boot DATSUN 610 1969 Workshop Manual

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Q

1

Cylinder

2

Return

spring

3
Piston

4

Secondary
cup

5
Piston

cup

6

Supply
valve
seat

7

Supply
valve
stem

8

Supply
lIOlve

spring
9

Spring
seat

10
Va
ve

stem

stop

11

Stopper
gasket

12
Gasket

ring

13
Push
rod

14
Push
rod
ht
lld

15
Wdd
nut

16
Lock
nut
17
Piston

stopper

18

Stopper
ring

19
Boots

20
Oil
reservoir

21
Rese1l
Oir
band

22

Reservoir

cop

23

Cap

24

Pipe
seat
J

J

5

9

a

ID

1

Cylinder

2
Return

spring

C1

3
Piston

4

Spring
seat

5
Push
rod

6
Nut

7

Stopper
ring

8

Stopper

9
Dust
cover

10
on
reservoir

1
J
Reservoir
balld

12
Reservoir

cap

Fig
E

14
Section

through
the
clutch
master

cylinder

Adjusting
nut

Fig
E
l
S

Adjusting
the
clutch
withdrawal
lever

49

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

factory
parts

Installation

is
a

reversal
of
the
removal

procedure

REAR
SUSPENSION

ARM
Removal
and
Installation

Saloon

I
J
ad

up
the
car
at

the
rear
and

support
it
on
stands

2
Remove
the
road
wheel
and
brake
drum
as
described
in

the

section
BRAKES

3
Disconnect

the
drive
shaft
from
the
axle
shaft

4
Disconnect

the
handbrake
cable
from
the

equalizer
bracket

and
the
wheel

cylinder
lever
Disconnect

the
brake
hose

from
the
brake
line

by
removing
the
lock

spring
and
then

withdrawing
through
the
connector

Plug
the
end
of
the

brake

line
to

avoid
loss

of
fluid
and

ingress
of
dirt

5
Remove
the
wheel

bearing
locknut

Fig
H
9
the
rear

axle

shaft

wheel

bearings
and
oil
seal
Remove
the
rear
brake

assembly
from
the

suspension
ann
See
section
BRAKES

6
Jack

up
the

suspension
arm
to

relieve
the
tension
on
the

shock
absorber
and
disconnect
the
shock
absorber
from

the
lower

mounting
Lower
the

jack
gradually
and
remove

the
coil

spring
seat
and

bump
rubber

7
Remove
the
bolts

securing
the

suspension
arm
to

the

suspension
member

Fig
H
IO
and
withdraw
the

suspension

arm

The
rubber
bushes
can

be
drawn
out

of
the

suspension
arm

if

necessary
using
the

special
tool
ST
38280000

Fig
H
Il

O1eck
the

suspension
arm
for
distortion
or

cracks
and

inspect
the
rubber
bushes
for

signs
of
wear
or

damage
Renew

any
part
which

is

unsatisfactory

Installation

is
a

reversal
of
the
removal

procedure
Tighten

all
the

suspension
arm

mounting
bolts
with
the

weight
of

the

vehicle

resting
on
the
rear
wheels
The
self

locking
nuts
must

be
renewed
at
each
overhaul

REAR

AXLE
SHAFTS
BEARINGS
AND
SEALS

Saloon
Removal
and

Dismantling

I
Raise
the
vehicle
at
the

rear
and

place
stands
under
the

body
member

2
Remove

the
road
wheel
and
brake
drum

3
Disconnect
the
drive
shaft
from
the
axle
shaft
and
remove

the
wheel

bearing
locknut
The

special
wrench
ST
38060001

can
be
used
to
hold
the

flange
as

shownin

Fig
H
12

4
Withdraw

the
axle

shaft

assembly
as
shown
in

Fig
H
13

using
the

special
tool
ST
07640000

and
sliding
hammer

ST
36230000
Remove

the
rear
axle
drive

flange

5
Use
a
suitable
drift
or

special
tool
ST
37750000
See

Fig

H
14
to
drive

out
the
inner

bearing
and
oil
seal

F
6
Remove

the

grease
retainer
and
withdraw
the
outer

bearing
with
a
conventional

puller
DO
NOT
re
use
this

outer

bearing

REAR
AXLE
SHAFTS
BEARINGS
AND
SEALS
Saloon

Assembly
and
Installation

Oleck
the
axle
shaft
for

straightness
make
sure
that
it
is

not
cracked
or

damaged
in

any
way
00
NOT
heat
the
shaft

if

attempting
to
re
straighten

Make
sure
that
the

lip
of
the
oil

seal
is
not

damaged
or

distorted
Check
the

bearing
for
excessive

wear
and

damage

Oean
the
wheel

bearings
the
oil
seal

and
the
inside
of
the

axle

housing

When

installing
the
wheel

bearings
the
sealed
side
of
the

outer

bearing
should
face

the
wheel
and
the
sealed

side
of

the

inner

bearing
should
face
the
differential
See

Fig
H
IS

Pressure
must
be

applied
to
the
inner
race
when

fitting

When

replacing
the

suspension
arm
check
that
the
distance

piece
is
0
05
mm
0
002
in
shorter
than
the

length
of
the

housing
dimension
LI
See

Fig
H
16
The
distance

piece
and

axle

housing
code

markings
must
coincide

The
wheel

bearing
grease
must
be

replaced

every
50
000

km
30
000
miles
Pack
the
wheel

bearings
with

grease
at
the

positions
shown
in

Fig
H
IS
and
coat
the

lip
of
the
oil
seal

Renew
the
locknut
and
oil
seal
at

each
overhaul

Wheel

bearing
adjustment

Tighten
the
locknut
to

the

specified
torque
reading
of

25
33

kgm
181
239
lb
ft
and
check
that
the
rear
axle
shaft

end

play
does
not
exceed
0
15
mm
0
006
in
with
a

turning

torque
of
less
than
7

kg
em
6
11b
in
for
the
1400
and
1600cc

models
510

series
or
4
5

kg
em
3
91b
in
for
the
1800cc

610
series

If
the
correct
end

play
or

turning

torque
cannot
be

obtained
it
will
be

necessary
to

change
the
distance

piece
See

above

DRIVE
SHAFTS
Removal
and

Dismantlill8

Disconnect
the
end

flanges
and
remove
the
shaft
See

Fig
H
17
The
drive
shaft
should

only
be
dismantled
to

lubricate
the

splines
This

operation
will

only
be

necessary
every

two

years
or
50
000
km
30
000
miles

Remove
the
universal

joint
spider
at
the
differential
side

Refer
to
the

propeller
shaft
section
Remove
the

snap
ring

securiilg
the
sleeve

yoke
plug
and
take
out

the

plug
Compress

the
drive
shaft
and

remove
the

snap
ring
and

stopper
Fig
H
17

Disconnect
the
boot
and

split
the
shaft
Make
sure
that
the

balls
and

spacers
are
retained

DRIVE
SHAFTS

Inspection
and

Assembly

The
drive
shaft
should
be

replaced
as
an

assembly
if

any

part
is
found
to

be
defective

Check
the
shaft
for

straightness
damage
or
wear
Old

79

the
steel
balls
and
the
sleeve

yoke
for

damage
or
wear
Renew

the
boots
and
the
sleeve

yoke
plug
0

ring
if

necessary
Renew

the
universal

joint
jf

faulty

Check

the

play
in
the
drive
shaft

using
a
dial

gauge
as

shown
in

Fig
H
18
The
measurement
taken
with
the

dri
le

shaft

fully

compressed
should
not

exceed
O
lmm
0
004
in

Renew
the
drive
shaft
as

embly
if
the

specified
value
is
not

obtained

Oean

the
old
grease
from

the
sleeve

yoke
and
the
drive

shaft
ball

grooves
and
lubricate
with
oil

Asse

bly
of

the
drive
shaft

is
a

reversal
of
the

dismantling

procedure
noting
the

following
points

Align
the

yokes
and
make
sure
that

the
steel
balls

and

spacers
are
fitted

in
the
correct
order
Select
a

snap
ring
which

will

adjust
the
axial

play
of

the

universaIjoints
to
within
0
02mm

0
0008
in

Snap
rings
are
available
in

four
thicknesses
of

1
49
1
52
1
55

and
1
58
mm

0
0587
0
0598
0
0610

0
0622
in

Apply
a

generous

quantity
of
multi

purpose
grease
to
the

ball

groove
and
the
area
shown
in

Fig
H
19

REAR
AXLE
Removal
See

Fig
H
2

Estate
car
and
Van

Jack

up
the
vehicle
at
the
rear

and

support
it
on
stands

Remove

the
road

wheels
and
brake

drums
I

3
Disconnect
the
brake
hose
from
the

brake

pipe
Plug
the

end
of
the
hose
to

prevent
the

ingress
of

foreign
matter

4
Disconnect
the
handbrake
rear
cable
from

the
balance

lever

assembly

5
Disconnect

the

propeller
shaft
from
the
differential

flange

Release
the
lower
shock
absorber

self

locking
nuts
and

slide

the

mounting
eyes
of
the
shock
absorber
from
the

rear

spring
seat

pivot

6

Support
the
rear

axle
with

ajack
loosen
the
U
bolts
and

remove
the
nuts
from
the
rear

spring
shackles
Withdraw

the
shackles
from
the

spring
eyes

7
Remove
the
V
bolt
lock
nuts

completely
and
lower
the

jack
to

withdraw
the
rear
axle

assembly

REAR
AXLE

Dismailtling
and

Inspection

Disconnect
the
brake

pipes
from

the
wheel
cylinders
and

remove

the
brake

pipe
and
three

way
connector
Remove
the

cross
rod

clamp
and
the
balance
lever
from
the
rear
axle
case

Remove
both
cross
rod

ends
from
the

wheel

cylinder
lever

assembly

Unscrew
the
oil
drain

plug
and
drain
the
oil
from
the
axle

case
into
a
clean
container
The
oil

may
be
re
used
if
it
is
in

good
condition

Remove
the
nuts

securing
the
brake

backplate
to
the
axle

case
and
draw
out
the
axle
shaft

assembly
with
the

backpl
te

and
grease
catcher
A

sliding
hammer

ST
36230000
should
be

used
for
this

operation
as
shown
in

Fig
H
2Q

The

bearing
collar
can
be
removed
with
a

press
or

by

cutting
with
a
cold
chisel

and
the

bearing
withdrawn
with
the

puller
ST
3712001
as
shown
in

Fig
H
2t
Remove
the
brake

backplate
and
withdraw

the

gear
carrier
from

the
axle
case

Check
the
axle
shafts
for

straightness
wear
and
cracks

00
NOT

attempt
to

straighten
a
bent
shaft

by
heating
Check

the
oil
seal
lips
for

signs
of

damage
or
distortion
Make
sure

that

the

bearing
is
not
worn
or

damaged
REAR
AXLE

Assembly
and
Installation

Assembly
is
a
reversal
of
the

removal

procedure
noting
the

following
points

Thoroughly
clean
all

parts
and
fit
a
new

gasket
between

the
axle
case

and

gear
carrier

Tighten
the
nuts
in
a

diagonal

pattern
and
to

the

specified
torque
readings

Fit

the
grease
catcher

bearing
spacer
bearing
and
new

bearing
collar
onto
the
axle
shaft
A
load
of
4
5
tons
will

be

required
to

press
the

bearing
onto

the
shaft

Insert
the
wheel

bearing
with
the
seal
side

facing
the

wheel
and
ensure
that
the

oil
seal

lips
are
coated
with
wheel

bearing
grease
prior
to

fitting

Check
and

adjust
the
axial

play
between
the
wheel

bearing

and
the
axle

housing
using
a

dial
gauge
as

shown
in

Fig
H
22

The
axial

play
should
be

adjusted
to
within
0
3
0
5mm

0
0118
0
0197
in

on
the
1400
and
1600cc

models
and
to

within
O
lmm
0
0039
in
on

the
1800cc
models

Fill
the
rear
axle
with
the

specified
amount
of

oil
and

bleed
and

adjust
the
brake

system
as
described
in

the

appropriate

section

REAR
SPRING
Removal
and

Inspection

Estate
cars
aud
Vans

The
rear

springs
can
be
removed
in
the
following
manner

Jack

up
the

vehicle
at
the

rear
until
the
wheels
are
clear

of

the

ground
and

place
stands
under
the
rear
frame

Disconnect
the
shock
absorber
from

the

spring
seat

Fig
H
21a
and

support
the
rear
axle

housing
with

ajack

3
Take
off

the
locknuts

and
remove

the
U
bolts
shown

arrowed
in

Fig
H
2t
the

spring
seat
location

plates
and

seat

pads

4
Remove
the
nuts

securing
the
front
bracket
to
the

body

remove
the
bracket
from

the

spring
eye
and
car

body
and

withdraw
the
rear

spring

5
Remove

the

upper
and
lower

rear
shackle
nuts

Fig
H
23

and
remove
the
rear

spring
from
the
vehicle

Clean
the

spring
leaves

thoroughly
and
examine

them
for

fractures
or
cracks
Renew
the

assembly
if

necessary

Check
the
front

pin
shackle
U
boIts
and

spring
seat

for

signs
of
wear
cracks
and

damaged
threads
Renew
the

components
as

required

REAR
SPRING
Installation

Installation
of
the
rear

spring
is
a
reversal
of
the
removal

procedure
noting
the
following

points

The
front
bracket

pin
front
bracket

bushing
shackle

pin

and
shackle

bushing
should
be
coated
with
a

soapy
solution

prior
to

assembly

Tighten
the
front

pin
securing
nut

and
the
shock
absorber

lower

securing
nut
with
the
vehicle

weight
resting
on
the
rear

wheels

Ensure

that
the
flange
of

the
shackle

bushing
is

clamped

evenly
on
both
sides

The

tightening

torque
values
can

be
found

on
the

page

entitled
TIGHTENING

TORQUES

81

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

The

type
D3034C
carburettor
has
certain
additional

features

These
include
a

power
valve
mechanism
to

improve
the

performance

at

high
speed
a
fuel
cut
off
valve
which
cuts
the
fuel

supply

when
the

ignition
key
is
turned
to
the
off
position
and
an

idling

limiter
to

maintain
the

emissions
below
a

certain
level

Sectional
views
of
the
two

types
of

pumps
are
shown
in

Figs
8
1
and
B
2
An
EP
3
electrical
fuel

pump
is

located
in
the

centre

of
the
spare
wheel

housing
in
the
boot

Fig
B
3
shows
a

sectional
view
of
the

pump
with
its
contact

the
pump
mechanisms

solenoid

relay
and
built
in
filter

The
air
cleaner
uses
a

viscous

paper
type
element
which

should
be

replaced
every
40
000
km
24
000
miles

Cleaning

is
not

required
and
should
not
be

attempted

The

cartridge
type
fuel
strainer

incorporates
a
fibre
clement

which
should
be
renewed
at
inervals
not

exceeding
40
000
km

24
000
miles
Fit
B
4
shows
a
sectional
view
of

the
assembly

The
fuel
lines
should
not
be
disconnected
from
the
strainer
when

the
fuel
tank
is
full

unless
absolutely
necessary
as
the
strainer

is
below
the
fuel
level

FUEL
PUMP

Testing

Disconnect
the
fuel
hose
from
the

pump
outlet
Connect

a
hose
with

an
inner
diameter
of
approximately
6
mm
0
024

in
to

the

pump
outlet
and

place
a

container
under
the
end
of

the

pipe
Note
that
the
inner

diameter
of
the

pipe
must
not
be

too

small
or

the
pipe
will
be

incapable
of

delivering
the
correct

quantity
of
fuel
when

testing
Hold
the
end
of
the
hose
above
the

level
of
the

pump
and

operate
the

pump
for
more
than
IS

seconds
to
check
the

delivery
capacity
The

capacity
should
be

I
400
cc

3
24
U
S

pts
in
one
minute
or
less
The

pump
must

be
removed
from
the
vehicle
if
it
does
not

operate
or
if
a

reduced

quantity
of
fuel
flows
from
the
end
of
the
hose
Remove

the
pump
from
the
vehicle
and
test
as
follows

Connect
the

pump
to
a

fully
charged
battery
If
the

pump

now

operates
and

discharges
fuel

correctly
the
fault
does
not

lie
in
the

pump
but

may
be
attributed
to

any
of
the

following

causes

Battery
voltage
drop

poor
battery
earth
loose

wiring

loose
connections
blocked
hoses
or
a

faulty
carburettor

If
the

pump
does
not

operate
and

discharge
fuel
when

connected
to
the

battery
then
the

pump
itself
is

faulty
and

must
be
checked
as
follows

First
make
sure
that
current
is

flowing
This
will
be
indica

ted

by
sparking
at

the
tenninals
If
current
flows
the
trouble
is

caused

by
a

sticking

pump
plunger
or

piston
The

pump
must

be
dismantled
in

this
case
and
the

parts
thoroughly
cleaned
in

petrol

If

the
current
does
not
flow
a
coil
or
lead
wire
is
broken

and
the

pump
must

be
renewed
A

reduced
fuel
flow
is
caused

by
a

faulty
pump
inlet
or

discharged
valve
or
blocked
filter

mesh
The

pump
must

of
course

be
dismantled
and
serviced
as

necessary

FUEL
PUMP

Removing
and

Dismantling

Remove
the
bolts

attaching
the
fuel

pump
cover
to

the

floor

panel
see

Fig
B
S
Remove
the
bolts

attaching
the

pump
to
the
cover

2
Disconnect
the
cable
and
fuel
hoses
Withdraw

the

pump
Dismantle
as
follows

Slacken
the

locking
band
screws
and

remove
the
strainer

strainer

spring
filter
strainer
seal
and

locking
band

Remove
the

snap
ring
Withdraw
the
four
screws
from
the

yoke
and
remove

the
electromagnetic
ulJ
it
Press
the

plunger
down
and
withdraw
the
inlet
vaive

the

packing

and
the
cylinder
and

plunger
assembly

A
defective
eledrical
unit

cannot
be
dismantled
as

it
is

sealed
and
must

be
renewed
as
a

complete
unit

FUEL
PUMP

Inspection
and

Assembly

Wash
the
strainer
filter
and

gasket
in

petrol
and

dry
using

compressed
air
Renew
the
filter
and

gasket
if

necessary
Note

that
the
filter
should
be
cleaned
every
40
000

km
24
000

miles
Wash
the

plunger
piston
and
inlet
valve
in

petrol
and

make
sure
the

piston
moves

smoothly
in
the

cylinder
Replace

the

parts
if
found
to
be
defective

Insert
the

plunger
assembly
into
the

cylinder
of
the
electri

cal
unit
and
move

the

assembly
up
and
down
to

make
sure
tha
t

the
contacts
are

operated
If
the
contacts
do
not

operate
the

electrical
unit
is

faulty
and
must

be
renewed

Assembly
is
a
reversal
of

the
dismantling
procedures
tak

ing
care
to
renew
the

gaskets
as

necessary

CARBURETIOR

Idling
Adjustment

The
D3034C
carburettor
fitted
to

engines
equipped
with

an
emission
control

system
must
be

adjusted
as
described
under

the

heading
IGNITION
TIMING
AND
IDLING
SPEED
in
the

section
EMISSION
CONTROL
SYSTEM

Reference
should
be
made
to
carburettor

idling
adjustment

procedures
for
the
L14
L16

and
LI8

engines
when

adjusting

the
type
DAK
340
carburettor
fitted
to
the
G
18

engine
A
smooth

engine
speed
of

approximately
550

rpm
should
be
attained
in

this
case

FUEL
lEVEL

Adjustment
DAK
340earburettor

A
constant
fuellevcl
in
the
float
chamber
is
maintained

by

the
float
and
needle
valve
See

Fig
8
6
If

the
fuel
level
does
not

correspond
with
the
level

gauge
line
it
will
be

necessary
to

care

fully
bend
the
float
seat
until
the
float

upper
position
is

correctly

set

The
clearance
H
between
valve
stem
and
float
seat

should

be
I
5
mm
0
0059
in
with
the
float

fully
lifted

Adjustment

can
be
carried
out

by
carefully
bending
the
float
stopper
3

FUEL
lEVEL

Adjustment
D3034Ccarburettnr

The
fuel
level
should

correspond
with
the
level

gauge
line

Adjustment
can

be
carried
out
if

necessary
by
changing
the

gaskets
between
the
float
chamber

body
and
needle
valve
seat

The
gaskets
are
shown
as
item
4
in

Fig
B
7
When

correctly

adjusted
there
should
be
a

clearance
of

approximately
7
mm

0
027
in
between
float
and
chamber
as
indicated

STARTING

INTERLOCK
VALVE
OPENING

The

choke
valve
at
its

fully
closed
position
automatically

opens
the
throttle
valve
to
an

optimum
angle
of
14

degrees
on

the

type
DAK
340
carburettor
and
13
5

degrees
on
the
D3034C

carburettor
With
the
choke
valve

fully
closed
the
clearance

G

I
in

Fig
8
should
be
1

I
mm
0
0433

in
This
clearance

S19

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