spare wheel DATSUN 610 1969 Workshop Manual

Clutch

DESCRIPTION

CLUTCH
Removal
and

Dismantling

CLUTCH
Inspection
and

Adjustment

CLUTCH
Installation

CLUTCH
PEDAL
Removal
and
Installation

DESCRIPTION

Either
a

diaphragm
spring
or

coil

spring
type
clutch

is

fitted
to

the
vehicle
The

component
parts
of
the

diaphragm

spring
clutch
are
shown
in

Fig
E
l
and
the

component
parts

of
the
coil

spring
clutch
are
shown
in

Fig
E
2

The
clutch
is
of
the

single
dry
plate
type
consisting
of

the
drive

plate
clutch
coveT
and

pressure
plate
and
release

bearing

The
driven

plate
comprises
a

flexible
disc
and

splined
hub

which
slides
on
the

clutch
shaft
Friction
linings
are

rivetted
to

both

sides
of
the
disc

The
clutch
cover

and

pressure
plate
are
combined

by
nine

spring
setting
bolts
The

diaphragm
is
dished
to

maintain
a

constant

pressure
on
the

pressure
plate
which
in
turn
holds

the
driven

plate
in
contact
with
the

flywheel
The
release

bearing

is
a
sealed

type
ball

bearing
mounted
on
a

bearing
sleeve
Both

bearing
and
sleeve
are
operated

by
the
withdrawalleveT
when

the
clutch

pedal
is

operated

The
clutch

pedal
actuates
a
master

cylinder
which
transmits

fluid

under

pressure
to
a
slave

cylinder
The
movement
of

the

slave

cylinder
piston
operates
the
clutch
withdrawal
lever
via

a

push
rod
See

Fig
E
14

CLUTCH
Removal
and

Dismantling

The

gearbox
must

be
removed
from
the
vehicle
before

the
clutch
can

be
withdrawn
The

procedures
for

removing
the

gearbox
can
be
found
in
the
section
GEARBOX

If
a

diaphragm
clutch
is
fitted
insert
a

spare
clutch
shaft

or
a

special
alignment
tool
ST20600000
into
the

splines
of

the
driven

plate
So
that
the
dutch
is

supported
Slacken
the

six
bolts

securing
the
clutch
cover
to
the

flywheel
by
a
single

turn
at
a
time
and
in
a
diagonal

pattern
until
the

spring

pressure

is
relieved
Remove
the
bolts

completely
and
lift

away
the

clutch

assembly

When

removing
the
coil

spring
type
clutch
it
will

be

necessary
to
insert
suitable
hooks

under
the
release
levers
to

restrain
the
tension
of
the
clutch

spring
before

removing
the

clutch
cover
lx
llts

Ensure
that
the
friction

linings
of
the
driven

plate
do
not

become
comtaminated
with
oil
or

grease
when
removing
the

plate
from
the

splined
shaft

Diaphragm
clutch

The
clutch
cover
and

pressure
plate
assembly
should
not

be
dismantled
and
must
be

replaced
if
wear
or

damage
has

occurred
Make
sure
that
the
friction
face
of

the

pressure
plate
CLUTCH
PEDAL
Adjusting

CLUTCH
MASTER
CYLINDER

CLUTCH
SLAVE
CYLINDER

CLUTCH
WITHDRAWAL
LEVER

Adjusting

CLUTCH
SYSTEM

Bleeding

is
perfectly
flat
and
smooth

Coil

spring
clutch

A

special
tool
No
ST200S0000
is
available
to
ensure

that

the
clutch
can
be
dismantled
and

accurately
reassembled
The

tool
shown
in

Fig
E
3
consists
of
a
Base

plate
I
Centre

spigot
2
Distance

pieces
3

Height
gauge
4
Operating
lever

5

Securing
bolts
6

A
chart
is
included
to
indicate
the
various

parts
to
be
used

for
each

type
of
clutch

To
dismantle
the
clutch
place
the
distance

pieces
on

the

base
plate
as
shown
and

arrange
the
clutch
cover
on
the
base

plate
so
that
the
cover
holes
coincide
with
the
threaded
holes

in
the
base

plate
Insert

the

securing
bolts
provided
in
the
kit

and

tighten
them
gradually
and

evenly
in
a

diagonal
pattern

until
the
cover
is

firmly
attached
to
the
base

plate
Mark
the

clutch
cover

the

pressure
plate
lugs
and
the
release
levers
with

a

centre

punch
so
that

they
can

be
reassembled
in
their
original

positions

Remove
the

restraining
hooks
from
the
release
levers
and

unscrew
the
three
nuts
from
the

eye
bolts
Slowly
release
the

pressure
on
the
clutch
coil

springs
by
unscrewing
the
bolts

securing
the
cover
to
the
base

plate
and
lift
off
the
cover

springs

and

pressure
plate

CLUTCH

Inspection
and
Adjustment

Use
a
solvent
to
clean
the
dismantled

parts
with
the

exception
of
the
disc

linings
and
the
release

bearing

Check
the
clutch
cover

diaphragm
spring
and

pressure

plate
assembly
for
wear
or

damage
and
renew
the

complete

assembly
if

necessary
The

pressure
plate
on
the
coil

spring

clutch
can
be

lapped
if
necessary
as
described
below
Ensure

that
the
disc
rivets
are
not
loosened
and

inspect
the

linings
for

contamination
Grease
or
oil
should
be
removed
and
the

linings

dressed

using
a
wire

brush

Check
the
disc
for

run
ut

using
a
dial

gauge
as
shown
in

Fig
E
4
Position
the
dial

gauge
at
a

point
approximately
9Smm

3
74
in
from
the
centre
of
the
disc
and
check
that
the
run

out
does
not

exceed
the
permissible
limit
of
0
5
mm

0
02in

A
slight
deflection
can
be
corrected

by
hand

pressure
with

the
disc
mounted
on
the

gearbox
shaft

The
disc
must
be
renewed
or
relined
if
the
height
of
the

linings
above
the
rivets
is
less

than
0
3mm
0
012
in

Replace

the
bearing
sleeve
if
it
shows

signs
of
wear
at

the
point
of

contact
with
the
withdrawal
lever

Replace
the
release

bearing

if

grease
is

leaking
from
it
or
if
it
is

noisy
when
turned

43

The
coil

spring
clutch

pressure
plate
can

be

lapped
with
a

surface

grinder
to
remove

dents
or

scratches

only
the
minimum

amount
of
metal
should
be
removed
to
restore
the
surface

Check
the

plate
for
distortion

by
placing
it

on
a
surface

plate
with

the
friction
face
towards
the
surface

plate
Press

the
pressure

plate
down
and
insert
a
feeler

gauge
of
1
0mm

0
0039
in

between
the

pressure
plate
and
surface

plate
If
it

is

possible
to
insert
the
feeler

gauge
then
the

pressure
plate
must

be

repaired
or

replaced
The

plate
can
be
skimmed
but
the

maximum
amount
of
metal
that
can
be
removed
is
1
0mm

0
0039in

CLUTCH
SPRING

Diaphragm
clutch

With
the

diaphragm
spring
assembled
to
the

pressure
plate

inspect
the

spring
height
and
load
in
the

following
manner

Place
distance

pieces
of
7
8
mm

0
307
in
on
the
base

plate
as

shown
in

Fig
E
3
and
bolt
down
the
clutch
cover

using
the

special
bolts

provided
with
the
kit
Meas
Jre
the

height
B
in

Fig
E
5

at
a
diameter
of
44mm
1

732
in
The
release

fingers

should
not

exceed
a

height
of
43
45
mm
1
693
1
772
in

from
the
base

plate
Replace
the

spring
if

the

height
is
in
excess

of
the

figures

quoted

Press
the
dutch
down
as

shown
in
Fig
E
6
to
a

depth
of

7
8mm
0
307
in
or
until
the
clutch
driven

plate

upper
surface

lines

up
with
the
clutch
cover

mounting
face
If

the
load

applied

is
less
than
350

kg
770
lbs
it
will
be

necessary
to
renew
the

diaphragm
spring
Do
not

press
the
clutch
disc
down

by
more

than
9mm
0
35
in
or
the

diaphragm
spring
may
be
broken

CLUTCH
SPRINGS
Coil

spring
clutch

The
clutch

springs
must
be

replaced
as
a

set
if

any
of
the

springs
are
found
to
be
defective
Specifications
for
the

springs

are

given
in
Technical
Data
at
the
end
of
this
section

Generally

a

spring
may
be
considered
faulty
if
when
assembled
the
load
is

reduced

by
more
than
15
or
if
the
free

length
has
altered

by

more
than
1
5mm
0
0590
in
or
if
the
deflection
B
to
A

in

Fig
E

7
exceeds
5mm

per
100mm
0
2
in

per
3
94
in

Release

Bearing

The
release

bearing
should
be
renewed
if

excessively
worn

or
if

roughness
can
be
felt
when
the

bearing
is
turned

by
hand

The

bearing
should
also
be
renewed
if
the

grease
has

leaked

away
or
if
the
clearance

between
the
clutch
cover
and
inner

diameter
of

the
sleeve
is
more
than
0
5
mm
0
0197
in

The

bearing
can
be

removed

using
a
conventional

puller

as
shown
in

Fig
E
8
Two

types
of
release

bearings
are

available

and
care
must
be
taken
when

fitting
onto

the
bearing
sleeve

The
release
bearing
should
be

pressed
into

place
on
the

diaphragm

spring
type
of
clutch
with
a
force
of
400

kg
880
lbs

applied

at
the
outer
race
as
shown

in

Fig
E
9
On
the
coil

spring
clutch

the
same

force
must

be

applied
at

the
inner
race
as
shown
in

Fig
E
IO
It
should
be

possible
to
turn
the

bearing
freely
and

smoothly
when
it
is

pressed
into

place
CLUTCH

Assembly

Coil

spring
type

Press
the

pin
into
the

eyebolt
and

through
the

lug
on

the

pressure
plate
Place
the
three
distance

pieces
on
the
surface

of
the
base
plate
of
the

special
tool
ST20050000
and

position

the

pressure
plate

pressure
springs
and
retainers

on
the

plate

Set
the

retracting
springs
on
the
cover

and
insert
the

release
levers

through
the

spring
Place

the
clutch
cover
over

the

pressure
plate
and

springs
making
sure
that
the

retracting

springs
do
not

become
dislodged
or
distorted

Compress
the

pressure
springs
by
screwing
the

special
set

bolts
into
the
holes
in

the
cover

Tighten
the
bolts

gradually

in
a

diagonal

pattern
to
avoid

distorting
the
cover
Place
the

release
levers
on

the

eye
bolts
and
screw
OR
the

securing
nuts

Place

retaining
hooks
under
the
release
levers
and
remove
the

clutch
assembly
from
the
base

plate
slackening
the
set
bolts
in

a

diagonal
pattern

COIL
SPRING
CLUTCH

Adjusting

Screw
the
centre

pillar
into
the
base

plate
and

place
the

high
finger
over
the

pillar
The
height
of
the
release
levers
must

be

adjusted
by
turning
the
eye
bolt
nuts
until
the

tops
of

the

release
levers
are

just
touching
the

tip
of
the
gauge
See
Fig
E

11
Remove
the
centre

pillar
when
the
release
levers
are

correctly
adjusted
and
screw
in
the

actuating
lever
Fig
E
12

Turn
the

actuating
mechanism
several
times
to
bed
down
the

parts
and
then
recheck
the

height
of
the
release
levers
Check

for
run
out
as
near
to
the

edge
as
possible
and

readjust
if
the

deviation
is
more

than
0
5
mrn
0
020
in

CLUTCH
InsWlation

Ensure
that
the
friction
faces
are

free
from

oil
and

grease

and
place
the
driven

plate
on
the

flywheel
The

longer
chamfered

splined
end
of
the

assembly
should
face

the

gearbox
Use
a

spare
drive
shaft
to

align
the
driven

plate
The
shaft
must

be

inserted

through
the
splined
hub
of
the
driven

plate
and
into

the

pilot
bearing
of
the

flywheel

Place
the
clutch
cover
into

position
on

the
flywheel
and

tighten
the
dutch
bolts

gradually
in
a

diagonal

pattern
to
a

torque
reading
of
1
5
2
2

kgm
11
16Ib
ft

Remove
the

dummy
shaft
and
the

restraining
hooks
from
the
release
levers

Refit
the
release

bearing
and
the
bell

housing

CLUTCH
PEDAL
Removal
and
Installation

Remove
the
clevis

pin
from
the
end
of
the
master

cylinder
pushrod
and
disconnect
the
pushrod
Remove
the

return

spring
Remove
the

pushrod
after

slackening
the

pushrod

adjuster
Coil

spring
clutch

only
Remove
the

pedal
lever

securing
bolt
slacken
the
handbrake
bracket
bolts
and
lift
out

the

pedal

Clean
all

parts
thoroughly
and
check
them
for
wear
or

damage
paying
particular
attention
to
the
rubber

parts
return

spring
and

pedal
lever
bush

Installation
of
the
clutch

pedal
is
a
reversal
of

the

removal

procedures

45

The

type
D3034C
carburettor
has
certain
additional

features

These
include
a

power
valve
mechanism
to

improve
the

performance

at

high
speed
a
fuel
cut
off
valve
which
cuts
the
fuel

supply

when
the

ignition
key
is
turned
to
the
off
position
and
an

idling

limiter
to

maintain
the

emissions
below
a

certain
level

Sectional
views
of
the
two

types
of

pumps
are
shown
in

Figs
8
1
and
B
2
An
EP
3
electrical
fuel

pump
is

located
in
the

centre

of
the
spare
wheel

housing
in
the
boot

Fig
B
3
shows
a

sectional
view
of
the

pump
with
its
contact

the
pump
mechanisms

solenoid

relay
and
built
in
filter

The
air
cleaner
uses
a

viscous

paper
type
element
which

should
be

replaced
every
40
000
km
24
000
miles

Cleaning

is
not

required
and
should
not
be

attempted

The

cartridge
type
fuel
strainer

incorporates
a
fibre
clement

which
should
be
renewed
at
inervals
not

exceeding
40
000
km

24
000
miles
Fit
B
4
shows
a
sectional
view
of

the
assembly

The
fuel
lines
should
not
be
disconnected
from
the
strainer
when

the
fuel
tank
is
full

unless
absolutely
necessary
as
the
strainer

is
below
the
fuel
level

FUEL
PUMP

Testing

Disconnect
the
fuel
hose
from
the

pump
outlet
Connect

a
hose
with

an
inner
diameter
of
approximately
6
mm
0
024

in
to

the

pump
outlet
and

place
a

container
under
the
end
of

the

pipe
Note
that
the
inner

diameter
of
the

pipe
must
not
be

too

small
or

the
pipe
will
be

incapable
of

delivering
the
correct

quantity
of
fuel
when

testing
Hold
the
end
of
the
hose
above
the

level
of
the

pump
and

operate
the

pump
for
more
than
IS

seconds
to
check
the

delivery
capacity
The

capacity
should
be

I
400
cc

3
24
U
S

pts
in
one
minute
or
less
The

pump
must

be
removed
from
the
vehicle
if
it
does
not

operate
or
if
a

reduced

quantity
of
fuel
flows
from
the
end
of
the
hose
Remove

the
pump
from
the
vehicle
and
test
as
follows

Connect
the

pump
to
a

fully
charged
battery
If
the

pump

now

operates
and

discharges
fuel

correctly
the
fault
does
not

lie
in
the

pump
but

may
be
attributed
to

any
of
the

following

causes

Battery
voltage
drop

poor
battery
earth
loose

wiring

loose
connections
blocked
hoses
or
a

faulty
carburettor

If
the

pump
does
not

operate
and

discharge
fuel
when

connected
to
the

battery
then
the

pump
itself
is

faulty
and

must
be
checked
as
follows

First
make
sure
that
current
is

flowing
This
will
be
indica

ted

by
sparking
at

the
tenninals
If
current
flows
the
trouble
is

caused

by
a

sticking

pump
plunger
or

piston
The

pump
must

be
dismantled
in

this
case
and
the

parts
thoroughly
cleaned
in

petrol

If

the
current
does
not
flow
a
coil
or
lead
wire
is
broken

and
the

pump
must

be
renewed
A

reduced
fuel
flow
is
caused

by
a

faulty
pump
inlet
or

discharged
valve
or
blocked
filter

mesh
The

pump
must

of
course

be
dismantled
and
serviced
as

necessary

FUEL
PUMP

Removing
and

Dismantling

Remove
the
bolts

attaching
the
fuel

pump
cover
to

the

floor

panel
see

Fig
B
S
Remove
the
bolts

attaching
the

pump
to
the
cover

2
Disconnect
the
cable
and
fuel
hoses
Withdraw

the

pump
Dismantle
as
follows

Slacken
the

locking
band
screws
and

remove
the
strainer

strainer

spring
filter
strainer
seal
and

locking
band

Remove
the

snap
ring
Withdraw
the
four
screws
from
the

yoke
and
remove

the
electromagnetic
ulJ
it
Press
the

plunger
down
and
withdraw
the
inlet
vaive

the

packing

and
the
cylinder
and

plunger
assembly

A
defective
eledrical
unit

cannot
be
dismantled
as

it
is

sealed
and
must

be
renewed
as
a

complete
unit

FUEL
PUMP

Inspection
and

Assembly

Wash
the
strainer
filter
and

gasket
in

petrol
and

dry
using

compressed
air
Renew
the
filter
and

gasket
if

necessary
Note

that
the
filter
should
be
cleaned
every
40
000

km
24
000

miles
Wash
the

plunger
piston
and
inlet
valve
in

petrol
and

make
sure
the

piston
moves

smoothly
in
the

cylinder
Replace

the

parts
if
found
to
be
defective

Insert
the

plunger
assembly
into
the

cylinder
of
the
electri

cal
unit
and
move

the

assembly
up
and
down
to

make
sure
tha
t

the
contacts
are

operated
If
the
contacts
do
not

operate
the

electrical
unit
is

faulty
and
must

be
renewed

Assembly
is
a
reversal
of

the
dismantling
procedures
tak

ing
care
to
renew
the

gaskets
as

necessary

CARBURETIOR

Idling
Adjustment

The
D3034C
carburettor
fitted
to

engines
equipped
with

an
emission
control

system
must
be

adjusted
as
described
under

the

heading
IGNITION
TIMING
AND
IDLING
SPEED
in
the

section
EMISSION
CONTROL
SYSTEM

Reference
should
be
made
to
carburettor

idling
adjustment

procedures
for
the
L14
L16

and
LI8

engines
when

adjusting

the
type
DAK
340
carburettor
fitted
to
the
G
18

engine
A
smooth

engine
speed
of

approximately
550

rpm
should
be
attained
in

this
case

FUEL
lEVEL

Adjustment
DAK
340earburettor

A
constant
fuellevcl
in
the
float
chamber
is
maintained

by

the
float
and
needle
valve
See

Fig
8
6
If

the
fuel
level
does
not

correspond
with
the
level

gauge
line
it
will
be

necessary
to

care

fully
bend
the
float
seat
until
the
float

upper
position
is

correctly

set

The
clearance
H
between
valve
stem
and
float
seat

should

be
I
5
mm
0
0059
in
with
the
float

fully
lifted

Adjustment

can
be
carried
out

by
carefully
bending
the
float
stopper
3

FUEL
lEVEL

Adjustment
D3034Ccarburettnr

The
fuel
level
should

correspond
with
the
level

gauge
line

Adjustment
can

be
carried
out
if

necessary
by
changing
the

gaskets
between
the
float
chamber

body
and
needle
valve
seat

The
gaskets
are
shown
as
item
4
in

Fig
B
7
When

correctly

adjusted
there
should
be
a

clearance
of

approximately
7
mm

0
027
in
between
float
and
chamber
as
indicated

STARTING

INTERLOCK
VALVE
OPENING

The

choke
valve
at
its

fully
closed
position
automatically

opens
the
throttle
valve
to
an

optimum
angle
of
14

degrees
on

the

type
DAK
340
carburettor
and
13
5

degrees
on
the
D3034C

carburettor
With
the
choke
valve

fully
closed
the
clearance

G

I
in

Fig
8
should
be
1

I
mm
0
0433

in
This
clearance

S19