1969 DATSUN 610 wheel

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

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

Clutch
MIPTOOlS
Trouble
Shootmg
Steering
IYMmlMS

mDING
S1
1FFNESS

ITIBJJNG
IIl
ACJt

STEEIUNG
WANDER

WHEEL
SHIIlOlY

CAR
PUl
U
TO
ONE
IIDE

POOR
RECa
Dy
OF
STEERING

WHEEL
10
CENl1tE

EXCESSIVE
01
ABNORMAL
TYKE
WEAR
It
d
e
f
I
II
J

e
It
b
I
J
k1
D
0
P
41
r

nUTCH
SI
IPPING
WIu
NOT

ENGAGE
PROPERLY
CLUfCHDRAG
WILLNOT

DISENGAGE
PROf
ERL
Yl

a
1JTCH
JUDDE

a
tn
CII
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fON
ENCAGEMDIT

CLIJfCH
NOISE
SQUEAL

DEl
ltESSlNG
nlE
PEDAL

nUTCH
NOISE
RATTLE
WHEN
IDI
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CLUTCH
NOISE
CHATTER
ON

a
GAGEMENI
I
I
j
ILlm

ROUBLE
CAUSE

I
hllUtrident
f
lay
In
RIM
link

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facbllWl
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oil
cluu
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or
brotell
pralure
plate
coilsprinp
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or
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hub

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4
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1
rifla
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t
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djUlt
QOlTectly

I
djuttrelll
defe
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pIrtI

Ti
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n
r
pllCe
joints

h
t
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renc
bannp

i
Ttchtentoco
cttorqu

j
Tiaht
n
correct
torque

t
fiahten
con
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torque

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putl

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ith
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h

p
Rene
prinp

q
laJan
bnltct

r
lI
eaJian
Ull
Ielllllion
drio

TIghtenIng
Torques

LIB

engines
Three

speed
geabox
ENGINE

2
5
4
0

kgm
18
29
Ib
ft

0
3
0
4

kgm
8
13
IbJI

Ll
1
8

kgm
8
0
12
llbJt

1
6
2

5
kgm
12
18Ib
ft

I
I
1
8

kgm
8
0
12
llbJt

0
7
I
I

kgm
5
1
8
0

IbJt

17
2

lkgm
l2
15IbJI

7
0
12
0

kgm
51

87IbJI

0
8
1
0

kgm
5
8
7
2
IbJI

0
3
0
4

kgm
2
2
2
9Ib
ft

2
3

kgm
14
22IbJI

J
9
2
2

kgm
14
16IbJI
Gearbox
to

engine

Dust
cover

Front
cover

Rear
extension

Bottom
cover

Reverse
idler
shaft

Detent
ball

plug

Mainshaft
nut

Mainshaft

bearing
retainer

Speedometer
pinion
sleeve

lock

plate

Reverse

lamp
switch

Control
lever
nut
Cylinder
head
bolts

1st

stage

2nd
stage

3rd

slage
4
0

kgm
28
9Ib
ft

6
0

kgm
43
4lb
ft

6
5
8
5

kgm
47
0
61
5

Ib
ft

Connecting
rod

big
end
nuts

Ll4
Ll8

engines

Ll6

engine

Flywheel
bolls

Main

bearing
cap
bolts

Camshaft

sprocket
bolt
4
5
5
5

kgm
33
40
Ib
fl

3
2
3
8

kgm
23
27
lb
ft

14
16

kgm
l01
106Ib
ft

4
5
5
5

kgm
33
40Ib
ft

12
16

kgm
86
8
116IbJt

0
6
0
9

kgm
4
3
6

5IbJt

I
I
1
5

kgm
8
0
10
8

Ib
fl

2
3

kgm
14
5
21
7Ib
ft

5
6

kgm
36
43
Ib
ft

0
6
0
9

kgm
4
3
6
5
Ib

ft

12

16kgm
86
8
115
7

IbJt
LIB

engines
Four

speed
gearbox
Oil

sump
bolts

Oil

pump
bolts

Oil
drain

plug

Rocker

pivot
locknuts

Camshaft

locating
plate
bolts
2
5
4
0

kgm
18
29

IbJt

0
8
1
0

kgm
5
8
7
2Ib
ft

Ll
l

7kgm
8
12IbJt

Ll
I

7kgm
8
12Ib
ft

3
3
44

kgm
24
32IbJI

1
7
2
1

kgm
12
15

IbJt

2
3

kgm
14
22Ib
ft

0
5
0
7

kgm
3
6
5
IlbJI

0
8
I
I

kgm
5
8
8
0Ib
ft

0
8
Ll

kgm
5
8
8
01b
ft

0
8
1
0

kgm
5
8
7
2Ib
ft
Gearbox
to

engine

Dust
cover

Front
cover

Bottom
cover

Rear
extension

Detent
ball

plug

Reverse

lamp
switch

Lower
bracket
bolt

Shift
rod
nut

Cross
shaft
bracket
bolt

Gear

change
lever

mounting
bolt
Crankshaft

pulley
nut

Outch

mounting
bolts

L14
Ll6

Ll8
2
4
2

6kgm
174
18
8

Ib
ft

1
6
2
2

kgm
12
16Ib
fl

PROPELLER
SHAFf
AND
DIFFERENTIAL

GEARBOX

17

20kgm
l22
145IbJI

14
17

kgm
101
123Ib
ft

13
20

kgm
94
145Ib
fI
Drive
pinion
nuts
Saloon

Drive

pinion
nuts

Estate
car

Drive

pinion
nuts
Van
Ll4
and
L16

engines
Three

speed
Gearbox

Rear
extension
to
case

bolts
2
8
4
4

kgm
20
32lb
ft

Gearbox
10

engine
2
5
4
0

kgm
18
29Ib
fI

Bnttom
cover
L1
1
7

kgm
8
0
12
3
lb

ft

Ll
1
7

kgm
8
0
12
3
lb

fl

3
5
5
0

kgm
25
3
36
2

Ib
ft

1
8
2
1

kgm
13
0
15
2

Ib
ft

2
4

kgm
14
5
29
Ib
ft

0
7
L1

kgm
5
1
8
0
lb

ft

0
7
Ll

kgm
5
1
8
0
lb

fl

9
11

kgm
65
1
79

51b
ft
Crown
wheel
bolts

1400
and
1600

cc
Saloon

1400
and
1600
cc
Eslale

1800ce
Saloon

I800cc
Estate

1800cc
Van
7
8

kgm
51
58Ib
ft

4
8
5
5

kgm
35
40
Ib
ft

7
8

kgm
51
58Ib
ft

7
8

kgm
51
58Ib
ft

4
8
5
5

kgm
35
40
Ib
ft

0
9
1
2

kgm
6
5
8
7Ib
ft

1
9
2
6

kgm
13
7
18
8

IbJI

1
9
2
6

kgm
13
7
18
8

Ib
f
Front
cover

Drain

plug

Selector
lever
bolts

Side
retainer
bolts
Saloon

Drive

flange
bolts
Saloon

Reverse

lamp
switch

Idler
shaft

screw

Rear
cover
bolts

Cross
shaft
lock

pin

Final
drive
to

mounting
member

1400
and
1600cc
models
6
8

kgm
43
4
57
8IbJI

1800cc
models
5
7

kgm
36
2
50
6Ib
fI

Final
drive
to

suspension
member
6
7

kgm
43
4
51
0
Ib
ft

Final
drive
to
drive
shafls
5
6

kgm
36
431b
ft

Final
drive

flange
to

propeller
shaft
1
6
2
4

kgm
12
17
Ib
ft

Final
drive

flange
to

propeller

shaft
Eslale
1
6
2
4

kgm
l2
17Ib
ft

Mainshafl
locknut

Ll4
and
L16

engines
Four

speed
gearbox

Rearexlension
to
case

bolts
1
6
2
5

kgm
12
18Ib
ft

Gearbox
to

engine
2
5
4
0

kgm
18
29Ib
ft

Bottnm
cnver

L1
1
8

kgm
8
13
Ib
ft

Fronl
cover
L1
1
8

kgm
8
13
IbJI

Drain

plug
3
5
5
0

kgm
25
3
36
2

Ib
f

2
4

kgm
14
5
28
9IbJt

9
11

kgm
65
1
79
5Ib
ft
Final
drive

flange
to

propeller

shaft

l800cc
610

only
Reverse

lamp
switch

Mainshaft
nut
2
0
2
7

kgm
14
5
19
5
lb

ft

4
6

kgm
29
43
Ib
ft

Oil
drain
and
flller

plug
Saloon

129

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

ENGINE

Dismantling

Remove

the

engine
from
the
vehicle
as

previously
described

and

carefully
clean
the
exterior

surfaces
The
alternator

distribu

tor

and
starter
motor
should
be
removed
before

washing
Plug

the
carhurettor

air
horn
to

prevent
the

ingress
of

foreign
matter

Place
the

engine
and
transmission
on

the
engine
carrier
ST4797

0000
if

available
and
dismantle
as
follows

Remove
the

gearbox
from
the

engine
Disconnect
the
intake

manifold

water
hose
the
vacuum

hose
and
the
intake
manifold

to
oil

separator
hose
Remove
the
intake
manifold
with
the

carburettor
Fit
the

engine
attachment
ST3720OG18
to
the

cylin

der
block
and

place
tre

engine
on
the
stand
ST371
00000

Remove
the
clutch

@
Ssembly
as
described
in
the
section

CLUTCH
Remove
the
exhaust
manifold
and
heat
baffle

plate

Take
off
the
fan
blades
and
remove
the
water

pump
pulley
and

fan
belt
Remove
the
rocker
cover
hose
manifold
heat
hose
and

by
pass
hoses

Remove
the

generator
bracket
and
the
oil
fIlter
Extract
the

engine
breather

assembly
from
above
Note
that
the
breather

is
fitted
to
the

guide
and
is
installed
with
a
O

ring
which
is

pressed
into
the

cylinder
block

Flatten
the
10ckwasher
and
unscrew
the
crankshaft
pulley

nut
Withdraw
the

pulley
with
the

puller
ST44820000
if
available

but
do
not
hook
it
in
the
V

groove
of
the

pulley

Remove
the
rocker
cover
and
take
off
the
rubber

plug

located
on
the
front
of
the
cylinder
head

Straighten
the
lock

ing
washer
and
remove
the
bolt

securing
the

distributor
drive

gear
and
camshaft

sprocket
to
the
camshaft
Remove
the
drive

gear
and
take
off
the

sprocket
See

Fig
A
3

Remove
the

cylinder
head
bolts
in
reverse

order
to
the

tightening

sequence
sOOwn
in

Fig
A
18
and
lift
off
the

cylinder

head
as
an

assembly
See

Fig
A
4
Note

that
in
addition
to
the

ten

cylinder
head
bolts
there
are
also
two
bolts

securing
the

chain
cover
to

the
head
Invert
the

engine
and
remove
the
oil

sump
Remove
the
chain
cover
and
oil

flinger
Take
off
the
nut

securing
the
oil

pump
sprocket
and
withdraw
the

sprocket
with

the
chain
in

position
as
shown
in

Fig
A5
Remove
the
oil

pump

and
stramer
Note

that
two
of
the

pump
mounting
bolts
are

pipe
guides

Remove
the

timing
chain
crankshaft

sprocket
chain
ten

sioner
and
chain

stop

Remove
the

connecting
rod

caps
and

push
the

piston
and

connecting
rod
assemblies

through
the
tops
of
the
bores

Keep

all

parts
in
order
so

they
can
be
assembled
in
their

original
posi

tions

Take

out
the

flywheel
retaining
bolts
and
withdraw
the

flywheel
Remove
the
main

bearing

caps
but
take
care
not
to

damage
the

pipe
guides
Lift
out

the
crankshaft
and
main
bear

ings
noting
that
the

bearings
must
be
reassembled
in
their

original

positions
Remove
the

piston
rings
with
a
suitable

expander
and

take
off
the

gudgeon
pin
clips
The

piston
should
be
heated
to

a

temperature
of
50
to
600
122
to
1400F
before

extracting

the

gudgeon
pin
Keep
the
dismantled

parts
in
order
so

they

can
be
reassembled
in
their

original
positions

Remove
the
camshaft
rocker
ann
shaft
and
rocker
ann

assemblies
from
the

head

by
taking
off
the
cam

bracket

clamp

ing
nuts
It
is
advisable
to
insert
disused
bolts
in
the
No
1

and

No
5
bracket
holes
as
the
cam
bracket
will
fall
from
the
rocker

ann
shaft
when

it
is
removed
Remove

the
valve

cotters

using

the

special
tool
ST47450000

and
dismantle
the
valve
assemblies
Keep
the

parts
together
so

they
can
be
installed
in
their

original

order

ENGINE

Inspection
and
Overhaul

Cylinder
head
and
valves

Inspection
and
overhaul

procedures
can

be
carried
out

by

following
the
instructions

previously
given
for
the
L14
LI6

and
LIB

engines
noting
the

following
points

Measure
the

joint
face
of
the

cylinder
head

using
a

straight

edge
and
feeler

gauge
The

permissible
amount
of
distortion
is

0
03
mm
0
0012
in
or
less
The
surface
of
the
head
must
be

reground
if
the
maximum
limit
of
0

1
mm

0
0039
in
is

exceeded

Oean
each
valve

by
washing
in
petrol
then

carefully
examine

the
stems
and
heads
Discard

any
valves
with
worn

or

damaged

stems
Use
a

micrometer
to
check
the
diameter
of
the
stems

which
should
be
8
0
mm
0
315
in
for
both
intake
and
exhaust

valves
If

the
seating
face
of
the
valve
is

excessively
burned

damaged
or
distorted
the
valve
must
be
discarded
The
valve

seating
face
and
valve

tip
can
be
refaced
if

necessary
but

only

the
minimum
amount
of
metal
should
be
removed
Check
the

free

length
and
tension
of
each
valve

spring
and

compare
the

figures
obtained
with
those

given
in
Technical
Data
at
the
end

of
this
section
Use
a

square
to
check
the

springs
for
deformation

and

replace
any
spring
with
a
deflection
of
1
6
mm
0
0630
in

or
more

Valve

guides

Measure
the
clearance
between
the
valve

guide
and
valve

stern
The
stem
to

guide
clearance
should

be
0
025
0
055
mm

0
0010
0
0022
in
for
the
intake
valves
and
0
04
0
077
mm

0
0016
0
0030
in
for
the
exhaust
valves
The
maximum
clear

ance

limit
is
0
1
mm
0
0039
in
The
valve

guides
are
held
in

position
with
an
interference
fit
of
0
040
0
069
mm
0
0016

0
0027
in
and
can
be
removed

using
a

press
and
valve

guide

replacer
set
ST49730000
under
2
ton

pressure
This

operation

can

be
carried
out
at
room

temperature
but
will
be
more
effec

tively

performed
at
a

higher
temperature
Valve

guides
are

available
with
oversize
diameters
of
0
2
mm
0
0079
in
The

cylinder
head
guide
bore
must
be
reamed
out
at

normal
room

temperature
and
the
new

guides
pressed
in
after

heating
the

cylinder
head
to
a

temperature
of

approximately
800
C
1760F

The
standard
valve

guide
requires
a
bore
of
14
0
14
018
mm

0
551
0
552

in
and
the
oversize
valve

guide
a
bore
of
14
2

14
218
mm
0
559
0
560
in
Ream
out
the
bore
of
the

guides

to
obtain
the
desired
finish
and
clearance
Use
the
reamer
set

ST49710000
to

ream
the
bore
to
8
000
8
015
mm
0
3150

0
3156
in
The
valve
seat

surface
must

be
concentric
with
the

guide
bore
and
must
be
corrected
if

necessary
using
the
new

valve

guide
as
axis

Valve
seat
inserts

Check
the
valve
seat

inserts
for

signs
of

pitting
The

inserts

cannot
be

replaced
but

may
be
corrected
if

necessary
using
a

valve
seat
cutter

ST49720000

Scrape
the
seat

with
the
450

cutter
then

reduce
the
width
of
the

contacting
faces

using
the

150
and
600
cutters
for
the
intake
valve
inserts
and
150
cutter

for
the
exhaust
valve
inserts
Seat
correction
dimensions
are

shown
in
millimeters
in

Fig
A
6

Lap
each
valve
into
its
seat
after

correcting
the
seat
inserts

Place
a
small

quantity
of
fme

grinding
paste
on

the

seating
face

of
the
valve

and
lap
in
as

previously
described
for
the
Ll4
LI6

and
L
18

engines

S5