REAR
AXLE
AND
REAR
SUSPENSION
Rear
wheel
bearing
nut
Brake
backplate
25
33
kgm
181
239
IbJt
7
3
7
kgm
19
5
26
8
lb
ft
1400
1600
Shock
absorber
upper
mounting
3
kgm
l6
61b
ft
Shock
absorber
lower
mounting
3
kgm
16
6
Ih
ft
1800cc
Shock
absorber
mountings
1
6
2
2
kgm
12
161b
ft
Drive
shaft
to
differential
nuts
5
6
kgm
36
2
4341b
ft
Drive
shaft
to
rear
axle
flange
5
6
kgm
36
2
43
4lb
ft
Bump
rubber
nuts
2
8
4
0
kgm
20
29
Ib
ft
Bump
rubber
nuts
180Occ
1
6
2
2
kgm
12
16
Ib
ft
Wheel
nuts
Rear
suspension
member
mounting
nuts
8
9
kgm
58
651b
ft
10
kgm
72
Ib
ft
Differential
member
mounting
nuts
8
5
kgm
61
5Ib
ft
Suspension
arm
to
suspension
member
nuts
10
kgm
58
72
Ib
ft
Differential
to
differential
member
6
8
kgm
43
581b
fl
Propeller
shaft
flange
nuts
4
0
8
5
kgm
29
62
Ib
ft
Propeller
shaft
flange
nuts
I
800cc
2
0
2
7
kgm
14
201b
fl
Differential
to
suspension
member
6
8
kgm
43
58Ib
ft
1800cc
Estate
car
and
Van
610
Body
Shock
absorber
upper
mounting
0
9
1
2
kgm
6
5
8
7Ih
fl
Shock
absorber
lower
mounting
3
5
4
5
kgm
25
33Ib
ft
Rear
spring
U
bolt
clip
6
0
6
5
kgm
43
47
Ib
ft
Shackle
spring
6
0
6
5
kgm
43
47Ib
ft
Spring
front
pin
6
0
6
5
kgm
43
47Ib
ft
Brake
back
plate
Estate
car
Van
Differential
gear
carrier
to
axle
case
Propeller
shaft
flange
Bump
rubber
Wheel
nut
Drain
and
filler
plug
2
2
2
7
kgm
16
20IbJt
L5
2
0
kgm
II
14
Ib
ft
2
0
2
5
kgm
14
18Ib
ft
2
0
2
7kgm
14
20Ib
ft
0
9
1
2
kgm
6
5
8
7Ib
ft
9
kgm
58
65Ib
ft
4
2
6
9
kgm
30
4
49
9
lb
ft
FRONT
SUSPENSION
Front
hub
nut
3
0
3
5
kgm
21
7
25
3
Ib
ft
Disc
brake
backplate
to
strut
2
7
3
7
kgm
19
5
26
7
Ib
ft
Brake
ca1liper
bolts
7
3
9
9
kgm
52
8
71
6
Ib
ft
Brake
disc
bolts
3
9
5
3
kgm
28
381b
ft
Stabilizer
bolts
suspension
arm
side
1
2
I
7kgm
8
7
12
3
Ib
ft
130
Tension
rod
to
frame
Tension
rod
to
transverse
link
Strut
assembly
upper
nuts
Steering
lever
to
strut
Ball
joint
to
transverse
link
Ball
joint
to
knuckle
ann
Piston
rod
nut
Gland
packing
1400
and
1600
CC
models
Flange
mounting
bolts
Bali
stud
nut
Gear
ann
nut
Idler
ann
nut
Adjusting
screw
nut
Steering
gear
mounting
bolts
Idler
arm
bolts
1800cc
models
610
Body
Gear
ann
nut
Rear
cover
bolts
Sector
shaft
cover
Sector
shaft
adjusting
screw
locknut
Steering
gear
mounting
bolts
Steering
linkage
Idler
arm
to
frame
Ball
stud
nuts
Side
rod
locknuts
Column
shaft
Steering
wheel
nut
Column
clamp
COll
piing
worm
shaft
Coupling
mounting
bolts
Brake
pedal
pivot
Brake
pipe
connection
Brake
disc
bolts
Bridge
pipe
Brake
hose
to
cylinder
Brake
calliper
bolts
Wheel
cylinder
bolts
Stud
side
Hexagon
side
4
5
5
5
kgm
33
40Ib
ft
4
9
6
3
kgm
35
4
45
6
Ib
ft
3
9
5
2
kgm
28
2
37
6
Ib
fr
6
8
kgm
43
581b
ft
1
9
5
kgm
14
18Ib
fL
5
5
7
6
kgm
40
55Ib
ft
6
7
5
kgm
43
54Ib
ft
7
13
kgm
51
94Ib
ft
STEERING
1
8
2
5
kgm
13
18Ib
ft
5
5
7
6
kgm
40
55Ib
ft
12
5
14
0
kgm
90
101
lb
ft
5
5
7
6
kgm
40
55Ib
ft
1
8
2
5
kgm
13
18Ib
ft
10
kgm
72
Ib
ft
4
4
6
1
kgm
32
44Ib
ft
14
kgm
lOllb
ft
L5
2
5
kgm
II
18Ib
ft
1
5
2
5
kgm
II
18Ib
ft
2
0
2
5
kgm
14
5
18Ib
ft
6
8
kgm
43
4
57
8Ib
ft
4
4
6
1
kgm
32
44Ib
ft
5
5
7
6
kgm
40
55Ib
ft
4
4
6
1
kgm
32
44lb
ft
4
5
kgm
29
36
Ib
ft
1
3
1
8
kgm
9
4
13
0
lb
ft
4
5
kgm
29
36Ib
ft
L5
2
2
kgm
II
16Ib
ft
BRAKES
3
5
4
0
kgm
25
3
28
9
Ib
ft
1
5
1
8
kgm
10
8
13
0
lb
ft
3
9
5
3
kgm
28
2
38
3
IbJt
1
7
2
0
kgm
12
3
14
51b
fl
1
7
2
0
kgm
12
3
14
5lb
ft
7
3
9
0
kgm
52
8
65
llb
ft
0
5
0
7
kgm
3
6
5
llb
ft
1
4
1
8
kgm
10
13
Ib
ft
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
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
12
11
3
1
i
20
20
y
l
17
4
5
17
1
18
le
8
15
0
20
lQ
l
ah
rod
a
S
y
Dus
ewer
Stopper
rint
condiuy
putcm
cup
MaJler
cylinder
puto
Primmy
plJlan
cup
Inlet
l
tIhe
cwy
Pi
Jton
retunl
SPrin8
cylinder
body
RtJeTfoir
btJnd
au
y
Rel6l
Ou
Reservoir
cap
ass
Bl
der
screw
cap
Binder
screw
C1teck
l1a
1ve
spring
Chechob
y
Packin8
Piston
stopper
scrrw
Vain
cap
fllsJcet
Vah
e
cap
Components
of
the
single
master
cylinder
Jx
1
As
y
bm
ke
mtUtn
cylinder
2
Oil
rnenoir
ClIp
3
Brake
oil
1
turJ1
U
4
Oil
rnervou
hlznd
5
Dlertler
JCTeW
6
Blettkr
ta
W
azp
7
Va
lle
cap
8
Gtuket
9
b
y
nzJpa
10
Vah
e
tpriIog
11
Valve
Uflt
12
Stopper
1CTe
W
Components
of
the
tandem
master
cylinder
13
Itukin8
U
b
y
pbto
A
15
PUlon
cup
16
Cylbukr
17
Au
y
puto
B
18
A
y
voba
tpriIog
19
1nktvahatprilog
20
PUlan
cup
21
40
y
pw
r
rod
22
Stopper
rinr
23
Dwt
coper
Fig
D
Fig
D
2
4
1
A
S
y
catft7a
2
Equalizu
hmuJ
broke
J
R
B
Tt
lJ1
cab
4
AdiU3tt
T
cailk
rmr
5
S
1TiIw
retum
6
L
H
ntu
Ofbk
7
Pir
fulcrum
hand
braJcalev
r
8
aJ
Vb1l
front
hand
bmka
9
TrutUon
pin
hand
bt
rzU
ctlbk
10
P
atMock
rand
IRvke
azb1l
10
1
L
1
4
6
l
Nota
@
Apply
11lI
gteall
@ApplychlSSis
1
7
Fig
D
3
Handbtaka
linkage
system
1
Tandem
nmt
cylintkr
2
Two
MY
COnMC
or
3
Brake
line
prtSlf
e
difftrentiJzl
umil16
ootch
Fig
D
S
Layout
of
brake
piping
with
tandem
master
cylinder
I
530
BrakIng
System
Description
Front
disc
brake
Friction
pads
Front
disc
brake
Removal
and
Installation
Rear
drum
brake
Removal
and
Installation
Master
Vac
Servo
Unit
Handbrake
cables
Removing
Handbrake
Adjusting
Brake
pedal
Adjusting
Rear
drum
brake
Adjusting
Bleeding
the
hydraulic
system
DESCRIPTION
The
vehicle
is
fitted
with
disc
brakes
for
the
front
wheels
and
leading
trailing
shoe
type
drum
brakes
for
the
rear
wheels
A
conventional
single
master
cylinder
is
fitted
to
the
Standard
and
DeLuxe
models
See
Fig
D
I
for
details
The
DeLuxe
models
are
however
additio
ally
equipped
with
a
Master
Vae
servo
unit
which
provides
a
much
higher
braking
performance
with
minimum
force
required
on
the
brake
pedal
A
tandem
master
cylinder
and
Master
Vac
servo
unit
are
fitted
as
standard
equipment
to
the
Datsun
CL30UA
and
CL3
OUT
models
Fig
D
2
gives
an
exploded
view
of
this
type
of
master
cylinder
The
handbrake
is
of
the
mechanical
type
with
the
handle
linked
to
the
rear
shoe
operating
lever
through
a
system
of
rods
and
wires
See
Fig
D
3
As
on
previous
models
a
brake
pressure
differential
warn
ing
light
switch
is
incorporated
with
dual
brake
circuits
The
front
and
rear
brake
systems
are
connected
to
the
switch
which
provides
a
warning
via
a
warning
light
on
the
instnllnent
panel
when
a
pressure
difference
of
13
to
17
kg
sq
cm
IB5
to
242
lb
sq
in
occurs
between
the
front
and
rear
systems
Brake
piping
layouts
of
the
single
and
tandem
master
cylinder
systems
are
shown
in
Figs
D
4
and
0
5
FRONT
DISC
BRAKE
Friction
pads
The
disc
brakes
are
self
adjusting
but
the
friction
pads
should
be
checked
for
wear
after
the
fIrst
6
000
un
4
000
miles
and
then
every
5
000
km
3
000
miles
The
pads
must
be
replaced
if
the
friction
lining
on
any
pad
has
worn
to
less
than
1
0
mm
0
04
in
The
thickness
of
the
pads
can
easily
be
checked
after
remov
ing
the
anti
rattle
clip
from
the
calliper
plate
Full
servicing
procedures
are
given
in
the
section
BRAKING
SYSTEM
for
vehicles
fitted
with
Ll4
Ll6
and
Ll8
engines
FRONT
DISC
BRAKE
Removal
and
Installation
Refer
to
the
section
BRAKING
SYSTEM
for
the
Ll4
L16
and
LIB
engines
for
full
details
of
the
removal
and
installation
procedures
Check
the
thickness
of
the
friction
pads
as
previously
described
and
replace
them
if
necessary
Check
the
brake
disc
for
scoring
and
out
of
round
The
standard
diSc
thickness
is
10
0
mm
0
394
in
and
must
not
be
reground
below
8
40
mm
0
331
in
The
run
out
of
the
disc
should
be
less
than
0
06
mm
0
0024
in
and
can
be
checked
with
a
dial
gauge
positioned
near
the
outer
diameter
of
the
disc
as
previously
described
REAR
DRUM
BRAKE
Removal
and
Installation
The
rear
drum
brakes
See
Fig
D
6
can
be
removed
and
inspected
as
described
in
the
section
BRAKING
SYSTEM
for
vehicles
fItted
with
L14
L16
LIB
engines
Examine
the
brake
drums
for
scoring
and
out
of
round
The
maximum
inner
diameter
of
the
drum
must
not
exceed
229
6
mm
9
040
in
after
reconditioning
Out
of
round
should
be
below
0
05
mm
0
002
in
Renew
the
brake
shoe
linings
if
they
are
contaminated
or
incorrectly
seated
or
if
the
thickness
of
the
lining
has
been
reduced
to
1
5
mm
0
06
in
or
less
Oil
or
grease
can
be
re
moved
from
the
linings
by
cleaning
thoroughly
with
carbon
tetrachloride
or
petrol
Check
the
shoe
return
springs
and
replace
them
if
they
have
become
weakened
Check
the
bores
of
the
wheel
cylinders
for
signs
of
wear
damage
or
corrosion
Renew
the
cylinders
and
pistons
if
the
clearance
between
the
two
parts
exceeds
to
0
15
mm
0
006
in
Renew
the
c
ps
when
overhauling
the
wheel
cylinders
MASTER
V
AC
SERVO
UNIT
Removing
and
Dismantling
The
servo
unit
should
be
removed
and
overhauled
at
yearly
intervals
A
Master
Vac
repair
kit
is
available
and
all
parts
marked
in
Fig
D
7
should
be
renewed
after
dismantling
the
unit
These
items
are
all
supplied
as
part
of
the
repair
kit
The
unit
can
be
removed
as
follows
Remove
the
clevis
pin
from
the
push
rod
and
detach
the
Master
V
ac
unit
from
the
brake
pedal
2
Disconnect
the
brake
tube
from
the
master
cylinder
and
the
vacuum
hooe
from
the
Master
Vac
3
Take
off
the
retaining
nuts
and
remove
the
Master
Vac
and
spacer
then
separate
the
master
cylinder
from
the
Master
Vac
Mark
the
front
cylinder
shell
and
the
rear
shell
and
stud
assembly
before
dismantling
the
unit
then
proceed
as
follows
S31
inter
j
IJ
ITJJ
4
532
6
7
Fig
D
4
Layout
of
brake
piping
with
single
master
cylinder
3
15
7
6
e
2
1
rQt
coper
2
Adiwtint
Urim
3
dUe
4
Adiuster
5
Retum
springs
6
Anti
ttk
qJrinp
V
7
Adiwt
t
Fig
D
6
Rear
drom
brake
components
8
JIJmd
bnzke
Iner
9
Wh
1
cylinder
10
Lilli
11
A
nti
rattle
pim
3
4
1
PIIz
ed
st
tl1
2
Push
rod
3
Dittp
urtun
4
Rmr
Vrdl
J
Jbwer
phton
6
VQcwunl
OJlt
7
01
8
VQcuum
wzhe
9
fuppet
aucmb1y
10
Vah
body
pzrd
JEiID
12
II
Air
li
mur
Fzlter
12
V4lveopt
l
t1tintrod
13
Vobe
rdunuJNin8
14
lbppet
mum
Pri
If
15
AiTvah
e
16
RDut
17
Valve
plunger
18
Reaction
dUe
19
lJttp
rrqm
mum
Pri
If
20
Front
s
relJ
IS
Fig
D
Section
through
the
Master
Vac
unit
J
Bralee
rube
A
2
Front
COfIMctor
3
Bralee
tube
B
4
PreS
lJ
hO
e
front
R
H
5
Brake
tube
C
6
tubeD
7
Pressure
hose
front
L
H
8
2
way
connector
9
Brake
tube
E
10
Rear
connector
11
Pressure
hose
rear
R
12
Brake
tube
F
13
Brake
tube
G
14
PntruFe
h
e
raIT
L
H
IJ
Brake
hlbe
H
16
Hose
lock
plate
17
Hose
Jock
spring
Fig
US
Removing
the
air
silencer
retainer
Fig
D
9
Removing
the
valve
plunger
stop
key
G
lj
t
I
e
6
I
r
6
Fig
D
1O
Removing
the
bandbrake
front
cable
or
C
c
i
CI
7
vc
1
j
k
t
V
f
l
7D
Fig
D
l
t
Removing
the
handbrake
front
cable
Fig
D
13
Removing
the
rear
cable
Jt
A
G
L
J
CD
I
I
I
I
I
I
I
I
I
I
1
l
I
lSOt4
831
B
Fig
D
S
Adjusting
the
brnke
pedal
J
Fig
D
14
Adjusting
the
handbrake
cable
Fig
D
16
Setting
the
brake
light
switch
Fig
D
I7
Adjusting
the
rear
brakes
S33
Clamp
the
flange
and
bolt
assembly
in
a
vice
Push
the
rear
shell
and
stud
assembly
down
and
turn
it
anti
clockwise
to
release
Take
care
not
to
drop
the
valve
body
and
di
phrd
gm
plate
which
will
be
detached
at
the
same
time
Remove
the
retainer
and
detach
the
bearing
and
seal
from
the
rear
shelL
A
needle
can
be
used
to
remove
the
retainer
Pull
the
diaphragm
from
the
groove
in
the
diaphragm
plate
Remove
the
valve
body
guard
and
the
air
silencer
See
Fig
0
8
Remove
the
valve
plunger
stop
key
Fig
D
9
detach
the
valve
rod
and
plunger
assembly
and
the
air
silencer
fllter
from
the
valve
body
and
diaphragm
plate
Pull
out
the
reaction
di
c
To
dismantle
the
front
shell
and
stud
assembly
first
pull
out
the
push
rod
then
remove
the
plate
and
seal
and
the
check
valve
MASfER
V
AC
SERVO
UNIT
Assembling
inspect
the
components
and
replace
any
which
show
signs
of
wear
or
damage
As
previously
stated
the
repair
kit
contains
a
number
of
items
which
must
be
used
to
replace
the
original
parts
Assembly
is
a
reversal
of
the
dismantling
procedure
but
the
following
components
should
be
lubricated
with
silicon
grease
Grease
the
lip
and
face
of
the
seal
the
lip
of
the
poppet
both
faces
of
the
reaction
disc
Grease
the
diaphragm
edge
in
contact
with
the
front
and
rear
shell
Grease
the
face
of
the
plate
and
seal
assembly
which
con
tacts
the
front
shell
and
push
rod
the
face
of
the
check
valve
in
contact
with
the
packing
and
also
the
push
rod
at
the
point
of
contact
with
the
diaphragm
plate
Check
the
clearance
between
the
master
cylinder
and
push
rod
after
assembling
The
clearance
should
be
4
0
0
5
0
mm
ot
575
0
0197
0
in
and
can
be
adjusted
if
necessary
by
altering
the
length
of
the
push
rod
Installation
of
the
Master
Vac
unit
is
a
reversal
of
the
removal
procedure
HANDBRAKE
CABLES
Removing
The
cables
of
the
mechanical
handbrake
See
Fig
D
3
can
be
removed
in
the
following
manner
Front
cable
1
Release
the
hand
brake
and
disconnect
the
front
cable
by
removing
the
clevis
pin
1
in
Fig
D
I
0
at
the
handbrake
equalizer
Screw
out
the
adjusting
nut
2
to
disconnect
the
cable
from
the
handbrake
lever
2
Straighten
the
cable
clamp
I
in
Fig
D
II
and
pullout
the
the
lock
plate
2
to
extract
the
cable
from
the
retainer
3
Detach
the
cable
outer
casing
from
the
handbrake
control
bracket
then
pull
out
the
front
cable
Control
Stem
Removal
of
the
control
stem
is
a
straight
forward
opera
tion
Refer
to
Fig
D
12
and
take
out
the
clevis
pin
I
connect
ing
the
yoke
2
to
the
lever
3
Remove
the
clevis
pin
4
secur
ing
the
guide
5
to
the
bracket
6
then
withdraw
the
control
stem
S34
Re
lf
rnble
Remove
the
nut
from
the
adjuster
and
disconnect
the
left
hand
rear
cable
Disconnect
the
rear
cables
from
the
wheel
cylinders
Refer
to
Fig
D
13
pull
out
the
lock
plates
1
and
2
andremove
the
clevis
pin
HANDBRAKE
CABLES
Inspection
and
Installation
lnspect
the
cables
and
replace
them
if
any
of
the
wires
have
broken
Cables
which
have
stretched
must
be
renewed
as
it
will
no
longer
be
possible
to
adjust
the
handbrake
correctly
Check
the
springs
and
renew
them
if
they
have
weakened
or
broken
Oteck
the
centre
lever
trunnion
pin
and
equalizer
and
replace
as
necessary
Installation
is
a
reversal
of
the
removal
procedure
Grease
all
sliding
parts
and
adjust
the
handbrake
as
described
below
HANDBRAKE
Adjusting
Release
the
handbrake
and
adjust
the
rear
brake
shoes
as
described
under
the
appropriate
heading
Adjust
the
front
and
rear
cables
to
give
a
handbrake
lever
stroke
of
85
to
95
mm
0
35
to
3
74
in
by
setting
the
adjust
ing
nuts
shown
arrowed
in
Fig
D
14
BRAKE
PEDAL
Adjusting
Adjust
the
length
of
the
master
cylinder
push
rod
until
the
brake
pedal
pad
is
set
to
a
height
of
187
0
mm
7
36
in
with
the
brake
light
switch
free
from
the
pedal
stopper
Lock
the
push
rod
by
tightening
the
locknut
l
in
Fig
D
15
Screw
in
the
brake
light
switch
until
the
screwed
shaft
of
the
switch
makes
contact
with
the
stopper
brJ
cket
bolt
then
retighten
the
locknut
Adjust
the
stopper
bolt
2
until
the
brake
pedal
pad
is
set
to
a
height
of
183
0
mm
7
2
in
then
retighten
the
locknut
The
full
stroke
of
the
brake
pedal
should
now
be
set
to
150
0
mm
5
9
in
The
brake
lamps
should
light
up
when
the
pedal
is
depressed
15
0
mm
0
6
in
see
Fig
D
16
Lubricate
all
sliding
parts
with
bearing
grease
REAR
DRUM
BRAKE
Adjusting
Jack
up
the
vehicle
at
the
rear
and
release
the
handbrake
Depress
the
brake
pedal
several
times
and
turn
the
adjuster
clockwise
until
the
drum
is
locked
See
Fig
D
I
Turn
the
adjuster
in
the
opposite
direction
until
the
shoes
arc
just
dear
of
the
drum
and
the
wheel
can
be
turned
freely
by
hand
Repeat
the
operation
on
the
other
adjuster
and
then
depress
the
brake
pedal
to
make
sure
the
brakes
are
working
correctly
BLEEDING
THE
HYDRAULIC
SYSTEM
Refer
to
the
section
BRAKING
SYSTEM
for
L14
Ll6
and
LIS
engines
and
follow
the
instructions
given
under
the
appropriate
heading