transmission 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 6 of 171
EngIne
INTRODUCTION
ENGINE
Removal
ENGINE
DismantUng
ENGINE
Inspection
and
Overhaul
VALVES
VALVE
GUIDES
VALVE
SEAT
INSERTS
CAMSHAFT
AND
CAMSHAFT
BEARINGS
Checking
CYliNDER
BLOCK
PtSTONS
AND
CONNECTING
RODS
INTRODUCTION
The
1400
1600
cc
and
1800
cc
engines
are
four
cylinder
in
line
units
with
a
single
overhead
camshaft
and
fully
balanced
five
bearing
crankshaft
The
valves
are
operated
through
rockers
which
are
directly
activated
by
the
earn
mechanism
The
crankshaft
is
a
special
steel
forging
with
the
centre
main
bearing
equipped
with
thrust
washers
to
take
up
the
end
thrust
of
the
crankshaft
The
special
aluminium
pistons
are
of
the
strut
construction
to
control
thermal
expansion
and
have
two
compression
rings
and
one
combined
oil
ring
The
gudgeon
pins
have
special
hollow
steel
shafts
and
are
a
fully
floating
fit
in
the
pistons
and
a
press
fit
in
the
connecting
rods
The
aluminium
alloy
cylinder
head
contains
wedge
type
combustion
chambers
and
is
fitted
with
aluminium
bronze
valve
seats
for
the
intake
valves
and
heat
resistant
steel
valve
seats
for
the
exhaust
valves
The
cast
iron
camshaft
is
driven
by
a
double
row
roller
chain
from
the
crankshaft
pulley
The
engine
is
pressure
lubricated
by
a
rotor
type
oil
pump
which
draws
oil
through
an
oil
strainer
into
the
pump
housing
and
then
forces
it
through
a
full
flow
oil
filter
into
the
main
oil
gallery
ENGINE
Removal
Place
alignment
marks
on
the
bonnet
and
hinges
remove
the
bonnet
from
the
vehicle
2
Drain
the
cooling
system
and
engine
and
transmission
lubricant
Remove
the
radiator
grille
3
Discon
ect
the
battery
cables
and
lift
out
the
battery
4
Detach
the
upper
and
lower
radiator
hoses
remove
the
radiator
mounting
bolts
and
lift
the
radiator
away
from
the
vehicle
The
torque
converter
c
jng
pipes
must
be
disconnected
from
the
radiator
on
vehicles
fitted
with
automatic
transmission
S
Remove
the
COOling
fan
and
pulley
disconnect
the
fuel
pipe
from
the
fuel
pump
and
the
heater
hoses
from
the
engine
attachments
6
Disconnect
the
accelerator
control
linkage
and
the
choke
CRANKSHAFT
AND
MAIN
BEARINGS
CAMSHAFT
AND
SPROCKET
FLYWHEEL
ENGINE
Assembling
VALVE
CLEARANCES
Adjusting
ENGINE
LUBRICATION
SYSTEM
OIL
PUMP
OIL
FILTER
CHANGING
THE
ENGINE
OIL
cable
from
the
carburettor
7
Disconnect
the
wirings
from
the
starter
alternator
ignition
coil
oil
pressure
switch
and
temperature
sender
unit
8
Remove
the
clutch
slave
cylinder
Fig
A
2
and
its
return
spring
9
Disconnect
the
speedometer
cable
and
withdraw
the
plug
connector
from
the
reversing
light
switch
10
Disconnect
the
shift
rods
and
seJector
rods
and
remove
the
cross
shaft
assembly
as
described
in
the
section
Gear
box
II
Disconnect
the
front
exhaust
pipe
from
the
exhaust
manifold
disconnect
the
centre
pipe
from
the
rear
pipe
and
remove
the
front
pipe
pre
muffler
and
centre
pipe
assembly
12
Disconnect
the
propeUer
shaft
flange
from
the
companion
flange
from
the
gear
carrier
13
Jack
up
the
gearbox
slightly
and
remove
the
rear
engine
mounting
bracket
bolts
remove
the
mounting
cross
member
and
handbrake
cable
c1amp
14
Remove
the
bolts
securing
the
front
engine
mounting
brackets
to
the
crossmember
15
Attach
lifting
cable
or
chains
to
the
hooks
installed
at
the
front
and
rear
of
the
cylinder
head
Lower
the
jack
under
the
gearbox
and
carefully
lift
and
tilt
the
engine
and
gearbox
unit
Withdraw
the
engine
and
gearbox
from
the
compartment
making
sure
that
it
is
guided
past
the
accessories
installed
on
the
body
ENGINE
Dismantling
Remove
the
engine
as
previously
described
and
carefully
clean
the
exterior
surfaces
Cbeck
for
signs
of
fuel
oil
or
water
leaks
past
the
cylinder
head
and
block
Remove
the
air
cleaner
alternator
distributor
and
starter
motor
Plug
the
carburettor
air
horn
and
distributor
hole
to
prevent
the
ingress
of
foreign
matter
Remove
the
gearbox
from
the
engine
drain
the
engine
oil
and
coolant
Mount
the
engine
in
a
suitable
stand
the
special
engine
attachment
ST05260001
and
engine
ST0501SOO0
should
be
used
if
available
Fig
A
3
5
Page 23 of 171
TechnIcal
Data
L
14
16
and
18
Engine
GENERAL
SPECIFICATIONS
Cylinders
Displacement
L14
L16
L18
Bore
and
stroke
L14
L16
Ll8
Compression
ratio
L14
L16
single
carburettor
L16
SU
twin
carburettor
L18
single
carburettor
Ll8
SU
twin
carburettor
Valve
arrangement
Firing
order
e
idling
speed
Engine
idling
speed
with
automatic
transmission
Oil
pressure
Hot
at
2000
r
p
m
Valve
clearance
Hot
Intake
Exhaust
0
25
mm
0
0098
in
0
25
mm
0
0098
in
Valve
clearance
Cold
Intake
Exhaust
Va
head
diameter
L14
Intake
Exhaust
Vahoe
head
diameter
L16
Intake
Exhaust
0
20
mm
0
0079
in
0
20
mm
0
0079
in
38
mm
1
5361
in
33
mm
1
2992
in
42
mm
1
6535
in
33
rom
1
2992
in
Valve
head
diameter
L18
Intake
Exhaust
42
mm
1
6535
in
35
mm
1
3780
in
Valve
stem
diameter
Intake
7
965
7
980
mm
0
3136
0
3142
in
Exhaust
7
945
7
960
mm
0
3128
0
3134
in
Valve
length
L14
Intake
Exhaust
115
6
115
9mm
4
551
4
562in
115
7
116
0
mm
4
555
4
567
in
Valve
length
L16
LIB
Intake
114
9
115
2
mm
4
524
4
535
in
Exhaust
115
7
116
0
mm
4
555
4
567
in
22
4
in
line
1428
cc
87
1
cu
in
1595
cc
97
3
cu
in
1770
cc
108
0
cu
in
83
x
66
mm
3
27
x
2
60
in
83
x
73
7
mm
3
27
x
2
90
in
85
x
7B
mm
3
35
x
3
07
in
9
0
8
5
9
5
8
5
9
5
Overhead
valve
I
3
4
600
r
p
m
single
carburettor
650
r
p
m
twin
carburettor
650
r
p
m
single
carburettor
700
r
p
m
twin
carburettor
3
5
4
0
kg
sq
cm
50
57Ib
sq
in
VALVES
Valve
lift
Single
carburettor
Valve
lift
Twin
carburettor
10
0
mm
0
3946
in
10
5
mm
0
413
in
Valve
spring
free
length
LI4
Ll4
Intake
Ll4
Exhaust
outer
L14
Exhaust
inner
Valve
sprin8
free
length
L16
LIB
Outer
Inner
49
0
mm
1
929
in
49
98
mm
1
968
in
44
85
mm
1
766
in
49
98
mm
1
968
in
44
85
mm
1
766
in
59
0
mm
2
393
in
10
6
mm
0
417
in
Valve
guide
length
Valve
guide
height
from
head
surface
Valve
guide
diameter
inner
Intake
8
018
Exhaust
8
018
Valve
guide
diameter
outer
Intake
12
034
Exhaust
12
034
Valve
guide
to
stem
clearance
Intake
Exhaust
Valve
seat
width
L14
Intake
Exhaust
Valve
seat
width
L16
LIB
Intake
Exhaust
8
000
mm
0
3154
0
3150
in
clia
8
000
mm
0
3154
0
3150
in
clia
12
023
mm
0
4738
0
4733
in
clia
12
023
mm
0
4738
0
4733
in
clia
1
8
mm
1
1024
in
I
7
mm
1
0630
in
I
4
mm
0
0551
in
1
3
mm
0
0512
in
0
020
0
053
mm
0
0008
0
0021
in
0
040
0
073
mm
0
0016
0
0029
in
Page 28 of 171
The
thermostat
can
be
tested
by
suspending
it
with
a
thermometer
in
a
container
ftlled
with
water
Heat
the
water
gradually
and
stir
it
to
obtain
a
uniform
temperature
Maintain
a
constant
check
of
the
temperature
and
make
sure
that
neither
the
thermostat
or
thermometer
touch
the
sides
of
the
container
or
false
readings
will
be
obtained
The
thermostat
should
begin
to
open
at
a
temperature
of
820C
1
50C
179
60F
2
70Fj
and
should
be
fully
open
with
a
maximum
valve
lift
of
8
mm
0
315
in
at
a
temperature
of
950C
2030F
When
installing
the
thermostat
apply
adhesive
to
both
sides
of
the
gasket
before
refitting
the
water
outlet
elbow
RADIATOR
Removal
Drain
the
cooling
system
as
previously
described
and
remove
the
front
grille
2
Disconnect
the
radiator
upper
hose
lower
hose
and
hose
to
the
reservoir
tank
3
Remove
the
radiator
securing
bolts
and
lift
out
the
radiator
Fig
B
4
It
should
be
noted
that
cars
fitted
with
automatic
transmission
incorporate
a
transmission
oil
cooler
which
must
be
disconnected
Installation
is
a
reversal
of
the
removal
procedure
refill
the
system
as
previously
described
FLUID
COUPLING
The
water
pump
is
equipped
with
a
fluid
coupling
on
vehicles
fitted
with
an
air
conditioner
The
fluid
coupling
Limits
the
maximum
fan
speed
to
approximately
3000
r
p
ro
and
eliminates
noise
and
loss
of
power
at
high
engine
speeds
A
fault
in
the
coupling
may
be
caused
by
the
entry
of
foreign
matter
If
a
fault
developes
the
oupling
must
be
removed
and
dismantled
and
the
interior
cleaned
by
washing
in
solvent
The
condition
of
the
seal
and
bearing
must
be
care
fully
checked
and
the
coupling
replaced
if
the
latter
items
have
become
blackened
If
oil
leaks
occur
it
will
be
necessary
to
replace
the
water
pump
assembly
with
the
coupling
After
cleaning
the
unit
refill
with
11
5
cc
silicon
oil
using
a
suitable
syringe
TechnIcal
Data
Radiator
Radiator
cap
working
pressure
Radiator
core
heightxwidth
x
thickness
1400
and
1600
cc
engines
510
body
1600
and
1800
cc
engines
610
body
Corrugated
fin
type
0
9
kg
sq
cm
13Ib
sq
in
280x488x38mm
I
LOx
19
2x
1
49
in
360x502x32mm
l4
2x19
8x1
26
in
Thermostat
valve
opening
temperature
Standard
B20C
l
BOOF
Cold
climates
880C
1900F
Tropical
climates
76
50C
l700F
Max
valve
lift
Cooling
system
capacity
With
heater
Without
heater
Cooling
system
capacity
With
heater
Above
8
mm
0
31
in
6
8litres
1
75
US
gall
1
5
Imp
gall
6
4litres
1
75
US
gall
1
375
Imp
gall
1600
and
1800
cc
engines
610
body
6
5litres
l
7
US
gall
1
375
Imp
gall
6
0
Iitres
1
625
US
gall
1
375
Imp
gall
Without
heater
27
Page 40 of 171
FLOAT
LEVEL
Adjustment
A
constant
fuel
level
in
the
float
chamber
is
maintained
by
the
float
and
ball
valve
Fig
D
12
If
the
fuel
level
is
not
in
accordance
with
the
level
gauge
line
it
will
be
necessary
to
care
fully
bend
the
float
seat
until
the
float
upper
position
is
correctly
set
Fig
D
13
The
clearance
H
between
the
valve
stem
and
float
seat
should
be
1
0
mm
0
039
in
with
the
float
fully
lifted
as
shown
Adjustment
can
be
carried
out
by
carefully
bending
the
float
stopper
Fig
D
14
until
the
required
clearance
is
obtained
SU
TWIN
CARBURETTORS
Adjustments
It
is
essential
that
the
two
carburettors
are
correctly
adjusted
if
peak
m3l1ce
and
economical
fuel
consumption
is
to
be
realized
Incorrect
carburettor
a
ljustment
will
have
an
adverse
affect
during
idling
and
on
acceleration
etc
Carburettor
synchronization
and
idling
adjustment
Run
the
engine
until
it
reaches
its
normal
operating
temperature
remove
the
air
cleaner
and
slacken
the
front
and
rear
throttle
adjusting
screws
the
balance
screw
and
the
fast
idling
setting
screw
Make
sure
that
the
front
and
rear
throttle
shafts
are
not
connected
Fully
tighten
the
idling
adjustment
nuts
of
the
front
and
rear
carburettors
Fig
D
15
the
back
off
each
nut
by
an
equal
amount
and
by
one
and
a
half
to
two
tUrns
Screw
in
the
front
and
rear
throttle
adjusting
screws
by
a
few
turns
and
start
the
engine
Allow
the
engine
to
reach
its
normal
operating
temperature
before
proceding
to
the
next
stage
Adjust
the
front
and
rear
throttle
adjusting
screws
until
the
engine
speed
is
reduced
to
approximately
600
700
r
p
m
The
engine
should
turn
over
smoothly
and
consistently
Apply
a
flow
meter
to
the
front
carburettor
air
cleaner
flange
and
turn
the
adjustment
screw
on
the
flow
meter
so
that
the
upper
end
of
the
float
in
the
glass
tube
is
in
line
with
the
scale
Uft
off
the
flow
meter
and
apply
it
to
the
rear
carburettor
air
cleaner
flange
without
altering
the
setting
of
the
flow
meter
adjusting
screw
If
the
position
of
the
flow
meter
float
is
not
aligned
with
the
scale
adjust
the
rear
carburettor
throttle
adjusting
screw
to
align
the
float
with
the
mark
on
the
scale
With
the
carburettor
flow
correctly
adjusted
turn
the
idling
adjustment
nuts
of
both
carburettors
approximately
1
8
of
a
turn
either
way
to
obtain
a
fast
and
stable
engine
speed
Both
nuts
must
be
turned
by
an
equal
amount
Back
off
the
front
and
rear
throttle
adjusting
screws
and
adjust
the
engine
speed
to
the
specified
value
of
650
r
p
m
for
the
standard
engine
or
700
r
p
m
with
vehicles
fitted
with
automatic
transmission
Make
sure
that
the
air
flow
of
both
carburettors
remains
unchanged
Screw
in
the
balance
screw
until
the
screw
head
contacts
the
throttle
shafts
without
changing
the
idling
speed
setting
Move
the
throttle
connecting
shaft
and
accelerate
the
engine
a
few
times
then
check
that
the
idling
speed
is
unchanged
Turn
the
fast
idle
setting
screw
to
increase
the
engine
speed
to
approximately
1500
r
p
m
and
recheck
with
the
flow
meter
that
the
air
flow
for
both
carburettors
is
correctly
matched
If
the
air
flow
is
uneven
it
will
be
necessary
to
readjust
the
balance
screw
Finally
back
off
the
fast
idle
setting
screw
Fig
D
16
and
decrease
the
engine
speed
Apply
the
flow
meter
to
the
carburettors
to
confirm
that
the
float
positions
are
even
Re
adjust
if
necessary
by
means
of
the
throttle
adjusting
screws
Stop
the
engine
and
fit
the
air
cleaner
SU
TWIN
CARBURETTOR
Dismantling
Piston
and
suction
chamber
Dismantling
Unscrew
the
plug
and
withdraw
the
piston
damper
Fig
D
17
Remove
the
four
set
screws
and
lift
out
the
suction
chamber
withdraw
the
spring
nylon
washer
and
the
piston
Take
care
not
the
damage
the
jet
needle
and
the
interior
of
the
suction
chamber
Do
not
remove
the
jet
needle
from
the
piston
unless
absolutely
necessary
If
a
replacement
is
to
be
fitted
ensure
that
the
shoulder
of
the
needle
is
flush
with
the
lower
face
of
the
piston
This
operation
can
be
accomplished
by
holding
a
strai
edge
over
the
shoulder
of
the
needle
and
then
tightening
the
set
screw
as
shown
in
Fig
D
18
Wash
the
suction
chamber
and
piston
with
dean
solvent
and
dry
with
compressed
air
Lubricate
the
piston
rod
with
a
light
oil
Do
NOT
lubricate
the
large
end
of
the
piston
or
the
interior
of
the
suction
chamber
NOZZLE
Dismantling
The
nozzle
See
Fig
D
19
can
be
removed
quite
easily
but
should
not
be
dismantled
unless
absolutely
necessary
as
reassembly
of
the
nozzle
sleeve
washer
and
nozzle
sleeve
set
screw
is
an
extremely
intricate
operation
To
remove
the
nozzle
detach
the
connecting
plate
from
the
nozzle
head
pulling
lightly
on
the
starter
lever
to
ease
the
operation
Loosen
the
retaining
clip
take
off
the
fuel
line
and
remove
the
nozzle
Be
careful
not
to
damage
either
the
jet
needle
oc
the
nozzle
Remove
the
idle
adjusting
nut
and
spring
The
nozzle
sleeve
can
be
removed
if
necessary
by
taking
out
the
set
screw
but
as
previously
stated
should
not
be
dismantled
unless
absolutely
necessary
SU
TWIN
CARBUREfTOR
Assembly
Assemble
the
piston
assembly
into
position
but
do
not
fill
with
damper
oil
Assemble
the
nozzle
sleeve
washec
and
set
screw
by
temporarily
tightening
the
set
screw
Set
the
piston
to
its
fully
closed
position
and
insert
the
nozzle
until
it
contacts
the
nozzle
sleeve
When
the
nozzle
jet
contacts
the
jet
needle
the
nozzle
sleeve
must
be
slightly
adjusted
so
that
it
is
at
right
angles
to
the
centre
axis
and
positioned
to
leave
the
nozzle
jet
clear
of
the
jet
needle
Raise
the
piston
without
disturbing
the
setting
and
allow
it
to
drop
The
piston
should
drop
smoothly
until
the
stop
pin
strikes
the
venturi
with
a
liaht
metallic
click
See
below
under
Centering
the
jet
Tighten
the
nozzle
sleeve
set
screw
remove
the
nozzle
install
the
idle
adjustinJ
spring
and
adjusting
nut
on
the
nozzle
sleeve
and
refit
the
nozzle
39
Page 52 of 171
Gearbox
GEARBOX
Removal
GEARBOX
Dismantling
GEARBOX
Inspection
and
Overhaul
GEARBOX
Assembling
THREE
SPEED
GEARBOX
GEARCHANGE
CONTROL
Removal
and
Adjusting
AUTOMATIC
TRANSMISSION
Gearchange
control
linkage
DESCRIPTION
Three
types
of
transmission
are
available
for
the
Datsun
models
covered
by
this
manual
Either
a
three
speed
gearbox
a
four
speed
gearbox
or
three
speed
automatic
transmission
can
be
fitted
The
three
and
four
speed
gearboxes
are
equipped
with
nchromesh
on
all
forward
gears
with
the
three
speed
gearbox
operated
by
a
steering
column
gearchange
system
and
the
four
speed
gearbox
by
a
floor
mounted
gear
lever
Two
types
of
synchromesh
are
used
in
the
four
speed
gearboxes
Either
Borg
Warner
or
Servo
types
may
be
fitted
The
gearboxes
differ
only
in
the
synchromesh
devices
whereby
the
baulk
rings
synchronize
the
coupling
sleeve
with
the
main
shaft
gear
on
the
Warner
gearbox
This
action
is
accomplished
by
a
synchrcrring
on
the
servo
gearbox
THREE
SPEED
GEARBOX
Removal
I
Jack
up
the
vehicle
and
support
it
on
stands
2
Disconnect
the
hand
brake
cable
at
the
equalizer
bracket
Slacken
the
two
exhaust
pipe
centre
clamps
and
turn
the
centre
section
of
the
exhaust
assembly
to
the
left
as
shown
in
Fig
F
2
3
Disconnect
the
propeller
shaft
from
the
rear
axle
drive
flange
by
removing
the
four
securing
bolts
Seal
off
the
gearbox
extension
housing
to
prevent
the
loss
of
oil
and
withdraw
the
shaft
to
the
rear
4
Disconnect
the
speedometer
drive
cable
from
the
adaptor
in
the
gearbox
extension
housing
Fig
F3
S
Disconnect
the
lower
shift
rods
from
the
shift
levers
Fig
F
4
and
remove
the
cross
shaft
assembly
from
the
gearbox
casing
Remove
the
clutch
slave
cylinder
from
the
clutch
housing
Fig
F
5
6
Support
the
engine
with
ajack
positioned
underneath
the
oil
sump
making
sure
that
the
jack
does
not
foul
the
drain
plug
A
block
of
wood
should
be
placed
between
the
sump
and
jack
to
avoid
damaging
the
sump
7
Remove
the
bolts
securing
the
rear
engine
mounting
to
the
crossmember
Position
ajack
under
the
gearbox
and
remove
the
bolts
attaching
the
crossmember
to
the
body
Lower
the
jack
under
the
engine
so
that
the
engine
is
tilted
to
the
rear
Remove
the
starter
motor
and
the
bolts
securing
the
clutch
housing
to
the
engine
Lower
the
jack
slowly
and
withdraw
the
gearbox
towards
the
rear
of
the
vehicle
THREE
SPEED
GEARBOX
Dismantling
Drain
the
gearbox
oil
Remove
the
dust
cover
release
the
retainer
spring
and
remove
the
withdrawal
lever
complete
with
release
bearing
from
the
clutch
housing
See
section
CLUTCH
Remove
the
gearbox
bottom
cover
the
speedometer
drive
pinion
assembly
and
the
rear
extension
housing
Take
out
the
cross
shaft
retaining
rings
and
unscrew
the
nuts
securing
the
operating
lever
lock
pins
Use
a
hammer
and
punch
to
drive
out
the
pins
and
withdraw
both
cross
shafts
Fig
F
6
Remove
the
fr
mt
cover
and
withdraw
the
counter
shaft
Lift
out
the
countersbaft
gear
cluster
together
with
the
needle
roller
bearings
and
spacers
Fig
F
7
Remove
the
reverse
idler
gear
shaft
lock
bolt
and
remove
the
shaft
and
the
idler
gear
Fig
F
B
Drive
out
the
pins
securing
the
selector
forks
to
the
selector
rods
Unscrew
the
interlock
plug
and
remove
the
detent
ball
and
spring
Fig
F
9
Remove
the
first
reverse
speed
and
second
third
speed
selector
rods
and
lift
out
the
selector
forks
Withdraw
the
main
shaft
assembly
and
the
drive
shaft
assembly
from
the
gearbox
See
Fig
F
1O
and
F
11
To
dismantle
the
mainshaft
release
the
circlip
from
the
front
of
the
mainshaft
as
shown
in
Fig
F
12
and
remove
the
second
and
third
speed
synchronizer
hub
and
second
speed
gearwheel
Fig
F
13
Remove
the
circlip
securing
the
speedo
meter
drive
gear
and
withdraw
the
gear
together
with
the
ball
and
spacer
Fig
F
14
Remove
the
mainshaft
bearing
using
a
press
Hold
the
rnainshaft
reverse
gear
and
tap
the
shaft
on
a
piece
of
wood
to
release
the
reverse
gear
assembly
together
with
the
first
speed
gearwheel
GEARBOX
Inspection
and
Overhaul
Oean
all
parts
thoroughly
and
examine
the
gearbox
case
and
extension
housing
for
cracks
If
the
joint
faces
are
burred
or
pitted
it
may
be
necessary
to
replace
the
units
if
repair
cannot
be
carried
out
satisfactorily
Remove
any
adhesive
which
remains
on
the
faces
The
rear
extension
housing
bush
should
be
renewed
if
worn
unevenly
Clean
the
bearings
and
dry
with
compressed
air
taking
care
that
the
bearings
do
not
spin
Turn
the
ball
bearings
to
make
sure
that
they
run
smoothly
and
without
play
Replace
the
needle
bearings
if
worn
or
damaged
in
any
way
It
is
advisable
to
renew
the
needle
roller
bearings
after
they
have
been
installed
for
a
considerable
period
as
it
is
difficult
51
Page 64 of 171
Propeller
Shaft
and
DIfferentIaJ
DESCRIPTION
PROPELLER
SHAFT
DIFFERENTIAL
Removal
and
Dismantling
DIFFERENTIAL
Assembly
and
Adj
Jstment
DIFFERENTIAL
Installation
DIFFERENTIAL
Estate
car
and
van
TOOTH
CONTACT
PATTERN
Checking
DESCRIPTION
The
tubular
steel
propeller
shafts
are
shown
in
Fig
G
1
The
shaft
is
connected
to
the
drive
pinion
flange
by
a
yoke
flange
at
the
rear
and
to
the
transmission
output
shaft
by
a
splined
yoke
sleeve
at
the
front
The
Datsum
I800ce
station
wagon
and
van
has
a
three
section
shaft
in
contrast
to
the
two
piece
shaft
used
on
the
other
models
covered
by
this
manual
The
differential
carrier
houses
a
hypoid
bevel
gear
assembly
Although
this
manual
contains
dismantling
and
adjustment
procedures
for
the
differential
assembly
it
must
be
pointed
out
that
only
workshops
with
specialized
tools
and
equipment
will
be
able
to
carry
out
the
work
involved
PROPELLER
SHAFT
Removal
1
Release
the
hand
brake
jack
up
the
vehicle
at
the
fear
and
support
it
on
stands
2
Loosen
the
clamps
and
turn
the
pre
silencer
to
the
left
saloon
only
3
Remove
the
adjuster
nut
from
the
handbrake
cable
rear
adjuster
and
disconnect
the
left
hand
cable
Saloon
only
Remove
the
bolts
securing
the
centre
bearing
bracket
1800
cc
stati
n
wagon
4
Disconnect
the
fear
flange
from
the
rear
axle
flange
With
draw
the
propeller
shaft
to
the
rear
away
from
the
gear
box
mainshaft
Take
care
that
the
shaft
is
not
dropped
during
removal
or
the
balance
of
the
shaft
may
be
altered
5
Plug
the
gearbox
rear
extension
to
prevent
the
loss
of
oil
PROPELLER
SHAFT
Dismantling
and
Inspection
Oean
all
components
and
mark
them
before
dismantling
so
that
they
can
be
reassembled
in
their
original
positions
Correct
reassembly
is
most
important
otherwise
the
balance
of
the
shaft
may
be
affected
Remove
the
four
snap
rings
from
the
journal
assembly
and
withdraw
the
needle
bearing
cap
by
tapping
the
yoke
with
a
wooden
mallet
The
wear
on
the
spider
journal
diameter
must
not
exceed
0
15mm
0
006
in
the
standard
size
of
a
new
journal
is
14
7mm
0
579
in
Check
the
spider
seal
rings
and
replace
them
if
necessary
The
radial
backlash
of
the
sleeve
yoke
splines
to
gearbox
splines
should
not
exceed
0
5mm
0
002
in
Renew
the
sleeve
yoke
if
the
figures
are
in
excess
of
the
specified
value
E
Mount
the
shaft
between
the
centres
of
a
suitable
fixture
and
use
a
dial
gauge
to
check
that
the
run
out
of
the
shaft
does
not
exceed
0
6mm
0
024
in
at
the
centre
of
the
tubular
portion
The
shaft
can
only
be
straightened
with
a
hydraulic
press
it
is
advisable
however
to
renew
the
shaft
if
the
run
out
is
excessive
Check
that
the
dynamic
balance
of
the
shaft
does
not
exceed
15
grm
cm
0
208
oz
in
at
4000
r
p
m
PROPELLER
SHAFT
Assembly
and
11Istallation
r
Assembly
and
installation
is
a
reversal
of
the
removal
and
dismantling
procedures
not
the
following
points
Grease
the
needle
rollers
with
wheel
bearing
grease
before
placing
them
into
the
bearing
race
Lubricate
all
splines
with
gear
oil
Adjust
the
journal
radial
end
float
to
within
0
02mm
0
0008
in
using
a
suitable
snap
ring
Snap
rings
are
available
in
eight
thicknesses
from
2
00mm
0
079
in
to
2
14mm
0
084
in
and
are
colour
coded
as
detailed
in
Technical
Data
at
the
end
of
this
section
DIFFERENTIAL
Removal
Saloons
with
independent
rear
suspension
Remove
the
hand
brake
rear
cable
remove
the
propeller
shaft
and
drive
shafts
as
described
in
their
relevant
sections
2
Support
the
differential
with
ajack
and
remove
the
nuts
securing
the
differential
mounting
crossmemb
er
Fig
G
3
3
Remove
the
bolts
holding
the
differential
to
the
suspension
member
Withdraw
the
differential
and
jack
to
the
rear
4
Support
the
suspension
member
with
a
stand
to
prevent
the
mountings
from
becoming
twisted
or
damaged
DIFFERENTIAL
Dismantling
Before
dismantling
place
the
carrier
assembly
in
a
suitable
mounting
stand
or
special
stand
ST
06270001
and
carry
out
preliminary
checks
as
follows
Check
the
tooth
contact
pattern
of
the
crownwheel
and
pinion
by
applying
lead
oxide
to
three
or
four
teeth
of
the
crownwheel
Turn
the
crownwheel
several
times
to
obtain
an
impression
of
the
tooth
contact
pattern
Check
the
backlash
between
the
teeth
of
the
crownwheel
and
pinion
using
a
dial
gauge
The
backlash
should
be
within
0
10
0
20mm
0
004
0
008
in
63
Page 134 of 171
GIS
DESCRIYfION
ENGINE
Removal
and
Installation
ENGINE
MOUNTING
INSULATORS
ENGINE
Dismantling
Inspection
and
Overhaul
CHAMSHAFT
AND
CAMSHAFT
BEARINGS
CYLINDER
BLOCK
PISTONS
CONNECTING
RODS
CRANKSHAFT
ENGINE
Assembling
VALVE
CLEARANCE
Adjusting
DESCRIYfION
The
G
18
engine
is
a
short
stroke
unit
with
a
displacement
of
1
815
ce
The
aluminium
alloy
cylinder
head
has
cross
flow
ports
and
a
V
shaped
valve
layout
The
single
overhead
camshaft
is
driven
from
the
crankshaft
by
a
double
row
roller
chain
at
a
reduction
ratio
of
2
I
The
crankshaft
is
a
carbon
steel
forging
and
is
provided
with
five
main
bearings
and
four
balancing
weights
Aluminium
thrust
bearings
are
located
at
the
No
2
journal
The
cast
aluminium
alloy
pistons
have
two
comp
ression
rings
and
one
oil
ring
Gudgeon
pins
are
fully
floating
in
the
piston
bores
and
are
equipped
with
circlips
at
each
end
to
limit
the
amount
of
their
travel
The
forged
steel
connecting
rods
have
weight
adjusting
bosses
at
both
large
and
small
ends
to
insure
that
the
rods
are
correctly
balanced
during
operation
The
lubricating
system
is
of
the
pressure
feed
type
with
the
oil
pump
driven
by
a
gear
on
the
crankshaft
Oil
is
delivered
to
the
main
gallery
via
a
full
flow
ftlter
ENGINE
Removal
and
Installation
Although
the
engine
can
be
removed
as
a
single
unit
it
will
prove
an
easier
operation
to
remove
the
engine
with
the
transmission
Proceed
as
follows
Fit
the
engine
slingers
ST49760000
to
the
engine
Disconnect
the
battery
cables
and
lift
out
the
battery
Drain
the
coolant
and
engine
oil
2
Place
alignment
marks
on
the
bonnet
and
hinges
remove
the
bonnet
from
the
vehicle
3
Remove
the
blow
by
hose
from
the
rocker
cover
and
take
off
the
air
cleaner
4
Disconnect
the
accelerator
linkage
and
choke
cable
from
the
carburettor
S
Detach
the
upper
and
lower
radiator
hoses
remove
the
two
brackets
from
the
core
support
and
lift
the
radia
tor
away
from
the
vehicle
The
torque
convertor
oil
pipes
must
be
disconnected
from
the
oil
cooler
if
the
vehicle
is
equip
ped
with
automatic
transmission
Detach
the
fuel
pipe
if
fitted
from
the
engine
and
heater
hose
6
Disconnect
the
electrical
wires
from
the
alternator
thennal
EngIne
OIL
PUMP
OIL
PRESSURE
RELIEF
VALVE
OIL
FILTER
EMISSION
CONTROL
SYSTEM
IGNITION
TIMING
AND
IDLING
SPEED
Emission
control
system
EMISSION
CONTROL
SYSTEM
Maintenance
IGNITION
SYSTEM
IGNITION
TIMING
IGNITION
DISTRIBUTOR
Maintenance
SPARKING
PLUGS
transmitter
the
primary
side
of
the
distributor
oil
pressure
switch
starter
motor
and
reverse
light
switch
7
Remove
the
clutch
slave
cylinder
and
its
return
spring
from
the
transmission
as
described
in
the
section
CLUTCH
8
Disconnect
the
shift
rods
and
selector
rods
then
remove
the
cross
shaft
assembly
by
detaching
the
bracket
from
the
side
member
See
GEARBOX
section
9
Disconnect
the
speedometer
cable
and
detach
the
front
exhaust
pipe
from
the
exhaust
manifold
10
Disconnect
the
propeller
shaft
and
plug
the
gearbox
rear
extension
to
prevent
the
loss
of
oil
11
Jack
up
the
gearbox
slightly
and
remove
the
rear
engine
mounting
support
Take
out
the
bolts
which
secure
the
front
mounting
insulators
to
the
cross
member
12
Attach
chains
or
wire
rope
to
the
engine
Gradually
lower
the
jack
under
the
gearbox
and
carefully
lift
and
tilt
the
engine
and
gear
box
to
clear
the
compartment
Withdraw
the
unit
making
sure
that
it
does
not
foul
the
accessories
Installation
is
a
reversal
of
the
removal
procedure
RefIll
with
the
correct
quantities
of
oil
and
coolant
when
the
engine
is
installed
ENGINE
MOUNTING
INSULATORS
Replacing
The
front
and
rear
mounting
insulators
should
be
checked
with
the
engine
installed
to
make
sure
that
the
dimensions
conform
with
those
given
in
Figs
A
I
and
A
2
To
remove
the
front
insulator
proceed
as
follows
Position
a
jack
under
the
oil
sump
Make
sure
that
the
jack
is
clear
of
the
drain
plug
and
insert
a
wooden
block
between
the
jack
and
sump
to
prevent
the
sump
from
being
damaged
Remove
the
bolts
securing
the
insulator
to
the
front
suspension
member
and
the
nut
attaching
the
insulator
to
the
engine
mounting
bracket
Raise
the
jack
slightly
and
remove
the
insulator
To
remove
the
rear
mounting
insulator
proceed
as
follows
Position
a
jack
to
take
the
weight
of
the
gearbox
and
take
out
the
bolts
connecting
the
insulator
to
the
transmission
rear
extension
housing
Remove
the
bolts
attaching
the
cross
member
to
the
underside
of
the
body
and
withdraw
the
insulator
Installation
of
both
insulators
is
a
reversal
of
the
removal
procedures
S3
Page 136 of 171
ENGINE
Dismantling
Remove
the
engine
from
the
vehicle
as
previously
described
and
carefully
clean
the
exterior
surfaces
The
alternator
distribu
tor
and
starter
motor
should
be
removed
before
washing
Plug
the
carhurettor
air
horn
to
prevent
the
ingress
of
foreign
matter
Place
the
engine
and
transmission
on
the
engine
carrier
ST4797
0000
if
available
and
dismantle
as
follows
Remove
the
gearbox
from
the
engine
Disconnect
the
intake
manifold
water
hose
the
vacuum
hose
and
the
intake
manifold
to
oil
separator
hose
Remove
the
intake
manifold
with
the
carburettor
Fit
the
engine
attachment
ST3720OG18
to
the
cylin
der
block
and
place
tre
engine
on
the
stand
ST371
00000
Remove
the
clutch
@
Ssembly
as
described
in
the
section
CLUTCH
Remove
the
exhaust
manifold
and
heat
baffle
plate
Take
off
the
fan
blades
and
remove
the
water
pump
pulley
and
fan
belt
Remove
the
rocker
cover
hose
manifold
heat
hose
and
by
pass
hoses
Remove
the
generator
bracket
and
the
oil
fIlter
Extract
the
engine
breather
assembly
from
above
Note
that
the
breather
is
fitted
to
the
guide
and
is
installed
with
a
O
ring
which
is
pressed
into
the
cylinder
block
Flatten
the
10ckwasher
and
unscrew
the
crankshaft
pulley
nut
Withdraw
the
pulley
with
the
puller
ST44820000
if
available
but
do
not
hook
it
in
the
V
groove
of
the
pulley
Remove
the
rocker
cover
and
take
off
the
rubber
plug
located
on
the
front
of
the
cylinder
head
Straighten
the
lock
ing
washer
and
remove
the
bolt
securing
the
distributor
drive
gear
and
camshaft
sprocket
to
the
camshaft
Remove
the
drive
gear
and
take
off
the
sprocket
See
Fig
A
3
Remove
the
cylinder
head
bolts
in
reverse
order
to
the
tightening
sequence
sOOwn
in
Fig
A
18
and
lift
off
the
cylinder
head
as
an
assembly
See
Fig
A
4
Note
that
in
addition
to
the
ten
cylinder
head
bolts
there
are
also
two
bolts
securing
the
chain
cover
to
the
head
Invert
the
engine
and
remove
the
oil
sump
Remove
the
chain
cover
and
oil
flinger
Take
off
the
nut
securing
the
oil
pump
sprocket
and
withdraw
the
sprocket
with
the
chain
in
position
as
shown
in
Fig
A5
Remove
the
oil
pump
and
stramer
Note
that
two
of
the
pump
mounting
bolts
are
pipe
guides
Remove
the
timing
chain
crankshaft
sprocket
chain
ten
sioner
and
chain
stop
Remove
the
connecting
rod
caps
and
push
the
piston
and
connecting
rod
assemblies
through
the
tops
of
the
bores
Keep
all
parts
in
order
so
they
can
be
assembled
in
their
original
posi
tions
Take
out
the
flywheel
retaining
bolts
and
withdraw
the
flywheel
Remove
the
main
bearing
caps
but
take
care
not
to
damage
the
pipe
guides
Lift
out
the
crankshaft
and
main
bear
ings
noting
that
the
bearings
must
be
reassembled
in
their
original
positions
Remove
the
piston
rings
with
a
suitable
expander
and
take
off
the
gudgeon
pin
clips
The
piston
should
be
heated
to
a
temperature
of
50
to
600
122
to
1400F
before
extracting
the
gudgeon
pin
Keep
the
dismantled
parts
in
order
so
they
can
be
reassembled
in
their
original
positions
Remove
the
camshaft
rocker
ann
shaft
and
rocker
ann
assemblies
from
the
head
by
taking
off
the
cam
bracket
clamp
ing
nuts
It
is
advisable
to
insert
disused
bolts
in
the
No
1
and
No
5
bracket
holes
as
the
cam
bracket
will
fall
from
the
rocker
ann
shaft
when
it
is
removed
Remove
the
valve
cotters
using
the
special
tool
ST47450000
and
dismantle
the
valve
assemblies
Keep
the
parts
together
so
they
can
be
installed
in
their
original
order
ENGINE
Inspection
and
Overhaul
Cylinder
head
and
valves
Inspection
and
overhaul
procedures
can
be
carried
out
by
following
the
instructions
previously
given
for
the
L14
LI6
and
LIB
engines
noting
the
following
points
Measure
the
joint
face
of
the
cylinder
head
using
a
straight
edge
and
feeler
gauge
The
permissible
amount
of
distortion
is
0
03
mm
0
0012
in
or
less
The
surface
of
the
head
must
be
reground
if
the
maximum
limit
of
0
1
mm
0
0039
in
is
exceeded
Oean
each
valve
by
washing
in
petrol
then
carefully
examine
the
stems
and
heads
Discard
any
valves
with
worn
or
damaged
stems
Use
a
micrometer
to
check
the
diameter
of
the
stems
which
should
be
8
0
mm
0
315
in
for
both
intake
and
exhaust
valves
If
the
seating
face
of
the
valve
is
excessively
burned
damaged
or
distorted
the
valve
must
be
discarded
The
valve
seating
face
and
valve
tip
can
be
refaced
if
necessary
but
only
the
minimum
amount
of
metal
should
be
removed
Check
the
free
length
and
tension
of
each
valve
spring
and
compare
the
figures
obtained
with
those
given
in
Technical
Data
at
the
end
of
this
section
Use
a
square
to
check
the
springs
for
deformation
and
replace
any
spring
with
a
deflection
of
1
6
mm
0
0630
in
or
more
Valve
guides
Measure
the
clearance
between
the
valve
guide
and
valve
stern
The
stem
to
guide
clearance
should
be
0
025
0
055
mm
0
0010
0
0022
in
for
the
intake
valves
and
0
04
0
077
mm
0
0016
0
0030
in
for
the
exhaust
valves
The
maximum
clear
ance
limit
is
0
1
mm
0
0039
in
The
valve
guides
are
held
in
position
with
an
interference
fit
of
0
040
0
069
mm
0
0016
0
0027
in
and
can
be
removed
using
a
press
and
valve
guide
replacer
set
ST49730000
under
2
ton
pressure
This
operation
can
be
carried
out
at
room
temperature
but
will
be
more
effec
tively
performed
at
a
higher
temperature
Valve
guides
are
available
with
oversize
diameters
of
0
2
mm
0
0079
in
The
cylinder
head
guide
bore
must
be
reamed
out
at
normal
room
temperature
and
the
new
guides
pressed
in
after
heating
the
cylinder
head
to
a
temperature
of
approximately
800
C
1760F
The
standard
valve
guide
requires
a
bore
of
14
0
14
018
mm
0
551
0
552
in
and
the
oversize
valve
guide
a
bore
of
14
2
14
218
mm
0
559
0
560
in
Ream
out
the
bore
of
the
guides
to
obtain
the
desired
finish
and
clearance
Use
the
reamer
set
ST49710000
to
ream
the
bore
to
8
000
8
015
mm
0
3150
0
3156
in
The
valve
seat
surface
must
be
concentric
with
the
guide
bore
and
must
be
corrected
if
necessary
using
the
new
valve
guide
as
axis
Valve
seat
inserts
Check
the
valve
seat
inserts
for
signs
of
pitting
The
inserts
cannot
be
replaced
but
may
be
corrected
if
necessary
using
a
valve
seat
cutter
ST49720000
Scrape
the
seat
with
the
450
cutter
then
reduce
the
width
of
the
contacting
faces
using
the
150
and
600
cutters
for
the
intake
valve
inserts
and
150
cutter
for
the
exhaust
valve
inserts
Seat
correction
dimensions
are
shown
in
millimeters
in
Fig
A
6
Lap
each
valve
into
its
seat
after
correcting
the
seat
inserts
Place
a
small
quantity
of
fme
grinding
paste
on
the
seating
face
of
the
valve
and
lap
in
as
previously
described
for
the
Ll4
LI6
and
L
18
engines
S5
Page 144 of 171
carrying
out
extensive
tests
with
the
necessary
equipment
The
hoses
and
connectors
can
of
course
be
checked
for
signs
of
leakage
and
corrected
as
necessary
Also
the
tension
of
the
air
pump
belt
IGNITION
TIMING
AND
IDLING
SPEED
Emission
control
system
The
ignition
timing
should
be
set
and
the
idling
speed
mixture
adjusted
in
the
folloWing
manner
Run
the
engine
until
it
reaches
its
normal
operating
tem
perature
Connect
an
ignition
tachometer
and
timing
light
observ
ing
the
manufacturers
instructions
NOTE
If
the
vehicle
is
equipped
with
automatic
transmission
make
sure
that
the
dashpot
does
not
prevent
the
throttle
from
closing
Turn
the
throttle
shaft
arm
adjusting
screw
anti
clock
wise
so
that
the
tip
of
the
screw
is
clear
of
the
throttle
shaft
arm
see
Fig
A
26
Turn
the
throttle
adjusting
screw
to
set
the
idling
speed
to
700
r
p
m
650
rpm
for
automatic
transmission
Adjust
the
ignition
timing
to
5
A
T
D
C
Refererence
should
be
made
to
the
instructions
given
in
the
section
IGNITION
SYSTEM
for
the
L14
L16
and
LI8
engines
for
ignition
timing
details
Turn
the
idling
adjustment
screw
and
throttle
adjusting
screw
until
the
engine
runs
smoothly
a
t
the
correct
idling
speed
Turn
the
idling
adjustment
screw
clockwise
until
the
engine
speed
starts
to
drop
as
a
weaker
mix
ture
is
obtained
Now
turn
the
idling
adjustment
screw
anti
clockwise
by
one
turn
one
and
a
half
turns
for
automatic
transmission
to
obtain
a
richer
mix
ture
Adjust
the
idling
speed
to
700
rpm
650
rpm
for
automatic
transmission
by
turning
the
throttle
adjusting
screw
Make
sure
that
the
ignition
timing
remains
at
50
A
T
D
C
Turn
the
throttle
shaft
ann
adjusting
screw
clockwise
until
the
tip
of
the
screw
just
contacts
the
throttle
shaft
ann
The
screw
must
not
exert
pressure
on
the
throttle
shaft
arm
EMISSION
CONTROL
SYSTEM
Maintenance
The
system
should
be
inspected
and
serviced
every
I
2
months
or
20
000
km
12
000
miles
whichever
comes
fIrst
to
make
sure
that
the
exhaust
emissions
are
maintained
at
the
minimum
level
Check
the
carburettor
choke
setting
and
adjust
as
described
in
the
section
FUEL
SYSTEM
Check
the
carburettor
idling
speed
mixture
and
adjust
if
necessary
as
described
under
the
heading
IGNITION
TIMING
AND
IDLING
SPEED
in
this
section
2
Check
the
distributor
earn
dwell
angle
and
also
the
condi
tion
of
the
contact
breaker
points
Check
the
ignition
timing
and
adjust
if
necessary
The
distributor
dwell
angle
should
be
adjusted
to
49
55
degrees
and
the
points
gap
to
0
45
0
55
mm
0
0177
0
0217
in
3
Remove
and
clean
the
sparking
plugs
Renew
any
plug
with
badly
worn
electrodes
Set
the
plug
gaps
to
0
80
0
90
mm
0
0315
0
0355
in
by
adjusting
the
earth
electrode
IGNITION
SYSTEM
The
maintenance
and
servicing
procedures
for
the
compo
nents
of
the
ignition
system
on
vehicles
fitted
with
the
GIS
engine
are
basically
similar
to
the
instructions
previously
given
for
the
Ll4
LI6
and
LIS
engines
The
distributor
is
however
of
a
different
type
Either
an
Hitachi
0416
57
distributor
being
fitted
or
an
Hitachi
0423
53
if
the
vehicle
is
equipped
with
an
emission
control
system
The
distributors
have
different
advance
curve
characteristics
as
shown
in
Technical
Data
IGNITION
TIMING
Check
the
ignition
timing
with
a
timing
light
as
previously
described
for
the
LI4
L16
and
L
8
engines
Disconnect
the
distributor
vacuum
line
and
run
engine
at
idling
speed
or
slightly
below
The
timing
should
be
set
at
8
BTDCj600
rpm
for
the
D416
57
distributor
or
at
5
ATDCj600
rpm
for
the
D423
53
distributor
fItted
to
engines
with
emission
control
systems
IGNITION
DISTRIBUTOR
Maintenance
Maintenance
instructions
are
similar
to
those
given
for
the
L14
LI6
and
L18
engines
Set
the
contact
breaker
points
gap
to
0
45
0
55
mm
0
0177
0
0217
in
as
previously
described
SPARKING
PLUGS
The
sparking
plugs
should
be
inspected
and
cleaned
at
regular
intervals
and
renewed
at
approximately
20
000
kIn
12
000
miles
Clean
the
plugs
thoroughly
and
make
sure
they
are
of
the
same
type
and
heat
range
File
the
centre
electrode
nat
before
adjusting
the
gap
Set
the
gap
to
0
8
0
9mm
0
031
0
035
in
if
the
engine
is
fItted
with
emission
control
system
or
to
0
7
0
8
mm
0
028
0
031
in
if
emission
control
is
not
fitted
Adjustment
must
always
be
made
by
bending
the
earth
electrode
TechnIcal
Data
GENERAL
SPECIFICATION
GI8
Engine
Cylinders
Bore
and
stroke
Displacemen
t
Valve
arrangemen
t
Firing
order
Engine
idler
speed
Compression
ratio
Oil
pressure
at
3000
r
p
m
4
in
line
85x80
mm
3
346x3
150
in
1
815
cc
110
8
cu
in
OHC
134
2
600
r
p
m
STD
8
3
I
4
7
to
5
5
kgjsq
cm
66
8
to
78
2
Ibjsq
in
LIQUID
PACKING
APPLICATION
Cylinder
block
2
Cylinder
head
Oil
gallery
blind
plug
Expansion
plug
Gas
breather
guide
Rear
bearing
cap
fitting
surface
Rear
bearing
cap
side
seal
both
ends
Expansion
plug
Rubber
plug
Rea
Manifold
heat
pipe
3
Chain
cover
gasket
both
sides
S13
Page 160 of 171
Tighten
the
inner
socket
until
the
ball
seat
is
at
the
rack
end
then
back
off
the
socket
by
30
to
40
degrees
and
tighten
the
stop
nut
to
a
torque
reading
of
8
0
to
10
0
kgm
57
8
to
72
3
Ib
ft
as
shown
in
Fig
C
25
With
the
tie
rod
assembled
measure
the
force
required
to
swing
the
tie
rod
Hook
a
spring
balance
at
the
end
of
the
rod
as
shown
in
Fig
C
26
and
check
that
the
force
is
from
3
0
to
6
0
kgm
6
6
to
13
2
lb
Measure
the
stroke
of
the
rack
which
should
be
73
0
mm
2
874
in
Fit
grease
nipples
at
both
ends
of
the
rack
and
pinion
housing
Apply
multipurpose
ase
to
each
joint
until
a
small
quantity
of
grease
appears
at
the
out
let
hole
in
the
boot
Do
not
use
an
excessive
amount
of
grease
The
pinion
housing
should
be
lubricated
until
a
small
quantity
of
grease
appears
between
rack
and
housing
Remove
the
grease
nipple
and
fit
the
plug
Fit
the
boot
Fill
the
grease
reseIVoir
with
grease
and
attach
it
to
the
rack
housing
Adjust
the
length
of
the
tie
rods
at
both
sides
as
des
ribed
under
FRONT
WHEEL
ALIGNMENT
Assemble
the
steering
lower
joint
to
the
rack
and
pinion
and
tighten
the
lower
joint
bolt
to
a
torque
reading
of
4
0
to
5
0
kgm
29
0
to
36
0
Ib
ft
Installation
of
the
rack
and
pinion
assembly
is
a
reversal
of
the
removal
procedure
COLLAPSIBLE
STEERING
Removi
8
and
Dismantti
8
The
steering
coluJllfl
See
Fig
C
3
can
be
removed
in
a
similar
manner
to
the
standard
type
of
column
Take
care
not
to
drop
the
column
when
it
is
removed
from
the
vehicle
or
the
shaft
may
collapse
Do
not
exert
any
pressure
on
the
column
or
the
bellows
may
be
defonned
To
dismantle
proceed
as
follows
Remove
the
retaining
wire
and
pull
out
the
lower
shaft
Disconnect
the
control
linkage
if
the
vehicle
is
fitted
with
auto
matic
transmission
Slide
the
steering
shaft
bracket
away
With
draw
the
screws
and
separate
the
upper
and
lower
tubes
Assembly
is
a
reversal
of
the
dismantling
procedure
Note
that
the
slot
in
the
universal
joint
must
be
aligned
with
the
punch
mark
at
the
top
of
the
upper
steering
shaft
as
shown
in
Fig
C
28
When
installing
the
column
make
sure
that
the
bellows
do
not
become
bent
of
twisted
as
the
clamp
and
bottom
plate
bolts
are
tightened
TechnICal
Data
TYP
Gear
I1ltio
Rack
and
pinion
17
8
I
Steerin
column
shaft
spring
Wire
diameter
Freelenath
CoiltW
llJ
Load
length
Retainer
sprinJ
dimension
Wire
diameter
F
CoilturnJ
l
oadxlensth
Side
rod
SPrina
dimeruion
Wire
diameter
Fn
elenath
Coil
turns
Load
x
lensth
Side
rod
inner
ball
joint
ax
ia
I
play
Side
rod
outer
ball
joint
uiaJ
play
Pinion
thrultplay
Retainer
float
play
Rack
moke
Side
rod
inner
ball
joint
swinsinl
torque
Side
rod
uter
ball
joint
swingina
torque
Pinion
oration
torque
Rack
pre1
d
Wheel
alipment
1IIl1a
a
ondition
Cut
c
m
Kinl
pin
inclination
Toe
in
S
In
teerinlan
eOut
10
40
8005
12
15
mm
0
47
0
59
in
38024
35036
2
9
mm
0
11
2
in
36
5
mm
1
4370
in
3
25q
551
18mm
0
7087
2
6
mm
1
102in
26
3
mm
1
035
in
5
5
20
kl
lbs
16
3
mm
0
642
in
26
mm
0
102
in
19
0
mm
0
748
in
6
3
40
q
88Ibs
17
0
mm
0
669
in
0
06
mm
0
002
m
0
1
0
5
mm
0
0039
0
0197
in
less
than
0
3
mm
0
0118
in
0
09
mm
0
0035
in
73
mm
t
2
87
in
0
8
1
5
q
m
5
8
10
8Ib
n
0
8
J
S
kg
m
5
8
JO
8Ib
ft
8
20q
7
17
lb
in
8
18
q
l7
6
39
7Ibs
Strut
DlelDbly
Strut
outer
Ilia
50
8
mm
2
0
in
Piston
rod
di
a
20
mm
0
787
in
Cylinder
inner
dia
30mm
I
181
in
Dampinl
force
at
pistonlpeed
0
3
m
I
1
08
ft
I
Expansion
67
IOq
I47
7
221bs
Compression
25
4kl
55
1
8
81bs
Shock
absorber
inner
cylinderlcngth
IOmm
16
1
in
R
IlD
vchicle
LH
D
ehide
CoiIsprina
LIi
IlIi
OOIh
Wire
diameter
mm
in
12
0
472
12
0
472
12
0
472
Coil
diameter
mm
in
130
5
12
130
5
12
130
5
12
Coil
Ium
S
Coil
effective
turnl
6
5
6
5
6
5
Free
lenJth
mm
in
371
5
14
6
386
5
15
2
371
5
14
6
Installed
hei
ht
load
mmq
180
270
200
270
180
270
in
lb
7
1
594
7
9
594
7
1
594
SpriDgCOfl
ltant
ka
mm
1
45
US
1
45
529
1