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Service Manual Datsun Model 410 Series

1. lt lt apys 28 2129 2211102420490 1445 ru PSL ONIHSPE BAZATS 25 co gt 12 10 44 taramopaads 1 5 ASSY assy T VB DISASSEMBLY Front Bearing Retainer Release the front bearing retainer situated within the clutch housing by removing the nuts 7 Fw 6 Bearing 86 mission Cover of Trans all of which must be removed nuts Holding the cover in position are 14 set when the cover can be taken off Fig 7 Bottom Cover Fig 8 View of Inside Transmission 87 Fig 9 Take Gut the Ring 10 Take Off the Pin amp Nut Fig Counter Shaft amp Gear Using a soft and long metal drift drive out the counter shaft forward When the counter gear cluster and two thrust washers will drop the case These gear cluster can only be lifted from the case Fig 11 Counter Shaft Removal 89 Pull Out the Fork Rods 90 PROVES 4 ve vn etr cx Fig 13 B Pull Out the Fork Rods Revers Gear A lug which 15 an integral part of the main casting locates the forward end of the reverse gear shaft To secure the shaft position set bolt 1s screwed through the lug locating the shaft of r
2. l dou A SSV 00801 09S8F 194908 8012 2023 qod ASSY P 1V3S C gnvip 0090709999 pris 10N hea 5 2 9 2 1194 f LON LAN surot 1154 123302 Nid 131102 NId 00801 05689 55 00901 0 8 5 Lue 19 P ONTHSNG 0090 5 55 00901 59689 AQOu A SSV 00801 16648 AGO8 A SSV 00901 1668 1708 155 Steering Gear Housing Removal Removing the horn ring assembly from the steering wheel unscrew the column lock then disconnect higher up the column jacket from the housing First disconnect ball stud nut and draw out from the end of steering gear arm Unscrew the bolts secured to front suspension member Thus the steering NUT COLLAR WIRE WASHER lock ASS Y BUSHING Column jacket fix steering wheel 48050 10600 48105 30800 COMP COLUMN jacket 48050 10800 Ni use 48106 30800 fit one BALL roller 48107 30800 BALL roller b COMP COLUMN N yacket 48052 10650 ARM steering gear no mark 48053 16681 steering gear yellow line YR 48052 10652 ARM steering yellow 2 line 48052 10850 ARM stecrmg gear no mark 48032 10851 ARM steenng geer y
3. SEE X Ke Fe 2 3 ie 10 gt z Re Fig 3 Remove of Axle Shaft and Disc Assembly 131 SERVICE SPECIAL TOOLS DT 4679 Special Stand DT 4678 Swing Hummer Fig 4 Disassembly and Assembly of Axle Shaft When replacing the differential axle shaft do not forget the ajusting washer be tween the top of the axle flange and the brake disc assembly so as to keep the end play of the axle shafts Order of Rear Axle Shaft amp Brake Disc Assembly The rear axle bearing with the brake disc assembly 1s replaceable in one ope ration by pressing into place When fitting the axle shaft 1t should be compressed into the shoulder of the case end after inserting the end shim between its flange and hub Part No 43036 04100 The following points must be taken into consideration 1 Nominated Hypoid gear oil MP90 must be used In wamer district than 32 C use MP 140 2 It 1s prohibited to use any other kinds of gear oil or any oil of different viscocity The same brand must always be selected The standard capacity of oil 1s about 93 The method of feeding oil sho8ld be done by taking off the feeler plug at the rear cover of the housing and fill 1n full up to the feeding hole Dismounting amp Disassembling of Differential Gear Carrier 1 Take off and dram out the gear oil 2 At the of dismounting the gear c
4. n Noe TRANSMISSION Ass y cover transm ss on Ass y cover transmission Cover transmisston Ring O shift rod Pin control lever pivot Rod fork lst amp 2nd speed Fork lst 8 2nd speed Bracket rod lst amp 2nd Rod fork reverse Fork reverse Bracket rod reverse Pin fork reverse Pin cotter Spring pin reverse fork mi n Rod fork 3rd amp 4th speed Fork 3rd amp 4th speed Bracket rod 3rd amp 4th speed Ball checking Spring poppet pin Screw set Wire lock Ball checking Spring poppet shift rod Pin interlock Ball interlock Plug weld Plug weld Plate dust 104 BF mmm m 2 ET m 27 28 29 32 33 FORK amp ROD 4 SPEED Washer lock Bolt Plug Ass y lever control Boot control lever Knob control lever Spring lever control Cap cover transmission case Boot rubber Seat lever spring Screw stop reverse fork Nut plain 20 O G 11 12 13 14 15 16 17 13 12 TRANSMISSION GEAR 4 SPEED 1 4131 32 30 3127 26 Ass y gear reverse Bushing reverse gear Shaft reverse gear Screw set reverse gea Washer lock Gear counter Shaft counter Roller needie Countershaft spacer Ring retainer needle roller Washer thrust counter front Waeher thrust counter rear 3 9T Washer thrust counter rear 4 OT Washer thrust counter rear 4 1 Wash
5. 29 4 jq 13 5 XNVHO 2 NOLSId 6 815 eq InN Ww 7 ATquiasse 5 4201 jnu 84134935 I9 oq WO 104 Tousey 2 20 uid 14 398 814 28 ulu 993814 30 Fig 10 Crank Shaft PISTON Replacing Pistons and Connecting Rods Insert each piston and connecting assembly into the cylinder from which was taken 1t 1s essential that the split in the skirt of the piston 1s positioned to wards the camshaft Compress the piston rings with inserting piston using tool Fig 11 and gently tap the crown ot the piston with the wooden end of a hammer handie until the piston 18 clear of the piston ring clamp Fig 11 Piston Adapter 31 Now push the piston down the cylinder block the big end of the connecting rod just protrudes through the bottom of the cylinder bore then position upper half bearing shells NOTE Each upper amp lover bearing has two holes there by ensuring sufficient and it 1s of the greatest importance that the corresponding oil hole in the bearing shell registers with the oil way to provide an unobstructed passage Pull the connecting rod onto the crankpin taking care not to injure the bearing surface Insert the shell into the connecting rod cap position the cap and the lock ing washers Insert the setscrews and tighten with a
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7. 55 14 p y 1 UO18U aspi 5 Ona 89 12914 68014 M20 18 A SSV aansseid po uuLidvav 39 Main Bearing Caps Remove the flywheel and clutch Take off the timing chain the sump and strainer and the engine rear mounting plate Unlock and remove the bolts securing the main bearing caps to the cylinder block also the two bolts securing the front cap to the engine front bearer plate Note that a thrust washer 1s fitted on each side of the centre main bearing to take the crankshaft end thrust These thrust washers each consist of two semi circular valves one half having a lug which is located n a recess n the detach able half the bearing the other being plain 2 When fitting new bearings scraping 18 required as they are machined to tive the correct running clearance of 0005 0 002 0127 0 0508 mm Ensure that the locating tangs are properly engaged n their recesses Handle the new bearings carefully so as not to damage the fine surface finish Remove all traces dirt and oil from the housings and throughly dry them with a non fluffy rag Make sure that the oil ways are clear When fitting the bearing caps ensure that they are replaced
8. Fig 4 7 2 Check Voltage Put off Put on Pilot Lamp Relay First put on the lamp with con nection as shown n Fig 4 8 and read the voltage between N E by putting off the lamp moving the volt split point of the rubbing resistance This is a put off voltage From this state move the rubbing resistance volt splt point and lower the voltage and read the voltage when the lamp frares This 1s a put on voltage If the put off voltage 18 4 2 5 2V and the put on voltage 1s 0 5 0 3V t 1s all right 3 Adjustment of Gap Constant Voltage Pilot Lamp Relay The voltage adjust values of the constant voltage relay and the pilot lamp relay must be as shown n Fig 4 9 188 Constant Voltage Relay Pilot Lamp Relay 4 Adjustment of Voltage Put off voltage of the constant voltage relay and pilot lamp relay Adjust the voltage by bending the stopper up and down Bend upward to heighten adjust value and bend downward to lower adjust value 189 14 ITEMS ON HANDLING 1 When mounting on vehicle polish the contact points on both sides removing point rust or oil 2 Make sure the engine side pitch and dynamo side pitch of the front cover are well fitted together 3 Be attentive to the belt tension 4 Regulator 1s sealed with lead If the seal is removed during the claim period the claim will n vahd 5 If the earth 1s not correctly set the adjust value will change
9. 6 Connect the dynamo and battery with full attention When the battery poles are con nected reverse large current flows from battery to dynamo resulting in damages of diode or lead wire 7 Make sure the whole circuit 15 com pletely composed 8 Change wiring with full attention When after the engine started the dynamo 1s magnetized from the ignition switch so that in correct wiring will result in hampering magnetizauon and then generauon 9 Do not use the high voltage tester As diode 1s built in the diode will such as megger be damaged with high voltage 10 Engine room must be kept 1n the Because there 1s diode which will condition of standard usage deteriorate or be damaged with temperature higher than the normal 11 Do not separate the battery terminal Separation of the terminal causes dynamo A terminal during driving serge voltage within battery and vehicle damages diode 190 12 When cleaning with steam cleaner do not expose dynamo to steam directly When washing with water dynamo must be free from reckless pour of water When the battery is quickly charged with the quick charger the lead wire or regulator A terminal dynamo A terminal should be disconnected Put the key switch off when the engine 15 stop except when porticularly needed 191 If the diode 15 moistened the performance will be lowered Serge voltage of the quick charger will als
10. qserq A TYDS 1 LAMOVUuS 3198U1 Hd3HS VAM 98 lpueH 33971 404 1 eys gsoi5 708 ijeus 88012 eousuds ONIHSNG eus 88012 Suume121 59N 1444 i ddn 1828 1828 9812421 39 nus qods 4 5 33M0 Pe puz 9 qo ie Uns Or 1829 3215914 1912248 9 S 191102 NI d poi ijs 1 28 1 5 p ds 6 d p L4VHS A SSV yjeus SVAN L a 1108 uo 30 2 vivid 2421 19 1 ureld HAHSVA 384643 0 143 d S 259812 i e q Suny s pennau MJADS LAN Q 191102 d d 5 ets d ijpqs 1828 YOLY INSNI 5 12441 ugsuy2 281942 8381 HZQJAHTAISSSV 110ddns aads aSuey gt gt 5 Ud mines yk gt 01 apye 1892 NOINNAL Le 1343 p dv Susu G4N V L 38 faddn fusu 1V4S ioddne 12 0 55 5 1108 013402 9 Nid 1242814 xu uted 5 ets d HAHSVA Susu
11. 16164 08100 16011 31300 52 16052 08102 16143 p 16189 08102 5 16036 08100 16031 08100 P 16180 08102 4 mede 16137 31 ema 16140 31300 9 6193 31 d 246 16101 31 E Q 1 31 di 4 x T 16072 31300 in as 16064 31301 5141 4 3 1 16023 31300 gt 16280 31300 g 16061 21300 x Aer 6160 4 4 77 25 1 4 1 N 31300 g 2 t 201 20 6 pe 5 6 Vf is 7 x 29 69 a 16132 32200 45 4 Us 16191 91301 Ns jo ax 18272 21 6214 3130 16277 0831 e NO 16082 31300 16125 31301 gt d 5 16019 31301 254 16080 31300 NOU 25 4 lt 16282 31300 16108 31 16094 31 16038 31 CAS 16111 0810 16075 31300 2 16215 08100 16080 31300 R 16119 08100 CARBURETOR 48 SPECIFICATIONS Bore diameter 28 mm 30 mm Venturi diameter jet Main air breed Slow jet 80 48 60 48 Slow First 100 120 Slow air Second 220 Emulsion hole er 60 x 10 60 x 14 Slow economizer 20 x 2 Power jet 55 Power vaive Begins to open when the primary throttle valve 1s at 48 opening Float level 19 mm below the upper surface of the float chamber body The carburetor has the function of atomizing the fuel mixing it i
12. 19 012 19 37 mm 0 748 1 2 0 749 1 21n 25 003 to 35 7 19mm 63 64 to 1 13 32 m the cooling system by opening the radiator and cylinder block drain One 18 situated inlet tube at the backside of the radiator and other at the rear right hand side of the engine anit freeze mixture is in use it should be drained into a suitable container and retained for future use Disconnect the negative cable from the battery be extracting the terminal screw and removing the lug from the battery terminal post Slacken both the reta n ng clips on the hose connecting the radiator to the ther mostat housing and remove the hose Extract the termostat housing securing nuts and remove the housing and ther mostat Remove the aircleaner carburetor rocker cover and the inlet and exhaust manifolds Detach the high tension cables and remove the sparking plugs also disconnect the water temperature gauge connection from the thermostat housing Take off the rocker assembly not forgetting to slacken the external cylinder head nuts at the same time Withdraw the push rods keeping them n the order of removal The cylinder head can now be lifted off the cylinder block To facilitate breading the cylinder head joint tap each side of the head with a hammer using piece of wood interposed to take the blow Do not use excessive force 20 When lifting the head a direct pull should be given so that the head 1
13. C PUT 85 ipusis 3 1 1 5 99 DISASSEMBLE THE TRANSMISSION CASE FOR 4 STAGE FLOOR SHIFT Removal of Control Lever Twist the cap on the lower portion of the control lever counterclockwise with slight downward pressure Removal of Shift Rod amp Shift Fork Remove the cover from the transmission by detaching six bolts Rewerse Gear A lug which 16 an intergral part of the main casing locates the forward end of the reverse gear shaft To secure the shaft n position a setting screw 1s locked by tab washer Straighten the tab washer release the setting screw then tap forward and remove the reverse gear shaft Set out the reverse gear i Counter Shaft amp Gear Using soft meta drift drive out the counter shaft forward and out of case when the counter gear cluster and two thrust washers will drop to the bottom of the case These gears can only be lifted from the cas ng when the main and drive shafts together with their respective gears have been removed To remove the needle roller bearing within the counter gear cluster it 15 sary to break the retaining circlips before driving out the bearing with a suitable pece of metal tubing Main Shaft The main shaft can now be withdrawn from the transmission casing To remove the gears from the main shaft first slide off the third and forth speed synchronizer assembly then with a prece of wire inserted through the
14. w 4 m xe 48 RVICE MANUAL DATSUN 2 P 75 r MODEL 410 SERIES a a 5 T as 5 MET P 4 x rati _ SER Joe pod AIS te ze 5 v 7 S Us Wk z ES V 42 R 5 Tv XA a Patak NISSAN MOTOR LTD OTEMACHI BLDG OTEMACHI CHIYODA KU TOKYO JAPAN CABLES ADDRESS NISMO TOKYO PHONES 211 5281 9 m 19410 DATSUN BLUEBIRD MODEL TA wt INTRODUCTION This manual has been complies for purpose of assisting DATSUN distributors and dealers for effective service and maintenance of the Model P L 410 Each assembly of the major components 1s described in detail n addition com prehensive instructions are given for complete dismantling assembling and mspection of these assemblies It 1s emphasised that only genuine DATSUN Spare Parts should be used as replacements LE 5 SPECIFICATION ENGINE General Specifications COOLING SYSTEM Lubrication s OM Service Operations siti in Position Rocker Mechanism Removing amp Refitting Operation with the Engine BRAKER POINT AND IGNITION TIMING ADJUSTMENT Distributor
15. 7402 x SS 3101 218218 55 uo3 HAH OLY E w 910 aoye 21829 2001 As 21524 3401 um321 ONTD4d S Wa gt MOHS A SSY 7 Em 2 H 71 28 H8nl A SSV 160 FIG 4 ADJUSTING OF FRONT BRAKE 161 LNOMJ S 2014 142 225 1 51151 46 52591 1 Wy 09501 00501 09119 097700907 20119 194200901 COTTE 1 IN JO H Sutpuedxa 2045 Surpuedxa EA 7777 CDer 92 HOTE 1770901 706079 227 T Toso ozor jo 8 13 230 99014295 9 9 162 9 9 3 4907 Md4HSVA Suor 4 soz dod 477 eoue eq x1 01 L OddfS dWOoO xU 03 pues LON hn NIid 193302 es BS 88019 q o P trd oNr ds Bui L TI34 L332vug gt o 6 MGHSVAM y y viq Xj oj X A T O3 103302 NId aTqeo 88045 03 LA MIUS Loey 0 1 utd NOINNOUL puey _ Sy gt d
16. 8 6 9 1mm_ when releasing 7 3 8 1mm_ when depressing Less than 0 5 mm 0 05 0 15 mm 0 002 0 006 n pressure 15 85 mm 5 8 19 05 mm 3 4 Genuine super brake oil 1 6mm 87 mm 136 mm 5 kg 49mm 1 5 Less than 25 mm 7 8 About 300 kg 3 3mm 29 2 37 5 2 kg Ball bearing type From flywheel face to rear end of plate 50 5 0 2 mm Less than 03 0 0012 70 DRIVEN PLATE ASSEMBLY This 15 the flexible type in which the splined hub 18 indirectly attached to a disc which transmits the power and the over run through a number of coil springs held n position by retaining wires Two friction linings are riveted to the disc COVER ASSEMBLY The cover assembly consists of pressed steel cover and a cast pressure plate located by six pressure springs Mounted on the pressure plate are three release levers Adjusting nuts are screwed on the bolts of pressure plate Retainers of pressure spring insert to the clutch cover holes and anti rattle sp mgs load release levers RELEASE BEARING The release bearing consists of a carbon bearing shrunk into a bearing cup the cup bearing located by the operating fork and the release bearing retainer spring RUNNING ADJUSTMENT Owing to the hydraulic design of the clutch controls no adjustment 1s necessary to the clutch pedal Removing the Clutch gain access to the clutch it 1s first necessary to remove th
17. candenser defective ing at ter Contact point dirty m nals Breaker Point contact poor Breaker arm insulation defective Rotor shorted No gasoline in tank Strainer defective Pipe clogged Float valve sticking No air can enter tank Fuei pump not operating Plug spark carburetor Sparking at terminals Plugs do not spark i Gasoline ex Engine will not start No gasoline in carburetor 68 No gasoline or gasoline supply stopped Carburetor Engine seized ree of Lubrication insufficient trouble being sucked in Jet or pipe clogged Carburetor Float sunk Plugs k defective Float in high position will not descend arburetor attachment not secure Piston ring or valve sticky Compression poor s or connecting rod broken Valve seating poor Compres sion good Engine stopped 18 gasoline Breaker arm spring defective No spark ontact point poor ing from Rotor shorted coil line Although there Breaker Ignition coil or condenser defective arm good Distributor wet pes insulation defective Cord shorted or connection poor Wiring shorted or cut Sparking form coil line dirty or broken A Trouble Shooting Chart Compression weak Valve clearance incorrect Valve spring weak Valve deformed Muffler clogged po SE Valve timing incorrect 7 Ignition re
18. for wagon Fig 2 FUEL TANK MOUNTING 56 Troubles and Repairs of Gasoline Tank A When Fuel Leaks from Gasoline Tank When a crack distortion or damage 1s found in the tank repair or replace it To make repairs put marks with chalk at the leaking points and even after the fuel in the tank has been drained out blow with compressed air through the tank to force out stagnant gasoline vapor completely Repairs should be done only when the tank 1s completely dry Leakage 1s ordinarily mended by soldering When welding 15 necessary the above precaution must be strictly observed Otherwise there will be danger of explosion B When Gasoline Fails to Reach Gasoline Strainer If the fuel fails to reach the gasoline strainer when there is some fuel left in the gasoline tank and the operation of fuel pump 1s known to be satisfactory check the following points When it 1s difficult to confirm the delivery of at the strainer loosen the connector at the fuel intake of the carburetor 1 Check to see if gasoline pipe is clogged with dust and dirt This can be easily checked by disconnecting the connector of the pipe and blow ing with compressed air toward the direction of the tank Then from the tank end blow the pipe again and clean the pipe In many cases the of gasoline intake pipe of tank unit is clogged with dust and water Therefore together with cleaning of the pipe the interior of the tank sho
19. 5 2 8 E 2 4 Alternator Charge pilot lamp Fig 1 5 Charging System Fig 1 6 Outside Connection When the ignition switch 1s put on the battery current flows in the arrow marked direction passing through the dynamo E terminal brush slip ring field coil slip ring brush dynamo F terminal relay F terminal and IG terminal and completes the filed circuit It 1n difficult for the dynamo to stand up only by residual magneusm of the field core so that magneuzauon 18 necessary unul voltage rises to suit charging after the engine has started This 18 because the diode 15 used and when the voltage to add to 1t 18 50 low large proportional resistance shows up and current does not flow through the field coil unless the dynamo makes very high revolution 177 DISASSEMBLY AND ASSEMBLY A Disassembl The dynamo 1s disassembled n the following order a The completed 23100 61200 The parenthesized 1s the part number for SP310 Remove the brush cover 23107 12210 and pull off the brush 2 ea 23135 61200 Remove the cover 23130 12210 of bearing 23129 12210 JIS 862022 ZZCs and take off the hex bolt of shaft 178 Remove the hex nut 23153 12210 of pulley 23151 61200 and pull off the pulley and the half moon key 23195 12210 Be careful not to 1n jure the fan when the nut 18 removed Fig 2 4 Remove the through bolt 23131 12210 ughtening bolt front cover 23118 12210
20. Fig 2 Adjusting the Point Gap ADJUSTING THE IGNITION TIMING The ignition timing 16 adjusted to 10 degrees before top dead center with the engine stopped as shown in Fig 3 With this adjustment the automatic timing advancer of the distributor advances the ignition timing even further at the ume the engine starts to rotate and the timing 1s maintained constantly at valves suitable for the rotational speed With the engine stopped adjust so that the distributor breaker point just breaks when the piston of the No 1 cylinder 15 in its 10 degrees before top dead center position for compression timing lamp is used the standard ignition 2 44 timing 15 15 degress before top dead center at idling 600 rpm speed In the case marks which are not evenly spaced pointers indicate 10 deg 15 deg and 20 deg positions before top dead center Adjustment 15 made by the following procedure 1 Furst adjust the distributer to the correct gap as described previously 2 Turn the crankshaft gradually until the top dead center mark Fig 3 on the pulley perifery coincides with the mark for 10 deg before top dead center on the timing gear cover as the crankshaft approaches its positions somewhat be fore that corresponding to the end of the compression stroke of the No 1 piston Stop the crankshaft 1n this position The compression stroke of the No 1 piston can be determined if the spark plug of the No 1 cylinder
21. Release the setscrews and remove the clutch assembly from the base plate Refacing the Driven Plate If a new complete clutch driven plate 15 not available new linings may be fitted to the old driven plate in the following manner Each rivet should be removed by using drill The rivets should not be punched out Rivet one new facing in position then if the correct tool is not available use a bluntended center punch to roll the rivet shanks securely against the plate The second facing should then be riveted on the opposite side of the plate with the clear holes over the heads already formed in fitting the first facing The plate should then be mounted on a mandrel between centers and checked for run out as near the edge as possible if the wabbing 1s more than 0 02 n press over high spots until it is true within this figure It is important to keep friction facings free from oil or grease Refitting the Clutch Place the driven plate on the flywheel with the longer chamfered splined end of the driven plate hub towards the transmission The driven plate should be centralised by a dummmy drive shaft which fits the splined bore of the driven plate hub and the pilot bearing of the flywheel 77 The clutch cover assembly can now be secured to the flywheel by means of the holding screws tightening them a turn at a time by diagonal selection There two dowels in the flywheel to locate in the clutch cover Remove a dummy shaft a
22. Turn the adjusting nut down direction until the shoe becomes locked on the brake drum then turn back t upward direction the shoes becomes just free notches REAR BRAKES The rear brake shoe are not fixed but are allowed to slide and centrailse with the same effect as n the front brake They are hydraulically operated by wheel cylinder and independent hand brake mechanism WASHER nylon ASS Y BRACKET SPRING hand brake retainer 6 SHER lock 7 to fix hand brake bracket SPRING retainer ASS Y LEVER hand brake control SPRING nail COMP STEM hana hand brake control NAIL ratchet hand brake control SPACER ABLE nylon ront PIN clevis gt PIN set spring WASHER nylon amp exp hand brake lever Y SPRING set hand ASS Y GUIDE PIN brake lever hand brake clevis hand brake WASHER control nylon Fig 9 Hand Brake Control 166 Fig 10 Adjusting Brake Shoe Adjustment for the rear brake shoes 1s by means of the screw bolt which located at the outside of brake disc This precaution should be taken to nate the possibility of brake shoe drag due to mis adjusted parking brakes Turn the bolt to screw direction tightly and then turn back screw 2 3 notches until the wheel drum turns just free from the shoe 167 HD 1 514 1891 apis Suns
23. When indicator drops by about 2 in valves leak Faulty seating of valves 8 When indicator oscillates actively between 14 and 18 in valve stem guide is worn out 9 When with a slight speed ing up indicator moves between 10 22 mn and with increase of speed the range becomes larger valve springs are weak 10 When indicator remains still between 8 15 it 18 because either valve timing 18 retarded or valve clearances are not correct 11 When indicator settles bet ween 14 17 in ignition timing 18 retarded 12 When indicator moves slowly between 14 16 m it is because either elect rode gaps of plugs are too 14 When indicator oscillates regularly between 57 19 in there is leakage at cylin der head gasket Faulty clamping of gasket 15 When indicator first rises high drops down to zero and then returns to 16 in muffler 13 clogged narrow or breaker point 19 defective 13 16 When indicator points to 5 m or below there is leakage at intake manifold or gasket of carburetor Faulty clamping of gas ket When indicator moves slowly between 13 17 in carburetor is poorly ad justed Fig 3 Diagnosing Engine by means of a Vacuum Gauge Battery discharged or connections poor Timing poorly adjusted Air being sucked in Plug sparking weak Wiring incorrect Plugs dirty Timing incorrect Short n circuit No spark Ignition coil
24. and rear cover 23183 12210 pull off the front cover and rotor 23108 12210 Use a hammer of wood or plastic 1f necessary Remove the ball bearing from Front cover Remove the bolt 23352 09610 ughtemng the bearing plate 23123 12210 and or pull off the bearing with such as a hand press Slacken N terminal bolt on the rear cover side and remove the clip terminal then the rear cover and the stator can be separated Remove the rear cover and stator 23102 12210 Separate the silicon diode 3ea from the stator coil ead wire by melting soldering with an electric iron Slacken terminal bolt on the rear cover side and remove the chp terminal then the rear cover and the stator can be separated NOTE When temperature within diode gear up over 150 C the diode will lose functioning so that use the electric iron 100 200W for around 2 seconds at the soldered portions 179 Remove diode set and brush holder 23133 12210 from the rear cover when be careful not to lose small parts such as screws washers and bushings B AssemblY Assembly 1s done the reverse sequence of disassembly INSPECTION OF TROUBLES A Inspection of Output For inspection of output remove the dynamo from the vehicle and connect wiring as shown n Fig 3 1 and drive it with motor For Inspection of output of dynamo without removing it from the vehicle refer to Inspection of AC generator to be published la
25. 0 08 1n 0 05 mm 0 002 1n 0 4 mm 0 016 Amendment limit of short dimension Dittoed degree of real circle Dittoed limit of polarized wear Bush length Amendment limit Brush spring pressure 9 mm 0 36 1n 0 9kg 0 1 Construction and Operation The starter motor 1s a 1 0 horsepower sliding 1 type electric motor for use 1n starung The motor when mounted on the engine 15 on the front right side of the transmission with 118 pinion gear directly opposite to the ring gear construcuon of the starter motor 1s similar to that of the generator but differs only in that 113 armature shaft extends out backwards with a pinion group installed on the end as shown in Fig 1 amp 2 The connection diagram for the starter 1s shown 1n Fig 3 The starter switch 15 a key type combindd with the ignition switch turning switch to the right direction the relay on the magnenc switch move to permit current to flow to the starter and cause the armature to start turning suddenly 194 Fig 1 Magnetic Shift Type After advancing about 14 mm the pinion completes the meshing into the ring gear and drives t with a powerful torque The direction in which the pinion moves 15 from the end of the shaft towards the starter bracket thus reducung the bending torque After the engine starts and 1ts speed becomes greater than the no load speed of the starter the pinion 1s kicked back to unmesh and return to its former
26. 2 g H m sos Steering Angle Out 28936 Angie ot Kme Pa 6 2 Lead ng Front Leading Trailing Rear Lining Dimension Front 40x4 5x215 Master Brake Lining Dimension Rear 40x 4 5x 215 Total Braking Area 228 6 Sh Steering Wheel Dia RUNNING DEVICE inta of Drum From India of Drum Rear 23 81 Inner Dia of Master Cyl mm 22 22 India of Wheel Cyl 25 40 Q l Brake Front India of Wheel Cyl 23 81 mm Oil Pressure 3 kg cm Mechanical for Rear Wheel 115 Parking Brake Independent Suspension with Front Double Wish Bones Coil Springs Coil Spring Size 14x 94 325 5 8 Length x Width x Thickness BRAKE SYSTEM SUSPENSION 6 2 Parallel Semi Elliptic Spring Size 6 2 Length x Width x Thickness 1200 60 5 2 Helping Spring mm 2 Shock Absorber Front Telescopic Double Action Shock Absorber Rear Telescopic Double Action Stab l zer Front Torsion Bar Type Stabilizer Rear Torsion Bar Type Dimension Height x Width x Thickness m 265 m 5 75 SUSPENSION FRAME 1 ty 0 MODEL WP410 RUNNING PERFORMANCE CURVE Final gear ratio 4375 Ist speed ratio 3 518 speed ratio 1 725 3rd speed ratio 1 000 Gross vehicle weight 1235 kg Max grade ability Sin 0 32 5
27. Inner dia Area of surface cm2 22 22 mm Front wheels 25 40 mm Rear wheels 23 81 mm Fig 1 Front Brake Flange brake disc 158 A 5 EE MEER Fig 2 Front Brake Out Side The brake on all four wheels are hydraulically operated by foot pedal application directly coupled to a master cylinder in which the hydraulic pressure of the brake operating fluid is originated As supply tank cast integrally with the master cylinder provides a reservoir by which the fluid 18 replenished and a pipe line consisting of tube flexible hose and union inter connected the master cylinder and wheel cylin ders The pressure generated n the master cylinder by application with the foot pedal 18 transmitted with the equal and undimimshed force to all wheel cylinders simul taneously This moves the pistons out wards which 1n turn expand the brake shoe thus pro ducing automatic equalisation and efficiency n direct proportion to the effort sup plied at the pedal When the pedal 1s released the brake shoe spring return the shoe which then re turn the wheel cylinder pistons and therefore the fluid back into the pipe lines and master cylinder An independent mechanical linkage actuated by a hand brake mounted drivers seat side This 1s positioned on the right hand side of seat if the car has right hand steering and on the left hand si
28. Only when a complete overhaul 1s necessary should the hand brake linkage require resetting When this 1s correct the rear shoes should be locked to the drums the hand brake control just slightly applied and the wire rope set with the slackness just removed by means of a nut at the center rod of the equalizer drag link Fig 12 Adjusting Nut MASTER CYLINDER This 1s consists of an alloy body with a polished finished bore and reservoir with cap The inner assembly 18 made of the push rod stoper plate ring piston sec ondery cap return spring let out valve and check valve seat 169 The open end of the cylinder 15 protected by a rubber boot as shown Fig disassembling the Brake Master Cylinder Disconnect the pressure pipe union from the cylinder and remove the securing bolts when the master cylinder and fluid reservoir may withdrawn complete from the car Remove the filler cap and drain out fluid Pull back the rubber boot and remove the stopper ring with a pair of long nosed The push rod assembly can then be removed When the push rod has been removed the piston with the secondary cap wall be exposed therefore remove the piston assembly complete The assembly can be separated by taking out other small parts Exam ne all parts especially the rubber primary cap for wear or distortion and replace with new parts where necessary BRAKE CLUTCH GASKET filler SET CAP cap 5 fille gus SPRING return
29. Y BUMPER B reboun ront Susp BOLT y ASS Y LINK stopper lower front suspension EA 4 4 NIPPLE gicase COVER dust lower ball jon ASS Y JOINT ball 91 1 lower front suspension L H amp NIPPLE grease BUSHING SEAL dust lower hnk lower link bush SPINDLE lower hnk FRONT SUSPENSION LINK s 112 The dependent front suspension 15 known as the wishbone type since the top upper and lower bottom linkages roughly conform to the shape of a wishbone Between these two wishbones 1s the coil spring held under compression be tween the upper and lower which 1s secured to the lower suspension member by four bolts At the swivel axle end the upper and lower linkages are jointed by the ball joints The upper spindle bracket is bolted to the front suspension member with caster shims and the lower spindle 1s connected to the lower bracket of the suspension member oe 1 0211 1 1 1 1 1 1 2 2 Camber only 4 2 2 113 Both Camber amp Caster a thickness each shim 1m m Camber adjusting shims Parts No 54542 04100 1 mm 54543 04100 2mm 54544 04100 4mm Standard adjustment Camber 1930 R L difference within 40 Caster 1 30 R L difference within 40 BALL JOINTS AND BUSHES OF THE SWIVEL AXLE Wear if the swivel ball joint or wear of the screw bushes of links or both may be checked by jacking the front
30. be taken off from the body recondition it with a cutter and grinding tool When the surface of the valve 1s faulty place some very fine grinding com pound on the surface of a flat piece of glass plate and grind it lightly with the of a finger The standard thickness of the valve 15 1 6 mm The hole of the joint parts of diaphragm shaft and link may be worn to some extent This 18 not serious but when serious eccentric wear crack or break age 1s found the part must be replaced a remedial measure such wear can be compensated for at the time of dismantling and reassembling of the body by inserting packing made of thick paper between the lower body and diaphragm to raise the relative position of diaphragm shaft with respect to the lower body The rocker arm should be replace when its contact face with the cam and that with the link and pin hole are seriously worn 62 When its re employment by reconditioning 1s unavoidable add material to the rocker arm and link by welding and finish them with a file but this cannot last long and 1s no more than a temporary measure Renew the arm pin when t 1s found worn excessively The diaphragm spring arm spring seldom become faulty but when weakened replace them always with standard ones If the diaphragm spring 1 too stron results 1n overflow of the float cham ber of the carburetor The tension of the spring must not be strengthened or weakened arbitrarily by han
31. the switch serves to keep the circuit open The princo ples of operation can be seen from Fig 5 Closing the starter switch 5 allows the current to flow through the magnetic 199 5 m t Ignition switch Connect to others Battery Fig 5 Magnetic Starter Circuit If there 1s trouble in the magnetic circuit 1t should be corrected For improperly contacting starter brushed the brushes together with the ar mature should be checked and corrections or replacement made as found neces sary If all of the above checks with their corresponding repairs have been made and the starter still fails to operate the trouble can be assumed to be n the starter itself so that 1t should be removed from the engine and checked This 1s exceedingly rare but care should be taken to see that the starter p n on 1s not locked into the flywheel ring gear Cases lke this are usually caused by badly worn gears meshing improperly and if the defect 1s not too severe t can be remedied by placing the gear shift lever into fourth speed and rocking the car back and forth to free the gears If this trouble 1s frequently repeated the starter should be dismanted from the engine for checking and repairs 1 Starter turns but its turning power is weak and fails to start the engine If the trouble 1s due to a run down battery loose terminals troubles in magnetic shift switch worn and sticking brushes dirty and damaged com mutat
32. 500 r p m 14 24 5 up normal temp 2 500 r p m 14V 21 5A up high temp Pulley ratio 1 1 73 Regulator Mitsubishi Denk Co 23500 12200 Model RL A2 Type Tirrill type leaf spring Element Constant voltage relay Pilot lamp relay Constant voltage relay 3 contact point type 14 15V 4 000 r p m Battery resisung load 21 5 approx Adjust valve Dynamo revolution Load NOTE Use battery charged 1n full Pilot lamp relay 3 contact point type 4 2 5 2V 5 Part No 23100 61200 23500 12200 23153 12210 23151 12210 23131 12210 23118 12210 23102 12210 23120 12210 23108 12210 23129 12210 23230 12210 23183 12210 23133 12210 23135 12210 23127 12211 O Un a 21067 10800 4 Part Alternator ass y Regulator ass y Nut 17 Pulley Through bolt Front cover ass y Stator ass y Ball bearing Rotor ass y Ball bearing Diode set Rear cover Brush holder Brush Rear cover with diode set etc 175 we AM RIT 3 Q ty with slip ring N Diode set brush holder brush brush spring ball bearing each terminal GENERATOR Construction and Feature Different from the DC generator the AC generator turns the magnetic pol
33. Adjusting the ignition Tuning FUEL SYSTEM The Gasoline Tank Fuel Strainer Fuel Pump Adjustment and lepection of Paging CLUTCH _ TRANSMISSION Disassemble the Transmission Case Disassemble the Transmission Case For 4 Stage door Shift FRONT AXLE Disassembling the Front Hub Independent Front Suspension PROPELLER SHAFT amp UNIVERSAL JOINTS ten REAR AXLE o STEERING Steering BRAKE Front Brake Rear Brake a Hand Brake yi E PES wants fr nf Ris 4 A gt PARAT EM C ELECTRICAL SYSTEM 172 Alternator 174 Generator 176 Regulator 186 14 items on Handling etas 190 Trouble Shooting List 192 Starter Motor 194 s E IN us T LI 2 5 x d TL SPECIFICATION MAJOR SPECIFICATION Name and Model of Vehicle Datsun P410 Datsun P410 Kind of Vehicle 755 5 Vehicle Weight kg 885 Total Piston Displace 3 990 ment ltr 1 189 Overall Height mm 1 415 2 2 1 685 Wheel Base mm 2 380 AEN Vehicle Gross Weight kg Overall Length mm Overall Width mm Interior size of room Overhang to the end of 950 Space 5 mm 1 130 Cargo Sp
34. Assemble the pinion and side gear n the differential case Every parts should be cleaned and with new gear oil then the pinion mate side gear and the thrust washer should be assembled by the mentioned inspection and selection before pushing in the pinion mate to shaft Inspection should be made again in the clearance of between the washer or the backlash Adjustment must be made case any abnormal 18 found Strike in the pinion shaft locking pin from the right side of the case opposite side of drive gear and must be fixed by setting well the striking hole of it after putting 1t to the required piston so as the pin should not loosen the drive gear Ring gear with the differential case The drive gear as well as the drive Pinion should be well inspected ot they must be replaced as a set whenever the replacement 15 required Otherwise they would not properly lock after assembling 1s complected mounting the case the fitting surface must specially be cleaned and fixed with 8 set screws as well as lock washer bend the washer with sure ness after the drive gear shake 1s adjusted In tightening up the screw it should be set and supported by vice or any other setting tools so as not to damage it and screw up in a diagonal line with a wrench which fit correctly with the head of the screws The standard screwing torque for this 1s 25 ft lbs to 30 ft lbs Screw in for sure striking lightly the head of screw by one quart
35. Refitting Valve Guides Remove the cylinder head Remove the appropriate valve and spring Rest the cylinder head with its machined face downwards on a clean surface and drive the guide downward into the combustion space with a drift This should take the form of a hard ened steel punch See Fig 5 When fitting new valve guides these should be driven in from the top of the cylinder head Qr o Fig 5 Hardened Steel Punch Fig 4 Renewing a Valve Gude Renewing a Valve Spring in Position In an emergency a new valve spring can be fitted without removing the cylinder head When doing this the applicable piston must be brought to T D C position to eliminate any possibility of the valve falling into the cylinder Remove the spark plug from the cylinder concerned Hold the valve onto its sealing with the aid of suitable tool such as a bent screwdriver which will pass through the sparking plug orifice and locate on the valve head By using the rocker shaft as a fulcrum point the spring can be compressed with two screwdrivers or a fork ended bar Withdraw the valve cotters and renew the valve spring 25 3939819 3 3 8 8 128x201 ENN Re 3942918 A ysng 3jeus maid s 310 194904 9A VA 42488 193302 SANA 8 LAVHSWVD 9 urey Juru 1104 1895 94868 Mog 120 1 9381
36. and on the other the lamp 1s off when 3 diodes of the diode set are all right The same step 1s taken between the terminals N E When the same sult 1s obtained 3 diodes pressed in the cover are all right However if the simple test 1s all right but when the dynamo output 15 lower than the standard 1 2 diodes may often be opening so that one by one check will be necessary 182 Fig 3 7 b Separate Inspection Fig 3 8 Fig 3 9 Check between the lead wire and the diode set common with the other 2 diodes or the rear cover with the lamp and battery It 15 all right if one side flares and the other 1s off If both sides flare there 1s short circuit and both sides are off there 1s open E Inspection of Field Coil 3 10 183 As shown Fig 3 10 put tester between the slip ring of rotor and if there are 6 70 its all right Make sure there 18 no conduction between the rotor slip ring and the shaft F Ball Bearing Both sides sealed ball bearing 1s used so lubrication 1s not necessary G Inspection of Stator Armature a Conduction Test If the terminal connected to the diode 1s not conductive with the stator core that 1s all right If each terminal of the coil and the terminal connected to terminal are not conductive that 1s all right u Fig 3 12 E b Layer Test Connect the tester cord to 100V wire put the stator on the test stand and make the test
37. as 1t is do otherwise by cleaning the both surface with the rugs before disassembling and paint thinly and evenly with the mixed with thin on the gear surface drive side then turn the p n on with hand to print the track of t on the gear Which shows the situations of considerably worn out gear In case of unloaded test 1t 1s perfect that the gears contact for about three quarter at the center of 1 4 of whole gear length from too anterior end of the gear on the pitch line 4 Lock the side gear with pinion together with respective thrust 1n the gear case In case of the back lash over 0 2 mm and the clearance between the side gear and thrust washer exceeds 0 5 mm replace the thrust washer The else worn out parts should also be replaced The contact when ring gear 18 too Close to pinion center in case of back lash should be adjusted closely or gives much noise 5 Put the drive gear ring gear on the buoy block as 1t 1s fixed in the dif ferential gear case and measure with the dial indicator Revolve the drive gear to turn around the differential gear case as the bearing do not move on the buoy block Measure the shake at the rear side of gear by the scale and the shake should be within 0 5 mm In mounting the gear clean well the fitting face and rear face measured face of 1t and fix correctly then there should not be any shaking 139 ASSEMBLING ADJUSTMENT Assembling Differential Gear 1 2 3
38. attained its normal working temperature in which case the valve clearances will have to be checked again and reset if necessary Refit the inlet and exhaust manifolds Fit the craburetor and reconnect the control linkage Refit the ignition advance suction pipe to the connection on the carburetter but do not at this stage refit the air Cleaner or it will have to be removed later to check the valve clearances Re place the rocker cover taking care to fit the cork gasket correctly hse Place the thermostat and its housing n position and secure with the three nuts Reconnect the water temperature gauge wire and fit the radiator hose to the ther mostat housing Connect the cables to the battery Ensure that the radiator and cylinder block dram tapes are closed and refill the radiator Clean and adjust the sparking plugs and refit them clipping the hightension leads The firing order of the engine 15 17 3 4 2 Replace the clip which se cures part of the electrical whiring harness to the side of the head The ignition can now be switched on and the engine started When the normal operating temperature has been reached switch off and remove the rocker cover So that the valve clearances may be rechecked Replace the rocker cover and fit the air cleaner when the final check has been made Whilst the engine 1s running check that the water hose connections and fuel lne unions do not leak Tighten them if necessary 24 Removing and
39. bolt and from this point back into the sump Draining Oil Pan The oil pan 1s a metal pressing with the drain plug On new and reconditioned engines the sump must be drained and refilled with new ol after the first 1 000 km and subsequently at intervals of 5 000 km Drain the when the engine is hot since warm oil flows freely and takes with t any sludge or sediment which may have accumulated Never use petrol or paraffin for flushing purposes Such cleaning mediums are mever completely dispersed from the engine lubrication system and will remain 10 E to contaminate any fresh o1l This may cause premature bearing failure Oil Pressure The normal operating oil pressure s 60 lb sq in The warning light which is embodied in the instrument panel light if the oll pressure drops below 8 lb sq in under these circumstances do not attempt to run the engine or serious damage may result Refilling When refilling the sump do not pour the oil in too quickly as it may overflow from the filler orifice and mislead the operator as to the quantity of lubricant in the engine Before testing the level of the oll ensure that the vehicle 15 as near level as possible Always wipe the dip stick clean with a non fluffy cloth before taking the reading It should be remembered that ume must be allowed for new oil to reach to sump before reading the dipstick Check for Low Oil Pressure Check the level of o
40. hole im the gear cone de press the small spring loaded plunger which locates the splined washer at the for ward end of the main shaft turning the washer mto with the splines The third and second speed constant mesh gears together with their common phosphor bronze sleeve can now be pulled over the steel plunger and so clear of the mam shaft the phosphor bronze sleeves and their common driving washer are a tight fit on the shaft the shaft should be immersed n warm oil n order to expand the sleeves so that they will slide off the shaft when the second speed gear can be removed Take out the steel plunger and spring Next remove the splined washer separating the second speed constant mesh gear assembly from the first gear unit and then slide the first gear assembly free of the main shaft To release the speedometer wheel from the main shaft straighten the tab washer and unscrew its securing nut then slide the speedometer wheel off the shaft Do not lose the key Take off the distance piece and the main shaft bearing can be separated from its housing after the nut has been prised from the shaft If 1t 16 desired to dismantle the fourth and third speed coupling sleeve or the first speed gear these can be pressed clear of their splined synchronizers but care must be taken to retrieve the three balls and springs in each assembly Take out 100 the main shaft front needle rolier bearings from the end of the drive gear shaf
41. of the car and endeavouring to rock the wheel by grasping opposite points of the tyre in a horizontal position If any movement can be detected between the upper and lower swivel joints and the swivel axle as sembly the ball joints or the screw bushed are worn and must be stripped for exa mination Front Coil Spring Between the upper and lower links 1s the coil spring held under compression of 1t which 18 secured by nuts of the lower and upper ball joints Through the center of coil spring the telescorp type shock absorber which 15 connected to the top spring seat and lower link with nuts of the lower and upper 114 eye etg 115 The rubber bearing bushes screw bushes may time deteriorate and need renewing Excessive side ways movement in either of these bearings would denote softening of the rubber bushes or screw bushes The screwed bushes or the ball joints may develop excess free play due to wear of either of these parts This assembly can best be checked when the suspension has been dismantled Disassembling Order of Front Suspension 1 Remove shock absorber 2 Compress the coil spring by tool 3 Disconnect lower ball joint and rebound bumper from lower link 4 Release the coil spring by loosing the nut of tool 5 When the coil spring 1s fully extended take out t 6 Disconnect upper link spindle from suspension member if need to inspect for Removing the Coil
42. paragraph take off the p n on nut amp companion flange to mount again the drive pinion bearing spacer distance piece and nut Tighten up the nut as Fig 16 by using the torque wrench at the re gular torque of 100 120 ft per lbs The preload supportedly the bear ing in this case 1s different accord mg to the condition of the bearing adjusting shim inserted 144 The more of the shim inserted much the play pinion to the direction of axle 15 increased The less of the shim inserted the more the bearing tightened by the pre viously mentioned nuts and cause it to be burned if left and turned as 1 15 Therefore for readjustment of the bearing preload in this case 1t must be adjusted by increasing or decreasing the number of four kinds of ad justing shim as shown m the following hst and measuring with the use of the drive pinion bearing preload gauge as Fig 15 so as to make the revolv ing torque of pinion at 7 10 kg cm if there should not by any error the pinion with the head mark at 0 and the clearance should be sealed at 0 2mm 0 008 n by the feeler gauge thus pinion 15 regarded as at the correct position because the height of the gauge 1s made shorter for 0 2 mm than the standard size 51 0 mm Fig 17 Remarks When measuring the height of the pinion head set the semi circular side portions of the gauge on the side bearing seats insert a feeler gauge into the clearance between the
43. se 28 ob 9 fa E n ms Le 2 98 xo FRONT SUSPENSION C of Tightening torque he 97 k 2 3 zs E 1 1 E34 27 Same parts or upp lower side Center line of lower spindle WS PROPELLER SHAFT amp UNIVERSAL JOINTS JOURNAL NIPPLE ASS Y SHAFT grease propeller JOURNAL ASS Y YOKE m WASHER yoke to lock companion 4 RETAINER BOLT flange bearing SEAL o l c ASS Y BEARING RING snap PROPELLER SHAFT amp UNIVERSAL JOINTS Fore and aft movement of the rear axle and other components 1s allowed for by a sliding spline between the front end of the propeller shaft and the rear of the trans mission case Each universal joint consists of a center spider four needle roller bearings and tow yokes 125 Back lash of sleeve yoke spline 0 1 mm 0 004 Amendment limit of dittoed backlash 5 mm 02 in Outer diameter of universal joint journal 14 728 14 725 0 580 0 579 Inner dia of bearing lace 19 515 19 530 mm 0 768 0 769 m Number of roller of bearing needle 22 for each bearing Diameter x length on dittoed bearing needle roller 2 38 mm x 10 3mm Run out of shaft Less than 0 4 mm 0 015 n Tighting torque of companion flange nuts 15 18 ft lbs Outer dia 68 9 mm Inner dia 65 3 mm Parts No 37
44. that the holes 1n the cover coincide with the tapped holes in the plate insert the set screws provided and tighten them a little at a time by diagonal selection until the cover 15 firmly attached to the base plate at all possible points This 1s most important if the best results are to be achieved Mark the cover pressure plate lugs and release levers with a centre punch so that the parts can be reassembled in their relative position in order to maintain the balance of the clutch Detach the release lever plate from the eye bolts and remove the three lock nuts and adjusting nuts 73 z iv in 8 7 4 Disassemblmg Fig 74 Slowly release the pressure on the springs unscrewing by diagonal selection the set screws securing the cover to the base plate The clutch can then be lifted to expose all components for inspection The release levers and springs should be examined for wear and distorsion Renew these parts 1 necessary bearing n m nd that the pressure springs must only be renewed in sets Clean all parts and lubricate the bearing surfaces of the levers sparingly with grease Fig 5 Assembling Press the pin into the eye bolt hole through the lug on the pressure plate as shown 75 Place the pressure plate the base plate with the pressure springs 1n position on the pressure plate and put the pressure spring retainers on Cover
45. the Braker Points To adjust the braker points turn the engine crankshaft with the crank handle until the braker 15 fully open Then loosen the braker point fixing screw Next by turning the adjusting screw move the plate until a feeler gauge of 45 to 55 oe m 30104 22116 50000 ani lt 2 22184 50000 22123 30101 7 29 di X 22403 03020 22200 30100 34 22165 30101 22146 10360 22151 50001 77 54 toast 22102 50001 22121 07200 22123 30101 23553 25660 187 22183 30100 22201 30100 2 03020 27 7 O 43800 Ep O lt 30100 4 4 Fig DISTRIBUTOR 43 m mm 0 018 to 0 022 ins thickness slides easily between the braker points Then tighten the Fixing screw securely Finally check the gap once more then reinstall the rotor The interior and exterior of the cap 15 wiped clean witha soft dry piece of cloth extra attention being to the areas between the feT minals Clean the center electrode on the inside of theicap also he Wheth t not the vacuum type timing advancer 15 functioning properly can be determined by the inspection pointer located at the diaphragm if as the engine 15 being run this pointer moves when the engine speed 15 suddenly changed the advancer 15 satisfactory
46. the adapter A from the front end of the carrier and fix the tool at the side of stud in oppo site side tighten the screw to be the center of carrier as shown Fig 14 then mount 1t by using adaptor C as 1n a way of mounung the rear outer race The race 15 scarcely necessary to be taken off unless damaged Mount the rear bearing mner race and roller to the drive By using the round adapter attached to the drive pinion rear bearing inner race replacer which was employed at disassembling press in the drive pinion This might as well be done m pres sing in by the use of a certain drift b R AZ r 4 Mount the drive the carrier and adjust by measuring the position The pinion height must be adjusted as mentioned in the previous Fig 14 graph by mounting temperar ly the p n on in the carrier and the bearing be given a regular preload On the other hand the bearing of drive pinion should be newly after the pinion 1s inserted from the inside of the carrier the inserted end of pinion should be locked with front bearing corn and tightened up by the pinion nut fixing with the companion flange till the regular revolving torque 18 required As this 1s not yet at the final as sembling the bearing spacer distance piece bearing adjusting shim and oil seal are not mounted At the time of inserting the front bearing as pushing the inner race by pulling out the drive pin
47. the adjusting screw should be down until there 1s no free movement in the straight ahead position of the gear and adjustment secured by lock nut Final adjustment should be made once the gear has been reassembled to the housing It should be noted that as wear 1n use 1s normally greater in the straight ahead position than on lock provision 15 made for this n the design of the cam and 1t will be found that there 1s a slight end play towards each lock The steering gear housing should be filled with recommended gear 011 through the filler plug situated at the rocker shaft cover and then a final test made to en sure that the movement 1s free from lock Steering Faults Loose steering 1s invariably attributed end play of the worm gear through steering column which can be rectified by the removal of shimes located behind the gear housing front cover already mentioned To check for this end play disconnect ball joint stud at the end of cross rod from gear arm and turn the steering partly to the right or left lock 157 BRAKE GENERAL DATA Hydraulic expansion 72 shoes for 4 wheels Mechanical internal expansion rear 2 wheels braked Type Foot brake Hand brake Lining Width x Thickness x Length 40 x 4 5 x 215 mm Same for Front amp Rear 35 Front amp Rear Brake drum dia Front amp Rear 228 6 cm2 Same for Front amp Rear Master cylinder bore Inner dia Wheel cylinder bore
48. the right way round Each cap 18 punch Marked and the marks should face the camshaft side of the engine mz Fig 3 Engine Rear Side 40 Caution Never file the bearing caps to take up excessive play as this will cause ovality Always cover the bearing surfaces with engine oll when they are replaced The main bearing caps are held in position by set screws and lock washers Pull the set screws up tight with a torque wrench set to a loading of 75 80 Ib ft 10 36 11 05 kgm When refitting the main bearing caps tighten the center one first after each 15 tighten rotate the crankshaft to ascertain that t revolues freely If 18 tight remove the last cap tightened and examine the bearing and its seating for foreign matter Check the crankshaft end play by means of a dial gauge This should be 0 002 in 0 051 mm If a bearing has run t is essential to clean out all oil ways in the crank shaft and block Wash out the engine sump the strainer The o11 pump should be dismantled and cleaned Ensure that no of bearing metal are left within the engine lubrication system 1 alge 27 Fig 4 Removing a Bearing Cab amp Extractor 41 BRAKER POINT AND IGNITION TIMING ADJUSTMENT DISTRIBUTOR as Type Ignition timing standard at 600 r p m Apparatus of automatic advance Governor type Advance starting vacuum pressure 100 120 mm Hg z
49. tip of the gauge center rod and the pinion head and adjust the pinion The gauge rod 1s made 0 2 mm 8 1000 m shorter than the standard measurement 51 mm Therefore adjustment 1s made by selecting a feeler gauge n accord ance with the plus or minus valve marked on the pinion head If it 1s necessary to adjust the pinion height take off the drive pinion as well as pinion rear bearing outer race from the carrier to adjust by n creasing or decreasing the number of the adjusting shim In other words read the mark on the head of the drive pinion before adjusting by creasing or decreasing the number of drive pinion adjusting shim 110 5093 6 to msert the feeler gauge which 1s deducted for the number of mark 145 6 from 0 008 in n case m nus side added for the number of mark to 0 008 in in case of plus For instance the mark shows 2 adjust the position of drive pinion by deducting the number of shim so as to make the clearance at 0 008 n 0 002 m 001 in It is necessary to give the bearing a right load At the time of pushing the outer race into the carrier must be done in a right way otherwise Specially when the old bearing 1s to be used again n assembling the adjustment should be made at the lower torque than standard n accord ance with the conditions of practical use so as not to give it an over pre load When the former adjustment of preload of the bearing 1s complet
50. torque wrench to 21 7 24 6 lbs ft Finally knock back the lock washers Check the connecung rod big end for side clearance 7 1000 1n and see that the shell bearings are not binding on the crankpin when rotating the crankshaft If is difficult to turn undo the big end and examine the shell and seat for dirt or grit Before reassembling always apply a little clean oil to the piston surfaces and into the cylinder bore Never file the connecting rod caps or their mating surfaces as this creates ovality in the bearing Removing a Piston Remove the clamping bolt from the small end of the connecting rod and push out the gudgeon pin The gudgeon pin 15 push fit in piston at 70 F 21 1 C When reassembling ensure the gadgeon pin 18 positioned in the connecting rod SO that its groove 15 1n line with the clamp screw hole Check that the spring washer fitted under the head of the pitch bolt 1s not damaged PISTON PIN Diameter 17 447 17 452 mm 0 6869 0 6871 n Over s ze 5 1000 n 17 574 17 579 mm 0 6919 0 6921 n 10 1000 n 17 701 17 706 mm 1 0 6969 0 6971 n 15 1000 n 17 828 17 833mm 0 7019 0 7021 n Length 64 20 64 45 mm 2 568 2 578 in Clearance of pin and pin hole Degree to be able to push it by finger at 20 C Clearance of pin and connecting 0 003 0 010 mm rod bush hole 0 0001 0 0004 in 32 PISTON AND BORES There should be a cleara
51. 00 40 Effective radius of tire 0 287 m torque 9 3 kg m 3600 m Max ee 60 HP 5000 p m 151 s 55 7 7 7 400 30 5000 4 S 45 25 4000 00 20 85 ex Sl E 2 5 15 384 7 2 bb 10 EZ be Ea 2000 3 3 Sle gt d ob 7 192 772 m d 0 20 30 40 50 60 70 80 40 00 HO 120 130 140 150 Car speed km h x Running resistance MODEL P410 RUNNING PERFORMANCE CURVE Final gear 4 375 lst speed en 3 518 204 speed 1725 3rd speed ratio 1 000 Gross vehicle weight 1190 kg 500 Max grade ability 377777 0 34 40 Effective radius of tire 0 287 Max torque 9 3 kg m 3600 p m 151 ere 60 5000 r 35 8 Driving power kg Engine revolution m 4 7 4000 300 0 m E 200 C J max aa oz 5 2000 LX 3RD EP ar ANE 772 7 WY 20 30 40 50 60 70 80 90 100 10 120 130 Car speed km h 2 ENGINE The engine is of monobloc construction and 1s fitted with overhead valves operated by rockers and push rods from the camshaft seals are fitted to the valves Three steel backed bearings support the camshaft which is chain driven The oil pump and distrib
52. 000 11600 Comp shaft with joint Length between 1237 mm front amp rear joint Lubrication An oil nipple 16 fitted _ _ to each center spider for lubricating the bearings The central oil cham ber 1s connected to the four 011 reservoirs and to the needle roller bear ngs assemblies F g The needle roller bear ings are filled with 011 on assembly from the transmission Lubr cates the sliding splined joint between pro peller shaft and the trans mission Before refitting the propeller shaft to the transmission case smear the splines with the oil 1 Propeller shaft 2 Universal joint nipple Lubricating a universal joint of the propeller shaft 126 Removal Remove the rear propeller shaft flange from the pinion flange of the rear axle by taking out the securing nuts bolts and lock washers Place a clean tray under the rear end of the gear box to collect any surplus oil that may drain off The operator should now take the weight of the propeller shaft and then draw the splined end out of the transmission Dismantling Clean away the paints from all the snap rings and bearing faces to ensure easy extraction of the bearings Remove the snap rings by pressing these ends together and prise out with screw driver If the ring done not come out tap the bearing face lightly to relieve the pressure against the ring Hold the splined end of the shaft n one hand and tap the radius of t
53. 098 ut u iojge nsu H 7 OPERATION WITH THE ENGINE REMOVED The following operations are best performed with the engine removed from the car Although 1t may be found possible to carry out certain attentions with the engine in position it 15 more convenient to do the work on the bench Withdrawing Camshaft The camshaft 1s positioned by a locating plate held by three screws and shakeproof washers Note the position of the small lubricating oil hole in the locating plate when replacing should be to the right of the engine End play of 0 003 0 007 n 0 076 0 178 mm 1s controlled by the thickness of the locating plate and can be checked with a dial indicator set against the cam shaft gear Before withdrawing the camshaft the distributor and its driving spindle push rods and tappet will have to be removed Remove the oil pump and its drive shaft and take off the timing cover and gears The engine front mounting plate 18 now accessible and may be removed by withdrawing the setscrew and locking plates The dynamo swinging link must be removed Take out the setscrews securing the camshaft locating plate when the cam shaft can be withdrawn from the cylinder block CAMSHAFT BEARINGS White metal bearings with steel lining are used for the camshaft They can be taken out renewed when necessary t being usual to do this when the cylinder block 1s being reconditioned The bearings can be removed by drifti
54. 1s removed the hole plugged with a finger and the crankshaft turned With the crankshaft in the pre viously mentioned position the No 1 piston 15 1n its position of 10 deg before top dead center of compression Fig 3 Checking the Ignition Timing 3 Next inserting the driving shaft of the distributor at an angle to the engine 3 engage the gear on its lower and with the gear on the camshaft During this I assembly place the slot of the distributor drive of the upper end of the shaft some what to the left as shown n Fig 5 At this time the smaller of the semi circles 15 placed toward the front 45 3 Fig 4 Setting of Timing Gear Mark ES 4 Adjusting the direction of the rotor so that it engages the drive shaft slot a 57 mount the distributor to the engine During this assembly the directions of the distributor and rotor must be as shown n Fig 5 At the same time the breaker must be n position when it is just begining to open If these conditions do not comcide they are made to do so by slightly turning the distributor body only To determine the position when the breaker point is Just begining to open turn on the ignition key hold the end of the No 1 spark cord about 1 4 inch away from the E 4icylinder head and turn the body until spark jumps across the The off set slot position of the drive shaft when the No 1 piston 18 in its com pression top dead center p
55. 29 Saute ue 55 a W b E STATO NId o 2957 569 L 1O8 Aen lt ea OMA uua 8 A9 N 060 s 43 N d rqe xu 03 puey Y 2 Co e PIONIE wi e 8 SuvAS b B MN 90 b 9 9 2 NI StA9 O E 1j TIG VO poz 88012 WUNIVIGH 10015 TISYOv Itnd 5NTHdS E Sura Warp 01 tel D Section 44060 10500 Upper side XA VA ui 41128 30001 u 41129 30001 B Section Adjustment brake shoe This precaution should be taken to eliminate the possibility of brake shoe drag due to mis adjusted parking brakes Turn the bolt to screw direction tightly and then turn back screw 2 3 notches untill the wheel drum turns Just free from the shoe FIG 7 REAR BRAKE 1 164 Fitting of wheel cyl 44030 10600 0 44141 317 4 T 4142 31700 q 44149 31700 44144 31700 44145 3 700 44205 10500 4408 04100 44084 30000 FIG 8 REAR BRAKE NO 2 165 Adjustment for the front brake shoe 15 by means of the teeth of the gear which located at the lower position of the brake disc Remove the dust cover of the um servo housing Tap the adjuster housing and insert a screw driver through adjusting hole and engage the teeth on the wheel
56. 4 joys 49488 p 33846 wes WE _ yeneyxy jeg 9A UA 1 Sutuds 811148 19900 ysng m 8 93 ur 849 Butt 2194414 j ddo 2 Butads s rloo 93814 84113820 T 776 jou 8 12488 A 26 1 5 o E rew filler e Washer Pack ngs Cover valve rocker 13264 10600 Stud Manifold hole Gasket cyl head 11044 30004 for com ratio 8 2 11044 07200 for com ratio 8 0 11044 04000 for com ratio 7 6 Fig 7 CYLINDER HEAD 27 Removing and Replacing the Tappets Remove the carburetor and the rocker cover then take off the manifolds Disconnect the high tension leads from the sprking plugs remove the rocker assembly and withdraw the push rods keeping them in their respective positions so that they will be replaced onto the same tappets Remove the tappet covers and lift out the tappets also keeping them 1n same locations Fig 8 New tappet should be fitted by selective assembly so that they fall into the guids under their own wdight when lubricated Assembly 1s a reversal of the above procedure but car should be taken to see that tappet cover joints are oil tight and that the rockers are adjusted to
57. 5 cc for each bracket 201
58. 5 very rare and short circuits at the polar line are also rare Ordinarily there are many cases of side short c r cults C Inspection of Diode with Tester a Check between the terminals as shown 1n Fig 3 2 Set the dial of tester for conductivity and put the tester needles at both terminals alternately When one shows low resistance and the other shows pretty high resist ance the 3 diodes the diode set are all right Check between the terminals same as above When the same result 1s obtained 3 diodes are also all right However when there 1s no disorder found this simple test and the dynamo output 1s somewhat lower than the standard 1 2 diodes are often opening when one by one checking will be necessary ad Fig 3 3 b Separate Inspecnon Check resistance with the tester between the diode base commonly used for 2 diodes and lead wire on the rear cover 2 times changing the poles When one side shows low resistance and the other shows high resistance 24 181 There 15 disorder If both sides are low there will be short circuit and both sides are high there will be open Fig 3 4 Fig 3 5 D Inspection of Diode with Lamp a Simple Inspection Fig 3 6 Check between the terminals A N as shown n Fig 3 6 Connect with the lamp 12V in straight and put both ends at and terminals alternately On one side the lamp flares
59. F DISASSEMBLED PARTS Every parts after they are disassembled should be cleaned and cleaned by the compressed air before making an inspection and adjustment 1 Each bearing should be inspected every unit of ass y regard with the defect and defacement before deciding to re use them 2 The axle should be inspected respect of the crack and the defacement of spline measuring the shake with the gauge by holding the both end The dif ference over 0 4 mm should be adjusted with 0 8 m m or replaced The clearance between the end of rear axle case and brake disc should be adjusted with the adjusting end shim Part No 43036 04100 3 Every gear should be inspected as to the locking condition defacement or any defects on the surface to see 1f they can be re used In case of m sufficient standard back lash deformation or damage found replacement 1S necessary Specially the drive pinion and drive gear should be replaced in a set when ever the locking condition gets worse and the defacement 1s already n progress because it would cause the noise in later operation and be dif ficult to adjust even with proper adjustment 1s made The perfect driving condition at the surface of drive pinion gear should be about from 2 3 mm to 3 4 mm n unloaded driving while the gear surface should start to touch from tip to full surface in an ordinary loaded driving The inspection of this condition can be made 1 If 1t is hard to inspect them
60. HER r rubber specia e outter ROD connecting front stabihzer FRONT SUSPENSION MEMBER amp SHOCK ABSORBER 110 DISASSEMBLING THE FRONT HUB Dismantling of the front hub first jack the car until the wheel 15 clear of the ground and then place blocks under independent suspension spring plate Lower the car on to the blocks Remove the wheel and the screw If the drum appears to bind on the brake shoes The shoe adjusters should be slackened Lever off the hub cap and then extract the split pin from the spindle nut Using a box spanner remove the spindle nut and ease flat washer under the nut clear of the axle thread by carefully using a narrow rod into small holes n turn n each side of the spindle and tapping the race lightly With the hub removed outer bearing can be dismantled and by inserting a drift through the inner bearing and tapping the out bearing clear of the hub The inner bearing and 01 seal can then be removed by inserting the drift from the opposite side of the hub When assembhng the hub the inner bearing race should first be inserted into the hub Pack the hub with recommended grease Replace the hub oil seal over the inner bearing Renew the seal if it 15 damaged any way The hub can now be replaced on the spindle Gently tap the hub into position until the inner race bear against ehe shoulder the spindle Place the spindle flat washer into position and screw the nut down finger tight Spin
61. Inspection and Adjustment of Engine 1 Check the cooling water water level and extent of filthiness 2 Inspect the battery all connections level of electrolyte specific gravity of electrolyte and voltage 3 Inspect the 011 amount filthiness classification and viscosity 4 Cleaning of spark plugs and adjustment of their gaps 5 Measurement of compresssion pressure of cylinders The standard com pression pressure of the engine 1s approx 163 lbs per sq 1n at 350 p m Measurement of pressure s made in the following manner see Fig 1 First warm up the engine temperature of cooling water 70 80 C then remove spark plugs and pull out the throttle knob all the way that 15 in the carburetor the throttle valve and choke valve are fully opened press a compres sion gauge against each spark plug hole and running the starter motor with a fully charged battery read the maximum pressure ob tained within 5 8 rotations of rhe motor This measurement must be made as quickly as possible It the compression pressure of any one cylinder differs by 10 b sq n or more from that of another the cause must be n vestigated 6 Check and adjust the distri butor If the breaker contact points have defective contact surfaces dress them and adjust the gap to 0 45 0 55 Also turn the cam of the dis tributor clockwise and check to see if the governor can carry out advancing function 7 A
62. R AXLE CASE amp SHAFT SCREW to brake drum 43235 04101 ASS Y CATCHER grease L H 43234 04101 ASS Y CATCHER grease R H 129 T Tightening torque ressure 0 22158 43036 04100 223 04101 43010 10600 T 15 20gn 43070 04101 d 38212 04101 NN m 10600 NS 40221 04101 5 04100 7 80 90Kga Mis 1 42 3 24414 7 4 Smear grease a httle on the surface of shaft F ll up grease suffieiently on the surface of bearing race except other space N Press this collar by pressure 3 5 tons metric The collar 18 required to change new one when disassembled T Tightening torque FIG 2 COMPONENT OF REAR AXLE 130 Axle Shaft Removal Choke all the wheels not being operated upon jack up the car Lower the axle on to the blocks and remove the wheel using a screw driver un screw the drum locating screws release the hand brake and tap the drum off with the mallet If the brake linings should hold the drum when the hand brake 1s re leased slack off the brake shoe adjuster a few notches Take off the fix bolts of the brake disc and remove the axle shaft as shown Fig Tap with swing hammer holding the wheel studs bolt with the rear axle shaft stand draw out the shaft and disc assembly by gripping outside of the disc To rear axle case TUI I6 DRIED Ede
63. Spring METHOD A 1 Unscrew nut ot the shock absorber at the top and take out 1t from down side after unscrew lower flange of t from lower link Fit the service tool and screw up the spring compressor nut In the absence of the service tool a suitable tool will be required to release the compression from the coil spring Compressing the coil spring unscrew the 3 nuts of lower ball joint which located under the edge of lower link Remove these nuts and release the compression from the coil spring by loosing of nut of tool When the coil spring 15 fully extended take out t AF gt 1242 a z re 116 Detachment of Shock Absorber from Suspenston Detachment of Shock Absorber from Suspenston 117 P DM ELA Y m 407 pus Fjar iube dager xi uw f Be Detachment of Rebound Bumper Remove Shock Absorber Releasing the Nuts of Lower Ball Joints 118 METHOD Unscrew the four bolts of lower spindle which 18 secured to the suspension member Remove these bolts and release the compression from the coil spring When the lower link with spindle can be driven out Refitung the Coil Spring Use the coil compressor or jack against the lower link Screw up the screw bolts of the lower link spindle to the front suspension member and then secure the bolts of the lower spindle Release the compress
64. ace of set Y mm Front 505 Distribution of Vehicle Weight Without Load kg 5 60 13 4P Tire Size Rear 5 60 13 4P 380 Distribution ot Vehicle Proportion Front 95 2 Weight of Tire 60 With Load Rear 88 9 Proportion of Front Tire 51 7 Max Incli with Load nation Angle Rear Front 1 206 Tread mm mu 1 Gu lt gt COMPARISON WITH MAJOR SPECIFICATION OF MODEL P410 Vehicle Overall Length Vehicle Overall Width Vehicle Overall Height 1 415 interior Size t Overall Length 1 685 Cargo Space Overall Width T Overall Height 1 130 2 Front 1 206 5 Tread Front 1 206 2 m Wheel Base 2 380 Road Clearance 2 8 Floor Height 5 Overhang to the Front End Without 605 Bumper Overhand to the Rear End Without 950 Frame Overhand to the Front End Frame Overhang to the Rear End Front 5 60 13 4P Ein Rear 5 60 13 4P Vehicle Weight 915 Seating Capacity Max Payload 3 160 Vehicle Gross Weight 5 17 190 Distribution of 505 525 Vehicle Weight 17771307 Rear 380690 Distribution of 610615 Vehicle Weight With Load 560 575 565 WEIGHT Speed km h m h 128 80 m h m Flat Road W2 Load km m lt
65. ain and drive shaft gears 101 Drive Gear Shaft The ball journal bearing should now be drifted on to the shaft with its spring ring away from the geared end Position the geared end of the drive shaft in a dummy 3rd and 4th speed coupling sleeve put the washer over the bearing tighten the nut and lock it in position Smear grease the end of the shaft where the main shaft locates then load the needle rollers so that they adhere n position by means of the grease Turn the gear Casing to ensure that the counter teeth are below the drive shaft bearing housing Failure to do this will result in damage to both the counter gear and drive shaft geared ends The drive shaft can now be drifted into position from the clutch housing end Ensure that the spring ring resisters properly in the race on the gear case Main Shaft Press the main shaft center bearing complete with housing on to the shaft from the rear The bearing must be pressed firmly against the shoulder of the center splined portion of the shaft Lightly smear oil the shaft forward of the bearing and refit the first speed wheel assembly with the synchronizer pointing forward Refit the thrust washer on to the shaft followed by the baulking ring The phos phor bronze sleeve which carries the second speed 18 a tight fit on the shaft there it must be first immersed in warm oil and then slid into position on the shaft Fit second speed wheel over the sleeve then the driving w
66. an Belt Adjustment pulley when the midspan 15 pushed firmly After the correct tension has been obtained securely lock it in position again Front Precausions Freezing may occur first at the bottom of the radiator or the lower hose connections Ice in the hose will stop water circulation and may cause boiling A muff can be used to advantage but care must be taken not to run with the muff fully closed or boiling will result When frost 1s expected or when the car 1s to be used in a very low temperature make sure that the strength of the solution 18 fact up to the strength advised by the manufacturers The strength of the solution must be maintained by topping up with anti freeze solution as necessary Excessive topping up with water reduces the degree of protection afforded Solution must be made up n accordance with instructions supplied with the container Top up when the system 1s cold If the cooling system has to be drained run the mixture into a Clear coutainer and use again Protection by Draining On cars where anti freeze 15 not used the following precautions must be taken during frosty weather to obviate any damage due to freezing of the cooling system When heavy frost 15 imminent the cooling system must be completely drained It 1s not sufficient merely to cover the radiator and engine with rugs and musks There are two drain cocks one on the left hand side of the cylinder block and the T other at the bas
67. and set the clutch cover assembly on the base plate Compress the pressure springs by screwing down the cover to the base plate by using the special set screw placed through each hole in the cover Tighten the screws a little at a time by diagonal selection to prevent distortion to the cover Set the release lever on the eye bolt with lock nuts inserting for lug at the edge of pressure plate Gauging Screw the nuts into the bolts and proceed as follows Screw the centre pillar into the base plate and slip the distance piece over the pillar followed by the cam shaped height finger Adjust the height of the release levers by screwing or un screwing the bolt nuts until the height finger when roted just contact the heighest point on the tip of the release levers Replace the height finger and pillar by the clutch actuating mechanism See inset Fig 5 and actuate the clutch several times by operating the handle This will enable the parts to settle down on their knife edges Replace the height finger and distance piece and readjust the height of the re lease levers checked for run out as near the edge as possible as if the error 15 more than 0 02 n press over the high spots until it 15 true within this figure It 1s important to keep friction facings free from oil or grease Finally repeat the procedure to make quite sure the release levers are seat ing properly and gauge again Secure the lock nuts and fix the release lever
68. arrier pull out the both left and right axle shaft with the disc of the brake assembly 3 Take off the joint flange from the side of propeller shaft 4 Pull off the nuts of the housing and dismount forward the carrier ass y 5 Take off the side bearing cap of carrier and pry with a lever the differential gear case and the bearing 6 Dismount the differential side bearing As illustrated in Fig 5 with the aid of side bearing puller pull out the 132 bearing The puller should be handled with in catching the hedge of bearing inner lace which ts hard to hook Both the left and right bearing should be arranged separagely 7 Dismount the differential drive gear Ring gear by loosening the 8 vixing screws on the differential gear case spreading out the lock washer Loosen them n a diagonal line considering to keep from the gear bending Fig 5 Using of Side Bearing Puller DT 4686 8 Take out the differential pimon as well as the side gear The pinion mate shaft should first be pulled out by striking out the pmion mate shaft locking pin which 1s fixed on the differential case from left side from the side of ring gear fixed to the right before pulling out the pinion side gear and the thrust washer The gear as well as the thrust washer should be arranged separately as left and right front and rear 9 After taking the out nut of the carrier pull out the companion flange The drive pmion flange wrench sh
69. as shown the figure 7 Lubricate bushings with grease completely until extra grease will come out from dust seal Center of ball Joint Tightening Torque Nuts fixing upper ball joint and rebound bumper to the upper link 15 2 4 2 6kgm 17 4 18 8 lb ft Bolt fixing upper link spindle 4 7 5 kgm 34 36 2 16 4 Nut fixing lower link spindle 4 0 4 5 kgm 29 32 5 Ib ft Front Wheel Alignment Toe in 3 mm 1 8 m Caster 1 30 Camber 1930 King pin inclination angle 6 30 Adjust camber with adjusting shim at upper bush spindle fixing portion Adjust caster with the same shim or by turning upper link spindle only 1 2 one turn Turning of upper spindle 360 One turn 180 Half turn 4180 360 Caster Only clockwise See from back side Counterclockwise See from back side 2 121 gt 34336 10690 9 16217 1 277777 N 256 T C rn ZS gt 3 2 p o T Tightening torque 4 Center of lower ball joint R Section 11 5 Sv 2 4 E 8 i 35 260257 Center hne of front axle yo 123027 FRONT SUSPENSION A 122 FRONT SUSPENSION B 123 up 2 4 5
70. asher and the second bronze sleeve which carries the third speed wheel The two sleeves are locked together by the driving washer Now position the third gear over its sleeve Place the spring and plunger into the hole in the main shaft and slide the splined washer Depress the plunger with piece of wire through the hole in the third speed and slide the splined washer over the plunger Then turn the washer for the plunger to engage with a groove the washer The gear are now assembled on the main shaft 102 TRANSMISSION CASE 4 SPEED MO On DWF Q N 12 13 14 15 Case transmission Ags y extension rear Bushing rear extension Seal o l rear extension Bushing speedometer pinion Ass y breather Gasket rear extension Washer lock Washer lain Bolt Bolt rubber Bracket spring return Spring return Ass y suck oil level dip to fix rear extension Ass y plug drain Cover front transmission case Gasket front cover 103 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Stud Washer lock Nut Bolt Bolt Washer lock Nut Ass y pinion speedometer 18T to fix front cover to fix transmission case Ass y p n on speedometer 15T Ass y sleeve speedometer pinion R ng O speedometer pinion Retainer O ring R ng O pimon sleeve Plug speedometer pinion Screw set Washer lock Gasket cover transmission case Bolt Washer lock to reverse shaft
71. brake pedal SPACER piston A S PISTON brake master ASS Y VALVE CUP piston secondary ur E NUT 5 4 WASHER SPRING COVER d SS Y ROD push q valve SEAT CUP p ston valve BOLT Do primary RING snap BUSHING pedal Y PIN fulcrum fulcrum pIN SLEEVE pedal shaft clevis brake master cyl ASS Y PEDAL brake COVER pedal Fig 13 Brake Master Cylinder Bleeding the Hydraulic System Bleeding 1s necessary any a portion of the hydraulic system has been disconnected or 1f the level of the brake fluid has been allowed to fall so low that 170 Y 37 4 2 25 Susem Surre g MHAHSVA 099 M2IIS N 10101 4 88 Sut ernsul 7 2 M2IIS 2 2 s epoiq ES LAN WI AOD 5 ed 1 ALTERNATOR MITSUBISHI FIG 3104 841339 ste M i gt H 3 o 8 A L r T A bi 3 ALTERNATOR Alternator Mitsubishi Denki Co Model AC300 12AIR Nominal output 12V 300W Constant Successive Pole side ground Constant revolution 2 900 r p m No load minimum revolution 1 000 r p m down 14V normal temp Output current 2
72. ce Insert the spider in the yoke and tap the bearing 1n position with a foot nosed drift smaller in diameter than the hole in the yoke It 1s essential that the bearing races are a light drive fit in the yoke trun nions Repeat this operation for the other bearings The spider journal shoulder should be coated with shellac prior to fitting the re taimers to ensure a good seal If the joint appears to bind tap lightly with a wooden mallet which will relive any pressure of the bearings on the end of the journals 1 advisable to renew cork washers and washer retainers on speeder journals using a tublar drift Replacing the Shaft Assembling Smear the propeller shaft splines with oil and slide the splines into mesh with those of transmission main shaft Wipe the rear companion flange and flange yoke faces clean to ensure that the pilot flange registers properly and the Joint faces bed evenly all around and securely lock them in position It is advisable to use new lock n position t 18 advisable to use new lock washers 128 REAR AXLE SPACER oil seal rear axle PLUG taper SEAL oil rear axle shatt COLLER bearing rear axle bearing BEARING rear axle S EAL grease rear axle bea 43010 10600 COMP CASE rear axle 43010 10800 COMP CASE rear axle STUD gear carrier ASS Y PLUG dran ASS Y BREATHER 26 ING C x 8 ASS CARRIER gear WASHER H NUT REA
73. d Check to see if there 1s any warp on the joint surfaces of the cap and body and after disassembling 1s over renew the gasket to keep a r t ghteness Reassembling amp Installing Employ standard springs for the various uses stated before Install valves precisely for close contact with their respective seats In screwing in of upper and lower bodies and diaphragm fit them together according to the marks whcih were put before the disassembling and align one screwing hole to mate and then screw in at the position where the diaphragm 13 fully pulled down with the rocker arm pushed towards the side of the body by and pressure Do not screw n tight one by one since t causes warping Instead clamp all the screws round loosely and uniformly Then tighten them diagonally and lastly re tighten all of them in order to make sure As a general rule gaskets should be replaced by new ones Installation on the engine 1s done in the reverse order to that for disassembly Be sure to set the rocker arm so that 1t 1s contacting the eccentric of camshaft properly not the rear side or to one side Replace the gasket between the cylinder block and pump with a new standard one Checking Function When repairs of the pump s over or before 15 installed on the engine make a check to see When a vacuum gauge 1s connected to the pump inlet port and the pump 1s mounted on a tester the rocker arm 15 activated by the eccentr
74. d the throttle valve can be exactly maintained often the engine has started firing 2 Choke control link 43 Connecting rod Choke wire blacket Throttle wire Starting con rod Auxiliary lever Starting throttle lever Spring 8 Throttle adjusting screw Con rod Throttle wire clamp Throttle lever Scale Idle adjust screw Fig POWER CARBURETTING FUNCTION Main Carburetting System Same as the normal carburetung function the fuel flowing out of the passage at the bottom of the float chamber passes through the secondary main jet and be come minute drops mixing with the air coming from the main air bleed and 15 blown into the venturi through the main nozzle x Fig 6 Carburetor Model Nikki 2D 30C When the throttle valve of the normal carburetor 15 widely opened and the engine produces high power the throttle valve of the power carburetor begins to open by the sunchronized linkage However at the top of the power carburetor throttle valve 1s an auxiliary valve which 1s not open at a slow speed with a heavy load due to the load of the 52 counter weight connected to the valve shaft even when the throttle valve 15 open When the engine change to still higher revolutions the auxiliary valve open against the loat of the counter weight and the power carburetor Starts operation for high power When the normal carburetor throttle valve is in a full open the po
75. de 1f 1t has left hand steering Operated the rear wheels by mechanical expanders attached to rear wheel cylinder bodies FRONT BRAKE The front brakes are constructed by the two leading system with each two wheel cylinder The shoes are allowed to slide and centralize automatically during the actual braking operation which distributes the braking force strongly over the lining area ensuring high efficiency the brake disc caused by adjuster housing against the fric tion of the brake linings of front and rear shoes and even lining wear 159 LNOYS 5 CH T 1939 259 YAGNITAD A SSV og 12 41 sous anaes nus Suuds u3N1y 133 afer 9 Suuds 1 25 0 38 1ds werden gna su N 3 oyr apes 1 5 1814 134 09 M s p lq dv 001301 299 2 oou ODINOL 30 48 1 2 OND Wa 2 73 4 Bunde dno 8 3 2735 ODIO ioo e c 2 3 ws i m 9 19P9914 MANOS VT 100214 sip 234 ysiq x m 4 uojstd 999 410 S 001301 dowid oNIMdS
76. djust ignition taming correctly By utrlizing a power timing light the function of the governor can be checked together with the ignition timing illumination of carnk pulley will enable to in spect the conditions of running and advancing of the timing B T D C 20 8 Inspection of fuel pump and gasoline strainer 9 Adjust the slow setting of carburetor 65 10 Checking operation of generator Check the generating condition and functioning of the cut out relay by means of indications of the ammeter 11 Adju ment of slack n fan belt 12 Adjustment of valve tappet clearance 13 Road test While driving in 3rd speed at about 25 km hr suddenly step on the accelerator If only a slight knocking results the ignition timing 15 correct Slow speed adjustment 1s made so that the speed 15 about 15 km hr when driving in 3rd speed Diagnosing of Engine by means of Vacuum Gauge and Combustion Tester In diagnosing the engine the condition of each E cylinder can be assumed by measuring its com pression For employment of a vacuum gauge connect t to the engine intake manifold and refer to Fig 2 The use of a master motor tester as shown m Fig 216 convenient When a combustion tester 1s used install a special intake pick up n the exhaust tube and after the engine has been started analyze by means of a special gauge the combustion gas which flows through the connecting hose into th
77. e and fixes the armature making it generates 3 phase alternate current and recti fies all waves with the silicon diode each three that are built within and takes out as direct current Fig 1 1 Secttonal View of Dynamo Rotor ass y Diode set Brush cover Pulley with fan Front cover 9 Bear ng cover 8 Starter armature Brush holder 2 Diode Rear cover Brush The sealed ball bearings are used to support the rotor Clearance between the brush and brush holder 1s also made SO as to prevent it from dust Thus the AC generator will increase milage without maintenance Each 3 diodes are pressed n the rear cover and the diode base respectively Field core _ Field segment E Field coil Shaft T Fig 1 1 Sectional View of Rotor 176 s The clip ring pressed n the shaft 15 soldered at both ends of the field coil to pass magnetic current The pole of rotor makes out the magnetic circuit as shown n Fig 1 3 and all the poles are magnetized by doughnut Field coil Fig 1 3 Magnetic Circuit Fig 1 4 Connection within Dynamo The armature 1s of a three phase Y connection type and the silicon diode fies all waves It pulls out the neutral point and adds voltage having conducted 3 phase half wave recufication in the circuit of relay and controls the voltage coil of the pilot lamp relay Lx eg
78. e tester and judge the combustion condition ac cording to the mixture ratio of fuel and ar When measurement 18 to be made rainyor cold weather use an auxiliary condenser between the pick up and the meter otherwise the excessive moisture in the exhaust gas will damage the func tioning of the meter if permitted to enter it Fig 2 Motor Master Tester Available for 4 6 and 8 Engine When a tester 15 to be used make adjustments according to the following table Conditions Without load Suitable Weight Ratio of Mixture Low Speed Running 600 m 70 2 High Speed Running 85 5 2 000 m 2 66 Engine Trouble Shooting Fig 3 1s intended to be of assistance in the systematic analysis and 1sola of symptoms of engine troubles so that the defective points may be accurately traced and economically repaired 1 Normal condition Settles between 18 20 in 2 Normal condition When indicator fluctuates between a range of 0 251n as engine 18 raced rings and valves are in good conditions 3 Even if indicator settles if reading 18 low rings or oil are in faulty condition 4 When above 3 condition exists indicator will swing to 0 in if engine is raced 5 When indicator sometimes drops by 4 n or so valve sticking exists 67 6 When indicator drops by several inches at certain time valves are burnt 7
79. e dismantled easily by removing the two stud nuts mounting the starter on the engine The two stay bolts on the starter rear cover front end when mounted on the engine are removed After removing the band cover the brushes lead wires removed By properly protecting and holding the starter body the armature shaft is pulled out The armature and the front cover are taken out together To remove the pinion group from the armature shaft the cotter pin on the end of the shaft 15 pulled out and by removing the pinion nut the pinion group 15 removed Inspecting and Repairing Parts are YThe same procedure as that for the generator parts 1s followed the parts be ing cleaned and inspected after which determinations are made as to whether they can be reused or if repairs or replacements are necessary 197 1 2 3 4 5 The pinion 18 inspected for defects and if the tooth face 16 worn or the tooth edge s damaged the pimion should be replaced Worn or broken teeth will not only make the gear mesh poorly but will hasten the wear on the opposing gear and also poorly meshing gears will cause bending in the armature shaft For this last reason care should be taken when inspecting to also check the flywheel and take remedial measures 1f the ring gear is found worn or damaged When the pinion 18 found defective replaced the enure pinion group When inspecting the armature check the armature to core gap s
80. e filler cap 1f the temperature of the coolant 1s above boiling point or if the engine is running Topping up should only be required occasionally to re place water lost through the overflow pipe Top up when the engine 15 cold and if possible use clean soft water fF 3 por Vm MASS E 4 b z j S Fig 1 Radiator to within 1 2 of the bottom of the filler plug well Overfilling when the engine 1s cold may cause water to flow through the overflow pipe The capacity of the system 1s approximately 5 2 litres 54 m Thermostat In order to ensure maximum efficiency it 15 essential to keep the engine ope rating temperatures within certain limits To assist this bellows type thermostat 15 fitted being located in the water outlet at the front of the cylinder head The de vice consists of metallic bellows filled with a volatile liquied which controls a mushroom valve When the engine 1s cold this valve is closed and on starting the engine the flow of water to the radiator is temporarily restricted Due to this the temperature of the water in the cylinder head and cylinder jackets will quickly rise thus ensuring rapid warming up The heat so generated will gradually expand the bellows so opening the valve and ultimatelly permitting a full flow of water to the radiator The thermostat itself 1s detachable therefore should the occasion arise it can be removed from its housing and the ho
81. e mixture gas the acceleting pump opens its power valve from where the fuel also flows into the main system The power valve begins to operate when the throttle valve opens 48 from full closed position Slow Speed System Passing through the main jet the fuel passage separate from main line and flows through the slow jet slow air bleed first slow economizer slow air bleed second and inject from the by pass holes and idle holes Accelerating System Mechanical accelerating pump synchronized with the throttle valve 1s adapted When throttle valve 1s open the piston rod 1s pushed up with the linkage which pushed up the piston through the dumper spring When the piston 15 comming down the inlet check valve closes the out let check valve opens and the fuel within the pump 18 blown out from the pump jet by the compressed dumper spring and hits against the side wall of the small venturi to be minute drops compensating trancient sparseness of the fuel A jetting amount of the fuel can be varied with the two holes provided on the pump arm that 1s the inserting positions of the connecting Starting System The choke valve is provided with the spring and installed eccentrically on the normal carburetting device and synchronized with the throttle valve When the choke 15 fully closed the throttle valve opens about 14 from full close This 18 the best condition to start operation The synchronization of the choke valve an
82. e of the radiator block Both taps must be opened to drain the sys tem and the must be on level ground while draining The drain taps should be tested at frequent Intervals by inserting a piece of wire to ensure that they are cleare This should be done immediately the taps are opened so that any obstruction freed by the wire may be flushed out by the water The dra n ng should be carried out when the engine 1s hot When completely drained the engine should be run for a timed minute to ensure that all water has been cleaned from the system A suitable notice should be then affixed to the radiator indicating that the water has been drained Flushing the Radiator To ensure efficient circulation of the coolant and to reduce the formation of scale and sediment in the radiator the system should be periodically flushed with clear running water preferably before putting anti freeze in the winter and again when taking it out in the spring The water should be allowed to run through until it comes out clear from the drain taps At intervals a stiff prece of wire should be inserted into the taps during draining to ensure that they are not becoming clogged with sediment This method of radiator flushing may serve well but in cases where the fur ring up 1s excessive the operator will find it more efficient practice to remove the radiator completely and flush n the reverse way to the flow turn the radiator up side down and let t
83. e transmission complete from the engine Once the transmission unit is free a turn at a time by diagonal selection until the spring pressing 15 relived Then remove the screws completely and lift the clutch assembly away from the flywheel Finally remove the driven plate assembly The release levers are correctly set on assembly interference with this setting unless new parts have to be fitted will throw the pressure plate out causing judder Dismantling Assembling amp Gauging By using service tool the clutch can be quickly dismantled reassembled and adjusted to a high degree of accuracy The tool comprises the following parts base plate centre pillar spacing washers distance pieces hight finger actuating mechanism setscrews speed brace and metal box As this tool 1s universal a chart indicating the paticular parts to be used for paticular types of clutch will be found on the inside of the lid of the box 71 Z 1813 l Bu S 3 5 e 8 1 48 11889 4 00901 6020 ON 1240 00901 0010 1484 Aiquz sse YDIATD 216 4 211099214 q mi 420 p 1nN M144 1 A uoiuuna J 8 qon sinesatg Ce 12402 12 1104 243 2 72 Dismantling Place the clutch cover assembly on the three spring so
84. ed as in the previous paragraph inspect the pinion height again Unless any thing wrong 1s found loosen the pinion nut take off the flange insert the new 01 seal in the rear of the carrier and formerly fix the flange washer and pinion nut The nut should be tightened up at the standard torque In case the cotter pin hole fitted the adjustment should be made not by tightening the nut but by filling the washer C Mounting the Differential Gear Ass y in Carrier 1 2 Mount the complete unit of differential gear in the carrier and fix the bearing cap There is a engrayed mark on the side of cap which should be fitted with mark on the leg of bearing housing when mounting It 1s important to note that the fixing part of the cap of each bearing housing is machinerly finished up The differential gear case 15 inserted by the bearing adjusting shim with the side bearing as explained in 3 of A and by housing the bearing housing of carrier the bearing must be given therregular preload The screwing torque of the fixing nut of the side bearing 18 at 35 40 ft and should be equally locked with fixing cotter pin So far only the differential unit 1s mounted and the drive gear 15 locked with the drive pinion therefore the following adjustment must be made to acquire the regular side bearing preload amp the gear back lash Adjustment of side bearmg preload amp back lash To give the right preload on the side beari
85. elow hae L 48052 10852 ARM ste ing gear yellow 2line ROLLER needle SPACER l needle roller RACE needle toller RLUG ball roller to fix arm a wASHER V plain otter Y 5 ASHER NUT f rocker SEAL WASHER ol ASS Y throse rocker shaft BEARING worm aheft BUSHING steenng to mount gear housin P housing 5 STUD housing NUT BOLT front 48020 10800 48020 10600 ASS Y GEAR worm with column SCREW GASKET rocker rockershaft shaft 11120 10460 PLUG drain COVER 11120 10490 PLUG drain rocker sheft 45011 10601 ASS Y HOUSING ateenng 48011 10801 ASS Y HOUSING steenng STUD housing front NUT 9 TS Yal BOLT long worm E BOL T short VASHER loc 48210 10600 SHIN worm bearing f 48211 10600 SHIM worm bearing uee one 48212 10600 SHIM worm beanng shaft cover to fix rocker 48213 10600 SHIM worm bearing WASHER gt to fix front cover BOLT Fig 3 STEERING GEAR 156 gear housing assembly should be removed from posinon Disassembly Supporting the housing on the suitable bench leaving the rocker shaft free Remove the rocker shaft cover after extracting the four setscrews Tapped out the rocker shaft using a soft metal drift A ball roller 1s situated within needle rollers fitted in the ball plug of the shaft and care should be exercised that the rollers do not fall out t a ball rolle
86. ement of pinion height Besides the condi of defacement the carrier the pinion bearing must be taken into consideration though it will be explained in detail later B Fixing and adjustment of Drive Pinion 1 Drive pinion rear bearing outer race should be mounted in the carrier m this case after inserting the properly selected adjusting shim as pre viously mentioned between the carrier and bearing race mount the outer race by the special tool of drive pinion front rear bearing outer race re placer For adjustment of previously mentioned pinion height the shim at the rear side of this outer race 1s increased or decreased and the race also must be taken off each time for this adjustment therefore the tools must be handled properly to avoid such a situation as to make the bearing hole of carrier m on oval Referring to Fig 8 for handling method of tool set the adaptor ring on the corn 7 to guide the body of tool at the small hole of carrier put the rear outer race on the corn 8 as the bearing surfaces inside at the tip end of screw and put the split adaptor 142 2 3 4 inside race At the same time supporting it by the bar twist up the corn 7 till the adaptor and race come to the setted position then screw up the wing the 2 so as the race be housed properly at the setted pos tion Mount the front bearing outer race in the carrier For mounting the front outer race take off at first
87. emove the split pins flat washers and spring washers from each end of the shaft Slide the rockers brackets and springs from the shaft Unscrew the plug from the end of the shaft and clean out the oil way The two end rockers may be dismantled without the whole rocker assembly being drawn out This may be achived by turning the engine by hand until No 1 push rod reacher its lowest position Unlock the tappet adjusting screw and screw back as far as it will go Withdraw the split pin flat and spring washers and slide the rocker off the shaft Sometimes the valve spring will have to be slightly compressed by levering a screwdriver under No 2 rocker thus allowing the end rocker to slide off the shaft easily Repeat the procedure for No 8 rocker Reassembling the Rocker On reassembly tighten the pedestal bracket securing nuts a little at a time working diagonally from nut to nut left nut of 1 pedestal bracket right nut of No 2 left of No 3 and so on returning from the left nut of No 4 bracket and repeating the process until they are all tight If the rocker assembly has been completely stripped down and rebushed the oil holes will have to be redrilled and the bushes reamed down to size before assembly on the shaft The rockers and spring must be replaced their original position on the ends of the shaft Remember to replace the rocker shaft locating screw and lock plate Replace the spring and flat washers with the
88. er one turn reading the ammeter If there 15 short circuit on the coil swings of the ammeter abruptly 1ncrease and if there 15 no trouble there will be no change 184 Inspection of Brush Wipe with clean cloth when oil or dust 1s on the contact surface of the brush and slip ring Same as 1n case of DC generator replace the brush when wear of reached to the wear limit o 3 185 REGULATOR 1 Constution and operation 1 Construction Fig 4 1 2 Operanon of Constant Voltage Relay gt When the ignition switch 1s on carrent from the battery passes 8 through the dynamo terminal field m contact points P and the dynamo 1s magnetized While it also frows the regulator E terminal contact points P5 and the lamp flares ation coil To Fig 4 2 When engine starts and the dynamo 15 driven three phase alternate current generates on the stator coil passing through the three phase all wave rectifier diode and changes to direct current between the terminal A E for charging At the terminal voltage half of that between generates and passes through the circuit N terminal VC coil E terminal and with action of the VC coil the movable contact point Ps leaves from P and makes contact with Pg so that th damp 1s off and it passes through the circuit E terminal contact points Ps Pg resistance 2 coil and A termina
89. er pound hammer I Mount the side bearing in the differential case Press in the both side of the bearing by using the drift 15 important m this case to assemble by putting the side bearing adjusting shim to give the bearing a proper preload in fixing with the carrier 140 ASSEMBLING amp ADJUSTMENT BY GEAR CARRIER ASS Y It 1s to decide the assembling amp adjustment of gear which is very important n an rear axle ass y and should be carried in accordance with the exact sample shown by the manufacturer The construction and mechanism must well be comprehended referring to Fig 19 amp 21 and the adjustment amp repairing exactly according to the condition of practical use based on the adjustment by exact calculation A The Preparation for Mounting the Drive Pinion in the Gear Carrier 1 If the drive gear drive pinion and bearing are to the reused as they are as a result of disassembling and inspection they should be assembled n on order of disassembling at the previous condition of adjusting shim In case any item should be replaced or required to reuse even if any 18 worn out prepare the various shim as mentioned later because the po sition of drive pinion to be fixed with carrier must be adjusted by the ad justing shim between the carrier and pinion rear bearing outer race 2 There are few numbers with 0 amp or besides set number marked by an electric pen on the tip head surface of dr
90. er thrust counter rear 4 2T Gear ma n drive Bear ng ma n drive gear Spacer bearing 0 6T Ring snap main drive gear 1 6T Ring snap main drive gear 1 65 Ring snap main drive gear 1 74T Ring snap main drive gear 1 77T Shaft main Hub synchronizer Spring synchronizer hub 25 2423 22 18 19 20 21 22 23 24 25 26 27 28 29 32 33 34 35 36 37 38 39 40 41 2021 16 Ball amp ynchromizer hub Gear ma nshaft Ring baulk 2nd speed Washer thrust main shaft rear Gear 2nd speed Bushing 2nd speed gear Washer thrust main shaft Bushing 3rd speed gear Gear 3rd speed Washer thrust main shaft front 3 9T Washer thrust main shaft front 4 OT Washer thrust main shaft front 4 Peg locking Spring locking peg Hub synchro 3rd amp 4th speed Ring baulk 3rd amp 4th speed Sleeve synchro 3rd amp 4th speed Bearing main shaft Ass y reta ner main shaft bearing Peg locking Gear drive speedometer ST Gear drive speedometer 4T Piece distance main shaft Key woodruff Washer lock Nut main shaft Bearing main shaft pilot 105 Part 32264 26762 Adjust by 32264 6 26761 Pack the grease fNCS Li Smear on the lip of with CS 1 grease sufficiently fN Smear grease for sliding tace 106 Adjust by the part 3226 9 26760 End playu0 0 0 12 Dimension C Select end play as possible as small by par
91. eter of small end bush Standard CRANKSHAFT Clearance of bearing phery to cylinder block hole Material Clearance of bearing inner diameter and crank journal of main journal End play of crankshaft Crank pin diameter Standard Difference of crank pin diameter End play when flywheel was installed 144 0 03 mm Clevite F500 25 273 25 527 mm 0 995 0 005 n 1 8288 1 8352 mm 072 0 0725 n 51 346 mm 2 015 in 26 8 mm 1 055 1n 203 0 305 mm 008 0 012 17 450 17 462 mm 6870 0 6875 in 0 013 0 050 mm White metal Block side Clevit metal Cap side 0 0127 0 0508 mm 0 0005 0 0020 1n 50 183 50 825 mm 2 0005 2 001 n 0 051 0 076 mm 002 0 003 in l 47 640 47 652 mm 1 875 1 876 m Less than 0 012 mm 0 00048 Less than 0 05 mm 0 002 n The shell bearing are removable by hand The bearings are require 1n it is being only necessary to ensure that the housings are scrupu lously clean and dry and to place the bearings into position with the tangs located in their corresponding slots Always renew bearings if they are scored or dam aged in any way or following the regrinding of the crankshaft bearing surfaces In the latter case undersize bearings will be required and the kinds of sizes avai lable are 0 010 0 020 0 030 and 0 040 etc z
92. everse gear Release the lock washer then screw out Lift out the reverse gear shaft Fig 14 A Pull Out the Reverse Gear Shaft 91 T Removal of Drive Gear Shaft Fig 15 92 2 A IAS TEES tS xm 6 ARN 1 n n 14 B Pull Out the Reverse Gear Shaft Drive Shaft Tapped out the mam drive gear assembly in Fig Ma Fig 16 A Shaft Removal 93 Main Shaft Pull out the rear bearing and the speed gear sleeve by the bearing puller from the main shaft rear side 94 ja G n Reverse Gear A lug which 1s an integral part of the main casting locates the forward end of the reverse gear shaft To secure the shaft n position set pin 18 screwed through the lug locating n the shaft The set key 15 locked out side of the case Release the set pm then tap forward and remove the reverse gear shaft out the reverse gear Rear Oil Seal This oil seal 1s situated m the end of the rear bearing retainer and should not be dismantled unless suspected of leaking It is almost impossible to take off the seal without damage 1t consequently a new oil seal should be fitted if the old one has been removed This can be removed by using a punch and hammer Main Shaft Counter cluster gear n the case Insert the first gear to the main shaft together with second and third gear asse
93. f the jomt surfaces beforehand Removing the Timing Gear The timing cham 15 endless and it s necessary to remove both the crankshaft and camshaft gears together Before doing this notice the timing marks on both gears and their relationship to each other Draw off both the gears a little at a time first removing the crankshaftt gears reta n ng nut As the gears are withdrawn care must be taken not to lose the packing washers from behind the crankshaft gear Between the camshaft gear teeth 1s a r bber ring which acts as tensioner and ensures silent operation of the chain drive Examine the felt washer and renew it if 01 has been lost be seepage Refitting the Timing Gear Replacing the components of the timing gear is largely a reversal of the dis mantling process but special attention should be paid to the following points Fit the crankshaft and camshaft gears their respective shaftes Ensure the timing marks are opposite and in line 4 Turn the engine crankshaft until the keyway 15 at T D C and the camshaft with keyway in approximately the one o clock position 4 Place the gears into position ensuring that the keys are present n TE on the shafts Ensure that the timing marks on the gears are opposite to each other and line Drive the gears home The same number of packing washers taki from behind the crankshaft gear must be replaced unless a new crank or car
94. fter these screws are fully tightened 35 Ib ft 4 84 kg m Refit the release bearing and transmission case The weight avoid strain on the drive shaft and distortion of the driven plate assembly DESCRIPTION OF CLUTCH CONTROL The clutch 1s operated from a master cylinder by means of a suspended pedal A cylinder mounted on the clutch bell housing 1s coupled to the clutch operating shaft Fig 6 Components of the Master Cylinder D Push rod assembly Piston return spring Master cylinder rubber boots 2 Clutch master cylinder body ass y 8 Stopper ring 3 Let in valve release pin Piston secondary cup ring Ring Secondary cup Gasker Primary 9 Filler cap gasket Master cylinder piston d Cap Let n valve assembly 9 End plug gasket 6 Let in valve spring 9 End plug 40 Return spring seat When pressure to the clutch pedal 1s applied the piston of the master cylinder displaces the fluid 1n the cylinder and via a pipe line in turn moves the piston of the cylinder pushing against the lever of the clutch shaft The Master Cylinder The master cylinder consists of an alloy body with a polished finish bore and reservoir with cap The inner assembly 1s made up of the push rod ring stopper ring piston cups spring seat spring valve and valve spring The end of cylinder 15 protected by a rubber boot 78 Dismantling the Clutch Master Cylinder Disconnect the pressure pipe union f
95. ght Do s Air Type amp No Paper Filter 1 ea a T Diaphra phragm Showa Kyosan Fuel Tank Capacity of Fuel Tank 416 10 8 U S gallon Lubricating Method Forced Pressure Type Pump Type Trocoid Oil Filter Paper Filter Oil Pan Capacity U S gal 2 9 0 8 21 8 848 wn LUBRI CATION SYSTEM Water Cooling Closed Capacity of Cooling Water Type of Water Pump Centrifugal Type Bellet Type gt 4 COOLING SYSTEM 1 2 e 95 e GENERATOR ix 228 anas 00 Voltage amp Power 12 1 4 Engime Transmission Mechanism Engine Clutch Transmission DEVICE STARTER Single Dry Disc Hydraulic Operation ei 1 fact ng 2 Type Number of Plate Outdia x India x Thickness Clutch 200 130 3 5 lt Synchromeshed on 2nd 3rd amp 4th 4 forward reverse 410 UTY Operating Method Ist 3 945 2nd a 100 Length Outdia x India mm 1 237 x68 9x65 3 NS Type of Gear Hypoid f Final Gear Type of Numberof Gear Straight Bevel Pinion 2 5 Synchromeshed on 2nd Top amp 1 Reverse Transmission TRANSMITTING DEVICE et m 2 DIFF FINA GEAR GEAR 23 5
96. ght hand or left hand side of driver s seat 82 x Er ZTE TRANSMISSION 83 een CASE y NOISN3LX3 HV3H gt 3SVO NOISSINSNVYL 014 14 55 X AO 51013104 0101309 1991 CHHHSVA A SSV No 5 uolsu x 3jeus 880412 D Id 1709 1 e LSMSVO 1 5 MH4GHLV4Zug 19A02 A 3yeus 55042 1 3 1 3401 TIVAS TIO p 19402 3002 LON 5 YIOT 23814 1 X20 uOt8s1Uiqu 1 5 1018010181213 LON 30017 HHAOO 84 HV35 NOISSIN SNVHL 40 SLNSNOdWOO 9 913 312134391 0315421 HV HS 429 H3HSVA p 193 MOS l mq xi suwisip 39414 R 1210565 4 1 3unoo 1214102 20 nay YaHSVA vew 5 jjmpeos A33 4 85 Suus q winaq Usu 1 ASSY 4 04 ONTUdS 12012431 aioi iuo ijou ND uv35 1829 5 18 a g AnH utm p d
97. give the correct valve clearance Fig 8 Removing a Tappet k Piston and Connecting Rod Removal 25 Drain the cooling water from the engine and radiator Drain and remove the sump from the engine then disconnect and remove the oil strainer Take out the set screws and rock washers from the b g ends and withdraw the caps It will be noted that the caps are off set When used parts are replaced after dismantling it 1s essential they are fitted into their original positions To en sure correct refitting mark the caps and connecting rods on the sides to iden tify them together The piston and connecting rods must be with drawn up wards through the cylinder bores Release the connecting rod from the crankshaft and slowly push the piston and rod upwards through the cylinder bore 1 NOTE It may be necessary to remove the ring of carbon or lip from the top of the cylinder bore with a hand scraper to avoid risk of piston ring breakage ae Remove the assembly from the top of the cylinder block Check the crankpins for ovality with a pair of micro meter calipers and examine the bearing surface for scoring either defect will neces sitate the removal of the crankshaft for regrinding 28 CONNECTING ROD Distance between center of large end and small end Large end bearing Type Overall length Thickness Outer diameter Width of large end End play of large end Finishing dimension of inner diam
98. h Fig 5 Oil Pump 14 5 011 pump to cylinder block ASS Y SPINDLE driving 011 pump WASHER 5 lock to fix pump cover BOLT gt GEAR driven 29 11 pump 20 ASS Y SHAFT 011 pump z y 1 pump Washer 22 Bolt ASS Y STRAINER oil GASKET oil strainer to pump SCREW WASHER lock to fix strainer Fig 6 OIL PUMP 15 SERVICE OPERATIONS WITH POSITION 9 Removing Starting Nut and Pulley Remove the radiator Slacken the dynamo attachment bolts and remove the fan belt Bend back the tab on the starting dog nut locking washer Unscrew the starting dog nut by using Heavy duty Shock type spanner A few sharp blows an anti clockwise direction will slacken the nut Pull off the crankshaft pulley Removing the Timing C over The timing cover 15 secured by set screw bolts each having a shakeproof washer and a special plain washer Note that the special washer 1s of elongated shape and 1s fitted next to the timing cover flange The spring washers are immediately below the bolt heads Take out the set screw bolts remove the cover and its Joint washer Care should be taken not to damage the washer when breaking the joint If damage does occur fit a new washer cleaning of the faces o
99. haft to bushing clearance bending in shaft etc 1n the same manner as that for the generator and are corrected to the specified limits or the armature 1s replaced Special attention should be given to the clearance between the armature and the core to see that they are not contacting and corrosion found on the outside surface of the armature or the inner surface of the core should be removed by polishing and the surfaces painted with rust preven uve oil The armature 1s inspected and repaired n accordance with the procedures outlined for the generator Especially to 1mprove or correct the brush contacung condinon the brushes are reseated At the same ume the brush spring are checked and are corrected or replaced The insulation on the wires are carefully inspected and wires found with weak or damaged insulation should br replaced armature found with one part especially damaged by buring should be strictly tested by the 1nsulation test Assembling and Testi ng Starter Reassembling 1s performed by following the reverse procedure for disassembhng frictional parts are lubricated with mobile oil SAE 30 while the bearings are coated with a small amount of grease circuit in the Magnetic switch and causes the main circuit 55 in the magnetic circuit to close Releasing the starter switch opens the magnetic circuit which also opens Ss 1 Causes for magneuc switch failling to operate can be divided into electrical and mechan
100. he water flow n through the bottom hose connection and out of the top connection dWNd N31VA S 34 41231eq SW 103 run 00801 19012 x 5 00901 49012 3q ueg A ffnd 3 uej 103 qnH Buor N 102 HOOT IIM yeas 00801 16012 00901 16012 atma WATER PUMP After draining the water from the radiator remove the pump unit from the cylinder block by taking off the fan belt and releasing the setbolts with spring washers and hinge bolts to dynamo Removing the Pump Shaft Assembly Disconnect the fan blades pulley and cover The shaft and ball bearings 15 combined with one unit Put the pulley hub on the bench First press or knock the shaft end with a drift hard bar and draw out the pulley hub on the U type bench Take out the set pin from the slit which locked the shaft assembly to the pump body See Fig 1 Next turn the body upside down and press out the shaft assembly from the vane side on the U type bench Fig 4 The shaft and ball bearing assembly can be drewout from the body Thus take out the vane floating seal and seal which remained the pump body Reassembly P The reassembling of the pump 1 a reversal of the disassembly but a care should be taken to ensure
101. he work bench The gear arm should be with drawn from the shaft concerned using a suitable extractor The gear arm must not be hammered from its shaft 153 E Removing the Idler After the side and cross rods disconnected the idler can be detached from the body t is secured by two bolts the front suspenuon member Holding the idler body on the bench and take off rubber cover Unscrew the idler shaft out of the body Steering Gear Housing Removal Removing the horn ring assembly from the steering wheel unscrew the column lock then disconnect higher up the column Jacket from the housing First disconnect ball stud nut and draw out from the end of steering gear arm Unscrew the bolts secured to front suspension member Thus the steering 154 AOVNNIT ONINSSLS 9 3 doa ASSY 8 21461 da a H 7 apie H 55 Hu qe 301 el LAN poi apis m i LANDOS A SSV 1 137205 55 Ha 22001 apie LAADOS A SSV HT 21 LANDOS ASSY ssnp divv 12 R 199 3291 03 LAN LON opis l3320S A SSV ss218 371d dIN 45 por Ssnp TV3S 131102 NId LON
102. he yoke with a lead or copper hammer when the bearing will begin to emerge If difficulty 1s experienced use a small bar to tap the bearing from the inside taking care not to damage the race itself being careful not to lose any of the needles Repeat this operation the other bearing and the splined yoke can be removed from the spider The same procedure can be utilized to detach the other spider from yoke 127 EXAMINATION 8 CHECKING FOR WEAR When the propeller shaft has been in use for a long time the parts most likely to show signs of wear are the bearing races and the spider Journals The complete assembly should be renewed if looseness or stress marks are observed as no oversize journals or bearings are provided It 16 essential that bearing races are a light drive fit n the yoke trunions Any ovality in the trunion bearing holes indicates the fitting of new yokes The straightness of the shaft 15 determined by measuring the offcenter deflection of the shaft 1n rotation with dial gauge applied both ends If the deflection exceeds clearance limit Less than 0 4 mm correct or replace the shaft Reassembling See that the drilled holes in the journals are cleaned out and filled with oil Assemble the needle rollers the bearing races and fill with the oil Should diffi culty be experienced in assembly smear the walls of the races with petroleum jelly to retain the needle rollers 22 Nos 1n pla
103. ic of the camshaft revolving at 1000 rpm Then the gauge pressure should rise to higher than 400 mm of mercury column and even if operation 15 discontinued this condition should remain for more than 3 seconds When a gauge or tester 1s not available test in the following way Clost the inlet port and outlet port with finger tips Then after operating the rocker arm several times suddenly release the fingers The pump 15 good conditions 1f 3 to 5 seconds thence there can be heard strong inlet and outlet noise respectively The pump 1s mechanically fit for use when by connecting a hose to the inlet port t 15 able to draw up gasoline from a height of more than 0 5 m After installing the pump test its functions during operation 63 Connect the gasoline pipe on the inlet post side only Leave that on the outlet port side as 1t 1s and turn the engine 6 to 7 rotations by means of the crank handle and make sure that there 1s sure outflow of gasoline from the outlet port B Connect the gasoline pipe to the outlet port side and tighten all the piping joints Then turn the engine again several times to see if there 16 any leakage of air or gasoline from each connection ADJUSTMENT AND INSPECTION OF ENGINE The engine must always be operated in the best possible condition and for this purpose periodic inspection and adjustment must be maintained in a certain order while 1n use as well as after overhaul Order of
104. ical sources Causes for electrical troubles A Current failure in magnetic circuit When the starter switch 1n pressed and the current falls to pass through the magnetic circuit most of the trouble 1s due to broken soldered connec tion between the magnetic coil wire add the magnetic switch terminal and defective ground connection from the coil wire to the magnetic switch body Defective contact 1n circuit Ss When themagnetic circuit 18 satisfactory and Sg 18 closing but only a small current flowing due to high contact resistance and the opposite case of switch S1 opening but 5 remaines closed In either case the trouble lies 1n the faulty moving of the core or roughness of the contacting point surface Therefore polished the surface well then the operation will be come sausfactory 198 Causes for mechanical troubles T Failure to operate 1s caused in many cases by the guide shaft on the moving core of the magnetic switch main circuit 53 sucking against the cover hole Correction can be made 1n this case by loosening the cover screws 4 pieces and retightening them so that the shaft moves freely 2 Precaution In removing nuts from the magneuc switch main circuit terminals when 1 stalling or removing cables the lower nut of the double nuts should be kept n a tightened state while unscrewing the lower nut is loose the terminal bolt may turn together and ground the terminal to the c
105. iishaft has been fitted In this case the alignment of the gear faces and measuring the alignment with a feeler gauge To adjust the alignment it will be necessary to vary the number of pack ng washers 5 w i x a 16 4 d b s ER Fit the oil thrower behind the crankshaft gear so that 115 concave face it to wards the front of the car and check that the felt washer 1s position Valve Rocker Cover Removal Remove the air cleaner Unscrew the cap nuts securing the engine hfting brackets Remove the rocker cover and the cork Joint washer Removing the Rocker Assembly Drain the cooling system If anit freeze 13 use use a clean container for the fluid if it is to be used again It 1s necessary to drain the system and slacken the cylinder head nuts becaust four of the rocker shaft fixing nuts also secure the cylinder head If the cylinder head nuts are not slackened distonation may result and allow water to find way from the cooling system into the cylinders and pump Notice that under the right hand rear rocker stud nut 1s a special locking plate Completely unscrew the rocker shaft blacket nuts and remove the rocker assembly Complete with brackets and rockers Dismantling the Assembly To dismantle the rocker shaft assembly first remove the grub screw and locking plate from the rear rocker bracket uy RN B 17 R
106. il 1n the engine sump by means of the dip stick and top up if necessary If the warning light 15 still on after refilling the sump switch off and ascertain that the gauge strainer in the sump 1s clean and not choked with sludge sale that no air leakage exists at the strainer union on the suction side of the pump being defective remove the unit and rectify the fault Oil Release Valve The oil release valve should be ex amined If the engine bearings are worn the oil pressure will be reduced A complete bearing overhaul and the fitting of replace ment parts 1s the only remedy necess tating the removal of the engine from the classis Removing the By pass Filter Fw 2 04 Release Valve A new filter element should be fitted Seating every 15 000 km Spring The filter forms part of the main oil Screw Plug gallery of the engine To remove the filter Washer it 15 only necessary to unscrew the center bolt when the bowl can be removeed from 11 r GASKET oil filter body PLUG taper ASS Y SEAT element GASKET element seat BRACKET 011 m to SPRING caskET niter body top RING snap SPRING element setting gt O RING retainer RE TAINER element VALVE safely 70 ball 5 RING snap safety valve STUD to fix filter see 2 cylinder block section Fig 3 OIL FILTER
107. ine so as not to cause the oil leaks When t 1s mounted on the vehicle feed the gear oil immediately The oil of the designated hypoid gear oil 90 should be feed Feed the oil ull t comes up to the down side of the feeding hole 151 5SNIRM331S 11948 01 q 3LA8 diis ONIY 14818 uru xu MAUDS 1 91906 6 xy A 3HOS 1 01901 6 3 8 uiou DNIHSn uzoq LOVLNO2 Sutusnq SSV TAAHM ASSY 01511 02 8 8 I33HM ASSY 701901 00 8 5 o 3 18 otto T 9 bi 252 Gos eem ONIY ASSY 114 9 125 IS90I Z 8P Surrusou qya 01901 OZHBF 01901 22585 R lt azerd NOIHS n2 00511 22 8 00901 2298 55 00611 02 8 55 00901 02 85 8 55 00901 152 5 TEERING STEERING Type of gear Cam and Lever Gear Rano 14 8 1 Adjustment Adjusting screw and nut Diameter of steering wheel 405 mm Turning circle 5 000 mm The steering tube revolves a cam which engages 1n tur
108. ion by loosing the compresso nut or the yack screw down Set up the shock absorber by the double nut of upper side and the bolts of lower side METHOD C Replacing Order of Upper Link 1 2 3 4 3 6 7 8 9 Prepare to remove front wheel Jack up and support front suspension lower hnk Remove wheel Disconnect upper ball joint and rebound bumper from upper link Detach upper link and spindle from suspension member Disassemble upper link spindle from upper link by unscrewing link bushings Reassemble upper link spindle and bushings to upper link of replacing re inforced part carefully following undermentioned instruction Reassemble whole parts back again to complete unit Check and adjust front wheel alignment Instruction 1 2 3 4 5 Don t hold spindle ught against link when screwing 1n bushings Because the pitch of threads of spindle inner and outer screw of bushing and link sleeve are all same Apply ample grease on to the inner screw of bushing and spindle Pay careful attension not to damage the ghread when screwing in the bushing Tighten up bushing against link sleeve by the torque of 19 20 kg m 137 145 ft lbs Friction resistance torque between spindle and bushing should be within 0 5 kg m 3 6 ft lbs when assembled Adjust the relative position of spindle and link as shown in the figure by turning 120 the spindle 6 Align the direction of grease nipples
109. ion from the rear side of the carrier Put the rear side of the carrier downward and set the tool under it then supporting the end surface of drive pinion press in the bearing by using the drift The operation would be easier by using the drive pinion front bearing inner race inserter as shown n Tighten up the pinion nut by turning t slowly with hands with the use of preload gauge as Fig 15 to the degree that support the bearing preload at 7 10 kg cm When the drive pinion 1s mounted in the previously mentigned condition it 18 necessary to measure the height of rear surface of the p n on whether is higher or lower than the standard Make use of the special drive pinion arrangement gauge The standard height of the pinion 1s 51 0 mm from the bottom of the side bearing fixed with the carrier 143 m We gt y The fixing position can be measured by setting an arc of circle on both sides of arrangement gauge at the position of side bearing and insert the thickness gauge the clearance between the tip of gauge bar and the pinion such as to push in by scraping of the carrier in diagonal otherwise preload and the pinion height of the bearing would come out of order and tend to cause an unexpected trouble in future 3 97 5 The formal adjustment of the drive pinion bearing and preload After the fixing position of drive pinion 15 decided as mentioned in the pre vious
110. ive pinion Fig 13 Adjustment of Height 141 They show the manufacturing error a figure at the unit of 0 001 in 0 025 mm to decide the thickness of adjusting shim for adjustment of standard position The standard pinion height is 51 0 mm from axle center as shown n Fig 13817 If the figure 1s difficult to discriminate due to the corrosion scrape off the oxidize substance on the surface by a some what narrow grind stone with care not to scrape off even the mark Adjust to the direction of on arrow in accordance with the Pinion mark 3 The thickness of drive pinion adjusting shim are arranged as following The use of the adjusting shim will be explained the following paragraph of adjustment Supposing the drive gear and the drive pinion were re placed as a new set and the height of drive pinion previously used was right prepare the shim of thickness which equals to the difference of figures on the new and this Deduct the previously used shim im case it is plus increase in case of minus and have the general idea of required thickness of the shim for assembling to prepare 1 Drive pinion adjusting 38153 25660 0 75 mm shim 0 030 m 38154 25660 0 25mm 0 010 38155 25660 0 125 mm 0 005 in 0 075 mm 0 003 in 38156 25660 It 18 convenient to inspect the condition before disassembling in a way as mentioned later in the measur
111. keeping air tight 5 7 6 Plug Packing 6 Wire Bracket Gasket O Strainer screen 0 Nut G Check valve Glass Bolt Washer Pipe terminal Fig 4 Fuel Strainer Assembly 59 FUEL PUMP o C KS CN gt Cap screw washer Fuel pump cap Fuel pump cap gasket Angle connector Body set screw Spring washer Rocker arm side spacer Rocker Valve packing Fuel pump valve ass y Valve retainer ass y Lower body Valve screw gasket cap Diaphragm Fuel pump shield Diaphragm spring Lower body gasket cap Hand primer lever rod Lower body gasket Lower body gasket sheet Hand primer lever primer chip Hand primer pin Lock washer Nut Rocker arm side spacer Rocker arm Spacer 42 arm ass y ocker arm p n Rocker arm s de spacer Joint washer Fig 5 COMPONENT OF FUEL PUMP 60 FUEL PUMP Type Diaphragm pump Method driven Driven by camshaft Diaphragm spring Free legnth 36 5 0 1 mm Length in use and tension 18 mm 1 6 0 1 kg Rocker arm spring Free length 30 mm Valve spring Free length 9 5 mm Thickness of valve 1 6 mm Performance Max quantity discharged 1300 cu cm per minute at 1000 m of cam 500 mm 1n suction height Max pressure discharged 110 130 mm in mercury column Max degree of suction vacuum More than 400 mm 1n mercury colum
112. l then the coil animated and 186 prepares to vibrate the movable contact point 2 of the constant voltage relay When the dynamo revolution gets higher the contact point Pe separates from P with electric magnetism of the coil and the field current from the circuit of the dynamo E terminal field coil terminal and resistance R and when the contact point Pa contacts with the current flows through the circuit of dynamo E terminal field coil F terminal contact points This 18 repeated according to vibration of the Fig 4 3 contact point P and the dynamo terminal voltage 18 kept evenly and continues charging al 2 ek 5 5 2 5 m E en 94 28 E d i L UO DR Dynamo Regulator 5 Dynamo Regulafori o Fig 4 4 4 5 When the dynamo revoluuon gets still higher the movable piece 1s drawn and the movable contact point P sucks to so that current almost does not flow the field and the generated voltage of dynamo goes down As the result the cont act point separates from Ps and the current from through the dynamo E terminal field coil terminal resistance and voltage goes up again At such a high speed with open and close of the contact points and P the dynamo terminal voltage 1s always kept evenly The operation of this time 15 ca
113. l out the front bearing outer race from the gear carrier set the tool body 3 as illustrated in Fig 7 pull it out with adapter B in the way of 1 Tommy 2 Wing nut 3 Tool body 4 Cone Adaptor for Front Bearing Outer Race Drive Pinion Front and Rear Bearing Outer Race Replacer Fig 8 Inner Race Replacer 135 FIG 9 SECTION OF DIFFERENTIAL CASE Tightening torque of nut drive pinion 1400 1680 kg en 100 120 ft lbs Adjust shims of adjusting drive pinion bearing without ear drive hypoid 8 seal oil Pre load for pinion bearing 7 10 kg Tightening torque nut diff brg 490 560 kg ca 35 40 ft lbs Gear ratio Transmission 3 gear Change 4 375 35 8 4 gear change 4 111 37 9 Optional 4 625 37 8 136 10 Fig 137 REAR AXLE 00 10 8128 mo 72 nn p note 00150 01685 00190 92786 Wc ep gp 10110 67991 962 08186 10190 mum 10190 9598 100190 19186 oo1vo estee 8 EN A rot v0 toree M 1965 727 00190 05786 199 001 0 0018 00190 60186 00190 20186 7 9 m fe 9 8 gt 00190 9298 x 09952 85785 50190 1298 REAR AXLE Fig 138 INSPECTION amp REPAIRING O
114. ld be ejected vigorounsly from the tip of the pipe once every two rotations of the crankshaft To test the function of the pump alone operation of the hand primer and checking the fuel ejection 1s enough Removal from engine Fuel pump can be easily removed by disconnecting the inlet and outlet unions and loosening the 2 attachment nuts ut Inspection prior to disassembling ai Prior to disassembling of the removed pump measure the distance between the rocker arm and flange of the lower body by means of a scale and see if the rocker arm rocker link and pins are worn Method of disassembling First wipe dirt off the outer surface of the pump and put marks both the upper and lower bodies to make their reassembling easy It 1s easily separated into two when the five screws around the upper body are loosened Take great care not to damage the diaphragm during this disassembly Checking amp Repaires of Parts Wash the disassembled parts well in gasoline then inspect them Replace the diaphragm af any damage impregnation by gasoline Replace a valve assembly if any wear or faulty operation 1s detected Even if repairs are unavoidably required the limit for repairs of warp or wear of the valve 15 0 001 n When the surface of the valve seat or valve is found irregular remove the valve seat of the outlet and dress the surface with a fine oilstone In case of irregularity of the seat surface of the inlet valve which cannot
115. linder head the valves and their seats should be examined for signs of pitting or burnt patches and distortion If these conditions are present the valve seats must be recut before attempt ing to grind in the valves whilst distorted valve heads should be trued or the valve renewed Only the minimum amount of metal should be removed in the turning process When grinding a valve onto its sealing the valve face should be smeared light ly with grinding paste and then lapped with a suction type grinding tool The valve must be ground to its seat with a semi rotary motiron A light coil spring interposed between the valve head and the port will assist considerably when lifting the valve in order to rotate the face to a different position This should be done frequently to spread the grinding compound evenly It 15 necessary to continue the grinding process until an even matt surface 15 produced on the seating and the valve face On completion the valve seats and ports should be throughly cleaned with gasoline soaked rag and dried and the subjected to a compressed air blast The valves should be washed in gasoline and all traces of grinding compound removed VALVES Valve head diameter Intake valve 34 798 34 935 mm 1 370 1 375 n Exhaust valve 30 023 30 150 mm 1 182 1 187 in Valve seat width 1 63x0 015 mm Valve stem outer diameter both intake and ex 8 6805 8 6932 mm 0 341 3 4 0 342 1 4 589 Overall leng
116. lled a high speed operation and the adjust voltage 1s colled a secondary voltage When the dynamo revolution goes down and charging capacity reduces the voltage between the terminals N E also lowers As the result the electric magneusm of VC coil weakens and the contact point Ps fixed with the movable piece can not con tinue contact with Pg and changes to P4 side and lights the lamp indicating non generation When the ignition switch is turned off to stop the engine the lamp goes out and the current to the field coil 1s suspended 187 3 Operation of Pilot Lamp Relay As shown Fig 4 2 this is made up with the contact points P and P6 The contact point 1s on the movable side and usually makes contact with P Between the terminals N E the movable piece 1s drawn when voltage half of the battery 1s added and Ps fixed to the movable piece separates from P4 and makes contact to Pg When the voltage between E terminals 15 conspicuously reducted Ps makes contact with P4 again The voltage between N E terminals necessary for to make contact with P 15 Put off voltage and that Ps changes from Pg to P is Put on voltage 2 Adjustment 1 Check Adjust Value of Constant Voltage Relay Connect the battery almost charged in full as shown and make the dynamo OT 8 9 2 revolution with 4 000 rpm d 3 When the voltage of this time 18 w 14 15V t is all right Fas 1
117. m the tank unit 15 grounded the wiring between the dash unit and tank unit is defective Therefore rewiring or repairing 18 required If when indicator fials to swing but sparking 1s observed when the wiring connecting the battery with the terminal on the dash unit 18 disconnected at the dash unit end and grounded it proves the wiring is satisfactory and the trouble 18 1n the dash unit itself If sparking does not occur the wiring which 18 thus 1ndicated to be out of order should be repaired or replaced Incorrect readings of the indicator probably means that the height of the float of the tank unit 1s 1n error In this case adjust the height of the float by bending the rod Troubles with the unit are difficult to repair so it should be replaced by a new unit In checking the tank unit be sure to insert fuel gauge in the circuit between the battery and the unit FUEL STRAINER Instruction for Disassembly To remove the bowl from the body loosen the strainer nut and remove the wire to a side Take off the bolt nut and washer from the wire and remove bowl gasket and screen The stra ner body 1s made of aluminum alloy Take good care not to break threads of each connection Pay attention not to tighten the strainer nut so excessively that the gasket and bowl are broken When installing the strainer assembly the strainer bracket should be cleaned sufficiently Dust and dirt on the bracket surface prevent plug from
118. mbly from rear hole and fit the first and reverse fork shifter over the first gear Fit the shift fork of the second and third gears assembly on the hub of synchro nizer Depress the main shaft bearing to the end of the case Change the dummy shaft to counter gear with the said shaft 95 DA Teq 9819491 9 381 22 1 EN s Sut 29942 5 x 381 4949 aBueyo x em 320 Z t 8 pa puz N CS 89012 1 MZHSVA S NZ Q Pag Nid NTM 9819A9 3 381 Pag puz 20 3yeus MGHSVA 4 A T LL THAI X420T NId 72 xaoy Pag 3 pug 1roy QOMH FIG 18 TRANSMISSION FORK amp ROD 96 g h d i baq 4 N 7 as dod I9 ASSEMBLY ORDER OF Fig amp CASE TRANSMISSION GEAR JOHLNOO SLOWSY 0 913 1949 O11uO2 HYHOLVTINSNI 310ddns 440 LTO ACT UAHSVM 557 poruo fuinjas ONTUdS 3 M de Bed LHUSNI 11204408 44 410ddns 3109918 ONIHSNG
119. mz Grade Ability Sin 2 e El Min Turning Radius m PERFOR MANCE mar m m Classification Gasoline Engine Cooling System Water Forced Circulation No of Oylnder amp Cycle 4 Wedge Valve Arrangement Compression Pressure kg cm r p 11 5 358 Max Exploding Pressure kg cm Mean Effective kg cm m 9 3 3 600 Max Power B H P r p m SAE Ring b E ER 34 1 Inlet Open 14 T D C o Valve Timing Inlet Close 907A B D C 5298 T D C o 0 35 ENGINE Outlet Close 12 A B D C Vaive Clearance Peke O5 MU Start ng Method Magnetic Starting System Ignition Method 3 IGNITION SYSTEM Battery Coil Type bis Ignition Timing B T D r p m 10 Firing Order 1 3 4 2 TEES 5 Fach Hanshin 5719771 TEL Distribution Manufacturer Hitachi Mitsubishi Ign Timing Advance Vacuum or Governor yst 2 1 45 6 Manufacturer Hitachi Spark Plug n Nihontokushutokr mm is mm Type amp No 2D 30CE lea Manufacturer Nihonkikaki Throttle Valve Bore mm mm mm m ilii ENGINE 25 14 7 115 48 Carburetor Power let m 55 _ Air Drau
120. n Hand primer quanty discharged 80 cu cm at 20 strokes The fuel pump which 1s of the diaphragm type 1s mechanically driven by the eccentric part of the camshaft of the engine It draws gasoline from the tank and delivers it under pressure to the carbure tor Even when the engine 1s not running fuel can be delivered under pressure by moving the hand primer up and down By the rotation of camshaft rocker arm 15 pushed and pull rod of diaphragm 15 pulled down At the same time diaphragm goes down against diaphragm spring and then 15 pushed up again by spring By the movements of the diaphragm and functioning of the valves at the inlet and outlet of the pump chamber gasoline 1s drawn up from the tank to the carbu retor If the float chamber of the carburetor contains enough gasoline and the needle valve 1s closed gasoline 15 not allowed into the carburetor Thus gasoline 1 stored in the pump chamber and due to pressure the diaphragm 1s kept down and cannot return Under this condition the rocker arm works in vain as the rod remains low The rocker arm spring serves to prevent noise keeping the rocker arm pushed against the eccentric of the camshaft 61 Disassembling amp Inspection 4 Checking with fuel pump installed on engine Switch off and stop the engine Disconnect the fuel pipe at the inlet union of the carburetor and then turn the engine with the crank handle Now the gasoline shou
121. n pe JOHS assy 79949 94919 MAMA ONINdS zc qm 2482q ONINIT i218n pe 359 03A T 1 3d d V 320 GS NS 2048 15 55 1 77 4 48 13 1994 1821 021501 1921 3 1514 pu 9 NO LSild uo3s d ano 9 ul 23914 ONINI 1 Y 0 39np M4A02 exei pd 114 4 2 2510 55 opis s puq4 1445 19 2214 33 Suusn ps IWIHS ODINOL Sunsn pu yy Hs oouvN g Sunsnipe yy HS 051401 Sunsn pe WIHS 021301 44A47 A SSV 021 041 ODINOL 0140 2 224 1821 440N11A2 A SSV 2 0 ysiq 1921 JOHS A SSV 168 HAND BRAKE The hand brake operates on the rear wheels only and 1s applied by a pull up type of lever situated along side the driver s seat The cable from the control 18 attached to the toggle lever connected with the rear brake disc The hand brake linkage 1s set when leaving the works and should not require any attention under normal maintenance
122. n suitable ratio to air and supplying the mixture to the engine It 1s therefore an important part which can influence the performance of the engine The Model 2D 30C carburetor 1s highly efficient carburetor of two barrel two step and down draft type having the following special features Y Construction and Operation p Secondary Side Yu mun ni jq T il b Pr mary S de Secondary S de Fig 2 O Body assembly Ventury Float chamber Throttle shaft Mam yet jet carrier Float chamber cover Float 9 Main air bleed Air bent pipe Choke valve 42 Choke control link 3 Connecting rod 9 Choke wire blacker 5 Throttle wire blacket Lower body Fig 3 2 Auxiliary throttle valve Throttle valve By pass hole 9 Slow jet Venturi Q Ausihary valve shaft Main jet Mam air bleed Pump injector Out let valve Inlet check valve Power valve 9 Pump piston Air vent hole 8 Pump piston return spring Connecting rod 50 Carburetting System The fuel flowing out of the passage at the bottom of the float chamber passes through the primary main jet and then mixed with the air comming from the main air bleed to be minute drops and inject into the venturi through the main nozzle When the throttle valve 1s widely open and the engine requires dens
123. n with a taper peg fit ted to a rocker shaft within roller bearing This assembly 15 enclosed in an oll tight casing which carries two ball bearings at either end of the cam When the steering wheel 15 turned the tube revolves the cam which 1n turn causes the taper peg to remove over a predetermined arc thus giving the rocker shaft its desired motion connected the rocker shaft s a steering 15 a steering side cross rod lever that links up with the steering linkage The steering 1s of the three cross rod connecung the side and cross rod lever to the gear arm on the idler shaft Two shorter side rod one on either side connect the steering gear arm to the steering gear and idler arms respectively Side Cross Rods The side and cross rods are held 1n position by a castllated nut and spht pin at each end To remove the rod withdraw the split pin and release the nut at each end of the rod and then carefully tap the rods clear of the levers to which they are con nected Removing the Steering Gear Arm These are secured to the steering gear rocker shaft and idler shaft respec tively by a nut and split pin each Normaly these levers need not be removed for any general maintenance The only occasion requiring their removal would be when damage has occurred under which circumstances the steering box or idler should also be remove for inspection when the arm concerned can be withdrawn once the steering gear box or idler has been removed to t
124. nce of 0 0010 0 0016 in 0 025 0 040 mm PISTON RINGS The piston ring gap should be 0 008 0 013 n 0 203 0 330 mm when checked n the cylinder bore The clearance of the compression rings in their grooves should amount to 0 0015 0 0035 in 0 038 0 089 mm and the oil control ring 0 0016 0 0036 1n 0 041 0 092 mm Because the piston rings not travel to the end of the cylinder bores a lip 1s eventually formed due to wear This may be checked with a dial gauge and must be removed If this 16 done there will be a tendency to noisy operation or a fractured ring caused by the top piston ring striking the lip Piston and rings are available in 0 010 in 0 254 mm 0 020 n 0 508 mm 0 030 n 0 762 mm and 0 040 in 1 016 mm oversizes The p ston r ngs Fig 12 should always be fitted from the crown of the piston and never pushed upwards over the skirt Before f tt ng the rings remove any carbon deposit from the grooves n the piston When fitting note that the second compression 15 tapered type and oil control ring is slat type processed by chromium plating 33 REMOVING amp REFITTING Experience has shown that it 18 much easier to remove the engine and trans mission as a single unit than to detach the engine by itself To remove the engine and transmission upwars proceed as follows Completely drain the cooling system and the transmission disconnect and remove the battery a
125. nd its supporting tray Remove the upper and lower radiator hoses by undoring the retaining clips Disconnect the capacitor lead at the distributor also the high tension and switch wires at the Take off the dynamo lead and disconnect the starter motor cable at the motor end Remove the oil gauge and water temperature gauge leads from their terminals on the engine The throttle and choke controls must be disconnected from the carburetor Disconnect the fuel pipe from the tuel pump Next remove the exhaust pipe from the manifold From below the vehicle remove the gear change selector rod from the lever on the transmission casing Disconnect the earth strap from the starter motor Remove the hand brake control rod supporting from transmission Disconnect the speed meter cable from the transmission Uncouple the pro peller shaft pmion franges at rear axle and draw the shaft out of the transmission To allow the engine and transmission to be drawn forward the radiator must be removed by undoing the four securing bolts 84 35 z put F 3NIDN3 34 Sutuen jeg aaa 21814 85015 z useA 4 8 gt M b s s 2 34014 Suiyunoui ur u 8 Es n 36 34013 11
126. ng of differential gear case and n pressing the bearing the differential case adjust by inserting inside the bearing adjusting shim of thickness calculated in accordance with the following method of computation There 1s marked numberal of adjusting basis on the bearing housing of the gear carrier and differential case The numberal is the manufacturing erro in a unit of 1 1000 in against each standard measurement D in Fig To measure the width of the side bearing on left and right use the stand ard gauge 20 0 mm thickness and dial gauge on a flat board In this case place the load on the bearing with the aid of weight block for about 2 5 kg to acquire the steady figures Calculate the error on minus side against the each standard measurement of 20 0 mm on the unit basis of 1 1000 and assume each of them as E amp F Take the left side bearing for example When the measured width 18 19 8 mm it 1s 0 2 mm 0 008 in against the standard measurement and the 1s by excluding the minus sign 0 008 in 146 The thickness of the shim 18 acquired by applying the numerals to the following method of computation It may as well be assembled by using the shim of thickness which 18 1n accord ance with above method of computation The left and right bearing must be well pressed n otherwise the preload changes Measure the backlash of the drive p n on amp ring gear as Fig 20 by using the dial indicator
127. ng them out of their housings When fitting new bearings care must be taken to line up the oil holes with the corresponding holes n the cylinder block Tap the new bearings into position and ream them to give a running clearance of 001 0 002 n 025 0 051 mm Refitting the Camshaft This 1s a reversal of the introductions for removal Care should be taxen however to align and engage the drive pin in the rear end of the camshaft with the slot n the pump drive shaft 37 V 034 0883 du d f n my o anis Smd gaHSVA SP ASSY 911024 139402 2192 mey 12419214 557 Nvd ASSY usd 19 daxsvo ued po nj o1 Som jgysyr 2883 9181 4 Sujunou 103A quads 1108 S SS SS 1102 xi ei des Suds saysa 29 081445 po JON pup E SS HZHSVA 12914 Tos 9 Q meds 5 Jo 19402 Sununog D 5047 woz my 2 4 m f 31y 14 di 0 y d 2 7 05 1821 1 5 2 SSS 4 ARDS 8 4 h rf ___ 1 4 129 MaRS VA un 2892 40912 00 4 3 wwdirpisva 03 13402 9 moade amd 1901 my 1801 Immuno b
128. nto the pump vaa the filter and 18 delivered through internal oil ways to the non adjustable relief valve which 1s situated at the rear left hand side of the crankcase From the relief valve the oil passes into the main oil gallery on the right hand x s side of the engine The flow then passes via Connecting oilways to the mam big end and cam shaft bearings through drill ings in the crankshaft The connecting ends are drilling in the cylinder block and the rear rocker shaft bracket to lubri cate the rockers and then drains back into the engine sump via the push rod apertures Oil from the center camshaft bearing enters a gallery on the left hand side of the engine and lubricates the tappe pets through individual drillings As the camshaft rotates two grooves n the front journal register with a small hole in the camshaft thrust plate thus allowing a small amount of oil to pass into the timing 1 0 camshaft to provide lubrication for the timing chain and gears From the timing case the oil returns via a drain hole back to the engine sump The filter therefore forms part of the main oil gallery and as such 1s filled with 011 under pressure A proportion of the oil enters the element through holes 1n the casing and Fig 1 passes through the element into the an 1 nular space round the center bolt This space is sealed top and bottom so that the oil can only escape through a small hole into the hollow center
129. nue turning the key time after time but try to save the battery In this case check for the cause of the trouble and correct so that the engine will start Checking While in Operation 1 t 2 vetat 3 With a fully charged battery and with the lamps lighted the starter switch is used If the lamps become dim especially when the engine does not start the current 1s flowing through the starter motor coil but for some reason the armature 1s not turning Careful check should be made since the starter pinion may be locked n the flywheel ring gear and unable to return a trouble usually caused by turning on the starter while the engine is still runing When the starter switch 18 turned up and the starter motor fails to turn although the hghts remain bright the switch should first be checked the switch 1s 1n satisfactory condition then the condition of all the terminal and ground connecuons of the battery starter switch and starter are checked If the starter motor runs but its movement 1s sluggish it indicates either a high resistance due to loose connection in the starter circuit a badly dis charged battery If after the above troubles are corrected and the starter fails to operate occasionally and shows defective performance t 15 due to internal defects so that n this case t should be dismantled and checked Lal Dismantling and Disassembling 1 2 3 4 5 6 The starter can b
130. o damage diode When the key switch 1s on magnetic current always flows on the field and might dam age the dynamo and often cause over discharge of battery TROUBLE SHOOTING LIST 5 1 Over discharge of battery 1 Slackness of fan belt Adjust 2 Earth or breakage of stator coil Repair or replace 3 Breakage of rotor coil Replace 4 Mal contact of brush and shp ring Replace brush clean holder 5 Mal func on of diode Replace as a set 6 Adjust voltage of constant voltage relay 15 low Readjust 7 Mal contact of low speed side contact point of constant voltage ready Polish contact point 8 Adherence of high speed side contact point Replace 9 Shortage or unfitness of electrolyte Add disniled water check 5 10 Mal function of battery pole short circuit Replace or repair 11 Mal contact of battery terminal Clean retighten terminal 12 Mal contact or breakage between Repair ignition switch and relay IG terminal 13 Mal contact or breakage between Repair regulator F terminal and dynamo F terminal 14 Excessive electric load Check power consumed 5 2 Over charge of battery 1 Constant voltage relay adjust voltage Readjust 1s too high 2 Constant voltage relay coil breakage Replace or rare short 3 Constant voltage relay coil straight Replace 4 resistance breakage 4 Constant voltage relay low speed Replace side contact point adherence 192 5 Constant voltage relay high speed side con
131. of use because over preload 1s given to the bearing with the shim of thickness calculated from above method of computation 4 TES aH x e V Fig 21 Using the Differential Side Cap Gauge 149 Smear grease P to the lip of oil seal Tightening torque 350 420 kg cm 25 30 ft lbs Back lash 0 1 0 2 FIG 22 CARRIER 150 38140 2566011105120 38127 256 0 38128 25660 1105112 138129 25660 1105113 38130 25860 1105114 7 38153 2566001105092 Thus the adjustment 1s completed way of precaution measure with michro meter of the large size the L measurement which 1s within 173 40 173 55 mm as Fig 21 Service No tool DT 4685 If it is insufficient add an additional shim of 0 002 n 0 05 mm left and right In this case the said michrometer Fig 21 or special gauge should be employed for scaling The shake of the back of drive gear which has been fixed with the carrier should be measured by dial indicator to confirm that 1s within 0 05 mm Mountin the Gear Carrier Ass y on the Rear Axle Housing Interior of the axle housing should be cleaned well The carrier packing should also be replaced with new one Mount the gear carrier ass y without mistaking its upper side with down side and through 8 studs then fix with the lock washer amp nut The nut must be tightened n a diagonal l
132. or rectly when refitting Removing the Oil Pump Remove the pan and pick up stramer Three of the five bolts securing the oil pump bottom cover are long enough to secure the pump to the crankcase Fig 4 illustrates the pump in explosed form Unscrew the long bolts and remove the pump with drive shaft Dismantling the Oil Pump Remove the setscrews and spring washers which secure the cover to the body and take off the cover On tlting the body upside down the inner rotor with its drive shaft and the outer rotor with 4 slide out 13 Refitting the Sump Clean out the sump by washing it in paraffin the care to remove any traces of the paraffin before refitting the oil to the engine Pay paticular attention to the 011 pan and crank case joint faces and remove any traces of old jointing material Examine the joint washer and renew it if necessary The old joint washer can be used again if it is sound but it 18 advisable to fit a new one Smear the faces of the joint with grease and fit the joint washer the pan into posi tion and insert the setscrews into the flange tighting them up evenly Reassembling the Oil Pump The outer rotor Fig 4 has a chamfered edge is of great important that this chamfer be towards the base of the body filure to assemble in this way will result 1n the cover 1s tightened down Insert the slotted end of the drive shaft into the body and bring the rotors into mes
133. or etc the checking and repairs are made the same manner described in the preceding chapters If the outer surface of the armature is rubbing against the core the starter should be dismantled disassembled and repaired Besides the above there 1s the case of the pimon meshing improperly If the trouble 1s due to the gear teeth being badly worn the gears should be replaced but if t 1s due to the screw guide on the pinion shaft being dirty and not allowing the pinion to advance smoothly and causing improper meshing the shaft should be cleaned and oiled 2 Starter exceeding noisy when in operation The flywheel ring gear 1s checked and if the teeth are deformed they should be repaired or the gear replaced Rattling noise caused by loose starter mounting bolts are corrected by ughtening the bolts Noise caused by brushes improperly contacting the armature required cor recting as this condition not only produces noise but will hasten wear on both parts 200 Noises made by the armature rubbing against the core while in operation 15 _ caused by too large a clearance between the armature shaft and the bushing so the worn parts should be replaced Wear between the shaft and bushing 15 due to lack of oil so that attention should be given to proper lubrication Lubricate once every half year using good grade of machine or mobile oil and lubricate the parts through the nipples The amount of required 15 about 0
134. osition 18 shown here 5 Next put the distributor cap on and clamp it securely with the clip 6 Tothe No 1 spark plug connect the cord froni the terminal to which the arm of the rotor 15 pointing Thereafter connect the terminal cords to their spark plugs An the counter clock wise order SO as to obtain a 17 3 4 2 firing order 7 Upon completion of the wiring cover the distributor with a rubber cap The engine should now start properly Ordinarily the pointer of the octane selector 1s set at 1ts zero reading during the ignition timing adjustment If the octane number of the fuel being used 1s low and the engine knocks the pointer 1s adjusted to the right R to the optimum advance angle Fig 5 Assembly Angle of Drive Shaft Q Distributor shaft Q Distributor drive shaft G Distributor fixing plate Conversely the octane number 15 high the pointer 15 adjusted to the left A One unit of calibration of the selector corresponds to 2 deg of the distributor angle and to 4 deg of the crankshaft angle When a timing lamp 1s used the standard setung 1s 15 deg before top dead center with the engine idling 600 620 In any case the opumum ad justment 1 that in which a slight knocking 15 heard when with the car running at low speed in HIGH TOP gear acceleration 15 applied suddenly 47 FUEL SYSTEM CARBURETOR 16141 03100 16271 32200 16116 31300 16165 08100
135. ould be employed setting four points in the holes of flange to keep it from moving take off the nuts with the box wrench 10 Take out the drive pinion of gear carrier by striking out lightly to the back wards the front end at the side of companion flange of drive pinion with the drift of metal Thus the would be taken out together with the inner lace of rear bearing and roller distance piece and the adjusting shim and the oil seal outer lace and pinion of front and rear bearing well as the pinion adjusting shim left in the carrier 11 Pull out the rear bearing inner race of the drive pinion As illustrated in Fig No 6 the drive pinion rear bearing inner lace re place and the adaptor should be employed this case The adapter in the the round form 1s for fixing and the other for taking off It 1s easy to handle with the vice fixing one end of replacer 12 Taking out the rear bearing outer race of gear carrier The drive pinion bearing outer race replacer as illustrated in Fig 6 should be employed in this case In other upon the stud so as to make the screw at the center of carrier and set the adapter at the lower frim of the race Supporting the tommy bar 1 and screw up till the corn 7 closely touches the adapter then screw the wing nut to take out the rear outer race 133 Tool No DT4782 DT4631 amp DT4689 Fig 6 Pull out the Bearing Race 134 Fe ek 13 To pul
136. over and cause damage Starter Troubles Their Causes and Remedies The following 15 a list of troubles which can be determined from the state the starter 1s installed on the engine 1 Starter fails to turn The engine 1s checked to see 1f 1t can be cranked by hand If t cannot be cranked the engine 15 at fault and should be checked If it can be cranked easily the starter 1ncluding the wiring should be checked and corrections made accordingly Is the battery run down Check the specific gravity of the battery fluid to see 1 1t 15 over 1 240 and recharge or replace the battery as found necessary All loose battery and ground cables should be cleaned and properly ughtened Magneto grease or Gargoyle BRB No 1 All cord connections are carefully ughtened and special attention given to the condition of insulation The assembly check 15 made by testing the starter as Fig 4 Torque Testing Apparatus a single unit using a fully charged battery Tests are made with a starter motor tester or with the apparatus shown n Fig 4 by which braking otrque 1s measured In this case the normal value should be 0 9 m kg Construction of Magnetic Switch and Instructions The magnetic switch 1s an apparatus when the engine 1s being started by shift lever serves to close the circuit between the battery and the starter motor and permuts a large current to flow and actuate the starter motor After starting or when the engine 1s stopped
137. pos1tion Starting switch Contactor Series coil AAA Ing gear Pinion sleeve spring 1 Pinion sleeve Spring 2 Fig 2 View of Starter System Operational Precautions The instructions to be observed when starting the engine are as follows 1 The starter should be securely mounted the engine and should not show any looseness 2 Tmhe starter switch should be operated properly and should be release immediately when the engine starts 195 ing R sleeve 2 WAS ASS Y SWITCH magnetic PIN cotter PIN LEV ER ASS Y BRUSH SPRING pinion pinion sleeve CREW CLIP SDS ASS Y COVER brush s N XN PRING p n on 1 YA E STOPPER pinion WASHER Pinion stopper fM pi 2 d y 6 d 8 W SE al s 7 R 4 gt 3 NW x m 2 lt lt gt s lt Sig gt n n lt m FIG 3 STARTER MOTOR HITACHI at 196 SCREW set pole core 3 4 Excepting 1n extremely cold weather the engine should normally start within 10 seconds The starter switch should not be operated when the engine 1s running If the engine fails to start allow ume for the pinion to come to rest before turning the starter switch again When the engine fails to start after turning the starter key for over 10 seconds do not conti
138. r 18 removed It should only be re moved if showing an appreciable amount of wear Disconnect the three nuts of the front cover n position and release this cover with shims Take off column jacket way The complete unit should now be up ended with the steering housing uppermost By bumping the end of the worm gear against a wooden block tap out on the floor the worm gear with rear bearing will be displaced The complete inner assembly can then be withdrawn from the housing through the open end of Then with the steering wheel held to prevent if from turning endeavour to turn the side rod and gear arm Should the steering wheel have a tendency to lift may be assumed that there 1s excess end play n the worm gear Assembling Reassembly of the gear housing 1s merely a reversal of the dismantling pro cedure however adjusting shims should be fitted behind the front cover so that there s no end play on the column but at the same time they should not be pre loaded otherwise damage to the ball races may ensue When the rocker shaft 1s dropped into position ensure that it 1s good fit in housing and that the seal at the rear cover of the housing 1s making good contact Before refitting the rear and front cover screw back the adjusting nut Ensure that all joint are oil tight Adjusting the Gear The adjusting screw in the cover should be slackened by releasing the lock nut and unscrewing the screw a few turns Then
139. re moved the valves can be taken out To do this compress the valve spring with the special valve spring com pressor as shown in Fig 1 Removal Remove the two cap retaining collets Release the valve spring the valve spring cap valve oil seal Inlet valve only and its retainer Withdraw the valve from the guide Keep the valves in therf relative positions when removed from the engine to ensure replacement in their original valve guides Fig 1 Valve Spring Compressor 21 Replacement Note that the diameter of the exhaust valve heads are smaller than the inlet valve To replace the valves insert each valve into its guide and replace the spring oil seal and retainer Fit oil seal chamfered side down wards The oil seals are more easily fitted if they have been soaked in engine oil for a short period before use The seal 1s used for the intake valve only Replace the valve spring and compress the valve spring Refit the cap retainers and secure them by means of the valve cotters Remove the compressor Inner Sp Outer Sp Free length mm 50 mm 52 mm Length 1n use and loaded mm kg 36 9 13 1 0 7 38 9 29 1 5 Turnning Nos coil 8 5 6 5 Effective turn of coil 6 5 4 5 Dia of coil wire 5 6 0 2 8 5 0 2 mm Diameter of coil 24 mm 33 7 mm VALVE SPRING 2 p S AD Fig 2 Valve Spring Valve 22 Valve Grinding Before replacement of the cy
140. rom the cylinder and remove the securing bolts then the master cylinder and may be withdrawn complete from the Remove the filler cap and drain out the fluid Pull back the rubber boot and move the stopper ring with a pair of long nosed pliers The push rod and ring can then be removed and unscrew the release pin When the push rod has been removed the piston with caps attached will be ex posed remove the piston assembly complete The assembly can be separated by lifting the spring seat edge over the shouldered end of the piston Depress the piston return spring allowing the valve assembly to slide through the elongated hole of the spring seat thus releasing the tension on the spring Examine all parts especially the gasket cylinder bore and piston cups for wear or distortion and replace the new parts where necessary Assembling Smear the assembly well with the recommended brake fluid and msert the sembly into the bore of the cylinder end first easing the piston cups lips in the bore Replace the push rod with the secondary cup ring into the cylinder followed by the stopper ring which engages into the groove machined im the cylinder body Replace the rubber boot and secure the unit by means of the two bolts on the flange and refit the rpessure pipe union into the cylinder The Operating Cylinder This cylinder 18 of simple construction consisting of the body piston piston with cup spring and bleed screw
141. rvoir with the recommended fluid and by using slow full strokes pump the clutch pedal until the fluid entering the container is free from air bubbles On a down stroke of the pedal screw up the bleed screw re move the bleed tube and replace the dust cap When the clutch pedal is depressed the force 1s transmitted to the ball bearing and the surface pushed the release plate Effectual stroke of the pedal 15 128 mm leaving 30 mm surplus n stroke 95 mm until the clutch disengages When there 15 undue surplus or shortness mstroke readjust the pedal position with the adjust shim 80 TRANSMISSION 3 stage for forward 1 stage 4 stage for forward synchro for reverse mesh on for speed Remote control Full synchromesh on for ward gears Type of gear Synchro meshed helical 2nd 3rd amp 4th gear gear type Ratio 1 3 518 Ratio 2 1 725 Ratio 3 1 000 84 Reverse 4 125 81 DISASSEMBLE THE TRANSMISSION CASE First drain the oil from the transmission by removing the dram plug The drain plug 1s situated beneath the case Disconnect the propeller shaft starting motor clutch lever and shift levers Shift Lever Remote Control The shift lever 1s positioned on the right hand side of the case of transmission if the car has right hand steering wheel and on the left hand side if it has left hand steering wheel Shift Lever Floor Gear Shift Lever The shift lever 16 located on the ri
142. s pulled evenly up the studs Remove the cylinder head gasket Decarbonising Remove the cylinder head With the valves still position remove the carbon from the combustion chambers and the valve faces Leaving the valves in posi tion for this operation ensures that damage cannot be caused to the seats by the wire brush which should be used for the removal of carbon If the exhaust valve heads are coated with a very hard deposit this maybe re moved by using a chisel shaped piece of hardwood Remove the valves and using the wire brush clean out the carbon from the inlet and exhaust ports Blow out all traces of carbon dust with compressed air or type pump and finally clean the ports with gasoline and dry them out The carbon should now be removed from the piston crowns Rotate the engine until the piston to be worked on 1s at T D C Protect the other cylinder bore from the entry of carbon particles by push ing a non fluffy rag into them Using a chisel shaped piece of hardwood Carefully remove the carbon from the piston crowns A ring of carbon should be left round the periphery of each piston and the deposit round the top of the cylinder bore should not be touched An indication as to when decarbonisation 1s require 1s generally given by an all round loss of power Cars used mainly on short runs will require this attention more often than those used for long runs Removal and Replacement of a Valve Whilst the cylinder head 15
143. se reconnected to avoid laying up the car Should the thermostat be tight there are two tapped holes on the top which may be utilized to ease it from casting When the sys tem has been completely emptied it is essential to allow air to escape through the thermostat valve and then finally top up The thermostat opening 15 set by the manufacturer and cannot be altered It open at a temperature of 76 5 1 5 During decarbomising is policy to test this open ing by immersing the thermostat water raised to the requisite temperature The valve should open under these conditions but if it fails to open a new unit should be fitted Fig 2 Pellet Thermostat Overheating Overheating may be caused by a slack fan belt excessive carbon deposit in the cylinders running with the ignition too far retarded incorrect carburetor adjust ment failire of the water to circulate or loss of water Fan Belt Adjustment The fan 1s driven from the crank shaft by a belt this also driving the alternator A New belt can be fitted by first loosening the clamp bolts Fig 3 which hold the dynamo position and moving the dynamo towards the engine Shde the belt over the fan and onto the fan pulley Adjustment 1s then made by bring ing the alternator away from the en gine The belt should be sufficiently tight to prevent slip yet the belt should have 10 to 15 mm slack be tween the generator and crankshaft Fig 3 F
144. split pins on the ends of the shaft Replace the rocker cover and gasket The vent pipe should be at the front of the engine Secure the cover by means of the two cap nuts ensuring that the rubber bushed and engine lifting plates are in position If the rocker cover gasket or the rubber bushes are found to be faulty they must be renewed otherwise leaks will result Push Rod Removal If the valve rocker assembly has already been removed all that remains 1s for the push rods to be lifted out They may on the other hand be taken out with out detaching the rocker assembly Remove the air claner and rocker cover S di Slacken all the tappet adjusung screws to their full extent then using a screwdriver with the rocker shaft as a fulcrum depress the valve spring slide the rocker side ways and lift out the push rod but the end push rods can be withdrawn in this way These will have to be withdrawn after the removal of the two end rockers from the shaft When re placing push rods ensure that the ball ends register in the tappet cups From here onwards reassembly is a straight forward reversal of the dismantling process Adjusting Valve Rocker Clearances Remove the air cleaner and rocker cover There should be a clearance of 0 014 in 0 35mm between the face of the rocker and the base of the valve stem Whilst checking the clearances it is im portant to maintain pressure with a screw driver on the tappet adjus
145. sung plate k The nut must tighten surly after fixing the dimension of iz Rod Adjusting plate Nut Fig 9 54 FUEL SYSTEM The fuel tank has a capacity of 41 0 litres and 15 situated at the rear of the luggage compartment The fuel pump operated off the camshaft draws fuel from the tank and forces 1t into the carburetor float chamber A large and efficient air cleaner filters the air supply to the carburetor THE GASOLINE TANK Draining the Fuel The fuel tank 1s drained by turning the wrench operated dram cock Fuel Tank Gauge Unit Fig 1 Fuel Tank Securing Situated on the top face of the tank 1s the gauge unit To remove withraw the set screws which secure the unit to the tank not forgetting to disconnect the electrical lead beforehand Care must be taken not to strain or bend the float lever as this may serously effect subsequent gauge readings Remember thts also applies when refitting the unit Examine the joint washer to ensure that 1t 1s in position and undamage This 1s essential as the Joint between the tank and gauge unit must be fuel tight 55 Breather tube Band Fuel tank front for sedan Washer strainer gauge Grommet strainer Grommet Tube to strainer Screw 4 V asher s Ventilation G 4 x tube E Grommet Ventilation tube D Cap ass y Bolt V asher qp Joint washer Drain plug Fuel tank
146. t Rear Oil Seal This oil seal 18 situated 1n the end of the rear cover and should not be dismantled unless suspected of leaking It 1s almost impossible to take off the seal without dam aging 1t consequently a new oil seal should be fitted if the old one has been moved It will be seen that the seal housing 1s pinched into position This can be re moved by using a punch and hammer ASSEMBLING THE TRANSMISSION The 2nd speed gear the 3rd and 4th speed coupling sleeves are each paired with their respective eynchronizers Only mated pairs of these parts should therefore fitted Reverse Gear Refit the reverse gear into the gear case with the large gear to the rear Oil the reverse gear shaft before inserting and secure the shift with locating screw and lock washer Counter Shaft Gears First put the two thrust washers to the counter gears ensuring that the larger washer 15 at the front and then place the gear cluster in the gear case Check that there 15 end play for the cluster gears between 0 04 mm and 0 12mm 0015 0 0046 and remedy if necessary by fitting a thicker or thinner rear washer Thickness of front thrust washer Part No Thickness 32224 26760 3 91 3 96T Thickness of rear thrust washer Part No Thickness 32226 26760 3 9T 32227 26760 4 0T 32228 26760 4 1T 32229 26760 4 2T Replace the counter shaft with a thin temporary rod which will permit the gear cluster to remain out of mesh with the m
147. t 2 gt Advance angle by vacuum 12 18 Crankshaft I pressure of 340 mm Hg 6 9 Distributor 27 Number of revolution at the E start of advance angle 450 r p m 5 i Max advance angle at crankshaft 11 15 at 2400 r p m _ Rotating direction of cam Counterclockwise A ka Firing order _ 1 3 4 2 2 Point gap 0 45 0 55 mm 0 018 0 022 1n Dowel angle 50 55 TEE lt Contact arm spring pressure 0 5 0 65 kg 2 Condenser capacity 20 0 24 mfd 7 Inside the distributor 15 braker point as shown in Fig 2This braker makes and brakes contact several thousand times in one minute Each time this braker brakes contact a spark 1s generated 1n one of the spark plugs Therefore the maintenance of this braker must not be treated hghtly Also because the time during which the ignition coil current flows varies with the gap between these braker points see that this gap 18 maintained at the standard value which 18 45 mm 0 018 to 0 022 i The braker points must be kept free of grease and oil If the points should become burnt blackened they are cleaned with a fine honing stone or croucus cloth after which they should be wiped clean with a piece of cloth which has been dampened with gasoline If the points are badly burnt they must be replaced Braker points must _ always be replaced as sets tod Adjusting
148. t No 32264 26762 6 26761 Dimension B Dimension A Smear the brake grease Part 44003 30100 play As possible as little end by the washer Part No 32264 26762 Adjust and tight here Bearing play 1 5 2 240 280 kg cm 32264 6 26761 by push edjuster be TRANSMISSION FIG fore fitting return spring TRANSMISSION 4 Speed shift gear type rii X Adi FRONT AXLE 109 KIT ABSORBER shock front NUT lock e NUT NUT ASHER special 6 outer BUSHING BOLT ASHER shock absurber special Qe inner bb SEAT rubber shock 5 WASHER ront 54468 10600 BUSHING NUT WASHER special outer absorber Special 8 54469 10600 ror r rubber BUSHING rubber stabilizer BRACKET stab l zer mounting WASHER lock P WASHER Qe BOLT plain 5 1 BOLT EAT lower front spring WASHER special lt front 54464 10600 upper front rear 54465 10600 g NUT Suspension member mounting BAR tension front stabihzer WAHER special outer WASHER susuinc Special rubber inner SPACER front bit al stabilizer specia inne r BUSHING WASHER rubbe r special CY outer __BUSHING WAS
149. tact point mal contact 6 Breakage or rare short of pilot lamp relay 7 Mal contact of pilot lamp relay contact point Mal function of regulator earth 9 Mal contact or breakage between regulator N terminal and dynamo terminal 5 3 Noises of Dynamo 1 Mal function of bearing 2 Mal function of diode 3 Earth or rare short of stator 193 Polish contact point Replace Polish contact point Adjust Repair Replace Replace diode as a set Replace je STARTER MOTOR Type S114 72 Voltage 12 volts Output 1 0 HP Starting current voltage Less than 500 amps 9 5 valts Lock torque Over 0 9 kg m Type of pinion gear Number of tooth on pinion gear Bendex type 9 120 Number of tooth on ring gear Amendment limit of short dimension on shaft dia pinion side Amendment limit of short dimension of shaft dia rear end Gap between shaft and bush p n on side Amendment limit dittoed gap Gap between shaft and bush rear end Amendment limit dittoed gap Amendment hmit of deflection on shaft 0 1 mm 0 004 in 0 1 mm 0 004 in 0 038 0 095 mm 0015 0 0038 in 0 02 mm 0 008 in 0 03 0 076 mm 0 0012 0 0030 n 0 2 mm 0 008 1n 0 1 mm 0 004 in Outer dia of commutator 2 mm
150. tarded too much adjustment poor Power weak Gasoline supplied insufficiently Carbon deposits excessive Gasoline of poor grade Intermittent 277 qeleme Engine operation lack of power Valves sticking defective during Pre ignition running Engine gives off abnormal noise Bearing worn Plugs dirty Sparking Breaker point defective z Intermittent shorting Mausfir ng M xture too rich Insufficient gasoline supply to carburetor Sparking normal Water in gasoline Nozzle clogged B Trouble Shooting Chart 69 CLUTCH GENERAL DATA Type Construction of disc Outer dia of facing Inner dia of facing Thickness of facing Gross friction area Thickness of disc ass y Disc run out Backlash at splines part Operating method Inner dia of master cylinder Inner dia cylinder Operating liquid Return spring withdrawal wire b of operating Free length Length in used amp tension PRESSURE SPRING Free length Compressed length Turn numbers Power of comp full Wire diameter Length 1n use and load RELEASE BEARING Construction Height of release plate Release plate run out If use master disc 7 8 mm 0 5 mm height height of release lever 15 50 5 0 2 mm 271 Single dry disc plate With coil spring 200 mm 130 mm 3 5 mm 363 cm
151. ter A mmeter x a meter 28 NOTE Use the battery charged 2 n full up to the normal 7 23 capacity Fig 3 1 Through wiring shown in Fig 3 1 magnetic current flows from the battery to the field coil of dynamo In this state raise revolution of dynamo slowly up to the speed where there 1s no reverse flow 2A approx to the field coil and read the revolution Correct revolution is approx 1 000 rpm without load Next increase load resistance to the maximum and almost stop flowing of load current and put off the switch Then raising the load current slowly increase revoluuon of dynamo Observe thus increasing output current as revolution of dy namo increases 180 If there 15 no large difference from the specification 1t 18 correct No matter how the battery 1s over charged or discharged 1 the charging current 15 small first make sure either the dynamo or the relay 15 in disorder See the charging current by inserting the ammeter between A terminal of relay and the battery Disconnect wire passing from the dynamo F terminal to the relay terminal at the relay F terminal and make the removed lead wire short circuits at the relay A terminal when if the charging current highly increases the relay 1s in disorder Short Circuits on Diode Side It can be judged as the pilot lamp does not flare even if the key switch s turned on Actually a trouble such as diode open 1
152. th PS Intake valve 109 54 mm 4 5 16 1n Ex valve 108 74 mm 4 9 32 mn VALVE GUIDE Length Intake valve 47 63 mm 1 7 8 in Exhaust valve 57 94 mm 2 9 32 in Outer diameter both intake and exhaust 14 313 14 440 mm 0 5635 0 5685 n Inner diameter both intake and exhaust 8 733 8 860 mm 3438 0 3443 Inner diameter at guide inlet to insert both intake and exhaust 14 3 mm 0 5634 n Clearance of valve stem and guide both intake and exhaust 0 0394 0 0648 mm 0 0015 0 0025 in 23 Refitting the Cylinder Head Ensure that the cylinder head and cylinder block joint faces are clean The cylinder head gasket 1s marked Top so that it will be placed head in correctly Place the gasket into position and lower the cylinder head into place Fit the cylinder head securing nuts finger tight Insert the push rods replacing them n the positions from which they were taken Screw back all the tappet adjusting screws Replace the rocker assembly and screw down the securing nuts finger tight Evenly tighten the eleven cylinder head nuts a little at a time in the order given in Fig 3 finally pulling them down with a torque wrench set to 45 lbs ft o Fig 3 The Order of Tighting the Cylinder Head Nuts r Reset the valve clearances and finally check them when the engine 16 not hot or cold The cylinder head huts may pull down slightly more after the engine has
153. that the shaft assembly 15 fitted correctly for a slit a hole of set ring with a groove of shaft so as to insert and set the said ring correctly Pulley 55 6 Setscrew Pulley hub H 7 L 0 4 0 5 mm ES 1 24 5 lt 5 SS S lt saate aa o ao sed u E thickness geuge N M N N N bearings Floating seal Thickness 5 Vane Seal NN 2222 AL RG 21035 04000 gt Set ring pin mi Set bolt 7 UM Spring washer Body Cover Fig 6 Section View of the Water Pump Fig 7 Adjusting the Clearance the Vane End and Body First press down the shaft fitting with a groove line to insert the set Inserting thickness gauge Thickness 0 4 0 5 mm between the vane end on the U block bench Take out the thickness gauge and find out good condition Screw up with the cover and cork washer Pulley Shaft amp bear nee assembly Set pin Insert here thickness gauge 0 4 0 5 m x of 1 Case twice during case revolution of the LUBRICATION Circulation Pressure lubrication is used throughout the unit and is provided ecentric non draining 011 pump The pump 15 bolted into the left hand side of the crank case and 15 driven from the camshaft gear by a short vertical shatt Oil is drawn i
154. the open end of the cylinder being protected by a rubber dust cover The cylinder 15 mounted under side of the starting motor Dismantling Remove the rubber dust cap from the bleed screw attach a bleed tube open the bleed screw three quarters of a turn and pump the clutch pedal until all the fluid has been dramed into a clean container Unscrew the flexible pipe union and adjustable push rod The operating cylinder can now be removed Removed the rubber cover and 1f compressed air line 15 available blow out the piston from the side union Examine all parts especially the seal and replace if worn or damaged Assembling Place the seal into the stem of the piston with the back of the seal against the piston replace the springs with the small end on the stem smear well with the recommended fluid and insert into the cylinder Replace the dust cover and mount the cylinder in position making sure the push rod enters the hole in the rubber boot Secure the cylinder with the bolt and screw in the pipe union Adjust the push rod by the screw driver at top of withdrawal lever with the adjustable rod of 79 operating cylinder to give the end play 2 5 3 0 Bleeding the Clutch System Remove the bleed screw dust cap at the operating cylinder open the bleed screw approximately three quaters of a turn and attach a tube immersing the open end into a clean receptacle containing a small amount of brake fluid Fill the master cylinder rese
155. the whell and examine the resistance Tighten the nut A shghtly increased resistance to the spinning of the wheel will then be noticed The bearings are now preloaded and the split pin should be inserted to lock the nut Tap the hub cap to the hub after packing the cap with grease Replace the brake drum and secure with machine screws It 1s important that the drum 16 fully home before this screws 1s ughtened and if necessary the drum should be pressed in position by tightening two wheel nut Refit the wheel and nuts are best finally tightened when the car 1s off the facking blocks but readjust the brake shoes if necessary before the car 1s lowered to the ground STANDARD CAP road wheel COLLAR front spindle front hub 5 seal front hub WASHER ASS Y DRUM brake front wheel bearing front wheel FRONT HUB amp DRUM 111 Ei 54542 04101 SH M camber 1 0t 54543 04101 0 SHIM gmber 2 Or grease m 55 Y SHIM camber BUSHING NUT upper hnk ASS Y LINK n m upper ASS Y JOINT ball upper ie fx front suspension SEAL 4 upper ink upper ball ASS Y SPINDLE T knuckle with not L H v 5 ss SPINDLE ASS Y x z 1 24240 1 BOL T upper hnk STOPPER upper 1 24735 1 BOLT WASHER rebound o NUT ARM knuckle LH NUT
156. ting screw 18 to disperse the film of oil from the push rod Failure to follow this procedure will result in a wrong reading being taken Turn the engine over by hand Starting handle the push rod stops falling the valve 15 fully closed Fig 2 Adjusting the Rocker Clearance To adjust Fig 2 msert a screw driver in the adjusting screw slot and slaken the lock nut Then insert 014 in feeler gauge between the face of the rocker and the valve stem Raise or lower the adjusting screw until the correct clearance 18 obtained 5 Tighten the lock nut and recheck the clearance It 1s important to note that while the clearance 1s being set the tappet of the valve being adjusted must be on the back of the cam opposite to its peak nO o 19 15 Rocker shaft Length Quter diameter Rocker arm bush Type diameter before mounting Inner diameter Reamer finished dimension after mounting Th ckness before reamer finishing Clearance Rocker arm Bore Lever ratio CYLINDER HEAD Removing the Cylinder Head i oc taps 355 63 mm 14 1 32 m 15 850 15 875mm 0 624 625 1n 2 White with steel lining 19 075 19 101 mm 0 751 0 752 in 15 888 15 901 mm 0 625 1 2 0 626 n 1 644 1 727 mm 0 065 1 2 0 068 1n 0 013 0 051 mm 0 0001 2 0 002 in
157. to make sure that is within 0 1 mm 0 2 mm 0 004 0 008 Ifitis much move to left by taking off the right shim for adjustment Co a L 49 aL 5 2 45 4 ES 21 MARK MARK 2 22 23 i Fig 18 Thickness of Shim on Left Side Thickness of Shim on Right Side Left 7 Right Side 0 6 B D F 0 150 Example of calculation A 1 E 8 0 2 mm 0 025 mm 8 B 2 10 0 25 mm 0 025 mm 10 Left T A C D E 7 0 025 mm x 20 0 5 mm 1 1 3 8 7 Right 2 0 6 0 025 mm x 15 0 375 2 3 10 6 T A D C 0 07 E Ty B D 0 006 F 0 001 0 002 0 002 0 007 0 002 0 003 0 006 0 010 0 008 0 016 0 015 Thickness of left side shim Thickness of right side shim 147 The numeral marked by the electric pen on the side of the drive gear shows that of the recommended back lash besided the set number For example b 6 means the back lash of 006 in 0 025 mmx6 0 15 mm 1 Dial gauge 2 S T D gauge 20 mm thickness 3 Weight block 4 The bearing measured Fig 19 After the Operation Fig 20 M easurement of Backlash for the Drive Pinton amp Ring Gear 148 If 16 necessary to use the bearing again at the time of repairing the thick ness of each shim of left amp right must be reducted for 0 001 0 003 on the basis of 80 60 against standard preload n accordance with the practical condition
158. uld be cleaned by removing the drain plug at the bottom of the tank Check to see 1f the gasoline pipe of the tank unit 18 so bent as to fail to reach the fuel surface The standard position of the bottom end of pipe 18 about 3 4 in apart from the bottom 1n order to prevent its sucking up sediments on the tank bot tom not normal remove tank unit adjust the bend of the pipe Fig Wiring of Fuel Gauge Check too the vent hole of the filler cap 1s clogged with dust and dirt Unit gauge Ignition switch Fuse 5 Ammeter not supplying air to the tank G Fuel gauge 6 Battery According to the degree of vacuum within the tank fuel cannot be drawn up even by the operation of fuel pump So be sure to clean the air vent the cap you should lose the cap and substitute a wooden plug for it a measure which 1s sometimes witnessed the condition inside of the tank becomes the same as though 1t were sealed up Always use only the standard cap Operation and Repairs of Fuel Gauge shown n Fig 3 the fuel gauge consists of the dash unit and tank unit The dash unit which is installed on the instrument panel has two coils that cross each other at right angles whose magnetic forces control the movement of a keeper ron piece with a hand indicator On the tank unit a contact arm slides over a resistance in response to the float level As shown Fig 3 if the ignition switch 18 t
159. urned on when the tank 15 empty electric current will flow from the battery through the ammeter into coil A and then through the contact arm to the ground Coil A s then magnetized attracts the iron piece and the indicator points to E As the float 1s raised and the contact arm moves tank unit increases resis tance in the circuit and thus the current which traveled through coil A then flows this time both contact arm and coil B and finally to the ground AS both A and B cils are so wound as to have their magnetic poles 1n the same direction the 1ron piece will rotate to the direction where the magnetic power of the two coils can be balanced with the indicator deflecting 1n the direction of That 15 this 1s a gauge of electric resistance control type E signifies Empty level and F Full level Troubles with Fuel Gauge and their Remedies When something 15 wrong with the readings of the fuel gauge first dis connect the wiring at the unit and turning on the ignition switch ground and un ground the terminal end of the said wiring to the body of the car If the indicator of the dash unit swings actively between E and the wiring between the dash unit and the said terminal end is in good condition with the de fect existing either in tank unit itself or in poor ground of this unit In the test mentioned in the preceeding section if the indicator does not swing but it moves moves to E when the dash unit end of the wiring fro
160. utor are driven from the camshaft each component having its own drive shaft The pistons are each fitted with two compression rings and a slotted oil control ring Bearings of the thun shell preformed type are fitted to the connect ing rod big ends and to the main bearings counter blanced crankshaft 1s fitted The end thrust on this component is taken by special washers at the center main bearing The centrifugal water pump and cooling fan are driven by the dynamo beit GENERAL SPECIFICATIONS No of Cylinder 4 Bore 73 025 mm 2 875 n Stroke 71 mm 2 796 n Volume 1 189 brake horse power 60 HP at 5000 Torque 9 3 kg m at 3600 m Firing order 1 3 4 2 Valve arrangement Overhead valve push rod type Compression pressure 163 lbs sq in 11 5 kg cm at 350 p m Compression ratio 8 2 1 ENGINE RIGHT SIDE LEFT SIDE me E COOLING SYSTEM efficient cooling system 1 of major importance to ensure the satisfactory running of the engine and t 15 therefore necessary to pay paucular attention to maintance 4 Deseription The cooling system 1s maintained by water pump circulation combined with an efficient fan cooled radiator and thermostat The system is pressurised and the relief valve incorporated n the radiator filler cap controls the pressure at approximately 0 4kg per sq cm Do not remove th
161. wer craburetor throttle valve 1s also to be in a full open Float Chamber The float chamber 18 provided cover of which 1s made of glass of facihtate for inspecting 1nside condition through the marked line of cover of 1t Adjustment of the float level can be done from outside by adding or subtracung the needle valve carrier gasket after removing the float needle valve installed at the inlet connector As ventilation within the float chamber 18 of a air vent method and pressure within the venturi and the float chamber 1s always constant no matter how suctional registance of the air cleaner varies fuel consumption can be always economically maintained Pump arm Float valve sheet gasket Float valve sheet Union bolt Banjo union Needle valve Spring retainer Needle valve spring 6 Choke wire clamp Fig 7 Float Chamber Adjusting Fuel Level Float level 1s shown the float chamber cover with the hne 19 mm below the body top to which fuel 1s to be adjusted Adjusting the float level 15 done by adding or subtracting the gasket of float valve seat needle valve carrier Addition or subtraction of 2 numbers gasket make the float level up or down about 1 mm 53 Accelerating Linkages rap 4 gin 2 Ws T 9 4852 2225 SK 2 il 18142 10601 D 4 18022 67000 aK at do Y kN Y Fig 8 Dimensions of D 1 adjusted to 86 5 mm by rod and adju
162. x the crankcase complete with the element Take care not to lose the rubber sealing ring Remove the element and note the assembly of the components Wash out the bowl with pettol so that it is clean It 1s important to thorough dry the bowl to obviate any contamination of the lubricating oil Replacing the Filter With the center bolt the washer and the spring together with the collar 1n posi tion in the bowl insert a new element Place the distance piece over the center bolt with the flanged end towards the element The bowl of filter must now be filled with oil Offer up the complete assembly to the engine and secure into position by means of the center bolt Removing the Oil Pan The sump capacity 1s 3 1 litres Drain the oil and replace the drain plug Remove the set screw bolts which are inserted from the underside of the se curing flange and the lower bolts from the bottom edge of the bell housing Lower the oil pan from the engine taking care not to damage the joint wahsers inthe pro cess Removing the Strainer With the snup lowered it is possible to remove the 01 strainer through which 1s drawn into the 011 pump To remove the strainer unto the union Connecting the oil pick up to the pump and unscrew the securing bolts The strainer may be dismantled for cleaning purpose by removing the delivery pipe flange bolts Notice that there are the dowel pins to the cover which must be positioned c

Service Manual Datsun Model 410 Series

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