1969 DATSUN 610 length
[x] Cancel search: lengthPage 83 of 171
REAR
SHOCK
ABSORBERS
Replacing
Estate
cars
and
Vans
Jack
up
the
reaT
of
the
vehicle
and
place
stands
under
the
rear
axle
housing
Disconnect
the
lower
end
of
the
rear
shock
absorber
from
the
spring
seat
Fig
H
23
Remove
the
shock
absorber
upper
attachment
nuts
and
withdraw
the
shock
absorber
The
upper
attachment
nuts
are
located
behind
the
Tear
seat
backrest
as
shown
in
Fig
H
24
Check
the
shock
absorber
for
leakage
or
cracks
and
make
sure
that
the
shaft
is
straight
Inspect
the
rubber
bushings
for
damage
and
deterioration
Renew
all
defective
components
lnstallation
is
a
reversal
of
the
removal
procedures
Tighten
the
upper
and
lower
shock
absorber
attachment
nuts
to
the
torque
readings
stipulated
in
TIGlITENING
TORQUES
NOTE
The
weight
of
the
vehicle
must
be
resting
on
the
fear
wheels
when
tightening
the
lower
mounting
to
damp
the
rubber
bushes
in
an
unloaded
position
TechnICal
Data
I
Type
Independent
suspension
with
semi
tralllI1g
arms
or
semi
floating
COIL
SPRINGS
14
2mm
0
559
in
14
5mm
0
571
in
90
mm
3
543
in
306
mm
12
047
in
299
mm
II
772
in
290
mm
11417
in
I
1400
and
1600cc
Wire
diameter
Wire
diameter
hard
suspension
Coil
diameter
Free
length
R
H
Free
length
L
H
Free
length
Hard
suspension
1800cc
Wire
diameter
Coil
diameter
Free
length
RHD
R
H
Free
length
RHD
L
H
Free
length
LHD
both
Free
length
Hard
suspension
RHD
R
H
RHD
L
H
LHD
both
14
5
mm
0
571
in
90
3
54
in
321
mm
12
6
in
307
mm
12
1
in
321
mm
12
6
in
306
mm
12
0
in
299
mm
I
1
8
in
306
mm
12
0
in
SHOCK
ABSORBERS
34
56
kg
75
123
lb
21
39
kg
46
86
lb
SHOCK
ABSORBERS
Estate
cars
and
Vans
1400
and
1600cc
estate
cars
and
rigid
axle
sedan
Piston
diameter
2S
mm
0
984
in
Stroke
205
mm
8
071
in
Max
length
518
mm
20
39
in
Damping
force
at
0
3
in
see
Estate
cars
Expansion
Compression
Damping
force
at
0
3m
jsec
Sedan
Expansion
Compression
1400
and
1600
cc
Piston
diameter
Piston
diameter
Hard
suspension
Stroke
Max
length
Damping
force
at
0
3m
sec
Expansion
Compression
1800
cc
Stroke
Max
lengtb
Damping
force
at
0
3
m
sec
Expansion
Compression
82
35
mm
1
378
in
40
mm
1
575
in
206
mm
8
110
in
568
mm
22
362
in
45
kg
99
21b
28
kg
61
7
lb
220
mm
8
60
in
595
mm
23
4
in
90
kg
198
4
lb
50
kg
110
3
lb
75
kg
165
4Ib
40
kg
88
2
lb
1800cc
Estate
cars
Stroke
Max
length
Damping
force
at
O
3m
sec
Estate
cars
Expansion
Compression
205mm
8
071
in
518
mm
20
39
in
63
87
kg
139
192
lb
33
43
kg
73
95
lb
Damping
force
at
0
3
m
sec
Estate
car
and
Van
with
hard
suspension
Expansion
Compression
97
131
kg
214
289
lb
29
43
kg
64
95
lb
REAR
SPRINGS
1400
and
1600cc
Estate
car
Length
Width
Thickness
No
of
leaves
Free
camber
Laden
camber
1200mm
47
2
in
60
mm
f2
362
in
6
mm
0
236
in
4
137
mm
5
394
in
15
mm
265
kg
0
59
in
584
lb
Spring
eye
bolt
diameter
Front
Rear
45
mm
I
772
in
30
mm
U81
in
1400
and
1600
cc
Free
camber
Laden
cam
her
rigid
axle
sedan
100
mm
3
937
in
15mm
250
kg
0
591
in
551
lb
1800cc
Estate
Laden
camber
Turning
torque
15
mm
265
kg
0
591
in
1
584
lb
2
2
kg
mm
123
Ib
in
REAR
AXLE
SHAFT
less
than
4
5
kg
cm
3
91b
in
less
than
0
1
S
mm
0
006
in
DRIVE
SHAFT
AND
JOURNAL
Spring
constant
End
play
Sliding
resistance
1400
and
1600
cc
Sliding
resistance
1800cc
0
15
kg
0
33
lib
less
than
20
kg
44
lb
Radial
play
of
ball
spline
less
than
O
lmm
0
004
in
Page 89 of 171
Removal
from
the
vehicle
can
be
carried
out
in
the
following
manner
Jack
up
the
front
of
the
vehicle
and
support
it
on
stands
2
Remove
the
stabilizer
bar
and
tension
rod
from
the
transverse
link
as
previously
described
Remove
the
knuckle
arm
fixing
bolts
and
separate
the
ball
joint
from
the
strut
asse
m
bly
3
Remove
the
transverse
link
mounting
bolt
Fig
J
16
and
detach
the
transverse
link
from
the
suspension
member
Remove
the
cotter
pin
from
the
knuckle
arm
castle
nut
and
remove
the
knuckle
arm
from
the
ban
joint
Unfasten
the
ball
joint
securing
nut
and
withdraw
the
ball
joint
from
the
transverse
link
r
The
bushing
can
be
withdrawn
from
the
transverse
link
using
a
press
and
the
special
tools
shown
in
Fig
J
17
TRANSVERSE
LINK
AND
LOWER
BALL
JOINT
Inspection
The
transverse
link
bushing
is
shown
in
Fig
J
18
If
the
rubber
and
inner
tube
joints
are
melted
or
cracked
the
complete
transverse
link
assembly
must
be
replaced
The
ban
joint
cannot
be
dismantled
and
should
be
replaced
if
the
dust
cover
is
split
or
if
the
axial
play
of
the
joint
exceeds
1
0
mm
0
039
in
Oleck
the
axial
play
with
a
spring
balance
The
force
required
at
the
cotterpin
hole
pOsition
is
between
6
6
1
I
3
kg
15
25
lb
Lubricate
the
ball
joint
with
multi
purpose
grease
every
50
000
km
30
000
miles
or
two
year
whichever
comes
first
A
grease
nipple
must
be
installed
in
place
of
the
plug
See
Fig
J
19
and
the
old
grease
completely
replaced
If
a
high
pressure
grease
gun
j
used
make
sure
that
the
grease
is
injected
slowly
and
is
not
forced
out
through
the
joint
clamp
Remove
the
grease
nipple
and
replace
the
plug
TRANSVERSE
LINK
AND
BALL
JOINT
Installation
Installation
is
a
reversal
of
the
removal
procedure
noting
the
following
points
Remove
all
rust
from
the
transverse
link
bushing
interior
with
a
piece
of
emery
cloth
The
bushing
and
transverse
link
bore
should
be
wetted
with
soapy
water
so
that
the
bushing
can
be
more
easily
inserted
Fit
the
bushing
into
the
transverse
link
using
the
special
tool
ST
36700000
Adjust
the
bushing
inner
tubes
so
that
the
distances
from
the
transverse
link
collar
ends
are
equal
at
both
sides
88
Install
the
lower
ball
joint
on
the
transverse
link
and
tighten
the
installation
bolt
to
a
torque
reading
of
1
9
5kgm
14
18Ib
ft
Oean
the
knuckle
arm
and
the
ball
joint
stud
install
the
knuckle
arm
on
the
ball
joint
and
tighten
the
castle
nut
to
a
torque
reading
of
5
5
74
kgm
4o
53Ib
ft
fit
the
cotterpin
and
bend
it
over
Apply
sealing
agent
over
the
ball
joint
castle
nut
to
prevent
the
formation
of
rust
Locate
the
knuckle
arm
beneath
the
strut
assembly
and
tighten
the
mounting
bolts
to
a
torque
reading
of
4
9
63kgm
35
46Ib
ft
Make
sure
that
the
shorter
of
the
bolts
is
fitted
at
the
front
Install
the
transverse
link
on
the
suspension
crossrnember
and
temporarily
tighten
the
mounting
bolts
Make
sure
that
the
nut
faces
the
front
of
the
car
and
not
the
bolt
head
Fit
the
tension
rod
and
stabilizer
bar
Lower
the
vehicle
and
remove
the
jack
Tighten
the
trans
verse
link
mounting
bolts
to
a
torque
reading
of
9
0
10
0
kgm
65
72
Ib
ft
with
the
vehicle
unladen
FRONT
WHEEL
ALIGNMENT
The
castor
and
camber
angles
are
preset
and
cannot
be
adjusted
If
the
angles
do
not
conform
with
the
fIgures
in
Techni
al
Data
then
a
check
must
be
made
for
damage
to
the
uspenSlon
system
Wheel
alignment
is
carried
out
with
the
tyres
mflated
to
the
correct
pressures
and
with
the
vehicle
on
a
level
surface
The
toe
in
should
be
checked
and
adjusted
if
necessary
by
slackening
the
locknuts
FigJ
20
and
turning
the
track
rods
by
an
equal
amount
until
the
correct
toe
in
is
achieved
The
standard
length
between
the
ball
joints
is
309
5
mm
12
19
in
for
the
1400
and
1600
cc
models
and
105
5
mm
4
14
in
for
the
1800
cc
models
ADJ
USTING
THE
STEERING
ANGLE
The
steering
angle
at
the
full
lock
positions
must
be
checked
with
the
front
wheels
placed
on
a
turntable
Adjust
ment
can
be
made
changing
the
length
of
the
stopper
bolt
shown
arrowed
in
FigJ
21
The
clearance
between
the
tyre
and
tension
rod
should
be
30
mm
1
181
in
or
more
and
can
be
increased
if
necessary
by
extending
the
length
of
the
stopper
bolt
The
bolt
length
should
not
exceed
27
5
mm
1
083
in
when
the
adjustment
is
completed
Steering
angle
figures
are
given
in
Technical
Data
at
the
end
of
this
section
Page 91 of 171
Wire
diameter
Coil
diameter
No
of
turns
Free
length
1800
CC
1610
Body
Left
side
spring
Van
and
Estate
Right
side
spring
Van
and
Estate
Both
springs
Saloon
Free
length
1400
and
1600
cc
Left
side
spring
Right
side
spring
f
Fitted
height
Left
side
spring
Right
side
spring
Parts
No
Items
Strut
outer
dia
mm
in
Piston
rod
dia
mm
in
Cylinder
inner
dia
mm
in
Damping
force
at
piston
0
3
m
s
1
08
ft
s
Expansion
kg
Ib
Compression
kg
Ob
Stroke
mm
in
90
54302
UO
100
50
8
2
0
20
0
787
30
I
181
40
88
2
25
55
1
178
7
01
COIL
SPRINGS
12
mill
0
4
in
130
mm
5
I
in
8
371
mm
04
61
in
386
mm
15
20
in
386
mm
15
20
in
354
mm
13
94
369
mm
14
52
in
185
mm
270
kg
7
29
in
560
lb
200
mm
270
kg
7
87
in
560
lb
FRONT
SUSPENSION
UNITS
54302
3
U0500
54302
UOI10
54302
3
U051O
80
176
4
40
88
2
54302
N
1200
22
0
866
32
1
260
40
88
2
25
55
1
Page 98 of 171
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
Page 108 of 171
BRAKE
PEDAL
ADJUSTMENT
The
brake
pedal
height
and
free
play
can
be
adjusted
in
the
following
manner
1400
and
1600
CC
models
Adjust
the
length
of
the
master
cylinder
push
rod
until
the
height
of
the
pedal
pad
is
187
mm
7
36
in
for
manual
gear
boxes
and
202
mm
7
95in
for
automatic
transmission
vehicles
without
brake
light
switch
Fig
L
31
Retighten
the
locknut
Screw
in
the
brake
light
switch
until
the
screwed
part
of
the
switch
is
against
the
front
of
the
stopper
bracket
then
tighten
the
locknut
Screw
in
the
stopper
bolt
until
the
moveable
part
of
the
switch
is
completely
pushed
in
by
the
pedal
and
tighten
the
locknut
in
this
position
Make
sure
that
the
lamp
is
00
when
the
pedal
is
pushed
down
by
1
5mm
0
06
in
1800cc
models
Adjust
the
bolt
of
the
brake
lamp
switch
until
its
end
face
is
flush
with
the
locknut
then
tighten
the
locknut
securely
See
Fig
L
32
Adjust
the
pedal
stopper
until
the
pedal
pad
is
positioned
at
a
height
of
185
mrn
7
28
in
from
the
floor
then
tighten
the
stopper
with
the
locknut
Adjust
the
length
of
the
master
cylinder
push
rod
until
a
pedal
free
play
of
I
5mm
0
04
D
2in
is
obtained
then
retighten
the
locknut
Depress
the
brake
pedal
several
times
to
make
sure
that
a
full
travel
of
145mm
5
7
in
is
available
and
that
the
pedal
moves
freely
and
without
noise
Technical
Data
BRAKE
PEDAL
Pedal
height
1400
and
1600cc
models
I
87mm
7
362in
manual
gearbox
202mm
7
953in
auto
matic
185mm
7
28in
145mm
5
71
in
1800cc
models
Full
stroke
MASTER
CYUNDER
Inner
diameter
Piston
running
clearance
19
05mm
0
75
in
0
15mm
0
006
in
WHEEL
BRAKE
CYLINDERS
Inner
diameter
1400
and
1600cc
Front
drum
Front
disc
Rear
with
front
drum
Rear
with
front
disc
22
22mm
7
8in
50
8mm
2
0
in
22
22mm
7
8in
20
64mm
13
16
in
Inner
diameter
I
BOOcc
Front
drum
20
6mm
13
16in
Front
disc
Rear
50
8mm
2
0in
22
2mm
7
8
in
BRAKE
DRUM
AND
BRAKE
DISC
Drum
inner
diameter
Drum
outer
diameter
Out
of
round
maximum
Repair
limit
of
drum
Maximum
disc
run
out
Repair
limit
of
disc
228
6mm
9
0in
232mm
9
13in
0
05mm
0
002
in
230mm
9
055
in
0
06mm
0
0024
in
8
4mm
0
331
in
BRAKE
UNINGS
Drum
brakes
Width
x
thickness
x
length
40
x
4
5
x
219
5mm
1
575
x
1
772
x
8
642in
Disc
brakes
39
7
x
9
x
86mm
1
563
x
0
354
x
3
386in
Total
braking
area
Front
drum
brake
Front
disc
brake
Rear
351
sq
cn
54
4
sq
in
114
2
sq
cm
17
7
sq
in
351
sq
cm
54
4
sq
in
107
Page 112 of 171
stopper
to
the
overrunning
clutch
side
and
removing
the
stopper
clip
Remove
the
stopper
and
overrunning
clutch
as
shown
inFig
M
7
Oean
the
dismantled
components
and
check
them
for
wear
or
damage
Cbeck
the
brushes
and
renew
them
if
worn
below
6
5mm
0
257
in
Fit
new
brushes
if
the
brush
contact
is
loose
Cbeck
the
brush
holders
and
spring
clips
and
make
sure
that
they
are
not
bent
or
distorted
The
brushes
should
move
freely
in
their
housings
and
can
be
eased
with
a
file
if
necessary
The
brush
spring
tension
should
be
approximately
0
8kg
1
76Ib
and
can
be
checked
with
a
spring
balance
as
shown
in
Fig
M
S
Armature
assembly
Make
sure
that
the
surface
of
the
commutator
is
not
rough
or
pitted
Oean
and
lightly
polish
with
a
No
500
emery
cloth
if
necessary
If
the
commutator
is
badly
worn
or
pitted
it
should
be
skimmed
in
a
lathe
only
a
light
cut
must
be
taken
to
remove
the
minimum
amount
of
metal
If
the
commutator
diameter
wear
limit
of
0
2mm
0
OS
in
is
exceeded
the
assembly
must
be
renewed
Undercut
the
mica
between
the
commutator
segments
when
the
depth
of
mica
from
the
surface
of
the
segment
is
less
than
0
2mm
0
08
in
The
depth
should
be
between
0
5
0
8mm
0
0197
0
0315
in
as
shown
in
Fig
M
9
The
armature
shaft
should
be
checked
for
straightness
by
mounting
between
the
centres
of
lathe
and
positioning
a
dial
gauge
as
shown
in
Fig
M
I
O
Renew
the
armature
if
the
bend
of
the
shaft
exceeds
0
08mm
0
0031
in
Field
coils
testing
Test
the
field
coils
for
continuity
by
connecting
a
circuit
tester
between
the
positive
terminal
of
the
field
coil
and
the
positive
terminal
of
the
brush
holder
as
shown
in
Fig
M
I
I
If
a
reading
is
not
obtained
the
field
circuit
or
coil
is
open
Cbnnect
the
tester
to
the
yoke
and
field
coil
positive
teoninal
as
shown
in
Fig
M
12
to
check
the
field
coils
for
earthing
Unsolder
the
connected
part
of
each
coil
and
check
the
circuit
for
earthing
in
a
similar
manner
Renew
the
field
coils
if
they
are
open
earthed
or
short
circuited
Outch
assembly
The
overrunning
clutch
must
be
replaced
if
it
is
slipping
or
dragging
Examine
the
pinion
and
sleeve
making
sure
that
the
sleeve
is
able
to
slide
freely
along
the
armature
shaft
spline
Inspect
the
pinion
teeth
for
signs
of
rubbing
and
check
the
fly
wheel
ring
gear
for
damage
or
wear
Bearings
Inspect
the
metal
bearing
bushes
for
wear
and
side
play
The
bushes
must
be
renewed
if
the
clearance
between
the
bearing
bush
and
armature
shaft
is
in
excess
of
0
02mm
0
008
in
New
bearing
bushes
must
be
pressed
in
so
that
they
are
flush
with
the
end
of
the
case
and
reamed
ou
t
to
give
a
clearance
of
0
03
0
10
mm
0
0012
0
0039
in
H
Solenoid
assembly
Inspect
the
solenoid
contact
surface
and
replace
if
showing
signs
of
wear
or
roughness
Replace
the
pinion
sleeve
spring
if
weakened
Check
the
series
coil
by
connecting
an
8
12
volt
supply
between
the
Sand
M
terminals
as
shown
in
Fig
M
13
The
series
coil
is
normal
if
the
plunger
operates
Test
the
shunt
coil
by
connecting
the
S
terminal
the
M
terminal
and
the
solenoid
body
as
shown
in
the
lower
illustration
of
Fig
M
13
Open
the
M
terminal
when
the
plunger
is
operated
the
shunt
coil
is
satisfactory
if
the
plunger
stays
in
the
operated
position
Measure
the
length
L
between
theylonger
adjusting
nut
and
solenoid
cover
Press
the
plunger
against
a
firm
surface
as
shown
in
Fig
M
14
and
check
that
the
dimension
is
within
the
figures
given
Turn
the
adjusting
nut
if
necessary
until
the
required
dimension
is
obtained
STARTER
MOTOR
Assembly
and
Installation
The
assembly
and
installation
procedures
are
a
reversal
of
the
removal
and
dismantling
operations
When
assembling
the
starter
smear
the
armature
shaft
spline
with
grease
and
lightly
oil
the
bearing
bushes
and
pinion
ALTERNATOR
The
alternator
is
driven
by
the
fan
belt
and
has
an
advant
age
over
a
dynamo
in
that
it
provides
current
at
low
engine
speeds
thereby
avoiding
battery
drain
Maintenance
is
not
normally
required
but
the
tension
of
the
fan
belt
should
be
checked
and
adjusted
if
necessary
as
described
in
the
section
COOLING
SYSTEM
Care
must
be
taken
not
to
overtighten
the
fan
belt
or
the
alternator
bearings
will
be
overloaded
The
alternator
output
can
be
checked
with
the
alternator
in
the
vehicle
by
carrying
out
the
following
test
Ensure
that
the
battery
is
fully
charged
Withdraw
the
connectors
from
the
alternator
F
and
N
terminals
and
connect
a
jumper
lead
between
the
F
and
A
terminals
Connect
a
voltmeter
to
the
E
and
A
alternator
terminals
with
the
negative
lead
to
terminal
E
and
the
positive
lead
to
the
terminal
A
as
shown
in
Fig
M
IS
Switch
the
headlamps
on
to
full
beam
and
start
the
engine
Increase
the
engine
speed
gradually
and
note
the
reading
on
the
voltmeter
when
the
engine
reaches
a
speed
of
approximately
lOaD
rpm
The
alternator
is
operating
satisfactorily
if
the
voltmeter
shows
a
reading
above
12
5
volts
If
the
reading
is
below
12
5
volts
the
alternator
is
defective
and
should
be
removed
for
inspection
ALTERNATOR
Removal
Disconnect
the
negative
lead
from
the
battery
and
the
two
lead
wires
and
connector
from
the
alternator
Slacken
the
alter
nator
mounting
bolts
and
take
off
the
fan
belt
Take
out
the
mounting
bolts
and
withdraw
the
alternator
from
the
vehicle
III
Page 116 of 171
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
Page 118 of 171
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