
and front of rear wheels raise
jack stands
then take off wheel and
the front of the vehicle and support on

2
the wheel
Remove
nuts
of the hub and tap into position

4
Apply wheel bearing grease to the inner cone and
drum
3
remove
Remove the dust

huh
split pin
rollers of the outer hub bearing place the hub asselflbly on

the stub axle and fit the roller bearing to the hub
5
Fit the D washer and castellated nut on the stub
and
nut and washer
lil il
ret
Remove the outer
assembly
withdraw the
cover
bearing
cone
and withdraw hub
axle
from the stub axle
Place the assembly in
vice and
using
drift
or
Wash
the
bearings
solvent
cap
If the split pin hole does nor line up with

the nut release the nut until pin can be installed
NOTE
cups and hub assembly in
and
out
carry
mix new and used parts

3
Once having removed the grease seals
8 Instal the road wheels and

shoes Lower the vehicle to the floor
TO REMOVE
1
they shauld
with new seals

Check the stub axle for miS alignmen t and the
replaced
4
inner
bearing seating area
for
is
scoring
TO
ASSEMBLE
Disc
Type
re
adjust
the
brake
Brakes
Place blocks at front and rear of rear wheels

Raise the front of the vehicle and support with
Screw off the wheel retaining
nots
and lift off the
road wheel
Check
badly damaged
slot in
jack stands
the castellated nut and the thread on the

stub axle for damage or wear If the thread on the stub axle
5
thorough
cleaning
inspection of component parts
2
Inspect bearing cups and cones for scoring and
chipping Should it be necessary to renew either a bearing
a complete unit Do not
or cup they must be renewed as
be
the nut until a
Slacken off the nut until there is a slight end float

bearings and then tighten with the fingers until
the end float is just removed
7
Fit a new split pin and replace the grease retaining
TO CLEIN AND INSPECT
rotating the hub tighten

placed on the hub bearings
in the hub
bearing cups from the hub assembly
suitable
is
suitable hand tool tap out the grease seal

6
Lift out the inner bearing cone re mount hub
assembly in a vice and using a suitable drift tap out both
inner and outer
and while
slight preload
the suspension unit must be
Disconnect the hydraulic brake hose

adjacen t to
from the brake pipe and plug the pipe to
avoid leakage of hydraulic fluid
5 Remove the retaining bolts securing the caliper to
4
the chassis
replaced
the stub axle flange and withdraw the caliper assembly

6 Remove the dust cover arid split pin unscrew the
nut from the stub axle
7
Withdraw the hub and disc assembly from the stub
AND INSTAL
in the
cups into
position
I Drift the two hub bearing
hub ensuring that their tapers are opposed to each other
2
Pack the space in the hub between the cups with
axle
8
Remove the washer and outer bearing
the hub
HUB
BEARING
KEYED
BEARING CUP
NG CUP
B A
SEAL
t
o
B A
WASHER
NG
CAP
NUT
0dW
SPUT PI
BACKING PLATE
AND BRAKE ASSY
Exploded View of Front Hub Assembly with Backing Plate Assembly

118
Drum Brakes
cone
from
Front
3
Place the assembly in a vice and using a drift or

tool tap out the grease seal
10 tift out the inrier bearing cone re mount the
assembly in the vice and using a suitable drift iap out both
9
and
II
inner
Check the stub axle for
misalignment and the
inner
bearing seating area for scoring
hand
suitable
SUspension
Check the castellated nut and the lhread on the

for damage or wear If the thread is badly
axle
stub
bearing cups from the hub assembly

Remove the bolts connecting the disc to the hub
damaged
outer
the
suspension
unit must be
replaced
assembly and separate the disc from the assembly

TO CLEAN AND iNSPECT
Assembly
Wash
solvents
the bearings cups hub assembly in cleaning

Inspect bearings and cups for scoring chips and
pitting if damaged replace
Inspect
the
Replace where
as
to that of removal
2 When
the
complete asseinbly
chipping or cracking
replacing the disc also
to
disc for distortion

When
necessary
Renew the
manufacturer
STABILlSER
Place
1
vehicle
stands
the
Chock
fit the
rear
wheels
raise
the
and
special spring clips
of the
front
support
on
jack
road wheels
engine splash cover
3
Remove the retaining nuts rubber bUshes and
washers attaching the stabiliser bar link to the lower
suspension arms
4 Take out the retaining bolts attaching ihe stabiliser
2
Remove the
supporting
to
chassis
the
stabiliser bar from the vehicle

5
Inspect the bar for distortion and
With
upwards
sweep of the
the bar with
the
urn
NOTE
the
stabiliser
mark to rhe
left
with
hand side
of
the
ends
nstai the
facing
in
the
self locking nuts

on the siabiliser bar
mounting bracket s
specified
Specification
section
vehicle is in the lowered
position
torque
see
Ensure
the
when
is carried out
painted
the vehicle
RADIUS
remove
Remove the
retaining
bolts
the
forward
end
attaching
nui
the radius
washer
of the
Hjd from the bracket on th under frame

Check the radius rod for distortion and fatigue Renew
rod
all nibber bushes and washers if necessary

Replace the radius rod where necessary
and rubber
radius
rod and
CUP WASHER
CUP WASH
RADIUS R D
n
STOP WASHER
the
ROD
withdraw the
to the lower support arm

2
Remove the retaining
from
link
Instal the engirie splash cover

6 Lower the front of the vehicle and
spring clips
TO REMOVE
bushes
its
bar
stabilisingbar
Renew
TO INSTAL
iden tification
and t st the brakes
holes Instal each half bush and washer on
final tightening procedure
Instal
see
mounting bushes and secure with bolts and lock wash rs

4
Tighten the nuts on the ends of the stabiiiser bar
all rubber bushes if necessary
NOTE
torque
flat washer and rubber half bush on each of

so that the flange of the half bush is
the erids of the bar link and fit the
link to the
fatigue
position
suspension
the
withdraw
and
specified
ihe stabiliser bar links

adja ent to the washer
Remove the
brackets
instructions
BAR
TO REMOVE
Tighten and adjust to

Specification sectiori
4 Bleed the hydraulic system
grease seal
reassembling the bearings to the hub pack

bearings and hub with heavy duty wheel bearing grease
3
renew the bolts

2
and installation procedure is the reversal

See also Drum Type Brakes
Nfl
RUB8ER BUSH
r
RUBBER BUSH
Radius Rod Forward Mounting 1200 Model

119
FLAT WASHER
lrn
Front
lO
Suspension
TO INSTAL
Installation procedure is the reversal of removal with
attention to the
Tighten
Specific3tion
set
and ensure
that
the
rods
are
2
The rods are marked L H and R H and must be
fitted accordingly
3
Ensure that the metal bush and rubber bushings are
fqllowing points
the nuts and bolts to the
ion
sec
fitted correctly
specified torque
seated correctly
a
TO
REMOVE
from
in the
fit
the special spring clips
to
maintain the coil
9 Disconnect the radius rod and stabiliser bar from

the lower suspension control arm
spring
compressed position
Raise ilie front of the vehicle and support with
jack stands
4
split pin
5
the
suspension unit Withdraw the backing plate

assembly from ihe stub axle and support the backing plate
to avoid
damage to the hydraulic line and hose
8 Withdraw the split pin and unscrew the castellated
nut securing the tie rod end ball bolt to the steering arm
Remove the ball bolt from the steering aim
I
Block the rear wheels Raise the vehicle wi th a jack
under the suspension control arm on the side that is to be
removed and rerilOve the road wheel
2 Wijh the full weight of the vehicle still on the coil
spring
UNIT
SUSPENSION
10
Place
Remove
jack
under the lower
suspension control
ann
Remove the hub grease retaining cap withdraw the

and remove the stub axle nut and washer
Withdraw the brake drum and hut assembly from
the stub axle Remove the outer wheel
the
control arm to the
12
bearing
Raise the
compartment
Where disc brakes are jilted use the procedilre for

removal of hub disc and calipaDisconnect the brake hose
13
bonnet
and working from the engine

retainjng nuts securing the
the upper support member
remove
unit to
suspension
NOTE
bolts securing the suspension

unit and ball joint
two
suspension
Lower the
the
jack
and
remove
the
suspension
unit
from the vehicle
mid plug the hydraulic line

6
the
Uriscrew the four
bacIdng plate
7
to
ihe
Now remove
retaining
stub i
Jhe
nuts
and bolts securing
TO CLEAN AND DISMANTLE
le flange
hydraulic
br
Iin
retainingc
lip
Prior to
dismantling
thoroughly and en iUre

prior t6 dismantling
2
that
of the suspension unit clean

clean working area is available
Fit the strut attachment
tool ST35650000
tn
the
buter
casing and mount in a vice Fit coil spring

compressor to the suspension unit and compress the spring
until the insulator can be turned by hand
strut
NOTE
the lock nut from the piston rod instal

of the bolts connecting the suspension to the
bodv and llsing as a lever base app v a screw driver to the
lock nut Ind using a levering action release the lock nut
a
nul
To
Il
renlOve
one
Remove the
bearing spring
se
suspension mounting insulator
bumper rubber
and dust
Back off the spring compressor and
thrust
cover
remove
the coil
spring
5
Using special gland packing
gland packing
wrench
remove
the
NOTE
Prior to removal push the piston rod down to the

lowest point clean the gland nul and surrounding area
If
the
seal and
n Side
Ori
Suspension Unit
gland packing nut has

gland nu t
been caulked
break the
remove
6 Pull the piston rod slowly upwards remove the 0

ring from the tnp of the piston goide and withdraw the
piston rod and cylinder assembly
1200 Models
120
Front
Suspension
II
NUT
1
WASHER
ISTON
ROD
t
8EARING
STU
r
STRUT ASSEMBLY
e
U88ER
BUMP
Strut and Coil
Spring Assembly
Strut and Coil Spring
1200 Model
Do not remove the piston rod and g

1ide
cylinder as they are serviced as an assembly
from the
NOTH
To
suspension
3

oil
Drain
the
from
casing
and
wash
cylinder
Inspect
the
spindle
for distortion Check the base
general
thrust
Check
bearing
for
pitting
instal
outer
i
faulty operation
casing
to
the
piston
the
rod and cylinder assembly in the

with the specified quantity
casjng
special tool No ST35550000 gland packing guide
gland
packinf
and check
NOTE
scoring
unit bo y
Place the
se
to
fatigue
the
4 Fit the 0 ring to the top of the piston rod guide

and assemble the gland packing Take care not to damage
the oil se l during assembly
cracks
4
and result in
fit
hydraulic fluid
be osed every time the assembly is dismantled

3
Check the strut outer casing for distortion and
and threaded section for fatigue

5
Test the coil spring for sag and
rubber components
1200 Model
and type of oil

The operating efficiency of the suspension unit is
greatly influenced by the specified quantity and quality of
components and dry off with ompressed air

Non metalic parts to be cleaned by air only
2
New gland packing 0 ring and hydraulic fluid is
to
cylinder
reassemble
casing and fill
outer
I
in the
lodge
could
ponimts
Co
and
Prior
the piston
bleeding of
wear
to
rod
tightening the gland packing
approximately
90
mm
nut
3 54 in
to
withdraw
f cilitate
the shock absorber
TO ASSEMBLE
5
1
Avoid
Prior
damage
to
assembly
ensure
to work ng parts
Do not use cotton
waste
that all parts
are
clean
packing
they are precision ll1ade

for wiping down Particles
Using special
nut
to
the
tool ST35500000
specified
torque
tighten the gland

see Specification
section
as
121
Bleed
the
air
from
the
shock
absorber
by
12
Jlront
Suspension
up and down until all au is expelled

This is carried ou t in the foHowing manner Have the
down position when the piston is drawn
pumping he piston
spindl
l tI1e
upwards and the spindle
piston is pushed down
Expulsion
by
in the upper
positian
anu oil
Fit
the
al
are
new
specified
when the
torque
Remove
unit
suspension
of all air from the system can be determined

in either direction of the piston
lubricated pnor w assemblY

washer and self locking nut and tighten
the
to
see
Specification
to
section
coil spring compressor and fit the

the vehicle Renew all parts where
necessary
even pressure
Fully extend the piston rod and fit the coil spring
spring seat and dust cover Compress the coil
spring and fit the bearing assembly and mounting insulator
7
bump
TO INSTAL
rubber
NOTE
Ensure
that the thrnst
bearing gland packing

6
IItIC
SVSPENSION
Using the reverse procedure to that of removal

the specification
observing torque settings set out in
section fit the suspension unit to the vehicle
ONTROI
ARM
Check the rubber bushings for damage and or

Should the rubber bushing require replacing mount
the control arm in the press and remove the bush from the
2
TO REMOVE
fatigue
wheels raise the front of the vehicle
stands Remove the road wheel
2
the retaining bolts and nuts connecting
Ref
1ove
the iadi
rod and stabiliser bar to the control arm
3
Remove the lower ball joint retaining bolts
4
Unscrew the retaining nuts connecting the control
I
Block the
and support with
arm
to the
from the
rear
jack
body member
control
arm
To replace the bushing lubricate the bushing with

and fit the
soapy solution mount the arm in the press
to
arm
the
bushing
Ensure that the bushing protrudes equally from either
end of the
and withdraw the control arm
arm
collar when fitted
member
TO INSTAL
TO INSPECT
Insta11atio
conirol arm and inspect the metalic

1
section for distortion and fatigue Replace if damaged
Clean
procedure
is the reverse to that of
removal
the
NOTE Tightening torque for respective nurs and bolts are

contained in the Torque Setting Specification section
WASHER
UT
FU8B R BUSHES
BOLT
LOWER BALI
JOINT
Lower Control Arm and Ball Joint
Components 1200 Models
TO REMOVE
joint retaining
raise the vehicle and support

Remove the road wheel
Remove the bolts and nuts attaching the stabiIiser
I Block
on jack stands
the rear wheels
steering
nut and disconnect the ball
joint from
the
arm
Remove the two bolts connecting the steering arm

suspension unit and remove the steering arm
6 Mount the steering arm in a vice remove the split
5
bar and radius rod to the lower control arm

3
Take out the retaining bolts attaching the stub axle
to the
assembly and suspension unit to the st ring arrrl

4 Withdraw the split pin remove the tie rod ball
pin
arm
122
and castellated nut and withdraw the ball bolt from the
Front
Clean the ball joint in suitable cleaning fluid and
when found
4
ball
join
for excessive end
play
of torque
required
be defective
base
of
To lubricate the ball joint
the ball
is
Installation
35 60
kg
within
all times
TO INSTAL
to move the ball
reading should be between

If the readings are not
ai
remove the plug at the

joint fit a grease nipple and fill with grease
until old grease is expelled When lubricating with high
pressure gun ensure dust cover is not damaged
NOTE
should be replaced
3
Check the shaking torque by mountiog the ball
joint in a vice and attaching a spring gauge to the top of the
ball joint bolt beneath the castellated nut and measure the
The torque
in
30 52 Ib
to
Renew the dust cover
and
metal fatigue
When the end play between the upper spring seat and
top of the spring exceeds 1 0 mm 0 039 in the ball joint
amount
13
tolerances the ball joint should be replaced

The ball joint is not repairable and must be renewed
carry out inspection

2 Inspect the
Suapenaion
em
removing
Tightening
these
the
torque
procedure
reverse
is
set
in
out
the
to
that
of
Specification
section
8 SUSPENSION ASSEMBLY
3
TO REMOVE
with
I
on
jack
Block the
rear
wheels raise the vehicle and support
stands
Disconnect and plug the left and right hand brake
hose then
remove
Remove the radius rod from the vehicle
Disconnect the stabiliser bar from the chassis
engine
Using
suitable
and remove the
engine lifting device support

engine mounting bolts from
the
the
member
6 Place a floor jack under the
crossmember and supporting the meniber
connecting the member to the chassis
7
Remove
self
the
locking
nuts
centre
remove
suspension crossmember for cracking

mounting bolt holes
attention to the
the lower
control
arm
for distortion
or
ge
5
Remove
of the
Replace
component parts where necessary
the bolts
TO INSTAL
connecting
the
Installation procedure is the reversal

suspension units to the upper support members

8 Lower the floor jack slightly and withdraw the
suspension assembly from the
the
the brake drum and hub assembly and

inspect the bearings and stub axle Where disc brakes are
fi tted inspect the disc distortion and fatigue
6
Check the coil springs for sag and cracking
7 Inspect the strut for distortion and upper support
mounting for cracking
8 Check the ball joint operation
retaining spring clips
the hose
Check
particular
4
Inspect
to
that of removal
the
stabiliser
bar
with
the
1 Instal
paint
identification mark fitted to the left hand side of the
vehicle
vehicle
Instal the radius rods
the vehicle
I
fatigue
Inspect all insulator rubbers
and rubber bushes for
fi tted in this
and wear
2 Check the stabiliser

distortion and thread damage
bar
and
radius
rod
for
manner
Lubricate all applicable points
CarTY
out
adjustments
and
torque
settings
as
ANGLES
TO CHECK AND ADJUST TOE IN
Prior to carrying
out
wheel alignment select
to carry out the necessary
area
Inflate tyres
to
With the vehicle on
level floor
jack
up the front
of the vehicle
adjustments
2
Carry out a thOtough inspection of the steering
linkage front wheel bearing adjustment suspension joints
and rods springs and suspension unit recoil action Replace
or repair where necessary
3
Inspect the tyres for even tread If found defective
with
serviceable tyres
replace
4
to their respective sides on

marked LH and RH and must be
SUSPENSION AND STEERING
ADJUSTMENT
are
annotated in the Specification section
clean and level
The rods
Spin
chalk mark
each front wheel in turn and using a piece of

line around the periphery ofeach tyre as near
to the cen tre as
possible
of the vehicle to the floor and

bounce the vehicle up and down several times and let it find
its own level Set the front wheels in the straight ahead
3
position
correct pressure
123
Lower the front
14
Fronl
SuapemiOn
the
Mark
approximately
in front of the
suspension
the
Using
two
front
line
centre
208 254
both
on
tyres
at
10 in above the floor and
mm
suitable telescopic gauge place it between

tyres on the chalk marks and record the
distance between the centres of the tyres

6
Maintaining the wheels in the
straight ahead
position roll the vehicle forward until the marks are the
same distance
above the floor but to the rear of the
suspension
7
Again
gauge to measure and

record the distance between the marks on the tyres The
distance measured at the front of the tyres should be less
use
the
telescnpic
than the measurement at the rear of the tyres

8
If adjustment is required loosen the lock nut on
each end of each tie rod and turn each rod by equal
amounts until the toe in is correct
Tighten the four tie rod lock nuts
NOTE
is
important
make
to
equal adjustments
on
the manufacturer
necessary adjust as previously described

4
Check the caster camber and swivel inclination
according to the instructions set down for alignmen t

equipment being used and compare with the manufacturers
specifications
5 If the caster angle is incorrect check the radius rod
brackets and rubber bushes Also check the suspension
control
rubber pivot bushes for wear

If the camber and swivel inclination angles are both
incorrect check the suspension unit upper mounting and
instlUcnons
arm
lower ball joint for wear orlooseness Check the suspension

control arm for distortion and its rubber pivot bushes for
wear
7
If the swivel inclination angle is correct and the
camber angle is incorrect the stub axle is bent A new
suspension unit should be installed
each
tie rod to maintain the central position of the steering gear

f an optical or other type of toein guage is used
follow
vehicle up and down several times and let it find its own
level
3
Check the front wheel alignment toe in and if
Measure the toe
either
or
or right
unequal length
may be ben t
In the latter case
and the
Before any attempt is made to check the camber or

caster angles or to check and adjust front wheel toe in the
suspension unit should be thoroughly checked to ascertain
I
a serviceable condition
The tread of the tyres should be examined for excessive
uneven wear as certain conditions of tyre wear are
that it is in
or
of damaged or worn componen ts in the

suspension steering linkage and or wheels and bearings
The vehicle shoold be unladen except for the normal
indica tive
amount of
petrol
oil and wateI
the normal pressure

2
Check and
vehicle
with
up
according
with the tyres inflated to
of the front wheels
or one or
the steering
steering linkage
The
Note
toe out on
re
both
armis
steering
must be renewed
adjusted
maximum minimum
steering angle
toein
also detennined by the distance

between the face of the adjustable stop fitted to the
steering arm and the bracket on the rear of the lower
control arm when the wheels are turned from lock to lock
toeout on
is
turns
adjusting the steering angle by stop adjuster

the distance between the radius rod and the tvre is
When
ensure
81 in
less than 30 mm
Should the clearance be
less than specified adjust the angle stop outwards until a
length reading not exceeding 27 5 mm 11 083 in on the
not
adjust
the tyre pressures and set the

9
For
angle
Specification
section
alignment equipment being used
to the manufacturers instructions
FRONT
Bounce the
and
adjustment
settings
SUSPENSION FAUI T DIAGNOSIS 1200 SERIES
I Front end noise

Possible
Remedy
cause
Loose upper suspension mounting
or
Tighten mounting andlor adjust piston rod bearing
piston rod
bearing
Loose
or worn
suspension
d
e
Mal
adjusted
front hub
Adjust tighten
unit lower ball joint
Noise in shock absorber unit

Worn steering linkage or idler
arms
stop adjuster bolt is obtained
the
10
turns
hand turn is incorrect then the
both left
tie rods are Gf
TO CHECK CAMBER AND CASTER
out on
using the equipment according to instructions

If the toein is correctly adjusted and the
arm
or renew
lower ball joint
Renew shock absorber unit

Renew defective components
components
Readjust
bearings
124
or renew
hub
bearings
see
Front
2
15
Heavy steering
Possible
Remedy
cause
Check tyres and inflate
Steering
Check and
Lack oflubricant in steering linkage joints
gear
Ascertain
readjust
cause
steering linkage
d
Front suspension
worn
Mis
alignmen t between steering

mountings
Soft or sagging front springs
Steering pulls
Uneven tyre
Incorrect front end
d
e
steering
where
align
applicable
wear renew
worn
components
end
front
Check and align steering gear and column mountings
gear and column
Renew springs and check front end alignment
to one side
Possible
re
recommended pressures
to
gear
of loss of lubricant and lubricate
Check front end for
or out of alignment
and
Suapenaion
wear or
Remedy
cause
Check condition of tyres and inflate to recommended
pressure
pressures
Check front end
alignment
Dragging brakes
Broken or sagging rear spring so
Broken rear spring mounting bolts
Damaged front suspension or front
alignment
Check and adjust brake shoes

Renew
Renew
sub frame
faulty springs
faulty components
Check and
renew
damaged
Check and
renew
front crossmember
components
members
Faulty
or
damaged front crossmember
Front wheel wobble
or
shimmy
Possible
Looseness in
Uneven tyre
and
Tyre
Front
I
g
h
or
Remedy
cause
steering
wear or
Rectify
gear
incorrect tyre pressures
wheel unbalance
or
worn
adjust
pressures
Check and balance
as
to
recommended
necessary
Check and rectify front end damage and alignment

Check condition and adjust wheel bearings
damaged or out of alignment

Worn or badly adjusted front wheel bearing
Front wheel align men incorrectly adjusted
Loose
and
Check condition of tyres and inflate
Check and
tie rod ends
Check and
Check and
Faulty shock absorbers
adjust front wheel toe in alignment

renew faulty components
renew as a pair
Steering erratic or wandering
Possible
a
b
c
d
e
Remedy
cause
Check and renew components to
Incorrect
or uneven camber and or castor setting

Smooth front tyres
Excessive play in steering gear and or linkage
Check and
renew
tyres
as
rectify
necessary
Check and renew faulty components readjust

Check and inflate to recommended pressures
Excessively high or low lyre pressures

Loose or incorrectly adjusted front wheel
Check and
bearings
125
adjust front wheel bearings
REAR
SUSPENSION
I IA TIO
SPE
Type
Semi
elliptic
Station wagon
leaf
spring and
double acting
7 and 11 mm
0 236 0 275
and
shock absorbers
Spring length
433
0
in
1I10mm
43 70 in
1000 SERIES
Spring
Spring width
50mm
free camber
Sedan and conpe
100mm
Station wagon
131mm
4 291 in
1968 in
Leaf thickness
Sedan
5 157 in
7mm
Spring
0 275 in
Station wagon
Spring
mm
and
433
0
eye diameter
Front
35mm
Rear
23mm
377
1
in
1150 mm
45 275 in
156mm
I67mm
6 574 in
6 142 in
Coupe and
161 5mm
station wagon
180mm
7 086 in
in
358
6
Number of spring leaves
Shock absorber stroke
in
0 905 in
Shock absorber stroke
Sedan
Spring free camber
StMion wagon
mm
0 433 in
0 197 0 275
Sedan
II
7 and
II
Spring length
laden camber
160mm
6 299 in
Shock absorber mounting
nuts
1200 SERIES
Spring
width
Spring
50mm
kg
I8Ib
ft
4kg
29Ib ft
1 968 in
Shackle bolt nuts
Leaf thickness
Sedan and coupe
U bolts
2 5
Front
6 and 7 mm
0 236 and
4kg m
29Ibjft
2 5 kg m
Rear
0 275 in
18Ib ft
I
The
rear
suspension comprises
semi
elliptic leaf springs
with double acting type tubular shock absorbers

The shock absorbers are mounted just to the
axle
housing
and connect
to the
RIPTION
DES
rear of
the body The third pin and rubber bush are fitted
lower section of the spring hanger through the
the
spring mounting plate
The rear end of the
at
two
rubbers
by
the
1200 Series differ to the

conventional type in that they are mounted on the shock
absorber spindle
bump
on
spring on 1200 Series is connect

s
plates three shackle pins and nu
complete with rubber bushes Two shackle pins passing
through the upper section of the plate insulated by rubber
bushes connect the upper section of the spring hanger to
by
plates
two U bolts with self locking nuts and mounting plate

Plastic inserts are fitted to the ends of the lower spring
leaves to reduce metal friction
The front end of the
to the vehicle
to
the
upper and lower shackle pins and bushes

The spring centre bolt is located in a hole in the axle
housing bracket and the spring is attached to the assembly
the lower end and to the body at the upper end

Shock absorber mountings are in the form of rubber
bushes
The
spring is connected
to
spring eye
the body by
The only mounting variation between the 1000 and

1200 series is thar the front end of the rear spring of the
NOTE
two
1000 series is connected direc ly to the chassis by a single

shackle pin and insulating rubber bushes through the spring
eye
126
Rear
or
damage
cannot
Raise
the
of the
wheels and support
on
vehicle
block
5
bushes
axle
2 Disconnect
the
shock
attachment at its upper end
3
Disconnect the
lowet
absorber
at
the
be
and
for
repaired
fluid leakage The shock absorbers

and should be renewed if
in service
found defective
the front
under
the rear
stands
jack
placed
rear
Inspect
the
retaining
which
to
special
LOCKNUT
shock absorber
is
can
JT
HER
WA
equipment
testing
rubber
end of the shock absorber at
TO TEST AND BLEED

extent
and
required
body
under TO TEST AND BLEED
The
washers
nuts
Renew the rubber bushes as
the spring plate attachment and remove the shock absorber

from the vehicle
Installation procedure is the reversal to that of removal
Check test and bleed the shock absorber as described
without
SHO
K AUSORIIERS
Suspension
TOt
SHOCK ABSORBER
RU
BER
be tested
limited
to
the
following
upright in the vice by
mounting eye or stem
2
Grasp the upper half of the shock absorber pull up
to the fully extended position and then slowly push down
until the shock absorber is fully compressed
3
Repeat operation 2 several times to remove any
slack spots caused by air in the system If slack spots exist
and cannot be removed by this f1ethod the shock absorber
is obviously defective and should be renewed
I
Mount the shock absorber
the lower
NOTE The resistance will be greater on the upward stroke

ofthe shock absorber than on the downward stroke
4
Check the
Shock
body of the
Absorber
shock absorber for
with
Assembly
Component
SHOCK
denting
SPRlNf S
7
Support the axle housing on stands and lower the

spring to the floor Remove the rubber bushes
from the body and spring
8
Remove the nut s from the spring front mounting
s
and
withdraw the pin so Lower the spring to the floor
pin
and remove the bushes from the spring eye and body
9 Inspect the spring for sag and cracking
rear
Jack up the vehicle and support

the rear
on
stands placed
spring front hanger
With a jack under the centre of the fear axle case

the axle assembly sufficiently to take strain off the
shock absorbers
2
raise
Disconnect the shock absorber lower mounting at

spring mounting plate and push the shock absorber up
clear of the axle housing
3
the
Lower
springs remove
mounting plate
5
the
the nuts
Remove the
to
10
Check rubber bushes for
II
Check shackle pins for wear and cracking

Replace all worn or damaged parts
fatigue
where
necessary
TO ASSEM OLE AND INSTAL

rear
shackle nuts and washers
Remove the shackle plates noting the position of

the shackle pins the retaining nut is installed towards the
centre
of the
12
take the weight off the

from the V bolts and take off the
housing
MOUNTING
1200 Models
TO REMOVE AND OISMANTLE
LOWER
Rubber
Bump
just forward of
ABsoRBER
Install the front spring eye bushes and the bushes
1200 only in the chassis with the special tool used to re

move the old bushes Ensure that the bushes are fitted cor
of the vehicle
rectly
127
Rear
SU31Xm3ion
SUMP RUBBER
SHACKLE PLATE AND PINS
SY
A
NUT
WASHER
tn
CAP
UBOLTS
SPRING EYE
BUSH
PLATE
SPRING BUSHES
SHACKLE PIN
SPRING EYE
J
I
PAO
PLATE
WASHERSYV
B SH
WASHER
NUTS
NUT
OJ
AND
View of Rear
PLATE
JI
PAD
WASHER
Ope
Exploded
PINS
CAP
NUT
it
Li
SHOCK ABOSRBER BUSHES
SPRING ASSV
AACKlE
CENTRE BOLT
U BOL T NUT
AND
WASHERS
PLATE
Spring Components
1000 Models
Lubricate the bushes with a liquid soap prior to fitting

2 Instal the rear bushes in the spring eye and spring
ASY
hanger
Refit the spring to the vehicle using the
procedure
points
to
removal
attention
Do not tighten the V bolts
specified torque
CLAMP
with
or
the
spring
and
to
nuts
rear
the
reverse
following
in excess of the
axle casing may be
affected
b Do
weight of
not
fully tighten the
the vehicle is on the
shackle bolts until the full
wheels This will prevent

the rubber bushes from being overstressed when in the
normal working position
rear
SlR NG BUSHES
tI
11
I
SPRING
ASSY
cI
SHACKLE PLATE
Ci
WASHERS
Exploded
sPRING ASSY
NUTS
View of the Front Hanger of the Rear

1200 Models
Exploded
Spring
View of the Rear Shackle
Spring
Assembly
1200 Models
128
of the Rear
ANO
PINS
Rear
4
1 Noise in
SIOFAITI T III
SITSI
U OSIS
suspension
Remedv
Possible cause
Defective shock absorber and or mounting

Loose or worn rear shackle bolts and bushes
Loose
Broken
Sprong or
Worn
g
h
Faulty
Loose
spring anchor bolt and

spring leaf or leaves
or worn
rear
or
Tighten
Tighten
boshes
or
or
or renew loose or worn

or
Renew axle
bent axle tube
overtight spring seat

spring leaf clamps
broken
loose
renew
or worn
or
components
complete spring
casing
Check and
renew inserts
Check and
adjust
Tighten
renew
or
components
faulty clamps
with front wheels
alignment
Possible
faulty components
Renew broken leaves
deteriorated spring leaf inserts
2 Rear wheels not in
or
Renew
Remedv
ause
I
Broken main leaf of spring
forward of spring
Renew main leaf
or
complete spring
Renew main leaf or
complete spring
seat
Broken main leaf of spring at
rear
of spring
seat
c
el
Broken spring mounting bolts or
rear
shackle
Renew
one side
3 Rear brake locked
on one
components
spring
casing
Renew axle
side
Possible
Remedv
cause
Broken spring main leaf forward of spring
Broken
Broken
spring
spring
fauity
Renew defective
Spring badly sagging

Sprong or bent axle casing
on
Renew main leaf or
seat
centre bolts
Renew
anchor bolt
Renew
129
complete spring
spring centre bolt
spring anchor bolt
Sllspension
4
BRAKES
SPECI
Type
ICATIO
Braking
front
1000
Drum
1200
Disc
area
Front drums
Rear drums
Fnot brake
Hydraulic
Front discs
Handbrake
Cable
rear
cm2
14 0 in2
Wheel cylinder
drums
Front and
203 2
Dot of roond limit in diameter
0 05 mm
rear
diameter
Rear diameter
1746
Piston clearance limit
204 2 mm
Caliper cylJllder
Thickness
48 1
212 5 mm
370
8
in
Diameter
9 5
4
8
Machining limit
Master
cylinder
Diameter
1746mm
0 687 in
0 13mm
0 005 in
0 03 mm
0 0012 in
1200
Brake
42 5 mm
1 673 in
10 3
Thickness
Length
5 570 in
Available brake pedal height

adjusting shim thickness
linings
35 0 mm
Width
378
1
First size
0 50 mm
Second size
0 80
0 0197 in
in
4 8mm
Thickness
mm
0 0315 in
0 189 in
195 0 mm
Length
mm
1415mm
1200
mm
2 091 in
rear
144 5
5 688 in
in
53 1
pedal height
1000
mm
406
0
0 15mm
0 006 in
in
mm
0 331 in
Run out limit
mm
1 894 in
mm
374
0
Front and
0 15mm
0 006 in
1200
Diameter
Front pads
Width
mm
0 687 in
8 039 in
Front disc
64 mm
1200 with disc
only
0 002 in
in diameter
20
0 812 in
mm
8 00 in
Machining limit
in2
3
90
rear
Diameter
in2
cm2
273
t42
wheels only
Front and
em
42 3
Drum
Type rear
Operation
273
drum
or
1 60mm
Third size
0 0630 in
7 680 in
Calliper securing
bolts
Master cylinder securing bolts
kg m
44 ft
lb
Backing plate retaining bolts
3 7
Wheel cylinder securing bolts
2 2
21
Brake
kglm
pedal
fulcrum pin
27 ft lb
Brake disc retaining bolts
kg
16 ft
5 9 kg
lb
Brake pipe connection
2 2
Brake hose
kg
l6ft
lb
ft lb
2 9 kg m
21 ft lb
18
kg
13 ft lb
2 0 kg
14 ft lb
43 ft lb
Rear brake adjuster securing bolts
2 9 kg
Master cylinder cap bolt
130
3 5 kg m
25 ft lb
Brakes
IlIPTIOI
DES
DRUM BRAKES
applied
The four wheel

standard
as
hydraulically operated
equipment
to
all
drum brakes
are
1000 and 1200 models
Two leading sho lype brakes are jilted un each uf the

front brake assemblies and trailing shoe type on each rear
assembly
The
frunt
brakes
operate each shoe

operated by a single
use
whereas
separate wheel cylinder to

the rear wheel shoes are
ended type whee
DISC BRAKES
The
wheel
cyJinders aJso incorporate the
handbrake operating levers which protrude from the rear
backing plates Handbrake cable pull applied at the outer
As
J 200
ends
of the levers allows the inner ends of the levers to

operate directly on the rear wheel cylinder pistons
rear
wheel cylinders
for the
rear
The
safety
item
for high speed
available with
are
driving
front
later model
wheel disc type
caliper assemblies
are of the
floating type and
lateral direction
As found with most disc
type brakes the assemblies
not
allowed to float in
are
are
self adjusting and
require no adjustment in service As pad

wear takes
place the caliper piston is allowed to slide
outwards through its seal to take
up a new position in the
caliper cylinder bore
When the brakes are in the off position a minimum of
brake shoes
Each front brake shoe is adjusted by a hexagonal

headed earn which is located on the outer section of the
brake
vehicles
brakes
rigidly attached to
their respective backing plates and are capable of sliding on
the plates within limits to provide a self centring action
are
which
cylinder only
rear
The
A square end on the outer
portion of the adjuster

protrudes through the brake backing plate
enables rear brake shoe adjustment to be carried out
The single and the dual circujt type master cylinders
are operated
directly by a push rod from the pendant type
brake pedal
The hydraulic system incorporates bleeder valves at the
dual type master cylinder and a bleeder valve at each of the
wheel cylinder assemblies
and
fitted
backing plate
Rear wheel shoe
adj stment is made available by a

single tapered adjuster unit bolted rigidly on the brake
backing plate positioned diametrically opposite the wheel
cylinder The adjuster operates on both shoe at the same
clearance is maintained between the pads and disc

Elastic deformation of the piston seal on the piston
takes place when the brakes are applied and returns the
time and also acts
released
as
shoe anchor when the brakes
SIX iil E
piston
are
JIR
UIT
to
its
STER
normal
off position when the brakes
are
YLlNDIlIl
TO REMOVE ANDINST AL
I Raise
the
engine bonnet
both front fenders

2
Disconnect the brake fluid pipe at the front end of
the master cylinder and plug the pipe to prevent entry of
dirt
3
Remove the
spring pin and withdraw the clevis pin

cylinder push rod clevis and pedal
4 Unscrew the two nuts securing the brake master
cylinder to the engine bulkhead and remove the cylinder
from the
NOTE
master
Care
should
be
exercised when removing or

installing
assembly to ensure that brake
fluid is not permitted to drop onto the surrounding
paintwork of the vehicle Brake fluid if accidentallv spilt
should be immediately washed away with water and then
allowed to dry natural v and not wiped with cloth
the master cvlinder
IIlstallation
attention to he
is
following
Fill the master cylinder reservoir with clean brake fluid

Bleed all air from the system as described in the
HYDRAULIC SYSTEM section
Single
Circuit
Type
Master Cvlinder Mounted
Bulkhead Typical
131
on
Engine
Brakes
the brake
Adjust
pedal height
oomponen ts of the cylinder

prove to be unserviceable
7 Renew all
See rel vant section for
that upon
adjusting procedure
checking
assembly
Check the master cylinder for fluid leaks

NOTE It is always advisable tu instal new UPS check valve
dust boot to a master cylinder that has been
and
TO DISMANTLE
This
dismantled
the reservoir cap and seal and drain the
I
fluid from the cylinder reservoir
2
Pull back the dust boot from the rear end of the
service
Remove
cylinder
and with a suitable
the snap ring

3
From the
pair of
snap
ring pliers
I Soak all internal components of the cylinder in

c1ean hydraulic brake fluid before assembling
2
Carefully instal the secondary cup to its recess in
the
careful not to
5
secondary
the piston
SCore
Loosen the reservoir to
piston being
cup from the
piston
Ensure that the leading lip of the cup is facing

front of the piston
order
Remove the
Instal
cylinder retaining clip
the
check valve seat
scoring
3
Check the master

or
cylinder
in clean
bore for excessive
the piston for pilling
or
scoring
Check the piston to cylinder clearance and renew
the piston and or cylinder if the clearance is in excess of
that specified see SPECIFICATION section for piston
4
6
or
or
Fit the
reservoir
eN AND SEAL
of the
cylinder
seal
and bleed
the
V
C
Check the piston compression spring for weakness
rusting
RESERVOIR
SECONDARY CUP
rs PIN
CHECK VALVE SEAT
PRIMARY CUP
and
cap
distortion
rear
cylinder by hand by slowly pumping the piston via the push

rod at the rear of the cylinder until all trapped air is
expelled from the cylinder
clearance limit
5
Check the lips on the primary and secondary cups
for wear and the check valve rubber fnr swelling
perforation
the
to
making sure that the dust boot is positioned correctly over

its retaining lip on the cylinder body
6
Attach the reservoir to the cylinder and fit and
securely lighten the reservoir retaining dip
7 Fill the reservoir with clean hydraulic brake fluid
wear
excessive wear
spring
rear
ring
snap
Instal the dust boot
pitting
Inspect
the
cylinder
cylinder and instal the
to
end of
Ensure that the leading lip of the primary cup
is facing towards the front of the cylinder
4
Fit the push rod assembly to the rear of thc
the
thoroughly
check valve
in that order into the
primary cup and piston
and
detach the reservoir
I Wash all component parts

brake fluid or alcohol
thorough overhaul and long
TO ASSEMBLE
cylinder withdraw the

push rod assembly with dust boot piston primary cup
return spring check valve and check valve seat in that
4
remove
end of the
rear
ill ensure
l
from the unit
BOOT
cUP
illl
ON
SPRING PIN
PUSH
ROO
ASSV
nu u
CHECK
RETURN SPRING
IR
UIT
The dual circuit type master cylinder assembly

introduced as a safety factor on later type vehicles and
be of either Nabco or Tokico manufacture
VALVE
cyLINDER
BODY
Dismantled View of Single Circuit Type Master Cylinder

ST
II
was
the
can
system
The
dash
panel
UND
when
malfunction
occurs
within
the
switch is actuated by a shuttle valve when a

3 and 17 kg 185 and 242
difference
of lH
pressure
is
encountered
between
the
two hydraulic circuits
psi
hu
The front and rear brakes are

circuits
remaining
If
malfunction
circuit is
capable
applied by independant
occurs in
one
circuit the
of stopping the vehicle safely
The complete switch assembly should be renewed if

found to be unserviceable Under no circumstances
NOTE
switch
warning light
if corporated within the system allows a bulb to glow
A brake line pressure differential
it
is
should
on
132
an
attempt be made
to
repair the switch
4
Brakes
Pull back
the dust boot from the
rear
end of the
cylinder
Raise the
Using a suitable pair of snap ring pliers remove the

and
snap ring from the groove at the rear of the cylinder
detach the push rod assembly
5
Tap the open end of the cylinder on a block of
wood and allow the primary piston assembly to become
dislodged from the cylinder bore
6
Using the same procedure remove the secondary
from the cylinder bore
assembly
piston
7
Using the correct fitting ring spanner and with the
master cylinder body assembly securely clamped in a vice
4
bonnet and fit fender covers to
engine
both front fenders

2
Disconnect
outlets on the
the
two
cylinder plug
brake fluid pipes from the

the pipes to prevent entry of
dirt
split pin and
Remove the
withdraw the clevis
pin
from the master cylinder push rod clevis and brake pedal
Unscrew the two nuts securing the brake master
4
cylinder to the engine bulkhead and remove the cylinder
should
Care
NOTE
installing
fluid is
exercised when
be
the master cvlinder
permitted
not
to
paintwork of the vehicle

Brake fluid if accidentally spilt
should be
away
and
wiped with cloth
attention
given
to the
Fill the master
following
cylinder reservoirs
surrounding
immediareZv
naturally
procedure
two
bolts and washers from
cap
the
front
underside portion of the cylinder body

8
Lift out the front and rear check valve and spring
assemblies from the cap bolt apertures
Unscrew and
remove
from the
the bleeder valve s
side of the cylinder body

10
If found necessary loosen the reservoir retaining
clips
Installation is
the
remove
or
that brake
with water and then allowed to drv
washed
not
removing
ensure
assembly
drop onto the
to
and detach the reservoirs

11 Withdraw the spring
spring retainer and then the

primary cup from the spigot on the front end of the
secondary piston
the two
12 Using a suitable blunt instrument remove
of the
from
rear
end
seco
rubbers
the
ndary
opposing
secondary piston Be careful not to score the piston during
this operation
witl
with clean brake
fluid
Bleed all air from the system as described in the

HYDRAULIC SYSTEM section
Check the brake pedal height and adjust if necessary
See relevant section
13
Remove
bolt
the
from
the
aperture
of the
retainer and dismantle the two
TO DISMANTLE
spring
primary piston spring
retainers primary cup and shim from the spigot end of the
primary piston
14 Again using a blunt probe remove the secondary
careful not
cup from the recess in he primary piston being
to score the piston
NABCO
1 Remove the reservoir caps and seals and drain the

hydraulic fluid from the cylinder and fluid reservoirs into a
suitable container
2
screw
Unscrew
with
and
sealing
the secondary piston stop

from the side of the master
remove
washer
TO DISMANTLE
TOKICO
cylinder body
Remove the reservoir caps and filters and drain the
hydraulic fluid from the cylinder and fluid reservoirs into a
suitable container
Pull back the dust boot from the
2
BLEED VALVE
rear
end of the
cylinder
Using a suitable pair of snap ring pliers remove the

ring from the groove at the rear end of the cylinder
3
snap
RETAINER
I
t
CYLINDER BODY
SEAL
CAP
SPRING
BOLY
PUSH ROD
WASHER
SPR
ddd
STOP SCREW
CAP BOlT
BOLT
RETURN
Exploded
SPRING
RETAINER
PRIMARY
PISTON
SNAP
RING
DUST BOOT
View of NABCO Dual Circuit Master Cylinder Components
133
Brakes
I
RETURN
STOP WASHER
SPRING
SNAP RING
Exploded View of TOKICO Dual Circuit Master Cylinder Components

and detach the push rod assembly
4
Tap the cylinder gently
5
on
block of wood and
to
Lift out the front and
from the cap bolt apertures

7 Dismantle the spring
rear
retainer and
probe
NOTE
secondary
piston
assembly
is
and
the
primary
TO ASSEMBLE NABCO
1 Soak all internal components of the cylinder in

clean hydraulic brake fluid before assembling
2 Carefully instal the new cups to the primary and
preset
secondary piston assemblies Ensure that the shim is fitted

behind the primary cup of the primary piston and that all
piston cups except the rear cup on the secondary piston
have their leading lips facing towards the front end of their
respective istons
at
manufacture and should not be dismantled If components

of the assembly are unserviceable then renew the complete
piston assemhZv
9
and the check
Once a cvlinder is dismantled it is always advisable

instal
all new rubber components This will ensure a
to
thorough overhaul and long service from the unit
has to be used
The
wear
NOTE
cup from the spigot which is situated at the front end of

the primary piston assembly
8 Remove the secondary cup from the primary
piston rear groove being careful not to SCore the piston if a
blunt
lips on all cups for

swelling or distortion
7 Renew all components of the cylinder assembly

that upon inspection proves to be unserviceable
check valve assemblies
spring
the
6
Check the piston compression springs
check valve springs for weakness or rusting
primary and then the secondary piston assemblies

become dislodged from the cylinder bore
5
Using the correct fitting ring spanner and with the
master cylinder securely clamped in a vice remove the two
of
cap bolts and washers from the front underside portion
the cylinder body
allow the
Check
valve rubbers for
Unscrew the bleeder valve ftom the side of the

NOTE Instal the secondary cup of the secondary piston
with its leading lip facing towards the rear portion of the
cylinder body
10 If deemed necessary loosen the reservoir retaining
clips and detach the reservoirs
TO CLEAN AND INSPECT NABCO AND
cvlinder
Instal the spring retainers and compression spring
primary piston and fit and tighten the special bolt
through the front spring retainer aperture
4
Instal the spring retainer and spring to the spigot
end of the secondary piston
5 Now that the primary and secondary piston
assemblies are assembled lubricate the bore of the cylinder
and carefully enter the secondary and primary piston
lCO
TOK
to the
Wash all componen ts
thoroughly
in clean
hydraulic
alcohol
brake fluid or
2
Check the master
scoring
3
or
cylinder
bore for excessive
wear
pitting
Check both pistons for pitting
excessive wear
or
scoring
4
Check the
the
pistons and
or
that
specified
see
assemblies in that order into the
piston to cylinder clearance and renew

cylinder if the clearance is in excess of
Fit the
rod
cylinder
assembly
cylinder and instal the snap ring
7 Instal the dust boot 0 the
SPECIFICATION section for piston
clearance limit
134
push
to
the
rear
rear
of the
of the cylinder
6
Brake
making sure that it is seated correctly over its retaining lip
on the cylinder body
8 Compress the cylinder pistons via the push rod and
instal the secondary piston stop bolt and sealing washer
9
Instal a check valve assembly into each of the cap
bolt apertures in the cylinder body
10 Secure the master cylinder in a vice and fit and
See specification
tighten both cap bolts and washers
section for torque setting
I 1 Attach the reservoirs to the cylinders if they
were removed
and securely tighten the two retaining clips
Fit
and
tighten the cylinder bleeder valve s
12
13 Fill both reservoirs with clean hydraulic brake
fluid and fit the reservoir caps and seals Bleed the cylinder
by hand by slowly pumping the pistons via the push rod
assembly at the rear until all air is expelled from the
cylinder
TO ASSEMBLE
I
clean
TOKICO
internal components of the cylinder in

brake fluid
Soak all
hydraulic
Carefully instal the new cups to the primary piston

assembly with their leading lips facing frontwards
2
NOTE
The secondary
piston
should be renewed
unserviceable
assemb v
if
cups etc appear to be
Assemble the spring seat and compression spring

spigot end of the primary piston
3
the
to
Lubricate the bore of the cylinder with clean

hydraulic brake fluid and carefully enter the secondary and
4
primary piston assemblies in that order into the cylinder

5
Fit the push rod assembly to the rear of the
cylinder and instal the snap ring
6 Instal the dust boot to the rear of the cylinder
making sure that it is seated correctly over its retaining lip
on the cylinder body
7
Attach the reservoirs to the cylinder if they were
removed and securely tighten the two retaining clips
8 Instal a check valve spring seat and valve into each
cap bolt aperture in the cylinder body
9 Secure the master cylinder in a vice and fit and
ten
both cap bolts and washers
tigh
10
Screw the bleeder valve s
into position in the
cylinder body
11
Position the reservoir filters into the reservoir
chambers and fill the reservoirs with clean hydraulic brake
fluid Fit the reservoir caps and seals
12
Bleed the cylinder by hand by slowly pumping

rear ofthe cylinder until
the pistons via the push rod at the

all air is expelled from the cylinder
should not be dismantled and
REAR BRAKE
as an
ASSEMBLY

Raise the rear of the vehicle and support
on
chassis
stands
Remove the road wheel release the handbrake and
withdraw the brake drum

NOTE
adjuster
It may be necessary to back off the brake shoe

in order to remove the brake drum
Detach the return spring remove the clevis pin and

the
handbrake cable or rod whichever is
disconnect
applicable
from the
4
from the handbrake
rear wheel
Mark
lever
protruding
correct
assembly
operating
cylinder
each
brake
shoe
for
turn
shoe
the
compress the shoe retaining spring on

top washer through 90 deg and remove the spring washer
and retainer pin Use the same procedure to remove the
retainer spring washers and pin from the remaining shoe
one
Back
off
the
brake
shoe
adjuster
in
an
anti clockwise direction until it is in the full off position
Using
suitable
pair
of brake
spring pliers
disconnect the upper return springs from each brake shoe

7
Ease the end of the brake shoes from the adjuster
tappets and whee cylinders and detach the brake

8
Position
rubber
band
lengthwise
shoes
around
Method
the
135
of
Oisloding Adjusting Plates

Cylinder Assembly
from
Rear Wheel
Brakes
7
wheel
cylinder to
becoming dislodged
9
Disconnect
he
prevelll
the lower
Jnd cup
piston
brake shoe
return
2
If the linings are still serviceable check for oil
saturation and gumminess and renew 3S required
from
Check the brake drum for cracks ovality or scoring

or
machine
as
See
found necessary
SPEClFICA nON section for drum ovality and machining
3
spring
and
from the brake shoes
10
cylinder
to prevent
II
brake
the rear uf the

entry of dirt
Remove
back of the wheel

and
backing pl
from behind
plates
and
adjusting
shims
lrom the
rake
for
te
14
If it
brake shoe
is necessary to
dismintle
by
and
the
wear or
adjuster components
damage and
renew
in solvent
and
jf required
comparis on
with
new
springs
and make
replacements
as
TO ASSEMB
E AND INSTAL
the
TO CLEAN AND
compressed
boot
found necessary
adjoster tappets and withdraw them

frnm the adjuster housing Unscrew the adjuster wedge bolt
from the housing
Mark
rubber
Check the tension of the brake shoe return springs
the
backing plate
15
for
check
unscrew
remove the two nuts and
and withdraw the assembly from the brake
adjuster
lock washers
remove and
with
air
or
necessary
7
Clean
Detach the retaining clip and rubber boot from

the open end of the wheel cylinder and withdraw the piston
and seal Detach the seal from the spigot end of the piston
13
dry
in
components
and piston seal for

damage and renew as necessary
6 Check the wheel cylinder piston and cylinder bore
and
renew the
assembly if
wear and or pitting
ueterioration
cylinder assembly
cylinder
wheel
and blow
the
Cpeck
cylinder assembly
rhe wheel
the
Wash
methylated spirits
the
and unscrew the bleeder valve from the
Withdraw the retainer
remove
limits
4
the rubber dust cover
backing plate
12
the brake fluid pipe from the wheel

backing plate and plug the pipe
Disconnect
at
renew
I Lubricate
if thickness is found
linings
for
wear
be less than 1 5
Renew the
mm
linings
0 059 in
SHOE RET
BRAKE BACKING PLATE
Position
the
adjuster
AI
ER
BRAKE SHOE
SPRING
A LE
View of
Right
FLANGE
Hand Rear Brak
adjuster assembly
the
grease screw the wedge bolt into
the
to
and
instal
according
adjuster tappets
adjuster housing
the marks made on dismantling
INSPECT
Check the shoe
the components of the
with zinc oxide
Shoe
136
Assem
ly with Drum Removed
assembly
on
the
brake
NUT
tfOJ
RETAINING
Bral es
B
PIN
lFRING
WEDGE BOLT
WASHER
BOD
lrDJUSTER
ReT1JRNSPRING
d
AING
RETAINING
WASHER
RETAINING WASHER
iCf
il
BLEED
ADJUSTING
2J
le
f
HANDBRAKE
PLATES
DUST BOOT
RETAINIHGCLJP
BOOT
NERS
11
VALVE
s
EA
lIl
H
RETA
P1STO
CYUNDERou
sPRING
tB
OPERATING
and
handbrake operating link at the

Check that the wheel cylinder
plate
LEVER
on
moVe
the
10
smear
assembly
backing
is free to
face
backing plate
Place
of the
rear
of zinc oxide grease
on
each brake
shoe support pad on the brake backing plate inner face

II Connect the brake shnes together with the lower
Exploded
View of Rear Brake
brake shoe
COmponents
12
backiQg plate
and secure wjth the two
lockwashers
Position
jining
ret
nuls
and
according
elastic band around the assembly
an
to prevent the tappets from becoming dislodged

3
Lubrieate the wheel cvlinder bore with clean brake
fluid also dip the piston and seal in the fluid and instal the
seal
the
piston
towards the spigot
on
so
that the
end of
lip of
the piston
the seal will be
ar
groove
Ensure thut the seal is seatiilg

in the
care
NOTE
seal
not to turn back the
assembly into
cylinder
lip of the
lip
must
face
retaining
of the
clean
bore
cllinder
Position the rubber boot
cylinder and secure
on
plate
retaining clip
in the wheel
cylinder body
operating lever in the backing
position the wheel cylinder on the plate from
the
position
on
retaining pin through
and shoe
from behind
the
adjuster
the hole in
and instal the
hers and
pipe
and the bleeder valve to
cylinder
Instal the brake drum
on
the axle
Ilange
and lit
the road wheel
It will be Ilccessan to
18
system
as
19
ehicle is luwered
tv
fullv tighten the road wheel

ground
the
the brake shoes and bleed the hydraulic

described in the appropriate sections
Reconnect the handbrake cabie or rod whichever
Adjost
is
applicable to the handbrake operating lever and instal

the return spring It may be necessary to back off the
Instal the
the whee
adjusting plates and spring retainers 011

cylinder from the rear of the brake backing
handbrake cable
plate
20
9
the other shoe into
Fit the brake fluid
when the
inside
to
locating
adjuster tappet and with the handbrake

entered in the aperture provided in the
lock into
tighten
NOTf
Insert the handbrake
and
backing plates
the open end of the
it with the boot
Position the handbrake operating lever in he slot

end of the wheel cylinder body locating the lever pivot in
recess
wa
to
17
the
deg
the wheel
and
5
lever
the
brake shoes
bore
wheel
the
on
dismantling
on
spring turn the top washer through

position Instal the other shoe retaining
pin washers and spring in a similar manner
15
Using a suitable pair of brake spring pliers instal
the two upper return springs to the adjuster ends of the
seal on entry
the blind end
on
backing plate
16
The sea
the marks made
tappet and wheel cylinder

14
Insert the shoe
in fhe
into the
insert it
to
Pull
13
facing
90
and
spring
brake shoe
piston
4
Dip the piston
hydraulic brake fluid and
Take
correct v
shoe
operating
the
NOTE
return
Position the brake shoes
Insla
the rubber dust boot
over
the wheel cylinder
road wheel
137
adjuster
tu cunnect
Lower the vehicle
relaining
nuts
to
the
and road
the cable
ground folly tighten the

test
the vehicle
Brake8
HEIL
FIlONT
DIll1
Remove
cylinder
Raise the
front
on
chassis stands
2
Remove
the
and
hob
retaining
grease
withdraw the split pin undo the stub

the road wheel and brake drum
ax
caps
nut anu remove
It may be necessary to back off each shoe adjusting

eam in order to remove the wheel and drum assembly
Matk
to the
If
necessary
unscrew
cylinder bleeder valve

9 Repeat operations
NOTE
KIS
the bolts and nuts securing one wheel

backing plate and withdraw the cylinder
7 Remove the rubber boot and withdraw the piston
cup spring seat and spring in that urder from the open end
of the whecl cylinder
Im
each
brake shoe for correct assembly

retaining spring on one shoe turn the
top washer through 90 deg and remove the spring washers
and retainer pin Use the same procedure to remove the
retainer spring washers and pin from the remaining shoe
4
Pull the shoe away from the wheel cylinder piston
other
wheel
dismantle
the
dismantling
will be unnecessary
and
remove
7 and 8
cylinder
the
whee
to remove
Any
and
further
compress the shoe
and
I Check the shoe linings for wear Renew the linings

if thickness is found to be less than 1 5 mm 0 059 in
2 If the linings are still selViceable check for oil
saturation and
of the other wheel cylinder Unhook the return spring at

the shoe web and at the brake backing plate and remove the
shoe
gumminess
and renew
as
required
the other end of the shoe from the blind end
disengage
and spring
Remove
the
other
shoe
in
the
Linings must be renewed as sets onlv with

corresponding linings on the other front wheel
NOTE
same
manner
Disconnecr and remove the short hydraulic bridge

which
connects the two wheel cylinders at the rear of
pipe
tile backing plate and also the remaining steel brake pipe
which runs from one wheel cylinder to the strut bracket
5
RETAINING
the
and
Check the brake drum for cracks ovality or scoring

See
or
machine
as
found necessary
renew
SPECIFICA nON section for drum ovality and machining

limits
WASHER
l6
RETURN SPRING
RETAINING
BOOT
@ If
PISTON
e
VE
SPRING
cuP
SEAT
sPRING
ft
SPRING
SPRING
BODY
CY
1BlE O
I
NT
BfllDGE PIPE
CYLlNOER BOO
WASHER
SlRIN
7m
iT
cup
RING SEAT
IJ
SPRING WASHER
PISTON
SPRING
r@
BOOT
liiiit
RETAINING WASHER
E11r
R
Exploded
1M
NG
filM
View of Right Hand Front Brake Shoe
Components
138
1000 Series Sedan Front and Rear Brake Drums

Note Additional Ribbing on Front Drum Periphery
Brakes
l0
DUST BOOT
View
Wash
the
of
Right
Hand
Front
Brake Shoe
wheel
in
cylinder
components
with compressed air
5
Check the rubber boot and cylinder cup for
deterioration or damage and renew as nec ssary
6 Check the wheel cylinder piston and cylinder bore
for wear and or pitting and renew the assembly as
Fit the cylinder bleeder valve where necessary

Repeat operation I and 5 inclusive to assemble
and instal the other wheel cylinder
methylated spirits and blow dry
necessary
7
Check the adjusters in the
or
looseness and renew
as
backing plate
for
with Drum and Hub Removed
Assembly
Instal the short connecting pipe between the two
cylinders
8
and
tighten
the unions
of high melling point grease on each

of the brake shoe support pads on the brake backing plate
and instal each brake shoe and return spring according to
the marks made on dismantling
wear
required
Check the tension of the brake shoe return springs

with new springs and renew as found
Place
smear
by comparison
Insert the shoe retaining pin through the hole in

backing plate and shoe from behind and instal
retaining washer and spring turn the top washer
the brake
necessary
the
through
90 deg to lock into position Instal the othershoe

retaining pin washers and spring in a similar manner

I
cylinder
2
Lubricate the internal components and the wheel

bore with clean hydraulic brake fluid
Instal the spring spring seat cup and piston in the
Ensure
Ihat the brake shoe ends are proper v
NOTE
located on the wheel cylinder pistons and also on he blind
end of the cylinder Ensure that tile brake shoe adjusting
open end of the cylinder Ensure that the cup is installed

with its lip facing towards the blind end of the cylinder
3 Position the rubber dust boot over the spigot
cams are
10
portion of the piston

Fit
rubber
and over the open end of the cylinder

band lengthwise around the assembly to
prevent the piston and cup from becoming

the cylinder bore
4
locating
tighten
Position
the
from
onto
full offposilion
Instal and
tighten
the steel brake
wheel cylinder to the
strut
adjust the
hub
pipe
which runs
bracket union
Instal the brake drum and road
the stub axle and
the FRONT SUSPENSION section

hub caps
cylinder assembly in the

backing plate and instal and
retaining bolls and
one
II
from
wheel
hole in the brake

the
dislodged
in Ihe
wheel assembh
as detailed in
Refit the grease and
bearings
12 Bleed the hydraulic system and adjust the brake

shoes lower the front of the vehicle and road test
stud nuts
139
ll
Brakelt
RONT WHEEl
OIS
BR
5
in
Raise
the
front
of the vehicle
and support
on
chassis stands
Remove the hub cap and road wheel
Remove the caliper pads as follows
2
3
Withdraw
the
retaining spring clip
from
the
pad
retaining pins
Remove the pad retaining pins and coil spring noting
spring is installed on the lower pin
that the
two anti rattle
Disengage and remove the

Mark
pads
the
and anti
crayon to facilitate correct
pliers
nosed
withdraw the
squeal
clips
shims with chalk
assembly and with
pads with
pair
shims from the
or
long
caliper
of
assembly
Disconnect
steel brake tube
the
at
the
Remove
unit
the
to
two
the
rust or
a
facing
worn
foreign
matter
Do not attempt to use carbornndum
plated surface of
12 Lubricate the caliper cylinder bore and seals with

small amount of rubber grease and position the new seals
in their respective grooves in the cylinder bore
13
If the nylon bias spring was removed from the

piston then instal the spring rounded portion first
into the piston bore Press the bias spring down far enough
to allow it to seat on the bottom of the piston bore
inner
14
towards wheet
Renew the brake pads if lining thickness is

less than 16 mm 0 063 in
disc
Smear
small amount of rubber grease
on
the
sliding surfaces of the caliper pistons and carefully enter the

pistons into the cylinder Slowly push the piston into the
cylinder by hand until the piston rims are approximately
flush with the ends of the cylinder
rotation
to
except the
the caliper pistons
following points
Tighten the caliper assembly to stub axle flange bolts
BRAKE
See
to
the
correct
specified
torque
SPECIFlCAnON section for correct torque setting
Instal and tighten the two steering arms to lower
suspension unH bolts to the correct specified torque See
FRONT SUSPENSION section for correct torque setting
Instal the brake pads and anti squeal shims according to
the marks made when dismantling If new shims are being
arrows
components
paper or similar abrasive materials on the
procedure with
attention to the
tiUed then instal with shim
caliper
all
in
NOTE Iris permissible to lightly hone the caliper cylinder

bore with fine carborundum paper to remove accumulated
the stub axle
Installation is
Clean
methylated spirits and examine for wear Renew all

components that upon inspection prove to be excessively
scored pitted or worn
Discard the piston seals and also the dust boots
pads
bolts securing
the lower
steering arm and separate the
unit far enough away from the steering arm to
to the two caliper assembly mounting bolts
6
Unscrew the two caliper assembly to stub axle
flange mounting bolts and detach the caliper assembly from
suspension
suspension
gain access
the
II
caliper
and strut bracket
cylinder
Note or mark which way the
pistons are positioned

cylinder to facilitate correct assembly This is
important as the two pistons are not interchangeable
6
Rcmnve the retaining rings and detach the dust
boots from the ends of the cylinder
7
Using finger pressure press both pistons out of the
cylinder body
8
Again using the fingers carefully lift and remove
the two piston seals from their respective grooves in the
caliper cylinder bore
9 Disengage the two caliper plate springs from the
caliper plate
10
With a suitable pair of pliers withdraw the nylon
bias spring from the bore of the inner piston Only remove
the bias spring if it is found to be unserviceable
TO REMOVE AND INSTAL BRAKE CALIPER

I
KES
down
NOTE Brake pads should Dilly be renewed in sets offour

It will be necessafl to bleed the hl
ic Sl stem when
drau
NOTE Ensure that the pistons are not pushed tou far into
the cylinder bore otherwise the piston seals will be allowed
to drop into the stepped portion of the pistons and may be
installation is completed
damaged
TO DISMANTLE AND ASSEMBLE
15
I
Thoroughly
clean
accomulated
dirt
from
the
outside of the caliper cylinder

2 Unscrew the bleeder valve and drain the hydraulic
fluid from the caliper cylinder
3
Securely position the
plate
in
flanged
16
end of the caliper
are not
to
caliper cylinder
dust
boots and
caliper plate springs
on
the
small amount of rubber grease to the

and caliper plate sliding surfaces and
cylinder
to
the
caliper plate
It
may
be
necessary to tap the caliper plate head with a soft faced

hammer to seat the plate tongue fully into the nylon bias
allowed
two
If removed instal Ule
assemble the
vice
With
the
plate
17 Apply
caliper cylinder
soft faced hammer carefully tap the caliper

plate head until the cylinder assembly is dislodged from the
caliper plate During this operation enSure that the pistons
4
Instal
retaining rings
spring
18
slide from the cylinder body

140
Fit and
tighten
the
cylinder
bleeder valve
kes
Br
12
ExplOded View of Brake Caliper Components

ANTI
RATTLE
6
BOOT
DUST BOOT
ANTI
TUEAL
TO REMOVE AND INST
I
c
the front
AtBRAKE
SPRING CU
of the
vehicle and support
Remove the hub cap and road wheel

Remove the brake pads and caliper
on
described in
12
assembly
as
Detach the grease cup from the disc hub

Withdraw the split pin from the castellated nut on
the stub axle and tighten the nut
slightly to eliminate any
end float that may be present on the hub and
bearing
a
dial indicator gauge
that the dial
periphery
plungl f
is
on
bearing
the
on
suspension
the
outer
NOTE If a
specified
have been mode
IIR
although
and proved
ron
or
out
the abOl ementioned checks

0
be not the run out
cause
the hub flange and brake disc

If the fault is in the hub flange then new the
on
separate v
ilub assembll
9 Remove the stub axle nut thrust washer and outer

hub bearing and withdraw the hub and disc assembly
10 Mark the hub in relation to the disc and remove
REAR
disc was JUted and excessive
then check the mn out
limit
flew brake
is still evident even
and or if the disc is scored then machining ofthe

disc will be necessary
See SPECIFICATION section for brake disc run out
the four securing bolts Separate the hub and brake disc
II If necessary remove the hub bearings and seal
brake disc and the
recheck the hub flange and disc mating surfaces for dirt
burrs and the hub bearings for correct adjustment
of the disc
reconditioning
the
of
Clean the mating faces
U Zero the dial gauge and rotate the disc to assess the
maximum run out of the brake disc
8
If the disc run out is in excess of the limits
limit and
of this
14 Mount a dial gauge to the brake disc as pr viously

described and again check the disc run out
15 If the run out is in excess of the limit specified
assembly
Mount
section
13
If the hub bearings and seal have been removed
assemble instal and adjust the hub bearings as described in
the FRONT SUSPENSION section of this manual
so
the FRONT SUSPENSION
hub flange and instal and correctly torque the four securing
bolts See SPECIFICAnONS for torque setting
rl
IN
manual
lnit
l
AINI
lllQ
UUtl
assis stands
3
PAD
DISCS
AL SHIM
PADS
SPRING
Raise
ANTI SQ
SlUM
Q1f
O
CLIP
fit
If the hub flange is troe and the fault is

disc and again check he mn out
in tile disc then
a new
16
Further installation
is
reversal of the
removal
procedure
as
KE
IIA
KIX6
PI
TE
Raise the
rear
on
hydraolic brake pipe at

Plug the pipe to prevent
chassis
stands
2
3
to
casing
several
I may be necessan to release the brake adjuster

notches if the brake dmm proves difficult to
are
Disengage
the
or
return
rod
Withdraw the axle shaft assembly from the axle

If found necessary use a slide hammer and
adaptor
Keep intact the end float adjustment shims which

fitted between the backing plate and casing
NOTE
remove
handbroke cable
backing plate
the Joss of fluid or entry of dirt
5
Remove the nuts retaining the brake backing plate
the axle casing through the holes provided in the axle
shaft flange
Remove the wheel hub cap

Loosen off and remove the rear wheel and brake
drum
NOTE
the rear of the brake
spring and disconnect the

whichever is applicable and the
the
141
Place the axle shaft assembly on an anvil so that

hearing retaining collar is supported by the anvil Using
13
Brakelt
a
hammer
and cold
chisel make
ell
in the top of the
reraining collar
NOT
Use care
damage the Qde shaft with

cui complelelv Ihrough
t to
m
chisel if il is found necessary 10

collar
Usualv it
in order
to
the
the
vi be necessary to make shallow cuts onlv

expand he cailar sufficiently for il to be
remrJJled
on
Using
the
inner
press and press
plates support
the
bearing

special tool No ST37130000 to pull the
race
bearing or use
bearing from the shaft
9
Detach the brake backing
plate
with the
bearing
and grease trap

attention to the fonowing points
Use a new
bearing retaining
collar when
reassembling
the axle shaft assembly

Check the axle shaft end float
as
described in the
AXLE SHAFT AND BEARING of the REAR AXLE
section
Adjust end tloat if necessary by subtraction or
addition of shims to the shim pack between the brake
backing plate and axle casing

left Hand
Adjust
Brake Assembly Showing Shoe Adjuster

and Handbrake linkage 1000 Model
Rear
FIlONT
and
bleed
the
brake
system
See
relevant
sections
BIlAKE
BACKIN CO
PIATt
TO REMOVE AND INSTAL DRUM BRAKES

Raise the
front
of
the vehicle and support
on
BACKING
chassis stands
Remove the road wheel with the brake drum and
hub
as
LATE
WHEEL CYlINOER
MOUNTING HUTS
NOTE
It mav be
adjusting
cams
necessarv
Co
back ojf the brake shoe
in order to withdraw the brake dmm
from
the shnes
Disconnect the steel hydraulic brake pipe which

from the whee cylinder to the flexible hose at the
3
runs
strut
bracket
4
Unscrew and remove the four bolts
backing plate and grease shield

and withdraw the backing plate and
brake
stub axle
Separate
installation is
securing the
the stub axle flange

grease shicld from the
to
the
a
backing plate and grease shield

attention to the
following
Tighten the brake backing plate securing bolts to the
correct specified lorqoe See SPECIFICATIONS section for
torque setting
Ensure that the hub bearings are adcquately lobricated
with wheel bearing grease and instal and adjust the hub
bearings as detailed in the FRONT SUSPENSION section of
UST COVER
BLEED VALVE
this manual
On
completion
system and
before road
adjust
testing
of installation
the brake shoes
bleed the
on
hydraulic
Rear View of 1000 Series
Right Hand Front Backing Plate

Assembly Typical also of 1200 Models
both front wheels
142
Brake
AND FRONT CABLE
HANDBRAKE LEVER ASSEMBLY

Chock
the
two
rear
wheels and release the
the full off position

handbrake
2
Withdraw the spring retainer and clevis pin and
disconnect the front cable from the handbrake lever
3
Remove the spring retainer and clevis pin and
to
disconnect the handbrake

end of the handbrake lever
4
guide
puli
NOTE Renew cables that
lever
yoke
from
mechanism when
and
secures
on
standslI
TO
the handbrake cable to the

From
7
adjusting
8
underneath the
turn
through
4
lock
chassis
on
the
BRAKE
1200
suitable working height and
stands
Still working from under the vehicle withdraw the

at the front cable lower
plate
5
fixing point
and
puil
pull
the
underbody
At the upper end of the front cable and working

within
the vehicle withdraw the lock plate to
disconnect the cable from its upper fixing point

6
Remove the handbrake lever cover
bracket
from
the
handbrake lever assembly

7
spring pin and dismantle the pull lever assembly

Observe the position of the pawl and spring and also the
handbrake pull set spring to ensure correct assembly
11
Check the handbrake poll lever components and
the front cable for serviceability and make replacements as
found necessary
lever
Rear Underbody View of 1000 Series
AND INSTAL
cable clear of the
remove
10
in
from the rear cable
cable
the cable from the vehicle

If found necessary drive out the handbrake
described
Release the handbrake to its full off position

Working from underneath the vehicle back off the
buckle adjusting nut and disengage the front cable
from
assembly
as
and detach the cable from the bottom lever

Still working from under the vehicle withdraw the
at the lower cable fixing point and pull the cable
the top
that
the
vehicle unscrew the
or
assembling
hand brake
Raise the vehicle to
support
nut
lock plate
clear of the underbody
9
Pull th
cable
and
REMOVE
I
working height
clamp which
underbody
disconnect
stretched
ADJUSTMENT section
the vehicle raised to a suitable
supported
the
Adjust
disconnect the pull guide from the assembly bracket

5
The handbrake pull lever assembly can now be
removed from the vehicle
With
excessively
are
or broken braid

attention to the following
Lubricate all
working points of the handbrake
the lower
On the upper end of the pull lever and at the pull

withdraw the spring retainer and clevis Rio and
chaffed
have
1000
road
ASSEMBLY
HANDBRAKE
14
Unscrew
assembly
front
to the
the
body
nuts
securing
the
cable attached from the vehicle
Remove
disconnect
the
the
front
pin
and
clevis
handbrake
cable
from
spring
assembly
Showing Handbrake
143
handbrake lever
assembly with
and remove the lever
Cable and Rod Arrangement
pin
the
and
lever
I5
Brakes
Rear Underbody View of 1200 Series

9
and
Check
replacements
as
for
cable
Rear Handbrake Cable Arrangement
assembly on the differential housing

wheel cylinder assemblies
assembly components
serviceability and make
the handbrake lever
front
the
Showing
have
Rench cables thai
chaffed
or
both
rear
found necessary
TO REMOVE
NOTE
across
1200
excessiveJv stretched or that
are
broken braid
II
Raise the vehicle to
suitable working
height
and
chassis staf ds
support
1 Working from underneath the vehicle back off the
turn buckle
adjusting nut and disengage the rear cnbJe from
on
IJ
nstal tion
is
attention given to the following poir IS

Lubricate all
working points of
with
procedure
the
the front cable
handbrake
mechanism when assembling
Adjust the handbrake

ADJUSTMENT section
as
described in
the
fi xing
BRAKE
4
at
Raise the vehicle to a suitable

on
working height
and
chassis stands
2 Working
cable front
retorn
springs and disconnect
the cables
cylinder assemblies
Remove
the
and separate the two
rear
cable assemblies
from underneath the vehicle withdraw the
and clevis pin and detach the rear cable from the
balance lever which is located on the differential housing
TO INSPECT
split pin
assem
rear
hanger strnp mounting holts at the

differential
assembly and remove the complete rear
handbrake cable assembly as a unit
6
If found necessary undo the hanger strap unit nut
TO REMOVE 1000
Detach the
the wheel
5
REAR HANDBRAKE CABLE
support
Withdraw the lock plate at the

on the differcnt al housing
point
BOTH MODELS
Check the cables for excessive stretching chaffing
bly
or
broken braid
NOTE It
the
mal
be
In back
necessar
of the fron
rear
off thc adjusting

pill
cable 10 aIow the cleris
Check all clevis pins and eyes for wear

Renew all components that upon inspection
be unservileable
nut at
fO
be
wil ulralVll
split pin and clevis pin and disconnect

the rear cable at the lever protruding
of
portion
down from the centre of the underbody
3
Remove the
TO INSTAL
prove
to
BOTH MODELS
the front
The
rear
cable
can
now
be
removed
from
lnstallation is
the model
the
procedure
for
applicable
Apply lubricant to all working points when installing

Adjust the rear brake shoes and then the hand brake as
described in the following BRAKE ADJUSTMENT section
vehicle
If found necessary disengage the return springs
and remove the cross rods which run from the balance lever
5
144
Brakes16
10
TO ADJUST FRONT BRAKE SHOES
BRAKE
USTMENT
accornpJjshed easJer with
Drum TyPe
the vehicle
I
Raise the fron t of the vehicle so that the wheels are
clear of the floor and support on chassis

2
Check that the wheels rotate
is
end noat in the hub
no
and that there
bearings
Working from under the vehicle and at the back of

the brake backing pia ie rotate one of the
adjusting cams in
a
forward direction until the brake shoe locks the brake
two operators
in the
underneath
one
sitting
driving position
assessing the pull lever stroke
stands
freely
arid the other
Lower the vehicle to the
ground
check
ahd
handbrake operation on an incline Check that

binding is evident when the handbrake is in
released position
no
the
brake
the fully
TO ADJUSTHANDBRAKE CABLE 1200
drum
4
Slowly back
off the adjuster until the wheel will

without any sign of brake drag
5
Carry out operations 3 and 4 on tne other shoe
adjuster for the Same wheel and again check that the wheel
just
rotate
will rotate
6
freely
stands
same
procedure adjust the shoes
on
the
Disc brakes
and
fifted to the front wheels are

manual adjustment is provided or
of the
as
on
chassis
previously
ground
4
placed
support
shoes
lock nut at the turn buckle and lower the vehicle to the
TO ADJUST REAR BRAKE SHOES ALL MODELS

1
brake
within the vehiCle This should be equivalent to

approximately six notches on the
ratcJ
tet
The adjusting operation wil be accomplish d easier
with two operators one under the vehicle and the other
stroke
sitting in the driving position assessing
itehver
3
When correct adjustmeni is obtained
tighten ire
where
no
rear
lever
ground
selfadfusting
required
of the vehicle
ihe
2
Back off the locknut and adjust the turn buckle
tietween the front and rear cabies untii an application
stroke of 78 5 mm 3 091 in is obtairied on the handbrake
other front wheel and lower the front of the vehicle to the
NOTt
rear
adjust
described
freely
Using the
Raise the
and
Raise the rear of the vehicle and support on stands

under the axle housing so that the wheels are clear
Check handbrake
operation
ensure that no brake binding is evident

is in ihe fully rele sed positioo
on
an
when
inciine
and
the hand brake
ground
Release the handbrake pull lever
to
the full off
BRAKE PEDAL HEIGHT ADJUSTMENT 1000
position
3
Back the front
handbrake cable adjusting
nut
several turns at the

adjusting point under the vehicle
4
Check that both rear wheels are capable of
rotated without any sign of brake drag
i Loosen the brake pedai stop lock nut and back the
stop well away from the brake pedal arm
off
being
Adjust the brake pedal to a height of 146 5 mm

by adding or subtracting shims between the
master cylinder assembly and the engine bulkhead See
SPEC FICAnON section for shiin sizes available
5 767 in
5
Working from beneath the vehicle and at the rear
of the backing plate turn the square on the adjuster in a
clockwise direction ontil the brake drum is locked by the
rear
NOTE If shim adjustment is necessary ensure that the shim

thickness for upper and lower bolts are of an even thickness
shoes
6
Back off the adjuster a little at a time until the
wheel is just free to rotate without
dragging
7
Using the same procedure adjust the shoes on the
other fear wheel
8
when instaJiJig
shims
Pedal height dimension should be measured from the
top of the pedal pad down to the sloping section of the
bulkhead
Adjust the handbrake cable
following
section
as described in the
lower the vehicle to the floor and road
height
TO ADJUST HANDBRAKE CABLE
Whep
1000
has been
sloping section
I
stands
Raise the
and
described
rear
adjost the
of the vehicle
rear
brake
support
shoes
as
on
satisfied
the abovementioned pedal

adjust the pedal stop down
against the pedal arm until a height of 144 5 mm 5 689 in I
is established between the top of the pedal pad and the
test
chassis
that
obtained
of the
Tighten
the
erigine bulkhead
peaal stop lock nut
previously
BRAKE PEDAL
HEIGHT
ADJUSTMENT
1200
From underneath the vehicle adjust the front cable

adjusting nut until an application stroke of between I i 0
I Loosen the lock huts and back off the combined

stop light switch and pedal stop well away from the brake
and
330
4
120 mm
and 4 724 in is obtained on the
handbrake pull lever stem within the vehicle This wiJ be
pedal
145
arm
Brakes
17
2
5 650
master
Adjost the brake pedal to a height of 143 5 mm

by adding or subtracting shims between the
cylinder assembly and the engine bulkhead See
tup of the pedal pad down

bulkhead
in
SPECIFICATIONS section for shim sizes available
When
satistied
that
tv
the
the
sloping
sedivfl
abovementioned
vf the
pedal
the combined stop light

switch and pedal stop down against the pedal arm until a
height of 141 mm 557 in is established between the top
has been obtained
height
NOTE Ifshim adjustment is necessan ensure that the shim
thickness for upper and lower bolts are of an even thickness
of the
when installing shims
pedal pad
and the
adjost
sloping
Pedal height dimemion should be measured from rhe
the
Securely tighten the

pedal height is not altered
section of the bulkhead
two
lock
nuts
ensuring
that
BYDRAULI
S STE
II
TO BLEED
its travel and lock up the bleeder valve

return without assistance
the hydraulic system is not a routine

operation and should only be necessary when
some
portion of the hydraulic equipment has been
disconnected or fluid drained off thereby allowing air to
5
Repeat operation 4 until a constant stream of
clean fluid without air bubbles is being discharged into the
enter the system
manner
Bleeding
maintenance
There
may
cylinder
each
are
glass jar
the bleeding operations in the same
remaining bleeder valves in he system
Always work from the longest line in the system down to
the shortest
6
five parts in the system where bleeder valves

to be fitted
One on each front wheel
found
be
or
rear
caliper
where fitted with disc brakes
wheel cylinder and
one
one
NOTE
assembly
the
1 Fill the fluid reservoir on the master cylinder with

clean hydraulic brake fluid and maintain it at least half full
throughout the entire bleeding operation
2
the
Remove the dust cover from the bleeder valve
master
cylinder attach
or
Unscrew the bleeder valve one
Depress
the brake
out
the
fluid ill the reservoir ro fall below

during the bleeding operatioll
may enter the system and afresh start will have to be
Always use Ilewfluid for toppillg up the reservoir
Do nor allow the
air
on
rubber bleeder tube to the
small amount offluid contained in
on
half full level
made
covers
valve and allow the other end of the tube to be immersed in

a
Carry
on
the master cylinder
on
Allow the pe al to
Finally
to the
at anv
time
remove the bleeder tube

refit the dust
bleeder valves and lOp up the fluid in the
reservoir
clean glass jar
pedal slowly
complete
to
NOTE It is obvjous that two operators will be needed

bleed the brakes when using the abovementioned system
turn
the full extent of
146
to
18
Brake8
12
1
BRAKIl
FAULT
DI
anSIS
Brake pedal hard
Remedy
Possible cause
Frozen
pedal pivot
Restricted brake line from master cylinder
Frozen wheel
Vacuum
cylinder or calliper piston

system inoperative
Check free up or renew pistons

Check servo system and rectify
so
servo
Brake drag due to
build up
pressure
Possible
Remedy
cause
Check and clean master cylinder and fluid reservoir

Check free up or renew pistons
cylinder ports
Frozen wheel cylinder or calliper piston so
Frozen handbrake linkage
Broken or stretched brake shoe return springs
Frozen handbrake cables
Blocked vent in fluid reservoir cap
Free up or renew cables

Check vent and remove obstruction
master
Clogged
b
c
Check and replace linings with recommended type

Rectify or renew pivot pin and bush if fitted
Check brake line u
Id remove restriction or renew line
linings fitted
Incorrect shoe
Lower spongy brake
Free up or renew
Renew defective
linkage
springs
pedal
Remedy
Possible cause
a
Check and adjust brake shoes

Check for leaks replenish fluid to
Incorrectly adjusted brake shoes

Lack ofsufficient fluid in system
specified
level and
bleed brake system

Air in brake
Bleed hydraulic system
hydraulic system
Brake locks on application

Possible cause
a
Gummy linings
or
disc
pads due
to oil
or
fluid
Clean and
renew
Remedy
linings or disc pads
contamination
Bent or eccentric brake drum so
Incorrect
Broken or stretched brake shoe return
Brake
a
b
c
faulty drum so
linings in pairs with recommended
renew
type
Check and renew faulty spring so
spring so
Remedy
cause
Bent or eccentric brake drum
or
Check and
disc
Adjust
front hub bearings

Bent rear axle shaft
Loose or
worn
Incorrect shoe
or renew
Check and
renew
faulty components
Remedy
Check and adjust shoe to drum clearance
Check and renew faulty component
Renew contaminated liningso
or bent brake drum

saturated with hydraulic fluid
Lining
Incorrect
disc as required
front hub bearings
cause
adjustment
Eccentric
renew drums or
high speed
Possible
renew
and
pedal pulsates
Brake fade at
a
Check
linings fitted
Possible
Check and
Check and instal recommended
linings fitted
linings in sets
Brakes overheat
Possible
a
b
c
d
e
f
g
Ii
Incorrect shoe
Remedy
cause
Check and adjust shoe to drum clearance

Renew faulty spring so
Check cables renew or adjust
adjustment
Broken shoe return spring so

Faulty handbrake cables and
or
adjustment
faulty components
or renew hydraulic hose
Clear compensating port
Free up
Frozen wheel cylinder pistons

Obstructed or damaged hydraulic hose or line
or
renew
Remove obstruction
Obstructed master cylinder compensating port

Blocked vent in master cylinder reservoir cap
Broken rear spring main leaf or centre bolt
147
Check and
remove obstruction
Check and
renew
in vent
faulty components
or
line
ELEcndCAL
SYSTEM
SPE
IFICATIONS
Brush spring tensiun
LT 125 02
BATfERY
11 volts
Type
Capacity
at 20
deg
9
1
AS202SA
C
1 260
fully charged
120
1
discharged
350 g
120z
250
LTl33 05
earth
Specific gravity
68 deg F
13 oz
Nega tive
Polarity
380g
II
250
LT125 06
40 amp hrs at
20 hr rate
300
350 g
120z
300
400 g
I1
140z
13mm
Drive belt detlection
0 5 in
Rotor shaft
ALTERNATOR
run out
aU units
0 10 mm
0 004 in
Make and type

Hitachi
ALTERNATOR REGULATOR
LTl25 02
LTl25 06
I
AS202SA
MitsubislU
MaxiInum output
Hitachi LTl2S 02
LT125 06
LTl33 0S
Mitsubishi AS202SA
LT12S 02 alternator
TLlZ lOA
LT12S 06 alternator
AS2025A 1 alternator
TLlZ 37
LTl33 05 alternator
TLlZ 37
Tirril
constant
24 amps
25 amps
Type
33 amps
25 amps
Mechanical
Negative
Polarity
Stator windings
and model
Application
LTl33 05
voltage relay
earth
Settings
TLlZIOA Voltage regulator

Armature to frame air gap
Star connected
Diode identification
Red markings
on base
Armature to core air gap
Negative
Black markings
on base
Point gap
Pilot
4
0
0 039 in
sinks and
or
0 2mm
0 5
04
Point gap
TLlZ 37 Voltage regulator
F
4 07 ohms
LT125 06
40 ohms
4
LT133 05
4 50 ohms
AS202SA
0 5 mm
0 020 in
Non adjustable
1 0 mm
06
0 024
3
0
Point gap
0 039 in
4 mm
0
0 012
7 ohms
mm
0 024 in
0 016
pack assembly
deg
0 6
0 020
Diode rectifier
LT12S 02
mm
0 020 in
0 008 in
end
LTl2S 06
Field resistance at 20 deg C 68
0 047 in
O S
lamp relay
bracket
LTl33 05
1 2 mm

Diodes in heat
0 8
0 0 6
LTl2S 02
0 016 in
Charge relay
length
19 0mm
L T12S 02

0 748 in
LT12S 06
I4 S mm
LTl33 05
14 Smm
4
0
Point gap
models
0 6 rom
0 024 in
RL2220 BS
Voltage regulator
length
wear all
1 0 mm
0 016
13 0mm
0 SI2in
Brush minimum
adjustable
0 8
0 039 in
0 S70 in
AS202SA
Non
0 031
0 570 in
Maximum
10 mm
0 031
Rectification
Brush
0 9
0 035
Positive
AS202SA
RL2220BS
7 0mm
08
I I rom
0 031
0 275 in
0 043 in
148
Electrical
Armature to
core
12
0 8
air gap
mm
Amperage draw
60 amps
Revolutions
4800 rpm
minimum
0 047 in
3
0
4
0
mm
Lock test
0 012
Hitachi
3 volts
6
Volts
0 016 in
420 amps
Amperage draw
Pilot Lamp Relay

0 8
maximum
mm
Torque
0 031
0 9 kg m
6 5 ft lb
minimum
0 043 in
Armature to
core
0 9
air gap
1 2
Mitsubishi
mm
draw
Amperage
0 047 in
0 8
6 volts
Volts
0 035
Poin t gap
470 amps
maximum
I I mm
Torque
0 031
0 68 kg
5 ft lb
minimum
0 043 in
Brush
length
new
Voltage Relay
Adjust engine speed to
Primary and secondary side set
voltage to 14 2 volts at
Brush
16mm
Mitsubishi
ISmm
voltage setting by
length
worn
Hitachi
9 5mm
Mitsubishi
8mm
374
0
68
deg
Armature shaft maximwn bend
10 deg C
20
deg
all
25
28 oz
0 08 mm
0 003 in
F
Commutator out of round
voltage setting by
maximum
0 1 volts for every ambient
temperature drop of
in
800 g
700
all
Brush spring tension
0 1
rise of
in
315
0
volts for every ambient
Increase
Hitachi
0 590 in
2500 rpm
20 deg C
ambient temperature of
temperature
a 630 in
Electrical Settings
Reduce
maximum
0 031
Point gap
System
all
0 20 mrn
0 008 in
10
deg C
20 deg F
Undercut of commutator
ts
all
segmen
0 50
0 80 mm
0 020
Electrical Settings
Charge Relay
4 5
Operating voltage
Commutator diameter
5 2
Hitachi
0 031 in
33 mni
Mitsubishi
32mm
299
1
volts
in
1 259 in
STARTER MOTOR
Commutator minimum diameter

31mm
Hitachi
1220 in
Make and Model

Sl14
Hitachi
87
S114
Mitsubishi
Drive
all
Commutator minimum diameter
87L
MW
VIR
Over
running
30mm
Mitsubishi
181
1
clutch solenoid
maximum
0 20
all
all
Number ofbrushes
No Load Test
Amperage
Centre bush maximum clearance
2or4
45
0
Hitachi
12 volts
draw
Armature end fioat
0 05
all
60 amps
mm
SO
mm
a 012 iri
7000 rpm
Pinion clearance
pinion
pinion
all
stop solenoid energised
minimum
to
30
0
0 012
Mitsubishi
Volts
30
0
a 002
maximum
Revolutions
mm
0 018 in
Hitachi
Volts
mm
0 008 in
operated
Number of poles
in
Bush to shaft clearance
0 059 in
II volts
149
Electrical
Solenoid face
to
System
adjusting
plunger depressed
nut
all
TVA 4 F1 L
I 7
3170
30
32
mm
voltage
Firing
order
9 volts
9 842
Hitachi
deg at
in hg
8 5
10 5
0412
53
0411
61
Dwell
angle
Capacitor capacity
Control
49
55
deg
deg
deg
in
0411
61
9 5
0412
63 commences
0412
63 manual
Maximum
TVA 4 Fl L
hg
hg
9 842 in hg
Maximum
at
6 5
600 rpm
8 deg at
7
deg
Contact point gap
at
deg
hg
6 5
deg
at
13779 in hg
45
0
0 55 mm
all
Contact spring tension
all
500
650 g
18
21
oz
Shaft to housing clearance

Maximum
0 08 mm
Shaft to
0 005
0 003 in
4 SO rpm
at
earn
clearance
0 001 in
1000 rpm
13 0 deg
SPARK PLUGS AND LEADS
11 0
commences
Maximum
11 5
mm
0 0002
at 500 rpm
6 7
9 5 deg
1440 rpm
547 rpm
Maximum
0 029
1300 rpm
1 8 deg
o
at
at
mm
0018
600 rpm
5 deg at
12 deg
deg
350
0 022 in
at
700 rpm
Cen trifugal advance
0412
53 commences
hg
at
250 mm
600 rpm
automatic
hg
deg
12 in
centrifugal
8 deg
61 manual
hg
305 mm
600 rpm
0411
10 5
13 779
at
5 905 in hg
9 5 deg at
Ignition timing
4 FI L
350
hg
150 mm
commences
Maximum
advance
TVA
8 7
8 5
Vacuum advance
53
hg
at
mm
0 24 mfd
0 20
and
0412
250
at
mm
0412
63
TVA 4 FI L
Anti clockwise
Rotation
hg
8 7
deg
Model
Mitsubishi
at
8 volts
Mitsubishi
Hitachi
hg
deg
5 5
DISTRIBUTOR
Make
at
6 299 in
in
MaxiInum
Mitsubishi
1 248
272
1
Solenoid pull in
Hitachi
deg
160 mm
at
0411
61
deg
Make
or
63 commences
Maximum
Early
12 5
Later mode vehicles
deg
commences
I SO mm
hg
5 905 in
Maximum
5 deg
9
305
95
L45
L46 P
NGK
at 2100 rpm
53
model vehicles
550 rpm
Vacuum advance
0412
NGK
Hitachi
2400rpm
0412
Hitachi
at
Early model vehicles
Later model vehicles
BP 6E
High
hg
tension leads
6E
Radio
suppressed
at
mm
hg
Firing order
deg
hg
at
Reach
19mm
12 in
0 750 in
150
Electrical
Thread diameter
Plug gap
L4S and B
14mm
0 7
6E
measured
Resistance
0 8
68 deg F
51
C 14
mm
primary
at
20
deg C
resistance
3 2
028
0
0 031 in
0 8
6E
L46P and BP
0 9
15
secondary resistance
maximum
Tightening torque
II
6mm
Spark gap
in
2 0
4 1
ohms
20000 ohms
mm
0 031
D3S
O
4
System
minimum
kg
C6R200
primary
3
1
resistance
IS ft lb
16
ohms
14000 ohms
secondary resistance
maximum
14
series resistor
IGNITION COIL
18
ohms
Make
Spark
Hitachi
7mm
gap
minimum
Mitsubishi
HPS
Hanshin
JOE
resistance
primary
Type
Cf4
Hitachi
secondary
51
C6R
200
Mitsubishi
HPS
JOE
Hanshin with series resistance
HPS
13E
with series resistance
BATTER
If the
the
mainly
of
regular inspection
and
servicing
I
Keep
the
battery
Give
surroundings clean and

battery particular attention to
and its
the top of the

electrical
leakage between the cell terminals
prevent
2
Remove the vent
plugs
6mm
minimum
Maintenance consists
17 000 ohms
resistance
Spark gap
MAINTENANCE
are
4 1
maximum
dry
ohms
check the
transfer electrolite from
one
Keep
6
a
excessive amount of
an
should be sought If overcharging is

the regulator setting
If one cell in
topping up
suspected check
particular is at fault
apply
and see that the vent holes
battery required
cause
the
case
for
cracks
Never
cell to another
positive and negative terminals clean
small amount of petroleum jelly
to
and
the terminals to
prevent corrosion
clean
3
Check the electrolite level and top up as necessary

just over the top of the separators Do
The correct level is
acid will escape through the vent holes with

detrimental effect to the connections and adjacent parts of
not
the
overfill
or
car
Use only distilled
water
Release the terminal
screws
and carefully
the cables from the terminal posts

2 Release the battery holding
battery from
for topping up
clamp
and
remove
lift the
the car
operation to instal the battery and

petroleum jelly on the terminals to prevent
corrosion Do not over tighten the terminal screws and
make sure of the correct earth polarity
Reverse the above
naked light when examining

NOTNever use
battery as the gases given off bv the battery can
dangemuslv explosive
a
the
smear
be
AI TIlHNATOH
As it is not
DESCRIPTION
alternating
charging unit uses a rotating field and
pole shoe assembly and together form a rotor unit Low
amperage current is fed through the slip rings and brushes
to the field windings so wear on brushes and slip rings is
very slight and maintenance is reduced to a minimum
The alternator
the
the
possible
current
to
recharge
it is necessary to
storage battery with

rectify the output of
windings to direct current DC This is done by

bank of diodes mounted within the alternator end
stator
bracket
The output of the alternator is
governed by
the control
unit and built in characteristics of the alternator
output current is generated in the fixed stator

and is three phase alternating current AC
The stator windings are wound on a laminated soft iron
The
An
windings
electrical cut
out
aiternator charging system
fanner and are star connected
current flow
151
through
unit is not necessary with the

as
the diodes stop a reverse
the alternator
Electrit al System
S
SERVICE PRECAUTIONS
Connect
test
voltmeter 0
20 vults between the A
terminal of the alternator and the

Make
way Refer to
Du
to
the battery is connected the
SUTe
correct
the
battery
short out
or
ground
any terminals common
the charging circuit

t3 Always disconnect the battery before connecting
If
ohms with
parallel circuit
to negative
S
Le
positive
to
and
ne
a 12 volt supply pressure

battery or terminals in the
engine is running
O S in
Keep battery
terrninals
clean
and all
electrical
connections tight
8
Disconnect the battery and alternator when
welding
on
arc
the vehicle
Never connect
capaeitor to
the field F
terminal
I Fit covers to both fenders and disconnect the

battery terminal
2 Disconnect the terminal block at the alternator if
used by pulling on the terminal block not the wires or
variable
the
When
AS202SA
testing
Hitachi
Remove the fan belt from the pulley

S
Remove both mounting bolts while supporting the
aiternator with the hand do not drop or bump the
alternator
particul
ir
1
is indicaied on the amtJleter

The speed of the
alternator should be approximately 1000 rpm at this point
When testing the Hitachi LTl2S 06 and LTl33 0S
charge
slowly increase the alternator speed to

approximately 800 rpm and close the On Off switch at the
positive
battery terminal gradually increase the
aitematar speed until the voltmeter reading reaches 14
volts at this point the alternator speed Should be less than
alternators
looq rpm if the

Ii 0 Close
unit is serviceabl
the switch of the variable
increase the alternator
slowly
mounting lugs could
refer
Do
Apply pressure
when
not
adjusting
over
It
12
TO TEST ON
The
qut
terminals
of
THE ALTERNATOR
the rpm
increase
in
is increased
there be any drop off in
not meet
out
lfor
altcrll
the
the
test
above
prove
tes s
it
tested
that the alternator is
hattery is not receiving all

regulator unit test procedure
electrical
tHE VEHICLE
regulator
unit must not be in circuit when
this test disconnect the
the
the
components
drrying
before connecting any

equipment and make sure that the battery is
test
battery
Remove
the
alternator
I Disconnect the wiring from the Nand F terminals

of tlie al ernatoL
from
the
vehicle
as
2
Connect a 0 20 volt test voltmeter between the A
terminal of the alternator and a good earth check that the
heading TO REMOVE AND INSTAL

the
Mount
aiternator
on an electrical test bench
t2
equipped for testing charging circuits
3
Using a fully charged battery connect a 0 50 amp
in series
between the positive

terminal and the alternator A terminal witli
ammeter
switch in series at the

4
should
as
fully charged
described under the
test
but
the mounting end bracket only
the fan belt
Check the wiring where soldered to the slide on

rmillals ill tlie t
rmin bluck ur where soldered to lhe
tl
cye
TEST
nor
If the
charge carry
TO
figure
noticeable
no
occur
Should the alternator
serviceable
tension the fan belt

to
this
ove
SpeCifications
will have to be dismantled and all
result
resistance and
speed to approximately 2500
rpm adjus the variable resistance Until the voltmeter reads

14 volts The alternator output should be at maximum
reverse
attention to the
Do not
the variable resistance
NOTE Do not leave the variable resistance in circuit longer

than is llecessarv to do the teSt
of the removal procedure with

following
overtighten the mounting bolts as broken
a
the
out ut
Installation is
with
resistapce
speed
nuts
battery
switch open slowly increase the

of the alternator
until the reverse current flow is eliminated and a 2 amp
wiring from
mounting bolt
variable
battery terminals leaving
positive
alternator output shoul9
the terminals
negative
LT12S 02 and Mitsubishi

close the On Off switch at the
alternators
reading
Loosen both
the
load resistance of 3S amps IS
circuit
remove the terminal nuts and lock washers to remove the

3
to
switch
gative
check fan belt tension dellection should
Regularly
to
maintain
to
circuit while the
be 13 mm
positive t
it in
disconnect the
Never
charging
to
connect
alternator frame
switch in series across the
Open
booster battery is used always
the
battery terminal
7 Connect
battery charger
4
Earth
Specifications
not
terminal of
negativ
Bridge
the
voltmeter
on
off
battery terminal
F
terminal
and A terminal
at
battery
voltage
when
the
battery
is
3
Connect a jumper lead between the F and A
terminals of the alternator
4
Connect a tachometer to the engine according to
the manufacturers instructions
battery
an
reads
reconnected
the
alternator
engine
152
Reconnect
the
battery termihais and

speed
and allow to idle at its minimum
start
the
Electrical
PULLEY HALF
STATOR
DRIVE END BRACKET
FAN
WINDINGS
ROTOR
TAGS
BEA
liNG
BRUSH
6
System
END
BRACKET
it
fJ
WASHER
tu
me
GH BOL TS
THRO
BEARING RETAINER
TERMINAL
SPACER
ER SCREWS
DIODE HEAT SINK
BOlT
lIb
w
@fit
WASHER
RETAI
I
IG
51 4
BRUSH
TERMINAL BOLT
When
011
the
headlamps
Switch
on
Slowly
increase the
to
load across the
to
approximately
apply
engine speed
COVER
SCREWS
t
DIODE HEAT SINK
SCREW
BRUSH HOLDER
1000 rpm The oltmeter should give a miniInum reading of

12 5 volts if the alternator isserviceable should the reading
be below this figure the alternator will have to be removed
for
COVER
BRUSH SCREW
Reassembling
l6
battery
WASHE
Exploded View of Mitsubishi

Alternator Showing Tags on
Stator Leads for Identifica tion
NUT
fT
N
CONNECTOR
repairs
WIRING
CONNECTOR
h
NOTE
has been
Do not switch
off
the
headlamps until
the
engine
stopped
TO DISMANTLE
lt is
iInportant
of pointed
the
pliers
before
that the diode wire be held with
TERMINAL
pair
pliers when soldering and unsoldering the leads

dissipate some of the heat and so protect the
diode from
All
being damaged
wiringcorulections
rem oval
to
avoid
should be marked and tagged

wrong
connections
during
L
reassembling
i
and the
2
On
Mark the assembled
position of both end
winding lamination
Remove the brush cover
brackets
stator
models
LTl25 06 and
holder mounting
brushes
screws
LTl33
05
and brush cover

remove
the
brush
screws and remove the brush holder and
3
Remove the through bolts and separate the drive
end bracket and rotor frow the stator win9ings and brush
e d bracket
NOTi Ir may be necessary to gently tap the drive end

bracket with q soft faced hammer to separate it from the
stato laminations and brush end bracket
DIODE
4 Carefully s pport the rotor in a vice fitted with

soft jaws and remove the pulley nut pulley fan woodruff
key where fitt d and spacer
Hitachi
Alternator
LT125 02
Terminals and
153
HEAT
SINK MOUNTING SCREWS
showing
Wiring
Diode
Connector
Locations
Electrical
5
System
Remove he
bearing plate retaining
screws
TU3 05
Models L Tl25 06 alld f
from the
Unsolder the
drive end bracket

a
6 Support the drive end bracket on the bed of press
the
from
and
drive end bearing
and carefuBy
the rotor
using
with
press
pair
stator
soldering
of
bearing puller remove the bearing from the

the shaft
rotor shaft remove the bearing retainer plate from
end
from
the
bracke1
and the bearing dust seal
8 Remove the slip ring end bearing using the bearing
pointed pliers
Using
nut and remove the rectifier diode
retainirlg
the end bracket
from
TO CLEAN PARTS
Models LT125 02 and AS2025A l

Remove the heat sink retaining bolt nuts and washers
solvents
from the end bracket

On units fitted with
similar
wire with a
brush holder retaining
pair of pointed pliers
remove
same
time
easing
the
winding and
wiring terminal
the
cleaning
windings will result
Clean the brushes and brush holders using a petrol

rag and check and remove any burrs from the
Remove the brush holder screws from the two heat

and
sink type units and remove the brush terminal screws
damp
holders
the brush holder
The bearings are of the sealed ball type and are

shielded bearings and should be replaced when
the alternator is overhauled if they show signs of being dry
6
Unsolder the stator leads from the diodes using a very

hot soldering iron while holding the diode wire with a pair
of pointed
to
assembly and check for any damage or wear Never machine

the slip rings Any burrs or burn marks can be polished out
with very fine sand paper noi emery paper
through
remove
immerse units of the alternator in
3
Compressed air can be used to carefully blowout
the dust from the stator winding and the field winding on
the rotor
4
Using a petrol damp rag carefully clean the slip ring
screws
reassembly
wiring
not
damage
after cleaning
the
the end bracket cover plate hole note

position of aU insulator washers and spacers for
connector
Do
as
The end brackets may be washed in kerosene or

cleaning fiuid after they have been completely
dismantled from the unit They should be thoroughly dried
one
Remove the end bracket from the stator
heat sinks at the
the stator
heat sink with the negative

J
the
diodes fitted directly into the end bracket unsolder
stator leads using a very hot soldering iron while holding
the diode
Separate
pack
pack assembly
windings from
the end bracket
puller
the
leads from the rectitler diode pack

holding the diode leads
iron while
Remove the A terminal nut and the rectifier diode
bracket
7
hot
pre
pliers
Unsolder the bridging wires

preparation for testing
from
the
diodes
packed
and rough
in
nRM
jL
USH
LOCk WASHER
BRUSH
COVERSCRE
j
t
i
BRUSH
SCREWS
154
SPRING
Cover
Hitachi Alternator L T125 02 with Brush
Brsh
ounting Positions
RelT9ved Sh9 ing
Electrical
PULLEY HALF
DRIVE END BRACKET
FAN
RETAINING
CUP
RETAINER
FELT SEAL
SCRE
BRUS
NI
OP
t
WASHER
8
Sysrem
END BRACKET
NAL NUTS WASHERS

AND INSULATORS
I
lit
LOCK WASHER
0
00
I
t
BRUSH COVER
SLIP RINGS
ROTOR
S
BEARING
04
SCREWS
COVER SCREWS
o
STATOR WINDINGS
Hitachi L T125 02 Alternator
TO CHECK AND TEST COMPONENT PARTS
non
the test leads one to each field wire and note the ammeter
All parts being electrically tested should be resting

conductive pad
reading
on a
high reading
over
circuit within the coil No

an
3 5 amps indicates a bridged

on the armf1eter indicates
reading
open circuit exists in the field coiL In both the above

rotor assembly will have to be fitted
cases a new
Slip Rings
I
Visually
check the
Remove all
slip ring assembly
for
Stator
damage
burrs and burn marks with fine sand
paper not emery paper

3
With a 110 volt AC test
slip ring
unit for
The test
lamp should
an
The insulation to earth test is done with the 110
I
volt test
and prods test the

electrical bridge between the slip rings
not
Windings
lamp
equipment
and
wire
field leads
disconnected
If the test
electrical bridge
fitted
an
Using
lamp lights up or burns dimly indicating

a new slip ring assembly will have to be
If the
to one stator
laminated stator
new
lamp lights
stator
winding the lamp should light Repeat the operation

to the remaining leads alternately
5
If the light fails to light on anyone of the tests
then the stator winding assembly will have to be renewed
110 volt AC test lamp and prods check the
to
Diodes
6
If the test
electrical short
lamp lights up or burns dimly indicating

a new slip ring assembly will have to be
Models LTI2S 02 and AS202SA
fitted
CA UTION Never
Field
prod
the
Connect the test leads across any two leads of the
turn
an
test
to
stator
earth insulation by holding one prod on the

shaft
and
rotor
touching the other prod to each slip ring in
slip ring
one
or burns dimly indicating a short

windil g assembly must be fitted
3
To
test the continuity of the stator winding
connect a pair of test leads to a 12 volt battety connect in
series with one of the leads a 36 watt globe
The above test is carried out with the
connect
other test prod
winding frame
light
circuit a
NOTE
the
Windings
and Rotor
to test
Assembly
The insulation to earth test is done with the 110
use
hand driven generator type tester
diodes
Before the diodes can be tested the wiring has to be

unsoldered from the diode leads using a very hot soldering
iron and holding the diode lead with a pair of pointed pliers
volt test equipment connect one of the test prods to one of

the field wires and the other test prod to one pole piece of
heat and protect the diode unsolder each

after marking and noting their connected
the rotor
to
If the test lamp lights or burns dimly and no visual

earthing can be seen and rectified a new rotor assembly
wire
will have to be fitted
a 12 volt battery with a

lead touch the diode wire
with one lead and the heat sink of that diode with the other
lead then reverse the leads
To check for
in
turn
positions
Connect
internal shorting of the

field coil connect a pair of test leads to a 12 volt battery
with an ammeter connected in series with one lead connect
3
dissipate the
bridged
1 5 walt
or
155
globe
pair of
test leads to
in series with
one
Electrreal
System
DRIVE END BRACKET
l
HALF PULLEV
FAN
WASHER
BRUSH END 8RACJlET

STATOR
WINDINGS
TERMINAL NUTS AND WASHERS
i1
ji
SEAL
SPACER
NUT
COVER
BR
SJE
OLOER
WASHER
030
l7
NUT
WASHER
CUP
BRUSH
THROUGH BOL TS
Exploded
globe should
only
If anyone or more of the diodes
prove faulty a new
heat sink or the faulty diode s will have to be replaced
light
are
connected in
one
COVER
View of Hitachi LT125 06 and L T133 05 Alternator
tests to all diodes in turn The
when the leads
OLDER
INSULATOR
SLIP RINGS
RETAINER SCR
Repeat the
BEARING
ROTOR ASSV
oe
L
and
way
out the
Carry
cleaning operations
of component parts
checking
appropriate sections
2 Replace all
as
damaged
worn
and the testing

laid down in the
shorted
or
open
circuited components
Models LT126 06 and LT133 0S
when
These
nits have the diode
mounted in
rectifier pack
Connect
globe
Connect
pair of
test leads to
12 volt battery with a
in series with one lead
one
test lead to the A terminal
and the other lead to each heat sink in
connecting link
turn the globe
light only when the lead is connected to one of the

heat sinks if the globe fails to light or light in both cases
the rectifier diode pack is unserviceable which will
necessitate a renewal of the assembly
Springs and
Press the
Instal
bracket with
should
Brush
to
damage
the
slip ring assembly
refitting
4
Resolder the field leads to the slip rings using a
very hot soldering iron
5
Ensure that both ball races are serviceable Fit new
bearings when in doubt
assembly and should anyone diode prove unserviceable the

rectifier pack will have to be replaced as an assembly
1 5 watt
Take care not
slip ring and bearing onto the rotor shaft

bearing dust seal into the drive end
the bearing
bearing retainer and retainer
the
screws
Press the
bearing
and drive end bracket onto the
shaft using a hollow arbor that will fit

shaft and contact the bearing centre
rotor
over
the rotor
Brushes
NOTE
When
Brush spring tension is tested with a push type

spring tension gauge push the sptlng and brush into the
brush holder with the gauge until the face of the brushes
pressure
on
and holder are
9
Instal the fan spacer and fit the woodruff key
when used into its keyway
jitring bearings always apply the fitting

the section of the bearing being fitted Do
not apply pressure through the balls or rollers
flush
A serviceable
within specification limits
reading
spring should give a

Replace unserviceable
springs
10
The
brushes should protrude from their holders

tension on their springs when checking brush
without
length
II
nut
Fit new brushes when the measurement is less than
to 3 8
to
Fit the fan with the blades towards the alternator

Instal the
kg m
pulley
lock washer and nut tighten the
27 ft lb
specified
12 On LTI25 02 and AS202SA I models resolder

the stator leads to the diodes according to the tags and
marks made before unsoldering the leads take the
Bearings
necessary
Check both tracks and balls
roughness Fit new bearings

serviceability of the old bearings
or
when
rollers for
in
precautions to protect the diodes from being

damaged by excessive heat
13 Resolder the terminal wiring back onto their
original positions
chips
doubt
and
of the
14 Align
the marks made on the brush end bracket
and stator laminations before

TO ASSEMBLE
leads
The assembly procedure
is
the
dismantling operations with attention
poin ts
dismantling
and assemble the
two components while feeding the terminal

reverse
to
the
of
the
through
the end bracket
cover
15
Instal the heat sink
insulation washers as noted when
following
the retaining nuts evenly

156
wiring
plate hole
assembling
dismantling
or
bolts
stator
and
and tighten
Electrical
dismantling taking
l0
the necessary precautions to protect the

Instal the brush holder and
from heat damage
diodes
brushes
screws
System
connect
and
21
tighten
the
wiring terminals
to their
respective
all screws and terminals
Refit the end bracket brush cover and
retaining
screws
THROUGH BOLT
End View of Hitachi Alternator Showing Wiring Terminals

and Diode Rectifier Pack Models L T125 02 and L T133 05
ALTIlRNATOR REGUlATOR
Vol tage relay and voltage regulator gap adjustment
should be made with the regulator unit removed from the
vehicle
DESCRIPTION
a two unit type comprising a
voltage regulator
A cut out relay is not required as a reverse current
cannot flow from the battery to the alternator at any time
even with the engine stopped
due to the effect of the diode
The alternator regulator is
pilot lamp relay
Electrical tests and
and a
the
regulator
equipment
unit
on
should be made with
adjustments
the
vehicle
G
TU E
rectifiers
BLADE
The voltage relay directs the charging system voltage to

the field circuit when the engine is running
When the ignition is switched on
current from the
battery flows through the charge indicator light a parallel
resistance and the voltage regulator contacts to the field
coil of the rotor to supply a starting current for the
alternator to commence charging This is necessary as the
residual magnetism retained by the alternator is insufficient
to start a voltage build up within the alternator The voltage
regulator controls the alternator output according to the
voltage of the battery and pm of the engine
ARMATURE
FRAME
TO
AlA GAP
using
reliable
test
NG BlADE
DJUSTlNGfJTDP
1i
VOLTAGE
REGULA
BOBBIN
REGULATOR ADJUSTMENTS
the
When testing or adjusting the alternator regulator on

vehicle disconnect the earth lead at the battery
negative
terminal before attempting to connect the test

removing or replacing the regulator cover or
instruments
making any adjustments This is to obviate the possibility

of short circuiting any of the regulator terminals or wires to
earth which would result in serious damage to the
alternator
or
MitJubishi
regulator
Regulator
with
Hitachi Early Model
iS7
Cover
Removed
Voltage Control
Typical
Unit
of
ll
Electrical
Sy
tem
FRAME
AIR GAP ADJUSTING SCREW
ARMATURE
SPRING BLADE
Mitsubishi
from
Apart
the
normal
attempt should be made
Dirty
contact
to
testing and adjusting no

repair the alternator regulator
should be dressed with fine emery

thoroughly after in
points
Regulator
with Cover Removed
cloth or carborundum stone and washed

a
cleaning
solvent Burned or
the unit
being replaced
NOTE
Do
solvent
as
YOKE
not
damage
pitted points
will necessitate
the
terminal
screws
3
Disconnect the wiring terminal block and
the unit from the vehicle
immerse the
to
Disconnect the battery negative

Remove the regulator mounting
regulator unit in cleaning

coil windings could result
Installation is the
reverse
to the removal
remove
procedure
MECHANICAL ADJUSTMENTS
GAP
lIIlE
lo
The mechanical
GAP
following
A1RGAP
order
adjustmellls
starting with
Voltage Regulator
the
should be carried out in the
vultage regulatur
TLlZ I OA and RL2220BS
I Remove the regulator from

harness and connector
HANGER
unit
the vehicle
with its
Polish the regulator points using very fine emery

thoroughly after polishing
cloth clean
3
Early
Model Hitachi
Regulator
Check the air gap between the armature blade and

a feeler gauge of the correct dimension
adjust
frame using
Pilot Lamp Relay
the
air gap by loosening the armature

the blade against the feeler
armature
TOP POINTS
blade
screw
POINT GAP
ARMATURE
AIR GAP
d
Ii
LOWER POINT SCREW
LOWER POINT
LOWER POINT SCREW
TOP POINT SCREW
Hitachi TLlZ 37 Regulator Showing Point Gaps and Air

158
blade
gauge and
moving
Gaps
screw
retighten
and
the
Electric l
System
12
AIR GAP
RAME
IR GAP
VOLTAGE REGULATOR BOBBIN CORE
TOP POINT AOJUSTMENT SCREW
Hitachi TlIZ 37
Regulator
with Cover Removed
Check the air gap between the bobbin

blade
using a feeler gauge

dimension adjust by bending the primary
armature
of
core
the
contact
Voltage Regulator
and
support
gap
stments
Charge Relay
TLIZ37
Remove the regulator from the vehicle with its
by
bending
the
secondary
contact
the regulator points with very fine emery

thoroughly after polishing
Check the air gap between the bobbin core and
Polish
support
blade
armature
dimension
Pilot Lamp Relay
to
support
TLIZIOA
support to
I Check the yoke air gap between the armature blade

yoke frame using a feeler gauge of the correct
dimension adjust the gap at the annature set screw
4
Check the point gap with the armature at rest using
feeler gauge of the correct dimension adjust the l int gap
by loosening the lower point s pport retaining screw and
a
Check the air gap between the bobbin core and

blade using a feeler gauge of the correct
dimension adjust the air gap by loosening the retaining
2
moving the point support

retighten the retaining screw
armature
of the upper contact point blade and moving the

in the direction required using a screw driver
positioned
in the
adjusting
using a feeler gauge of the correct

adjust the air g p by loosen ng the top point
frarpe retaining screw and move the point
give the corre ct air gap retightel1 the retaining
screw
and
blade
and
Poi1t Adj
cloth clean
bracket
screw
and
harness and connector
Check the point gap with the armature at rest

feeler gauge of the correct dimension adjust the
Gap
correct
bracket
using
point
Air
Showing
to
obtain
the
correct
gap
ELECTRICAL ADJUSTMENTS
Charge Relay
slot
Check the point gap between the armature blade

point and the lower fixed point with the armature blade at
rest against the top point use a feeler gauge of the correct
dimension
check
to
the
gap
loosening the point support

support up or down to obtain
and
screw
the
adjust
gap
The charge relay check and adjustment is done with the

regulator removed from the vehicle
by
ARMATURE BLAOE
and moving the point
the correct gap
AIR GAP
0
L
POINT GAP
RELAY FRAME
r
t
1
VOLTAGE REGULATOR ADJUSTING SCREW
f
t
f
l
POINT GAP ADJUSTING SCREW
i
1
LFhli
Hitachi TlIZ 37
Regulat
with Co
er
Removed
159
Showing Regulator Adjusting Screws
13
Electrical
System
Djsconnecl the
1I
2
Remove the
negative
regulator from
Remove the
Using
voltmeter reading which will rise with he engine speed

until the regulator voltage is reached when the voltmeter
needle will give a sligl t kickback refer Specit1catiuns fur
tenninal
lthe regulator
fro
ver
fully charged 12
battery
the vehicle
volt
battery
connect
correct
setting
3 ohm variable resistance with a switch in series between

the posi tive
terminal and the N terminal yellow wire
rpm and
of the regulator wiring socket
Specification
leave the switch in the off
and the resistor at maximum
position
5
the
Connect
positive
12 volt 3 watt
battery
12
voltage setting of the regulator not

Specifications stop the engine and remove the
negative
battery terminal remove the regulator cover
and bend the voltage regulator armature spring blade stop
up to increase the voltage setting and down to decrease the
globe
in series between
terminal and the L terminal red
with white trace wire of the
regulator wiring socket
voltage selting
0 20 volt test voltmeter between the

regulator side of the variable resistor and the E terminal or
Connect
negative
battery
Turn
Should the
with
meet
Connect the negative

battery terminal to the E
black wire of the regulator
terminal
7
Increase the engine speed to approximately 2200

c that the voltage reading remains within
chec
amount t
the
on
It
NOTE
n
term
and
switch
reduce
slowly
is
only
bend the stop
to
necessary
alter the
minute
voltage setting
the
resistance of the variable resistor until the test

goes
out note the
reading at this point which should be
13
After making the adjustment replace the cover of
the regulator reconnect the negative
battery terminal
between 4 5 and 5 2 volts
an
lamp
voltage
To
maximum
in
adjust
turn off the switch turn the resistor to
loosen
the lock
increase
and
nut
and
screw
engine
14 Repeat operations
voltage setting is obtained
the adjusting
decrease the boltage at

which the lamp will go out tighten the locknut after each
adjustment and recheck as in item 8
screw
10
remove
regu at
Afte
the
f
the
unit cover and
Check
it
repl
it with a
and
o
adjustments
2
3
th
be
fully charged
is
completed
reconnect
one
before the electrical
negative
tests
To
negative
sure
vehi le and
firmly joined
7 Connect
t4e
tJiat
terminals reconnect the
TLlZ37
adjust
the
voltage setting
the
regulator
installed in its mounted position
on
the
J Check that the regulator points are clean and free

from pits or urn marks
2
Check the state of charge of the vehicle battery
not he fully charged either charge it or replace it

fully charged one before the electrical tests and
adjustments are attempted
3
Disconnect the negative
battery terminal
4 Disconnect
the A
terminal wiring from the
should it
with
regulator unit is firmly mounted to

the wiring terminal connection is
tachometer
to
the engine
according
Reconnect the negative

battery terminal and
temperature
the engine and bring to operating
9 Mount a thermometer on the cover of the regulator
bient
temperature
the
thermometer
a 0
50 amp test ammeter and a
ohm resistor in series with the terminal and
disconnected lead bridge the resistor and ammeter with a
0 25
to
the a
alternator and connect
the manufacturer s instructions
er
check and
unit should be
on
20 volt test voltmeter in parallel

battery terminal and a good earth
battery lead
between the alternator
tl regis
wiring to the correct

battery terminal
vehicle
terminal
5
Connect
start
all
Voltage Regulator
4
Connect a 0 50 amp test animeter in series
between the disconnected wire and the alternator
battery
the
correct
attempied
alternator
ake
the
lS After the voltage regulator adjustment has been

corrected stop the engine and disconnect the negative
battery terminal remove the test instruments and
battery terminal
neg tive
Disconnect the wire rom the battery terminal
until
unit
and wiring and instal the

the unit onto the vehicle
Disconnec t4e
such as the
13
If the voltage build up of the aItemator cannot be

contrulled by the regulator it indicares thar the regulator
unit is at fault and should be replaced with a serviceable
TLlZIOA and RL2220BS
are
to
NOTE
the state of charge of the vehicle battery

under three quarters charged rech rge or
shpuld
ce
instal
to
charge relay adjustment
instruments
test
Voltage Regtlato
I
out
restart the
can
jumper
lead to
commences to
protect the ammeter until the alternator
charge
Connect
0 20 volt test voltmeter between the A
terminal ofthe alternator and the
be held in place with a lump of putty or similar substancec

10 wJien the engine reaches operating temperature
Connect
the manufacturer
and the ambient temperature reaches its maximum allow

the e gine to idle then
slowly increase the rp and rote the
tachometer
instructions
Make sure an
turned off
160
light
negative battery terminal

the engine according to
to
switches
and accessories
are
Elec rical
Mount
8
to
re
ster
the
thermometer
ambient
on
the
thermometer may be held in place with

similar substance
9
of the regulator
cylindrical type
lump of putty or
cover
temperature
a
a
Start the engine and allow it to reach operating
jumper I d bridging the ammeter

resistor
engine speed to approximately
2500 rpm the ammeter reading should be less than 5 amps
after a few minutes operation
lP With the engine operating at 2500 rpm check the
voltage reading on the voltmeter and note the ambient
temperature reading on the thermometer compare the
readings with Specifications
12 If the voltage reading is not to specifications
allow the engine to idle and reconnect the jumper lead
bridge to protect the ammeter then stop the engine
13
Remove the negative
battery termjnal
14 Remove the regulator cover
Remove
the
and increase
Reconnect the
16
Start the engine again and
bridge
17
temperature
10
15
Loosen the
adjusting
screw
decrease
the
in
negative battery
adjusting
to
reading
Tighten
terminal
remove
screw
increase
the
14
System
the jumper lead
lock nut and turn the
reading arid
locknut
out
after
to
each
adjustment
the
NOTE The adjustment
be made within
must
one
minute
of the regulator cover as the change in

temperature occuring in the unit will alter the voltage
setting and the procedure will have to be repeated after the
unit has normalised with the cover installed
the removal
after
18
and
After the
remove
the
instruments
test
is completed stop the engine

battery term nal disconnect
adjustment
the negative
and
reconnect
the
alternator
terminal and wiring

19
Reconnect the
negative battery
terminal
STARTER MOTOR
he engine fires the over runrung clutch of the drive
assembly prevents high speed rotation of and
possible damage to the starter armature if the solenoid
wjndings are not immediately de energised by releasing the
switch key
The startersolenoid switch windings are energised by
t e key operated combination ignition and starter switch
DESCRIPTION
As
1ion
pi
The starter motor is a 12 volt series wound four pole

or two brush unit
a solenoid actuated
The starter motor is equipped wi
four brush
running clutch assembly

r frame
the solenoid
The solenoid is attached
and driv
clutch
is
connected
to
over
the
running
plunger
lever and pivot pin
a
link
assembly
pinion
through
pre
engaging
starter drive and over

to
the start
arrangement
TO TEST ON THE VEHICLE
Should the starter fail to operate when the switch is

moved to the start posipon che k the following points
i Check the battery condition and slate ofcharge
the
When tpe solenoid windings are energised

plunger
on the lever and pivot engages the drive pinion with
the flywheel ring gear and at the same time closes the
switch supplying power from the positive lead of the
acting
battery
to
the
starter
motor
refer to batt
ry
field coils to operate the
YOKE WINDOWS
motor
Y
DR V
END
section of this ITlanuaL
KE
BRACKET
J
lEVER
18
iZJ hf
SO
JQCDVER
NOID
BRUSH
TERMINALS
SPLIT PIN
SOLENOID SCREWS
YPIVOT
PIN
WASHERS
CENTRE BRACKET
RETAINER
CIRClIP
b I
P
COLLAR
ARM
i
4JI
TURE
t
ro
THRDUGH BOLTS
BRUSH PLATE
i
0t n
Y
t
L
BRUSHES
a
Exploded View of Hitac i Starter Motor
BRUSH SHEW
161
15
Elecfrical
2
Clean the
tem
Sy
battery terminals taking particular care

terminal post and
positive
to remove the scale from the
terminal
3 Check
cleanliness do
4
for tightness and

overtighten the terminals
on the headlamps and operate the starter
Switch
control
if the
tch
heard to operate it
high resistance has
could
earth connections
the
not
go dim but the starter is not

could indicate that a short circuit or
lights
in the
developed
starting system which
be either external or internal

Check all the external wiring to make Sure the fault
if the external circuit proves satisfactory
is not external
that the problem is in the starter assembly

unit will have to tie removed and bench checked
indicating
the
mounting screws The pole shoes must be replaced

same position from which t ley were
removed
in the
TO CHECK AND INSPECT
With the starter motor dismantled check the brush

using a 11 0 volt test prod equipment
holder insulation
with
in series with
globe
Connect
test
lead
one
prod lead
on the brush holder

positive
negative side If ihere is ally
indication of leakage the globe will light or an arcing will
occur at the point of short ng
l1er r pair or replace the
ei1
one
side and the other lead
the
on
brush holder if a short circuit is evident

2 Check the brushes for adequate length Brushes
should
be
renewed
when
their
length is below
itcations
spe
Theys ould be a free sliding fit in the b
guides
I
Disconnect the battery terminal negative lead

Disconnect the battery lead from the starter
solenoid
3
washers
5
Remove the starter motor from the engine

The installation procedure is the reverse
Check the brush spring tension with

with Specifications
Check that the commutator is f e from pitling

clean with a petrol moistened
clotand
polish With a strip of fine glass paper
to
and
burning
the
segments
TO DISMANTLE
the
field
lead
from
the
solenoid
terminal
Remove the split pin from the pinion lever
the pivot pin
piyot
remove
3
Remove the
solenoid
tpe
plunger
solenoid and plunger
4
Replove the
solenoid mounting screws

from the pinion lever and
d unhook
re
ove
the
assembly
Remove
Remove the brush terminal
prod
yok
from the YOl e windows

screws and remove the
cover
light
indicat
windings
open brcuit in
an
the
on
Failure Of
wiring of
C eck the
fjelq coil for grounq by pla ing one test
anthe other lead
the field coil lead
on he starter
If the
globe lights
or
remove
arcing occurs between the

field coils ana repair or
the
renew
7 Remove
the
two assembly through
bolts
and
the commutator end bracket
Separate th drive
yoke
with
end bracket and armature from
9
assem
Remove the armature pinion and clutch
ly
with the pinion lever from the drive end bracket
10 Remove the circlip and collar from the armature
shaft tap the collar towards the pinion to gain access to the
circlip
II
to
field coils and earth
brushes
the
lamp
the field coils
remove
nFld c04s
dust seals from the solenoid mounting

dust
or by using
the test prods in series with the field

the
position
tpe
Specifications
Check the
growler
I Disconnect
to
armature for short circuit

using a
the 110 volt test prods and globe
6 Place one fthe t srprods n
o the arniat re Core or
shaft and moye t e other
pro
arounq ipe cif umference of
the commutator If the test lamp lights at any point the
armature is faulty ahd should be replaced
7 Test the
tor
cohtin
uity
by connectjng
5
pull scale
A badly Yom commutator may be cleaned

up by
mounting the armature in a lathe spinning at high speed
and a lighLcuLtaken ac JSS
e commutatOLWillLa yefJ
iI
sharp tool After turning r cut tlJe insulation betweeii
removal operations
pin and
Discunnect the switch wire from the solenoid

Remove the two starter mounting nuts and lock
Compare
Remove the clutch and pinion
lre
armat
shaft
12
Remove
the
centre
assembly
bracket from
from the
the armature
shaft
13
If the field coils
location of each individual
are
pole
to
be removed
marl
the
NOTE
bushes for
as
wear
necessary
Check
The
old
The new bushes must not be reamed to size
as
reaming will impair the porosity of the bushes and cause

early failure New bushes should be allowed to stand
immersed in clean light engine oil for 24 hours before
fitting This time period may be short ned to two hours in
case
2120F
ofurgel cy i the oil is heated to Jooe
centres
162
shaft
brushes plust be removed and the pew ones pressed illto the
end brackets and centre bracket using a
polished mandrel of
the exact diameter of the armature shaft
10
shoe before removing the
Check the armature
speCifications and replace
Check
using
the
a
armature
dial
gauge
shaft
Refer
for
bend
between
Specifications
for
Electrical
16
System
Showing
Method
of
Measuring
Protruding
length
of
Plunger from Solenoid Face
to
Adjusting Nut
Replace the armature if it is not within

Specifications
II Check the drive assembly clutch pinion teeth for
A clutch in good condition
wear scoring or chipping
should take up the drive in one direction only lt should
rotate easily and smoothly in the non drive direction and
the assembly should move smoothly along the armature
Instal the centre bracket to the armature shaft

Assemble the clutch and pinion to the shaft fit the
collar with the cup away from the pinion fit the circlip and
helical
distance from the face of the solenoid to the face of the flat
surface
adjust the adjusting nut to give the correct
tolerances
2
3
stake in position and fit the collar over the circlip

4 Check
the
protruding length of the plunger
nut by pressing the solenoid plunger against a fiat
adjusting
surface
splines
completely depress
to
NOTE Do not wash the drive assembly or clutch in solvent

as this will destroy the clutch lubricant and cause early
measurement Refer
failure of the
and
unit
NOTE Make
teeth replace
to
as
are correc
necessary
the
7
TO ASSEMBLE
I
splines
start
clutch pinion lever
tly
sure
the thrust washer
assgmbly and the
lever
meshed
Instal the armature and drive end bracket assembly
yoke
Instal the commutator end thrust washers to the
armature shaft
8
Lubricate the drive assembly
the
measure
bracket to the drive end bracket
To replace the thrust plate and spring remove the

from
the sleeve while compressing the spring with
circlip
the thrust plate
13 Check the ring gear for chipped worn and or bent
12
plunger
Specifications
Assemble the armature
cen tre
the
on
the armature shaft
Tighten
end float
shaft bushes and solenoid switch moving

stud with a light coating ofmulti purpose grease
armature
plate bracket and through bolts

through bolts and check the armature
Instal the brush

the
Refer
Specifications
adjust
corrmutatoT end
163
with
shiIns
at
17Electrcal
System
Hitachi Starter Motor Showing Pinion to Pinion
Instal the brushes into their
10
correct
fit their tenninal screws and tighten

II Instal the solenoid dust seals
tu the
plunger
pinion lever
lever
pinion
holders and
and the solenoid
position to instal the pivot pin

pivot pin hules and instal the
the
fit
solenoid
mounting screws and tighten
pivot pin
instal the split pin to the pivot pin
align
Instal the dust
12
solenoid
mounted
on
operating
cover over
the
the
yoke
windows
To
in
should be
starter
but
vice
with
tested
and
motor
the
with the
connected
starter
field
unit
in its
jumper
lead with
lead
the
on
energised long enough to

damage to the solenoid could
the solenoid
as
heating
pinion stop clearance is not within

the solenoid and adjust the plunger
instal the solenoid and recheck the clearance
pinion
to
remove
operation
until
the
clearance
is
within
When
to
pinion
he
remove
to pinion stop clearance is

the jumper leads and connect the
the terminal of the solenoid
Starter Motor
M terminal of the solenoid
the battery and connect
Proceed with the
adjusting
switch in series to the solenoid S
the solenoid and
noload
test after
checking and
pinion clearance
of reading 0 500
terminal and the
battery
positive
amps
solenoid B terminal using heavy core cable
3 Earth the negative battery terminal to the starter
2
Connect
an
ammeter
capable
in series with the
Close the switch the solenoid should be activated

into the solenuid moving the
plunger pulled smartly
on the shaft
To test the hold in coil connect the solenoid case
to the negative battery tenninal energise the solenoid as for
the series coil test then remove the M terminal connection
body using heavy core cable

4
Bridge the B terminal and
solenoid using a jumper lead with
The solenoid plunger should remain held in the solenoid if

the hold in winding is serviceable
series
check the pinion to pinion stop clearance

as above to move the pinion into its
shaft
To
over
If the
field wire
pinion assembly forward
Only hold
from
repeat
terminal
and the
pinion and the

for the correct clearance
Specifications
the series coil mount the starter motor

connect the negative terminal of 3 fully
Specifications
make the measurement
securely
charged 12 volt baltety to the
using a suitable jumper lead
2 Make an 8 volt tapping
a
NOTE
correctly adjusted
test
a
pinion stop
occur
disconnected
Refer
specifications
adjusting nut
unit
position
Measure the clearance between the
the
TEST AND ADJUST

Starter Solenoid
The
invert the starter to allow the
into
to move
the solenoid to
move
Clearance
Stop
Connect
revolution
the
a
S terminal of the
switch connected in
counter
to
the armature
6 Close the switch in the jumper lead between the B

and S terminals and note the rpm and current draw of the
energise the solenoid

mesh position
164
Electrical
To carry out the lock torque test mount the starter

on a starter test bench and make the connections
starter motor compare the readings with specifications

7
After completing the starter test remove the test
motor
according
instruments and leads
or
to
the manufacturer
instructions
use
high
amperage variable resistor in the battery circuit so that the

voltage can be controlled accurately as small variations in
NOTE High amperage reading with low revolu tions check

for shorted armature shorted fields worn bushes bellt
armature shaft or poling armature high amperage draw
with no revolutiolls check for shorted field coils shorted
armature
18
System
voltage
and amperage
considerably alter the torque of

Specifications for the correct test
can
the starter motor Refer
figures
shorted brnshes
DISTRIBUTOR
pitting arid
DESCRIPTION
the dwell
angle should
be checked and
adjusted
if necessary
The
is
distributor
driven
by
camshaft Mechanical advance and
skew gear from
incorporated in the distributor

by centrifugal weights mounted to the
are
shaft and
one
The
advance
consists
to
of
smooth
traces of oil
61
oil
or
grease
To
badly pitted and burned should

are
all
square surface on a fine oil stone Remove
the
them
in
from
points by washing
petrol as
on
the
points will
remove
pitting and burning

points firstly remove the
cause
the breaker
terminal from behind the screw

2
Loosen the fixed plate retaining
remove
screws
do not
the screws
Slide the breaker point assembly away from the

retaining screws and adjusting screw at the same time lift
3
TO CLEAN AND ADJUST BREAKER POINTS
the breaker
At intervals of 4000 km
3000 miles the contact
breaker points should be checked for excessive burning and
points
clear of the distributor
LOW TENSION PIG TAIL
MOVING
POINT
LOW TENSION TERMINAL
CONTACT POIN
FIXED POIN
ADJUSTING
SCRE
RETAINING
SCREW
RETAINING SCREW
DIAPHRAGM LINK
MOUNTING
be
still serviceable should be cleaned
distributor cap and rotor button then loosen the low

tension lead screw on the fixed point and slide the wire
diapragrn unit
mounted externally onto the distributor body with linkage
advance is
to the breaker plate from the diaphragm
controlled by engine loadings
vacuum
are
replaced Points that
governed
advance spring on all models except 0411

which has two advance control springs
by
Points that
the
advance systems
Mechanical advance is
vacuum
SCREWS
Distributor with
165
Cap and
Rotor Removed
Eleclrical
19
4
Syatem
To instal the breaker points
the removal
rever
procedure
S
Turn the engine until the rubbing block of the
moving contacts is on the highest point of the cam lobe
6 Slightly loosen the tixed contact plate lock screw
and using a suitable screwdriver move the contact plate in
Non
lock
Again check
then retighten
plate
the fit of the feeler gauge blade between the contact points
screw
gap
lower
Ihe gap allhe
Turn the
each earn lobe
arm
cam
Measure the breaker
by pulling
points see SpeciHcations
SCREW
set
engine and measure the contact poiot gap

being sure that the heel of the breaker
block
is in the position of maximum lift on
rubbing
7
at
tension tester
CLII
E
being filled
use
are
poinls
at
each
ROTOR
new
for some time but are still sen iceable set the
approximatelv mid way betlveen the upper and
limits of the specifications
been in
the necessary direction until a clean feeler gauge blade of

the specified thickness is a neat sliding fit in the point gap
the contact
If
as the initial wear of a new

upper limit of the specifications
will
breaker arm rubbing bluck
be rapid If the poinlS have
at
arm
pressure with
right angles
spring
with the breaker
9
Place a smear of high melting point grease on the
lobes of the earn assembly and instal the rotor arm and the
SCREW
distribotor cap
MOVINGPOINT
Connect the dwell meter and check the contact
10
adjust if necessary to specifications

II Connect the timing light and check
dwell
FIXEDpOINT
the ignition
timing
TO REMOVE
8REAKERPLATE
With the distributor cap removed turn the engine

ignition timing mark indicates number one
the
until
cylinder
is on tdc that is
extreme left hand mark
with the pointer in line with the

the pulley when looking at the
on
engine from the front of the vehicle and the rotor button in
line with number one high tension lead tennina position
Remove the
vacuum
advance control unit

3 Remove the
SHMT
TAll
SPACER
lead
ignition
from
the
Remove the set bolt holding the mounting plate to

block and remove the distributor from the
primary
terminal block
AU
EARTH PIG
SCREW
advance line from the vacuum
WASHER
the engine
engine
P1G
CLlP
TAIL
TO DISMANTLE
SHIMS
I Remove
2
VACUUM
ADVANCE
UNIT
mounting
diaphragm
SCREWS
CAPACITOR
the rotor button
Remove
to breaker
Remove the
CLIP
a
PLATE
0
post and separate

5
REW
DRIVE
plate
WASHER
View
61
0411
Remove
clip
the breaker
the
low
to the distributor
control
linkage
remove
unit
from
the
the advance unit
from the moving point pivot
points
tension
terminal
block
and
body and
remove
the breaker
plate
assembly
7
GEAR
To
dismantle the
to the
gain
spring taking care
spring and plate and the
spring
Exploded
plate and
advance
the
capacitor from the distributor body

6 Remove the two screws holding the fIXed breaker
0THRUST
PIN
vacuum
disconnect
3
Loosen the contact breaker point retaining screws
terminal
screw slide out the wire terminal and remove
and
the contact breaker points
VI
O RING SEAL
the
screws
and
Model
Distributor Component
two Control Springs
Distributor u
of the
166
to
access
breaker plates compress the

circlip and remove the circlip
not to lose the balls between the

two breaker
plates
El ctrical
BALLS UNDER SPRING AR
Syatem
20
CIRCLIP
Under Side
of
Fixed
Brea
Breaker
er
Plate Sho ing
Spring
and
Check the distributor shaft and body for

necessary Maximum clearance betweel1
S
8
Invert the distributor body and
remove
the screw
distributor
body
mounting plate
the
Support the distributor shaft near the drive end
using a hammer and suitable drift tap the drive pin
holding
the
to
renew
as
body
should
not exceed 0 08
clearance is in
9
and
Check the low tension and earth yires for
excess
the shaft
ial
of
Check the
renev
from the shaft and drive gear
NOTE Mark the position of the drive gear in relation

ect
will necessitate
to
assembly
Clearance in
shims from the distributor body

12 Mark the position of the rotor drive
pivot pin
Inspect
9
key of the
assembly in relation to the shaft with a daub of quick
drying paint on the centrifugal weight carrier of the shaft
and an arm of the advance plate of the earn assembly
13 Remove the earn assembly retaining screw and the
cam assembly
14
Mark the position fthe centrifugal weights and
the control spring s using quick drying paint
15
Remove bofu centrifugal weights the advance
c mt olsprings and carn assembly thrust
washer from the
burned
ess
s4aft and
if the
0 p03 in
it will necessitate the
mm
figure
wear
or
roughness
variations in
the c
assembly
between the shaft and
of this
is 0
029
figure
mm
0 0015
earn
ill
will necessitate the
earn assembly
the governor
weights for binding
wit
the
Check the distributor cap for cr cks carbon tracks

or
corroded terminal
Check centre carbon for
10
II
12
wear
Check rotor for damage or

Check the vacuum adv
diaphragm
co
ecting
release the
should hold
03
shaft
a d protrusion
terioiati on
mut for leaking

tpe diaphragm
link p lace a fmger ave the s ction p pe and
connecting link The vacuum on the finger
To
for at
do
this
least
Check the
ce
in
push
on
30 seconds
rubber
ring
eal
anq
renew
as
necessary
Thoroughly clean
TO ASSEMBLE
all
parts with cleaning solvent
immerse the capacitor

care lot to
advance unit ip solvent
2 Check and test the capacitor using
taking
or
vacuum
Assembly is
capacitor
necessary
re
set
the weights before assembling

2 Instal the control spri gs
Check the contacts for pitting and burning and if

w as

i Apply a small amount of high melting point grease
to the centrifugal weight pivot posts and rubbing points of
tester
3
ex
and
in excess of 0 05 mm 0 002 in
the clearance
renewal of the shaft and
cam
cams
maximum clearance
assembly
Remove
wear
body
cams for
renewing
Check
the drive gear spacer washer 0 ring

seal and mounti g plate from the distributor body
I I Remove the shaft assembly spacer washers and
10
of this
and
two
lift between a y
the shaft for co
possible
fractures
Plate Assem ly
only
as
marked
or
oted
on
dismantling
NOTE Points should be cleaned with
stone never use emery cloth or
contact
sandpap
file
or
oil
assembly
167
Instal the
as
marked
cam
on
assembly
di mantling
thrust washer and
am
Electrical Sy8fent
21
lrm
CU
VOTE Un all Slflg C
sprillg HtJJl ls check IWI the
long slot in the com assembly udJ ilnce plate is jiued to the
weight with the cOIJtro spring arrilcheJ ami the shorr slot is
fitted to the weight without the control spring
011 dual control
sprmg mudels the shvneH sprmg is
centrifugal weight which is installed into

the long sJot of the cam assembly advance plate and the
longer spring is fitted lO the weight which is installed intu
the short SIOl of the advance plate
attached
the
to
Instal
the
cam
assembly
retaining
screw
and
tighten
5
Place the washers on the distributor shaft and
instal the shaft into the housing
Starting from the top the washers are ill the

washer bakelite washer and adjusting
following order
washer Lubricate the shaft with engine oil before installing
NOTE
Instal the muunting plate and the
0 ring seal
to
distributor body and instal the moun ting plate to

distributor body screw with the scale at the centre position
the
tighten the
screw
Instal the drive gear and thrust washer on the shaft

and align the marks made on dismantling instal the drive
7
pin
Measure the end thrust of the shaft with a feeler
dial gauge the end l10at should nut exceed 0 40
gauge
or
0 015 in
mm
restore
to
the
If the end fluat exceeds the maximum

clearance by
correct
installing
suitable
adjusting washer
Assemble
between the
with
plates
the breaker
plates and lubricate the balls

spring and lower plate
high melting point
fit the
Mark on Crankshaft
Pulley
in Line with
Timing Cover and Distributor Rotor

Cylinder Firing Point
at
No 1
TOIN TAL
Instal the vacuum advance unit and connect the
11
Check that the engine has not been rotated after

was removed by rechecking the timing
as described
in item
I of the TO REMOVE
position
link t9 the pin on the moveable plate and lightly lubricate

with hi
melting point grease
12 Instal the capacitor terminal connections earth
pigtail wire and cap retaining clips

13 Lightly lubricate the pivot post
set
and assemble
ie
the
2
points
If the rotor is inclined

retard position the
to
cause
to
the
50
of the
one
that the rotor button

tension terminal for
rotor
one
in
clockwise
tooth
its
mounting hole
fully engaged and that
the rotor button is pointing to the cap clip aI1d the position
of the high tension terminal for number one cyUnder instal
the mounting plate to engine retaining bolt
4 Check that the contact breaker points are just
3
making
centrifugal weights are free to operate by turning the rotor

button against the centrifugal control spring while holding
the drive assembly when the rotor button is released it
should return freely to the fully retarded position
17
Turn the distributor shaft
position
high
number
cylinder then turn the
direction sufficiently to move the gear
breaker points
section TO CLEAN AND ADJUST BREAKER POINTS

16
Instal the rotor button and check that the
the
distributor
section
of the contact
14 Instal the breaker points onto the breaker plate

lightly lubricate the carns and apply a small dab of high
melting point grease to the rubbing block of the moving
point
J 5 Adjust the contact breaker gap as described in the
to
on
retaining
screws
breaker
Timing
Pointer
grease
Instal tbe breaker plates and
10
Tdc
and between the
starting
Instal
sure
the
distributor
into
that the drive geat is
to open when the e3rn
assembly
is turned in the
direction of rotation and tighten the mounting plate

engine retaining bolt
5
stick or does not return

should be located and
plug
168
Instal the distributor cap and connect the spark
leads
6
rectified
to
Instal the low tension lead
Electrical
7
Check the ignition timing with a timing light and

adjust the dwell angle if necessary
advance
check and
Instal the
vacuum
TO TIME ENGINE AND
SET IGNITION TIMING
breaker points are clean

specified clearance
2
Rotate the crank haft until No 1 piston is at tdc at
the end of the compression stroke
3
Align the pointer on the timing cover with the
extreme left hand mark on the crankshaft pulley when
viewing the pulley from the front of the car
4
The position of the rotor should be in alignment
with No I high tension lead terminal of the cap and the
contact breaker points should be just starting to open
5
To adjust loosen the anchor plate to mounting
bracket screw and move the distributor body in the
direction required then retighten the screw
6
Road test the vehiCle and make final adjustments
to obtain best
performance and smoothest operation
1
TO ADJUST
Using
1
light
that the contact
Ensure
adjusted
to the
to
the
within
Start
dwell
tachometer
engine
according
meter
the
to
Adjust
vacuum
the
the distributor in which
case
the distributor will
engine
and
bring
to
normal operating
the
engine
igle
speed
to
POINTER
Showing Ignition Timing
TIMING
to
the
MARKS
Marks and Distributor Advance and Retard Scale
169
va
uum
advance line and
angle
adjust
speCifications
Remove the test instruments and reconnect any
disconn ctcd wiring etc
specifications
IGNITION
Reconnect
engine idle
11
the
the
After checking and adjusting the dwell

the
recheck
ignition timing and adjust if necessary
and timing
manufacturer
temperature
3
from
After
10
the
line
advance position with the

the crankshaft pulley equals 5
the
have to be removed for uverhaul
instructions
2
vacuum
setting the contact dwell at idle speed

engine speed t0 approximately 2500 rpm
checking the dwell angle as the rpm s increase Any
orn parts
variation greater than specifications indicate
8
increase
IGNITION TIMING AND DWELL ANGLE
check
the distributor cap and rotor button removed to carry out

this operation
instruments
Connect
the
unit and
22
timing light each division on

degrees refer specifications for the correct setting
5
Adjust the timing position by loosening the
mounting plate retaining bolt and rotate the distributor
body in the slot if the adjustment is not possible at this
point it will be necessary to loosen the screw holding the
mounting plate to the distributor body both these screw
holes are elongated for this adjustment
COffect
6 After the
timing position has been
determi ed make sure the mounting plate to engine
retaining bolt and the mounting plate to distributor body
screws are firmly tightened
7
Check the contact dwell refer Specifications for
the correct setting adjust by opening or closirig the contact
breaker pain t gap the engine will have to be stopped and
advance line
Static method
and
Disconnect
System
23
Erectriea
Sy
nt
PLUGS
SPARKIXf
of
TO SERVICE
too
these
spark plugs should be removed for inspection

cleaning and resetting at intervals of 5 000 to 6 000 km
3 000 to 4 00Q
miles
Spark plugs removed from an engine in good condition
operating under nonna conditions should have a light
powdery deposit ranging in colour from liglit brown to
greyish tan After considerable service the electrodes will
show signs of wear or nOllllal buming Spark plugs showing
a thick
black oily deposit indicate an engine in poor
mechanical condition or possibly that a plug with too low
The
the earthing electrode

testing machine
NOTE Neve
the
possibly
7
The
high tension cables between
the
that
HIGH TENSION
sparking plugs
and
tension terminal
the
coil
high
ignition
distributor cap and the

manufacture and have a carbon impregnated
the normal wire core
are
core
of
to
If
Always
on
instead of
Two
types
IGNITION
circuit a
special
used with
in the
12 volt coil is used which is marked

ance
l
S
ITf
H
perishing
or
it will
cause
misfiring
cracking and
renew as
as
necessary
performance
of the vehicle
The series resistance is
secondary primary circuit This secondary circl it

at the coil terminal resulting in
allows a
a stronger spark for starting purposes as any voltage drop
caused
by the heavy starter draw is automatically
compensated for by the circuitry
a
full 12 volt pressure
be
IIIlADI
DIPPER
OT
DESCRIPTION
The
core
Never attempt to repair defective cables

cables may be carefully cleaned using
brings in
is mounted near the coil and when
SIGNAL
plug
broken
by passed when the ignition switch is moved to the start

position by an internal bridge in the ignition switch which
or disregarded when the primary

being checked disconnected or connected
TURN
COli
better
used cannot be overlooked

circuit is
Specifications
cunjunction with
special coil a high secondary voltage is obtained
throughout the speed range of the engine resulting in
series resistance
The series resis
threads and using new gaskets fit

a torque wrench tighten to the
the
primary
to
on
When the series resistance is used in
of primary ignition circuits are used on

simple circuit and a series resistance
the
simple primary circuit

a series resistance is incorporated
bending
cap for evidence of arcing and renew
The primary circuit which does not include a resistance

between the ignition switch and coil uses a normal 12 volt
When
tlte electrode gap bv
plug
outside of the cap Renew the cap if cracks or tracking is

evident
Check the carbon brush in the centre of the distributor
circuit
coil and
bending
by
reliable
the
a cloth
The
moistened with kerosene then wiping completely dry
Also check the distributor cap for cracks or tracking
between the high tension tenninals on both the inside and
the cable from a sparking plug by

r move
the cable terminal Use the same care when
these vehicles
sanding
cracked insulator wiI result
the cable to the
cable has
required
eliminate
spark plug
Check the cables for
special
unserviceable
pulling
to set
a
UlADS
connecting
on
radio interference care must be

exercised when removing the cables from the sparking plugs
to ensure that the cables are not damaged by stretching
the cable
which will break tlie core and render
This is
on
and test
the plugs finger tight Using

recommended torque Refer
plugs
the distributor cap and the centre
attempt
centre electrode or
Clean the
or
plugs
machine and blow clean with compressed air

Set the electrode gap see Specifications
yellowish deposit
or
are
trodes
ele
pon elain and burning 01 the
If the heat range is correct clean the
heat range has been fitted
Spark plugs howing a white

indicate sustained high speed driving
1l tIued particularlv when

bC
accompanied by blistering of the
high heat range have
deposits
AND
HORN BUTTOX
HORN BUTTON
To Remove and Instal
signal switch is a multi purpose unit

mechanism for the turn signal lamps with
switch
comprising
automatic cancelling the headlight dipper switch a high
beam flasher contact for overtaking and the hum wiring
turn
Disconnect the battery negative tenninaL

Pull out and remove the horn button medallion
Remove the horn button
contacts for the horn button circuit
170
Early Model 1000
retaining ring
24
Electrical System
4
Remove
the
wheel
steering
washer and flat washer

5
Remove the horn
bar
retaining
assembly
from
lock
nut
To
dismantle the horn
screws and
the non conductive
To
springs from under
the insulator
The
assembling screws
8
Separate
contact plate and
contact plate
the
Remove
0
insert and
remove
bar remove
horn
insulator
ring
horn
three
the
reverse to
steering
the
the
and medallion
on
terminal in the steering wheel hub

medallion
horn
button
and
turn
in
Remove the horn button
Remove the three
to the
steering
screws
wheel hub and
spring
holding the
remove
remove
the button and
thumh press buttons from the

E clips retaining the thumb
the
remove
remove the two
and
press button to the medallion
an
anti clockwise direction to release it from the retainer

3
To
medallion
battery negative terminal
the
battery negative terminal

holding the horn button
to
the
assembly
steering wheel working from
steering
Later Model 1000
Disconnect the
in
1200
the underside of the wheel

3
Raise the button and medallion assembly from the
wheel and disconnect the horn wire from the
Press
is the
Remove the two screws
suitable puller
using
holding the turn signal trip
horn contact slip ring and trip insert
a
screws
Assembly
dismantling procedures
assembling and installation procedure
Disconnect the
I
wheel
and installation is
ring
removal and dismantling operations
To Remove af d Instal
seat
contact
and sponge rubber
the insulators between the horn bar and
Remove the
the
dismantle
plate
from the horn ring
ring
and
Remove the contact
6
Remove the three
blocks from the
horn button
the steering
wheel
6
button remove the three
retaining
remove
washers and
Remove the nut
the button
wiring terminal from
he centre terminal screw

retainer
the retainer
plate
QUADRANT ASSY
plate
HOUSING
WEDGE
RETAINER SCREWS
J
STEERING SHAFT
UJ
HORN BUTTON
LEVER
Dismantled
COVER
COVER SCREWS
Top of Steering Column Automatic

Transmission later Model 1000
View of
SPRINGS
Q NToL
INSULATOR RING
Dismantled View of Horn Contacts
171
WAHER
Ie
10
INSULATORS
SCREWS
Early
t
JACKET
Model 1000
1
NUT
I
ju
Electrical
6
Remove
contact
SY3tem
the
insulation
bIOl k
spring
and
assembly
Installation is
procedure
TURN SIGNAL SWITCH

I
2
Disconnect the negative battery terminal

Remove the horn button assembly and retainer
where used
3
Remove
the
steering wheel retaining nul and

steering wheel
4
Remove the horn contact rubbing plate from the
underside of the steering wheel and remove the contact
spring and plunger
washer
and
remove
Remove the
steering column
6
cover
the
Screws
holding
together
and
the
two
the
remove
On automatic transmission models
SCREWS
halves of the
cover
disconnect the
quadrant light wires and remove the quadrant assembly

7 Disconnect the turn signal wiring at the terminal
connecting block a t the dash panel
8
On 1000 models loosen the
mounting screw in the
top of the switch and tap downwards to release the locating

remove the switch from the
steering jacket
9 On
1200 models remove the switch retaining
ClIP
E
wedge
screws
from the
clamp
loosen the switch from the steering

peg and remove the switch from
jacket to free the locating

the steering jacket
Installation is
Dismantled View of Turn
Signal
Switch
Later Model 1000
procedure
BUTTON
CONTACT
rNG
flJ
INSUt
TOR
WIRES TO BUTTONS
SWITCH ASSY
CLlPS
E
WASHERS
NUT
Horn
Button
and Medallion
Removed
HORN CONTACT
View of Turn Signal Switch Assembled 1200 Models

172
Assembly
1200 Models
Electrical
INHIBITOR SWITCH
HEADLAMP SWITCH
Disconnect the
Press
in
on
battery
negative
the
switch
knob
the
escutcheon
nut
Refer to
terminal
and
in
turn
anti clockwise direction to remove the knob from
3 Remove
removing tool
5
switch and remove the switch

Installation is a reversal of the removal
adjustmen t
AUTOMATIC TRANSMISSION section
the
and service
procedure
the rod
STOP LIGHT SWITCH
special
using
for
an
The 1000 model vehicles use a hydraulically operated

switch which is mounted on the four way connection
Remove the switch from the rear of the panel

Disconnect the wiring terminal block from the
26
tem
SWITCHES AND CONTROLS
10
Sy
attached to the engine firewall

The 1200 model vehicles use a mechanically operated
switch which is mounted on a bracket under the dash panel
procedure
WINDSCREEN WIPER SWITCH
and is operated by the brake pedal
The removal and installation pro edure is the
same
Hydraulic Type
as
for the head lamp switch
remove the hydraulic type switch disconnect the

from
the switch terminals and unscrew the switch
wires
To
IGNITION SWITCH
Standard Type
from its
Disconnect the
negative
battery
Remove the switch escutcheon nut
using
the
the
wiring terminal
from
the
removal procedure
switch
switch
To
Installation is the reverse to the removal
remove
the mechanical type switch disconnect the

loosen the lock nut and
wires from the switch connections
procedure
remove
Steering
the
Mechanical Type
Disconnect
Lock
the reverse to
the
switch bracket
and remove the
is
with the addition of bleeding the brake system as necessary

Refer to the BRAKES section for the bleeding procedure
special
removing tool on 1000 models remove the switch from

dash panel on 1200 models remove the switch from
3
mounting position
Installation
terminal
the
nut
mounting
To instal the stop
Type
section
and the switch
manual under the
of this
PEDAL HEIGHT ADJUSTMENT
ignition switch is turned to the lock position

removed
from the switch a plunger engages
key
collar on the steering shaft locking the steering wheel
When the
to the BRAKES
sub heading BRAKE
light switch refer

1200
and the
into
NOTE
and shaft
The
ignition switch is mounted onto the end of the

without removing the
barrel and is
locking
replaceable
locking barrel and key assembly
l To replace the steering
assembly
use
The
applied
bv the handhrakc lever
tl l
eu
du
switch is
switch is mounted
the
place by
buzzer
cllmplcting
cover
and
the
warning light
warning light
indicator also acts

as
both systems
as
are
light indicator
DUAL BRAKE SYSTEM WARNING LIGHT SWITCH
Description
two screws
switch disconnect
the
The
wire
Should
the
earth switch
to
terminals
Remove
an
when the handhrake is
when the handbrake is released the switch is opened

breaking the warning light circuit
the steering lock

assembly and operated when the vehicle door is opened
while the switch is in the unlocked position
The buzzer is mounted behind the dash panel on the
remove
aultv
circuit
Warning Buzzer
To
operated by
is
warning light
controlled
the dual brake system warning light

wired through the same dash warning
left hand side and is held in
as
remove
buzzer
adjusted
could result
The handbrake dash
The
adjusT the stop light swirch
HANDBRAKE WARNING LIGHT

lock
the lock assembly

Installation is the reverse to the removal procedure bu t
shear type mounting bolts should be used
the bracket and
to
is checked and
pedal height
brake uperatio
suitable drill to drill out the old shear type assembly bolts
2
Remove the two ordinary assembling screws from
new
DO NOT atTempr
unless the
remove
the
two
switch
a
failure
is
differential
occur
in either
type pressure s vitch

the front or rear brake
system the switch piston will be forced
mounting
lowest
screws
pressure earthing
connection
Installation is the reversal of the removal procedure

173
completing
the
contact
to
the side with the
of
the circuit of the dash
the
electrical
warning light
Electrical
27
System
6
To Test
choke cable complete towards the
the
Remuve
interior of the vehicle
suitable jumper lead earth the terminal on the

switch the dash warning light should come on if the circuit
is serviceable if the warning light fails to uperate check the
Using
Installation is
globe and live circuit using a test light

After testing the electrical circuit check the switch in
the foHowing manner Connect a bleeder tube and suitable
container to a front brake bleeder nipple have a second
operater apply pressure to the brake pedal and release the
bleeder nipple the warning light should come on repeat
the operation to the rear brake system
NOTE After each test lock off the bleeder nipple and
check the brake fluid level in the resen oir Top up as
NOTE
HEATER CONTROLS
Remove
Press in
on
switch
the
using
frol the
l
special
tool
panel
dash
and
lighter body from
the
front of the
to
battery
the
knob and
turn
anti clockwise to
remove
the knob
Working from behind the dash panel

panel retaining screws
Remove the escutcheon nut
Disconnect the choke inner cable from the choke
the
Remove the demister duct tubing and ash tray

Disconnect the booster fan switch wiring and
the heater control unit from behind the dash panel
Installation is
remove
control
5
terminal
negative
battery terminal
the control knobs
Screws
holding
grub
Disconnect the
2
the control levers and remove the knobs
3 Disconnect the control cables at the heater levers
4
negative
1200
heater control is mounted in the dash panel on

the removal procedure is as follows
Remove the
two
stem
Remove the escutcheon nut
The
CHOKE CONTROL
remove
are
1200 model vehicles
body
Disconnect the
1000 model vehicles
HEATER CONTROL
panel
1000
disconnect the wiring from the switch
Remove the negative

battery terminal
the
element
Remove
lighter
3
Working from behind the dash panel remove the
wiring tenninal and unscrew the outer case from the
Remove the
to
the heater unit with the booster fan control
to
from the switch
according
switch mounted in the dash panel

1 To remove the booster fan control switch press in
on the knob and turn anti c1ockwise to release the knob
dash
the choke cable
The hearer controls on the
attached
CIGARETTE LIGHTER
ter
4frer installing adjust
instruction in the FUEL SYSTEM sectiull
necessary
cigarette ligh
procedure
procedure
valve lever
5
Remove the outer cable from the bracket
FAN
AND HEAT CONTROL LEVER
View
of
Heater
AIR CONTROL 1I NKAGE
Control
Assembly Removed from
11
TO REMOVE AND INST AL
Disconnect the
CONTROLS
1000
Remove
windscreen
the
wiper
negative
Panel 1200 Models
INST
nUIlNT CI USTER
installation
Dash
battery terminal
section
uf
this
manual for
removal and
procedures
Remove
the
steering
column
upper
cover
on
transmission models disconnect the quadrant

refer TURN
and
remove the quadrant indicator
wiring
heater booster fan switch and the

AND
switch
refer
SWITCHES
automatic
174
control cable from the dash panel refer SWITCHES AND

CONTROLS section of this manual for removal and
SIGNAL SWITCH seciion of this manual for removal and

installation
procedures
the speedo
Disctlfinect
speeao
drive cable
casing from the
in tal1 ati9n procedures
eirove
head
Move the instrument Cluster towards the steering

arid disconnect the twelve point plug from the
5
wheel
prlnted
6
circuit ter
panel
inst llation
TURN
5
cluster
instrument
from
the
Remove
hav
1200
Disconnect the
negative
Re
radio
retaining
3
the
ove
head light switch
unit
windscreen
procedures
two
screws
the
speedo
knobs
instrument
drive
casing
from
the
complete with cover panel

Instailation is a reversal of the
terminals
rcuit
ci
8 Remove the instrument cluster from the dash
printed
cigarette lighter
switch and choke
12
the
Move the instrument cluster towards the steering

disconnect the twelve point plug from the
battery terminal
knobs and spindle
wiper
holding
models with round instruments

screw holding the instrument cluster to the
wheel and
control
the heater control
refer
cover
this manual for
panel
Disconnect
speedo
ntits
Remove
upper
of
head
ij
the
column
section
dash panel
6
steering
SWITCH
cluster to the dash
dash
only
is
the
SIGNAL
removal and installation
inals
the
Remove
28
SY3tem
Electrical
removal
panel
procedure
WIPER
WINDSCREll
Remove the
linkage
and
pivot
boxes
from
the
vehicle
I Disconnect
2
FroI1
spindle
the wiper
the
the
ne
battery
ative
panel
under the dash
on
to linkage retairiing
terminal
tIn tallatidn
the left side remove

nut
and disconnect
to
is
irgj articula
bodji
care
reversal of the
to the
reniov 1
serviceability
of the
procedure
pivot box
seals
linkage
3
Disconnect the
wipe motot
4 Remove
5 Remove
wiring terminal
connector
at the
the
retainirig bolts
vehicle
partictiiar atiention being paid to the sealing between the
wiper spindle and vehicle body
wiper
e
th
motor
wiper m
tor from the
NOTE
The automaric parking posirion is not adjustable

Theonly adjuslinent is bv the positioning of the wiper aims
on ihe spindles
to REMOVE
AND
INSTAL tHE
PIVOT BOXES
Disconnect the negative

baitery terminal
Remove the wiper arm to spindle retaining
and remove the wiper arms and blades
I
2
nuts
panel remove the pivot box

wiper motor spindle to linkage
From under the dash
retaining bolts
retaining nut
and
the
Wiper Motor 1000 MOdelS
Ii
IP U
TO REMOVE AND iNST AI HEADLAMP uNIT
1 r Disconriect the negative

2
coupes
Remove the
un
uupe
headlamp
mudels
battery t
rim
retaining
rminai
screws
and
remove
the
grille
headlamp retaining bezel screws

the lamp unit and disconnect the wiring
Remove the
Remove
plug
all models except

the
radiator grille
on
remuve
ITS
Installation is
175
procedure
29Eleclrical
Syslem
particular
TO ADJUST HEADLAMPS
lamp
body
luggage compartment
the
Make
sure
the
inflated
are
lyres
to
their correct
eJ follow the
pressures
if
head hght aiming
hine is
ma
manufacturer s instructions for operating procedures

3
To raise or lower lhe head lamp beam the top
adjusting screw is used

4 To move the beam
screws are used

When using head lamp aiming board cover the light
being adjusted with a suitable cloth so that only one
or
right the
adjusting
5
not
beam is
projected
Reference
governing head lamp focus and the lamps
according v
regulations
focused
retaining
lamp
and
holding
the lens and shield
Remove the bulb from the bulb holder
Remove
NOTE
screws
between
unit and remove the shield and lens
the
the
lamp
body
retaining
screws
and
lamp
Disconnect the
InstaHation is
should be
wiring
at the
junction and
41wavs
remove
replace
damaged
or
burnt out bulb with
bulb of the same voltage and wattage

been removed
LAMP
Remove the two lens
sealing
the unit from the vehicle
TO REMOVE AND INSTAL FRONT TURN SIGNAL
PARK
the
4
should be made to the local
NOTE
AND
Remove the two screws
remove
onto the board
to
avoid waler entry into the
to the
the left
given
to
LICENCE PLATE LAMP
side
to
artention should be
and vehicle
as
thar which has
remove
the lens
2
Remove the bulb or bulbs
as
necessary
according
the
lamp type
Replace the bulb with one of the same wattage and
voltage when renewing bulbs
4
To remove the lamp unit on 1000 models remove
the lamp retaining nuts working from inside the engine bay
disconnect the wiring at the connector and remove the
lamp unit
5
To remove the lamp unit on 1200 models remove
the lamp retaining nuts working from under the fender
disconnect the wiring at the connector and remove the
lamp unit
lnstaHation is a reversal of the removal procedure
to
LAM
REAR COMBINATION
On sedan model vehicles it is

the lens
or
lamp
unit to
replace
not
necessary to remove
faulty bulb
as
access to
the bulb holder is from inside the luggage compartment

he bulb holder and remove the holder and bulb from
turn
the
lamp body
On cotipe models
and
remove
and
remove
remove
the
the
retaining screws
luggage compartment
cover
the cover from inside the
bulb holders and bulbs
as
for the sedan
models
To remove the lamp units remove the retaining nuts
and washers from inside the luggage compartment
HeadJamp with Rim Removed ShoWing Adjusting Points

and Retaining Screws Typical
176
Electrical
WIRING
BODY
LENS SCREWS
SEAL
TURN SIGNAL INSERT
Exploded View
of Front
Parking lamp
1000 Model
PARK
TURN SIGNAL LENS
BULB
Exploded View
of Front
Parking
REVERSE
BEZElL
1200 Model
lamp
REVERSE
LAMP LENS
it
tV
SEAL
BODY
TURN
SIGNAL
L
D
Exploded
View of Rea
Combination lamp
TURN SIGNAL BULB
REVERSE
MOUNTING
BULB
MOUNTING NUTS AND WASHERS
Exploded
BOOY
BULB
TURN SIGNAL LENS
BULB SOCKETS
STOPTAIL
J
4
p fI
@i4
LAMP BULB
sJTAIl
1000 Models
TURN SIGNAL LENS
f
1
BULB
SEALS
LAMP BULB
BEZEll
NUTS
View of Rear
AND WASHERS
Combination lamp
REVERSE
1200 Models
177
LAMP LENS
Sy
30
tem
ll
Electrical System
14
ELIlCTRICAL
FAULT
DIAGNOSIS
BA TTERY AND ALTERNATOR SYSTEM
Battery
undercharged
Possible
or broken alternator drive belt
o0se
1
Ii
Defective
or
alternator
Faulty
Remedy
cause
Adjust
or
renew
drive belt
adjust regulator
new or
unH
regulator unit
Renf wor repair battery
Over auior replace unit
Check and repair or replace
battery
alternator
d
e
Faulty
Falilty connection
Defect in charging circuit wiring

in
wiring harness
unit
charging
Check and
renew or
repair
faulty components
Baltery
over
charged
Possible cause
Defective
or
Re ew
fernator voltage regulator

b
Remed
unit or
relay
sharge
Faulty battery
Faulty
adjust voltage regulator
Renew or repair
Overhaul
alternator
circuit
Faulty charging
connections
3 Indicator
or
and charge relay
wiring
or
renew unit
Check and repair
or
Loose or broken drive belt

Incorrectly adjusted regulator
Faulty alternator regulator
Low regulator voltage seding
4 Indicator
light does
riot
Remedy
Light globe blown

Open circuit in wiring
NoiSe in drive belt
or
Drive belt
frayed
or
renew drive belt
adjust regulator lInit

Check and overhaul faulty unit
Check and adjust voltage setting
t regulator
Remedy
cause
Check and
renew
faulty globe
Check and rectify open circuit
globe socket
or
alternator
Possible
lj 1s1
A
Check and
unit
operate
Possible
a
renew defective
light remains on
Possible caUse
or
coniponen ts
or
out
Remedy
cause
of alignment
Renew drive belt and or
puileys
Loose alternator mounting bolts or
worr bearil gs
align pulleys
with
Tighten mounting bolts and

renew
Tighte pulley retaining nut
pulley
Loosealtemator
Fauity illternator
Faulty diode s
or
bearings
Overliaul faulty unit

Overhaul alternator test diodes
178
Electrical
System
BA ITERY AND STARTING SYSTEM

Starter lacks power to crank
engine
Remedy
Possible cause
Check charging system and rectify
Battery undercharged
as
will not hold
Battery faulty
Battery terminals loose or corroded
Faulty starter motor
Faulty starter solenoid switch
d
e
or
attempt
to crank
Possible
Open
Clean and
or renew battery
tighten terminals
Check and overhaul starter motor

Check and
renew
solenoid
as
necessary
contacts
Starter will not
necessary
Check and repair
charge
circuit in
engine
Remedy
cause
dirty or loose terminals dirty

faulty solenoid faulty switch
Check for fault or short circuit in system
Check for locked drive and ring gears internal
starter fault or seized engine
Check for
starting system
commutator
Discharged battery
Battery fully charged but will
crank engine
b
c
not
IGNITION SYSTEM
I Engine will not start
Possible cause
Remedy
b
Fault in ignition primary circuit wiring

Fault in ignition switch
Fault in coil
Check circuit and
primary winding
Burnt or dirty contact breaker points
Faulty capacitor or capacitor lead
d
e
Fused
renew
arm
Renew low tension block and wires
or broken wire between breaker

and low tension terminal
Crack in distributor rotor
Renew rotor
Check and
Faulty high
Faulty or incorrectly adjusted spark plugs
Engine
capacitor
coil
as
or
leads
clean and adjust
spark plugs
Remedv
cause
Renew and
Faulty dirty or incorrectly adjusted

spark plugs
Dirty or incorrectly adjusted
Uneven
Condensation
wear
on
distributor
or
clean and adjust spark plugs
Clean and adjust points
Check and overhaul distributor
earn
Check and dry
oisture on inside or
out
and examine for minute cracks
outside of distributor cap
necessary
renew
Renew and
contact breaker
so
starts but misfires under load
Possible
renew
adjust point
Renew distributor cap
tension leads
and
or renew
Test and
necessary
Check and
Fault in coil high tension circuit

Cracks in distributor cap
as
Clean and
g
h
OJ
repair
ignition switch
Renew coil
Renew
Cracked spark plug insulator

Faulty ignition coil
Renew
faulty plug s
Renew or check coil
179
J2
33
3
Electr cal
Engine
runs
System
but lacks power

Possible
Remedy
cause
Check and readjust ignition timing

and or contact points
Ignition timing incorrectly set or

points require adjusting
Vacuum advance mechanism sticking or
excessively worn
Vacuum advance unit inoperative
contact
b
c
Overhaul distributor
Check for faulty
vacuum
pipe
or
faulty
advance unit
d
Vacuum advance unit operates but
Advance unit link disconnected
ineffective
requires adjustment
or
AUTOMATIC TRANSMISSION 1000

ANO 1200 MODELS
1
Kickdown switch
Kickdown
Fuse
solenoid
DATSUN 1000 MANUAL TRANSMISSION
panel
4 Ignition switch
COLOR CODE
5 I nhibitor switch
6 Starter
7
motor
and solenoid
Battery
l8
r
BY
J
t
1
11 Il s
I
Yellow
Black
Green
White
Red
BL
Blue
WR
White red
WB
RB
Whiteblack tracer
Red black
BW
Black white
VB
GV
black
Vel
low
Greenyellow
BG
Black green
GB
GR
Greenblack tracer
Greenred tracer
VW
Yellow white tracer
tracer
tracer
tracer
tracer
tracer
RW
Red white tracer
GW
Greenwhite
BR
Black red
tracer
tracer
BY
Black
WBL
White blue
yellow
tracer
tracer
GBL
Greenblue
tracer
COLOR CODE
BBL
Black blue
traeer
Green
BLR
Black
BLW
RB
Red with black
Blue red tracer

Bluelwhite tracer
Black white tracerlwhite ideeve
BY
Black with
BWtw
BIG
tracer
yellow
tracer
180
Black green sleeve
Electrical
L
G
r
34
System
1
T1
IL
ll
P
i
A
Q
1l
F
N
E
Y
1l
J
1
crj D
c1feD
P
N
r
@fIl
2
w
I
tIDE
fi
wo
or
f1
ri3 i
CD
28
1
T
lt
B
e
rJ
O LII
OC
7
1
Alternator
Aegulator
Ignition switch
3 4 Horns
23
Battery
5 Horn
24 Starter motor and solenoid
S fuse
9
10
Cigar lighter
11
Windscreen
12
Heater
13 Windscreen
14
15
16
17
18
19
20
R H
26
R H front side
27
wiper switch
BD
f Jil
Jf 1
51
fog lamp
turn
R H
Engine temperature sender unit

Oil pressure warning tamp switch
38 High beam indicator lamp
39 R H turn signal indicator lamp
40 Oil pressure warning lamp
37
signal
41
Fuel gauge
Instrument voltage stabiliser

Ignition winning lamp
44 LH turn signal indicator lamp
42
lamp
wiper
reversing lamp
R H turn signal lamp
A H stop and tail lamps
Reversing lamp vans
only
Licen
plate lamp
Interior lamp and switch
Courtesy lamp door switches
R H
switch
25
panel
Radio
it
36
Lighting
Distributor
RW
for 1000 Models with Manual Transmission
22
relay
6Ignition coil
sJ1ss
Ji
Wiring Diagram
fjj
2L
J
R1
wt
BIl
p
f
Bl
r
1lIi
oJlG
1
f
i
1
turn
signal and parking
lamp
Fog lamp switch
29 R H headlamp
30 LH headlamp
31 LH turn signal and parking
28
43
45
46
Engine temperature gauge

Instrument panel harness
connector
47
Reversing lamp switch

LH reversing lamp
49 LH turn signal lamp
50 LH tail and stoP lamps
48
lamp
32 LH
front side turn
33 L H
fog lamp
signal lamp
signal and combination

switch
35 T
signal relay unit
34 Turn
51
Fuel gauge sender unit
52
Clock
53
54 Instrument panel lamps

Stop lamp switch
55
181
35
Eleclrical
System
Co
J
IL
L
T
IF
cpJ
rW
l
Llu
Ul
Uf
Y
G
F
2
CA
Alternator
25
Regulator
26 Starter
5 Horn
28
R H
Resistor
9 Fuse
panel
10 Windscreen
wiper switch
11 Windscreen wiper
12
Heater
13
Heater switch
14
R H
reversing lamp
15
R H
turn signal
16
lamp
R H tail and stop lamp
Interior lamp
Interior lamp switch
Courtesy lamp door switches
Stop lamp switch
Passing lamp relay
turn
signal
parking
lamp
R H
headlamp
30 Engine temperature sender unit
31
32 33 34
35
Instrument
panel lamps
Fuel gauge
Engine temperature gauge

37 Ignition warning lamp
38 Oil pressure warning lamp
39 High beam indicator lamp
36
45
23 Windscreen washer
46
Fuel gauge sender
24
47
Cigar lighter
18
19
20
21
22
Wiring
harness connectors
Battery
40
41
42
43
44
BL
Fuse
indicator
lamp
51 LH turn signal indicator lamp
52 Turn signal relay
53 Turn signal and combination
50
R H
turn signal
182
tracer
White red
WB
White black
RB
Red
blaCk
tracer
tracer
tracer
Black white
YB
Yellow black
GY
Greenyellow
headlamp
55 LH turnsignal and parking
lamp
56 LH front side turn signal lamp
BG
Black green
tracer
GB
Green black
tracer
GR
Green red
YW
Yellow white
57
RW
Red white
GW
Greenwhite
BR
Black red
BY
WBL
Black yellow tracer

White blue tracer
GBL
Green blue
BBL
Black blue
switch
LH
lighting switch
COLOR CODE
it
Blue
WR
BW
54
Oil pressure switch
Ignition switch
Revening lamp switch
licence plate lamp
LH tail and stop lamps
L H turn signal lamp
LH reversing lamp
17
49
turn signallainp
and
8110 Models with Manual Transmission
and solenoid
R H front side
29
EJt1
48 Radio
motor
Xl
relay
6 Distributor
7 Ignition coil
Fuse
3 4 Horns
Ii
Wiring Diagram for 1200
CD
@
ICD
Lfl
tracer
tracer
tracer
tracer
tracer
tracer
tracer
tracer
Yellow
BLR
EUue
Black
BLW
Blue white
Green
BW W
Black white
White
Red
red
tracer
tracer
tracer
tracer
white steeve
BIG
BI ck oreen sleeve
Electrical
IF
k1
ow
r
30
BWr
tj
5j
1t
4
idfC
il
il
t
Ufe
l
c
11
IG
1 Alttirnator
Regu ator
2
3
Fuie
4 5
HOrns
27
for
motor and solenoid

29 R H front side clearance lamp
relay
bistributor
31
Ignition
32 Windscreen
6 Horn
9 Resistor
Windicreim wiper switch
11 Fuse panel
12 Windscreen wiper
13 Heater switCh
14 H ter
19
lS
Heater reSinance
R H reversing amp
17 R H rear tiun signaHamp
18 R H tail and stop lamps
16
19
20
21
22
23
24
25
26
Interior tamp
Warning b z er Switch
Warni
rlg
Interior
buzzer
lamp
iWitch
Courtesy lamp door sWitch
Stop lamp sWitch
Reverse lamp switch
Harness connector
and
rlting
a
R H
headlamp
lIme
33 Engine temperature sender unit
34
35
pressure warning sWitch
Oil
37 Instrument lamps
38 Handbrake warning lamp
39
36
Fuel gauge
pr8ssur warning
44
Manual
Transmission for North AmeriCa
Si Cigar lighter
White
54
Red
Radio
55 Fus
i9h beam indicitor lamp

Tachometer
BL
57
Lighting switch
R H tur signal
58
56
lrn
tl
WR
indicator iamp
1dieator
sign 1 i
switch
47
Handbrake warning lamp sWitCh

Dual brake warning lamp sWitch
48
licenee
LH
tail
O LH
tUrl
lte
pl
FIB
BW
fB
GY
Hazard signal relay
BG
62
Hazard signal Switch
GB
64
L H
GR
headlamp
turn
signal and parking
lamp
L H
front side
clearance
66 Clock
lamp
YW
W
COLOR carie
and
B
G
183
Yell ow
Black
Green
Greenfyellowtracer
Black green tracer
Green bl ck tracer
Green reet tracer
Yeliow whltt tracer
Red white tracer
Green whit traCer
BR
Black
red tracer
Bladc yellow tracer
G8l
bIUe tracer
Green blue tracer
88L
BIack blue
BLR
8i
BLW
J11 l
f
BW W
ilcick
t
WBL
lamp
BiiJe
White red tracer
W hii black i acer
Red blaCk tracer
Black White tracer
eiiow biack tracer
GW
BY
stop lamps
signal lamp
51
H r 8
iersing
lamp
52 Fuel Puge sender unit
49
WB
61
45 Ignition switch
46
lamp
59 rbrn siQnal relav

60 Turn signal and combination
lImp
43 H
Q1
63 LH
Igine temPerature gauge

41 Ignition warning lamPs
40
42 Oil
Mode s with
Battery
turn signal
U
r
28 Starter
30 R H
cOil
1200
iflt
t
@
rJ
Wiring Diagr
r r
0i
ltF
111
J
j
r@
36
System
VVhit
white tr fe
white
BIG
tracer
red tracer
llte
tracerl
Sleeve
Slack green
sleeve
BODY
I
WINDOW GLASS
AND REAR
WINDSCRIlIlN
rubber
body
to
windscreen
To Remove
groove
I Cover the bonnet ndscuttle panel with a suitable

protective cloth to avoid damage to the paint work
Reinove
the
windscreen
wiper
glass
trapped
weatherstrip lip under the top and sides

of the windscreen aperture flange from inside tHe vehicle
Push the
lipping tool for this purpose

Applying firm pressure from inside the
car
joint
from
the glass
Remove
weathertrip
of the
out
push
and weatherstrip
the weatherstrip
joint
the
compound
from the
glass
across
10
and
off any excess sealing compound with

petrol and wipe the assembly clean
Replace
the windscreen
wiper
arms
and blades
body flange grooves in the weatherstrip and from the

Check the weatherstrip for
of the body
flange
aperture
REAR WINDOW GLASS
deterioration
2
Place the
weatherstrip correctly
on
the windscreen
glass
suitable
and
sealing
Using
pressure
compound apply the compound to the weatherstrip rubber
to body groove
4
lrisert a length of strong cord in the weatherstrip
gun
for removing the rear glass are similar

described in the previous section for
removal aild installation of the windscreen
The
the
to
FRONT
procedures
procedures
DOOR
To Instal
INTERIOR HANDLES AND TRIM PANEL

To Remove
Remove
and
screw
Remove
regulator
handle
retaining
the handle arid thrust washer
the inside door handle
retaining
screw
the escutcheon
clips
plate
arm
rest
retaining
screws
if
an
arm
door
of die retaining hole taking

pairit work
6
trim
Lever each
clip free
care
not
Position the
trim
are
correctly
and inserts
into its recess and
panel
with the mounting inserts

4
Check
each clip individually
the
pressure
5 Wind
rest
thrust washer
4
On 1200 models remove the door pull mounting
screwS and door pull
5 Using a thin wide bladed lever inserted between the
trim panel and the door near a ret ining clip lever the clip
out
splash shields
damaged
trim panel retaining clips
or
Check the
to
is fitted and remove the arm rest
to
that the dust and
replace damaged pints
on
the escutcheon plate retaining screw

remove the handle and thrust washer or
Remove the
Check
fitted and not torn
remove
1200 models
3
the window
remove
1000 models
on
glass assembly
clip
Clean
cloth soaked in
sealing
firm pressure to the outside

that the ends of the cord are not
applying
between the weatherstrip and the body fiange

From inside the vehicle carefully pull each end of
cover
Clean all old
position the
centrally in the
operator
assembly
7
Using a suitable pressure gun with swan necked
nozzle and sealing compound apply the compound to the
rubber to glass groove
8
Replace the finish strip in its groove in the
weatherstrip with the use of the lipping tool Replace the
To Instal
the inside
on
second
the bottom of the lower corners of the body aperture to

seat the lip of the rubber over the body aperture flange
the windscreen and weatherstrip assembly forward arid out

of the windscreen aperture
cover clip and pull the finish
sj Pri e out the
strip
the
periphery of
the start of the cord
the cord from the lower centre of the
Use a suitable
4
of
the
cross
the glass
to
the aid
windscreen aperture
of the glass Ensure
the rear vision
mirror
3
With
windscreen
and blades
arms
from the front of the windscreen and remove
and
to meet
and tape both ends
the lower centre of the
starting at
assembly and continuing around
WINDSCREEN
with the
panel
and start
the window
over
the
at
before
applying
and work down
top
position fit the

correspond
retaining screw and
to the closed
spindle fit
opposite door
the
align the
the handle to
and instal the
tighten
6
On
door handle
damage the
the
opposite
1000 models fit the thrust washer
spindle position
panel
184
plate
cutcheon
es
Refit the door
pull
and
and
over
correspond
door and instal the retaining screw
models instal the
in turn and remove the door
the handle to
on
the
with
1200
retaining screw
arm rest
where
applicable
Bod
SUTTON
PER
SNI1
LOCt ING
ROD
REMOTE
CONTROL
DOOR
LOCK REMOTE
CONTROL
DIVISIO
AR
TRIM
RETAINER
INSERTS
RETAINING
REGULATOR ARM
SCREWS
TRIM RETA N
Front
Door
with Trim Panel and
Splash
Shields Removed
Front
1200 Models
INSERTS
Qoor with
Trim Pane
4
and SplashShiel
1 000
Removed
lel
r
GEAR
AND
RACKf
PIVOT
REGULATOR
ARM
ROLLER PIVOT
Ca
r Ci
1
SPINDLE
I
THRUST
SJ
WASHER
HANDLE
RETAINING
SCREW
Front Door Window
Regulator Assembly 1QOO Models
WINDOW REGULATOR
I
2
THRUST
Remove the interior handles and door trim

panel
RemQve the dust and splash shields from the door
WASHER
DLE
HANDLE
inner apertures
Raise the window to the closed position and hold

in this position with rubber wedges
4 Remove the screws
holding the regulator to the
door panel and
lowbr
the
SCREW
regulator down inside the door
Front Door WindoW Regulator

Assembly 1200 Models
185
Body
RETAINING SCREW
REMOTE
INSIDE H
REMOTE
CONTROL
CONTROL LINK
a
NDlE
INSIDE
THRUST
5
Slide the regulator
window lift channel
throJlgh
panel
Rem
arm
PlA If
NUTS
ER
WASI
from
its
slide
in the
OUTSIDE
W HERS
t7
lP
Ct
qNK
the window regulator unit from the door

the large hole at the
l1 of the door inner
bottoJ
HANDLE
ve
Installation is
rever
al of the removal
K NG
l
lINK
lOCK
procedure
RETAINING
NOTE Make
sure
fitted cpmctly
the
rill panel
that
over t
the dust and splash shields
ioor
lel
pa1
ClIP
are
ap rtures before fitting
Fron
ARREl
Door Lock
Assem
y Removed Later
Modell
JOO
WINDOW GLASS
To
and Instal
Remove the interior handles and door trim panel

Remove the dust and splash shields from the door
I
2
inner pertu es
Remove the window regulator
the window stop and lower the glass to

ofthe door
Remove the quarter window
ptounting screws and
RellJqve
the
bbttdm
5
the
lower division
6
emove
bar wounting scr w

the quarter window assembly from
the
door
7 Rptate
is
lift
To
ll
LqCK
2
od of R ri1C
so
that the
glass
lift channel
AND
and
MOTE CONTROL
ove
I
et
glass
glass
channel aSsembly through the top of the dpor
DOOR
Showing
the door
the front of the vehicle and remove the
Vards
tQ
Remove the interjoT handles anq door trim fp

iel
inner apertures
3
Wind the window to the fully closed position
4
Remqve the screw holding the bpttoin section of
the rear glass run channel and move the channel to clear the
vin9 Front poor Gia s

REW
dock
do
ReMOTE CONTROL ASS
I
ROO
r
H
NOlE
Flush Type Inside DOor Handle and Remote Control 1200
VIodels
186
4
Body
5
Disconnect
locking
the
lever
from
the
locking
barreL
6
locking barrel spring retaining plate by

retaining grooves in the barrel
Remove the locking barrel and seal from the outer
Remove the
sliding it
7
out of the
door skin
8 Remove the snipper button from the inside
locking
rod
9
10
Remove the door lock retaining screws

Remove the door lock remote control retaining
screws
Remove
the door lock assembly from the door
through the aperture

To Instal
Installation is
attention to the
With
following adjustment points

the door lock installed adjust the position of
the remote control so that the remote control lever of the

lock is just touching the lock body when the inside handle
is at rest
then
tighten the remote control mounting screws

operation
and check the lock
Cy
8ARAEl
LOCKING
LEVER
Front
REMOTE CONTROL ROD
Position with Method of

Shown Early Model 1000
lock in Mounted
LOCKING ADD
NIPPER
OUTSIDE
Door
locking Barrel Connection
ADD
HANDLE
RELEASE
LEVER
REMOn
CONTROL ROD
SPRING
Fron
Door lock Assemblv Showing
Operating
Mechanism
1200 Models
OCKING
NIPPeR ROD
187
LEVEA
Body
Close the door and push it firmly shut
6 Press the outside release button and carefully open
without moving the striker plate
door
the
the three mounting set bolts and again
7
5
OUTSIDE HANDLE
Tighten
the interior handles and door trim
Remove
Remove the dust and
splash
shields from the door
Wind the window
glass
to
the
plate
striker
If further
the three set bolts
handle and seal

On 1200 models
washers
remove
the
mounting
the door handle from the

the handle to lock linkage and
ease
disconnect
and
nuts
G
RETURN SPRING
skin
door
remove
the
plate
fully closed position
On 1000 models remove the two mounting nuts

washers lock washers and plate and remove the outside
4
and
door and slack off the three set bolts and move the striker
and retighten
a small amount in the direction required
apertures
inner
checking the operation of the door lock

adjustment is necessary open
close the door
panel
NUTS
the
handle and seal when fitted remove the linkage

attention to the following
adjustment procedure
for 1200
models
I
Instal the handle to lock linkage with the nylon
adjusting nut positioned correctly in the lever adjust the
nylon nut to give a free movemen t of from 2 to 3 rom
0 079 to 0 1 8 in on the rod lock the nylon nut in
LOCK STRIKER
To Renew and
Adjust
reverse
NYLON ADJUSTER
following adjustment points

4
Refit
tighten
position
the
striker
plate according
to
the
pencil
removing refit the three set bolts but only

them sufficiently to hold the striker plate in
on
View of the Front Outside Door Handle Showing Adjusting

Point of Lock Operating Rod 1200 Models
REAR
DOOR
INTERIOR HANDLES AND TRIM PANEL
WINDOW
The operating
door except that
removed
but the
I
2
is the same as for the front

door pull does not have to be
following additional operations will be
procedure
the
inner
an
Remove
remove the ash
the ash tray
body mounting
tray body from the door
screws
REGULATOR
Remove the dust and
splash
panel
shields from the door
apertures
3
ash tray is fitted to the door panel

Remove the ash container from the ash tray
necessaty when
ROO
of the removing operations with attention to the
marks made
OPERATING
RUBBER STOP
position of the striker plate with a pencil

three Phillip head set bolts and remove
the
2 Remove
the striker plate inspect and replace parts where necessary
3 To instal the striker plate the procedure is the
Mark the
MOUNTING STUDS
HANDLE
position with adhesive
Wind the window glass to the closed position and
hold with rubber wedges

and
panel
guide
188
Remove the two screws and washers holding the

slide to the door panel on 1000 models
arm
6
Body
Door Lock Striker

5
Remove
the screws
Door Lock Striker Later Model 1000 and 1200 Models
Early 1000 Model

holding the regulator
to the
door panel and lower the regulator

6
Slide the regulator arm 1200 models and the
from their slides in the window
arm
1000 models
guide
OUARTER
Jfr
WIN
lift channel
7
Lower the
regulator to
wind the arm to the down
with the
regulator
the bottom of the door and
position align
regulator arm 1000 models

through the large aperture
out
the
guide
DIVISION
8AR
arm
and remove the

of the door panel
TOP
TRIM
RETAINING CHANNEL
both models
Installation is a reversal of the removal
procedure
L
NOTE
Make
sure
the
ectly over
trim panel
co
the dust and splash shields
fitted
door panel apertures before fitting the
are
j
I
WINDOW GLASS
c

1 Remove the interior handles and door trirn panel
2 Remove the dust and splash shields from the door
inner
DOOR LOCK
SC
WS
iI
g
or
T
AIN
INSERT
VISlDN
EW1
A
Remove the window regulator and let the glass rest

in the bottom of the door it will be necessary to remove
the window stop on 1200 models
Remove the
screws
the door inner
TOR
rOR
WlNDOW REGUl A
apertures
and the
REGUL
HAND
I
J
QJ
11
i Do
SC
screws
at the
top of the division
TRIMRETAINERINSeRTS
Jr
BOTTOM TRIM RETAINING CHANNEL
bar
holding the bottom of the division bar
to
Rear Door with Trim Panel and Splash Shields Removed
panel
4 Door 1000 Model
189
8ody
ROllER
THRUST WASHER
I
c
Rear Door Window
Regulator Assembly 1000 Model
MOUNTING SCREWS
It
Door with Trim Panel and Splash Shield
RETAINING SCREW
Showing Method
REGULATOR ARM
Rear
HANDLE
of
Removing Rear DoOr Window
Removed
f
r
z
1j
OLLER
G i j
Ie
RETAINING
THRUST WASHER
ARM
Rear Door Window
Regulator Assembly
190
1200 Model
SCREW
Glass
B
Bod
PLATE
@1
REMOTE CONTROL
and
Ease
remove
the
division
it from the door
ar
wi
Remove the
Turn the window
dow opening outer moulding

glass so hat the lift channel is
towards the qU lfter wiridow

8 Raise the glass up through the door glass opening
and working from outside the door lif the glaSs clear of the
CONTROL lI
REMOTE
rsJ
THRUST WASHER
opening
Installation is a reversal of the
After installing make sure the glass
slides without undue side movement
adjustment is obtained by
positioning
removal procedure
freely iq the
HANDLE
mov
A small amount of
he division bar
RETAI
DOOR WCK AND REMOTE CONTROL
I
2
panels
RelIlove the dust ine splash shields from the door
jVinclow
Remove the two
to the door inner

5
1000
inner apef ures

3 Wind the
4
G SCREW
Rear Door Lock A sembly Removed with loor Lock

Reversed to ShOw Detail Lock Barre and Lever Shown
in In et 1000
odel
to the
screws
l sed position
61dillg the remote control
paneL
Remove the door lock
RETA
mo
rmg
N NG SCREW
crews
Rear
qoor LockshoWin
Levei
al d Chi
P oofLoc
ing
Door Lock Roller Early 1000 Model
JOl O Model
Latel
191
Body
RETURN
1
I
NUTS
t
1
SPRING
ll
UFFER
iCI
a
f
rr
LEVER
Remove the lower division bar screws
Remove
their mounted
edge of the
MOUNTING
STUDS
Outside Door Handle for Rear Door
1200 Models
1200
the remote control and door lock from
posi ions and slide them towards the front
door
Remove the interior handles and door trim panel

8 Working through the door aperture disconnect the

lock from the remote control rod and remove the lock and
remote control from the door
Insianation is
reversal
inner apertures
3
Wind the window to the closed
position
Remove the outside door handle retaining nuts and

washers and remove the door handle
5 Remove the two screws holding the remote control
of the removal procedure

PAWL
to the door inner
panel
Remove the snipper button

7
he snipper rod and
love
Rel
screw washer and nylon bush
8
the rod
locking
rod
pivot
Remove the snipper rod from the door

panel and
retaining tapes
9 Remove the door lock retaining

the door lock through the aperture
Installation is
screws
and
remove
OUTSIDE HANDLE
Remove the
Remove the dust
interior handles
jDd
and door trim
splash shields from
the top
rear door
3
washers
panel aperture
Remove the outside handle
and
remove
the
retaining nuts and

outside handle from the door
panel
Installation is
LOCKING
Rear
ROD
EVER
LOCKING
lr lock As emb y
D
ETURN
SPRING
taking particular care

serviceable
1200 Model

that the outside handle weather seal is
II
4
ENGINE BONNET
To Remove
bonnet and
remove the bonnet stay from its guide

Remove the mounting bolts holding the
the bonnet and remove the bonnet
J
2
each
Release the bonnet catch and

open the bonnet
around the outside edge of
Using a pencil I
lark
Cover both fenders with
protective
cover
to
To Instal
hinge plate
3
hinges
1
Holding the bonnet in the pOSItion previously
marked fit the bonnet hinge bolts and tighten to
over
to
prevent damage to the paint work

4 With the
help of a second operator support the
fmger tight
Just
192
Bodyl0
2
MALE SECTION OF C
Close the
bonnet and by pushing with the hand

position the bonnet evenly in its opening
3
Open the bonnet carefully and tighten the
mounting bolts
4
loosen
5
Recheck
one
bolt at
for
a
positioning
adjust
correct
time to
if
LOCK
necessary
SAfPY
fingers
To
then loosen the
9lT
The male section
for adjustment and

aftfor adjustment
OVE
I
NOTE
CATCH
li
adjust first mark the base position with a

mounting bolts and move the catch
the desired girection tighten the bolts and rech ck
6
pencil
the
of the catch will move sideways

female section will move fore and
Close the bonnet and check the
too loose shorten the dove tail bolt

the dove tail bolt
NurJ
Check the bonnet catch when the catch is released
the bonnet should pop up sufficiently to enable the

to release the safety catch and lift the bonnet
in
TCHFI
MOUNTING BO
locking position
if
if too tight lengthen
8 To adjust the dove tail bolt loosen the lock nut

d Screw the bolt in or out using a screw driyer
LUGGAGIl
Engine
Bonnet Lock
Components
COMPARTMENT 1 10
To Remove
t2 When the lid is correctly positioned carefully open

tighten the hinge bolts and recheck
3
To adjust the closed posiiion of the lid loosen the
striker plate screws and move the striker plate in the
required direction
and
Open the lid with a pencil mark the edges of the

mounting plate to lid position on both sides
2 Support the lid and remove the torsion bars
3
While supporting the lid remove the two bolts from
each hinge plate and remove the lid
NOTE
The
striker
is
adjustable sideways
down
To Instal and
Adjust
Installation
is the
with the addition of the
following points
the mounting bolts to just over finger tight

and close the lid check for even clearance around the lid
and push into position with the hands
I Tighten
Boot Lid Striker Plate
1000 MOdels
Boot Lid Lock 1000
193
VIOdels
and
up and
l
1
Body
LOCKING BARREL
I Open the lid and lever the retaining clip from the
Jock and remove me locking baIfel
In tallat on is a reversal of the removal
procedure
r
I
riD
Boot lid
Support
Bracket 1000 Model
View
Boot
liHingtl Showi
Adjusting
SC
Slots 1000 Model
194
of
luggage Compartment lid

1200 MOdels
ock
and
Striker
WHEELS
AND
TYRES
SPIlCIFI
ATIOXS
1000 MODELS
1200 MODELS
Wheel type
Tyee
Pressed steel
Wheel type
size
Sedans
550x 12
4
Station sedan
Rear
sedans
Rear
station sedans
12
Inflation pressures normal speed

Front and rear
WHIlIlI
17
for
NO
sustained high
TYIIIl
2
wear
Apply
the handbrake
Detach the hub cap from the wheel to be removed

3
Unscrew
the
wheel
nuts
approximately
three quarters of a turn
5
3
4
Tighten
do not over
Inspect tyres regularly for damage and abnormal

Any abnormal wear may be due to one or more of
Ensure that tyres are kept free of oil or grease

Inspect the whee studs and nuts for thread damage
and the stud holes in the wheels for elongation

5
Check the wheels for radial and lateral
for damage to the flanges and bead seats
TO INSTAL
attention to the
4 SSIlMBI
Attention
should
e
to
give
l
in the tyre which will allow the entry
of moisture into the carcass resulting in premature failure
from the vehicle
following points
the wheel nuts in the order of 1
Tighten
wheel
Periodically
retaining
and
torque
tyresaccording
2 and 4 and
to
Proper tyre and whfel maintenance is essential for

operation
I
and
Check
adjust tyre pressures when the tyres are
economical and safe
out
the illustration sequence

8
Maintain correct wheel balance
tigbten
cold condition
investigated and
run
nuts to the correct
rotate wheels and
TO MAINTAIN
in
psi
section
Diagnosis
penetrations or cuts
Jack up the vehicle

Remove the wheel nuts and withdraw the wheel
Installation is
speed driving
the faults shown in the illustrations or listed in the Fault
kg cm2
psi
NOTE Increase the above pressures by 0 3 kg cm2
TO REMOVE
ply
2
1
rear
2 kg cm2
1
17 psi
1 2 kg cm2
17 psi
I 4 kg cm2
20 psi
600x 12
4
ply front
6 ply
Inflation pressures normal speed
Front
all models
Sedans and station wagons
ply
500
4
Pressed steel
size
Tyee
the
Frequent loss
leakage rectified
of pressure should be
NOTE Never
adjust tyre pressures when the tyres are wann

otherwise pressures will be incorrect when the lyres cool
Diagram for Correct Wheel Rotation
down
to
Prolong Tyre
Life and Minimise Tyre Wear
TUBIlD TVRES
TO REMOVE
flange
and using tyre levers with rounded edges lever the

bead of the tyre over the inside edge of the flange
Jack up the vehicle and
Remove the valve cap and valve
Separate
the
remove
the wheel
NOTE
core
inside bead from
the inside wheel

195
Exercise
extreme
during operation 3 to
damage the tube by forcing it
care
ensure
that the levers do not
against
the rim
Wheels and Tvres
Push the valve of the inner tube into the lyre

4
interior and withdraw the inner tube out between the inner
Place
3
valve
Screw
bead of the tyre and the inner flange of the wheel

Separate the outside beau of the tyre from the
outside flange at the wheel and using lyre levers with
the inner tube inside the tyre and insert the

in the wheel
through the hole
valve to
valve
core
on
the end of the
the tyre levers or a rubber mallet and

the
side
that
of the bead adjacent to the tube valve
ensuring
flange using
inner
TO INSTAL
over
goes
the wheel
NOTE in the event
emery paper
2
Position the inside
correct
fiange
dot
of the wheel partially
one of the tyre beads and using tyre levers in good

condition lever the remainder of the tyre bead over the
flange onto the wheel
place
tvre balance
position themselves
6
NOTE During operation 2 ensure that the position of the

the levers are applied is
lyre bead opposite the side where
of the
on
the
Bounce
the wheel bead seats
tyre
on
the
floor several times to
position the tyre beads against the wheel flanges Inflate the
tyre and tube to the recommended pressure and finally
wheel rim
check the valve core for
TUBEI IlSS
leakage and instal
the wheel removed from the vehicle
the valve cap
IlIlS
NOTE Should the fracture he in excess

in tlte repair should be carried out by
TO TEST FOR LEAKS

With
of a tvre being marked with a balance

adjacent to the valve stem to maintain
5
Staod the wheel and tyre upright fit the valve core
and inflate the tube until the tyre beads commence to
inside
the Velbase
the dot
last
flange
1 Remove any loose or excessive scale or rust from

the wheel flanges and finally clean with a wire brush or
tool
back into the interior of
the tyre when the other tyre bead is being placed on the
wheel
4
Fit the second bead of the tyre over the wheel
rounded edges lever the bead of the tyre over the inside
flange of the wheel separating the two components
seating in
removing
slipping
the valve
prevent
of 6
an
35 mm
0 250
aUlhorised tyre
dealer
inflate
the recommended pressure immerse the tyre

the tyre
and wheel in a water tank and check for leaks
2 Place the assembly in the tank so that the valve is
to
uppermost
then
submerge
If the valve stem is leaking deflate the tyre and

from th wheel Remove the valve from the wheel
and inspect for splitting crushing or dirt between the wheel
4
remove
the valve and check for bubbles
and the valve Clean
Release and allow the assembly to float ensuring

the channel between the rim flange and the tyre is filled
with water carefully check for air bubbles emitting from
3
When
over and submerge the

already submerged and check for leaks
5
Submerge the assembly and fill the channel
between the flange and the tyre allow to float and check
for leaks If leaking wipe area dry and mark the position of
Turn
correctly seated
the wheel assembly
tools
not
to
TO REPAIR LEAKS
rim
Do not
Remove the wheel from
use
pliers
or
similar hand
the vehicle
remove
the
core
both inside and outside beads from the

that the beads are in the base of the rim
Separate
wheel flanges
so
3
Using tyre levers with rounded edges lever the
beads of the tyre one at a time off the inner flange of the
wheel
Prior to removal use a soap solution on the beads and
Repair of a small fracture not exceeding 2 38 mm

in the tyre may be repaired by applying sealing
cement or dough with a suitable applicator
2
Minor repairs to the rim seat can be effected by
deflating the tyre and holding the bead away from the seat
and cleaning off the affected area
To repair fractures not exceeding
3
35 mm 0 250
6
in in diameter remove the tyre from the wheel and repair
the fracture by inserting a rubber plug coated in cement
into the hole with the needle provided in the repair kit
Withdraw the needle after ensuring it has fully penetrated
the tyre and cut the rubber leaving approximately 6 35
I
0 093 in
protruding
on
fit valve
valve cap and
0 250 in
if necessary
wet the valve stem and valve
replace
valve
TO REMOVE
the leak with chalk
mm
area or
a new
hole with soap and insert from the inside of the wheel
Using Schrader tool No 553 pull the valve through until
this area
wheel rivets if
fitting
flange and see that the beads

the point of leverage are seating
wellbase
wheel
diametrically opposite
on
the bottom of the
TO INSTAL
1
wheel
Remove loose
taking
if necessary
above the tread

196
care not
or
to
excessive scale or rust from the
damage paint Repaint
the wheel
Wheels and
2
Remove any dents from the rim

a moist rag
flanges
and
wipe
clean with
With the valve core removed
connect the air hose
and inflate the tyre until the beads have sealed correctly It
may be necessary to bounce the tyre while inflating
3
Remove the air hose fit the valve core and infiate
Clean off the tyre beads moisten tyre beads rim

3
surfaces and tyre levers with clean water or soap solution
Fit the tyre in the normal way use narrow levers
4
the tyre to 2 81 kg cm2 40 psi

deflate to the normal pressure
and taking small bites to avoid strain and damage to the

beads Avoid damage at all limes as the sealing quality of
Test the tyre for leaks and
the tyre is determined by the condition of the bead

5
Fit the second bead so that the part of the bead
nearest the valve goes over the rim flange last
TO INFLATE USING A TOURNIQUET
NOTE Do
use
not
use
hammer or mallet to
Ensure that the balance mark
on
fit
l Inflate the tyre with the assistance of a tourniquet

Dunlop tool No
l or its equivalent follow the
TT
fitting instructions included in the kit
tubeless tvres
the lyre is adjacent
to
the
valve
With the valve
the beads
TO INFLATE
the assembly upright
tyre on the ground at several points

periphery This will help to seat the beads on
rim seats and provide a partial seal
4
wear on
sealed
core
against
removed
the
inflate the tyre until
flanges
Remove the hose
and inflate the tyre to 2 81 kg cm2 40

Test the tyre for leaks and defiate to normal pressure
core
bounce the tread of
the
Abnormal
are
fit the valve
psi
i Holding
around
the
its
NOTE A s an alternative methud a tourniquet can be made

bv using a piece of rope and a suitable lever e g a bar tyre
tapered
TynE
lever
WE R
ora
DI
piece ofwood
lOSIS
both sides of tread
Pussible
Remedy
cause
Under inflation of tyres
Check and inflate to recommended pressures
Over
Reduce maximum loading
loading
2 Abnormal wear in centre of tread
Possible cause
Tyres 3
Remedy
Over inflation oftyres
Check and reduce to recommended pressures
197
and
4Wheel
3 Abnormal
Tyre
inside of tyres
wear on
Possible
al
Insufficient camber
Sagging
Loose or worn front hub
Bent stub axle
Loose
front coil
Check front end alignment and adjust

Check and renew faulty spring s
angle
spring
Check and
Check and
bearings
suspension
or worn
Remedy
cause
arm
adjust
or renew
hub
as
necessary
bearings
faulty components
Check and renew faulty components Align front
components
renew
end
4 Abnormal wear on outside of tread
Possible
Check front end alignment and adjust as necessary

Check and instal recommended replacement spring
Excessive camber angle

Incorrect coil spring s fitted
Spotty
Remedv
cause
or
irregular
wear
Possible
Static
or
Remedy
cause
dynamic unbalance of wheel
Check and balance wheel and tyre assembly
and tyre
assembly
b
Lateral
Excessive
play
in wheel hub
Excessive
play
in
Lightly
run
worn
out of
spots
wheel
bl
7
bearing
centre
renew
wheel
bearing
at centre of tread
Remedy
cause
Check and balance wheel and tyre assembly

Check and renew wheel
Static unbalance ofwheel and tyre assembly

Radial run out eccentricity of wheel
Flat spots at
or
Check and adjust or renew hub

Check and renew ball joints
steering knuckle ball joints
Possible
a
Check and true up
of tread
Possible
Eccentric brake drurn
Repeatedly
Lack of tyre rotation
severe
brake
Remedy
cause
Check and
renew
brake drum
Revise driving habits
application
Periodically change tyres by

assembly
198
rotation of wheel tyre
8 Heel and toe
wear
sawtooth effect
Possible
cause
Remedy
Over loading
Revise
max
High speed driving
Avoid
as
Excessive
Revise
driving
braking
Feathered edge
on one
edge
um
as
loading
possible
h bits
side of tread pattern
Possible
insid e
far
cause
Remedy
excessive toe in
Sharp
One tyre sharp inside edge other tyre
sharp
Check and adjust wheel alignment

Check for bent steering arm and renew
outside
edge
199
AND
LBBRICATION
MAINTENANCE
1000 SER ES
1200 SERIES
ENGINE
ENG NE
Sump
without filter
3 04 litre
352
5
Sump wi thou t
fiI ter
45
6
Sump
US pt
3 58 litre
6 125 Imp pt
with filter
Sump with
Grade of lubricant
R litre
8 US
pt
b
p
5 5 litre
Capacity
9 125 Imp pt
1 US pt
11
Type
equivalent
3N71 A
or
9750 Imp pt
II 750 US pt
Lubricant
grade
equivalent
REAR AXLE
Capacity
0 710 litre
250
1
Imp
0 75 litre
Capacity
pt
375
1
5 US pt
1
Lubricant grade
Imp
pt
1 625 US pt
SAE 90 HD
Lubricant grade
STEERING BOX
SAE 90 HD
STEERING BOX
0 240 litre
Capacity
0 5
0 23 litre
Capacity
Imp pt
375
0
Imp pt
0 500 US pt
0 6 US pt
Lubricant grade
SAE 90 HD
Lubricant grade
COOLING SYSTEM
SAE 90 ffD
COOLING SYSTEM
3 8 litre
Without heater
6 750
Without heater
Imp
pt
4 2 litre
375
7
Imp pt
8 875 US pt
8 US pt
45 litre
With heater
4 9 litre
With heater
8 Imp pt
9 6 US pt
9 625
378
10
FUEL TANK
Imp pt
US pt
FUEL TANK
35 litre
Sedan
7 875
18
9
Capacity
Type
3N71A
or
REAR AXLE
Capacity
Imp pt
AUTOMA TIC TRANSMISSION

5 250 litre
Lubricant grade
25
2 50 US pt
SAE 90 HD
Lubricant grade
AUTOMATIC TRANSMISSION
Capacity
12 litre
Capacity
SAE 90 HD
grade
Imp pI
6 875 US pt
SAE 30
MANUAL TRANSM SSION
15 Imp
Lubricant
pt
pt
3 24 litre
filter
5 750
MANUAL TRANSM SSION
Capacity
Imp
5 750 US
7 5 US pt
SAE 30
Grade of lubricant
2 7 litre
4 760
Imp pt
Station
Wagon Van
Capaci ty
Us
8 75
Capacity
Imp gal
8 8 US
40 litre
00 5
gal
30 litre
6 750
Sedan
Imp gal
Coupe
200
gal
Station Wagon Van 38 litre

375 Imp
8
Ip
gal
Imp gal
US
O US
gal
gal
L
I
2
Drain fiush and refill the cooling system with
clean water every 10 000 km
16 000 km 6000
10 000
miles
1 Check oil daily and top up with specified grade

when necessary
2
Drain and fill the sump at the first i 000 km 600
miles again at 3000 km 2000 miles Continue to change
FUEL SYSTEM
I Clean the fuel pump filter every 10 000 km 6 000

miles and check fuel pump operation every 20 000 km
12 000 miles
reading
every 5000
km 3000 miles
If vehicle is operating under dusty or
severe conditions change oil and filter more
frequently
3
Change the oil filter at 5000 km 3000 miles and
every 10 000 km
six months
Clean the oil
miles
6000 miles
petrol dry
Clean
crankcase
20 000 km
control
ventilation
Change
valve
the fuel pump filter every 20 000 km
12
000
miles
2 Remove air cleaner element every 5000 km 3 000

miles and tap out dust Using low pressure air blowout
the remainder of the dust Clean the air cleaner body and
oHvery
filler cap every 10 000 km

out and ie oil
Wash in
5
during oil change
and Uaifltenance 2
ENGINE
CRANKCASE AND OIL FILTER
oil at every 3000 km 2000 iniles until the mileage

is 10 000 km 6000 miles
Subsequent changes
1 rication
6000
fe
instal element
air
The
every
12 000 miles
40 000
cleaner
km
element should
24 000
miles
be
changed
every
when
under dusty conditions Do not washer the paper
element in petrol or solvent of any kind
or
frequently
more
operating
COOLING SYSTEM
Lubricate
accelerator Iinkag
points
with
few
drops of engine oil

Check
coolant level in radiator daily and top up
with clean water
vvhen
every 10 000 km 6000 miles

Lubricate the carburettor linkage every 10 000 km
necessary
6000 miles with
few
drops of engine
oil
TRANSMISSION
GEARBOX
2
I
Check the oil level and top up as necessary every

5 000 km 3 000 miles with correct grade of lubricant
2
Drain and refill the
completed
40 000
km
gearbox
600 miles
1000 km
24 000
iniles
with
REAR
when the vehicle has
and
the
ce
unserviceable
Repl
the
universal
when
joints
found
to
be
AXLE
subsequently
correct
iubricant
every
grade of
1
necessary
heck the oil level iri the rear axle and top up as
every 5000 km 3000 miles with the correct
grade ofIubricant
PROPELLER SHAFT
Drain and refill the rear axle when the vehicle has
completed 1000km
I
Repack
the
universal
joints
every
50 000
km
30 000
6000 miles and

miles
with the
subsequently
correct
every
of
grade
lubricant
30 000 miles with lithium based grease
km
50 000
SUSPENSION
AND STEERING
FRONT SUSPENSION
3
I
wheel
Remove
bearing
earlier if
clean and
repack
the hub
bearings
grease every 50 000 km 30 000 miles

severe conditions
STEERING
1
Steering box
Clean the
and
5
is filled on
level iri the
steering box every 10 000 km

correct grade of oil when
and top up with
necessary
or
operating under
joint
over
Check oil
6000 miles
with
area
surrounding
every 50 000 km 30 000 miles

6 Lubricate the steering
assembly and must not be
filled
the
suspension ball
every 20 000 km 12 000 miles

Rehew the lubricant in the suspension ball
grease
linkage
joint
every 20 000 km
12 000 miles
2 Check for leaks and if excessive

remove and
rectify refill with correct amount and grade of oil
7
Renew the lubricant in the steering linkage every
50 000 km 30 000 miles
201
bricaiion and Maintenanfe
t
BRAKE FLUID
RESERVOIR
When disc brakes
are
OUS
BATTERY
fitted
fluid
flush and
every 20 000 km
clean heavy duty hydraulic brake fluid
hydraulic brake
lIsn IL
change the
with
Check and top lip electrolite with distilled
12 000 miles
required
or
at
least
water
as
fortnightly
TYRES
ALTERNATOR
Test
pressures
The alternator
assembly
and
no
bearings
further
are
packed with
lubricating
during
during
grease
is necessary
operatioQ
inflate
and
required
or at
when
cold to
recommended
least fortnightly
Rotate tyres every 10
000
km
6000 miles
BODY
DISTRIBUTOR
I Remove ihe distributor
cap and rotor and insert
6000 miles
2
Smear
melting point
Check
the
distributor
cleaning
or
lobes
with
high
the contact points have

renewal
been
earn
following
components
striker
2
Lubricate
drops of engine
grease when
lubricate the
and
every 10 000 km 6000 miles with dry lubricant

Door locks and strikers bonnet catch luggage lock and
few drops of oii in the top of the distributor shaft earn

assembly to lubricate the earn bearing every 10 000 km
removed for
as
the following components with a few

Door hinges luggage compartment
oil
lock mechanism and
Lubricate the
brake linkages and
202
hinges
brake linkages
hand
remote
coritrollever
clutch
and foot
EMISSION
CONTROL
SPECIFIfATIONS
5
Ignition timing
Engine idle speed
deg btdc
Flow guide valve

Make
Manual transmission
700 rpm
600 rpm in D
Automatic transmission
Hitachi
Model
FGA
Opening
range
hg
4in
Distributor
Control valve
Make
Hitachi
Model
D412
Capacitor capacity
Dwell angle
0 22 mfd
49
Point gap
Make
63
55
508
0
Hitachi
Model
TPA28 1
Operating depression
deg
at
sea
level manual transmission
566
mm
579
0 020 in
22 8 in
Make
NGK
Model
BP
Gap
0 80
Servo
6E
Full stroke
Q35
0
0 197 in
in
Operating stroke
no
1700
loading
engine
Hitachi
Model
LT133
Capacity
12 volt
33 amp
To reduce Carbon Monoxide

Hydrocarbons and
Oxides of Nitrogen which are the three primary automative
Make
Hitachi
emissions
Model
DCG306
emission
Type
Dual throat
Datsun range of vehicles
downdraft
setting at full
CO percentage setting
choke
17 5
2
1800
rpm
0S
Carburet tor
Fast idle
hg
5 0mm
Alternator
Make
hg
diaphragm
0 90 mm
0 031
air
on
three distinct types of

used in the BIIO Series
pollution
systems
are
pollution standards involved the system

collectively or separately to the
may be found to be fitted
fRANKt ASE
causing
control
Depending
deg
vehicle
NTII ATION S HiTEM
DESCRIPTION
The Closed
wi thin
Two types of crankcase ventilation systems are used as

standard equipment on the 8110 series engines One is
known as the sealed system and the other as the closed
the
arrester
System
air cleaner
and into
draws clean induction air from
assembly through
meshed flame
hose which is connected to the rocker
cover
The air is then passed through the engine and into the
manifold via an oil separator hose and regulating
valve Crankcase vapours are thereby fed back into the
inlet
system
was
used on some earlier
type
replaced by the closed system which is
standard equipment on all models which are exported
sealed
vehicles but
now
mm
3
22
Spark plug
The
10mm hg
pressure
system
was
to the USA and Canada

The Sealed System
rocker cover
to the
cylinders
are
consists of
a hose connecting the

assembly Pressure drop
assembly by air flow permits
This system is most effective
where
crankcase vapours to flow from the crankcase via the rocker

cover into the air cleaner assembly where they are drawn
into the inlet manifold and consumed in the cylinders
pa
at
vacuum
all crankcase vapours through the regulating valve

and into the inlet manifold Under these conditions the
crankcase
atmosphere
drawing
To
prevent air cleaner element oil contamination

through crankcase vapour the hose inlet connection into
the air cleaner assembly is so situated that the
vapour
not pass
and filler cap
to draw
The engine oil dipstick and also the oil filler cap are
sealed to prevent crankcase fumes from escaping into the
entering the assembly does
dipstick
part throttle operation

is present in the inlet
ticularly high
manifold to allow the regulating valve to open and for all
crankcase vapours to be scavenged from the crankcase At
full throttle operation the manifold vacuum is insufficient
air cleaner
created within the air cleaner
and consumed
As with the sealed system the oil

sealed from the atmosphere
high
ventilation
flow is reversed
203
the
fumes
If the engine is excessively worn and blow by is at a

level then irrespective of throttle operation a certain
amount of crankcase vapour will re

rocker cover and into the air cleaner
through the element
with
into the air cleaner instead of the inlet manifold
cycle back through
the
Emission Control
FLAME TRAP
HOSE PC
VALVE TO CRANKCASE
DISPOSABLE PCV
VALVE
CLIPS
ttOSE
Q
I
TO VALve COVER
AIRCLEANER
HOSE
PCV VAlV
d
I
AIR
CLEANER
BASE
OIL FILLER CAP
DIPSTICK
l
QO
Components of Closed Type Ventilation System

Note inset PCV Valve Disposable Type
A baftle
plate
and
meshed
dipstiCk Renew the seals if they

sealing qualities are suspect
lIIter which is located
within the crankcase prevents engine oil from

upwards into the inlet manifold
being drawn
TO CHECK AND TEST OPERA liON
Sealed Svstem
As this system is
or
recommended
intervals
12 000 miles with
regulating
place
finger
over
the
valve
should immediately be felt
as
the
inlet A strong
finger
is
placed
If the regulating valve is found to be partially or fully

inoperative then renew the valve as a complete assembly It
is not practicable to dismantle and clean the valve
4
A faulty regulating valve may give rise to anyone
of
12
months
or
or
more
18 000
particular attention given
to
valve
Check
being
manifold hose
Note
Carefully
check for
deterioration Renew the hoses

Check the seals on
blocking collapsing
XH
liST
following
conditions
Engine hunting at idle

Engine idle fluctuates but engine does not stall
Loss of power and surging at speeds above idle
Engine stalls after stops and runs roughly after
restarted with indications of a lean mixture
To ensure effident operation of the ventilation

system if is adl isahle to renew he regulating vah e everv
50000 kilomerres 30 OliO
miles
or
found necessary
the engine oil filler cap and the
as
of the
Black smoke emerging from the exhaust
the condition of the rocker cover to air

cleaner assembly hose and also the crankcase to inlet
speed
over the valve
the rocker cover to air cleaner assembly

collapsing blocking or deterioration Renew the
hose if after checking it is found to be unserviceable
2 Check the seals on the engine oil filler cap and the
dipstick Renew the seals if they are damaged or if their
sealing qualities are suspect
Closed System
The system should also be serviced at
the
idle
noise will be heard at the valve when
sharp hissing
vacuum
hose for
kilomctres
follows
Now
18 000 kilornetres
12 000 miles
I Check
the
if their
or
the hose is disconnected
recommended intervals of 12 months
as
With
the engine running at a steady
disconnect the hose from the regulating valve
relatively simple and

regulating valve it is only a matter of
checking the following components at the
periodically
damaged
are
Check the operation of the ventilation regulating
3
valve
does not incorporate
RING
TII
DESCRIPTION
I S
STE
Moditications
introduction
The engine modifications system is utilized to reduce

the percentage of pollutant gases being expelled from the
engine exhaust
of
the distributor carburettor and the

throttle opening device were used to
to
achieve this result

It is known that when a
the
204
coasting
throttle valve is fully closed
an
condition exists and
inadequate
fuel air
Emission Con trol

mixture is drawn into the
burnt
resulting
in
hydrocarbon exhaust emission

The throttle opening device
carburettor
valve
throttle
where it is
engine
excessive
carbon
incompletely
monox
and
de
Connect
designed
to open the
these
coasting
whenever
therefore reducing the level
the
inlet
manifold
the
control
valve
control
to
valve
tube
vacuum
4
is
conditions exist This allows an adequate fuel air mixture to

be drawn into the engine where proper combustion takes
place
Connect
to
diaphragm
servo
tube
vacuum
Check the operation of the valve and

as described in a
following section
if
adjust
necessary
of hydrocarbon and
SERVO DIAPHRAGM
carbon monoxide emission

The basic components
of the throttle
opening device
To Remove
are
Control Valve
Servo diaphragm
Interconnecting
tubes
vacuum
When
manifold
the
vacuum
to
chamber
vacuum
connected
to
the
actuates
place and
control
be
As
diaphragm assembly
vacuum
takes
deceleration
increases
vacuum
valve
routed to
shown
the
in the
is mounted
on
inlet manifold
servo
the
diagram
As
servo
With
placed
the carburettor and is
to
Remove
the
on
carburettor
diaphragm
servo
from
the
engine
as
in the Fuel Section
the carburettor removed from the vehicle and

work bench withdraw the split pin and
disconnect the
throttle lever through Iinkage Applied

the servo diaphragm and linkage to the
carburettor thus slightly opening the throttle valve

desired
permitting
diaphragm
opens
Detach the vacuum hose from the

chamber connection
servo
diaphragm
link
from the carburettor
throttle lever
4
the
servo
degree
Loosen and
diaphragm
the locknut and detach the
remove
from
the
moun
bracket
ting
the
on
carburettor
manifold
lowers to a predetermined level

speed decreasing the con trol valve begins
to close The control valve closing aBows the inlet manifold
vacuum to be maintained at the constant predetermined
vacuum
due to the vehicle
NOTE It is not practical to dismantle and
repair
the servo
assemblv If the unit is malfunctioning then renew the

diaphragm assembll
servo
level
An altitude corrector is built into the
body
control valve
To Instal
and is
adjusted to a slight preload to compensate for

any variation in atmospheric pressure
This system does not effect engine braking which is
normally desired during deceleration
Position the
bracket and instal and

2
Connect
diaphragm on
tighten the locknut
servo
the
diaphragm
servo
carburettor throttle lever and retain with

3
CONTROL VALVE
Instal the carburettor to the
the carburettor
Iink
new
to
the
split pin
engine as described
in
the Fuel Section

4
To Remove
vacuum
Raise the
Disconnect
vacuum
bonnet
inlet
manifold
to
control
Disconnect the
control valve to
adjust if
procedure
valve
attaching bolts at
The
vacuum
servo
necessary
control
valve
as
to
the servo
diaphragm
diaphragm for
See following
correct
text
operation
for
correct
diaphragm
servo
remove
the two control valve
AND CONTROL VALVE
assembly
the inlet manifold
control valve
assembly
engine compartment
can
now
NOTE Make all checks and adjustments after first bringing

the engine to operating temperature Ensure that the choke
be removed
valve is in the fullv open
NOTE
hose
TO ADJUST SERVO DIAPHRAGM
Loosen and
from the
Check the
and
tube
the
tube
3
vacuum
engine
Attach the
chamber connection
It is not
practicable to di mantle
valve If the unit is malfunctioning
an aHem bly
and
repair
the
then
renew
the
position
Connect
a tachometer
Disconnect the servo
Disconnect the control valve
to
the engine distributor

pipe at the control
vacuum
valve
To Instal
vacuum
pipe
at
the
inlet manifold
I
Position
compartment
2 Instal
attaching
on
the
control
valve
back
in
the engine
straight
the inlet manifold
and
tighten
the
control
valve
assembly
note
screws
205
the
Now
to
connect
the
Start the
diaphragm vacuum pipe

by passing the control valve
without working the throttle
servo
the inlet manifold
engine and
engine rpm reading on
the tachometer scale
4EmiJJ ion Control

NOTE As
soon
should
vacuum
link
diaphragm
body
6
as
the
is started
engine
the
actuate
inlet
diaphragm
seroo
and
manifold
pull the
until the link stop abuts the
upwards
CARBURETfOR
To
servo
important
setting are
If the
servo
diaphragm adjustment
is correct the
The
engine speed should read between 1700 and 1800 rpm

7 If the engine speed is below the lowest figure
then
quoted
the
back off the lock
clockwise
screw
until
slightly
nut
the
and turn the
adjusting
engine speed falls
To
within
9 Retighten the locknut after adjusting as described

operation 7 or 8 whichever was applicable making
that the
adjusting
Speed
Connect
Start and
it
is
checked and adjusted
regarding exhaust
tachometer to the
run
to operate for
conjunction
speed of 750 rpm
smooth idle
engine distributor
the engine until it reaches normal
in
screw
to
emission control
and Mixture
the throttle adjusting
Adjust
is not disturbed
screw
Idle
mixture
control
emission
carburettor idle speed and mixture

periodically checked and accurately adjusted
3
Allow the engine
idling speed
obtained
sure
exhaust
the
the tinal result
Adjust
figures quoted
When the engine speed is above the highest figure

quoted back off the locknut and turn the adjusting screw in
an anti clockwise direction until the correct engine speed is
effective
that
choke setting should be
affecting
in
obtain
one
screw
with each
is obtained
minute
and
other
at
the idle
until
780 rpm for
automatic transmission
5
diagram for
See
NOTE
situation
of adjusting
and
screw
Now
reduce
locknut
turn
the
the idle mixture
speed
engine
automatic
Start the
engine
and disconnect the servo vacuum
hose
from the inlet manifold and reconnect back to the

control valve
Reconnect the control valve vacuum pipe
back to the inlet manifold
diaphragm
position
II
vacuum
The control valve and
piping should now
be back in its
Restart
the
throttle lever
screw
rpm
clockwise
750
rpm
to
for
transmission
after
For
vehicles
operation
and any
subsequent slight adjustment
made
servo
original
IMPOR TANT
out
carrying
carburettor
700
that are fitted with automatic

transmission the idle speed should be 600 rpm when the
shift lever is moved to the D position This can be checked
6
10
to
engine and by actuating the

by hand bring the engine up to
Ex treme
adjustment
care
should
be exercised
when
with the transmission in the drive
pas tion
3000 rpm
Stop the engine
and disconnect the tachometer
12
Release the throttle lever and let the engine speed

decrease of its own accord
3
The
to 1000 rpm in 3 5 to
equipped vehicles and 2

transmission
equipped
to 3 5
seconds
vehicles
the control valve
adjusting
screw
falls within the lime
figures
the
as
screw
and
Spark plugs
adjusting
situation
Turn the adjusting

the
engine
lengthen
anti clockwise
direction
to
Remove and sand blast the plugs at the recommended

checking intervals Check each plug thoroughly for
cracking chipping and for excessive wear at the electrodes
Renew the plugs as found necessary
If the spark plugs are still serviceable file the centre
electrodes flat prior to setting gaps with the correct
adjusting tool See Specifications section for correct
in
a clockwise direction to
and an
decrease time
shorten the engine speed
screw
speed
efficient burning of the fuel in the engine

it is important that all electrical
chamber
be periodically checked for serviceability as a

fault in anyone piece of electrical equipment usually has
adverse effects on other related components as well as
affecting the final result regarding exhaust emission control
engine speed decrease time

quoted in operation 13
See diagram for control valve lock
NOTE
EQUIPMENT
equipment
lock screw and turn the vacuum
slightly until
ensure
combustion
engine speed decrease tUnes are not within

specified for respective applicable model then
the limits
screw
To
for automatic
If the
14
loosen
ELECTRICAL
decrease from 3000 rpm

5 seconds for manual transmission
4
engine speed should
decrease time
electrode gap
IS When satisfied the adjustment is correct tighten
the control valve lock screw and recheck the engine speed
adjustment
not
altered
to ensure that the vacuum
adjusting
screw
High
has
Tension Leads
Remove the distributor cap with high tension leads

from the engine assembly
position
206
Emission COlltrol
MoUNTING
BRACKET
VACUUM
ADJUSTING
SKONDAllY
V
CARBURETTOR
PRIMARY
VENTURI
SCRTW
Nrr
INlET MANIfOLD
Opener Control System Arrangement
Throttle
Using
an ohmmeter check the resistance in each
Set the gap and dwell angle to specificaiions in the

normal mariner and then check and adjust the ignition
iirning as follows
high
tension l ad
Tq make
end of the
adaptor
the test fit a plug adaptor into the spark plug

lead and connect the ohmmeter between the
and the
corresponding
terminal in the
distributor
gap
2
If
the resistance in any lead is more than 30 000 ohms

carefully remove the lead from the cap and check
le d
the
resistance separately
over
30 000 ohms then renew the
Carbon filled high tension leads must be

handled carefullv at ail times Mishandling of leads will
to
Instal
5
Loosen the distributor reiaining screw far
allow ihe distributor to be moved by hand
breakdown in lead continuity
iiniing
Distributor
ihe
With
to 5
deg
The distributor breaker points should be checked at the

recommended mileage iJitervals and renewed if abnormaJ
pitting and wear is evident
Ensure that the points are in correct alignment so that
full contact will be made when the points
are
enough
ii ing light adjust the ignition
aid of the
btdc
NOTE The 5 deg mark
graduation
and correct
rpm
iMPORTANT
a
plugs for serviceability
the
leads ai fault
cause
the spark
an ignition timing light and a tachometer to

engine
3 J Wipe the crankshaft pulley s
o that the iimihg
marks are clearly visible
4 Warm up the engine and set the idling speed to
100
cap
If resistance is still
Check
on
the crank
on the right side
of the
shaft pulley
is the first
tdc mark
7
Tighten the distributor set screw when ihe ignition
timing is correctly adjusted but make sure that the timing is
not altered by moving the disiributor
in the
closed position
Set
the
idie speed
and
mixture
as
previously
descriOed
EVAI OIlATn ll t OXTIlOI S
DESCRIPTION
STI
M
Positive sealed fuel tank
Vapour
vent Une
Flow
Vapour liquid separator
guide
valve
The evapora tive control system is another approach in

reducing the amount of vehicle hydro carbon emission It
engine is at rest
evaporation gradually fills the air
has been
vapour liquid separator and

fuel tank is fitted with a positive type sealing
cap vapour
pressure builds up within the system
The flow guide valve opens wt
the vapqur pressure
ten
When
estimated that approximately 20 percent of all

hydrocarbon eniissi9n results from evaporative
loss from the fuel tank
The
basic
components
of the
fuel vapour through
space in the fuel tank

irapot vent lines and as the
automotive
system
the
evaporative control
within the sysiem exceeds
are
207
10
mm
hg
4 in
0
hgJ
Excess
Emis ion CoJltrol

vapour is then
hose
by passed
When the engine
into the crankcase via
connecting
TO TEST
Vacuum created within the
inlet manifold opens the positive crankcase ventilation valve

and also the crankcase side of the flow guide valve Vapour
all hoses and then

wide valve from the vehicle
which has been stored in the crankcase vent line separator

and fuel tank is then drawn into the inlet manifold and
3
Apply a low pressure of air to the fuel tank F
side aperture of the valve The air shuuld flow through the
valve and out the crankcase C side aperture
4 If no air pressure is felt at the crankcase
C
starts
consumed in the cylinders

When vapour pressure
within
the system drops
cleaner side of the flow guide valve
the air
sufficiently
aperture then
opens This permits atmospheric air pressure to be routed

from the air cleaner assembly to the fuel tank A flame
is situated
arrester
the
flow
in
case
of backfire
through
difficulties including
high
cause
engine bonnet
renew
remove
the now
the valve
air pressure to the crankcase C side of

Renew the valve if air flow is felt from the air
apply
cleaner A and fuel tank
the
apertures
When air pressure is applied to the air cleaner A

aperture it is nonnal for air pressure to be felt at the
carhurettor
Allowing air into the system prevents

forming within the system which could
Now
the valve
in the line between the air cleaner and
guide valve
Raise the
Disconnect
vacuum
crankcase
F sides of the valve
C and fuel tank
technical
crushed fuel tank
FUEL TANK
VAPOUR LIQUID SEPARATOR
AND
VAPOUR VENT LINE

FLOW GUIDE VALVE
To Test
The flow
guide
valve
most
import ant function

entering the vapour
is to
vent
prevent crankcase blow by from
line and fuel tank The valve should be removed and
I Check the
serviceability
checked for serviceability at the recommended intervals It

is not practicable to repair the valve if it is found to be
tank filler cap and all hoses for
guide
unserviceable
For easy identification the valve apertures are clearly

with A F and C denoting
Air Cleaner
Fuel
Disconnect the vapour vent line from the flow

valve F aperture
3 Connect a tee piece with manometer and a suitable
cock into the vapour vent line
engraved
Tank
fuel
Crankcase
Slowly apply
air pressure
cock until the manometer indicates
to
the system via the
14 5 in
Aq then close
the cock
5
then
FROM AIR CLEANER
Leave the system undisturbed for

the height of the liquid in the
measure
The
variation
of height in the
should remain wi th 1 0 in
5 minutes and
2
manometer
test
Aq
7
AIR CLEANER
FROM VALVE COVER
FLAME TRAP
INLET MANIFOLD
FLOW GUIDE
VALVE
GAS TIGHT
FROM CRANKCASE
il
VAPOUR LIQUID
SEPARATOR
FUEL TANk
PCV
T
TO INLET MANIFOLD OR
r
TA
VALVE
Diagram showing Evaporation Control System

with Engine at Slow Running Speed
CRANKCASE
208
instrument
Emission Control
If the
test
is
satisfactory
remove
blockage must be rectified

delivery to the crankcase
the tank filler cap

drops quickly to
and check that the fluid in the manometer
to
ensure
sufficient vapour
If the test instrument reading was unsatisfactory in

operation 6 check the tank filler cap and hoses for
9
zero
If the fluid height in the manometer drops off

a
blocked vapour vent line is indicated The
slowly
EXHAUST CONTROl
leakage Rectify
S
as
STFM FAIJLT
found necessary
IUAt NOSIS
Engine knock when coasting

Possible
Incorrectly adjusted throttle
Malfunctioning
2 Erratic
Remedv
cause
Adjust
opener
control valve
throttle opener
Renew control valve
engine idle
Remedy
Possible cause
Incorrect
Incorrect carburettor
Reset ignition timing

Adjust carburettor
ignition timing
adjustment
Engine idling too fast

Remedy
Possible cause
Incorrectly adjusted throttle opener

Malfunctioning throttle cable or linkage
c1
Malfun tioning control valve
4
throttle opener
Adjust
Check throttie cable
or
linkage and rectify
Renew control valve
Engine stops
Remedy
Possible cause
Incorr ct cafburettor
Incorrect
Adjust
adjustment
Reset
ignition timing
MIlNDIlD
RIlCO
To
ensure
system it
is
important
be carried out
mileage
on
that the
following
service
procedure
the items mentioned at the recommcndeu
points
spark plugs
Check high tension leads for serviceability
Tune and test engine
4
Carry out the following service procedure
the
following
service
procedure
Carry
out
every
the
following
service
procedure
Renew carburettor
air cleaner element
CRANKCASE VENTI LA TlON SYSTEM
Carry
out
the
following service procedure
every
valve
cam
every
20 000 km 12 000 miles

Check for correct operation of crankcase regulating
6000 miles
Sparingly lubricate distributor
every
40 000 km 24 000 miles
every
Check and adjust ignition liming

Check and adjust engine idle speed and mixture
Remove clean and regap spark plugs
2
the following service procedure
Renew
5000 km 3000 miles

Check distributor points for serviceability and adjust
dwell angle
10 000 km
out
12 000 miles
Renew distributor contact
ENGINE
out
Carry
20 000 km
intervals
I Carry
ignition timing
INTF NANCt
I
3
efficient operation of the emission control
carburettor
Check all hoses and connection for leaks
and cam heel
209
Emiuion Control
EXHAUST CONTROL SYSTEM
I Carry
20 000 km
out
the
following
EVAPORATIVE CONTROL SYSTEM

service
procedure
every
12 000 miles
Check and adjust control valve and
servo
diaphragm
I Carry out the following service procedure every

20 000 km 12 000 miles
Check hoses pipes and connections for
leakage
Remove and
210
test
flow guide valve for
correct
operation
INDEX
To Service
To Service
ENGINE
7
Specifications
Description
Engine
and Transmission
Adjust Float Level

Choke Interlock Adjustment
Primary and Secondary Throttle
11
To Remove and Dismantle
II
To Assemble and Instal
11
Cylinder
12
Head
38
38
To Assemble
To Check and
9
10
10

Rocker Arms and Shaft
37
Top Cover
Flange
Interlock
Adjustment
Adjust Idling Speed and
Fuel Pump
Description
To
39
40
40
Mixture
41
42
42
42
To Remove
To Dismantle
12
To Check and Inspect

To Renew Valve Guides
13

To Dismantle
13
To Clean and Check
43
To Check Valve
13
To Assemble
44
To Assemble
To Assemble
14
14
Fuel Pump Capacity Test

Air Cleaner
44
Adjust Valve Clearance

Engine Sump
14
Description
12
Spring
To
43
45
45
IS
To Remove

Timing Chain and Cover
15
Fuel
15
To Instal
To Remove
15
To Instal
15
CLUTCH
Camshaft and Tappets
16
16
Specifications
Description
47
To Remove
To Instal
18
18
18
19
19
Clutch Unit
48

Master Cylinder
49
Connecting Rods
Pistons and
To Fit New Piston Rings

To Reassemble and Instal
Bores and Pistons
To Check Cylinder Bores
20
20
Deglazing Cylinder Bores

Checking Piston Skirt Clearance
Crankshaft and Main Bearings
20

Oil Pump and Filter
Cylinder
45
System
Fault
45
Diagnosis
45
47
49
49

To Dismantle
To Clean and
50
SO
SO
50
Inspect
To Assemble
Slave Cylinder
To Clean and Inspect
SO
21
23
51
Hydraulic System
51

To Dismantle and Assemble
23
To Bleed
Outch Throw out
51
52
Engine Mountings
25

Engine Fault Diagnosis
21
21
Bearing
Mechanically Operated Clutch
23
Front
25
Rear
25
Renew
Renew
Specifications
28
Description
28
28
Radiator
To Remove
To Check
To Instal
Thermostat
To Check
1200
28
28
29
29
29
29
FUEL SYSTEM
52
to
Series
Hydraulic Clutch
1200 Series
COOLING SYSTEM
to
1000 Series
Mechanically Operated Clutch
25
51
to
52
Renew
53
Clutch Pedal
Hydraulic Clutch
Pedal and Control Cable
To Remove and Instal 1000 Series
To Remove and Instal 1200 Series
54
54
Adjustments
Hydraulic Clutch
To Adjust Pedal Height
Hydraulic Clutch
To Adjust Withdrawal Lever
55
54
54
54
54
54
55
55
55
Specifications
34
Carburettor
35
35
35
Free Travel
55
To
55
To Dismantle
To Clean Parts
36
To Service Main Body
17

To Adjust 1200 Series
Clutch Fault Diagnosis

To Service
37
211
Adjust
1000 Series
55
55
55
56
lndex
MANUAL TRANSMISSION
Specifications
57
Part I
Three Speed Transmission
Gearbox
57
Description
57

To Dismantle
58
58
60
To Assemble
Gear Change Assemble
Part 2
Four Speed Transmission
Gearbox
60
Description
64

To Adjust Gear Change Rods
64
To Dismantle
To Assemble
Part 3
Propeller Shaft
65
Description
70

Part 4
Manual Transmission Fault
71
Diagnosis
63
To Assemble and Adjust

Differential
Axle Shaft and Bearings
To Remove
To Renew Axle Shaft Bearings
To Instal
Rear Axle Assembly
Part 2
Rear Axle
1200 cc Models
Description
91
93
93
93
93
94
94
94
94
63
64
64
65
DIFFERENTIAL CARRIER ASSEMBLY

To Dismantle
To Assemble and Adjust Drive
Pinion
To
Adjust
Bearing Pre Load

To Assemble and Adjust Differential
68
68
70
Pinion
Drive Pinion Oil Seal

To Renew Oil Seal and or Pinion Flange
Axle Shaft and Bearing
To Remove
To Renew Axle Shaft Bearing
To Instal
Rear Axle Assembly
Rear Axle Fault Diagnosis
71
71
AUTOMATIC TRANSMISSIONS
94
94
96
96
98
98
99
99
101
101
101
101
101
101
102
Specifications
Description
73
Engine Tuning
Specifications
74
Towing
74
Hydraulic Fluid
To Check and Top Up
74
Description
Steering Gear Assembly
74
To Drain and Fill

Transmission Selector Linkage
To Clean and
76
To Assemble
103
104
104
104
76
To
Collapsible Steering
106
76
Description
106
73
Adjust
Neutral Safety Switch
To Adjust
STEERING
76
76
To Remove and
Cohujm
78
78
Rear Axle

Idler Arm
80
80
81
81
82
Linkage Adjustment
To Adjust Steering Lock Stops
To Check and Adjust Toe in
Steering
85
1000 Models
86
Differential Carrier Assembly

To Dismantle
86
Diagnosis
109
110
FRONT SUSPENSION
Part I
1000 Series
87
Specifications
Spring and Lower Control
88
To Remove and
Inspect
III
112
88
To Instal
Upper Control Arm
To Remove and Inspect
86
To Assemble and Adjust Drive

To Adjust Pinion Bearing
Fault
lO7
107
107
107
108
108
108
108
108
108
86
Description
Pinion
107
Instal
Steering Linkage
79
REAR AXLE
Part I
106
106
Inspect
Clamp
Inspect and
82
Specifications
Inspect
Jacket Tube
Automatic Transmission Fault
Diagnosis
103
To Dismantle
Kickdown Switch and Downshift

Solenoid
To Check and Test
Stall Test
Line Pressure Test
To Check and Test
Transmission Assembly
To Remove
To Instal
103
91
212
III
Arm
III
113
113
Index
fJ
To Instal
Stub Axle Swivel
114
BRAKES
114
Specifications
130
To Remove and
114
Description
114
Drum Brakes
131
131
Disc Brakes
Single Circuit Master
To
Inspect
Check and Adjust Castor
and Chamber
Angles
To Instal
114
Shock Absorbers
To Test and Bleed
1 IS
Ball Joints
Front Suspension Fault Diagnosis

Part
1200 Series
Specifications
115
1000 Series
Wheel Hub and Bearings

Drum
Type Brakes
To Remove Disc Type Brakes
Stabiliser Bar
To Remove
131
131
115

To Dismantle
115
115
To Clean and
To Assemble
132
115
Dual Circuit Master Cylinder

To Dismantle Nabco
To Dismantle Tokico
To Clean and Inspect Nabco and Tokico
To Assemble Nab co
To Assemble Tokico
117
117
117
Description
131
Cylinder
118
118
118
118
118
Rear Brake
132
Inspect
132
Assembly
To Remove
To Clean and Dismantle
120

To Assemble
121
121

Front Wheel Drum Brakes
Front Wheel Disc Brakes
To Remove and Instal Brake Caliper
To Remove and Instal Brake Discs
Rear Brake Backing Plate
Front Brake Backing Plate
To Remove and Instal Drum Brakes
To Instal
122
Handbrake
To Instal
Radius Rod
To Remove
Suspension
119
119
119
119
120
Unit
120
Control Arm
To Remove
To
119
119
To Instal
Suspension
119
120
Assembly
Handbrake Lever Assembly and
122
122
122
Inspect
Cable
to
Remove and Instal
1000
122
Lower Ball Joint

To Remove
122
To Remove

To Instal
Suspension Assembly
123
To Remove
23
In
134
134
135
135
136
136
138
138
138
139
140
140
140
141
141
141
142
142
143
143
1000
144
144
123
123
Brake
Adjustment
To Adjust Front Brake Shoes
Drum Type
To Adjust Rear Brake Shoes All Models
To Adjust Handbrake Cable 1000
To Adjust Handbrake Cable 1200
Brake Pedal Height Adjustment 1000
Brake Pedal Height Adjustment 1200
Hydraulic System
145
To Bleed
Brake Fault Diagnosis
146
122
123
Susp nsion and Steering Angles

Adjustments
To Check and Adjust Toe In
123
To Check Camber and Caster
124
Front
124
Fault Diagnosis
134
1200
To Inspect Both Models
To nstal Both Models
To Instal
Suspension
133
133
143
To Instal
Inspect
133
Front
To Remove and Instal 1200

Rear Handbrake Cable To Remove
To Clean and
132
123
123
144
144
145
145
145
145
145
145
146
147
REAR SUSPENSION
Specifica lions
Description
127
ELECTRICAL SYSTEM
127
Specifications
Shock Absorbers
To Test and Bleed
128
Battery
148
151
128
Maintenance
151
Alternator
151
Springs
128
128
Description
151

128
128

Service Precautions
152
129
152
Suspension
Fault
Diagnosis
213
151
4lndex
To Test the Alternator
To Test on the Vehicle
To Dismantle
152
To Clean Parts
To Check and Test
To Assemble
154
licence Plate Lamp

Electrical Fault Diagnosis
152
176
178
153
154
BODY
Windscreen and Rear Window
184
156
Windscreen
184
Alternator Regulator
157
184
Qescription
Regulator Adjustments
157
158
158
159
Front Door
Interior Handles and Trim Panel
Rear Window Glass
Window Regulator
Window Glass
Door Lock and Remote Control
Outside Handle
Lock Striker
188
Rear Door
Interior Handles and Trim Panel
188
Window Regulator
Window Glass
Door Lock and Remote Control
OutJide Handle
188
Components Parts
157
Mechanical Adjustments
Electrical Adjustments
Starter Motor
161
161
Description
ToTest on the Vehicle
161
To Dismantle
162

To Assemble
Test and Adjust
Distributor
162
162
163
Description
To Clean and
To Remove
Adjust
Breaker Points
164
165
165
165
Engine
Bonnet
Luggage Cumpartment
188
189
191
192
192
lid
To Remove
166
184
184
185
186
186
188
To Instal and Adjust

Locking Barrel
193
193
193
194
To Dismantle
166
167
To Assemble
167
To Instal
To Time Engine and Set Ignition Timing
To Adjust Ignition Timing and Dwell Angle
168
169
WHEELS AND TYRES
169
Sparking Plugs
170
To Service
170
Wheel and Tyre Assembly

To Remove
To Instal
High
170
To Maintain
195
170
Tubed Tyres
195
To Remove
195
170
To Instal
196
Description
170
196
Horn Button
170
Tubeless Tyres
To Test for Leaks
Turn
172
To
Repair
173
To
To
To
To
Remove
Tensiun Leads
Ignition Coil
Turn Signal Switch Headlight Dipper
and Horn Button
Signal Switch
Switches and Controls

Headlamp Switch
Windscreen Wiper Switch
Ignition Switch
Inhibitor Switch
Stop Light Switch
Handbrake Warning light
Dual Brake System Waming light Switch
173
173
173
173
174
Headlamp
Unit
195
196
196
196
196
197
197
197
Engine
Cooling System
201
201
Fuel
201
System
Transmission
Gear Box
Propeller Shaft
Rear Axle
174
174
174
174
175
Suspension and Steering

Front Suspension
Steering
175
175
Miscellaneous
Brake Fluid Reservoir
Alternator
Distributor
175
175
To Adjust Headlamps
To Remove and Instal Front Turn
Signal and Park Lamp
Rear Combination Lamp
Inflate
195
LUBRlCAnON AND MAINTENANCE
173
Choke Control
Heater Controls
1000
Heater Controls
1200
Instrument Cluster
1000
1200
Windscreen Wiper
To Remove and Instal the Pivot Boxes
Instal
Inflate
195
195
173
174
Units
Leaks
Using a Tourniquet
Tyre Wear Diagnosis
173
Cigarette Lighter
Lamp
Specifications
194
175
176
Battery
Tyres
Body
176
176
214
201
201
201
201
201
201
201
202
202
202
202
202
202
202
Index
EMISSioN
CONTROL SYSTEM
Specifications
Crankcase Ventilation System
To Gheck and Test Operation
Exhaust Control System
Control Valve
Servo
Diaphiagm
Adjust Servo Diaphragm
To
and Control Valve
Carburettor
To Adjust Idle Speed and Mixture
Electrical Equipment
Spark Plugs
High
Tension Leads
Distributor
Evaporative
De
Control System
cription
Flow Guide Valve
S
208
To Test
203
203
204
204
Fuel Tank Vapour Liquid Separator and

Exhaust Control System Fault Diagnosis
Recommended Maintenance
209
205
Engine
209
205
205
206
206
206
206
Crankcase Ventilation
209
206
ROAD TESTS
207
Da tsun 1000 4 Door
218
207
Datsun 1000 2 Door
219
207
Datsun
220
208
Da tsun
Vapour Vent
Line
System
Exhaust Control System
Evaporative Control System
208
209
210
210
GLOSSARY OF TERMS
215
2004 Door
I 200 2 Door
221
OF
GLOSSARY
AND
NAMES
ENGINE
SLAVE C
Air filter
Clutch
LINDER
WITHDRAWAL LEVER
BI MET AL SPRING
Thermostat spring
CAMSHAFT SPROCKET OR GEAR
Timing gear timing
operating cylinder
Throw
oUl
lever clutch fork
release fork
wheel
TRANSMISSION
CRANKSHAFT SPROCKET
OR GEAR
Timing
gear
timing wheel
ENGINE
ENGINE
CIRCLlP
End tlUJt end clearanl
END PLAY
Snap ring spring clip
GEAR SHIFT LEVER
FLYWHEEL RING GEAR
Starter
ring
gear starter drive
Piston
Cluster gear shaft
wrist
pin
pin
induction
MAINSHAFT
Third
secondary shaft
Intake valve induction valve

INLET VALVE
MUFFLER
Silencer
PROPELLER SHAFT
Rubber O
Rubber
oil
ring
SELECTOR FOR
eal
SELECTOR SHAFT
nil seal
lL
se
gear
motion
shaft
output
Selector rod selector rail shift rail
shift rod shifter shaft

SPIGOT BEARING
Pilot bearing support bearing
SPRING RING
SVl1chro spring encrgising spring
OUTER ROTOR
OIL PUMP Gear type
DRIVE GEAR
SYNCHRO HUB
Rotor type
INNER ROTOR
SYNCHRO SLEEVE
DRIVEN GEAR
and
gearbox
cone
Release valve
or
UNiVERSAL
JOINT CROSS
UNIVERSAL JOINT YOKE

Valve
solid
lifter
synchro key
shift
TOP GEAR
Rocker tappet
SCREEN Gauze type
Filter
SUMP
Oil pan
Hydraulic
UNIVERSAL
Synchro bar
plate
High gear high speed
JOINT
Drive coupling
sliding key
ARM
TAPPET
Baulk ring synchro

Clutch sleeve
SYNCHRONISER PLATE
RELIEF VALVE
RockER
Clutch hub
SYNCHRO RING
Engine
shaft
Drive shaft tail sh3ft

Shift fork shifter tork
OIL PUMP
POWER UNIT
shaft
speed first
First
LOW GEAR
manifold
manifold
NEOPRENF SEAL
second motion
intermediate shaft
Intake
NEOPRENE Q RING
main
intermediate gear
LAYSHAFT
MANIFOLD
first motion shaft
primary shJfl main drive gear spigot shaft

LAYGEAR
Cluster
motion
second
gear
gear
Petrol pump
GUDGEON PIN
lever gear selector
drive shaft
gear
FUEL PUMP
Change speed
lever gear change lever

INPUT SHAFT
Clutch shaft
Motor
STEADY
Stabiliser support
MOUNTING
Mounts supports
INLET
vlind
vlinder
actuating
AIR CLEANER
TERMS
Joint trunnion
Universal joint fork
cam
follower
REAR AXLE
TIMING CHAIN TENSIONER
Chain tightener
VALVE COTTER
Valve collet valve keep valve key
WATER PUMP IMPELLER
Rotor
AXLE SHAFT
Drive shaft
AXLE
BEARING
axle
CLUTCH
CLUTCH HOUSING
DRiVEN PLATE
Clutch
Clutch
DRJVEN PLATE FACINGS
clutch bell housing

driven disc clutch disc
Driven
PRESSURE PLATE
Clutch drive
PRESSURE
plate linings clutch
wheel
hearing
rear
gear
COVER
Differential pinion bevel pinion

DRIVE PINION
PINION FLANGE
Drive coupling
plate
Clutch
housing
clutch
FRONT SUSPENSION STEERING
cover
RELEASE BEARING
Throw out
withdrawal bearing
RELEASE BEARING PLATE
thrust plate
RELEASE
Rear
race
Differential bearing side bearing

BEARtNG
CROWNWHEEL
Ring gear
DIFFERENTIAL PINION
Spider pinion inion gear
DIFFERENTIAL SIDE GEAR
Axle shaft gear spider
linings
PLATE
half shaft
CARRIER
cover
plate
SHAFT
LEVER
Clutch
bearing thrust bearing

BUMP RUBBER
Throw
linger
out
bearing plate
release
Bumper
CONTROL ARM
Wishbone suspension arm link

CONTROL ARM SHAFT
Fulcrum pin fulcrum shaft
finger
pivot pin
throw out lever
IDLER ARM
216
Intermediate lever
or arm
KING PIN
Swivel pin
PITMAN ARM
SECTOR SHAFT
arm
GLOBE
drop arm
Roller shaft pitman
Steering
arm
sector shaft
arm
arm
shaft drop
sha ft
SHOCK ABSORBER
STABILlSER BAR
STEERING CONNECTING ROD

STEERING LINKAGE
light llasher
HEADLAMP
Head light main light

HIGH TENSION LEADS
Plug wires
Tie rod relay rod
HORN PUSH
Track rods
Horn switch horn button
INSTRUMENT LIGHT
STEERING GEAR
Steering gearbox steering box

Worm shaft steering column
STEERING SHAFT
LENS
Swivel axle
STUB AXLE
STUB AXLE SUPPORT
Steering knuckle support swivel
link control arm link
TiE ROD
Track rod steering link rod

TIE ROD BALL JOINT
Tie rod end
WHEEL ALIGNMENT
Toe in track alignment
Panel light
rvslal
NUMBER PLATE LIGHT

Licence plate
MEDALLION
Name plate cover
PARKING
LIGHT
Side light side lamp

AlternalO
REGULATOR
ROTOR ARM
light
regulator
alternator
COl1trol
Rotor button
Brake
light
STARTER
Starter motor
STARTER DRIVE
Bendix gear drive pinion
TAIL LIGHT
Rear light
TEMPERATURE GAUGE
Heat gauge
WARNING LIGHT
Indicator light
BACK PLATE
Brake plate backing plate

Brake hose flexible
FLEXI BLE BRAKE PIPE
lass
STOP LIGHT
BRAKES
PISTON
Direction indicator
TURN SIGNAL SWITCH

Direction indicator switch
flasher switch trafficator switch
Damper
Ride stabiliser sway bar

Knuckle arm steering lever
STEERING ARM
Bulb lamp
TURN SIGNAL LIGHT
light trafficator light
connector
WINDSCREEN WIPER
Plunger
Windshield wiper
PRIMARY CUP
Main cup maio rubber seaL

Pull off spring retractor spring
SECONDARY CUP
Piston seal
BODY
RETURN SPRING
WHEEL CYLINDER CUP
cylinder
DOOR GLASS
Wheel cylinder rubber wheel
FENDER
seal
WHEEL CYLINDER
Door window window glass
Mudguard wing
GLASS LIFT CHANNEL

GLASS REGULA TOR
Actuating cylinder
ADJUSTABLE CONTACT
GLASS RUN CHANNEL
ALTERNATOR
bailey channel
CAPACITOR
Breaker point
AC Generator
DIPPER SWITCH
GENERATOR
arm
HEADLINING
point
HOOD
Interior
light roof light
glass
runner
Roof lining
Bonnet
REAR GLASS
Back light back window
VENTILATOR GLASS
No draught ventilator vent glass
ventilator flipper window quarter glass
WEATHERSTRIP
Weathershield
WINDSCREEN
Windshield
Dimmer switch
Petrol gauge
Dynamo
GENERATOR REGULATOR
Glass channel
engine compartment lid

LUGGAGE COMPARTMENT
Boot
Condensor
COURTESY LIGHT
FUEL GAUGE
Breaker
regulator window
winder
ELECTRICAL
BREAKER ARM CONTACT
Window lift channel

Window lift
Voltage regulator control
box
217
DatsWl
MAKE
BODY
4 door
TYPE
white
COLOR
sedan
MILEAGE
1899
PRICE
nil
OPTIONS
1000
MODEL
4790
START
4930
FINISH
13cwt
WEIGHT
FUEl CONSUMPTION
Overall
35 2 rnpg
36 39 mpg
Cruising
TEST CONDITIONS
Weather
fine
Surface
persons Fuel
SPEEDOMETER
hot mix
Load
two
ERROR
30
40
50
60
70
30
37
45
53
62
Indicated mph
Actual
bitumen
premium grade
mph
Road test
PERFOR JA CE
figures courtesy
Wheels
Magazine
from its October 68 Sydney report
2320 it min
speed at m6X bhp
16 4 mph
Top gear mph per 1000 rpm
4660 rpm
Engine rpm at max speed
4250 rpm
Engine rpm at cruising speed
24
Lbs laden per gross bhp
power to weight
Piston
MAXIMUM SPEEDS
Fastest run
Average of all runs

Speedometer indication fastest
In
1st 23
gears
82 mph
mph
2nd
38
82
mph
82
mph
SPECIFIC
3rd
mph
53
4th
mph
ENGINE
four in
Cylinders
Bore and stroke
ACCELERATION
44
sec
capacity
Compression ratio
0 40 mph
8 1
see
Valves
mph
12 2
sec
Carburettor
18 2
sec
Fuel pump
23 0
sec
Oil
through
mph
60mph
mph
0 70
3rd gear
20 40
30 50
40 60
50 70
line
by 59mm
73mm
988
Cubic
gears
0 30
0 50
TIONS
89mph
run
mph
mph
mph
60
see
75
sec
75
see
8 2 sec
mph
sec
HaUachi d draft
mechanical
filter
full flow
62 8 at 6000 rpm
61 51b ft at 4000 rpm
TRANSMISSION
11 5 sec
Type
12 5 see
Clutch
Gear lever
STANDING QUARTER MILE

Fastest run
20 2
see
Average of all
20 3
sec
runs
speed all syncro

single dry plate
floor
location
Direct ratio
1st
3 76
2nd
2 t7
3rd
140
100
4th
Final
111
4
drive
CHASSIS and RUNNING
4T
Suspension
Suspension
unitary
front
rear
absorbers
steering type
wishbones transverse spring

leaf
G V4
Mil E20 3
MPH
1ST
L
2
TOP
PEED
82 KP H
15
in
drum drum
8 in
diameter
89 sq In
7 ft 5 in
3ft
Track
3 ft 10
rear
Width
Fuel
tank capacity
Make
I4
L
1
eLAPSED
TIME IN
10
1S
gal
lYRES
5
40
SECONDS
218
on
GROUND
50 12
17 psi
Pressures
1520
in
ft 6 in
4ft 5in
4ft 8il in
Height
PH
tOI in
12
Size
MPH
28 2 ft
Wheelbase
Track front
Length
10
ratio
DIMENSIONS
ACCDERATION THROUGH
GEARS WITH CHANGE
POtNTS
6
1
0
15
28
Turning circle
Steering wheel diameter
Brakes type
Dimensions
Friction area
AD
recirc
TurnS l to I
oc
4C
springs
telesCopic
Shock
to t
GEAR
Construction
oc
STANDI
cc
fa 1
pushrod
overhead
2 bbl
Power at rpm
Torque at rpm
4thgear
82
85
test
car
Dunlop Dunsafe
CLEARANCE
Registered
7i in
33lf
l
17
0
00
q 375
Datsun
MAKE
MODEL
BODY
1000 coupe
ntl
white
OPTIONS
2 dr coupe
4 dr sedan
TYPE
2119
2145
PRICE
1000
white
COLOR
WEIGHT
t3 25 ewt
FUEL CONSUMPnON
Overall
mpg
32
29 mpg
30 34 mpg
34 38 mpg
Cruising
13 1 ewt
TEST CONDITIONS
Weather
tine
Surface
hot mix
Load
bitumen
2 persons
Fuel
Road test
premium grade
SPEEDOMETER ERROR
Indicated mph
30
40
50
60
70
Actual
28
37
47
57
66
29 5
39 0
48 0
57 0
67 0
mph
figures
from its
courtesy Wheels
August
1969
4thgear
3rd gear
20 40
mph
30 50 mph
40 60 mph
50 70 mph
PERFORMANCIl
Piston
speed at Max bhp

2310 ft min
15 5 mph
Engine rpm at Max speed
5350rpm
4900rpm
Lbs laden per gross bhp power to weight
22 6 23 6
MAXIMUM SPEEDS
Fastest run
89 0
Average of all nms

run
In gears
1st 29 mph
50
0
0
of
all
mph
3rd
75
2nd 49
40mph
mph
60 mph
70 mph
80 mph
0mph
81 mph
tor
7C
6C
mph
sees
10 1
sees
76
sees
11 2
sees
7 0 sees
10 7 sees
10 0 sees
13 7
sees
20 3 sees
20 4 sees
sees
82
secs
72
sees
00 6
sees
0 5 sees
05 0
secs
15 2 sees
23 2
sees
210 sees
36 5
sees
STAN
M U
75 MPt
7f
20 4
T1G
OM
4 speed
Clutcl1
Gear lever location
V6 I
TOP
SPEED
86
76
MP H
PH
GEARS
15
ELAPSED TIME
l
I
WITH CHANGE
POINTS
cc
ohv
2 bbl
66 at
downdraught
6000 rpm
62 at 6000 rnm
65 7Ib lt at 4000 rpm
lt at 4
drive
Nissan 3
speed tully automatic

torque converter
central floor column quadrant
1st 3 76
2 458
458
1
2nd 2 17
3rd 1 40 l 000l
4th 100
4 111 to 1
sdp
GEAR
unitary
SUSPENSION
Front
Rear
Shock absorbers
wishbones
transverse leaf
leaf
springs
telescopic
STEERING
recirc
Type
TUrns
I to
ball
34
26
Tumlng circle
It
BlAKES
dnnn front and
Type
rear
DIMENSIONS
AcmERATll THRJGH
20
sees
988
COnatnIction
sees
9 0 to 1
CHASSIS and RUNNING
2ND
SOMP
Final
lTANDIIIG
0
2ND
23 5
24 0
TRANSMISSION
Type
r
c
sees
four in line
by 59mm
Power at rpm
Torque at rpm
Automatic Sedan in brackets
3R
218
73mm
stroke
Cubic capacity
Compression ratio
Valves
Carburettor
76
48
MILE 2
67
Cyllnders
JuP i
4t
5 5sees
rWlS
Overall ratio
49
sees
ENGINE
32 6 secs
Figures
50
99
SPECIFI
ATIONS
76
92
sees
MILE
78 2 mph
mph
86 4mph
0 50
0
Average
Drive
64
Bore and
30
mph
4th 86 mph
Acceleration
through gears
0 30mph
0
STANDING QUARTER
Fastest run
Magazine
Sydney report
Wheelbase
Track
front
Track
rear
89 8 in
46 9 tn
46 5 in
12 It U in
Length
Hetght
Wtdth
tank
Fuel
capacity
l21t 5 6 tn
41t 3
6tn
4ft 5 in
4ft
8 9 in
7 7 gals
S gals
TYIES
t 1J
Size
Make
5 50 12
on
teat
car
Dunlop
Dunsafe
GROUND CLEARANCE
Registered
IN SECONDS
219
6 7 in
63
tn
Datsun
MAKE
4 dr
BODY TYPE
MODEL
Manuall
1200
edan
Automatic
Nil
OPTIONS
13 9
WEIGHT
MILEAGE START
1609
PRICE
FINISH
2023
COLOR
690
ewt
2108
Kg
2334
Red
fUEL CONSUMPTION
Overall
10 9 k Il
Cruising
29 33 mpg
Manual
13 2k ll
31mpg
Manual
Auto
03 5 15 3 k
32 36 mpg
28mpg
Auto
12 3 14 k l
rEST CONDITIONS
Weather tine Surface
two persons
SPEEDOMETER
Indicated
Fuel
ERROR
bitumen bonded gravel

premium grade
speed
Road test
mph
Actual
Piston
Load
30
40
50
60
70
37
46
54 5
64
PIlRFon I
max bhp
70 050
at
C
min
cm
Tcp gear mph per 1000 rpm

Lbs laden
per gross bhp
lXlWer
2760 ft min
25 8 kph
Autcmatic
16 0
2nd Gear
4200
22 2
toweight
10 kg bhp
MAXIMUM SPEEDS
Fastest run
Average of all runs
121 kph
120 5 kph

IN
run
75 5
mph
75 0 mph
146 kphJ 91 0 mph
1st
2nd
3rd
ACCELERATION
45 kph
74kph
60 mph
97 kph
75mph 120kph
75mph
120kphl
Through gears
0 30
mph
73
71
50 70
mph
91
tt6
0 50 mph
13 3
19 5sec
BRAKING
From 30 mph
to
From
to
60 mph
stroke
Compression
sec
STANC NG V4
MILE 21 5S
2ND
4MPH
MPH
5C
4C
Xl
PH
15T
28MP
I
MPH
75
15
ELAPSED
70 mm
2 87
1171cc
line
by
2 76 in
715cuin
90 W t
ohv
at
single
69
70 ft
rpm
all
bhp
lb 10 6 kg
syncro
Gear lever
CHASSIS AND RUNNING GEAR
Suspension
Suspension
front
146
coil struts
rear
Shock absorbers
to I
Turning circle
Brakes type
SPEED
Dimensions
PH
M
6000 rpnl
3600 rpm
3rd
140
integral
anti roll bar
lea
springs
telescopic
recirculating ball
steering type
Turns 1
at
Borg Warner Type 35

Single dry plate fluid
central T bar
Central
COnstruction
HELD
at
location
2nd 2 17
ratio 1st 3 76 2 46
4th 1000 finat drive 3 90
Overall
1 00
downdraft Aisan SU
rpm
at
I
TOP
by
ratio
Clutch
drum
8 in
15
to 1 ratio
27ft 82m
front and
20 2
em
rear
diameter
DlhUNSIONS
I
I
t
JND
t
73
Carburettors
IC
sec
TIO
S
Valves
TRANSMISSION
4 speed
Type
7C
sec
l Osec
3 05
CUbic capacity
see
Torque
JPH
7s
0
0
4 in
Bore and
Power
21 5
21 55 see
runs
Cylinders
sec
4 see
9
29 5
4t
ENGINE
6 1
60 mph
70 mph
52
60
SPE
IFlf
mph
0 40mph
64
Average all
46mph
87kph
63
STANDING QUARTER MILE

Fastest run
Held
Drive
mph
54mph
28
Drive
20 40 mph
30 50mph
40
GEARS
Automatic
figures courtesy Wheels Magazine

September 1970 Sydney report
from its
TIME
IN
90 6 in
Track front
48 8 in 124 ern
Track
ACCnERATIOH THRC1JGH
GEARS WITH CHANGE
JPOJ
Wheelbase
49 0 in
rear
Length
12 ft
Fuel tank
Tyres
Make
220
capacity
Size
on
GROUND
SECONDS
em
125 em
405
em
4 ft 6 7 in
Height
Width
6 9 in
243
test
139 cm
4 ft 10 9 in 124 cm
88 galls
32 5 litres
6 00 x 12 155 x 305
Dunlop
car
CLEARANCE
Registered
6 6
Dunsafe
16 8
em
Road test
from its
figures courtesy Wheels Magazine
MAKE
Datsun
MOOEL
BODY TYPE
1200
Coupe
door
2
Coupe
PRtCE
24t4
COLOR
Cream
MtLEAGE START
1971 report
ACCELERATION hhrough gears

039 mph
40 mph
0
050 mph
0 60 mph
070 mph
608
WEtGHT
1520 Ib
CONSUMPTION
Overall
31 mpg
37 38 mpg
Cruising
Weather
Hot mix
Load
2 persons
Fuel
premium
15 5
20 40
3rd gear
8 0 see
30 50
4 2
7 0 see
see
see
see
8 2
see
83
see
see
4th gear
11 6 see
96
see
10 5
see
4 see
12
STANDING OUARTER MtLE

19 1
run
Average all
Hot fine
Surface
see
22 1
2nd gear
4 0 see
Fastest
TEST CONDITIONS
see
77
32
mph
mph
4060 mph
5070 mph
1695 kg
54
10 9 see
80mph
Q
2t
MILEAGE FtNtSH
FUEL
Apri I
see
19 3 see
runs
BRAKING
From 30
mph
mph
From 60
to
1 7
to
3 6 sec
see
SPEEDOMETER ERROR Imph

Indicated
30
40
50
60
70
Actual
28 4
38 1
46 8
55 8
63 9
SPECI FICATIONS
ENGINE
Cylinders
Four in line
Bore and Stroke
2 87
2 76
73
Cubic
Capacity
Compression Ratio
715cu
Piston speed at max bhp

Lbs laden per gross bhp power
840
Fuel
2760 ft min
5500
22 Ib
weight
ns
Average of all
Speedometer ndication fastest
kph 88 mph
136 kph 85 mph
157 kph 98 mph
run
Full flow
6000
bhp
70 Ibltt 19 7 kglm @3600
69
rpm
at
rpm
4 manual
4 mph
28
45
kphl
51 mph 82 kph
77 5 mph 124 kph
88 mph 141 kphl
2nd
3rd
4th
all syncro
I
SDP
Clutch
Gear lever location
Floor console
RATIOS
Direct
Overall
6000 rpm
6000 rpm
1st
3 76
14 66
2nd
2 17
8 46
6000 rpm
5500 rpm
3rd
40
1
4th
1 0
Final Drive
3 9 1
IN GEARS
1st
pushrod
Meehan ical
TRANSMtSSION
Type
141
run
at
Torque
110 kg
MAXIMUM SPEEDS
Fastest
Pump
Power
Two barrel downdraft
Oil Filter
16
ta
Overhead
Carburettors
min
mm
1171
9to 1
Varves
PERFORMANCE
70
mm
5 46
3 9
CHASSIS and RUNNING GEAR
EJ19
MIL
PH
3RI
I
I
hJPH
2ND
Steering
Brakes
Wheel Diameter
20
25
35
38 1
em
Disc drum
90 6
48 8 in
Track Rear
49
230 eml
124
124 5
12 ft 6 in
382
4ft 5
Capacity
8 5
cm
em
em
135cm
4ft 11 6 in
Fuel Tank
30
IN
15
Track Front
1515
em
38 litres
gals
TYRES
t55SR
Size
Pressures
15
Telescopic
Recirculating ball
26 tt 8
8 2 m
Wheelbase
Width
EUlPSED TIME
leafs
elliptic
Semi
Type
Length
Height
l I 1
Unitary
McPherson struts anti roll bar
DIMENSIONS
ACCELERATION THROUGH
GEARS WITH CHANGE
POINTS
I
10
IlOP
MPH
Steering Type
Turning Circle
SPEED
88 P
MH
7r2BM1
I
Shock Absorbers
V1
4C
Suspension Front
Suspension Rear
VI
Construction
OING1
ST
Make
SECONDS
221
on
12
24 Ib all round
Test Car
Dunlop SP 3
GROUND CLEARANCE
Registered
6 7 in
17
em
DATE
REMARKS
222
REMARKS
1
QATE
223
REMARKS
DATE
Printed
by
Kenmure Press
Pty
Ltd
50
Derby
Street North Lidcombe

r
New South Wales
2141
at
b iid
5d
J
l
iizk
iT 1Z
ic
1
jj
tiJt

-教學資源-Datsun 1000 and 1200 A10 A12

Transféré par

Informations du document

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

-教學資源-Datsun 1000 and 1200 A10 A12

Transféré par

Droits d'auteur :

Formats disponibles

SCIENTIFIC PUBLICATIONS

WORKSHOP MANUAL SERIES

DATSUN 1000 1200

AUTOMATIC and MANtJAL TRANSMISSIONS

by Scientific Publications Ply

142 Oarence Street

2000 New South Wales

Press Ply Ltd

New South Wales

Copyright by Scientific Publications Pty Ltd

of Australia Registry Number

thank Nissan Motor

LUHIUCATION AND MAINTENANCE

OTHER TITLES IN THE SCIENTIFIC

Austin A40 Devon

Austin A40 Somerset

Dodge ASM 106

Lawn Mowers Vieta 2 Stroke

Morris Austin Mini

Morris Austin 1800

Ford Customline OHV

t Recommended retail price in Australia

Burbank California 91503

Valve seat insert outer diameter

Valve seat insert inner diameter

Valve seat insert

Inlet and exhaust

Insert interference fit in head

Valve seat width

GUIDES AND SPRINGS

Valve seat material

Interference fit in head

head bore diameter for valve

Valve seat insert

Fitted height above spring

Interference fit in connecting rod

Fitted length and load

temperature of 200C 680F

Big end bearing

CAMSHAFT AND BEARINGS

Connec ing rod bent

Big end end float

end bearing thickness

CONNECTING ROD AND BIG END BEARING

Crankpin taper or ovality

73 217 73267 nun

73 717 73 767 nun

PISTONS PISTON RINGS AND GUDGEON PINS

to valve stem clearance

Clearance outer rotor and body

Oil strainer bolts

Oil pump attachment bolis

Oil pump type

Crankshaft pulley bolt

chain tensioner bolts

Main bearing cap bolts

Cylinder head bolts

With new filter

Pump release valve plug

overhead valve engine has a cast iron

valve has its individual port and is operated by

The crankshaft is counter balanced and funs in three

bearings Crankshaft end float is taken at the centre

Pistons are slipper skirt aluminium alloy type with two