1969 DATSUN 610 steering wheel

inter
M
j

@W

J

1

i
I

r

p

@
2
1
Strut
mounting
inzulDtor

Thruu
b

aring

J
Coil

prins

4
rubber

j
Sl1ut

mbly

6
Compression
rod

Z
Bal

joint

8
T
1ink

9
Stabi
iur

10
ODS

rnt
r
i

L
St

Ting
wheel

2
Steering
column
maft

J
Rubb
rCOfl
linK

4

Sturing
lower
joint

5

St
rinuotlr
IwusUr8

6
Sid
rod

XlI

Fig
C
1
Front

suspension
assembly
Fig
C
2
The
steering

gear

iQ

r
y
y

v

I
Ii

1
1

Fig
C
3

Collapsible

steering

Fig
C
4

Disconnecting
the
brake
hose

I

f41
I
I
t

h
I

t
t

Il
t

k
I

Fig
C
5

Removing
the
front
hub
and
brake

disc
Fig
C
6

Detaching
the
brake
disc

522

Accelerator

pump

Piston
diameter

Pump
discharge

Outer
hole

position

Middle
hole

position

Inner
hole

position

Pump
nozzle
diameter

Main
nozzle

diameter

Primary

Secondary
14
0
mm
0
551
in

0
2
cc

per
stroke

0

4
cc

per
stroke

0
6
cc

per
stroke

0

5
mm
0
020

in

2
3
mm
0
0906
in

2
8
mm
0
110
in

Throttle

valve

fully
closed

angle

Primary
10

degrees

Secondary
20

degrees

Idling
opening
5

degrees
approx

Choke
valve

fully
closed

angle
10

degrees

Throttle

opening
at
full
choke
13
5

degrees

FUEL
PUMP

Type

Delivery
Electric

1400
cc
in
one
minute
Emission

control

system

Air

pump
bracket
to

cylinder

head
nut

Adjusting
bar
to
bracket
bolt

Air

pump
to

bracket
bolt

Air

pump
to

adjusting
bar

nut

Anti
backfrre
bracket
to

rocker

cover
0
4Q
0
65

kgm
2
94
7
lb
ft

Anti
backfire
valve
to

bracket
0
4Q
O
65

kgm
2
94

7
lb
ft

Sensing
hose

clamp
to
rocker

cover
0
4Q
0
65

kgm
2
M
7
Ib
ft

Air

gallery
to
exhaust
manifold

plug
5
Q
6

0

kgm
36
243
4lb
ft

Check

valve
to
air

gallery
9

0
10
5

kgm
65

1
75
9Ib
ft
1
6
2
4

kgm
I
1
6
17
4Ib
ft

1
6
2
4

kgm
I
1
6
17
4Ib
ft

1
6
2
4

kgm
I
1
6
17
4
lb
ft

1
6

2
4

kgm
11
6
17
4Ib
ft

Front

SuspensIon
SteerIng

Description

Steering
Maintenance

Wheel
hub
and

bearing

Stabilizer

Spring
and
strut

assembly

Transverse
link
and
lower
ball

joint

Suspension
member

Front
wheel

alignment

Steering
wheel
and
column

Rack
and

pinion
and
tie
rod

Collapsible
steering

DESCRIPTION

The
front

suspension
is
of
the
strut

type
with

the
coil

spring
and

hydraulic

damper
units
mounted
on
the
crossmember

and
transverse
link

assembly
See

Fig
C
I
Vertical
movement

of
the

suspension
is
controlled

by
the
strut

assembly
Forward

and
rearward
movement
is
absorbed

by
compression
rods
6

and
side
movement
controlled

by
the
transverse
links
Front

suspension
servicing
procedures
are
similar
to
those

given
for

vehicle
fitted
with
L14
Ll6
and
LIB

engines
and
can

be
carried

out

by
reference
to

the
instructions

given
in
the

appropriate

section
Camber
and
castor

angles
are

preset
and
cannot

be

adjusted
and
a

check
must

be
made
for

signs
of

damage
to

the

suspension
system
if
the

angles
do
not
confonn
to
the

figures

given
in
Technical
Data

The

steering
is
of
the
direct

acting
rack
and

pinion

type

See

Fig
C
2
A
rubber

coupling
which
absorbs
vibration
and

two
universal

join
ts
are

incorpora
ted
between
the

steering
wheel

and

gear
assembly
The

collapsible
type
of

steering
column

assembly

Fig
C3
is
an

optional
fitting
A
full

description
of
this

type
of

assembly
i

given
in
the

Steering
section
for
L14

L16
and
L18

engines

STEERING
Maintenance

The

steering
system
should
be
lubricated

every
two

years

or
50
000
km
30
000
miles
whichever
comes

fIrst

A
lithium
base

multipurpose
grease
must
be
used
for
the

rack
and

pinion
and
rack
and
tie
rod

joints
The

plug
on
the

steering
gear
housing
should
be
removed
and
a

grease
nipple

fitted
so
that
the
recommended

quantity
of
10
to

15

gram

0
35
to

0
53
oz
of

grease
can
be

injected
Remove
the

grease

nipple
and

replace
the
plug
when
lubrication
is

completed

The

grease
reservoir
on
the
tube
side
should
be

replenished
when

the
level
of

grease
falls
to

approximately
one
third
ofits

capacity

WHEEL
HUB
AND
BEARING
Removal
and
Installation

Wheel
hub
and

bearing
servicing
procedures
are
similar
to

those

previously
given
for
vehicles
fitted
with
L14
LI6
and
LIB

engines

S23

Remove

the
road
wheel
and
disconnect
the
brake
hose
at

the
connector
as

shown
in

Fig
C
4
of
this
section

Remove
the
brake

calliper
assembly
and
hub

cap
Withdraw

the
cotter

pin
and
remove
the
wheel

bearing
locknut

Remove
the
wheel

bearing
washer
and
take
off

the
hub

and
brake
disc

Fig
C
5
Remove
the

bearing
collar
take
out

the
outer

bearing
cage
and

prise
out

the
hub

grease
seal
Remove

the
inner
bearing
cage
and
drive
out
the
outer
races

of
the
inner

and
outer

bearings
using
the

special
drift
ST49120000

if
avail

able

Separate
the
brake
disc
from
the
hub
by
taking
out
the

retaining
bolts
as
shown
in

Fig
C
6

Installation
is
a

reversal
of
the
removal

procedure
Adjust

the
wheel

bearings
as

previously
described

taking
care
to

tighten
the
wheel

bearing
locknut
to
the

specified

torque
read

ing
of
3
0
to
3
5

kgm
21
7
to
25
3lb
ft
Turn
the
hub

several
times
to
settle
the

bearing
then
retighten
the
nut
to
the

same

figure
Slacken
the
locknut

by
a

quarter
turn
900
and

insert
the
cotter

pin
when
the
hole

in
the

spindle
is
aligned

with
the
hole
in
the
nut
Check
that
the
force

required
to
turn

the
hub
is
less
than
7
0

kg
cm
97
2
in
oz

STABILIZER
Removal
and
Installation

Remove
the

splash
board
and
take
off
the
bolts
I
in

Fig
C
7
which
attach
the
stabilizer
at

the
transverse
link
sides

Remove
the
bolts

attaching
the

stabilizer
bracket
2
to

the
frame
then

withdraw
the
stabilizer

Check

the
bar
and
rubber

components
for

signs
of
deforma

tion
or

damage
and
renew
as

necessary

Installation

is
a
reversal
of
the
removal

procedures
Tighten

the

fixing
bolts
to
a

torque
reading
of
1
2
to
I
7

kgm
8
7
to

12
3
lb
ft
at

the
transverse
link

side
and
1
9
to
2
5

kgm
13
7
to

18
llb
ft
at
the
frame
bracket

SPRING
AND
STRUT
ASSEMBLY

The

spring
and
strut
assembly
can
be
serviced

by
following

the
instructions
previously
given
for
the
assemblies
on
vehicles

fitted
with
the
L14
L16
and

Ll8engines

When

reassembling
make
sure
that
the

parts
shown
in

Fig
C
8
are

thomughly
greased
Installation
of
the

assembly

will
be

accomplished
more

easily
if
the
dust
cover
on
the
bonnet

ledge
is
removed

Tighten
the
nuts
and
bolts
to
a

torque
figures
given
in

TIGHTENING

TORQUES

TRANSVERSE
LINK
AND
LOWER
BALL
JOINT

The
transverse
link
and
lower
ball

joint
can
be

removed
in

a

similar
manner
to
the

parts
on
vehicles
fitted
with
L
14
L
16

and
L
18

engines

Renew
the
link

if
cracked
or

damaged
in

any
way
Check

the

measurement
A
in

Fig
C
9
The
measurement
between

front
and
rear
transverse

link
bushes
should
be
less
than
1
0
mm

0
039
in

Replace
the
bushes
if

necessary
The

lower
ball

joint

should
be

replaced
if
the
axial

play
of
the

joint
exceeds
0
03

to
0
6

mm
0
0012
to
0
0136

in
A

grease
nipple
must

be
installed

in

place
of
the
ball

joint

plug
so

that
the

joint
can
be
lubricated
with
multi

purpose
grease

as

previously
described

SUSPENSION
MEMBER

Removing
and

Installing

Jack

up
the
vehicle
and

support
it
on

stands

2
Remove
the

splash
board
Refer
to

Fig
C
I
0
and
detach

the

compression
rod
I
the
stabilizer
2
from
the
trans

verse
link
3
Detach

the
steering
linkage
from

the
suspen

sion
crossmember
4

3
Take
out

the
nuts

attaching
the
transverse
links
and
remove

the
links
at
both
sides
of
the
vehicle

4

Support
the

engine
with
a
hoist
as
shown
in

Fig
C
II

taking

care
not
to

damage
the
throttle
and
remote
control

linkages

and
then
remove
the

engine
mounting
bolts
at
both
sides

5
Remove
the

bolts
shown
arrowed
in
Fig
C
12

and
lift
the

suspension
member

away

Renew
the

suspension
member
if
it
is
cracked
or

deformed

in

any
way
Installation
is
a
reversal
of
the
removal

procedure

FRONT
WHEEL
ALIGNMENT

As

previously
stated
the
castor
and
camber

angles
are

preset
and
cannot

be

adjusted
A

thorough
check

should
be

made
of
the

steering
and

suspension
system
and
all
defective

parts
renewed
if

the

angles
are

incorrect
See
Technical

Data

The
front
wheels
should
toe
in

12
to

15
mm
0
4
7
to

0
59

in

Adjustment
can
be
carried
out

by
slackening
the
locknuts

1
in

Fig
C
13
and
then

turning
the
tie

rods

by
an

equal
amount

until
the
correct
toe

in
is
achieved
A
toe

in
gauge
will
of
course

be

required
for
this

operation

STEERING
WHEEL
AND
COLUMN
Removal

Disconnect
the
horn
wire
and
remove
the
horn
bar
Remove

the

steering
wheel
nut
and

pull
off
the

steering
wheel

2
Remove
the
turn

signal
and

lighting
switch

assembly
followed

by
the

steering
column
shell
covers

3
Remove
the
bolts
from
the
rubber

coupling
to

disconnect

the
lower

joint
See

Figs
C
14
and
C

I
5
if
the
car
is

fitted
with

right
hand
drive
The
lower
joint
upper
bolt

should
be
removed
to
disconnect
the

joint
if
the
car

is

fitted
with
left
hand
drive

4
Remove
the
cotter

pin
from
the
trunnion
and
disconnect

the

gearchange
rod
and
selector
rod

5
Remove
the

steering
column

upper
clamp
and
take
out
the

bolts

securing
the
lower

plate

STEERING
COLUMN

Dismantling
and

Assembling

Remove
the
C
washer
socket
screw
and

upper
bracket

bolt
Remove
the
lower
bracket
bolts
and
detach
the
remote

control

linkage
from
the
column

assembly

Remove
the

snap
ring
at
the

top
of
the
column
and
extract

the
column
shaft
from
the

jacket

Disconnect
the
rubber
coupling
from
the
lower

joint

then
remove

the
snap
ring
and
dismantle
the
lower
joint

S25

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

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

ENGINE

t
Main

bearing
cap
bolt

Connecting
rod
bolt

Flywheel
bolt

Crankshaft
nut

Cylinder
head
bolt

Camshaft

centre
bolt

Spark
plug

Oil
mtef
centre
bolt

Water

pump
blind

plug

Carburettor
bowl
set
screw

Rocker

cover

securing
screw

FRONT
SUSPENSION
Tlght
enlna

Torques

10
11

kg
m
72
3
79
5Ib
ft

4

5
5

kg
m

32
6
36
2Ib
ft

10
11

kg
m
72
3
79
5

Ib
fL

15
20

kg
m

l08
5
144
6Ib
ft

8
9

kg
m
57

9
65
1
Ib
fl

4
5
5
5

kg
m

32
6
39

81b
ft

3
4

kg
m
21
7
28
9Ib
ft1

2
8
3

2

kg
m

20
3
23
21b
ft

1
5
2

kg
m

l0
9
14
5Ib
ft

0
15

0
2

kg
m
Ll
I
4lb
ft

0
33
0
4

kg
m
2
4
2
9

lb
ft

Front
wheel

spindle
nut
3
3
5

kg
m
21
7
25
3
Ib
ft

Front

disc
brake
back

plate

to
strot

assembly
2
7
3
7

kg
m

19
5
26

7Ib

ft

Disc
brake

calliper
fixing

bolts

7
3
9
9

kg
m

52
8
71
6Ib
ft

Disc
brake
rotor

fixing
bolts
3
9
5
3

kg
m
28
2

38
3
Ib

ft

Stabilizer

fixing
bolts

transverse
link
bracket
side
1
2

1
7

kg
m

8
7
12
3Ib
fl

Stabilizer

fixing
bolts

frame
bracket
side
1
9
2

5

kg
m

13
7
18
1
lb
ft

Compression
rod
to
frame

bracket

bolts
7
2
9
6

kg
m
52
1
69
2Ib
fl

Compression
rod
to
transverse

link
bolts
4

9
6
3

kg
m
35
4
45

6
lb
ft

Strut

assembly

upper
support

nuts
3
9
5
2

kg
m
28
2
37
6Ib
ft

Steering
knuckle
arm
to

strut

assembly
6
0
8
0

kg
m
43
4
57
8Ib

ft

Transverse
link
to

suspension

cross

member
fixing
nut
12
2
13
5

kg
m
88
2
87

6Ib
ft

S36
Lower
ball

joint
to
transverse

link

fixing
nut

Lower
b
JH

joint
stud
nut

Suspension
aoss
member

mounting
boils

Engine
mounting
bracket

bolts

Piston
rod
self

locking
nut

Gland

packing

Wheel
nuts

BRAKING
SYSTEM

Fulcrum

pin
of
brake

pedal

Connection
of
brake
tube

Rotor

fixing
bolts

Wheel

cylinder
fixing
bolts

Studs
side

Hexagon
side

Bridge
tube

Brake
hose
to
wheel

cylinder

Calliper
to
knuckle

t1ange

Disc
to
knuckle

flange

Spindle
nut

STEERING

Steering
wheel
nut

Rubber

coupling
bolt

Lower

join
t
bolt

Retainer
locknut

Side

rod
inner
socket

stopper
nut

Side

rod
locknut

Side
rod
ball
stud
nut
1
9
5

kg
m
l3
7
18
llb
ft

7
6

kg
m
139
8
1

0
Ib
ft

1
9
2
5

kg
m

13
7

18
1
lb
ft

1
3
1
7

kg
m

9
4
1
3Ib
ft

6
0
7
5

kg
m
43
4
54
2Ib
ft

6
0
6
5

kg
m

43
4
47
0
Ib
fl

8
0
9
0

kg
m
57
8
65
I
Ib
ft

3
5
4
0

kg
m
25
3
28
9

Ib
fLl

1
5
1
7

kg
m

10
8
1
3
lb
ft

3
9
5
3

kg
m
28
2
38
3
Ib

fL

0
5
0
7

kg
m
3
6
5
1Ib

fL

1
5
2
1

kg
m

l0
8
15
2Ib
ft

I
7
2
0

kg
m
l2
3
14
5Ib
ft

17
2
0

kg
m
l2
3
14
5Ib
ft

73
9
0

kg
m
52

8
i5
1
Ib
ft

2
7

3
7

kg
m
l9
5
26
8Ib

ft

3
0
3
5

kg
m
21
7
25
3lb
ft

1
5
1
8

kg
m

10
8
13
0
Ib
ft

4
5

kg
m
28
9
36

2
Ib
ft

4

6

kg
m
28
9
43
4
lb

ft

8
10

kg
m
52
8
72
3Ib
ft

9

kg
m
65

llb
ft

5
5
7
6

kg
m
39
8
54
9Ib
ft

MO

MI
1224
D
I

KM

f
fMn
n

r
A
A
JP
I
I
T
I
I

I

Drain
ill

Changeelemenl
I
42

Cleantlement
3
I

II
r

I

Check
il
topup
4
I

Chinnloil

511
1

11
41

Gle

nelern
n
Ii

I
Orainlluid
7
I
I
I
I

Clunertmtn
81
1

I
I
I
I

I
27

Check

ailltop
up

Jf71

r

I
JIO
WI

28

Change
il

I
ill

limittdSlip
DiHlranti
1
Clleck

ilftopup
1J
I
I

I
Changelil
11
i

ill

ShdmgJolntt
Df
YlShlft
Check

11IIOpup
n
II
I

I

ChangeDl1
1
I
I

I
I

SHOCKASSORBERS
Check
Il

topup
5

PROP
DRIVESHAFTISI
lubncate
Hi

1

GREASE
GUN
POINTS

lubnCIl

it
PEOAlSHAFT

Sj
Lubrlc

te
18

HANDBHAKE
lubnc
1t

I
I

r
1
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R
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luhncll
2u
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ARlUWIORED
WHEELS
FREE

1m
I
I

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1121

wHEE
L
tll

AHINli
ronl

HepitCk

211

t
f
WHEEl

BEARINGS
Rur
Repack
77

U
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BRAKE
FLUID
R
nfWfbletd
1
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lf
13

117
I

t
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AH
UUWI
f
t1UN

11Itl
ih1tl

1
i

lcl
Check
oillevtl
B
l

r1i
BI1I1I1
r

Cap
Cleen

1ifj
j

I
Air
Cluner

Service
el
m

nt
l

J7
4

Replace
element
l
l
B

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5

Cteenfilter

1
C

l
I
I

I

4

Clun
va

vellllR
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I1

I
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Repl
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1

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I
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Cleen

jets
bOM
R

t
I

Top
liP

pisl
dempe

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I
r

L

LlIbncatelinkages
I

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Ctean

replace
5
j

I

Ch

ckoill
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l
j

16

Clun
replac
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11

R
fill
witll

fluid
38
I

Check
fluid
levll

IlL

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I

CI
ign
toil

t

i
I
t

1
l
9

CheCk
top
u

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10

Flulhryst
m

y

Cllecksolullon
44

Chltk
45

Lubrlc
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46
i

Clleck

top
up
L

L
Check
topup
4
aJdM

Cllltkspet

gl1vity
i

CI
en

gr
1S

liD

116
Lubriclt

1il

If
I

II
Clleck

topup
52

1
i

Chtck

topuplluid
3

I
I

Gre
rlm

4
I
1
I
I
I

Clunfiltlr
55

L
I

I

I
Chick
top

up
fluid

I6
w
W

e
I

ofi

Ldtir
1
Renewfiltlr
58

I

Check
topupflu
d

i91
i
I

i

Renrwfluid
I
I

I
I

I

ilinlil1r

11
I
I
I
I
I
I

CAR

DOWN
E

TERNAL
j

II
1
I
1

lOCKS
HINGES
Ell
Lubrictt

S21
r
1

el
L
Door
Dram

Hol
l

Clun
f
J

I
I
WIPER
SPINDLES
lubrictt
64
W
I
I

En

in
Dil
Filwr

GttrbOK
1968

Lubricate
and
Clean

ENGINE

Filt
r

GEARBOX

Dvttdrivt
Filt
r

AUTOMATIC
TRANSM

Filt
r

DIFFERENTIAL

PCV

Syllem

rburettor

s

FUll
Bowl

Filter
S1

Fu

llnjectionPump

Fittll
ll

AUTOMATIC
TRANSM

DISTRIBUTOR

Spindl
Ctm

COOLING
SYSTEM

CorrDlionlnllibitor

Anti
Frltl

W
t

rPump

CREENWASHER

ArrERY

Connections

3ENERATOR

STEERING

POMrStlering

CLUTCH
BRAKE

BRAKE
SERVO

HYDR

SUSPENSION

CAPACITIES

LUBRICANTS
Il
D
P
LUSClu
Service
Check

Adjust

CAR
UP

I

l
lletksumpbulttortM
1

Clled

rque
i6

ServiceJndclean
J1

Adjult
brake
bandl

tB

RtnMsumpgal
tt

fiS

Check
llJmpbnlttort

PROP
lOAIVE
SHAFT
S
Check
lor
wear

JJ

Tiglltenbolu
Jl

Check
tor
wear

n

Tiglltenboltl

Clllckbootgeiltrl

Clleckoperltion

Ch
CQmpon
l
welr

Tighten
bolts

Clleclbootgaiterl

Checktorqu

Gheck
edjult

Clllck
ljust

CIIRCk

adjult

Clleck

tighltnbolts

W

M

KSI

1
t

heCklMliiili
86

Check

ldjust
81

Overllllulcompl
rvll

Cleen

chltkwtlr
R9

Check
for
wear
0

Check

9

Checkforwp

lr
192

Il1Ipecttyrel
1IJ

Illte
II
blIl1nCl

Adjultpres
lure

Cllecktorul

liON

ET
OPE

l

heckcompression

Checktorqul

AdjUltclttr
nc

CheckoptTltion

Check
lIljLllt

AdjUlI

Clleck
alIj
tension

adj
t
nsion

I

Clun

selpp
jt1

Renew

Chetk

tPoint
tp

Renew

pointl

Check

6djult
110

J

Check

edjult
ill
i
ii

j
Tiglltenhoseclips
112

R

plece
lIastl

ill

PreSSIJ
test
114

1

STEERING
Clleek

play
adjust
ill
j
i

itl

e
Ti9htenboltl
ill

ii
Geometry
Check
U1L

H
CHECK
FOR
Oil
FUEL

WATER
etc
LEAKS
1181

I
I
R
DOWN
FXIE
HNA

11

1
1
lIGHTS

If
isfHUMt
NTS

Check
flll
C
lOn
f

3

Headlights
Checkllhgnmlnt
112Cr

WIPERS

Checkbladu

11111
J

TS

r
h
kIl

CII

I
Jrl7

iI

An
UH
OVNAUOMFTER
I
ST
I

BRAKES
CheCkemCienCY

1
I

AUTOMATIC
TRANSM

Clleek

op
rttioQ

T

ENGINE
Adjust
if

required
12

DEFECTS
Report
12
EVERY
MOnthl

Miles

1000

KMs
1000
lIBt
wtJichewl

ENGINE

EngmlMountings

Engine
Film
Trap

AUTOMATIC
TRANSM

24

2

30
SUSP
FRONT
REAR

Shock

Ablorb
rs

STEERING

1
21

5
1

c
e
U
80lTS

HANDBRAKE

CLUTCH

GEAR

LINKAGE

EXHAUST
SYSTEM

f

HFf
K
FOR
Oil

FllE
1

CAH

LUWI
RI
If

WHEEL
BEARINGS

BRAKES

UningsJDruml

Plds

Discl

Selhdj
Meclleni5l11

Cylinders
Hosel

ROAD
WHEELS

3S
Whe
1

Nun

AHllIIWN

ENGINE

Cyllnd
r
Held

Vllyes

Clloke

MiKtulli

ldling

linkagel

Timing
Ch
in

16
V

Belt

Is

SPARK
PLUGS

OISTRIBUTOR

Owell

Angle

Ignition
Timing

COOLING

SYSTEM

8

X

Automatic
Diffrrrntill

ICoolinginc
Ht
lltel

AntilrH1f

Ltr
lmoP
Ugo
IL
dmo

PII
U

Ou
HydrJBrak

Fluid

4

7
1
21
81
7
ULlma

II

USP
ULlmD
USP
L

L
tmoP

USQu

127

2
4
4

SAE
3O
2OW
411

SAE
lfrN
2fJ

IOWI3O

SAE1OW

IOW
30
320C

JOe

o
e
SAE80
EP

SAE90EP

SAE
140
EP

mmDIIIII

Ifn
c
ID

WIthDv
1

LI
obWt7
3
LtrJ
PtLUSPtL

3
2
0
75
T
3
1
8
B
8

WAGON

1
1
72
1

TYPE
A

SUFFIX
A
SAE80
EP

SAE90EP

SAE
140EP
0

aSoC
BFl

AUTOSERVICE
DATA

CHART
DATSUI

D

FurlT
nk

n
tln
G
0

Slltring

Re
I

lm
r
JSGI
11
1
No

4S

8
9
11
9
11
17
18

19
20
41
82
84

52

SSS
95
SAElll

SAE

80
c

14O

Part
NanleH
and
AlternatlyeS

Certain

parts
of
motor
cars
are

known

by
other
names
in
different

areas

and
countries
A

list
c
f
the
common
alternatives
is

given
below

ENGINE
ELECTRICA
L

Gudgeon
pin
Piston

pin
small
end

pin
Wrist
Generator

Dynamo

pin
Control
box
Cut

out
Voltage

regulator
Volt

Inlet
valve

Intake
valve

age
control
Circuit
breaker

Piston
oil
control

ring
Piston

scraper
ring

Capacitor
Condenser

Induction
manifold

Inlet
manifold
intake
manifold

Interior

light
Dome

lamp

Oil

sump
Oil

pan
Oil
reservoir

Sump
tray

Core

Plug
Expansion

plug
Welch

plug
Lens
Glass

Sealing
disc

Head

lamp
ring
Headlamp
surround

Headlamp

Dipstick
Oil

dipper
rod
Oil
level

gauge
mouldin

rod
Dillevel
indicator
Direction
indicators

Signal
lamps
Flashers

Silencer
Muffler

expansion
box
diffuser

Micrometer

adjustment
Octane
selector

Tappets
Valve

lifter

push
rods
Rear

lamps
Tail

lamps

Reversing
light
Back
u

pUgh
t

FUEL

Carburettor
choke
Carburettor

venturi
STEERING

Slow

running
jet
Low

speed
jet
Idler

jet

Drop
arm
Pitman
ann

Volume
control
screw

Idling
mixture
screw

Rocker
shaft
Pitman
shaft

Drop
ann
shaft

Fuel

pump
Petrol

pump
Fuel
lift

pump
Swivel

pin
Pivot

pin
King
pin
Steering
pin

Air
cleaner
Air
silencer
Muffler

Stub
axle
Swivel
axle

Fuel
lank

Petrol
Tank
Track

rod
Cross
tube

Tie
rod

Accelerator
Throttle

Drag
link
Side
tube

Steering
connecting

rod

CLUTCH

Steering
column

Steering
gear
shaft

Clutch
release

bearing
Throwout

bearing
Thrust

bearing
Steering
column

bearing
Mast

jacket
bearing

Clutch

lining
Disc

facing
Friction

ring
Steering
arm

Steering
knuckle
ann

Spigot
bearing
Clutch

pilot
bearing
Stator
tube
Control
tube

Clutch

housing
Bell

housing
Steering
joints
Steering
knuckles

GEARBOX
BRAKES

Gearbox
Transmission
Master

cylinder
Main

cylinder

Gear
lever

Change
speed
lever
Gearshift
Brake
shoe

lining
Brake
shoe

facing

lever

BODY

Selector
fork

Change
speed
fork
Shift
fork

Input
shaft
Constant

motion
shaft
First
gannet

Hood

motion
shaft
drive

gear
First

Luggage
locker
Boot

Luggage

compartment

reduction

pinion
Main
drive

pin

Luggage
locker
lid
Boot
lid
Rear
deck

ion

Clutch
shaft
Clutch
gear

Mudguards
Quarter
panels
Fenders
Mud

Countershaft

Layshaft
wings

Synchro
cone

Synchronizing
ring
Roof

Canopy

Reverse
Idler

gear
Reverse

pinion
Nave

plate
Wheel
disc
Hub

cap

Finishing

strip
Moulding
Chrome
strip

REAR
AXLE
Windscreen
Windshield

Rear
Axle
Final

drive
unit
Rear
window
Rear
windscreen
Rear
windshield

Crown
wheel

Ring
gear
Final
drive

gear

Spiral
Backlight

drive
gear
Quarter
ven
t
N
D
V

No

draught
ventilator

Bevel

pinion
Small

pinion
spiral
drive

pinion
Bumpers
Fenders

Loom
Harness

U
bolts

Spring

clips

Odometer

Trip
recorder

Axle
shaft
Half

shaft
Hub

driving
shaft
Jack

Bonnet
catch
Hood
latch

driving
shaft

Kerosene
Paraffin

Differential

gear
Sun
wheel

Boot
Trunk

Differential

pinion
Planet
wheel