wheel bolts DATSUN 210 1979 Service Manual

9
Make
SUre
there
is

proper
end

play
at

crankshaft

Crankshaft

end

play

0
05toO
15mm

0
OO20
to
0

0059
in

laJlk
h
end

play

J

EM486

Fig
EM

63

Checking
Crank

luJft

End

Play

10

Install
rear

oil
seal

using
suitable

drift

Fig
EM

64
n

talling
Rear
Oil
Seal

II
Install
rear

plate

12
Install

flywh
el

secwely
and

tighten
bolts
to

specified
torque

dl
Tightening
torque

Flywheel
and
drive

plate

A
14

engine
fixing
bolts

8
0

to
9

0

kg
m

58
to

65
ft
Ib

Drive

plate
A
15

engine

fixing
bolts

8
5

to
9
5

kg
m

61
to
69
ft
b

Fig
EM
65
n

talling
Flywheel

13

Rotate

engine
quarter
turn

and

install

piston
rod

assembly
using
Pis
Engine
Mechanical

ton

Ring
Compressor
EM03470000

EM497

Fig
EM
66

tolling
Platon
Rod

Assem

bly

Note

a

Insert

pistons
in
L

r
nding
cyl

inders

b

Apply
engine
oil

to

sliding
parts

c

Arrange
pistons
so
number

stamped

on

piston
head
faces
to
front
of

engine

d
Before

installing
piston
piston
rings

should
be

positioned
as
shown
in

Fig
EM
67

Second

ring

Oil

ring
lower
rail

EM49B

Fig
EM
67

Positioning
Piston

Ring

Gap

14

Apply

engine
oil
to

bearing

surfaces

dl
Tighte
ning
torque

Connecting
rod

cap
nuts

3

2
to
3

8

kg
m

23
to
27
ft
b

EM499

Fig
EM

68

Tightening
Connecting

Rod

Cap

Note

Am11
connecting
rods
and

connecting
rod

caps
so

cylinder

numben
face
in
same
direction

EM
14
I

S
Make
sure
there

exists

proper

end

play
at

connecting
rod

big
end

See

Fig
EM41

Big
end

play

0
1
to
0
2

mm

0
004
to
0
008
in

16

Insert
crank

sprocket
keys
in

keyways
of
crankshaft

Install
cam

shaft
and

crankshaft

sprockets

tempo

rarily
for

adjustment
of
tooth

height

by
using
adjusting
washers

Height
dif

Less1
h
l11

0

5
mm
0

020
in

Adjusting
washer

thickness

0
5
mm

10
020

in

EM500

Fig
EM
69

Adju
ting
Sprocket

Tooth

Height

17
Install

tinting
chain
and
cam

shaft

sprocket
with
their

markings

properly
aligned
See

Fig
EM
70

Then
set
No
I

piston
at
T
D
C
on

compression
stroke
See

Fig
EM
71

Oil

sprocket
teeth
and
chain
with

engine
oil

Match
mark

Key
groove

EM501

Fig
EM
70

Aligning
Markinga

Note
Make
sure
camshaft

sprocket

dowel
hole
and
crankshaft

sprocket

key
are

in
line
and
both
dowel
hole

and

key
are
located
downward

2
Loosen

belt
then
remove
fan

blade
from

torque
coupling
and

torque
coupling
and

pulley
from

hub

Air

conditioning
system
equipped

models

only

4
Remove

pump
assembly
and

gas

ket
from
front
cover

C0051

Fig
CO
3

Removing
Water

Pump

INSTALLATION

1
Be
sure
to
clean
the

gasket
sur

faces
in
contact
with

pU
flP
and
front

cover

Always
use
new

gaskets
when

installing
pump
assembly
Be

sure
to

tighten
bolts

i
l
Tightening

torque

Water

pump

securing
bolts

0
9
to
1
4

kg
m

6
5
to
10
1
ft
Ib

2
Fill

cooling
system
and

check
for

leaks
at

pump

3

InstaD
fan

pulley

spacer
or

torque

coupling
and

fan
blade

and

tighten
attaching
bolts

securely
Install

belt

and

adjust
for

specified
tension

4

Operate
the

engine
at

fast
idle

and

re

Check
for
leaks

S

Install
fan

shroud

Note

Ensure
that
clearance
between

shroud
and
fan
even
at

any

place

DISASSEMBLY

Water

pump
should
not
be
disas

sembled
Cooling

System

INSPECTION

Inspect
pump
assembly
for
the

following
conditions
and

replace
if

necessary

I

Badly
rusted

or
corroded

body

assembly
and
vane

2
Excessive
end

play
or

roughness

of

bearings
in

operation

Note
If

excessive
mechanical
seal

squeak
occurs
when

engine
is
mn

ning
use
suitable
water

pump
seal

lubricant
to

prevent
squeak

ADJUSTMENT

Check
belt
deflection
between

alternator
and

fan

pulley
by
a

force
of

10

kg
22
Ib

Fan
belt
deflection

8
to
12

mm

0
31
to
0
47
in

If

adjustment
is

necessary
loosen

bolt

retaining
alternator

adjusting
bar

to
alternator
Move
alternator
toward

or

away
from

engine
until
the

correct

tension
is

obtained

TORQUE
COUPLING

The

torque
coupling
keeps
the
fan

speed
at
2
900

rpm
rated

or
below
to

conserve

horsepower
at

high

engine

speed
It
also

helps
reduce
fan
noise
to

a
minimum

during
high
speed
opera

tion

This
unit
is
filled
with
a

special

silicone
oil
used

as
a
fluid

coupling

which
controls
the

fan

speed
Silicone

oil

can
not
be

replenished

The

torque
coupling
is
installed

only
on
the
model

equipped
with
the

air

conditioning
system
In
this
case

use
7
x
350
mm

13
78
in
diam

eter

cooling
fan

CO
3
C0052
t
Wheel

2
Disc

3

Bearing

Fig
CO

4

Torque
Coupling

REMOVAL

Lousen
fan

belt

2
Remove

fan
blade
from

torque

coupling

3
Remove

torque

coupling
from

pulley
and
water

pump
hub

by
re

moving
securing
nuts

INSTALLATION

I
InstaD
the

torque
coupling
in
the

reverse
order
of
removal

2
Install
belt
and

adjust
belt

ten

sian

DISASSEMBLY

The

torque
coupling
is
so

designed

that

it
can
not
be

disassembled

INSPECTION

Inspect
torque

coupling
for
oil

leak

age
If

necessary
replace

REMOVAL

AND

INSTALLATION

I

Jack

up
the

car

Note

Apply
parking
brake
and

place
wheel

chocks

2
Remove

screws

securing
lower

shelter
of

catalytic
converter

Loosen

flange
bolt

connecting

catalytic
converter
to

front
and

rear

exhaust
tube

Catalytic
converter

assembly
can

then
be
taken
out

3

Installation
i
in
the

reverse
se

quence
of
removal

CAUTION

a
Be

careful
not
to

damage
catalytic

co
when

handliilg

b
Never
wet

catalyzer
with
water
oil

etc

t
J

Tightening
torque

Catalyti
converter
bolts

2
6
to
3
4

kg
m

19
to
25
ft
lb
Emission
Control

System

EC075A

EC076A

Fig
EC
103

Removing
Catalytic

Converter

INSPECTION

PrelimInary
In
pectlon

Vi

ually
check
condition
of
all

component

parts
including
hose

tubes
and
wires

replace
if

necessary

Refer
to
Air

Injection

System
for

inspection

EC
34
Catalytic
converter

Whether

catalytic
converter
is

nor

mal
or
not
can
e

checked

by
ob

serving
variation
in
CO

percentage

The
checking

procedure
is

as
follows

Apply
parking
brake
Shift

gears

into

Neutral
for
manual
transmis

sion

and
N
or

P
for

automatic

transmission

position

I

Adjust
engine
idling

speed
and

CO

percentage
Refer
to

Adjusting

Carburetor
Idle
RPM
and

Mixture

Ratio
for

adjustment

2
Race

engine
1
500

to
2
000

rpm

two
or

three
times

under
no
load
and

make
sure

that

specified
CO

percent

age
obtained

3
Remove

cap
and
connect

air
hose

to
air

check
valve

If

idling
speed
increases

readjust

it
to

specified
speed
with
throttle

adjusting
screw

4

Warm

up
engine
for
about
four

minutes

at
2
000

pm
under
no
load

S

Measure

Ci
percentage
at

idling

speed
After

stepAhas
been

complet

ed
wait
for

one
minute
before

making

CO

percentage
measurement

6
If
CO

percentage
measured
in

step
5
is

less
than
0
3
the

catalytic

converter

is
normaL

7

If
CO

percentage
measured
in

step
5
is

over
0
3
recheck
AJ
S
and

1

replace
air
check
valVe

The
perform

inspection
steps
4

and
S

8

If
CO

percentage
is

still
over
0
3

in

step
7

catalyt
iC

converter
i

mal

functioning
Replace
catalytic
con

verter

REMOVAL

It
is
much
easier

to
remove

engine

and
transmission

as
a
single
unit
than

to

remove
alone
After
removal

engine

can
be

separated
from
the
transmission

assembly

WARNING

a
Place
wheel
chocks
in
fronl

of

front

wheels
and
in

rear
of

rear

wheels

b
Be
sure
to
hoist

engine
in
a
safe

manner

c
You
should
not
remove

engine

until
exhaust

system
has
com

pletely
cooled
off

Otherwise

you
may
burn

your

self
and
or
fire

may
break

out
in

fuel
line

Note
Fender
coven
should
be

used

to

protect
car

body

1
Disconnect

battery
ground
cable

from

battery
terminal
and
fusible
link

at
wire

connector

2
Remove
hood

as
follows

CAUTION

Have
an
assistant

help
you
so
as
to

prevent

damage
to

body

I
Mark
hood

hinge
locations
on

hood
to
facilitate
reinstallation

2

Support
hood

by
ltand
and
re

move
bolts

securing
it

to
hood

hinge

being
careful
not
to
let
hood

slip
when

bolts
are

removed
See

Fig
ER
2

3
Remove
hood
from
hood

hinge

f

Il

I

BF133A

Fig
ER
2

Removing
Hood

Remove

under
cover

Drain

radiator
coolant
and

engine
3

4

oil

5

Disconnect

upper
and
lower
hoses

from
radiator
and
disconnect
oil

cooler
hoses
automatic
transmission

only

6
Remove
four
bolts

securing
radia
Engine
Removal
Installation

tor

to

body
and
detach
radiator
after

removing
radiator
shroud

7

Remove
air
cleaner

assembly

from
carburetor
as
follows

1
Remove

fresh
air
duct
from
air

cleaner

2
Remove
hot
air
duct
from
air

cleaner

3

Loosen
air
cleaner
band
bolt

4
Disconnect
air

cleaner
to
air

pump
hose

at
air
cleaner

5

Disconnect
air
cleaner

ta
rocker

cover
hose

at
rocker
cover

6
Disconnect
air

cleaner
to
A
B

valve
hose
at
air

cleaner

7
Disconnect
air
cleaner
to
related

vacuum
hoses
at
air

cleaner

8
Disconnect
accelerator
control

wire
from
carburetor

9
Disconnect

the

following
cables

wires

and
hoses

Wire

to
auto
choke
heater

Wire
to

throttle

opener
cut
solenoid

or

throttle
switch

Wire

to
fuel
cut
solenoid

Wire
to

vacuum
switching
valve

High
tension

cable
between

igni

tion
coil
and
distributor

Battery
cable
to
starter
motor

Wire
to
distributor

Wire

to
thermal
transmitter

Wire

to
alternator

Engine
ground
cable
oil

pressure

switch
and

engine
harness
No
2

See

Fig
ER
3

o

1
Ground
cable

2

Engine
harness
No

2

3
Oil

pressure
switch

Fig
ER

3
EA368

Disconnecting
Cable
and

Wire

Fuel
hose

at
fuel

pump
and
fuel

return

hose
at
connection

Air

pump
air

cleaner
hose

Carbon
canister
hoses

Heater
inlet
and
outlet
hoses
if

so

equipped

ER
3
Vacuum
hose
of

brake
booster
at

intake
manifold

Air
conditioner

equipped

model

10
Remove

compressor
belt

To

remove
loosen
idler

pulley
nut

and

adjusting
bolt

1
Remove
air

pump

2
Remove

compressor
retaining

bolts
and
move

compressor
toward

fender
to
facilitate
removal
of

engine

Nole
Never

discharge
gas
from
com

pressor
while
work
is

being

per

formed

II

Compressor

EA478

Fig
ER
4

Location

of
Air

Compressor

3
Disconnect
vacuum
hose
of
air

conditioner
from
connector
of
intake

manifold

4
Remove

F
i

C
D

actuator
from

bracket

II
Remove
clutch

operating
cylin

der
from
clutch

housing
manual
trans

mission

only

dJ

Tightening
torque

Clutch

operating
cylinder

E
A3

to
clutch

housing

3
1

to
4
1

kg

22
to

30
ft
lbl

Fig
ER
5

Removing
Clutch

Operating

Cylinder

CLUTCH
DISC
AND

COVER

REMOVAL

1
Remove
transmission
from
en

gine
Refer
to

Removal
Section
MT

2

Insert
Clutch

Aligning
Bar

ST20610000
4

speed
tranSmission
or

KV30100IOO
5

speed
transmission

into

clutch
disc
hub

until
it

will
no

longer
gd
It
is

important
to

support

weight
of

clutch
disc
in
the

steps
that

follow

ST20610000

4

peed

transmission

KV30100100

S

peed

transmission

S

cL194

Fig
CL
W

Supporting
Clutch

Assembly
Clutch

CLUTCH
UNIT

n

j

3

Loosen
bolts

attaching
clutch

cover
to

flywheel
one
turn

each
at
a

time
until

spring

pressure
is
released

Be
sure
to
turn
them

out
in

a
crisscross

fashion

4
Remove
clutch
disc
and
cover

assembly

INSPECTION

Wash
all
disassembled

parts
except

disc

assembly
in
suiiable

cleaning
sol

vent
to
remove
dirt
and

grease
before

making
inspection
and

adjustment

FI
1
and

pressure
plate

Check
friction
surface
of

flywheel

and

pressure
plate
for

scoring
or

roughness
Slight
roughness
may
be

smoothed

by
using
fine

emery
cloth
If

surface
is

deeply
scored
or

grooved

the

part
should
be

replaced

Clutch
disc
sembi

Inspect
clutch
disc
for
worn
or

oily

facings
loose
rivets

and
broken
or

loose

torsional

springs

CL
7
1

Clutch
disc

assembly

2

Clutch
cover

assembly

3
ReleaJe

bearing

4

Bearing
sleeve

S

Withdrawal
lever

6

Withdrawa11ever
ball

pin

7
Return

spring

CL370

Fig
CL
9
Clutch
Unit

I
If

facings
are

oily
disc
should
be

replaced
In

this
case

inspect
transmis

sion

front
cover
oil
seal

pilot
bushing

engine
rear
oil
seals
and
other

points

for
oil

leakage

2
The

disc
should
also
be

replaced

when

facings
are
worn

locally
or
worn

down
io
ihe

specified
limit

Wear
limit
of

facing
A

Les
than
0
3
mm
0
012
in

9111

I

A

M

m

C
L336

Fig
CL
ll

M
asur

ng
Clutch

Facing

Wear

3

Check
disc

plate
for
runout
when

ever
the
old
disc

or
a

new
one
is

installed

4
If
runout
exceeds
the

specified

value
at
outer
circumference
of
fac

g

replace
or

repair
disc

Runout
limit

ltotal
indicator

reading

Less
than
0
5

mm
0
020
in

R
from
hub

center

85

mm
3
35
in

CAUTION

When

repairing
disc

plate
never
hold
it

forcibly
with

pUers
or
bend
it
exces

sively
otherwise

facing
will
be
dam

aged

CL112

Fig
CL

12

Repairing
DiM
Runout

5
Check
fit
of
disc
hub
on
transmis

sion
main
drive

gear

splines
for
smooth

sliding
If

splines
are
worn
clutch
disc

r
main

drive

gear
should
be

replaced

that

is
backlash
exceeds
the

specified

value
at
outer

edge
of

clutch
disc

Backlash

Less
than
0
4
mm

0
016

in

Clutch
cover
a

embly

I

Check
the
end
surface
of
dia

phragm
spring
for
wear
If
excessive

wear
is
found

replace
cluich
cover

assembly

2

Measure

height
of

diaphragm

springs
as
outlined
below

I

Place
Distance
Piece

ST20050100
on

Base
Plate

ST20050010

and
then

tighten
clutch

cover

assembly
on
base

plate
by

using

Set
Bolts
ST20050051
Clutch

ST200S0051

snOO50100

snoo
500
10

re1

F
A

J

eLlSl

Fig
CL
J3

Measuring
H

ight
of

Diaphragm
Spring

2

Measure

height
A
at

several

points
with

a
vernier

caliper
depth

gauge
If

height
A

of

spring
end
is

beyond
the

specified
value

adjust

spring
height
with

Diaphragm
Ad

justing
Wrench
ST20050240

as

sh
1wn

in

Fig
CL
I4

Diaphragm
spring

height
A

29

0
to
31
0

mm

1
142

to
1
220
in

If

necessary
replace
clutch

cover

assembly
Also
unevenness

of
dia

phragm

spring
toe

height
should
be

within
the

specified
limit

Unevenness
of

diaphragm
spring

toe

height

Less

than
0

5
mm
0
020
in

CL152

Fig
CL
I4

Adjusting
Spring

Height

3

Inspect
thrust

rings
for
wear
or

damage
As

these

parts
are

invisible

from
outside

shake
cover

assembly

up

and
down

to

listen
for

chattering

noise

or

lightly
hammer
on
rivets
for
a

slightly
cracked
noise

Any
of
these

noi

s
indicates

need
of

replacement
as

a

complete
assembly

INSTALlATION

I

Apply
a

light
coat
of

grease
in

cluding

molybdenum
disulphide
to

transmission
main
drive

gear
splines

Cl
8
Slide
clutch
disc
on
main
drive

gear

several
times
Remove

clutch
disc
and

wipe
off
excess
lubricant

pushed
off

by
disc
hub

Note
Take

special
care
to

prevent

grease
or
oil
rrom

getting
on
clutch

racing

2

Reinstall
clutch
disc
and

clutch

cover

assembly
Support
clutch
disc

and

cover
assemblies
with
Clutch

Aligning
Bar
ST20610000

4
speed

transmission
or
KV30100IOO
5

speed
transmission

Note
Be
sure

to

keep
disc

racings

flywheel
and

pressure
plate
clean

and

dry

KV30100100

5
peed

transmission

ST20610000

4

speed

trammisaion

CL32

Fig
CL
I5
Installing
Clutch

Diac
and

Cover

Aaembly

3

Install
bolts
to

tighten
clutch

cover

assembly
to

flywheel

squarely

Each

bolt
should
be

tightened
one

turn
at

a
time
in

a
crisscross
fashion

ifJ

Tightening
torque

Clutch
cover
bolt

1
6
to
2
1

kg
m

12
to
15
ft

Ibl

N

te
Dowels

are
used
to
locate

clutch

cover
on

flywheel

properly

4

Remove

clutch

aligning
bar

5

Reinstall
transmission

Refer
to

Installation

Section
MI

RELEASE
BEARING

REMOVAL

1

Remove
transmission
from
en

gine
Refer

to
Removal
Section
MI

2
Disconnect

return

spring
from

bearing
sleeve

3

Remove

release

bearing
and
sleeve

as
an

assembly
from
transmission

case

front
cover

with
the

pin
hole
of
the
internal

rotor

combined
with
the
manual

shaft
and

check
their

alignment
by

inserting
a

1
5
mm
0
059
in
diameter

pin
into

the

holes
If
the

alignment
is

correct

fasten
the
switch

body
with
the
bolts

pull
out
the

pin
tighten
up
the
screw

in

the
hole
and
fasten

the
selector

lever
as
before
Check

the

continuity

pin
with
the
lesler
If

Ihe
malfunc

tion
still
remains

replace
the
inhibitor

switch

STALL
TEST

The

purpose
of
this
test
is
to
check

the
transmission
and

engine
for
trou

ble

by
measuring
the
maximum
num

bers
of
revoiutions
o
the

cngine
while

vehicle
is
held
in

a
stalled

condition

The
carburetor
is
in

fullthrollle

opera

tion
with
the
selector
lever
in

ranges

1
2
and
I

respectively
Com

pale
the
measured

results
with
the

standard

values

Components
to
be
tested
and

test
itelJUl

I

Clutches
brake
and
band
in
trans

mission
for

slipping

2

Torque
converter
for

proper
func

tioning

3

Engine
for
overall

properly

STAU

TEST
PROCEDURES

Before

testing
check
the

engine
oil

and

torque
converter

oil
warm

up
the

engine

cooling
w

ter
to

suitable
tem

perature
by

running
at
1
200

rpm
with

the

selector
lever
in
the

range
P

for

sevcral
minutes

Warm

up
the

torque

converter
oil

to
suitable

temperature

60
to
lOOoC

140
to
2120F

I

Mount
the

engine

tachometer
at
a

location
that

allows

good
visibility

from

the
driver

s
seat
and

put
a
mark

on

specified
revolutions

on
the

meter

2

Secure
the
front
and
rear
wheels

with
chocks

and

apply
the
hand

brake

Be
SIIre

to

depress
the
brake

pedal

firmly
with
the
left
foot
before
de

pressing
the

accelerator

pedal

3
Throw
the

selector
lever
into
the

range
11

4

Slowly

depress
the

accelerator

pedal
until
the

throttle
valvc
is

fully
Automatic

Transmission

opened
Quickly
read
and

record

the

engine
revolution

when
the

engine

begins
to
rotate

steadily
and
then

release
the
accelerator

pedal

5
Shift
the
selector
lever

to
N

and

operate
the

engine
at

approxi

mately
1
200
rpm
for
more
than
one

minute
to
cool

down
the

torque
con

verter
oil
and
coolant

6
Make
similar
staU
tests
in

ranges

2
I
and
R

CAUTION

The

dill
test

operstion
81

specified
in

i18m
4

should
be

I118de
within

fiv

lIeonds

If
it
tBkes
too

long
the

oil

If

and
the
cluti
hn
blllke

and
b
nd

elll

ly
I
Suf

ficient

cooling
time
should

be

given

r

eech
test
for
the
four

IlInges

0
Z
1
end
R

JUDGEMENT

High
stall
revolution

more
than

staitdard
revolution

If
the

engine
levolulion
in

stall

condi
ion
is

higher
than
the
standard

values
it
indicates

that
onc
or
more

clutches
in
the

transmission
are

slipping
and
therefore
no

further
test

is

required

For
the

following
abnormalities

the

respective
causes
are

presumed

High
rpm
in

all

ranges
low
line

pr
ssure

High
rpm
in
0

2
and
I

and

normal

rpm
in
6R

Rear
clutch

slipping

High
rpm
in
D

and
2
and

normal

rpm
in

One

way

clutch

slipping

High
Ipm
in
R

only
Front

clutch
or
low

and
reverse
brake

slipping

To

determine
which
is

slipping

front

clutch
or
low
and
reverse

brake

a
road

test
is

needed

If
while

coasting
after

starting

with
the
levcr
in
I

range
engine

braking
does
not

work

properly
the

low

and
reverse
brake
is

slipping

Otherwise
the
front
clutch
is

slipping

Slipping
of
the
band
brake
is
diffi

cuJt
to
ascertain

However
jf
it

occurs

with

the
lever
in
1

range
engine

AT
41
revolution
increases

up
to
the
same

level

as
in
1st

range
It

is

impossible

to

check
it
in
the

stall
test

2
Standard
stall
rnoluiion

If
the

engine
revoluiion
in

stall

ondition
is
within

he
standard

values
the
control
elements
are

nOf

mally

operating
in

the

ranges
D

2n
I

and
R

Also
the

engine
and
one

way

clutch
of
the

torque
converter
are

norinal
in

performance
and

operation

The

one

way
clutch

of
the

torque

converter

however
sometimes

sticks

This
is
determined

in
the
road

test

3

Lower

stall
revolution
than
lIand

ard

revolution

If

the

engine
revolution
in

stall

condition
is

lower
than
the

standard

values
it

indicates
that
the

engine
is
in

abnormal

condition
or
the

torque
con

verter
s
one

way
clutch
is

slipping

4
O
hers

I
If

the

accelerating
performance

is

poor
until
vehicle

speed
of

approxi

mately
SO

kmfh
30
MPH
is
attained

and
then
normal

beyond
that

speed
it

can
be

judged
that
the

torque
con

verte
c

s
one

way
clutch
is

slipping

2

If
the

torque
converter

sane

way
dutch
sticks

vehicle

speed
can

not

exceed

approximately
80

kmfh

SO
MPH
in
the

road
tesl

In
such

a

case
the

torque
converter

oil
tem

perature
rises

abnormally
and
so

special
care
is

required

3
If
the

transmission
does
not

op

erate

properly
at
all
vehicle

speeds
it

indicates

poor
engine
performance

ROAD

TEST

An

accurate

knowledge
of
the
au
to

matic

transmission
is

required
for
an

exact

diagnosis

II
is

recommended
that
a

diagnosis

guide
chart
with
the
standard

vehicle

speeds
for
each

stage
of

the

up
and

down

shiftings
be

prepared
Measured

vehicle

speeds
are
to

be
filled
in

the

adjoining
column
after
each

testing

Also
it

is
advisable
to

mount

a

stopper
for

positioning
the
throttle

opening

Propeller
Shaft
Differential
Carrier

DIFFERENTIAL
CARRIER

When

a
differential
carrier
is

sus

pected
of

being
noisy
it
is
advisable

to
make

a
thorough
test
to
determine

whether
the
noise

originates
in

the
tires

road
surface
exhaust
universal

joint
propeller
shaft
wheel

bearings

engine
transmission
or
differential

carrier
Noise

which

originates
in

Condition

Noise
on
drive
coast

and
float

Noise

on
turn

Knocking
sound

during
starting
or

gear

shifting

Seizure
or

breakage
Probable
cause

Shortage
of
oil

Incorrect
tooth
contact
between

ring

gear

and
drive

pinion

Incorrect

ring
gear
to
drive

pinion
backlash

Seized
or

damaged
ring
gear
and

drive

pinion

Seized
damaged
or
broken
drive

pinion

bearing

Seized

damaged
or
broken
side

bearing

Loose

clamp
bolts

or
nuts

holding
ring
gear

side
retainers

bearing
cap
etc

Seized

damaged
or
broken
side
and

pinion

gear

Seized

damaged
or
broken
side

gear
and

pinion
thrust
washer

Pinion

gears
too

tight
on
their
shaft

Excessive
backlash

Incorrect
backlash

ring
gear
to
drive

pin

ion

or
side
ta

pinion
gear

Worn

gears
or
case

Worn
side

flange
or
rear
axle
shaft
and

side

gear
spline

Pinion

bearing
under

preload

Loose
drive

pinion
nut

Loose

clamp
bolts
or
nuts

holding
ring
gear

side
retainers

bearing
cap
etc

Shortage
of
oil
or
use
of
unsuitable
oil

Excessively
small
backlash

Incorrect

adjustment
of

bearings
or

gears

Severe
service

due
to
an
excessive

loading

improper
use
of
clutch

Loose
bolts
and
nuts
such
as

ring
gear
clamp

bolts

PD

13
other

places
cannot
be
corrected

by

adjustment
or

replacement
of

parts

in
the
rear
axle

assembly

orrective
action

Supply

gear
oil
Rebuild
differential
carrier

if

necessary

Adjust
tooth
contact
or

replace

hypoid
gear

set

Adjust
backlash
or

replace
hypoid
gear
set
if

necessary

Replace
hypoid
gear
set

Replace
pinion
bearing
and

damaged
parts

Replace
side

bearing
and

damaged

parts

Clamp
to

specified
torque
and

replace

damaged
parts

Replace
damaged

parts

Replace
damaged

parts

Replace
damaged
parts

Adjust
backlash

Replace
worn

parts

Replace
worn

parts

Adjust
preload

Repair
or

replace

Clamp
or

replace
if

necessary

Refill
or
use
correct
oil

Adjust
backlash
and

replace
as

required

Replace
worn
or

damaged

parts

Replace
damaged

parts

Tighten

Front
Axle

Front

Suspension

INSPECTION
AND
ADJUSTIVIENT

INSPECTION

Inspect
in
accordance
with

periodic

maintenance
schedule

Block
rear
wheels
with
chocks

2

Jack

up
the
front

of

car
and

support
it
with

safety
stands

Refer
to

Section
GI
for

lifting

points
and

towing

3

Shaking
each
fiont
wheel

by

grasping
the

upper
and

lower
surfaces

of
the
tires
check

suspension
parts
for

looseness
wear
or

damage
Tighten
aU

loose
bolts
and

nuts
to
the

specified

torque
Replace
all
worn

parts
as

described
under
Front

Suspension

4

Check
wheel

bearings
If

there
is

any
axial
end

play
adjust

bearings
to

specifications

Replace
worn
or

damaged
bearings

as
described
under
Front

Axle

S
Check

strut
for
oil

leakage
or

damage

ADJUSTMENT

WHEEL

BEARING

Block

rear
wheels
with
chocks

2

Jack

up
the
front
of
car
and

support
it

with

safety
stands

3

Remove
brake

pads
Refer
to

Section
BR
for

pad
replacement

4

Remove
hub

cap
cotter

pin
ad

justing

cap
and
wheel

bearing
nut

S

Sparingly
apply
recommended

multi

purpose

grease
to
threaded

por

tion

of

spindle
and

contact
surface

between
wheel

bearing
washer
and

outer
wheel

bearing

6

Tighten
wheel

bearing
nut

using

a
suitable

torque
wrench

P
Tightening

torque

Wheel

bearing
nut

3
0
to
3
5

kll
m

22

to
25
ft

Ibl
Fig
FA

Tighlening
Wheel

Bearing

Nul

7
Turn

wheel
hub
several
times
in

both
directions
to

seat
wheel

bearing

correctly

again
tighten
wheel

bearing

nut
to
the
above

torque

8
Turn
back
wheel

bearing
nut
A

degrees

Return

engle
AU

900

Install

adjusting
cap
and

align
any

of
its
slots
with
hole
in

spindle
If
the

above

procedure
fails
to

align
hole
and

slot

together
then

tighten
lock

nut
as

much
as
I

S

degrees
until
hole
in

spindle
is

aligned
with

eny
slot

CAUTION

00
not

overtighten
wheel

bearing
nuts

as
this

can
cause
wheel

bearing
seizure

9
Turn

hub
in
both

directions
two

or
three
times

measuring
its

turning

torque
and

axial

play
to

ee
if

they
are

within
the

specified
range
If

they
are

not

adjust

Axial

play

Omm

Din

Wheel

bealing
starting
torque

With

new

gleaS8
l8al

A

measured
et

wheel

bearing

nut

less
than
7

kg
cm

G
1
in
Ibl

FA
2
AJ
measuled
et
wheel
hub

bolt

Less
then
1
2

kg
12
G
Ibl

With
u
ed

gr
seal

AJ
measured

at
wheel

bealing

nut

1
0
to
4
5

kg
cm

0
9
to
3
9
in
b

AJ
measuled
at

wheel
hub

bolt

0

17
to
0
79

kg

0
37
to
1
741bl

FA413

Fig
FA
2
Metr

uring
Bearing
Starting

Torq
ue

Repeat
above

procedures
until
cor

rect

starting
torque
is

obtained

Note

a

Correctly
meas
e
rotation

slar
ting

force

toward

tangential
direction

against
hub
bolt

b

Above

figures
do
not

include

dragging
resistance
with

pads
re

moved
on
disc
brake
models

c

Any

slightest
wheel

bearing
axial

play
cannot
be
tolerated

10
Insert
new
cotter

pin
with
the

legs
through
hese
two

parts
spread

legs
away
from
each
other

against
sides

of
wheel

bearing
nut

Turning
engie
of
front

wheel

Inner
wheel
380
to

42

Outel
wheel
31
0

to
35
0

Tightening
torque
of
bolts

and
nuts

kg
m

ft
lb

@
3

9
to
5
3
28
to
38

@
3
0
to
3
5

22
to
25

@
5
5
to
10
0
40
to
72

@
7
3
to
9

9
53
to

72

@
5
1
to
6
1
371044

ear
wheels
with
chocks

fron
t

of
car
and

support
Front
Axle
Front

Suspension

FA125

Fig
FA

6
AdjU

ting
Steering

Angle

FRONT

AXLE

1
Grease
seal

2
Inner
wbeel

bearin

3

Wheel
hub

4

Outer
wheel

bearins

5
Wheel

bearing
washer

6
Wheel

bearing
nut

7

Adjusting
cap

8
O

ring

9
Hub

cap

10

Disc
brake
rotor

FA803

Fig
FA
7
Front
Axle

it
with

safety
stands

3
Remove
wheel
and
tire

assembly

4

Remove
brake
tube
brake

caliper

assembly

referring
to

Section
DR

FA
4
4
After

adjustment

l
ck

adju

ment
nut

Note

Turning
angle
of
outer
wheel

will

automatically
be
Set

by

adjust

ing
turning
angle
ofin

f
U
wheel
to

specified
values

FA726

Fig
FA
8

RemouingBroke
Caliper

5
Work

off
hub

cap
from

hub

using

t

n
screwdrivers
as
shown
below

If

necessary
tap
around
it

with
a
soft

hammer
while

removing

cap

F
A386

Fig
FA
9

Remouing
Hub

Cap

Note

During
operation
be
careful
to

avoid

deinaging
O
ring