oil DATSUN 610 1969 Repair Manual

STEERING
GEAR

Inspection
and

Adjustment

Thoroughly
clean
all

parts
and
examine
them
for

signs

of
wear
or

damage
Replace
any
comIK
nent
found
to
be
un

satisfactory

It
is
advisable
to
renew
the
assemblies
if
the

steering
column

or
ball
nut

assembly
is
defective
as

the

adjustment
procedures

required
to
overhaul
the
units
are
rather
involved

The

dismantling
and

adjustment
procedures
for
the
ball

nut

assembly
can
be
carried
out
in

the
following
manner
if
it

is

decided
that
overhaul
procedures
are
to

be
carried
out

Ball
nut

Remove
the
ball

guide
tube

clamp
withdraw
the

guide

tubes
from
the
ball
nut
and
collect
the
steel
balls

Turn
the
nut

upside
down
and
rotate

the
steering
column

backwards
and
forwards
until
all

36
steel
balls
have

dropped

out
of
the
ball
nut
Pull
the
ball

nut
from
the
column

Inspect
the
ball

guide
tubes

and
make
sure

that

they
are

not

damaged
Pay
particular
attention

to
the
ends
of
the
tubes

that

pick
up
the

balls
from
the
helical

path
Renew
the
tubes
if

they
are

unsatisfactory
Check
the
steel
balls
and

the
ball
nut

for
wear
and

replace
the

complete
unit
if

necessary

Assemble
the
ball
nut
on

the
worm
with
the
ball

guide

holes

upwards
Drop
18
balls
into
each
of

the
two
holes
on
the

same
side
of
the
ball
nut

until
all
36
balls
are
installed
The

column
should
be

gradually
turned

away
from
the
hole

being

filled
and
if
the
balls
are

stopped
by
the
end
of
the
column
hold

down
those

already
installed
with
a

clean
rod
or

punch
while

turning
the
column
several
times
in
the
reverse
direction
The

filling
of
the
circuit
can
then
be
continued
but
it

may
be

necessary
to
turn
the
column
backwards
and
forwards

holding

the
balls
down
first
in
one

hole
and
then
the
other
to
close
the

spaces
and

completely
fill
the
circuit

Place
the

remaining
22
balls
in
the
ball

guide
halves
11

balls
for
each
half
Fit
the
other
half
of

the

guide
tube
to
each

f11led
half

hold
the
two
halves

together
a
ld

plug
each

open
end

with
vaseline
to

prevent
the
balls

falling
out

Push
the

guide
tubes
into
the

ball
nut

guide
holes
and

assemble
the

guide
tube

clamp

Inspection

Oteck
the
axial

clearance
between
the
ball
nut
and
the

balls
If
the
clearance
exceeds
0
08
mrn
0
003
in
the

complete

unit
must
be
replaced
Inspect
the

gear
teeth
of
the

sector

shaft
for
wear
or

damage
Replace
any
worn
or

imperfect

bearings
Examine
the

steering
column
shaft
for

straightness

and
check
that
the
maximum
deflection
does
not
exceed
0
2mm

0
008
in
at

point
C
in

Fig
K
9
when
the
shaft

is

supported

at

points
A
and
B
Check
the
sector
shaft
and

steering

column
shaft
serrations
for
wear
Renew
the

parts
as

necessary
STEERING
GEAR

Assembly
and

Adjustment

Grease
the

lip
of
the
oil
seal
and

press
it
into
the

housing

Insert
the
column

assembly
into

the
column

jacket
and
fit

the
worm

bearing
shims
to
the

gear
housing
Install
the

flange

securing
bolts
and

tighten
them
to
a

torque
reading
of

1
8

2
5

kgm
13
18lb
ft
If
a

new
column

bearing
assembly
is

fitted
it
must
be
filled
with

bearing
grease
and
cemented
to
the

column

The

preload
of
the
worm

bearing
can
be

adjusted
by

altering
the
thickness
of
the
worm
bearing
shim
Four
shim

thicknesses
are
available
in
sizes
of
0
76
0
254
0
127
0
050mm

0
0300
0
100
0
005
in
0
002
in

This

adjustment
check
is
carried
out
without

the
sector

shaft
fitted
and
with
the
worm

bearings
oiled

Install
the

steering
wheel
as
shown
in

Fig
K
9
use
a

spring

balance
as
indicated
to
check
that
the
force
required
to
turn

the
wheel
is
between
4
0
8
0

kg
cm
56
l120z

inch

Select
a
suitable
shim
from
the
sizes

given

Assemble
the
selector
shaft

adjuster
with
a
shim
into
the

sector
shaft
Measure
the
end
clearance
of
the

adjuster
with
a

feeler

gauge
as

shown
in
Fig
K
1
O

The
correct
clearance
is
0
01
0
03mm
0
0004
O
0012in

and
can
be

adjusted
by
varying
the
thickness
of
shim
Four

thicknesses
of
shim
are
available
as

follows

1
57
mm
0
0618
in

1
55
mm
0
0610
in

1
52
mm
0
0598

in

1
50
mm
0
0591
in

To
assemble
the
sector
shaft
into
the
gear
housing
rotate

the
column

by
hand
until
the
ball
nut
is
at
the
central

position

of
its
travel
so
that
the
centre
tooth
of
the
sector
shaft
enters

the
centre
tooth

space
of

the
ball
nut
Fit
a
new

gasket
and

push

the

sector
shaft
cover

and
sector
shaft
into

place

Ensure
that
a
certain
amount
of

play
is

present
between

the
rack
and
sector
teeth
before

tightening
the
cover

bolts
to

a

torque
reading
of
1
5
2
5

kgm
10
9
18
llb
ft

Temporarily
lock
the

adjusting
screw
with

the
locknut

Move
the
sector
shaft
several
times
from

the

pitman
arm
side

to
make
sure
that
it
turns

smoothly

Connect
the

pitman
arm
to
the
sector
shaft

taking
care

that
the

alignment
marks
on

the
arm
and
shaft
coincide

Adjust
the
backlash
with

the
steering
in

the
central

position
using
a
dial

gauge
as
shown
in

Fig
K
II
Turn
the

adjusting
screw
with
a
screwdriver
until
the
amount
of
free

movement
at
the

top
of
the

pitman
arm
is

within
O
lmm

0
0039
in
at
a

radius
of

127
mm
5
0
in
Lock
the

adjusting

screw
with
the
locknut
Fig
K
12
and
recheck
the
free
move

ment

Fill
the

steering
gear
housing
with
the
correct
amount
of

recommended
lubricant

Refit

the

steering
gear
to
the
vehicle
as

previously
described

Make
sure

that
the
steering
wheel
is

correctly
aligned
and
that

93

inter
G

@lfi

r

OIl

ll

V
V

1
Re
rvoir

azp

2

Resovoir
tank

3

condDry
piston
rrtrun

rprins

4
Secondary
pitton

5

Primary
piston
tum

spring

6

Primary
piston

7
uvd

gau

Fl
L
I
Tandem
master

cylinder
level

gauge

on
SSS
models

only
Fig
L
2
Section

through
the

single
master

cylinder

I

Independent
axle
Rigid
axle

Fig
L
3

Layout
of
brake
lines
with
tandem

master

cylinder

A
Ji

I
I

f

tf

A1

r

Fig
L
4
Section

through
the
brake

warning

light
switch

Fl
L
5
View
of
the
front
drum

brake

98

brake
shoe
is
in
contact
with
the
drum
The

adjuster
must
be

turned
from

the
rear
of

the

backplate
and
the
drum
turned

by

hand

When
the
shoe
contacts
the
drum
turn
the

adjuster
in

the

opposite
direction
until
the

shoe
is

just
clear
and
the
drum

can

be
rotated

freely
by
hand

Depress
the
brake

pedal
and
make
sure
that
the
brakes

operate
correctly
The

adjusters
must

be
released

slightly
if

the

brake
shoe
binds

FRONT
DISC
BRAKE
Friction

pads
Fig
L
14

The
disc
brakes
are
self

adjusting
but
the
friction

pads

should
be
checked
for
wear

every
5
000
km
3
000
miles
and

replaced
if
the
thickness
of

the
friction

lining
on

any

pad
is
less

than
1
0mm
0
004
in
In
effect
this
means
that
renewal
is

necessary
when
the
total
thickness
of

pad
and

lining
is
less
than

8
4mm
0
24
in

To

replace
the
friction

pads
proceed
as

follows

Siphon

out
some
of
the
fluid
in
the
master

cylinder
reservoir
Jack

up

the
front
of
the
vehicle
and
remove

the
road
wheel

Remove
the
anti
rattle

clip
from
the

calliper
plate
Fig
L
lS

Unhook
the

hanger
spring
and
withdraw
the
brake

pads

and
shims

Fig
L
17

It
should
be
noted
that
the
friction

pads
must
be

replaced

as
a
set
and
renewed
at
both
sides
of
the
vehicle
otherwise
the

braking
action
will
be
uneven

Oean
the

calliper
and

pad
at

their
installation

positions

Press
the

pistons
into
the

calliper
bores
so
that
the
new
friction

Pads
can
be
installed
The

pistons
can

be
installed

by
applying

light

pressure
as
shown
in

Fig
L

16
but
care
must

be
taken
to

avoid

pushing
them
too
far
or
the

groove
of
the

piston
will

damage
the
seal

If
the

pistons
are

pushed
down

excessively
it
will
be

necessary
to
dismantle
the

calliper
as

described
under
the

appropriate
heading

Assemble
the

anti

squeal
shims
to
the
friction

pads
with

the
arrow
mark
on
the
shims

pointing
in
the
direction
of

forward
disc
rotation

Refit
the

pads
and

retaining
pins
and
assemble
the
coil

spring
to

the

retaining
pin
furthest
away
from

the
air
bleed
screw

After

installing
the
new

pads
and
shims

depress
the
brake

pedal
several
times
to

reposition
the
pistons
in
the

calliper

O1eck
the
fluid
level

in
the
master

cylinder
reservoir
and
refill

to
the
correct
level

FRONT
DISC

BRAKE
Removal
and

Dismantling

1
Jack

up
the
front
of

the
vehicle
remove
the
road
wheel

and
take
out

the
friction

pads

2
Disconnect
the
brake
hose
from
the
brake

tube
and

plug

the

opened
end
to

prevent
the
loss
of
fluid
3
Remove
the
bolts

securing
the
brake

calliper
to

the

knuckle

flange
and
remove
the

calliper
assembly
Fig
L
IS

4
Remove
the
hub
nut

and
withdraw
the
hub
and
disc

To
dismantle
the
calliper
remove
the
anti
rattle

clip
and

withdraw
the
brake

pads
Remove
the
tension

springs
and

pull

the
cylinder
out
of
the

calliper
Blow
out

the
piston
with
com

pressed
air

applied
at

the
brake
hose
connection

Oean
the

components
in
brake
fluid
and
examine
them

for

signs
of
wear
or

damage

The

cylinder
walls
can

be
carefully
polished
with
fine

emery
cloth
if

they
are
rusted
or
contaminated
If
the

parts

are

excessively
corroded

they
should
be
renewed

Replace
the

pistons
if

they
are

unevenly
worn

damaged

or
rusted
The
sliding
surface
of
the

piston
is

plated
and
no

attempt
should
be
made
to

use

emery
cloth
or
similar
abrasives

for

cleaning
purposes

Check
the
thickness
of
the
friction
pads
as

previously

described
and
replace
them
if

necessary
Renew
the

piston
seals

and
the
dust
covers

O1eck
the
brake
disc
for

scoring
and
out
of
round
The

standard
disc
thickness
is
10
Omm
0
0394
in
and
must
not

be

reground
below
8
4mm
0
3307
in

Check
the
disc
run
out
with
a
dial

gauge
as
shown
in

Fig

L
19
Position
the
gauge
near
the
outer
diameter
and
check
that

the
run
out
does
not

exceed
0
06mm
0
0024
in

FRONT
BRAKE
DISC
Assembly
and
Installation

Rinse
the

cylinder
bore
with
brake
fluid
and
fit
the

piston

seal
into
the

cylinder

groove
Fig
L
20
Fit
the
wiper
seal
and

lightly
grease
the
bore
of
the

cylinder
Clean
the
brake
disc

and
fit
it
to
the
hub
Install
the
hub
to
the
knuckle

spindle

Carefully
insert
the

piston
into
the

cylinder
until
the
face

of
the

piston
is
almost
flush
with

the

wiper
seal
retainer
The

relieved

part
of
the

piston
should
face
the

piston
pin

Fit
the
cylinder
to
the

calliper
plate
and
secure
in

position

with
the
two
torsion

springs
Assemble
the
hold
down
pin

the

spring
washer
and
the
nut
to

the

support
bracket
Secure

the
nut

with
a
cotter

pin

Assemble
the

calliper
to

the
mounting
bracket

using
the

pivot
pin
washer

spring
washer
and
nut

Tighten
the
nut
and

secure
with
a
cotter

pin
Hook
the
hold
down
bracket
to
the

top
of
the

mounting
bracket
and
turn
the

calliper
plate
to

make

sure

that
it
can
slide

smoothly
Fit
the

calliper
assembly
to
the

knuckle

flange

Fit
a
shim
to
the
inner

pad
and
insert
the

pad
Draw
the

calliper
towards
the
chassis
and
insert
the
lower
cuts
on

the

pad

into
the

mounting
bracket
and

push
the

pad
in
until
it
contacts

the

piston
Move
the

calliper
away
from
the
chassis
and
insert

the

upper
cuts
Centre
the
indentation
of

the
outer

pad
in
the

calliper
plate
Fit
the
anti
rattle

clip
Fig
L
14

103

inter
f
illl

@
l

l

Au

y
l
ver

I

R
H

I
Equaliler
b2nd

i
b7ke

Pl
te

Iock
band
buk

able
I

I

I

T

@A
Adjuster
cable

oo

pm
Odb
k
SPd
wm

LH
able

C

Note

@
Apply
bearing

grease

@APPIYch
S

i

Pin
fulcrum
hand

brab
lever
6c

1l

Clip
cable
frout
N
nd
brake

Fill
L21
Handbrake

linkage
1400
and
1600
c
c

Saloons

1
I
J

Pull

priDg

1

Clt
vU

Balance
leve

I

I

J
c

1
1

I

I
1

l

J

L

I

iL

Note

@
Apply
engine
oil
8

S

J

@

I

Aj

Fran
able
Rear
cable

L

I
r

f
7

n
t

i

Adjust

position
A

Fig
L
22
Handbrake

linkage
1400
and
1600

c
c

Estate

cars

1
Control
sUm

2
Control
ratchet

Xing

3
O
mtrol
ratchet

4
O
mtro

guide

5

Control
bracket

6

OJntrol
yoke

7
wer

spring

8
Control
lever

Fig
L
23

Handbrake

linkage
1800

c
c
models

104
able

s

Fig
L
19

Checking
the

brake
disc
for

run
out

1

j

v

fti

r

v

r

Fig
L
20

As
embling
the

piston
seals
and

retainer

ti

J

4

Fill
L
24
The
handbrake

cable

adjuster
Saloons

9

Front
cable

10
Centre

lever

II
Rear
cable

adjuster

12
DIble

lock

plate

13

Return

spring

14

RI
fU
cabk

15
Qevis

interQ
8
j

@W
2

m
tV

r
ReJld

cop
level

th
elk

FIg
M
I

llIecking
the

specific
gra
ity
of
the

battery
electrolyte
I
Thermal
u
e

Hydrometer

f
j
0
l

Q

I
iJ

Qy@

I
@
@

@
ti

II
@
@

Fig
M
3
Brush
cover
removed

j
i

Fill
M
2
Starter
motor

components

1

L
u
uJIner

pin

2
Drive
mil
Nack

t

3
Dult
COPD

4
E
mmtle
r

5
Aut
mzl

6
Solmoid
mlch

7
Arm
zturr

8
Thnut

9
IJriv
mil

blllck
t
bush

10
17uust

WdSMr

11

Stop
washer

12
CiTc
ip
13
PirUon

srap
collar

14
Pinion

IS
IWfni1l6
clutch

16
Field

coil

17
Yok

18
Politive
brwh

19

N
J1iP
bnuh

20
Bnuh

rprinK

21
Brullr
holder

22

Bearing
bwh

23
Rmr
COJIU

24

Through
botrr
@

FIg
M
5
Yoke

assembly
removed

Fill
M
4
Solenoid
switch
1

108
Fig
M
6
Annatore

assembly
and

engagemenr

lever

removed

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

inter
r
0J

@
jll@

FIg
M
7

Over
unning
clutch

assembly
1

m
ILE

COMMUTATOR

0
5
to
0
8
mrtl

ROUND

O
0197
to
0
0315
nl

SEGMENT

MICA

CORRECr
INCORRECT

Fig
M
9

Undercutting
the
commutator
insulation

Fig
M
11

Testing
the
field
coils
for
continuity

5

y
SERIES
COIL

5

r
SHUNT
COIL

Fig
M
13

Testing
the
solenoid
witch

10
J

Fig
M
8

Checking
the
brush

pring
tension

Fig
M
lO

Checking
the
armature
shaft
for
run
out

J

I

I
J

I

L
j
J

j

Fig
M

12
Testing
the
field
coils
for

earthing

1

rl

wr

v
E
L
DIMENSION

131
7

to
32
3mm
1
248
to
1
272
in

I

Adjus
llUt

2
PluJlKeradjuster

F
8
M
14

Measuring
the

gap
between

pinion

and

pinion
stop

I

stopper
to

the
overrunning
clutch

side
and
removing
the

stopper
clip
Remove
the

stopper
and

overrunning
clutch
as

shown

inFig
M
7

Oean

the
dismantled

components
and
check
them
for

wear
or

damage

Cbeck
the
brushes
and
renew

them
if
worn
below
6
5mm

0
257
in
Fit
new
brushes
if
the
brush
contact
is
loose
Cbeck

the
brush
holders
and

spring
clips
and
make
sure

that

they
are

not
bent
or
distorted
The
brushes
should
move

freely
in

their

housings
and
can
be
eased
with
a
file
if

necessary
The
brush

spring
tension
should

be
approximately
0

8kg
1
76Ib

and

can
be
checked
with
a

spring
balance
as

shown
in
Fig
M
S

Armature

assembly

Make
sure
that
the
surface
of
the
commutator

is
not

rough
or

pitted
Oean
and

lightly
polish
with
a
No
500

emery

cloth
if

necessary
If
the
commutator
is

badly
worn
or

pitted

it
should
be
skimmed
in
a
lathe

only
a

light
cut
must

be
taken

to
remove

the
minimum
amount

of
metal
If
the
commutator

diameter
wear
limit
of
0
2mm
0
OS
in

is
exceeded
the

assembly
must
be

renewed

Undercut

the
mica
between
the
commutator

segments

when
the

depth
of
mica
from
the
surface
of
the

segment
is

less
than
0
2mm
0
08

in
The

depth
should
be
between

0
5
0
8mm
0
0197
0
0315
in
as
shown
in

Fig
M
9

The
armature
shaft
should
be
checked
for

straightness

by
mounting
between

the
centres
of
lathe
and

positioning

a
dial

gauge
as
shown
in

Fig
M
I
O
Renew

the
armature

if
the

bend
of
the
shaft
exceeds
0
08mm
0
0031
in

Field
coils

testing

Test
the
field
coils
for

continuity
by
connecting
a

circuit

tester
between
the

positive
terminal
of
the
field
coil
and
the

positive
terminal
of
the
brush
holder
as
shown
in

Fig
M

I
I
If

a

reading
is
not

obtained
the
field
circuit
or
coil
is

open

Cbnnect
the
tester
to
the

yoke
and
field
coil

positive

teoninal
as

shown
in

Fig
M
12
to

check
the
field
coils
for

earthing

Unsolder
the
connected

part
of
each
coil
and
check
the

circuit
for

earthing
in
a
similar
manner

Renew
the
field

coils

if

they
are

open
earthed
or
short
circuited

Outch
assembly

The

overrunning
clutch
must
be

replaced
if
it
is

slipping

or

dragging
Examine
the

pinion
and
sleeve

making
sure
that

the

sleeve
is
able
to
slide

freely

along
the
armature
shaft

spline

Inspect
the

pinion
teeth
for

signs
of

rubbing
and
check
the

fly

wheel

ring
gear
for

damage
or
wear

Bearings

Inspect
the
metal

bearing
bushes
for
wear
and
side

play

The
bushes
must

be
renewed
if
the
clearance

between
the

bearing

bush

and
armature
shaft

is
in
excess
of
0
02mm
0
008
in

New

bearing
bushes
must
be

pressed
in
so
that

they
are
flush

with
the
end
of
the
case
and
reamed
ou
t
to

give
a
clearance
of

0
03
0
10
mm
0
0012
0
0039
in

H
Solenoid

assembly

Inspect
the
solenoid
contact
surface
and

replace
if

showing

signs
of

wear
or

roughness
Replace
the

pinion
sleeve

spring
if

weakened

Check
the
series
coil

by
connecting
an

8
12

volt

supply

between
the
Sand
M
terminals
as
shown
in

Fig
M
13
The

series
coil
is
normal
if
the

plunger
operates

Test
the
shunt
coil

by
connecting
the
S
terminal
the
M

terminal
and
the
solenoid

body
as
shown
in
the
lower
illustration

of

Fig
M
13

Open
the
M
terminal
when
the

plunger
is
operated

the
shunt
coil
is

satisfactory
if
the

plunger
stays
in
the

operated

position

Measure
the

length
L
between

theylonger
adjusting
nut

and
solenoid
cover

Press
the

plunger
against
a

firm
surface
as

shown
in

Fig
M
14
and
check
that
the
dimension
is
within

the
figures

given
Turn
the

adjusting
nut
if

necessary
until
the

required
dimension
is
obtained

STARTER
MOTOR

Assembly
and
Installation

The
assembly
and
installation

procedures
are
a
reversal

of
the
removal
and

dismantling
operations
When

assembling

the
starter
smear

the
armature
shaft

spline
with

grease
and

lightly
oil
the

bearing
bushes
and

pinion

ALTERNATOR

The
alternator
is
driven

by
the
fan
belt
and
has
an
advant

age
over
a

dynamo
in
that
it

provides
current
at

low

engine

speeds
thereby
avoiding
battery
drain
Maintenance
is
not

normally
required
but
the
tension
of
the
fan
belt
should
be

checked
and

adjusted
if

necessary
as

described
in
the

section

COOLING
SYSTEM
Care
must
be
taken
not
to

overtighten

the
fan
belt
or

the
alternator

bearings
will
be
overloaded

The
alternator

output
can
be
checked
with
the
alternator

in

the
vehicle

by
carrying
out
the

following
test
Ensure
that
the

battery
is

fully
charged
Withdraw
the
connectors
from
the

alternator
F
and
N
terminals
and
connect
a

jumper
lead
between

the
F
and
A
terminals

Connect
a
voltmeter
to
the
E

and
A
alternator
terminals

with
the

negative
lead
to

terminal
E
and
the

positive
lead
to

the
terminal
A
as
shown
in

Fig
M
IS
Switch
the

headlamps

on
to
full
beam
and
start

the

engine
Increase
the

engine
speed

gradually
and
note

the

reading
on
the
voltmeter
when
the

engine
reaches
a

speed
of

approximately
lOaD

rpm
The

alternator
is

operating

satisfactorily
if
the
voltmeter
shows
a

reading
above
12
5
volts
If

the

reading
is
below
12
5
volts
the

alternator
is
defective
and
should
be
removed
for

inspection

ALTERNATOR
Removal

Disconnect
the

negative
lead
from

the

battery
and
the
two

lead
wires
and
connector
from
the
alternator

Slacken
the
alter

nator

mounting
bolts
and
take
off

the
fan
belt
Take
out

the

mounting
bolts
and
withdraw
the
alternator
from
the
vehicle

III

Pr
d
rp

r

1

J

Fig
M

20
Pulling
out
the
rear

bearing

Fig
M
23

Testing
the

stator
for
conduction

Fig
M
25

Inspecting
the

positive
diodes
inteN
Il1JIi

OJaIlir

J

Fig
M
lI

Testing
the
rotor
coils
for
conduction

Fig
M
ll

Testing
the
rotor
coils
for
earthing

Fig
M
24

Testing
the
stator
for

earthing

TERMINAL

OPLATE

Fig
M
26

Inspecting
the

negative
diodes

113

ALTERNATOR
Dismantling

Refening
to

Fig
M
16
remove

the

pulley
nut
and
take
off

the

pulley
rim
fan
and

spacer
Withdraw
the
brush
holder

retaining
screws
and
remove
the
brush
holder
cover
Withdraw

the
holder
and
brushes
as
shown
in
Fig
M
17

Slacken
and
remove
the
three

through
bolts
and

separate

the
diode

housing
from
the
drive
end
housing
by
tapping
the

front
bracket

lightly
with
a
wooden
mallet

Fig
M
18

Remove
the
screws
from
the

bearing
retainer
and

separate
the

rotor
from
the
front
cover

Fig
M
19

Remove
the
rear

bearing
from
the
rotor

assembly
with
the

aid
of
a

puller
as
shown
in

Fig
M
2D
Take
off
the
diode
cover

and
unsolder
the
three
stator
coil
lead
wires

from
the
diode

terminal

Remove
the

A
terminal
nut
and
diode
installation
nut
and

remove
the
diode

assembly
Do
not
force

the
diode

assembly

when

removing
or
it

may
be

damaged
Remove
the
stator
from

the
rear
cover

ALTERNATOR

Inspection

Use
an

ohmmeter
as

shown
in
Fig
M
21
to
test

the
rotor

field
coil

Apply
the
tester
between
the

slip
rings
and
check
that

the
resistance
is

approximately
4
4
ohms
at

normal
ambient

temperature
Check
the

conductivity
between

slip
ring
and
rotor

core
as
shown
in

Fig
M
22
if

conductivity
exists
the
field
coil

or

slip
ring
must
be

earthing
and
the
rotor

assembly
should
be

renewed

Cbeck
the
stator
to
ensure
that
there
is

conductivity

retween
the
individual
stator

coil
terminals
as
shown
in

Fig
M

23
If
there
is
no

conductivity
between
the
individual
terminals

the
stator
is
defective

Check
each
lead
wire

including
the
neutral
wire
as
shown

in

Fig
M
24
If
there
is

conductivity
between

any
wire
and
the

stator
COTe

the
stator
core

is

earthing
and
the
stator
must

be

replaced

Diodes

Three

positive
diodes
are
mounted
on
the
positive
plate

and
three

negative
diodes
are
mounted
on
the

negative
plate

The
diodes
allow

current
to
flow
in
one
direction

only
The

diodes
on
the

positive
plate
only
allow
current
to
flow
from

the
terminal
to
the

positive
plate
whilst
the
diodes
on
the

negative
plate
only
allow
current
to
flow
from
the

negative

plate
to
the
terminal
A
diode
which
allows
current
to
flow

in
ooth
directions
or
does
not

allow
current
to
flow
in
the

correct
direction
is
unserviceable
and
all
six
diodes
must
be

replaced
Use
a
tester
as
shown
in
Figs
M
25
and
M26
to
check

each
diode

Brushes

Check
the
movement
of
the
brushes
in
their
holders
The

brushes
should
move

freely
and
can
be
eased
in
necessary
by

carefully
ming
the
sides
Oean
the
brush
holders
before

replacing

the
brushes
Renew
the
brushes
if

they
are
worn
below
a
length

of
7mm
0
275
in
With
the
brush

projecting
approximately

2mm
0
08
in
from
the
holder
it
is
possible
to
measure
the

brush

spring
pressure
using
a

spring
balance
as
shown
in

Fig
M
27

The

pressure
of
a
new
brush
should
be
255
345

grammes

9
0
12
2
oz
the

pressure
will
however
decrease

by
approxi

mately
20

grammes
per
I
amm
0
039

in
of
wear

ALTERNATOR

Assembly
and
Installation

Asssembly
is
a
reversal
of
the

dismantling
prQcedure
noting

the

following
points
The
stator
coil
lead
wires
must
be
resoldered
to
the
diode

assembly
terminal
as

quickly
as

possible
or

the
diodes

may
be

damaged
When

installing
the
diode
A
tenninal
make
sure

that

the

insulating
bushing
and
tube
are

correctly
fitted

The

pulley
nut
should
he

tightened
to
a

torque
reading
of

350
400

kg
cm
301
344Ib
in
Mount
the

assembly
in
a

vice
as
shown
in

Fig
M
28
and
when
the

pulley
is

tightened

make
sure
that
the
deflection
of
the

pulley
groove
does
not

exceed
O
3mm
m
o
118

in

ilEA
D
LAMPS

Replacing

All
weather

type
sealed
beam

headlamp
units
are
fitted
to

the
vehicle
Each

lamp
is
of
the
double
fIlament

type
with
a

full
beam
filament
of
50W
and
a
dipped
beam
filament
of
40W

The

replacement
of
the
sealed
beam
unit
can

be
carried

out
as
follows

Remove
the

wiring
socket
from
the
back
of
the

headlamp

unit
On

Coupe
models
withdraw
the
screws

attaching
the

front

grille
to
the
radiator
core

support
On
all
other
models

remove

the
three

retaining
screws
and
remove
the

headlamp
rim

Withdraw
the
three

retaining
screws

securing
the

retaining

ring
3
in

Fig
M
29
and
remove

the
sealed
beam
unit

When

installing
a
new
sealed
beam
unit
make
sure
that
the

Top
mark
on
the
ring
is

uppennost
when
fitted

HORNS

The
circuit
for

the
horns
is
shown
in

Fig
M
30
The
horns

can
be
adusted
for
v01ume
and
tone
in

the

following
manner

Remove
the
connector

and
the

retaining
nut
in

the
centre

of
the
horn
withdraw
the
horn
from
the
vehicle
Connect
a

voltmeter
and
ammeter

into
circuit
as
shown
in

Fig
M
3I
Set

the
switch
to
ON
and
check
that
the
voltmeter
shows
a

reading
of
12
to
12
5
volts
The
sound
can
be

regulated
by

turning
the

adjusting
screw

Fig
M
32
A

reading
of

2
5

amps

should
be
obtained
for
the
flat

type
of
horns
or
5
0

amps
for

the

spiral
type
of
horns

Turning
the

adjusting
screw
clockwise
will
increase
the

current

turning
anti
clockwise
decreases
the
current

Install
the
horns
in
the
vehicle
and
check
that
the
correct

sound
can
still
be
obtained
when
the

higher
voltage
of
14
15

volts
is

generated
by
the
alternator
Turn
the

adjusting
slightly

if

necessary
then

tighten
the
locknut

INSTRUMENT
PANEL
Removal

The
instrument

panel
holds
the
various
meters

and

indicators
A
printed
circuit
board
is
located
at
the
rear
of
the

panel
and
the
connections
to
it
are

multiple
connectors
When

the

panel
is
remove

the
instruments
are

easily
withdrawn
for

inspection
and

servicing

Disconnect
the

battery
negative
terminal

2
Remove
the
windscreen

wiper
switch

lighting
switch
and

choke
control
knobs

by
pressing
them
in
and

turning

anticlockwise
Remove
the
escutcheon

3
Disconnect
the

cigarette
lighter
cable
at
the
rear
of
the

instrument

panel
and
turn

the

cigarette
lighter
outer
case

so
that
it
can
be
removed

115