weight DATSUN PICK-UP 1977 User Guide

CHECKING
AND

ADJUSTMENT

CAP
AND
ROTOR
HEAD

Cap
and
rotor
head
should
be
in

spected
periodically
as

specified
in
the

Maintenance
Schedule
Remove
cap

and
clean
all
dust
and
carbon
deposits

from

cap
and
rotor
If

cap
is
cracked

or
is

leaking
replace
with
a
De
one

CONTACT
POINT

Contact

point
should
be

replaced
in

accordance
with
the
Maintenance

Schedule

Standard

point
gap
is
0
45
to
0
55

mm
O
OIS
to
0

022
in
In

case
size

is
off
the
standard

adjustment
is
made

by
loosening
point
screws

Gap
gauge

is

required
for

adjustment

When

point
surface
is

rough
take

off

any
irregularities
with

fine
sand

paper
of
No
500
or
600
or
with
oil

stone

When
wear

on
contact

points
is

noticeable
replace
points
together

with
contact

arm
To

replace

proceed

as

follows

EE322

Fig
EE
58
Adju
ting
point

gap

EE321

I

Primary
lead
termina

2
Ground
lead
wire

3
Set
screw

4

Adjuster

5
Screw
Fig
EE
59
Breaker
Engine
Electrical

System

First
turn
out
set

screws
1
to

1
5

turns
at
contact
arm
and

primary
lead

wire

connection

just
for

enough
to

pull
out

primary
lead
terminal

Referring
to

Figure
EE

59
unSCrew

two
contact
set

fixing
screws

and

remove
lead
wire

While

holding
contact
arm

by

fingers

pull
out
contact
set

toward

you
by

raising
it

slightly
Contact

point
and

afm
can

then
be

removed

together

Install
new
contact

point
and

arm

assembly
in

reverse
sequence
of

removal

Coat
cam
with
a

light
coating

of

grease

ADVANCE
MECHANISMS

Specifications

Application

Vacuum
advance

Distributor

degrees
distributor

mmHg
inHg

Centrifugal
advance

Distributor

degrees

distribu
tor

rpm

For
Canada

Vacuum

advance
mechanism

mechanical

parts

If
vacuum
advance
mechanism
fails

to

operate
properly
check
for
the

following
items

and
correct
the
mal

function
as

required

1
Check
vacuum
inlet
for

signs
of

leakage
at
its

connection

Ifnecessacy

retighten
or

replace
with
a
new
one

2
Check
vacuum

diaphragm
for
air

leak

If
leak
is

found

replace
vacuum

controller

assembly

3

Inspect
breaker

plate
for
smooth

moving

If

pia
te
does
not

move

smoothly

this
condition
could
be
due
to

sticky

steel
balls
or

pivot
Apply
grease
to

steel
balls
or
if

necessary

replace

breaker

plate
as
an

assembly

EE
31
CONDENSER

Satisfactory
performance
of
con

denser

depends
on

capacity
and

degree

of
insulation

requiring
attention

to
be

sure

that
terminals
are
clean
and
set

screws
are

tight

Checking
of

condenser
is
made

by
a

condenser
tester

D4A4
06

D4A6
07
D4A4
07

D4A6
0S

Automatic

transmission
Manual
transmission

00
150
5

91

30
250
9

S4
00
170
6

69

6
50
300

1I
S1

00
550

11
0

2

300
00
600

110
1
950

Centrifugal
advance

mechanical

parts

When
cause
of

engine
malfunction

is

traced
to

centrifugal
advance
me

chanical

part
use
distributor
tester
to

check
its
characteristic

See
the

specifications
above

When

nothing
is

wrong
with
its

characteristic
conceivable
causes
are

break
down
abnormal

wearing
out
of

driving
part
or
others
So
do

not

disassemble

it

In

case
of

improper
characteristic

take
off
contact
breaker

assembly
and

check

closely
cam

assembly

governor

weight
shaft
and

governor
spring
etc

In
case

centrifugal
advance
me

chanical

part
is
reassembled
be

sure
to

check
advance
characteristic

by
dis

tributor
tester

DISASSEMBLY

To
disassemble
follow
the
below

proccd
ure

I
Take

off

cap
and
disconnect
rotor

head

2
Remove
vacuum
controller

EE291

Fig
EE
60
Removing
vacuum

controller

3
Remove
contact
set

Refer
to

Page
EE
31
when
contact

set
i
removed

EE323

Fig
EE
61

Removing
contact
tel

EE324

Fig
EE
62

Removing
breaker

plate
Engine
Electrical

System

4
When
breaker

plate
is
removed

be
careful
not
to
lose
steel

balls

between
breaker

spring
and
breaker

plate

5

Pul
roll

pin
out
and
siconnect

collar
to
remove
the
entire

rotating

parts

EE325

Fig
EE
63
Removing
roll

pin

EE326

Fig
EE

64
Removil1l
rotation
paTta

6
Remove

packing
from
the

top
of

cam

assembly
and
unscrew
earn
astern

bly
setscrew
Put
match
mark
across

earn
and
shaft
so
that
original
combi

nation
can
be
restored
at
assembly

EE
32
EE075

Fig
EE

65
Removing
cam

7

When

governor
weight
and

spring

are
disconnected
be
careful
not
to

stretch
or
deform

governor
spring

After

disassembling
apply
grease
to

governor
weights

ASSEMBLY

To
assemble
reverse
the
order

of

disassembly
Carefully
observe
the

fol

lowing
instructions

Align
match
marl

s
so
that

parts

are
assembled

to
their

original
posi

tions

2

Apply

grease
to
the

top
of
cam

assembly
as

required

3
Check
the

operation
of

governor

before

installing
distributor
on

engine

4

Adjust
ignition
timing
afteT
dis

tributor
is
installed
on

engine

Vacuum

advance
mechanism

mechanical

parts

If
vacuum
advance
mechanism
fails

to

operate

properly
check
for
the

following
items

and
correct
the

prob

lem
as

required

1

Check
vacuum
inlet
for

signs
of

leakage
at
its
connection
If

necessary

retighten
or

replace
with

a
new
one

2

Check
vacuum

diaphragm
for
air

leak

If
leak
is

found

replace
vacuum

controller

assembly

3

Inspect
breaker

plate
for
smooth

moving

If

plate
does
not
move

smoothly

this

condition
could
be

due
to

sticky

steel

balls
or

pivot
Apply
grease
to

steel
balls
or
if

necessary
replace

distributor

assembly

Centrifugal
advance

mechanical

parts

When

cause
of

engine
malfunction

is
traced

to

centrifugal
advance
mecha

nical

parts
use
distributor
tester
to

check
its
characteristics
See
to
the

specifications
above

If

nothing
is

wrong
with
its

charac

teristics
conceivable
causes
are

faulty

or

abnormal
wear
of

driving
part
or

others
So
do
not
disassemble
it

In
the
event
of

improper
character

istics
check

closely
rotor

shaft
assem

bly

governor
weight
and
shaft

If

any
of
above

parts
are
malfunc

tioning
replace
distributor

assembly

DISASSEMBLY

To

disassemble
follow
the

pro

cedure
below

1
Take
off

cap
and
remove

rotor

head

2
Remove
two
screws
shown
in

Figure
EE
69
and
detach
vacuum

con

troller
Engine
Electrical

System

EE291

Fig
EE

69

Removing
vacuum

controller

3
Remove

pick
up
coil

assembly

4

Using
two

pry
bars

pry
reluctor

from
shaft
Be
careful
not

to
distort
or

damage
the
teeth
of
reluctor

Remove

roll

pin

S
Remove

breaker

plate
setscrews

and
remove

breaker

plate
assembly

E330

Fig
EE
70

Removing
breaker
plate

etscrews

6
Pull
roll

pin
out
and
remove

collar

7
Remove
rotor
shaft
and
drive

shaft
assembly

EE331

Fig
EE
71

Removing
rotor

shaft
and

drive

shaft
assembly

8
Mark
rotor
shaft
and

drive
shaft

Remove

packing
from
the

top
of

rotor

shaft
and
unscrew
rotor
shaft

setscrew

EE

35
EE075

Fig
EE
72

Removing
rotor

shaft

9

Mark
one
of
the

governor
springs

and
its
bracket
Also
mark

one
of
the

governor

weights
and
its

pivot
pins

10

Carefully
unhook
and
remove

governor

springs

11
Remove

governor
weights

Apply
grease
to

governor
weights

after

disassembling

ASSEMBLY

To

assem
ble

reverse
the
order
of

disassembly

Carefully
observe
the
fol

lowing
instructions

1

Align
match
marks
so
that

parts

are
assembled
to
their

original

posi

tions

2

If
for

any
reason
contactor
is

removed
from
breaker

plate
adjust

cam
to
contactor
clearance

to
0
3

mm

0
012
in

as
shown
in

Figure
EE
73

after
installation

T

EE298

Fig
EE
73
Cam
to
contactor

clearance

3

Ensure
that
reluctor
is

properly

orien

ted
when

installing
on
shaft

Always
drive
in

roll

pin
with
its

slit

toward
the
outer
end
of
shaft
See

Figure
EE

74
Be

sure
to
use
a

new
roll

pin

DESCRIPTION

REMOVAL
AND
INSTAllATION

Removal

Installation

DESCRIPTION

The
clutch
is

a
single
dry
disc

type
CLUTCH

CLUTCH

CONTENTS

CL
2

Cl2

CL
2

CL
3
DISASSEMBLY
AND
ASSEMBLY

D

isassemb
I

y

Assembly

INSPECTION
CL
3

Cl3

CL
3

CL
4

using
a

diaphragm
spring
It
consists
of

the

clutch
disc

pressure
plate
dia
phragm
spring
thrust

rings
clutch

cover

I
and
clutch
release

bearing

e

M

0

s
8

o

8

l150
5
91
dia

225
8
86
dia

REMOVAL
AND

I
NSTALLATIO

Removal

1
Remove
transmission
from
ve

hicle

For
details
of
transmission
removal

refer
to
Transmission
Section

2

Insert
Clutch
Aligning
Bar

KV30100200
into
clutch
disc
hub

until
it
will
no

longer
go
It
is
im
A

u

o

6

o

C
62

2
44

dia

I

260

10
2
dia

CL231

Fig
CL
l

Construction
of
clutch
disc
and
COller
assembly
Unit
mm
in

portant
to

support

weight
of
clutch

disc

during
further

steps
See

Figure

CL
2

3

Loosen
six
screws

attaching

clutch
cover
to

flywheel
one
turn
at
a

time

each
un
til

spring
pressure
is

re

leased
Be
sure
to
turn
them
out
in
a

crisscross
fashion

Note
Exercise

special
care
to
avoid

grease
or
on

getting
on
clutch

linings

CL2
Fig
CL
2

Supporting
clutch

assembly

REMOVAL

In

dismounting
transmission
from

the
vehicle

proceed
as
follows

I
Disconnect
battery
ground
cable

from
terminal

2

Place
transmission
control
lever
in

neutIal

position

3
Remove
E

ring
and
control
lever

pin
from
transmission

striking
rod

guide
and
remove
control
lever
See

Figure
MT
4

TM335

Fig
MT

4
Remouing
controllelJ
r

4
Jack

up
the
vehicle
and

support

its

weight
on

safety
stands
Use
a

hydraulic
hoist
or

open
pit
if
avail

able

Confirm
that

safety
is
insured

5
Disconnect
exhaust
front
tube

6
Disconnect
wires
from
reverse

lamp
switch
See
Figure
MT
5

7
Disconnect

speedometer
cable

from
rear
extension

housing
See

Figure
MT
5

8
Remove
clutch

operating
cylinder

from
transmission
case
See

Figure

MT5

O

m

J

@

1

Speedometer
cable

2
Reverse

lamp
switch

3
Outch

operating
cylinder

TM774

Fig
MT
5
Bottom
view
of
car
Manual
Transmission

9
Remove
bracket

holding
center

bearing
on
3rd
crossmember

by

loosening
off

attaching
bolts
See

Figure
MT
6

PD219

Fig
MT

6
Removing
center
balring

holding
brucket

10
Uetach

propeller
shaft
from

companion
flange
of

gear
carrier

by

removing
four
bolts

See

Figure
MT
7

Not

a
Remove

propeller
shaft

carefully
so

as
not
to

damage

spline
sleeve

yoke

and
rear
oil
seal

b

Plug

up
the

opening
in
the

rear
of

rear
exteDSion

housing
to

prevent

oil
from

flowing
out

P0220

Fig
MT
7

Remouing
four
bolt

6ecuring
prop
ller

shtJft
to

companion
ltJnge

11

Support
engine
by
locating
a

jacft
under
oil

pan
with
a
wooden

block
used
between
oil

pan
and

jack

12

Support
transmission
with
a

transmissionjack

13
Remove
exhaust

pipe
btacket

by
unscrewing
attaching
bolts
2

California
models

only
See

Figure

MT
8

14
Remove
rear

engine
mounting

insulator

securing
bolts
I
and
rear

mounting
member

securing
bolts
3

See

Figure
MT
8

MT
4
E
A277

Fig
MT
8

Removing
engine
mounting

rear

support

15

Remove
starter
motor

16
Remove
bolt

securing
transmis

sion

to

engine

After

removing
these
bolts

support

the

engine
and
transmission
with

jacks

and
then
slide
tra
ion
rearward

away
from

engine
and
remove
from

the
vehicle

Note
Take
care
in

dismounting
trona

mission
not
to
strike

any
adjacent

parts
and
main
drive
shaft

DISASSEMBLY

TRANSMISSION
CASE

DISASSEMBLY

I
Prior
to

disassembling
transmis

sion

thoroughly
wipe
off
dirt
and

grease
from
it

2

Drain
oil

thoroughly

3
Remove
dust
cover
from
trans

mission
case

Remove
release

bearing
and
with

drawallever

4

Remove
reverse

lamp
switch

5
Move

gear
to
Neutral

6
Remove
speedometer
pinion
and

pinion
sleeve

by

taking
off
lock

plate

7
Remove
E

ring
and

stopper
guide

pin
from
rear
end
of

re
ll
extension

See

Figure
MT

9

TM337

Fig
MT
9

Removing
triking
rod

E

ring
and

topper
pin

Automatic
Transmission

REMOVAL
AND
INSTALLATION

TRANSMISSION
ASSEMBLY

REMOVAL

INSTALLATION

TRANSMISSION

ASSEMBLY

When

dismounting
the
automatic

transmission
from

a
vehicle

pay
at

tention
to
the

following
points

1

Before

dismounting
the
trans

mission

rigidly
inspecl
it

by
aid
of
the

Troubleshooting
Chart
and
dis

mount
it

only
when
considered
to
be

necessary

2
Dismount
the
transmission
with

utmost

care
and

when

mounting

observe
the

tightening

torque
indi

cated
on
another
table
not
to
exert

excessive
force

REMOVAL

In

dismounting
automatic
transmis

sion
from
vehicle

proceed
as
follows

I

Disconnect

battery
ground
cable

from
terminal

2

Disengage
torsion
shaft
from
ac

celerator

linkage

3
Jack

up
vehicle
and

support
its

weight
on

safety
stands
Recommend
a

hydraulic
hoist
or

open
pit
be
utilized

if
available

Make
sure
that

safety
is
insured

4
Remove

propeller
shaft

Note

Plug
up
the

opening
in
the
rear

extension
to

prevent
oil
from

flowing
out

5
Disconnect
front
exhaust
tube

6

Disconnect
selector

range
lever

from
manual
shaft

7

Disconnect
wire

connections
at

inhibitor
switch
CONTENTS

AT
33

AT
33

AT

33
TRANSMISSION
CONTROL
LINKAGE

REMOVAL
AND
INSTALLATION

ADJUSTMENT
AT
35

AT
35

AT
35

8
Disconnect
vacuum
tube

from

vacuum

diaphragm
and
wire

connee

lions

at
downshift
solenoid

9
Disconnect

speedometer
cable

from

rear
extension

10
Disconnect
oil

charging
pipe

II
Disconnect
oil
cooler
inlet
and

outlet
tubes
at
transmission

case

12

Support
engine
by
locating
a

jack
under

oil

pan
with
a
wooden

block
used
between

oil

pan
and

jack

Support
transmission

by
means
of
a

transmission

jack

13
Detach
converter

housing
dust

cover
Remove

bolts

securing
torque

converter
to
drive

plate
See

Figure

AT
4

AT261

Fig
AT
47

Removing
torque
conv
rter

attaching
bolts

Note
Before

removing
torque
con

verter
scribe
match
marks
on

two

parts
so
that

they
may
be

replaced
in
their

original
posi

tions
at

assembly

14
Remove
rear

engine
mount

securing
bolts
and
crossmember

mounting
bolts

15
Remove

starter
motor

16
Remove
bolts
securing
transmis

sion
to

engine
After
removing
these

AT
33
bolts

support
engine
and
transmission

with

jack
and
lower
the

jack
gradually

until
transmission
can
be
removed
and

take
out
transmission
under
the
car

Note

Plug

up
the

opening
such
as
oil

charging
pipe
oil
cooler
tubes

etc

INSTALLATION

Installation
of
automatic
transmis

sion
on
vehicle
is

reverse
order
of

removal
However
observe
the
follow

ing
installation
notes

Drive

plate
runout

Turn
crankshaft
one
full
turn
and

measure
drive

plate
mnou
t
with

indi

cating
finger
of
a
dial

gauge
rested

against
plate
See

Figure
AT
48

Replace
drive

plate
if

in
excess

of

0
5
mm
0

020
in

Maximum

allowable
mnout

0
3

mm
0
012
in

A
T262

Fig
AT
48
MeCJ
uring
drive

plate

runout

2
Installation
of
torque
converter

Line

up
notch
in

torque
converter

with
that
in
oil

pump
Be
extremely

careful
not
to
cause
undue
stresses
in

parts
in

installing

torq
e
converter

See

Figure
AT
49

PROPELLER
SHAFT

8l

DIFFERENTIALCAAR
ER

CHECKING
AND

CQRRECTING

UNBALANCED

PROPELLER
SHAFT
anced

propeller
shaft

proceed
as

follows

I
Remove

undercoating
and
other

foreign
materials
which
could

upset

shaft
balance
and

check
shaft

vibra

tion

by
road
test

2
If

shaft
vibration
is

noted

during
To
check

and
correct
an
unbal

SERVICE
DATA

Pe
issible

dynamic
unbalance

Axi

play
of

spider

journal

Journal

swinging

torque

Propeller
shaft
front

and
rear
out
of

round

Tightening
torque

Shaft
to

conipanion
flange
Gear
carrier
bolt

Self

locking
nut
front
shaft

Flange
yo
e
rear
shaft
to

companion
flange

front
shaft
bolt

Center

bearing
bracket
to
cross
member
bolt
road

test
disconnect

propeller
shaft
at

differential
carrier

companion

flange

rotate

companion

flange
180

degrees

and

reinstall

propeller
shaft

3

Again
check

shaft
vibration
If

vibration
still

persists
replace

pro

peller
shaft

assembly

gr
cm
in
oz

3S
0
49
at
S
800

rpm

mm
in

Less
than
0
02
0
0008

kg
em
in

Ib
Less
than
IS
O
13

mm
in

Less
than
0
6
0
024

kg
m

ft
lb

kg
m

ft
Ib

kg
m
ft
lb

kg
m
ft
lb
2

4
to
3
3
17

to
24

20
0
to
24
0

l4S
to
174

2
4
to

3
3
17
to
24

1

6
to
2
2

12
to
16

TROUBLE

DIAGNOSES
AND

CQRRECTIONS

Condition

Probable

cause

Vibration

during
at

medium

or

high
speed
Worn

or

damaged
universal

joint
needle

bearing

Unbalance

due
to
bent
or

dented

propeller

shaft

Loose

propeller
shaft

installation

Worn
transmission
rear

extension

bushing

Damaged
center

bearing
or
insulator

Tight
universal

joints

Undercoating
or
mud
on
the
shaft

causing

unbalance

Tire
unbalance

Balance

weights
missing

PD
4
Corrective

action

Replace

I
l
eplace

Retighten

Replace

Replace

Impact
yokes
with
hammer
to
free

up

Replace
joint
if
unable
to
free

up
or
if

joint

feels

rough
when

rotated

by
hand

Clean

up
shaft

Balance
wheel
and
tire

assembly
or

replace

from
known

good
vehicle

Replace

PROPElli

ER
SHAfT
DIFFERENTIAL
G

ARRIERf

Notes

a
PUller
should
be
handled
with

care

in

catchins
the

edge
of

bearing

inner

race

b
Be
careful

not
to

confuse
left
and

right
hand

parts

2
Remove

ring

gear
by
spreading

out
lock

strap
and

loosening
ring
gear

bolts
in

diagonally

3

Punch
off

pinion
mate

shaft
lock

pin
from

ring

gear
side

using
Solid

Punch
ICV31100300

KV31100300

PD022

Fig
PD

13

Removing
lock

pin

Note

Lock

pin
i
cauIked
at

pin
hole

mouth
on
differential
case

Do
not

punch
it
off

forCibly
without

checkins
how
it
is
uIked

4

Draw

out

pinion
shaft
and

re

move
thrust

block

pinion
mates
side

gears
and

thrust
washers

Note
Put
marks

on

gear
and
thrust

Wasliersotliat

they
can
be
reinstaD

ed
in

their

original
positions
from

which

they
were
removed

INSPECTION

Thoroughly
clean

all
disassembled

parts
and
examine

them
to
see
if

they

8re

worn

damaged
or
otherwise

faulty
and

how

they
are
affected

Repair
or

replace
ail

faulty

parts

whichever
is

necessaiy

I

Check

gear
teeth
for

scoring

cracking
and

chipping
and

make
sure

that

tooth
contact

pattern
indicates

correct

meshing
depth
If

any
fault
is

evident

replace
parts
as

required
Note
Drive

pinion
and

ring
gear
are

supplied
for

replacement
as
a
set

therefore

should
either

part
be

damaged
replace
as
a
set

2

Check

pinion
shaft
and

pinic
m

mate
for
scores

and

signs
of
wear
and

replace
as

required

Follow

the
same

procedure
for

side

gear
and
their
seats

on
differential

case

3

Inspect
all

bearing
races
and

rollers
for

scoring
chipping
or
evi

dence
of
excessive
wear

They
should

be
in

tiptop
condition
such
as
not

worn
and

with
mirror
like

surfaces

Replace
if
there
is
a
shadow

of
doubt

oil

their
efficiency
as
an
incorrect

bearing
operation
may
result
in
noises

and

gear
seizure

4

Inspect
thrust

washer
faces

Small

faults
can

be
corrected
with

sand

paper
If

pinion
mate

to
ide

gear

backlash
or

the
clearance

between

side

gear
and
thrust
washer
exceeds

limits
0

02

to
0
08
nun
0
0008
to

0
0031
in

replace
thrust
washers

S

Inspect
carrier

and
differential

case
for
cracks

or
distortion

If
either

condition
is

evident

replace

faulty

parts

6
As

a

general
rule

oil
seal
should

be

replaced
at
each

disassembly

ASSEMBLY

AND

ADjUSTMENT

Assembly
can
be

done
in

the

reo

verse

order
of

disassembly
The
foDow

ing
directions
for

adjustment
and

usage
of

special
tools
enable
to

obtain

a

perfect
differential

operation

PRECAUTIONS
IN

REASSEMBLY

I

Arrange
shims
w

shers
and
the

like
to
install
them

correctly

2

Thoroughly
clean

the
surfaces
on

which
shims

washers

bearings
and

bearing

caps
are
installed

3

Apply
gear
oil

when

installing

bearings

4

Pack

grease
cavity
between

lips

when

fitting
oil
seal

PD
8
ASSEMBLY
OF

DIFFERENTIAL
CASE

I

Assemble

pinion
mates
side

gears
thrust
block
and

thrust
washers

in
differential

case

2
Fit

pinion
shaft
to
differential

case
so

that
it

meets
lock

pin
holes

3

Adjust

pinion
mate

to
ide

gear

backlash
or
the
clearance

between
the

rear
face
of

side

gear
and
thrust

washer
to
0
02
to

0
08
mOl
0
0008

to
0

0031
in

by

selecting
side

gear

thrust
washer

Side

gear
thrust

WlISber

Thickness

nun

in

Over

0
7S

to
0
80

0
029S
to
0
03IS

Over

0
80
to
O
8S
Om

IS
to
0
033S

Over

0
8S
to
0
90
0

033S
to
0
03S4

Over

0
90
to
0
9S
0
03S4

to
0
0374

4

Lock

pinion
shaft
lock

pin
using
a

punch
after
it

is
secured
into

place

S

Apply
oil
to

gear
tooth

surfaces

and
thrust
surfaces
and
check
if

they

turn

properly

6
Place

ring

gear
on

differential

case

and
install

bolts
and
lock
washers

Torque
bolts
to

specification
and

bend

up
lock

strap

Tightening

torque

7
0
to
8
0

kg
m

S1to
Sifft
Ib

Notes

ao
Use

only
genuine
ring
gear
bolts

and
new
lock

strap

b

Tighten
bolts
in

criss
cross
fashion

lighdy
tapping
fOund
bolt

heac
Js

with
a
hammer

7

When

replacing
side

bearing

measure

bearing
width

using
a

stand

ard

gauge
20
00
nun
0
7874
in

thickness
and
a

weight
block
2
5

kg

S
S
Ib

prior
to
installation
See

Figure
PD

I4

Standard
bearing
width

20
00
nun
0
7874
in

s

Install
tension

rod
at
rear
end

tighten
nut
to

make
the

distance
of

rubber

bushing
to
be
33
4
mm
1
315

in
and

torque
lock
nut
to
1

6
to
2
2

kg
m
12

to
16
ft
lb

6

Install
tension
rod
bracket

to

chassis

frame
bracket
and

torque
nut

to
1

6
to
2
2

kg
m

12
to
16
ft
lb

When

two
rubber

bushings
are
dif

ferent
in
size

arrange
adjusting
nut

Standard
dimension
is
11
0
mOl
0
433

in

as
shown
in

Figure
FA

16

Torque

lock
nut

to
1
6
to
2
2

kg
m

12
to
16

ft
lb

Il
0

11

0
0
433

t

lP

33
4
1
315

I

11
0

0
433
1
0
11
0

0

433

Adjusting
nut

Y
i

w

36
6
l
441

Unit
mm

in

FA235

Fig
FA
16
Tension
rod
detail

INSPECTION

I

Check
tension

rod
for
bend
and

the

thread
for

faulty
condition

Repair

or

replace
as

required

2

Check

bushing
rubber
for
wear

and
deterioration

Replace
if
neces

sary

TORSION

BAR

SPRING

REMOVAL
AND

INSTALLATION

Removal

1
Raise
vehicle
on
a
hoist
or
stands

2
Remove
wheel

3
Loosen
nuts
at

spring
anchor

bolt
Front
Axle
Front

Suspension

4
Remove
dust

cover
at
the
rear

end

of
torsion
bar

spring
and

detach

snap

ring

S
Withdraw
torsion
bar

spring
rear

ward

after

pulling
ou
t
anchor
arm

realWard

I

nstallalation

Install
torsion
bar

spring
in
the

reverse

sequence
of

removal

noting

the

following
instructions

I

Coat

grease
on
the
serrations
of

torsion
bar

spring
and
install
it

to

torque
arm

Note
Be

sure
to
install

right
and
left

torsion
bar

springs
correctly
They

can

be
identified
with
R

Right

and
L

Left
marked
on
the
end

surface

2
Install

anchor
arm
and

tighten

adjusting
nut
to

obtain
A
dimen

sion
See

Figure
F
A
17

When
anchor

arm
is

properly
adjusted
to
A

specification
upper
link
should
be
in

contact
with

rebound

bumper
rubber

See

Figure
FA
18
Install

snap
ring
and

dust
cover

Temporarily
tighten

adjust

ing
nut
until
B

specification
is

reached

I

I

I

FA236

Fig
FA
17

Installing
anchor
arm

Specifications
for
torsion
bar

spring

Diameter
x

length
mOl

in

Torsional

rigidity

kg
m

deg
ft
lb

deg

FA
9
Anchor
arm

setting
post
ion
A

ISt02Smm

0
59
to

0
98
in

Temporary
tightening
distance
B

60
to
70

mOl

2
36
to
2

76
in

UjPPje
Rebound

bumper

rubber

j

4W

Fig
FA

18

Setting
procedure

Notes

3
A

and
8

specifications
are

only
the

preliminary
rough
settings

directions
for

performing
the
final

adjustment
that

determines
the
ride

height
are
found
on

page
F
A
II

under

Adjustment

b
Discard
old

snap
ring
after

re

moving
it

Replace
with
new

one

during
reinstallation

3
Install
wheel
and

lower
vehicle

Adjust
vehicle

posture
at
curb

weight

full
fuel

tank
no

passengers
refer

ring
to

Adjustment

4

Torque
lock
nut
to
3
1
to
4
1

kg
m
22
to
30

ft
lb

INSPECTION

Check
torsion
bar

spring
for
wear

twist
etc
When

adjusting
vehicle

posture
replace
torsion
bar

spring

with
a
new
one
if
the

specified
height

can
not

be
obtained

All
models

21

9
x
830
0
862
x

32
68

3
74
27
I

WHEEL
ALIGNMENT

Correct
front
wheel

alignment

attains

proper
vehicle

handling
charac

teristics
and
the
least

steering
effort

with
a
minimum
amount
of
tire
wear

Before

adjusting
front
wheel

align

ment
make
sure
to

carry
out
a

pre

liminary
inspection
of
the
front
end

parts
for
the

following
conditions

1
Tire

pressure
and

balance

2
Wheel

bearings
and
nuts

3

Steering

gear
play

4

Steering
gear

housing
at
frame

S

Steering
linkage
and
connections

6
Shock
absorber
action

When

using
the

equipment
for
front

wheel

alignment
inspection
follow
the

inst

c
tions
furnished

with
the

equip

ment
Furthennore
the

inspection

should
be
made
with
the

vehicle
level

and
at

curb

weight

Camber
and

caster

Measure
camber
and
caster

and

adjust
them
in

accordance
with

the

following
procedures
if

necessary

Both
camber
and
caster

are
ad

justed
by
increasing
and

decreasing

thickness

of

adjust
shim

inserted
be

tween

upper
link

spindle
and

upper

link

mounting
bracket

To

adjust
caster

make
a

difference

between

thickness
of
front

and
rear

shims

By

adding
a
shim

I
mm
0

039

in

at
front
side

caster
will
be
de

creased

by
33

At
the

same
time

camber

will
also
be

decreased

by
6
S

To

adjust
camber
add
or
remove
an

equal
amount
of

shims
to
front

and

rear
sides

By

adding
a

pack
of
shims
I

mOl
0
039
in

thick
at
both

sides

camber

will

be
decreased

by
13

Shims

are
available
in
I

mm
0
039

in
2

mOl
0
079
in
and
4

mOl
0
157

in

thickness
Front
Axle
Front

Suspension

FA243

Fig
FA

25

Adjustingcamberand

cCJ
ter

Notes

a
Do
not
make
difference

between

front

and
rear
shims

in
thickness

beyond
2
mm

0
079
in
on
a

upper

link

spindle

b

Umit
shim
thickness
for

anyone

stack
within
6

nun
0

236
in

c
Do
not

use
shims
for

anyone
stack

more
the
2

sheets

Toe
in

Measure
toe
in

and

adjust
if
neces

sary
For

adjustment
carry
out
the

follOWIng
procedures

Turn

steering
wheel
to

straight

ahead

position
with
front
wheels
in

the
same

position
Then
check

steer

ing
gear
straight
ahead

position

Loosen
lock
nuts

@
left
hand

thread
and

ID
right
hand
thread

and
turn
cross
rod

CD
to

adjust
toe
in

Turn

cross
rod
to
forward

direction
as

shown

by
arrow
and
toe
in
is

reduced
When

cross
rod
is
turned
to

opposite

side
toe
in
is
increased

After

correct
toe
in
is

obtained

tighten
lock
nut

to
8

0
to
10

0

kg
m

S8
to

72
ft
Ib

r
J

r

CD

0

HI

r
I

e

f

FA244

Fig
FA

26

Adju6ting
toe
in

STEERING
ANGLE

Check

steering
angle
and
use
the

follow

ng
procedures
if

necessary

Loosen
lock
nut
at

stopper
bolt
and

adjust
steering
angle
with

stopper
bolt

Mter

obtaining
correct

steering

angle

secure
lock
nut

firmly

FA245

Fig
FA

27

Adjusting
steering
angle

Model
Item

All

models

mOl
in
1
2
to
3
0
079
to

0
118

Toe
in

degree
2

10
to
16

Camber

lOIS
Io

Caster
10SO

4S

I
60IS

Kingpin
inc

inal10n

I
Inner
wheel

360
10

Steering
angle

I
Outer
wheel

310
10

1
The

extreme
front
and

rear
of
the
tire

center

Unladen

2
The
total

angle
of

the
both
tires

FA
12