torque DATSUN 610 1969 Service Manual

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

that
it
is
clear
of
the
oil
hole
Install
the

bearing
caps
and

tighten
the

bolts
to
a

torque

reading
of
10
0
1
LO

kgm
72
3

79
51b
ft

The
standard
main

bearing
clearance
is
0
03
0
06
mm

0
0012
0
0024

in
with
a
wear
limit
of
0
1
mm
0
0039

in

If
the

specified
limit
is
exceeded
an

undersize
bearing
must

be

fitted
and
the
crankshaft

journal
ground
accordingly
Bearings

are
available
in
four
undersizes
See
Technical
Data

Connecting
rod

bearing
clearance

Check
the

connecting
rod

bearing
clearances
in
a
similar

manner
to
the
main

bearing
clearances
The
standard
clearance

is
0
03
0
06
mm
0
0012
0
0024
in
with
a
wear
limit
of
0

1

mm
0
0039
in
Undersize

bearings
must
be
fitted
and
the

crankpins
reground
if
the

specified
limit
is
exceeded
Bearings

are
available
in
four
undersizes
See
Technical

Data

Fitting
the
crankshaft

bearings

Check

the
fit
of
the

bearing
shells
in
the

following
manner

Install
the

bearings
on
the
main

bearing
caps
and

cylinder
block

bearing
recess
and

tighten
the

cap
bolts
to
the

specified
torque

reading
of
10
0
11
0

kgm
72
3
79
5
Ib
ft
Slacken

one
of
the

cap
baits
and
check
the
clearance
between
the

cap
and

cylinder

block
with
a
feeler

gauge
as
described
for
the
L14
Ll6
and

LIS

engines
The

bearing
crush
should
be
from
0
to
0
04
mm

0
to
0
0016
in

Replace
the

bearing
if
the
clearance
is
not
correct

Check
the

connecting
rod

bearings
in
a

similar
manner

after

tightening
the
rod

cap
bolts
to
a

torque
reading
of

4
5
5
0

kgm
32
6
36
2
Ib
ft

ENGINE

Assembling

Make
sure
that
all

components
are

perfectly
clean
before

starting
to
assemble
the

engine
Refer
to

the
instructions

given

for
the
L14
U6
and
LIS

engines

Cylinder
Head

Install
the
valve

spring
seats
and
valves
Fit
the
oil
seal

rings
on
the
valve
stems

and

place
the
seal

ring
covers
over

the

oil
seal

rings
Note

that
a

gap
of
from
0
3
to
0
7
mm
0
0118

to
0
0276
in
should
be

present
between
the
seal

ring
cover
and

spring
seat

If
the

gap
is
less
than
0
3
mm
0
0118
in

the
oil

seal

ring
or
the
cover
must
be

replaced
Assemble
the
valve

springs
and
retainers

Compress
the
valve

springs
and
install
the

cotters
See
instructions
for
the
LI4
U6
and
Ll8

engines

Assemble

the
camshaft

brackets
valve
rockers
seats

spacers

and

springs
on
the
rocker
shafts
in
the
order
shown
in

Fig
A
l
O

Note

that
the
exhaust
rocker
shaft
has
identification
marks

but

the
intake
rocker
shaft
has
not
Make
sure
that
the
oil
holes

point
in
the
direction
shown
It

may
be
advisable
to
insert

any

convenient
bolts
into
the
bolt
holes
of
the
front
and
rear
cam

shaft
brackets
to

prevent
the

assembly
from

being
displaced

Mount
the
camshaft
on

the
head
fit

the
rocker

assembly

and

tighten
the

nuts
Make
sure
that
the
mark
on
the

flange
of

the
camshaft
is

aligned
with
the
arrow
mark
on
the
No
I
earn

shaft
bracket
as
shown
in

Fig
A
II

Pistons
and

connecting
rods

Assemble
the

pistons
gudgeon
pins
and

connecting
rods

in
accordance
with
the

cylinder
numbers
Heat
the

piston
to
a

temperature
of
500
to
600
1220
to

1400F
and

press
the

gudgeon
pin
in

by
hand
The

pistons
and

connecting
rods
must
be
assembled
as
shown
in

Fig
A
12
with

the
arrow
mark
on
the
head
of
the

piston
pointing
to
the
front

of
the

engine

Fit
new

clips
to
both
ends
of
the

gudgeon
pins
as
indicated

in
Fig
A
13
Fit
the

piston
rings
with
the
marks

facing
upwards

Place
the

bearings
on
the

connecting
rods
and

caps
making
sure

that
the
backs
of
the

bearing
shells
are

perfectly
clean

Assembling
the

engine

Insert
the
oilscal
into
the

grooves
of
the

cylinder
block

and
rear

bearing
cap
Fit
the
seal
down
with
the

speCial
tool

ST49750000
if
available
as
shown
in

Fig
A
14

and
trim
off

the
excess
with
a
knife

Apply
sealing
agent
to

the
oil

plug
and

install
it
in
the
cylinder
block

Fit
the
main

bearings
lubricate
with
clean

engine
oil
and

install
the
crankshaft
Fit
the

bearing
caps
and

tighten
the
bolts

to

a

torque
reading
of
10
0
to
I
LO

kgm
72
3
to
79
5
Ib
ft

Note
that

liquid
packing
should
be

applied
to

the
rear
bear

ing
cap
surfaces
as
shown
in

Fig
A
15

Fit
the
thrust
washers
at
both
sides
of
the
No
2

bearing

with

the
oil
channel
in

the
washers

facing
the
thrust

face
of
the

crankshaft
Install
the
rear

bearing

cap
side
seal
so

that
is

projects

0
2
to

0
6
mm
0
008
to

0
024
in

from
the
lower
surface
of

the

cylind
r

block
then

apply
liquid
packing
to
the

projecting

tip

Install
the

engine
rear

plate
Fit
the

flywheel
and

tighten

the
bolts
to
a

lorque
reading
of
10
0
to
11
0

kgm
72
3
to
79
5

ib
ft

using
new
lock
washers

Lubricate
the
crankshaft

journals
pistons
and
cylinder

bores
with
clean

engine
oil
and
install
the

piston
and

connecting

rod
assemblies
The

pistons
should
be

arranged
so
that

the
arrow

marks
face
towards
the
front
and
with
the

piston
ring
gaps
at

1800
to
each
other
Make
sure
the

gaps
do
not
face
to
the

thrust
side
of
the

piston
or
in
the
same
axial
direction
as
the

gudgeon
pin

Install
the

connecting
rod

caps
o
that
the
marks
face
the

same

way
and

tighten
the
bolts
to
a

torque
reading
of
4
5
to

5
0

kgm
32
6
to
36
2
Ib
ft
Bend
the
lock
washers
as
shown

in

FigA16

Fit
the
oil

jet
to
the
front
of
the

cylinder
block
Install

the
chain
tensioner
and

stopper
crankshaft

sprocket
and
timing

chain

Note
that
the

timing
mark
on
the
chain
must
be

aligned

with
the
mark
on
the

sprocket
as
shown
in

Fig
A
17

Smear
the

mounting
face
of
the
oil

pump
with

sealing
agent

Three
Bond
No
4
or

equivalent
install

the

pump
and

tempora

rily
tighten
the

mounting
bolts

Adjust
the
tension
of
the
oil

pump
chain

using
the

pin
as
the
central

point
then

tighten
the

mounting
bolts

Install
the
oil
thrower
Fit
the
chain
cover
into

position

after

coating
the
new
cover

gasket
with

sealing
compound
Cut

off
the

projecting
parts
of
the

gasket

Fit
the
crankshaft

pulley
and

tighten
the

pulley
nut
to
a

torque
reading
of
15
0
to
20
0

kgm
108
5
to
144
61b
ft
Bend

the
lock
washer
Install
the
oil
strainer
and
oil

pump

Invert
the

engine
and
set
the
No
I

piston
to

T
D
C
of
the

compression
stroke
Note

that
the
notch
on
the
crankshaft

S9

pulley
should
be

aligned
with
the
T
mark
on
the
chain
cover

Install

the
cylinder
head

assembly
Coat

the

cylinder
block

side
of
the
head

gasket
with

sealing
agent
Three
Bond
No
4

or

equivalent
but
take
care
that

the
scaling
agent
does
not

enter

the

cylinders

Tighten
the
head
bolts
in
several

stages
to
a

torque
reading

of
8

0
to
9

0

kgrn
58
to
65
lb

ft
Tighten
the
bolts
to
the

sequence
shown
in

Fig
A

IB

Pull
the

timing
chain
out
of
the
chain
cover
and
set
it
on

the
camshaft

sprocket
so
that
the

timing
marks
are

aligned
then

place
the

sprocket
and
chain
on

the
camshaft

Install
the
distributor
drive

gear
on
the
camshaft
and

tighten
the
bolt
to
a

torque
reading
of
4
5
to

5
5

kgrn
32
6
to

39
8
lb
ft
Note
that
the
camshaft
bolt
has
a
left
hand
thread

Adjust
the
valve
clearances
as
described
under
the

appro

priate
heading
Fit
the
rubber

plugs
at
the
front
and
rear
of
the

cylinder
head

taking
care
to

apply
sealing
agent
to
the
rear

plug

Install
the
chain

adjusting
screw
and

adjust
the
tension

of
the
chain
in

the

following
manner

Rotate
the
crankshaft
clockwise
to
establish
the
correct

chain
tension
screw
the

adjusting
screw

fully
home
then
back

it
off

by
half
a
turn

and
secure
with
the
locknut

Install
the
valve
rocker
cover
and
fit
the
water

pump
Note

that
one
of
the
water

pump
mounting
bolts
also
secures
the

generator
adjusting
arm

Install
the
bracket
and
alternator
water

pump
pulley
fan

blades
and
fan
belt

Tighten
the
fan
bolts
and
lock
each
pair

of
bolts

together
using
wire
inserted
through
the
holes

provided

in
the
bolts

Install
the
oil
filter
and
fit
the
rocker
cover
hose
Install

the
distributor
so
that
the
vacuum
control
unit

and
rotor

arc

positioned
as
shown
in

Fig
A
19

Oil
the
distributor
driven

gear
Fit
the
breather

assembly

the
clamp
of
the

pipe
is

tightened
together
with
the
exhaust

manifold
Install
the

spark
plugs
and
connect
the

high
tension

leads

Install
the
exhaust
manifold
Fit
the
head
shield

plate
and

engine
slinger
and

tighten
them

together
Note
that
the
exhaust

manifold

gasket
must
be
fitted
with
the
steel

plate
facing
the

manifold
Install
the
clutch
as
described
in
the
section
CLUTCH

Remove
the

engine
from
the

mounting
stand
and
install

the
gearbox
intake
manifold
and
carburettor
stater
motor

engine
mounting
oil

pressure
warning
switch
etc

Fill
the

engine
and

gearbox
to
the
correct
levels
with

recommended
oils
and
refill
the

cooling
system
Adjust
the

ignition

timing
and
carburettor

as
described
in
the

appropriate

sections

VALVE
CLEARANCES

Adjusting

The
valves
clearances
can

be
adjusted
in
a
similar
manner

to
the
instructions

given
for
the
L14
LI6
L18

engines

Initially
adjust
the
clearances
with
the

engine
switched
off
and

cold
to

0
2
mm
0
0079

in
for
both
intake
and
exhaust
valves

Set
the
final
clearances
to
0
28
mm
0
011
in
for
both
intake

and
exhaust
valves
with
the

engine
warmed
up
to
its
normal

operating
temperature
OIL
PUMP

The

gear
type
oil

pump
is

chain
driven
from
a

sprocket
on

the

crankshaft
The

pump
can

be
removed
in
the

following
manner

1
Remove

the

sump
plug
and
drain
the

engine
oil
Remove

the
distributor
as
described
in
the
section
IGNITION

2
Remove
the

cylinder
head

assembly
fan
belt
crankshaft

pulley
and

oil

sump

3
Take
off
the
chain
cover
with

oil
fl

inger

4
Remove
the
oil

pump
and
crankshaft

sprockets
with
the

drive
chain
then
withdraw
the

pump
after

removing
the

four

mounting
bolts

Separate
the
cover
from
the

body
by

unscrewing
the
four

securing
bolts
and
withdraw
the
drive
and
idler

gear

assemblies
Unscrew
the
threaded

plug
and

take
out

the

relief
valve
and

spring

Clean
the

parts
thoroughly
and

inspect
them
four

signs

of
wear
or

damage
Check

the

following
clearances

Gear
backlash
0

1
to

0
5
mm
0
0039
to

0
0195

in

Side
clearance
between

gear
and

body
0
016
to
0
15
mm
0
0006
to

0

0059
in

Clearance
between

drive
shaft
and

body
0
016
to
0
1
mm
0
0006
to

0
0039
in

Clearance
between

drive
shaft
and
cover
0
02
to
0
1
mm
0
00078
to

0
0039
in

Clearance
between

idler

gear
and
idler
shaft
0
016
to

0
1
mm
0

0006
to

0
0039
in

Assembly
is
a
reversal
of
the

dismantling
procedures
taking

care
to

position
the
gears
so

that
the
dotted
mark
is
towards
the

cover

Install
the

pump
and

adjust
the
tension
of
the
drive
chain

by
ph
otting
the
pump

body
as

shown
in
Fig
A
20

When
the

chain
is

correctly
tensioned
it
should
be

capable
of
a
deflection

of
2
0
to

3
0
mm

0
079
to

0
118
in
as

indicated

OIL
PRESSURE
RELIEF
VALVE

The

pressure
relief
valve
shown
in

Fig
A
21
is
not

adjustable

This
valve

regulates
the
oil

pressure
to
4
55
4
85

kg

sq
cm

64
7
69
0
lb

sq
in
and
when

opened
allows
the
oil
to

by
pass

through
a

passage
in
the

pump
body
and
return
to
the

sump

Check
the
free

length
of
the

spring
which
should
be
64
0

to
66
0
mm
2
51
to
2
60
in
The

compressed
length
should

be
50
mm
at

7
8
to

9
7

kg
1
96
in
at
17
2
to
21
4Ibs
Renew

the
spring
if

necessary

OIL
FILTER

The
oil
filter
is
of
the
full
flow

type
with
a

replaceable

element
and

incorporates
a

by
pass
valve
in
the
cover

Oil

leaks
can
be
corrected

by
replacing
the

body
centre

shaft
or
cover

gaskets
The

body
and
centre

shaft

gaskets
should

always
be
renewed
after

dismantling
the
filter

S
1

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

inter
C

7
j
l

l

IJ

Fig
C
22

Checking
the

pinion
tluust

play
Fig
C23
ML
Io

b
the

torque
required
to
rotate
the

pinion

Fig
C
24

Measuring
the
rack

pre
load

Fig
C
25

Tightening
the
tie
rod
inner
socket

stop
nut

S
rod
I
p
ing

Boot
Spring

I
Boot

cl
np

Side
rod
1

t
I
I

Lock
n
rt

38
5n
m
1

5115in

Staaj
xial

p1
Y
o
l5errm
0
02

5in

Fig
C
26

Measuring
the

torque
required
to

swing
the
tie
rod
Fig
C
2
Section

through
the
tie
rod
ball

joint

Slila

niversatjoint

Punch
marif

located
on

upper
nd
of
upper

steering
shaft

Fig
C
28

Aligning
the
universal

joint
with

upper
steering
shaft

528

Tighten
the
inner

socket
until
the
ball
seat
is
at

the
rack

end
then
back

off
the
socket

by
30
to

40

degrees
and

tighten

the

stop
nut

to
a

torque

reading
of
8
0
to
10
0

kgm
57
8
to

72
3
Ib
ft
as

shown
in

Fig
C
25

With
the

tie
rod
assembled
measure
the
force

required
to

swing
the
tie
rod
Hook
a

spring
balance
at
the
end
of

the
rod

as
shown
in

Fig
C

26
and
check
that
the
force
is
from
3
0
to

6

0

kgm
6
6
to
13
2
lb
Measure

the
stroke
of
the

rack
which

should
be
73
0
mm

2
874
in
Fit

grease
nipples
at
both

ends
of
the
rack
and

pinion
housing
Apply
multipurpose
ase

to
each

joint
until

a
small

quantity
of

grease
appears
at

the
out

let

hole
in
the
boot
Do
not
use
an
excessive

amount
of

grease

The

pinion
housing
should

be
lubricated
until
a
small

quantity

of

grease

appears
between

rack
and

housing

Remove

the

grease
nipple
and
fit
the

plug
Fit
the
boot

Fill

the
grease
reseIVoir
with

grease
and
attach
it
to

the
rack

housing
Adjust
the

length
of

the
tie
rods
at
both

sides
as

des
ribed
under
FRONT
WHEEL

ALIGNMENT

Assemble
the

steering
lower

joint
to
the

rack
and

pinion

and

tighten
the
lower

joint
bolt
to

a

torque
reading
of
4
0
to

5
0

kgm
29
0
to

36
0
Ib
ft
Installation
of

the
rack
and

pinion
assembly
is
a
reversal

of

the
removal

procedure

COLLAPSIBLE

STEERING

Removi
8
and

Dismantti
8

The

steering
coluJllfl
See

Fig
C
3
can
be
removed

in
a

similar
manner
to
the
standard

type
of
column

Take
care
not

to

drop
the
column

when
it
is
removed
from
the

vehicle
or
the

shaft

may
collapse
Do
not
exert

any
pressure
on

the
column
or

the
bellows
may
be
defonned
To
dismantle

proceed
as
follows

Remove
the

retaining
wire
and

pull
out

the
lower
shaft

Disconnect
the
control

linkage
if
the
vehicle
is
fitted
with
auto

matic
transmission
Slide
the

steering
shaft
bracket

away
With

draw
the

screws
and

separate
the

upper
and
lower
tubes

Assembly
is
a
reversal
of

the

dismantling
procedure
Note

that
the
slot
in
the
universal

joint
must
be

aligned
with
the

punch

mark
at
the

top
of
the

upper

steering
shaft
as
shown
in

Fig
C
28

When

installing
the
column
make
sure
that

the
bellows
do
not

become
bent
of
twisted

as
the

clamp
and
bottom

plate
bolts

are

tightened

TechnICal
Data

TYP

Gear
I1ltio
Rack
and

pinion

17
8
I

Steerin
column
shaft

spring
Wire
diameter

Freelenath

CoiltW
llJ

Load

length

Retainer

sprinJ
dimension
Wire
diameter

F

CoilturnJ

l
oadxlensth

Side
rod

SPrina
dimeruion
Wire
diameter

Fn
elenath

Coil
turns

Load
x

lensth

Side
rod
inner
ball

joint
ax
ia
I

play

Side
rod

outer
ball

joint
uiaJ

play

Pinion

thrultplay

Retainer
float

play

Rack
moke

Side
rod
inner
ball

joint

swinsinl
torque

Side
rod
uter
ball

joint

swingina
torque

Pinion
oration

torque

Rack

pre1
d

Wheel

alipment
1IIl1a
a
ondition

Cut

c
m

Kinl
pin
inclination

Toe
in

S
In

teerinlan

eOut
10
40

8005

12

15
mm
0
47
0

59
in

38024

35036
2
9

mm
0
11
2
in

36
5
mm

1
4370
in

3

25q
551
18mm
0
7087

2

6
mm
1
102in

26
3
mm
1
035
in

5
5

20

kl
lbs

16
3

mm
0
642
in

26
mm

0
102

in

19
0
mm
0
748

in

6
3

40

q
88Ibs
17
0

mm
0
669
in

0
06
mm
0
002
m

0
1
0
5
mm

0
0039
0

0197
in

less
than
0
3
mm
0

0118
in

0
09
mm
0
0035
in

73
mm
t

2
87
in

0
8
1

5

q
m

5
8
10

8Ib
n

0
8
J
S

kg
m
5
8
JO
8Ib
ft

8

20q
7
17
lb

in

8
18

q
l7
6
39

7Ibs

Strut

DlelDbly

Strut
outer
Ilia

50
8
mm

2
0
in

Piston
rod
di
a

20
mm

0
787
in

Cylinder
inner
dia
30mm
I
181
in

Dampinl
force
at

pistonlpeed

0
3
m
I

1
08
ft
I

Expansion
67

IOq
I47
7
221bs

Compression
25

4kl
55
1

8
81bs

Shock
absorber
inner

cylinderlcngth
IOmm
16
1

in

R
IlD
vchicle

LH
D

ehide

CoiIsprina

LIi
IlIi
OOIh

Wire
diameter
mm

in
12
0
472
12
0
472
12
0
472

Coil
diameter
mm
in

130
5
12
130
5

12
130
5
12

Coil
Ium
S

Coil

effective
turnl

6
5
6
5
6
5

Free

lenJth
mm
in
371
5
14
6
386
5
15

2
371
5
14
6

Installed
hei
ht
load

mmq
180
270
200

270
180
270

in
lb
7
1
594
7

9
594
7
1
594

SpriDgCOfl
ltant

ka
mm

1
45
US
1
45

529

1

ENGINE

t
Main

bearing
cap
bolt

Connecting
rod
bolt

Flywheel
bolt

Crankshaft
nut

Cylinder
head
bolt

Camshaft

centre
bolt

Spark
plug

Oil
mtef
centre
bolt

Water

pump
blind

plug

Carburettor
bowl
set
screw

Rocker

cover

securing
screw

FRONT
SUSPENSION
Tlght
enlna

Torques

10
11

kg
m
72
3
79
5Ib
ft

4

5
5

kg
m

32
6
36
2Ib
ft

10
11

kg
m
72
3
79
5

Ib
fL

15
20

kg
m

l08
5
144
6Ib
ft

8
9

kg
m
57

9
65
1
Ib
fl

4
5
5
5

kg
m

32
6
39

81b
ft

3
4

kg
m
21
7
28
9Ib
ft1

2
8
3

2

kg
m

20
3
23
21b
ft

1
5
2

kg
m

l0
9
14
5Ib
ft

0
15

0
2

kg
m
Ll
I
4lb
ft

0
33
0
4

kg
m
2
4
2
9

lb
ft

Front
wheel

spindle
nut
3
3
5

kg
m
21
7
25
3
Ib
ft

Front

disc
brake
back

plate

to
strot

assembly
2
7
3
7

kg
m

19
5
26

7Ib

ft

Disc
brake

calliper
fixing

bolts

7
3
9
9

kg
m

52
8
71
6Ib
ft

Disc
brake
rotor

fixing
bolts
3
9
5
3

kg
m
28
2

38
3
Ib

ft

Stabilizer

fixing
bolts

transverse
link
bracket
side
1
2

1
7

kg
m

8
7
12
3Ib
fl

Stabilizer

fixing
bolts

frame
bracket
side
1
9
2

5

kg
m

13
7
18
1
lb
ft

Compression
rod
to
frame

bracket

bolts
7
2
9
6

kg
m
52
1
69
2Ib
fl

Compression
rod
to
transverse

link
bolts
4

9
6
3

kg
m
35
4
45

6
lb
ft

Strut

assembly

upper
support

nuts
3
9
5
2

kg
m
28
2
37
6Ib
ft

Steering
knuckle
arm
to

strut

assembly
6
0
8
0

kg
m
43
4
57
8Ib

ft

Transverse
link
to

suspension

cross

member
fixing
nut
12
2
13
5

kg
m
88
2
87

6Ib
ft

S36
Lower
ball

joint
to
transverse

link

fixing
nut

Lower
b
JH

joint
stud
nut

Suspension
aoss
member

mounting
boils

Engine
mounting
bracket

bolts

Piston
rod
self

locking
nut

Gland

packing

Wheel
nuts

BRAKING
SYSTEM

Fulcrum

pin
of
brake

pedal

Connection
of
brake
tube

Rotor

fixing
bolts

Wheel

cylinder
fixing
bolts

Studs
side

Hexagon
side

Bridge
tube

Brake
hose
to
wheel

cylinder

Calliper
to
knuckle

t1ange

Disc
to
knuckle

flange

Spindle
nut

STEERING

Steering
wheel
nut

Rubber

coupling
bolt

Lower

join
t
bolt

Retainer
locknut

Side

rod
inner
socket

stopper
nut

Side

rod
locknut

Side
rod
ball
stud
nut
1
9
5

kg
m
l3
7
18
llb
ft

7
6

kg
m
139
8
1

0
Ib
ft

1
9
2
5

kg
m

13
7

18
1
lb
ft

1
3
1
7

kg
m

9
4
1
3Ib
ft

6
0
7
5

kg
m
43
4
54
2Ib
ft

6
0
6
5

kg
m

43
4
47
0
Ib
fl

8
0
9
0

kg
m
57
8
65
I
Ib
ft

3
5
4
0

kg
m
25
3
28
9

Ib
fLl

1
5
1
7

kg
m

10
8
1
3
lb
ft

3
9
5
3

kg
m
28
2
38
3
Ib

fL

0
5
0
7

kg
m
3
6
5
1Ib

fL

1
5
2
1

kg
m

l0
8
15
2Ib
ft

I
7
2
0

kg
m
l2
3
14
5Ib
ft

17
2
0

kg
m
l2
3
14
5Ib
ft

73
9
0

kg
m
52

8
i5
1
Ib
ft

2
7

3
7

kg
m
l9
5
26
8Ib

ft

3
0
3
5

kg
m
21
7
25
3lb
ft

1
5
1
8

kg
m

10
8
13
0
Ib
ft

4
5

kg
m
28
9
36

2
Ib
ft

4

6

kg
m
28
9
43
4
lb

ft

8
10

kg
m
52
8
72
3Ib
ft

9

kg
m
65

llb
ft

5
5
7
6

kg
m
39
8
54
9Ib
ft