height DATSUN 610 1969 Owner's Manual

greased
Install
the

flange
washer
and

pinion
nut
Tighten
the

nut
to
a

torque
reading
of

14
17

kgm
101
130
Ib
fL
If

the
cotter

pin
hole
is
not

correctly
aligned
a
suitable

washer

should
be
fitted
Do

NOT

adjust
by
overtightening
the

pinion

nul

Van

Lubricate
the
front

bearing
with
oil
and

place
it
in
the

carrier
Grease
the

lip
of
the
oil
seal

and
install
it
to
the
final

drive

housing
Install
the
drive

pinion
the
new

collapsible
spacer

and

the
drive

flange

Fit
the
drive

pinion
nut
and

tighten
temporarily
until
all

slackness
is
eliminated
from
the
front

and
rear
of
the
drive

pinion

NOTE

Ensure
that
oil
and

grease
have
been

completely

removed
from

the
threads
of
the

pinion
gear
the

pinion

nut
and
the
washer

Tighten
the

pinion
nut
and
check

the

preload
with
a

preload

gauge
As
the
nut

is

tightened
to
the

specified
torque

reading
of
13
20

kgm
94
0
144

6Ib
fL

the

preload
must
be

measured
at

every
five
to
ten

degrees
turn
of

the

pinion
nut

As
the

pinion
nut
is

tightened
the

stepped
portion
of
the

spacer

is
deformed
See

Fig
G
29
J
and
the

length
between
the

bearings

adjusted

The
drive

pinion
bearing
preload
with
oil
seal
and
new

bearing
is
7
15

kg
cm
6
1
13
0
lb
in

Turn
the
drive

pinion

to
settle
the

bearing
and
re
check
the

preload
and

tightening

torque
If
the

preload
rate
is
exceeded
it
will
be

necessry
to
fit

a
new

spacer
the
old

spa
cr
cannot
be

reused
and
the
preload

must
not
be

adjusted
by
loosening
the
pinion
nul

Side

bearing

pre
load

adjusting

If

the

original
side

bearings
arc
to
be
used

the
shims
must

be
of
the

same
thickness
as
those

previously
fitted

To
select
shims
for
new

side

bearings
proceed
as
follows

The
standard

width
of
the
side

bearings
is

given
in

Technical
Data
This

width
must

be
measured
before

attempting

to

calculate
the

required
thickness
of
the

adjusting
shims
Place

a

weight
of

approximately
5

kg
5
5
lb
and
of

predetermined

height
onto
the
side

bearing
as
shown

in
Fig
G
30
Mcasure

the

width
of
the

bearing
with
a
dial

gauge
as
illustrated

turning

the

bearing
two
or

three
times

to

gain
an
accurate
meaSurement

Dimensional
variations
from
the
standard
measurements

are
marked
on
the
left

side

bearing
housing
of
the

gear
carrier

on

the

right
side

bearing
housing
of
the

gear
carrier
and
on

the

differential

case
These

variations
are
marked
in

units
of

l
lOOmm

and
are
used
for
the

f
rmula
to

calculate
t1H
thickness
of

the

adjusting
shims
in
the

following
manner

Where
TI

equals
the
left
side

bearing
shim

crownwhecl

side

T2

equals
the

right
side

bearing
shim

pinion
gear
A

equals

the

figure
marked
on

the
left
side

bearing
housing
B

equals
the

figure
marked
on
the

right
side

bearing
housing
C
and
0

equals

the
figure
marked
on

the
differential
case
and

E
and
F
is
the

difference
bctween
the

width
of

the
side

bearings
and
the

standard

bearing
width
H
the

figure
marked
on
the

crownwhcel
Fig
G
31
The
following

formulae
can
now
be
used

to
deter

mine
the

required
shim

thicknessl
s
for

both
side

bearings

I
OOcc
Estate
car

Left

side

bearing
TI
A
C

D
H
x

0
01
0
100
E

Right
side

bearingT2
B
D
H
x

0
01
0
090
F

I800cc

Van

Left
side

bearingTI
A

C
D
H

xO
OI
0
175
E

Right
side

bcaringT2
8
D
H
x
0
01

0
150
F

As
an

example
where
A
1
B
C
2
D
3
E
0
02mm

H
I

The
formula
for
the
left

side

bearing
is

T
I
I
1
3
1

x
0
01

0
175
0
02
0
205mm

1400
and

1600cc
Estate
car

The

required
thickness
of
shim
can
be
found

using
the

following

formula
in

a
similar
manner
to

that

previously
described
for

the
1800cc
models

Left

side

bearing
T
I
A

C
D
E
7

Right
side

bearing
T2
B
D
F

6

Shims
are
available
in
five
thicknesses
of
0
05
0
07
0
10

0
20
and
0
50
mm

0
002
0
0028
0
0039
0
0079
and

0
0197

in

Fit
the
selected
side

bearing
adjusting
shims
on
the

differential

cage
and

press
in
the
side

bearing
inner
races

using

a

suitable
ddfL
nstall
the
differential
cage
into

the
carrier
and

fit
the

bearing

caps
Ensure
that
the
marks
on

the

caps
coincide

with
the
marks
on
the
carrier

Tighten
the

bearing
cap
bolts
to

the

specified
torque
reading
See

Tighte
ing
torques

Measure
the
dimension

between
the
outer

edges
of

the

left

and

right
hand

caps
using
a

large
micrometer
as
shown
in

Fig
G
32
This
dimension
should
be
198
40
198
55
mm

7
8110
7
8169

in
for

the
1400

and
1600
ce
Estate
cars
and

1800
ce

Van
and
173
23
17329
mm
6
8201
6
8244
inl

for

the
1800
cc

Estate
cars

Measure
the
backlash
of
the
crownwhcel
and

pinion
with

a
dial

gauge
The
backlash
must
be

adjusted
to
0
13
0
18
mm

0
005

0
007
in
on

the
1800
CC
models

and
to
0
15
0
20mm

0
006
0
008
in
on
the
1400
and
1600
cc
models

Adjustment

can
be
carried
out

by
moving
side

bearing
shims
from
the

right

hand
side
to
the
left
hand
side
if
the
backlash

is
too

high
or
vice

verca
if
the
backlash
is
too
low

Tighten
the

bearing
cap
bolts

to

the

specified
torque

reading
after

adjusting
Ensure
that
the

run
out
at
the
rear
of
the
crown
wheel

does
not

exceed
O

05mm

0
002
in

Finally
heck
the
tooth
contact

pattern
as
described
below

TOOTH
CONTACT
PATTERN

Checking

The
final
check
on

reassembly
is
an

inspection
of
the

tooth

contact

markings
of

the
crownwhed
and

pinion

Apply
a

coal
of
red
lead
in

oil
to
4
or
5
teeth
of
the
crown

wheel
Turn
the
crownwheel
backwards

and
forwards
several

times
to
obtain
a
clear

impression
of
the
contact
areas

Heel
contact

Fig
G
3
1

71

inter

Q1Ju@
j1l

J

Ikli
l1t
J

T

II
ill

4
LU

I

Il

lJr

I
I

II
Ii

wrllJ
I

l

Y
1iJ

u
r
1

o

77

1
I
l

0
L
J

Dm
hJtl
lllL
l
m
h

t
l
u

c

N

I
Fig
G
29

Measuring
the
clearance
between
the

height
gauge
and

dummy
shaft
3

i
T

O
O
1
L
Th
t
nn

mu
U
J

Fig
G
28
Location
of
the

dummy
shaft
and

drive
pinion
setting
gauge
Fig
G
JO

Measuring
the
width
of
the
side

bearing

under
load

j
Fig
G
32

Measuring
the
dimension
between
left
and

right
hand

bearing
caps
see
text

Fig
G
3
Calculating
the
differential
side

bearing

shims

Af
A

A

HEEL
DRIVE
HEEL
COAST
HEEL
DRIVE
HEEL
COAST

HEEL
DRIVE
HEEL

COAST

SIDE
SIDE
SlOE
SIDE

SIDE
SIDE

Fig
G
33
Heel
contact
Fig
G
34
Toe
contact

Fig
G
35
Flank
contact

TOE
TOE

A
A

HEEL
DRIVE
HEEL
COAST
HEEL
DRIVE
HEEL
COAST

SIDE
SIDE
SIDE
SIDE

Fig
G
36
Face
contact
Fig
G
37
Correct
contact

72

increase
the
thickness
of
the
drive

pinion
adjusting
shim

and
washer
to
move
the
drive

pinion
closer
to
the
crown
wheel
A
correct

contact

pattern
showing
the

impressioll
ithill

a

range
of
2

3
to
4

of
the

distance
bct
l
en

t
h

tip
lllU
till

root
of
the
teeth

under
no

load

Toe

contact

Fig
G
34

Rcdu
e

the
thickness

of
the
drive

pinion
adjusting
shim
and

washer
to
move
the
drive

pinion
away
from
the
crown
wheel
It
will
be
neCL

ssary
to
rc

check
the
backlash
bl

tW
Cl1
drivt

pinion
and
crown

wheel
if
the

adjusting
shim

1l1d
washer
arc

changed

Flank
contact

Fig
G

35

DIFFERENTIAL
Installation

This

pattern
should
be

adjusted
in

a
similar
manner

to
toe

contact

Face
contact

Fig
G
36
Installation
of
the
differential
carrier
is
J

reversal
of
the

removal

procedure
Reference
should
be

made
to
the
section

REAR
AXLE
AND
REAR
SUSPENSION
for
a
dl

saipIion
of

the

operations
required
to

replace
the
axle

shafts

This

pattern
should
be

adjusted
in

a
similar
manner
to

heel
contact

Correct
contact

Fig
G
37

Technical
Data

PROPELLER
SHAFT

Axial

play
of

spider
journal
0800

Axial

play
of

spider
journal
1400
and
1600
cc
0
Q2
mm

0
0008
in

0
08
mm
0
003
in

Max
run

out
of
shaft

Wear
limit
of

spider
diameter
0
6
mm
0
024
in

0
15
mm

0
006
in

Permissible

dynamic
unbalance

Two

joint
shaft

Three

joint
sh
lft
15
gr
em

0
208
in
oz
at
4000

rpm

35

gr
cm
0
5
in

oz
at
5800

rpm

FINAL
GEAR
RATIOS

1800cc
Saloon
6101

ISOOcc
Estate
Car

610

1800cc
Van
610

1600cl
SJloon
610

1400

and
1600cc

510
4
Door
Saloon
RHO

4
Door
Saloon
LHD

De

Lu
e
4
Door
Saloon
RHO

SSS
4
Door
Saloon
RHO

Door
Saloon
LHO
3700

3
889

4
375

3
900

4375

4111

3
889

3
900

3
700

DRIVE
PINION

InitiJI

turning
torque
without
oil
sea

Saloon
modds

Estate
CJr
models
7

10

kg
em

0
506
0
723Ib
ft

10
13

kg
em
0
723
0
940Ib
ft

Thickness
of

pinion
height

adjusting
washers
1400

and
1600
CC

Saloon

1400
and
1600cc
510

Thickncss
of

pinion
height

adjusting
washers
0800
cc
Saloon
0
4
mm
0
078
0
086
0
094
in

3
09
3
66mm

0
1
17

0
1441
in

in
increments
of
0
03
mm

0
00
I
in

Thickness
of

pinion
height

adjusting
washers
0800
n
Estate
car
0
050
0
070
0
100
0
200
0
500mm

0
0020
0
0028
0
0039
0
0079
0
0197
in

Thickness
of

pinion
height

adjusting
washers

1800
CL
Van
37
97111m
0
0933
0
I
69
in

in
increments
of
0
03
mm
0
00
I
in

73

J

Thickness
of

pinion
height

adjusting
shims
1400
and
160Occ
Saloon

Thickness
of

pinion
height

adjusting
shims

1400
and
1600
cc
Estate

Length
of
drive

pinion
bearing

adjusting
washers
Saloon
Estate

Length
of
drive

pinion
bearing

aqjusting
screws
Saloon

y
Length
of
drive

pinion
bearing

adjusting
spacers
1400
and
1600
cc
Estate

Length
of
drive

pinion
bearing

alljusting
spacer
1800cc
Estate

1800
cc
Van

Backlash
between
gears

Saloon

1400
1600
cc
Estate

1800
cc
Estate
Van

Run
out
at

rear
of

crown
wheel

1800
cc
1400
1600cc
Estate

1400
1600cc
Saloon

Thickness
of
side

gear
thrust
washers

Saloon

Estate

Qearance
between
side

gear
and
washer
Saloon

aearance
between
side

gear
and
washer
Estate

74
L09
1
27
mm
0
0429
0
0500
in

in
increments
of
0
02
mm
0
0008
in

0
75
0
50
0
25
0
125
mm

0
0295
0
0197
0
0098
0
0049
in

2
31
2
59mm
0
0909
0
1020

in

in
increments
of
0
02
mm
0
0008
in

56
20
57
20
mm
2
213
2
252
in

in
increments
of
0
02
mm
0
0008
in

59
25
59
50
597Omm

2
338
2
343
2
358
in

48
4
48
6
48
8
49
0

0
9055
1
9134
1
9213
1
9291
in

Non

adjustable
collapsible
SP3
O
L

CROWNWHEEL

0
10
0
20
mm
0
004
0
008
in

0
15
0
20
mm
0
006
0
008
in

0
13
0
18
mm
0
005
0
007
in

Less
than
0
05
mm
0
002
in

Less
than
0
08
mm
0
003
in

DIFFERENTIAL
GEARS

0
775
0
825
0
875
mm

0
0305
0
0325
0
0344
in

0
78
0
83
0
88
1
03
1
23
mm

0
10
0
20
mm
0
004
0
008
in

0
05
0
20
mm
0
002
0
008

in

Rear
Axle
Rear

SuspensIon

DESCRIPTION

REAR
AXLE
AND
SUSPENSION
Removal
Saloons

COIL
SPRINGS
Saloons

REAR
SHOCK
ABSORBERS
Saloons

REAR
SUSPENSION
ARM

Saloons

DESCRIPTION

Saloon
models
are
fitted
with

independent
rear

suspension

with
semi

trailing
arms

suspension
arms
coil

springs
and

telescopic
hydraulic
double

acting
shock

absorbers
The
differ

ential

gear
carrier
and

suspension
member
is
mounted

directly

onto

the

body
structure

via
rubber

mountings
See
Fig
H
I

Estate
cars
and
1800
ce
Vans
are
fitted

with
a
semi
floating

rear
axle
with
semi
elliptic
leaf

springs
and

telescopic
hydraulic

shock
absorbers
mounted
on
rubrer
bushes
See

Fig
H
2

REAR
AXLE
AND
SUSPENSION
Removal

Saloon
models

I
Jack

up
the
rear
of
the
vehicle
and

support
it
on
stands

2
Remove
the
road
wheels
disconnect
the
hand
brake

linkage

and
the
return

spring
Fig
H
3

3
Remove
the
exhaust
tail

pipe
and
silencer

4
Disconnect
the
brake
hoses
and
plug
the
openings
to

prevent

the

ingress
of
dirt

5
Remove
the

propeller
shaft

assembly
as
described
in
the

relevant
section
after

marking
the

propeller
rear

flange

and
differential

pinion
flange

6
Jack

up
the

suspension
ann

and
remove

the
shock

absorber

lower

mountings
taking
care
not
to
lose
the
rubber

bushings

7
Place

ajack
under
the
centre
of
the

suspension
member

and
differential

carrier
and
remove

the
nuts

securing
the

suspension
member
to
the

body
7
in

Fig
H
3
Remove

the
differential

mounting
nuts
8

8
Carefully
lower
and
remove
the

suspension
assembly

REAR
SUSPENSION

Inspection

Saloons

Examine
all

parts
for

wear
and

damage
paying
particular

attention
to
the
rubber
bushes

in
the

suspension
arms
and
the

bump
rubbers
Check
the
condition
of
the

spring
rubber
insulators

in
the

suspension
member

and
differential

mounting
memrer

The
rubber
insulators
must
be

replaced
if
the
dimension
A

in

Fig
H
4
is
less

than
5mm
0
2
in
REAR
AXLE
SHAFTS
BEARINGS
AND
SEALS
Saloons

DRNE
SHAFTS

REAR
AXLE
Removal
Estate
cars
and
Vans

REAR
SPRING
Estate
cars
and
Vans

REAR
SHOCK
ABSORBERS
Estate
cars

and
Vans

REAR
SUSPENSION
Installation

Saloons

Installation
is
a
reversal
of
the
removal

procedures
noting

the

following
points

Ensure
that
the
suspension
member
and
differential
mount

ing
member
are

correctly
aligned
as
shown
in

Fig
U
5
and
insert

the
rubber
insulators
from
the
underside
of

the
vehicle

Tighten
the
differential

mounting
member
the

suspension

member
and
lower
shock
absorber
nuts
to

the
specified
tighten

ing
torques

COIL
SPRINGS
Removal

Saloons

Jack

up
the
rear
of
the
vehicle
and

support
it
on
stands

2
Remove
the
road
wheels
and
disconnect
the
handbrake

linkage
and
return

spring

3
Remove
the
drive
shaft
flange
nuts
at
the
wheel
side

Fig

H
6
and
the

bump
rubber

securing
nuts

4
Place

ajack
under
the
suspension
ann
and
remove
the

shock
absorber
from
the
lower

mounting
bracket
Carefully

lower
the

jack
and
remove

the
coil

spring
spring
scat

and

bump
rubber
Fig
H7

COIL
SPRINGS
Installation

Saloons

Oleck
the
coil

springs
for

signs
of
deformation
or
cracks

Test
the

spring
for
its
free

length
and
height
under
load
and

compare
the

figures
obtained
with
the
information
in
Technical

Data
Inspect
all
rubber

parts
and

replace
any
which
are

damaged

or
deformed

Installation
is
a
reversal
of
the
removal

procedure
making

sure
that
the
flat
face
of

the
spring
is
at
the

top

REAR
SHOCK
ABSORBERS
Removal
and
Installation

Saloons

Remove
the
trim
in
the
boot
trunk
and
take
off
the
two

nuts

securing
the

upper
shock
absorber

mounting
See

Fig
H
S

Detach
the
shock
absorber
from
the
lower

mounting
bracket

The
shock
absorber
should
be
tested
and
the

fIgUres
com

pared
with
the

specifications
in
Technical
Data
Cbeck
for
oil

leaks
and
cracks
Make

sure
that
the
shaft

is
straight
and
that
the

rubber
bushes
are
not

damaged
or
defonned
Renew
all
unsatis

75

Wire
diameter

Coil
diameter

No
of
turns

Free

length
1800
CC
1610

Body

Left
side

spring
Van

and
Estate

Right
side

spring
Van
and
Estate

Both

springs
Saloon

Free

length
1400
and
1600
cc

Left

side

spring

Right
side

spring

f
Fitted

height

Left
side

spring

Right
side

spring

Parts
No
Items

Strut
outer

dia
mm

in

Piston
rod
dia

mm
in

Cylinder
inner
dia

mm
in

Damping
force
at

piston

0
3
m
s
1
08
ft
s

Expansion

kg
Ib

Compression
kg
Ob

Stroke
mm

in

90
54302
UO
100

50
8
2
0

20
0
787

30

I
181

40
88
2

25
55
1

178
7

01
COIL
SPRINGS

12
mill
0
4
in

130
mm

5
I
in

8

371
mm
04
61
in

386

mm
15
20

in

386
mm
15
20
in

354
mm

13
94

369
mm

14
52
in

185
mm

270

kg
7
29
in
560
lb

200
mm

270

kg
7
87
in
560

lb

FRONT
SUSPENSION
UNITS

54302
3
U0500
54302
UOI10
54302
3
U051O

80
176
4

40
88
2
54302

N
1200

22
0
866

32
1
260

40
88
2

25
55
1

BrakIng

System

DESCRIPTION

MASTER
CYLINDER
Removal

dismantling
and
Overhaul

BRAKE
LINES

Replacing

BRAKE
WARNING
LIGHT
SWITCH

FRONT
DRUM
BRAKE
Removal

inspection
and
Overhaul

REAR
DRUM
BRAKE
Removal

inspection
and
Overhaul

FRONT
DRUM
BRAKE

Adjusting

DESCRIPTION

The
vehicle
is
fitted
with
either
disc

brakes
or
two

leading

shoe

type
drum
brakes
for
the
front
wheels
and

leading
trailing

shoe

type
drum
brakes
for

the
rear

wheels

All
brakes
are

hydraulically
operated
from
the
brake

pedal

with
the
rear
brakes

additionally
operated

by
a
mechanical

handbrake
and

linkage
system
Either
a

single
or
a
tandem

master

cylinder
can
be
fitted
The
tandem
master

cylinder

provides
a
dual

braking
circuit
in
which
the
front
and
rear

brakes
are

separately
supplied
If
ODe
circuit
fails
the
other

circuit
will

still

operate
and
provide
a
reduced
but
efficient

braking
action

The
brake

pipes
are

double
wall
steel
tubes
and
are

galvanized
at
the
sections
beneath
the
vehicle
floor
to

prevent

corrosion

MASTER

CYLINDER
Removal

Either
a

tandem
or

single
master

cylinder
can

be
fitted

to

the
vehicle

Fig
L
I
shows
a
cross
sectional
view

through
the

tandem
master

cylinder
and

Fig
L
2
a
cross

sectional
view

through
the

single
master

cylinder
The
removal
and

dismantling

procedures
are

similar
for
both

types
and
are

carried
out
in

the

following
manner

1
Remove
the
clevis

pin
and

separate
the
brake

pedal
from

the
master

cylinder
push
rod

2
Disconnect
the

brake
tubes
from

the
master

cylinder

3
Remove

the
master

cylinder
mounting
bolts
withdraw

the
shims
and
take
out
the
master

cylinder
assembly

MASfER
CYLINDER

Dismantling
and
Overhaul

Drain
the
brake
fluid
from
the

cylinder
and
remove
the

stopper
bolt
Remove
the

dust
cover

the

snap
ring
the

stopper

ring
and
the

pusbrod
assembly

Take

out
the
primary

piston
and

secondary
piston

assemblies
and
the

piston
spring

Remove
the
valve

cap
and
take
out
the
valve

assembly

Oean
all
the

components
with
brake

fluid
and
check

them

for
wear
or

damage
Make
sure
that
the

cylinder
bore
and

piston
are
not

damaged
or

unevenly
worn

The
clearance

between

cylinder
and

piston
must
not
exceed
0
15mm
0
006

in
REAR
DRUM
BRAKE

Adjusting

FRONT
DISC
BRAKE
Friction

pads

FRONT
DISC
BRAKE
Removal
and

Dismantling

FRONT
DISC
BRAKE

Assembly
and
Installation

HANDBRAKE
Removal
and
Installation

BLEEDING
THE
HYDRAULIC
SYSTEM

BRAKE
PEDAL
ADJUSTMENT

Check
the
return

springs
for

damage
or
loss

of
tension

Replace
any
part
which

is
in
an

unsatisfactory
condition

MASfER
CYLINDER

Assembly
and
Installation

Assembly
of
the
master

cylinder
is
a
reversal
of
the

dismantling
procedure
noting
the

following
points

Wet
the

cylinder
bore
and

piston
etc

with
brake
fluid

before

assembling
Care
must
be
taken
to

prevent
dust
and

foreign
matter

entering
the

cylinder
and
reservoir
Ensure
that

cups
and
soals
are
not

damaged
when

locating
them

After
the
master

cylinder
is
reinstalled
the

system
must

be
bled
and
the

pedal
height
adjusted
as
described
under
the

appropriate
headings

BRAKE
LINES

Replacing

The

layout
of
the
metal
brake

pipes
and
flexible

hoses
is

shown
in

Fig
L
3

The
brake

pipes
can

be
removed

by
taking
off
the
flare

nuts
at
both
ends
of
the

pipe
and

removing
the

clips
securing

the

pipe
to

the

body
Similarly
the
brake
hoses
can
be
removed

by
taking
off
the
flare
nuts

Thoroughly
clean
the

pipe
or
hose
after

removing
from

the
vehicle
and
check
for

collapsing
cracking
or

rusting
of

the

pipe
and
for

signs
of

expansion
and

weakening
of
the
hose

Any
pipe
or
hose
which
is
not
in
a

satisfactory
condition
must

be
renewed
Remove

any
dust
from
the
brake

clip
and
replace

the

clip
if
the

vinyl
coating
is
torn

Installation
is
a
reversal
of
the
removal

procedure
Make

sure
that
the
brake

pipes
cannot
vibrate

against
any
part
of

the
vehicle
and
the
brake
hoses
are
not
twisted
and

rubbing

against
the

tyres
or

suspension
units
If
the
brake
hose
is

disconnected
from

the
three
way
connector
on

the
rear
axle

housing
it
will
be

necessary
to
fit
a
new

copper
sealing
washer

Do
not

overtighten
the
installation
flare
nuts

the
correct

tightening
torques
are
as
follows

Three

way
connector
master

cylinder
and
brake
hoses

1
5
1
8

kgm
II
13Ib
ft

Fill
the
master

cylinder
with
recommended
fluid
and
bleed

the

system
as
described
under
the

appropriate
heading
Make

sure
that
fluid
is
not

leaking
from

any

part
of
the

system
by

fully
depressing
the
brake

pedal
for
several
seconds
Check
the

pipes
and
connections
and

replace

any
defective

part

99

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

4

Cylinder
head

gasket

Cylinder
block
side
6
Oil

pump

5
Intake
manifold
Block

installing
surface

near
to

oil
exit

Control
valve

Angle
tube
connector
7
Rocker
cover

Tapping
screw
of
bume

plate
installing

SPECIFICATION

a
Valve

mechanism

Valve
clearance
cold
In
0
25
mm
0
0098
in

Ex
0
25
mm
0
0098
in

Hot
Reference
value
0
0098
in

In
0
28
mm
0
011
in

Ex
0
28
mm
0
011
in

Valve
head
diameter
In
42mm
1
654
in

Ex
35mm
1
378
in

Valve
stem
diameter
In
Ex
8mm
0
3150

in

Valve

length
In
116
4
mm
4
58
in

Ex
117
2
mm
4

61
in

Valve
lift
9
0mm
0
354
in

Valve

spring
free

length
Outer
42
5
mm
1
673
in

Inner
414mm
1
630

in

Valve

spring
loaded

length
Outer
29
0
mm
I
142
in

Inner
26
0
mm
1
024

in

Valve

spring
assembling
height
Outer
37
0mm
I
457

in

Inner
34
0
mm
1
339
in

Valve

spring
effective
wind
number
Outer
4
5mm
0
1772
in

Inner
6
25
mm
0
2461
in

Valve

spring
wire
diameter
Outer
4
2mm
0
1654
in

Inner
29mm
0
1142
in

Valve

spring
coil
diameter
Outer
27
5
mm
1
083
in

Inner
19
9mm
0
733

in

Valve

guide
length
In
48mm
1
890
in

Ex
60mm
2
362
in

Valve

guide
height
from
cylinder
head
In
Ex
16
7mm
0
657
in

Valve

guide
inner
diameter
In
Ex
7mm
0
2756
in

Valve

guide
outer

diameter
In
Ex
14
2mm
0
559
in

Valve

guide
to
stem
clearance
In
0
025
0
055

mm

0
0010
0
0022
in

Ex
0
04
0
077
mm

0
0016
0
0030
in

Valve

guide
interference
fit
In
Ex
0
040
0
069
mm

0
0016
0
0027
in

Max
tolerance
of
above
clearance
In
Ex
0

1
mm
0
0049
in

Valve
seat
width
In
Ex
2
05
2
33mm

0
0807
0
0917
in

Valve
seat

angle
In
Ex
900

b
Camshaft
and

timing
chain

Camshaft
end

play
0
07
0
148
mm

0
0028
0
0058
in

Cam

height
36
53
mm
1
438
in

Camshaft

journal
diameter
37
45
37
475
mm

1
474

1
475
in

S14