engine DATSUN B110 1973 Service Repair Manual

ENGINE
REMOVAL

INSTAllATION

5

Disconnecting
clutch

wire
on

right
hand
drive

model

On

left
hand
drive

model
disconnect

hydraulic
line
from

the

clutch
slave

cylinder

Disconnect
the

clutch
wire
at
the

portion
of
the

withdrawal
lever
See
the
section

covering
the
clutch

6
Remove
the
exhaust
front

tube

ij

f

I

Fig
ER
11

Disconnecting
dutch
wire

7

Disconnect
the

cable
to
the

back

up
lamp
switch

8

Disconnect
the

speedometer
cable

9

Remove
the

propeller
shaft

Remove

four
bolts
used
in
the

differential
carrier
side

and

withdraw
the

propeller
shaft

10

Remove
the
shift
lever

Model

with
remote
control

shift
lever

Disconnect
the
remote
control

rod
at
the

portion
of

transmission
outer
lever

and

remove
the
remote

control

rod

Model

with
floor
shift

lever

Remove
the

boot
withdraw
the
lock

pin
and

remove

the
lever
The

operation
is
carried
out
in
the

passenger

compartment
Fig
ER
12

Removing
fTont
tube

Model
with

automatic
transmission

Remove

pins
from
both
ends
of

the
cross
shaft
and

remove

the
shift
rod

II

Suspend
the

engine
with
wire

Fig
ER
13

Removing
remote

control
rod

12

Remove
the
front

engine
mounting
installation

nuts

13
Remove

the
rear

engine
mounting
installation

nuts

14
When

removing
the

engine
mounting
installation

nuts
be
sure
to

apply
a

jack
beneath
the
transmission

ER
5

15
Lift

up
the

engine
toward
the
front

INSTALLATION

Install
the

engine
in

reverse

sequence
of
removal
CHASSIS

Fig
ER
14

Lifting
up
engine

SERVICE
JOURNAL
OR
BULLETIN

REFERENCE

DATE
JOURNAL
or

BULLETIN
No
PAGE
No

ER

6
SUBJECT

CHASSIS

REMOVAL

The
clutch

assembly
is

dismounted

primarily
in
the

same
manner
as
the

engine
assembly
Thus
when
dis

mounting
the

clutch

assembly
refer
to
the
Section

TM

Transmission
Removal
and
other

relative
sections

W

II

11
I
Clutch

assembly

I
2

I
Clutch
disc

assembly

Fig
CIr2
Clutch

assembly
and
disc

assembly

DISASSEMBLY

When

separating
the
clutch

assembly
from
the

flywheel
loosen

and
remove
the
installation
bolts

diago

nally
and

gradually

Note
When

separating
the
clutch

assembly
from

the

flywheel
support
the
clutch

cover

sufficiently
and

loosen
the
installation
bolts

gradually
and

carefully

because
the

diaphragm
spring
tension
is

always

applied

2

Removing
release
mechanism

I
Remove

the
dust
cover
from
the
clutch

housing

2
Remove

the
return

spring
from

the

bearing
sleeve

and

separate
the
withdrawal
lever
from

the

bearing
sleeve

3
Remove

the
release

bearing
and

bearing
sleeve

from

the

front
cover
and
remove
the
withdrawal

lever
from
the

withdrawal

lever
ball

pin
1

I
Withdrawal

lever
3

Release

bearing

2
Return

spring

Fig
CL
3

Disassembling
release
mechanism

3
Withdraw
the

release

bearing
from
the

bearing
sleeve

by
the
use
of
a

bearing
puller

I
t

I
Release

bearing

I
2

I
Bearing
sleeve

Fig
CIr4

Withdrawing
rekas

b04ring

INSPECTION
AND

ADJUSTMENT

Thoroughly
clean
all

disassembled

parts
except
for

disc

assembly
and
release

bearing
and
check
them

for

wear

crack
and
other

defective
conditions

Clutch

assembly

I

Check
the
clutch
cover

diaphragm

spring
pressure

plate
etc
for
excessive

wear
crack
and

damage
When

noise

occurs
on
the
clutch

assembly
replace

CL
2

CLUTCH

Operating
cylinder
clutch

Operating
cylinder
diameter

T
Ilhtening
torque
19
05
mm
0
750
in

Clutch

assembly
securing
bolt
1
5
to
2
2

kg
m

10
8
to
15
9

ft
Ib

TROUBLE
DIAGNOSES
AND

CORRECTIONS

Condition

Noises
audible

on

pedal

depression

Noises
audible

on

pedal
release
Probable
cause

Excessively
worn

damaged
or

poorly
lubri

cated
release

bearing

Seized
release

bearing
and

diaphragm

spring

fingers

Insufficient

pedal
free
travel

Weakened

unhooked
or
broken
clutch

pedal

return
and
control

springs

Weakened
clutch
withdrawal
lever
return

spring
broken
or
unhooked

Excessive

play
between
clutch
disc
hub
and

drive
shaft

spline

Misalignment
of
clutch
disc
to

flywheel

causes

slight
movement
of

disc
hub
in

respect
of

facings

This
noise
is

especially
audible
with

engine

idling
or

at
low

speed

Broken
or
weakened
clutch
disc
cushion

springs

Insufficient

pedal
free
travel

Weakened
unhooked
or
broken
clutch
con

trol
and

pedal
return

prings

CL
13
Corrective
action

Replace
the

bearing
which

being
cased

cannot
be

greased
inside

Replace
the
release

bearing
Clean

diaphragm

spring
fingers
with
metal
brush
and
smooth

out

bearing
contact
faces
with
felt

polishers

Readjust
pedal
free
travel

correctly

Set

springs
in

position
or

replace
them
if

weakened
or

snapped

Replace
the

spring
or
hook
it

up
as

required

Replace
the
clutch
disc
and

ensure
that

clearance
between

hub
of
new

clutch
and

drive
shaft
is

within
0
50
mm
0

0197
in

endwise
and
0

20
mm
0

0079
in
crosswise

When
clearances
exceed
above
limits

replace

the
drive
shaft
also

Set
level
of
clutch
disc
with
clutch
disc
in

place
on

drive
shaft
set
it
under

slight

rotation
and
check
for
no
run

out

using
a

scriber

Replace
the
clutch
disc

Set

pedal
free
travel

correctly

Check
the

springs
for
correct

position
and

replace
them
if

necessary

TRANSMISSION

TRANSMISSION

CONTENTS

DESCRIPTION

Specifications

REMOVAL

DISASSEMBLY

INSPECTION

Transmission
case

and
rear

extension

Bearing

Gear
and
shaft
TM
l

TM
l

TM
2

TM
4

TM
7

TM
7

TM
8

TM
8

DESCRIPTION

Three

speed
and
four

speed
manual
transmission

are

available

for
BJ
10
series

Specifications

Model

Item

Finalgear
atio

Type

Control

ystem

nd

J
d

4th

Rever

Speedometer
gear
aHo

Oil

apacity
TM
8

TM
9

TM
9

TM
9

TM
9

TM
9

TM

9

TM
l0

TM

16
Synchro
hub
thrust
washer

Baulk

ring

Shilting
insert

Oil
seal

Rear

engine

mounting
insulator

REASSEMBLY

AND
ADJUSTMENT

Selecting
counter

bearing
thrust
washer

Main
shaft

REINSTALLATION

This

chapter
describes

mainly
about
the
four

speed

manual
transmission

811O
5
U

8110
5
RU

VBIIO
S
U

3
900

R3W56L

Steering
olumn
shift

3
380

1
734

1
000

3
640

17
5

18
5
for
Van

I
2l
2

1
2
U
S

pl

1
8

Imp
pc

TM
l
BIIO
S
TU

LB110
S
T

BllO
5
TRU

DUlO
5
TR

L8110
TRU

L8110
TRN

VBllO
S
TU

VLBllO
5
T

VBllO
SIRU

VLBllO
SIR

VLBllO
TR

KBIIO
U

KLBllO

KLBllO
U

KLBI
O
N

3
900

F4W56L

Floor
shift

3
757

69

1
404

1

000

3
640

17
5

18
5
for
Van
i
r

i

1
2
t
2
1
2
U
S

pt

IJ8Imp
pt

l
OC

t

1

I
t

y
y

dt

k

J

t

i
r

CHASSIS

25T31T
31T

19Ti
r

n

1
I

l111
0

ILJULj

I
J
ll
J

j
Ll

Jd

c

C
J

13TF

t4T

iST
22T

p

3

t7T
J

3T27T
31T

1
T

l

Jpflh
I

I
I

r

1
II

AE

j
t

I

r
t

L

8
I

U
b
J

251
9T

29T
I
I

T

13T

l

Fig
TM
l
RJW56

gear
train
Fig
TM
2
F4W56

gear
train

The
transmission
assembly
consists
of

transmission
case

which
contains

gear
assembly
and
rear
extension

The
cast
iron

adapter
plate
supports
each
end
of
the

main
shaft
counter
shaft

and
reverse
idler
shaft
and

front
side
of
the
transmission
case

supports
the
other
ends

Moreover
the
rear
extension

supports
the
main
shaft

rear
end

The

gear
assembly
can
be
disassembled
with
the

gear

assembly
installed
on
the

adapter
plate

j

I

a
JI
I
Ir

I
i

iiffq

J

1

f
Fi
1
1
1

J
F4h
56
transmission

REMOVAL

When

dismounting
the

transmission
from
the
vehicle

j
the
following
instructions

ER

Engine
Removal
apply
Refer
to
the
section

TM
2

TRANSMISSION

I

Jack
up
the
vehicle
and

support
it
with
four
stands

If
available
recommend
a

hydraulic
hoist
or

open
pit
be

utilized

2

Disconnect
the
front
exhaust
tube

D
from
the

exhaust
manifold

Fig
TM
4
Underside

of
vehiJ
1e

3
Remove
the

propeller
shaft

@
by
removing
four

securing
bolts
from
the

companion
flange
of
the

gear

carrier
Seal
the
end
of
the
rear
extension

housing
to

prevent
oil

leakage

Fig
TM
5

Removing
propeller
haft
4
Disconnect
the

speedometer
drive
cable

ID
and

back

up
lamp
switch
cable
from
the
transmission
ex

tension
housing

s
Disconnect
the
shift
rods
from
the

shift
levers

by

removing
the
cotter

pin
and
remove
the
cross
shaft

assembly
@
from
the
transmission
case

r

J
f

f

1

I
Speedometer
cable

I
2

I
Cotter

pin

Fig
TM

6

Disconnecting
speedometer
cable

and
remote

controllinkag

6

hydraulic
clutch
control

Remove
the
clutch

operating
cylinder
from
the

clutch

housing

7
mechanical
clutch
control

Disconect
the
clutch
control
cable
from
the
withdrawal

lever

1

1
Withdrawal
lever
2

I
Clutch
control
cable

Fig
TM
7

Disconnecting
clutch
control
cable

8

Support
the

engine
with

ajack
placed
under
the
oil

pan
Do
not
loca

1
f
nder
the
oil

pan
drain

plug

I

i
l

TM
3

CHASSIS

To

prevent
the
oil

pan
from

damaging
insert

a
wooden

block

between
the

pan
and

jack

9

Remove
two
nuts

@
used
to
attach
the

transmission

to

the

rear

engine

mounting
member

Place

a

jack
under

the

transmission
and

remove
two
bolts

@
used
to

fix
the

rear

engine
mounting
member
to

the

body

It

I
Rear

engine
mou

ting

installation

bolts

I
Rear

engine
mounting

bolts

I
2

Fig
TM
8
C

oss

Fberremoval

10

Raise
the

jack
supporting
the

engine
to
incline
the

engine
in
a
rearward

direction
A

sufficient

space
will
be

provided
for
transmission

removal

I
Remove

the

starting
motor
a
d
the

bolts

attaching

the
clutch

housing
to
the

engine

12

Lower
the

jack
under
tlie

and
withdraw
thS
transmission

iJ

DISASSEMBI
Y
trans
fljssion
gradu3Ily

1

j

I
When

disassembling
the
transmission

the

following

procedure

sh
ould
pe
adopted
Since
the

casings
are
made

of
aluminum

alloy
be

careful
not
to

damage
any
of
the

castings
C

t

l
t1
Drain

gear
o

frqrP
the
transmission

I

2
Rc

ove
the

dust

cover
release
the

withdrawal
lever

n
turn

sprin
and
remove
the

withdrawal
lever
and
release

bC
lring
from
the
clutch

housing

h

IF
i

Iii

h

l
11
I
W

ithdrawallever

I
Return

spring

1

31
Release

bearing

Fig
TM
9

Removing
release

bearing
and

withdrawal

lever

3

Remove
three
bolts

securing
the

front
cover
and

remove
the

front
cover

II
I
Front
coveT

L
I
Bolt

Fig
TM
10
Remd

ving

fron
cover

4
Remove

the

spced
omcter

pinion
assembly

1f

SPEEDOMETER

PINION

ASSEMB
Y

w

Fig
TM

11

Removing
speedometer

pinion

TM

4

TR

ANSMISSION

Baulk

ring

I

Check
the
baulk

rings
for
wear

pitting
chips
or

burrs

If

any
abnormal
conditions
are
detected

they
must

be

replaced
with
new
ones

2

Place
the
baulk

ring
in

position
on
the
cone
of
each

gear
Push
the

ring
to
the

gear
and
check
the

gap
between

the
end
face
of
the
bauIk

ring
and
the
front
face
of

the

clutch
teeth
This

gap
should
be
within
1
05
to

I
4

mm

0

0413
to
0
0551
in

If
it
is
less
than
0
5
mm
0

0197

in
a

worn
bauIk

ring
may
be
the

cause
and

a
new

ring

should
be
fitted

ii
V

ilillltII

l
A

1
05
to
1
4

mm

0
0413
to
0
0551
in

Fig
TM
28

ulk

ring
to

cone

installing
dimension

ShiftiAg
insert

Replace
if
worn

excessively
worn

unevenly
de

formed
or

damaged

Oil
seal
i

T

l
l

11

tT

Replace
the
oil
seal
with
a
new
one
if

lip
is
deformed

f

worn
or
cracked
or
when
the

spring
is

dropped
off

When
it
is

necessary
to

replace
the
transmission
rear

oil

seal
use
the

following

procedurecto
prevent
d

age
to
the

extension

l

1
Insert
the
transmission

rear
oil

seal
remover

ST23850000
into
the
dust
cover

2
Attach

a
pipe
wrench
to
the
dust

cover
and
drive
out

the
dust

cover

together
with
the

oil
seal

by

rotating
the

wrench
four
or
five
turns

I
Oil
seal

Extension
IJ

y

Fig
TM
29

Removing
rear
oil
seal

r

VI
1

3

Apply
a

coating
of

sealing
material

to
the

periphery

of
the
dust
cover
when

pressing
a
new
oil

seal
into

position
Never

apply
an
adhesive

caulking
material

Rear

engine
mounting
insulator

Replace
rear

engine
mounting
insulator

if

weakened

a

deteriorated
or

cracked

7i
1

rt

REASSEMBLY
AND
AD
JUSTMENT

Selecting
counter

bearing
thrust

washer

l
Fit
the
counter

bearings
to
the

counter
shaft
both

front
and

rear

by
the

use
of

a
counter
shaft

bearing
press

stand

special
tool

ST23030000
and

by
means
of

pressing

r

j

Itf

Fig
TM

JO

Fitting
counter

shaft

bearing
r

JJff
i

it

l
t

i

j

IlK

Ji
t

l
k

TM
9

CHASSIS

SERVICE
DATA
AND

SPECIFICATIONS

GENERAL
SPECIFICATIONS

Type

No
of

speeds

Synchromesh
type

Gear
ratio

1st

2nd

3rd

4th

Rev

Speedometer

gear
ratio

Sedan
and

Coupe

Van

Oil

capacity

TIGHTENING
TORQUE

Transmission

proper

Engine
transmission
intallation
bolt

Engine
mount
rear
installation
bolt
to
the

body

Speedometer
pinion
installation
bolt

Front

cover
installation

bolt

TM
20
R3W56
F4W56

3
forward
I

reverse
4

forward
I

reverse

Warner

type
Warner

type

3
380

3
757

1734
2
169

1
000
1404

1

000

3
640
3

640

17
5
17
5

18
5

18
5

1
2
L
2
1
2
U

S

pt

2
1
8

Imp
pt
1
2

L
2
1
2
U
S

pt

21
8

Imp
pt

kg
m
ft
Ib

1
6
to
2
2

11
6

to
15

9

3
2

to
4
0
23
1

to
28
9

0
5
to
1
1
3
6
to
8

0

1
0
to
1
6
7
2
to
11
6