Datsun 411 Series Service manual

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MODEL 411 SERIES
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DATSUN
MODEL
411
SERIES
SERVICE
MANUAL
INISSANI
NISSAN MOTOR CO
OTEMACHI BLDG
OTEMACHI
TOKYO
CABLE ADDRESS
PHONES
LTD
CHIYODA KU
JAPAN
llNISMOll TOKYO
216
2311
INTR ODUCTION
This manual has been
complies
for
purpose
of
assisting
DATSUN distributors and dealers for effective service and
maintenance
major
of the Model
components
comprehensive
ing
detaiL
in
given
assembly
for
of the
In addition
complete
dismantl
and inspection of these assemblies
emphasised
should be used
described
instructions are
assembling
It is
is
Each
P L 411
as
that
only genuine
DATSUN Spare Parts
replacements
DATSUN
MODEL
1
411
U
CONTENTS
Page
MAJOR SPECIFICATIONS
ENGINE
1
Cooling System
3
Lubrication
8
SERVICE OPERATIONS
11
Rocker Mechanism
12
REMOVING
REFITTING
Operation with
the
25
Engine Removed
26
IGNITION TIMING
31
Distributor
31
Adjusting
the Ignition Timing
31
FUEL SYSTEM
34
Carburetor
34
The Gasoline Tank
37
Fuel Strainer
40
Adjustment
and Inspection of Engine
43
CLUTCH
48
TRANSMISSION
57
Cover of Transmission Case
58
Transmission Case
59
Extension of TransmiBBion Case
DiBaBSembly the
Transmission Case
CHASSIS
65
For 4
Stage Floor Shift
72
85
FRONT AXLE
85
DiBaBSembling the Front Hub
Indipendent Front Suspension
REAR AXLE
86
88
98
STEERING
112
BRAKE
119
Front Brake
120
Rear Brake
123
Hand Brake
126
ELECTRICAL SYSTEM
129
Alternator
130
Generator
132
Regulator
139
14 ItemB
Trouble
on
Handling
Shooting
Starter Motor
List
142
143
144
SPECIFICATION OF
MA
JOR
MODEL 41 1 SERIES
MODEL
ITEM
P L 411 U
WP L 411 U
P L 4 1 1 oUT
WP L 411 UT
Overall Length
3 995 mm
Overall Width
1
490
Overall Height
1
440
Wheel Base
157 3 in
3
995
mm
58 7 in
1
490 mm
58 7 in
mm
56
7 in
1
430
mm
56 3 in
2
380 mm
93
7 in
2
380 mm
93 7 in
1
710 mm
67 3 in
1
704 mm
67 1 in
Inner Width
1
240 mm
48 8 in
1
240 mm
48 8 in
Inner
1
130 mm
44 5 in
1
130 mm
44 5 in
1 206 mm
47 5 in
1
206
mm
47 5 in
47 2 in
1
198 mm
47 2 in
L
Room Space
Height
rront
Tread
A
Rear
Min
1
Road Clearance
Overhang
mm
175
mm
6
157
6
3 in
9 in
175
mm
9 in
605 mm
23 8 in
605
mm
23 8 in
950
37 4 in
947
mm
37 3 in
to the Front End
without bumper
Overhang
198
mm
to the Rear End
without bumper
Vehicle Weight
mm
885
kg 1951 Ib
960
Front
505
kg
1113 lb
Rear
380 kg
838 lb
160 kg
2557 lb
Front
600 kg
1323 lb
595 kg
1312 Ib
Rear
560
1234 lb
640
1411 lb
kg
2116 lb
500 kg
1102 Ib
460
kg
1014 lb
235
kg 2723 lb
Distribution
Vehicle Gross Weight
I
1
1
Distribution
9
Height of Gravity Center
580
Proportion of Front Tire
Angle
Inclination
22 8 in
mm
kg
580 mm
22 8 in
51 7
48 2
Right
46
46
Left
46
46
with load
Max
kg
I
r
DATSUN
MODEl
ITEM
Speed
Max
P l 411 U
WP l
U
411
P l
WP l
UT
411
UT
411
140 km
H
87 MPH
140 km
H
87 MPH
l
Fuel Consumption
p
0
r
p
Grade
Min
Ability
sinO
0 375
Turning Radius
l
5
18
5
0
P
km
0 417
18 5 km
UT
o
334
164ft
m
5
o
t
391
UT
0 m
164ft
135m
443ft
Po
Brake
Distance
Stopping
50
h
km
44 3 ft
135m
Model
J
Make
NISSAN MOTOR CO
Classification
GASOLINE ENGINE
Cooling System
No
of
WATER FORCED CIRCULATION
Arrang
Cylinder
4 IN LINE
Cycle
4
Combustion Chamer
BATHTUB TYPE
Valve Arrangement
l
LTD
OVER HEAD VALVE
Bore x Stroke
73 x 77 6 mm
DiBplacement
1299
c
2
874 x 3 055 in
7927cu in
c
Compression Ratio
8
2
as
lE
Compression PreBsure
350
kg cm2
r
p m
48 3600
kg cm2
r
p m
11 5
l
Max
Exploding
Max
Mean Effective PreBB
Max
B
Max
Torque SAE
Length
x
H P
PresBure
9 7 28000
SAE
Width
x
kg cm2
r
p m
67 5200 HP r p m
76 7 2800 ft Ib
Height
597
Weight
x
575
x
r
p m
690
mm
10 6 2800 kg
23
1 x 22
SPLIT SKIRT TYPE
PiBton Material
LO EX
2
r
p m
6x26 5 in
139 kg 306 Ib
PiBton Type
m
MAJOR SPECIFICATION
MODEL
ITEM
No
of
WP L 411 U
P L 411 UT
WP L 411 UT
2
PreBsure
PiBton Ring
riI
I
i
P L 411 U
011
1
Inlet Open
14
B T D
C
Inlet Close
50
A B D
C
Exh
Open
52
B
B D
C
Exh
CloBe
12
A T D
C
Valve Timing
@
f
riI
Intake
0 35 mm
0 014 in
ExhauBt
0 35
0 014 in
Valve
Clearance
p
riI
Eo
Starting Method
MAGNETIC STARTING SYSTEM
Type
N41
p
riI
Z
N50
14MZ
40
Ground Polarity
NEGATIVE
Type
AC300 12WR
Make
MITSUBISHI
ALTERNATOR
Generating Method
12V
Voltage
300 W
Capacity
Voltage Regulator
RL 2Bl
Type
S114 92
Make
HITACHI
Eo
on
I
l
z
Zl
l
12 1
Power
4V HP
BATTERY COIL TYPE
Ignition Method
t
9
Voltage
1 each
50 A H
riI
p
riI
2SMB
12V
Voltage
Capacity
p
0
Eo
mm
8
Ignition Timing
600 B T D C
1
Firing Order
3
4 2
3
r
p m
r
DATSUN
MODEL
ITEM
P
l 411 U
P l
UT
411
C1Z
Type
WP l
U
411
WP l
UT
411
18
Ignition Coil
Make
HITACHI
0411
Type
53
Distributor
Make
Distributor
HITACHI
Ign Timing
Advance System
VACUUM AND GOVERNOR
B
Type
Make
6E
NGK
Spark Plug
Thread
14 mm
Gap
0
7
08 mm
Type
l
0
Make
E
Carburetor
0
0315 in
NllIONKIKAKI
Throttle
Z
0
00275
D2630A 5A
Q
iI
I
Eo
0 551 in
P
S
Valve Bore
26
Venturi Size
20mm
30mm
mm
27 mm
Main Jet
192
1140
Slow Jet
148
I 48
Z
0
Pump
145
Jet
Power Jet
140
Air Draught
Type
DOWN
No
PAPER TYPE 1 each
Air Cleaner
Make
TSUCHIYA
Type
DIAPHRAGM
Fuel Pump
Make
Capacity
z
0
SHOWA
of Fuel Tank
41f
Lubrication Method
r
KYOSAN
10 8 U S gal
FORCED PRESSURE TYPE
9t2E
4
MAJOR SPECIFICATION
MODEL
a
ITE
C
p L 411 U
WP L 4 1 1 U
P L 411 UT
WP L 411 UT
TROCHOID TYPE
Oil Pump Type
E
0
l
f
CARTRIDGE TYPE
FULL FLOW TYPE
Oil Filter
p
Q
I
2
Oil Pan Capacity
9 fr 0 76 U S gal
H
WATER CUULING CLOSED TYPE
Type
l
riI
E
Radiator
l
t
Cooling
CORRUGATED FIN AND TUBE TYPE
Water
5 4 fr
Capacity
1
43 U
S
gal
as
H
0
0
U
Water
CENTRIFUGAL TYPE
Pump Type
PELLET TYPE
Thermostat
SINGLE DRY DISC HYDRAULIC OPERATION
Type
No
U
E
H
U
1
of Plate
Out dia
x
dia
In
x
200
Thickness
x
dia
of
In
dia
of Master
x
181
Total Friction Area
In
130
3
5 mm
x
2
cm2
19 05
Operating Cylinder
7
87 x 5
28 06
mm
15 87 mm
Cylinder
3 FORWARD
Type
FACING 2
1 REVERSE
x
12
x
0 138 in
2 sq in
3 4 in
5
8 in
4 FOREARD
1 REVERSE
ALL SYNCHROMESHED
SYNCHROMESHED ON
ON FORWARD GEARS
2ND
Gear Shift Method
REMOTE CONTROL
Oil Capacity
1
3RD
4TH
FLOOR SHIFT
Z
9
f
l
l
p
E
Gear Ratio
2
45 U S gal
7 fO
2
0
1st
3
197
3 945
2nd
1
725
2 402
3rd
1
000
1 490
4th
4
Reverse
125
1
000
5
159
0
I
1st
Length
Out
x
dia
x
In
1222 x 71
dia
0
0
Type
x
67 8 mm
SPICER TYPE
of Universal Joint
0
5
58 U
HYPOID
Gear Type
o
5
S
gal
r
DATSUN
MODEL
P L
0
i
1
1
L 411 U
P
ITEM
P L 41l
Gear Ratio
WP L 411 U
UT
411
WP L
U
4 375
WP L 41l
4
U
Housing Type
P L 41l
OP 3889
111
UT
411
UT
WP L 411 UT
BANJO
J
r
No
Type
is
of Gear
STRAIGHT BEVEL PINION 2 each
Oil Capacity
1 fO
Type
26 U
S
gal
RECIRCULATING BALL TYPE
Gear Ratio
15 0
Eo
ES
Steering
Angle
r
Out
I
Eo
360
Steering Wheel
280
Dia
405 mm
Oil Capacity
0 33 f
Wheel Arrangement
Front Axle
Toe
0
D
p
1
45
0
Inclination Angle of King Pin
6
Width
x
15
SEMI FLOATING TYPE
Type
FRONT 2 LEADING
Lining Dimension
p
l
2 REAR
3 mm
Type
j
f
087 UoS gal
Caster
p
l
95 in
WISHBONE BALL JOINT TYPE
Type
in
Rear Axle
Eo
15
2 FRONT
Camber
ES
36
x
REAR LEADING AND TRAILING
40
x
4 5 x 215 mm
1
575 x 0
177 x 8 465 in
40
x
4
1
575 x 0
177
Thickness
Length
5 x 215 mm
351
cm2
54 4 in2
351
cm2
54 4
Total Braking Area
U
in2
p
In dia
of Brake
F
228 6
R
228 6 mm
mm
9 0 in
Drum
q
6
9
o in
x
8
465 in
MAJOR SPECIFICATION
MODEL
ITEM
In dla
I
r
WP L 411 UT
of Master
22 22 mm
0
8748 in
F
25 40 mm
1
000 In
R
23
81 mm
0
9374 In
115
kg cm2
j
In dla
II
Q
I
r
I
0
of Wheel
Cylinder
H
n
WP L 411 U
P L 411 UT
Cylinder
II
Q
I
I
r
P L 411 U
0
II
I
r
Max
Oil PreSBure
1636 Ib ln2
MECHANICAL FOR REAR WHEEL
I
r
I
r
Type
II
Q
I
II
Q
I
Lining Dimension
40 x 4 5x215mm
1
575xO 177
x
8 465 In
t
351
Total Braking Area
cm2
54 4 sq in
II
In
of Drum
dla
228
6 mm
9
0 In
Po
Front
INDEPENDENT SUSPENTION WITH COIL SPRING
Suspension Type
R H
Coil
Wire dia
x
Free Length
Z
9
Z
I
r
Po
Rear
Coil dla
No
x
of Coils
14 2
Size
Length
Thickness
x
CAR
x
94 x
8
5
14 2
325 L
x
94
x
Width
6 2
x
1200 x 60 x
No
6
1200
x
60
5 2
P
ShOck Absorber
F
TELESCOPIC DOUBLE ACTION
Shock Absorber
R
TELESCOPIC DOUBLE ACTION
Stabilizer
F
TORSION BAR TYPE
Tire Size
e
F
5
60
13
4P
R
5
60
13
4P
12V 37 5 50W
Head Lamp Sealed beam
Po
H
x
Width Indicators
12V
8Wx2
Tail Lamps
12V
8W x2
12V
8W x2
LlcenBe Plate
325 8 5
LONGITUDINAL SEMI ELLIPTING SPRING
Suspension Type
Spring
L H
CAR
336 R
LampB
Stop Lamps
12V 25W x 2
Reverse LampB
12V 25W xl
Room
12V
Lamps
7
5W x 1
2
x
3
5 2
r
DATSUN
MODEL
ITEM
P L
U
411
WP L 411 U
P l
UT
411
WP L
Fog Lamps
12V 35W x 2
Inspection Lamps
12V
8Wx 1
Parking Lamps
12V
8Wx4
Turn Signal Lamps
12V 25W
Dash LampB
12V
x
4
3W x 4
p
32
Reflection
50 x
2
l
Warning Lamps
Turn
12V 15W
Signal
x
2
Main Beam
12V l
Ignition
12V 1 5W xl
Oil Pres sure
12V l
8
5W xl
5W xl
UT
411
oc
EJ
l
10
11
c
l
0f
o
9
8
zor
0E
300
7
z8 g
200
100
a
CENGI E URVE
J
MODEL
m
p
40
102
x
PERFOMANC
A
SPE D
ENGIE
W
U
8
SO
70
0
I
0
I
I
357
SO O
CURVE
375 197 725 000
4 3
1
1
160
1
382
lanD
O
d
I
t
r
0
40 0
20 0
30 0
p
280 T
8
kg
S
I
rn
sin8
O
35
Oc
I
1
I
0
10
I
60
m
kg
287 6rn
O
10
m
0
3
p
le
l
0
5
52o r
67HP
5
U
PMODEL ERFOMANC
L
P
RUNIG
100
1
3
411
ratio ratio ratio ratio ratio
geal spe d spe d
Final
1st
weight abilty radius SAE
spe d spe d vehicle grade ef ctive torque
2nd 3td 4th
160
ISO
140
130
120
110
90
30
80
SAE
BHP
70
40
Gron Max Tire Max Max
SOO
400
f
bii
200
300
u
I
2
VI Z
100
1il
Ian
60
SPE O
50
CAR
40
600
h
I
t
Iici
417
CURVE
kg
111 945 403 490 000 160
4 3 2
UT
PMODEL ERFOMANC
411
Pil
RUNIG
1
1
1
0
tan
280 r
m
kg
Crol
foo
287 6m
O
lSO
52o r
40
102 31
67HP
10
P
2nd 3rd 4th
10 0
J2000
P
joo
90
80
40
p
1st
30 0
m
weight radius SAE SAE
ratio ratio ratio ratio ratio abil ty
gear eed spe d spe d spe d vetlc1e rade ef ctive torque BHP
Final
40 U
t5
P
sinO
O
4S9
SO O
m
r
SO
70
45
sil
3040
s
1st
o
I
400
3oo
S
g
111
CURVE
945 403 490
4 3 2
1
1000
UT
411
L
WP
DEL
MO
PERFOMANC
ratio ratio
tio
ra
ratio ratio
gear spe d spe d spe d
Final
1st
cd
spl
2nd 3rd 4th
425
tan8
Ii 0
j
p
280 r
m
kg
287 6m
O
10
50 0
m
P
200
0
u
l
S
j
OI01
z
r
40 0
30 0
20 0
160
ISO
520 1
67HP
102 3 4
weight abilty radius SAE SAE
vehicle
llde
gt
Car
10
soo
m
Spe d
21
I
O
dn8
kg
60
Max Tire Max Max
391
h
100
ef ctive torque BHP
Gros Max Tire IMaxMu
90
80
h
70
45
SO
RUNIG
60
50
40
30
lat
20
10
o
600
100
f
I
0
II5
n
J
km
Spe d
Car
ENGINE
ENGINE
ENGINE
The
engine
is of monobloc construction
the valve are set in line in the
are
operated by
camshaft in the
and
cylinder head and
push rods from
left hand side of the engine
rockers and
running in three steel backed
is chain driven and has a
whitemetal bearings
and
oil
pump
are
driven
pistons
piston
are
the
split
skirt
type of
pins
two
carry
in
bolted
are
compression
ring
connecting
steel backed lead and copper
which have
changeable big
end bearings
The
A counter balanced crankshaft is fitted
on this
ust
thr
washers
at
centrifugal
from the camshaft
The
alloy
and
alloy
and a slotted oil control
The
rods
end
rubber chain tenssioner
distributor
rings
the
The camshaft
The
aluminum
component
the
center
water
is taken
main
and
pump
by special
bearing
cooling
The
fan are
driven by the generator belt
GENERAL SPECIFICA TlONS
J
Engine type
No
of
Bore
4
73
mm
1
Volume
brake horse power
10
Torque
Firing order
67 HP
at 5200
r
6
at 2800
r
kg
m
1
Valve arrangement
Compression
Compression
mm
77 6 mm
Stroke
Max
type
Cylinder
pressure
ratio
Overhead valve
163 lbs per sq in
11
5
kg cm2
299
p m
p
3
m
4
2
push rod type
at 350 r p
m
821
DATSUN
j
f
St
J
ENGINE RIGHT SIDE
ENGINE LEFT SIDE
2
ENGINE
COOLING SYSTEM
f
I
I
J
cooling BYBtem is of major
enBure the satisfactory running
efficient
An
importance to
of the engine and it iB therefore necessary
pay particular attention to its maintenance
to
Description
The cooling system iB maintained by water
pump circulation
combined with
an
efficient fan
cooled radiator and thermostat
system is pressurised and the relief
valve
incorporated in the radiator filler cap
controls the pressure at approximately 0 4 kg
The
per
cm
sq
Do not
remove
the
filler cap if
the temperature of the coolant is above boiling
point
or
should
if
Topping
Fig
the
1
Radiator
up
Fill to within 1 2
be required occasionally to replace
through the overflow pipe
Top up
is
cold
and
if
use
possible
engine
only
water lost
when
the engine iB running
plug well
may
cause
pipe
clean soft water
mately
3
of the bottom of the filler
Overfilling
when the engine is cold
through the overflow
water to flow
The capacity of the system is approxi
5 2 litres
DATSUN
housing and the hose reconnected to
avoid laying up the car
is
The
set
thennostat opening
by the
Thermostat
from
In order
to ensure maximum
essential
is
keep
to
the
efficiency
engine
temperatures within certain limit
this
pellet tyep thermostat
a
located
in
the
cylinder
head
outlet
water
is
at
it
manufacturer and
operating
To
being
front
of the
can
not be altered
During decabonising it is policy to test this
opening by immersing the thennostat in water
The valve
raised to requisite temperature
assist
fitted
its
should
Pellet type thermostat works by the principle
of rapid variation of solution of wax
open
fails to open
under these
conditions
but if it
unit should be fitted
a new
Overheating
belt
Overheating may be caused by a slack fan
excessive carbon deposit in the cylinders
with
running
the
far
too
ignition
carburetor
incorrect
adjustment
retarded
failure of the
water to circulate or loss of water
Fan Belt
The
a
V
A
Adjustment
fan
belt
is
belt
new
driven
this
from
the crankshaft
also driving
can
by
the alternator
by first loosening
be fitted
which hold the dynamo
3
the clamp bolts Fig
in position
and moving the dynamo towards the
Slide the belt
engine
2 Pellet
Fig
Thermostat
Type
The devise consists of metalic pellet
with the
which controls a mash
wax
by solution of
on
starting
the radiator is
Due
this
the fan and onto the
pulley
filled
valve
wax
When the engine
and
room
fan
over
the
is cold this valve is closed
engine the flow of
temporarily
water to
restricted
the temperature of the water in the
cylinder jackets will quickly
thus ensuring rapid warming up
The heat so generated will gradually press
cylinder
head
and
rise
up the
piston by shrinkage of synthetic rubber
so opening the
valve
and ultimately
pennitting a full flow of water to the radiator
sleeve
The thennostat itself is
should
be
occasion
detachable
arise
it
can
therefore
be removed
Fig
Part No
Standard
Optional for cold district
21200
21200
61001
61001
3
Fall Belt
Rated Temperature
Open at 76 5
Open fully at
Open
at 82
Open fully
4
AdjustmeTlt
t1
C
5
C
t1
90
5
C
t1
C
5
at 95 t 1
C
5
C
ENGINE
Adjustment
is
then
made
by bringing the
The belt
away
engine
Bhould be sufficiently tight to prevent slip yet
alternator
the
from
belt should have 10 to 15
the generator and
midspan
When completely drained the engine
the
mm
crankshaft
be
when
minute
to ensure
the
should
that all
system
suitable notice should be then affixed to
A
the radiator
indicating
that the water has been
drained
pushed firmly
is
timed
a
water has been cleaned from the
slack between
pulley
for
run
After the correct tension has been obtained
securely
lock it in position again
the Radiator
Flushing
To ensure efficient circulation of the coolant
Frost Precautions
Freezing may
the radiator
and may
advantage
must
care
closed
fully
expected
used in
low temperature
a very
or
it
up to the
up with anti freeze
solution
as
the
degree
be
made
of
in
up when the
where
weather to
frosty
of the
freezing
must
sufficient
anti freeze
mUBt
engine
drian
completely
merely
with rugs
cocks
one
and
on
not used the
is
taken
be
cylinder block and
radiator block
remove
during
setbolts
the cooling
the
masks
the
It
is not
radiator and
There are
left hand
two
side of the
other at the base of the
Both taps must
drain the system and the
ground while draining
car
be
must
opened
be
on
to
level
The drain taps should be tested at frequent
intervals
that
they
by inserting
are
immediately
clear
the taps
a
piece
This
are
of wire to enBure
should
opened
so
be
done
that any
obstruction freed by the wire may be flushed out
The draining should be carried
by the water
out when the
engine
completely and
to the
the bottom hose connection
and out of
Pump
the
pump unit from
by taking off
to
drained
cover
the
reverse
again
any damage due to
obviate
to
the radiator
remove
run
cooling system
be
to
After draining the water from the radiator
When heavy frost is imminent
system
At
the top connection
Water
precautions
through until
the drain taps
flow turn the
way
radiator upside down and let the water flow in
by Draining
cars
following
not
through
the mixture into a clear container and use
On
from
stiff piece of wire should be inserted
flush in the
instructions
If the cooling system has to be drained
Protection
a
clear
during draining to ensure that they
becoming clogged with sediment
practice
is cold
system
in the
excessive the operator will find it more efficient
neces
with the container
supplied
Top
with
accordance
in anti freeze
This method of radiator flushing may serve
well
but in cases where the
urring up is
topping up with water reduces
protection afforded Solution must
up
out
comes
are
Excessive
sary
and
into the taps
strength advised by the manufacturers
The
strength of the solution must be maintained by
topping
scale
and again when taking it out in the spring
intervals
make sure that
in fact
of
the
The water should be allowed to run
when the car is to be
of the solution is
the strength
winter
boiling will result
When frost is
formation
periodically flushed
preferably before putting
connections
be taken not to run
or
the
system should be
with clear running water
will stop water circulation
A muff can be used to
boiling
but
reduce
to
sediment in the radiator
hose
cause
with the muff
first at the bottom of
occur
in the lower hOBe
or
Ice in the
and
is hot
5
with
dynamo
the
fan belt
spring
the
and
washers
cylinder
block
releasing the
and hinge bolts
r
DATSUN
Seat
set
Sn
v
r
n
h
Boh
Pulley
21051 10600
131
m
m
db
21051 10800
143
m
m
dla
Beanng
k
WA
twi
j
1lj
lL
Bolt
I
L
Hub
for fan
pump
pullf
long
v
Gasket
FOlD
Screw
belt
21067 10600
21067 10800
Used for 2MB type
battery
4
Fig
the
Removing
Pump
Shaft
Disconnect the fan blades
The shaft and ball
one
bearings
Water
Pump
Assembly
pulley and
5Jtj
cover
is combined with
unit
Put the
pulley
First
press or knock the shaft end
drift
hard bar
bub
on
the bench
and draw
out the
pulley
with
hub
a
on
Fig
the U type bench
Take
locked
out
the
See Fig
Next
the
shaft
set
pin from
assembly
to
the
Example of the
Pump Body
Bench for
slit which
the pump
body
The shaft and ball bearing
6
drew out from the
turn the
out the shaft
5
body upside down and press
assembly from the vane side on the
Thus take out the vane
which remained the pump
U type bench
6
aBsembly
can
be
body
floating seal and seal
body
ENGINE
The
Reassembly
of the
905
0 2
21 O
Front
be
3
reassembling of the
taken
to ensure
fitted correctly for
Set
a
screw
pump is a reversal
but
disassembly procedure
that the
a
slit
a
a care
should
shaft assembly is
hole of set ring with
groove of shaft so as to insert and set the said
ring correctly
Shaft with
bearings
Adjusting Clearnace
End and Body
First
0 4
mm
O
5
Inserting thiclmess
pin
Insert here
bench
thickness
out
gauge
good
between
6
7
the
gauge
vane
fitting with
condition
Thiclmess
end
Take out the thiclmess
cork washer
Fig
shaft
a
pin
mm
o 5 mm
a
down the
groove line to insert the set
Clearance
Set
press
the Van
on
0 4
the U block
gauge
Screw up with the
and find
cover
and
r
DATSUN
LUBRICATION
Circulatiol
Pressure
unit and is
oil
The full of the oil enters the element
lubrication is used throughout the
provided by
an
ecentric
and is driven from
relief
valve
which is
oilways
situated at the
is
This space
the oil
to the
cover
the
pipe
the camshaft gear by a short vertical shaft
The oil is drawn into the pump via the filter
and is delivered through internal
through
through
element into the annular space round the center
The oil pump is bolted into the left
pump
hand side of the crankcase
and passes
cartridge
holes in the
draining
non
only
can
sealed top and bottom
through
escape
so
that
small hole into
a
the hollow center pipe and from this point back
into the oil pan
of
oil pump
the Oil
Draining
The
must
oil
be
on
and
new
drained
and
reconditioned engines
then filled with
after first 2000 mileB
3000 Lan
of
every 3000 miles
5000 Lan
is
at
The oil
the
oil pan
when the
new
oil
and at intervals
The drain plug
should be drained
is hot as the oil will flow more
engine
readilY
Before filling the oil
connect and
pan with new
oil dis
change the oil cartridge
Oil Pressure
The oil
lb
Fig
1
main
oil
gallery
on
oilways
the
to
the right hand side of the
and
the
rear
lubricate the rockers
are
drilling
rocker
in the
shaft
from
the
center
camshaft
a
to
b
ings
c
on
As
the camshaft rotates
case
two grooves in
timing
case
forms part of the main oil
and
as
at
will
noticeable drop in pressure
a
good supply
a
sludge
bearings to
That the
have
twice
This
gauge
as
bearings
the
excessive
of the correct
will
sides
when
more
which oil
correct
the oil
the
from
becomes
the
of
oil
the
is
more
bearings
warm
and
fluid
cause
in
clear
will escape
a
drop
in preBsure on the
compared with that
are
is fed under
working
good
order
shown when the
The relief valve in
the lubrication system deals with any excessive
oil pressure when starting from cold
When hot
The filter therefore
gallery
readings
engine is
give
low speeds
oil
new
in the oil pan
particularly
lubric ation for the timing chain and gears
From the timing case the oil returns via a drain
pan
sq in
when the
That the strainer in the oil pan is clean and
readily
revolution of the camshaft to provide
hole back to the oil
with
engines
there is
ances
register with a small hole in
the camshaft thrust plate thus allowing a small
amount of oil to pass into the
That
pressure
the front journal
during
New
10 lb
approximately
not choked with
enters a
the left hand side of the engine and
lubricates the tappets through individual drill
gallery
the gauge at normal
kg cm2 should be shown
grade of oil
The oil
bearing
on
the following points should be checked
and then drains back into
the oil pan via the push rod apertures
whilst
should there be
cylinder
bracket
kg cm2
1
considerably higher
big end and camshaft
drillings in the crankshaft
The connecting ends
7
idling
main
bearings through
block
0
The flow then passes via connecting
engine
2
road speeds
From the relief valve the oil passes into the
should not drop below 30
pressure
sq in
such is
the pressure
filled with oil under pressure
fluid
8
drops
as
the
oil becomes
more
ENGINE
Check for Low Oil Pressure
resistance
opened with
with
the
air
no
leakage
existB
Removing
after
new
unit and
the
remove
should
cartridge
Take
by hand
sealing ring
care
is
cylinder
block
it can
not
in
oil
sent
to
to
locker
element of
the
paasage
delivered to all
the
the
If the temperature
journal
filter
in
of lublicant oil
oil viscosity is high
or
oil
alve
which
are
the
securing
bottom edge
is
Notice
cover
pan
refitting
low at
embly
idge
I
Fig
pump
through
which
oil
to
is
To remove the strainer
connecting
2
Oil Filter
9
that there
which must
if the filtration
filter
strainer
pOBsible
iB
the
oil pick up to the
Becuring bolts
bolts
cylinder
and chain
blode
Relief
bolts
The Btrainer may be dismantled for cleaning
purpose by removing the delivery pipe flange
Flemfilt
Cyl
oil
lowered it
pump and unscrew the
the
with a relief valve
provided
Element
To
snup
drawn into the oil
the lubrication
crank pin
camshaft
arm
The oil filter is
starting
remove
the rubber
and finally returned to the oil
tensioner
With
removed
easily
lose
the oil
system crankshaft journal
bore
screw
underside of
the Strainer
Removing
of
unto the union
filtered
cartridge
gallery
part of the main oil
in the container as a unit
The
the
washers in the process
The element of oil filter is sealed
the engine
Drain the
and then every
3000 kIn
miles
changed
be
000 km after this
The forms
1 litres
flange and the lower bolts from the
Lower the oil pan from the
of the bell housing
not to damage the
care
taking
joint
engine
the Filter
first 2000
set
the
Remove
inserted from
filter
large
oil and replace the drain plug
the fault
rectify
A
defective
being
is
difference to bypass oil
pressure
The sump capacity is 3
at
strainer union on the suction side of the oil
pump
10
sale that
sludge
up
element
the relief valve will be
the Oil Pan
Removing
clean and not chocked
strainer in the sump is
filter
after refilling the
on
switch off and ascertain that the gauge
sump
oil
the
choke
caused by its
Check the level of oil in the engine sump by
of the dip stick and top up if necessary
means
If the warning light is still
of
be
the dowel pins to the
positioned correctly when
are
r
DATsUN
Removing
Remove
the Oil
the
oil
Pump
the
and pick up strainer
securing the oil pump
long enough to Becure the
inner
pan
Three of the five bolts
bottom
cover
pump to
pump in
and
are
the crankcaBe
remove
Unscrew the
long
tilting
rotor with its
the
body upside down
drive shaft
the
and the outer
rotor with slide out
3 illustrates the
Fig
explosed form
On
cover
Refitting
bolts
the pump With its drive Bhaft
the
Pump
Clean out the sump by washing it in paraffin
care to remove
any traces of the paraffin
before refitting the oil pan to the engine
Pay
the
particular attention to the oil pan and crankcase
joint faces and remove any traces nf oil jointing
material
it
if
Examine
used again if
fit a new one
it
the joint washer and
renew
The
necessary
is
oil joint washer can be
but it iB advisable to
sound
Smear the faces of the joint With
grease and fit the joint washer
Lift the oil pan
into
position
and insert
flange tighting
them up
Reassembling
the setscrews into the
evenly
the Oil
Pump
The outer rotor haB a chamfered
3
Fig
the base of the
Dismantling
Remove
which
the Oil
the
secure
Pump
I
cover
to the
Insert
spring
body
washers
n
i
f
j11 j
1
o
It is
failure to assemble in this
Jl
r
l
Fig
4
Oil Pump
10
cover
is tightened down
the slotted end of the drive Bhatt into the
body and bring the
and take off
I
r
body
way will result in the
setscrews and
the
edge
of great important that this chamber be towards
rotors into meBh
ENGINE
SERVICE OPERATION WITH
ENGINE IN POSITION
Removing Starting
Nut and
The
Pulley
washers
spring
are
immediately
below
the bolt heads
Remove the radiator
attachment bolts and
1
Slacken the
remove
Take
dynamo
the fan belt
Bend back the tab on the starting dog nut
Unscrew the starting dog nut
locking washer
by using Heavy duty Shock type spanner
A few sharp blows in an anti clockwise
not
out
the
set
to
the
damage
If
joint
cleaning
does
of
faces
remove
the
Care should be taken
washer
damage
the
bolts
screw
and its joint washer
cover
when breaking the
occur
fit
the
of
a new
washer
surfaces
joint
beforehand
direction will slackent the nut
Pull off the crankshaft
Fig
Removing
The
bolts
Removing
Timing
cover
having
special plain
a
is
secured by set
washer
Note that the
screw
and
is
endless
bOth the
remove
relationship
next
is
to each other
Draw off both
the gears a little at a time
first removing the crankshaft gear retaining nut
As
the gears are withdrawn care must be
taken
J
not
to
lose the
packing
behind
the crankshaft gear
shaft gear teeth is a rubber
a
tensioner
chain
renew
is
drive
Examine
the
special
Timing
attention
following points
11
ensures
from
ring which
acts as
silent operation of the
the
felt
washer
and
Gear
Replacing the componentB of the timing gear
largely a reversal of the dismantling process
but
2
and
washers
Between the cam
it if oil has been lost be seepage
Refitting
Fig
it
and
crankshaft and
camshaft gears together
Before doing this
notice the timing marks on both gears and their
a
special
washer is of elongated shape and is fitted
to the timing cover flange
chain
timing
necessary to
Gear
3
Fig
Cover
shakeproof
washer
Timing
the
1
The
the
timing
each
pulley
should
be
paid
to the
DATSUN
Fit the
crankshaft and camshaft gears into
Ensure
respective shafts
are opposite and in line
their
marks
in
at
and the camshaft with its
T D C
the one o clock
approximately
the
keys
ensuring that
Ensure
opposite
keyways
in
present
are
on
the shafts
If the
unless a new
In
been fitted
gear faces and
this
the
the
measuring
To
feeler gauge
be neceBsary
crank
caBe
to
adjust
vary
the
alignment
of the
alignment with a
alignment it will
gear
that
front of the
is in
thrower behind
its
car
Concave
and pump
stud nut is
the rocker
remove
rear
special locking plate
a
rocker
Completely
blacket
the rocker shaft
unscrew
and
nuts
Complete with
assembly
brackets and rockers
the
face it
the Rocker
Dismantling
Assembly
To
first
packing
the
remove
rear
Shaft
rocker
the
dismantle
from the
so
the
not siackened
are
Notice that under the righi hand
wash
Fit the oil
secure
camshaft has
or
number of
the
also
nuts
head nust
cylinder
cylinders
the gears are
that the timing marks
Drive the
in
line
to each other and
replaced
fixing
system and
because four of
distonation may result and allow water to find
its
Bystem into the
way from the cooling
on
gears home
The Bame number of packing washers taken
be
behind
the
crankshaft gear must
from
head nuts
cylinder
shaft
drain the
to
necessary
head
cylinder
keyway
poBition
Place the gears into position
is
rocker
the
crankshaft until the keyway
Turn the engine
is
the timing
It
slacken the
grob
shaft assembly
and
screw
locking plate
rocker bracket
crankshaft
towards
the
and check that the felt waBher
pOBition
ROCKER
MECHANISM
Valve Rocker Cover Removal
Remove
the air cleaner
Unscrew the cap
securing the engine lifting brackets
Remove the rocker cover and the cork joint
nuts
washer
Removing
the Rocker
Drain the
in use
UBe
Assembly
cooling sYBtem
Fig
Cylinder
5
Head
If anti freeze is
clean container for the fluid
Remove
the Bplit
washers
spring
Slide the rockers
the shaft
pins
from
brackets
Unscrew the
flat washers
each end of
plug
and
the shaft
and Bprings
from
from the end of the
shaft and clean out the oil way
The
two end rockers may
be
dismantled
without the whole rocker
out
This may be
by hand until
No
assembly being drawn
achived by turning the engine
1
push rod reacher
its lowest
pos ition
Unlock the tappet
adjuBting
screw
and
screw
it back as far as it will go
Withdraw
waBher
and
the
Bplit
slide
the
pin
rocker
flat
and
Bpring
off
the
shaft
Sometimes the valve spring will have to be
compressed by levering a Bcrewdriver
Fig
slightly
4
underNo 2 rocker
12
thus
allowing
the end rocker
ENGINE
to
slide
off
procedure for
the
shaft
No
Repeat the
easily
and lock plate
Replace the spring and flat washers with the
split pins on the ends of the shaft
Replace the
screw
8 rocker
the Rocker
Reassembling
rocker
cover
and gasket
o
s
0
Fig
On
reassembly tighten
nuts
securing
diagonally
from
bracket
pedestal
little
a
nut
the
at
to
pedestal
time
a
nut
3
and
No
4
bracket and repeating the
they
been
are
on
all tight
completely
stripped
holes will have
bushes
reamed down
on
No
down
to be
to
size
The
2
process
should
pipe
Secure the
the
Cylinder
be at
the front
by
cover
Head
of the
of the two
means
ensuring that the rubber bushed and
If the
lifting plates are in position
rocker cover gasket or the rubber bushes are
found to be faulty they must be renewed other
1
cap nuts
left of
engine
until
assembly
Reassembling
vent
engine
the left nut of
If the rocker
the oil
bracket
working
left nut of No
right nut of
returning from
No
so
8
Fig
6
wise oil leaks will result
has
and rebushed
redrilled and the
before assembly
the shaft
Push Rod Removal
If the
valve
rocker
has
assembly
already
been removed all that remainB iB for the push
rods to be lifted out
They may
hand be taken out without
on
detaching
the other
the rocker
aBsembly
Remove
the
Slacken
all
air cleaner and
the
then
their full extent
the rocker shaft
spring slide
the push rod
as a
the
using
a
cover
screws
screwdriver
to
with
fulcrum depress the valve
rocker side ways and lift out
All but the end push rods
in this way
rocker
adjusting
tappet
can
be withdrawn
These will have to be withdrawn
after the removal of the two end rockerB from
Fig
7
the shaft
The rockers and spring must be replaced in
their
original pOBition
on
Remember to replace the
the
Ocker
l
When
replacing push rodB
ensure
the ball ends register in the tappet cups
ends of the shaft
here onwards
shaft locating
reassembly
is a
straight forward
reversal of the dismantling process
13
that
From
DATSUN
Valve Rocker Clearances
Adjusting
the air cleaner and rocker
Remove
should
There
0
be
a
clearance
the
a
rod cup
result in
Turn
or
a
screw
driver in
lower the
adjusting
screw
until the correct
driver on
tappet adjusting
disperse the film of oil from the push
Failure to follow this procedure will
clearance is obtained
wrong reading being taken
hand
the engine
over by
important to note that while the
clearance is being set
the tappet of the valve
the
screw
to
screw
insert
slot and slaken the lock nut
Then insert 0
Whilst checking the
clearances it is important to maintain pressure
with
9
Fig
screw
014 in
feeler gauge between the
Raise
face of the rocker and the valve Btem
between the face of the rocker and
35 mm
the base of the valve stem
adjust
adjusting
To
cover
of 0 014 in
It
a
handle
until the
valve is
fully
push
starting
the
StopB falling
rod
9
Adjusting
nut
and
recheck
the
is
being adjusted must be
opposite to itB peak
closed
Fig
lock
the
Tighten
clearance
on
the back of the cam
the Rocker Clearance
CYLINDER HEAD
Rocker shaft
Length
OUter diameter
Removing
15 85
One
19 01
19 04
mmo
is
situated inlet tube at the backside of
the radiator
and
other
side of the engine
Inner diameter
15
89
dimension after
15 90
use
mmo
at
the
rear
right hand
If anti freeze mixture is in
it should be drained into a suitable container
and retained for future
use
the
Disconnect
the
negative cahle from
battery he extracting the tenninal screw and
removing the lug from the hattery terminal post
Slacken both the retaining clips on the hose
mounting
Rocker
Head
cocks
before mounting
Clearance
Cylinder
Drain water from the cooling sYBtem
by
opening the radiator and cylinder hlock drain
15 88 mm
Rocker inn bush
Outer diameter
Reamer finished
the
356 4
o
01 0 05 mm
arm
Bore
19 012 19 037
Lever ratio
1
mm
connecting the radiator
43
ing and
14
remove
the hose
to the thennostat hous
ENGINE
Extract
nuts
and
thermostat
the
the
remove
aircleaner
Remove the
securing
housing
and
housing
used for long
Detach the high tension cables and
also
the sparking plugs
temperature
thermostat
gauge
Removal and
Whilst
valves
the
from
rocker assembly
slacken the external
cylinder
spring
is
head
cylinder
removed
tbe
To do this compress
be taken out
with the
compressor as shown in
forgetting
not
the
can
the vaive
housing
Take off the
of the Valves
Replacement
remove
disconnect the water
connection
often than those
more
runs
rocker
carburetor
and the inlet and exhaust manifolds
cover
to
will require this attention
thermostat
special valve spring
Fig 1
head nuts at the
time
same
push rods keeping them in the
Withdraw the
order of removal
The
cylinder head
block
cylinder
cylinder
with
to
hammer
a
using
When
lifting the
given
so
the
of the head
piece of wood interposed
head
a
head is
the
Remove the
studs
a
breading
side
Do not use excessive force
blow
that
be lifted off the
now
facilitate
tap each
head joint
take the
can
To
should be
direct puil
puiled evenly
cylinder
up the
head gasket
Decarbonising
the
Remove
still
in
position
remove
Fig i
With the valves
cylinder head
the
carbon
combustion chambers and the valve faces
Leaving
ensures
seats
the valves in
damage
that
by the
position
cannot
for this
be
retaining coilets
Release
spring the valve spring cap
Inlet
valve oil seal
valve only and its retainer
valve
from
the guide
Withdraw the
Keep the valves in their relative positions
to
ensure
when removed
from the enigne
replacement in their original valve guides
Remove the two cap
caused to the
wire brush which should
are
the valve
be used
coated with
a
deposit this may be removed by using
chisel shaped piece of hardwood
very hard
a
Remove
the
valves
and
using
clean out the carbon from
brush
spring Compressor
Removal
operation
for the removal of carbon
If the exhaust valve heads
Valve
from the
the
wire
the inlet
and
exhaust ports
Blowout all
compressed
the ports with
carbon should
crowns
worked
cylinder
traces
type pump
gasoline and dry
is
now
at
and
dust
engine until
T D C
them out
the
with
Replacement
finally clean
be removed from the
Rotate the
on
of carbon
air or
the
heads
piston
piston
Protect
Note that the diameter of the exhaust valve
The
smailer
are
to be
replace
other
guide
the
and
retainer
bore from the entry of carbon particles
Fit
The
fluffy rag into them
chisel
a
shaped piece of hardwood
Using
the
remove
carbon from the piston
Carefuily
wards
ring of carbon should be left round
and the deposit
the periphery of each piston
round the top of the cylinder bore should not be
intake valve
by pushing
crowns
touched
tion is
a non
Replace
loss of power
the
oil
spring
seal charrifered
seals
are more
seal
side
easily
and
down
fitted if
only
the
valve spring and compress the
Refit the cap retainers and
an ail round
generally given by
Cars used mainly on
oil
valve into its
valve spring
An indication as to when decarbonisa
is
oil
To
inlet valve
insert each
they have been soaked in engine oil for a short
period before use
The oil seal is used for the
A
require
valves
replace
than the
means
short runs
of
compressor
15
the
valve
cotters
secure
them by
Remove
the
r
DATSUN
Inner
Free
length
Length in use
50mm
mm
loaded
and
36 9
mill kg
t0
of coil
Turning Nos
Effective turn of coil
Dia
of coil wire
Diameter of coil
Outer
Sp
13
1
7
cylinder
head the
valves and their seats should be examined for
i1
signs of pitting
5
6
5
6
5
4
5
mml
i
l
mm
Grinding
Before replacement of the
38 9 29
5
24
Valve
52mm
8
28
Sp
25 2
or
burnt patches and distortion
If these conditions
seats
i
4mml
i
mml
mUBt
the valves
in
should
the
be
present
are
the valve
be recut
before attemoting to grind
whilst distorted valve
heads
trued
mimmum
the valve renewed
or
amount
of
metal
Only
should
be
removed in the turning process
When grinding a valve onto its sealing
valve
face
be
should
type grinding tool
The
its seat with a semi
coil
lightly
paste and then lapped in with
grinding
to
smeared
valve must
rotary
a
the
with
suction
be ground
A
motiron
light
spring interposed between the valve head
and the port will assist
considerably
when
lifting
the valve in order to rotate the face to a different
This
position
should
be
done
frequently
to
spread the grinding compound evenly
It
is
process
on
necessary to continue the grinding
until an even matt surface is produced
the seating and the valve face
On
the
completion
should be
throughly
rag and dried and the
air
valve
seats
subjected
to a
The
valves
should
gasoline and all
traces
of
blast
and ports
cleaned with gasoline soaked
be
compressed
washed
removed
Fig
2
Checking Spring
Tension
i
t
tJ20
OI KI
l
1
O
Oi
J
U
lOO
tRl
bU1
Fig
3
Valve
Spring
g
l
Valve Ass y
Fig
16
4
Turning
in
grinding compound
the Value
Seating
ENGINE
VAL VES
Valve head diameter
Intake valve
34
Exhaust valve
30
I 63 t0
Valve seat width
and
mm
015
8 7
Valve stem outer diameter
both intake
9 mm
01
0
ex
mm
mm0
0
02
Overall length
Intake valve
Ex
109 54
mm
108 74
mm
valve
Fig
5
Cylinder
Head Distortion
Measurement
o
Dimensions
Place
mmq
A 40
Intake
34 5
mmdl
c 32 2
mmth
B
2
DO
the
securing
nuts
positions
29
4
C 26
8
B
D1
0
the tappet
rocker
Replace
the securing
1 2mm
eleven
the
with
nuts
given
a
adjusting
assembly and
head nuts
in
6
Fig
screws
down
screw
Evenly tighten
finger tight
cylinder
in the order
down
head
in the
push rods replacing them
they were taken
the
the
mmq
lower the
cylinder
from which
Screw back all
mmq
Exhaust
Fit the
finger tight
mm
mmq
A 3S
and
position
cylinder
Insert
O 4
into
gasket
head into place
little at
a
a
time
finally pulling them
set
torque wrench
to 45 lbs
1ft
VALVE GUIDE
9
7
3
1
47 6 mm
Length Intake valve
56
Exhaust valve
Outer diameter
5
both intake
14
mm
14
33 mm
74 8
76 mm
31
10
and exhaust
Inner diameter
both intake
8
and exhaust
Inner diameter at
guide
8
inlet to insert both intake
14
Fig
and exhaust
both intake and
004
007
15 5
15
guide
spring
from
them when the
9 mm
seat
the
Ensure that
The
BO
Cylinder
the
Head
cylinder
head and
will
that it will be
head gasket is marked
placed
finally
not hot or cold
check
The
have
to
in which case the valve clearances
be
checked
again and
reset if
necessary
cylinder
Refit the inlet and exhaust manifolds
faces are clean
cylinder
engine
is
cylinder head nuts may pull down slightly more
after the engine has attained its normal working
temperature
block joint
Tightening
Head Nuts
Reset the valve clearances and
valve
face of the
Refitting
Cylinder
mm
exhaust
Height of
6
2
The Order ot
6
the
Clearance of valve stem
and guide
4
3 mm
Fit the craburetor and reconnect the control
Top
linkage
head in correctly
17
Refit the ignition advance suction pipe
JN
DATSl
connection
the
at
this stage refit the air cleaner
it will have
or
later to check the valve clear
to be removed
the rocker cover
Replace
ances
on
but do not
the carburetter
to
taking
care
to
fit the cork gasket correctly
Place
and
thermostat
the
its
housing
in
and secure with the three nuts
position
Reconnect
the
water
gauge wire
temperature
and fit the radiator hose to the thermostat hous
Connect the cables to the
ing
that the radiator and
are
Clean and
adjust
clipping
the sparking plugs and refit
The
the hightension leads
on
the
firing order of
the clip which
wiring
block drain tapes
and refill the radiator
closed
them
cylinder
Ensure
battery
4 2
3
1
engine is
of
part
secures
Replace
Fig
the electrical
Location of Valve Guide
to be Fixed
9
harness to the side of the head
The ignition
can
started
engine
temperature
been
has
the rocker
remove
now
When
be switched on and the
the
normal
reached
cover
so
that
Remove the
operating
switch
the
Remove
off and
Rest
valve
Whilst the engine
water hose
not leak
is
a
punch
connections and fuel line unions do
When
Tighten them if necessary
clean
valve
with its
and spring
machined face
surface
and
drive the
drift
This
running check that the
head
downward into the combustion space with
gnide
final check has been made
a
on
head
appropriate
cylinder
downwards
Replace the
may be rechecked
air
cover
and fit the
cleaner when the
clearances
rocker
the
cylinder
the
should take the from of hardened steel
See Fig
fitting
8
new
valve
guides
these should
be driven in from the top of the cylinder head
Removing
and
Refitting
Valve Guides
Removing
a
Valve
Spring
in Position
I
Fig
7
Fitting
o
Fig
Position
of a
Valve Guide
l
8 Hardened Steel Punch
Fig
8
10
Checking Spring
Tension
ENGINE
In
an
emergency
a new
fitted without removing the
doing
to
this
its
T D C
driver which will pass through the sparking plug
orifice and locate on the valve head
By using
be
When
head
position
to
eliminate
the
can
any
Withdraw
Hold the valve onto its sealing with
concerned
a
suitable tool such
as
a
bent
as
a
fork ended bar
cylinder
the cylinder
spark plug from
fulcrum point the spring
be compressed with two screwdrivers or a
the rocker shaft
of the valve falling into the
Remove
aid of
cylinder
can
the applic able piston must be brought
possibility
the
valve spring
the
valve
and
cotters
renew
valve spring
screw
Cotter
Nut
Adjust
tr
screw nut
Valve rocker
Spdng
Locating
plate
out
11
i
tJ
smcke
j
d
C@l
s
I
Bush
Valve rocker shaft
Pin
VVaSher
VVasher
Valve
Valve rocker shaft
Rocker shaft bracket
8
COllet
Spring
etainer
G
Rubb
dng
Outer
tension
Bolt
Lock
w
jChaiD
hec
II
spring
Intake valve
Inner
lock washer
Bolt
Timing Chain
Camshaft
Valve Gear
19
od
spring
Valve hfter
earn
Locating plate
11
Push
Exhaust valve
e
Fig
Tappet adjwting
II
G
maft
screw
the
r
DATSUN
Oil
sherI
Washer
i
Nut
fix
to
Screw
i
is
iller
outlet elbow
e
Cover valve rocker
I
I
nCgaver
p
r
Jorntwash
at
Thennost
@
waSher
Heater outlet
I
Cy
a
Stud
Cover
j
@
Nut
I
i
plate
6
Q
I
1
bolt
J3Slinger
Guide
Q
Slinger
CyI
manioHd
froIit
Nut
Fig
Remove
the
the
valve
oo
12
Cylinder
t
ey head
Head
Tappets
and
carburetor
valve
in
head
Washer
e
e
Gasket
Replacing
ex
Guide
Ilil
Stud exh
and
rear
I
I
Removing
Nut
Washer
the
rocker
then take off the manifolds
cover
Disconnect the high tension leads from
sprking plugs
the
the rocker assembly and
withdraw the push rods keeping them in their
remove
respective positions
so
that they will be replaced
onto the same tappets
Remove
tappets
tappet
covers
them
and
lift out the
in same
locations
13
jFig
New
tappet
assembly
their
the
also keeping
own
Assembly
cedure
tappet
should
be
fitted
by
Belective
that they fall into the guides under
weigbt when lubricated
so
but
cover
is
car
a
reversal of the above pro
sbould
joints
are
be taken
oil
tight
to
see
that
and that the
Fig
20
13
Removing
a
Tappet
ENGINE
rockers
to
adjusted
are
CONNECTING ROD
the correct valve
give
clearance
i
mm
22 49
of tappet 22 48
of cyl
side hole 22 50
Dia
Dia
Clearance of the hole 0 01
Piston and
Drain
Connecting
cooling
the
large
04 mm
Rod Removal
water
from
and
then disconnect
remove
Outer
End
from
87
2
parts are replaced after dismantling
it is essential they are fitted into their original
To ensure correct refitting mark the
positions
and
caps
connecting rods on the sides to identify
F500
1 mm
34 mm
51 35
diameter
large end
play of large end
mm
31 mm
o
Finishing dimension of
inner diameter of
When used
them
1
Width of
and rock
Take out the setscrews
the big ends and withdraw the
It will be noted that the caps are off set
caps
22 0
t
Thickness
the oil
03 mm
Clevite
Overall width
engine
the
strainer
washers
t0
150
end and small end
Large end bearing
Type
Drain and remove the sump from
and radiator
the engine
0
Distance between center of
i
mm
22 52
20 0 31
17 450
mm
17 462 mm
small end bush Standard
CRANKSHAFT
connecting rods
upwards through the cylinder
The piston and
together
must be with drawn
Clearance of bearing
bores
peripbery
to
0
cylinder
013
0
050 mm
block hole
White metal
Material
Block side
Clevit metal
Cap side
Clearance of bearing
inner diameter and
crank
o
0127
0 0508 mm
813
50 825 mm
journal
Diameter of main
t
50
journal
End play of crankshaft
o 051 0 076
mm
47 640 47 652
mm
Crank pin diameter
Standard
Difference of crank pin
Less than 0
012 mm
diameter
Fig
14
Removing Connecting
Rod
flywheel
End play
with Pis ton
Release the connecting rod from the crank
is
Less than 0
05 mm
installed
shaft and slowly push the piston and rod upwards
the
through
cylinder
hore
NOTE
shell bearing are removable by hand
bearings are require no bedding in it is
being only necessary to ensure that the housings
and to place tbe
are scrupulously clean and dry
The
The
It may be necessary to remove the ring of
carbon or lip from the top of the cylinder bore
with
a
hand scraper to avoid risk of piston ring
bearings into position with the tangs located in
their corresponding slots
Always renew bear
bre akage
Remove
cylinder
the
assembly from the top of the
oval
Check the crankpins for
of micro meter calipers
ing
ings if they are scored or damaged in any way
the regrinding of the crankshaft
or following
In tbe latter case undersize
bearing surfaces
bearings will be required and the kinds of sizes
block
surface
necessitate
for
the
scoring
removal
with a
pair
and examine the bear
either
of
the
defect
will
available
crankshaft for
are
8
with punched mark
regrindin
g
21
12
25
50
75 and
100
f
DATSUN
P
on
P
f
og
ton
et
1
Bol
Key
Packing
Thrower
oil
1
Starting
nut
Bushing 1st
motion shaft
Jrgl
i
Fig
Fig
16
wNut
Pal
C nk shaft
15
Piston
Fly wheel
assembly
Budling
4
nut
Crankshaft
Crankshaft
PISTON
Replacing
Insert
assembly
taken
Pistons and
each
into
Connecting
and
connecting
cylinder from which it
piston
the
Rods
it is essential that the
split
rod
was
in the skirt of
the piston is positioned towards the camshaft
Fig
Compress the piston rings with inserting
and gently tap the
piston using tool Fig 18
crown of the piston
with the wooden end of a
hammer handle
17
Inserting
the Piston
untt the piston is clear of the
Fig
piston ring clamp
22
18 Piston
Adapter
ENGINE
push the piston down the cylinder block
until
big end of the connecting rod just
protrudes through the bottom of the cylinder
bore
then position upper half bearing shells
The
gudgeon pin
Now
piston
the
at 700 F
gudgeon pin
21 1
is a
push fit
in
C
reassembling ensure the gudgeon pin
positioned in the connecting rod so that its
groove is in line with the clamp screw hole
When
is
NOTE
spring washer fitted under
pitch bolt is not damaged
Check that the
head of the
lower bearing has two oil
by ensuring sufficient and it is of
the greatest importance that the corresponding
oil hole in the bearing shell registers with the
oilway to provide an unobstructed passage
Pull the connecting rod onto the crankpin
Each upper
the
there
holes
taking
Insert
not
care
the
position
to
the bearing surface
injure
connecting rod cap
locking washers
and
setscrews
tighten with a torque
21 7 24 6lbs 1ft
shell
into
the
the cap and the
Insert the
wrench t
Fig
20
Re
assembling Pistons
Connecting Rods
and
PISTON PIN
17 41
Diameter
Over size
Fig
19
Thrust Clearance
Measuring
of Connecting
o
125
2
o
250
3
o
375
65 3 mm
Length
Rod
mmli
1
Degree to he able
push it by finger
Clearance of pin and
pin hole
to
at
200 C
knock back the lock washers
Finally
clearance
bearings
are
rotating
the
turn
Clearance of pin and
the connecting rod hig end for side
7 1000 in
and see that the shell
Check
not
binding
on
If it
crankshaft
is
difficult to
undo the big end and examine the shell and
seat for dirt or
grit
reassembling always
Before
clean oil
cylinder
caps
01 mm
hole
crankpin when
the
o
connecting rod bush
or
the
to
bore
piston
Never
Piston and Bores
apply
surfaces
a
little
Insert
and into the
between
file the connecting rod
their mating surfaces
as
this
cylinder
at the lower
creates
angle
oval in the bearing
0 04 mm thick
gauge
bore and piston and measure
Feeler
to the
portion of
piston pin
the
cylinder bore
There should be a clearance of 0
at
right
015
0 030
the
spring
mm
Removing
Remove
end
of the
a
Piston
Pull out
the clamping
connecting
bolt
rod
and
push
out
with
feeler
gauge
scale and then inspect if
from the small
regulations
the
23
0
5
1
5
kg
by
the reading is within
or
not
DATSUN
Because
end of the
the
piston rings do not travel to the
bores a
1ip is eventually
cylinder
formed due to
wear
This may be
be
a
a dial gauge and
If this is not done there will
checked with
be removed
must
tendency
to
noisy operation
ring
lip
Piston and rings
0
0
or a fractured
caused by the top piston ring striking the
254
762
mm
mm
0 020
are
in
available in
0
010 in
0 508
0
030 in
and 0 040 in
1
mm
016 mm
over
piston rings should always be fitted
from the crown of the piston and never pushed
Before fitting the
upwards over the skirt
carbon
remove
deposit from the
any
rings
the
When
in
fitting note that
piston
grooves
sizes
Fig
21
Removing
Piston
Ring
The
the second compression is tapered type and oil
control ring is slat type processed by chromium
Piston
plating
Rings
The piston ring gap should be 0 008 0 013 in
0 330 mm when checked in the cylinder
0 203
bore
clearance of the compression rings
The
in their grooves should amount to 0
in
o
0
038 0
089
0016 0 0036 in
Fig
22
mm
0
0015 0 0035
and the oil control
041 0 092
ring
mm
Clearance Between
and Groove
Ring
Fig
24
23
Measuring Clearance of
Ring Joint
ENGINE
TROUBLES
REMEDIES
Excessive Oil Consumption
Lack of
Burning oil
Ignition system improperly adjusted
1
Rings
correctly seated
not
to
cylinder wall
1
Give Bufficient time for rings to seat
2
Piston
rings
worn
excessively
or
stuck in
Fit new
4
due
wall
cylinder
fitting
between
to
wear
and
piston
improper
or
walls
scored
tapered
or
out of
1
Recondition cylinders and fit
ring oil
Piston
return holes
new
pistons
clogged
2
3
Replace rings
7
rings broken
Replace ring S
stem
Replace
Leaking
1
2
Rocker
oil
4
or
leaking
5
cover
gasket
or
tightening
tappet cover damaged or loose
Tighten covers or replace gasket
1
Dirt in
gasoline tank
Air leaks in gasoline line
Fuel pump not functioning properly
or
repair fuel pump
Oil pan drain plug loose
2
drain plug
Oil pan retainer boltB loose
Carburetor choke partly closed
Adjust or replace choke mechanism
Over heat
oil pan bolts
Oil pan gasket
damaged
3
or
oil
into clutch
main
bearing
or
main
replace
Fan belt worn or oil
Water pump
Replace
flywheel housing
Adjust or replace
bearing oil seal
or
5
inoperative
water pump
Thermostat
sticking
Replace thermostat
24
soaked
Replace belt
4
leaking
Fan belt loose
Adj ust
Fuel pump loose or gasket damaged
Tighten fuel pump bolts or replace gasket
Rear main bearing
Lack of water
Refill BYBtem
Timing gear cover loose or gasket damaged
Tighten cover bolts or replace gasket
housing
Air cleaner dirty
Clean air cleaner
2
7
Dirt or water in carburetor
Carburetor air inlet restricted
Replace gasket
6
partly plugged
Replace
1
5
Gas line
Check gasoline lines and tighten
seals missing
check for sealing
seals
arm
Tighten
4
Ignition not properly timed
Set
ignition by the instruction under
correct Bpecification of engine
oil
Tighten
3
points and timing engine
Clean the tank
Piston
Valve
Distributor points not set correctly
Clean carburetor and fuel pump
with
carbon
6
and seat Bpark
Clean gas lineB
round
5
adjust
Lack of fuel
pistons
Cylinder
2
3
clearance
Excessive
Spark plug faulty
Replace or clean
Set distributor
ring grooves
Replace ring
3
Power
plugs
if neceBsary
Replace
Engine
closed
r
DATSUN
6
Cooling system clogged
Clean and
7
reverse
Incorrect ignition
4
flush
or
Improper
and
9
viscosity oil
being
6
to correct oil
or
Loose connections in
primary circult
Series
resistance in condenser circuit
Clean all connectiOnB in condenser circuit
Fuel mixture too lean
Overhaul
in
Tighten all connections in primary circuit
used
Change
corroded
Clean code and cap terminals
valve timing
5
grade
loose and
distributor cap
Retime engine
8
codes
Spark plug
7
adjust carburetor
Low
capacity condenser
Install proper condenBer
10 Valve
improperly adjusted
Adjust valves
11
Engine condition
1
ExhanBt system partly restricted
Clean
or
Grind valveB
replace
2
Over
cooling
holding
3
open
Replace thermostat
2
3
5
Faulty pistonB
1
Partially diBcharged battery
Change battery
undercapacity battery
connections
Clean and tighten
5
6
or
replace
motor or
2
starting switch
or
LooBe wiring connectionB
Faulty wiring
Replace faulty wiring
3
Faulty Bpark plugs
Clean or replace and adjust plug gap
replace points
Spark plugs improperly gapped
Set plug gap correctly
08 mm
and Detonation
2
corroded
Points improperly adjusted
07
Carburetor dirty and passageB restricted
Ignition trouble
Readjust points correctly
3
repair choke mechaniBm
Tighten all code connections
Distributor points burned
or
working properly
or
Throttle not Bet properly
Spitting
Ignition troubles
Clean
Choke not
Overhaul carburetor
1
1
cylinderB
connections
Faulty starter switch
Replace switch
Faulty starting
or
Set throttle
3
battery
ringB
Lack of power
AdjuBt
2
Poor
replace gasket
Carburetion
Replace battery
4
or
mounting
Tighten carburetor mounting boltB
See
Heavy engine oil
Change to lighter oil
or
Leaking manifold gasket
Tighten manifold bolts
Loose carburetor
Starting
Faulty
change
ValveB holding open
4
Slow cranking
1
or
Adjust valves
Thermostat
Hard
Valves burned
00275
0 0315 in
24
2
rl
ENGINE
REMOVING
Experience
to
remove
single
the
engine
unit than to
To
remove
upwards
Completely drain
transmission
and
detach
engine
the
proceed
battery
iliat
has shown
as
REFITTING
The
it is much easier
the
Next
remove
and
remove
change selector rod
transmission casing
the
at the coil
transmission
from
and water
Remove
Disconnect
pinion franges
starter motor cable at the motor end
ature gauge leads
from
the
the gear
lever
on
the
the
hand brake control
rod
the
speed meter cable from the
Uncouple the propeller shaft
at rear axle and draw the shaft
out of the transmission
To
temper
their terminals on the
allow the
drawn forward
engine
engine and transmission to be
the
radiator must be removed
1
i
t
Fig
25
f
remove
the
by undoing the four securing bolts
Fig
from
supporting from transmission
dynamo lead and disconnect the
gauge
pipe
Disconnect the earth strap from the starter
upper and lower radiator hoses
the oil
the exhaust
From below the vehicle
cooling system and the
by undoing the retaining clips
Disconnect the capacitor lead at the dis
tributor also the high tension and switch wires
Remove
must be
Disconnect
manifold
motor
Take off the
controls
the fuel pipe from the fuel pump
the engine by itself
and transmission
and its supporting tray
Remove the
choke
and
disconnected from the carburetor
transmission as a
follows
disconnect
throttle
2
r
DATSUN
OPERA nON
WITH
THE ENGINE
REMOVED
@
L a Iosulator engme
Bolt
mounting Front
J
InRUib
l
Bolt
I
Nut
Bolt
Nut
lo
fllii
W
I6fl
I
Washe
Nut self
lock
rfj
Washer
1 118
I
Bolt
f
Washer
Bolt
Washer
R H
r
Cross member
mounting
Bushing
engine
rear
f
f
i
f
spacer
Nut self lock
bushing
Fig
The following operations
are
3
Bolt
mounting F
rW
4
Removing
Washer
Bolt
Engine Mounting
best performed
Crank Gear
engine
ont
ri
he
out certain attentions with the
with the engine removed from the car
Although it may be found possible to carry
Fig
Insulator
it
is
more
convenient
to
engine
do the
in position
work
on
bench
Carn
Gear and Chain
Fig
26
5
Checking
Thrust Clearance
the
ENGINE
Camshaft
Withdrawing
The
plate
is
camshaft
held
positioned
three
by
screws
by
mounting plate is now accessible and may be
removed by withdrawing the setscrew and lock
The dynamo swinging link must be
ing plates
locating
shakeproof
a
and
position of the small lubricat
ing oil hole in the locating plate when replacing
should be to the right of the engine
washers
Note the
End
mm
of
0 003
is controlled
plate
set
play
and
can
by
007
0
in
0
076
the thickness of the
0
the camshaft gear
Before
withdrawing
will have
pump
timing
and its
to
the
camshaft
be removed
drive
and
cover
withdrawn from the
cam
when the camshaft can be
shaft locating plate
locating
the
trihutor and its driving spindle push rods
oil
Take out the setscrews securing the
178
cylinder
block
be checked with a dial indicator
against
tappet
removed
shaft
gears
Camshaft
dis
with steel lining are
They can be taken out
renewed when necessary it being usual to do this
when the cylinder block is being reconditioned
The bearings can be removed by drifting
and
White metal bearings
used for the camshafL
Remove the
and take off the
The
engine
Bearings
front
them out of their
housings
bearings care must be taken
oil holes with the corresponding
When fitting new
to line up the
holes in the
cylinder
block
Tap the new bearings into position and ream
them to give a running clearance of 0 001 0 002
in
0
025 0
015
mm
Refitting the Camshaft
This is
removal
align and
the
Fig
6
Pulling
out
27
reversal of the introductions for
Care
should be
engage the drive
taken however
pin
to
in the rear end of
camshaft with the slot in the oil pump drive
shafL
Camshaft
a
r
DATSUN
fix
xm
bo
gear
QUIlting
1
I
II1I
I
Au Y pan
Ass y tube
Stud
to
Fig
Cylinder
7
Adapter
it
it
breather
ap
lnk
cr
Block
p cDUre
fix fuel pump
to
switch
care
A
An
bI ock
th
Wl
cylinder
plug
Plug welch
cylinder
6
block
Au y
Washer Jock
oil
gauge
level
Bolt
Plug chain
tI
Q
r
ensione
oil
eed br us
Cock
drain
if
l
Y
Bearing crank Ih aft
half
Washer t
Cap
tand
st
Waiher
Seal
to
k
Seal
fiJ bearing
iI
rear
bunngo side
Fig
8
Cylinder
28
Block
B
hI
m2in b
rd
eanng
thrust
il
I
e
met a
frant
bl
1
upper
frent
metal
l
ower
bearing cap
plate
ENGINE
Main
Bearing Caps
Remove the
off
Take
strainer
and
Unlock and
flywheel and clutch
timing chain the
the
the
engine
remove
bearing caps
to the
the
sump and
mounting plate
bolts securing the main
cylinder
rear
also the
block
two
holts securing the front cap to the engine front
bearer plate
Note that
side of
the
thrust
a
centre
washer is
main
fitted
on
to
take
bearing
These thrust
crankshaft end thrust
each consist of two semicircular valves
having
a
each
the
washers
one
half
which is located in a recess in the
lug
detachable half of the bearing
the other being
plain
When
required
correct
0
0127
fitting
new
bearings no scraping is
they are machined to give the
running clearance of 0 0005 0 002 in
0508
0
Ensure
engaged
Main
Bearing Cap
locating tangs
are
properly
new
all
rag
traces
of dirt and oil
throughly dry
them
Make sure that
the
and
housings
bearings carefully
so as
not
the fine surface finish
Remove
clear
Removing
in their recesses
damage
fluffy
10
mm
that the
Handle the
to
Fig
as
When
fitting
from the
with a non
oilways
are
the
bearing caps ensure
that they are replaced the right way
round
Each cap is punch marked and the marks should
race
the camshaft side of the
engine
Removing Crankshaft
11
Fig
i
ii
r JL
0
0
0
fJ
0
0
O
L
l
0
r01
Or
j
10
0
0
O
Fig
9
Removing Fly
Wheel
Fig
29
12
Engine
Rear Side
r
DATSUN
Check the crankshaft end play
dial
I
If
L
block
1
I
q
a
1
by
means
002 in
0
of
a
051
run
oilwayB
out
the
in
it
the
is
essential to
crankBhaft
engine
sump and
and
the
strainer
1
I
If
has
bearing
Wash
The
II
I
a
clean out all
I
I
I
gauge
should be 0
mm
l
l
This
oil
cleaned
metal
pump
Ensure
are
left
should
be
dism antled
and
particles of bearing
the
engine lubrication
that no
within
system
I
i
J
13
Fig
Bend
Measuring
of Crankshaft
Fig
14
Fig
Measuring Crankshaft
15
Measuring
End Plav
of Crankshaft
Pin
and Journal
Caution
file the
Never
excessive
playas
Always
bearing
this will
cover
the
engine oil when they
The
by
main
setscrews
screws
up
loading of
When
refitting
one
the
freely
is
tight
examine
foreign
10
the main
held in position
Pull the set
wrench
36 11 05
bearing
set
caps
remove
BBcertain
the
the bearing
its
tighten
tighten
that it
last cap
and
to a
kgm
after each cap iB
crankBhaft to
rotate
and
torque
1ft
firBt
up
bearing surfaces with
replaced
caps are
with a
take
to
ovality
and lock washers
tight
volveB
If it
bearing
75 80 lb
the center
are
caps
cause
re
tightened
seating for
matter
Fig
30
16
Removilzg Crankshaft
ENGINE
IGNITION TIMING
DISTRIBUTOR
the Braker Points
Adjusting
Hitachi D411 53
Type
Ignition timing standard
To
is
Governor type
screw
advance
100
Advance starting
vacuum
120
120
is
60
90
the
01S to 0 022 ins
0
between the braker
of the cap is wiped clean with
Hg
of cloth
extra attention
at the start of
between
the
advance angle
electrode
on
450 r pm
Number of revolution
11
advance angle at
Max
advancer
soft
Clean
terminals
dry piece
to the areas
the
center
the inside of the cap also
or
not
the
type timing
can
be
properly
vacuum
is
01S 0 022 in
suddenly changed
1
0
a
being paid
o 45 0 55 mm
r
m
p
determined
Counterclockwise
cam
Point gap
3 4 2
500
Dowel angle
arm
Whether
at
then
more
functioning
the inspection painter located at
as the engine is being run
the diaphragm if
this painter moves when the engine speed is
2400
crankshaft
Rotating direction of
Firing order
Contact
15
Then
The interior and exterior
reinstall the rotor
Distributor
thickness
points
tighten the Fixing screw Becurely
check the gap once
Finally
Cranksbaft
vacuum
pressure of 340 mm
by turning
adjusting
plate until a feeler gauge of
the
55 mm
slides easily
pressure
Advance angle by
engine
braker point
the
Next
move
o 45 to 0
H
mm
turn the
points
Then loosen
fully open
fixing screw
center at 600 r p m
Apparatus of automatic
the braker
adjust
crankshaft with the crank handle until the braker
So before top dead
o 5
spring
by
the advancer is
satisfactory
55
0 65 kg
pressure
o 20 0 24 mfd
Condenser capacity
Inside
shown in
the distributor is
Fig
1
a
braker point
several thousand times in one minute
contact
Each time this braker brakes contact
is
as
This braker makes and brakes
generated
a
spark
There
spark plugs
in one of the
tbe maintenance of this braker must not be
fore
treated lightly
because the time
Also
during
which the ignition coil current flows varies with
see that
the gap between these braker points
is
this
maintained
gap
which is 0 45
The
grease
burnt
honing
or
Fig
points
must
be
blackened
they
stone or croucus
are
cleaned with
cloth after
should be wiped clean with
a
replaced
replaced
are
Braker
as
badly
points
the Point
Gap
before top dead center with the engine stopped
2
With this adjustment the
as shown in Fig
a fine
which they
timing advancer of the distributor
advances the ignition timing even further at the
time the engine starts to rotate and the timing
automatic
piece of cloth which
has been dampened with gasoline
If the points
Adjusting
ADJUSTING THE IGNITION
TIMING
The ignition timing is adjusted to 10 degrees
kept free of
If the points should become
oil
1
standard value
0 01S to 0 022 in
mm
braker
and
the
at
burnt
must
they must be
always be
maintained constantly
the rotational Bpeed
is
sets
31
at valveB
suitable for
DATSUN
slot of the distributor drive of the upper end of
engine stopped adjust so that the
distributor breaker point just breaks when the
piston of the No 1 cylinder is in its 10 degrees
With
the
the
4
is
before top dead center position for compression
the standard ignition
If a timing lamp is used
timing
idling
In
is
the case of marks
2
First
is
the front
which
are
not
evenly
adjust
distributor to the correct
the
described
as
center
dead
and
made by the following procedure
previously
Turn the crankshaft
the
gradually until
mark
Fig
2
on
the
top
pulley
perifery coincides with the mark for 10 deg
before top dead center on the timing gear
the
crankshaft
cover
as
approaches i tB
that
somewhat
before
corresponding
positions
to the end
No
Fig
center at
15 deg
pointers indicate 10 deg
center
before
dead
top
positions
Adjustment
gap
placed toward
shown in
as
the smaller of the semicircle
At this time
600 rpm
spaced
20 deg
1
degreBs before top dead
speed
15
shaft somewhat to the left
1
of the compression stroke
Stop the crankshaft
compression stroke
piston
in
With the crankshaft in the
1
4
Gear Mark
engages
distributor
the No
position of 10 deg
before top dead center of
drive
shaft
the
to
the
assembly
same
when
engine
do
During
of the
directions
is
just begining
distributor
4
Fig
At the
position
to open
If these
they
made to
conditions do not coincide
compression
the
this
the breaker must be in its
time
it
mount
slot
and rotor must be as shown in
is in its
mentioned position
the direction of the rotor so that it
Adjusting
the
previously
piston
Setting of Timing
this
of the
The
position
No
1 piston can be determined if the spark
the
plug of the No 1 cylinder is removed
hole plugged with a finger and the crankshaft
turned
3
Fig
of the
are
by slightly turning the distributor body
so
only
To
determine the position when the breaker
point is just begining to open
ignition key hold the end of the
turn on the
No
cord about 1 4 inch away from the
head
and
across
turn
the
body
1
spark
cylinder
until spark jumpB
the gap
The off set slot position of the drive shaft
when the No
I
piston
is in its
compression top
dead center position is shown here
Fig
2
Checking
the
Ignition Timing
5
Next
6
To the No l
put the distributor
securely with the clip
spark plug
cap on and
clamp
it
connect the cord from
the terminal to which the arm of the rotor is
3
Next
inserting
distributor at
an
the
driving shaft
angle to the engine
of
the
Thereafter connect the terminal
pointing
cords
engage
to
their spark
clockwise order
the gear on its lower and with the gear on the
camshaft
During this assembly place the
firing
32
order
so
plugs
as
in the counter
to obtain
a
1
3 4 2
iINE
EN
7
distributor with
should
now
Ordinarily
is
set
its
at
start
the
pointer is
a
The
rubber cap
pointer
the
engine
properly
pointer of the octane selector
reading during the ignition
If the octane number of the
low
adjusted
and
engine knocks
right R to the
the
to the
optimum advance angle
if the octane number
Conversely
adjusted
is
cover
wlrmg
zero
timing adjustment
fuel being used is
the
of the
Upon completion
to the left
A
is
high
the
One unit of
calibration of the selector corresponds to 2 deg
of the
distributor angle
crankshaft
When
and to 4 deg
of the
angle
a
timing lamp is used
the
standard
Fig
center with
setting is 15 dge before top dead
the
In any case
the engine idling 600 620
a
slight
optimum adjustment is that in which
knocking is heard when with the car running at
HIGH
TOP gear
acceleration
low speed in
is applied suddenly
33
4
Assembly Angle of Orive Shaft
CD
2
@
Distributor shaft
Distributor drive shaft
Distributor fixing plate
DA
UN
FUEL SYSTEM
I
CARBURETOR
Starting
con
SP ECIFICA TlONS
Primary
D2630A 5A
Bore diameter
Secondary
26 mm
30 mm
20mm
27
Venturi diameter
Pump planger
large
8
small
Pump
8
1192
11140
Main air bleed
1160
1160
1148
1148
Slow air bleed
first
100
Slow air bleed
second
valve
strainer
kit
Small venturi
Main jet
Slow jet
Pump
mm
Throttle shaft
arm
Fig
1
11120
11240
Emulsion hole
1160
low economizer
x
12
1160
x
20
Body gasket
11145
Power jet
Power valve
1140
Begins
to open whe
the
primary throttle
valve is at 48 opening
Float level
21 5
upper
float
mm
below the
Burface of the
chamber
body
The carburetor has the function of automizing
the fuel
mixing it
supplying
the mixture to the
in suitable ratio to
air and
engine
important part which
influence the performance of the engine
It is
therefore
an
The carburetor is
two
the
a
highly
efficient
Flange gasket
Secondary
can
one
Bide
Primary
side
of
barrel two step and down draft type having
following special
Construction and
features
Operation
Main air bleed
Pum p valve
Small venturi
l55embly
1
Power
jet sheet
gasket
Power Jet
Secondary
Fig
34
2
side
ENGINE
amount
of the
holes provided
fuel
be varied with the two
can
the pump
on
inserting pOBitions of
the
that is
arm
the
rod
Connecting
Starting System
The choke
and
installed
carburetting
close
adjust
valve
and
normal
When the choke is
is
the
best
closed
fully
from
condition
a
The synchronization of the choke
the throttle
valve
can
be
exactly
Carburetting System
The fuel flowing out of the passage at the
bottom of the float chamber passes through the
primary main jet
coming from the
drops and inject
and then mixed with
main
the
venturi
Slow
jet
embly
the air
air bleed to be
into
minute
through
the
main nozzle
When the throttle valve
the
engine
requires
acceleting
where
the
The
pump
fuel
dense
opens
its
is
widely
open
beings
Throttle
and
adjust
screw
mixture
power
gas
valve
also flows into the main
power valve
the
from
system
to operate when the
throttle valveopens480from full closed position
Slow
Con
Speed System
through
Passing
passage
separate
the
from
main
main
jet
line
the
and
fuel
flows
the
slow jet slow air bleed first slow
slow air bleed second and inject
from the by pass holes and idle holes
through
economizer
Accelerating System
Mechanical
accelerating
pump
with the throttle valve is adapted
valve is open
ihe
linkage
the dumper
down
the
synchronized
When throttle
the piston rod is pushed up with
which pUBhed up the piston
spring
full
to start
maintained often the engine has started firing
3
Fig
Main
screw
the
on
valve opens about 140
This
operation
Idle
eccentrically
device and synchronized with the
throttle valve
the throttle
valve is provided with the spring
When the
through
piston is coming
inlet check valve closes the out let
I
check valve opens and the fuel within the pump is
blown out from the pump jet by the compressed
Throttle lever
dumper spring and hits against the side wall of
the small venturi to be minute drops compensat
A jetting
ing trancient sparseness of the fuel
Fig
35
4
assembly
rod
spring
f
DATSUN
Float Chamber
4
of the
Adjustment
from outside
valve
4
As
a
5
by adding
subtracting the needle
gasket after removing the float
air
valve
at
installed
vent
method
matter
and
within
pressure
the
constant
always
registance of the air
fuel consumption can be always
suctional
how
cleaner varies
maintained
econmically
Carburetting System
Main
Same
the
as
the
fuel
flowing
of
the
float
secondary
normal
carbUretting function
Adjusting
out of the passage at the bottom
chamber
passes
through the
jet and become minute drops
main
mixing with
the
air
coming from
the main
1
Take off the
Raise
L
i1
JI
3
l
q
fl
float upper surface must
the float level is done by adding or
the gasket of float valve seat
throttle
valve
fT
of
and
the throttle
power
to
open
at the
is
an
subtraction of 2 numbers gasket
When the
tions
The accelerator must be
adjusting plate
at
to
adjusted by
normal
and of slight gap with pedal off
this
tighten
up
surely
After
the nuts of the
for
high
carburetor throttle
the
normal
the engine
valve of the
by
c
the syn
5
1
p
valve which is not
is
i1 l
J
Z
open
When
power
is
01
J
I
l
t
y
the
in a full
0
the power carburetor throttle valve is also
to be in a full open
open
Fig
36
7
1
J
I
c
still higher revolu
valve
on
adjusting
adjusting
plate
auxiliary
operation
the
the carburetor side that the
throttle valve may be full open with full pedal
throttle valve
engine change
so
valve open against the loat
of the counter weight and the power carburetor
starts
the
the
mm
mm
0 5
of accelerator
speed with aheavy load due to the
load of the counter weight connected to the valve
when
down about 1
or
is thickness
gasket
Adjustment
J
top of the power carburetor
auxiliary
or
J
11
opened
widely
Addition
open at a slow
even
hanger lip
r
chronized linkage
throttle valve
its
until
and parallel with the chamber top
Adjusting
one
6 Nikki Carburetor
carburetor begins
However
the
stage
make the float level up
1
i71
IIi
fl
Fig
5
ll
u
cl
IJr
v
power
slowly
needle valve carrier
J
U
U
c
produces high
At this
be level
J
jAYd
Lc
jll ffi p
the
of float chamber
subtracting
g
When
cover
the float
contact with the valve retainer
4
carburetor is
Fuel Level
2
air
bleed and is blown into the venturi through the
Il ain nozzle
shaft
the inlet connector
ventilation within the float chamber is of
venturi and the float chamber is
no
be done
can
carrier
needle
Fig
float level
or
0
ENGINE
i
D
Fig
Dimensions of
rod and
The
D
is
adjusted
to 86 5
mm
8
THE
by
GASOLINE
TANK
adjusting plate
nut must
tighten surly after fixing
the
The
dimension of D
and
is
fuel tank has
situated
a
at
capacity of
the
rear
41 Olitres
of the luggage
compartment
The
fuel
operated off
pump
draws fuel from the
carburetor float chamber
air
fillers
cleaner
the camshaft
tank and forces it into the
A
large and efficient
supply to the
air
the
carburetor
Draining
The
wrench
the Fuel
fuel
to
must
float lever
gauge
when
37
as
top
face of the tank is the
the unit to the tank not forgetting
disconnect the
Care
plate
the
To remove withdraw the set screws
which secure
9
CD Rod
o Adjusting
@Nut
on
by turning the
Unit
Gauge
Situated
gauge unit
drained
cock
operated drain
Fuel Tank
Fig
is
tank
be
electrical
this may
readings
refitting
not
taken
to
lead
beforehand
strain or bend the
serously
effect subsequent
Remember this also applies
the unit
r
DATSUN
Examine the joint washer to
is
as
in position and
the
joint
must be fuel
undamage
between
ensure
that it
This is essential
the tank
and gauge unit
I
J
tight
J
Fig
1
Fuel Tank
j
r
r
Securing
i
I
1
Ii
1
1
C
capass
J
y
Filler lube
Clamp
Fuel tank
for sedan
Breather
tube
Band
ear
Grommet
For SEDAN
Tube to
S crew
strainer
washer
Ventilation
tube
E
Gauge
Gas
ket
Bolt1
j
Washer
Fue
tank
for wagon
For WAGON
Fig
2 Fuel Tank
38
Mounting
E Gl
3
E
S
l
40
ENGINE
FUEL
PUMP
By the rotation of camshaft rocker arm is
pushed and pull rod of diaphragm is pulled down
At the same time
diaphragm goes down
against diaphragm spring and then is pushed up
its
again by
spring
By the movements
functioning of the valves
the
pump chamber
of
and
diaphragm
the
at the inlet and outlet of
drawn up from
is
gasoline
the tank to the carburetor
If the
chamber
float
of
the
carburetor
enough gasoline and the needle valve is
not
allowed
into
the
gasoline is
contains
closed
carburetor
Thus
and
gasoline
due to its
is stored in the pump chamber
the
pressure
is
diaphragm
kept
down and cannot return
the rocker arm works
Under this condition
5
Fig
in vain
The
FUEL PUMP
spring
18 mm
in use and
l
0
6
1 mm
0
1
Checking
kg
on
tension
Rocker
95
length
1
Thickness of valve
mm
6 mm
rom
at 1000
500
mm
I
p
m
110
height
130 mm in
the tip of the pipe
Fuel
once
very two rotations
function
mercury column
at 20 strokes
ing the
80 cu cm
pump
is
of the diaphragm
pump
mechanically driven by the eccentric
arm
scale
part of the camshaft of the engine
it under pressure to the carburetor
engine
running fuel can
by moving the hand
is not
be delivered under pressure
alone
can
be easily removed by dis
primer up and down
41
to
to
disassembling
disassembling
of
the
removed
measure the distance between the rocker
and flange of the lower
and
and pins
gasoline from the tank and delivers
Even when the
pump
2 attachment nuts
Prior
which
the
engine
Inspection prior
The fuel pump
of
connecting the inlet and outlet unions and loosen
scharged
It draws
the
test
Removal from
More than 400 mm in
suction vacuum
type
Disconnect
at the inlet union of the carburetor
operation of the hand primer and checking the
fuel ejection is enough
I ercury column
Hand primer quanty
is
installed
engine
To
of cam
in suction
pressure
discharged
Max degree of
di
pushed against
of the crankshaft
1300 cu cm per minute
quantity dis
charged
Max
arm
prevent
and then turn the engine with the crank handle
N ow the gasoline should be ejected vigorously
Performance
Max
fuel pump
with
the fuel pipe
30 mm
spring
Free
to
serves
Switch off and stop the engine
spring
length
arm
Free
Valve
Io
spring
Inspection
Disassembling
36 5
legnth
Length
arm
the eccentric of the camshaft
Driven by camshaft
Method driven
Free
pump
rocker
keeping the rocker
noise
Diaphragm
Type
IDiaghragm
as the rod remains
see
if the rocker
are worn
body by
arm
means
of
a
rocker link
DATSUN
Method
of disassembling
First
pump and
to make their
oodies
It is
screws
wipe dirt off the outer surface of the
put marks on both the upper and lower
reassembling
easily separated
around the upper
body
care notto
Take great
during this disassembly
are
Wasbthe disassembled parts weU in gasoline
then inspect them
diaphragm if any damage
impregnation by gasoline
Replace a valve assembly if any wear or
the
Replace
easy
into two when the five
loosened
of Parts
Repaires
Checking
damage the diaphragm
is detected
faulty operation
Even if repairs
the
limit for
unavoidably required
are
repairs of
of the
or wear
warp
valve is 0 001 in
When the Burface of th
is
found irregular
valve Beat
outlet and dress the surface with
In
of
case
irregularity
the inlet valve
the
body
or
valve
the valve Beat of the
remove
a fine
oilBtone
of the seat surface of
be taken off from
which cannot
recondition it with
cutter and
a
grind
ing tool
When the surface of the valve is faulty place
some
of
a
very fine grinding
compound
flat piece of glass plate and
with the tip of a finger
of the valve is 1 6 mm
on
the surface
grind
it
lightly
The standard thickness
The hole ofthe joint parts of diaphragm shaft
Fig
and link may be
6
crack
or
worn
This is
to some extent
but when serious eccentric
not serious
breakage
is
wear
the part must be
found
replaced
As
a
remedial
compensated for
reassembling
such wear can be
measure
at the time of
of the
dismantling and
a packing
body by inBerting
made of thick paper between the lower body and
diaphragm to raise the relative position of
shaft with respect to the lower body
arm should be replace when its
diaphragm
The rocker
contact face with the carn and that with the link
and its pin hole
When its
Fig
7
this
worn
by reconditioning
and finish them with
by welding
cannot
temporary
seriously
add material to the rocker
unavidable
link
are
employment
re
last long
and
is
no
arm
a file
is
and
but
than a
more
measure
Renew the
arm
pin when It
is found worn
excessively
arm spring seldom
The diaphragm spring
become faulty but when weakened replace them
always with standard ones
o
If the diaphragm spring is
to
strong
it
results in overflow of the float chamber of the
carburetor
The
tension
strengthened
Fig
8
42
or
of
the
weakened
spring
must
not
arbitrarily by
be
hand
ENGINE
disassembling
its air
is over
renew
there can be heard
thence
the gasket to keep
3 to 5 seconds
good conditions if
The pump is in
Check to see if there is any warp on the joint
and
after
surfaces of the cap and body
strong inlet and outlet
noise respectively
The pump is mechanically fit for
tighteness
by connecting
to draw up gasoline from
o 5 m
After installing
Installing
Reassembling
functions
Employ standard
springs
for
the
various
A
stated before
uses as
valves precisely
Install
for
contact
close
with their respective seats
screwing in of upper and lower bodies and
diaphragm fit them together according to the
marks which were put before the disassembling
In
and align
it is able
screwing
screw
position where the diaphragm is
with the rocker arm pushed
down
fully pulled
the body by and pressure
the
side
of
towards
Do not screw in tight one by one since it
causes warping
Instead clamp all the screws
tighten
As
of them in order to make
all
a
the
to set
the
contacting
is
engine
gasket
standard
a new
and turn the
by
means of the crank handle
there is
6 to 7 rotations
engine
and make
sure
outflow of gasoline from
sure
Connect the gasoline pipe to the outlet port
Then
any leakage
of air or
Bee
gasoline
if
from
ADJUSTMENT AND
INSPECTION OF ENGINE
re
must always be operated in the
possible condition and for this purpose
periodic inspection and adjuBtment must be
The engine
done
in
the
in a certain
maintained
well
rocker arm so that it is
eccentric
between the
is
sure
as
order while in
use
as
after overhaul
of camshaft properly
the rear side or to one side
not
it
each connection
order to that for disassembly
sure
as
best
the
on
its
during operation
there iB
should be re
gaskets
test
side and tighten all the piping joints
again several timeB to
new ones
Installation
Be
rule
general
placed by
reverse
diagonally and lastly
them
the pump
turn the eI gine
round loosely and uniformly
tighten
than
more
the outlet port
B
in at the
Then
height of
Connect the gasoline pipe on the inlet post
side only
Leave that on the outlet port side
that
and then
hole to its mate
one
a
when
use
a hose to the inlet port
Replace
Order of Inspection and
of Engine
the
block and pump with
cylinder
1
one
Check the
cooling
Adjustment
water
water level
and
extent of fillthiness
When
it
is
the pump is over
repairs of
installed
the
on
make
engine
or
a
InBpect
the
3
Inspect
the oil
before
check to
battery all connections level of
specific gravity of electrolyte
electrolyte
and voltage
2
Function
Checking
amount
classifi
filthiness
cation and
see
4
When
a
vacuum
is
gauge
connected to the
pump inlet port and the pump is mounted
the
tester
rocker arm is activated by
eccentric of the camshaft
revolving
their gaps
5
on a
the
at 1000 rpm
is discontinued
remain for
When
in the
a
gauge
see
finger tips
the
inlet
Then
several times
of the
tester is not available
test
remove
1
operating
suddenly
the
163 lbs
approx
Measurement of
p m
First
all
warm
cooling
spark
water
plugs
manner
up the
and
engine
70 80oC
pull
is
throttle
out
then
the
in the
knob all the way
that
carburetor the throttle valve and choke valve
port and outlet port with
after
r
made in the follOWing
is
Fig
is
engine
at 350
temperature of
than 3 seconds
or
cylinder
The
pressure
following way
Close
arm
more
of
per sq in
this condition should
compression pressure of
standard
compression
Measurement
pressure
Then the gauge pressure should rise to higher
than 400 mm of mercury column and even if
operation
viscosity
Cleaning of spark plugs and adjustment of
rocker
are
release the fingers
fully opened
against
43
each
press a compression gauge
and
spark plug hole
running
RUN
DA
the starter motor with a fully
read
5
8
the maximum pressure obtained within
This measure
rotations of the motor
ment
It
must
be made
quickly
as
the
compression pressure
cylinder differs by 10 lb Isq
form
Diagnosing of Engine by means
Vacuum Gauge and Combustion
charged battery
that
the
of another
as
of
in
cause
In
each
possible
diagnosing
cylinder call
be assumed
or more
compression
For employment of
must
it to the
any
one
be
the condition of
engine
the
of
Tester
by measuring
a vacuum
gauge
connect
intake manifold and refer to
engine
its
Fig
2
The
in
of
use
a
master motor tester as shown
2 is convenient
Fig
When
combustion tester is used
a
install
a
special intake pick up in the exhaust tube and
after the engine has been started
analyze by
the combustion gas
special gauge
the
which flows through
connecting hose into the
of a
means
and
tester
according
When
to
pick
up
excessive
Fig
Compression Gauge
1
combustion
the mixture
measurement is to
cold weather
the
the
judge
damage
the
use
be made
auxiliary
an
and
ratio of fuel
moisture
in
functioning
the
and air
rainy
or
condenser between
meter
the
in
condition
otherwise
exhaust
gas
the
will
of the meter if permitted
to enter it
6
Check and
adjust
the distributor
If the breaker contact points have defective
contact surfaces
gap to 0 45 0
Also turn the
and
dress them and
adjust
the
55 mm
cam
check to see
of the distributor clockwise
if the governor
can
carry
advancing function
Adjust ignition timing correctly
By utilizing a power timing light the function
of the governor can be checked together with
out
7
the
ignition
pulley
illumination
timing
of crank
will enable to inspect the conditions of
running and advancing of the timing
DC
8
9
B T
200
Inspection
of fuel pump and
gasoline
strainer
the slow setting of carburetor
Adjust
10 Cbecking operation
of
generator
Check the generating condition and functioning
of the cut out relay by means of indications
of the ammeter
11 Adjustment of slack
in fan belt
12 Adjustment of valve tappet clearance
13 Road test
While driving in 3rd
speed at about 25 lanl
If
hr
on
the accelerator
step
suddenly
the ignition
only a slight knocking results
is
Slow
correct
speed
timing
adjustment is
made so that the speed is about 15 Ian hr
when driving in 3rd speed
Fig
2 Motor Master Tester Available
4 6 and 8
44
Cylinder Engine
for
ENGINE
When a tester
ments
according
conditions
to be used
is
to the
Without
Speed Running
2
indicator
times
drops by 4 in
valve
sticking
so
exists
1
85
5
2
m
6
Trouble
indicator drops
When
several
by
Engine
some
12
70
Speed Running
000 r p
When
or
of Mixture
600 r pm
IEligh
5
Suitable Weight Ratio
load
Low
adjust
make
following table
certain time
Shooting
inches
valve
at
are
burnt
Fig 3 is intended to be of assistance in the
systematic analysis and isolation of symptoms
of engine
may
be
troubles
so
accurately
that
the
traced
defective points
and
economically
repaired
Normal Condition
1
Settles
7
indicator drops
When
between 18
by
20 in
about
leak
2 in
valve
Faulty seating of
valves
2
8
Normal condition
When
fluct
indicator
When indicator oscil
lates
14
of 0
stem
is
25 in
raced
valves
are
engine
as
and
rings
in
actively
between
and 18 in
uates between a range
guide
valve
is
worn
out
good
conditions
3
Even
if indicator set
tles
if
is low
reading
rings or oil
faulty condition
9
are
When
with
speeding
in
moves
in
a
slight
up indicator
between 10 22
and with increase
of s peed
the range
becomes larger valve
springs
4
When
above
dition exists
will
3
10
con
mains
indicator
swing to 0
engine is reaced
in
When
8
if
are
indicator
still
15 in
cause
timing
weak
re
between
it
either
is
valve
is retarded or
valve clearances
not correct
45
be
are
DATSUN
11
tles
14
between
ignition timing
in
14
set
indicator
When
indicator
When
lates
17
5
is
regularly
19
in
clamping
12
slowly between 14
in
it
is
When
15
When indicator moves
rises
16
row
or
are
first
bigh
and then
re
muffler
clogged
is
too nar
Faulty
gasket
drops down
turns to 16 in
either electrode gaps
of plugs
of
cylinder
indicator
to zero
because
is
there
at
leakage
head gasket
retarded
oscil
between
breaker point
is defective
13
When indicator
5
in
there
is
to
or
points
leakage
intake manifold
gasket
Faulty
Whenindicator
16
below
moves
slowly between
at
17
in
13
carburetor is
poorly adjusted
or
of carburetor
clamping
of
gas ket
Fig
3
Diagnosing Engine
bv Means
Sparking
B
g
o
c
Plugs
not
Gauge
at terminals
Timing
incorrect
Short in circuit
Ignition coil
spark
No sparking
at terminals
or
condenser defective
Contact point dirty
Breaker
defective
Point contact poor
Breaker
arm
insulation defective
Rotor shorted
1
c
No
6D
c
gasoline
in tank
Strainer defective
Pipe clogged
Float valve sticking
No
gasoline
poor
Wiring incorrect
Plugs dirty
do
Q
Vacuum
Battery discharged or connections
Timing poorly adjusted
Air being sucked in
Plug sparking weak
Plug spark
5
of a
in carburetor
No air
can
enter tank
Fuel pump not operating
46
ENGINE
No
trouble
Air
Carburetor
Plugs
spark
gasoline supply stopped
free of
good
a
a
o
or
Engine seized
Lubrication insufficient
carbureto
Compression
gasoline
defective
Jet
r
being sucked in
or pipe clogged
Float sunk
Float in high poSition
t
will not descend
Carburetor attachment not
secure
ring or valve sticky
Piston or connecting rod broken
Valve seating poor
Piston
l
r
Compression
E
poor
Breaker
No
ing from
foe
o
Plugs do
not spark
arm
spring defective
Contact point poor
Rotor shorted
spark
Ignition coil or condenser defective
Breaker
coil line
arm
Distributor wet
good
Cap insulation defective
5
Cord shorted
S parki ng form COI 11 me
A
Trouble
or
connection poor
Wiring shorted or cut
PIugs dlrty or broIre n
Shooting
Chart
Compression weak
Valve clearance incorrect
Valve spring weak
Valve deformed
Muffler clogged
Continuous lack
Valve timing incorrect
Ignition retarded too much
of power
Carburetor adjustment poor
Gasoline supplied insufficiently
Power weak
Carbon deposits excessive
Gasoline of poor
Intermittent
lack of power
Engine operation
defective during
renning
t
grade
Carburetor defective
Valves sticking
Pre ignition
Engine gives off abnormal noise
f
Overheating
Bearing
worn
Plugs dirty
MIS fIrIng
Sparking
Breaker point defective
irregular
Intermittent shorting
Mixture too rich
Sparking normal
Insufficient gasoline
Water in
Nozzle
B
Trouble
47
Shooting
gasoline
clogged
Chart
supply
to carburetor
r
DATSUN
CLUTCH
GENERAL DATA
DISASSEBLY
LEVER
Single
Type
Construction of disc
Outer dia
Inner dia
dis
ry
With coil
of facing
Clutch
i
pl
OF
CLUTCH
SIDFT
Housing
spring
200 mm
of facing
130
Thickness of facing
3
Gross friction area
5
86
when
7
9
mm
cm2
363
Thickness of disc ass y
mm
1 mm
releasing
3
8
1 mm
when depressing
Disc run out
Less than 0
Backlash at splines part
o
05
0
0 002
Operating method
Inner dia
0
5 mm
15
mm
006 in
Oil pressure
of master
15 85 mm
5 8 in
of operating
19 05 mm
3
cylinder
Inner dia
cylinder
Operating liquid
Fig
4 in
Genuine super
brake oil
Return
spring with
3
16 mm
drawal wire dia
Free length
Length
87 mm
in used
1
tension
136
5
rmn
j
d
r
J
kg
t
I
PRESSURE SPRING
Free
X
length
49
ompreBsed length
urn
mmct
1
7 8
of comp
in full
About 300 kg
ire diameter
ength
c
Less than 25 mm
numbers
ower
L
5
Fig
2
Fig
3
33 mm
in used and load
29 2 37
t2
5
kg
RELEASE BEARING
Construction
Ball
Height of release plate
From
bearing type
flywheel face
to rear end of
elease plate
run
out
height
use
master
mm
Less than 0 03
0
If
plate
10 2
5
50
disc
7
height of release lever
8 mm
is 50
0012 in
I
05
t0 2
5
rom
mm
48
CLUTCH
Driver Plate
attached to
indirectly
is
number
disc
a
the power and the over run
transmi ts
of
coil
To
held
springs
in
through
Two friction
a
are
access
to
the
clutch
time
by diagonal
pressing
riveted to the disc
the
Assembly
The
cover
Finally
and
a
six pressure
Mounted
the
are
the flywheel
plate
plate
are
Interference with this
set
on
unless
setting
will
parts have to be fitted
pressure plate out causing judder
three
assembly
correctly
new
the pressure
turn at
and lift
completely
from
driven
levers
release
assembly
springs
on
assembly away
remove
The
assembly consists of pressed steel
cast iron pressure plate located by
a
is relived
clutch
cover
first
complete
until the spring
selection
Then remove the screws
Cover
is
it
Once the transmission unit is free
position by
a
linings
gain
necessary to remove the transmission
from the engine
which
wires
retaining
the Clutch
Removing
is the flexible type in which the splined
This
hub
Assembly
throw
the
release levers
Adjusting
nuts
are
screwed
on
the bolts of
Retainers of pressure
pressure
plate
insert to
the clutch
spring
holes and anti rattle
cover
springB load release levers
By using
Release
The
Bearing
release
bearing
consists
of
a
quickly
a high degree
carbon
plate
the
Running Adjustment
no
clutch
is
speed brace
universal
parts to
and metal
a
to
chart
box
As thiB
indicating
the
be used for particular types
the box
clutch pedal
IF
0
adjusted
of accuracy
of clutch will be found on the inside of the lid of
hydraulic design of the clutch
adjustment is necessary to the
o
be
can
comprises the following parts base
pillar spacing washers distance
hight finger actuating mechaniBm Bet
particular
the
Fig
the
centre
pieces
tool
controls
tool
The tool
cup
screws
to
service
dismantled reassembled and
the
bearing shrunk into a bearing cup
bearing located by the operating fork and
release bearing retainer spring
Owing
Gauging
Dismantling Assembling
0
4
Fig
49
5
r
DAmUN
Ey
Clutch
bolt
caver
Pin with drawa 1
Preuure spring
etalner
Sleeve
bearing
Clutch
release
bearing
cav
i
Nut lock
Dutch disc
Cover
Pressure
@
F
assembly part
assembly Part
No
30100 10600
No
30209 10600
Tnmnicm
bush red
spring
S37kg
I
I
Lock washer
Bolt
Fig
6
Clutch
Dismantling
Place the clutch
spring
with the
screws
on
the three
time
by diagonal
cover
coincide
firmly
attached to the base plate at all possible
tapped holes in the plate insert the set
prOVided and tighten them a little at a
pointB
so
cover
aBsembly
that the holes In the
This
reBults
are
Mark
IB
selection until the
mOBt
parts
the
can
position
In
is
important if the best
to be achieved
cover
release leverB with
CD
cover
be
plate lugs and
punch so that the
pressure
a
centre
reassembled
in their
order to maintain the
relative
balance
of
the clutch
Detach the release lever plate from the eye
and remove the three lock nuts
and
bolts
adjusting
nutB
@
r
f
e
I
0
or
L
r
r
o
N
o
50
l
b
OLUTOH
@
@
8
e
fa
j
@
M
@
I
Fig
7
Disassembling
5
r
DATSUN
Slowly
release the pressure
on
selection
unscrewing by diagonal
screws
securing the coyer
The
clutch
can
then
to
the springs
the
Place the pressure
set
with
the base plate
be lifted to expose
all
The
release levers
wear
man
sprin
should
c
Renew these
down the
parts if necessary bearing in mind that the
springs must only be renewed in sets
Clean
all parts and lubricate the
bearing
special
the
pressure
sparingly
G
qB
nfn
on
poSition
preBsure
on
the
spring
Cover and set the clutch cover
sprlngB
screwing
plate by using fhe
placed through each hole In
sBure
pr
omp
Bsthe
El
cover
to the base
set screw
cove r
screw
a
little
at
a
time
by
diagonal
Belection to prevent distortion to the
cover
Set the release lever
with lock nuts
s1mm
the
the base plate
the base plate
Tighten the
with grease
put
on
in
springs
and
plate
assembly
and diatorsion
surfaces of the levers
pressure
retainers on it
components for inspection
examined for
the
pressure
plate
pressure
on
the eye bolt
inserting for lug at the edge of
plate
7j8mm
E
CD
Fig
8
Assembling
Press the pin into the eye bolt hole through
the lug on the pressure plate as shown
I
Fig
9
52
@
O
U OH
I
@
@
@
@
@
Fig
10
53
r
DATSUN
Gauging
Refitting
Screw the nuts into the boltB and proceed
Screw the centre
follows
Place the driven plate
as
into the
when roted
contact the
just
heighest point
flywheel
with
longer chamfered splined end of the driven
plate hub towards the transmission
The driven plate Bhould be centralished by a
dummy drive shaft which fits the spi ined bore of
or
bolt nuts until the height finger
the
unscrewing
the
on
the
base
pillar
plate and slip the distance piece over the pillar
followed by the camshaped height finger
Adjust
the height or the release levers by screwing
the Clutch
the driven plate hub and the pilot bearing of the
flywheel
on
the tip of the release leverB
Replace the height finger and pillar by the
clutch actuating mechanism S e insert Fig 5
and actuate the clutch several times by operating
the handle
This
will enable
their knife
the
partB
to settle down on
edges
Replace the height finger and distance piece
and readjust the height of the release levers
checked
for
possible
as
out
run
if the
press over the
as
error
near
the
edge
is more than 0
high spots until
as
02 in
it is true within
It is important to keep friction
figure
facings free from oil or grease
Finally repeat the procedure to make quite
this
the release levers
sure
and gauge again
the release lever
Release
clutch
assembly
a new
available
seating properly
and
setscrews
remove
Fig
the
The
complete clutch driven plate is
new
driven plate in
linings may be fitted
the following manner
to
one
rivets
new
should not be punched out
facing
the old
tool is not available
use
a
on
shaft
bluntended center
over
the heads
fitting the first facing
be mounted
checked
possible
press
figure
on a
for
already
out
be
at a time
by
dowels in the
after
these
4
84
screws
kg
flywheel to
a dummy
fully tightened
Remove
cover
are
m
The weight avoid strain
on
the drive shaft
assembly
formed in
The plate should then
as
near
the
edge
Description
as
The
of Clutch Control
clutch
is
of
operated
from
a
master
suspended pedal
cylinder by
A cylinder mounted on the clutch bell houBing
is coupled to the clutch operating shaft
means
It IB important to keep friction facings
or
turn
and diBtortion of the driven plate
high spots until it Is true within thiB
free from oil
now
Refit the release bearing and transmission
case
if the wabbing is more than 0 02 in
over
two
are
mandrel between centers and
run
can
of the holding
selection
35 Ibs ft
the opposite side of the plate with the
clear holes
a
flywheel by
tightening them
locate in the clutch
Rivet
sembly
screws
There
punch to roll the rivet shanks securely against
the plate
The second facing should then be
riveted
cover
means
diagonal
then if the correct
positiOn
in
clutch
secured to the
not
Each rivet Bhould be removed by using drill
The
11
from the base plate
the Driven Plate
Refacing
If
the
are
Secure the lock nuts and fix
grease
54
a
CLUTCH
Pull back the rubber boot and remove the stopper
ring with
pair of long nosed pliers
a
rod and ring can then be removed
the release pin
When
The
12
Components of
Cylinder
can be separated by lifting the
edge over the shouldered end of the
Depress the piston return spring
assembly
the valve
of the
the tension
the Bpring
Examine
Push rod
Master
assembly
cylinder
rubber boots
@ Stopper ring
@ Piston secondary
cup
cylinder
@ Secondary cup
@ Primary cup
Z Master cylinder
@
Let in valve release
mended
brake
pin
Ring
into the
bore
Return
spring
spring se at
Piston return
in valve
assembly
body
fluid in the
moves
the
of the
lips
Gasket
Replace
the
Filler cap gasket
cup
Cap
stopper
End plug gasket
machined In the
End plug
into
ring
ring
Replace
meanB
the
pipe line in turn
cylinder pushing against
The
body
with cap
push
a
push rod
the
with the
which
engages
boot and
of the two bolts on the
cylinder
is
cylinder
of
consists
bore
assembly
of
an
The
alloy
and reservoir
cylinder
starting
is
mounted
motor
is made up of the
ring
boot
the Clutch Master
Disconnect the pressure
cylinder
the
and
master
remove
cylinder
complete from
the
groove
secure
the unit
flange and refit
cylinder
simple
piston
seat
Dismantling
by
the
into
cylinder body
the rubber
stopper ring
piston
cups
spring valve and valve spring
The end of cylinder is protected by a rubber
spring
secondary
followed
cylinder
spring and bleed screw
cylinder being protected by
polished finish
The inner
rod
easing
Operating Cylinder
This
Cylinder
master
with
end first
cylinder
recom
assembly
in the bore
consisting of the body
The
insert the
the pressure pipe union into the
pedal is applied
cylinder displaces the
the lever of the clutch shaft
The Master
well with the
and
and via a
cylinder
piston of
fluid
the piston cups
by
piston of the master
gasket
for wear or
piston cups
replace the new parts where
Smear the assembly
y
When pressure to the clutch
the
the
Assembling
cyl
ass
especially
parts
necessary
spring
Clutch master
@
@
@
@
@I
@
piston
@Let
@
@
@
@
spring
through the
releasing
seat thus
and
and
Let in valve
inder
ring
all
bore
distortion
1
@
on
to slide
assembly
elongated hole
the Master
exposed
Beat
allowing
Fig
will be
the piston assembly complete
remove
spring
piston
attached
caps
unscrew
rod has been removed the
the push
with
piston
The push
and
pipe
Cylinder
union from the
the securing bolts
and
may
o
then
be withdrawn
the car
Fig
Remove the filler cap and drain out the fluid
55
13
the
a
construction
piston
with cup
open end
rubber dust
under
side
of the
cover
of
the
r
DATSUN
Dismantling
Remove the rubber dust cap from the bleed
attach
screw
a
bleed tube
three quarters
of
a
stem
and pump
cover
turn
the clutch
Bure
clean container
Unscrew
adjustable push
can
now
cover
be
and mount the
the
boot
the
flexible
The
rod
removed
well with the recommended fluid
and insert into the cylinder
the fluid has been drained into a
pedal until all
smear
open the bleed screw
union
pipe
and
in the
the
and if compressed air line is available
position making
enterB the hole in the ruhber
pipe union
and
Adjust
the pUBh rod hy
driver at top of withdrawal level with
the screw
rubber
in
Secure the cylinder with the bolt
Bcrew
operating cylinder
Removed the
puBh rod
Replace the dust
cylinder
rod of operating
adjustable
play 2
the end
5
3
cylinder
to
give
0 mm
blowout the piston from the side union
Examine all
replace if
especially
damaged
parts
worn or
the seal
and
the Clutch
Bleading
System
J
Fig
14
16
Fig
Assembling
Remove
Place the seal into the stem of the piston
with the back of the Beal against the piston
operating
replace the springs with the
a
small end
on
the bleed
dust
Bcrew
open
cylinder
approximately three quaterB
the
of
at
cap
bleed
a turn
the
screw
and attach
immersing the open end into a clean
receptacle containing a Bmall amount of brake
the
tube
fluid
Fill the master
cylinder reservoir
by using slow
with
the recommended fluid and
I
Btrokes
I
pump
entering the
II
v
On
a
bleed
down
full
the clutch pedal until the fluid
container is free from air bubbles
stroke
screw
of the pedal
remove
screw
up the
the bleed tube and replace
the dust cap
When
the clutch
pedal
depressed
is
force is transmitted to the ball
p
surface
i
a
o
stroke
i1
pushed
in
stroke
disengages
shorness
Fig
15
with the
56
release
of the pedal is
surplus
c
the
bearing
mm
mm
Effectual
plate
leaving
until
the
30
shim
readjust
the
pedal
mm
clutch
When there is undue Burplus
Instroke
adjust
95
128
the
and the
or
position
o
ob
ntkg places
2
0
32 0
ces
place46485
3QO O 0410
46482 46460
v
S
3
pl
2
10602
46520
0870
46123
4
1
tOrque
Tightenig
2
1
J
Vlc
t
Pe
stOP
pad
Brake
uteh
up
Cl
lock
with
lon
pedal
dimeuS
adjustmen
sa1d
pl
places
0870
1
the
the
1
465W
345
U
9
stroke stroke
pedal pedal
Clutch Brake
lb
9
30614 304
4
18
14 14
t7
145
1
28
kl
to
5
15215 1 145 h2
9 9
h
plateslower
ting
2
3
eacn up er
dl
r
uu
t
side
6t
height
ed
1
l
U
k
St
a
1
3
05mIl
v
kg kg
58
45
16
3
15 17
m1ll
nun
143
120
foot fun
Y
bl
OL
sUlt
end
iert
ke
trC
l
1
strOKe
at
level
1y
iu
uU
oke
sb
strength
pedal stroKe pedal pedal pedalBu uM
t
e
n
c
e
pedal
27260 rele
tull
full
Ilt
h
d
r
a
w
l
e
v
r
C
l
u
t
c
h
46182760 Clutch Withdrawl Clutch presing
0
prdS1ng
e
the
I
8t 5t
hy
strokee1lcestopendl top Ces pushedped3for1 n stroke
of
0
27260
ndQtd
461 7 461 9
ped
M4
95
32
mtn
kt
ntm
ntm
kg
place place
at
25 32
2
pl
contaced pedal
GJ
1
2
ce
arm
the
ce
j
point
stop er lodung nut tandhe
height Adjust Stop er After end
without
The
of
0410
4648
of
mark
the
the
t
Wi
For
e
Brake
kg
60
DATSUN
56
2
TRANSMISSION
TRANSMISSION
i
Fig
Model
3
stage for forward
for
f
1
1
stage
reverse
4
stage for forward
mesh
on
for
speed
Remote control
Full
synchromesh
on
forward
gears
t
Type of
ge ar
Synchro
meshed helical gear
2nd
3rd
4th gear
type
Ratio
1
3
197
3
94
Ratio
2
1
725
2
40
Ratio
3
1 000
Ratio
4
ReverBe
1 49
4 125
57
1
00
5
159
synchro
r
DATSUN
COVER
CASE
OF
TRANSMISSION
Drain out the gear oil from the
ing
case
the cover in position are 14 set
which must be removed when
nuts
cover can
DlSASSEBL Y
Hold
Front
all of
be taken
COURSE
Bearing Retainer
Release the front
off
within the clutch
Fig
1
bearing retainer situated
housing by removing the nuts
1
Fig
I
i
u
Ii
iV
p
j
1
i
f
Fig
Fig
3
2
View
Bottom Cover
of Inside of
Transmission
58
Fig
2
Fig
3
TRANSMISSION
TRANSMISSION
CASE
CROSS SHAFT
IL SEAL
GJ G l1
I
r
101
3
n
Q
1
1
1
1
Fig
Fig
4
Plug
1
Cross Shaft
PLUG CROSS SHAFT
Fig
Fig
5
2
fIIIIIIM
1
SPRING CHACK BALL
PLUG INTER LOOK HOLE
Fig
CRACK BALL
Fig
6
59
3
DATSUN
j
o
1
n
i
J
I
Ii
1
C
j
Ii
I
l
I
o
ul
1
co
f
C
f
c
f
c
L
tS
G
8
7
t
I
it
1
b
4
k
I
i
Fig
f
D
i
i
I
1
r
Press out the
Fig
6
Fig
7
pin from fork shaft
Disassembly Insert the pin and
tap into the shaft and hole fork
hole
setting
Take out the cross shaft from the
case
F
6
j
J
r
1
Q
n
II
I
1
0
J
I
1
3
I
rf
CO
S
I
H
I
t
I
I
L
I
j
4
III
I
I
iI
H
ii
j
ot
Ii
i
J
Ii
1
N
il
I
d
U
c
Fig
5
Fig
60
8 Take
off the
Pin
Nut
of
Cross
Shaft
TRANSMISSION
Fig
Fork
9
Pull out the Cross
Shaft
Fig
12
Shaft
1V
LF
R
O
llh
1
111
I
t
i
O
lO
O
i
J
I
II
J
J
I
0
0
I
1
I
r4
I
1
h
I
1
J
I
1
r
u
Fig
10
Fig
11
Fig
13
Fig
61
zt
Detach the Fork
14
from
Take out the Fork
I
the Gear
Shaft
r
DATSUN
front
and
small one
cluster gears in the
Fig
Fig
15
Pull out the
place
the
Assembly Course
Shaft
J
I
I
Counter Shaft
17
at the rear then
case
Gear
J
I
J
t
1
u
I
bc
j
s
ja
I
f
1
I
J
v
I
j
r
J
c
0
3
D
THFW
r
9
T
FRON
ER
r
Fig
it
j
r
M
Ii
3IfI
E
J
c
Fig
iJ
18 Disassemblv Course
I
o
16
Disassembly
Using
a
soft and
long
metal drift
out the counter shaft forward
pushing
When the counter
gear cluster and two thrust washer will
the
drop in
case
Assembling
First locate the two washers to the counter
gearB
ensuring that the larger washer
is at the
Fig
62
19
TRANSMISSION
Main Shaft
Pull out the
sleeve by the
rear
Fig
bearing and the speed gear
bearing puller from the main shaft
rear
side
20
Fig
23
of Main Shaft
Assembly
Removal
I
trmIC
lJ
I
l
J
Fig
21
Pull Out the Reverse Gear
8
Shaft
I
ffJ
C
E
0
t
Main Drive Shaft
4
I
1
r
Fig
24
Take olll the Main Drive
Gear
Fig
22
63
0
DATSUN
Caver fcoat
tnmmhl10ll
Glldu tfront
covel
o
fi1
ft
Oil
Aa y breather
l
G
Plug
IlIion
d
PlugCI
OQ
ri
go
AD y enelJlilXl
Caver
botoom
An y
d
Fig
25
x bottom
fi
rear
cover
plug
Transmission Case
Rear Extension
5
AI
Aa y
pinion
speedomete
Y
hev
speedometer
OD
in
Sleeve
Gear 3 rd
coupling
Per
tfvun
Spring
for peg
speed
Piece
6
washer
din
i
CeardrivinS
eedometer
Gear
reverst
mailld1aft
I
r
w
counter
1
mg
Gm count
ring
It
Washer
ft
An y gear
n
erseidler
I
Bushing
1
Walber lock
0
Jd
fix
revent
fevet1 t
gUf
shaft
Scre
Fig
26
Components of
64
duwt
CCIWlter
C
frOUt
Sbaft
pee
Transmission Gear
TRANSMISSION
Reverse Gear
A
lug which iB an integral part of the main
casting locateB the forward end of the reverse
To Becure the Bhaft in pOBition a
gear Bhaft
set pin is screwed through the lug locating in the
rl
The Bet key is locked out side of the
shaft
F
case
Release the set pin
f
then tap forward and
remove
the reverBe gear
reverse
gear
shaft
Lift out the
If
seal is
oil
ThiB
bearing
rear
and
should
not
dismantled unleBs suspected of leaking
almoBt impossible
damage
it
fitted if the old
This
to take
consequently
can
1
1
be
i
li
I
J
L
It is
Q
off the seal without
a new
J
R2
C
situated in the end of the
retainer
l
Ilr
r
I
Rear Oil Seal
I
I
r
oil seal should be
has been removed
one
removed
by uBing
a
punch
and
hammer
Main Shaft
Counter cluster gear in the
Insert the
case
Fig
first gear to the main shaft together with second
and third gear assembly from rear hole and fit
the first and
reverse
fork shifter
over
2
Detatchment
of
the first
gear
Fit the
shift fork of the second and third
assembly on the hub of synchronizer
DepreBs the main shaft bearing to the end of
gears
the
case
Change the dummy shaft
the
B
to counter gear with
aid shaft
EXTENSION OF
TRANSMISSION
CASE
r
r
r
5
oJ
l
Fig
II I
0
Fig
1
c
1
0
Speedometer
L
1
Pinion Gear
65
3
Rear Extension
r
QATSUN
Fig
4
Fig
1ever
5
change
2nd
1
3
to
cha
Fork 2nd
3rd
Fork
Roo frok
1st
10
Rod fork
2nd
reverse
1
3
I
Lever change
1st
PI
Pin
6
NU
Was
DDg
r
Pm
loC k
operatmg
lever to
maft
Lever
operating
D
Washer lock
Nut
I
tJ
6
Transmission Fork
66
reverse
Spring checking
1G
Jm
ta
r
Fig
at
checking
inter lock
Ball
Leve
ClOSS
Ball
Spring
Rod
2pd
Shaft
ball
fix
ver
TRANSMISSION
i
I
e
I
0
n
01
trf
0
T
CD
IJ
ell
Fig
u@
7
Components of
Transmission
WaSher lock
Bolt location
upper support
bracket
co
J
S
Pin
pivot
control lever
Fig
8 Remote Control
6
e
DATSUN
o
o
11
o
e
MAIN SHAFT
Fig
9
Assembling
order
through
Disassembly
Fig
10
Main
11
Shaft
of Main Shaft
Front Side
Shaft ComPlete Assembly
Disassembling
Fig
the Main
Taking
1
Course
out
by
the
Sliap Ring
Plier
Fig
68
13
TRANSMISSION
Disassembly
of Main Shafti
Fig
Fig
14
Fig
Main
Shaft Bearing
Fig
18
Fig
Tapping
out
Retainer
69
Take out
16
the
Spacer
@
3
@
17 Press out the
Fig
15
19
Fig
20
S
l
setnb
ing
k tUng
the Bau
Qoo
nO
Fig
21
w
Fig
j
22
Fig
Fig
23
10
24
TRANSMISSION
I
Fig
25
Fig
29
Fig
26
Fig
30
Fig
Fig
27
I
Jo
Fig
31
Jli
f
Fig
28
1
32
Oil Seal F Ollt COlier
r
DATSlffl
Insulator
rod
gearshift
Ass y lever
2nd
3M
Truman gear
shift rod
change speed
Washer
asher
W
r
Pin
cotter
J
i
j
Nut
Tn
spechtl
Wa
e@
@
S
Washer
plain
Washer
plain 2 Ot
1 6t
I
we
t
f
lone
cJD
a
il
n
l
t
Bolt
rOd
lock
Wa h
tf
Ass y bracket
supPort
low er
Seat
Retainer
Ch nge
change speed
lever upper
Clamp
lower
support bracket
syeed
lever
Rod shift
Fig
DISASSEMBLE
33
Remote Control
the
cap
lever
the
on
with
a
slight
These
casing
Removal of Shift Rod
detaching
cover
To
Shift Fork
from the transmission
lug which is an integral part of
casing locates the forward end of the
To
Straighten
screw
can
be
only
respective gears
remove
lifted from
the
and drive shafts together
the needle
have been removed
roller bearing within
a
suitable
piece of metal tubing
Main Shaft
A
screw
gears
when the main
bearing with
Reverse Gear
setting
when the counter
the counter gear cluster itis necessary to break
the retaining circlips before driving out the
by
six bolts
gear shaft
drive out the counter
case
gear cluster and two thrust washers will drop to
the bottom of the case
lower portion of the
counterclockwise
Gear
Using soft metal drift
with their
the
Handle
Left
shaft forward and out of
downward pressure
Remove
For
gear
Counter Shaft
of Control Lever
Twist
control
Linkage
reverse
THE
TRANSMISSION CASE
For 4 Stage Floor Shift
Removal
1st
secure
is locked
the main
the shaft in position
by
the tab washer
a
The main
from
a
tab washer
can
now
be withdrawn from
To remove the gears
the main shaft first slide off the third and
forth
speed synchronizer assembly then with a
piece of wire inserted through the hole in the
release the setting
then tap forward and remove the
Set out the reverse gear
shaft
the transmission casing
reverse
reverse
cone
deprese the small spring loaded
plunger which locates the splined washer at the
gear
gear shaft
72
TRANSMISSION
forward
end
shaft
main
of the
The
be
now
pulled
the steel
As the
clear of the main shaft
sleeves and their
tight fit
immersed in
sleeves
the
Oil the
and
should
First
counter
is
the
release the
shaft
unscrew
speedometer
o
inserting
screw
and
and
washer
gears
between 0
thicker
end play for the cluster
04 mm and 0
12 mm
and remedy
0046
or
to the
thrust washers
if necessary
thinner rear washer
0
0015
by fitting
a
its securing nut then slide the speedo
Thickness of front thrust washer
meter wheel off the shaft
Do not lose the
piece
locating
ensuring that the larger washer
and then place the gear cluster
at the front
gears
wheel from the
tab
the
straighten
two
the
put
in the gear case
Check that there is
from the first gear unit and then slide the first
gear assembly free of the main shaft
main
the shift with
secure
Counter Shaft Gears
splined washer separating
the second speed constant mesh gear assembly
To
rear
gear shaft before
will slide off the shaft when
they
remove
reverse
into the gear case
be
expand the
the second speed gear can be removed
Take out the steel plunger and spring
Next
gear
lock washer
washer are
shaft
reverse
with the large gear to the
so
phosphor bronze
in order to
oil
warm
that
so
shaft
Refit the
can
plunger and
driving
common
the
on
bronze sleeve
phosphor
over
Reverse Gear
third
together
and second speed constant mesh gears
with their common
the
turning
into line with the splines
washer
and
key
shaft
main
the
its
separated from
been prised from
Take off the distance
bearing
after
housing
can
the
Thic knes s
Part No
be
nut has
32224
the shaft
3
26760
3
91
96T
is desired to dismantle the fourth and
If it
Thickness of
or the first speed
third speed coupling sleeve
gear these can be pressed clear of their splined
but
synchronizers
must
care
be
taken
rear
thrust washer
Thickness
Part No
to
the three balls and springs in each
Take out the main shaft front needle
assembly
roller bearings from the end of the drive gear
retrieve
shaft
oil
seal
and
rear cover
situated
is
take
off
consequently
the old
one
the
It is
seal
can
in the end of the
a new
oil
4 1T
32229 26760
4 2T
It will be
pinched
by using
the
counter
shaft
with
a
thin
impossible
damaging
It
Drive Gear Shaft
The
seen
ball
journal
into
drifted on to the shaft
a
from
position
punch and
the
geared
end
bearing should
now
be
with its spring ring away
Position the geared end
dummy 3rd and 4th speed
coupling sleeve put the washer over the bearing
tighten the nut and lock it in position
of the drive shaft in
hammer
Assembling
sleeves
are
the 3rd and 4th
each p aired with
a
Smear grease in the end of the shaft where
the main shaft locates
then load the needle
the Transmission
The 2nd speed gear
coupling
32228 26760
shaft gears
seal should be fitted if
has been moved
be removed
almost
without
that the oil seal housing is
This
32227 26760
temporary rod which will permit the gear cluster
to remain out of mesh with the main and drive
should not be dismantled unless
suspected of leaking
to
3 9T
40T
Replace
Rear Oil Seal
This
32226 26760
rollers
speed
so
that they adhere in pOSition
by
means
of the grease
Turn the gear casing to ensure
the
counter
teeth are below the drive shaft
that
their
respective synchronizers
Only mated pairs of
these parts should therefore fitted
bearing housing
3
DATSUN
the counter
both
gear
and
drive shaft
bronze
drive
position from
can
the clutch
that
Ensure
properly
shaft
the
now
be
drifted
housing end
spring ring
into
is
tight
a
on
warm
th
main
shaft
on
oil and then slid into position
bearing
Place
to the shaft from the
main
Lightly
assembly
and
with
refit the
the
first
speed
synchronizer
with a
the hole in the third speed
washer over the
oil the shaft forward of
position the third gear
spring and plunger into the hole in
shaft and sUde the spUned washer
Depress the plunger
bearing
Now
the
the
the
the
its sleeve
over
The bearing must be pressed firmly against
the shoulder of the center splined portion of the
smear
over
then the
rear
shaft
the second speed
Fit second speed wheel
the driving washer
complete with housing
shaft
driving washer and the second
bronze sleeve which carries the third speed
wheel
The two sleeves are locked together by
sleeve
Main Shaft
center
the
The phosphor
there it must be first
fit on the shaft
the shaft
to
on
baulking ring
sleeve which carries
immersed in
resisters
in the rece on the gear case
Press
thrus t washer
followed by the
geared
ends
The
the
Refit
Failure to do this will result in damage to
plunger
wire
through
and the slide
spUned
piece of
Then turn the washer
for the plunger to engage with
wheel
a
groove in the
washer
pointing
The
forward
shaft
4
gear
are
now
assembled
on
the
main
TRANSMISSION
l
1
22
1
7
25
t
fl
16
11
5
lO
2i 2i
f1 fIT
13
Case
transmission
Ass y
extension
rear
@
Stud
@
Washer lock
@
Nut
@
Bolt
@
Bushing
@
Seal
@
Bushing speedometer pinion
@
Bolt
@
Ass y breather
@
Wa8her
Gasket
@
Nut
oil
rear
extension
rear
rear
extension
extension
lock
to fix transmission case
Washer
lock
@
Washer
plain
@
Bolt
@
Ass y sleeve
@
Bolt rubber
@
Ring
Bracket spring return
@
Retainer
@
Ring
@
Plug speedometer pinion
to fix rear extension
return
@Ass
y
stick
@Ass
y
plug
@Cover
@Gasket
front
front
oil level
dip
pinion
speedometer 18T
Ass y
pinion
speedometer 15T
O ring
Oft
pinion sleeve
Washer lock
transmission case
@
Gasket
@
Bolt
@
Washer
Transmission Case
5
4
speedometer pinion
speedometer pinion
Screw set
drain
cover
Ass y
0
s
to fix front cover
@
Spring
ff
8910
26
CD
b
cover
lock
Speed
1
to fIx reverse shaft
transmission case
DATSUN
28
t
29
14
15
9
8
Ass y cover
Ass y
cover
transmission
transmission
Cover transmission
Ring
O shift rod
Pin control lever
@
@
@
Rod fork
Fork 1st
@
@
@
@
@
@
t3
@
2nd speed
Fork
2nd
1st
Bracket rod
Rod fork
pivot
2nd speed
1st
reverse
reverse
Bracket rod
Pin fork
reverse
reverse
Boot control lever
Pin cotter
Spring pin
Rod fork
reverse
3rd
Fork 3rd
fork
4th speed
4th speed
Bracket rod
3rd
4th
speed
Ball checking
@
@ Wire lock
checking
Ball
@
Spring
poppet shift rod
@
Pin
interlock
@
@ Ball interlock
@ Plug weld
@ Plug weld
@ Plate dust
@ Washer lock
@ Bolt
@ Plug
@ Ass y Iever control
@
@
@
@
@
Knob
control lever
Spring
Cap
Boot
lever
cover
rubber
Seat lever spring
Spring poppet pin
Screw stop
Screw set
Nut
6
reverse
plain
Rod 4
Transmission Fork
control
transmission
SpeedJ
fork
case
TRANSMISSION
16
13 12
34
3S
L
38
IS
d
1c
JL
33373639 0
l
S
ll
CD
@
Ass y
Bushing
Shaft
reverse
reverse
Screw set
@
@
@
@
@
@
@
@
@
reverse
gear
gear
gear
reverse
gear
Washer lock
8
@
@
Gear counter
Shaft counter
Roller needle
Counter shaft spacer
@
@
@I
@
@
@
@
@
@
@
@
Ring retainer
Washer thrust
needle roller
counter front
9T
Washer thrust
counter rear 3
Washer thrust
counter
rear
4
Washer thrust
counter
rear
4
1T
Washer thrust
counter
rear
4
2T
@
@J
@
@
@
@
@
@
@
@
@
@
@
@
@
OT
Gear main drive
main drive gear
Bearing
Spacer bearing 1 6T
Ring snap main drive
gear
1
Ring
Ring
snap
main drive gear
1
65T
snap
main drive gear
1
74T
Ring
snap
main drive gear
1
77T
Shaft
Hub
6T
main
synchronizer
Spring synchronizer
Ball
synchronizer
l
I
hub
hub
Transmission Gear 4
Gear main shaft
Ring
2nd speed
main shaft rear
Gear 2nd
speed
Bushing 2nd speed
gear
main shaft
Washer thrust
Bushing 3rd speed gear
Gear 3rd speed
Washer thrust
main shaft front
3
Washer thrust
main shaft front
4 OT
Washer thrust
main shaft front
4
Peg locking
Spring locking peg
Hub synchro
3rd
Ring baulk 3rd
Sleeve
synchro
Bearing
Ass y
4th speed
4th
speed
3rd
4th speed
main shaft
retainer
main shaft
bearing
Peg locking
Gear drive
Gear drive
Piece
speedometer 5T
speedometer 4T
distance
main shaft
Key woodruff
Washer lock
Nut main shaft
Bearing main shaft pilot
Speed for
n
baulk
Washer thrust
1200 cc
Engine
9T
1T
ii
with
seal
mficently
oil
control
lever 08 0
32841
Ass
of
lip
the
on
4T
spedomtr 0720
greas
drive
l
NCS
O
0
Gear 32701
y
Smear
32 64 267 0
mm No
12
26761
C
0
smal 26761
3posible 2647
9
as
part
the
by
Dime on
play
End
Adjurt
B
cc
Dimenso Selct
26762
32 64 32 64
120
by
play s
end No
6
Engine
6
part
by
No
Adjust Part
play
for
26761
lit le 26762 32 64
water 32 64
end
6
l
Transmio
NCS
A
gre
Pack
0
2
No
here
As by Pa
tight
Dimenso pOSlibe
the
m
as
the
and
before
aplay djuster spring
5
1
rod
return
Adjust Bearing push fit ing
by
em
I
grease 3010
brake 4 0 3
the
No
Smear Part
J ex
kg
280
240
T
TRANSMISSION
Transmission
4 forward
i
type
Ii
Fig
1
Fig
2
3
Rear extension
Gear ratio
New
Floor shift
Former
rod
setting through
extension is set in rear extension
1
1
3 657
3
2
2
177
2 402
3
1
419
1
490
4
1
000
1
000
Rev
3
638
5
159
Transmission
The
cover
bottom of
945
case
of transmission is attached to the
case
Fig
4
oo
ro 0
QO
Fig
Fig
2
9
5
the
rear
DATSUN
3
Reverse
It is
4
lamp switch
placed
Speedometer pinion
sleeve
at the side of rear extension and
directly operated
reverse
shift fork
Fig
LAMP
Fig
SW
7
TCH
6
@
80
Revene
Lamp
Switch
TRANSMISSION
81
DATSUN
SECTIONAL
OF
VIEWS
TRANSMISSION
I
I
SECTION C
SECTION
C
B
SECTION A
B
A
IE
3F
T
2
I
IAkg
m
T
A
B
9
11 kg
m
C
i
J DIMENSION
SELECT AND ADJUST THE END PLAY OF
REVERSE GEAR IDLER SO AS TO FIT
J
0 05
0 15
H DIMENSION
ADJUST THE
mm
END PLAY OF COUNTER GEAR
SO AS TO FIT 0 05
352
32225 14600
665
HZ
2 3
BY PART No 32285 14600 1
1 2 3 4
0
15 mm BY PART No
4
TRANSMISSION
II
o
i
F
SEer ON
1ST
2ND
N
45
17lo
IllS
REV
D
4
T
27 37 kg
m
GEAR RATIO
7
1ST
2177
2ND
9
4TH
Tol7
23 kg
m
SECTION E
83
E
D
D
S
l
A
84
CHASSIS
ASSIS
CFI
FRONT AXLE
Fig
1
85
r
DATSUN
NUT
lock
10
e
NUT
o
UTj
ASHER
JSpecial
rubber shock
absorber
ASHER
inner
ear
Z
o
front
PAD
rubber
ront
special o
oi
ASS Y
MEMBER
LT
BUSHING
outer
fJv
suspension
10600
466
V54
S44b7
1060
o
g
li
NUT
WASHER
@special
e
USHING
ruhber
8hock
ab SOl ber
SEA T
WASHER
specla I
hb er
ru
iront 54468
t
ear
54469
l
tfi
l
lii
10600
10600
or
outer
WASHER
front
SEA T
u
front
er
iPring
p
rea r
54464
10600
10600
front
suspension member
mounting
special
54465
outer
BUSHING
rubber
BAR
n front
stab1l1zer
tens
NUT
WAHER
o
@
special
outer
BUSHING
rubber
BUSHING
rubber
tabilizer
WASHER
pecia I
BRACKET
tabili er
llSl
WASHER
outer
I
BUSHING
rubber
BOLT
WASHER
special
lock
uutter
BO LT
C
DISASSEMBLING
THE
of the front hub
Dismantling
car until the wheel is
clear
OD connecting
front stabilizer
EAT lower
front spring
Suspension
2 Front
Fig
Remove
FRONT HUB
and
first jack the
appears to bind
adjusters
Lever
on
screw
the brake shoes
out
bearing
clear of the hub
seal
then be
can
removed by inseriing the drift from the opposite
side of the hub
If the drum
When
The shoe
race
and then extract the
bearing
inner
assembling the hub the
should first be inserted into the hub
hub oil seal
over
the inner
Pack
Replace the
the hub with recommended grease
should be slackened
off the hub cap
tapping the
The inner bearing and oil
of the
Lower the car on to the blocks
the wheel and the
Shock Absorber
Member
ground and
then place blocks under independent suspension
spring plate
BUSHING
rubber
specia
WASHER lock
ClrWASHER
C
t
Inner
mountIng
WASHER
e
plain
SPACER
front
stabilizer
Renew the
bearing
split pin from the spindle nut
Using a box spanner remove the spindle nut
seal if it is damaged any way
and
Gently tap the hub into position until the inner
race bear against the shoulder on the spindle
ease
flat washer under the nut
axle thread by carefully using
small boles
in turn
and
the
The hub
clear of the
a narrow
rod into
in each side of the
be replaced
on
the
spindle
Place the spindle flat washer into position
spindle
and
With the hub
lightly
removed
outer bearing can be dismantled and
by inserting a drift through the inner bearing
tapping
can now
race
screw
wheel l
Ild
nut
86
the nut down
finger tight
examine the resistance
Spin the
Tighten the
CHASSIS
A
the
slightly increased resistance to
The
spinning of the wheel will then be noticed
bearings are now preloaded and the split pin
should be inserted to lock the nut
Tap the hub
cap to the hub after packing the cap with grease
Replace the brake drum and secure with
machine
It is
screws
is
home before this sc rews is
fully
the drum
if necessary
position by tightening
wheel and nuts
important that the drum
car
the
brake shoes
is
lowered to the
NUT
two wheel nut
if necessary before the
ground
knuckle
WASHER
front wheel
ASS V
WHEEL
Learing
Fig
Front Hub
1
0
Drum
n
NIP PL E
T
8
ASS
BUS
O
4Jt
Y
HING
in
NUT
r
Hl 04101
be
ca
SHIM
rr
154
5
NIP
1
2 0
Ul
J
04101
10
lr
Ji
11
o
2
i
3
ri
1
SS
Y
fro
JOI
T
b
lI
pp
pennon
opp
b
n
JOin
BOLT
upper
front
pe
LJl
UT
on
CLAMP
o
ASS
Y
STOPPER
bnuId
BOLT WASHER
CO
dUll
ER
up
bdl
DIll
NUT
PIN
Nlf
SS
tr
BUSHING
10
link
J
SEAL dua
lowe
hnk
buoh
aOLT
SPINDLE
I
NUT
lInke
Fig
2 Front
8
Refit the
best
pindle
runt
and
finally tightened when
off the backing blocks
but readjust
are
the
CQLLAR
tightened
should be pressed in
Suspension
Link
colte
car
is
DATSUN
INDEPENDENT
FRONT
SUSPENSION
The dependent front suspension is known
the wishbone
since the
as
Fig
type
top
bottom linkages roughly conform
to the
shape of
CD
a wishbone
are
two
wishbones
under compression
is
member
axle end
jointed by
@ Front coil spring
@ Front suspension
between the
by
four
the upper and
the ball
joints
bolts
Ai
caster
shims
and
the
lower linkages
spindle
Oil pan
@
Front
Exhaust front tube
swpension
memb
r
@
Lower link
@
@
Stabilizer
spindle
Outch
operating
cylinder
The upper spindle
the lower
CD
@
lower link
bracket is bolted to the front suspension member
with
suspension
the coil
and lower which is secured to the lower
suspension
swivel
these
held
spring
Front
upper link
Between
upper
1
upper and lower
@Speedometer cable
@Trommhsion
is
connected to the lower bracket of the suspension
Cross rod
member
Change
Adjust for
the number of Shims
0001
0029
0016
0
31
0002
0
31
1
0 04
0029
1
1
0
15
2
2
0
Zl
1
1
0
15
2
2
0
Zl
1
Caster
1
Camber only
Caster
Back side
Front side
1
Both Camber
Camber
88
CHASSIS
a
thickness of each shim
1 m m
Camber adjusting shims
Parts No
Standard adjustment
BALL
JOINTS
AXLE
BUSHES OF
54542 04100
1
mm
54543 04100
2mm
54544 04100
4mm
Camber 1
30
R
L difference within 40
Caster
30
R
L difference within 40
1
THE
SWIVEL
Wear
screw
if
the swivel ball
bushes of links
by jacking the front of
to
rock the
the
tyre
joint
both
or wear
movement
of the
may be checked
and
the car and
endeavouring
wheel by grasping opposite points of
in
Front Coil
or
a
horizontal
the ball
assembly
are
be detected between the upper
can
lower swivel
worn
and must
joints and the swivel axle
joints or the screw bushed
be stripped for examination
If any
position
Spring
UPPER
LINK
SPiNDLE
1J
PER
l
BALL
0
rOINT
CeJ
0
It
O
UPPER
t
LINK
I
a
J
o
LOWER
LOWER
Fig
Between the upper and lower links is the coil
spring
held under
secured by
nuts
compression of it
of the
lower and
LINK
I
SPINDLE
2
Through
the
center
of
coil
spring
the
shock absorber whcih is connected
which is
upper
LINK
telescorp type
to the top spring
ball
joints
seat and lower link with nuts of
the lower and upper
89
r
DATSUN
Fig
3
FRONT SUSPENSION
Fig
The rubber
may
in
time
4
bearing
bushes
deteriorate
and
or screw
need
bushes
The screwed bushes
develop
renewing
Excessive side ways movement in either of
these
bearings
robber bushes
would
or screw
denote
softening
of these
checked
of the
bushes
excess
parts
when
dismantled
90
or
the ball joints may
free
play due to wear of either
This assembly can best be
the
suspension
has
been
CHASSIS
Disassembling
Front
METHOD A
Order of
Suspension
1
1
Remove shock absorber
2
Compress the coil spring by
3
Disconnect
lower
tool
4
5
When tbe coil
too
is
fully
extended
take
out it
6
Disconnect upper link spindle from
sion member if need to inspect for
flange
Fit the
lower ball joint and rebound
bumper from lower link
Release the coil spring by loosing the nut of
spring
Unscrew nut of the shock absorber at the
top
and take out if from down side after unscrew
compressor nut
In the absence of the service tool a suitable
tool
will
be
release
required to
the
compression from the coil spring
Compressing the coil spring unscrew the 3
nuts of lower ball joint which located under
the
suspen
of it from lower link
serVice tool and screw up the spring
edge of lower link
Remove these nuts and release the
compres
sion from the coil
spring by loosing of nut
Removing the Coil Spring
too
When the
coil Spring is
fully
extended
take
out it
Fig
5
Front
Suspension
Assembly
Fig
6
Detachmellt of Shock
Absorber from Suspension
Fig
91
7
Detachment
of Shock
from Suspension
Absorber
DATSUN
E
I
I
Fig
8 Remove Shock Absorber
Fig
9
Detachment
of
Rebound
Bumper
Assembling
Tightening torque
4 04 5 kgm
A
Fig
10
Releasillg
the Nuts
92
of
Lower Ball JOillts
CHASSIS
METHOD
B
Unscrew
which is
the
four bolts of lower spindle
the suspension member
secured to
Remove these bolts and release the compression
from the coil spring
spindle
can
Refitting
When the lower link with
be driven out
the Coil
Spring
Use the coil compressor or
lower
link
member
Fig
the
to
the
bolts of the
front
suspension
the bolts of the lower
Release the compression
by loosing
jack screw down
shock absorber by the double nut
nut
compressor
Set
11
spindle
and then secure
spindle
the
jack against
Screw up the screw
lower link
up the
or
the
of upper side and the bolts of lower side
METHOD
Replacing
@
C
Order of
Upper Link
1
Prepare
2
Jack up and support front suspension lower
to remove front wheel
link
3
Remove wheel
4
Disconnect
5
ball
upper
bumper from
and
joint
rebound
upper link
Detach upper link and
spindle from suspension
member
6
Fig
12
Disassemble upper
link spindle from upper
link by unscrewing link bushings
7
Reassemble upper link spindle and bushings
to
@
link
upper
of
replacing reinforced part
carefully following
undermentioned instruc
tion
8
Reassemble
complete
9
whole
parts
back
again
to
unit
Check and
adjust
fron wheel
alignment
Instruction
1
Don t hold
screwing
in
spindle
tight against link when
Because the pitch of
bushings
threads of spindle
inner and outer screw of
bushing and link sleeve
Fig
13
93
are
all
same
r
DATSUN
2
Apply
sufficiently grease on
of bushing and spindle
screw
3
careful
Pay
attension
not
to
the
Assemble
inner
damage
to
to
4
ue
5
resistance
bushing
when assembled
Adjust
the
spindle
reiative
shown
as
so
as
lower link to the
9
5
12
5
3
m
nut
kgm
Connect with upper
link to the suspension
5 0 kg m
tightening torque 4 7
forget to insert the adjusting shims
member by
torque between spindle
should be within 0 5 kg
ft 1bs
link
Lower
bushing against link sleeve by the
20 kg m
of 19
137
145
ft
ibs
up
Friction
and
and
upper
Tightening torque for ball joint
7 kgm
Upper 6
the
thread when screwing in the bushing
Tighten
the
knuckle spindle
Do not
6
of chamber
position of spindle and
in
the figure by turning the
to the link and the spindle to
bave dimension of it
6
Align the direction
of
nipples
grease
as
shown in the figure
7
Lubricate
bushings with grease completely
until the grease will
out from dust seal
come
Center of ball joint
Center of
ball
joint
S5
sj
5
15
Fig
til0
rS4
Front Wheel
sS
189
Fig
Nuts
174
Assembling of Upper
ball
joint and rebound
2
link
4
2
6
link spindle 4 7
kgm
4
kgm
r30
1
6030
camber with
bush spindle
ing
fixing
fixing
lower link spindle 4 0
5
upper
link
30
shim at upper
portion
spindle
Turning of
install the
screw
bush
sufficient
grease shall
screw
Pay
be applied in the inside of the bush
threads of the spindle
carefull
attension
threads when screwing in the
24
adjusting
caster with the same shim or
360
up
8 in
only
1 2
by
one
turn
turn
upper
spindle
32 5Ib ft
Prior to
and
1
King pin inclination angle
Adjust
kgm
5 0
mm
Camber
Adjust
upper
3
36 2 Ib ft
Nut
29
upper
the upper
fixing
Alignment
Caster
Link
188Ib ft
Bolt
34
fixing
to
Lower Link
Toe in
14
Tightening Torque
bumper
Assembling of
not
to
damage
bushing
bushing against link sleeve by
25 kgm
One turn
0032
Caster
180
Only
180
0013
360
027
Half
turn
0018
the
Tighten
the torque of
Clockwise
See fro n back side
Counterclockwise
94
See from back side
CHASSIS
s
t
I
0
0
CJ
t
or1
I
D
o
i
r
1f 1J
I
I
I
J
J
o
0
1U013
oq
O
n
U
3
11
Front suspension
95
A
I
i
DATSUN
c
0
C
o
c
r
di
rl
II
JJ
C
0
Q
I
I
1
ji
i
c
2
0
c
U
o
0
C
I
lC
C
c
l
C
U
@
@
@
0
I
Q
41
It
2
I
Q
Front
Suspension
96
B
o
ww w
body
of
line
BaISe
torque
Tightenig
T
N
0
0
C0
1g
0
lu
of
of
HJ
r
ente
C
limo
spIndle
spIndle Bue up er
up er
I
spindle
lower
of
front
line
condit loading Center
SIde
embl
r
under
M
Tight
cs
of
5
1
l
standr
r
DATSUN
REAR AXLE
4
I
6
Hand brake
11
Rear trunk drain hole
2 Muffler
Rear
7
Hand brake cable
12
Rear shock absorber
3 Pre muller
8
Rear
13
Rear axle
4
Side rod
9
Hand brake balance lever
14
Exhaust
5
Propeller
Rear
IS
Rear
spring
seat
10
shaft
Plu
43010 10600
43010 10800
Camp
Camp
swing
arm
spring U bolt
spring shackle pin
per
axle
Stud gear carrier
Ass y
plug
drai
Ass y breather
Drum brake
43235 04101 Ass y catcher
43234 04101 Ass y catcher
Fig
1
tube
spring
axle
ia1
aXI
case
case
case
grease
L H
grease
R
Rear Axle Case
98
H
I
Shaft
CHASSIS
r8 D
Smear grease
on
a
little
the surface of shaft
Fill up grease
on
UK91ft
the
raCe
suffieiently
bearing
surface of
excpet other space
Press this collar by
pressure
3
v
5 tons
T
metric
Tightening torque
The collar is required
to
change
new one
when
disassembled
Fig
2
Axle
Component of Rear
Axle Shaft Removal
Choke all the wheels not
jack
Lower the axle
the
being operated
brake
upon
up the car
is
adjuster
on
to the blocks and remove
release
a
slack
off the brake
shoe
few notches
Take off the fix bolts of the brake disc and
wheel
using a screw driver unscrew the
drum locating screws
release the hand brake
and tap the drum off with the mallet
If the
brake linings should hold the drum when the hand
remove
the
axle shaft
swing hammer
the
disc
99
rear
holding
as
shown Fig
Tap with
the wheel studs bolt with
axle shaft stand draw out the shaft and
assembly by gripping
it outside of the disc
DATSUN
Order of Rear Axle Shaft
Disc
Brake
Assembl
The
axle bearing with the brake disc
replaceable in one operation by
When fitting the axle shaft
pressing into place
it should be compressed inlo the shoulder of the
rear
assemblv
is
end after
case
flange
its
The
inserting the end
hub
and
following
Part
points
shim between
No
must
43036 04100
be taken
into
consideration
1
Nominated
used
oo
Hypoid
In
gear oil No
district
warner
MP90 must be
than
32
C
use
MPII 140
o
2
It is
oil
to use any other kinds of gear
The
any oil of different viscocity
brand must always be selected
prohibited
or
same
The
standard
capacity of oil is about oil
93
The method of feeding oil should be
done by taking off the feeler plug at the rear
cover of the bousing
and fill in full up to the
L
o
feeding
hole
Dismounting
of
Disassembling
Differential Gear Carrier
Fig
3
Remolle
of Axle Shaft
and
1
Take off and drain oul the gear oU
2
At
the
carrier
Disc Assemblv
axle
ti me
of
pull
with
shaft
dismounting
out the
the
the
gear
both left and
right
disc
of
the
brake
assembly
3
propeller
G
Fig
DT
Axle
5
of
so
Pull off the nuts
Take
case
the side of
of the
housing
and dis
off the side bearing cap of carrier
pry with a lever the differential gear
and the bearing
DT 4678
6
Swing
Assembly
Hammer
Dismount
of
Shaft
the
side bearing
Fig 5 with the aid of
side bearing puller
pull oul the bearing
The puller should be handled wilh care in
catching the hedge of bearing inner lace
As
differential
illustrated
which
is
in
to hook
hard
right
bearing
separately
When
not
joint flange from
shaft
mount forward the carrier ass y
and
4679
and
4
4
Special Stand
Disassembly
Take off the
replacing the differential axle shaft do
forget the adjusting washer between the top
the axle flange and the brake disc assembly
as to keep the end
play of the axle shafts
7
Dismount
Ring
100
gear
the
by
Both the left and
should
be
differential
loosening
arranged
drive
the
8
gear
fixing
CHASSIS
screws
the
on
spreading
differential gear
and
case
11
out the lock washer
illustrated
Fig
in
bearing
pinion
the adapter should
rear
Loosen them in
to
As
adiagonal line considering
from
the
keep
gear bending
The
case
for
No
adapter
be
drive
the
employed
in the round
and the other for
fixing
6
inner race replace and
taking
in this
form is
off
easy to handle with the vice fixing
end of replacer
is
12
Taking
out the
rear
gear carrier
The
drive
pinion
replacer
as
bearing
outer
stud
to make the screw at the center
up
so as
till the
adapter
and
the
set
In other upon the
the
adapter
at
1 and screw
tommy bar
7
closely touches the
corn
then screw the
wing
nut to take
DT 4686
8
Take
the
out the differential
side gear
Tbe
pinion
well as
as
shaft
mate
pinion
should first be pulled out by striking out
the
mate shaft
pinion
the
fixed
on
side
from
the
from
case
side of ring gear fixed to
before pulling out the pinion
right
well
front and
9
the
as
arranged
left
the
side gear and the thrust washer
as
which is
locking pin
differential
thrust
separately
The gear
washer
left
as
should be
and
right
rear
After taking out the nut of the carrier pull
out
the companion flange
The
pinion flange wrench should be
drIve
employed
Tool No
setting its four points in the holes of
flange to keep it from moving take off the
Fig
nuts with the box wrench
10
Take out
the drive
by striking
front end
pinion of gear
carrier
out lightly to the backwards the
at the side of
companion flange
of drive pinion with the drift of soft metal
Thus
the
pinion
ing and roller
adjusting
and
well
would
taken
distance
piece
shim and the oil seal
pinion of front and
as
be
out
with the inner lace of rear bear
together
the
bearing
as
shim left
in
rear
pinion adjusting
and the
outer lace
the carrier
11
Pull out the
rear
bearing
inner race of the
drive pinion
101
6
the
race
out the rear outer race
Puller
race
6 should be
in this case
Supporting
Using of Side Bearing
outer race of
illustrated in Fig
lower frim of the
5
one
employed
of carrier
Fig
bearing
It
DT4782
DT4631
Pull out the
DT4689
Bearing
Race
r
j
UN
DAT
13
To
pull
from
3
out
lhe front
hearing
the gear carrier
as
adapter
set
illustrated in Fig
B
7
When the drive
outer race
Drive
the tool body
pull
pinion
Tightening
it out with
14 t7
100
in the way of rear race
kg
ion
torque
nut
with
kg
120 ft lbs
M
m
hypoid drive
adjust the irk
tion of rotation
so
the torque is
be
19
kg
to
em
Tightening torque
Drive Pinion Front and Rear
Bearing Outer Race Replacer
Fig
8 Inner Race
4 2
4 8
kg
m
30 35 ft lb
Replacer
Fig
102
10
the
washer of drive
pacer
Fig
by
pinion bearing and
0
7
17
without the oil
adjust
C
tightened
al of
7
0
is
torque 14
m
gear
Fig
pin
nut
9
Section
of Differential
Case
CHASSIS
38440 04100
Gear drive
38101
04101
137Tl
38120 04100
38189 027
38210 25660
INSPECTION
REPAIRING OF
DISASSEMBLED PARTS
Every parts after
they
are
locking condition defacement or
on the surface to see if they
disassembled
should be cleaned and cleaned by the compressed
air before making an inspection and adjustment
1
Each
should
bearing
every unit of ass y
be
back lash
in
The
re use
axle should be inspected in respect of
the crack
and
cause
spline
of
the defacement
0 4 mm
m
or
m
The
axle
adjusted
with 0
between
clearance
case
Part No
and
with
brake
the
the
disc
adjusting
or
be re
standard
damage found
would
8
cause
the
noise
be difficult to
adjustment
in later
adjust
even
is made
perfect driving condition at the surface
pinion gear should be about from 2 3 to
while the gear
4
in unloaded driving
3
mm
from tip to full
should
start
to
touch
surface
The
end
of
end
of drive
rear
should
be
shim
surface in
43036 04100
Every gear should be inspected
it
with proper
replaced
adjusted
3
should be
insufficient
deformation
operation and
measuring the shake with the gauge by
The difference
houlding the both end
over
of
replacement
Specially the drive pinion and drive gear
should be replaced in a set whenever the
locking condition gets worse and the
be
defacement is already in progress
them
2
case
is necessary
inspected
regard with the defect
and defacement before deciding to
In
used
any defects
can
an
ordinary
loaded
driving
The inspection of this condition
as
to the
as
103
it is
can
be made
r
DATSUN
is
If it
hard
to
inspect them as it is do
by cleaning the both surface with the
rugs before disassembling and paint thinly and
evenly with the mixed wi th thin oil on the gear
Strike in the pinion shaft locking pin from
right side of the case opposite side of
otherwise
drive side
surface
then
the
situations of
drive gear
on
the gear
considerably
the gears
4
of whole gear
interior tip end of the gear
4
Lock the
with
In
is perfect that
contact for about three
center of 1
quarter
length
drive
Fix the
differential
at the
the pin should
Ring
gear
gear
with the
well
as
as
the drive pinion
should be well inspected to they must be
replaced as a set whenever the replace
ment is required
Otherwise
they would not properly lock
side gear with pinion together
respective thrust in the gear case
of the back lash over 0 2 mm and
after assembling is complected
case
In mounting in the case
the fitting surface
the clearance between the side gear and
thrust washer exceeds 0 5 mm replace the
must
thrust washer
washer with sureness after the drive gear
The
else
out
worn
be cleaned and fixed with 8
set screws as well as lock washer bend the
should also be
parts
specially
shake
adjusted
is
replaced
screw
The contact when ring gear is too close to
pinion center in case of back lash should
vice or any other
be
with
adjusted closely
or
it
gives
damage
much noise
a
Put the drive gear ring gear on the buoy
block as it is fixed in the differential gear
and
case
measure
In
and
it
setting tools so as not to
up in a diagonal line
screw
wrench which fit
Screw in for
sure
of
one
screw
by
correctly
with the
The standard screw
screws
ing torque for this
with the dial indicator
tightening up the
and supported by
should be set
it
head of the
5
as
case
The drive gear
from tooth
the Pitch line
on
so
out
2
it
by setting
not loosen
gear
In case of unloaded test
required piston
to lhe
Which
worn
and must be fixed
well the striking hole of it after putting it
turn the pinion with
hand to print the track of it
shows
the
is 25
it lbs
to 30 ft lbs
striking lightly the head
quarter pound hammer
Revolve the drive gear to turn around the
differential
gear
not move on the
case
as
the bearing do
buoy block
3
Measure the
In
rear side of gear by the scale
the shake should be within 0 5 mm
mounting the gear clean well the fitting
face and
and fix
rear
face
correctly
measured face
side bearing in the differential
case
shake at the
and
Mount the
of it
Press in the both side of the bearing
the drift
by
It is important in this
by
the
putting
give the bearing
then there should not be
any shaking
a
proper
with the carrier
ASSEMBLING ADJUSTMENT
Asseinbling
1
Differential Gear
Assemble the pinion and
differential
side gear in the
case
Every parts should be cleaned
with
new
gear
oil
and oiled
then the pinion mate
side gear and the thrust washer should be
assembled by the mentioned inspection
and selection before pushing in the pinion
mate to shaft
Inspection should be made
again
in the
washer
or
clearance
the back lash
be made in
case
of
between
Adjustment
any abnormal
the
must
Fig
Is found
104
case
side bearing
12
to assemble
adjusting
preload
shim to
in
fixing
CHASSIS
ASSEMBLING
ADJUSTMENT BY
GEAR CARRIER ASS Y
It
is to decide
the assembling
They
adjustment
of gear which is very important in an rear axle
ass y and should be carried in accordance with
the
be
the
the
exact
sample
in
0
by the manufacturer
shown
a
show
the
figure
at
standard
21 and
comprehended referring to Fig 19
to
repairing
according
adjustment
exactly
condition of practical use based on the
center
adjustment by
shim
for
exact calculation
shown
as
figure
for
Preparation
1
drive gear
bearing
as
a
drive
Adjust
they are
disassembling and
of
3
because
later
of drive
shim
right
the
which
pinion
adjusted by
between
rear
bearing
the
to be fixed
with carrier must be
the
carrier
outer
There
are
race
besides
few numbers with 0
set
electric pen
drive
on
number
the
tip
marked by
pinion adjusting
arranged as following
of the adjusting shim will be
prepare the
equals
figures
on
Deduct
the
it
case
2
narrow
explained in the following paragraph
of adjustment
Supposing the drive
gear and the drive pinion were re
placed as a new set and the height of
drive
pinion previously used was
Qut prepare the various shim
mentioned
adjusting
off the
scrape
the surface by a
grind stone with
on
The thickness of drive
The use
previous condition of adjusting shim
In case any item should be replaced
or required to reuse even if any item
and pinion
17
is difficult to discriminate
to the direction of on arrow in
in on
they should be assembled
order of disassembling at the
position
axle
13
to the reused as
are
result
worn
from
accordance with the Pinion mark
inspection
as
standard
not to scrape off even the mark
care
and
pinion
what
some
the
Mounting
shim are
is
Fig
due to the corrosion
Drive Pinion in the Gear Carrier
If the
0 mm
in
oxidize substance
A The
of
adjustment
The
position
pinion height is 51
If the
error
of 0 001 in
to decide the thickness of
025 mm
adjusting
The construction and mechanism must well
manufacturing
the unit
the
difference
and
new
have
the
general idea of
required thickness
assembling to prepare
head surface of
shim in
increase in case of
of
an
of
this pinion
used
previously
plus
and
minus
or
is
shim of thickness
the
to
the
pinion
shim
for
Standard
Part No
Thickness
Leaf No
Drive
0 75
pinion
adjusting
mm
1 0
38153 25660
shim
0 030 in
O
25
1
0
mm
2
3815425660
0 010 in
O
125
0 005 in
0 075
is
1
0 003 in
inspect the condi
disassembling in a way as
convenient
tion before
mm
2
38156 25660
It
rnm
2 1
3815525660
to
mentioned later in the measurement
of
pinion height
Besides the condi
tion of defacement on the carrier
pinion
bearing
consideration
Fig
13
Adjustment of
Pinion
explained
Height
must
be taken
though
it
will
the
into
be
in detail later
105
e
r
DATSUN
B
and Adjustment of
Drive Pinion
Fixing
1
Drive pinion
rear
bearing
outer race
in the
carrier in
should be mounted
this case
after inserting the
selected
adjusting
mentioned
bearing
shim as
between
the
carrier
mount the
race
properly
previously
and
outer race
the
special tool of drive pinion
rear
outer
bearing
race
replacer
by
front
For
of
adjustment
previously
mentioned pinion height the shim at
the rear side of this outer race is
increased
decreased
or
and the
race
also must be taken offln each time for
this
adjustment
must
be
such
therefore
handled properly to
ing hole of
Referring
the
This might
in
to
8
Fig
for
handling
the adaptor
set
guide the body
corn to
4
as
use
well be done In pressing
a certain drift
of
Mount the drive pinion in the carrier
and
ring
of 1001 at
adjust by measuring
the position
The pinion height must be
adjusted
mentioned in the previous paragraph
outer race on the corn as the
by mounting temporarily the pinion in
the carrier and the bearing be given
a regular preload
On the other hand
the bearing of drive pinion should be
At the
same
bearing
lwist up
race come
be
10
up the
housed
race
supporting it by the
the corn till the adaptor
and
screw
screw
lime
bar
then
the
setted position
wing
properly
so as
at
the
the
setted
bearing
outer race in
is
mounting the
fronl
ouler race
off at first the adapter from
front end of the
1001
at
side
the
carrier
side of
tighten the
center
the
inside
of the carrier
of
Ihe
and fix the
as
at the final
assembling
At the
time
bearing
as
of
as
the
rear
Put the
side of the carrier
rear
side of the carrier down
ward and set the tool under it
the
rear
bearing
inner
and roller to the drive pinion
the
using
round adapter
By
attached to
pinion rear bearing inner
replacer which was employed at
disassembling
press
in
then
supporting the end surface of drive
pinion press in the bearing by using
the drift
The operation would be
easier by using the drive pinion front
bearing inner race inserter as shown
race
the drive
race
the
inserting the front
pushing in the inner race
out
the drive pinion from
by pulling
to be the
shown Fig
14
as
in
a
adaptor
by using
of
outer
the
rear
race
way
mounting
carrier
yet
not mounted
stud in opposite
screw
not
bearing spacer distance piece bear
ing adjusting shim and oil seal are
then mount it
Mount
the
by the pinion nut fixing with the
companion flange till the regular
revolving torque is required
As this
the carrier
take
oiled after the pinion is inserted
from
up
Mounl the front
For
newly
inserted end of pinion should be locked
with front bearing corn and tightened
race
position
3
as
the small hole of carrier put the rear
surfaces inside at the tip end of
and put the split adaptor inside
2
by
the
carrier in on oval
method of tool
on
avoid
situation as to make the bear
a
14
Fig
the tools
the drive
in
pinion
Tighten
106
up the
pinion
nut
by turning
it
CHASSIS
slowly
preload
with
with
hands
the
use
of
The
preload
that
the
7
kg
shim inserted
10
When
the
is
cm
the drive pinion
case
is
the
bearing
different according to
condition of the bearing adjusting
mounted in
is
previously mentioned condition it
necessary to measure the height of
rear
is
in this
supportedly
Fig 15 to the degree
support the bearing preload at
gauge as
surface of the
higher
or
pinion whether in
than the standard
lower
special drive pinion
Make use of the
arrangement gauge
The standard height of
the
the bottom
from
51 0 mm
pinion
is
of the side
bearing fixed with the carrier
The fixing position can be measured
by setting an arc of circle on both
sides
of arrangement guage at the
position of side bearing and insert the
thickness
in
gauge
between the
pinion such
as
to
of the carrier in
preload
and
the
bearing would
the
clearance
of gauge bar
tip
come
tend to cause an
and the
The
out of order and
unexpected trouble
16
Fig
push in by scraping
diagonal otherwise
pinion height of the
the
more
of the shim inserted
to the
play of pinion
much
direction of
axle is increased
in
fulure
The
less
the
more
previously
it
of
shim inserted
the
tightened by
bearing
mentioned nuts and
the
the
cause
to be burned if left and turned as it
is
Therefore
for
readjustment of
bearing preload in this case it
must be adjusted
by increasing or
decreasing the number of four kinds
the
of adjusting
shim
as
shown
following list and measuring
use
ofthe drive pinion
gauge
Fig
5
The
formal
the
and
bearing
fixing position
decided
as
paragraph
15
of the drive
After
preload
mentioned in
pinion is
the previous
of drive
take off the
pinion
companion flange to
drive pinion bearing
and nut
Fig
15
adjustment
pinion
as
nut
mount
again the
spacer
distance
up the nut as
piece
Tighten
Fig 16 by using the torque wrench at
the regular torque of 100 120 ft per
Fig
lbs
IO
17
so
in
the
with the
bearing preload
as
to make the
DATSUN
revolving torque
of
pinion at
by any
if there should not
cm
7
10
kg
error
practical use
over preload
in
so as
not
to
it an
give
the pinion with the head mark at 0 and
the
clearance should be sealed at 0 2
0
mm
thus
008
in
6
pinion is
position because lhe height
correct
When the former
the previous paragraph
of
wrong
the
pLnLOn
head
set the semi circular side portions of the
gauge
on
the side
bearing
insert
seats
a feeler
The guage rod is made 0 2 mm 8
shorter than the standard measurement
Is made
by selectlug
feeler gauge in accordance with the plus
minus valve marked on the pinion head
a
If it
is
necessary to
take
height
well
as
adjust
off the
pinion
rear
bearing
on
of
head
the
increas
insert
110 50936
o
008 in
feeler
for
and
to
So
2
shows
make
o
002 in
to
At
0 001 in
0
used
It is necessary
again in
adjustment
lower
should
torque
accordance
with
only
2
fi lbs and
the
differential unit is
and the drive gear is locked
therefore
the
of side bearing preload
Adjustment
back lash
bearing
is to
To
give
the
bearing
be
at
the
in
standard
in
the
of the side
the gear back lash
assembling
than
at
pin
far
load
it must be done in a
when the old
nut
35 40
fixing
is
follOWing adjustment must be made to
acquire the regular side bearing pre
otherwise
right way
Specially
of A
in the
with the drive pinion
in
008
give the bearing a right preload
the time of pushing the outer race
into the carrier
be
at
the
cap
mounted
the number of shim so as to
the clearance
with the
3
should be equally locked with fixing
cotter
the mark
of
bearing
008 in
adjust the position of drive pinion by
deducting
by housing
torque
in case of minus side added
instance
is inserted
bearing housing
of carrier the bearing must be given
The screwing
the regular preload
in case of plus
For
case
by the bearing adjusting shim
side bearing as explained in
which
the number of mark to 0
Mount the complete unit of differential
The differential gear
drive
is
gauge
deducted for the number of mark from
the
the washer
finished up
pinion before adjusting by increasing
or decreasing
the number of drive
pinion adjusting shim
by filling
but
It is important
ing when mounting
to note that the fixing part of the cap
of each bearing housing is machinerly
as
outer race
the
adjustment
the side of cap which should be fitted
with mark on the leg of bearing hous
ing or decreaSing the number of the
In other words read
adjusting shim
the mark
In case the
the
gear in the carrier and fix the bearing
There is a engrayed mark on
cap
the pinion
adjust by
form the carrier to
1
or
drive pinion
up at the standard torque
CMounting the Differential
Gear Ass y in Carrier
51 mm
adjustment
insert the new oil
of the carrier and
cotter pin hole fitted
nut
the pinion
Therefore
rear
should be made not by tightening the
gauge into the clearance between the tip of the
gauge center rod and the pinion head and adjust
1000 In
the
thing
formerly fix the flange washer and
pinion nut The nut should be tightened
Remarks
height of
in
inspect
in
the
loosen the pinion nut
take off the flange
seal
measuring the
is found
as
Unless any
pinion height again
the gauge is made shorter for 0 2 mm
than the standard size 51 0 mm
When
of pre
adjustment
load of the bearing is completed
by the feeler gauge
regarded as at the
made
conditions
the
pressing
differential
of
inside the
108
right preload
of differential
the
on
gear
the side
case
bearing
in
and
the
adjust hy inserting
bearing adjusting shim of
case
CHASSIS
calculated
thickness
with
the
0
accordance
in
0 008
004
off the
If it is much
following
method
of
taking
marked
numberal
of
Thickness of Shim of
bearing housing
Left Side
right
move
to left
by
for adjustment
shim
computation
There
is
adjusting
of
a
basis on the
carrier and differential
the gear
case
manufacturing
in
the
erro in a unit of 1
1000
ment of A B
C D
and
place
case
kg
5
to
acquire
and
1000
the
applying
the
E
8
F
10
D
E
0
0
A C
1
mm
bearing
Right
on
A
side
measure
o
the unit basis of
o
each of them as E
B D F 6
T2
0
025
O 07 E
C
D
001
0 002
002
0 007
008
Thickness
for
bearing
mm
by excluding
of
the
shim
ring
to
as
0
1
3
8
7
15 0 375mm
0
002
o
3
10 6
006
0
006
F
003
0
016
010
0 015
Thickness
of left
of right
side shim
The
numeral marked by the electric pen
the
side of the drive
For
example
in
0 025 mm
shows
which
is
b 6
x
6
means
0
in
20
make sure that it
by using
right
otherwise the
pinion
the dial indicator
is within 0
1 mm O
2
on
of the
the back lash of 0
15 mm
using the
The left and
that
gear
recommended back lash besided the set number
sign
is
the back lash of the drive
Fig
8
10
20 0 5 mm
B D
0
in accordance with
bearing must be well pressed
preload changes
gear
x
T2
acquired by
the following method
above method of computation
Measure
mm
side shim
0 008 in
the minus
well be assembled by
shim of thickness
x
2
0
0 2
is
numerals to
as
025 mm
O 025 mm
mm
0 025 mm
7
of computation
It may
O
2 mm
25
1
o 008 in
thickness
T
Left
against the standard measurement and
The
2
In this
minus
on
error
assume
mm it
the E is
1
B
When the measured width
example
18 3
the
A
the
steady figures
Take the left side
F
is
on
each standard
the
ment of 18 5
1
load
the
the
Calculate
against
flat board
on a
7
aid of weight block for about
with the
2
side
use
F 6
Right Side T2 B
D
Example of calculation
18 5 mm thickness
standard guage
and dial gauge
right
Pinion mate side
C
E
measure
of the
A
on
Right Side
Ring gear side
Left Side T 1
18
Fig
width
left
on
in
the
measure
bearing
standard
each
against
To
is
numberal
The
Thickness of shim
mm
Fig 19
Fig
109
006
DATSUN
After the
Operation
JJ
I
I
Fig
20 Measurement of Back Lash for the
Drive Pinion
Ring Gear
If it is necessary to
use
the
bearing again
at
of each shim
the time of repairing the thickness
001
of left
right must be reducted for 0
against
with the practical
in
accordance
preload
standard
becuase over preload is given
condition of use
o 003
to
the
on
the basis
bearing
calculated
from
with
of 80
the
or
shim
60
of
Fig
thickness
above method of computation
110
21
Using the Differential
Bearing Cap Gauge
Side
CHASSIS
3
11
DJ4
1
l
Wl
Jl
J
OJ4
JO
J
JI3IDH
Jill
OJ4
JIm
UJ4
Select from
J
J
J
IJ
bJ4 1J
QJ411D
IIHOII
7
J8
Ok
D94M
J8
M4011
IJ
J81
1
O
3
1
40
3
10
15132
38166131011
MOO
O
3
167
1410
400
J6153
Impact chassis
the lip of oil
in
grease
al
pinion
and
1001
361541061
361551U6UI
O
18
36157
10
I
shims
by adjusting
mesh
good
of drive
to
161561001
the hack lash O 19
Adjust
IJ2
bearing cap
H
38
Ca1culwes
Thickness of shim for
Left side
11
32
03
38101
A
Tl
C
D
ide
preload
E
0 025
0
1
0
hearings
0
175
8 D
F
x 0 025
O 150
Right side TZ
To tight this head of bolt
tapping slightly with
4
1
0 1
pound
kg hammer
Tightening torque
3 5
4 2
klOm
25 30 ft lhs
JIJIJ
13700
Contact wide of tooth
must
he
more
Back lash O
Give
with
by
than three
1
O
3B453 10500
3BJj S410
forth
t
2
Refer ential
dirnension
Q
fS51050
n
384561050Q
J
3 457
IT3Sf
050
preload for side berings
adjusting
him
gained
alculuses
Fig
22
Carrier
the Gear Carrier Ass y
the Rear Axle Housing
Mounting
Thus the
of precaution
large
173
measure
55
DT 4685
is
Interior of the axle housing should be cleaned
well
L measurement which is within
size the
40 173
completed
By way
with michrometer of the
adjustment
mm
as
Fig
21
If it is insufficient
shim of 0 002 in
Tbe
has
05 mm
Service No
add
an
The carrier packing should also be replaced
tool
additional
with
new one
Mountthe gear carrier ass y withoutmistak
ing its upper side with down side and through 8
The
studs then fix with the lock washer
nut
In
right
21 or
the said michrometer
this case
Fig
special gauge should be employed for scaling
0
left and
shake of the back of drive gear which
fixed with the carrier should be
nut must be
dial indicator to confirm that is
When it
by
within 0 05
tightened
to cause the oil
been
measured
on
is
mounted
gear oil
immediately
hypoid gear oil No 90
mm
Feed the oil till it
of the feeding hole
III
in a diagonal line so as not
leaks
on
the vehicle
The oil of the
feed the
designated
should be feed
comes
up to the down side
I
DATSUN
STEERING
48400 10600 Ass
y wheel
steering black
48420 10600 Ass
horn black
y iug
48420 11500 Ass
y ing
born yellow
48422 10610
Pad horn ring
black
48327 10651 Set shell
rteering black
48327
11550 Set shell
48422 11510
Pad horn
steering yellow
48327 10851 Set shell
steering black
ring
Plate
yellow
clamp
Bushing horn
l4
jthion
f
bwhing
Bushing
horn
A y
contact
horn
at
3 10610 1 Screw
to fix shell
3 30614 1 Screw
to fix turn signal
switch
to
shell
Fig
1
Steering
Wheel
Type
Recirculating ball type
Gear
15 0
steering
Rotational numbers
2
the
connected to the rocker shaft is
96
Distance between
sector shaft
steering linkage
three
rod
worm
shaft
45 mm
0ear oil capacity
Two
o 3L
side cross rod lever
cross
lever
to
the
The worm
ing and stable functioning
gear
with
and
lower
supported
upper
angular contact
ball
bearings to the housing is meshed with the
through the circulating steel ball and
ball nut
This assembly is enclosed in an oil
tight casing which carries two ball bearings at
sector arm
either end of the earn
When the steering wheel is turned the tube
revolves
the
taper peg to
earn
which
in
remove over a
turn
causes
predetermined
the
arc
thus giving the rocker shaft its desired motion
112
The
the gear arm
side
rod
steering
gear and idler arms
Steering system consist of the recirculating
ball type robust structure and gives light handl
steering
steering
is
rod connecting the side and
shorter
connect
a
gear
is a
that links up with
on
one
the
on
arm
respectively
to
of the
cross
idler shaft
either
side
the steering
CHASSIS
Side Cross Rods
The
by
side and
To
rods
cross
castllated
a
Steering
and
nut
held in position
split pin
the rod
remove
are
withdraw the split pin
carefully tap the rods clear
they are connected
of the levers to
from the end of
steering
Unscrew the
These
the
are
Steering
secured
to
the
split pin
not be removed
The
nance
only
steering
for any
casion
o
removal would be when
general
position
STEERING GEAR
mainte
requiring
damage
its
gear
respectively by a
Normally these levers
shaft and idler shaft
each
member
gear arm
bolts secured to front suspen
Thus the steering gear housing
assembly should be removed from
nut
need
sion
Gear Arm
rocker
and
Removal
First disconnect ball stud nut and draw out
which
Removing
Housing
Removing the horn ring assembly from the
steering wheel unscrew the column lock then
disconnect higher up the column jacket from the
housing
at each end
and release the nut at each end of the rod and
then
Gear
Adjuster
their
screw
has occurred
under which circumstances the steering box or
idler should also be remove for inspection when
the
arm
concerned
steering gear box
can
or
be withdrawn
once
the
idler has been removed to
the work bench
The gear arm should be with drawn from
shaft concerned using
gear
arm
a
suitable extractor
must not be hammered from its
the
Recirculating
The
ball
nut
shaft
Removing the Idler
Referential Figure of
Recirculating Ball Type
Ball Nut
After the side and
the
idler
can
secured by
cross
rods disconnected
be detached from the
two
bolts to
Assembly
body
It is
the front suspention
member
Holding
off rubber
the idler
body
on
the bench and take
Slip the
cover
Unscrew the idler shaft out of the
body
nut over the worm with the ball
holes up and the shallow end of the
113
rack
guide
teeth
DATSUN
Align the grooves in the worm and
ing through the ball guide holes
Count
This
is
58
balls
into
a
nut
suitable
Assemble
by sight
being
container
screw
the proper number of balls for this ball
the
nut
see
Drop balls
side of nut
this
operation
either side of nut
same
side must be used
Shake the nut
being filled
ball
guide clamp
to the nut
then tighten the
screw
assembly by rotating
that it moves freely
clamp
Check
securely
the nut on the worm to
into each of two holes on the same
from
end
the
sure to use a lock washer under the
may be
perfonned
but two holes
on
the
not two holes on same
away from hole
until all 42 balls are
gradually
Continue
installed
Place remaining 16 balls in ball guides
8
o
in each of two halves
9
o
ASSEMBLING
1
2
Fix the
completed gear housing with needle
roller beearings and oil on the vice
Set
the
0
3
easily
guides into the guide holes of the
If the guides do not push all the way down
tap
lightly
into
the
wonn
@
correctly
adjust
the
shims and
bearing
to the
housing
Push the
nut
Insert
column unit to the gear
main
@
housing with
@ o ring
4
place
0
Tight
5
6
To
carry
after
of
7
finding
8
1
on
oiling
2 5
the
kg
surely
13
m
adjustment
for the
CD
correct position
the bOlts
0
Retighten
ing torque
the bolts with
temporarily
washer after
wonn
witli tighten
18 lbs feet
of main column
bearing by
rotation
steering wheel
Motive
power
shims
2 3
cm
should
4
be
with 200
adjusted
450
by
@
grams at 20
R on the circumference of steering handle
ADJUSTING
a
Adjust
fixing
114
for
rotation
the main
of steering gear
after
column and coltJ inh gasket
CHASSIS
Roller shaft adjust shim
c2
@
Bearing
@
C
1
ing
c3
1
575
Roller shaft
1
@801t
550
525
1
500
1
Sector shaft gasket
1
48204 16500
e
Sector shaft
1
48201 16500
Bolt
5
16
cover
24
x
g
Lock washer 5
h
Lock nut
3
18
3
1
24518
16
3
9
15115
1
9
11346
8 24
Filler plug
48029 71200
1
o
48030 71200
2
48031 71200
1
o
48032 71200
1
o 050
Parts Name
a
Q ty
Steering column
assembly
bl
Worm
b2
Worm
b3
Worm
b4
Worm
bearing
bearing
bearing
bearing
48064 16500
127
Part No
1
48024 16500
shim
1
48029 71200
shim
2
48030 71200
shim
1
48031 81200
shim
1
48032 71200
1
48035 71200
1
48025 16500
0
d
ring
Steering worm
e
Bolt
3
1
24520
Lock washer
3
9
15115
c
1
762
o 254
Signs
48132 71200
525 mm
d
f
No s
1 48131 71200
adjust shim
550 mm
1
Roller shaft adjust shim
c4
iWasher
Part No
48130 71200
mm
bearing
f
b
Insert
ing
sector shaft and then attach hous
cover
Part Name
Signs
a
the
Steering
Q ty
sector shaft
Arm sector shaft
b
Roller shaft
screw
Roller shaft
adjust
48103 16500
1
48502 16500
I
1
48502
1
1
575r l 600
mm
1
shim
1
@CD
1
for LH
cl
y
Part No
for RH
Arm sector shaft
CD
@
170001
Set with the selected 4 numbers shims
C3 C4
after fitting
the
adjusting
Cl C2
screw
to
the sector shaft
48135 32200
o
48129 71200
Gap
at
adjust
should be 0
liS
E
01
screw
0
03
to the direction of shaft
mm
r
DATSUN
ADJUSTING
2
Correct the position of ball nut to the center
1
Attach
with
and insert oiled sector shaft to the housing
temporary sector gear arm
Rotating slowly the sector shaft
find and
Stick the gasket
center of
meshed point of the clearance
adjust
3
the housing with sealing
on
0
at
cover
4
screw
Fitting with @ adjust screw
temporarily the bolt and washer with G
l
housing
5
Pull
the
direction of
m
13
Fix
3
Make sure smooth rotation of gears
4
The
@the
lock nut
the
cover
up
housing
2
up
2
sector
shaft
cover
retighten
3
mm
the
bolts
with the torque 1 8
cover
to
2
5
the
by
of
k lash of gear arm should be
bi
the
screw
0
0
1
mm
at
adjusted
the
kg
18 lbs ft
5
After
finishing adjustment
repeatedly then lock @ the
retightening adjust
9
11246
rotate
screw more
Tightening torque
2
the gears
surely
nut
1
8
5kg
m
Select and adjust with the shim by
part No
48204 16500
as
to
48129 30
31
3271200
the clearance is to be 0 01
Type
Distance between
4Smm
Gear ratio sector
15 0
and column
450
Locking angle
Ge oil
45
IX
N
Impact
Grease
NCS
17112
tl
1
at assem
bling
I
Tightening torque
l4kg
m
neutral
position
9 1l252
116
MP90
0
33L
so
0 03
1
after
6 up
CHASSIS
0
49
0
4
r
19
18 17
3
4
CD
Steering gear housing
@
Steering
2
Needle bearing complete
@
Steering column assembly
0
Expantion plug
@
Steering
G
Secter shaft oil seal
@
Secter shaft adjusting
screw
@
Secter shaft cover
@
Secter shaft
shim
@
Secter shaft
@J
Lock nut
J
Plug
@
Bolt
@
Bolt
@
Lock washer
@
Lock washer
@
Nut
@
Washer
@
Steering gear
@
Lock washer
@
Nut
@
@
Worm
0
bearing
y
gasket
shim
ring
@ Steering
@
cover
ass
column jacket complete
Steering column bearing assembly
Fig
2
Components of steering
II
worm
bearing
sector shaft
adjusting
arm
Gears
D TSUN
i
Bolt
to
fix idler
Nut
to
body
Nut
to
lock ball
to bar
joint
Ass y
Ass y socket
ide
rod inner R H
Ass y socket ride
rod inner
s1y
As
rod
side
Fig
3
R H
Ass y rod
R H
side
t H
Steering Linkage
Steering Faults
Loose steering is
play
of the worm gear
which
can
be rectified
invariably
attributed end
already
through steering column
by
the removal of shimes
located behind the gear housing front
cover
mentioned
To check for this end
play
disconnect ball joint stud at the end of cross rod
from gear arm and turn the steering partly to
the right
as
118
or
left lock
CHASSIS
BRAKE
GENERAL DA TA
Type
Hydraulic expansion
Foot brake
Mechanical
Hand brake
internal expansion
2 shoes for 4 wheels
rear
2 wheels braked
Lining
Width
x
Thickness
Area of surface
Brake drum dia
Master
cylinder
x
40 x 4
Length
5
x
215 mm
Same for Front
Rear
35 Front
Rear
for Front
Rear
cm2
Front
228
Rear
6
cm2 Same
bore
22 22 mm
Inner dia
Wheel cylinder bore
Front wheels 25 40 mm
Inner dia
Rear wheels 23
Fig
1
Front Brake
Brake Disc
119
Flange
81 mm
DATSUN
i
00
o
B
on
f
y
o
o
lI
P
ll
Fig
The brake
all four wheels
on
hydrauli
are
cally operated by foot pedal application
directly
which
the
cylinder
hydraulic pressure of the brake operating fluid
is originated
As supply tank cast integrally
the
with
master cylinder provides a reservoir
coupled
to
a
master
in
is
by which the fluid
replenished
line consisting of tube
inter connected
and
a
pipe
flexible hose and union
the master
cylinder
Out Side
2 Front Brake
and wheel
This
turn
moves
the
the
expand
pistons
brake
proportion
to
shoe
thus
which in
producing
and efficiency in direct
equalisation
automatic
out wards
the effort
supplied
at the
pedal
When the pedal is released the brake
spring
wheel
return
the
shoe
cylinder pistons
shoe
which then return the
and therefore the fluid
and master cylinder
the pipe
mechanical
An independent
linkage actuated by a
back
lines
into
mounted drivers seat side
This is
cylinders
hand brake
generated in the master
by application with the foot pedal is
transmitted with the equal and undiminished
force to
all wheel cylinders simultaneously
positioned on the right hand side of seat if the
car has
right hand steering and on the left
The
pressure
cylinder
FRONT
The front
by mechanical
Operated the rear wheels
expanders attached to rear wheel cylinder bodies
BRAKE
brakes
leading system
The shoes
hand side if it has left hand steering
with
are
are
each two
by the two
wheel cylinder
over
allowed to slide and centralize
automatically druing the
which distributes
ensuring high efficiency the
brake disc caused by adjuster housing against
the friction of the brake linings of front and rear
constrocted
force
lining
shoes and
actual braking operation
the braking
the
strongly
120
even
area
lining
wear
CHASSIS
55 Y TUBE
f oftt I
J
It
L
r
O
BL
NG
tI
r
p
S
ao
ft
t
T
l
RET
INER
plln
h
CYLlND
H
S Y
Fig
Fig
Adjustment
3
4
for the front brake shoes
of the bolts of
adjuster
Turn
Adjusting of Front
is
H
Brake
direction until the shoe becomes
by
locked
on
the
the shoe
dru then turn back it until
becomes just free form the brake drum
which located at
adjusting bolt
I
Frollt Brake L H
brake
the lower and upper position of the out side of
the brake disc
BCOl
A
I
l
means
i
to the left
III
SuN
l
IA
o
o
c
w
pll
Fig
5
Front Brake
l22
L B
ELECTffiCAL SYSTEM
BRAKES
REAR
The
allowed
effect
hrake
rear
shoe
are
not
fixed but
to slide and centralize with the
in
as
front
the
They
hrake
hydraulically operated by
are
wheel
and
cylinder
independent hand brake mechanism
same
are
WASHER
nylon
ASS
Y
BRACKET
hand brake
control
lSPR1rtaiNnGer
loe k
WASHER
WASHER
to fix
BOLT
hand brake bracket
nylon
PIN
cl
hand
brake control
SPRING nail
hand brake
control
NAIL
ratchet
hand brake
control
COMP
hand
STEM
brake control
I
WASHER nylon
PIN
clevis
YOKE
hand brake
control
Fig
WASHER
nylon
6 Halld Brake COlltrol
Adjustment
means
of
the
for the
screw
outside of brake disc
0
rear
brake shoes
bolt which
This
located
is
by
at the
precaution should
taken to eliminate the possibility of brake
shoe drag due to mis adjusted parking brakes
be
I
n
I
i
0
fl
If
I
Turn
r
I
turn
JJ
IJ
II
J
A
ttt J
7
Adjusting
screw
2
3 notches
tightly
Brake Shoe
123
and then
until the wheel
drum turns just free from the shoe
I
Fig
the bolt to screw direction
back
DATSUN
o
0 Section
A
B
I
Dl
ci
44060
10500
Upper
side
Sett1l
44118 JOOO I
g jl
of
Feq
Isio
4
eCt10I
A
Jrle
21 5
Fq
4407
44 00
JOOO
10600
f
o
I
41128 JOOOI
j
B
B Section
41129
LI055
Adjustment
JOOOI
of brake shoe
This precaution should be
taken to eliminate
the
possibility of brake shoe drag due to
adjusted parking brakes
Turn the
bolt to Screw direction
tightly and then turn
mis
screw
Fig
8 Rear Brake
No
1
2
3 notches
just free from
124
the
back
until the wheel drum turns
shoe
CHASSIS
85
A
A Section
44118 30001
44030
10600ML H
44020
10600
4414131700
44142 31700
4414931700
I
C SectiDn
31700
44145
31700
S
44205 10500
44081 04100
c
J
44144
44084 30000
Fig
8 Rear Brake
125
No
2
R H
Fitting
Df wheel
cyl
DATSUN
55
COVER
A
SS Y
LEVER tTOKICO
B
dust
COVER
duH
LEVER
htel
TOKICO
8
PL
BCO
S
SABCO
TE
TOKlCO
PL
HE
i
S
5
iDER
CYLl
SHIM
A8CO
8 TOKlCO
SHlM adJuumg
adJuuln
B NASCa J
adjatlng A TOKICO
SHIM
oa
SHIM
SCREW bl
ASS
Y
bral
SHOE
e
SPRING
fOle
bralshoe
return
yhnder
Ide
CAP bleeder
COVER dun
COVER
A TOK
S
A
du
BCO
brake
CUP
r
RI
PISTON
HOUSIN G
e
W
SHER
TAPPET
bral hoe
ASS
e
rerun
V
adJuulU
adjuSI
r
bral
WEDGE
adjuster
SHOE
bral after
e
de
ung
TAPPET
J
SUT
adJu
adjuster
locl
Fig
9
Rear Brake
L H
BRAKE
HAND
The hand brake
only and
situated
is
operates on the rear wheels
applied by a pull up type of lever
along
side the driver
s
seat
l
r
I
The cable
tk
j
the control is attached to the toggle lever
connected with the
rear
brake disc
brake linkage is set when
leaving the
should not require any attention
maintenance
Only
is
should
necessary
when
a
c
The hand
under normal
r
Jf
complete overhaul
the hand
brake
linkage
require resetting
When this
is correct
be locked to the drums
the
i
5
works and
rear
shoes should
t
J
f
0
the hand brake control
just slightly applied and the wire rope set with
the slackness just removed
by means of a nut
at the center rod of the
equalizer drag link
Fig
126
10
cyhnder
wheel
snap
bra shoe
SPRING
PISTO
l
TOKICO
RING snap
NASCa
G
ASS Y
LINING
u
p
cylinder
heel
TOKICO
from
d
e
I
LIISG
NASCO
adjuulng
Adjusting
Nut
ABCO
CHASSIS
MASTER CYLINDER
This
is
consists
polished
The inner
The
a
with
alloy body
an
filler cap and drain out fluid
a
rubber boot and
and reservoir with cap
assembly
stoper plate ring
spring
of
finished bore
is made of the
secondery
piston
pair of long nosed
assembly can then be removed
push rod
return
cap
let out valve and check valve seat
open end of the
rubber boot
as
shown
Fig
pipe union from the
securing bolts when
cylinder
the
cylinder
master
the
withdrawn complete from the
with
piston
the
cap will be
all
Examine
Remove the
ar
the
other small parts
fluid reservoir may
and
removed
When the push
xposed therefore remove
the piston assembly complete
The assembly can be separated by taking out
Disconnect the pressure
remove
been
secondary
is
Brake Master Cylinder
and
has
rod
protected by
disassembling the
cylinder
Pull back the
the stopper ring with a
The push rod
pliers
remove
of distortion and replace
cap
with
parts where necessary
new
the rubber
especially
parts
for
primary
wear
GASKET filler
SET CAP
ap
s
fille
s
SPRING
eturn
brake
pedal
SPACER
piston
up
r
1
PISTON brake
aJP
piston
secondary
NUJASHER
lJ
i
COVER dos
ASS y ROD
P
J
1sterj
ru
s
1
Y VALVE
i
l
AS
s
f
T
orWASHER
NUT
SPRING
alve SEAT
n
alve
BOLT
I
I
IOCk
i
RING soap
NUT
BUSHING
pedal
1
PIN fulcrum
fulcrum
PlN
SLEEVE pedal shaft
clevis
brake master cyl
STOPPER
brake pedal
ASS Y PEDAL
brake
Fig
Bleeding
the
necessary any time a portion of
system has been disconnected or
hydraulic
so
low
that
air
has
entered
the
brake
and
the
remove
a
to seat
remove
This process must
all
the
supply
hydraulic
tank
topped
connections
up with the fluid
the cap from the bleed valve
bleed tube
over
the bleed valve
free end of the tube in
of the other wheel
secure
a clean
and
Always keep
immersing the
jar containing a
that
quarters of
pedal with
a
turn and
a
slow
a
screw
cap
bleed tube
be
repeated
for each
cylinder
a
careful
check
on
the
supply
full level is maintained
supply
tank
tion must be
valve cap about three
the brake
then operate
full stroke until the
now
bleed
Should air reach the master
the
the bleed
air
the
free
tank during bleeding since it is most important
fit the
liltle brake fluid
Unscrew
of
downstroke of
completely
during
tighten the
pedal
sufficiently
master
is
jar
Then
bubbles
cylinder
With
the
entering
if the level of the brake fluid has been allowed to
fall
Cylinder
Hydraulic System
is
Bleeding
the
Brake Master
11
correct
full
l2
cylinder
from
bleeding opera
repeated
bieeding top up the supply tank to its
level of approximately three quarters
After
fluid
the whole of the
r
DATSUN
Never
fluid
use
that
has
bleed
been
from
the
a
brake system for topping up the supply tank as
this brake fluid may be to some extent aerated
Such
one
fluid must
day
be allowed to stand for
before it is used again
fluid lime to disperse
in the
and especially
any part of the hydraulic system
so where the brake fluid is concerned
at least
This well
bubbles
air
Great cleanliness is essencial when dealing with
allow
fluid
Dirly
must
be
never
added
to
the
system
to
l
ASS Y
CABLE front
RE TAINER
fix
rn
a
to
l
llg
acket
spring
I
SPRING
j
ARM
Eo
1
PLATE
LU
0
PIN
ck
clevlS
f
h nr
to
PIN
cleVis
t
6q
c
PIN den
f
to hx
ablepIN
b a1 ance
lever
NUT
hand brake
cable
rSCRE
brackeUWASHER
plaln
If
to
fix
to
wheel
rod
cylinder
f
leverl
BRACKET
hanger
i
W
1oss
PIN
BRACKET@ PIN
PIN
cotter
djll
Nul
NU
to flXbracket
ROD cross
hand brake
cotter
WASHER
Fig
12
Hand Brake
128
fix
cable to
balance
Linkage
fa
rod
ROD cross
hand brake
short
rod
balance lever
FELT
ng
CARRIER
balanct lever
to
leverl
long
to
cottoc to
hanger
PIN
clevis
1I
T
PIN
e
CI
rod
d
v
tI
co
er
rosa
II
0
clevis
LEVEK
RING
balance
felt
ra
e
tH
e
handk
lock
SPRING pull
off
TOSS
rod
A
If
N1PPLE
grease
0
FERRULE
cross
BOLT
Gl
adjustlllg NltT
hx
od
0
ASS i
CABLE
hand
brake
after
TO
TRUNNION pIn
hand brake
cable to lever
pull
U
PIN de
brak
lac k
COMP SUPPORT
balance lever
o
IrP
P
IoI u oJ r J
ComblfOt
rD
el o
tr1ttr1 o
tr1
JIP
I3
Il
Combhun
lamp
lamp lamp lamp lamp
lamp pilot pilol warm
I
lamp
g
O
l1ll
lompv
r
itch
RighI
Sid
unit
Tank
lW
0
1
auQe
itc
Lamp
Door
InJl1me TUrn Mom Ignitu prul
Wi3
TS
IL
OIL
IG
i
1
womlng
Ilgnal beam
Left
u
b
I
r
d
or
lamp
2
n
OIo
0
th
nUl n
DIm er
tM
B
Combuled
L
I
OJ
ICSJ
urn
Hl
swi
r
C
igniton
llr
1
k
toc
GII
l
i
i
col ur
line
c
Block Whu
B
f
w
Red Gr
R
G
Blu
Yelow
Y
l
Elet
wneh
witch
lIghting
Wiper
i
1k
r
ll
ll
twitc
lamp
1I
SlOp
l
Bt
j
lff
lH
b
molar
nlLJJ
1
I
Aldrm
l
Wiper
r
Speak
AI
100
111
t
plug
I
i
ij
1Irl
linn
t
Conectd
Head
ight
R
Hight
Horn
HClrn
lo
r
u
J
llp
lol
Igmp
Bolery
lo
alall
lp
RightlParun
Onel
turn
IF
Fog
OO
Right
hl
Porhng ligtIC omp
l
ft
l
12t
t
ND
o
to
C
COnCl
1
Spark
H
rt F
lomp
H
ft
L
10mp
C
DATSUN
1
SCREW
WASHER
TI
BRUSH
cove
d
COVER
BEARING
over
DIODE
1
set
WASHER
BEARING ball
W
ASHERl
WASHERl
BEARING
K
WASHER
l
BEARING washer
Fig
Alternator Mitsubishi
1
AL TERNA TOR
Altemator
Mitsubishi Denki Co
Model
12V 300W
Nominal output
Constant
side ground
2
Constant revolution
No load minimum
revolution
current
000
1
500
r
r
p m
14V normal
2
500
24 5A up
r
21 5A up
1
1
Note
resisting
Battery
battery charged
in full
73
Mitsubishi Denki Co
Model
Use
Pilot
lamp relay
3 contact
point type
RL 2BI
Tirrill type
Type
Element
leaf spring
Put off voltage
Constant voltage
Pilot
voltage relay
relay
lamp relay
3 contact
4 5
point type
130
5
2V
Put
15V
4 000r p m
m
14V
23500 12200
Constant
14
load 21 5A approx
14V
high temp
ratio
Regulator
Battery
Load
side
15V
4 OOOr p
revolution
p
down
Secondary
side
normal temp
2 500 r p m
Pulley
14
Dynamo
m
temp
p m
valve
djust
Successive
Pole
Output
Primary
AC300 12WR
on
o 5
voltage
3V
ELECTRICAL SYSTEM
COMPONENTS OF
AL TERNA TOR FOR 41 1
MAJOR
8
0
0
10
9
12
14
11
2
3
19
0
ljG
L
I
j
181716
Part Name
Part No
Il
1817
Fig
ey
0
1700
@
13
lf0
1
Major Components
Q ty
Key
23100 14600
As s y
alternator
Ass y
alternator
Mitsubishi 12V 300W
1
2
23108 14610
23116 14610
Ass y
1
rotor
1
seal
Washer
1
23159 14610
Grommet
23233 14610
Clip
22
23118 14610
Ass y
23
23121 14610
Washer seal
1
24
23120 14611
Bearing ball
1
25
23123 14610
Retainer
21
1
Mitsubishi 12V 300W
23100 14602
Q ty
Part Name
Part No
No
No
1
front
cover
1
1
bearing
3
3
23120 14610
Bearing ball
1
26
23352 12210
Screw
4
23102 14610
Ass y
1
27
22203 32210
Wasber
3
23151 14610
Ass y
1
5
23131 14610
stator
through
Iy cover
6
23127 14610
Ass
7
23230 14610
Ass y
diode
8
23133 14610
Ass y
holder brusb
9
23135 14610
Ass y brush
rear
set
1
29
23152 12210
Wasber
1
30
23162 12210
Wasber
1
31
23153 35010
Nut
2
32
23139 12900
Bolt
9 15115 1
Washer lock
34
9 11245 1
Nut
spring
2
23352 09160
Screw 4 ti
12
22156 01302
Washer
13
23156 14610
Ass y
14
23158 14610
Screw
1
15
23161 14610
Insulator
1
16
23157 14610
Insulator
1
17
22213 71311
Washer
1
19
20
Washer
23139 12210
Bolt terminal
Washer
spring
spring
to
bracket
fix
1
1
1
1
teminal
22203 22210
22203 32210
fltema
33
11
18
to
2
brush
1
1
1
Cover
1
spring
plain
X 10
23107 14610
10
28
4
Bolt
spring
puUey
E
Part No
23500 14602
Remarks
Part Name
Regulator
ass
y
The con
nectar was
1
23100 14602
Alternator
1
24299 14801
Connector regulator
enlarged
1
24299 14800
Connector alternator
in this
l31
ass
y
type
r
DATSUN
GENERA TOR
Construction and Feature
Different
from
generator
turns
armature
making
the
DC
generator the AC
magnetic pole and fixes
generates 3 phase alternate
current
and rectifies all
waves
each three
diode
it
and takes out as direct current
tn
S
A
Tenn
T
l
i
Ito bolt
ra
k
cet
lon
l
It
tn
bn h
n
ulot
A
8ail
8
11
N
o
a
IocoW
10
M
p
e
0
It
n
l
l
Au
U
2 1
Fig
1
Sectional View
of Dynamo
r
@
sealed ball bearing
The
with the silicon
that are built within
the
@
are
r
used to
Clearance between the brush
support the rotor
and brush holder is also made so as to prevent
from
it
dust
Thus
the
AC
generator will
I
increase
Each 3
milage without maintenance
diodes are pressed in the rear cover and the
diode base respectively
@
I
@
Fig
2 1
3
Magnetic
Circuit
f
sw
C
Relay
i
r
R
CD
Field
core
I
0
I
o
o
0
s
Field segment
e
I
h
Fig
2 1
2
Sectional
View
The
at
of
Rotor
clip ring pressed
Field coil
o Shaft
I
s
I
I
L
in tbe shaft is soldered
both ends of the field coil
to pass
magnetic
Fig
current
The
pole
circuit as
are
of rotor
shown
in
makes out the
Fig 1 3 and all
magnetized by doughnut coil
magnetic
poles
the
J
2 1
4
Connection within Dynamo
The armature is of a three
type
132
and
phase
Y connection
the silicon diode rectifies
all
waves
ELECTRICAL SYSTEM
It pulls
out the
neutral point
and adds voltage
Disassembly
having conducted 3 phase half wave rectification
in the circuit of relay and controls the voltage
coil of the
A
pilot lamp relay
and
Assembly
Disassembly
The
is disassembled in the
dynamo
following
order
r
r
I
I
0
a
l
E
j 1l
SC
o
U
9 i
Hi
FC
Dynamo
t
lePl
I
2 1
Fig
i
O
Charging System
5
Regulator
2 2
Fig
1
The completed
is
rhe parenthesized
the part number for
SP311
b
l
1
ji 1
0
I
f
I
r
I
I
Charge pilot lamp
Fig
When
battery
the
2 1
Outside Connection
6
switch
ignition
current
flows
in
the
direction passing through the
is
put
on
arrow
dynamo
a t
the
marked
E termInal
brush
field coil
slip ring
slip ring brush
dynamo F terminal
relay F terminal and IG
terminal and completes the field circuit
It in
difficult for the dynamo to stand up only by
Fig
Remove
brush
residual
magnetism of the field core so that
magnetization is necessary until voltage rises to
suit charging after the engine has started
This
is
the
voltage
proportional
the brush
cover
pull off
1
because the diode is used and when
to
add
to
resistance
it
is
shows
so
low
large
to
add
to
resistance
it
is
shows
so
low
t
r
up and current
0
t
makes very high revolution
This is because the diode is used and when
large
0
c
f
1
0
j
0
up and current
does not flow through the field coil unless the
dynamo
and
c
dynamo
voltage
proportional
2
2 ea
does not flow through the field coil unless the
the
2 2
makes very high revolution
Fig
133
2 2
3
the
DATSUN
Remove the
the hex
cover
of bearing and take off
bearing from the front
or tightening the
bearing plate and or pull off the bearing
the
Remove
bol t of shaft
d
ball
Remove
cover
with such
as
a
the bolt
hand press
Slacken N terminal bolt
side and
the
rear
the
and
cover
the
on
rear cover
clip terminal
the
remove
stator
then
be
can
separated
g
r
oQ
2 2
Fig
4
pulley and pull off
Be
the pulley and the half moon key
Remove
nut of
the hex
careful not to injure the fan when the nut
is removed
2 2
Fig
e
the
Remove
7
and stator
rear cover
Separate the silicon diode
3
stator coil lead wire
soldering
I
the
P
0
2 2
Remove
front
the
cover
front
cover
Use
a
and
and
cover
5
functioning
rear
of
tightening bolt
cover
pull off the
wood
or
plastic
iron
seconds
so
100
the
at
for
then
can
be
h
y
6
i
A
Fig
134
2 2
the electric
around
2
soldered portions
if
f
2 2
terminal
that use
200W
necessary
Fig
rear cover
the stator
and rotor
hammer
the
When temperature within diode gear
up over 150 C the diode will lose
holt
through
by melting
separated
NOTE
Fig
on
the clip
remove
rear
from the
ea
ea
with an electric iron
Slacken N terminal bolt
side and
3
8
ELECTRICAL SYSTEM
the diode
Remove
and brush holder
set
Installation
from the rear cover
When be careful
such
B
as
not to lose small
washers
screws
parts
Assembly
the heat sink or end
Support
and bushings
which fits
over
Press down
Assembly
is done in the reverse sequence of
disassembly
Always
make sure the
polarity
of alternator
I
case
positive
the
i
the
or
regulator
shows
coloured
diode
Fig
or
Black
2 2
AI
n
J
k
m
Black
Red
k
m
mark
9
2 2
Fig
Inspection
12
of Troubles
Inspection of Output
A
For inspection of output
Diode
2 2
10
ExPloded
inspection
removing it from
View
of AC
remove
a
diode
use
support the end of the frame
a
generator
of
output
of
the
as
dynamo
shown in
dynamo
the vehicle refer to
to be
without
Inspection
published later
lAe
suitable tool to
or heat sink
wiring
1 and drive it with motor
For
Removal
To
3
Fig
remove
the vehicle and connect
from
Fig
@
I
l
should be mounted in the frame of slip ring end
and the black coloured diode in the heat sink
Red
i
ff
i
red
alternator
ground
of B
I
j
lable which is attached to each model
In
the diode in the mount
ing bore of C portion to the lower edge
portion of the diode
Checking the replaced diodes
regulator before replacing the diode either
The polarity of alternator
positive or negative
or regulator is usually marked on the name plate
the
a
the outer diode edge A portion
perfectly
or
or
frame with
suitable tool and then press the diode in the heat
sink and end frame by using the tool shaped @
and
l
Ammeter
Q
push
s
the diode
own
out
by using
an
arbor press
as
I le
II
Volt
the below
meter
0
Fig
NOTE
Press
so
1
Use the battery charged in full up to
the normal
out
2 3
not to
capacity
injure the mounting
bore of the frame
Through
the heat sink
magnetic
field
Fig
2 2
11
the
coil
of
revolution
of
135
wiring
shown
current flows from
the
In this
dynamo
dynamo slowly up
in
Fig
3
1
battery
to the
state
raise
to
the speed
DATSUN
where there is
2 A approx
flow
no reverse
the field coil and read the revolution
revolution is approx
Next
and
the load current
to
resistance
stop
the
Then
shows
one
load
of
flowing
and put off the switch
current
dynamo
load
almost
alternately
low resistance and the
other shows pretty high resistance the 3
3 diodes in the diode set are all right
When
Without load
1000 rpm
increase
maximum
at both terminals
to
Correct
raising
increase revolution of
slowly
Observe thus increasing output current
U there is
as
revolution of
no
large difference from the specification
increases
dynamo
it is
correct
No matter
or
bow the
if the
discbarged
first make
sure
is in disorder
inserting the
battery
charging
either the
is over
charged
current is small
dynamo
or
the
relay
See the charging current by
ammeter between A terminal of
rei ay and the battery
Disconnect Wire passing from the
terminal to the
F terminal at
relay
dynamo
the relay
A terminal
relay
charging current highly
the
at
increases
as
When the
the
are
is
in disorder
However
Short Circuits
on
Diode
Side
flare
a
rare
and
also
rare
C
judged
if
even
Actually
of
be
the
the pilot lamp does not
as
short
switch
key
trouble such
as
at the
circuits
there
Ordinarily
is
turned
diode open
one
result is obtained
simple
test and the
many
are
often in opening
checking will
a
b
Separate Inspection
are
caseS
Diode with Tester
Simple Inspection
2 3
Fig
Check
shown
for
between
in
Fig
the
3 2
conductivity
Fig
2 3
4
Fig
2 3
5
2
terminals
dynamo output
A N
as
Set the dial of tester
and put the tester needles
136
1
when one
be necessary
side short circuits
Inspection of
3diodes
when there is no disorder found
on
is very
polar line
are
same
is somewhat lower than the standard
diodes
It can
same
also all right
in this
B
A E
above
when if the
relay
3
Check between the terminals
F
terminal and make the removed lead wire short
circuits
2 3
Fig
F
2
by
ELECTRICAL SYSTEM
Check resistance with the tester between
When
the diode base
the other shows high resistance
commonly
and lead wire
on
used for 2 diodes
the rear cover
2 times
no
disorder
will
changing the poles
side shows
one
be
If both sides
lnspectioll of
there is
low
there
are
open
Diode with Lamp
Simple Inspection
a
Check pOSitive diodes
negative diodes
Method
Lamp
Test
Lamp
Method
Connection
Lamp
Result
Light
Good
Test
Method
Connection
Should be
Connect
conductive
to
to
Check
Test
Test
@
are
short circuit and both sides
high there will be
D
low resistance and
@
to@
@
EEl
8
Lamp
Result
Light
Good
Method
Should be
and
non
No
Defective
Light
@
@
ductive
8 to
to @
Connect
con
and
No
Defective
Light
to@
Should be
Connect
non
to
con
@
8
No Light
and
8 to @
ductive
Defective
Light
@to@
Should be
Good
con
duc
tive
@
8 to
@andEjjto@
Connect
to
@
The
soldering for the lead wires should be
performed in less than 20 seconds as the
excessive
heat
may
Defective
Light
No
Good
Light
damage
the diodes
J
I
C
I
o
rii
i
1
l
Fig
Check
between
shown in
Fig
Connect with
and
3
the
A N
terminals
2 3
alternately
as
and
6
the lamp
put both ends
6
12V
at A and N
in
on
diodes
straight
terminals
l3
the
of
On
one
side the lamp flares
other the lamp is off
the
diode
set
are
all
when 3
right
DATSUN
Fig
2 3 9
Check between the lead wire and lhe diode
set common wilh lhe olher 2 diodes or lhe
with lhe lamp and
rear cover
is all
right
is off
If bolh sides flare
circuit
battery
It
if one side flares and the olher
and
bolh
sides
lhere is short
are
off
lhere is
open
E
Fig
The
same
terminals
is
step
N
all right
is all
right
is
E
taken
between
lhe
result
in lhe cover
if lhe simple test
but when the
lower lhan lhe standard
so
same
pressed
However
often be opening
Field Coil
7
When lhe
3 diodes
obtained
are
2 3
Inspection
dynamo output
1
that one
is
2 diodes may
by
one
check
will be necessary
b
Separate Inspection
Fig
As shown in Fig
Fig
2 3
8
tween
6
7 j
the slip
it
is
all
ring
2 3
3
of
right
10
10
put lhe tester be
rotor and
Make
sure
conduction between lhe rotor slip
shaft
138
if lhere
there is
ring and
are
no
lhe
ELECTRICAL SYSTEM
F
Ball
Both
Connect the tester cord to IOOV wire
Bearing
sides sealed ball
the stator
bearing
is
used
tester
so
lubrication is not
necessary
G
Inspection of
stator
the
turn
of the ammeter
Armature
there is
If
the ammeter
reading
abruptly
trouble
no
put
test stand and make the
short circuit on the coil
there is
Conduction Test
a
one
on
swings
increase and
there
will be
if
no
change
If the terminal connected to the diode is
not conductive with the
is all
stator core
that
H
Inspection of Brush
right
Wipe
with clean cloth when oil or dust is on
the contact
Same
as
surface of the brush and slip ring
in case of DC generator replace the
brush when wear of it reaoohed to the
wear
limit
REGULA TOR
L Construction and
1
Operation
Construction
Fig
2 3
11
Fig
2 3
12
If each
terminal
terminal connected
conductive
b
of
the
coil
and
Fig
the
to N terminal are not
Operation of
2
that is all right
3 1
Constant
1
Voltage Relay
r
Layer
Test
I
0
I
e
Isc
o
I
I
s
Fe
Dynamo
3 1
ignition switch is
through
battery passes
terminal
the
139
field coil
dynamo
LEecril
2
When the
13
c
J
Fig
2 3
S
E
I
Fig
O
o
I
II
c T
J
a
I
the
III
R
is
contact
magnetized
on
current from
the
points
dynamo
P2 PI
E
and
DATSUN
While it alBa flowB the
contact pOints
regulator
E terminai
iB kept
and continueB charging
evenly
and the lamp flares
PS P4
r
I
r
r
I
I
I
c
I
0
I
I
I
sc
Cl
U
r
I
I
I
I
l
I
Dynamo
I
L
II
In
I
I
I
I
I
I
I
I
I
I
I
o
I
L
RegulatornJ
lbn
J
3 1
Fig
3
iB
When the
the movable
piece
on
three phaBe alternate current generates
the stator coil
pas Bing through the three
contact point
Pz
phase all
direct
wave
current
Btarts and the
rectifier
diode
dynamo
and changeB
the terminal A E for
between
between A E
terminal
generates and
N terminal
circuit
voltage
pasBes
coil
VCI
with action of the VC coil
half
of
voltage
RZ
VCZ
through the
the movable contact
I
I
I
I
I
I
field
I
Dynamo
Regulator
J
L
I
c
tl
a
S
Fe
Jr
I
N
namo
Dy
contact point
flows
through
Pz
secondary voltage
When the dynamo
the terminalB
As
3 1
VCI
4
revolution goeB down and
the
coil
N E
result
weakep
s
the circuit of
PI
dynamo
voltage
between
the
electric
magnetiBm of
and the contact point
can
Ps
fixed
not continue contact
and changes to P
side and lights the
4
the current
With
E terminal
lamp indicating
P6
the
alBo lowers
with the movable piece
contactB With
6
charging capacity reduces
J
Fig
3 1
J
The operation of this time is called a high
Bpeed operation and the adjuBt voltage iB called
t
0
always kept evenly
Fe
u
I
voltage
I
and when the
IL
R
is
voltage
Fig
ISC
and
lsc
r
I
I
RI
and the
terminal
I
dynamo revolution getB higher the
point Pz BeparateB from PI With electric
magnetiBm of the VCZ coil and the field current
I
reBiBtance
P3
E
I
contact
HI
dynamo
I
I
When the
F terminal and reBiBtance
BeparateB from
the
generated
AB the reBult
r
then
voltage relay
coil
that current
BO
P3
I
E terminal
P2
through
terminal
dynamo
VCZ coil animated and prepares to vibrate
the movable contact point Pz of the conBtant
dynamo
P3
At such a high speed with open
goes up again
and close of the contact pilints
the
P2 and
the
from the circuit of the
and the movable
drawn
goeB down
F terminal
field coil
E terminal and
coil and A terminal
iB
BtickB to
dynamo
current from
of that
point Ps leaves from P 4 and makeB contact With
P6 BO that the lamp iB off and it paBBeB through
the circuit
E terminal
contact pointB PS
P6
reBistance
still higher
dynamo revolutiongetB
the contact point
the N
5
almOBt does not flow the field and the
to
charging
At
re
I
driven
When the engine
l
I
I
n
3 1
Fig
n
1
I
Regulator
I
J
gr
I
S
Fe
I
o
I
tl J
I
t
ISC
t
8 aT
II
j
I
l
a
I
non
generation
ThiB iB repeated
vibration of the
When the ignition SWitch is turned off to stop
the engine the lamp goes out and the current to
contact
terminal
the field coil is
field coil
F terminal
contact
according to
and
the dynamo
point Pz
pointB
Pz
PI
voltage
140
Buspended
ELECTRICAL SYSTEM
3
Operation of
As
Pilot Lamp
shown in Fig
3
1
with the contact points
contact
point
is
P5
2
N
terminals
E
the
First
put on the lamp with connection
shown in Fig 2 2 and read the voltage
this is made up
The
P5 and
P4
P6
N
Between the
4
movable piece is drawn
when voltage half of the battery is added and
From this state
volt split point
the
between N E terminals is conspicuously reduced
makes contact with P
4
voltage
to make contact with
sary for
P5
voltage
and
Put
2
on
that
P5
is
P6
changes from
P6
P4
is
3
voltage
Check
a
is 4 2
the rubbing resistance
put
lamp flares
voltage
on
5 2V
it is all
If the
and the put
on
Adjust
of
Constant
is
right
Adjustment of Gap Constant Voltage
Pilot Lamp Relay
voltage adjust values of the
voltage relay and the pilot lamp relay
2 3
as shown in Fig
The
Value
put off
voltage
Put off
to
Adjustment
1
is
5 0 3V
o
neces
move
and lower the voltage and read
when the
voltage
This
again
The voltage between N E terminals
betweel
E
P5
fixed to the movable piece separates from P
4
and makes contact to
When the voltage
P6
P5
as
by putting off the lamp moving the volt split
This is a put
point of the rubbing resistance
off voltage
the movable side and
on
makes contact with P
usually
Relay
Voltage
constant
must be
Relny
Gap
0
1
g
u
3 2
Fig
Connect the
shown
battery
and make the
G2
Gl
J
Constant
0
8
1
0
0
o
8
1
2
o 8
Voltage Relay
1
almost charged in full
revolution
dynamo
Pilot Lamp
as
7
G3
0 9
o 3
0 4
1
o
1
1
8
1
Relay
with
4000 rpm
When the
is all
2
voltage of this
time is 14
15V
it
right
Check
Voltage of Put off
Put
on
Auxiliary
leaf
spring
Pilot
Lamp Relay
r
I
L
I
I
I
I
Thrusting
I
I
J
esistance
I
I
I
I
I
Fig
I
N
r
3 2
3
I
I
p
l
I
1
p
I
p
I
4
I
I
Put off voltage of the constant voltage
I
E
VC2 R2
I
I
I
I
I
and pilot lamp
Adjust
I
I
L
n
Adjustment of Voltage
E
and donw
the
relay
voltage by bending
3 2
2
141
the stopper up
adjust value
Bend upward to heighten
and bend downward to lower
Fig
relay
adjust
value
r
DATSUN
14 ITEMS
ON
HANDLING
Prohibition
Reason
1
When mounting on vehicle polish the contact pOints
on both sides removing point
rust or oil
2
Make
sure
pitch
of
the
engine side pitch and dynamo side
cover are well fitted together
the front
3
Be attentive to the belt tension
4
Regulator
removed
sealed
is
during
the
lead
with
seal
If the
claim period
the claim
is
will
invalid
5
If the earth is not correctly set
will change
6
Connect the
the
adjust
value
and battery with full attention
dynamo
When the
battery poles
battery
dynamo
to
ages of diode
7
Make
the whole
sure
circuit is
completely
or
are
connected in
current flows
large
reverse
from
in dam
resulting
lead wire
com
posed
8
Change wiring
with full attention
When
after
dynamo
is
switch
the engine
started the
magnetized from the ignition
that
so
incorrect wiring will
result in hampering magnetization and
then generation
I
9
Do not
use
the high voltage tester such
as
megger
I
As diode is built in
damaged
10
Engine
room
must be
kept
in the condition of stand
ard usage
Because
11
Do
not
the battery terminal
during driving vehicle
separate
terminal
there
deteriorate
ature
dynamo
the diode will be
with high voltage
or
higher
is
diode
will
be damaged with temper
than the normal
Separation ofthe terminal
voltage
which
within
battery
causes
and
serge
dam ages
diode
12
When
cleaning with steam cleaner do not expose
When washing with
dynamo to steam directly
water
dynamo must be free from reckless pour of
If the diode is
mance
moistened
the
perfor
will be lowered
water
13
When the
battery
charger
the
dynamo
14
Put
the
is
lead
A terminal
key
quicklv charged with the quick
regulator A terminal
wire or
Serge voltage
also
damage
of the
quick charger will
diode
should be disconnected
switch off when the
engine
in a stop
except when particularly needed
When
the
key switch is on magnetic
always flows on the field coil
and might damage the dynamo and often
causes over discharge of
battery
current
142
ELECTRICAL SYSTEM
TROUBLE SHOOTING LIST
Trouble
5 1
Over
Cause
Remedy
discharge of battery
1
Slackness of fan belt
2
Earth or
3
Breakage of
4
Mal contact of brush and slip ring
Mal function of diode
5
Adjust
breakage of
stator coil
Repair or replace
Replace
Replace blUsh clean holder
Replace as a set
rotor coil
6
Adjust voltage
7
Mal contact of low speed side contact point of
constant
of constant voltage relay is low
voltage relay
Polish contact point
8
Adherence
9
unfitness of electrolyte
Mal function of battery pole
short circuit
Add distilled water
11
Mal contact of
battery
Clean
12
Mal contact or
breakage between ignition switch
10
Shortage
and
of
Readjust
high
point
relay
terminal
IG terminal
Mal contact
14
Excessive electric load
or
terminal and
Over
contact
or
13
5 2
side
speed
1
Constant voltage
Constant
3
Constant
between
regulator
4
Constant
F terminal
Repair
Check power consumed
5
Constant voltage
relay adjust voltage
voltage relay coil
is too
breakage
or
high
Replace
voltage relay
coil straight resistance
Replace
voltage relay low speed side
contact
point adherence
9
Replace
relay high speed side
contact
point mal contact
Breakage or rare short of pilot lamp relay
Mal contact of pilot lamp relay contact point
Mal function of regulator earth
Mal contact or breakage between regulator N
terminal and
5 3
Noises
Readjust
rare
breakage
8
repair
retighten terminal
F
short
7
check S G
or
charge of battery
2
6
Replace
Repair
breakage
dynamo
Replace
dynamo
N terminal
Polish contact point
Replace
Polish contact point
Adjust
Repair
of Dynamo
1
Mal function of
2
Mal function of diode
3
Earth
or rare
bearing
Replace
Replace diode
Replace
short of stator coil
143
as
a
set
r
DATSUN
STARTER MOTOR
with the
the
right
switch
direction
to
move
and
starter
switch
ignition
By turning
the
permit
relay
the
switch to
magnetic
current to flow to the
the armature
cause
on
to start
turning
suddenly
CONTACTOR
ARMATURE
BRUSH
Fig
Type
S1l4
92
Make
Hitachi
After
Weight
4 6
completes
kg
S114
Type
Rated Output
V
Kw
12
92
1
No Load Rev
rpm
Brush Normal Height
mm
Brush Wear Limig
mm
4
5
kg
o
8
Spring Tension
Commutator
Above 7
mm
14
33
Dia
rom
2
bending torque
reducting
After the engine starts and
speed becomes greater than the no load
speed of the starter the pinion is kicked back to
unmesh and return to its former position
000
rom
pmlOn
its
60
Dia
the
shaft towards the starter bracket thus
Magnetic
V
Under 12
14
the
0
No Load Current
A
about
advancing
meshing into the ring gear and
drives it with a powerful torque
The direction
in whicll the pinion moves is from the end of the
the
Meshing Device
Brush
Magnetic Shift Type
1
Motor
Starting
STARTING
SWITCH
CONTACTOR
Commutator Wear
Limig
Pinion Operating
Voltage
Gap
V
Pinion
Under 8
3 5
mm
RING GEAR
PINION SLEEVE SPRING
Construction and
The
starter
sliding
inertia
on
the
The
similar to
in that its
with
in
a
Fig
The
0
horsepower
motor
for
directly opposite
that of the
Fig
in
2 A View
of
Starter System
engine
to the
ring
Operational
generator but differs only
Precautions
armature shaft extends out backwards
pinion group installed
1
use
construction of the starter motor is
on
The instructions to be observed when
the end as show
the engine
2
connection
shown in Fig
The
1
a
front right side of the transmission
with its pinion gear
gear
is
The motor when mounted on the
starting
is
motor
type electric
1
PINION SLEEVE SPRING 2
Operation
diagram
for the starter
1
switch is a
key type
starting
follows
is
3
starter
are as
combined
The
the
144
starter
should be
securely
engine and should not
mounted
on
show any looseness
ELECTRICAL SYSTEM
PIN
ASS y lever
PIN lever
ASS y
ASSrY switch
I
cotter
pinion shift
magnetic
shift
case
gear
n
o
SCREW
Fig
3
set
pole
core
Hitachi
starter Motor
Checking
2
The
starter
switch
should
be
and should be release
properly
operated
1
immediately
should
engine
normally
switch
starter
engine
fails to start
come
to
switch
rest
is
weather
start
within
the
engine does
through the
10
should not be operated
running
gear
allow time for the pinion to
before turning the starter
engine fails
the starter
continue
key for
turning
to save the
for the
starter
is used
when the
the current is
flowing
motor coil but for some
the armature is not turning
Careful
should be made since the starter
in the
and unable to return
a
flywheel ring
trouble
caused by turning on the starter
engine is still running
usually
while the
again
When the
try
not start
pinion may be locked
If the engine
2
4
and with the
starter switch
lamps lighted
lamps become dim especially
reason
when the
fully charged battery
a
check
The
Operation
If the
seconds
3
in
the
when the
engine starts
Excepting in extremely cold
With
While
cause
the
to
over
key
battery
When the starter switch is turned up and the
start after
turning
10 seconds
do not
remain
lime after time but
checked
If the switch
In this case
condition
then
starter motor fails to turn
check
of the trouble and correct
terminal
so
that the engine will start
battery
145
bright
and
the
the
should first be
is
in
condilion
ground
starter
although the lights
switch
satisfactory
of
all
the
connections
of
the
switch
and
starter
are
r
DATSUN
checked
If the starter motor
movement
is
sluggish
resistance
high
the
starter
it
runs
taken
but its
indicates either
when inspecting
to
flywheel and take remedial
a
to loose connection in
due
circuit
or
the
badly discharged
a
If after the above troubles are corrected and
the
starter fails to operate
internal defects
that in this
so
2
occasionally and
shows defective performance
it
is
due to
same
are
Dismantling
and
starter
starter on the
to
be
two
dismantled
stud
nuts
core
the
check
the
armature
shaft
in
bushing
etc
that for the
as
to
shaft
gap
bending
manner
in the
generator and
corrected to the specified limits
is
not
easily by
mounting
the
replaced
the
or
attention
Special
and corrosion found
contacting
outside surface of the armature
surface of the
engine
The two stay bolls on the starter rear cover
front end when mounted on the engine are
removed
core
should
the
on
the inner
or
be removed
by
and the surfaces painted with rost
polishing
2
replaced
should be given to the clearance between the
armature and the core to see that they are
Disassembling
can
the
removing
the
inspecting
clearance
it should
case
When
armature
The
if the
When
damaged
pinion is found defective
pinion group
armature
be dismantled and checked
1
check the
entire
battery
3
gear is found worn or
ring
also
measures
preventive oil
3
The
armature
inspected
is
and
repaired
in
accordance with the procedures outlined for
3
After removing the band cover
and lead wires are removed
the broshes
the
broshes
4
By
properly
body
starter
and
protecting
the
armature
holding
the
Especially
generator
correct the
are
brosh
brush
The
insulation
At the
same
checked
spring are
corrected or replaced
shaft is pulled
improve
contacting condition
reseated
the
to
or
the
time
and
are
out
4
5
The
out
6
and the front
armature
taken
cover are
the
remove
shaft
armature
pinIOn
group
from
the
5
the cotter pin on the end of
the
nut
and
Inspection
The same
inspected after
or
group
Repairing
procedure
parts is followed
as
pinion
the
as
is
which determinations
they can be reused
replacements are necessary
pinion
tooth
face
damaged
the
generator
a
or
are
if
shaft
will
weak
or
cause
especially
strictly tested
part
one
by buring should be
test
only
L dimension
For this last reason
between
the
pinion
in
Fig
4 must be
following
L
0 3
5 mm
adjust
plunger gap of the magnetic switch by following
paragraph b
Pay attention that theLdimension
must
be measured when the pinion is
pushed
wear on
out
by the shift lever of
the
atmostly
plunger and
the back lash ofthe
pinion is eliminated by pUSh
ing gear inward with finger as Fig 3 shows
poorly meshing
in the armature
care
clearance
In case that the Ldimension is incorrect
make the
but will hasten the
bending
correct
stopper and pushed out pinion which is shown by
inspected for defects and if the
the
worn or
tooth edge is
the pinion should be replaced
poorly
found with
Meshed Pinion Position by Magnetic Switch
The
made
repairs
is
opposing gear and also
gears
carefully
are
with
ADJUSTMENT
is
Worn or broken teeth will not
gear mesh
wires
found
parts being cleaned and
to whether
The
armature
by the insulation
1
1
the
wires
removed
Parts
that for lhe
An
damaged
the shaft is pulled out and by removing the
pinion
on
damaged insulation should be replaced
together
To
and
inspected
If the L dimension is incorrect
should be
146
It wll1
be
the
ELECTRICAL SYSTEM
possible
cause
wear and
of
large meshing
noises or
of the pinion
damage
and
early
ring gear
7
Y
I
10
1O
3
1
Slltllt
1
Fig
Fig
4
Checking
6
Measurement
of Plunger Cap
Dimension
l
1
t
r
Battery
1
CH
I
r
J
Fig
5
I
of
Adjust
Cable Connection
Dimension
Adjustment of Plunger Gap
of
I
r T
Magnetic
Switch
The
o
dimension when the plunger gap is
L
compressed
L
31
7
This
to
0
must
be
following
in
t
I
00
b
i
Fig
Fig
6
a
o
Removing Magnetic
Switch
32 3 mm
adjustment
is carried out at the
adjuster
and the adjusting nut
DISASSEMBLING AND ASSEMBLY
OPERATION
5
1
Disassembling the Armature
Gear Case
and Pinion
Disassembling
Fig
order is shown
by Fig
a
to
c
o
Disassembly
is
operated
by removing
magnetic switch fixing bolts through bolts and
the armature shaft clip
Before disassembling
main
fixing
body
remove
screws as
brushes by unscrewing brush
Fig
0
Q
0
I
Fig b Drawing out Brushes
After removing fixing screw
6
14
rj
DATSUN
ARMATURE
PINION
STOPPER
o
Fig
c
Drawing
Out Yoke
Fig f Disassembling
o
Armature
GEAR CASE
SHIFT
d
Fig
Disassembling
LEVER
Armature and
Fig
g
Gear Case
Removing
Pinion
Clip
SL
EEVE
PINION SLEEVE
SPRINC3
PINION
seREVV
Fig
e
STOPPER
CLIP
Id
DRIVER
Removing
Pinion
Fig
Stopper
148
h
Disassembling
Subassembly
Pinion
ELECTRICAL SYSTEM
L
0
8
oo
01
1
o 0
o
0
r
r
e
M
OIV
Q
MJJ
i
Fig
DisPlay of all Component
Disassembling Pinion
the
current
magnetic
Disassembling is carried
pinion clip as Fig g
will
Assembling
of
sequence
be
out
by removing
in
magnetic
B
and
Testing
R oassembling is
reverse
frictional
8AE
30
parts
are
Starter
disassembling
are
All
coated with
82
switch
opens
the
opens
Releasing
magnetic
the
wire
coil
to
the
body
8
case
of switch
lies
in the
81
opening but
In either case
faulty moving
the
of the
roughness ofthe contacting point
Therefore polished the surface
then the operation will become
surface
the starter
well
circuit which also
satisfactory
Causes for mechnical troubles
for
operate
can
mechanical
magnetic
be
switch
failing
to
cases
divided into electrical and
core
sources
82
Causes for electrical troubles
to
the
starter
can
freely
149
caused
in
cover
many
hole
be made in this
the cover screws
retightening them
switch in pressed and
is
sticking against the
Correction
Current failure in magnetic circuit
operate
by the guide shaft on the moving
of the magnetic switch main clrcuit
loosening
When
magnetic
and defective ground
or
core
82
Causes
A
from
switch
opposite
Failure
1
wire add the
remaines closed
trouble
a
82
to close
coil
Defective contact in main circuit
the
small amount of grease circuit in the magnetic
switch and causes the main circuit
in the
magnetic circuit
trouble is
magnetic circuit is satisfactory
and 82 is closing but only a small current
flowing due to high contact resistance and
lubricated with mobile oil
while the bearings
of the
the
When the
performed by following the
for
procedure
through
pass
most
terminal
connection
At
assembly check each dimension and major
specification standard
Assembling
magnetic
switch
reverse
disassembling operation
circuit
to
due to broken soldered connection between
the
done
falls
so
4
case
pieces
that the shaft
by
and
moves
DATSUN
2
Construction of Magnetic Switch
Precaution
and Instructions
In removing nuts from the magnetic switch
main circuit terminals when installing or
magnetic switch is
the engine is being started by
removing cables the lower nul of the double
nuts should be kept in a tightened state while
to
If the lower
unscrewing
nut
the
is loose
terminal bolt may turn together and ground
the terminal to the cover and cause damage
Remedies
The following is
a
from
installed on the
engine
1
is
engine
cranked
by
state
starter
flow
starting
actuate
the
when
the
or
switch serves to
a
large
starter
keep the
current to
motor
is
engine
After
the
stopped
circuit open
the
starter
The
is
m
CONNECT TO
OlHERS
to see if
checked
it
can
be
hand
the engine is at fault
If it can be cranked
and should be checked
starter
the
be
should
and permits
motor
and
IGNITION SWITCH
If it cannot be cranked
easily
serves
close the circuit between the battery and the
Starter fails to turn
The
apparatus when
shift lever
list of troubles which can
the
be determined
an
principles of operation can be seen from Fig 7
Closing the starter switch 81 allows the current
to flow through the magnetic
and
Then Causes
Starter Troubles
The
checked
the
including
and
BATTERY
wiring
correclion
made
accordingly
Is the
battery
gravity
1
over
battery
of
the battery
and
240
as
Check the specific
down
run
fluid to
recharge
see
If there is trouble in the magnelic circuit
found necessary
tightened
Magneto grease or Gargoyle BRB No 1
All cord connections are carefully tightened
given to the condition
The assembly check is made
attention
of insulation
by testing the starter as
a fully charged battery
with
a
starter
motor
apparatus
shown in Fig
torque is
measured
a
single
unit
4
be
9
this
m
checked
made
case
all
the
assumed
the
ce
l
I
7ffiVolt
Startu
the
to
see
with
their
itself
so
that it
usually
improperly
15v
Gl
can
500A
forth
motor
Torque Testing Apparatus
to
repairs
150
wt care should be
ring gear
by badly
Cases like this
worn
are
gears meshing
and if the defect is not too severe it
by placing the gear shift lever
be remedied
into fourth
Battory 12v
rare
that the starter pinion is not locked
speed and rocking the
free the
the
car
back and
If this trouble is
gears
repeated
dismantled from
7
should
replacement
checks
starter
exceedingly
flywheel
frequently
Fig
above
in the
be
caused
Ammeter
dynamometer
of
This is
into the
Bai
or
should be removed from the engine and checked
kg
mot
corrections
corresponding repairs have been made and the
starter still fails to operate the trouble can be
taken to
Starter whe
and
found necessary
as
If
using
with
starter broshed
the broshes together with the armature
by which braking
In
normal value should be 0
or
improperly contacting
For
Tests are made
tester
it
should be corrected
cleaned and properly
special
Starter Circuit
Magnetic
replace the
or
All loose battery and ground cables should be
and
8
Fig
if it is
starter
the engine
for
should be
checking and
ELEOTRIOAL SYSTEM
1
Starter
turns but its
and fails to start the
turning
engine
If the trouble is due to
worn
damaged
are
described in the
If
the
outer
etc
made in the
or
the
dirty and
checking
same manner as
preceding chapters
surface
of the
armature
is
the starter should
rubbing against
be dismantled
disassembled and repaired
the
deformed
are
noise
Rattling
mounting bolts
there is the case of the
loose
starter
by brushes improperly contact
required correcting as this
ing
condition not only produces noise but will
hasten
wear
on
the
by the
large
a
and the bushing
rubbing against
the worn
parts should be
between the shaft and
replaced
bushing is due to lack of oil so that attention
should be given to proper lubrication
so
Wear
grade
once
every half year using good
of machine or mobile oil and lubricate
through the oil nipples
required is about 0 5
amount of oil
each bracket
151
armature
while in operation is caused by too
clearance between the armature shaft
Lubricate
when operation
both parts
core
shaft should be cleaned and oiled
screw
exceeding noisy
by
corrected by retightening
Noise caused
guide on the pinion shaft being
dirty and not allowing the pinion to advance
smoothly and causing improper meshing the
Starter
caused
are
the bolts
the parts
2
they should be repaired
the gear replaced
Noises made
If the trouble
pinion meshing improperly
is due to the gear teeth being badly worn
the gears should be replaced but if it is due
to
gear is checked and if the
the armature
the core
Besides the above
flywheel ring
The
teeth
down battery
and sticking brushes
commutator
and repairs
run
troubles in magnetic shift
loose terminals
switch
a
power is weak
The
cc
for
r
DATSUN
BODY
DISMOUNTING
ASSEMBLING
Parts
Body
Mechanism of
Hood Bonnet top
the Hood Lock
Disassembling
To
completely remove the hood Bonnet top
simply a matter of detatching the bolts of the
hood and hinge at each side
visible when the
hood is remove after disconnecting the support
is
Detach the
grill of
radiator from the front of
body
Disconnect the relurn spring of the hood lock
lever from back of the radi
r
top frame
of it
Assemhling of the
dismantling process
hood is
a
reversal
of
Hood Lock
To
adjust
the position of the hood lock bolt
for the hole of the radiator top frame
To
remove
up or down way
By removing the
nut at the
top of the center
bolt of the spring unit
the spring center bolt
etc
can be separli
d from the hracket to the
bonnet top
To remove left or
right
side way
By removing the position of the hood and
hood
hinge
to left or
bolts
can
he
adjusted
Disconnect the Return
right side
Adjusting
Remove the hood lock lever
working
clamp
Detach the
loose through
assemhly
of female from the front
panel
the lever the hood lock cannot he hold the hood
tightly
Adjust by removing the position
lock lever as showing the figure
Adjust
the Position
of Hood
from its
lever
the Hood Lock Lever
In the event of the hook
Spring
the direction
of the hood
Disconnect the Hood Lock Male
Assembly from the Hood
Lock Lever
152
BODY
Assembling of the hood lock
reversal of disassembling routine
system
Front Fender
is a
Detatch the front bumper
Jack up the
front wheels and take out the
Disassemble
the head
tire
lamps
and
parking
lamps from front the
Remove the
body
antena assembly
Detatch the fender milar and side emblem
Disconnect the bolts and
the
Disconnect the Hood Lock Female
Adjusting
the Position
for Upper
or Lower Direction
153
figures
screws as
showing
r
DATSUN
moulds inside and out must be removed also the
door
glass must be removed from
upwards through the main aperature
the
door
Front Dopr
Front door trim
1
Take out the door
inside
regurator handle
shown the figure
as
handle
I
I
T3
panel
lO
I
J
J
T3 261
2
Assembling of the front
the disassembly routine
fender is
a
reversal of
Front Door Window
To
a front
change
the door trim
the
drive
door window
first
then lower the window
screws
that
secure
remove
Extract
the window
rear
channel to the door frame
Rear Door Window
The
window
routine
same
is
door window
instance
front
bracket
and
for removing
a rear
as
that outlined for
namely
removal of trim
adopted
window
regulator
channel
In
a
door
front
in this
window
stop
addion the window
154
Take out the
moulding garnish
inside
and wind
BODY
Remove
the
the
front door finish
as
showing
in
Remove the
figure
Springing
fixing
bolts and
screws as
show
ing figure
Door Trim
Clips from
Assembling of the front door
the disassembling routine
is
a
Remove the Front Door Ventirator
Door Shell
reversal of
Front Door Glass
Take out the panel of front
strip
the vinyl
Loosing
the
cover
on
the
screws
door trim and
operation hole
remove
the door
regulator
Unscrew the Bolts
Detaching
Door
Screws
Regulator
T3 245
Remove the Velltilator Glass Frame
155
r
DATSUN
The
door
glass
be removed from
must
the
door upwards through the main aperture
1
Remove the nut
2
Detach the
of pivot pin and the spring
rivet
and then
remove
the venti
lator window
Remove the Door Glass
3 Take off the lock of ventilator
4
Removing
the front door
glass
from the
Change
bezel of channel
1
Remove
slightly
the
glass
of channel
the
the front
glass as same as
glass replacement
method
the
of
Door Lock Mechanism
by tapping
with wooden hammer
Removing
1
Detach
body
the
door trim panel from
front
and strip the
vinyl
cover
the
of the operation
hole
2
Take off the 2 numbers set
screws
and detach
out side handle from the door
I
tt
J
i
0
I
To
fixing
for the channel
insert the
v
7I
r
8
i
I
2J
glass
with the weather strip in the bezel and tap
b
18
with wooden hammer
slightly
Detaching
r
156
Outer Handle
J
I
I
BODY
Loosing the
of front door
in the
detach
screws
the
lock remote control
assembling
as
the shown
figures
e
i
T3 257
Remollal the
3
Remove
cylinder
the
and
Retaining
retaining plate of
detach
the
Plate
the
door lock
cylinder assembly
Front door
1
Removing
the
pin of
the door check
linkage
detash the check link
l3 56
Extract the Door Lock
Cylinder
2
Detach
pillar
the
bolts of door hinge at the front
take off the door
assembly
Wind Shield Glass
Removing the wind glass
Unscrew the Front Door Lock
IS
1
Extract the
2
Detach the shield
3
Strip out contact portion between the weather
strip and the body with a spatula
wipper
arms
molding
if used
DATSUN
4 Detach the front wind
strip carefully
as
glass with the
showing the figure
weather
4 Offer the window to the
car
5 Remove the weather
wind
maintains pressure
the detached
strip from
glass assembly
on
aperture frame of the
from the outside and whilst
on
the inside of the
the
car
glass
1
Assembling
material
glass
gloove
erture
outer rubber
to the wind sheild
insert
sheild
front
Iass
body
the above
assembly
the
edge
over
which will
the scuttle
bring
the
side and
Finally peel out the cord so that the rubber
lip settles over the fascia
side fillets and
headlining
Pushing or tapping the front
wind ghl sS assembly from the outside of it
assemble the glass as pulling out the cotton
string to a right angle slowly
the prepared wind
to
lip
over
top window frame
insert the strong cotton
cord to the
of the weather strip inside around of
it
2 Then
the ap
operator then
The outside
arrange the outer
the weather strip with the sealing
cemendine 366E
frame
operator
the operator
should peel out the
cord of the inner lip which fits
Fixing the wind glass assembly
one
frame of the
where the bezel is to fit
t
3
To assemble to fix for the frame
Two operators
wind
First
glass
are
essential when
fitting
the
5
glass
the rubber must be sprung over the
which fits into the deep square groove
whilst the
large portion
of the bead
bulges
6
and bead
on
sealing compound
between
up
to
between
Clean
and
spatula
Fixing
glass
158
sealing
the
wipe
around
the
of the front
the outside face
the
366E
material
the inside of the curvature
Next insert
Filling
material
weather
off
the
the
excess
weather
wind glass
glass fixing
rear
cemendine
strip and body
strip
sealing
by a
is a same method
m