DATSUN 610 1969 Workshop Manual

Onter
1

2

I

J
I

I

I
r

f
r

1
Float
SelllC

2
F10aI

3
Ffotzt
toppt
T

4

Nudk
m
1
F10at

2

Float
WJlve
ltat

3
Float
valJ1e

4

AcJiwtiflK
tpsket

5

Stopper

Fig
B
6

Adjusting
the
fuel
level
DAK340
C3tbutettor

Fig
B
7

Adjusting
the
fuel
level
D3034C

carburettor

1

11

J
Xi

I

tf
J
t

I

3

J

I

J
Th

1
Choke
mr

r
2

Otoke
m

LuL
3

Conn
ting
rod

4
Connectinlla
o

5
TIuottle
lever

Fig
B
S
Adjusting
the

starting
interlock

opening

6
O
1
Co1UJeCdrlK
lev

2
Rerum

plate

3

Adiust
pWe

4
17rrottle
clrzmber

5
Throttle
valve
1
S
Throttle
arm

2
S

Throttle
ntum
lever

3
Link

4
P1lIrortle
tml

5
P

1lIro
lle
valve

l

I

4
J
L

5
iF
l

1

L

Fig
B
9

Adjusting
the
throttle
valve
interlock

opening
OAK340
carburettor
Fig
B
lO

Adjusting
tbe
throttle
valve
interlock

opening
D3034C

carburettor

520

between

primary
throttle
valve

and
the
wall
of
the
throttle

chamber
can

be

adjusted
if

necessary
by
carefully

bending
the

choke

connecting
rod
3

THROTILE

VALVE
INTERLOCK
OPENING

With

the

primary
throttle
valve
of
the

type
DAK340

carburettor

opened
to
600
as
shown

in
Fig
B
9
the

adjusting

plate
3
should
contact

the

connecting
lever

J
This

being

the

point
before
the

secondary
throttle
valve
is

brough
into

operation
The

linkage
between

primary
and

secondary
throttles

is

working
correctly
if
the
clearance

G
between

primary
throttle

valve
and
the
wall
of
the
chamber
is
738
mm
0
3937
in

Adjust
if

necessary
by
carefully

bending
the
adjusting

plate
at

point
A
until
the
correct

setting
is
obtained

With
the

primary
throttle
valve
of
the

type
D3034C
car

burettor

opened
at
an

angle
of
500
the

connecting
link
3
in

Fig
B
IO
should
ge
at
the
extreme
left
of
the
slot
in
the
throttle

ann
4
With
the

linkage

positioned
as

shown
measure

the

clearance
between

primary
throttle
valve
and
the
wall
of
the

chamber
as
described
for
the
DAK340

carburettor

Adjustment

can

be
made
if

necessary
by
bending
the

connecting
link
until

the
correct
clearance
is
obtained

CARBURElTOR

Removing
and

Dismantling

The
carburettor
can
be
removed

by
following
the

instruc

tions

previously
given
for
carburettor
removal
on
the
Ll4
L16

and
LIB

engines

Dismantle
the
type
DAK340
carburettor
as
follows

Remove
the

primary
throttle
return

spring
Take
off
the

E

ring
and
remove

the
pump
and

connecting
rod
Remove
the

split
pin
and
choke

connecting
rod
Remove
the

secondary

throttle
return

spring
Remove
the
choke
wire
arm
choke
valve

shaft
and
valve

spring
Take
off
the

clip
and
remove

the
choke

lever
and

spring
To
dismantle
the
float
chamber
take
off
the

diaphragm
cover
and
remove
the

spring
and

diaphragm
Remove
the

diaphragm
chamber
and

gasket
Take
off

the
float
chamber

cover
and
remove
the

gasket
level

gauge
rubber
seal
and
float

Remove
the
screw
from
the
filter
and
withdraw
the

nipple

and
filter
Remove
the

needle
valve
Take
off
the

cylinder

cover

and

pump
cover

and
withdraw
the

piston
piston
return

spring
and
inlet
valve
Remove
the

primary
main
air
bleed
the

secondary
main
air
bleed
and
emulsion
tube
Take

off
the

small
venturi
and
remove
the

primary
and

secondary
slow

jets

and
slow
air
bleeds
Remove
the
drain

plugs
and
take
out
the

primary
and

secondary
main

jets

To
dismantle
the
throttle
chamber
remove
the
throttle

adjusting
screw
and

spring
and
the
idling
adjusting
screw
and

spring
Withdraw
the
throttle
lever

spring
hanger
sleeve

connecting
lever
return

plate
and

adjusting
plate
Withdraw

the

primary
throttle
valve
and

primary
throttle
shaft
Withdraw

the

secondary
throttle
valve
and

secondary
throttle
shaft

The

type
D3034C
carburettor
can
be
dismantled
as
follows

Detach
the

starting
connecting
rod
from
the
choke

lever
and

accelerator

pump
connecting
rod

Remove
the
air
horn

pump
rod
slow

jets
the

primary
and

secondary
small
venturies
Detach
the

primary
and

secondary

linkages
Take
off
the

diaphragm
chambe
cover
and
take
out

the

spring
and

diaphragm
Remove
the

diaphragm
chamber
and

gasket
Separate
the
float
chamber
from
the
throttle
chamber

take
off

the
float
chamber
cover
and
remove
the

components

Remove
the
inlet
strainer
and
float
valve
seat
Remove
the
main

jets
and

take
off
the
fuel

cut
off

valve

CARBURETTOR

Assembly
and
Installation

The

assembly
and
installation
of
the
carburettor
is
a

reversal
of
the

dismantling
and
removal

procedures

Clean
and

inspect
all

components
as
described
for
the

carburettors
fitted
to
the
Ll4
Ll6
and
LI8

engines

TechnIcal
Data

CARBURETIOR
Small
ven
turi

First
7mm

8mm

Carburettor

Type
DAK340
Second
14mm
16mm

Main

jet
02
155

Primary
Secondary
Slow

jet
50
80

Main
air
bleed
60
80

Outlet
diameter
30mm
34mm
Emulsion
hole
0
5
mm
O
5mm

Venturi

diameter
23
mm

29
x
9
mm

Slow
air
bleed

Main

jet
119
165
First
160

Main
air
bleed
220
100

Second
150
220

Slow

jet
48
90

Slow
economizer
1
6
mm

dia

Slow
air
bleed
130
100

Power

jet
50

Slow
economizer
L4mm

Cushion

jet
120

Economizer
bleed
1
2mm

Air

jet
150

Carburettor

Type
D3034C
Power

system
Vacllum

acting

Vacuum

piston
diameter
9
0
mm
0
354
in

Primary

Secondary
Piston

spring
100

gr
0
220
Ibs
31
mm

1
22
in

Bore
30mm
34mm
Power
valve

spring
40

gr
0
0882
lbs
8
6mm

Large
venturi
23mm

28mm
0
34
in

52

inter
M
j

@W

J

1

i
I

r

p

@
2
1
Strut
mounting
inzulDtor

Thruu
b

aring

J
Coil

prins

4
rubber

j
Sl1ut

mbly

6
Compression
rod

Z
Bal

joint

8
T
1ink

9
Stabi
iur

10
ODS

rnt
r
i

L
St

Ting
wheel

2
Steering
column
maft

J
Rubb
rCOfl
linK

4

Sturing
lower
joint

5

St
rinuotlr
IwusUr8

6
Sid
rod

XlI

Fig
C
1
Front

suspension
assembly
Fig
C
2
The
steering

gear

iQ

r
y
y

v

I
Ii

1
1

Fig
C
3

Collapsible

steering

Fig
C
4

Disconnecting
the
brake
hose

I

f41
I
I
t

h
I

t
t

Il
t

k
I

Fig
C
5

Removing
the
front
hub
and
brake

disc
Fig
C
6

Detaching
the
brake
disc

522

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

inter
l
m

@
j1l

i

Iii

il

Fig
C

8

Greasing
points
on

the

strut
mounting
insulator

Fig
C
7

Remofing
the
stabilizer

Fig
C
t
0
View
of
the
front

sospension

Fig
C
13

Adjusting
the
toe
in

524
FRONT

l

I

I
I
REAR

Fig
C
9
Section
through
the
transverse

link
bush

r

I

r

Fig
C
t
1

Supporting
the

engine

fig
el2

Removing
the

suspension
member

Fig
C
14

Removing
the
rubber

coupling
bolts

R
H
D

Remove

the
road
wheel
and
disconnect
the
brake
hose
at

the
connector
as

shown
in

Fig
C
4
of
this
section

Remove
the
brake

calliper
assembly
and
hub

cap
Withdraw

the
cotter

pin
and
remove
the
wheel

bearing
locknut

Remove
the
wheel

bearing
washer
and
take
off

the
hub

and
brake
disc

Fig
C
5
Remove
the

bearing
collar
take
out

the
outer

bearing
cage
and

prise
out

the
hub

grease
seal
Remove

the
inner
bearing
cage
and
drive
out
the
outer
races

of
the
inner

and
outer

bearings
using
the

special
drift
ST49120000

if
avail

able

Separate
the
brake
disc
from
the
hub
by
taking
out
the

retaining
bolts
as
shown
in

Fig
C
6

Installation
is
a

reversal
of
the
removal

procedure
Adjust

the
wheel

bearings
as

previously
described

taking
care
to

tighten
the
wheel

bearing
locknut
to
the

specified

torque
read

ing
of
3
0
to
3
5

kgm
21
7
to
25
3lb
ft
Turn
the
hub

several
times
to
settle
the

bearing
then
retighten
the
nut
to
the

same

figure
Slacken
the
locknut

by
a

quarter
turn
900
and

insert
the
cotter

pin
when
the
hole

in
the

spindle
is
aligned

with
the
hole
in
the
nut
Check
that
the
force

required
to
turn

the
hub
is
less
than
7
0

kg
cm
97
2
in
oz

STABILIZER
Removal
and
Installation

Remove
the

splash
board
and
take
off
the
bolts
I
in

Fig
C
7
which
attach
the
stabilizer
at

the
transverse
link
sides

Remove
the
bolts

attaching
the

stabilizer
bracket
2
to

the
frame
then

withdraw
the
stabilizer

Check

the
bar
and
rubber

components
for

signs
of
deforma

tion
or

damage
and
renew
as

necessary

Installation

is
a
reversal
of
the
removal

procedures
Tighten

the

fixing
bolts
to
a

torque
reading
of
1
2
to
I
7

kgm
8
7
to

12
3
lb
ft
at

the
transverse
link

side
and
1
9
to
2
5

kgm
13
7
to

18
llb
ft
at
the
frame
bracket

SPRING
AND
STRUT
ASSEMBLY

The

spring
and
strut
assembly
can
be
serviced

by
following

the
instructions
previously
given
for
the
assemblies
on
vehicles

fitted
with
the
L14
L16
and

Ll8engines

When

reassembling
make
sure
that
the

parts
shown
in

Fig
C
8
are

thomughly
greased
Installation
of
the

assembly

will
be

accomplished
more

easily
if
the
dust
cover
on
the
bonnet

ledge
is
removed

Tighten
the
nuts
and
bolts
to
a

torque
figures
given
in

TIGHTENING

TORQUES

TRANSVERSE
LINK
AND
LOWER
BALL
JOINT

The
transverse
link
and
lower
ball

joint
can
be

removed
in

a

similar
manner
to
the

parts
on
vehicles
fitted
with
L
14
L
16

and
L
18

engines

Renew
the
link

if
cracked
or

damaged
in

any
way
Check

the

measurement
A
in

Fig
C
9
The
measurement
between

front
and
rear
transverse

link
bushes
should
be
less
than
1
0
mm

0
039
in

Replace
the
bushes
if

necessary
The

lower
ball

joint

should
be

replaced
if
the
axial

play
of
the

joint
exceeds
0
03

to
0
6

mm
0
0012
to
0
0136

in
A

grease
nipple
must

be
installed

in

place
of
the
ball

joint

plug
so

that
the

joint
can
be
lubricated
with
multi

purpose
grease

as

previously
described

SUSPENSION
MEMBER

Removing
and

Installing

Jack

up
the
vehicle
and

support
it
on

stands

2
Remove
the

splash
board
Refer
to

Fig
C
I
0
and
detach

the

compression
rod
I
the
stabilizer
2
from
the
trans

verse
link
3
Detach

the
steering
linkage
from

the
suspen

sion
crossmember
4

3
Take
out

the
nuts

attaching
the
transverse
links
and
remove

the
links
at
both
sides
of
the
vehicle

4

Support
the

engine
with
a
hoist
as
shown
in

Fig
C
II

taking

care
not
to

damage
the
throttle
and
remote
control

linkages

and
then
remove
the

engine
mounting
bolts
at
both
sides

5
Remove
the

bolts
shown
arrowed
in
Fig
C
12

and
lift
the

suspension
member

away

Renew
the

suspension
member
if
it
is
cracked
or

deformed

in

any
way
Installation
is
a
reversal
of
the
removal

procedure

FRONT
WHEEL
ALIGNMENT

As

previously
stated
the
castor
and
camber

angles
are

preset
and
cannot

be

adjusted
A

thorough
check

should
be

made
of
the

steering
and

suspension
system
and
all
defective

parts
renewed
if

the

angles
are

incorrect
See
Technical

Data

The
front
wheels
should
toe
in

12
to

15
mm
0
4
7
to

0
59

in

Adjustment
can
be
carried
out

by
slackening
the
locknuts

1
in

Fig
C
13
and
then

turning
the
tie

rods

by
an

equal
amount

until
the
correct
toe

in
is
achieved
A
toe

in
gauge
will
of
course

be

required
for
this

operation

STEERING
WHEEL
AND
COLUMN
Removal

Disconnect
the
horn
wire
and
remove
the
horn
bar
Remove

the

steering
wheel
nut
and

pull
off
the

steering
wheel

2
Remove
the
turn

signal
and

lighting
switch

assembly
followed

by
the

steering
column
shell
covers

3
Remove
the
bolts
from
the
rubber

coupling
to

disconnect

the
lower

joint
See

Figs
C
14
and
C

I
5
if
the
car
is

fitted
with

right
hand
drive
The
lower
joint
upper
bolt

should
be
removed
to
disconnect
the

joint
if
the
car

is

fitted
with
left
hand
drive

4
Remove
the
cotter

pin
from
the
trunnion
and
disconnect

the

gearchange
rod
and
selector
rod

5
Remove
the

steering
column

upper
clamp
and
take
out
the

bolts

securing
the
lower

plate

STEERING
COLUMN

Dismantling
and

Assembling

Remove
the
C
washer
socket
screw
and

upper
bracket

bolt
Remove
the
lower
bracket
bolts
and
detach
the
remote

control

linkage
from
the
column

assembly

Remove
the

snap
ring
at
the

top
of
the
column
and
extract

the
column
shaft
from
the

jacket

Disconnect
the
rubber
coupling
from
the
lower

joint

then
remove

the
snap
ring
and
dismantle
the
lower
joint

S25

inter
Il
l

@
l

10
9
8
7
6
3
5
4

I
i

I
I
I

I
I

I
I

I
1

Snap
ring

I
2
P
antwashor

I

3
St

ng
column

bNring

4
S

eerinK
column

shaft

5

Str
nUIx
column

jacket

6
St

riJrg
column

spring

7
Dust
covu

I
8
Rubber

coupling

9
Rubber

coupling

f10nre
I

10
Str

t
rin8lcwer
joint

mbly

I

I
1
Z

I

1

J

Fig
ClS
1be

steering
column

lfj

II

J
1
Pinion

2
ck

3
Oil
i6d

4
Pinion
bearing

Locknut

6
RetlliMr

print

7
Ret11inn

adjwt
fC1
r
W

9
FiIJd

plug

9
FiJILr

p1u
1
a

Steering

gear
boot

11
Locknut

12
Sid

rodinmr
f1fUtl

13
Side
rod

5
Jring
seat

4
Inner
socket

15
Sid
rod
baD
stud

16

DustceJVqclomp

1
Z
Side
rod

assembly

7

5

2

Fig
Cl6
9

The
rack
and

pinion
with
tie
rod

I

1

il
1

W

y
o

Ol

l
r
I

J

I

t4

I

J
Z

i

I
i

r

t
I
1
Ball

stud
mil

2
Knuckkamr

3
DultCOver

4
lll
tud

5

Sid
rod

Fig
C
IS
Tie
rod
ban
stud

526
J

1

26
3

Windiameler
2
6mm
al02in

Fffl
I

ngth
J6
3
mm

1
035
in

CoillUms
5
5

Load
I

ngth
JOkg
44
b
jx

16
3
mm
0
642
in

FiS
C
20
Retainer

sprins

t

Wire
diameter

Free

Ie

Q
U
tums

Load
x

1ensth

Fig
C
21

Fig
C
17

Removing
the

splash
board

Fig
C
19

Removing
the
retainer
locknut

Gean
all

parts
thoroughly
and
renew
if

damaged
If
the

column
shaft
or

jacket
is

excessively
damaged
the

steering
gear

housing
must

be
checked
A

damaged
bearing
must

be

replaced

together
with
the
column

jacket
assembly

Assembly
is
a

reversal
of
the

dismantling
procedures
The

column
shaft

journal
should
be
lubricated
with

multipurpose

grease
which
can
also
be
used
to
fill

up
the
dust
cover
Grease

the
needle

bearing
when

assembling
the
universal

joint
Use

the

tightest
snap

ring
available
when

fitting
the
needle

bearing
Snap

rings
are

supplied
in
oversizes
of
0
95
mm
05
mm
and
1

5

mm

0
0374
0
0413
and
0
0453

in

Installation
of
the
column

assembly
is
a
reversal
of
the

removal

procedures
Tighten
the
rubber

coupling
bolts
to
a

torque
reading
of
I
S
to
1
8

kgm
I
0
8
to

13
0
Ib
ft
Refit
the

steering
wheel
and

tighten
the
nut
to
a

reading
of
4
0
to
5
0

kgm
28
9
to
36
2Ib
ft

RACK
AND
PINION
AND
TIE
ROD

Removing
and

Dismantling

1

Jack

up
the
vehicle
and

support
it
on
stands
Remove
the

road
wheels

2
Slacken
the
bolts

connecting
the

pinion
to
the

steering

lower

joint
See
Figs
C

16

3
Remove
the
bolts
from
the
steering
column
rubber
coupl

ing
See

Fig
C
15
and
remove
the

splash
board

Fig
C
17

4

Remove
the
tie
rod
ball
stud
nut
and
disconnect
the
tie

rod
from
the
knuckle
arm

Fig
C
I8

5
Lift
the

engine
slightly
with
suitable
tackle
but
take
care

not
to

damage
the
accelerator
or
remote
control

linkage

Remove
the
bolts

securing
the
steering
gear
housing
to
the

suspension
member
Withdraw
the
rack
and

pinion

assem

bly

Dismantle
as
follows

Detach
the

steering
lower

joint
from
the
rack
and

pinion

assembly
Clamp
the
unit
in
a
vice

taking
care
not
to

damage

the

steering
gear
housing

Refer
to

Fig
C
16
and
take
off
the
dust
cover
and
boot

clamps
at

both
sides
Slacken
the
stopper
nut

remove
the
tie

rod
inner
socket
and
disconnect
the
tie
rods
from
the
rack

Withdraw
the

spring
seat
and
tie

rod

spring
Take
off
the

steering

gear
boots
at
both
sides
Slacken
the
locknut
and

disconnect
the
tie
rod
outer
socket
from
the
ball

Slacken
the
locknut
remove
the
retainer

adjusting
screw

and
withdraw
the
steering

gear
retainer
See

Fig
C
19

Take
off
the
oil
seal
remove
the
snap
ring
and
withdraw

the

pinion
Remove
the

snap
ring
and
withdraw
the

bearing
from

the

pinion
Remove
the
filler

plug
and
take
out
the
rack
Remove

the

grease
reservoir

Clcan
all

parts
thoroughly
and

replace
any
which
show

signs
of
wear
or

damage
Check
the
axial
play
of
the
inner

and

outer
ball

joints
The

play
should
be
0
06
mm
0
0024
in
for

the
inner
ball
joint
and
from
0
1
to
0
5
mm
0
0039
to
0
0197

in
for
the
outer

joints
Use
a

spring
balance
to
check
the
force

required
to

swing
the
ball

joints
this
should
be
between
0
8
to

LS

kgm
5
8
to
10
8Ib
ft
Renew
the
oil
seal
Examine
the
retainer
and

tie
rod

springs

and

compare
them
with
the
values

given
in

Figs
C
20
and
c
n

RACK
AND
PINION
AND
TIE
ROD

Assembling
and
Adjusting

Press
the

bearing
on
to

the
pinion
gear
and
fi
t

the
tigh
test

snap
ring
available

Snap
rings
are

supplied
in
the

following
over

sizes

Snap

Ring
Thicknesses

1
04
to
1
09
mm
0
0409
to
0
0429
in

1
09
to
I
14
mm

0
0429
to
0
0449
in

1

14toI19mm
0
0449toO
0469in

Ll9
to
1
24
mm

0
0469
to
0
0488
in

1

24
to
1
29
mm
0
0488
to
0
0502
in

Clamp
the

steering
gear
housing
in
a

vice
Grease

the
teeth

and
friction
surfaces
of
the
rack
with

multipurpose
grease

Lubricate
the

gear
housing
from
the

pinion
housing
side

Ensure
that
the
rack

projects
by
an

equal
amount

of

96
mm

3
8
in
in
both
ends
of
the

housing
with
the
rack

teeth

directed
towards
the

pinion
shaft

Grease
the
pinion
teeth
end

bushing
and

pinion
bearing

Engage
the
tccth
of
the

pinion
with
the
rack
and
insert
the

pinion
Make
sure
that
the

bushing
does
not
become
damaged

The
rack
must

project
from
the

housing
by
an

equal
amount

at
each
side
with
the

groove
on
the

pinion
serration

facing

upwards

Fit
the

snap
ring
into
the
housing
groove
to
hold
the

bearing
outer
race

in

position
The

snap
ring
must

fit

tightly

and
can
be
selected
from
the

following
oversizes

Snap
Ring
Thicknesses

LS5
to

1
60
mm
0
0610
to
0
0630
in

1
60
to
1
65
mm
0
0630
to
0
0650

in

1
65
to
I
70
mm
0
0650
to
0
0669
in

1
70
to
I
75
mm
0
0669
to
0
0689

in

Fit
the
oil
seal
Use
a
dial

gauge
as

shown
in

Fig
C
22
to

check
the
thrust

play
of
the
pinion
The

play
should
be
less

than
0
09mm
0
0035
in

Grease
the
retainer
and
insert
it

with
the
spring
Tighten

the
retainer
adjusting
screw

fully
then
back
it
off

by
20
to

25

degrees
Tighten
the
locknut
to
a

torque
reading
of
4
0
to

6
0

kgm
28
9
to
43
4lb
ft
Coat
the
locknut
with

liquid
pack

ing
Three
Bond

When
the
rack
and

pinion
is
assembled
measure
the
force

required
to
rotate

the
pinion
and
also
the

preload
of
the
rack

Use
a

spring
balance
as
shown
in
Figs
C
23
and
C
24
and
check

that
the

pinion
torque
is
8
to
20

kg
cm
7
to
17
Ib
in
and
the

rack

preload
is
from
8
to
18

kg
17
6
to
39
7Ibs
Take
care

to
slide
the

assembly
over
the

complete
range
of
the
stroke

Fit
a
dust
cover

clamp
at

each
end
of
the
housing
Install

the

stop
nut
on
the
threads
of
the
rack

Liberally

grease
the
ball
joint
friction
area
of
the
tie
rod

assembly
Assemble
the
spring
and
ball
seat
and
fit
the
inner

socket

part
of
the
tie
rod

assembly
to
the
rack
Make
sure
the

boot
is

positioned
at
the
ball
stud
end
Note
that
the
left
hand

tie
rod
is
marked
with
an

L
the

right
hand
rod
is
not
marked

527

inter
C

7
j
l

l

IJ

Fig
C
22

Checking
the

pinion
tluust

play
Fig
C23
ML
Io

b
the

torque
required
to
rotate
the

pinion

Fig
C
24

Measuring
the
rack

pre
load

Fig
C
25

Tightening
the
tie
rod
inner
socket

stop
nut

S
rod
I
p
ing

Boot
Spring

I
Boot

cl
np

Side
rod
1

t
I
I

Lock
n
rt

38
5n
m
1

5115in

Staaj
xial

p1
Y
o
l5errm
0
02

5in

Fig
C
26

Measuring
the

torque
required
to

swing
the
tie
rod
Fig
C
2
Section

through
the
tie
rod
ball

joint

Slila

niversatjoint

Punch
marif

located
on

upper
nd
of
upper

steering
shaft

Fig
C
28

Aligning
the
universal

joint
with

upper
steering
shaft

528

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