weight DATSUN 610 1969 User Guide

The

standard
width
of
the
side

bearings
is
20
0mm

0
7874

this
width
must
be

measured
before

attempting
to

calculate
the
thickness

of
the

adjusting
shims
Use
a

dial

gauge

and
surface

plate
to
ohtain

the
measurement
Place
a

weight
of

approximately
2

5

kg
5
5
lb
on
the

bearing
to

obtain

steady

readings

Install
the
differential

cage

assembly
in

the
carrier

Fit
the

sckcted

shims
and
O

rings
into
both

differential
side

bearing

covers

and
install
the
covers

in
the

carrier

using
the

special
tool

ST
33720000

Fig
G
16
l
Make
sure

that
the
side

bearing

outer

races
are
not

damaged

by
the

roller
Measure
the
backlash

between
the

teeth
of

the
crown
wheel

and
drive

pinion
with
a

dial

gauge
as
shown
in

Fig
G
I
Sct
the
dial

gauge
to
0
10

f
O

mm

0
004
0
008
in

I
If
the

backlash
is

less
than
the

specifIed

value
move
he
left
side

adjusting
shim
to
the

right
side
and
vice

versa

if
the
backlash

exceeds
the
specified
figure

Check

that
the
run
out
at
the
rear

of
the

crownwheel
does

not

excecd
O
OSmm
0
002

in
for

the
1800ce
model
or

O
08mm
0

003
in

for
the
1400
Check
the

drive

pinion

turning

torque
Thc

turning
torque
should
be

higher

by
I
3

kg

em

compared
with
the

turning
torque
obtained
before

fitting

the
differential

cage
in
the
carrier
The

higher
value
can

be

provided
if

necessary
by

dmnging
the

jde
cover

shims
Note

howcver

that
any
decrease
or
increase
in

the
thickncss
of
shims

wjJl

alter
tht
budlush

between
the
teeth
of
the
crownwhee1

and

pinion

Check

the
tooth
contact

pat
tern

of
the
crown
wheel
and

pinion
as

described
under
the

appropriate
heading

DIFFERENTIAL

Installation

Secure
the
differential

carrier
on
the
rear

suspension
mem

ber

using
the
four

bolts
and
washers
Fit
the
differential

mounting
member
to
thc

mounting
holes

by
pushing
it
forwards

with
a

suitable
lever

Fig
G
18

Tighten
the

nuts
to
a

torque

reading
of
8

5

kgm
61
5

Ib
ft

Tighten
the
bolts

attaching
the

gear
carrier
to
the

suspension
member
to
a

torque
reading
of

6
7

kg
36
5Ilb
ft
t

The

rcmainder
of
the
installation

operations
are
a
reversal

of

thc
removal

procedure
Fill
the
differential
with

the
correct

quantity
of
recommended
oil

DIFFERENTIAL
CARRIER

Removal
and

Dismantling

Estate
car
alld
Vanl

To

remove
the
differential

carrier
disconnect
and
remove

rhe

propeller
shaft
as

previously
described

and
remove

the
two

rear
axle

shafts
as

described
in

the
section
REAR
AXLL
With

draw

the
nuts

securing
the
differential

and
remove

the
carrier

from
the
rear
axle

Mount

the
unit
on
the

special
attachment
as
shown
in

Fig
G
19
and

carry
out
a

preliminary
check
before

dismantling

Oleck
the
tooth
contact
of
the

crownwheel

and

pinion
by

applying
lead
oxide

to
three
or
four

teeth
of
the

crownwheel

Turn
the
crown

wheel
several
times

to
obtain
an

impression
of

the

tooth
contact

pattern
Check
the
backlash

between
the
teeth

of
the
crownwheel
and

pinion
with
a

dial

gauge
Hold
the
drive

pinion
with
one

hand
and
move

the
crown
wheel

backwards
and
forwards
to

check

that
the
backlash
is
Io

ithin
thL

speL
ified
limits

Shims
and

adjusting
washers
must
bL
altered
if

the
tooth
con

tact

pattern
and
backlash

is

incorre
L
the
neL

cssary
details
for

these

operations
can
be
found
towards
the

end
of

this
section

under
the

appropriate
he
Jdjn

s
Fil1JJly
mark
the

bearing
caps

with
a
hammer

and

punch
to
ensure
correct

t1ignment
on
re

assembly

Remove
the

bearing

caps
nd
withdraw

the
differ

ntial

cage
make

a
note
of

the
left
and

right
hand

positions
so
h
Jt

the

bearing
caps
and
outer
race
can

be
re

assembled
in

their

original
positions

Withdraw

the
side

beJrings
with
the
s

cjal

puller
as

shown

in

Fig
G
20

taking
care
not
to

catch
the

edge
of
the

bearing

inner
races

Place
the

assembly
in
a
vice
and
detach

the
crownwheel

by
slackening
the

retaining
bolts
in
a

diagonal

patter
Fig
G
lf

Drive

out
th

pinion
shaft
lock

pin
from

left
to

right
using
a

suitable

punch
or

special
tool
ST
23520000

Fig
C
22

With

draw
the

pinion
shaft
and
take
out

the

pinions
side

gears
and

thrust
washers

Store
the

gears
and
thrust
washers
so
that

they

can

be
assembled
in
their

original

positions

Check
the
initial

turning
torque
of
the

drive

pinion
with

the

preload
gauge
ST
3190000

and
measure

the

height
of

the

drive

pinion
with
the

special
gauge
ST
31941000

Compare
the

figures
obtained
with
those

givcn
in

Technical
Data
at

the
end

of
this
section

Hold
the
drive

pinion
with

the

speciaJ
wrench
ST
3
J
530000

as
shown
in

Fig
C

23
and
unscrew
the

drivc

pinion
nut

then

pull
out
the
drive

pjnion
flange

Tap
the
drive

pinion
assembly
to
the
rear
with
a

plastic

mallet
and
withdraw
it

together
with

the
rear

bearing
inner
race

bearing
spacer
and
adjusting
washer

Remove

and
discard
the
oil
seal
and

withdraw
thc
front

bearing
inner
race
Drive
out
the
outer
races

of
the
front
and

rear

bearings
with
a
suitable

drift

Fig
G
25

The
drive

pinion
rear

bearing
inncr
race
can
be
removed

with
the

special
tool
ST
300310000
as

shown
in

Fig
G
24

DIFFE
l
ENTlAL

Inspection

Clean
all

components
thoroughly
and

examine
for

signs

of
wear
or

damage

Check
the
teeth
of
the

crownwhcel

and

pinion
for

scoring

and

hipping
Ii
should
be

noted
that
the
crownwhecl

and

pinion
are

supplied
as
a

matched
set
and
if
either

part
is

damaged

the

complete
set
must
be

replaced

Examine
the

inner
faces
of
the
side

gears
and
seats
on
the

differential
case

Inspect
the

bearing
races
and

rollers
and

replace

them
if

necessary

Small
defects

on
the
faces
of

the
thrust

washers
can
be

corrected

using
emery
cloth
however
if

the
clearance
between

side

gear
and

thrust
washer

exceeds
0
1
O
2mm
0
0039

0
0079

in
it
ill
be

necessary
to

replace
the
washer

Various

sizes
of
washers
are
available

and
the
thicknesses
arc
detailed

under
the

heading
DIFFERENTIA
L

GEAR
CAGE

Assembling

69

greased
Install
the

flange
washer
and

pinion
nut
Tighten
the

nut
to
a

torque
reading
of

14
17

kgm
101
130
Ib
fL
If

the
cotter

pin
hole
is
not

correctly
aligned
a
suitable

washer

should
be
fitted
Do

NOT

adjust
by
overtightening
the

pinion

nul

Van

Lubricate
the
front

bearing
with
oil
and

place
it
in
the

carrier
Grease
the

lip
of
the
oil
seal

and
install
it
to
the
final

drive

housing
Install
the
drive

pinion
the
new

collapsible
spacer

and

the
drive

flange

Fit
the
drive

pinion
nut
and

tighten
temporarily
until
all

slackness
is
eliminated
from
the
front

and
rear
of
the
drive

pinion

NOTE

Ensure
that
oil
and

grease
have
been

completely

removed
from

the
threads
of
the

pinion
gear
the

pinion

nut
and
the
washer

Tighten
the

pinion
nut
and
check

the

preload
with
a

preload

gauge
As
the
nut

is

tightened
to
the

specified
torque

reading
of
13
20

kgm
94
0
144

6Ib
fL

the

preload
must
be

measured
at

every
five
to
ten

degrees
turn
of

the

pinion
nut

As
the

pinion
nut
is

tightened
the

stepped
portion
of
the

spacer

is
deformed
See

Fig
G
29
J
and
the

length
between
the

bearings

adjusted

The
drive

pinion
bearing
preload
with
oil
seal
and
new

bearing
is
7
15

kg
cm
6
1
13
0
lb
in

Turn
the
drive

pinion

to
settle
the

bearing
and
re
check
the

preload
and

tightening

torque
If
the

preload
rate
is
exceeded
it
will
be

necessry
to
fit

a
new

spacer
the
old

spa
cr
cannot
be

reused
and
the
preload

must
not
be

adjusted
by
loosening
the
pinion
nul

Side

bearing

pre
load

adjusting

If

the

original
side

bearings
arc
to
be
used

the
shims
must

be
of
the

same
thickness
as
those

previously
fitted

To
select
shims
for
new

side

bearings
proceed
as
follows

The
standard

width
of
the
side

bearings
is

given
in

Technical
Data
This

width
must

be
measured
before

attempting

to

calculate
the

required
thickness
of
the

adjusting
shims
Place

a

weight
of

approximately
5

kg
5
5
lb
and
of

predetermined

height
onto
the
side

bearing
as
shown

in
Fig
G
30
Mcasure

the

width
of
the

bearing
with
a
dial

gauge
as
illustrated

turning

the

bearing
two
or

three
times

to

gain
an
accurate
meaSurement

Dimensional
variations
from
the
standard
measurements

are
marked
on
the
left

side

bearing
housing
of
the

gear
carrier

on

the

right
side

bearing
housing
of
the

gear
carrier
and
on

the

differential

case
These

variations
are
marked
in

units
of

l
lOOmm

and
are
used
for
the

f
rmula
to

calculate
t1H
thickness
of

the

adjusting
shims
in
the

following
manner

Where
TI

equals
the
left
side

bearing
shim

crownwhecl

side

T2

equals
the

right
side

bearing
shim

pinion
gear
A

equals

the

figure
marked
on

the
left
side

bearing
housing
B

equals
the

figure
marked
on
the

right
side

bearing
housing
C
and
0

equals

the
figure
marked
on

the
differential
case
and

E
and
F
is
the

difference
bctween
the

width
of

the
side

bearings
and
the

standard

bearing
width
H
the

figure
marked
on
the

crownwhcel
Fig
G
31
The
following

formulae
can
now
be
used

to
deter

mine
the

required
shim

thicknessl
s
for

both
side

bearings

I
OOcc
Estate
car

Left

side

bearing
TI
A
C

D
H
x

0
01
0
100
E

Right
side

bearingT2
B
D
H
x

0
01
0
090
F

I800cc

Van

Left
side

bearingTI
A

C
D
H

xO
OI
0
175
E

Right
side

bcaringT2
8
D
H
x
0
01

0
150
F

As
an

example
where
A
1
B
C
2
D
3
E
0
02mm

H
I

The
formula
for
the
left

side

bearing
is

T
I
I
1
3
1

x
0
01

0
175
0
02
0
205mm

1400
and

1600cc
Estate
car

The

required
thickness
of
shim
can
be
found

using
the

following

formula
in

a
similar
manner
to

that

previously
described
for

the
1800cc
models

Left

side

bearing
T
I
A

C
D
E
7

Right
side

bearing
T2
B
D
F

6

Shims
are
available
in
five
thicknesses
of
0
05
0
07
0
10

0
20
and
0
50
mm

0
002
0
0028
0
0039
0
0079
and

0
0197

in

Fit
the
selected
side

bearing
adjusting
shims
on
the

differential

cage
and

press
in
the
side

bearing
inner
races

using

a

suitable
ddfL
nstall
the
differential
cage
into

the
carrier
and

fit
the

bearing

caps
Ensure
that
the
marks
on

the

caps
coincide

with
the
marks
on
the
carrier

Tighten
the

bearing
cap
bolts
to

the

specified
torque
reading
See

Tighte
ing
torques

Measure
the
dimension

between
the
outer

edges
of

the

left

and

right
hand

caps
using
a

large
micrometer
as
shown
in

Fig
G
32
This
dimension
should
be
198
40
198
55
mm

7
8110
7
8169

in
for

the
1400

and
1600
ce
Estate
cars
and

1800
ce

Van
and
173
23
17329
mm
6
8201
6
8244
inl

for

the
1800
cc

Estate
cars

Measure
the
backlash
of
the
crownwhcel
and

pinion
with

a
dial

gauge
The
backlash
must
be

adjusted
to
0
13
0
18
mm

0
005

0
007
in
on

the
1800
CC
models

and
to
0
15
0
20mm

0
006
0
008
in
on
the
1400
and
1600
cc
models

Adjustment

can
be
carried
out

by
moving
side

bearing
shims
from
the

right

hand
side
to
the
left
hand
side
if
the
backlash

is
too

high
or
vice

verca
if
the
backlash
is
too
low

Tighten
the

bearing
cap
bolts

to

the

specified
torque

reading
after

adjusting
Ensure
that
the

run
out
at
the
rear
of
the
crown
wheel

does
not

exceed
O

05mm

0
002
in

Finally
heck
the
tooth
contact

pattern
as
described
below

TOOTH
CONTACT
PATTERN

Checking

The
final
check
on

reassembly
is
an

inspection
of
the

tooth

contact

markings
of

the
crownwhed
and

pinion

Apply
a

coal
of
red
lead
in

oil
to
4
or
5
teeth
of
the
crown

wheel
Turn
the
crownwheel
backwards

and
forwards
several

times
to
obtain
a
clear

impression
of
the
contact
areas

Heel
contact

Fig
G
3
1

71

factory
parts

Installation

is
a

reversal
of
the
removal

procedure

REAR
SUSPENSION

ARM
Removal
and
Installation

Saloon

I
J
ad

up
the
car
at

the
rear
and

support
it
on
stands

2
Remove
the
road
wheel
and
brake
drum
as
described
in

the

section
BRAKES

3
Disconnect

the
drive
shaft
from
the
axle
shaft

4
Disconnect

the
handbrake
cable
from
the

equalizer
bracket

and
the
wheel

cylinder
lever
Disconnect

the
brake
hose

from
the
brake
line

by
removing
the
lock

spring
and
then

withdrawing
through
the
connector

Plug
the
end
of
the

brake

line
to

avoid
loss

of
fluid
and

ingress
of
dirt

5
Remove
the
wheel

bearing
locknut

Fig
H
9
the
rear

axle

shaft

wheel

bearings
and
oil
seal
Remove
the
rear
brake

assembly
from
the

suspension
ann
See
section
BRAKES

6
Jack

up
the

suspension
arm
to

relieve
the
tension
on
the

shock
absorber
and
disconnect
the
shock
absorber
from

the
lower

mounting
Lower
the

jack
gradually
and
remove

the
coil

spring
seat
and

bump
rubber

7
Remove
the
bolts

securing
the

suspension
arm
to

the

suspension
member

Fig
H
IO
and
withdraw
the

suspension

arm

The
rubber
bushes
can

be
drawn
out

of
the

suspension
arm

if

necessary
using
the

special
tool
ST
38280000

Fig
H
Il

O1eck
the

suspension
arm
for
distortion
or

cracks
and

inspect
the
rubber
bushes
for

signs
of
wear
or

damage
Renew

any
part
which

is

unsatisfactory

Installation

is
a

reversal
of
the
removal

procedure
Tighten

all
the

suspension
arm

mounting
bolts
with
the

weight
of

the

vehicle

resting
on
the
rear
wheels
The
self

locking
nuts
must

be
renewed
at
each
overhaul

REAR

AXLE
SHAFTS
BEARINGS
AND
SEALS

Saloon
Removal
and

Dismantling

I
Raise
the
vehicle
at
the

rear
and

place
stands
under
the

body
member

2
Remove

the
road
wheel
and
brake
drum

3
Disconnect
the
drive
shaft
from
the
axle
shaft
and
remove

the
wheel

bearing
locknut
The

special
wrench
ST
38060001

can
be
used
to
hold
the

flange
as

shownin

Fig
H
12

4
Withdraw

the
axle

shaft

assembly
as
shown
in

Fig
H
13

using
the

special
tool
ST
07640000

and
sliding
hammer

ST
36230000
Remove

the
rear
axle
drive

flange

5
Use
a
suitable
drift
or

special
tool
ST
37750000
See

Fig

H
14
to
drive

out
the
inner

bearing
and
oil
seal

F
6
Remove

the

grease
retainer
and
withdraw
the
outer

bearing
with
a
conventional

puller
DO
NOT
re
use
this

outer

bearing

REAR
AXLE
SHAFTS
BEARINGS
AND
SEALS
Saloon

Assembly
and
Installation

Oleck
the
axle
shaft
for

straightness
make
sure
that
it
is

not
cracked
or

damaged
in

any
way
00
NOT
heat
the
shaft

if

attempting
to
re
straighten

Make
sure
that
the

lip
of
the
oil

seal
is
not

damaged
or

distorted
Check
the

bearing
for
excessive

wear
and

damage

Oean
the
wheel

bearings
the
oil
seal

and
the
inside
of
the

axle

housing

When

installing
the
wheel

bearings
the
sealed
side
of
the

outer

bearing
should
face

the
wheel
and
the
sealed

side
of

the

inner

bearing
should
face
the
differential
See

Fig
H
IS

Pressure
must
be

applied
to
the
inner
race
when

fitting

When

replacing
the

suspension
arm
check
that
the
distance

piece
is
0
05
mm
0
002
in
shorter
than
the

length
of
the

housing
dimension
LI
See

Fig
H
16
The
distance

piece
and

axle

housing
code

markings
must
coincide

The
wheel

bearing
grease
must
be

replaced

every
50
000

km
30
000
miles
Pack
the
wheel

bearings
with

grease
at
the

positions
shown
in

Fig
H
IS
and
coat
the

lip
of
the
oil
seal

Renew
the
locknut
and
oil
seal
at

each
overhaul

Wheel

bearing
adjustment

Tighten
the
locknut
to

the

specified
torque
reading
of

25
33

kgm
181
239
lb
ft
and
check
that
the
rear
axle
shaft

end

play
does
not
exceed
0
15
mm
0
006
in
with
a

turning

torque
of
less
than
7

kg
em
6
11b
in
for
the
1400
and
1600cc

models
510

series
or
4
5

kg
em
3
91b
in
for
the
1800cc

610
series

If
the
correct
end

play
or

turning

torque
cannot
be

obtained
it
will
be

necessary
to

change
the
distance

piece
See

above

DRIVE
SHAFTS
Removal
and

Dismantlill8

Disconnect
the
end

flanges
and
remove
the
shaft
See

Fig
H
17
The
drive
shaft
should

only
be
dismantled
to

lubricate
the

splines
This

operation
will

only
be

necessary
every

two

years
or
50
000
km
30
000
miles

Remove
the
universal

joint
spider
at
the
differential
side

Refer
to
the

propeller
shaft
section
Remove
the

snap
ring

securiilg
the
sleeve

yoke
plug
and
take
out

the

plug
Compress

the
drive
shaft
and

remove
the

snap
ring
and

stopper
Fig
H
17

Disconnect
the
boot
and

split
the
shaft
Make
sure
that
the

balls
and

spacers
are
retained

DRIVE
SHAFTS

Inspection
and

Assembly

The
drive
shaft
should
be

replaced
as
an

assembly
if

any

part
is
found
to

be
defective

Check
the
shaft
for

straightness
damage
or
wear
Old

79

the
steel
balls
and
the
sleeve

yoke
for

damage
or
wear
Renew

the
boots
and
the
sleeve

yoke
plug
0

ring
if

necessary
Renew

the
universal

joint
jf

faulty

Check

the

play
in
the
drive
shaft

using
a
dial

gauge
as

shown
in

Fig
H
18
The
measurement
taken
with
the

dri
le

shaft

fully

compressed
should
not

exceed
O
lmm
0
004
in

Renew
the
drive
shaft
as

embly
if
the

specified
value
is
not

obtained

Oean

the
old
grease
from

the
sleeve

yoke
and
the
drive

shaft
ball

grooves
and
lubricate
with
oil

Asse

bly
of

the
drive
shaft

is
a

reversal
of
the

dismantling

procedure
noting
the

following
points

Align
the

yokes
and
make
sure
that

the
steel
balls

and

spacers
are
fitted

in
the
correct
order
Select
a

snap
ring
which

will

adjust
the
axial

play
of

the

universaIjoints
to
within
0
02mm

0
0008
in

Snap
rings
are
available
in

four
thicknesses
of

1
49
1
52
1
55

and
1
58
mm

0
0587
0
0598
0
0610

0
0622
in

Apply
a

generous

quantity
of
multi

purpose
grease
to
the

ball

groove
and
the
area
shown
in

Fig
H
19

REAR
AXLE
Removal
See

Fig
H
2

Estate
car
and
Van

Jack

up
the
vehicle
at
the
rear

and

support
it
on
stands

Remove

the
road

wheels
and
brake

drums
I

3
Disconnect
the
brake
hose
from
the

brake

pipe
Plug
the

end
of
the
hose
to

prevent
the

ingress
of

foreign
matter

4
Disconnect
the
handbrake
rear
cable
from

the
balance

lever

assembly

5
Disconnect

the

propeller
shaft
from
the
differential

flange

Release
the
lower
shock
absorber

self

locking
nuts
and

slide

the

mounting
eyes
of
the
shock
absorber
from
the

rear

spring
seat

pivot

6

Support
the
rear

axle
with

ajack
loosen
the
U
bolts
and

remove
the
nuts
from
the
rear

spring
shackles
Withdraw

the
shackles
from
the

spring
eyes

7
Remove
the
V
bolt
lock
nuts

completely
and
lower
the

jack
to

withdraw
the
rear
axle

assembly

REAR
AXLE

Dismailtling
and

Inspection

Disconnect
the
brake

pipes
from

the
wheel
cylinders
and

remove

the
brake

pipe
and
three

way
connector
Remove
the

cross
rod

clamp
and
the
balance
lever
from
the
rear
axle
case

Remove
both
cross
rod

ends
from
the

wheel

cylinder
lever

assembly

Unscrew
the
oil
drain

plug
and
drain
the
oil
from
the
axle

case
into
a
clean
container
The
oil

may
be
re
used
if
it
is
in

good
condition

Remove
the
nuts

securing
the
brake

backplate
to
the
axle

case
and
draw
out
the
axle
shaft

assembly
with
the

backpl
te

and
grease
catcher
A

sliding
hammer

ST
36230000
should
be

used
for
this

operation
as
shown
in

Fig
H
2Q

The

bearing
collar
can
be
removed
with
a

press
or

by

cutting
with
a
cold
chisel

and
the

bearing
withdrawn
with
the

puller
ST
3712001
as
shown
in

Fig
H
2t
Remove
the
brake

backplate
and
withdraw

the

gear
carrier
from

the
axle
case

Check
the
axle
shafts
for

straightness
wear
and
cracks

00
NOT

attempt
to

straighten
a
bent
shaft

by
heating
Check

the
oil
seal
lips
for

signs
of

damage
or
distortion
Make
sure

that

the

bearing
is
not
worn
or

damaged
REAR
AXLE

Assembly
and
Installation

Assembly
is
a
reversal
of
the

removal

procedure
noting
the

following
points

Thoroughly
clean
all

parts
and
fit
a
new

gasket
between

the
axle
case

and

gear
carrier

Tighten
the
nuts
in
a

diagonal

pattern
and
to

the

specified
torque
readings

Fit

the
grease
catcher

bearing
spacer
bearing
and
new

bearing
collar
onto
the
axle
shaft
A
load
of
4
5
tons
will

be

required
to

press
the

bearing
onto

the
shaft

Insert
the
wheel

bearing
with
the
seal
side

facing
the

wheel
and
ensure
that
the

oil
seal

lips
are
coated
with
wheel

bearing
grease
prior
to

fitting

Check
and

adjust
the
axial

play
between
the
wheel

bearing

and
the
axle

housing
using
a

dial
gauge
as

shown
in

Fig
H
22

The
axial

play
should
be

adjusted
to
within
0
3
0
5mm

0
0118
0
0197
in

on
the
1400
and
1600cc

models
and
to

within
O
lmm
0
0039
in
on

the
1800cc
models

Fill
the
rear
axle
with
the

specified
amount
of

oil
and

bleed
and

adjust
the
brake

system
as
described
in

the

appropriate

section

REAR
SPRING
Removal
and

Inspection

Estate
cars
aud
Vans

The
rear

springs
can
be
removed
in
the
following
manner

Jack

up
the

vehicle
at
the

rear
until
the
wheels
are
clear

of

the

ground
and

place
stands
under
the
rear
frame

Disconnect
the
shock
absorber
from

the

spring
seat

Fig
H
21a
and

support
the
rear
axle

housing
with

ajack

3
Take
off

the
locknuts

and
remove

the
U
bolts
shown

arrowed
in

Fig
H
2t
the

spring
seat
location

plates
and

seat

pads

4
Remove
the
nuts

securing
the
front
bracket
to
the

body

remove
the
bracket
from

the

spring
eye
and
car

body
and

withdraw
the
rear

spring

5
Remove

the

upper
and
lower

rear
shackle
nuts

Fig
H
23

and
remove
the
rear

spring
from
the
vehicle

Clean
the

spring
leaves

thoroughly
and
examine

them
for

fractures
or
cracks
Renew
the

assembly
if

necessary

Check
the
front

pin
shackle
U
boIts
and

spring
seat

for

signs
of
wear
cracks
and

damaged
threads
Renew
the

components
as

required

REAR
SPRING
Installation

Installation
of
the
rear

spring
is
a
reversal
of
the
removal

procedure
noting
the
following

points

The
front
bracket

pin
front
bracket

bushing
shackle

pin

and
shackle

bushing
should
be
coated
with
a

soapy
solution

prior
to

assembly

Tighten
the
front

pin
securing
nut

and
the
shock
absorber

lower

securing
nut
with
the
vehicle

weight
resting
on
the
rear

wheels

Ensure

that
the
flange
of

the
shackle

bushing
is

clamped

evenly
on
both
sides

The

tightening

torque
values
can

be
found

on
the

page

entitled
TIGHTENING

TORQUES

81

REAR
SHOCK
ABSORBERS

Replacing

Estate
cars
and
Vans

Jack

up
the
reaT
of
the
vehicle
and

place
stands
under
the

rear

axle

housing

Disconnect
the
lower
end
of
the
rear
shock
absorber
from

the

spring
seat

Fig
H
23

Remove
the
shock
absorber

upper
attachment
nuts
and

withdraw
the
shock
absorber
The

upper
attachment
nuts
are

located
behind
the
Tear
seat
backrest
as
shown
in

Fig
H
24
Check
the
shock
absorber
for

leakage
or
cracks
and
make

sure
that

the
shaft
is

straight
Inspect
the
rubber
bushings
for

damage
and
deterioration
Renew
all
defective

components

lnstallation

is
a

reversal
of
the
removal

procedures
Tighten

the

upper
and
lower
shock
absorber
attachment
nuts
to
the

torque
readings
stipulated
in
TIGlITENING

TORQUES

NOTE
The

weight
of
the

vehicle
must
be

resting
on
the
fear

wheels
when

tightening
the
lower

mounting
to

damp
the
rubber

bushes
in
an
unloaded

position

TechnICal
Data

I
Type
Independent
suspension
with
semi
tralllI1g
arms
or

semi

floating

COIL
SPRINGS

14
2mm
0
559
in

14
5mm
0
571
in

90
mm
3
543
in

306
mm

12
047
in

299
mm
II
772
in

290
mm

11417
in

I
1400
and
1600cc

Wire
diameter

Wire
diameter
hard

suspension

Coil
diameter

Free

length
R
H

Free

length
L
H

Free

length
Hard

suspension

1800cc

Wire
diameter

Coil
diameter

Free

length
RHD
R
H

Free

length
RHD
L
H

Free

length
LHD
both

Free

length
Hard

suspension

RHD
R
H

RHD
L
H

LHD
both
14
5
mm

0
571
in

90
3
54
in

321
mm

12
6
in

307
mm

12
1
in

321
mm

12
6
in

306
mm

12
0

in

299
mm

I
1
8
in

306
mm

12
0
in

SHOCK
ABSORBERS

34
56

kg
75
123
lb

21
39

kg
46
86
lb

SHOCK
ABSORBERS

Estate
cars
and
Vans

1400
and
1600cc
estate
cars
and

rigid
axle
sedan

Piston
diameter
2S
mm
0
984
in

Stroke
205
mm

8
071
in

Max

length
518
mm
20
39
in

Damping
force
at
0
3
in
see

Estate
cars

Expansion

Compression

Damping
force

at
0
3m
jsec

Sedan

Expansion

Compression
1400
and
1600
cc

Piston
diameter

Piston
diameter
Hard

suspension

Stroke

Max

length

Damping
force
at
0
3m
sec

Expansion

Compression

1800
cc

Stroke

Max
lengtb

Damping
force
at
0
3
m
sec

Expansion

Compression

82
35
mm
1
378
in

40
mm

1
575
in

206
mm
8
110
in

568
mm
22
362
in

45

kg
99
21b

28

kg
61
7
lb

220
mm
8
60
in

595
mm
23
4
in

90

kg
198
4
lb

50

kg
110
3
lb

75

kg
165
4Ib

40

kg
88
2

lb
1800cc
Estate
cars

Stroke

Max

length

Damping
force
at
O
3m
sec

Estate
cars

Expansion

Compression
205mm
8
071
in

518
mm
20
39
in

63
87

kg
139
192
lb

33
43

kg
73
95
lb

Damping
force
at
0
3
m
sec

Estate
car
and
Van
with
hard

suspension

Expansion

Compression
97
131

kg
214
289
lb

29
43

kg
64
95
lb

REAR
SPRINGS

1400
and
1600cc
Estate
car

Length

Width

Thickness

No
of
leaves

Free
camber

Laden
camber
1200mm
47
2
in

60
mm
f2
362
in

6
mm
0
236
in

4

137
mm
5
394
in

15
mm

265
kg
0
59
in

584
lb

Spring
eye
bolt
diameter

Front

Rear
45
mm

I
772
in

30

mm
U81
in

1400
and
1600
cc

Free
camber

Laden
cam
her
rigid
axle
sedan

100
mm
3
937
in

15mm
250

kg
0
591
in

551

lb

1800cc
Estate

Laden
camber

Turning
torque
15
mm

265
kg
0
591

in
1

584
lb

2
2
kg
mm

123
Ib
in

REAR
AXLE
SHAFT

less
than
4
5

kg
cm
3
91b

in

less
than
0
1

S
mm

0
006
in

DRIVE
SHAFT
AND
JOURNAL
Spring
constant

End

play

Sliding
resistance
1400
and

1600
cc

Sliding
resistance
1800cc
0
15

kg
0
33
lib

less
than
20

kg
44
lb

Radial

play
of
ball

spline
less
than
O
lmm
0
004
in

GIS

DESCRIYfION

ENGINE
Removal
and
Installation

ENGINE
MOUNTING

INSULATORS

ENGINE

Dismantling
Inspection
and
Overhaul

CHAMSHAFT

AND
CAMSHAFT
BEARINGS

CYLINDER
BLOCK

PISTONS

CONNECTING

RODS

CRANKSHAFT

ENGINE

Assembling

VALVE
CLEARANCE

Adjusting

DESCRIYfION

The
G
18

engine
is
a
short

stroke
unit
with
a

displacement

of
1
815
ce
The
aluminium

alloy
cylinder
head
has
cross
flow

ports
and
a
V

shaped
valve

layout
The

single
overhead
camshaft

is
driven
from
the
crankshaft

by
a
double
row
roller
chain
at
a

reduction

ratio
of
2
I

The
crankshaft
is
a

carbon
steel

forging
and
is

provided

with
five
main

bearings
and
four

balancing
weights
Aluminium

thrust

bearings
are
located
at

the
No
2

journal

The
cast
aluminium

alloy
pistons
have
two

comp
ression

rings
and
one
oil

ring
Gudgeon

pins
are

fully
floating
in
the

piston
bores
and
are

equipped
with

circlips
at

each
end
to
limit

the
amount

of
their
travel
The

forged
steel

connecting
rods

have
weight
adjusting
bosses
at
both

large
and
small
ends
to

insure
that
the
rods
are

correctly
balanced

during
operation

The

lubricating
system
is
of

the

pressure
feed

type
with

the
oil

pump
driven

by
a

gear
on
the
crankshaft
Oil
is
delivered

to
the
main

gallery
via
a
full
flow
ftlter

ENGINE
Removal
and
Installation

Although
the

engine
can
be
removed
as
a

single
unit
it

will

prove
an
easier

operation
to
remove

the

engine
with
the

transmission
Proceed
as
follows

Fit
the
engine
slingers
ST49760000
to
the

engine

Disconnect
the
battery
cables
and
lift
out

the

battery

Drain
the
coolant
and

engine
oil

2
Place

alignment
marks
on
the
bonnet
and

hinges
remove

the
bonnet
from
the
vehicle

3
Remove
the
blow

by
hose
from
the
rocker
cover
and
take

off
the
air
cleaner

4
Disconnect
the
accelerator

linkage
and
choke
cable
from

the
carburettor

S
Detach
the

upper
and
lower

radiator
hoses
remove
the

two
brackets
from
the
core

support
and
lift
the
radia
tor

away
from
the
vehicle
The

torque
convertor

oil

pipes
must

be
disconnected
from
the
oil
cooler
if
the
vehicle
is

equip

ped
with
automatic
transmission
Detach
the
fuel

pipe
if

fitted
from
the
engine
and

heater
hose

6
Disconnect
the
electrical

wires
from
the
alternator
thennal
EngIne

OIL
PUMP

OIL
PRESSURE
RELIEF
VALVE

OIL
FILTER

EMISSION
CONTROL
SYSTEM

IGNITION

TIMING
AND
IDLING
SPEED

Emission

control

system

EMISSION
CONTROL
SYSTEM
Maintenance

IGNITION
SYSTEM

IGNITION
TIMING

IGNITION
DISTRIBUTOR
Maintenance

SPARKING
PLUGS

transmitter
the

primary
side
of
the
distributor
oil

pressure

switch
starter

motor
and
reverse

light
switch

7

Remove
the
clutch
slave

cylinder
and
its
return

spring
from

the
transmission
as
described
in
the
section
CLUTCH

8
Disconnect
the
shift
rods
and
selector
rods
then
remove

the
cross
shaft

assembly
by
detaching
the
bracket
from

the
side
member
See
GEARBOX
section

9
Disconnect
the

speedometer
cable
and
detach
the
front

exhaust

pipe
from
the
exhaust
manifold

10
Disconnect
the

propeller
shaft
and

plug
the

gearbox
rear

extension
to

prevent
the
loss
of
oil

11
Jack

up
the

gearbox
slightly
and
remove
the
rear

engine

mounting
support
Take
out

the
bolts
which
secure
the

front

mounting
insulators
to
the
cross
member

12
Attach
chains
or
wire

rope
to
the

engine
Gradually
lower

the

jack
under
the

gearbox
and
carefully
lift
and
tilt
the

engine
and
gear
box
to
clear
the

compartment
Withdraw

the
unit

making
sure

that
it
does
not
foul
the
accessories

Installation
is
a
reversal
of
the
removal

procedure
RefIll

with
the
correct

quantities
of
oil
and
coolant
when
the

engine
is
installed

ENGINE
MOUNTING
INSULATORS

Replacing

The

front
and
rear

mounting
insulators
should
be
checked

with
the

engine
installed
to
make
sure
that
the
dimensions

conform
with
those

given
in

Figs
A
I
and
A
2

To
remove
the
front
insulator

proceed
as
follows

Position
a

jack
under
the
oil

sump
Make
sure
that
the

jack
is
clear
of
the
drain

plug
and
insert
a
wooden
block
between

the
jack
and

sump
to

prevent
the

sump
from

being
damaged

Remove
the
bolts

securing
the
insulator
to
the
front

suspension

member
and
the
nut

attaching
the
insulator
to
the

engine

mounting
bracket
Raise
the

jack
slightly
and
remove
the

insulator
To
remove
the
rear

mounting
insulator

proceed
as

follows

Position
a

jack
to
take
the

weight
of
the

gearbox
and
take

out

the
bolts

connecting
the
insulator
to

the
transmission
rear

extension

housing
Remove
the
bolts

attaching
the
cross
member

to

the
underside
of
the

body
and
withdraw
the
insulator

Installation

of
both
insulators

is
a
reversal
of
the

removal

procedures

S3

CAMSHAFT
AND
CAMSHAFT
BEARINGS

Check
the
camshaft

bearing
and

journals
for

signs
of
wear

Plastigage
should
be

used
to

check
the
clearance
between
bear

ing
and

journal
which
should
be
0
025
0
075
mm
O
OOl

0
0030
in

The

cylinder
head

assembly
must
be
renewed
if
the

wear

limit
of

0
mm
0
0039
in

is
exceeded

Place
the
camshaft
in
V
blocks
and

apply
a

dial

gauge

to
the
centre

journal
to
check

the
amount
of

camshaft
bend

The

run
out

of
the
camshaft
must
not
exceed
0
03
mm
0
0012

in
It
should
be
noted
that

the
actual
run
out
will
be
half
the

value
indicated
on
the
dial

gauge
when
the
camshaft

is
turned

one

full
revolution
Check
the
camshaft
end

play
which
should

be
within
0
07
0
148
mm
0
0028

0
0058

in

Check
the
earn

contacting
surfaces
of
the
valve
rocker
and

the
earn
heels
of
the
camshaft

Slight

damage
can
be
corrected

using
a
fine
oil
stone
It
is
advisable
at
this

stage
to

check
the

clearance
of

the
rocker
shaft
and
rocker
bushes
which
should
be

0
016
0
052
mm
0
0006
0
0020

in
The

parts
must

be
renewed

if

the
wear

limit
of
0
07
mm

0
0028
in
is
exceeded

CYLINDER

BLOCK

Inspection
and
Overhaul

Check
the
block
for

signs
of
cracks
or
flaws
Measure
the

joint
face
for
distortion

using
a

straight

edge
and
feeler
gauge

as

described
for

the
L14
Ll6
and
L18

engines
The
surface

must

be

reground
if
the
maximum
limit
of
0
10
mm
0
0039
in

is
exceeded

Check
the

cylinder
bores
for
wear
out

of
round
and

excessive

taper
Use
a
bore

gauge
to
take

readings
at
the

top

middle
and
bottom

positions
of
the
bore
as

previously
described

The
standard
bore
diameters
are

85
000
mm
0
035
0
mm

3
347
0
0014
0
in

with
a
wear
limit
of
0
2
mm
0
0079
in

Out
of
round
and

taper
must
not
exceed
0
02
mm
0
0008
in

If

any
of

the
bores
are

worn
or
in
excess
of
the

specified
limi
t

then
all
bores
must
be
rebored
at
the
same
time

Pistons
are

available
in
five
oversizes
and
should
be
selected

in
accordance
with
the
amount
of
wear
of
the

cylinder
Refer

to

the
instructions

given
for
the
Ll4
L16
and
L18

engines
and

select

pistons
from
the
table
below

PISTON
SIZE

Standard

250
5

500
5

750
S

1000
S

1250
S
OUTER
DIAMETER

84
958
84
990
mm
3
345
3
346

in

85
220
85
240
mm

3
355
3
356
in

85
470
85
490
mm
3
365
3
366

in

85720
85
740
mm
3
375
3
376
in

85
970
85
990

mm
3
3846
3
3854

in

86
220
86
240
mm
3
394
3
395
in

Cylinder
liners
can

be
fitted
if
the
bores
areworn

beyond

the
maximum
limit
Undersize
liners
are
available
with
outer

diam
ters
of
89
091
89
126

mm
3
507
3
509
in

and
inner

diameters
of
83

5
84
5
mm

3
287
3
327

in
The
liners
are

an

interference
fit
in
the
block
and
must
be
rebored
after

fitting

PISTONS

Checking

Oteck
the

pistons
for

signs
of
seizure
and
wear

measure

the
side
clearance
of
the

rings
in
the

ring
grooves
and
check

the

piston
ring
gaps
as

previously
described
for
the
L14
Ll6
and

Ll8

engines
Compare
the

figures
obtained
with
those

given
in

the
tables

opposite
Side
clearance
in

grooves

Top

ring

Second

ring

Oil

ring
Standard

0
04

0
08
mm

0
0016
0031
in

0
02
0
06
mm
0
0008
0

0024
in

0
02

0
06
mm
0

0008
0
0024
in

Limit

LO

mm
0
0039
in

LO
mm

0
0039
in

LO

mm
0
0039
in

Piston

ring

gap
Top
ring

Second

ring

Oil

ring

Top

ring

Second

ring

Oil

ring
Standard

0
35
0
55
mm
0
01

38
D
021
7
in

0
3
5
mm
0
0138
0
0197

in

0
35
55

mm
O
oJ38

0217

in

Limit

LO
mm

0
0394
in

LO
mm
0
0394

in

LO
mm

0
0394
in
Top

ring

Second

ring

Oil

ring

Measure
the
outer
diameter
of
the

gudgeon
pin
in
relation

to
the
hole
diameter
in

the

piston
Compare
the

figures
obtained

with
those

given
in
Technical
Data
and

replace
the

piston
and

pin
if
the
wear
limit
is
exceeded

CONNECTING
RODS

Checking

Check
the

connecting
rods
for
bends
or

twists

using
a

suit

able

connecting
rod

aligner
The
maximum
deviation
should
not

exceed
0
05
mm
0
0020
in

per
100
mm
3
94

in
of
rod

Straighten
or

replace
any
rod
which
does
not

comply
with
the

specified
limit
When

renewing
a
rod
make

sure
that
the

weight

difference

between
new
and
old
rods
in
within
6

gr
212
oz

Install
the

connecting
rods
with

bearings
to

the
correspond

ing
crank

pins
and
check

that
the
end

play
of
the

big
ends
is

between
0
10
0
246
mm
0
0043
0
0097
in

Replace
the

appropriate
rod
if

the
maximum
limit
of
0
3
mm
0
0118

in

is
exceeded

CRANKSHAFT

Inspection
and
Overhaul

Clean
the

crankshaft

thoroughly
and
check
the

journals

and
crank

pins
for

taper
and
out
of
round
Use
a

micrometer
to

measure
the

journals
and

crankpins
at
the

positions
shown
in

Fig
A

7
It
will

be

necessary
to

regrind
the
crankshaft
if
the

specified
limit
of
0
03
mm
0
0012
in
is

exceeded
and
then

fit

the

appropriate
undersize

bearings
Place
the
crankshaft
in

V

blocks
as
described
for
the
L14
L16

and
LIB

engines
and

apply
a

dial

gauge
to
the
centre

journal
to
check

that
the
bend

limit

of
0
05
mm

0
0020
in
is
not

exceeded
The
actual
bend

value
will
be
half
the

reading
obtained
on

the
gauge
Install
the

crankshaft
in
the

cylinder
block
and
check
the
crankshaft
end

float
which
should
be
0
060
0
192
mm

0
0024
0
0076
in

Replace
the
centre

shims
if
the

specified
figure
is
exceeded

Make
sure
that
the

main
drive
shaft

pilot
bearing
at

the
rear
of

the
crankshaft
is
not
worn
or

damaged
in

any
way
Remove

the

bearing
if

necessary
using
the

special
tool
ST49700000
as

shown
in

Fig
A
8
Clean

the

bearing
hole
oil
the
outer

side
of

the
new

bearing
and
use
a
drift
as
shown
in

Fig
A
9
to

drive

it
into
the
hole
Insert

2

grams
0
07
oz

of
multi

purpose
grease

into
the
hole
as
illustrated

Main

bearing
clearance

Check
the
main

bearing
clearances

as
described
for

the

Ll4
Ll6

and
Ll8

engines
The

Plastigage
should
be

placed
so

57