DATSUN 610 1969 Workshop Manual

inter
Il
IT
Q

riA

I

I

II

l

11
L
6
Removing
the
wbeel

cylindeIli

1
Brd
be

2
Wllul

cylinder
bolts

J
BridI
pip

I

g
L
8
Front
drum
brake
lubricating

positions

Fig
L
9
Removing
the
rear
wheel

cylinder

1
BnrIce

pip

2
Handblllke
cable

J
CIMJ

pin

4
Lnu

5
DustCI1ft
1
Fig
L
7
Front
drum
brake

components
J

T
Broke
rim

Return

Print

J
rhoe
cmembly

4
Front
wM
1

cylinder

5
Rear
wMtl

cylindu

6
A
iT
bleed
W

o

1

Fig
L
I0
Rear
drum
brake

components

1

BllIke
ckp
tzrc

2
RthUn

spring

3

Brate

ad
JlSkr

4
Front
brake
h

5

Anti
rottk

pin

6
Lever

7
Wheel

cylinder
8
Return
sprins

9
Air

bleed
JCrew

10

Lockp
orc

11

Lockp
tzrc

12

Lockplizte

13
Dust
cover

14

Rt
t1T
brake
dr
oe

Fig
L
II
View
of
the
rear
drum
brake

I
Broke
3Iwe

adjuJter

2
BraJ
e
shot

3
Retum

4
A
ntHuttle

pin

100
11
L
12
The
front
brake
shoe

adjusting

cams

BRAKE
WARNING
UGHT
SWITCH

A

hydraulically
operated
warning
light
switch
is
located

in
the

engine

compartment
Fig
LA

The
front
and
rear
brake

systems
of
the
dual
circuit
are

connected
to

the
switch
which

provides
a

warning
via
the

warning
light
on
the
instrument

panel
when
a

pressure
difference

of
13
17

kg

sq
cm
185
242Ib

sq
in
occurs
between
the

front
and
rear
brake

systems
The

switch
cannot
be

repaired

and
must

be
renewed
if

faulty

FRONT
DRUM
BRAKE
Removal

1
Jack

up
the
front
of

the
vehicle

and

support
it
on
stands

2
Remove
the
brake
drum
and
the
hub

cap
and
hub

assembly

3
Disconnect
the
brake

pipe
at
the
bracket
on
the
front

suspension
strut
as

previously
described
in
the
section

FRONT
SUSPENSION

4
Unhook
the
two
return

springs
shown
in

Fig
L
5
and

remove

the
brake
shoes

5
Disconnect
the

bridge
pipe
3
in

Fig
L
6
and
remove

the

two
wheel

cylinders

6
Take
out

the
installation
bolts
and
withdraw
the
brake

backplate
from
the

spindle

FRONT
DRUM

BRAKE

Inspection
and
Overhaul

Examine
the
brake
drums
for

scoring
and
out
of
round

The
maximum

permissible
inner
diameter
of
the

drums
must

not
exceed
228
6mm
9
00
in
and
out

of
round
should
be

below
0
02mm
0
0008in

The
brake
shoe

linings
must
re
renewed
when
worn
down

to
a
thickness
of
1
5mm
0
06

in
or
below
Renew
the

linings
if

they
are
contaminated
in

any
way
or

incorrectly

seated
The

complete
set

of

linings
must

be

replaced
if
any

single
lining
is

unsatisfactory

O1eck

the
shoe
return

springs
and
if

they
have
become

weakened

replace
them

Withdraw
the

pistons
and

springs
from
the
wheel

cylinders

and

inspect
the
bore
of
the

cylinders
for

signs
of

wear

corrosion
or

damage

Renew
the

cylinder
and
the

piston
if
the
clearance
between

the
two

exceeds
O
15mm

0
006

in
Renew
the
rubber
boots

and

cups

FRONT
DRUM
BRAKE

Assembly
and
Installation

Assembly
and
installation
is
a
reversal
of
the
removal
and

dismantling
procedure
noting
the

fOllowing
points

Apply
a
thin

layer
of

special
grease
to

the
piston

cup
and

other
rubber

parts
when

assembling
the
wheel

cylinder
The

internal

components
of
the

cylinder
should
be

dipped
in
brake

fluid
and
assembled
whilst
still
wet
Install
the
wheel

cylinders
on
the
brake

backplate
and

smear
the

cylinder
backplate
and

cylinder
lever
fulcrum
with

grease
Fig
L
8

Tighten
the

backplate
mounting
bolts
to
a

torque
reading

of
2
7
3
7

kgm
19
5
26
71b
ft

Adjust
the
brake
shoes
and
bleed
the

hydraulic
system
as

described
under
the

appropriate
headings

REAR
DRUM
BRAKE
REMOVAL

Fig
L
IO

Jack

up
the
vehicle
at
the
rear
and

support
it
on

stands

Remove
the
road
wheel

2
Release
the
handbrake
remove
the
clevis

pin
3
from
the

rear
wheel

cylinder
lever
4
see

Fig
L
9
Disconnect
the

handbrake
cable
2
and
remove

the
return

spring
I

3
Remove
the
brake
drum
Remove
the
shoe
retainers
the

return

springs
and
brake
shoes

Fig
L
II

4
Disconnect
the
fluid
line
from
the
wheel

cylinders
and

plug

the
opened
end
to

prevent
to
loss
of
fluid

5
Remove
the
dust
cover

adjusting
shims
and

plates
then

remove
the
wheel

cylinder
from
the

backplate

6
The
brake

backplate
and
axle
shaft

assembly
can
be
with

drawn
if

necessary
by
taking
out
the
four

flange
bolts

and

removing
the

assembly
as
described
in
the
section

REAR
AXLE
AND
REAR
SUSPENSION

REAR
DRUM
BRAKE

Inspection
and
Overhaul

The

inspection
and
overhaul

procedures
fpr
the
rear

drum

brakes
are
similar
to

those

previously
described
for
the
front

drum
brakes

Tighten
the
brake

backplate
mounting
bolts
to
a

torque

reading
of

3
9
5
3

kgm
28
38Ib
ft

FRONT
DRUM
BRAKE

Adjusting

Jack

up
the
vehicle
and

pump
the
brake

pedal
several
times

With
the
brake
drum
installed
turn
one
of

the
adjusting
cams

clockwise
until

the
brake
shoe
is
in
contact
with
the
drum

This

operation
is
carried
out
from
the
rear
of

the
backplate

When
the
brake
shoe
contacts
the
drum
turn
the
cam
in

the

opposite
direction
until
the
shoe
is

just
clear
and
the
brake

drum
can
be
rotated

freely
by
hand

Repeat
the

operation
on
the
other

adjusting
cam
and
then

depress
the
brake

pedal
to
make
sure
that
the
brakes
are

working

correctly
The

adjusters
must
be
released

slightly
if
the
brake

drum
binds
when
turned

by
hand

Fig
L
12
shows
the

adjusting

cams

REAR
DRUM
BRAKE

Adjusting

Jack

up
the
vehicle
at

the
rear
and

pump
the
brake

pedal

several
times
Turn
the
brake
shoe

adjuster
Fig
L
13
until
the

101

inter
J
i
J
I

E

FJB
L
13
Rear

brake
shoe

adjusling
cams

Top
Saloons

Bottom
Estate
CI1TJ

and
vam

FIg
L
15

Removing
the
anti
attle

clip

I
J

t
h

0

M

FJB
LI7

Removing
the

brake

pad

102
Al
g

b5m

tt

s

t

td
@

Fig
L
14
Front
disc
brake

components

1
Retainer

2

Wiper
It
tZI

J
Paton
seal

4
PiJton

5
Hold
down

pin

6
S

7

Support
bracket
8

Ollliper
plate

9

Clip

10
Bleed
sa

rw

11

Cylinder

12
Tension

spring

13
Brake

pad

14

MountinK
bmcket

1
5
Pi
lOtpin

Fig
L
t
6

Moving
the

piston

Fig
L
IS

Removing
the
brake

calliper

brake
shoe
is
in
contact
with
the
drum
The

adjuster
must
be

turned
from

the
rear
of

the

backplate
and
the
drum
turned

by

hand

When
the
shoe
contacts
the
drum
turn
the

adjuster
in

the

opposite
direction
until
the

shoe
is

just
clear
and
the
drum

can

be
rotated

freely
by
hand

Depress
the
brake

pedal
and
make
sure
that
the
brakes

operate
correctly
The

adjusters
must

be
released

slightly
if

the

brake
shoe
binds

FRONT
DISC
BRAKE
Friction

pads
Fig
L
14

The
disc
brakes
are
self

adjusting
but
the
friction

pads

should
be
checked
for
wear

every
5
000
km
3
000
miles
and

replaced
if
the
thickness
of

the
friction

lining
on

any

pad
is
less

than
1
0mm
0
004
in
In
effect
this
means
that
renewal
is

necessary
when
the
total
thickness
of

pad
and

lining
is
less
than

8
4mm
0
24
in

To

replace
the
friction

pads
proceed
as

follows

Siphon

out
some
of
the
fluid
in
the
master

cylinder
reservoir
Jack

up

the
front
of
the
vehicle
and
remove

the
road
wheel

Remove
the
anti
rattle

clip
from
the

calliper
plate
Fig
L
lS

Unhook
the

hanger
spring
and
withdraw
the
brake

pads

and
shims

Fig
L
17

It
should
be
noted
that
the
friction

pads
must
be

replaced

as
a
set
and
renewed
at
both
sides
of
the
vehicle
otherwise
the

braking
action
will
be
uneven

Oean
the

calliper
and

pad
at

their
installation

positions

Press
the

pistons
into
the

calliper
bores
so
that
the
new
friction

Pads
can
be
installed
The

pistons
can

be
installed

by
applying

light

pressure
as
shown
in

Fig
L

16
but
care
must

be
taken
to

avoid

pushing
them
too
far
or
the

groove
of
the

piston
will

damage
the
seal

If
the

pistons
are

pushed
down

excessively
it
will
be

necessary
to
dismantle
the

calliper
as

described
under
the

appropriate
heading

Assemble
the

anti

squeal
shims
to
the
friction

pads
with

the
arrow
mark
on
the
shims

pointing
in
the
direction
of

forward
disc
rotation

Refit
the

pads
and

retaining
pins
and
assemble
the
coil

spring
to

the

retaining
pin
furthest
away
from

the
air
bleed
screw

After

installing
the
new

pads
and
shims

depress
the
brake

pedal
several
times
to

reposition
the
pistons
in
the

calliper

O1eck
the
fluid
level

in
the
master

cylinder
reservoir
and
refill

to
the
correct
level

FRONT
DISC

BRAKE
Removal
and

Dismantling

1
Jack

up
the
front
of

the
vehicle
remove
the
road
wheel

and
take
out

the
friction

pads

2
Disconnect
the
brake
hose
from
the
brake

tube
and

plug

the

opened
end
to

prevent
the
loss
of
fluid
3
Remove
the
bolts

securing
the
brake

calliper
to

the

knuckle

flange
and
remove
the

calliper
assembly
Fig
L
IS

4
Remove
the
hub
nut

and
withdraw
the
hub
and
disc

To
dismantle
the
calliper
remove
the
anti
rattle

clip
and

withdraw
the
brake

pads
Remove
the
tension

springs
and

pull

the
cylinder
out
of
the

calliper
Blow
out

the
piston
with
com

pressed
air

applied
at

the
brake
hose
connection

Oean
the

components
in
brake
fluid
and
examine
them

for

signs
of
wear
or

damage

The

cylinder
walls
can

be
carefully
polished
with
fine

emery
cloth
if

they
are
rusted
or
contaminated
If
the

parts

are

excessively
corroded

they
should
be
renewed

Replace
the

pistons
if

they
are

unevenly
worn

damaged

or
rusted
The
sliding
surface
of
the

piston
is

plated
and
no

attempt
should
be
made
to

use

emery
cloth
or
similar
abrasives

for

cleaning
purposes

Check
the
thickness
of
the
friction
pads
as

previously

described
and
replace
them
if

necessary
Renew
the

piston
seals

and
the
dust
covers

O1eck
the
brake
disc
for

scoring
and
out
of
round
The

standard
disc
thickness
is
10
Omm
0
0394
in
and
must
not

be

reground
below
8
4mm
0
3307
in

Check
the
disc
run
out
with
a
dial

gauge
as
shown
in

Fig

L
19
Position
the
gauge
near
the
outer
diameter
and
check
that

the
run
out
does
not

exceed
0
06mm
0
0024
in

FRONT
BRAKE
DISC
Assembly
and
Installation

Rinse
the

cylinder
bore
with
brake
fluid
and
fit
the

piston

seal
into
the

cylinder

groove
Fig
L
20
Fit
the
wiper
seal
and

lightly
grease
the
bore
of
the

cylinder
Clean
the
brake
disc

and
fit
it
to
the
hub
Install
the
hub
to
the
knuckle

spindle

Carefully
insert
the

piston
into
the

cylinder
until
the
face

of
the

piston
is
almost
flush
with

the

wiper
seal
retainer
The

relieved

part
of
the

piston
should
face
the

piston
pin

Fit
the
cylinder
to
the

calliper
plate
and
secure
in

position

with
the
two
torsion

springs
Assemble
the
hold
down
pin

the

spring
washer
and
the
nut
to

the

support
bracket
Secure

the
nut

with
a
cotter

pin

Assemble
the

calliper
to

the
mounting
bracket

using
the

pivot
pin
washer

spring
washer
and
nut

Tighten
the
nut
and

secure
with
a
cotter

pin
Hook
the
hold
down
bracket
to
the

top
of
the

mounting
bracket
and
turn
the

calliper
plate
to

make

sure

that
it
can
slide

smoothly
Fit
the

calliper
assembly
to
the

knuckle

flange

Fit
a
shim
to
the
inner

pad
and
insert
the

pad
Draw
the

calliper
towards
the
chassis
and
insert
the
lower
cuts
on

the

pad

into
the

mounting
bracket
and

push
the

pad
in
until
it
contacts

the

piston
Move
the

calliper
away
from
the
chassis
and
insert

the

upper
cuts
Centre
the
indentation
of

the
outer

pad
in
the

calliper
plate
Fit
the
anti
rattle

clip
Fig
L
14

103

inter
f
illl

@
l

l

Au

y
l
ver

I

R
H

I
Equaliler
b2nd

i
b7ke

Pl
te

Iock
band
buk

able
I

I

I

T

@A
Adjuster
cable

oo

pm
Odb
k
SPd
wm

LH
able

C

Note

@
Apply
bearing

grease

@APPIYch
S

i

Pin
fulcrum
hand

brab
lever
6c

1l

Clip
cable
frout
N
nd
brake

Fill
L21
Handbrake

linkage
1400
and
1600
c
c

Saloons

1
I
J

Pull

priDg

1

Clt
vU

Balance
leve

I

I

J
c

1
1

I

I
1

l

J

L

I

iL

Note

@
Apply
engine
oil
8

S

J

@

I

Aj

Fran
able
Rear
cable

L

I
r

f
7

n
t

i

Adjust

position
A

Fig
L
22
Handbrake

linkage
1400
and
1600

c
c

Estate

cars

1
Control
sUm

2
Control
ratchet

Xing

3
O
mtrol
ratchet

4
O
mtro

guide

5

Control
bracket

6

OJntrol
yoke

7
wer

spring

8
Control
lever

Fig
L
23

Handbrake

linkage
1800

c
c
models

104
able

s

Fig
L
19

Checking
the

brake
disc
for

run
out

1

j

v

fti

r

v

r

Fig
L
20

As
embling
the

piston
seals
and

retainer

ti

J

4

Fill
L
24
The
handbrake

cable

adjuster
Saloons

9

Front
cable

10
Centre

lever

II
Rear
cable

adjuster

12
DIble

lock

plate

13

Return

spring

14

RI
fU
cabk

15
Qevis

HAND
BRAKE
Removal

The
mechanical
handbrake

linkages
are
shown
in

Figs
L
21

1
22
and

1
23

1400
and
1600cc
models

Front
cable

Release
the
hand
brake
and
disconnect
the
front
cable

by

removing
the
clevis

pin
from
the
lever
Unscrew
the

adjusting

nut
from
the
rear
of
the
front
cable

Fig
L
24
Remove
the

cable
from

the
hand
brake
lever

Remove
the

clamp
holding
the
cable
to
the
under
body

Pull
out
the
lock

plate
holding
the
front
cable
to
the
retainer

and
completely
withdraw
the
cable
Withdraw
the
cable

by

unfastening
the
outer

casing
which
is

pressed
into
the
handbrake

control
bracket

Handbrake
lever

Fig
1

25

Remove
the
clevis

pin
connecting
the
lever

yoke
and
lever

Remove
the
clevis
pin
connecting
the
control

guide
and
the

control
bracket
Lift
out
the
handbrake

assembly

Rear
cable
Saloons

Remove
the

adjusting
nut

from
the

adjuster
Fig
L
26

and
disconnect
the
left
hand
rear
cable
from
the
handbrake

adjuster
Pull
out
the
lock

plates
and
remove
the
clevis

pin

connecting
the
cables
to
the
levers
of
the
rear
wheel

cylinders

Rear
cable
Estate
car
and

rigid
axle
saloon

Remove
the
clevis

pin
from
both
ends
of

the
rear
cable

Remove
the
connecting
rods

by
extracting
the

puU
off
springs

and
clevis

pins

1800cc
models

Handbrake
lever

Disconnect
the
terminal
from
the
hand
brake

warning

switch
Remove
the
nuts

securing
the
control
bracket
to

the

dashboard
Pull
out

the
lock
pin
and
cotter

pin
and
withdraw

the
handbrake
lever

assembly

Front
cable

Remove
the
return

spring
and
loosen
the

adjuster
10cknuL

Detach
the
front
cable
from
the
handbrake
lever
Remove
the

nuts

securing
the
cable
to
the
dashboard

Fig
L
27
and
with

draw
the
cable
towards
the

engine

Rear
cable
Saloon

Disconnect
the

cable
at
the

adjuster
and
detach
the
return

spring
from
the
centre
lever

See
Fig
L
28
Remove
the
cable

lock

plates
from
the
rear

suspension
Remove
the
clevis

pin

attaching
the
cable
at
the
rear

wheel

cylinder

Rear
cable
Estate
car

and
Van

Unfasten
the

pull
spring
and
remove
the
clevis

pins
at
the

balance
lever
and
wheel

sides

Fig
L
29
Detach

the

connecting

rod
Remove
the
nut

securing
the

connecting
rod
balance
lever

and
the
lever
from
the
rear
axle

housing
HANDBRAKE
Installation

Check
the
cables
for

signs
of
deterioration

fraying
etc

Examine
the
handbrake
lever
and
ratchet
for
wear
and
renew

as

necessry

Check
the

springs
for
evidence
of
weakness
and
make
sure

that
the
balance
lever
and
bushes
are

satisfactory

Installation
is
a
reversal
of
the
removal
procedure
Make

sure

that
all
sliding

parts
are

greased

Adjust
the
hand
brake
in
the

following
manner

Release
the
hand
brake
and

adjust
the
rear
brake
shoes
as

previously
described

The
1400
and
1600cc
Saloon
handbrake
is

adjusted
to

give
a
lever
stroke
of
85
95mm
3
34
3
74
in

by
setting

the

adjusting
nuts

Fig
L
24
The
lever
stroke
on
the
estate

car
should
be

adjusted
to
50
75mm
2
0
3
0
in

by
turning

the

adjuster
shown
in
Fig
L
30

Adjust
the
1800cc
models
to

give
a
handbrake
lever
stroke

of

90
100
mm
3
5
3
9in

by
turning
the

adjuster
2
in

Fig
L

28

Retighten
the
locknut
after

adjusting

BLEEDING
THE
HYDRAULIC
SYSTEM

The
hydraulic
system
must
be
bled
if
the
circuit
has
been

opened
at

any
point
or
if

the
level
of
the
fluid
in
the
master

cylinder
reservoir
has
fallen
too

low
allowing
air
to
enter

the

system

Bleeding
is

usually
a
two
man

operation
as
assistance
will

be

required
to
work
the
brake

pedal
The
master

cylinder

reservoir
must
be

topped

up
constantly
throughout
the

operation

whilst
a
check
is
carried
out
on

the
fluid

expelled

Bleeding
should
be
carried
out
at
the
master

cylinder
nrst

then
from
the
brake
furthest

away
from
the
master

cylinder

and

working
round

finally
to

the
brake
nearest
to
the
master

cylinder
Bleeding
should
therefore
be
carried
out

in
the
follow

ing
order
Rear
left
wheel
rear

right
wheel
front
left
wheel

front

right
wheel

Oean
the
area
round
the
master

cylinder
cover
take
off

the
cover

and

top
up
the
reservoir
if

necessary
Clean
the
rele

vant

air
bleed
screw
and
take
off
the

cap

Attach
a
suitable
hose
to
the
bleed
screw
and

place
the

free
end
of

the
hose
in
a

glass
jar
containing
brake
fluid

Open
the
bleed
screw
and

depress
the
brake

pedal
to
allow

the
fluid
to
enter
the

glass
container

Tighten
the
bleed
screw

when
the

pedal
is
fully
depressed
and
allow
the

pedal
to
return

Repeat
the

procedure
until
the
fluid
is

completely
free

from
air
bubbles
then

carry
out
the
same
operation
on
the

other
three
wheels

Top
up
the
fluid
in
the
reservoir
to
the
correct
level
but

do
not
re
use
the
fluid

previously
withdrawn
from
the

system

105

inter

jjiC@
V

6iIiIIlli
I
Ii

r

f
r

7
r

Y

t
I

10

1
L

u

N
c

I

F
ll
L
2S
The
handbrake

mbly

Fig
L
27
Front
handbrake
cable
attachment

nuts

e7
rl
A

I
r

I
r

J
i

I
f

I
I

I
of

II

J

F

F
ll
L29
Balance
lever
Estate
ClU1l
and
Vans

F
ll
L
30

AdjWltins
the
handbrake
cable

Estate
ClU1l

106
J

ei
Fig
L
26

Removing
the
lock

plates
see
text

I

7
I

i

1

@
i
1

0
1

e

V

O
V

I
r

r

if1
1i

cl

t
Ji
Y

a

t

3

F
ll
L
28
Rear
cable

layout
1800
C
c
SatOOWl

ok

pedat
height
H

87
mm
7

362
in

202
mm

7
953
ill
Jltznual
transmission

AutomItic
transmission

y
Brake

pedal
full
stroke
L

141
0149
mm

5
55
to
5
86
in

Brake

pedal
p
tJv
P

5
to

15
mm

0
2
to
0
6
ilL

Fig
L
31
Brake

pedal
adjWltment
1400
and
1600
c

c

models

l

car

Ll
1
f
1

J

111

I
l
j
u

n

l

71

t
i1

Unit
mfll
in
1
Push
rod

adjusting
scrt

W

2
Ptdlz

stop

3
Brake

Iilmp
switch

4
Clevis

pin

Fig
L
32
Brake

pedaladjWltment
800
c
c

models

BRAKE
PEDAL
ADJUSTMENT

The

brake
pedal
height
and
free

play
can
be

adjusted
in

the

following
manner
1400
and
1600
CC
models

Adjust
the

length
of

the
master

cylinder
push
rod
until
the

height
of
the

pedal
pad
is
187
mm
7
36
in

for
manual

gear

boxes
and
202
mm
7
95in
for

automatic
transmission
vehicles

without
brake

light
switch

Fig
L

31

Retighten
the
locknut

Screw
in

the
brake
light
switch
until
the
screwed

part
of
the

switch
is

against
the
front
of
the

stopper
bracket
then

tighten

the
locknut

Screw
in
the

stopper
bolt
until
the
moveable

part
of
the

switch
is

completely
pushed
in

by
the

pedal
and

tighten
the

locknut
in
this

position
Make
sure

that
the

lamp
is
00

when
the

pedal
is

pushed
down

by
1
5mm
0
06
in

1800cc
models

Adjust
the
bolt
of
the
brake

lamp
switch
until
its
end
face

is
flush
with
the
locknut
then

tighten
the
locknut

securely

See

Fig
L
32

Adjust
the

pedal
stopper
until

the

pedal
pad
is

positioned
at
a

height
of
185
mrn

7
28
in
from
the
floor

then

tighten
the

stopper
with
the
locknut

Adjust
the

length

of

the
master

cylinder

push
rod
until
a

pedal
free

play
of
I
5mm

0
04
D
2in
is
obtained
then

retighten
the
locknut

Depress
the
brake

pedal
several
times
to
make
sure
that
a

full
travel
of
145mm
5
7
in
is
available
and
that

the
pedal

moves

freely
and
without
noise

Technical
Data

BRAKE
PEDAL

Pedal

height

1400
and
1600cc
models
I
87mm

7
362in
manual

gearbox

202mm
7
953in
auto

matic

185mm

7
28in

145mm
5
71
in
1800cc
models

Full
stroke

MASTER
CYUNDER

Inner
diameter

Piston

running
clearance
19
05mm
0
75
in

0
15mm
0
006
in

WHEEL
BRAKE
CYLINDERS

Inner
diameter

1400
and
1600cc

Front
drum

Front
disc

Rear
with
front
drum

Rear
with
front
disc
22
22mm
7
8in

50
8mm

2
0

in

22
22mm

7
8in

20

64mm
13
16
in

Inner
diameter
I
BOOcc

Front
drum

20
6mm

13
16in
Front

disc

Rear
50
8mm
2

0in

22
2mm
7
8
in

BRAKE
DRUM
AND
BRAKE
DISC

Drum
inner
diameter

Drum
outer
diameter

Out
of
round
maximum

Repair
limit
of
drum

Maximum
disc
run
out

Repair
limit
of
disc
228
6mm
9
0in

232mm
9
13in

0
05mm
0
002

in

230mm
9
055
in

0
06mm
0
0024
in

8
4mm
0
331
in

BRAKE
UNINGS

Drum
brakes

Width
x

thickness
x

length
40
x
4
5
x
219
5mm

1
575
x
1
772
x
8
642in

Disc
brakes
39
7
x
9
x
86mm

1
563
x
0
354
x

3
386in

Total

braking
area

Front
drum
brake

Front
disc
brake

Rear
351

sq
cn
54
4

sq
in

114
2

sq
cm

17
7

sq
in

351

sq
cm
54
4

sq
in

107

interQ
8
j

@W
2

m
tV

r
ReJld

cop
level

th
elk

FIg
M
I

llIecking
the

specific
gra
ity
of
the

battery
electrolyte
I
Thermal
u
e

Hydrometer

f
j
0
l

Q

I
iJ

Qy@

I
@
@

@
ti

II
@
@

Fig
M
3
Brush
cover
removed

j
i

Fill
M
2
Starter
motor

components

1

L
u
uJIner

pin

2
Drive
mil
Nack

t

3
Dult
COPD

4
E
mmtle
r

5
Aut
mzl

6
Solmoid
mlch

7
Arm
zturr

8
Thnut

9
IJriv
mil

blllck
t
bush

10
17uust

WdSMr

11

Stop
washer

12
CiTc
ip
13
PirUon

srap
collar

14
Pinion

IS
IWfni1l6
clutch

16
Field

coil

17
Yok

18
Politive
brwh

19

N
J1iP
bnuh

20
Bnuh

rprinK

21
Brullr
holder

22

Bearing
bwh

23
Rmr
COJIU

24

Through
botrr
@

FIg
M
5
Yoke

assembly
removed

Fill
M
4
Solenoid
switch
1

108
Fig
M
6
Annatore

assembly
and

engagemenr

lever

removed

ElectrIcal

EquIpment

DESCRIPTION

BATTERY
Maintenance

STARTER
MOTOR

Removal
and

Dismantling

STARTER
MOTOR

Testing

STARTER
MOTOR

Assembly
and
Installation

ALTERNATOR
Removal

Dismantling
and

Inspection

DESCRIPTION

A
12
volt

negative
earth
electrical

system
is
used
in
which

the

battery
is

charged
by
an
alternator
In
the
alternator
a

magnetic
field
is

produced
by
the
rotor

which
consists
of
the

alternator
shaft
field
coil

p
le

pieces
and

slip
rings

Output
current
is

generated
in
the
armature
coils
located

in
the
stator
Six
silicon
diodes
are

incorporated
in
the
alternator

caSing
to

rectify
the

alternating
current

supply
A
voltage

regulator
and

pilot
lamp
relay
are
built
in
the

regulator
box

which

nonnally
does
not

give
trouble
or

require
attention

The
starter
motor
is
a

brush

type
series
wound
motor

in

which

positive
meshing
of
the

pinion
and

ring

gear
teeth
are

secured

by
means
of
an

overrunning
clutch

BATTERY
Maintenance

The

battery
should
be
maintained
in
a
clean
and

dry

condition
at
all
times
or
a
current

leakage
may
occur

between

the
terminals
If

frequent
topping

up
is

required
it
is
an

indication
of

overcharging
or
deterioration
of
the

battery

When

refitting
the
cables
clean
them

thoroughly
and
coat

their

terminals
and
the
terminal

posts
with

petroleum
jelly

Check
the
level
of
the

electrolyte
in
the

battery
at

frequent

intervals
and

top
up
if

necessary
to

the
level
mark
on

the

battery
case
with
distilled
water
A

hydrometer
test
should
be

carried
out

to
determine
the
state

of

charge
of

the

battery
by

measuring
the

specific
gravity
of
the

electrolyte
It
should
be

pointed
out

that
the
addition
of

sulphuric
acid
will
not

normally

be

necessary
and
should

only
be
carried
out

by
an

expert
when

required

The

specific
gravity
of
the

electrolyte
should
be
ascertained

with
the

battery

fully
charged
at
an

electrolyte
temperature
of

200C
680F

The

specific
gravity
of
the

electrolyte
decreases
or
increases

by
0
0007
when
its

temperature
rises
or
falls

by
10C
1
80F

respectively

The

temperature
referred

to
is
that
of
the

electrolyte
and

not
the
ambient

temperature
to
correct
a

reading
for
an
air

temperature
it
will
be

necessary
to

add
0
0035
to
the

reading

for

every
50C
above
200C

Conversely
0
0035
must

be
deducted

for

every
SOC
below
200C
Test
each
cell

separately
and
draw

the

liquid
into
the

hydrometer
several
times
if
a
built
in

thermometer
type
is
used

The
correct

specific
gravity
readings
should
be
as
follows
ALTERNATOR

Assembly
and
Installation

HEAD
LAMPS

Replacing

HORN

INSTRUMENT
PANEL
Removal

WINDSCREEN
WIPERS

WINDSCREEN
WASHERS

IGNITION
SWITCH
AND
STEERING
LOCK

Cold
climates

Temperature
climates

Tropical
climates
Permissible

value

Over
1
22

Over
1
20

Over
1
18
Fully
charged
at
200C

680F

1
28

1

26

1
23

The

battery
should
be

recharged
if
a
low

specific
gravity

reading
is
indicated

Always
disconnect
both
terminals
of
the

battery
when

charging
and
clean
the
terminal

posts
with
a

soda

solution
Remove
the
vent

plugs
and

keep
the
electrolyte

temperature
below
450C
l130F
during
charging

Check
the

specific
gravity
after

charging
and
if
it
is
above

1
260
at

200C
680C
add
distilled
water

STARTER
MOTOR
Removal
and
Dismantling

As
previously
stated
the
starter
motor

is
brush

type
series

wound
motor
in
which
the

positive
meshing
of
the

pinion
and

ring
gear
teeth
are
secured

by
an

overrunning
clutch
The
over

running
clutch

employs
a
shift
lever
to
slide
the

pinion
into

mesh
with
the
flywheel
ring

gear
teeth
when
the
starter
is

operated

When
the
engine
starts
the

pL
lion
is

permitted
to
overrun

the
clutch
and
armature

but
is
held
in
mesh
until
the
shift
lever

is
released
An

exploded
view
of
the
starter

is
shown
in

Fig
M
2

To
remove
the
starter

motor

proceed
as
follows

Disconnect
the

battery
earth
cable

2
Disconnect
the
black
and

yellow
wire
from
the
solenoid

terminal
and
the
black
cable
from
the

battery
terminal

3
Remove
the
two
bolts

securing
the
starter
motor
to
the

clutch

housing
Pull
the
starter
motor

assembly
forwards

and
withdraw

it
from
the
v
hicle

To
dismantle
the
starter

motor
ftrst
remove
the
brush

cover
and
lift
out

the
brushes
as
shown
in

Fig
M
3

Loosen
the
nut

securing
the

connecting
plate
to

the

solenoid
M
terminal
Remove
the
solenoid

retaining
screws

take
out

the
cotter

pin
and
withdraw

the
shift
lever

pin
Remove

the
solenoid

assembly
as
shown
in

Fig
M
4

Remove
the
two

through
bolts

and
rear
cover

assembly

then
remove

the
yoke
assembly
by
lightly
tapping
it
with
a

wooden
mallet

Fig
M
S
Withdraw
the
armature
and
shift

lever

Fig
M
6
Remove
the
pinion

stopper
from
the

armature
shaft

by
removing
the

stopper
washer
pushing
the

109