1969 DATSUN 610 light

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

brake
shoe
is
in
contact
with
the
drum
The

adjuster
must
be

turned
from

the
rear
of

the

backplate
and
the
drum
turned

by

hand

When
the
shoe
contacts
the
drum
turn
the

adjuster
in

the

opposite
direction
until
the

shoe
is

just
clear
and
the
drum

can

be
rotated

freely
by
hand

Depress
the
brake

pedal
and
make
sure
that
the
brakes

operate
correctly
The

adjusters
must

be
released

slightly
if

the

brake
shoe
binds

FRONT
DISC
BRAKE
Friction

pads
Fig
L
14

The
disc
brakes
are
self

adjusting
but
the
friction

pads

should
be
checked
for
wear

every
5
000
km
3
000
miles
and

replaced
if
the
thickness
of

the
friction

lining
on

any

pad
is
less

than
1
0mm
0
004
in
In
effect
this
means
that
renewal
is

necessary
when
the
total
thickness
of

pad
and

lining
is
less
than

8
4mm
0
24
in

To

replace
the
friction

pads
proceed
as

follows

Siphon

out
some
of
the
fluid
in
the
master

cylinder
reservoir
Jack

up

the
front
of
the
vehicle
and
remove

the
road
wheel

Remove
the
anti
rattle

clip
from
the

calliper
plate
Fig
L
lS

Unhook
the

hanger
spring
and
withdraw
the
brake

pads

and
shims

Fig
L
17

It
should
be
noted
that
the
friction

pads
must
be

replaced

as
a
set
and
renewed
at
both
sides
of
the
vehicle
otherwise
the

braking
action
will
be
uneven

Oean
the

calliper
and

pad
at

their
installation

positions

Press
the

pistons
into
the

calliper
bores
so
that
the
new
friction

Pads
can
be
installed
The

pistons
can

be
installed

by
applying

light

pressure
as
shown
in

Fig
L

16
but
care
must

be
taken
to

avoid

pushing
them
too
far
or
the

groove
of
the

piston
will

damage
the
seal

If
the

pistons
are

pushed
down

excessively
it
will
be

necessary
to
dismantle
the

calliper
as

described
under
the

appropriate
heading

Assemble
the

anti

squeal
shims
to
the
friction

pads
with

the
arrow
mark
on
the
shims

pointing
in
the
direction
of

forward
disc
rotation

Refit
the

pads
and

retaining
pins
and
assemble
the
coil

spring
to

the

retaining
pin
furthest
away
from

the
air
bleed
screw

After

installing
the
new

pads
and
shims

depress
the
brake

pedal
several
times
to

reposition
the
pistons
in
the

calliper

O1eck
the
fluid
level

in
the
master

cylinder
reservoir
and
refill

to
the
correct
level

FRONT
DISC

BRAKE
Removal
and

Dismantling

1
Jack

up
the
front
of

the
vehicle
remove
the
road
wheel

and
take
out

the
friction

pads

2
Disconnect
the
brake
hose
from
the
brake

tube
and

plug

the

opened
end
to

prevent
the
loss
of
fluid
3
Remove
the
bolts

securing
the
brake

calliper
to

the

knuckle

flange
and
remove
the

calliper
assembly
Fig
L
IS

4
Remove
the
hub
nut

and
withdraw
the
hub
and
disc

To
dismantle
the
calliper
remove
the
anti
rattle

clip
and

withdraw
the
brake

pads
Remove
the
tension

springs
and

pull

the
cylinder
out
of
the

calliper
Blow
out

the
piston
with
com

pressed
air

applied
at

the
brake
hose
connection

Oean
the

components
in
brake
fluid
and
examine
them

for

signs
of
wear
or

damage

The

cylinder
walls
can

be
carefully
polished
with
fine

emery
cloth
if

they
are
rusted
or
contaminated
If
the

parts

are

excessively
corroded

they
should
be
renewed

Replace
the

pistons
if

they
are

unevenly
worn

damaged

or
rusted
The
sliding
surface
of
the

piston
is

plated
and
no

attempt
should
be
made
to

use

emery
cloth
or
similar
abrasives

for

cleaning
purposes

Check
the
thickness
of
the
friction
pads
as

previously

described
and
replace
them
if

necessary
Renew
the

piston
seals

and
the
dust
covers

O1eck
the
brake
disc
for

scoring
and
out
of
round
The

standard
disc
thickness
is
10
Omm
0
0394
in
and
must
not

be

reground
below
8
4mm
0
3307
in

Check
the
disc
run
out
with
a
dial

gauge
as
shown
in

Fig

L
19
Position
the
gauge
near
the
outer
diameter
and
check
that

the
run
out
does
not

exceed
0
06mm
0
0024
in

FRONT
BRAKE
DISC
Assembly
and
Installation

Rinse
the

cylinder
bore
with
brake
fluid
and
fit
the

piston

seal
into
the

cylinder

groove
Fig
L
20
Fit
the
wiper
seal
and

lightly
grease
the
bore
of
the

cylinder
Clean
the
brake
disc

and
fit
it
to
the
hub
Install
the
hub
to
the
knuckle

spindle

Carefully
insert
the

piston
into
the

cylinder
until
the
face

of
the

piston
is
almost
flush
with

the

wiper
seal
retainer
The

relieved

part
of
the

piston
should
face
the

piston
pin

Fit
the
cylinder
to
the

calliper
plate
and
secure
in

position

with
the
two
torsion

springs
Assemble
the
hold
down
pin

the

spring
washer
and
the
nut
to

the

support
bracket
Secure

the
nut

with
a
cotter

pin

Assemble
the

calliper
to

the
mounting
bracket

using
the

pivot
pin
washer

spring
washer
and
nut

Tighten
the
nut
and

secure
with
a
cotter

pin
Hook
the
hold
down
bracket
to
the

top
of
the

mounting
bracket
and
turn
the

calliper
plate
to

make

sure

that
it
can
slide

smoothly
Fit
the

calliper
assembly
to
the

knuckle

flange

Fit
a
shim
to
the
inner

pad
and
insert
the

pad
Draw
the

calliper
towards
the
chassis
and
insert
the
lower
cuts
on

the

pad

into
the

mounting
bracket
and

push
the

pad
in
until
it
contacts

the

piston
Move
the

calliper
away
from
the
chassis
and
insert

the

upper
cuts
Centre
the
indentation
of

the
outer

pad
in
the

calliper
plate
Fit
the
anti
rattle

clip
Fig
L
14

103

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

ElectrIcal

EquIpment

DESCRIPTION

BATTERY
Maintenance

STARTER
MOTOR

Removal
and

Dismantling

STARTER
MOTOR

Testing

STARTER
MOTOR

Assembly
and
Installation

ALTERNATOR
Removal

Dismantling
and

Inspection

DESCRIPTION

A
12
volt

negative
earth
electrical

system
is
used
in
which

the

battery
is

charged
by
an
alternator
In
the
alternator
a

magnetic
field
is

produced
by
the
rotor

which
consists
of
the

alternator
shaft
field
coil

p
le

pieces
and

slip
rings

Output
current
is

generated
in
the
armature
coils
located

in
the
stator
Six
silicon
diodes
are

incorporated
in
the
alternator

caSing
to

rectify
the

alternating
current

supply
A
voltage

regulator
and

pilot
lamp
relay
are
built
in
the

regulator
box

which

nonnally
does
not

give
trouble
or

require
attention

The
starter
motor
is
a

brush

type
series
wound
motor

in

which

positive
meshing
of
the

pinion
and

ring

gear
teeth
are

secured

by
means
of
an

overrunning
clutch

BATTERY
Maintenance

The

battery
should
be
maintained
in
a
clean
and

dry

condition
at
all
times
or
a
current

leakage
may
occur

between

the
terminals
If

frequent
topping

up
is

required
it
is
an

indication
of

overcharging
or
deterioration
of
the

battery

When

refitting
the
cables
clean
them

thoroughly
and
coat

their

terminals
and
the
terminal

posts
with

petroleum
jelly

Check
the
level
of
the

electrolyte
in
the

battery
at

frequent

intervals
and

top
up
if

necessary
to

the
level
mark
on

the

battery
case
with
distilled
water
A

hydrometer
test
should
be

carried
out

to
determine
the
state

of

charge
of

the

battery
by

measuring
the

specific
gravity
of
the

electrolyte
It
should
be

pointed
out

that
the
addition
of

sulphuric
acid
will
not

normally

be

necessary
and
should

only
be
carried
out

by
an

expert
when

required

The

specific
gravity
of
the

electrolyte
should
be
ascertained

with
the

battery

fully
charged
at
an

electrolyte
temperature
of

200C
680F

The

specific
gravity
of
the

electrolyte
decreases
or
increases

by
0
0007
when
its

temperature
rises
or
falls

by
10C
1
80F

respectively

The

temperature
referred

to
is
that
of
the

electrolyte
and

not
the
ambient

temperature
to
correct
a

reading
for
an
air

temperature
it
will
be

necessary
to

add
0
0035
to
the

reading

for

every
50C
above
200C

Conversely
0
0035
must

be
deducted

for

every
SOC
below
200C
Test
each
cell

separately
and
draw

the

liquid
into
the

hydrometer
several
times
if
a
built
in

thermometer
type
is
used

The
correct

specific
gravity
readings
should
be
as
follows
ALTERNATOR

Assembly
and
Installation

HEAD
LAMPS

Replacing

HORN

INSTRUMENT
PANEL
Removal

WINDSCREEN
WIPERS

WINDSCREEN
WASHERS

IGNITION
SWITCH
AND
STEERING
LOCK

Cold
climates

Temperature
climates

Tropical
climates
Permissible

value

Over
1
22

Over
1
20

Over
1
18
Fully
charged
at
200C

680F

1
28

1

26

1
23

The

battery
should
be

recharged
if
a
low

specific
gravity

reading
is
indicated

Always
disconnect
both
terminals
of
the

battery
when

charging
and
clean
the
terminal

posts
with
a

soda

solution
Remove
the
vent

plugs
and

keep
the
electrolyte

temperature
below
450C
l130F
during
charging

Check
the

specific
gravity
after

charging
and
if
it
is
above

1
260
at

200C
680C
add
distilled
water

STARTER
MOTOR
Removal
and
Dismantling

As
previously
stated
the
starter
motor

is
brush

type
series

wound
motor
in
which
the

positive
meshing
of
the

pinion
and

ring
gear
teeth
are
secured

by
an

overrunning
clutch
The
over

running
clutch

employs
a
shift
lever
to
slide
the

pinion
into

mesh
with
the
flywheel
ring

gear
teeth
when
the
starter
is

operated

When
the
engine
starts
the

pL
lion
is

permitted
to
overrun

the
clutch
and
armature

but
is
held
in
mesh
until
the
shift
lever

is
released
An

exploded
view
of
the
starter

is
shown
in

Fig
M
2

To
remove
the
starter

motor

proceed
as
follows

Disconnect
the

battery
earth
cable

2
Disconnect
the
black
and

yellow
wire
from
the
solenoid

terminal
and
the
black
cable
from
the

battery
terminal

3
Remove
the
two
bolts

securing
the
starter
motor
to
the

clutch

housing
Pull
the
starter
motor

assembly
forwards

and
withdraw

it
from
the
v
hicle

To
dismantle
the
starter

motor
ftrst
remove
the
brush

cover
and
lift
out

the
brushes
as
shown
in

Fig
M
3

Loosen
the
nut

securing
the

connecting
plate
to

the

solenoid
M
terminal
Remove
the
solenoid

retaining
screws

take
out

the
cotter

pin
and
withdraw

the
shift
lever

pin
Remove

the
solenoid

assembly
as
shown
in

Fig
M
4

Remove
the
two

through
bolts

and
rear
cover

assembly

then
remove

the
yoke
assembly
by
lightly
tapping
it
with
a

wooden
mallet

Fig
M
S
Withdraw
the
armature
and
shift

lever

Fig
M
6
Remove
the
pinion

stopper
from
the

armature
shaft

by
removing
the

stopper
washer
pushing
the

109

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

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

GIS

DESCRIYfION

ENGINE
Removal
and
Installation

ENGINE
MOUNTING

INSULATORS

ENGINE

Dismantling
Inspection
and
Overhaul

CHAMSHAFT

AND
CAMSHAFT
BEARINGS

CYLINDER
BLOCK

PISTONS

CONNECTING

RODS

CRANKSHAFT

ENGINE

Assembling

VALVE
CLEARANCE

Adjusting

DESCRIYfION

The
G
18

engine
is
a
short

stroke
unit
with
a

displacement

of
1
815
ce
The
aluminium

alloy
cylinder
head
has
cross
flow

ports
and
a
V

shaped
valve

layout
The

single
overhead
camshaft

is
driven
from
the
crankshaft

by
a
double
row
roller
chain
at
a

reduction

ratio
of
2
I

The
crankshaft
is
a

carbon
steel

forging
and
is

provided

with
five
main

bearings
and
four

balancing
weights
Aluminium

thrust

bearings
are
located
at

the
No
2

journal

The
cast
aluminium

alloy
pistons
have
two

comp
ression

rings
and
one
oil

ring
Gudgeon

pins
are

fully
floating
in
the

piston
bores
and
are

equipped
with

circlips
at

each
end
to
limit

the
amount

of
their
travel
The

forged
steel

connecting
rods

have
weight
adjusting
bosses
at
both

large
and
small
ends
to

insure
that
the
rods
are

correctly
balanced

during
operation

The

lubricating
system
is
of

the

pressure
feed

type
with

the
oil

pump
driven

by
a

gear
on
the
crankshaft
Oil
is
delivered

to
the
main

gallery
via
a
full
flow
ftlter

ENGINE
Removal
and
Installation

Although
the

engine
can
be
removed
as
a

single
unit
it

will

prove
an
easier

operation
to
remove

the

engine
with
the

transmission
Proceed
as
follows

Fit
the
engine
slingers
ST49760000
to
the

engine

Disconnect
the
battery
cables
and
lift
out

the

battery

Drain
the
coolant
and

engine
oil

2
Place

alignment
marks
on
the
bonnet
and

hinges
remove

the
bonnet
from
the
vehicle

3
Remove
the
blow

by
hose
from
the
rocker
cover
and
take

off
the
air
cleaner

4
Disconnect
the
accelerator

linkage
and
choke
cable
from

the
carburettor

S
Detach
the

upper
and
lower

radiator
hoses
remove
the

two
brackets
from
the
core

support
and
lift
the
radia
tor

away
from
the
vehicle
The

torque
convertor

oil

pipes
must

be
disconnected
from
the
oil
cooler
if
the
vehicle
is

equip

ped
with
automatic
transmission
Detach
the
fuel

pipe
if

fitted
from
the
engine
and

heater
hose

6
Disconnect
the
electrical

wires
from
the
alternator
thennal
EngIne

OIL
PUMP

OIL
PRESSURE
RELIEF
VALVE

OIL
FILTER

EMISSION
CONTROL
SYSTEM

IGNITION

TIMING
AND
IDLING
SPEED

Emission

control

system

EMISSION
CONTROL
SYSTEM
Maintenance

IGNITION
SYSTEM

IGNITION
TIMING

IGNITION
DISTRIBUTOR
Maintenance

SPARKING
PLUGS

transmitter
the

primary
side
of
the
distributor
oil

pressure

switch
starter

motor
and
reverse

light
switch

7

Remove
the
clutch
slave

cylinder
and
its
return

spring
from

the
transmission
as
described
in
the
section
CLUTCH

8
Disconnect
the
shift
rods
and
selector
rods
then
remove

the
cross
shaft

assembly
by
detaching
the
bracket
from

the
side
member
See
GEARBOX
section

9
Disconnect
the

speedometer
cable
and
detach
the
front

exhaust

pipe
from
the
exhaust
manifold

10
Disconnect
the

propeller
shaft
and

plug
the

gearbox
rear

extension
to

prevent
the
loss
of
oil

11
Jack

up
the

gearbox
slightly
and
remove
the
rear

engine

mounting
support
Take
out

the
bolts
which
secure
the

front

mounting
insulators
to
the
cross
member

12
Attach
chains
or
wire

rope
to
the

engine
Gradually
lower

the

jack
under
the

gearbox
and
carefully
lift
and
tilt
the

engine
and
gear
box
to
clear
the

compartment
Withdraw

the
unit

making
sure

that
it
does
not
foul
the
accessories

Installation
is
a
reversal
of
the
removal

procedure
RefIll

with
the
correct

quantities
of
oil
and
coolant
when
the

engine
is
installed

ENGINE
MOUNTING
INSULATORS

Replacing

The

front
and
rear

mounting
insulators
should
be
checked

with
the

engine
installed
to
make
sure
that
the
dimensions

conform
with
those

given
in

Figs
A
I
and
A
2

To
remove
the
front
insulator

proceed
as
follows

Position
a

jack
under
the
oil

sump
Make
sure
that
the

jack
is
clear
of
the
drain

plug
and
insert
a
wooden
block
between

the
jack
and

sump
to

prevent
the

sump
from

being
damaged

Remove
the
bolts

securing
the
insulator
to
the
front

suspension

member
and
the
nut

attaching
the
insulator
to
the

engine

mounting
bracket
Raise
the

jack
slightly
and
remove
the

insulator
To
remove
the
rear

mounting
insulator

proceed
as

follows

Position
a

jack
to
take
the

weight
of
the

gearbox
and
take

out

the
bolts

connecting
the
insulator
to

the
transmission
rear

extension

housing
Remove
the
bolts

attaching
the
cross
member

to

the
underside
of
the

body
and
withdraw
the
insulator

Installation

of
both
insulators

is
a
reversal
of
the

removal

procedures

S3

inter
lliJ
i

@
j2J

c
Arrow
m
lrk

J

II
J

Fig
A
13

Installing
the

gudgeon
pin
circlip

Fig
A
12

Assembling
11

piston
and

connecting
rod

Fig
A
14
Installing
the

cylinder
block
oil
se
l
Apply
liquid
packing
he
e

Fig
A
IS
Rear
be

ring
cap

9
3
6
8

r

r
Q
i

ig
JtJl
f
it

I

1
f

l
O

2

1

lJ@O
j
0

i4i

Front
o

7
5
2
4

10

Fig
A
16
Connecting
rod

caps
and
lock
wIshers
Fig
A
18

Cylinder
head
boils

lightening
sequence

Fig
A
19

Imta1ling
the

ignition
distn1
utOT
note

the

position
of
rotOf

56
Fig
A
20

Tensioning
the
oil

pump
drive
dlain