steering wheel DATSUN 610 1969 User Guide

I

Fig
K
16

Removing
the
column
sheD
covers
inter
i
mj

rD
1
f

1

A
iJI1i

j
j
r

I

I

s
Ii

i

FIg
K
15

Removing
the

steering
wheel
Fig
K
l7

Removing
the
rubber

coupling

securing
bolt

1
bclttt
ube

2
Column

clamp
Fig
K
19

Steering
lock
installation

Fig
K
18
The
standard
dimension
between

coluDDl
clamp
and
lower

jacket

J

A
6

c
V
1

Rubbt
r

coupling

2

Steen
column

3
Worm

1

4
Dash

ptmd

5

ColUmrl
3hDf

6

Colli
clamp

7
Lowt
r

jacket
flangt

FIg
K
20

Installing
tbe

steering
column

assembly

96
f
ftb

Fig
K
21
The
outer
tie
rod
ball

joint

I

I

t

I

Fig
K
22
The
centre
tie
rod
ball

joint

3
Free

the
ball
studs
from
the
knuckle
arms

by
placing
a

hammer
behind
the
boss
and
striking
the

opposite
side

with
another
hammer

4
Remove
the
centre

tie
rod
ball

studs
in
a
similar
manner

to
that
described
above
and
remove
the
centre

tie
rod
and

outer

tie
rods
as
an

assembly

5
Remove
the
idler

assembly
from
the
side
member

by
with

drawing
the

retaining
bolts

SfEERING
LINKAGE

Dismantling

Disconnect
the
tie
rods
from
the

centre
rod

Loosen
the

clamp
bolts
unscrew
the
socket

assembly
and
remove
the

socket
from

the
tie
rods
Remove
the
idler
arm
nut

and
dismantle

the
idler

assembly

Check
the
idler
arm
rubber

bushing
for

signs
of

damage

wear
or

play
and

replace
the

bushing
if

necessary
Oteck
the

centre
and
outer

tie
rod
for

damage
or

bending

Inspect
the
ball

joints
and

replace
them
i
the
amount
of

play
is

excessive
or
if

the
dust
cover

is
cracked
Further
infor

mation
can
be
found
in
the
section
FRONT
SUSPENSION

See
also

Figs
K
21

and
K
22
STEERING
LINKAGE

Assembly
and
Installation

Assembly
is
a
reversal
of
the
removal

procedure
noting

the

following

points

To

assembly
the
idler
arm

assembly
coat

the
outer
dia

meter
of
the

bushing
with

soapy
water
and

press
the

bushing

into
the
idler
arm

until
the

bushing
protrudes
equally
at
both

sides

Fit
the
idler
arm

body
in
the
rubber

bushing
Ensure
that

the
centre
line
of
the

idler
arm
is

parallel
with
the
centre
line

of
the
chassis

Installation
is
a

reversal
of

the
removal

procedure
The

outer
tie
rods
must
be
set
so
that
the

lengths
between
the
ball

stud
centres
are
309

5
mm

12
18
in
for
the
1400
and
1600cc

models
and
313
2
mm

12
33
in
for
the
1800cc

models

Tighten
the
ball
stud
nut

to
a

torque
reading
of
5
5
7
6

kgm
39
8
55Ib
ft
the
idler
ann
nut
to
5
5
7

6

kgm

39
8
55Ib
ft
and
the

pitman
arm
nut
to
14

kgm
lOllb
ft

The
front
wheel

alignment
toe
in
and

steering
angle
should

be
checked
and

adjusted
as
described
in

the
section
FRONT

SUSPENSION

TechnIcal
Data

Steering
type

Gear
ratio

Steering
angle

Inner
wheel

l800cc

Outer
wheel
1800
cc

Inner
wheel

1400
and
1600cc

Saloon

1400
and
1600cc
Estate

Outer
wheel
1400
and
1600cc

Saloon

1400
and
1600cc
Estate

Steering
wheel

play
1400
and

1600cc

Steering
wheel

play
1800cc

Standard
total
thickness
of

worm

bearing
shims

End

play
between
sector
shaft

and

adjusting
screw

Initial

turning

torque
of

worm

bearing

l800cc
models

1400
and
1600cc
models
Worm
and
recirculating
ball

15
0
I

370
380

30040
32040

380

380
30

31020

330

25
30mm
0
98
1
18
in

less
than
35mm
1
378
in

at
outer

rim
of

steering

wheel

1
5
mm
0
059
in

0
0
I
0
03mm

0
0004
0
0012
in

4
0
6
0

kg
cm
55
6
83
4

in
oz

4
0
8
0

kg
cm

55
6
112

in

oz

97

ElectrIcal

EquIpment

DESCRIPTION

BATTERY
Maintenance

STARTER
MOTOR

Removal
and

Dismantling

STARTER
MOTOR

Testing

STARTER
MOTOR

Assembly
and
Installation

ALTERNATOR
Removal

Dismantling
and

Inspection

DESCRIPTION

A
12
volt

negative
earth
electrical

system
is
used
in
which

the

battery
is

charged
by
an
alternator
In
the
alternator
a

magnetic
field
is

produced
by
the
rotor

which
consists
of
the

alternator
shaft
field
coil

p
le

pieces
and

slip
rings

Output
current
is

generated
in
the
armature
coils
located

in
the
stator
Six
silicon
diodes
are

incorporated
in
the
alternator

caSing
to

rectify
the

alternating
current

supply
A
voltage

regulator
and

pilot
lamp
relay
are
built
in
the

regulator
box

which

nonnally
does
not

give
trouble
or

require
attention

The
starter
motor
is
a

brush

type
series
wound
motor

in

which

positive
meshing
of
the

pinion
and

ring

gear
teeth
are

secured

by
means
of
an

overrunning
clutch

BATTERY
Maintenance

The

battery
should
be
maintained
in
a
clean
and

dry

condition
at
all
times
or
a
current

leakage
may
occur

between

the
terminals
If

frequent
topping

up
is

required
it
is
an

indication
of

overcharging
or
deterioration
of
the

battery

When

refitting
the
cables
clean
them

thoroughly
and
coat

their

terminals
and
the
terminal

posts
with

petroleum
jelly

Check
the
level
of
the

electrolyte
in
the

battery
at

frequent

intervals
and

top
up
if

necessary
to

the
level
mark
on

the

battery
case
with
distilled
water
A

hydrometer
test
should
be

carried
out

to
determine
the
state

of

charge
of

the

battery
by

measuring
the

specific
gravity
of
the

electrolyte
It
should
be

pointed
out

that
the
addition
of

sulphuric
acid
will
not

normally

be

necessary
and
should

only
be
carried
out

by
an

expert
when

required

The

specific
gravity
of
the

electrolyte
should
be
ascertained

with
the

battery

fully
charged
at
an

electrolyte
temperature
of

200C
680F

The

specific
gravity
of
the

electrolyte
decreases
or
increases

by
0
0007
when
its

temperature
rises
or
falls

by
10C
1
80F

respectively

The

temperature
referred

to
is
that
of
the

electrolyte
and

not
the
ambient

temperature
to
correct
a

reading
for
an
air

temperature
it
will
be

necessary
to

add
0
0035
to
the

reading

for

every
50C
above
200C

Conversely
0
0035
must

be
deducted

for

every
SOC
below
200C
Test
each
cell

separately
and
draw

the

liquid
into
the

hydrometer
several
times
if
a
built
in

thermometer
type
is
used

The
correct

specific
gravity
readings
should
be
as
follows
ALTERNATOR

Assembly
and
Installation

HEAD
LAMPS

Replacing

HORN

INSTRUMENT
PANEL
Removal

WINDSCREEN
WIPERS

WINDSCREEN
WASHERS

IGNITION
SWITCH
AND
STEERING
LOCK

Cold
climates

Temperature
climates

Tropical
climates
Permissible

value

Over
1
22

Over
1
20

Over
1
18
Fully
charged
at
200C

680F

1
28

1

26

1
23

The

battery
should
be

recharged
if
a
low

specific
gravity

reading
is
indicated

Always
disconnect
both
terminals
of
the

battery
when

charging
and
clean
the
terminal

posts
with
a

soda

solution
Remove
the
vent

plugs
and

keep
the
electrolyte

temperature
below
450C
l130F
during
charging

Check
the

specific
gravity
after

charging
and
if
it
is
above

1
260
at

200C
680C
add
distilled
water

STARTER
MOTOR
Removal
and
Dismantling

As
previously
stated
the
starter
motor

is
brush

type
series

wound
motor
in
which
the

positive
meshing
of
the

pinion
and

ring
gear
teeth
are
secured

by
an

overrunning
clutch
The
over

running
clutch

employs
a
shift
lever
to
slide
the

pinion
into

mesh
with
the
flywheel
ring

gear
teeth
when
the
starter
is

operated

When
the
engine
starts
the

pL
lion
is

permitted
to
overrun

the
clutch
and
armature

but
is
held
in
mesh
until
the
shift
lever

is
released
An

exploded
view
of
the
starter

is
shown
in

Fig
M
2

To
remove
the
starter

motor

proceed
as
follows

Disconnect
the

battery
earth
cable

2
Disconnect
the
black
and

yellow
wire
from
the
solenoid

terminal
and
the
black
cable
from
the

battery
terminal

3
Remove
the
two
bolts

securing
the
starter
motor
to
the

clutch

housing
Pull
the
starter
motor

assembly
forwards

and
withdraw

it
from
the
v
hicle

To
dismantle
the
starter

motor
ftrst
remove
the
brush

cover
and
lift
out

the
brushes
as
shown
in

Fig
M
3

Loosen
the
nut

securing
the

connecting
plate
to

the

solenoid
M
terminal
Remove
the
solenoid

retaining
screws

take
out

the
cotter

pin
and
withdraw

the
shift
lever

pin
Remove

the
solenoid

assembly
as
shown
in

Fig
M
4

Remove
the
two

through
bolts

and
rear
cover

assembly

then
remove

the
yoke
assembly
by
lightly
tapping
it
with
a

wooden
mallet

Fig
M
S
Withdraw
the
armature
and
shift

lever

Fig
M
6
Remove
the
pinion

stopper
from
the

armature
shaft

by
removing
the

stopper
washer
pushing
the

109

4
Remove
the
shell
covers

from
the

steering
column
slacken

the

screws
securing
the
meter

housing
and
withdraw
the

panel
from
the
facia

Fig
M
33

5
Pull

out
the
12

pole
round

shaped
connector
and
remove

the

speedometer
cable
union

nut
then
remove
the
instru

ment

panel
completely

WINDSCREEN
WIPERS

A
two

speed
wiper
motor
is
fitted

The
motor
has
an
auto

stop
mechanism
and
drives
the

wiper
arms

through
a
link

mechanism
located
behind
the
instrument
panel
If
the

wiper

system
does
not

operate
check
the
fuses
connectors
control

switch
and
motor
If
the

wiper
speed
does
not

change
the

switch
must

be
repaired
or

replaced
If

the

wiper
motor
becomes

unserviceable
it
can
be
removed
from
the
vehicle
in
the

fOllowing

manner

I
Remove
the
connector

plug
from

the
motor
See

Fig
M

34

2

Working
from
the

passenger
compartment
side
of
the
dash

panel
remove
the
nut

connecting
the

wiper
motor
worm

wheel
shaft
to
the

connecting
rod

3
Remove
the
three
bolts

securing
the

wiper
motor
to

the

cowl
and
lift
out
the
motor

Battery

Starter
motor

Type

Output

No
load

Terminal

voltage

Current

Revolution

Load

Terminal

voltage

Current

Torque

Brushes

Brush

length

Wear
limit

Spring
tension

Commutator

Standard
outer

diameter

Wear
limit

Depth
of

nuca

Repair
limit

Repair
accuracy

Qearance
between
armature

shaft
and

bushing

Repair
liinit

Repair
accuracy

Armature
shaft
ou
ter

diameter

Pinion
side

Rear
end

Wear
limit

Bend
limit
The

wiper
arms
can
be
removed
quite
easily
by
taking
off

the
attachment
bolt
as
shown
in

Fig
M

J
5
and
then

pullin

the

wiper
arm
from
the

pivot
shaft
When

installing
the

wiper

arm
make
sure
that
the
blade
is

positioned
approximately

27mm
1
06
in
away
from
the

bottom
of
the
windscreen
and

tighten
the

wiper
arm
attachment
bolt

WINDSCREEN
WASHERS

The
windscreen
washer
SWItch
and

wiper
switch
are
com

bined
in
a

single
unit
See

Fig
M
36
the
washers
can
be

operated
by
turning
the
switch
in
the

appropriate
direction
It

should
be
pointed
out
that
it
is
inadvisable
to

operate
the
washers

for
more
than
30
seconds
at
a
time
If
the
washers
are

operated

in
short

spells
of

approximately
10
seconds
duration
their

working
efficiency
will
remain

unimpaired
for
a
considerable

length
of
time

IGNITION
SWITCH
AND
STEERING
LOCK

The

steering
lock
is
built
in

to
the

goition
switch
When

the

key
is
turned
to
the
LOCK

position
and

then
removed

the
steering
system
is

automatically
locked

by
the

steering
lock

spindle
which

engages
in
a
notch
in
the
collar
on
the

steering

shaft

See

Fig
M
37
The
heads
of

the
screws
are
sheared
off

on
installation
so
that
the

steering
lock

system
cannot
be

tampered
with
If

the

steering
lock
is
to

be

replaced
it
will
be

necessary
to
remove
the
two

securing
screws
8
and
then
drill

out

the
self

shearing
screws
7
When

installing
a
new

steering

lock

tighten
the
new
self

shearing
screws
until
the
heads
shear

TechnICal
Data

12
volt

HITACHI
S114
87M

1
0KW

12
volts

Less
than
60

amperes

More

than
7000
r

p
m

6
3

volts

Less
than
420

amperes

More
than
0
9

mkg
6
5
lb

ft

16
mm

0
630
in

6
5mm
0
256
in

0
8

kg
1
8
lb

33mm
1
299
in

2mm

0
078
in

0
2mm
0
008
in

0
5
0
8mm
0
0197

0
0315
in

0
2mm
0
008

in

0
03
O
lmm
0
0012

0
0039
in

13mm
0
512
in

11
5
mm

0
453
in

O
lmm
0
0039

in

0
08

mm
0
0031

in
Oearance
between

pinion
and

stopper
0
3
1
5mm
0
0118

0
0591
in

ALTERNATOR

Type
HITACHI
LTl25
06

HITACHI
LTl33
05
USA

Canada

More
than
18

amps
at

14

volts
2500
r

p
m

More
than
25

amps
at

14

volts
5000
r

p
m
Output
current

LTl25
06

Output
current

LT
133
05

More
than
24

amps
at

14

volts
2500
r

p
m

More
than
33

amps
at
14

volts
5000
r

p
m

Brushes

Lengtb

Wear
limit

Spring
pressure
14
5mm
0
571
In

7mm
0
2756
in

0
25
0
35

kg
0
55
0
771b

Slip
ring

Outer
diameter

Reduction
limit

Repair
limit

Repair
accuracy
31
mm
1
220
in

I
mm

0
039

in

O
3mm
0
0118
in

0
05
mm

0
0197
in

VOLTAGE
REGULATOR

Type

Regulating

voltage
HITACHI
TL
lZ
37

14
3
15
3
volts
at
200C
680F

117

Clutch
MIPTOOlS
Trouble
Shootmg
Steering
IYMmlMS

mDING
S1
1FFNESS

ITIBJJNG
IIl
ACJt

STEEIUNG
WANDER

WHEEL
SHIIlOlY

CAR
PUl
U
TO
ONE
IIDE

POOR
RECa
Dy
OF
STEERING

WHEEL
10
CENl1tE

EXCESSIVE
01
ABNORMAL
TYKE
WEAR
It
d
e
f
I
II
J

e
It
b
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r

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a
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CLIJfCH
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SQUEAL

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PEDAL

nUTCH
NOISE
RATTLE
WHEN
IDI
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CLUTCH
NOISE
CHATTER
ON

a
GAGEMENI
I
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ROUBLE
CAUSE

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coilsprinp
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djUlt
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defe
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Ti
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Ballonce
h

p
Rene
prinp

q
laJan
bnltct

r
lI
eaJian
Ull
Ielllllion
drio

REAR
AXLE
AND
REAR
SUSPENSION

Rear
wheel

bearing
nut

Brake

backplate
25
33

kgm
181
239

IbJt

7

3
7

kgm
19
5
26
8

lb

ft

1400
1600
Shock
absorber

upper
mounting
3

kgm
l6
61b
ft

Shock
absorber
lower

mounting
3

kgm
16
6
Ih
ft

1800cc
Shock
absorber

mountings
1
6
2
2

kgm
12
161b
ft

Drive
shaft
to
differential
nuts
5
6

kgm
36
2
4341b
ft

Drive
shaft
to
rear
axle

flange
5
6

kgm
36
2
43
4lb
ft

Bump
rubber
nuts
2
8
4
0

kgm
20
29
Ib

ft

Bump
rubber
nuts

180Occ
1
6
2
2

kgm
12
16
Ib
ft

Wheel
nuts

Rear

suspension
member

mounting
nuts
8
9

kgm
58
651b
ft

10

kgm
72
Ib
ft

Differential
member

mounting
nuts
8
5

kgm
61
5Ib
ft

Suspension
arm
to

suspension
member
nuts
10

kgm
58
72
Ib
ft

Differential
to
differential

member
6
8

kgm
43
581b

fl

Propeller
shaft

flange
nuts
4
0
8
5

kgm
29
62
Ib
ft

Propeller
shaft

flange
nuts

I
800cc
2
0
2
7

kgm
14
201b

fl

Differential
to

suspension
member
6
8

kgm
43
58Ib
ft

1800cc
Estate
car
and
Van
610

Body

Shock
absorber

upper
mounting
0
9
1
2

kgm
6
5
8
7Ih

fl

Shock
absorber
lower

mounting
3
5
4
5

kgm
25
33Ib
ft

Rear

spring
U
bolt

clip
6
0
6
5

kgm
43
47
Ib
ft

Shackle

spring
6
0
6
5

kgm
43
47Ib
ft

Spring
front

pin
6
0
6
5

kgm
43
47Ib
ft

Brake
back

plate

Estate

car

Van

Differential

gear
carrier

to
axle
case

Propeller
shaft

flange

Bump
rubber

Wheel
nut

Drain
and
filler

plug
2
2
2
7

kgm
16
20IbJt

L5
2
0

kgm
II
14
Ib
ft

2
0
2
5

kgm
14
18Ib
ft

2
0
2

7kgm
14
20Ib
ft

0
9
1
2

kgm
6
5
8

7Ib
ft

9

kgm
58
65Ib
ft

4
2
6
9

kgm
30
4
49
9
lb

ft

FRONT
SUSPENSION

Front
hub
nut

3
0
3
5

kgm
21
7
25
3

Ib
ft

Disc
brake

backplate
to
strut
2
7
3
7

kgm
19
5
26
7

Ib
ft

Brake

ca1liper
bolts
7
3
9
9

kgm
52
8
71
6

Ib
ft

Brake
disc
bolts
3
9
5
3

kgm
28
381b
ft

Stabilizer
bolts

suspension

arm
side
1
2
I

7kgm
8
7
12
3

Ib
ft

130
Tension

rod
to
frame

Tension

rod
to

transverse
link

Strut

assembly
upper
nuts

Steering
lever
to

strut

Ball

joint
to

transverse
link

Ball

joint
to
knuckle
ann

Piston

rod
nut

Gland

packing

1400
and
1600
CC
models

Flange

mounting
bolts

Bali
stud
nut

Gear
ann
nut

Idler
ann
nut

Adjusting
screw
nut

Steering
gear
mounting
bolts

Idler
arm

bolts

1800cc

models
610

Body

Gear
ann
nut

Rear
cover

bolts

Sector
shaft
cover

Sector
shaft

adjusting
screw

locknut

Steering
gear
mounting
bolts

Steering
linkage

Idler
arm
to
frame

Ball
stud
nuts

Side
rod
locknuts

Column
shaft

Steering
wheel
nut

Column

clamp

COll

piing
worm
shaft

Coupling

mounting
bolts

Brake

pedal
pivot

Brake

pipe
connection

Brake
disc
bolts

Bridge
pipe

Brake
hose
to

cylinder

Brake
calliper
bolts

Wheel

cylinder
bolts

Stud
side

Hexagon
side
4

5
5
5

kgm
33
40Ib
ft

4
9
6
3

kgm
35
4
45

6

Ib
ft

3
9
5
2

kgm
28
2
37

6

Ib
fr

6
8

kgm
43
581b
ft

1
9
5

kgm
14
18Ib
fL

5
5
7
6

kgm
40
55Ib
ft

6
7
5

kgm
43
54Ib
ft

7
13

kgm
51
94Ib

ft

STEERING

1
8
2
5

kgm
13
18Ib
ft

5
5
7
6

kgm
40
55Ib
ft

12

5
14
0

kgm
90
101
lb

ft

5
5
7
6

kgm
40

55Ib
ft

1
8
2
5

kgm
13
18Ib
ft

10

kgm
72

Ib
ft

4
4
6
1

kgm
32
44Ib
ft

14

kgm
lOllb
ft

L5
2
5

kgm
II
18Ib
ft

1
5
2
5

kgm
II
18Ib
ft

2
0
2
5

kgm
14
5
18Ib
ft

6
8

kgm
43
4
57
8Ib
ft

4
4

6
1
kgm
32
44Ib
ft

5
5
7
6

kgm
40
55Ib
ft

4
4
6
1

kgm
32
44lb
ft

4
5

kgm
29
36
Ib
ft

1
3
1
8

kgm
9

4
13
0
lb

ft

4
5

kgm
29

36Ib
ft

L5
2
2

kgm
II
16Ib
ft

BRAKES

3
5
4
0

kgm
25
3
28
9

Ib
ft

1
5
1
8

kgm
10
8
13
0
lb

ft

3
9
5
3

kgm
28
2
38
3
IbJt

1
7
2
0

kgm
12
3
14
51b

fl

1
7
2
0

kgm
12
3
14
5lb

ft

7
3
9
0

kgm
52
8
65
llb
ft

0
5
0
7

kgm
3
6

5
llb
ft

1
4
1
8

kgm
10
13
Ib
ft

inter
M
j

@W

J

1

i
I

r

p

@
2
1
Strut
mounting
inzulDtor

Thruu
b

aring

J
Coil

prins

4
rubber

j
Sl1ut

mbly

6
Compression
rod

Z
Bal

joint

8
T
1ink

9
Stabi
iur

10
ODS

rnt
r
i

L
St

Ting
wheel

2
Steering
column
maft

J
Rubb
rCOfl
linK

4

Sturing
lower
joint

5

St
rinuotlr
IwusUr8

6
Sid
rod

XlI

Fig
C
1
Front

suspension
assembly
Fig
C
2
The
steering

gear

iQ

r
y
y

v

I
Ii

1
1

Fig
C
3

Collapsible

steering

Fig
C
4

Disconnecting
the
brake
hose

I

f41
I
I
t

h
I

t
t

Il
t

k
I

Fig
C
5

Removing
the
front
hub
and
brake

disc
Fig
C
6

Detaching
the
brake
disc

522

Accelerator

pump

Piston
diameter

Pump
discharge

Outer
hole

position

Middle
hole

position

Inner
hole

position

Pump
nozzle
diameter

Main
nozzle

diameter

Primary

Secondary
14
0
mm
0
551
in

0
2
cc

per
stroke

0

4
cc

per
stroke

0
6
cc

per
stroke

0

5
mm
0
020

in

2
3
mm
0
0906
in

2
8
mm
0
110
in

Throttle

valve

fully
closed

angle

Primary
10

degrees

Secondary
20

degrees

Idling
opening
5

degrees
approx

Choke
valve

fully
closed

angle
10

degrees

Throttle

opening
at
full
choke
13
5

degrees

FUEL
PUMP

Type

Delivery
Electric

1400
cc
in
one
minute
Emission

control

system

Air

pump
bracket
to

cylinder

head
nut

Adjusting
bar
to
bracket
bolt

Air

pump
to

bracket
bolt

Air

pump
to

adjusting
bar

nut

Anti
backfrre
bracket
to

rocker

cover
0
4Q
0
65

kgm
2
94
7
lb
ft

Anti
backfire
valve
to

bracket
0
4Q
O
65

kgm
2
94

7
lb
ft

Sensing
hose

clamp
to
rocker

cover
0
4Q
0
65

kgm
2
M
7
Ib
ft

Air

gallery
to
exhaust
manifold

plug
5
Q
6

0

kgm
36
243
4lb
ft

Check

valve
to
air

gallery
9

0
10
5

kgm
65

1
75
9Ib
ft
1
6
2
4

kgm
I
1
6
17
4Ib
ft

1
6
2
4

kgm
I
1
6
17
4Ib
ft

1
6
2
4

kgm
I
1
6
17
4
lb
ft

1
6

2
4

kgm
11
6
17
4Ib
ft

Front

SuspensIon
SteerIng

Description

Steering
Maintenance

Wheel
hub
and

bearing

Stabilizer

Spring
and
strut

assembly

Transverse
link
and
lower
ball

joint

Suspension
member

Front
wheel

alignment

Steering
wheel
and
column

Rack
and

pinion
and
tie
rod

Collapsible
steering

DESCRIPTION

The
front

suspension
is
of
the
strut

type
with

the
coil

spring
and

hydraulic

damper
units
mounted
on
the
crossmember

and
transverse
link

assembly
See

Fig
C
I
Vertical
movement

of
the

suspension
is
controlled

by
the
strut

assembly
Forward

and
rearward
movement
is
absorbed

by
compression
rods
6

and
side
movement
controlled

by
the
transverse
links
Front

suspension
servicing
procedures
are
similar
to
those

given
for

vehicle
fitted
with
L14
Ll6
and
LIB

engines
and
can

be
carried

out

by
reference
to

the
instructions

given
in
the

appropriate

section
Camber
and
castor

angles
are

preset
and
cannot

be

adjusted
and
a

check
must

be
made
for

signs
of

damage
to

the

suspension
system
if
the

angles
do
not
confonn
to
the

figures

given
in
Technical
Data

The

steering
is
of
the
direct

acting
rack
and

pinion

type

See

Fig
C
2
A
rubber

coupling
which
absorbs
vibration
and

two
universal

join
ts
are

incorpora
ted
between
the

steering
wheel

and

gear
assembly
The

collapsible
type
of

steering
column

assembly

Fig
C3
is
an

optional
fitting
A
full

description
of
this

type
of

assembly
i

given
in
the

Steering
section
for
L14

L16
and
L18

engines

STEERING
Maintenance

The

steering
system
should
be
lubricated

every
two

years

or
50
000
km
30
000
miles
whichever
comes

fIrst

A
lithium
base

multipurpose
grease
must
be
used
for
the

rack
and

pinion
and
rack
and
tie
rod

joints
The

plug
on
the

steering
gear
housing
should
be
removed
and
a

grease
nipple

fitted
so
that
the
recommended

quantity
of
10
to

15

gram

0
35
to

0
53
oz
of

grease
can
be

injected
Remove
the

grease

nipple
and

replace
the
plug
when
lubrication
is

completed

The

grease
reservoir
on
the
tube
side
should
be

replenished
when

the
level
of

grease
falls
to

approximately
one
third
ofits

capacity

WHEEL
HUB
AND
BEARING
Removal
and
Installation

Wheel
hub
and

bearing
servicing
procedures
are
similar
to

those

previously
given
for
vehicles
fitted
with
L14
LI6
and
LIB

engines

S23

Remove

the
road
wheel
and
disconnect
the
brake
hose
at

the
connector
as

shown
in

Fig
C
4
of
this
section

Remove
the
brake

calliper
assembly
and
hub

cap
Withdraw

the
cotter

pin
and
remove
the
wheel

bearing
locknut

Remove
the
wheel

bearing
washer
and
take
off

the
hub

and
brake
disc

Fig
C
5
Remove
the

bearing
collar
take
out

the
outer

bearing
cage
and

prise
out

the
hub

grease
seal
Remove

the
inner
bearing
cage
and
drive
out
the
outer
races

of
the
inner

and
outer

bearings
using
the

special
drift
ST49120000

if
avail

able

Separate
the
brake
disc
from
the
hub
by
taking
out
the

retaining
bolts
as
shown
in

Fig
C
6

Installation
is
a

reversal
of
the
removal

procedure
Adjust

the
wheel

bearings
as

previously
described

taking
care
to

tighten
the
wheel

bearing
locknut
to
the

specified

torque
read

ing
of
3
0
to
3
5

kgm
21
7
to
25
3lb
ft
Turn
the
hub

several
times
to
settle
the

bearing
then
retighten
the
nut
to
the

same

figure
Slacken
the
locknut

by
a

quarter
turn
900
and

insert
the
cotter

pin
when
the
hole

in
the

spindle
is
aligned

with
the
hole
in
the
nut
Check
that
the
force

required
to
turn

the
hub
is
less
than
7
0

kg
cm
97
2
in
oz

STABILIZER
Removal
and
Installation

Remove
the

splash
board
and
take
off
the
bolts
I
in

Fig
C
7
which
attach
the
stabilizer
at

the
transverse
link
sides

Remove
the
bolts

attaching
the

stabilizer
bracket
2
to

the
frame
then

withdraw
the
stabilizer

Check

the
bar
and
rubber

components
for

signs
of
deforma

tion
or

damage
and
renew
as

necessary

Installation

is
a
reversal
of
the
removal

procedures
Tighten

the

fixing
bolts
to
a

torque
reading
of
1
2
to
I
7

kgm
8
7
to

12
3
lb
ft
at

the
transverse
link

side
and
1
9
to
2
5

kgm
13
7
to

18
llb
ft
at
the
frame
bracket

SPRING
AND
STRUT
ASSEMBLY

The

spring
and
strut
assembly
can
be
serviced

by
following

the
instructions
previously
given
for
the
assemblies
on
vehicles

fitted
with
the
L14
L16
and

Ll8engines

When

reassembling
make
sure
that
the

parts
shown
in

Fig
C
8
are

thomughly
greased
Installation
of
the

assembly

will
be

accomplished
more

easily
if
the
dust
cover
on
the
bonnet

ledge
is
removed

Tighten
the
nuts
and
bolts
to
a

torque
figures
given
in

TIGHTENING

TORQUES

TRANSVERSE
LINK
AND
LOWER
BALL
JOINT

The
transverse
link
and
lower
ball

joint
can
be

removed
in

a

similar
manner
to
the

parts
on
vehicles
fitted
with
L
14
L
16

and
L
18

engines

Renew
the
link

if
cracked
or

damaged
in

any
way
Check

the

measurement
A
in

Fig
C
9
The
measurement
between

front
and
rear
transverse

link
bushes
should
be
less
than
1
0
mm

0
039
in

Replace
the
bushes
if

necessary
The

lower
ball

joint

should
be

replaced
if
the
axial

play
of
the

joint
exceeds
0
03

to
0
6

mm
0
0012
to
0
0136

in
A

grease
nipple
must

be
installed

in

place
of
the
ball

joint

plug
so

that
the

joint
can
be
lubricated
with
multi

purpose
grease

as

previously
described

SUSPENSION
MEMBER

Removing
and

Installing

Jack

up
the
vehicle
and

support
it
on

stands

2
Remove
the

splash
board
Refer
to

Fig
C
I
0
and
detach

the

compression
rod
I
the
stabilizer
2
from
the
trans

verse
link
3
Detach

the
steering
linkage
from

the
suspen

sion
crossmember
4

3
Take
out

the
nuts

attaching
the
transverse
links
and
remove

the
links
at
both
sides
of
the
vehicle

4

Support
the

engine
with
a
hoist
as
shown
in

Fig
C
II

taking

care
not
to

damage
the
throttle
and
remote
control

linkages

and
then
remove
the

engine
mounting
bolts
at
both
sides

5
Remove
the

bolts
shown
arrowed
in
Fig
C
12

and
lift
the

suspension
member

away

Renew
the

suspension
member
if
it
is
cracked
or

deformed

in

any
way
Installation
is
a
reversal
of
the
removal

procedure

FRONT
WHEEL
ALIGNMENT

As

previously
stated
the
castor
and
camber

angles
are

preset
and
cannot

be

adjusted
A

thorough
check

should
be

made
of
the

steering
and

suspension
system
and
all
defective

parts
renewed
if

the

angles
are

incorrect
See
Technical

Data

The
front
wheels
should
toe
in

12
to

15
mm
0
4
7
to

0
59

in

Adjustment
can
be
carried
out

by
slackening
the
locknuts

1
in

Fig
C
13
and
then

turning
the
tie

rods

by
an

equal
amount

until
the
correct
toe

in
is
achieved
A
toe

in
gauge
will
of
course

be

required
for
this

operation

STEERING
WHEEL
AND
COLUMN
Removal

Disconnect
the
horn
wire
and
remove
the
horn
bar
Remove

the

steering
wheel
nut
and

pull
off
the

steering
wheel

2
Remove
the
turn

signal
and

lighting
switch

assembly
followed

by
the

steering
column
shell
covers

3
Remove
the
bolts
from
the
rubber

coupling
to

disconnect

the
lower

joint
See

Figs
C
14
and
C

I
5
if
the
car
is

fitted
with

right
hand
drive
The
lower
joint
upper
bolt

should
be
removed
to
disconnect
the

joint
if
the
car

is

fitted
with
left
hand
drive

4
Remove
the
cotter

pin
from
the
trunnion
and
disconnect

the

gearchange
rod
and
selector
rod

5
Remove
the

steering
column

upper
clamp
and
take
out
the

bolts

securing
the
lower

plate

STEERING
COLUMN

Dismantling
and

Assembling

Remove
the
C
washer
socket
screw
and

upper
bracket

bolt
Remove
the
lower
bracket
bolts
and
detach
the
remote

control

linkage
from
the
column

assembly

Remove
the

snap
ring
at
the

top
of
the
column
and
extract

the
column
shaft
from
the

jacket

Disconnect
the
rubber
coupling
from
the
lower

joint

then
remove

the
snap
ring
and
dismantle
the
lower
joint

S25

Gean
all

parts
thoroughly
and
renew
if

damaged
If
the

column
shaft
or

jacket
is

excessively
damaged
the

steering
gear

housing
must

be
checked
A

damaged
bearing
must

be

replaced

together
with
the
column

jacket
assembly

Assembly
is
a

reversal
of
the

dismantling
procedures
The

column
shaft

journal
should
be
lubricated
with

multipurpose

grease
which
can
also
be
used
to
fill

up
the
dust
cover
Grease

the
needle

bearing
when

assembling
the
universal

joint
Use

the

tightest
snap

ring
available
when

fitting
the
needle

bearing
Snap

rings
are

supplied
in
oversizes
of
0
95
mm
05
mm
and
1

5

mm

0
0374
0
0413
and
0
0453

in

Installation
of
the
column

assembly
is
a
reversal
of
the

removal

procedures
Tighten
the
rubber

coupling
bolts
to
a

torque
reading
of
I
S
to
1
8

kgm
I
0
8
to

13
0
Ib
ft
Refit
the

steering
wheel
and

tighten
the
nut
to
a

reading
of
4
0
to
5
0

kgm
28
9
to
36
2Ib
ft

RACK
AND
PINION
AND
TIE
ROD

Removing
and

Dismantling

1

Jack

up
the
vehicle
and

support
it
on
stands
Remove
the

road
wheels

2
Slacken
the
bolts

connecting
the

pinion
to
the

steering

lower

joint
See
Figs
C

16

3
Remove
the
bolts
from
the
steering
column
rubber
coupl

ing
See

Fig
C
15
and
remove
the

splash
board

Fig
C
17

4

Remove
the
tie
rod
ball
stud
nut
and
disconnect
the
tie

rod
from
the
knuckle
arm

Fig
C
I8

5
Lift
the

engine
slightly
with
suitable
tackle
but
take
care

not
to

damage
the
accelerator
or
remote
control

linkage

Remove
the
bolts

securing
the
steering
gear
housing
to
the

suspension
member
Withdraw
the
rack
and

pinion

assem

bly

Dismantle
as
follows

Detach
the

steering
lower

joint
from
the
rack
and

pinion

assembly
Clamp
the
unit
in
a
vice

taking
care
not
to

damage

the

steering
gear
housing

Refer
to

Fig
C
16
and
take
off
the
dust
cover
and
boot

clamps
at

both
sides
Slacken
the
stopper
nut

remove
the
tie

rod
inner
socket
and
disconnect
the
tie
rods
from
the
rack

Withdraw
the

spring
seat
and
tie

rod

spring
Take
off
the

steering

gear
boots
at
both
sides
Slacken
the
locknut
and

disconnect
the
tie
rod
outer
socket
from
the
ball

Slacken
the
locknut
remove
the
retainer

adjusting
screw

and
withdraw
the
steering

gear
retainer
See

Fig
C
19

Take
off
the
oil
seal
remove
the
snap
ring
and
withdraw

the

pinion
Remove
the

snap
ring
and
withdraw
the

bearing
from

the

pinion
Remove
the
filler

plug
and
take
out
the
rack
Remove

the

grease
reservoir

Clcan
all

parts
thoroughly
and

replace
any
which
show

signs
of
wear
or

damage
Check
the
axial
play
of
the
inner

and

outer
ball

joints
The

play
should
be
0
06
mm
0
0024
in
for

the
inner
ball
joint
and
from
0
1
to
0
5
mm
0
0039
to
0
0197

in
for
the
outer

joints
Use
a

spring
balance
to
check
the
force

required
to

swing
the
ball

joints
this
should
be
between
0
8
to

LS

kgm
5
8
to
10
8Ib
ft
Renew
the
oil
seal
Examine
the
retainer
and

tie
rod

springs

and

compare
them
with
the
values

given
in

Figs
C
20
and
c
n

RACK
AND
PINION
AND
TIE
ROD

Assembling
and
Adjusting

Press
the

bearing
on
to

the
pinion
gear
and
fi
t

the
tigh
test

snap
ring
available

Snap
rings
are

supplied
in
the

following
over

sizes

Snap

Ring
Thicknesses

1
04
to
1
09
mm
0
0409
to
0
0429
in

1
09
to
I
14
mm

0
0429
to
0
0449
in

1

14toI19mm
0
0449toO
0469in

Ll9
to
1
24
mm

0
0469
to
0
0488
in

1

24
to
1
29
mm
0
0488
to
0
0502
in

Clamp
the

steering
gear
housing
in
a

vice
Grease

the
teeth

and
friction
surfaces
of
the
rack
with

multipurpose
grease

Lubricate
the

gear
housing
from
the

pinion
housing
side

Ensure
that
the
rack

projects
by
an

equal
amount

of

96
mm

3
8
in
in
both
ends
of
the

housing
with
the
rack

teeth

directed
towards
the

pinion
shaft

Grease
the
pinion
teeth
end

bushing
and

pinion
bearing

Engage
the
tccth
of
the

pinion
with
the
rack
and
insert
the

pinion
Make
sure
that
the

bushing
does
not
become
damaged

The
rack
must

project
from
the

housing
by
an

equal
amount

at
each
side
with
the

groove
on
the

pinion
serration

facing

upwards

Fit
the

snap
ring
into
the
housing
groove
to
hold
the

bearing
outer
race

in

position
The

snap
ring
must

fit

tightly

and
can
be
selected
from
the

following
oversizes

Snap
Ring
Thicknesses

LS5
to

1
60
mm
0
0610
to
0
0630
in

1
60
to
1
65
mm
0
0630
to
0
0650

in

1
65
to
I
70
mm
0
0650
to
0
0669
in

1
70
to
I
75
mm
0
0669
to
0
0689

in

Fit
the
oil
seal
Use
a
dial

gauge
as

shown
in

Fig
C
22
to

check
the
thrust

play
of
the
pinion
The

play
should
be
less

than
0
09mm
0
0035
in

Grease
the
retainer
and
insert
it

with
the
spring
Tighten

the
retainer
adjusting
screw

fully
then
back
it
off

by
20
to

25

degrees
Tighten
the
locknut
to
a

torque
reading
of
4
0
to

6
0

kgm
28
9
to
43
4lb
ft
Coat
the
locknut
with

liquid
pack

ing
Three
Bond

When
the
rack
and

pinion
is
assembled
measure
the
force

required
to
rotate

the
pinion
and
also
the

preload
of
the
rack

Use
a

spring
balance
as
shown
in
Figs
C
23
and
C
24
and
check

that
the

pinion
torque
is
8
to
20

kg
cm
7
to
17
Ib
in
and
the

rack

preload
is
from
8
to
18

kg
17
6
to
39
7Ibs
Take
care

to
slide
the

assembly
over
the

complete
range
of
the
stroke

Fit
a
dust
cover

clamp
at

each
end
of
the
housing
Install

the

stop
nut
on
the
threads
of
the
rack

Liberally

grease
the
ball
joint
friction
area
of
the
tie
rod

assembly
Assemble
the
spring
and
ball
seat
and
fit
the
inner

socket

part
of
the
tie
rod

assembly
to
the
rack
Make
sure
the

boot
is

positioned
at
the
ball
stud
end
Note
that
the
left
hand

tie
rod
is
marked
with
an

L
the

right
hand
rod
is
not
marked

527