torque DATSUN 610 1969 Owner's Guide

SteerIng

DEsn
IPTION

S
i
EERlNG
MaintenaDce

STEERING
WHEEL
AND
STEERING
GEAR

Removal
and
Installation

STEERING
GEAR

Dismantling

STEERING
GEAR

Inspection
and
Adjustment

DESCRIPTION

A
worm
and

recirculating
ball

type
steering
system
is

fitted
to

the
vehicle
the

component
parts
of
the

steering
gear

are
shown
in

Fig
K
I

The

steering
linkage
consists
of
the
centre
tie
rod

pitman

ann
idler
arm
outer
tie
rods
and
the
knuckle
arms
as
shown

in

Fig
K
2

A

collapsible
steering
column
assembly
can
be
fitted
to
the

vehicle
to

protect
the
driver
from

injury
in
a
head
on

collision

Details
of
this

type
of

assembly
are

given
under
the

appropriate

heading

STEERING
Maintenance

O1eck
the
oil

level
in
the

steering
box
every
10
000
km

6
000
miles
and

top
up
with
recommended
lubricant
if

necessary

Grease
the

steering
linkage
every
50
000
km
30
OOO

miles
It
will
be

necessary
to

replace
the

plug
in
the
tie
rod
ball

joints
with
a

grease
nipple
for
this

operation
as

previously

described
in
the
section
FRONT
SUSPENSION

Use
a

grease
gun
to

completely
replace
the
old

grease
with

new

grease
making
SUfe
that
the

grease
is
not
forced
from
under

the
cover

clamp
if
a

high

pressure
gun
is
used

STEERING
WHEEL
AND
STEERING
GEAR
Removal

1
Take
out
the

retaining
bolts
and
remove
the
horn
ring

remove
the

steering
wheel
nut

Fig
K
3
and

pull
off

the

steering
wheel
The
special
tool
ST
27180000
should
be

used
if
available

2
Disconnect
the

battery
leads
remove

the
steering
column

shell
covers

and
the
turn

signal
and

lighting
switch
assembly

3
On
vehicles
fitted
with

steering
column

gear
change

assemblies
the

gear
lever
must
be
removed
from
the

control
rod

assembly
Unscrew
the
retaining
boltg
and

disconnect
the

gear
lever

4
Remove
the
bolts
from
the

steering
column

upper
clamp

Fig
K
4
and
the
bolts

holding
the
lower

plate
Fig
K
5

5
If
the
vehicle
is
fitted
with

steering
column
gear
change

remove
the

cotterpin
from
the
trunnion
and
detach
the

gearchange
rod
and
selector
rod
from
the

change
lever
and

selector
lever
STEERING
GEAR

Assembly
and

Adjustment

COLLAPSIBLE
STEERING

COLLAPSIBLE
STEERING
Removal
and

Inspection

COLLAPSIBLE
STEERING
Installation

STEERING
LINKAGE

6
Remove
the
bolts

securing
the

steering
gear
housing
to

the
car

body
Fig
K
6
and

pull
the
steering

gear
towards

the

engine
compartment

Remove
the
gearchange
control
from
the

steering
gear

assembly
as
described
in
the
section
GEARBOX

STEERING
WHEEL
AND
STEERING
GEAR
Installation

Installation
is
a
reversal
of
the
removal

procedure
When

the
installation
has
been
completed
make
sure
that
the

steering

wheel
can

be
turned

smoothly
and
is
correctly
aligned
The

free
travel
of
the

steering
wheel
should
be
between
2S
30mm

0
9B
1
18
in
Tighten
the

steering
wheel
locknut
to
a

torque

reading
of
4
0
5
0

kgm
29
36Ib
ft
and
the

steering
column

upper
clamp
and
plate
bolts
to
a

torque
reading
of
1
3
1
8

kgm

94
1
3
Ib
ft

Ensure
that
the

steering
box
is
topped
up
to
the
correct

level
with
recommended
lubricant

STEERING
GEAR

Dismantling

Remove
the

pitman
arm

retaining
nut

and
pull
out
the
arm

The

special
puller
ST
27140000
should
be

used
if
available

Remove
the
drain

plug
from
the

steering
gear
housing
and

drain
the
oil

Slacken
the

adjusting
screw
nut
and
turn
the
sector
shaft

adjusting
screw
a
few
turns
in
the
anti
clockwise
direction

Remove
the
sector

shaft
cover

retaining
bolts
and

pull
the

sector
shaft
cover
and
sector
shaft
from
the
gear
housing
Fig

K
7

Remove
the
bolts

securing
the
column

jacket
to
the

gear

housing
and

carefully
withdraw
the
main
column
jacket
assembly

from
the
gear
housing
Fig
K
B

NOTE
The
ball
must
not
be
allowed
to
run
to
either
end
of

the
worm
or
the
ends
of
the
ball

guides
will
be

damaged

Pull
the
column
assembly
from
the
column
jacket
Remove

the
sector
shaft
oil
seal
and
take
out
the
rear

bearing
outer

race

from
the
column

jacket
with
a
suitable

puller

Withdraw
the

bearing
inner
races
from

the
front
and
fear

worm

bearings

Remove
the
column
shaft

bearing

91

STEERING
GEAR

Inspection
and

Adjustment

Thoroughly
clean
all

parts
and
examine
them
for

signs

of
wear
or

damage
Replace
any
comIK
nent
found
to
be
un

satisfactory

It
is
advisable
to
renew
the
assemblies
if
the

steering
column

or
ball
nut

assembly
is
defective
as

the

adjustment
procedures

required
to
overhaul
the
units
are
rather
involved

The

dismantling
and

adjustment
procedures
for
the
ball

nut

assembly
can
be
carried
out
in

the
following
manner
if
it

is

decided
that
overhaul
procedures
are
to

be
carried
out

Ball
nut

Remove
the
ball

guide
tube

clamp
withdraw
the

guide

tubes
from
the
ball
nut
and
collect
the
steel
balls

Turn
the
nut

upside
down
and
rotate

the
steering
column

backwards
and
forwards
until
all

36
steel
balls
have

dropped

out
of
the
ball
nut
Pull
the
ball

nut
from
the
column

Inspect
the
ball

guide
tubes

and
make
sure

that

they
are

not

damaged
Pay
particular
attention

to
the
ends
of
the
tubes

that

pick
up
the

balls
from
the
helical

path
Renew
the
tubes
if

they
are

unsatisfactory
Check
the
steel
balls
and

the
ball
nut

for
wear
and

replace
the

complete
unit
if

necessary

Assemble
the
ball
nut
on

the
worm
with
the
ball

guide

holes

upwards
Drop
18
balls
into
each
of

the
two
holes
on
the

same
side
of
the
ball
nut

until
all
36
balls
are
installed
The

column
should
be

gradually
turned

away
from
the
hole

being

filled
and
if
the
balls
are

stopped
by
the
end
of
the
column
hold

down
those

already
installed
with
a

clean
rod
or

punch
while

turning
the
column
several
times
in
the
reverse
direction
The

filling
of
the
circuit
can
then
be
continued
but
it

may
be

necessary
to
turn
the
column
backwards
and
forwards

holding

the
balls
down
first
in
one

hole
and
then
the
other
to
close
the

spaces
and

completely
fill
the
circuit

Place
the

remaining
22
balls
in
the
ball

guide
halves
11

balls
for
each
half
Fit
the
other
half
of

the

guide
tube
to
each

f11led
half

hold
the
two
halves

together
a
ld

plug
each

open
end

with
vaseline
to

prevent
the
balls

falling
out

Push
the

guide
tubes
into
the

ball
nut

guide
holes
and

assemble
the

guide
tube

clamp

Inspection

Oteck
the
axial

clearance
between
the
ball
nut
and
the

balls
If
the
clearance
exceeds
0
08
mrn
0
003
in
the

complete

unit
must
be
replaced
Inspect
the

gear
teeth
of
the

sector

shaft
for
wear
or

damage
Replace
any
worn
or

imperfect

bearings
Examine
the

steering
column
shaft
for

straightness

and
check
that
the
maximum
deflection
does
not
exceed
0
2mm

0
008
in
at

point
C
in

Fig
K
9
when
the
shaft

is

supported

at

points
A
and
B
Check
the
sector
shaft
and

steering

column
shaft
serrations
for
wear
Renew
the

parts
as

necessary
STEERING
GEAR

Assembly
and

Adjustment

Grease
the

lip
of
the
oil
seal
and

press
it
into
the

housing

Insert
the
column

assembly
into

the
column

jacket
and
fit

the
worm

bearing
shims
to
the

gear
housing
Install
the

flange

securing
bolts
and

tighten
them
to
a

torque
reading
of

1
8

2
5

kgm
13
18lb
ft
If
a

new
column

bearing
assembly
is

fitted
it
must
be
filled
with

bearing
grease
and
cemented
to
the

column

The

preload
of
the
worm

bearing
can
be

adjusted
by

altering
the
thickness
of
the
worm
bearing
shim
Four
shim

thicknesses
are
available
in
sizes
of
0
76
0
254
0
127
0
050mm

0
0300
0
100
0
005
in
0
002
in

This

adjustment
check
is
carried
out
without

the
sector

shaft
fitted
and
with
the
worm

bearings
oiled

Install
the

steering
wheel
as
shown
in

Fig
K
9
use
a

spring

balance
as
indicated
to
check
that
the
force
required
to
turn

the
wheel
is
between
4
0
8
0

kg
cm
56
l120z

inch

Select
a
suitable
shim
from
the
sizes

given

Assemble
the
selector
shaft

adjuster
with
a
shim
into
the

sector
shaft
Measure
the
end
clearance
of
the

adjuster
with
a

feeler

gauge
as

shown
in
Fig
K
1
O

The
correct
clearance
is
0
01
0
03mm
0
0004
O
0012in

and
can
be

adjusted
by
varying
the
thickness
of
shim
Four

thicknesses
of
shim
are
available
as

follows

1
57
mm
0
0618
in

1
55
mm
0
0610
in

1
52
mm
0
0598

in

1
50
mm
0
0591
in

To
assemble
the
sector
shaft
into
the
gear
housing
rotate

the
column

by
hand
until
the
ball
nut
is
at
the
central

position

of
its
travel
so
that
the
centre
tooth
of
the
sector
shaft
enters

the
centre
tooth

space
of

the
ball
nut
Fit
a
new

gasket
and

push

the

sector
shaft
cover

and
sector
shaft
into

place

Ensure
that
a
certain
amount
of

play
is

present
between

the
rack
and
sector
teeth
before

tightening
the
cover

bolts
to

a

torque
reading
of
1
5
2
5

kgm
10
9
18
llb
ft

Temporarily
lock
the

adjusting
screw
with

the
locknut

Move
the
sector
shaft
several
times
from

the

pitman
arm
side

to
make
sure
that
it
turns

smoothly

Connect
the

pitman
arm
to
the
sector
shaft

taking
care

that
the

alignment
marks
on

the
arm
and
shaft
coincide

Adjust
the
backlash
with

the
steering
in

the
central

position
using
a
dial

gauge
as
shown
in

Fig
K
II
Turn
the

adjusting
screw
with
a
screwdriver
until
the
amount
of
free

movement
at
the

top
of
the

pitman
arm
is

within
O
lmm

0
0039
in
at
a

radius
of

127
mm
5
0
in
Lock
the

adjusting

screw
with
the
locknut
Fig
K
12
and
recheck
the
free
move

ment

Fill
the

steering
gear
housing
with
the
correct
amount
of

recommended
lubricant

Refit

the

steering
gear
to
the
vehicle
as

previously
described

Make
sure

that
the
steering
wheel
is

correctly
aligned
and
that

93

3
Free

the
ball
studs
from
the
knuckle
arms

by
placing
a

hammer
behind
the
boss
and
striking
the

opposite
side

with
another
hammer

4
Remove
the
centre

tie
rod
ball

studs
in
a
similar
manner

to
that
described
above
and
remove
the
centre

tie
rod
and

outer

tie
rods
as
an

assembly

5
Remove
the
idler

assembly
from
the
side
member

by
with

drawing
the

retaining
bolts

SfEERING
LINKAGE

Dismantling

Disconnect
the
tie
rods
from
the

centre
rod

Loosen
the

clamp
bolts
unscrew
the
socket

assembly
and
remove
the

socket
from

the
tie
rods
Remove
the
idler
arm
nut

and
dismantle

the
idler

assembly

Check
the
idler
arm
rubber

bushing
for

signs
of

damage

wear
or

play
and

replace
the

bushing
if

necessary
Oteck
the

centre
and
outer

tie
rod
for

damage
or

bending

Inspect
the
ball

joints
and

replace
them
i
the
amount
of

play
is

excessive
or
if

the
dust
cover

is
cracked
Further
infor

mation
can
be
found
in
the
section
FRONT
SUSPENSION

See
also

Figs
K
21

and
K
22
STEERING
LINKAGE

Assembly
and
Installation

Assembly
is
a
reversal
of
the
removal

procedure
noting

the

following

points

To

assembly
the
idler
arm

assembly
coat

the
outer
dia

meter
of
the

bushing
with

soapy
water
and

press
the

bushing

into
the
idler
arm

until
the

bushing
protrudes
equally
at
both

sides

Fit
the
idler
arm

body
in
the
rubber

bushing
Ensure
that

the
centre
line
of
the

idler
arm
is

parallel
with
the
centre
line

of
the
chassis

Installation
is
a

reversal
of

the
removal

procedure
The

outer
tie
rods
must
be
set
so
that
the

lengths
between
the
ball

stud
centres
are
309

5
mm

12
18
in
for
the
1400
and
1600cc

models
and
313
2
mm

12
33
in
for
the
1800cc

models

Tighten
the
ball
stud
nut

to
a

torque
reading
of
5
5
7
6

kgm
39
8
55Ib
ft
the
idler
ann
nut
to
5
5
7

6

kgm

39
8
55Ib
ft
and
the

pitman
arm
nut
to
14

kgm
lOllb
ft

The
front
wheel

alignment
toe
in
and

steering
angle
should

be
checked
and

adjusted
as
described
in

the
section
FRONT

SUSPENSION

TechnIcal
Data

Steering
type

Gear
ratio

Steering
angle

Inner
wheel

l800cc

Outer
wheel
1800
cc

Inner
wheel

1400
and
1600cc

Saloon

1400
and
1600cc
Estate

Outer
wheel
1400
and
1600cc

Saloon

1400
and
1600cc
Estate

Steering
wheel

play
1400
and

1600cc

Steering
wheel

play
1800cc

Standard
total
thickness
of

worm

bearing
shims

End

play
between
sector
shaft

and

adjusting
screw

Initial

turning

torque
of

worm

bearing

l800cc
models

1400
and
1600cc
models
Worm
and
recirculating
ball

15
0
I

370
380

30040
32040

380

380
30

31020

330

25
30mm
0
98
1
18
in

less
than
35mm
1
378
in

at
outer

rim
of

steering

wheel

1
5
mm
0
059
in

0
0
I
0
03mm

0
0004
0
0012
in

4
0
6
0

kg
cm
55
6
83
4

in
oz

4
0
8
0

kg
cm

55
6
112

in

oz

97

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

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

ALTERNATOR
Dismantling

Refening
to

Fig
M
16
remove

the

pulley
nut
and
take
off

the

pulley
rim
fan
and

spacer
Withdraw
the
brush
holder

retaining
screws
and
remove
the
brush
holder
cover
Withdraw

the
holder
and
brushes
as
shown
in
Fig
M
17

Slacken
and
remove
the
three

through
bolts
and

separate

the
diode

housing
from
the
drive
end
housing
by
tapping
the

front
bracket

lightly
with
a
wooden
mallet

Fig
M
18

Remove
the
screws
from
the

bearing
retainer
and

separate
the

rotor
from
the
front
cover

Fig
M
19

Remove
the
rear

bearing
from
the
rotor

assembly
with
the

aid
of
a

puller
as
shown
in

Fig
M
2D
Take
off
the
diode
cover

and
unsolder
the
three
stator
coil
lead
wires

from
the
diode

terminal

Remove
the

A
terminal
nut
and
diode
installation
nut
and

remove
the
diode

assembly
Do
not
force

the
diode

assembly

when

removing
or
it

may
be

damaged
Remove
the
stator
from

the
rear
cover

ALTERNATOR

Inspection

Use
an

ohmmeter
as

shown
in
Fig
M
21
to
test

the
rotor

field
coil

Apply
the
tester
between
the

slip
rings
and
check
that

the
resistance
is

approximately
4
4
ohms
at

normal
ambient

temperature
Check
the

conductivity
between

slip
ring
and
rotor

core
as
shown
in

Fig
M
22
if

conductivity
exists
the
field
coil

or

slip
ring
must
be

earthing
and
the
rotor

assembly
should
be

renewed

Cbeck
the
stator
to
ensure
that
there
is

conductivity

retween
the
individual
stator

coil
terminals
as
shown
in

Fig
M

23
If
there
is
no

conductivity
between
the
individual
terminals

the
stator
is
defective

Check
each
lead
wire

including
the
neutral
wire
as
shown

in

Fig
M
24
If
there
is

conductivity
between

any
wire
and
the

stator
COTe

the
stator
core

is

earthing
and
the
stator
must

be

replaced

Diodes

Three

positive
diodes
are
mounted
on
the
positive
plate

and
three

negative
diodes
are
mounted
on
the

negative
plate

The
diodes
allow

current
to
flow
in
one
direction

only
The

diodes
on
the

positive
plate
only
allow
current
to
flow
from

the
terminal
to
the

positive
plate
whilst
the
diodes
on
the

negative
plate
only
allow
current
to
flow
from
the

negative

plate
to
the
terminal
A
diode
which
allows
current
to
flow

in
ooth
directions
or
does
not

allow
current
to
flow
in
the

correct
direction
is
unserviceable
and
all
six
diodes
must
be

replaced
Use
a
tester
as
shown
in
Figs
M
25
and
M26
to
check

each
diode

Brushes

Check
the
movement
of
the
brushes
in
their
holders
The

brushes
should
move

freely
and
can
be
eased
in
necessary
by

carefully
ming
the
sides
Oean
the
brush
holders
before

replacing

the
brushes
Renew
the
brushes
if

they
are
worn
below
a
length

of
7mm
0
275
in
With
the
brush

projecting
approximately

2mm
0
08
in
from
the
holder
it
is
possible
to
measure
the

brush

spring
pressure
using
a

spring
balance
as
shown
in

Fig
M
27

The

pressure
of
a
new
brush
should
be
255
345

grammes

9
0
12
2
oz
the

pressure
will
however
decrease

by
approxi

mately
20

grammes
per
I
amm
0
039

in
of
wear

ALTERNATOR

Assembly
and
Installation

Asssembly
is
a
reversal
of
the

dismantling
prQcedure
noting

the

following
points
The
stator
coil
lead
wires
must
be
resoldered
to
the
diode

assembly
terminal
as

quickly
as

possible
or

the
diodes

may
be

damaged
When

installing
the
diode
A
tenninal
make
sure

that

the

insulating
bushing
and
tube
are

correctly
fitted

The

pulley
nut
should
he

tightened
to
a

torque
reading
of

350
400

kg
cm
301
344Ib
in
Mount
the

assembly
in
a

vice
as
shown
in

Fig
M
28
and
when
the

pulley
is

tightened

make
sure
that
the
deflection
of
the

pulley
groove
does
not

exceed
O
3mm
m
o
118

in

ilEA
D
LAMPS

Replacing

All
weather

type
sealed
beam

headlamp
units
are
fitted
to

the
vehicle
Each

lamp
is
of
the
double
fIlament

type
with
a

full
beam
filament
of
50W
and
a
dipped
beam
filament
of
40W

The

replacement
of
the
sealed
beam
unit
can

be
carried

out
as
follows

Remove
the

wiring
socket
from
the
back
of
the

headlamp

unit
On

Coupe
models
withdraw
the
screws

attaching
the

front

grille
to
the
radiator
core

support
On
all
other
models

remove

the
three

retaining
screws
and
remove
the

headlamp
rim

Withdraw
the
three

retaining
screws

securing
the

retaining

ring
3
in

Fig
M
29
and
remove

the
sealed
beam
unit

When

installing
a
new
sealed
beam
unit
make
sure
that
the

Top
mark
on
the
ring
is

uppennost
when
fitted

HORNS

The
circuit
for

the
horns
is
shown
in

Fig
M
30
The
horns

can
be
adusted
for
v01ume
and
tone
in

the

following
manner

Remove
the
connector

and
the

retaining
nut
in

the
centre

of
the
horn
withdraw
the
horn
from
the
vehicle
Connect
a

voltmeter
and
ammeter

into
circuit
as
shown
in

Fig
M
3I
Set

the
switch
to
ON
and
check
that
the
voltmeter
shows
a

reading
of
12
to
12
5
volts
The
sound
can
be

regulated
by

turning
the

adjusting
screw

Fig
M
32
A

reading
of

2
5

amps

should
be
obtained
for
the
flat

type
of
horns
or
5
0

amps
for

the

spiral
type
of
horns

Turning
the

adjusting
screw
clockwise
will
increase
the

current

turning
anti
clockwise
decreases
the
current

Install
the
horns
in
the
vehicle
and
check
that
the
correct

sound
can
still
be
obtained
when
the

higher
voltage
of
14
15

volts
is

generated
by
the
alternator
Turn
the

adjusting
slightly

if

necessary
then

tighten
the
locknut

INSTRUMENT
PANEL
Removal

The
instrument

panel
holds
the
various
meters

and

indicators
A
printed
circuit
board
is
located
at
the
rear
of
the

panel
and
the
connections
to
it
are

multiple
connectors
When

the

panel
is
remove

the
instruments
are

easily
withdrawn
for

inspection
and

servicing

Disconnect
the

battery
negative
terminal

2
Remove
the
windscreen

wiper
switch

lighting
switch
and

choke
control
knobs

by
pressing
them
in
and

turning

anticlockwise
Remove
the
escutcheon

3
Disconnect
the

cigarette
lighter
cable
at
the
rear
of
the

instrument

panel
and
turn

the

cigarette
lighter
outer
case

so
that
it
can
be
removed

115

4
Remove
the
shell
covers

from
the

steering
column
slacken

the

screws
securing
the
meter

housing
and
withdraw
the

panel
from
the
facia

Fig
M
33

5
Pull

out
the
12

pole
round

shaped
connector
and
remove

the

speedometer
cable
union

nut
then
remove
the
instru

ment

panel
completely

WINDSCREEN
WIPERS

A
two

speed
wiper
motor
is
fitted

The
motor
has
an
auto

stop
mechanism
and
drives
the

wiper
arms

through
a
link

mechanism
located
behind
the
instrument
panel
If
the

wiper

system
does
not

operate
check
the
fuses
connectors
control

switch
and
motor
If
the

wiper
speed
does
not

change
the

switch
must

be
repaired
or

replaced
If

the

wiper
motor
becomes

unserviceable
it
can
be
removed
from
the
vehicle
in
the

fOllowing

manner

I
Remove
the
connector

plug
from

the
motor
See

Fig
M

34

2

Working
from
the

passenger
compartment
side
of
the
dash

panel
remove
the
nut

connecting
the

wiper
motor
worm

wheel
shaft
to
the

connecting
rod

3
Remove
the
three
bolts

securing
the

wiper
motor
to

the

cowl
and
lift
out
the
motor

Battery

Starter
motor

Type

Output

No
load

Terminal

voltage

Current

Revolution

Load

Terminal

voltage

Current

Torque

Brushes

Brush

length

Wear
limit

Spring
tension

Commutator

Standard
outer

diameter

Wear
limit

Depth
of

nuca

Repair
limit

Repair
accuracy

Qearance
between
armature

shaft
and

bushing

Repair
liinit

Repair
accuracy

Armature
shaft
ou
ter

diameter

Pinion
side

Rear
end

Wear
limit

Bend
limit
The

wiper
arms
can
be
removed
quite
easily
by
taking
off

the
attachment
bolt
as
shown
in

Fig
M

J
5
and
then

pullin

the

wiper
arm
from
the

pivot
shaft
When

installing
the

wiper

arm
make
sure
that
the
blade
is

positioned
approximately

27mm
1
06
in
away
from
the

bottom
of
the
windscreen
and

tighten
the

wiper
arm
attachment
bolt

WINDSCREEN
WASHERS

The
windscreen
washer
SWItch
and

wiper
switch
are
com

bined
in
a

single
unit
See

Fig
M
36
the
washers
can
be

operated
by
turning
the
switch
in
the

appropriate
direction
It

should
be
pointed
out
that
it
is
inadvisable
to

operate
the
washers

for
more
than
30
seconds
at
a
time
If
the
washers
are

operated

in
short

spells
of

approximately
10
seconds
duration
their

working
efficiency
will
remain

unimpaired
for
a
considerable

length
of
time

IGNITION
SWITCH
AND
STEERING
LOCK

The

steering
lock
is
built
in

to
the

goition
switch
When

the

key
is
turned
to
the
LOCK

position
and

then
removed

the
steering
system
is

automatically
locked

by
the

steering
lock

spindle
which

engages
in
a
notch
in
the
collar
on
the

steering

shaft

See

Fig
M
37
The
heads
of

the
screws
are
sheared
off

on
installation
so
that
the

steering
lock

system
cannot
be

tampered
with
If

the

steering
lock
is
to

be

replaced
it
will
be

necessary
to
remove
the
two

securing
screws
8
and
then
drill

out

the
self

shearing
screws
7
When

installing
a
new

steering

lock

tighten
the
new
self

shearing
screws
until
the
heads
shear

TechnICal
Data

12
volt

HITACHI
S114
87M

1
0KW

12
volts

Less
than
60

amperes

More

than
7000
r

p
m

6
3

volts

Less
than
420

amperes

More
than
0
9

mkg
6
5
lb

ft

16
mm

0
630
in

6
5mm
0
256
in

0
8

kg
1
8
lb

33mm
1
299
in

2mm

0
078
in

0
2mm
0
008
in

0
5
0
8mm
0
0197

0
0315
in

0
2mm
0
008

in

0
03
O
lmm
0
0012

0
0039
in

13mm
0
512
in

11
5
mm

0
453
in

O
lmm
0
0039

in

0
08

mm
0
0031

in
Oearance
between

pinion
and

stopper
0
3
1
5mm
0
0118

0
0591
in

ALTERNATOR

Type
HITACHI
LTl25
06

HITACHI
LTl33
05
USA

Canada

More
than
18

amps
at

14

volts
2500
r

p
m

More
than
25

amps
at

14

volts
5000
r

p
m
Output
current

LTl25
06

Output
current

LT
133
05

More
than
24

amps
at

14

volts
2500
r

p
m

More
than
33

amps
at
14

volts
5000
r

p
m

Brushes

Lengtb

Wear
limit

Spring
pressure
14
5mm
0
571
In

7mm
0
2756
in

0
25
0
35

kg
0
55
0
771b

Slip
ring

Outer
diameter

Reduction
limit

Repair
limit

Repair
accuracy
31
mm
1
220
in

I
mm

0
039

in

O
3mm
0
0118
in

0
05
mm

0
0197
in

VOLTAGE
REGULATOR

Type

Regulating

voltage
HITACHI
TL
lZ
37

14
3
15
3
volts
at
200C
680F

117

Clutch
MIPTOOlS
Trouble
Shootmg
Steering
IYMmlMS

mDING
S1
1FFNESS

ITIBJJNG
IIl
ACJt

STEEIUNG
WANDER

WHEEL
SHIIlOlY

CAR
PUl
U
TO
ONE
IIDE

POOR
RECa
Dy
OF
STEERING

WHEEL
10
CENl1tE

EXCESSIVE
01
ABNORMAL
TYKE
WEAR
It
d
e
f
I
II
J

e
It
b
I
J
k1
D
0
P
41
r

nUTCH
SI
IPPING
WIu
NOT

ENGAGE
PROPERLY
CLUfCHDRAG
WILLNOT

DISENGAGE
PROf
ERL
Yl

a
1JTCH
JUDDE

a
tn
CII
eRA
fON
ENCAGEMDIT

CLIJfCH
NOISE
SQUEAL

DEl
ltESSlNG
nlE
PEDAL

nUTCH
NOISE
RATTLE
WHEN
IDI
ING

CLUTCH
NOISE
CHATTER
ON

a
GAGEMENI
I
I
j
ILlm

ROUBLE
CAUSE

I
hllUtrident
f
lay
In
RIM
link

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CllIlclldilC
facbllWl
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dM
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oil
cluu
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d
ana

d
Wellk
or
brotell
pralure
plate
coilsprinp
or
diapht
m
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to
Alrinhydr
lIlie
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r
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h
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dlx
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Clutch
dilc
faclnf
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w
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CO
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tnlllmblllon
or
rlIkm

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Clutch
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LoC
drift
plate
hub

p
Relr
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Reina
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r
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d
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b
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brk
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laeomctl
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116
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sacu
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wb
100II

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mountiJl
both
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defoc
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ll
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balln
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C
Lubnclte

4
Check
1
rifla
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t
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e
djUlt
QOlTectly

I
djuttrelll
defe
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pIrtI

Ti
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n
r
pllCe
joints

h
t
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renc
bannp

i
Ttchtentoco
cttorqu

j
Tiaht
n
correct
torque

t
fiahten
con
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torque

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Ballonce
h

p
Rene
prinp

q
laJan
bnltct

r
lI
eaJian
Ull
Ielllllion
drio

TIghtenIng
Torques

LIB

engines
Three

speed
geabox
ENGINE

2
5
4
0

kgm
18
29
Ib
ft

0
3
0
4

kgm
8
13
IbJI

Ll
1
8

kgm
8
0
12
llbJt

1
6
2

5
kgm
12
18Ib
ft

I
I
1
8

kgm
8
0
12
llbJt

0
7
I
I

kgm
5
1
8
0

IbJt

17
2

lkgm
l2
15IbJI

7
0
12
0

kgm
51

87IbJI

0
8
1
0

kgm
5
8
7
2
IbJI

0
3
0
4

kgm
2
2
2
9Ib
ft

2
3

kgm
14
22IbJI

J
9
2
2

kgm
14
16IbJI
Gearbox
to

engine

Dust
cover

Front
cover

Rear
extension

Bottom
cover

Reverse
idler
shaft

Detent
ball

plug

Mainshaft
nut

Mainshaft

bearing
retainer

Speedometer
pinion
sleeve

lock

plate

Reverse

lamp
switch

Control
lever
nut
Cylinder
head
bolts

1st

stage

2nd
stage

3rd

slage
4
0

kgm
28
9Ib
ft

6
0

kgm
43
4lb
ft

6
5
8
5

kgm
47
0
61
5

Ib
ft

Connecting
rod

big
end
nuts

Ll4
Ll8

engines

Ll6

engine

Flywheel
bolls

Main

bearing
cap
bolts

Camshaft

sprocket
bolt
4
5
5
5

kgm
33
40
Ib
fl

3
2
3
8

kgm
23
27
lb
ft

14
16

kgm
l01
106Ib
ft

4
5
5
5

kgm
33
40Ib
ft

12
16

kgm
86
8
116IbJt

0
6
0
9

kgm
4
3
6

5IbJt

I
I
1
5

kgm
8
0
10
8

Ib
fl

2
3

kgm
14
5
21
7Ib
ft

5
6

kgm
36
43
Ib
ft

0
6
0
9

kgm
4
3
6
5
Ib

ft

12

16kgm
86
8
115
7

IbJt
LIB

engines
Four

speed
gearbox
Oil

sump
bolts

Oil

pump
bolts

Oil
drain

plug

Rocker

pivot
locknuts

Camshaft

locating
plate
bolts
2
5
4
0

kgm
18
29

IbJt

0
8
1
0

kgm
5
8
7
2Ib
ft

Ll
l

7kgm
8
12IbJt

Ll
I

7kgm
8
12Ib
ft

3
3
44

kgm
24
32IbJI

1
7
2
1

kgm
12
15

IbJt

2
3

kgm
14
22Ib
ft

0
5
0
7

kgm
3
6
5
IlbJI

0
8
I
I

kgm
5
8
8
0Ib
ft

0
8
Ll

kgm
5
8
8
01b
ft

0
8
1
0

kgm
5
8
7
2Ib
ft
Gearbox
to

engine

Dust
cover

Front
cover

Bottom
cover

Rear
extension

Detent
ball

plug

Reverse

lamp
switch

Lower
bracket
bolt

Shift
rod
nut

Cross
shaft
bracket
bolt

Gear

change
lever

mounting
bolt
Crankshaft

pulley
nut

Outch

mounting
bolts

L14
Ll6

Ll8
2
4
2

6kgm
174
18
8

Ib
ft

1
6
2
2

kgm
12
16Ib
fl

PROPELLER
SHAFf
AND
DIFFERENTIAL

GEARBOX

17

20kgm
l22
145IbJI

14
17

kgm
101
123Ib
ft

13
20

kgm
94
145Ib
fI
Drive
pinion
nuts
Saloon

Drive

pinion
nuts

Estate
car

Drive

pinion
nuts
Van
Ll4
and
L16

engines
Three

speed
Gearbox

Rear
extension
to
case

bolts
2
8
4
4

kgm
20
32lb
ft

Gearbox
10

engine
2
5
4
0

kgm
18
29Ib
fI

Bnttom
cover
L1
1
7

kgm
8
0
12
3
lb

ft

Ll
1
7

kgm
8
0
12
3
lb

fl

3
5
5
0

kgm
25
3
36
2

Ib
ft

1
8
2
1

kgm
13
0
15
2

Ib
ft

2
4

kgm
14
5
29
Ib
ft

0
7
L1

kgm
5
1
8
0
lb

ft

0
7
Ll

kgm
5
1
8
0
lb

fl

9
11

kgm
65
1
79

51b
ft
Crown
wheel
bolts

1400
and
1600

cc
Saloon

1400
and
1600
cc
Eslale

1800ce
Saloon

I800cc
Estate

1800cc
Van
7
8

kgm
51
58Ib
ft

4
8
5
5

kgm
35
40
Ib
ft

7
8

kgm
51
58Ib
ft

7
8

kgm
51
58Ib
ft

4
8
5
5

kgm
35
40
Ib
ft

0
9
1
2

kgm
6
5
8
7Ib
ft

1
9
2
6

kgm
13
7
18
8

IbJI

1
9
2
6

kgm
13
7
18
8

Ib
f
Front
cover

Drain

plug

Selector
lever
bolts

Side
retainer
bolts
Saloon

Drive

flange
bolts
Saloon

Reverse

lamp
switch

Idler
shaft

screw

Rear
cover
bolts

Cross
shaft
lock

pin

Final
drive
to

mounting
member

1400
and
1600cc
models
6
8

kgm
43
4
57
8IbJI

1800cc
models
5
7

kgm
36
2
50
6Ib
fI

Final
drive
to

suspension
member
6
7

kgm
43
4
51
0
Ib
ft

Final
drive
to
drive
shafls
5
6

kgm
36
431b
ft

Final
drive

flange
to

propeller
shaft
1
6
2
4

kgm
12
17
Ib
ft

Final
drive

flange
to

propeller

shaft
Eslale
1
6
2
4

kgm
l2
17Ib
ft

Mainshafl
locknut

Ll4
and
L16

engines
Four

speed
gearbox

Rearexlension
to
case

bolts
1
6
2
5

kgm
12
18Ib
ft

Gearbox
to

engine
2
5
4
0

kgm
18
29Ib
ft

Bottnm
cnver

L1
1
8

kgm
8
13
Ib
ft

Fronl
cover
L1
1
8

kgm
8
13
IbJI

Drain

plug
3
5
5
0

kgm
25
3
36
2

Ib
f

2
4

kgm
14
5
28
9IbJt

9
11

kgm
65
1
79
5Ib
ft
Final
drive

flange
to

propeller

shaft

l800cc
610

only
Reverse

lamp
switch

Mainshaft
nut
2
0
2
7

kgm
14
5
19
5
lb

ft

4
6

kgm
29
43
Ib
ft

Oil
drain
and
flller

plug
Saloon

129