recommended oil DATSUN 510 1969 Service Repair Manual
[x] Cancel search | Manufacturer: DATSUN, Model Year: 1969, Model line: 510, Model: DATSUN 510 1969Pages: 171, PDF Size: 10.63 MB
Page 18 of 171
h
W
and
connecting
rod
assemblies
Use
a
piston
ring
compressor
to
install
the
pistons
through
the
top
of
the
cylbder
bore
Make
sure
that
the
pistons
and
rings
and
the
cylinder
bores
are
lubricated
with
clean
engine
oil
The
pistons
should
be
arranged
so
that
the
F
mark
faces
to
the
front
and
with
the
piston
ring
gaps
positioned
at
1800
to
each
other
Each
piston
must
be
refitted
into
its
original
bore
NOTE
Single
inlet
valve
springs
are
used
on
the
1400
cc
engine
double
valve
springs
are
used
on
the
1600cc
and
1800
cc
engines
Screw
the
valve
rocker
pivots
with
the
locknuts
into
the
pivot
bushing
Set
the
camshaft
locating
plate
and
install
the
camshaft
in
the
cylinder
head
with
the
groove
in
the
locating
plate
directed
to
the
front
of
the
engine
Install
the
camshaft
sprocket
and
tighten
it
together
with
the
fuel
pump
earn
to
a
torque
reading
of
12
16
kgm
86
116
IbJt
a
eck
that
the
camshaft
end
play
is
within
the
specified
limits
Install
the
rocker
arms
using
a
screwdriver
to
press
down
the
valve
springs
and
fit
the
valve
rocker
springs
Gean
the
joint
faces
of
the
cylinder
block
and
head
thoroughly
before
installing
the
cylinder
head
Turn
the
crank
shaft
until
the
No
1
piston
is
at
T
D
C
on
its
compression
stroke
and
make
sure
that
the
camshaft
sprocket
notch
and
the
oblong
groove
in
the
locating
plate
are
correctly
positioned
Care
should
be
taken
to
ensure
that
the
valves
are
clear
from
the
heads
of
the
pistons
The
crankshaft
and
camshaft
must
not
be
rotated
separately
or
the
valves
will
strike
the
heads
of
the
pistons
Temporarily
tighten
the
two
cylinder
head
bolts
1
and
2
in
Fig
A
37
to
a
torque
reading
of
2
kgm
14
5
lb
ft
Fit
the
crankshaft
sprocket
and
distributor
drive
gear
and
install
the
oil
thrower
Ensure
that
the
mating
marks
on
the
crankshaft
sprocket
face
towards
the
front
Install
the
timing
chain
making
sure
that
the
crankshaft
and
camshaft
keys
are
XJinting
upwards
The
marks
on
the
timing
chain
must
be
aligned
with
the
marks
on
the
right
hand
side
of
the
crankshaft
and
camshaft
sprockets
It
should
be
noted
that
three
location
holes
are
provided
in
the
camshaft
sprocket
See
Fig
A
38
The
camshaft
sprocket
being
set
to
the
No
2
location
hole
by
the
manufacturers
A
stretched
chain
will
however
affect
the
valve
timing
and
if
this
occurs
it
will
be
necessary
to
set
the
camshaft
to
the
No
3
location
hole
in
the
camshaft
sprocket
The
chain
can
be
checked
by
turning
the
engine
until
the
No
1
piston
is
at
T
D
C
on
its
compression
stroke
In
this
position
adjustment
will
be
required
if
the
location
notch
on
the
camshaft
sprocket
is
to
the
left
of
the
groove
on
the
camshaft
locating
plate
as
shown
in
the
illustration
The
correction
is
made
by
setting
the
camshaft
on
the
No
3
location
hole
in
the
camshaft
sprocket
the
No
3
notch
should
then
be
to
the
right
of
the
groove
and
the
valve
timing
will
have
to
be
set
using
the
No
3
timing
mark
Install
the
chain
guide
and
chain
tensioner
when
the
chain
is
located
correctly
There
should
be
no
protrusion
of
the
chain
tensioner
spindle
See
Fig
A
39
A
new
tensioner
must
be
fitted
if
the
spindle
protrudes
Press
a
new
oil
seal
into
the
timing
cover
and
fit
the
cover
into
position
using
a
new
gasket
Apply
sealing
compound
to
the
front
of
the
cylinder
block
and
to
the
gasket
and
to
the
top
of
the
timing
cover
Ensure
that
the
difference
in
height
between
the
top
of
the
timing
cover
and
the
upper
face
of
the
cylinder
block
does
not
exceed
0
15
mm
0
006
in
Two
sizes
of
timing
cover
bolts
are
used
the
size
M8
0
315
in
must
be
tightened
to
a
torque
reading
of
1
0
1
6
kgm
7
2
17
Ib
ft
and
the
size
M6
0
236
in
to
a
torque
reading
of
0
4
0
8
kgm
2
9
81b
ft
Install
the
crankshaft
pulley
and
water
pump
tighten
the
pulley
nut
to
a
torque
reading
of
12
16
kgm
86
8
115
7Ib
ft
then
set
the
No
1
piston
at
T
D
C
on
its
compression
stroke
Finally
tighten
the
cylinder
head
bolts
to
the
specified
torque
reading
in
accordance
with
the
tightening
sequence
shown
in
Fig
A
3
The
bolts
should
be
tightened
in
three
stages
as
follows
First
stage
Second
stage
Third
stage
4
kgm
28
9
lbJt
6
kgm
43
4
IbJ
t
6
5
85
kgm
47
0
61
5lb
ft
The
cylinder
head
bolts
should
be
retightened
if
necessary
after
the
engine
has
been
run
for
several
minutes
Install
the
oil
pump
and
distributor
drive
spindle
into
the
front
cover
as
described
under
Engine
Lubrication
System
r
rf
i
Install
the
fuel
pump
water
inlet
elbow
and
front
engine
slinger
Fit
the
oil
strainer
into
position
coat
the
oil
sump
gasket
with
sealing
compound
and
fit
the
gasket
and
oil
sump
to
the
cylinder
block
Tighten
the
oil
sump
bolts
in
a
diagonal
pattern
to
a
torque
reading
of
0
6
0
9
kgm
4
3
6
5
IbJt
Adjust
the
valve
clearances
to
the
specified
cold
engine
ftgures
following
the
procedures
described
under
the
appropriate
heading
Final
adjustments
will
be
carried
out
after
the
engine
has
been
assembled
completely
and
warmed
up
to
its
nonnal
temperature
Install
the
rear
engine
slinger
exhaust
manifold
and
inlet
manifold
Refit
the
distributor
and
carburettor
assemblies
as
described
in
their
relevant
sections
Install
the
fuel
pipes
and
vacuum
hose
making
sure
that
they
are
securely
cl
ped
Refit
the
thermostat
housing
thermostat
and
water
outlet
together
with
the
gasket
Bond
the
rocker
cover
gasket
to
the
rocker
cover
using
sealant
and
fit
the
rocker
cover
to
the
cylinder
head
Install
the
spark
plugs
and
connect
the
high
tension
leads
Fit
the
left
hand
engine
mounting
bracket
and
install
the
clutch
assembly
using
the
alignment
tool
ST20600000
to
fit
the
clutch
to
the
flywheel
as
described
in
the
section
ClUfCR
Lift
the
engine
away
from
the
mounting
stand
and
into
the
engine
compartment
Install
the
alternator
bracket
adjusting
bar
alternator
fan
pulley
fan
and
fan
belt
in
the
order
given
Check
the
tension
of
the
fan
belt
by
depressing
the
belt
at
a
point
midw
y
between
the
pulleys
The
tension
is
correct
if
the
belt
is
deflected
by
8
12
mm
0
3
0
4
in
under
thumb
pressure
Fit
the
right
hand
engine
mounting
bracket
the
oil
filter
oil
pressure
switch
oil
level
gauge
and
water
drain
plug
Take
care
not
to
overtighten
the
oil
nIter
or
leakage
will
occur
Fill
the
engine
and
gearbox
to
the
correct
levels
with
recommended
lubricant
and
refill
the
cooling
system
Adjust
the
ignition
timing
and
carburettor
as
described
in
the
appro
priate
sections
17
Page 51 of 171
other
end
of
the
tube
into
a
clean
container
partly
filled
with
brake
fluid
Top
up
the
master
cylinder
reservoir
with
recommended
fluid
and
open
the
bleed
screw
approximately
three
quarters
of
a
turn
Depress
the
clutch
pedal
slowly
and
hold
it
completely
down
re
tighten
the
bleed
screw
and
allow
the
pedal
to
return
slowly
Repeat
the
operation
until
the
fluid
emerging
from
the
tube
is
free
from
air
bubbles
It
should
be
noted
that
assistance
will
be
required
when
carrying
out
bleeding
operations
as
not
only
must
the
fluid
entering
the
glass
container
be
watched
but
also
the
clutch
pedal
has
to
be
operated
and
the
reservoir
topped
up
frequently
throughout
the
procedure
When
the
fluid
is
completely
free
from
air
bubbles
the
bleed
screw
should
be
retightened
on
a
down
stroke
of
the
pedal
Finally
remove
the
bleed
tube
and
replace
the
dust
cap
TechnIcal
Data
Outch
type
Pressure
spring
Free
length
Fitted
length
and
load
Side
distortion
Permissible
deterioration
of
spring
force
Outch
release
levers
Oearance
between
release
bearing
and
diaphragm
spring
release
levers
Height
between
diaphragm
spring
and
flywheel
Height
between
release
levers
and
flywheel
Outch
driven
plate
Outer
diameter
Inner
diameter
Thickness
of
facingS
Total
friction
area
TIrickness
of
clutch
plate
Free
Compressed
No
of
torsion
springs
Permissible
minimum
depth
of
rivet
heads
from
facing
surface
Permissible
run
out
of
clutch
facing
P
rmissible
free
play
of
splines
Outch
pedal
1400
and
1600cc
models
Pedal
height
in
the
rest
position
P
da1
free
stroke
P
da1
effort
Master
cylinder
Diameter
Maximum
clearance
between
piston
and
cylinder
Pressure
plate
Permissible
refacing
limit
Outch
pedal
180Occ
models
P
da1
height
Play
at
clevis
pin
Full
stroke
P
da1
effort
50
Diaphragm
spring
or
coil
spring
52
3mm
2
059
in
29
2mm
44
2kg
1
149
in
197
t
4
4
lb
5mm
per
IOOmm
0
2in
per
3
94
in
15
1
2
I
4mm
0
047
0
055
in
44
t
Imm
1
732
t
0
039
in
50
5
t
0
05mm
1
988
t
0
0197
in
200mm
7
87
in
130mm
5
12in
3
5mm
0
140in
362
sq
cm
56
11
sq
in
8
6
9
0mm
0
3386
o
3543in
7
65
7
95mm
0
3012
o
3130in
6
O
3mm
0
0118
in
0
5mm
0
0197
in
0
4mm
0
0157
in
182mm
7
17in
R
H
D
207mm
8
15in
L
H
D
25mm
0
984in
15kg
33
lb
15
87mm
0
625in
O
13mm
0
005lin
Imm
0
0394in
175mm
6
89in
1
5mm
0
04
0
20in
135mm
5
3lin
10
5kg
23Ib
Page 70 of 171
The
standard
width
of
the
side
bearings
is
20
0mm
0
7874
this
width
must
be
measured
before
attempting
to
calculate
the
thickness
of
the
adjusting
shims
Use
a
dial
gauge
and
surface
plate
to
ohtain
the
measurement
Place
a
weight
of
approximately
2
5
kg
5
5
lb
on
the
bearing
to
obtain
steady
readings
Install
the
differential
cage
assembly
in
the
carrier
Fit
the
sckcted
shims
and
O
rings
into
both
differential
side
bearing
covers
and
install
the
covers
in
the
carrier
using
the
special
tool
ST
33720000
Fig
G
16
l
Make
sure
that
the
side
bearing
outer
races
are
not
damaged
by
the
roller
Measure
the
backlash
between
the
teeth
of
the
crown
wheel
and
drive
pinion
with
a
dial
gauge
as
shown
in
Fig
G
I
Sct
the
dial
gauge
to
0
10
f
O
mm
0
004
0
008
in
I
If
the
backlash
is
less
than
the
specifIed
value
move
he
left
side
adjusting
shim
to
the
right
side
and
vice
versa
if
the
backlash
exceeds
the
specified
figure
Check
that
the
run
out
at
the
rear
of
the
crownwheel
does
not
excecd
O
OSmm
0
002
in
for
the
1800ce
model
or
O
08mm
0
003
in
for
the
1400
Check
the
drive
pinion
turning
torque
Thc
turning
torque
should
be
higher
by
I
3
kg
em
compared
with
the
turning
torque
obtained
before
fitting
the
differential
cage
in
the
carrier
The
higher
value
can
be
provided
if
necessary
by
dmnging
the
jde
cover
shims
Note
howcver
that
any
decrease
or
increase
in
the
thickncss
of
shims
wjJl
alter
tht
budlush
between
the
teeth
of
the
crownwhee1
and
pinion
Check
the
tooth
contact
pat
tern
of
the
crown
wheel
and
pinion
as
described
under
the
appropriate
heading
DIFFERENTIAL
Installation
Secure
the
differential
carrier
on
the
rear
suspension
mem
ber
using
the
four
bolts
and
washers
Fit
the
differential
mounting
member
to
thc
mounting
holes
by
pushing
it
forwards
with
a
suitable
lever
Fig
G
18
Tighten
the
nuts
to
a
torque
reading
of
8
5
kgm
61
5
Ib
ft
Tighten
the
bolts
attaching
the
gear
carrier
to
the
suspension
member
to
a
torque
reading
of
6
7
kg
36
5Ilb
ft
t
The
rcmainder
of
the
installation
operations
are
a
reversal
of
thc
removal
procedure
Fill
the
differential
with
the
correct
quantity
of
recommended
oil
DIFFERENTIAL
CARRIER
Removal
and
Dismantling
Estate
car
alld
Vanl
To
remove
the
differential
carrier
disconnect
and
remove
rhe
propeller
shaft
as
previously
described
and
remove
the
two
rear
axle
shafts
as
described
in
the
section
REAR
AXLL
With
draw
the
nuts
securing
the
differential
and
remove
the
carrier
from
the
rear
axle
Mount
the
unit
on
the
special
attachment
as
shown
in
Fig
G
19
and
carry
out
a
preliminary
check
before
dismantling
Oleck
the
tooth
contact
of
the
crownwheel
and
pinion
by
applying
lead
oxide
to
three
or
four
teeth
of
the
crownwheel
Turn
the
crown
wheel
several
times
to
obtain
an
impression
of
the
tooth
contact
pattern
Check
the
backlash
between
the
teeth
of
the
crownwheel
and
pinion
with
a
dial
gauge
Hold
the
drive
pinion
with
one
hand
and
move
the
crown
wheel
backwards
and
forwards
to
check
that
the
backlash
is
Io
ithin
thL
speL
ified
limits
Shims
and
adjusting
washers
must
bL
altered
if
the
tooth
con
tact
pattern
and
backlash
is
incorre
L
the
neL
cssary
details
for
these
operations
can
be
found
towards
the
end
of
this
section
under
the
appropriate
he
Jdjn
s
Fil1JJly
mark
the
bearing
caps
with
a
hammer
and
punch
to
ensure
correct
t1ignment
on
re
assembly
Remove
the
bearing
caps
nd
withdraw
the
differ
ntial
cage
make
a
note
of
the
left
and
right
hand
positions
so
h
Jt
the
bearing
caps
and
outer
race
can
be
re
assembled
in
their
original
positions
Withdraw
the
side
beJrings
with
the
s
cjal
puller
as
shown
in
Fig
G
20
taking
care
not
to
catch
the
edge
of
the
bearing
inner
races
Place
the
assembly
in
a
vice
and
detach
the
crownwheel
by
slackening
the
retaining
bolts
in
a
diagonal
patter
Fig
G
lf
Drive
out
th
pinion
shaft
lock
pin
from
left
to
right
using
a
suitable
punch
or
special
tool
ST
23520000
Fig
C
22
With
draw
the
pinion
shaft
and
take
out
the
pinions
side
gears
and
thrust
washers
Store
the
gears
and
thrust
washers
so
that
they
can
be
assembled
in
their
original
positions
Check
the
initial
turning
torque
of
the
drive
pinion
with
the
preload
gauge
ST
3190000
and
measure
the
height
of
the
drive
pinion
with
the
special
gauge
ST
31941000
Compare
the
figures
obtained
with
those
givcn
in
Technical
Data
at
the
end
of
this
section
Hold
the
drive
pinion
with
the
speciaJ
wrench
ST
3
J
530000
as
shown
in
Fig
C
23
and
unscrew
the
drivc
pinion
nut
then
pull
out
the
drive
pjnion
flange
Tap
the
drive
pinion
assembly
to
the
rear
with
a
plastic
mallet
and
withdraw
it
together
with
the
rear
bearing
inner
race
bearing
spacer
and
adjusting
washer
Remove
and
discard
the
oil
seal
and
withdraw
thc
front
bearing
inner
race
Drive
out
the
outer
races
of
the
front
and
rear
bearings
with
a
suitable
drift
Fig
G
25
The
drive
pinion
rear
bearing
inncr
race
can
be
removed
with
the
special
tool
ST
300310000
as
shown
in
Fig
G
24
DIFFE
l
ENTlAL
Inspection
Clean
all
components
thoroughly
and
examine
for
signs
of
wear
or
damage
Check
the
teeth
of
the
crownwhcel
and
pinion
for
scoring
and
hipping
Ii
should
be
noted
that
the
crownwhecl
and
pinion
are
supplied
as
a
matched
set
and
if
either
part
is
damaged
the
complete
set
must
be
replaced
Examine
the
inner
faces
of
the
side
gears
and
seats
on
the
differential
case
Inspect
the
bearing
races
and
rollers
and
replace
them
if
necessary
Small
defects
on
the
faces
of
the
thrust
washers
can
be
corrected
using
emery
cloth
however
if
the
clearance
between
side
gear
and
thrust
washer
exceeds
0
1
O
2mm
0
0039
0
0079
in
it
ill
be
necessary
to
replace
the
washer
Various
sizes
of
washers
are
available
and
the
thicknesses
arc
detailed
under
the
heading
DIFFERENTIA
L
GEAR
CAGE
Assembling
69
Page 92 of 171
SteerIng
DEsn
IPTION
S
i
EERlNG
MaintenaDce
STEERING
WHEEL
AND
STEERING
GEAR
Removal
and
Installation
STEERING
GEAR
Dismantling
STEERING
GEAR
Inspection
and
Adjustment
DESCRIPTION
A
worm
and
recirculating
ball
type
steering
system
is
fitted
to
the
vehicle
the
component
parts
of
the
steering
gear
are
shown
in
Fig
K
I
The
steering
linkage
consists
of
the
centre
tie
rod
pitman
ann
idler
arm
outer
tie
rods
and
the
knuckle
arms
as
shown
in
Fig
K
2
A
collapsible
steering
column
assembly
can
be
fitted
to
the
vehicle
to
protect
the
driver
from
injury
in
a
head
on
collision
Details
of
this
type
of
assembly
are
given
under
the
appropriate
heading
STEERING
Maintenance
O1eck
the
oil
level
in
the
steering
box
every
10
000
km
6
000
miles
and
top
up
with
recommended
lubricant
if
necessary
Grease
the
steering
linkage
every
50
000
km
30
OOO
miles
It
will
be
necessary
to
replace
the
plug
in
the
tie
rod
ball
joints
with
a
grease
nipple
for
this
operation
as
previously
described
in
the
section
FRONT
SUSPENSION
Use
a
grease
gun
to
completely
replace
the
old
grease
with
new
grease
making
SUfe
that
the
grease
is
not
forced
from
under
the
cover
clamp
if
a
high
pressure
gun
is
used
STEERING
WHEEL
AND
STEERING
GEAR
Removal
1
Take
out
the
retaining
bolts
and
remove
the
horn
ring
remove
the
steering
wheel
nut
Fig
K
3
and
pull
off
the
steering
wheel
The
special
tool
ST
27180000
should
be
used
if
available
2
Disconnect
the
battery
leads
remove
the
steering
column
shell
covers
and
the
turn
signal
and
lighting
switch
assembly
3
On
vehicles
fitted
with
steering
column
gear
change
assemblies
the
gear
lever
must
be
removed
from
the
control
rod
assembly
Unscrew
the
retaining
boltg
and
disconnect
the
gear
lever
4
Remove
the
bolts
from
the
steering
column
upper
clamp
Fig
K
4
and
the
bolts
holding
the
lower
plate
Fig
K
5
5
If
the
vehicle
is
fitted
with
steering
column
gear
change
remove
the
cotterpin
from
the
trunnion
and
detach
the
gearchange
rod
and
selector
rod
from
the
change
lever
and
selector
lever
STEERING
GEAR
Assembly
and
Adjustment
COLLAPSIBLE
STEERING
COLLAPSIBLE
STEERING
Removal
and
Inspection
COLLAPSIBLE
STEERING
Installation
STEERING
LINKAGE
6
Remove
the
bolts
securing
the
steering
gear
housing
to
the
car
body
Fig
K
6
and
pull
the
steering
gear
towards
the
engine
compartment
Remove
the
gearchange
control
from
the
steering
gear
assembly
as
described
in
the
section
GEARBOX
STEERING
WHEEL
AND
STEERING
GEAR
Installation
Installation
is
a
reversal
of
the
removal
procedure
When
the
installation
has
been
completed
make
sure
that
the
steering
wheel
can
be
turned
smoothly
and
is
correctly
aligned
The
free
travel
of
the
steering
wheel
should
be
between
2S
30mm
0
9B
1
18
in
Tighten
the
steering
wheel
locknut
to
a
torque
reading
of
4
0
5
0
kgm
29
36Ib
ft
and
the
steering
column
upper
clamp
and
plate
bolts
to
a
torque
reading
of
1
3
1
8
kgm
94
1
3
Ib
ft
Ensure
that
the
steering
box
is
topped
up
to
the
correct
level
with
recommended
lubricant
STEERING
GEAR
Dismantling
Remove
the
pitman
arm
retaining
nut
and
pull
out
the
arm
The
special
puller
ST
27140000
should
be
used
if
available
Remove
the
drain
plug
from
the
steering
gear
housing
and
drain
the
oil
Slacken
the
adjusting
screw
nut
and
turn
the
sector
shaft
adjusting
screw
a
few
turns
in
the
anti
clockwise
direction
Remove
the
sector
shaft
cover
retaining
bolts
and
pull
the
sector
shaft
cover
and
sector
shaft
from
the
gear
housing
Fig
K
7
Remove
the
bolts
securing
the
column
jacket
to
the
gear
housing
and
carefully
withdraw
the
main
column
jacket
assembly
from
the
gear
housing
Fig
K
B
NOTE
The
ball
must
not
be
allowed
to
run
to
either
end
of
the
worm
or
the
ends
of
the
ball
guides
will
be
damaged
Pull
the
column
assembly
from
the
column
jacket
Remove
the
sector
shaft
oil
seal
and
take
out
the
rear
bearing
outer
race
from
the
column
jacket
with
a
suitable
puller
Withdraw
the
bearing
inner
races
from
the
front
and
fear
worm
bearings
Remove
the
column
shaft
bearing
91
Page 94 of 171
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
Page 142 of 171
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
Page 154 of 171
Accelerator
pump
Piston
diameter
Pump
discharge
Outer
hole
position
Middle
hole
position
Inner
hole
position
Pump
nozzle
diameter
Main
nozzle
diameter
Primary
Secondary
14
0
mm
0
551
in
0
2
cc
per
stroke
0
4
cc
per
stroke
0
6
cc
per
stroke
0
5
mm
0
020
in
2
3
mm
0
0906
in
2
8
mm
0
110
in
Throttle
valve
fully
closed
angle
Primary
10
degrees
Secondary
20
degrees
Idling
opening
5
degrees
approx
Choke
valve
fully
closed
angle
10
degrees
Throttle
opening
at
full
choke
13
5
degrees
FUEL
PUMP
Type
Delivery
Electric
1400
cc
in
one
minute
Emission
control
system
Air
pump
bracket
to
cylinder
head
nut
Adjusting
bar
to
bracket
bolt
Air
pump
to
bracket
bolt
Air
pump
to
adjusting
bar
nut
Anti
backfrre
bracket
to
rocker
cover
0
4Q
0
65
kgm
2
94
7
lb
ft
Anti
backfire
valve
to
bracket
0
4Q
O
65
kgm
2
94
7
lb
ft
Sensing
hose
clamp
to
rocker
cover
0
4Q
0
65
kgm
2
M
7
Ib
ft
Air
gallery
to
exhaust
manifold
plug
5
Q
6
0
kgm
36
243
4lb
ft
Check
valve
to
air
gallery
9
0
10
5
kgm
65
1
75
9Ib
ft
1
6
2
4
kgm
I
1
6
17
4Ib
ft
1
6
2
4
kgm
I
1
6
17
4Ib
ft
1
6
2
4
kgm
I
1
6
17
4
lb
ft
1
6
2
4
kgm
11
6
17
4Ib
ft
Front
SuspensIon
SteerIng
Description
Steering
Maintenance
Wheel
hub
and
bearing
Stabilizer
Spring
and
strut
assembly
Transverse
link
and
lower
ball
joint
Suspension
member
Front
wheel
alignment
Steering
wheel
and
column
Rack
and
pinion
and
tie
rod
Collapsible
steering
DESCRIPTION
The
front
suspension
is
of
the
strut
type
with
the
coil
spring
and
hydraulic
damper
units
mounted
on
the
crossmember
and
transverse
link
assembly
See
Fig
C
I
Vertical
movement
of
the
suspension
is
controlled
by
the
strut
assembly
Forward
and
rearward
movement
is
absorbed
by
compression
rods
6
and
side
movement
controlled
by
the
transverse
links
Front
suspension
servicing
procedures
are
similar
to
those
given
for
vehicle
fitted
with
L14
Ll6
and
LIB
engines
and
can
be
carried
out
by
reference
to
the
instructions
given
in
the
appropriate
section
Camber
and
castor
angles
are
preset
and
cannot
be
adjusted
and
a
check
must
be
made
for
signs
of
damage
to
the
suspension
system
if
the
angles
do
not
confonn
to
the
figures
given
in
Technical
Data
The
steering
is
of
the
direct
acting
rack
and
pinion
type
See
Fig
C
2
A
rubber
coupling
which
absorbs
vibration
and
two
universal
join
ts
are
incorpora
ted
between
the
steering
wheel
and
gear
assembly
The
collapsible
type
of
steering
column
assembly
Fig
C3
is
an
optional
fitting
A
full
description
of
this
type
of
assembly
i
given
in
the
Steering
section
for
L14
L16
and
L18
engines
STEERING
Maintenance
The
steering
system
should
be
lubricated
every
two
years
or
50
000
km
30
000
miles
whichever
comes
fIrst
A
lithium
base
multipurpose
grease
must
be
used
for
the
rack
and
pinion
and
rack
and
tie
rod
joints
The
plug
on
the
steering
gear
housing
should
be
removed
and
a
grease
nipple
fitted
so
that
the
recommended
quantity
of
10
to
15
gram
0
35
to
0
53
oz
of
grease
can
be
injected
Remove
the
grease
nipple
and
replace
the
plug
when
lubrication
is
completed
The
grease
reservoir
on
the
tube
side
should
be
replenished
when
the
level
of
grease
falls
to
approximately
one
third
ofits
capacity
WHEEL
HUB
AND
BEARING
Removal
and
Installation
Wheel
hub
and
bearing
servicing
procedures
are
similar
to
those
previously
given
for
vehicles
fitted
with
L14
LI6
and
LIB
engines
S23