ABS DATSUN PICK-UP 1977 Service Manual

FOREWORD

This
service
manual
has
been

prepared
for
the

purpose
of

assisting
service

personnel
of

authorized
NISSAN
DATSUN
dealers
fu

providing
effective
service
and
maintenance
of

the

1977
Datsun
Pick

up

Since

proper
maintenance
and
service
are

absolutely
essential
fu

satisfying
the
Datsun

owners
this
inan
la1
should
be

kept
fu
a

handy
place
for

ready
reference
and
should
be

carefuny
studied

This
man
la1
fucludes

procedures
for
ma
futenance

ac
1justrnents
minor
service

operations

remowl
and
installation
and
for

disassembly
and

assembly
of

components

Some
of
these
service

operations
require
the

use
of

Special
Tools

especially
designed
for

effectiveperfonnance
of
service

operations

The

special
tools
are

presented
in
the
SE

section

As

you
read

through
the

maintenance

procedures
in
this
service
manual

you
will

occasionally
corne
across

paragraphs
headed
NOTE
or
CAUTION
A
NOTE
is

supplemental

infortl1ation
that
is

important
to
B

particular
procedure
CAUTION

warns
of

steps
that
must

be

fonowed
to

prevent
personal
injury
and
Qr

damage
to
some

part
of

your
DATSUN

The

Quick
Reference
Index
on
the
first

page
enables
the
user
to

quickly
locate
the

desired

section
At
the

beginning
of
each
individual
section
is
a
table
of
contents
which

gives
the

page
number
on
which
each

major
subject
begins
An
index
is

placed
at
the

beginning
of
each

major
subject
within
the
section

All
information
illustrations
and

specifications
contained
in
this
manual
are
based
on
the

latest

product
information
available
at
the
time
of

publication
approval
If

YOUT
DATSUN

model
differs
from
the

specifications
contained
in
this
manual
consult

your
NlSSAN

DATSUN
dealer
for
information

Rights
for

alteratiohat

any
time
of

specifications
and
methods
are

reserved

liability
for

any
personal
injury
or

property
damage
occasioned

by
the
use

of
this
service

man
la1
in

effecting
maintenance
or

repair
of

your
Datsun
is
in
no

way
assumed

by
Nissan

M9tor
Co
Ltd

Accordingly
anyone
using
a

service

procedure
or

tool
which
is

not

specifically
w

mended

by
Nissan
must
fust

completely
satisfy
himself

that
neither
his

safety
nor
the

vehicle
s

safety
wi11be

jeopardized
by
the
service

method
selected

NISSAN
MOTOR
CO
LTD

TOKYO
JAPAN

@
1976
N1SSAN
MOTOR
CO
LTD
Printed
in

Japan

3

Check

ignition
system
with

regard

to

the

following
items

Refer
to

Inspection
of

Ignition
System

1

Ignition
AMP

2
Distributor
Emission
Control

System

3

Ignition
coil

4

High
tension
code

5

Spark

plug

4

Check
idle

CO

adjustment
Refer

to

Inspection
of
Idle

CO

Adjustment
Note
Even
if
there
is

nothing

wrong

with

engine
the

warning
lamp
may

come
on
if
vebicle
is

being
driven

on
a

steep
slope

continuously
in

lower

gears
at

high
engine
speeds

EVAPORATIVE

EMISSION

CONTROL
SYSTEM

CONTENTS

DESCRIPTION

OPERATION

INSPECTION

FUEL
TANK

VAPOR
LIQUID

SEPARATOR

AND

VAPOR
VENT
LINE

DESCRIPTION

The

evaporative
emission
control

system
is

used
to

reduce

hydrocarbons

emitted
to
the

atmosphere
from
the

fuel

system
This

reduction
of

hydro
EC
30

EC

30

EC

31
CARBON

CANISTER
PURGE
CONTROL

VALVE

CARBON
CANISTER

FILTER

FUEL

TANK

VACUUM
RELIEF
VALVE
IEC
32

IEC
32

EC

32

EC
31

carbons
is

accomplished
by
activated

charcoals
in
the
carbon
canister

This

system
is
made

up
to

the

following

I

Fuel
tank
with

positive

sealing
filler

cap

@
2

Vapor
liquid
separator

3

Vapor
vent

line

4
Carbon

canister

5
Vacuum

signal
line

6
Canister

purge
line

5

OPERATION

Fuel

vapors
from

the
sealed
fuel

tank
are
led

into
the
carbon
canister
1
Fuel
tank

2
Fuel
nIler

cap
with
vacuum

relief

valve

3

liquid

vapor
separator
4

Vapor
vent
line

5

Canister

purge
line

6
Vacuum

signal
line

7
Carbon

canister

EF274

Fig
EC
76

Schematic

drawing
of
l
Iaporotive

emiaion

control6ydem

The

canister
is
fined
with
activated

charcoals

to
absorb

the
fuel

vapors

EC
30
when
the

engirie
is

at
rest
or
at

idlin
ll

See

Figure
EC

77

Condition

Clutch
chatters

Noisy
clutch

Clutch

grabs
CLUTCH

Probable
cause
and

testing
Corrective
action

Clutch

chattering
is

usually
noticeable
when
vchicle
is

just
rolled
off
with
clutch

partially

engaged

Weak
or
broken
clutch
disc
torsion

spring

Oil
or

grease
on
clutch
facing

Clutch

facing
out
of

proper
contact
or

clutch
disc

runout

Loose
rivets

Warped

pressure
plate
or
clutch
cover

surface

Unevenness
of

diaphragm
spring
toe

height

Loose

engine
mounting
or
deteriorated

rubber

A
noise
is
heard
after
clutch
is

disengaged

Damaged
release

bearing

A
noise
is

heard
when
clutch
is

disengaged

Insufficient

grease
on
the

sliding
surface

of

bearing
sleeve

Clutch
cover
and

bearing
are
not
installed

correctly
Replace

Replace

Replace

Replace

Repair
or

replace

Adjust
or
replace

Retighten
or

replace

I
Replace

Apply
grease

Adjust

A
noise
is
heard
when
vehicle
is

suddei11y
staited
off
with
clutch

partially
engaged

Damaged
pilot
bushing

I
Replace

When

grabbing
of
clutch
occurs
vehicle
will
not
start
off

smoothly
from
a

standing
start
or

clutch
is

engaged
before
clutch

pedal
is

fully

depressed

Oil
or

grease
on
clutch

facing

Clutch

facing
worn
or
loose
rivets

Wear
or
rust
on

splines
in

drive
shaft
and

clu
tch
disc

Warped
flywheel
or

pressure
plate

Loose
mountings
for

engine
or

power

train
units

CLll
Replace

Replace

Clean
or

replace

Repair
or

replace

Retighten

R
RANGE
REVERSE

In
R

range
the

front
clutch
and

the
low
and
reverse
brake
are

applied

The

power
flow
is

through
the

input

shaft
front
clutch
and

connecting

shell
to
the

sun

gear
Clockwise
rota

tion
of
the
sun

gear
causes
counter

clockwise
rotation
of
the

rear

planeta

ry
gears
With
the

connecting
drum

held

stationary
by
the
low
and

reverse

brake
the
rear

planetary
gears
rotate

the
rear
internal

gear
and
drive
the

flange
counterclockwise
The

rear

drive

flange
splined
to
the

output
shaft

rotates
the

output
shaft
counterclock

wise
at
a

reduced

speed
with
an

increase
in

torque
for
reverse

gear
Automatic
Transmission

R

Fig
AT

26
Power

tranamis
ion

during
R

range

m
i

1

A
TOBS

Fig
A
T
21

Optrationof
each
mechanism

during
R

range

When
the
manual
valve

V
is

posi

Clutch
Low

Band
servo
One

tioned
at

R

range
the
oil

having
the
Gear

Partina

Ranae
re
ne

way

line

pressure
7
is

directed
to
line
ralio

Front
Rear

brake
Openlion
Relulie

clutch
plwl

pressure
circuits
5

and
6
The

pressure
in
the
circuit
5
actuates
the
Park
on
on

low
and
reverse

brake
after

being
Ruene
2
182
on
on
on

introduced

into
line

pressure
circuit

Neutral

12

through
the
I

st
2nd
shift
valve

ID
The

pressure
in

the
circuit

op
DI
Low
2
458
on
on

erates
the
release
side
of
the
band

servo
and
the
front
c1u
tch
after

being
Driowe
D2
Second
1
458
on
on

led
to
line

pressure
circuit
0
D3

Top
1
000
on
on
on

through
the
2nd
3rd
shift
valve

@

2
Second
1
458

The
throttle

pressure
I
6
and
the
line
on
on

pressure
6
which

vary
with
the

12
Second
S8
on
on

degree
of
accelerator

pedal
depression

II
Low
2
458

both
act
the

pressure
regulator
on

on

on

valve

CD
and

press

against
its
valve

CD

increasing
line

pressure
7
In
Rn

range
the

governor

pressure
is
absent

making
all

such
valves
as
the
1st
2nd

shift
valve

ID
lnd
3rd
shift

valvc

@
and

pressurc
modifier
valve

inoperative

AT16

Automatic
Transmission

R
RANGE
REVERSE

R

In
R

range
the

front
dutch
and

the
low
and

reverse
brake
are

applied

The

power
flow
is

through
the

input

shaft
front
clutch
and

connecting

shell
to

the
sun

gear
Clockwise
rota

tion

of
the

sun

gear
causes
counter

clockwise
rotation
of
the
rear

planeta

ry

gears
With
the

connecting
drum

held

Slationary
by
the
low
and
reverse

brake
the
rear

planetary
gears
rotate

the
rear
internal

gear
and
drive
the

flange
counterclockwise
The
rear

drive

flange
splined
to
the

output
shaft

rotates
the

output
shaft
counterclock

wise
at

a
reduced

speed
with
an

increase
in

torque
for
reverse

gear

f

When
Ihe
manual
valve

CV
is

posi

tioned
at
R

range
Ihe
oil

having
Ihe

line

pressure
7
is

directed
to

line

pressure
circuits
5
and

6
The

pressure
in

the
circuit
5
actuates
the

low
and
reverse
brake
after

being

introduced
into
line

pressure
circuit

12

through
the
I
st

2nd
shift
valve

@
The

pressure
in
Ihe

circuit

op

erates
the
release
side
of
the
band

servo
and

the
front
clutch
after

being

led
to

line

pressure
circuit

10

through
the
2nd
3rd
shift
valve

@

The
throtlle

pressure
16
and
the
line

pressure
6

which

vary
with
the

degree
of
acceJerator

pedal
depression

both
act

on
the

prcssure
regulator

valve

CD
and

press

against
its
valve

CD

increasing
line

pressure
7
In
R

range
the

governor

pressure
is
absent

making
all
slldl

valves
as
the
J
SI

2nd

shift
valve

@
2nd
3rd
shift
valvc

@
and

pressure
modifier
valve

j

inoperative
C

Fig
AT

26
Power

transmi
ion

during
R

range

A
TOS5

Fig
AT
27

Operation
attach
mechanism

during
R

range

G
Clutch
Low
A

Band
servo
One

Parkin

Ran
no
wa

plwl
ratio

Front
Rear

brake

Operllioo
Rdr
ue

clutch

k
on
on

Revctte
1
181
on
on
on

Neutnl

DI
Low
1
418
on
on

Driw
D2
Second
1
458
on
on

DJ

Top
1
000
on
on
on
on

2
Second
1
458
on
on

12
Second
1
458
on
on

I

II
Low
2
458
on
on

AT
16

Automatic
Transmission

LINE
PRESSURE
GOVERNOR
FEED
PRESSURE

At

cut
back

point
After
cut
back

Throttle

opening
under

approximately
over

approximately

15

kmfh

10
MPH
35
kmfh
22
MPH

Unit

mmHg
Unit

kgfcm2
psi
Unit

kgfcm2
psi

Full
throtlle
0
9
4

to
11
0

134

to
156
5
5
to
6
5
78
to

92

Minill1um
throttle
450
3

0
to
4

0
43to
57
3
0
to
4
0

43
to

57

Fulllhrotlle
0
10
0

to
12
0

142
to

171
5

5
to
7
0

78

to
100

Minimum

throttle
450
6
0
to
12
0
85to171
5
5
to
7
0
78
to
100

Full
throtlle
0
14
0
to
16

0
199
to

228
14
0
to
16
0
199

to
228

Minimum
throttle
450
3
0
to
5
5
43
to
78
3
0
to

5
5
4
lo

78
Range

D

2

R

Notes
a
The
line

pressure
during

idling
corresponds
to
the
oil

pressure
before
cut
down
at

minimum
throttle

b
The
oil

pressure
After
cut
back
means
that
after
the

pressure
modifier
valve
has

operated

JUDGEMENT
IN
MEASURING

LINE
PRESSURE

Low

idling
line

pressure
in
the

ranges
D
2
I
R
and
pH

This
can
be
atlributed
to
trouble
in

the

pressure
supply
system
or
too
low

output
of

power
caused

by

I
A
worn
oil

pump

2
An

oil

pressure
leak
in
the
oil

pump
valve

body
or
case

3
A

sticking
regulator
valve

2
Low

idling
line

pressure
in
cer

tain

ranges
only

This
is

presumably
caused

by
an
oil

leak
in
the
devices
or
circuits
con

nected
to
the
relevant

ranges

I
When

there
is
an
oil
leak
in

the

rear
clutch
and

governor
the
line

pressure
in
D
2
and
I

are
low

but
the

pressure
is

norrrial
in
R

2
When
an
oil
leak
occurs
in
the

low
and

reverse
brake
circuit
the
line

pressure
in
R
and
P
are
low
but

the

pressure
is
normal
in
D

2
and

I

3

High
idling
line

pressure

This
is

presumably
caused

by
an

increased
vacuum
throttle

pressure

owing
to
a
leak
in

the
vacuum
tube
or

dia

phragm
or

by
an
increased
line
pressure
due
to
a

sticking
regulator

valve

Vacuum
leakage
is
checked

by

directly
measuring
the

negative
pres

sure
after

removing
the
vacuum

pipe

A

puncture
of
the
vacuum
dia

phragm
can
be

easily
ascertained

because
the

torque
converter
oil
is

absorbed
into
the

engine
and
the

exhaust

pipe
emits
white

smoke

4

Items
to
be
checked
when
the

line

pressure
is

increasing

In

this
check
the
line

pressure

should
be
measured
with
vacuums
of

450

mmHg
and
0

mmHg
in
accordance

with
the
stall
test

procedure

I
If

the
line

pressure
do
not
n

crease

despite
the
vacuum
decrease

check
whether
the

vacuum
rod
is

incorporated

2
If
the
line

pressure
do
not
meet

the
standard

it
is
caused

mostly
by
a

sticking
pressure
regulating
valve

pres

sure

regulating
valve

plug
or

amplifier

TROUBLE
SHOOTING

CHART

INSPECTING
ITEMS

1

Inspection
with
automatic
trans

mission
on
vehicle

AT
53
A

Oil
level

B

Ra
lge
select

linkage

C
Inhibitor
switch
and

wiring

D
Vacuum

diaphragm
and

piping

E
Downshift
solenoid
kickdown

switch
and

wiring

F

Engine
idling

rpm

G
Oil

pressure
throttle

H

Engine
stall

rpm

I
Rear
lubrication

J
Control
valve
manual

K
Governor
valve

L
Band
servo

M
Transmission
air
check

N
Oil

quantity

o

Ignition
switch
and
starter
motor

P

Engine

adjustment
and
brake
in

spection

2

Inspection
after

inspecting
auto

matic
transmission

on
vehicle

m
Rear
clutch

n
Front
clutch

q
Band
brake

r
Low
and
reverse
brake

s
Oil

pump

t

Leakage
of
oil

passage

u
One

way
clutch
of

troque
coilVerter

v
One

way
clutch
of
transmission

w
Front
clutch
check
ball

x
Parking

linkage

y
Planetary

gear

Front
Axle

Front

Suspension

FRONT
AXLE
AND

FRONT
SUSPENSION

CONTENTS

GENERAL
DESCRIPTION

FRONT
AXLE

REMOVAL
AND
INSTALLATION

WHEEL
BEARING
ADJUSTMENT

DISASSEMBLY
AND
ASSEMBLY

INSPECTION

SHOCK
ABSORBER

REMOVAL
AND
INSTALLATION

INSPECTION

STABILIZER

REMOVAL
AND
INSTALLATION

INSPECTION

TENSION
ROD
FA
2

FA
3

FA
3

FA
4

FA
4

FA
5

FA
8

FA

8

FA
8

FA
8

FA
8

FA

8

FA
8
REMOVAL

AND
INSTALLATION

INSPECTION

TORSION
BAR

SPRING

REMOVAL
AND

INSTALLATION

INSPECTION

UPPER
AND
LOWER
LINKS

FjEMOVAL
AND

INSTALLATION

DISASSEMBLY

AND
ASSEMBLY

INSPECTION

ADJUSTMENT

VEHICLE
POSTURE

WHEEL

ALIGNMENT

STEERING
ANGLE

GENERAL
DESCRIPTION

uUl
FA

8

FA

9

FA

9

FA
9

FA

9

FA
10

FA
l0

FA
ll

FA
ll

FA
Il

FA
ll

FA

12

FA
12

FA224

Fig
FA
j
SectionallJiew

of
fronta
xle
and

fron
t

suspension

FA
2

The

design
of
the
front

suspension

adopts
the

independent
double

wishbone

type
suspension
used
the

torsion
bar

spring
Both
the

upper
and

lower
links

are
installed
on
the
bracket

which
is
welded
on
the
frame

A
1d
the

above
links

swing
to
allow
the
knuckle

spindle
to
move

freely
in
a
vertical

dimension

The

top
and
bottom

of
the
knuckle

spindle

support
are
connected
to
the

upper
link

through
rubber

bushing
and

to
the
lower
lick

through
screw

bushing

The
tension

rod
held

by
the
brack

ets
on
the
chassis
frame
and
lower
lick

wiih
rubber

bushings
bears
the
force

of
fore
and
aft
direction

The
front
end

of
the
torsion

bar

spring
is

installed
to
the

torque
arm

which

attaches
to
the
lower
link
The

opposite
end
is

installed
to
the

spring

anchor
that

secures
to
chassis
frame

firmly
The
both
ends
of

the
torsion

bar

spring
are
serrated

The

shock
absorber
is

double

action

telescopic

hydraulic
type

The

upper
stem
is
attached
to
the

bracket
of
the
chassis
frame
The

lower
insulated
bracket
is

bolted
to

the
lower
lick

The

bumper
rubber
secured
to
the

bracket
Of
the
frame
limits
the
verti

cal
motion
of
the

suspension
lick

The
knuckle

spindle
is

connecied
to

the
k

ufkle
spindle
arm

by
the

king

pin
The

king

pin
bushings
are
fitted

to

the

upper
and
lower
arm

portIOns
of

the
knuckle

spindle
and

seals
are

provided
at
the

portions
mentioned
to

keep
water
and

dirt
from
enteri

g

The
knuckle
arm
is

connected
to

the
lower
end
of
the
knuckle

spindle

to
transmit

ttLe
movement
of
the

steering
wheel
to
the
knuckle

spindle

The
wheel
hub
is

supported
by
two

taper
roller

bearings
on
the

knuckle

spindle
Tlie
brake
drum
and
wheel
are

secured
to
ihe
hub

by
the

hub
bolts
Front
Axle
Front

Suspension

FRONT
AXLE

REMOVAL
AND

INSTALLATION

Removal

I
Jack

up
and

support
vehicle
on

the
stands

at
the
frame
in

a
safe

manner

2
Remove

front
wheel

3
Re

ove
brake
hose

together
with

connector
from
wheel

cylinder

4
Remove

brake
drum

S

Remove
hub

cap
and
then

remove

cotter

pin
adjusting
cap
and

spindle

nut
from
knuckle

spindle

6
Remove
wheel
hub
outer
and

inner

wheel

bearings
bearing
washer

and

grease
seal
from
knuckle

spindle

7
Remove
brake
disc

assembly
from

the

flange
of
knuckle

spindle

8

Remove
knuckle
arm
from

knuckle

spindle

9
Remove

king
pin
lock
bolt

FA225

Fig
FA
R

mol1ing
king
pin
loch
nut

10
After

removing
air
breather
re

move

plug
from
the

top
of

king
pin

with
the

following
method
Drill
a

10
5
mm
0
413
in

diameter
hole
on

the

plug
thread
hole
with
a

tap

M
12
1
2S
screw
a
bolt
into
threaded

hole
and

pull
out
the

plug

II

Apply
drift
to
the

top
of

king

pin
and
drive
out

king
pin
along
with

lower

plug

12

Tap
spindle
with
a
soft
haJnmer

and

detach
it
from
knuckle

spindle

support
Take

care
not
io

drop
thrust

bearing

FA
3
FA226

Fig
FA
3
R

moving
knuckle

piridle

Installation

Install
front
axle
in
reverse
se

quence
to
removal

by

noting
the
fol

lowing
matters
Furthermore

when

installing
front
axle

lightly
coat

grease

to

sliding
parts

I
Insert

O

ring
on
the
lower
end
of

knuckle

spindle
support
Install
thrust

bearing
and

spindle
shim

together
with

knuckle

spindle
to
knuckle

spindle

support

In

this

operation
select

spindle

shims
to
obtain
the

specified
clearance

between
knuckle

spindle
and
knuckle

spindle
support
To

measure
the
Clear

ance
with

a
filler

gauge
jack
up
the

bottom
of

spindle
slightly

Standard
clearance

0
1

mOl
0
004
in
or
less

Note
Be

sure
to
iristsll
thrust

bearing

to
face
coverea
side

upward

2
Line

up
locking
bolt
hole
of

knuckle

spindle
support
with
the

notch
in

king
pin
and

secure
lock
bolt

Be
sure
to
check
killJckle

spindle
for

smooth
movement
Be

certain
to
move

knuckie

spindle
smoothly
and

reailjust

shim
if

necessary
In
addition
check

bushings
and

king
pin
as

required

3
Press
fit

plug
to
the

upper
of

knuckle

spindle
Then
install
lower

plug
to
the
lower
knuckle

spindle

Note
Make
sure
to

place
lower

plug

conectly

4

Secure
knuckle

arm
to
knuckle

SHOCK
ABSORBER

REMOVAL
AND

INSTAUATION

1
Raise
vehicle
on
a
hoist
or
stands

2
Remove

wheel

3
Hold
the

upper
stem
of
shock

absorber
and

remove
outs
washer

and

rubber
bushing

4

Remove
bolt
from
the
lower
end

of
shock
absorber

FA232

Fig
FA

13
Shock
absorber

S
Retain

lower
rubber

bushing
in

position
install
the

lower
end
of
shock

absorber
to
the
bracket
of
lower
link

and

torque
the
bolt

to
3

1

to
4

1

kg
m

23
to
30
ft
lb

Note
Insert
the
bolt
from
the
front

side
of
vehicle

6
Install
the

upper
end
of
shock

absorber
to

body
bracket
and

tighten

lock

n
Jt
to
the

specifjcations

Tightening
torque

1

6
to
2

2

kg
m
121016
ft
lb

INSPECTION

I

Check
shock
absorber
for
visible

defects
and
oil

leaks
Place
shock

absorber

vertically
in

a
vise
and
hand

stroke
shock
absorber

as
outlined
be

low

Extend
and

compress
shock
ab

sorber

as
faI

as

possible
travelling
as

long
as

possible

If
smooth

hydraulic
resistance
is

not

present
in

bqth
Iirection
replace

absorber

2

Replace
rubber

bushing
if
crack

or
deterioration
is
detected
Front
Axle
Front

Suspension

Specifications
for

shock
absorber

Model

Item

Piston
stroke

mm
in

Damping
force

kg
lb

0
3

m
sec
0

98
ft
sec

j

Rebound

Compression

STABILIZER

REMOVAL

AND

INSTAUATION

I

Raise
vehicle
on
a

hoist
or
stands

2

Remove
wheel

3
Loosen

secUring
nut
at
the
lower

link
side
of

stabilizer

4

Remove
bolt

securing
stabilizer

mounting
bracket

to
chassis
frame

Install
stabilizer
in

the
reverse
se

quence
to
removal

noting
the
follow

ing
instructions

S
Attach
stabilizer

mounting
brack

et
to
chassis
frame

tightening
bolt
to

1
6
to
2
2

kg
m
12

to
16
ft

lb

torque

6
Install
stabilizer
lower
link
side

to

connecting
rod
and

tighten
nut
to
the

specifications
as
shown

in

Figure

FA
14
Then

torque
lock

nut
toJ
6

to

2
2

kg
m
12
to

16
ft
lb

F

A233

Fig
FA
14
Stabilizer
detail

INSPECTION

Check

stabilizer
for
deformation

FA
S
All
models

110
4
3

76
168

38
84

and
rubber

bushings
for

crack
wear

and
deterioration

Replace
if
ne

cessary

TENSION
POD

REMOVAL
AND

INSTALLATION

I

Raise
vehicle
on

a
hoist

or
stands

2
Remove

wheel

3

Remove
nuts

CD
from

both
ends

of
tension

rod

4

Remove
bracket
bolt

@
from
the

front
end
of
tension
rod
and
remove

tension
rod

with
bracket

CD

@

f
A234

Fig
FA
15
Ten
ion
rod

Install
tension

rod
in

reverse
00

qunce
to
removal

noting
the

following

instructions

UPPER
AND
LOWER

LINKS

REMOVAL
AND

INSTALLATION

Removal

I
Raise

vehicle
on
a
hoist
or

stands

2
Remove
wheel
and

brake
drum

as

an

assembly

3
Remove
wheel
hub
Refer
to
see

tion
Front
Axle

4

Loosen
bolts

retaining
brake
disc

to
knuckle

spindle
and

remove
brake

disc

5
Remove

knuckle
arm
torsion
bar

spimgJ
stabilizer
shock

absorber
and

tension

rod
in

t
ili
order

referring
the

related
sections

6
Remove

upper
fulcrum
bolt
se

curing
knuckle

spindle
support
to

upper
link

assembly
and
disassemble

them

7
Remove

upper
link

bushings
from

knuckle

spindle
support

8

Remove
screw
bushings
from

both
ends
of
lower
link
fulcrum

pin

9
Loosen
nut
at
lower

portion
of

knuckle

spindle
support
from
inside

and

pull
out
cotter

pin
retaining
ful

crum

pin

10
Pull

out
fulcrum

pin
with

drift

and
remove
knuckle

spindle

support

with
knuckle

spindle
from
lower
link

Then
detach
dust

cover

FA237

Fig
FA

19

Removing
fulcrum
pin

II

Remove
bolts

retaining
upper

link

spindle
and
remove

upper
link

spindle
with
camber

adjusting
shims

from

body
bracket
FrClnt

Axle
Front

Suspension

FA238

Fig
FA

20

Removing
upper
link

spindle

12
Remove
nut

retaining
lower
link

spindle
and
remove

lower
link

spindle

Remove
lower
link

with

torque
arm

from

mounting
bracket

13

Using
Transverse
Unk

Bushing

Replacer
ST36070000
to

lower
link

bushing
tap
it

with
a

hammer
and

drive

out
lower

link

bushing
from

bracket

F

A239

Fig
FA

21

Removing
lower
link

bushing

InstallatIon

Install

upper
and

lower
links
in

the

reverse

sequence
to
removal

noting

the

following
instructions

I

When
the

collar

inside
of

lower

link

mounting
bracket
and

bushing

outside

are
rusted

remove
rust
with

emery

paper

2

Fit
lower
link

bushing
into
lower

link

mounting
bracket

using
Trans

verse
Link

Bushing
Replacer

ST36070000
When

tapping
the
frift

with
a
hammer
be
careful

to
hit
the

drift

squarely

3

Secure
lower
link
to
lower
link

bushing
with
lower
link

spindle
and

torque
nut
to
74

to
8
0

kg
m
54

to

S8
ft
Ib

1

4
1n
4
Install

upper
link

spindle
to

upper

link

mounting
bracket
with

used

camber

adjusting
shims
and
bolts

Torque
bolt
to
7

0
to
9
0

kg
m
SI

to
6S
ft

lb

S

Install
dust
seat
to

the
lower
end

of

j
nuckle

spindle
support

6
Coat

grease
on
the
thread
of

fulcrum

pin
and
line

up
the

notch
of

fulcrum

pin
with

knuckle

spindle

sup

port
for

inserting
cotter

pin
Fit

fulcrum

pin
to

spindle
support
with
a

soft
hammer
Secure
cotter

pin
and

torque
lock
nut
to
0
8

to
1
1

kg
m

S
8

to
8
0
ft
lb

7

Coat

grease
to
the
tIuead

portion

of

screw

bushing
inside

liberally
Posi

tion

knuckle

spindle
support
at
the

center
of
lower
link
and
secure
screw

bushings
temporarily
by
hand
Mter

ascertaining
the
dimensions
become

correct
as
shown
in

Figure
F
A

22

torque
screw

bushings
to
20
to
30

kg
m

I4S
to
217
ft
lb

3

9
05
to

11
05

36
5
9
05
to
11
05

0
3563
to
0
4350

1
431
0
3563
to

0
4350

FA240

Fig
FA
22
In

tailing
IICrew
bu

hing

8

Replace
filler

plug
with

grease

nipple
and

pack
grease
until

grease

comes
out
from
dust
cover
Reinstall

filler

plug

9

Upon
installation
make
sure
that

fulcrum

pin

operates
smoothly
with

the

following
torque

Operating
torque

Less
than
0
5

kg
m
3
6
ft
lb

10
Install

upper
link

bushing
to

knuckle

spindle
support

I
I
Install
knuckle

spindle
support

to

upper
link
insert
fulcrum
bolt
and

torque
nut
to
3
9

to
S
3

kg
m
28
to

38
ft
lb