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Service Manual Datsun Truck Model 320

1. Sr x But 99 14 Jaysem xooT x st 4 R Y Asse ooqM J uid uojsiq L uo3stq 8913 uojsiq Ka gt e r gH z 0 u a SC elem u E ay r Pare Stu xs LC M cC MA PISTON Replacing Pistons and Connecting Rods k ki Insert each piston and connecting rod assembly into the cylinder from which it was taken it 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 12 and gently tap the crown of the piston with the wooden end of a hammer handle until the piston is clear of the piston ring clamp Fw 12 Piston Adapter z b E 2 Now push the piston down the cylinder block until 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 lower bearing has two 011 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 ughten with a torque wrench to
2. Spacer Drive pinin adjust shes Drive p mon Drive pimon rear bearing ja Lock pin Thrust washer Pmion mate Shaft m Diff gear case bide gear bide gear thrust washer x Drive gear Lock strap Drive gear bolt Body drive gear tightening terque z 484 553 kg cm Tighten by tepp ing bolt head with 1 4 Ib humer 38312 01300 38313 01300 oth contact ef differential gear ia more than 3 4 of ite width and backlash is 0 1 0 22 m Reference dimension 198 40 19855 amal After ass y of carrier gear pear as direeted apply ah m adjusting drive gear 38153 41516 27160 38161 27160 with thickness computed threagh the equations and give bearing diff side preleat 143 Thus the adjustment 1s completed By way of precaution measure the L measurement which is within 198 40 198 55 mm as Fig 12 If it is insufficient and an additional shim of 0 002 ins 0 05 mm n left and right In this case the large size of m chrometer as Fig 12 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 it 1s within 0 1 0 2 mm Mounting 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
3. wal DATSUN TRUCK MODEL 320 0x SERVICE MANUAL NISSAN MOTOR CO LTD OTEMACHI BLDG OTEMACHI CHIYODA KU TOKYO JAPAN CABLE ADDRESS NISMO TOKYO PHONES 211 5281 9 MODEL 320 NEW MODEL 320 U alton ie 4 INTRODUCTION This manual has been complies for purpose of assisting DATSUN d str butors and dealers for effective service and maintenance of the Model P L 320 U Each assembly of the major components 1s described in detail In addition comprehensive instructions are given for com plete dismantling assembling and inspection of these assemblies It 1s emphasised that only genuine DATSUN Spare Parts should be used as replacements 224 7 24 da a M f Lind CONTENTS SPECIFICATION ENGIN E General Specifications COOLING SYSTEM Lubrication ty owes Z Service Operations with Engine m Position Rocker Mechanism Removing 8 Refitting Operation with the Engine Removed FUEL SYSTEM The Gasol ne Tank Fuel Strainer Fuel Pump Adjustment and Inspection of Engine lk Carburetor BRAKER POINT AND IGNITION TIMING ADJUSTMENT Distributor Adjusting the Timing Checking the Spark Plugs CLUTCH Clutch Description of Clutch 661 TRANSMISSION e 3 Transm ss on D sassembl ng the Case Assembl ng the Transm ss on Selector Inner amp
4. 83 Fig 6 Clutch Release Lever 1 Carbon bear ng 2 Clutch lever 84 TRANSMISSION CROSS SHAFT ASSEMBLY COUPLING 85 TRANSMISSION GENERAL DATA Model 4 stages for forward 1 stage for reverse remote controled Synchro meshed for speed 2 3 8 4 Type of gear Synchro meshed helical gear type 320 UP UR 320 U UN 32010 07200 32010 07301 Speed 1 4 94 1 3 94 Speed 2 3 01 2 40 Speed 3 1 73 1 49 Speed 4 1 00 1 00 Reverse 6 46 5 16 1 No of tooth of gear Ma n dr ve gear 17 20 Ma n shaft 3rd gear 24 25 Ma n shaft 2nd gear 31 31 Ma n shaft Ist gear 28 spur gear 28 Counter dr ve gear 31 31 Counter th rd gear 26 26 Counter second gear 20 20 Counter f rst gear 11 spur gear 11 Reverse dler gear 13 amp 17 spur gear 13 amp 17 BACKLASH OF VERIOUS GEARS Play on revolutional direction Between main drive gear and counter drive gear 0 075 0 125mm 003 0 005 n Between third gears 0 075 0 125 mm 0 003 0 005 in Between second gears 0 075 0 125 mm 0 003 0 005 in Between low gears 0 075 0 125 mm 0 003 0 005 in Between speed 3 amp 4 Synchronizers and main 0 03 0 12mm 0 0014 0 0048 1n Between peripheral gears of speed 3 amp 4 synchronizers and coupling sleeve 0 075 0 125 mm 0 003 0 005 n Between speed 3 8 4 coupling sleeves and main drive gear 0 075 0 125mm 0 003 0 005 n 86 Between s
5. 9 11052 9020 32200 A e 48032 32200 9 15115 9 21440 48219 32200 Housing cover front 51124 109 Assembling and Inspection In case the replacement of parts 18 required due to the defacements and damages of steering gear and housing bush disassemble and adjust n the following order Dismounting of the Steering 1 Take off the steering wheel Pull out the three screws of the back side of steering wheel boss then take off the horn button retainer as well as horn button After unscrewing and taking off the wheel nut pull out the steering wheel with the steering wheel puller 2 Disconnect the clamp on and under the remote control rod which 1s fixed on the jacket tube after unscrewing the steering jacket clamp bolt under the in strument panel and disconnect the horn cord 3 Disconnect the steering gear arm with the drag link unscrewing the end plug at the side of steering gear arm of drag link thus 1s taken off from the gear arm 4 Take off the f x ng bolt of steering gear box which 1s fixed with the side mem ber of frame 5 Pull out the steering assembly to the downward direction Disassembling and Inspection of the Steering Gear After the steering assembly is dismounted and the gear oil 18 completely drained the steering gear box should be fixed on the vice setting the steering tube on level 1 Taking off the steering gear arm Take off the nut of gear arm and roller shaft cover and strike out
6. Construction and Operation Fig 1 Starter Motor The starter motor s a 1 horsepower sliding inertia type electric motor for use n starting The motor when mounted on the engine 1s on the front right side of the transmission with its pinion gear directly opposite to the ring gear The construction of the starter motor 1s similar to that of the generator but differs only in that 1ts armature shaft extends out backwards with a pinion group installed on the end as shown in Fig 2 m Fig 2 A Secttonal View of Starter Motor 175 da 1 Bracket 5 Field core 19 Pinzon group Commutator side 6 Flat head screw 11 Band 2 Oil cap C Armature 12 Through bolt 3 Yoke 8 Bracket Mounting side 13 Terminal bolt Field coil 9 Nipple 14 Commutator The connection diagram for the starter 1s shown in Fig 3 The starter switch 1s a key type combined with the ignition switch By turning switch to the right direction the re lay on the magnetic switch moves to permit current to flow to the starter and cause the d armature to start turning suddenly However the pinion n the pinion group does not turn be I Fig 3 Starter Connection caust of the counter weight but advances along the screw cut on the pinion shaft and meshes 1 Battery 3 Magnetic switch into the ring gear After advancing about 41 2 Starter button 4 Starter motor mm the pinion completes the meshing int
7. If the commutator surface 1s only oxidized t can be corrected with No 00 sandpaper 4 but if it is worn as described above cor b rections can be made only by supporting g ni N z both ends of the armature shaft and mach n 7 AVE ing s shown in Fig 4 However if worn over 3 mm t should be replaced Cont nued use of a commutator which A Correct finish 1S worn so that the depth of the segment B Incorrect finish mica 1s shallow may result n part of the mica becoming higher than the surface of 1 Maca insulation the commutator This condition will make 2 Commutator segment the brushes jump and produce sparks to burn and damage the commutator surface Fig 4 Undercutiing Commutator The depth of the mica 1s corrected by un der cutting the cuts being carefully made with a hacksaw to the condition shown in Fig 4 commutator surface is then finished by smoothing it with sandpaper or commutator stone Checking Brush and Brush Spring A If the brush does not seat properly against the commutator surface cor rections are made by reseating However if the brush 18 worn beyond the wear limit or is broken t should be replaced To reseat the brush a piece of sand paper of about No 150 fineness 1s wrapped around the commutator and with the brush installed n the holder over the sandpaper the holder 1s revolved For finishing sandpaper of about No 320 rating s used Af
8. side of the engine and 1s driven by a fan belt at 1 34 times the speed of the crankshaft As shown in the diagram of the generating system Fig 1 the generator terminal is grounded to the car body and the 4 circuit line goes through the voltage regulator and ammeter to charge the battery The generator s a constant voltage type equipped with a carbon pile type b Fig 1 Diagram of Generating system 1 Generator 2 Voltage regurator 3 Ammeter 4 Battery 6 Fuse 6 Lighting switch 7 Lamp The constant voltage type generator when charging maintains a fixed voltage at the generator terminals regardleds of the vehicle speed that 18 over a wide range of engine speeds and also produces an output conformmg to the load other words conform ng to the state of battery charge the charging current 1s au tomatically regulated preventing excessive charging or discharging When the load 18 increased suddenly the output will increase correspondingly so that the life of the battery will be prolonged Generator Construction As shown in Fig 2 the generator 1s flange mounted pulley driven type shunt wound and ventilated by a fan mtegral with the pulley 1s a so called enclosed ventilated type with the brush part covered with an easily removable band to faci litate inspection and cleaning 162 Servicing Generator Care should be taken to see that the exterior and the interior of the generator al
9. 44060 32201 Rear brake shoe ass y 153 Front Brake Adjustment 154 Remove the adjuster boot and insert a screw driver through adjusting hole and engage the teeth on the wheel Turn the adjuster wheel down upward direction until the shoe becomes locked on the brake drum then turn t up approximately 12 notches until the wheel turns lightly MASTER CYLINDER This 1s consists of an alloy body with a polished finished bore and reservoir with cap The inner assembly s made of the push rod stoper plate ring piston se condary cap return spring let out valve and check valve seat The open end of the cylinder 1s protected by a rubber boot as shown Fig 5 disassembling the Brake Master Cylinder Disconnect the pressure pipe umon from the cylinder and remove the securing bolts then the master cylinder and fluid reservoir may withdrawn complete from the car Remove the filler cap and drain out Pull back the rubber boot and remove the stopper ring with a pair of long nosed pers The push rod has been removed the piston with the secondary cap will 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 Fig 5 Components of Brake Master Cylinder 1 Push rod assembly 8 Return spring 2 Master cylinder rubbe
10. POWER CARBURETTING FUNCTION Main Carburetting System Same as the normal carburetting function the fuel flowing out of the passage at the bottom of the float chamber passes through the secondary mam jet and be come munute drops mixing with the air coming from the main air bleed and is blown into the venturi through the main nozzle E z A Fig 12 Carburetor Model Nikki 2D 30C 1 Float level 3 Needle valve 2 Float 4 Needle valve carrier When the throttle valve of the normal carburetor 18 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 18 an auxiliary valve which 1s not open at a slow speed with a heavy load due to the load of the 57 counter weight connected to the valve shaft even when the throttle valve 1s 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 18 n a full open the power craburetor throttle valve 18 also to be n a full open Float Chamber The float chamber 1s provided cover of which 1s made of glass of facilitate for inspecting inside condition through the marked line of cover of it Adjustment of the float level can be done from outside by adding or subtracting the n
11. bottom in exactly a straight line In reaming the upper hole insert the adaptor of taper in the bottom hole from up side and at its guide scrape the upper side SPINDLE Dia of king pin 20 000 19 980 mm 0 8 0 799 in Finishing dimension of inner dia of king pin bush 20 035 20 010 mm 801 0 800 in Finishing dimension of outer dia of king pin bush Gap of pin amp bush Amendment limit of dittoed gap Thickness of spindle shim Thickness of spindle shim Thickness of spindle shim 22 930 22 880 mm 917 0 915 in 0 10 mm 0 004 in 0 75 mm 0 03 in 0 25 mm 0 01 in 0 075 mm 0 003 in 118 Vertical gap of spindle 0 08 0 13 mm 0032 in Tightening of wheel bearing nut Tighten it at 30 ft lb and turn it 1 8 revolution back Front spindle shim 40032 25660 Front spindle shim 40033 25660 Front spindle shim 40034 25660 The bottom hole can be made and finished up in a reverse way as well Give the reamer an average force and finish up by turning to right so as the scraping face should be made smoothly At the time of pulling out the reamer t must be handled with much care turning to right direction to avoid giving any scratch on the surface The standard fitting of the king pin with the bush 1s 0 010 mm 0 055 mm Clean the both of them well smear with new oil They should be n a condition that can be turned lightly and be pushed n at the top
12. rear bearing inner race replacer and the adaptor should be employed in this case The adaptor n the round from 1s for fixing and the other for taking off It 15 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 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 adaptor at the lower frim of the race Supporting the tommy bar and screw up till the corn closely touches the adaptor then screw the wing nut to take out the rear outer race 13 To pull out the front bearing outer race from the gear carrier set the tool body pull it out with adaptor n the way of rear race INSPECTION amp REPAIRING OF 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 in every unit of ass y in regard with the defect and defacement before deciding to re used them 2 Every gear should be inspected as to the locking condition defacement or any defects on the surface to see if they can be reused In case of insufficient standard backlash deformation or found replacement 15 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 1n prog
13. 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 gasol ne strainer 9 Adjust the slow setting of carburetor 49 Tn 10 Checking operation of generator Check the generating condition and functioning of the cut out relay by means of indications of the ammeter 11 Adjustment of slack n fan belt 12 Adyustment of valve tappet clearance 13 Road test VVhile dr v ng n 3rd speed at about 25 km hr suddenly step on the accelerator If only a slight knocking results the ignition timing 18 correct Slow speed adjustment 1s made so that the speed 1s about 15 km hr when driving n 3rd speed Diagnosing of Engine by means of Vacuum Gauge and Combustion Tester In diagnosing the engine the condition of each cylinder can be assumed by measuring its com pression For employment of a vacuum gauge connect it to the engine intake manifold and refer to Fig 2 The use of a master motor tester as shown in Fig 21s convenient When a combustion tester 1s used install a special intake pick up 1n 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 the tester and judge the combustion condition ac cording to the mixture ratio of fuel and air When measurem
14. Dismantling With the clutch assembly select three spacing washers Fig 2 inset dnd place them over the code letter B on the base plate 1 Release lever height indicator 2 Distance piece 3 Center pillar 4 Clutch cover 5 Set screw 6 Pressure plate 7 Thrust spring 8 Spacing washer 9 Base plate 10 Lock nut 11 Adjusting screw 12 Release lever 69 Now place the clutch assembly on the three spring washer so that the holes n the cover coincide with the tapped holes in the plate insert the setscrews provided and tighten them a little at a time by diagonal selection until the cover 18 firmly attached to the base plate e B rh at all possible points This is most m 8 e q portant f the best results are to be a 11011 2 chieved Mark the cover pressure plate lugs and release levers with a centre i punch so that the parts can be reassem bled in their relative position in order to maintain the balance of the clutch Detach the release lever plate from the retaining springs and remove the three eye bolt nuts or adjusting nuts Slowly release the pressure on the Springs unscrewing by diagonal selec tion the setscrews securing the cover to the base plate The clutch can be lifted to expose all components for inspection meg e ae a A Rg ge co uve d SSS LN due N p m m Pa S E atik TUR lt
15. LOWER LINK F g 6 TENSSION poo 121 TIGHTENING TORQUE Parts Name Nut fulcrum upper link bolt Nut lower link spindle bolt Nut upper spindle fixing bolt Nut cross member front susp fixing bolt Threading bush lower link Threading bush upper link spindle Tighting torque kgm Fitting Upper Link Apply the rubber bush to joint of the upper link and the knuckle support and tighten with the bolt Pert Be 54542 04101 11 5 Shia 34543 04401 t2 6 cember 34844 04101 14 0 Fig 7 Fit the torque arm on the side of lower link Temporarily insert and tighten the tension rod Fit the lower link to the frame with the lower link spindle but tighten temporarily the lower link spindle nut Insert one end of the torsion bar to the torque arm In this case be attentive to the symbols R and L marked on the right and left sides of the bar Insert the anchor to the other end of the torsion bar and fit it to the second cross member After adjusting the vehicle carriage Tighten the lower link spindle nut under the torque of 8 5 9 5 kgm 122 FRONT SUSPENSION 8 Smear the graphite Trees s bere Tightening torque 14 16 n kg B 85661308 n Ben Torssion bur TT Upper wae if y T aap x xu Ni H 2 8281 _ b z Spindle gt 7385169398 Lower 13 upper torqu
16. 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 n use and loaded mm kg 36 9 13 1 0 7 38 9 29 1 5 Turnning Nos of coil 8 5 6 5 Effective turn of coil 6 5 45 Dia of coil wire 5 6 20 2mm 8 5 2 0 2 mm Diameter of coil 13207 08 a 000 e 13203 0810 5 Valve Grinding Before replacement of the cylinder 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 in with a suction type grinding tool The valve must be ground to its seat with a semi rotary motiron A light coil spring nterposed between the valve head and the port will assist considerably when lifting the valve n order to rotate the face to a different position This should be done frequently to spread the grinding compound evenly It 1s necessary to continue the grinding process until an even matt surface 1s produced on the seating and the valve face On completion the valve seats and ports should
17. 0 025 0 040 mm PISTON RINGS 7 The p ston r ng gap should be 0 008 0 013 n 0 203 0 330 mm when checked n the cylinder bore The clearance of tne 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 n 041 0 092 mm Because the piston rings do nor travel to the end of the cylinder bores a hp s eventually formed due to wear This may be checked with a dial gauge and must be removed If this is not 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 in 0 762 mm and 0 040 in 1 016 mm oversizes The piston rings should always be fitted from the crown of the piston and never pushed upwards over the skirt Before fitting the rings remove any carbon deposit from the grooves n the piston When fitting note that the second compression 1s tapered type and oil control ring 1s slat type processed by chromium plating y ph 33 REMOVING amp REFITTING Experience has shown that it is 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 upwards proceed as follows Completely drain the cooling system and the transmission disconnect and remove the battery and its supporting tray Remove the up
18. 40 amp hr 20 hr 50 amp hr 20 br 4 positive side 0 2 KW Carbon pile type STARTER MOTOR Voltage and power CLUTCH Type Operating system Master cylinder inside dia Operating cylinder inside dia TRANSMISSION Type Gear ratios lst speed 2nd speed 3rd speed 4th speed Reverse Oil capacity REAR AXLE Type 12 volts 1 4 hp Dry single plate type Hydraulic 15 85 mm 5 8 n 19 05 mm 3 4 n Four forward speeds and one reverse Synchromesh on 2nd 3rd and top gears For 3200 320 UN For 320UP 3 94 4 94 2 40 3 01 1 49 1 73 1 00 1 00 5 16 6 46 2 0 litres 0 53 U S gal Semi floating Gear ratio 4 875 39T 8T for 320 U 320 UN 5 143 36T 7T for 320 UP Oil capacity STEERING SYSTEM Gear mechanism Gear ratio FRONT AXLE Toe n Camber Caster K ng p n inclination BRAKE SYSTEM Type Foot brake Hand brake for other 320 series as potional 0 85 litres 0 22 U S gal Worm and roller 17 3 1 2 3mm 1 deg 30 min 4 deg 15 m n 6 deg Front Hydraulic uniservo type Rear Hydraul c duoservo type Mechan cal rear wheels braked Brake drum dia front and rear Master cylinder bore Wheel cylinder bore Front wheels Rear wheels SUSPENSION SYSTEM Front suspension Front springs e Dimension Dia x Length Rear spr ngs CAP 2 G Th
19. 5 wm EDS The field coil 1s placed in series with an ammeter between the positive and negative terminals of a 12 volt electrical source the ammeter shows an ex ceedingly high reading the field coil is shorted and should be replaced Rated currents are Hitachi 10 5 amperes Lead Wire Test Circuit Test To test the lead wire that 1s the wiring from the plus brush holder to the generator A terminal the two leads from the growler are contacted with both ends of the lead wire If the test lamp lights there are no defects but if it fails to hght there 1s a break in the lead wire which should be replaced If one test lead 1s contacted with one end of the lead wire and the other test lead contacted to the body and the test lamp lights the lead wire is grounded Plus Brush Test s One lead from the growler 1s grounded and the other lead is contacted with the plus brush holder If the test lamp lights the brush holder 1s grounded and should be replaced 165 ev 0 Testing for Grounding in Armature To test 1f the armature 1s grounded or not one lead from the growler 18 con tacted with the armature shaft and the other lead with the commutator segment If the test lamp lights the armature 1s grounded and should be replaced Testing for Sherts in Armature To test for shorts in armature coil the armature 1s placed on top of the growler and with iron piece held over the armature coil the armatu
20. 5 300 kg 660 lbs High gear 4 forward 1 reverse Low 3 94 2nd 2 40 3rd 1 49 high 1 00 reverse 5 16 N320 4 155mm 163 6 n 1 497 mm 58 9 n 1 530 mm 60 3 n 2 470 mm 97 2 m 1 560 mm 61 6 in E 1 254 mm 49 4 n 430 mm 16 9 in 955 kg 2 100 lbs 24 500 kg 1 100 lbs Low 3 94 2nd2 40 3rd 1 49 4th 1 000 Reverse 5 16 FINAL GEAR Gear ratio 5 143 36T 7T SUSPENSION Front Wishbone type independent suspension with torston bar Rear thickness and number of spring leaves 6 mm 4 12 mm 1 Supplemental Sp Shock absorbers Front Single acting Rear S ngle act ng Opt onal TIRE SIZE AND PRESSURE Front 5 50 14 6PL T 22 1b 7 Rear 5 50 14 6PL T 46 Ib PERFORMANCE Max speed 110 KPH 70 MPH Grade ability 0 30 Min turning gt rad us 5 2 m 17 ft 4 875 39T 8T mm 12mm 1 108 mm 80 mm S ngle act on S ngle act on 0 14 6PL 0 5 5 5 50 14 6PL 120 KPH 74 6 MPH 0 30 S 2 m 17 ft NOTE Other specifications are same as Model 320 U ENGINE vt M d Ns 8 TEL ENGINE The engine is of monobloc construction and 18 fitted with overhead valves operated by rockers and push rods from the camshaft 311 seals are fitted to the valves Three steel backed bearings support the camshaft which 1s chain driven The 611 pum
21. B 6E R Thread d ameter 14mm Plug gap 0 60 0 8 mm The spark plug has the function of igniting the air fuel mixture with the spark which jumps between its electrodes During 118 operation 11 18 subjected to ex tremely high temperature and pressure Ir this vehicle NGK Model B 6E Spark plugs are used Care should be taken to see that the specified spark plugs are always used for replacement Spark plugs are apt to become dirty with deposits of carbon and 011 droplets which may cause leakage or shoring between the delecto rodes Furthermore the spark plugs are sub ject to wear after long use Therefore remove the plugs every 2 000 km 1 200 miles of driv ing clean them and measure and correct their gaps to 6 to 0 8 mm In correcting the gaps always be sure to bend only the ground 5188 electrode never bend the center electrode If the insulator 1s damaged replace the spark plug A wire feeler type plug gap gauge should be used When screwing n the spark plugs be sure not to forget the copper washers If these have been flattend out or are worn they will not be gas tight and will cause such trouble as nter ference with the dissipation of heat To install a spark plug first screw it n as far as t will go by hand then finally tighten it by means of a socket wrench The use of such unsuitable tools as an adjustable wrench may crack the Spark Plug Section 1 Center electrode 2 Ground s
22. CS 16189 IE sum 16180 08102 16137 313 m 5 s janes 16036 08 na 20 1617831991 UE A 16310 08103 Q t im A 16103 31301 s 6063 91300 x TOR 16125 31301 16079 31301 yg 16080 31300 SY e S NN Se A doom 08100 The fuel tank has a capacity of 31 0 litres and 18 situated at the rear of the luggage compartment The fuel pump operated off the camshaft draws fuel from the tank and forces t into the carburetor float chamber A large and efficient air cleaner filters the air supply to the carburetor THE GASOLINE TANK Draining the Tank and Fuel Gauge The fuel tank 18 drained by turning the wrench operated drain cock Fuel Tank Gauge Unit Fig 1 Fuel Tank Securing Situated on the top face of the tank is 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 this also applies when refitting the unit Examine the joint washer to ensure that 1t 18 1n position and undamage This 1s essential as the joint between the tank and gauge unit must be fuel tight 39 GASOLINE TANK MOUNTING 1 14625 1 17422 08700 13414 1 9 15416 1 9 15116 1 9 11146 1 17488 28760 17424
23. Rivet one new facing n position then if the correct tool 1s 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 1n 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 in press over high spots until it s 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 80 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 are two dowels n the flywheel to locate n the clutch cover Remove a dummy shaft after these screws are fully ughtened 35 lb 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 is operated from a master cylinder py means of a suspended pedal A cylinder
24. shakeproof washers Note the position of the small lubricating 011 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 1s 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 1t being usual to do this when the cylinder block 18 being reconditioned The bearings can be removed by drifting them out of their hosings When fitting new bearings care must be taken to line up the oil holes with the corresponding holes n the cylinder block 3 Tap the new bearings into position and ream them to give a running clearance of 0 001 0 002 in 0 025 0 051 mm Refitting the Camshaft This 18 a reversal of the introductions for removal Care should be taken however to align and engage the drive pin n
25. 08700 1 14625 1 9 15416 1 9 18116 9 141 g q 1 14825 1 Troubles and Repairs of Gasoline Tank A When Fuel Leaks from Gasoline Tank When a crack distortion or damage is found in the tank repair or replace t 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 is 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 1s some fuel left in the gasoline tank and the operation of fuel pump 1s known to be satisfactory check the following points When t 1s difficult to confirm the delivery of fuel at the strainer loosen the connector at the fuel intake of the carburetor 1 Check to see 1f gasoline pipe 15 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 tip of gasoline intake pipe of tank unit is clogged with dust and water Therefore together with cleaning of the pipe the interior of
26. 21 7 24 6 lbs ft F nally knock back the lock washers Check the connecting rod big end for side clearance 7 1000 n and see that the shell bearings are not binding on the crankpin when rotating the crankshaft If 1t is difficult to turn undo the big end and exam ne the shell and seat for dirt or grit I Before reassembling always apply a little clean 011 to the piston surfaces and nto the cylinder bore Never 116 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 1s a push fit n piston at 70 F 21 1 C When reassembling ensure the gadgeon pin 1s positioned n the connecting rod So that its groove 1s n line with the clamp screw hole Check that the spring washer fitted under the head of the pitch bolt is not damaged PISTON PIN Diameter 17 447 17 452 mm 0 6869 0 6871 in Over s ze 5 1000 n 17 574 17 579 mm 0 6919 0 6921 in 10 1000 1n 17 701 17 706 mm 0 6969 0 6971 n 15 1000 in 17 828 17 833 mm 0 7019 0 7021 in Length 64 20 64 45 mm 2 568 2 578 n Clearance of pin and pin hole Degree to be able to push it by finger at 20 C Clearance of p n and connecting 0 003 0 010 mm rod bush hole 0 0001 0 0004 n 32 PISTON AND BORES There should be a clearance of 0 0010 0 0016 n
27. 50000 22165 30101 22 CP 2146 10360 22139 83060 22157 50001 22132 85060 22132 07200 I 2 yi 22184 50000 cUm 22102 50001 22123 30101 22301 07200 22127 07200 SS 7 22171 30100 22123 30101 BE e Ay fee T 4 e 22403 03020 q 22156 85060 22108 30102 60 4 0g P 22183 30100 22201 30100 22167 03020 7 55 22180 30101 E 22101 30101 22204 30100 2 22118 43800 22119 03020 22121 30100 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 1s wiped clean with a soft dry piece of cloth extra attention being paid to the areas between the terminals Clean the center electrode on the inside of the cap also Whether or not the vacuum type timing advancer 1s functioning properly can be determined by the inspection pointer located at the diaphragm if as the engine 1s being run this pointer moves when the engine speed 1s suddenly changed the advancer 1s satisfactory Adjusting the Point Gap ADJUSTING THE IGNITION TIMING The ignition timing 1s adjusted to 10 degrees before top dead center with the engine stopped as shown in Fig 1 With this adjustment the automatic timing advancer of the distributor advances the ignition timing even further at the t
28. 6 e 3urids 38954 avq 80 830 H 010 5 CH 1 00 50 60098 Sud zoyouy 68095 006V0 Z60 2 1 9 621 6 1 91951 6 d T SVI11 6 1 S11S1 6 00 90 0809 8utads 30017 BN IINU us 0995 99 3ur1de uoaz _ r e qong a 59488 Toq 3 snfps Je your 0 lt lt 09952 12195 0 160 9 H 130060 998095 KAS 955 6 195 T 81 1 6 gt utd mong 81191 6 H 7000690 1609 H 3 0 uorsu poy 09952 62195 00690 0029 mw 99621 6 4 1 91S51 6 gt 00190 9 198 09952 12195 099S2 62195 09952 62195 126 1 8bS11 6 REAR AXLE 40300 32700 40206 32200 3 24414 T 04 Q5Kg 43215 32200 Rear axle shaft berring 43216 32200 Grease catcher 43217 32200 Packing 40227 32901 40315 32200 Wheel cap Supply Wheel bearing grease as much as the clearance Capacity 031 seal spacer e ae ga 43070 44000 L 40225 04100 38212 11300 nen d I N 40921 04101 T 60 90 Bearing_lock nut Tu Lock Er 23069 12200 Serration bolt T49 21Ag m 9 12446 End ah m 432 9 32200 Bearing cage 4308 3220 44000 01201 4400 91291 L E Vheel nut RM OY 127 REAR AXLE THE CONSTRUCTION amp HANDLING The rear axle 18 semi floating and the hypoid bevel gear 18
29. 9 9 2 2 5 CHARGING HOUR CHARGING HOUR Fig 3 Constant Current Charging Fig 4 o Constant Voltage Charging Characteristics Characteristics 2 Instructions on quick charging For charging without the necessity of removing the battery from the car and for making the charge n a short time the quick charger is used In using the quick charger there is a tendency to pass a large current to hasten the charging time but in order to protect tht plates and also the life of the battery the speci fied current should not be exceeded and the charging current made as small as possible 186 Storing Instructions 1 Even if the battery 1s not being used it will self discharge Therefore a battery which has not been in use for a long period of time should be checked for its state of charge the battery 15 not to given a full charge at the start and a light maintaining charge every month thereafter 2 If the battery 1s not removed from a car which is to be stored the ground terminal on the battery should be disconnected in order to prevent discharging and fire hazards 3 If the battery alone 18 to be stored t should be kept n a cool place and away from direct sunlight 4 When battery fluid overflows and adheres to the surface of the battery the acid should be neutralized by wiping with alkali solution and the surface wiped to keep t n dry condition 187
30. Operating Lever Shaft PROPELLER SHAFT amp UNIVERSAL JOINT gt Propeller Shaft amp Universal Joints STEERING FRONT AXLE Front Axle vs n Setting of Tension Rod ee x g Page dar 106 114 REAR AXLE Rear Axle Assembling Adjustment BRAKE 5 IGNITION SYSTEM ELECTRICAL SYSTEM Page 117 118 122 138 Starter Motor Battery 147 150 164 171 SPECIFICATIONS For Model 320 U VEHICLE DIMENSIONS Length overall approx Width overall approx Height overall approx 2 1 505 mm Wheelbase 2 470 mm Tread Front 1 170 mm Rear 1 187 mm M n road clearance 177 mm CARGO SPACE DIMENSIONS Interior length 1 850 mm Interior width 1 427 mm Interior height 406 mm WEIGHTS Dry vehicle weight empty 945 kg Seating Capacity Max cargo weight Model 320 U 225 kg Model 320 UN 800 kg Model 320 UP 910 kg PERFORMANCE Max speed Grade ab l ty S n 4 M n turn ng rad us ENG NE Name K nd SO aes ote Q Cylinder No ane arrangement Cycle V lve arrangement Bore x Stroke Total p ston d splacement 120 KPH 75 MPH 4 185 mm 164 8 in 1 515 mm 59 6 19 2 1 2 5 2 m 17 ft 59 3 m 97 2 1n 46 1 n 46 7 n 7 0 n 080 1bs 2 500 165 000 lbs 000 155 38 Model El Gasoline engin
31. Side Example of calculat on K 2 LE gt w Ng NOOO non tl s Sa 2 5 2 N NN yu H nom R 3 F 0 015 0 002 0 003 0 006 0 010 T 8 40 006 0 001 0 002 0 002 0 007 0 008 0 016 A D C 0 007 E T Thickness of right shim Thickness of left shim 140 F g 10 1 D al gauge 2 STD gauge 20 0 mm thickness 3 Weight block 4 The bearing measured After the Operation 2 If t is necessary to use the bearing again at the time of re pairing the thickness of each shim of left amp right must be reduced for 001 0 003 on the basis of 80 or 60 against standard preload in accordance with the practical condition of use because over preload s given to the bearing with the shim of thick ness calculated from above method of computation Fig 11 141 pad Fig 12 Using the Differential Side Bearing Cap Gauge 142 DIFFERENTIAL GEAR CARRIER SECTION ML 38216 01300 38215 01300 7738210 25660 Companion flange wy m Q l seal Z 38140 04100 Z Pimon front bearing Supply chassis grease to oil seal lip when 855 Adjust Sh m edjust ng dr ve p nion and fShim adjusting diff bearing cap and correct tooth contact of gear hypoid making backlaab 1 0 15 ma Pinion bearing adjust shimis
32. The inspection for this should be made in a way as to make sure of the equal Conditions of backlash at the position of steering wheel when turned fully to left and right In case the backlash d ffers greatly the interlocking position of worm gear must be adjusted again The correct backlash at the both ends of worm gear should be made sure of after putting the more shim n the side of larger backlash at the gear arm and for equalizing pull out the shim on the opposite side and tighten up the bolt again adjusting with the shim in front of and the shim behind the gear housing The backlash at the center locking should also be checked and adjusted if necessary Installation of Steering Wheel Inspection by steering wheel The steering wheel 1s celation locked with the shaft and it may as be fixed to the forwording direction tightened may as well be fixed to the forwording direction 112 tightened with nuts The standard revolving weight gravity of the wheel on the wheel r m circle as for as it 18 rightly assembled s 500 700 gr measured by the spring scale The play allowed on the circle of wheel 1s 40 50 mm Installation and adjustment of horn button The horn button should be installed in a reverse order of dismounting Inspection and Adjustment of Steering Fixed on Car The inspection and adjustment of the steering system installed n the car should be made n following order 1 Set the car on the levelling place w
33. a new one Smear the faces of the Joint with grease and fit the joint washer L ft the 011 pan into position and insert the setscrews into the flange tighting them up evenly Reassembling the Oil Pump The outer rotor Fig 4 has a chamfered edge It 1s of great importance that this chamfer be towards the base of the body filure to assemble n this way will result in the cover 1s tightened down Insert the slotted end of the drive shaft into the body and bring the rotors into mesh 13 we 311 pump dr ve sp ndle O lpump pla n washer Q l pump gasket m 311 pump gear amp shaft ass y i 7 plain washer Lock washer L Dowei pin Onl pump Nut Lock washer Bolt Onl pump pla n washer Lock washer Q l pump drive spindle I ot Fig 4 Oil Pump 14 SERVICE OPERATIONS WITH ENGINE IN POSITION 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 start ing dog nut by using Heavy duty Shock type spanner A few sharp blows n an anti clockwise direction will slacken the nut Pull off the crankshaft pulley Removing the Timing Cover The timing cover 1s secured by set screw bolts each having a shakeproof washer and a special pla n vvasher Note that the special washer 1s cf elongated s
34. above the battery plates If the fluid level becomes low the specific gravity will rise due to fluid becoming concentrated the paste in the exposed part of the plate will become severely concentrated through oxidation the battery per formance will be lowered together with difficulty in recovery and shortening of the battery life The fluid level should be checked about twice a week during summer or n hot regions and about once a week during winter or n cold regions and the fluid replenished if found low If visual caps are used the fluid can be ob served directly from the top without the necessity of removing the vent plugs As shown in Fig 2 the plug center will apear colored if the fluid level is normal and appear white if the level 1s low Replenishing fluid The battery fluid s replenished with distilled water provided the loss 1s due to water only and not to battery troubles or overflowing Dilute sul FERMISSIBL phuric acid 1s not used 1s this case e lt 6 51 LEVEL If distilled water is not obtamable Ru PERMISSIBLE pO LOWEST LEVEL water from city mains or other clean T WHEN CORRECT WHEN TOO LOW water may have to be used As city water n many cases contains iron or purifying agents a filter suchas Fig 2 Checking Fluid Level Through puric should be sued Vent Plug After replenishing the battery fluid the battery should be charged at least 20 minutes n order to allow the tluid to mix thoro
35. 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 r p m Measurement of pressure 1s made n the following manner see Fig 1 First warm up the engine temperature of cooling water 70 80 C then remove all spark plugs and pull out the throttle knob all the way that 1s 1n the carburetor tne 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 Ib sq n or more from that of another the cause must be in vestigated 6 Check and adjust the distri butor If the breaker contact points have defective contact surfaces dress them and adjust the gap Compression Gauge to 0 45 0 55 mm Also turn the cam of the dis tributor clockwise and check to see 1f the governor can carry out advancing function 7 Adjust ignition timing correctly By utilizing a power timing light the function of the governor can be checked
36. and starter are checked If the switch is n satisfactory condition then the condition of all the terminal and ground connections of the battery starter switch and starter are checked If the starter motor runs but its movement 1s sluggish t indicates either a high resistance due to loose connection n the starter circuit or a badly dis charged battery 3 If after the above troubles are corrected and the starter fails to operate occasionally and shows defective performance it 18 due to interna defects so that n this case 11 should be dismantled and checked Dismantling and Disassembling 1 The starter can be dismantled easily by removing the two stud nuts mounting the starter on the engine 2 The two stay bolts on the starter rear cover front end when mounted on the engine are removed 3 After removing the band cover the brushes and lead wires are removed 4 By properly protecting and holding the starter body the armature shaft 1s pulled out 5 The armature and the front cover are taken out together 6 To remove the pinion group from the armature shaft the cotter pin on the end of the shaft 1s pulled out and by removing the pimon nut the pinion group is removed Inspecting and Repairing Parts The same procedure as that for the generator parts 1s followed the part being cleaned and inspected after which determinations are made as to whether they can be reused or 1f repairs or replacements are necessa
37. at the center rod of the equalizer drag link ADJUSTING BRAKES Raise the truck and place stand jacks front and rear so that all four wheels rotate freely Disconnect the parking brake cables at the cross shaft lever This precaution should be taken to eliminate the possibility of brake shoe drag due to mis adjusted parking brakes 152 Md COMPONETS OF REAR BRAKE P ston rear wheel cyl nder 44108 32200 44112 32200 Spacer rear wheel cyl brake 44135 32200 44109 32200 Adjuster screw 10 41146 32200 8 8 tm i 1 3 41147 32200 L H 41209 32200 pring UE a 11208 32200 I dr ock spr ng 44105 32200 tg M T az S Wheel 671 04 1 B M Adjuster wheel 41207 32200 R H 41208 32200 L H Adjuster housing ass 41203 32200 5 d m 41130 04100 41214 04100 Ss 41158 04100 44128 32200 41128 30001 41129 30001 44035 32200 R H 44036 32200 L H 4032 32200 Toggle lever 44034 3220 44033 32200 o 44070 32200 upper Reas brake return spring 44030 32200 44084 32200 44082 32200 7 32200 4 2 d Brake lining 41039 32201 1 cy 41158 04100 Adjuster boot41153 04100 Rear brake d sc 44010 32201 R H 44011 32201 L H link Rear return spr ng Lover 44071 32200 Adjuster 41200 32200 R H Juster 41201 32200 L H
38. be n the starter it self so that 1t should be removed from the engine and checked 180 This 1s exceedingly rare but care sgould be taken to see that the Starter pinion 1s not locked into the flywheel ring gear Cases like this are usually caused by badly worn gears meshing improperly and if the defect 1s not too severe 1t Can 52 be remedied by placing the gear sh ft lever into fourth speed and T rock ng the car back and forth to free the gears If this trouble 1s Pi 5 requently repeated the starter should be d smanted from the engine for checking and repairs Magnetic Switch 1 Starter turns but its turning power 1s weak and fails to start the engine If the trouble 1s due to a run down battery loose terminals trouble in magnetic switch worn and sticking brushes dirty and damaged commutator etc the checking and repairs are made in the same manner as described in the preceeding chapters If the outer surface of the armature 1s rubbing against the core the starter should be dismantled disassembled and repaired Besides the above there s the case of the pinion meshing improperly the trouble 1s due to the gear teeth being badly worn the gears should be re placed but if it is 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 exceedingly noisy when n opera
39. 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 E 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 m Valve seat width 1 63320 015 mm Valve stem outer diameter both 1ntake and ex 8 6805 8 6932 mm 0 341 3 4 0 342 1 4 n Overall length Intake valve 109 54 mm 4 5 16 in Ex valve 108 74 mm 4 9 32 in VALVE GUIDE Length Intake valve 47 63 mm 1 7 8 n Exhaust valve 57 94 mm 2 9 32 in Outer diameter both intake and exhaust 14 313 14 440 mm 5635 0 5685 n Inner diameter both intake and exhaust 8 733 8 860 mm 3438 0 34431n Inner diameter at guide inlet to insert both intake and exhaust 14 3 mm 5634 n Clearance of valve stem and guide both intake and exhaust 0 0394 0 0648 mm 0 0015 0 0025 1n Y 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 2 Screw back all the tappet
40. by the upper link bracket The lower link 1s connected to the lower side of the frame by the lower link bracket The torsion bar arrests the shocks from the road and the tension rod deter mines the lower link position 120 40030 25810 1 1174 1 pz 54519 08100 64521 04300 56129 2880 s 214 4711087001 seer ne S s S pred 2 4 710087001 4 3545330490 55127 2540 40080 04100 54541 04100 za san 2590 G NND m e 5 56123 a Z Spindle bush R P 40016 04300 amp 62 3 4 04101 0 56110 04 X d 2 lt Q lt Od N 39 37 1 a 54538 04101 31200 1234 1 488201 mi md 54541 04100 p 9 16211 40 07200 RH lt d 32202 4607 0 1 24740 1 Sa GAME Et 8700 M ZEK S J sq mmo 54501 04100 ssns 1 15115 s 7 2 r GA Q Gy AT e e 80088 7 4 f win i 5 gt 91118524 asi dei p ad PA ci 5 14 59 48 093 25660 5 11144 1 8 15115 1 Naso 54503 30000 54502 08700 ep p gt 54504 08700 7 sma 55155 04300 54701 04300 8 123471 8 astra 54529 07400 R B Ass y ANCHOR 54085 O4300 RH UPPER LINK OUNTING 54086 M SPINDLE ANCHOR PIN 54093 04300 TORSIN BAR Wu 54010 04300 RH 54009 04300 LH LOWER LINK SPINDLE
41. clutch housing end Ensure that the spring ring resisters properly in the racess 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 spl ned portion of the shaft Laghtly 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 phosphor bronze sleeve which carries the second speed is a tight fit on the shaft there t must be first immersed n warm 01 and then slid into position on the shaft Fit the second speed wheel over the sleeve then the driving washer 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 intothe hole in the main shaft and slide the splined washer Depress the plunger with a piece of wire through the hole n the third pseed and slide the splined washer over the plunger Then turn the washer for the plunger to engage with a groove in the washer 98 The gears are now assembled on the ma n shaft and there should be end move ment for the f rst speed gear between the center bear ng and the keyed washer at the rear of the second speed gear Assemble the two baulking rings to the third and top speed s
42. following methods can also be used to determine the con dition of the battery charge An tester 1s used to determine the voltage drop by contacting both terminals of the cell and permitting a large current to flow through the tester A battery tester 1s used to measure the terminal voltage of each cell By the values measured the condition of the battery charge can be determined A method frequently used to determine the state of battery charge 1s to place a wire or metal tool across the battery terminals to permit a spark to fly and mak ing the determination by observing the strength of the spark This method should absolutely be avoided as there 1s danger of igniting the gas generated from the battery of near by combustible fumes The previously described methods and the following chart should be used instead to determine the condition of the battery Terminal voltage B a Battery condition Complete discharge Impossible to use 1 4 charged 1 2 charged 3 4 charged Fully charged 184 Alrhough the internal performance of a battery can be eas ly determined by making a discharge test with a battery tester frequent use 18 not recommended as t will lower the capacity of the battery It is necessary that tests be made in accordance with the following chart and within 15 seconds Determining Repairability The above completes the instructions on Correct use and maintenance of the battery It the battery 1s overdischarged the pla
43. gear on left and right and drives at equal speed the rear axle on the straight line In case of turning or meeting at the resistance of some obstacles on the ground the pinion revolves itself on the pinion shaft and drives differentially the side gear as well as the rear axle show the revolution of left and right wheels differs The external side of axle shaft which locks with the side gear 1s inclined and fixed to axle housing with the brake disc The shaft 1s supported by the taper roller bearing to the axle tube with the brake disc fixed by the four bolfs together with the adjusting shim It 1s not necessary to check the lubrication to the bearing but need to feed the new wheel bearing grease in proper quantity when disassembled The proper lubr cation to the gear housing 1s also necessary otherwise it would shorten the durability of the gear to cause the trouble 128 6 The following points must be taken into consideration 1 Nominated Hypoid gear 011 No MP 90 must be used Temperature over 32 C SAE MP 140 ll 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 oll 15 about 0 9 The method of feeding 011 should be done by taking off the feeler plug at the rear cover of the housing and fill in full up to the feeding hole The brake system would not work if over feed the oil by causing it to flow out of the bath end of the rear
44. mounted on the clutch bell housing 1s coupled to the clutch operating shaft Fig 4 Components of the Master Cylinder 1 Push rod assembly 11 Piston return spring 2 Master cylinder rubber boots 12 Clutch master cylinder body 3 Stopper ring ass y 4 Piston secondary cup ring 13 Let in valve release pin 5 Secondary cup 14 R ng 6 Pr mary cup 15 Gasket 0 Master cylinder piston 16 Filler cap gasket 8 Let in valve assembly 17 Cap 9 Let in valve spring 18 End plug gasket 10 Return spring seat 19 End plug 81 When pressure to the clutch pedal s appl ed the p ston 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 1s protected by a rubber boot Dismantling the Clutch Master Cylinder Disconnect the pressure pipe union from the cylinder and remove the securing bolts then the master cylinder and may be withdrawn complete from the car Remove the filler cap and drain out the fluid Pull back the rubber boot and remove the stopper ring with a pair of long nosed pliers The push rod and ring can then be removed and u
45. o H T 00F1L0 2I 00 QO esmer vi un E 38923 H H 00810 51 898 H H 00220 969T oee 10799108 933903 poy X 1194 3utop H T 0090 H U 00710 LEPPE H T 00FLO LEPVE Sur4snfpe poy 9 8 y o T 202 3OVXNI1 7OYLNO9 31034 8 1 3 4 O0PLO GIPPE 1 81212 6 40133 9 oLyuo 00 20 5 658 215 221 91 Selector Rods amp Forks Using a soft metal drift tap forward for a short distance each of the three rods and prise out the keys which are fitted to prevent the rods from turning Now drive each rod forward clear of the forks and extract them from the case Care should be exercised n order not to lose the spring loaded ball fitted to each fork Lift out the three forks noting carefully their respective positions to assist reassembly Fitting behind the third speed fork 1s a distance piece which must be retrieved from the case when removing this fork Reverse Gear A lug which is an integral part of the main casting locates the forward end of the reverse gear shaft To secure the shaft n position a setpin 1s screwed through the lug locating n the shaft The setpin 1s locked by a tab washer Straighten the tab washer release the setpin then tap forward and remove the re verse gear shaft Lift out the reverse gear 27 259 38780 33331 00100 2
46. of it with a thumb without any play It must be noted to open the okl feeding hole which connect with 011 nipple at the top and bottom after the finishing of bush 1s completed After making the hole by the drill of the diameter in mm adjust the roll at the interior of the bush FRONT AXLE Type Independent suspension by torsion bar spring Toe n 2 3 mm Camber 1 20 30 Caster L 320 U 30 U L 320 U 3 50 L 320 UN 4705 0 320 U 3725 L 320 UP 1 30 1 Angle of ncl nat on of king 30 pin 6 Tread 1 170 mm Turning angle of front wheel inside 34 outside 29 30 Min turning radius 5720 metres ASSEMBLING amp ADJUSTMENT The assembling 1s made n a reverse order of disassembling with care to the following points 1 Inspect the locking part of the king pin and bush The inspection must be 119 made whether there 1s the oil hole or not after the bush 1s replaced 2 At the time of fixing the spindle with the axle the thrust washer should be replaced n an ass y because it consists of the armed blonze washer with the oil groove clipping two carburized rapping steel washer of upper and bottom and two covering covers 3 Use standard clearance the play to the direction of the axle between the upper end of king pin boss of the axle and the spindle is 08 0 13 mm In case of exceeding the standard clearance adjust it by inserting the front spindle shim 4 After the ki
47. of the wiring from the tank unit 1s grounded the wiring between the dash unit and tank unit 18 def ctive Therefore rewiring or repairing 1s required If when indicator fials to swing but sparking is observed when the wiring connecting the battery with the terminal on the dash unit 1s disconnected at the dash unit end and grounded it proves the wiring 1s satisfactory and the trouble 1S 1n the dash unit itself If sparking does not occur the wiring which 1s thus indicated 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 n error In this case adjust the height of the float by bending the rod Troubles with the unit are difficult to repair so 1t should be replaced by a new unit 47 m checking the tank unit be sure to insert a fuel gauge n 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 strainer 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
48. shaft gear second speed bush 43 Second speed synchronizer ring 44 Main shaft rear thrust washer 45 Second speed synchromzer hub Synchronizer spring Ball Main shaft bearing retainer assembly Bearing retainer locator Key Main shaft spacer Speed meter drive gear Main shaft lock washer Main shaft nut Locking peg Locking peg spring Counter shaft gear Counter shaft needle roller Counter shaft front thrust washer shaft snap ring Counter shaft spacer Counter shaft Snap ring Needle roller Rear thrust washer Reverse shaft Reverse gear bush Reverse gear assembly Counter If 1t 1s 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 n each assembly Take out the main shaft front needle roller bearings from the end of the drive gear shaft Rear Oil Seal This 011 seal is situated n the end of the rear cover and should not be dis mantled unless suspected of leaking It s almost impossible to take off the seal without damaging 11 consequently 8 new 011 seal should be fitted if the old one has been moved It will be seen that the 011 seal housing 1s pinched into position This can be removed by using a punch and hammer Drive Gear Shaft Before driving the drive shaft from its position tilt the counter gears now in the bottom
49. small bubbles appear and the specific gravity starts rising If the charging 1s continued as 1s the charging current being small will make the charging time very long so that the voltage should be adjusted from time to time in order to maintain a steady charging current of 6 to 8 amperes When the charging progresses so that the voltage in each cell becomes higher than 2 5 volts and the specific gravity over 1 280 gas will be given off vigorously and the fluid will present a milkey appearance When this condition 1s reached the charging current 18 reduced to about 4 amperes and the charging continued until the specific gravity becomes constant That 1s the charging 1s continued until three consecutive readings of the terminal voltage and the specific gravity Corrected to temperature taken every hour shows a contant value the charging being made by passing a 20 hour rate current through the battery 185 If the temperature should rise higher than 45 C during charging the current is reduced to one half or the charging 1s discontinued for a while until the tem perature drops The above is the constant current charging method generally used Initial charging 1s made by using a low current and long charging time but for ordinary recharging a current described above 1s used and the charging completed n about 12 to 16 hours The point to be observed n charging 1s determining the ume when the charg ng should be discontinued The
50. spider from its yoke 104 EXAMINATION amp CHECKING FOR WEAR When the propeller shaft has been n use for a long time the parts most likely to show signs of wear are the bear ng 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 1s essential that bearing races are a light drive fit n the yoke trunions Any ovality n the trumion bearing holes indicates the fitting of new yokes The straightness of the shaft 1s determined by measuring the offcenter deflection of the shaft n rotation with a dial gauge applied both ends If the deflection exceeds clearance limit Less than 4 mm correct or replace the shaft Reassembling See that the drilled holes n the journals are cleaned out and filled with 011 Assemble the needle rollers n the bearing races and fill with the oll Should diffi culty be experienced in assembly smear the walls of the races with petroleum jelly to retain the needle rollers 22 Nos n place Insert the spider n the yoke and tap the bearing n position with a foot nosed drift smaller in diameter than the hole 18 the yoke It s essential that the bearing races are a light drive fit n 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 j
51. taps At intervals a stiff piece 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 n cases where the fur ring up 1s excessive the operator will find 1t more efficient practice to remove the radiator completely and flush n the reverse way to the flow turn the radiator upside down and let the water flow 1n through the bottom hose connection and out of the top connection WATER PUMP After dra n ng the water from the rad ator remove the pump un t from the cylinder block by taking off the fan belt and releasing the setbolts with spring washers and hinge bolts to dynamo WATER PUMP S 1 9 15115 13 14580 1 Removing the Pump Shaft Assembiy D sconnect the fan blades pulley and cover The shaft and ball bearings is 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 The shaft and ball bear ng assembly can be drewout from the body Thus take out the vane floating seal and seal which remained the pump body Reassembly The reassembling of the pump 1s a revers
52. the rear end of the camshaft with the slot in the oll pump drive shaft 35 1 m Main Bearing Caps Remove the flywheel and clutch Take off the timing chain the sump and stramer and the engine rear mount ing 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 1s located in a recess in the detach able half of the bearing the other being plain When fitting new bearings no Scraping 1S required as they are machined to give the correct running clearance of 0 0005 0 002 in 0 0127 0 0508 nn Ensure that the locaung tangs are properly engaged in their recesses Handle the new bearings carefully so as not to damage the fine surface finish Remove all traces of dirt and oil from the housings and throughly dry them with a non fluffy rag Make sure that the oil ways are clear When f tt ng the bearing caps ensure that they are replaced the right way round Each cap is punch marked and the marks should face the camshaft side of the engine Engine Rear Side 36 Caution Never file the bearing caps to take up excessive play as this will cause ovality Always cover the bearing surfa
53. the suction side of the oil pump being defective remove the unit and rectify the fault 11 Removing the Filter A new filter element should be fitted every 6 000 km The filter forms part of the main oil gallery of the engine To remove the filter 1t 18 only necessary to unscrew the center bolt when the bowl can be removed from the cylinder block complete with the element For full flow type El engine it 15 necessary to cover with some of rugs to prevent from flow oil on the generator when remove the body 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 is important to thoroughly dry the bowl to obviate any contamination of the lubricating oil i Fig 3 Components of Oil Filter Replacing the Filter M Put the element with seat of it on the bracket Cover with the filter body after putting the element reta ner spring and the gasket n position Insert the center shaft into position and screw up it with tighting torque 2 2 5 kg m and secure into position by means of the center bolt 12 Removing the Oil Pan The sump capacity s 3 1 litres Drain the oll and replace the drain plug Remove the set screw bolts which are inserted from the underside of the se cur ng flange and the lower bolts from the bottom edge of the beli hous ng Lower the oll pan from the engine ta
54. their original positions To en sure eorrect refitting mark the caps and connecting rods on the sides to 1den ufy them together The piston and connecting rods must be with drawn up wards through the cylinder bores gt Release the connecting rod from the crankshaft and slowly push the piston and rod upwards through the cylinder bore 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 Remove the assembly from the top of the cylinder block Check the crankpins for oval ty 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 D stance between center of large end and smali end Large end bear ng Type Overall length Thickness Outer diameter Width of large end End play of large end Finishing dimension of inner diameter of small end bush Standard CRANKSHAFT Clearance of bearing 1 phery to cylinder block hole Material Clearance of bearing inner diameter and crank journal Diameter 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 Copperish metal with steel lining upper side White metal with steel lining lower side 25 273 25 527 mm 0 995 0 005
55. to settle the piles after which the push up voltage 1s rechecked 6 After rechecking the F screw 1s unscrewed until the specified no load voltage 15 16 volts 2 500 rpm 1s shown The F screw 1s then fixed 172 7 After the P and F screws are fixed the generator 15 stopped t 18 then restarted until t reaches the specified speed and the no load voltage 18 checked to see that t has the specified value It is important that before making this test the pile be given a light shock in order to bring it to a stable condition When the above adjustments have been completed the output should auto matically conform to the specified value This 1s checked by ratating the gene rator at the specified speed and impressing a load Checking Cut Out Relay The voltage at which the cut out relay points pim s checked This Adjust Spring voltage 1s determined by slowly in Point gap creasing the speed of the generator and reading the voltmeter connected Gap core EZ as shown in Fig 8 until the points to arm close The cut n voltage 15 to Adjust Arm from 12 7 13 3 volts at 1 250 rpm Nee If the voltage checked 1s found to be R too high when the points close the i relay adjusting arm shown n Fig 8 1s lowered to weaken the flat spring and if too low the adjusting arm is raised to strengthen the spring Relay 2 However t should be noted that the Fig 9 C
56. used for slowing down the speed The engine power 18 transmitted through the transmission to the propeller shaft then to the drive pinion and finally drives the left and right rear axle with the differential gear which 15 housed n the axle housing The axle housing s made out of the pressed steel plate n the form of Banjo and 1s constructionally strong enough against the torsion or the bending for its light weight with its rear cover being welded The gear carrier 1s made out of light and strong alloy of aluminum and the d f ferential gear ass y is so constructed as to make easy dismounting and the adjust ment of each gear carrier The rear axle shaft 1s materially made out of molydenum chrome steel of highly strength and the spline 1s of the involute gear type Inside the housing the drive pinion drives the bevel gear which 1s closely con nected with the differential gear case The each two pinions and side gears are fixed in this case and locked each other The pinion locks with the pinion shaft which 1s supported by the gear case while the side gear which 18 so supported as to function freely inside the gear case 1s connected with the spline at the top end of rear axle shaft Thus the construction of differential gear conbined with these gears has the function of controlling the difference of revolution of the rear wheels in case of turn ng to the various directions The pinion as t stays on the pinion shaft drive equally the side
57. 0 0012 in Play of pedal Approximately 25 30 mm 98 1 18in 67 DRIVEN PLATE ASSEMBLY This 15 the flexible type n which the splined hub is indirectly attached to a disc See Fig 1 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 11 and a cast iron pres sure piate 2 located by six thrust springs Mounted on the pressure plate are three release levers which pivot on floating Pins retained by eye bolts Adjustment nuts are screwed on the eye bolts and se cured by stak ng Struts are interpossed between the lugs on the pressure plate and the outer end of release levers Anu rattle springs load the release levers and retainer spring connect the re lease lever plate RELEASE BEARING The release bearing consists of a carbon bearing shrunk into a bearing 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 pedai 6 x21 9 0232 01 14 30231 02100 11 30211 37180 12 9 153 13 1 15 20814 m y m 30222 01300 11 19 16 30510 30100 5 m 30531 30100 n 22 30898 20002 Fig 1 68 1 Cl
58. 0 C159 N amp De H H opts m 00 50 6059 3 S 00190 07589 0190 6858 006Y0 Z790 0 0 0998 0011 6 ZOCLE 6 pol 88012 00190 02589 89211 6 20 26 6 006970 1158 0020 02589 H T 794006 pol 8801 H H 394908 pol 9801 35VXNII 9NISN331IS 115 FRONT AXLE ROSS MEMBEF nada Y REBOUND BUM Za 3 FENSSION R e noce K Fig 1 FRONT AXLE DISASSEMBLING OF FRONT AXLE Disassembling and d smount ng of the front axle should be carried out n the fol lowing order if required n case that it is bended by the violent shock or with any other reason 1 Unscrew the connector of the brake hose for the front wheel on left and right at the side of frame 2 The front axle unit can be disassembled further as follows Taking off the cover loosen the spindle nut after the hun cap 18 taken off It can be easily removed first by tapping lightly around the cap and pry with the screw driver 116 Take off the front brake d sc ass y Pull out first the machine screws and after taking off the oil catcher with the packing remove the four cap screws which fixed the disc to the spindle Thus the disc ass y can be dismounted Dismounting of the tie rods The tie rod ass y can be dismounted by disconnecting the stud nut of the rod socket on the both end of side rod Taking out the spindle of the axle The king pin must be pulled out first Pul
59. 1n 1 8288 1 8352 mm 072 0 0725 nn 51 346 mm 2 015 in 26 8 mm 1 055 n 0 203 0 305 mm 008 0 0121n 17 450 17 462 mm 0 6870 0 68751n 0 013 0 050 mm Forged steel 0 0127 0 0508 mm 0005 0 0020 1 50 183 50 825 mm 2 0005 2 001 in 0 051 0 076 mm 002 0 003 in 47 640 47 652 mm 1 875 1 876 n Less than 0 012 mm 0 00048 n Less than 05 mm 002 n The shell bearing are removable by hand The bearings are require no bedding n 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 n their corresponding slots Always renew bearings if they are scored or dam aged n 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 29 LAVHS MNV49 NOLSId 7 5 NET r NO se 3 1 jnu 7577 7 yN K 2 2 N d 594401 Sutqsnq poz 8 h 8 w N D Ysng por 913229903 gt 89132915 2 E b 4 JOYSEM A SSE yjeys yun goopanu I Bulu 4858 r w 5 Yumg J9MOIg 10 17J0YS YUN 5 s y v eqs 9 s S quel amo e o d Aay ILYS 92 bad N ssu pol Sur12euuo t Gae e
60. 2 4 5 6 7 8 9 10 11 12 13 14 15 16 Pr m ry S de Body assembly Venturi Float chamber Throttle shaft Main jet Ma n jet carrier Float chamber cover Float Main air bleed Air bent pipe Choke valve Choke control link Connecting rod Choke wire blacket Throttle wire blac ket Lower body 17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 Auxiliary throttle valve Throttle valve By pass hole Slow jet Venturi Auxiliary valve shaft Ma n jet Ma n air bleed Pump injecter Out let valve Inlet check valve Power valve Pump piston Air vent hole Pump piston return spring Connecung rod 55 Main Carburetting System The fuel flow ng 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 dense mixture gas the acceleting pump opens 115 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 yet the fuel passage separate from mam line and flows through the slow jet slow air bleed first slow economizer slow air bleed second and inject from the
61. 2mm Tension when n stalled 19mm 8 6 0 4 kg Diameter of check ball 5 16 in 7 94 mm Control rod return spring Free length 81 7mm Coil diameter 10 5mm 318 of wire 1 2mm Tension when installed 54mm 3 3 kg Change speed lever spring Free length 35 mm Coil diameter 20 mm Dia of wire 1 6mm Tension when installed 12 mm 6 0 3 kg Cross shaft spring Free length 38 mm Coil diameter 21 mm Dia of wire 23mm Tension when installed 20 mm 15 1 kg 311 to be used Standard of oil Genuine gear oil MP 90 Hypoid gear oil In warmer district than 32 C use 140 311 quantity necessary 32101 01300 Transmission case Ka t 1 14537 9 B 4 AS lt 15115 1 bz KS GG men 11791 04100 Hear extension 2220 6720 asa biy A 1131 0000 Amy 33296 0015 90943 01201 320 0 UN T M 32010 07300 T M Case 32102 01900 320 UP UR T M Asa y 32010 07200 T M Case 32101 01300 1320 U UN 32010 07400 32101 01400 1320 UP 32010 01600 32101 01400 lig 1 A Components of Transmission Case 89 DISASSEMBLING THE CASE First drain the oil from the transmission by removing the drain plug The drain plug 1s situated beneath the case at the left hand side Clutch Withdrawal Lever Bend back the lock washer remove the nut its spring washer and screw the bolt out of the bracket The leg of the clutch withdrawal
62. 3 12228 001 18 s s osioo 3280 0905 20 29960 1283 0160 21 17 132 04 32304 90100 22 pum risen Y 151141 a j vi amas o Gaal S i u mao mo 12 ss 6 6 6 6 A 10 22889 00100 Z 11 22213 0166 lt 20 EN s TL 5 1176 4 5 12114 1 4 9 18415 1 154146 1 32917 001 eS 96 15114 32312 09000 3 Fw 2 Fork Shaft 92 1 Operat ng change speed fork 14 Selector cross shaft lever assembly 15 Lock pin 2 Change speed cross shaft 16 Plane lock washer amp plane nut 3 Change speed operating fork 17 Change speed gate assembly 4 Change speed operating fork 18 Reverse fork 5 Fulcrum pin 19 Reverse fork rod 6 Change speed cross shaft 20 Check ball lever 21 Locking ball spring 7 Lock pin 22 Fork rod lock ng strip big 8 Selector shaft assembly 23 Fork rod lock ng strip small 9 Selector shaft 24 F rst amp second speed fork 10 Taper p n 25 F rst amp second speed fork rod 11 Selector cross shaft inner 26 Third amp fourth speed fork lever 27 Third amp fourth speed rod 12 Cross shaft oil seal 13 Felt ring Counter Shaft amp Gear Using a soft metal drift drive the counter shaft forward and out of the case when the counter gear cluster and two thrust washers will drop to the bottom of the case These g
63. 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 6 finally pulling them down with a torque wrench set to 45 lbs ft 8 4 2 6 Fig 6 The Order of Tighting the Cylinder Head Nuts Reset the valve clearances and finally check them when the engine 1s not hot or cold The cylinder head nuts may pull down slightly more after the engine has attained 115 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 Place the thermostat and ts 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 drain tapes are closed and refill the radiator Clean and adjust the sparking plugs and refit them clipping on the hightension leads The firing order of the engine is 3 4 2 Replace the clip which se cures part of the electrical whiring
64. al of the disassembly procedure but a care should be taken to ensure that the shaft assembly 1s 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 Setacrev Pulley vs Pulley hub N di 0 4 0 5 25 Float ng seal Thickness 5 mm Vane Seal ITEICOL C 811 ZER Sp ear AZ Z KEN 21035 04000 Set ring pin Fig 1 Sectional View of the Water Pump Adjusting the Clearance the Vane End and Body First press down the shaft f tt ng with a groove line to insert the set pin 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 Shaft amp bear ngs 2 assembiy Set pin Floating seal Insert here thickness gauge 0 4 0 5 m LUBRICATION Circulation Pressure lubrication 18 used throughout the unit and 1s provided by gear oil pump The oil pump 18 bolted into the left hand side of the crankcase and 18 driv en from the camshaft gear by a short vertical shaft Oil 18 drawn into the pump via the filter and 1s delivered through internal oil way The relief valve directly 15 situated n the oil filter body From the relief valve the oil passes into the main oil way if caused the element fail to pass rhe 011 The flow then passes via
65. arance 0 013 0 051 mm 0001 2 0 002 n Rocker arm Bore 19 012 19 037 mm 748 1 2 0 749 1 2 m Lever ratio 25 003 to 35 719 mm 63 64 to 1 13 32 in CYLINDER HEAD Removing the Cylinder Head Drain the cooling system by opening the radiator and cylinder block drain taps One 1s situated inlet tube at the backside of the radiator and other at the rear right hand side of the engine If anti freeze mixture 18 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 retaining clips on the hose connecting the radiator to the thermostat housing and remove the hose Extract the termostat housing securing nuts and remove the housing and thermostat Remove the aircleaner carburetor rocker cover and the inlet and exhaust manifolds Detach the high tension cables and remove the sparking plugs also dis connect 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 in the order of removal 20 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 a piece of wood interposed to take the bl
66. axle housing into brake drum Dismounting amp Disassembl ng of Differential Gear Carrier 1 Take off and drain out the gear oil 2 At the time of dismounting the gear carrier pull out the both left and right axle shaft or pull out for at least 4 inches 3 Take off the joint flange from the side of propeller shaft 4 Pull off the nuts of the hous ing 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 2 with the 4 of s de bear ng puller pull out the bear ng The puller pull out the bear ng The puller should be handled w th care n catch ng the hedge of bear ng nner race which 1s hard to hook Both the left and r ght bear ng should be arranged separately 7 Dismount the differential dr ve gear by loosening the 8 al vixing screws on the differen p 22 tial gear case and spreading Std 2 ller ot Dock deber Fig 2 Using of Side Bearing Pu oe mee 129 Loosen them n a diagonal line considering to keep from the gear bending 8 Take out the differential pinion as well as the side gear The pinion mate shaft should first be pulled out by striking out the pinion mate shaft licking pin which 1s fixed on the differential case from left side from the side of ring gear fixed to the right before pulling
67. be centralised by a dummy drive gear shaft which fits the splined bore of the driven plate hub and the pilot bearing of the flywheel The clutch cover assembly can now be secured to flywheel by means of the holding screws tightening them a turn at a time by diagonal selection There are two dowels in the flywheel to locate in the clutch cover Remove the dummy shaft after these screws are fully tightened Finally remove the dummy shaft and refit the withdrawal bearing and transmission The weight of the trans mission must be supported during refitting n order to avoid strain on the first motion shaft and distortion of the driven plate assembly Finally repeat the procedure to make quite sure the release levers are seating properly and gauge again Secure the eye bolt nuts and fit the release lever plate on the tips of the release levers then secure by means of the three retaining Springs Release the setscrews a little at a time by diagonal selection and remove the clutch assembly from the base plate Refacing the Driven Plate a new complete clutch driven plate 18 not available new linings may be fitted to the old driven plate in the following manner Each rivet should be removed by using a 3 5mm diameter drill The rivets should not be punched out Rivet one new facing n position then if the correct tool 71 18 not available use a blunted center punch to roll the rivet shanks securely against the plate The second facing shou
68. begining to push the directly and the voltage rises rapidly This as the push up voltage 15V NO LOAD TERMINAL VOLTAGE Fig 6 Postion of bile pressure screw and no load terminal voltage 171 The voltage is measured by connecting a voltmeter between the A and E terminals as shown n Fig 8 Lock Screw Fig 7 Adjusting Core The procedure outlined below should be fol lowed n making necessary adjustments from this stage on 1 With the connections made as shown in Fig 8 have the generator at no load B ter minal disconnected and rotating at specified speed 2 500 rpm 2 Set the pile pressure screw position 3 Tighten the adjusting core F screw and determine the push up voltage If the F screw 18 tightened beyond the push up voltage 10 5 volts 2 500 rpm the voltage rises extremely fast so that care should be taken Fig 8 Wiring hook up to tighten as slowly as possible when near meassuring push up voltage the push up voltage 4 If by adjusting the F screw the specified push up voltage cannot be ob tained but 1s less than 10 5 volts Case A the F screw 1s unscrewed back nearly to the noload voltage and the P screw 18 slightly tightened If more than 10 5 volts Case A the P screw 18 lightly loosened Then by following the procedure shown n 111 the push up voltage 1s redetermined S When the required voltage 1s obtained the P screw 1s fixed and the pile 18 given a light shock
69. by pass holes and 1016 holes Accelerating System Mechanical accelerat ng 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 1s comming down the inlet check valve closes the out let check valve opens and the fuel within the pump 1s 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 compensat ng trancient sparseness of the fuel A jetting amount of the fuel can be varied with the two holes provided on the pump arm that is the inserting positions of the connecting rod Starting System The choke valve 1s provided with the spring and installed eccentrically on the normal carburetting device and synchronized with the throttle valve When the choke 1s fully closed the throttle valve opens about 14 from a full close This is the best condition to start operation The synchronization of the choke valve and the throttle valve can be exactly maintained often the engine has started firing 56 12 Choke control l nk 13 Connecting rod 14 Choke wire blacket 15 Throttle wire blacket 33 Start ng con rod 34 Auxiliary lever 35 Starting throttle lever 36 Spring 37 Throttle adjusting screw 38 Con rod 39 Throttle wire clamp 40 Throttle lever 41 Scale 42 Idle adjust screw
70. ces with engine oil when they are replaced The main bearing caps are held n position by set screws and lock washers Pull the set screws up tight with a torque wrench set to a loading of 75 80 lbs ft 10 36 11 05 kgm When refitting the main bearing caps tighten the center one first after each cap 1s tighten rotate the crankshaft to ascertain that t revolues freely If t is 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 n 0 051 mm If a bearing has run t is essential to clean out all oil ways n the crank shaft and block Wash out the engine sump and the strainer The 611 pump should be dismantled and cleaned Ensure that no particles of bearing metal are left within the engine lubrication system Fig 15 Removing a Main Bearing Cab amp Extractor 37 16124 31300 16277 081 16 a 16111 08101 _ 1 m m T A 16091 x w 16114 31 16121 31300 Ec 16193 31300 z 16072 31300 aae 79 M po z 16192 2 103528 16145 3130 16031 31300 16255 08102 16080 31300 E TR Le S si o FUEL SYSTEM 16141 08100 A 16116 31300 31300 5 y R 31300 16131 ma 31300 16065 31300 gt 8100 epi EN Gy p PORR
71. chanically 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 1S pushed and pull rod of diaphragm 18 pulled down At the same time diaphragm goes down against diaphragm spring and then 1s pushed up again by its spring By the movements of the diaphragm and functioning of the valves at the nlet and outlet of the pump chamber gasoline 18 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 1s not allowed into the carburetor Thus gasoline 1s stored n the pump chamber and due to ts pressure the diaphragm 19 kept down and cannot return Under this condition the rocker arm works n 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 45 Disassembling amp Inspection 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 should be ejected vigorounsly from the tip of the pipe once every two rotations of the crankshaft To test the function of the p
72. ckwise Firing order 1 3 4 2 Point gap 0 45 0 55 mm 018 0 022 n Dowel angle 50 55 Contact arm spring pressure 0 5 0 65 kg Condenser capac ty 0 20 0 24 mfd Inside the distributor is a braker point as shown n Fig This braker makes and brakes contact several thousand times n one minute Each time this braker brakes contact a spark 1s generated n one of the spark plugs Therefore the maintenance of this braker must not be treated lightly Also because the time during which the gn t on coil current flows varies with the gap between these braker points see that this gap 1s maintained at the standard value which is 0 45 mm 0 018 to 0 022 in The braker points must be kept free of grease and oil If the points should become burnt or 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 Adjusting the Braker Points To adjust the braker points turn the engine crankshaft with the crank handle until the braker is fully open Then loosen the braker point fixing screw Next by turning the adjusting screw move the plate until a feeler gauge of 0 45 to 0 55 59 R pats fa a 4 Os Z DISTRIBUTOR 22136 30101 E 22162 30104 22208 30100 22116
73. completion time must be such that there 18 no overcharging or undercharging If overcharged more than necessary the charg ng current will be used up n decomposing the water n the battery fluid and not only wil the loss be great but this will hasten the aging of the plates due to tem perature rise Efficient charging 1s attained when the charging 1s made with the least possible amount of gas being generated Gas begins to be generated at the time the battery voltage begins its sudden rise from around 2 3 to 2 4 volts Therefore if the electrical source voltage 1s maintained at 2 3 to 2 4 volts the battery voltage will be unable to rise higher and the battery can be charged with the lease amount of gas being generated This 1s the constant voltage charg ing method n which an exceedingly large amount of current flows at the start but as the charging progresses the current decreases and when the battery voltage becomes equal to the electrical source voltage there will be practically no current flowing However to adjust the specific gravity after completing the charge 11 1s necessary to use the constant current charging for this purpose ms ui t 89 z s 6 Erard olo o xo 5 27 2 gt 24 m 26479 8 09 Z L RAVITY 5 5 28 24 60 eo S el 7 424 DmrE 24 RESOURCE VOLTAGE 426 122 B 229 40 Ht E Hohe 23 TERMINAL VOLTAGE gt 08 a 2 M3 ELECTROLYTE TEMPERATURE CURRENT zs m Oe 27 2946 6 7
74. connecting 011 ways to the main big end and cam shaft bearings through drillings n the crankshaft The connecting rod ends are drilling in the cylinder block and the rear rocker shaft bracket to tubri cate the rockers and then drains back into the engine sump via the push rod aper tures Oil from the center camshaft bearing enters a gallery on the left hand side of the engine and lubricates the tappets through individual drilhngs 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 case twice during case re volution of the camshaft to provide lubrication for the timing chain and gears From the t m ng case the oil returns via a drain hole back to the engine sump The filter there fore forms part of the main 011 gallery and as such 1s filled with 011 under pressure The full of 011 enters the ele ment through holes in the casing and passes through the element into the annular space round the center bolt This space s sealed top and bottom so that the 011 can only es cape through the hole into the hol low center bolt and from this point back into the inlet passage through the element 10 Draining the Sump Oil Pan The sump 1s a metal pressing with the drain plug One new and reconditioned engines the sump must be drained and refilled with new oil after the first 1000 km and subsequentl
75. d fourth speed fork Now tap the third and fourth fork rod through the casing Continue tapping the rod through its fork until t reaches its final position Next locate the reverse gear fork and then enter the first and second selec tor fork rod and the reverse gear fork rod through the casing and into their respec tive forks When driving the fork rods hole remember to retrieve the pilot bars as they leave the forks The key ways n the rod ends are offset and when fitted the narrow face should be at the bottom SELECTOR INNER amp OPERATING LEVER CROSS SHAFT With the selector lever Fig 1 B pinned to its respective cross shaft also change speed cross shaft lever assembly cottered to 1ts own cross shaft the two shafts should be positioned in the case with the respective levers nearest to the side cover opening Note that the eelector cross shaft takes the forward position n the case At the same time that the shafts are placed inthe case the change speed gate should be threaded over the levers and the whole assembly put into the case as one unit The gate is located in position by its rounded ends n the machined recesses of the side cover seating Before fitting the levers the oil seal and felt ring must be fitted to each shaft in that order The levers are cottered to their respective shaft Side Cover Secure the side cover into position by means of the bolts and screws ensuring that the side Cover 1s intact Front Cove
76. d the nega tiveplates Thus as the discharging continues the sulphuric acid n the electrolyte becomes more dilute the specific gravity drops and the discharge capacity becomes less If this time a charger is placed between the positive and negative terminals and current forced to flaw n the opposite direction to that of discharging the lead sul fate covering the plated will be decomposed to increase the density of the dilute sul phuric acid raise the specific gravity and restore the battery to its former state The above 18 an outline of the discharging and charging principles of the battery t is re quested that these principles be thoroughly understood before servicing the battery Servicing 1 External inspection Rust or corrosion on battery terminals Damage 1n battery case Damage n battery posts and improper contact It 1s feasible to check the above points without removing the battery from the car Care should be taken to keep the battery clean at all times so that any abnormal cor rosion of the connections overflowing of the battery fluid and other visible troubles can be quickly detected and the cause determined 182 2 Battery electrolyte Fluid level Since the battery fluid gradually decreases due to the loss of water caused by evaporation and electrolytic action the vent plugs n each cell are removed and the fluid level checked It 1s important to maintain the fluid level at about 20 to 24 mm
77. drive pinion adjusting shim are arranged as following hz mmm 38153 25660 0 75 mm 0301n 1 38127 04100 38154 35660 0 25 mm 0 010 in 2 38128 04100 38155 25660 0 125mm 0051n 2 38129 04100 38156 25660 0 075 mm 0 003 1n 2 38130 04100 The use of the adjusting shim will be explained in the following paragraph of adjustment Supposing the drive gear and the drive pinion were replaced 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 pinion Deduct the previously used shim in case it 1s plus increase in Case of minus and have the general idea of required thickness of the shim for assembling to prepare 1s convenient to inspect the condition before disassembling in a way 88 men tioned later in the measurement of pinion height Beside the condition of defacement on the carrier the pinion bearing must be taken into consideration though it wall be explained n detail later Drive pinion adjusting shim B Fixing and Adjustment of Drive Pinion 1 Drive pinion rear bearing outer lace should be mounted n the carrier In this case after inserting the properly selected adjusting shim as previously mentioned between the carrier and bearing race mount the outer lace by the special tool of drive pinion front rear bearing outer race replacer For adjustment of previously mentioned pinion h
78. e 4 cyls In line 4 cycle Valve in head 73871 mm 2 875 n x 2 796 n 1 77 2 5 cu in Compression ratio palm P a S 429 82 S oues c c 5 60 HP at 5 000 r p m SAE Max torque 9 3 kg m e ft lb har 3 600 r p m Qi leet 1 3 4 2 F r ng order Q 4 4 ta aps Valve t m ng Inlet opening Inlet closing Exhaust opening Exhaust closing Valve clearance Both ilet and chas Hot IGNITION SYSTEM Ignition timing Spark plugs Spark plug gap FUEL SYSTEM Carburetor Throttle valve dia Ventiro dia Mann jet dia t Slow jet dia Power jet dia Slow economizer Slow air First Slow air Second Float level Fuel tank capacity LUBRICATION SYSTEM Oil pan capacity COOLING SYSTEM Cooling water capacity BATTERY 7 Type Voltage Capac ty Term nal grounded A q GENERATOR 2 Capac ty Voltage current regulator 14 deg B T C 50 deg A B C 52 deg 8 B C 12 deg A T C 0 35 mm 014 in 10 deg B T C 600 rpm NGK Model B 6E 14 mm 0 7 0 s mm Primary Secondary 28 mm 30 mm 21 8 mm 25 14 7 mm 98 115 48 40 40 145 100 x 220 r 19 mm 35 E 3 U S gal 3 1 litres 0 86 U S gal 5 4 litres 1 4 U S gal 12K 14M2 M39 12 12 volts 2SMS
79. e Knucle arm link 8 5 9 5 kg iR S de rod t Cross rod i Idler ara D f SY 7 um Dimention emi N Fig 8 123 The torsion bar spring is a seration fit at both ends but t 18 easy to set in or remove Apply ample chassis grease before hand to the serrated position Apply a few drops of motor oji to the anchor adjust bolt Fig 9 SETTING OF TENSION ROD Fig 77 1 Frame 8116 bracket 2 Bracket 3 Tenssion rod 4 Bolt 124 After the torsion bar has been assembled tighten it so as the compressed d mension of the rubber 18 to be 11 mm respectively as shown the lower link side is tightened first and the frame side next A tightening nut 1s provided on the lower side and two on the frame side front and rear Tighten these nuts alternately and gradually until the dimension of rubber be come 11 mm Adjustment of Vehicle Carriage Jack up the vehicle at the position as shown and after redusing the twisting torque loading upon the torsion bar to the minimum turn the anchor adjust bolt to right or left so as the dimension as shown 18 to be the following valve Turning the bolt to right makes the carriage higher and to left makes it lower Dimension B 320 U 74 5 mm when unloaded V320 U 88 5 mm 125 ONIddS INOH3 I3 4 o gt ect 1 81551 6 1 82591
80. e 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 1 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 74 Z 8 3 1 84 5 3 5 et Xutrd inss ld 00901 6020 ON 18d quiossw 1240 00901 0010 ON 1196 41 289 381p q nt 21514 aanseasd 21 pos ysnd N O1 3nN TEMBIP ulla 19A97 uovuunz J fut1esq 38592 2 ux I9u191941 8 13 19 aansseaid Ry 12402 Mono pemeip ujta uid 29101 oq 244 75 Dismantling Place the clutch cover assembly on the three spr ng so that the holes n the cover coincide with the tapped holes in the plate msert the set screws provided and tighten them a little at a time by diagonal selection until the cover 18 firmly attached to the base plate at all possible points This is most important the best re
81. e engine room which makes it easy to inspect when the hood 1s raised However there 1s a tendency to be lax n servicing the battery Improper care will not only shorten the life of the battery itself but will lower the performance of the car so that care should be taken to always maintain the battery in the best of condition The construction of the battery to CHARGER gether with the chemical action caused by charg ng and d scharg ng are shown 1 1 The construction 18 exceeding simple consisting of ebon te cells fil led with electrolyte in which are placed chocolate colored positive plates and gray colored negative plates with wooden separaters inserted in between plates When a load 1s placed between the DILUTE SULPHURIC ACID positive and negative terminals the o FORM LEAO 3 u w 2 amp SPONGE DILUTE SULPHUR C ACID SULPHURIC ACID battery will discharge due to the A DISCHARGING 8 CHARGING chemical action of the active sub stances 1 lead dioxide n the Fig 1 Chemical Action of Battery positive plates sponge form lead in the negative plates and dilute sulphuric acid n the electrolyte occurring within the battery as shown n Fig 1 A In this case the lead dioxide and the sponge form lead react with the dilute sulphuric acid the lead portion and the sulfate portion com b n ng to form a lead sulfate film on the surfaces of both the positive an
82. e eye bolt with lock nuts inserting for lug at the edge of pressure plate vy 79 Screw the nuts nto the bolts and proceed as follows Screw the centre p llar 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 nset 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 s more than 0 02 in press over the high spots until it is true within this figure It is 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 Release the setscrews and remove the clutch assembly from the base plate Refacing the Driven Plate If a new complete clutch driven plate 1s 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
83. e primary coil and battery then measure the current If there 18 no current at all this signifies a break in the circuit In such cases the coil must be renewed For through nspection a coil tester should be employed 159 ELECTRICAL SYSTEM Lu ub 23 2 1 R ty ERT cd ms era Tl er ea 1 fdr loo n T ERE MN 1 i pu ur q 4 n F p m sie MK 8 T aadj ma 160 109 8T 12 Generator 1 Nut 8 Ball bearing 15 Brush 2 Washer 9 Chip 16 Brush holder 3 Pulley 10 cover 17 Brush spring 4 Spacer 11 Key 18 Front cover 5 Pack ng 12 Armature 19 Rear cover 6 Retainer 13 Field coil 20 Brush cover 7 Spring 14 Yoke ass y GENERATOR dct H tach G115 53 12 volts 200 watt 1 93 Model Voltage Out put Pulley ratio Amendment limit of deflec tion of shaft Amendment limit of short dimension on commutator Shunt V 0 1 mm 004 in 3mm 0 1201n More than 7A at 1000 r p m 161 TA Degree of real c rcle or commutator 0 05 mm 002 in L m t of polar zed wear on commutator 0 4mm 016 an 6 8 A at 950 1150 Motoring test A The generator 1s mounted on the front
84. e the standard 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 8 F Take the left side bearing for example When the measured width is 19 8mm itis 0 2 mm 0 008 n against the standard measurement and the E is by excluding the minus sign 0 008 n The thickness of the shim is acquired by opplying the numerals to the follow ing method of computation It may as well be assembled by using the shim of thickness which 18 18 ac cordance 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 pinion amp ring gear as F g 9 by using the dial indicator to make sure that it is within 0 1 mm 0 2 mm 0 004 0 008 If it s much move to left by taking off the right shim and a vice versa for adjustment The numeral marked by the electric pen on the side of the drive gear shows that of the recommended backlash besides the set number For example 6 6 means the backlash of 0 006 n 139 40 3N YILNI 7 Thickness of shim on right side Thickness of shim on left stde B D 0 006 in F Right Side T A D C 40 007 in E Left
85. ear Degree of real circle of drum Amendment limit of dittoed degree Allowable limit of inner dia of drum BRAKE SHOE Lining dimension both front amp rear wheel Length x Width x Thickness Lining area per brake shoe Adjustment of shoe clearance Front amp Rear brake Play for pedal BRAKE Four wheel brak ng by 011 pressure Mechan cal brak ng for rear wheels 19 05 mm 77 n Front wheel 19 05 mm Rear wheel 19 05 mm 0 5 0 8 kg sq cm 254 mm 10 in Less than 0 05 mm 0 002 in 0 20 mm 0 008 n 0 80 x 2 mm 0 032 in x 2 244 mm x 45 mm x 4 5 mm 110 sq cm Fasten adjusting gear notch completely and them make 12 turnings back 10 14 mm The brakes 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 1s originated A supply tank cast integrally with the master cylinder provides a reservoir by which the fluid 1s replenished and a pipe line consisting of tube flexible hose and nuron inter connected the master cylinder and the wheel cylinders 148 COMPONENTS OF FRONT BRAKE Wheel eyl body ass 4111332300 y F wheel eyl 327 Retainer 2 41122 32700 Adjuster screw 41146 32200 R H Dust 41147 32200 L H shield cover a 44124 31700 Lock spr ng Adjuster wheel 41208 32200 L H N 41207 32200
86. ears can only be lifted from the casting when the main and drive shafts together with their re spective gears have been removed Remove the needle roller bearing within the count ter gear cluster it 1s necessary to break the retaining circlips before driving out the bearing with a suitable piece of metal tubing Main Shafi 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 fourth speed synchronizer assembly then with a piece of wire inserted through the hole in the gear cone de press the small spring loaded plunger which locates the splined washer at the forward end of the main shaft turning the washer into line 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 main shaft the phosphor bronze sleeves and their common driving washer are a tight fit on the shaft the shaft should be immersed n warm 011 in 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 n
87. eedle valve carrier gasket after removing the float needle valve installed at the inlet connector As ventilation within the float chamber 1s of a air vent method and pressure within the venturi and the float chamber 15 always constant no matter how suctional registance of the air cleaner varies fuel consumption can be always economically maintained 4 he 43 Pump arm 44 Float valve sheet gasket 45 Float yalve sheet 46 Union bolt 47 Banjo union 48 Needle valve 49 Spring retainer 50 Needle valve spring 51 Choke wire clamp Float Chamber Adjusting Fuel Level Float level 18 shown on the float chamber cover with the line 19 mm below the body top to which fuel is to be adjusted Adjusting the float level is 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 58 mI BRAKER POINT AND IGNITION TIMING ADJUSTMENT DISTRIBUTOR Type H tach D406 01 Ignition timing standard 10 before top dead center at 600 r p m Apparatus of automatic advance Governor type Advance starting vacuum pressure 100 120 mm Hg Advance angle by vacuum 12 18 Crankshaft pressure of 340 mm Hg 6 9 Distributor Number of revolution at the start of advance angle 450 r p m Max advance angle at crankshaft 11 15 at 2400 r p m Rotating direction of cam Counterclo
88. eight the shim at the rear side of this outer race is increased or decreased and the race also must be taken off in each time for this adjustment therefore the tools must be handled pro perly to avoid such a situation as to make the bearing hole of carrier in an oval Referring to handling method of tool set the adaptor ring on the corn to guide the body of tool at the small hole of carrier put the rear outer lace on the corn as bearing surface faces inside at the tip end of screw and put the spl t adaptor inside race At the same time supporting t by the bar twist up the corn till the adaptor and lace come to the setted position then screw up the wing nut so as the race be housed properly at the setted 1 tion 2 Mount the front bearing outer lace n the carrier 135 For mounung the front outer lace take off at f rst the adaptor from the front end of the carrier and fix the tool at the side of stud in opposite side ughten the screw as to be the center of carrier then mount it by using adap tor as n a way of mount ng the rear outer race The race 18 scarcely necessary to be taken off unless damaged 3 Mount the rear bearing inner race and roller to the drive pinion By using the round adaptor attached to the drive pimon rear bearing inner race replacer which was employed at disassembling press in the drive pinion This might as well be done n pressing n by the use of a certain drift 4 Mount the drive pon in
89. en indicator oscillates actively between 14 and 18 in valve stem guide 15 worn out 9 When with a slight speed ing up indicator moves between 1022 in and with increase of speed the range becomes larger valve springs are weak 10 When indicator remains still between 8 15 in it s because either valve timing 1s retarded or valve clearances are not correct 11 When nd cator settles bet ween 14 17 in ignition timing s retarded 12 When indicator moves slowly between 14 16 in it s because either elect 14 When indicator oscillates regularly between 5 19 in there 18 leakage at cylin der head gasket Faulty clamping of gasket 15 When nd cator first r ses h gh drops down to zero and then returns to 16 n My rode gaps of plugs are too narrow or breaker point 1s defective muffer is clogged 13 16 When indicator moves slowly between 13 7 19 carburetor is poorly ad justed When indicator points to S n or below there 1s leakage at ntake man fold or gasket of carburetor Faulty clamping of gas ket Battery discharged or connections poor Timing poorly adjusted ir being sucked in Plug sparking weak Plug spark Wiring incorrect k t 1 Plugs d rty m nals Spark ngat termin Timne incorrect h t Plugs do __ Short in circui not spark lgnition coil or condenser de
90. ent 1s to be made 1n 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 Avatlable for 4 6 and 8 Cylinder Engine When a SUN tester s to be used make adjustments according to the following table Conditions Without load Suitable Weight Ratio of Mixture Low Speed Running 600 r p m 70 2 H gh Speed Runn ng 5 2 000 r p m 85 22 50 Engine Trouble Shooting Fig 3 s intended to be of assistance n the systematic analysis and 1sola tion 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 25 n as engine 15 raced rings and valves are in good conditions 3 Even if indicator settles if reading 1s low rings or oil are in faulty condition 4 When above 3 condition exists indicator will swing to 12 engine 15 raced 5 When indicator sometimes drops by 41n or so valve sticking exists 51 6 When indicator drops by several Inches at certain time valves are burnt 7 When Indicator drops by about 2 n valves leak Faulty seating of valves 8 Wh
91. er Bend the washer with sureness after the drive gear shake 1s adjusted In tightening up the screw t should be set and sup ported by vice or any other setting tools so as not to damage it and screw up n a diagonal line with a wrench which fit correctly with the head of the screws The standard screwing torque for this is 35 ft lbs to 40 ft lbs Screw in for sure striking lightly the head of screw by one quarter and pund hammer 3 Mount the side bearing 1n the differential case Press n the both side of the bearing by using the drift It 18 1mportant n this case to assemble by putting the side bearing adjusting shim to give the bearing a proper preload in fixing with the carrier 132 x 3 5 09142 19 9 5 9 25186 n Q JJG 0185 5 0080 0018 60610 0185 ed Nn n 2 98 39S ooL80 0018 44 an 00210 69186 001 0 06 6 8 12186 H 00610 9178 00 10 S1Z8 0995Z 0128 22112 6 S0666 6 00640 01 8 00 20 68186 00190 09186 09952 92986 9 005 0 8 ASSEMBLING amp ADJUSTMENT BY GEAR CAARIER ASS Y It 1s to decide the assembling amp adjustment of gear which 15 most important n an rear axle ass y and should be carried in accordance with the exact sample shown by the manufacture The construction and mechanism must well be c
92. er consists of a body contaimng spring spring seats pistons piston cups cylinder cover lock wheel cylinder cover and adjust screw The shoes are allowed to slide and centralise during the actual braking opera tion which distributes the braking force equally over the lining area ensuring high effeciency and even lining wear The brake shoes rest on the dimples formed n the back plate and are held n position by one return spring which connecting with the hole of shoes 150 REAR BRAKES The rear brake shoes are not fixed but are allowed to slide and centralise with the same effect as in the front brakes They are hydraulically operated by wheel cylinder and independent hand brake mechanism BRAKE DRUM SIDE HAND BRAKE CABLE ADJUSTER BOOT BRAKE DISK BAC m Fig 2 Rear Brake 151 Fg 3 HAND BRAKE The hand brake operates on the rear wheels only and 18 apphed 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 Only when a complete overhaul 1s necessary should the hand brake linkage require reseting When this 1s correct the rear shoes should be locked to the drums the hand brake control just shghtly applied and the wire rope set with the slackness just re moved by means of a nut
93. er is anchored n 118 pivot by a nut and bolt whilst the pivot 1s connected to the cross shaft Front Cover Release the front cover situated within the clutch housing by removing the nuts and spring washers At this stage of disassembling do not attempt to remove the cover and front washer The operation will prove easier if the shift fork selector rods are tapped for ward thus pushing the cover away from the casing 90 1 99111 6 8101 6 r ama 111 8 ryiysi e e n 1 59111 6 amp o0ece Eecrre eme gt 1 91191 6 amp 1 91151 6 verme 981p 8 9893 00220 0669 1 5 6 20000 22826 us 88020 IS 2 WK DE u AR o ue z 3uridno 00720 669 H T 00 9 0055 0 9 1017109 99648 efusqo 88035 85 c 00100 21626 H H 00006 9 K oak eee 1 99111 6 1 91951 6 r 1 91191 6 5 1 51191 6 TUT 00002 21992 por 10798788 HUTT 1 911 1 AW 0010 1999 9 Conve 1 919 1 6 dg 8 8033 a 3 A ooooc ov e 0000 12 1 S19S1 6 xo ilm o Ss ants YG 00006 1 8 00 20 996 ge I 1 1 9 1004 3 8 88033 1 61191 6 e LITS
94. et to keep its air tighteness Reassembling amp Installing Employ standard springs for the various uses as stated before Install valves precisely for close contact with their respective seats In screwing n 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 its mate and then screw n at the position where the diaphragm 1s 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 it 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 n the reverse order to that for disassembly Be sure to set the rocker arm so that it 18 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 1s over or before it 1s installed on the engine make a check to see When a vacuum gauge 1s connected to the pump inlet port and the pump 15 mounted on a tester the rocker arm 18 activated by the eccentric of the camshaft revolving at 1000 rpm Then the gauge pressure should rise to higher than 400 mm of mercury column and even if
95. ete 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 Remove 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 011 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 t 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 screwdrivei under No 2 rocker thus allowing the end rocker to slide off the shaft easily Repeat the procedure for No 8 rocker 16 Fig 2 Rear Locking Plate 1 Plate 2 Locat ng Stud Reassembling the Rocker On reassembly t ghten the pedestal bracket secur ng nuts a little at a t me working diagonally from nut to nut left nut of No 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 011 holes will have to be redrilled and the bushes reamed down to s
96. fective No spark ing at ter Contact point dirty m nals Breaker defective z Breaker arm nsulat on defective Rotor shorted No gasol ne n tank carburetor Gasoline existsiu Point contact poor Engine will not start Strainer defective Pipe clogged No gasoline in carburetor Float valve sticking No air can enter tank Fuel pump not operating 52 No gasoline or gasoline supply stopped Carburetor Engine seized free of acan msufficient Compres trouble Air being sucked in sion good Jet or pipe clogged Carburetor _ Float sunk _Plugs defective spark Float in high position will not descend Carburetor attachment not secure Piston ring or valve sticky ompression poor or connecting rod broken Valve seat ng poor Breaker arm spring defective No spark Contact point poor ing from Rotor shorted coil line Breaher Ignition coil or condenser defective arm good Distributor wet Engine topped Although there 18 gasoline spark Cap nsulat on defective Cord shorted or connection poor Wiring shorted or cut Sparking form coil hine Plugs dirty cor broken A Trouble Shooting Chart Compression weak Valve clearance incorrect Valve spring weak Valve deformed Muffler clogged Continuous lack of power Valve timing incorrect lIgnition retarded too much Carburetor adjustment poor Power vvea
97. fferential gear in the carrier and fix the bear ing cap There 1s a engraved 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 1s machinerly f n ished up The differential gear case 1s inserted by the bearing adjusting shim with the side bearing as explained and by housing n the bearing housing of carrier the bearing must be given the regular preload The screwing torque of the fixing nut of the side bearing cap 15 at 30 35 ft lbs 420 490 kg cm and should be equally locked with fixing cotter pin So far only the differential un t 1s mounted and the drive gear 1s locked with the drive pinion therefore the following adjustment must be made to acquire the regular side bearing preload amp the gear backlash 2 Adjustment of side bearing preload amp backlash oe To give the right preload on the side bearing of differential gear case and n pressing the bearing n the differential case adjust by inserting inside the 4 bearing adjusting shim of thickness calculated in accordance with the following method of computation There s a marked numeral of adjusting basis on the bearing housing of the gear carrier and differential case The numeral is the 22 55 error in a unit of 1 1000 in against each standard measurement of A B C D in Fig 8 To measure the width of the side bearing on left and right us
98. firmly As the drive 18 taken on the V of the pulleys it 1s not necessary to have the fan belt tight to do so may cause excessive wear to the dynamo and water pump bearings After the correct tension has been obtained securely lock the dynamo n position again Fig 3 Fan Belt Adjustment 1 Generator hinge bolt 2 Adjusting link bolt Frost Precautions gt A Freezing may occur first at the bottom of the radiator or n the lower hose connections Ice n 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 18 a very low temperature make sure that the strength of the solution 15 n fact up to the strength adv sed 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 z Relations of freezing temperatures of alchol water and glycerine mixtures ratio 10 2030 60 50 6070 80 6 10 20 30 40 50 60 TO 80 Alcohol Water 92 Glycerine Water mixture Top up when the system 1s cold If the cooling system has to be drained run the mixture into a clear conta ner and use aga n Protection by Draining On car
99. g 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 MERE 3jeus weg urey 1 1 3198 9071 938 9 911920 3ATVA 14VHSAVO 4992 av Ve ar 3589 pa ei 1198 591 9A 9A 9 83 uotsu ursu ko a e Bulids 49180 4 2 saqa 20 pues Sura 59 P T 649438 Sutjsn pe jedde L co HS Butidg 4 Y Velit fuss 22109 P eg 8 7 y y siq jJeus 5 20 i 33 I 3204 JALLA fr gb N A 284 e v G lt bi a D B usng jjeus 19y901 A BA 3 manos 109 apts ino 93919 ie dio 193901 SABA 2 8u138207 h 2 389 3335 3snipy diy m 2 amp o 19YSEM 22 bo vi E utd 193107 my 4 ze tay 2 Ve E nt L CS d x M t R x 4 E t oa wt yin 4 TW 1 oic li sN S w mm 1 yd 4 A I 4 A r a t k Fw 9 Cylinder Head 1 Engine sling bracket 2 Oil filler cap 3 Valve locker cover 4 Washer Cover joint 5 Thermostat 6 Joint washer 7 Cylinder head Li 27 e M 7 z 2s ae ES 55 r
100. gear carrier ass y without mistaking its upper side with down side and through 10 studs then fix with the lock washer amp nut The nut must be tightened n a diagonal line so as not to cause the oil leaks When it 1s mounted on the vehicle feed the gear oil 1mmediately The oil of the designated hypoid gear 011 No 90 should be feed Feed the oil till it comes up to the down side of the feeding hole HU oodco lo Fig 13 When replacing the differential axle shaft do not forget the adjust shim between the end of the axle flange and the shaft with the brake disc assembly so as to keep the end play of the axle shafts Axle Shaft Removal Jack up the axle on the blocks Unscrew and remove the brake drum using a screw driver If the brake linings should hold the drum when the hand brake 1s released slack off the brake shoe adjuster a few notches Take off the fix bolts of the brake disc and remove the axle shaft assembly as shown Fig 14 Tap out with swing hummer holding the wheel stud bolts with the rear axle shaft Draw out the shaft and disc assembly by gripping t outside of the brake disc Referring to Fig 14 assemble to the axle tube with the axle shaft with brake disc assembly Brake disc Grease catcher packing Grease catcher Bearing cage Grease seal Spacer tapper roller bearing Lock washer and Bearing lock nut In this case the shaft must be given a regular end play which ts the end play of direction to the spline of
101. h TUTTI t The release levers eye bolts struts and springs should be examined for wear and gt distortion Renew these parts if neces sary bear ng in mind that the thrust springs must only be renewed n sets gt Clean all parts and lubr cate the bear ng surfaces of the levers eye bolts etc spar ngiy w th grease VRAT A PEG 2 3 is EYE US f Fig 3 Assembling Tool Assembling Place the pressure plate over the three Spacing washers on the base plate with the thrust springs in position on the pressure plate See Fig 3 Assemble the release lever eye bolt and p n holding the threaded end of the eye bolt and the inner end of the lever as close together as possible With the other hand insert the strut n the slots on the pressure plate lug sufficiently to allow the plain end of the eye bolt to be inserted in to the hole n the pressure plate Move the strut upwards into the slot n the pressure plate lug and over the r dge on the short end of the lever and drop it into the groove formed n the latter Fit the other two levers n a similar manner Place the cover over the assem bled parts ensuring that the anti rattle Springs are in position and that the tops of the thrust springs are directly under the seats in the cover In addition the machined portions of the pressure plate lugs must be directly under the slots n the cover through which
102. hape and 18 fitted next to the timing cover flange The spring washers are 1mme d ately 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 of the joint surfaces beforehand Fig 1 Heavy Duty Shock Type Spanner Removing the Timing Gear The t m ng cha n is endless and it 15 necessary to remove both the crank shaft 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 crankshaft gear retaining 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 18 a rubber ring which acts as a tensioner and ensures silent operat on of the chain drive Exam ne the felt washer and renew t if oll has been lost be seepage Refitting the Timing Gear Replacing the components of the timing gear 18 largely a reversal of the dis mantl ng process but special attention should be paid to the following points 15 Fit the crankshaft and camshaft gears into their respective shafts Ensure the timing marks are opposite and in line Turn the engine crankshaft until the keyway 1s at T D C and the camshaft with its keyway n approximately the
103. harged battery 12 volts and about 50 ampere capacity ammeter are required With the units connected for the tester The generator is turned as a motor and from the condition of the current and speed troubles occur ring in the generator can be checked A The generator is in normal condition if the ammeter indicates from 5 to 7 amperes and the generator rotates smoothly with only a faint hum If the generator fails to rotate there 1s trouble n the electrical circuit The rated currents are 8 amperes at 750 r p m B H the ammeter indicates higher than the reated values there 1s a short or grounded connection provided there are no mechanical defects It should be noted that a fairly large current will flow if the frictiona resistance of the rotating parts 15 great If the fotation is irregular there is a short or ground n the armature and if the rotation 1s slow the trouble may be due to short or ground n the field coils Furthermore if the rotation 1s normal but the ammeter pointer vibrates exceed ingly the trouble will also be due to short or ground in the interior parts C If the ammeter indicated below the rated values or if the rotation 1s un even or slow there 18 8 defective con nection n the interior parts or a high frictional part In this case repairs or replacement of defective parts are made Diagnosing troubles with a tester With the above motoring test the generator can be checked to see if
104. 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 engif is running check that the water hose connections and fuel line unions do not leak Tighten them if necessary 24 Removing and Refitting Valve Guides Remove the cyl nder 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 8 When fitting new valve guides these should be driven n from the top of the cylinder head 42 Fig 8 Hardened Steel Punch Fig 7 Renewing a Valve Gude Renewing a Valve Spring in Position gt In an emergency a new valve spring can be fitted without removing the cyl nder head When doing this the applicable piston must be brought to its 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 a suitable tool such as a bent screwdriver which will pass through the sparking plug orifice and locate on the valve head By usin
105. hin carbon discs By applying pressure to both ends of the carbon pile as shown in Fig 1 the resistance will change The utilization of this characteris tic is the carbon pile voltage regulator the wiring diagram of which is shown in Fig 2 2 3 4 5 6 8 Fig A Sectional View of Carbon Pile Regulator 168 Pile pressure screw Carbon pile Pile holder Moving core Compression spring Compression spring Magnet coil Flux adjusting screw PRESSURE VOLTMETER CARBON PILE BATTERY AMMETER PRESSURE RESISTANCE fig B Characteristics of Carbon Pile Fig 2 Wiring Diagram Without a voltage regulator the gener 1 Carbon pile 5 Stabilizer 8 8 2 Spr ng 6 Cut out relav 7 7 7 with 7 3 Magnet col and other factors but a carbon p le regulator 4 Temperature compensat ng will maintain constant voltage by the follow resistance ing action When used n conjunction with the generator and the voltage becomes high the current through the magnet coil increases and makes the attractive force greater This increases the carbon resistance so that the current through the field coulis decreased and also decreases the generated current Conversely when the volt age becomes low the generated current increases Thus by properly matching the carbon pile regulator limits the current by means of the current coil there 1S no need of specially providing a curren
106. ickness number Shock absorbers Front Rear TIRES 320 UN 320 UP Rear 320 U 5 60 14 6PL T 24 1b 5 50 14 6PL T 22 Ib 6 00 14 6 T 22 Ib 254 mm 10 in 19 05 mm 77 in 19 05 mm 77 n 19 05 mm 0 77 n Wishbone type Independent suspension Torsion bar spring 20 5 x 664 5 mm Parallel semielliptic leaf spring 017 for 320 U Fs 7 i 1 for 320 UN 7 for 320 UP with 12 57 1 helper rubber s ngle act on s ngle act on 5 60 14 6PL T 30 Ib 5 50 14 GPL T 36 Ib 6 00 14 8 T 60 ib 4 i For RUNCH SEDAN U320 Double Seat 2 DOOR ST WAGON V320 amp N320 Single Seat VEHICLE DIMENSIONS Length overall approx Width overall approx Height overall approx Wheel base CARGO SPACE DIMENSIONS Interior length Interior width Interior height WEIGHTS Vehicle weight Seating and loading capacity TRANSMISSION Gear train Gear ratio U320 V320 4 285 mm 4 155 mm 168 7 1n 163 6 n 1 497 mm 1 497 mm 58 9 in 58 9 1n 1 520 mm 1 515 mm 59 8 n 59 6 in 2 470 mm 2 470 mm 97 2 1n 97 2 1n 880 mm 241 555 mm 34 6 In 61 2 1n 1 245 mm 54940 mm 49 1n 1 180 1n 420 mm 905 mm 16 5 in 35 6 n 1 000 kg 1 020 kg 2 200 155 2 255 lbs 54 400 kg 24 500 kg 880 155 1 100 lbs
107. ide electrode nsulator Each spark plug must be tightened 3 securely yet not too t ght 4 Insulator porcela n Any dirt 011 or such impurities adher 5 Cyl nder head ing to the outside of the spark plugs will impair their performance Therefore frequently M amp clean the spark plugs by wiping with a piece of clean cloth 65 CLUTCH 66 CLUTCH GENERAL DATA Type Single dry disc plate Construction of disc With coil spring Outer dia of facing 184 mm 7 249 1n Inner dia of facing 127 mm 5 003 in Thickness of facing 3 4mm 0 1339 in Gross friction area 139 x 2 sq cm Thickness of disc ass y 8 85 mm 0 346 in when releasing 7 5mm 0 30 in when depressing Disc run out Less than 0 5 mm 0 02 in Backlash at splined part 0 05 0 15 mm 0 002 0 006 n Surface strain of pressure plate Less than 0 05 mm 002 n Ditto 0 10 mm 0 004 n Operating method Oil pressure Inner dia of master cylinder 22 2 mm 7 8 in Inner d a of operating cylinder 19 05 mm 3 4 1n Operating liquid Genuine super brake oil PRESSURE SPRING Free length 49 5 mm Compressed length Less than 30 mm Surn 8 Effective turn 6 Coil wire diameter 3 5 0 03 mm Length n use and load 35 7 mm 57 1 kg RELEASE BEARING Construction Carbon bearing type Height of release plate From flywheel face to rear end of plate 58 0 5 mm Release plate run out Less than 0 03 mm
108. ime 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 1s in its 10 degrees before top dead center position for compression If a timing lamp 1s used the standard ignition 61 t M timing 1s 15 degress before top dead center at dl ng 600 rpm spegd 7 In the case of marks which are not evenly spaced pointers indicate 10 deg 15 deg and 20 deg positions before t p dead center Adjustment 1s made by the following procedure 5 i 1 First adjust the distributer to the Correct gap as described previously 2 Turn the crankshaft gradually until the top dead center mark F g 1 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 compress i troke of the No 1 piston Stop the crankshaft n this position The compressiomstrok of the No 1 piston can be determined if the spark Plug of the No 1 cylinder is removed the hole plugged with a finger and the crankshaft turned With the crankshaft n the pre viously mentioned position the No 1 piston 18 n 115 position of 10 deg before top dead center of compression se aaa i Wer RS Pay ara Fu 1 Checking
109. ime of pushing the outer lace into the carrier it must be done in a right way other wise lt 5 x 4 Remarks When measuring the height of the pinion head set the semi circular side portions of the gauge on the side portions of the gauge on the side bearing seats insert a feeler gauge into the clearance between the tip of the gauge center rod and the pinion head and adjust the pinion The gauge rod 18 made 0 2 mm 8 1000 n shorter than the standard measurement 21 mm Therefore adjustment 1s made by selecting a feeler gauge in accordance with the plus or minus valve marked on the pinion head Special when the old bearing 1s to be used again n assembling the adjust ment should be made at the lower torque than standard 1n accodanced with the conditions of practical use so as not to give it an over preload 6 When the former adjustment of preload of the bearing 18 completed as n the previous paragraph inspect the pinion height again Unless any thing wrong is found loosen the pinion nut take off the flange insert the new oil seat in 138 the rear of the carrier and formerly fix the flange washer and pinion nut The nut should be tightened up at the standard torque n 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 n the Carrier 1 Mount the complete unit of di
110. 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 5mm In mounting the gear clean well the fitting face and rear face measured face of t and fix correctly then there should not be any shak ing ASSEMBLING ADJUSTMENT Assembling Differential Gear 1 Assemble the pinion and side gear in the differential case Every parts should be cleaned and oiled with new gear oil then the pinion mate side gear and the thrust washer should be assembled by the mentioned inspection and selecuon before pushing n the pinion mate to shaft Inspection should be made again n the clearance of between the washer or the backlash Adjustment must be made n case any abnormal 1s 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 it to the required piston so as the pin should not loosen 2 Fix the drive gear ring gear with the differential case The drive gear as well as the drive pimon should be well inspected or they must be replaced as a set whenever the replacement 1s required Otherwise they would not properly lock after assembling 1s completed In mounting in the case the fitting surface must specially be cleaned and fixed with 8 Nos screws as well as lock wash
111. interlocking ring on 2nd 8 3rd gear bush 3 937 3 962mm 0 1549 0 1559 in 87 Th ckness of rear thrust washer on ma n shaft 4 826 4 801 mm 1900 0 1890 n End play of 2nd amp 3rd gear 0 12 0 16 mm 0 0048 0 0062 n Amendment limit of dittoed play 0 25mm 0 01 in Synchromzer spring Free length 127 mm 0 49 in Outer diameter 6 7 mm 25 n Coil diameter 0 8mm 0 03 in Tension 2kg at8 mm Outer dia of synchronizer locating hole 9 32 n 7 144 mm COUNTER GEAR Inner d a at gear bear ng 22 420 22 433mm 0 8826 0 8831 in Outer dia of shaft 16 391 16 401 mm 0 6452 0 6456 in Type of bearing Needle roller bearing No of needies 20 x 2 front amp rear Dia x length 3mm x 23 8 mm 0 118 0 936 in Thickness of front thrust washer 3 91 3 96 mm 0 154 0 156 in Thickness of rear thrust washer 3 96 3 91 mm 0 1560 0 1540 in 4 013 3 988 mm 0 1580 0 1569 in 4 089 3 140 mm 0 161 0 160 in 4 166 4 140 mm 0 164 0 163 in Eng play 0 04 0 06 mm 0015 0 0023 n Amendment limit of dittoed play 0 10mm 0 004 in REVERSE GEAR Inner dia of bush 14 338 14 376 mm 0 564 0 566 n Outer dia of reverse shaft 14 249 14 262mm 0 561 0 5614 in Gap between shaft amp bush 0 076 0 127 mm 0 03 0 005 n SHIFT ROD Locking ball spring Free length 30 2 mm 88 Coil diameter 7 9mm Dia of wire 1
112. it is faulty and the troubles approximately lo cated but 1t would be more advantageous to use a multitype tester shown n Fig 3 Furthermore by using a portable dynamo tester tests can easily be made without removing the generator fromthe Fig 3 Generator Starter motor car and Regulator Tester 164 4 In making these tests the A and F terminals of the generator are connected together the volumeter 18 connected between generator A term nal and the ground and the ammeter is connected between regulator 8 terminal and the battery The engine 1s turned over at medium speed generator speed about 2 000 rpm the ammeter pointer fails to move or 1f current 1s being generated but when the load 1s increased to 20 amperes the voltmeter indicates below 13 volts the gen erator 1s defective and requires repairing When the generator 18 disassembled and the parts are to be inspected the armature growler 1s used for this purpose n the following manner Testing for Grounding in Field Coil The ground terminal of the field coil 1s removed one lead from the growler 1s e grounded while the other lead 1s contacted with the other field coil terminal im If the test lamp on the growler lights the field coil 18 grounded so that it should be replaced with new coil the test lamp fails to light the field coil is free from grounding z TRE Y j 4 H Testing for Shorts in Field Coil x
113. ith the front wheels fixed to the forwording direction Take measure of the position of lower part of wheel and tube with the finger of one hand spin the wheel to left and right to the extent of wheel s play by another hand When the wheel moves up and down there should be found a play n the worm bearing to the direction of axle Inthis case the f1xing bolts n front and rear upper or lower of gear housing are loose on the bearing 1s worn out The shim should be pull off in a way as explained n the item of worm bearing and the adjustment should be made as explained n the item of inspection and adjustment after assembling 2 In case the roller shaft moves to the direction of axle shaft as the wheel spined hardly to left and right the roller shaft adjusting screw 1s loose The adjustment should be carried n a way as explained n adjustment of the posi tion of steering roller 3 In case the roller shaft shakes to left and right the roller shaft or the bush 1s worn out therefore they should be replaced with new one and adjusted 4 In this case the fixing bolt for gear housing front and rear upper or lower is loose or the bearing 1s worn out for which the shim should be pulled out in a way as mentioned n the item of worm bearing and the adjustment should be made as inspection and adjustment after assembling 5 Incase the roller shaft moves to the axle shaft by returning the wheel to left and right the roller shaft ad
114. ize before assembly on the shaft The rockers and spring must be replaced n 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 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 011 leaks will result Push Rod Removal If the valve rocker assembly has already been removed all that remains 18 for the push rods to be lifted out They may on the other hand be taken out without detaching the rocker assembly Remove the air cleaner and rocker cover Slacken all the tappet adjusting screws to their full extent then using a screwdriver with the rocker shaft as a fulcrum depress the valve spring 17 slide the rocker side ways and lift out the push rod All but the end push rods can be withdrawn m this way These will have to be withdrawn after the removal of the two end rockers from the shaft When replacing push rods ensure that the ball ends register n the tappet cups From here on wards reassembly 1s a straight forward reversal of the dismantling process Adjusting Valve Rocker Clearances Remove the air cleaner and rocker co
115. justing screw 1s loose for which the adjust ment should be made in a way as explained 1n adjustment of the position of steering roller 6 in case the roller shaft trembles to left and right the roller shaft or the bush 1s worn out and they should be replaced with new one and adjusted 7 Take off the drag link at the end of steering gear arm In case the play should be found by holding the arm and move it strongly back and forth the backlash of roller and worm gea 1s too large The adjustment for this should be done n a way as explained n the above section setting the steering wheel at the center of turning to left and right 8 In case the operation of steering wheel felt heavy and becomes light when the 113 front axle 18 jacked up the trouble 18 with the front axle system In case the wheel 1s still felt heavy even when the front axle 1s jacked up the trouble 1s connected with the front axle 9 When the front axle 1s jacked up the inspection of contacting and tightening parts of ue rod socket nackle arm drag link and the steering arm should be possible 10 Hold both the top and down end of front wheel and move it strongly and the pin would rattle if any as well as the looseness of the wheel should be found Adjustment of Idler After tightening the idler shaft nut under the torque of 14 kgm adjust the idler so as the diemnsion from the idler body frame fitting plane to the idler arm lower end 1s to be 157 mm by
116. k Gasol ne supplied insufficiently Carbon deposits excessive Gasolin of poor grade Carburetor defective Valves sticking Pre ignition __Intermittent lack of power Engine operation defective daring running Engine gives off abnormal noise overheating Bear ng worn Plugs dirty Spark ng i Breaker point defective Intermittent shorting Misfiring M xture too rich Insufficient gasoline supply to carburetor Sparking normal Water n gasoline Nozzle clogged B Trouble Shooting Chart CARBURETOR SPECIFICATI0NS Bore diameter 30 mm Ventur diameter 25 14 7 mm Main jet 115 Main air breed 60 Slow jet 48 Slow Air First 160 Slow Air Second Slow Economizer Power jet Power valve Begins to open when the primary throttle valve is 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 t 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 18 a highly efficient carburetor of two barrel a two step and down draft type having the following special features i i Construction and Operation thy E CRIT z NI n Li 54 Secondary S de 1
117. king care not to damage the joint washers n the process Removing the Strainer no lt aa With the sump lowered t 1s possible to remove the oll strainer through which oil s drawn into the oil pump To remove the stramer unto the union connecting the 011 pick up to the pump and unscrew the securing bolts zi The strainer may be d smantled for cleaning purpose by removing the de livery pipe flange bolts Notice that there are the dowel pins to the cover which must be positioned correctly when refitting Removing the Oil Pump Remove the oil pan and pick up strainer 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 its drive shaft Dismantling the Oil Pump Remove the setscrews and spring washers which secure the cover to the b dy and take off the cover On t lt ng the body upside down the inner rotor with its drive shaft and the outer rotor with slide out Refitting the Sump Clean out the sump by washing it n paraffin the care to remove any traces of the paraffin before refitting the oil pan to the engine Pay pat cular attention to the 011 pan and crank case joint faces and remove any traces of old jointing material Exam ne 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
118. l out the king pin lock bolt and take off the spindle plug on the spindle by a graver Strike downwards the king pin by the drift and take off the plug at the bottom The pin thus can easily be removed The spindle can be dismounted with the spindle shim and thrust washer assembly INSPECTION amp ADJUSTMENT AFTER DISASSEMBLING Every parts must be cleaned with the cleaning 11 Any parts of damage or de fect should be replaced and adjusted Adjust ment of Spindle D ak cover 40315 32200 bee 60300 08700 Disk vheel Front wheal hab 46202 12200 40221 04101 N Hab bolt E 11430 40040 04100 Castle nut Wheel inner bearing L 40211 32200 NON Front hab gonso spacer A 40231 31200 Front hab grease seal N Front spindle coller N 40029 Fg 3 The inspection should be made specially in regard with the crack and any other scratch Check the defacement of king pin and spindle bush If the clearance be tween the pin and bush 18 over 0 10 mm replace the pin or bush For replacement of spindle bush make use of king pin bush driver and can insert the bush it 1s easily removed without giving any scratch on the surface of t tapping with the hammer After the bush 1s replaced the interior dia meter of t should be finished up exactly n accordance with the standard mesurement The king pin bush reamer should be employed n this case It can ream the holes at the upper and Fig 4
119. ld then be riveted on the opposite side of the plate with the clearance holes over the heads already formed n 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 wabbling 1s more than 0 02 in press over high spots until it is true within this figure It is important to keep friction facings free from oil or grease 72 CLUTCH NEW TYPE GENERAL DATA Type Construction of disc Outer dia of facing Inner dia of facing Thickness of facing Gross friction area Thickness of d sc 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 dia Free length Length n used amp tension of operating PRESSURE SPRING Free length Compressed length Turn numbers Power of comp n full Wire diameter Length in use and load RELEASE BEARING Construction Height of release plate Release plate run out Single dry disc plate With coil spring 200 mm 130 mm 3 5 mm 363 cm 8 6 9 1 mm when releasing 7 3 8 1 mm when depressing Less than 0 5 mm 0 0570 15 mm 0 002 006 n Oil pressure 15 85 mm 5 8 in 19 05 mm 3 4 in Genuine super brake oil 1 6 mm 87 mm 136 mm 5 kg 49mm 1 5 Less than 25 mm 7 8 About 300 kg 3 3 mm 29 2 37 512 kg Ball beari
120. lightly the the bolt then pull the gear arm out of roller shaft 2 Dismounting the housing cover androller shaft assembly In dismounting the cover the column jacket and roller shaft assembly after unscrewing the three nuts the adjusting shim of the housing gear must be han dled with care not to loose them 3 Taking off the housing end plate Unscrew the three nuts at the front end of the housing and they should also the handled carefully not to loose them 4 Dismounting and inspection of the worm shaft and bearing The main shaft could be dismounted together with the roller bearing assem bly and upper bearing corn by fixing the wheel nut on the tip of main shaft and striking out lightly without damage 5 Take the column jacket out of the gear housing thus the outer lace of upper bearing can easily be dismounted The adjust shim must be carefully handled not to loose them n taking off the housing gear 110 6 Inspection and adjustment of dear housing column jacket and front cover Adjust the steering gear by changing the total thickness of the adjust shims of the worm bearing so that the starting torque for revolving worm shaft 1s 0 08 0 15 kg at the circum ference of steering wheel In this case tighten it with the end cover by applying the 0 ring Use the said ring 3 1 1 mm thicker than the used shims And further adjust by changing the thickness of the worm bearing adjust shims exchanging the rear and fr
121. ly with the clip 6 Tothe No 1 spark plug connect the cord from the terminal to which the arm of the rotor 1s pointing Thereafter connect the terminal cords to their spark plugs n the counter clock Wise order so as to obtain a l 3 4 2 firing order 7 Upon completion amp of the wiring cover the distributor with a rubber cap The engine should now start properly Ordinarily the pointer ot the octane selector 18 set at its 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 a l 63 te 4 fon ite Fig 3 Assembly Angle of Drive Shaft 1 D str butor shaft 2 D str butor drive shaft 3 Distributor fixing plate Conversely 1f the octane number 1s high the pointer 1s 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 th crankshaft angle 3 When a timing lamp 1s used the standard setting 1s 15 deg before top dead c center with the engine idling 600 620 In any case the optimum ad justment s that in which a slight knocking 1s heard when with the car runnin at tow speed in HIGH TOP gear acceleration 1s applied suddenly n E TP PE i Za X 64 Spark Plug Type N G K
122. m 41158 04100 uar B F wheel esl sensei o 41130 04100 p Adjuster housing ass y 41203 32200 pus Adjuster retaining Spring 41213 04100 41209 32200 Adyuster boot 41153 04100 W Q Lock plate 314 0100 3 K 11147 1 NER 41002 3 L H 41110 32700 Front brake shoe Fore 0 41158 041 B Bleeder screw 41128 041 41030 32202 curae 240 41129 30001 41021 32200 i Shoe return 4 spring 41023 32200 Front brake shoe After 41031 32202 41939 32202 41021 32200 Front brake shoe return spring 149 The pressure generated n the master cylinder by application with the foot pedal s transmitted with equal and undiminished force to all wheel cylinders simul taneously This moves the pistons outwards which n turn expand the brake shoe thus producing automatic equalisation and efficiency n direct proportion to the effort supplied at the pedal When the pedal 18 released the brake shoe springs return the shoes which then return 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 left or right side operates the rear wheels by mechanical expanders attached to the rear wheel cylinder bodies FRONT BRAKES The front brakes are operated by each one wheel cylinder Each wheel cylind
123. maged insulation should be replaced 5 An armature found with one part especially damaged by burning should be strictly tested by the insulation test Assembling and Testing Starter Reassembling 1s performed by following the reverse procedure for disassem bling All 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 53 in the magnetic circuit to close Releasing the starter switch button opens the magnetic circuit which also opens S 1 Cause for magnetic switch failling to operate can be divided into electrical and mechanical sources Causes for electrical troubles A Current failure 1n magnetic circuit When the starter switch button n pressed and the current fails to pass through the magnetic circuit most of the trouble 1s due to broken soldered connection between the magnetic coil wire add the magnetic switch 4 terminal and defective ground connection from the coil wire to the magnetic switch body B Defective contact in main 1 1 5 When the magnetic circuit 1s satisfactory and 5 18 closing but only 8 small current flowing due to high contact resistance and the opposite case of switch S opening but S remaines closed In either case the trouble lies n the faulty moving of the core or roughness of the contacting point surface Therefore polished the surface well then the operation
124. minal 2 Pr mary cord terminal 3 Secondary cord terminal 4 Primary coil 5 Secondary coil 6 Core Iron 158 nspection and Repairs r 5 Most troubles with the ignition coil can be attributed to short circuit of pri mary or secondary coils caused by their defective insulation overheating or interior damage With such a faulty ignition coil it does not generate sufficient secondary voltage and the engine will misfire But as repairs of troubles are very difficult except n cleaning terminal connection replace a defective ignition coil Check of functioning of coil Remove the cap of the distrrbutor and turn the crankshaft until the contact point of the contact arm closes tact arm closes Then switch on the ignition switch draw out the secondary cord from the central electrode on the distributor cap and holding its tip about 6 mm away from a metal portion of the engine open and close the point by moving the contact arm by hand If blush white and strong spark are created between the t p of the cord and xthe metal portion the coil may be considered to be all right When the sparks are feeble and reddish or when sparking does not take place unless the gap with the metal portion is extremely reduced the coil must be de Sf ctive Since these are cases when the condenser and gn t on switch are all right to be exact employ a coil tester To check by menas of an ammeter connect th
125. ng pin is fixed strike the expansion plug both on upper 8 bot tom The plug should be new one 5 The outer lace drift should be used to press in or strike in at the time of mounting the inner bearing outer bearing and oil seal on the front wheel hub The 011 seal should be replaced with a new one 6 Smear well the oil on the bearing at the t me of mounting the front wheel hub on the other hand the grease housing should be fitted out only for 50 of the space In tightening up the spindle nut settle down the bearing by turning and clamping up the wheel hub turn back for about 1 8 and lock with the cotter pin This 1s 1mportant to decide the play at the wheel bearing to the direction of the axle There should not be any rattle and t should be turned lightly 7 If the front axle ass y 1s mounted on the chassis feed oil to the king pin After this as mentioned later inspect the alignment of the front wheel Inspect the turning angle at the same time and then adjust the stopper Front Axle and Suspension As showing above Fig l is adopted an independent suspension and is directly connected to the upper l nk bracket The front suspension 1s provided with the lower link spindie and the torsion bar The tension rod are fitted to restrict the back and forth movement of the lower links The upper and lower links come out of the upper and lower sides ot the knuckle support fitted to the wheel The upper link 1s connected to the frame
126. ng type From flywheel face to rear end of plate 50 5 0 2 mm Less than 0 03 0 0012 m If use master disc 7 8 mm 5 mm height height of release lever is 50 5 2 mm 73 DRIVEN PLATE ASSEMBLY This 18 the flexible type in which the splined hub is 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 hmings are riveted to the disc COVER ASSEMBLY The cover assembly consists of pressed steel cover and a cast iron pressure plate located by s x 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 springs 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 To gain access to the clutch it s first necessary to remove the transmission complete from the engine Once the transmission unit 18 free a turn at a ume by diagonal selection until the spring pressing 1s rehved Then remove the screws completely and lift the clutch assembly away from th
127. nscrew the release pin When the push rod has been removed the piston with cups attached will be ex posed remove the piston assembly complete The assembly can be separated by lifting the spring seat edge over the shoulder ed 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 insert the assembly into the bore of the cylinder end with piston cups lips n 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 in the cylinder body Replace the rubber boot and secure the unit by means of the two bolts on the flange and refit the pressure pipe union not the cylinder The Operating Cylinder The cylinder 1s of simple construction consisting of the body piston piston with cup spring and bleed screw the open end of the cylinder being protected by a rubber dust cover The cylinder 1s mounted under side of the starting motor 82 Dismantling Remove the rubber dust cap from the bleed screw attached a bleed tube open the bleed screw three quarters of a turn and pump the clutch pedal until all the fluid has been d
128. o the ring gear and drives t with a powerful torque The direction in which the pinion moves 1s from the end of the shaft towards the starter bracket thus reducing the bending torque After the engine starts and its speed becomes greater than the no load speed of the starter the pinion 1s kicked back to unmesh and return to its former position Operational Precautions The instructions to be observed when Starting the engine are as follows 1 The starter should be securely mounted on the engine and should not show any looseness 2 The starter switch should be operated properly and should be released m mediately when the engine starts Excepting in extremely cold weather the engine should normally start within 10 seconds 3 The starter switch should not be operated when the engine 1s running If the engine fails to start allow time for the pinion to come to rest before turning the starter switch again 4 When the engine faisl to start after turning the starter key for over 10 seconds do not continue 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 With a fully charged battery and with the lamps lighted the starter switch 1s used If the lamps become dim especially when the engine does not start the current is flowing through the starter motor coil but for some reason the armature 1s not
129. of the case to clear the drive shaft gear Using a long drift inserted through the main shaft opening drive the drive shaft forward complete with bearing and circlip from the case The counter gears may now be removed from the case To remove the bearing from shaft knock back the tab locking washer and un screw the shaft nut This nut has a left hand thread The bearing can now be driven from the shaft preferably by resting the circlip 95 of the outer race on the jaws of an open vice and driving the shaft downward Use a hide or lead hammer for the operation as great care must be exercised to prevent the end of the gear shaft from spread ng ASSEMBLING THE TRANSMISSION Synchromesh Sub Assembiy During manufacture both speed gear and the third and fourth speed coupling sleeves are each paired with their respective synchronizers Only mated pairs of these parts should therefore fitted Special guides are available to facilitate the reassembling of the three balls and springs into the synchronizers The guide s of the same diameter as the coupl ing sleeve as shown Fig 5 The guide 1s slipped over the synchronizer and turned until the hole coincides with one of the three sockets A spring and ball are then placed n position the ball depressed and the guide rotated for each spring and ball in turn until they are all depressed The guide is then pushed further along the synchronizer splines followed by the coupling
130. oint appears to bind tap lightly with a wooden mallet which will relive any pressure of the bearings on the end of the journals It 1s 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 n position t is advisable to use new lock in position lt is advisable to use new lock washers 105 CONSTRUCTION OF CHASSIS STEERING STEERING GEAR Type Sem external mesh worm and roller Gear ratio 17 3 1 WORM GEAR Thickness of adjusting shim tor housing end play Shim for adjusting front end play 0 762 mm 0 030 1n m 0 254 mm 0 010 1n 0 127 mm 0 005 in 075 mm 003 in 0 050 mm 002 in Shim for adjusting rear end play 0 254 mm 0 010 in 127 mm 005 n 0 075 mm 0 003 n 0 050 mm 0 002 n Center d stance 52mm Lock ng angle 40 Starting torque for revolving worm shaft 0 08 0 15 kg Backlash between worm amp roller 0 0 2 mm at top center of gear arm Tightening torque for cover nut 2 5 kg m Roller shaft nut 14 kg m Gear box fix bolts 4 5 kg m The type of steering gear 1s worm and rolle
131. omprehended referring to Fig 4 amp 6 and the adjustment amp repairing exactly according to the con dition 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 they are as a result of d sassembl ng and inspection they should be assembled n order of disassembling at the previous condition of adjusting shim n case any item should be replaced or required to reuse even if any item 1s worn out prepare the various shims as mentioned later because the position of drive pinion to be fixed with carrier must be adjusted by the adjusting 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 up head surface of drive pinion Fig 4 Adjustment of P nton Height 134 They show the manufacturing error n 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 61 0 mm from axle center as shown if Fig 5 the figure is difficult to discriminate due to the cor rosion scrape off the oxidize substance on the surface by a some what nar row gr nd stone w th Care not to scrape off even the mark Adjust to the direction of an arrow in accordance with the pinion mark 3 The thickness of
132. on given to the condition of insulation The assembly check s made by testing the starter as a single unit using a fully charged battery Tests are made with a starter motor tester or with the apparatus shown in Fig 4 by which braking torque 1s measured Fig 4 Torque Testing Apparatus In this case the normal value should be 0 9 m kg To test the starter motor when installed on the engine the engine 1s first warmed up Then with the throttle velve n fully closed po sition the starter 1s actuated In addition if a starter motor tester 1s used performance tests can be made easily and accurately Construction of Magnetic Switch and Instructions The magnetic switch 1s an appratus when the engine 1s being started serves to close the circuit between the battery and the starter motor and permits a large current to flow and actuate the starter motor After starting or when the engine 18 stopped the switch serves to keep the circuit open The principles of operation can be seen from Fig 5 Closing the starter switch S allows the current to flow through the magnetic If there 1s trouble n the magnetic circuit it should be corrected For improperly contacting starter brushes the brushes together with the armature 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
133. one o clock position Place the gears into position ensuring that the keys are present in keyways on the shafts Ensure that the timing marks on the gears are opposite to each other and in line Drive the gears home The same number of packing washers taken from behind the crankshaft gear must be replaced unless a new crank or camshaft has been fitted In this case the alignment of the gear faces and measureing the alignment with a feeler gauge To adjust the alignment t will be necessary to vary the number of packing washers 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 n position Valve Rocker Cover Removal Remove the air cleaner Unscrew the cap nuts securing the engine lifting brackets Remove the rocker cover and the cork joint washer Removing the Rocker Assembly Drain the cooling system If anti freeze 15 m use use a clean container for the fluid if it is to be used agan It 1s necessary to drain the system and slacken the cylinder head nuts because four of the rocker shaft f x ng nuts also secure the cylinder head If the cylinder head nuts are not slackened distonation may result and allow water to find its 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 Compl
134. ont shims 7 Inspection and adjustment of the roller shaft The shaft itself should be check and replaced with new one when it 1s worn out The roller shaft assembly should be replaced n a unit n case the roller pin becomes loose and damages or defacement of surface of roller 1s found The replacement can be limited to the worn out parts after disassembling Fit the roller shaft to the gear housing after inserting the adjust shims to the adjust screw and adjusting said screw so as the end clearance along the roller shaft 1s to be 0 01 0 03 mm with the shims The backlash at the top of gear arm 18 to be 0 0 2 mm nn the vertical rolling center of the roller shaft and lock the nut up after comf rm ng that the roller 1s smoothly rolling over the worm gear 8 Assemble and Disassemble of the linkage The joint parts of the linkage are constructed with the spring sheet spring plug and so forth and this order must be conformed with in assembling the unit 111 Fe 3 Otherwise the spring would not action besides giving a shock to the every part of the unit wearing out both the steering gear arm and linkage of the steering which furtherly will be easily pulled off endangering the operation I 15 therefore important to check and to set aside the parts in assembling when disassembled Inspection and Adjustment after Assembling It is important that the center of interlocking roller 1s located in the center of worm gear
135. operation 15 discontinued this condition should rema for more than 3 seconds When a gauge or tester 18 not available test n the following way Clost the inlet port and outlet port with finger ups Then after operating the rocker arm several times suddenly release the fingers The pump 15 16 good conditions if 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 it 1s able to draw up gasoline from a height of more than 5 m After installing the pump test its functions during operation 47 A Connect the gasoline pipe on the inlet post side only Leave that on the outlet port side as it 15 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 is any leakage of air or gasoline from each connection 48 ADJUSTMENT AND INSPECTION OF ENGINE The engine must always be operated n the best possible condition and for this purpose periodic inspection and adjustment must be maintained n a certain order while n use as well as after overhaul Order of Inspection and Adjustment of Engine 1 Check the cooling water water level and extent of filthiness 2 Inspect the battery
136. ose used for long a BA Zes 2 Ot a eo708 YR g runs e MAN or g soz cum rw ta x ir e pores g l M 21 5 uy uA wo dal e eT wad fe Removal and Replacement of a Valve Whilst the cylinder head is removed the valves can be taken out To do this compress the valve spring with the special valve spring compressor as shown 1n Fig 4 Removal s ez ms ER lt Pun 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 n their re lative positions when removed from the engine to ensure replacement n their original valve guides Y P rU ee PED eee LE S akt 1 a te AR RSS lt age M rN Tecate ten RE Tage eR YI R Fig 4 Valve Spring Compressor we 21 uy m x y z n Z 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 n engine oil for a short period before use The oll seal 18 used for the intake valve only Replace the valve spring and compress the valve spring
137. 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 nut of the carrier pull out the companion flange The drive pinion flange wrench should be employed setting its 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 compinion flange of drive pinion with the drift of soft metal Thus the 018108 would be taken out together with the inner race of rear bearing and roller distance piece and the adjusting shim and the 011 seal outer race and pinion of front and rear bearing as well as the Pinion adjusting shim left n the carrier 17 Ass y geur carrier amp gear 38300 03800 39T 8T 38300 08701 361 77 38300 T 4 84 5 53 kgn 35 401t 1ba 10 Fig 3 Differential Gear Carrier 130 1 Compan on flange 10 Pinion shaft 2 Carrier assembly 11 Diff side bearing 3 Drive pinion front bearing 12 Rear axle shaft 4 Drive pinion rear bearing 13 Gear carrier packing 5 Hypoid drive pinion 14 Washer 6 Hypoid drive gear 15 Nut 7 Diff gear case 16 Stud 8 Diff bevel side gear 17 Drive pinion nut 9 Diff bevel pinion mate 11 Pull out the rear bearing inner race of the drive pinion The drive
138. ow Do not use excessive force When lifting the head a direct pull should be given so that the head 1s pulled evenly up the studs Remove the cylinder head gasket Decarbonising Remove the cylinder head With the valves still in position remove the carbon from the combustion chambers and the valve faces Leaving the valves in position 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 may be removed 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 18 at T D C Protect the other cylinder bore from the entry of carbon particles by pushing 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 required is generally given by an all round loss of power Cars used mainly on short runs will require this attention more often than th
139. p and distributor are driven from the camshaft each component having ts own drive shaft The pistons are each fitted with two compression rings and a slotted oll control ring Bearings of the thin shell preformed type are fitted to the connect ing rod big ends and to the main bearings counter blanced crankshaft s fitted The end thrust on this component 1s taken by special washers at the center main bearing The centrifugal water pump and cooling fan are driven by the dynamo belt GENERAL SPECIFICATIONS No of Cylinder 4 Bore 73 025 mm 2 875 n Stroke 71 mm 2 796 in Volume 1 189 cc Max brake horse power 60 HP at 5000 r p m Torque 9 3 kg m at 3600 r p m F r ng order 1 3 4 2 Valve arrangement Overhead valve push rod type Compression pressure 163 lbs per sq in 11 5 kg cm at 350 r p m Compress on rat o 8 2 1 ight si R Engine ine Left si Eng COOLING SYSTEM An efficient cooling system is of major importance to ensure the satisfactory running of the engine and it is therefore necessary to pay paticular attention to its ma ntance k l Description The cooling system 18 maintained by water pump circulation combined with an efficient fan cooled radiator and thermostat The system 1s pressurised and the relief valve incorporated n the rad ator filler cap controls the pressure at approximately 0 4 kg per sq cm Do not remove the filler cap if the temperat
140. peed 3 amp 4 coupling sleeves and speed 3 gear 0 075 0 125mm 0 003 0 005 n Between speed 2 synchronizer and main shaft spline 0 003 0 12mm 0014 0 0048 n Between 2 synchronizer and speed 1 gear 0 075 0 125mm 003 0 005 in Between speed 1 gear and speed 2 gear 0 075 0 125mm 0 003 0 005 in MAIN DRIVE GEAR AND SHAFT Inner diameter of bearing at rear end of main drive gear 20 485 20 503mm 8064 0 8072 in Outer dia of bearing at front end of main shaft 14 460 14 448mm 0 5693 0 5688 n Ma n shaft p lor bearing Needle roller bearing No of needles of needle roller bearing 18 Dia x height of dittoed bearing 3 mm x 28 mm 118 in x 1 102 1n Inner da of 3rd gear bearing hole 33 388 33 401 mm 0 3144 1 3149 in Outer dia of 3rd gear bush 33 312 33 325mm 1 3114 1 3119 in before pressing n Play of periphery of 3rd gear bush 0 06 0 09mm 0023 0 0035 n Amendment limit of dittoed play 15mm 0059 in Inner dia of 2nd gear bearing hole 33 388 33 401 mm 1 3144 1 3149 in Outer dia of 2nd gear bush 33 312 33 325mm 1 3114 1 3119 in Gap at periphery of 2nd gear bush 0 06 0 09 mm 0023 0 0035 in Amendment limit of dittoed gap 15mm 0059 1n Thickness of front thrust washer on main shaft 3 975 4 001 mm 0 1564 0 1575 1n 4 026 4 051 mm 0 1585 0 1595 n b 4 077 4 102mm 1605 0 1614 in Th ckness of
141. per 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 coil Take off the dynamo lead and disconnect the starter motor cable at the motor end Remove the oll gauge and water temperature gauge leads from their terminals on the engine Engine amp Transmission Assembly beg lifted from Chassis The throttle and choke controls must be disconnected from the carburetor Disconnect the fuel pipe from the fuel pump Next remove the exhaust p pe from the man fold 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 p n on 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 34 OPERATION WITH THE ENG NE REMOVED i The following operations are best performed with the engine removed from the car Although t may be found possible to carry out certain attentions with the engine n position it 15 more convenient to do the work on the bench Z Withdrawing Camshaft The camshaft 18 positioned by a locat ng plate held by three screws and
142. prevent plug from keeping air ht w 9 11146 1 17901 96700 v 2 85190 m Fuel Stramer Assembly 43 FUEL PUMP COMPONENTS OF FUEL PUNP Cap screw washer Fuel pump cap Fuel pump cap gasket Body set screw 12 y Angle connector Spring washer Rocker arm 2 5 s de spacer K Rocker arm pin Valve pack ng Fuel pump valve ass y Valve retainer ass y Lower body Valve screw gasket cap N Diaphragm ass y Diaphragm spring Lower body gasket cap Lower body gasket Fuel pump shield ass y X Hand primer lever rod S Lower body gasket sheet Hand primer lever Rocker arm side spacer Gy 15 q E primer cl p Hand primer pin Lock washer QS Nut Rocker arm 7 ocker arm pin oint h J washer Rocker arm side spacer 44 FUEL PUMP Type D aphragm pump Method dr ven Dr ven by camshaft Diaphragm spring Free legnth 36 5 0 1 mm Length n use and tension 18 mm 1 6 0 1 kg Rocker arm spr ng Free length 30 mm Valve spr ng Free length 9 5 mm Thickness of valve 1 6 mm Performance Max guant ty d scharged 1300 cu cm per m nute at 1000r p m of cam 500 mm 18 suction height Max pressure d scharged 110 130 mm n mercury column Max degree of suction vacuum More than 400 mm n mercury column Hand primer quanty discharged 80 cu cm at 20 strokes The fuel pump which 15 of the diaphragm type 18 me
143. r The front cover and gasket should now be positioned over the securing studs and attached by means of the seven nuts and lock washers 100 REMOTE CONTROL LINKAGE PROPELLER SHAFT amp UNIVERSAL JOINTS Fg 7 Propeller Shaft amp Joint 1 Dust cover 8 Propeller shaft assembly 2 Sleeve yoke 9 Flange yoke 3 Journal 10 Companion flange 4 Oil seal bearing retainer 11 Bolt 5 Oil seal 12 Nut 6 Bearing assembly 13 Plane washer 7 Snap ring 14 Drive pimon nut 15 Cotter pin 102 PROPELLER SHAFT amp UNIVERSAL JOINTS Backlash of sleeve yoke spl ne 0 1 mm 0 004 in Amendment limit of dittoed backlash 0 5 mm 0 02 in Outer diameter of universal joint journal 14 728 14 725 mm 0 580 0 579 1n Inner dia of bearing lace 19 515 19 530mm 0 768 0 769 n Number of roller of bearing needle 22 for each bearing Diameter x length on dittoed bearing needle roller 2 38 mm x 10 3 mm Run out of shaft Less than 4 mm Olsun Tighting torque of companion flange nuts 15 18 ft lbs Outer dia 68 9 mm Inner dia 60 3mm Length between front amp rear joint 1320 mm Lubrication An oil nipple 1s fitted to each center spider for lubr cat ng the bearings The central 011 chamber 1s connected to the four 011 reservoirs and to the needle roller bearing assemblies Fig 2 The needle roller bear nge are filled with oil on assembly il from the tran
144. r and has the drum type of worm gear at the lowest end of main steering shaft The main steering shaft 1s incased 1n the jacket tube and the steering wheel 18 fixed with at the top end of it The worm gear inter locks with the roller which 1s fixed on the roller shaft and works upon t to turn and through which turns the steering arm around the axle of shaft at the operation of steering wheel The motion of the steering arm 1s that of back and forth n front of drag link and turns the spindle around the king pin with the connecting knuckle arm through which changes the bushings of front wheels 107 The roller shaft tself 18 supported by the two bear ngs both s des n the gear hous ng i Fig 1 108 STEERING GEAR 48338 01300 Complete cord with contact 48050 07200 plate 9 11245 9 15115 worm bear ng sh m 48029 32200 Steering column 48032 32200 complete an n 48035 32200 1 2 48037 32200 0 ring 48064 27160 9 11346 48204 32200 48025 30800 d gt Roller shaft cover G Loe 48201 32200 UE shaft adjust 48129 32200 ing shin 48102 32201 Set 48132 3 48103 07200 48135 32200 2X 48208 30800 eU 0 ring 7 48097 32300 Complete gear 48011 07400 L type QC 48035 32200 1 2 48011 07200 R H type 0 Ring hous 48127 37200 upper Housin 48128 o ower b 48137 26760 9 15422 48501 07200
145. r boot 9 Let out valve assembly 3 Stopper plate ring 10 Check valve seat 4 Piston secondary cup 11 Brake master cylinder body 5 Master cylinder piston 12 Fuler cap gasket 6 Piston primary cup 13 Filler cap 7 Return spring seat 155 Bleeding the Hydraulic System Bleeding 1s necessary any time a portion of the hydraulic system has been d s connected or if the level of the brake fluid has been allowed to fall so low that air has entered the master cylinder With all the hydraulic connections secure and the supply tank topped up with the fluid remove the cap from the bleed valve and fit the bleed tube over the bleed valve immersing the free end of the tube n a clean jar containing a little brake fluid Unscrew the bleed valve cap about three quarters of a turn and then operate the brake pedal with a slow full stroke until the fluid entering the jar 1s completely free of air bubbles Then during a downstroke of the brake pedal tighten the bleed screw cap sufficiently to seat remove bleed tube This process must now be repeated for each of the other wheel cylinder Always keep a careful check on the supply tank during bleeding since it is most important that a full level is maintained Should air reach the master cylinder from the supply tank the whole of the bleeding operation must be repeated After bleeding top up the supply tank to its correct level of approximately three quarters full Never use fluid tha
146. r gre m ga lt sa 1 e 4 Nt 67 i tet eu pu 9 4 E UH 1 M z 2 40 yeti rod Ml A Uh 07 a 5 iv X a a 7 Removing and Replacing the Tappets A Remove the carburetor and the rocker cover thenit ke off the manifolds D sconnect the high tension leads from the sprk ng plugs remove the rocker assembly and withdraw the push rods keeping them n 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 in same locations Fig 10 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 gt 4 above procedure but car should be taken to see that tappet cover joints 2 are 011 t ght and that the rockers are adjusted to g ve the correct pen valve clearance Fig 10 Removing a Tabbet Piston and Connecting Rod Removal Drain the cooling water from the engine and radiator Drain and remove the sump from the engine then disconnect and remove the 011 strainer Take out the set screws and rock washers from the big ends and withdraw the caps It will be noted that the caps are off set When used parts are replaced after dismantling t 1s essential they are fitted into
147. rained into a clean container Unscrew the flexible pipe union and push rod The operating cylinder can now be removed Remove the rubber cover and f compressed air line is available blow out the piston from the side of unton Examine all parts especially the seal and replace 1f worn of 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 n position making sure the push rod enters the hole n the rubber boot Secure the cylinder with the pinch bolt and screw in the pipe union Bleeding the Clutch System Remove the bleed screw dust cap at the operating cylinder open the bleed screw approximately three quarters 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 reservoir with the recommended fluid and by using slow full strokes pump the clutch pedal until the fluid entering the container 1s free from air bub bles On a down stroke of the pedal screw up the bleed screw remove the bleed tube and replace the dust cap When the clutch pedal is depressed the force 1s transmitted to a carbon bearing and the surface pushed the release plate The carbon bearing has high resistance against wear and does not need lubrication
148. re 1s rotat ed by hand If the 1ron piece rs attracted to the armature coil the armature coil is shorted and should replaced Checking Armature Shaft and Bushing The clearance between the armature shaft and bearing bushing rs checked and if the shaft 1s found to be worn or badly bent t should be replaced If there 1s excessive looseness between the armature and the core becomes non uniform during rotation so that not only will the output be reduced and the smoothness of rotation be destroyed but this will cause the shaft to bend and cause the parts to touch The specifications should be referred to and defective parts should be re placed or repaired Checking Armature Coil This 1s a visual check up The connection between the armature coil and the commutator are inspected and all loose or defective soldered connections are corrected Checking Commutator When the commutator becomes worn so that the oval ty of 0 4 mm differ ence in diameters between th largest and smallest dimensions 1s exceeded or the depth of the mica segments from the surface of the commutator becomes less the allowable limit of 0 2 mm corrections should be made When the commu tator surface dirty of rough or is worn so that 11 1s elliptical or stepped it will not only result n the brushes contacting poorly and causing decreasing output and further the burning damage on the commutator surface but will also hasten the wear of the brushes 166
149. ress because it would cause the noise n later operation and be difficult 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 1n 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 as 11 15 If t 18 hard to inspect them as 1t 18 do otherwise by cleaning the both with the rugs before disassembling and paint thinly and evenly with the mixed with thin oil on the gear surface drive side then turn the pinion with hand to print the trace of it on the gear Which shows the situations of considerably worn out gear 131 In case of unloaded test t 1s perfect that the gears contact for about three quarter at the center of 1 4 of whole gear length from tooth interior tip end of the gear on the pitch line 3 Lock the side gear with pinion together with respective thrust n the gear case In case of the backlash 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 is too close to pinion center 1n case of backlash should be adjusted closely or it gives much noise 4 Put the drive gear ring gear on the buoy block as it 1s fixed in the differen ual gear case and measure with the dial
150. rive pinion arrangement gauge The standard height of the pinion 1s 21 mm from the carrier The fixing position can be measured by setting an arc of circle on both gauge as Fig 7 to the degree that support d previously mentioned condition it 18 nec than the standard Make use of the special the bottom of the side bearing fixed with sides of arrangement gauge at the position 5 of side bearing and insert the thickness gauge n the clearance between the t p of gauge bar KY 7 JEPAE and the pinion such as to push n by scraping Fig 7 Use of Drive Pinton of the carrier in diagonal otherwise pre Beanng Pre load Gauge load and the pinion height of the bearing would come out of order and tend to cause an unexpected trouble n future 5 The formal adjustment of the drive pinion bearing and preload After the fixing position of drive pinion 1s decided as mentioned in the previous paragraph take off the pinion nut amp companion flange to mount again the drive pinion bearing spacer distance piece and nut Tighten up the nut as Fig 7 by using the torque wrench at the regular torque of 100 120 ft lbs 1400 1680 kg cm The preload supportediy the bearing n this case 1s different according to the condition of the bearing adjusting shim inserted The more of the shim in serted much the play of pinion to the direction of axle 1s increased The less of the shims inserted the more the bearing tigh
151. round 0 when driving at 30 to 40 km per hour If the indication 1s more than minus 10 amperes check up should be made n the manner as described n 3 During the day even with the battery fully charged about 30 amperes charging current may be indicated 1mmediately after operating the starting motor There is no need to worry since this 1S to restore the temporarily consumed battery and t will return to the normal charging condition within 5 minutes STARTER MOTOR Voltage Output Starting current voltage Lock torque Type of pinion gear Number of tooth on pinion 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 pinion side Amendment limit dittoed gap Gap between shaft and bush rear end Amendment limit dittoed gap Amendment limit of deflection on shaft Amendment limit of short dimension Dittoed degree of rear circle Dittoed limit of polarized wear Bush length Amendment limit Brush spring pressure 12 volts 1 0 HP Less than 500 amps 9 5 volts Over 0 9 kg m Bendex type 0 1 mm 0 004 in 1 mm 004 n 0 038 0 095 mm 0915 0 0038 0 02 mm 0 008 m 0 03 0 076 mm 0 0012 0 0030 n 2 mm 008 n 0 1 mm 004 in 2 mm 0 08 mn 0 05 mm 0 002 in 0 4 mm 0 016 n 9 mm 36 n 0 9 kg 0 1 174
152. ry 1 The pinion is inspected for defects and if the tooth face 1s worn or the tooth edge 1s damaged the pinion 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 n the armature shaft For this last reason care should be taken when inspecting to also check the fly wheel and take remedial measures if the ring gear is found worn or damaged When the pinion 1s found defective replaced the entire pinion group 2 When inspecting the armature check the armature to core gap shaft to bushing clearance bending in shaft etc n 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 178 surface of the armature or the nner surface of the core should be removed by polishing and the surfaces painted with rust preventive oil 3 The armature 1s inspected and repaired n accordance with the procedures outlined for the generator Especially to improve or correct the brush con tacting condition the brushes are reseated At the same time the brush and brush spring are checked and are corrected or replaced 4 The insulation on the wires are carefully inspected and wires found with weak or da
153. s mission Lubricates the sliding splinded joint between propeller shaft and the transmission Before retitting the propeller shaft to the transmission case smear the splines with the oil Fig 2 Lubricating a Universal Joint of the Propeller Shaft 1 Propeller shaft 2 Universal joint mpple 103 Removal Remove the rear propeller shaft flange from the p n on flange of the rear axle by tak ng out the secur ng 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 in one hand and tap the radius of the 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
154. s where anti freeze is 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 18 mm nent 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 other at the base of the radiator block Both taps must be opened to drain the sys tem and the car must be on level ground while draining The drain taps should be tested at frequent intervals by nserting 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 draining 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 n the radiator the system should be periodically flushed with clear running water preferably before putting n anti freeze n the winter and again when taking it out n the spring The water should be allowed to run through until t comes out clear from the drain
155. shaft by the thickness of adjusting shims inserted at the time of assembling 144 77948 e X 3 5 10210 F9188 Turqovd 58893 2 10190 12209 91901 9 i 9885 3urre q 9 3 9 jozze re0ce N 1898 688938 Yuxa raq 105 9 480 V AW s X999dS ooopy ozo 1edde ogesz ovvee 9 oor e S N 88 HOOT Buravaq 9 5898 00222 9122 1909389 98893 000 556 0005 0558 000 6156 00556 615 0 0276 6176 urus qsnfpy 1898 TO 7J8y8 9 5 1roy 00610 21286 00222 89069 N OOTSS ZZE8E 1 02592 2 00210 0102 A 888 9883 9 5 8 9 10226 t806v 2194 9885 Surreog 1 9 1 6 145 ADJUST SHIMS INSERT HEAR Fig 14 In adjustment for this end play select the adjusting shims for one side Left or Right at the first Insert selected shims standard 1 5 mm between the axle tube and the shaft assembly fit the end play of axle shaft 0 85 1 10 mm Secondary attach the other side of axle shaft assembly and adjust end play 0 05 0 10 mm by selecting adjust shims 146 THE INSPECTION WHEN THE CAR STOPS 1 Operat ng the s de brake and setting the revolving of axle shaft the gear backlash and the defacement of the spline n
156. shown with the line n Fig 5 to terminal B and make meas urements through the circuit of terminal B and a fully charged battery Measurement of the output 1s made by reading the voltmeter and ammeter through the variable resistance circuit with the battery circuit cut out During the measurement of the no load regulating voltage the N P Serew terminal A voltage and termi nal B voltage should be practi cally the same these tvvo voltages differ considerably this indicates a resistance in the charging circuit 18 this case check the cut out relay for such defects as burnt contact points and repair as necessary Lock Screw Adjusting Regulator After Reassembly When reassembling adjustments are made throught the adjusting core and the pile pressure screw The regulator 1s con nected up to the generator at no load and revolving at specified speed 2 500 rpm the adjusting core F screw is tightened by turning it in clockwise direction as shown in Fig 6 This will cause the voltage to drop at first but it will rise again This is due to SET POSITION the fact that at first the gap between the F e screw and the moving core to increase the PILE ADJUSTING SCREW contacting resistance of the pile sheets and lower the terminal voltage As the F screw 18 ughtened further the gap to the moving core reaches 0 and the terminal voltage shows a minimum value With further tightening the flux adjusung screw
157. sleeve As the coupling sleeve replaces the guide the balls find their correct location in the coupling sleeve It should be noted that the coupling sleeve has a much greater depth of flange on one side and on reassembly this should fall towards the rear of the box In addition the internal splines must be correctly located to allow the baulking ring to pass through the machined grooves between the teeth TEIG te FS toe x Sel 2 lt Fig 5 Using a Special Guide to Reassemble the Three Balis and Springs into Synchronizers 96 ar P Em Q 3 gt it m 2 8 0 7 i 7 LI E 7 3 y Fig 6 Assembly Order of Transmission Gears 1 Main drive gear Counter gear 2 Main shaft 4 Reverse gear pm 57 P 2 y j sma gt gt 7 0 N i 557 8 5 5 77 v s I E ds t V MS x teh 5 d r De DESL ALES ately 3 p 4 Ey DP Fe SUM 4 5 A pa pin RES xs a oe N ein ry lt 2 METEN 9 wi T T amp IW y X AU ge A 1 23 7 Mw e Ao Eg FE v Fig 7 Components of Gears Synchronizer 97 Counter Shaft amp Gears F rs
158. sults are to be achieved Mark the cover pressure plate lugs and release levers with a centre punch so that the parts can be reassembled n their relative position 18 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 76 imani ner Fig 4 Disassembling 77 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 if necessary bearing in mand that the pressure springs must only be renewed n sets Clean all parts and lubricate the bearing surfaces of the levers sparingly with grease Assembling Fig 5 Press the p n nto the eye bolt hole through the lug on the pressure plate as shown 78 Place the pressure plate on the base plate with the pressure springs n position on the pressure plate and put the pressure spring retainers on t Cover 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 n the cover Tighten the screws a little at a ume by diagonal selection to prevent distortion to the cover Set the release lever on th
159. support bracket on the steering part of the car 1s threaded do not therefore try to knock the bolt out or the threaded n the support bracket will be stripped Screw the bolt out Detach the rubber dust cover around the withdrawal lever from within the clutch housing Cross Shaft Levers The cross shaft levers are positioned on the right hand side of the case of transmission if the car has right hand steering and on the left hand side if left hand steering A cotter pin spring washer and nut secures each lever to its shaft After the nuts and washers have been removed the pins may be tapped out and the levers lifted off the shafts Side Cover Holding the side cover n position are set bolts and set screw with serrated washers all of which must be removed when the cover can be taken off Change Speed Cross Shafts amp Selector Arm Once the side cover 1s removed both the selector arm and change speed lever cross shafts can be drawn from the case bringing with them the change speed gate Gentle pressing prising may be necessary to assist removal of the gate as its rounded ends are a tight fit in the machined recesses on the side cover seat ing After withdrawal the gate can be threaded off the selector arm and change speed lever At this stage the shafts oil seals and felt washers can be with drawn from the case at the operating lever side To remove the selector arm the shaft tap out the securing pin The engage ment lev
160. t cut out Also the coil in series with s the field 1s for improving the charging characteristics at low speed while the fixed resistances are for preventing variations in characteristics due to temperature changes LX Wiring Precautions 1 Generator 2 Field coil 3 Carbon pile 4 Compression spring 5 Moving core 6 Voltage coil ULU OAOT Fig 3 Voltage Regulat ng Principles In connecting up the generator and the voltage regulator care should be taken to note the signs on the terminals shown in Fig 4 to make the connections tight and to make sure not to forget to connect the ground terminals 1 al amme a an eed Tr pod 69 However caution should be taken not to damage the terminals screws and other parts by tightening more than necessary For wiring heavy wires are used be tween A A and B B because of large currents flowing between these points and light wire 1s used between F F Care should be taken not to mistake the s ze of these wires When the wires have been n service for a long period of time they are repaired or replaced In these cases the same or larger size wires should be used to replace the wires formerly used and wire to wire connections should be amply soldered and wound with black tape to preserve the insulation Repairs Adjustments Inspection The voltage regulating part of the voltage regulator has been subjected to rigid inspection so that
161. t has been bleed from a brake system for topping up the supply tank as this brake fluid may be to some extent areated Such fluid must be allowed to stand for at least one day before it 1s used again This will allow the air bubbles in the fluid time to disparse Great cleanliness is essencial when dealing with any part of the hydraulic system and especially so where the brake fluid 1s concerned Dirty fluid must never be added to the system 156 IGNITION SYSTEM The ignition system 15 a system which is necessary for gn t ng the com pressed fuel air mixture within the engine cylinders The electric current from the electric power source battery and generator flows through ammeter 5 and 1gmition switch 6 into ignition coil 7 The low voltage current through the primary coil 14 1s interupted by contact breaker 9 of the distrubutor This charges the magnetic field within the ignition coil intermittently thus inducing high voltage The high voltage current 1s distributed by the distributor 10 through the high tension cord 16 to the spark plugs installed in the combustion chambers of the cylinder head The spark plugs are made to spark to ignite the fuel air mixture in the cylinders To diagnose defects of the ignition system always have this distribution prin ciple in mind and check the low and high voltage circuits separately As shown in Fig 3 the ignition coil has two coils with primary current which 15 sent
162. t locate the two thrust washers to the counter gears ensur ng that the larger washer 1s at the front and then place the gear cluster n the gear case Check that there 18 end play for the cluster gears of between 0 04 0 06 mm 0 0015 0 0023 and remedy if necessary by fitting a thicker or thinner rear washer Thickness of front thrust washer 3 91 3 96 mm 154 0 156 n Thickness of rear thrust washer 3 96 3 91 mm 0 156 0 154 n 4 013 3 988 mm 0 1580 0 1569 in 4 089 4 064 mm 0 161 0 160 in 4 166 4 140 mm 0 164 0 164 n 0 44 0 06 mm 0 0015 0 0023 n Temporarily replace the counter shaft with a thin rod which will permit the gear cluster to remain out of mesh with the main and drive shaft gears 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 1n position Smear grease n the end of the shaft where the main shaft locates then load the 18 needle rollers so that they adhere in position by means of the grease Turn the gear casing to ensure that the counter teeth are below the drive gear 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 dr fted into position from the
163. tened by the pre viously mentioned nuts and cause it to be burned if left and turned as it is Therefore for readjustment of the bearing preload in this case t must be ad justed by increasing or decreasing the number of four kinds of adjusting shim as shown in the following list and measuring with the use of the drive pinion bearing preload gauge as Fig 6 so as to make the revolving torque of pimon at 7 10 kg cm 1f there should not by any error in the pinion with the head mark at 0 and the clearance should be sealed at 0 2 mm 0 008 n by the feeler gauge thus pinion is regarded as at the correct position because the height of the gauge 18 made shorter for 2 mm than the standard size 21 0 mm If it is necessary to adjust the pinion height take off the drive pinion as well as pinion rear bearing outer lace from the carrier to adjust by increasing or decreasing the number of the adjusting shim In other words read the mark on the head of the drive pinion before adjusting by increasing or decreasing the number of device pinion adjusting shim to insert the feeler gauge which 1s deducted for the number 137 of mark from 0 008 n 1n case of minus side added for the number of mark 0 0 008 n ncase 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 in 0 002 m 010 n It 1s necessary to give the bearing a right preload At the t
164. ter reseating it should be blown with compressed air and after cleaning the dust off thoroughly the brush 16 wiped with a dry cloth The max permissible wear of the brush 18 1 3 the length over which the brush should be replaced B If the brush spring does not have the proper tension t should be replaced Since the brush spring has considerable effect on the proper contacting be tween the brush and the commutator rt is necessary to determine the tension by the tester of spring tension with brush istalled A weak spring will increase the electrical resistance causing sparking and pitting on the commutator while too strong a spring will hasten wear m the brush and commutator Thus when re placing a good grade brush and correct s ze spring should be used VOLTAGE REGULATOR On the voltage regulators 1s the carbon tile H tach Model R123 50 used Hitachi generator 167 Fig 1 H tach Model CCA Carbon Pile Type Voltage Regulator Model Cut out relay point gap 0 6 0 8mm No load adjusting voltage 15 16 volts at 2500 r p m Flux screvv locat ng voltage 12 5 13 5 volts at 2500 r p m Cut in voltage 9 11 volts at 2500 r p m Release current Less than 5 amps Construction and Operation As shown n the above figure the regulator consists of the carbon pile magnet coil moving core spring and fixed resistances The principal part 1s the carbon pile which consists of several dozen layers of t
165. tes inside the cells will become warped and the surface of the plates will be covered with white lead sulphate This will plug the many small holes n the wooden separators to increase internal resistance and cause the voltage drop which will make recharging difficult t will be necessary n this case to repair or replace the plates n the battery Charging Whenever the battery has been repaired and when the battery fluid has been replaced and also while the battery 1s n use and the voltage drops due to large ele ctrical consumption the generator installed on the car 1s unable to maintain suffici ent charging In such cases the battery fluid is replenished or replaced if in faulty condition and the battery charged by connecting it to a battery charger 1 Instructions on normal charging procedures The fluid level is checked to see that it is about 22 mm above the top ot the plates on visible type plugs t should be up to the normal level indication Note The vent plugs on all cells should be removed while charging The terminals should be polished to remove all dirt and fluid adhering to the surface The 4 of the battery terminal 1s connected to the 4 direct current terminal of the charger and the terminal of the battery to the terminal of the charger The charging 1s made with a current of 6 to 8 amperes As the charging progresses the battery voltage rises so that the charging cur rent beings to decrease while
166. the Ignition Teming Um B 3 Next what to the left as shown n F 1s placed toward the front VA a inserting the driving shaft of the distributor at an angle to the ngine engage the gear on its lower and with the gear on the camshaft During this assembly place the slot of the distributor drive of the upper end of the shaft some g 2 At this time the smaller of the semi circles 2 2 _ pa 5 5 d gt 2 ENS R 62 m E ZZ t x P i ae Hp nib m ae 4 Adjusung the direction of the rotor so that it engages the drive shaft 106 e mount the distributor to the engine During this assembly the directions of the distributor and rotor must be as shown n Fig 3 At e Same time the 5 Ts must be n 116 position when it s just begining to open If these conditions do not coincide they are made to do so by slightly turning the distributor body only To determine the position when the breaker point 18 just begining to open turn o on the ignition key hold the end of the No 1 spark cord about 1 4 inch away from the cylinder head and turn the body until spark jumps across the gap The off set slot position of the drive shaft when the No 1 piston 1s in its com pression top dead center position 15 shown here UR E 5 Next put the distributor cap on and clamp it secure
167. the carrier 7 Me and adjust by measuring the position The pinion height must be adjusted as x mentioned n the previous paragraph by mounting temperar lly the pinion n the carrier and the bearing be given a regu gular pre load On the other hand the bearing of drive pinion should be newly oiled after the pinion 1s inspected 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 Fig 5 flange till the regular revolving torque 1s required As this 1s not yet at the final assembling the bearing spacer distance piece bearing adjusting shim and oil seal are not mounted 136 At the time of inserting the front bearing as pushing in the inner race by pulling out the drive 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 lace inserter as shown Tighten up the pinion nut by turning it as emin slowly with hands with the use of pre load ee A SH 2 the bear ng pre load at 7 10 kg cm When the dr ve p n on 1s mounted n the essary to measure the height of rear surface q of the p n on whether t 1s higher or lower oa d
168. the housing can be found by in spec ng the motion of the propeller shaft as moving it to left and right Specially in case of the drive pinion comes out and in the pinion bearing 15 worn out or the adjustment 1s necessary 2 Another inspection should be carried n a way by tacking up one of the wheels and spin it back and forth 3 Holding the tire ot the wheels jacked up and spin and move to every di rection When the shock 1s felt inspect the degree of tightness and adjust 12 vf if 4 Inspect and confirm the volume and quality of the oll n the housing Inspection in Motion 1 In case of giving the high metalic noise when speeding up the backlash 1s at the least or too much at the drive gear and the drive pinion 2 Giving any abnormal noise in speeding up or slowing down the drive pinion bearing 1s worn out or damaged aff Uf if 3 It 15 the bearing that tives the constant humming noise at high speed and the gear that makes a periodic nose at low speed In case there 1s any da mage of the gear 1t must be immediately disassembled and repaired because if it is used as it is the broken gear cause to breake the other gear and ano ther and so forth finally to the big accident 147 GENERAL DATA Type operated by foot operated by hand Inner dia of master cylinder Inner dia of wheel cylinder Residual pressure of brake oil BRAKE DRUM Inner dia of drum both front amp r
169. the tank should be cleaned by removing the drain plug at the bottom of the tank Check to see if 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 1s about 3 4 in apart from the bottom n order to prevent its sucking up sediments on the tank bot tom If not normal remove tank unit and adjust the bend of the pipe Fig 2 Waring of Fuel Gauge Check too seeif the vent hole of the 1 Umt Gauge 4 Ignition Switch filler cap is clogged with dust and dirt 2 Fuse 5 Ammeter not supplying air to the tank 3 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 gt 4 So be sure to clean the a r vent of the cap If you should lose the cap and subst tute a wooden plug for t a measure which is sometimes witnessed the condition inside of the tank becomes the same as though t were sealed up Always use only the standard cap Operation and Repairs of Fuel Gauge As shown in Fig 2 the fuel gauge consists of the dash unit and tank unit The dash unit which 1s installed on the instrument panel has two coils that cross each other at right angles whose magnetic forces control the movement of a keeper iron piece with a hand indicator On the tank unit a contact arm slides over a resistance n response to the float level As shown n Fig 2 if the igni
170. there should be practically no changes while n use and no necessity for adjustments If trouble should occur however the regulator should not be touched without previous prepara trons or this will on the contrary lead to big ger troubles Before adjusting the principles outlined above should be thoroughly understood and with a voltmeter and other instruments on hand adjustments should be made correctly B When adjusting the gap between the adjusting core and the moving core 1t 18 difficult to deter mune this distance dimensionally so that it 18 of importance to make this adjustment electrically Fig 4 as shown n Fig A Wiring Diagram Adjusting when Voltage Changes after long Period of Service li e Fig 5 Wiring During Adjusting 170 In this case adjustments are made through the pile compression screw only As shown n Fig 5 to the A terminal of the regulator a voltmeter V 1s connected Terminal B 1s connected via an ammeter to the circuit switch of the battery and variable resistance With the generator running at no load battery and resistance circuit cut out and at rated speed generator 2 500 rpm engine 1 860 rpm the voltmeter 1s read As shown n Fig 5 tightening the pile compression spring will raise the volt age so that if the voltage 1s low screw in and conversely if the voltage 1s high unscrew To measure the cut in voltage and cut out current connect the voltmeter as
171. they have to pass 70 Compress the pressure springs by screwing down the cover to the base plate by using the special set screw placed through each hole n the cover Tighten the screw a little at a time by diagonal selection to prevent distortion to the cover The eye bolts and pressure plate lugs must be guided through the holes n the cover at the same time Gauging Screw the nuts into the eye 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 unscrewing the eye bolt nuts until the height finger when roted just contact the heighest point on the up of the release levers Replace the height finger and pillar by the clutch actuat ng mechanism See inset Fig 3 and actuate the clutch several t mes 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 02 n press over the high spots until it 18 true within this figure It 18 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
172. through the primary cord 1s sent and cut the magnetic field within the pri mary coil changes and by mutural nducuon a voltage of 10 000 volts or more 1s created n the secondary coil At this moment self induction voltage in the primary coil causes sparking at the contact points of the distributor contact breaker resulting in a decrease n the induced voltage of the secondary coil and pitting of the contact points BATTERY JGN TION B20 20A Ba BA t f x 5 x x i 2 Fig 7 Ignition System Therefore the primary circuit 1s provided with condenser to prevent drop of secondary voltage and absorb the spark at make and break contacts 157 6 6 i 14 swe PES EE 1 OH Te 5 69 6 E 2 Fig 2 Wiring Diagram of Ignition System 1 Battery 9 Distributor 2 Magnetic switch 10 Distributor cap 3 Starter motor 11 Cylinder head 4 Starter button 12 Voltage regulator 5 Ammeter 13 Generator 6 Ignition switch 14 Primary cord 7 Ignition coil 15 Secondary cord 8 Condenser 16 High tension cord IGNITION Type C TZ 01 1 Pr mary voltage 12 volts o Ma 2 z q L SITIS 0 v 3 42 F g 3 Section of Ignition Coil YAY N BAN NAN ALA 1 Primary cord ter
173. tion The flywheel ring gear 1s checked and if the teeth are deformed they should be repried or the gear replaced Rattling noise caused by loose starter mounting bolts are corrected by re tightening the bolts Noises caused by brushes improperly contacting the armature requires cor recting as this condition not only produces noise but will hasten wear on both parts Noise made by the armature rubbing against the core while n operation 1s caused by too large a clearance between the armature shaft and the busing so the worn parts should be replaced Wear between the shaft and bushing 1s 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 oli and lubricate the parts through the oil nipples The amount of oll required is about 5 cc for each bracket BATTERY Voltage 12V Capacity 50AM 20H Earth Specific gravity of electrolyte 1 280 at 20 C 181 Level of electrolyte 10 mm Above electrode Gross weight About 21 kg The DATSUN 15 equipped with one of the above makes of batteris meeting the specifications of the Japanese Standatd Type battery The interior construction con sists of 6 cells each having a terminal voltage of 2 volts the voltage produced be tween the 4 and terminals being 12 volts and when installed on the car the terminal 18 made the ground The battery when installed on the car 1s located on the right side of th
174. tion switch is turned on when the tank 1s empty electric current will flow from the battery through the ammeter into coil A and then through the contact arm to the ground Coil 18 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 in 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 in the direction of F That 1s this 1s a gauge of electric resistance control type E signifies Empty level and F Full level Troubl s with Fuel Gauge and their Remedies When something 1s 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 F the wiring between the dash unit and the said terminal end 18 n good condition with the de fect existing either in tank unit itself or n poor ground of this unit In the test mentioned in the preceeding section if the indicator does not swing but 3t moves moves to E when the dash unit end
175. tration The specific gravity varies with the temperature so that the temperature of the fluid 1s measured and with the use of the following conversion factor corrections are made to the condition at 20 C in order to determine the actual state of battery charge If the specific gravity falls below 1 220 the battery should be charged at once until the fully charged state of 1 280 1s reached Specific gravity when fully charged 1 280 at 20 C Temperature conversion factor for 1 C 0 0007 For each 1 C rise in temperature the specific gravity decreases 0 0007 and reversely a drop in temperature increases the specific gravity correspondingly The reason for using a fluid having specific gravity of 1 260 for replenishing or replacing as mentioned above 1s to take into consideration the fluid becoming concentrated due to charging and lowering of fluid level in making the fully charged specific gravity about 1 280 Even if a specific gravity of 1 280 1s shown when the fluid 1s at the normal level of about 22 mm above the top of the plates the fluid level when t becomes even with the top of the plates will concentrate the fluid to a specific gravity of over 1 310 If the specific gravity becomes higher than 1 30 caution should be taken since the life of the battery will be shortened rapidly 3 Terminal voltage at each cell By the above method of determining specific gravity the state of battery charge can be determined but the
176. 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 running 2 When the starter switch 1s turned up and the starter motor fails to turn 176 00190 096 00006 20422 00190 98262 00190 98662 00190 12662 0010 96CEZ 00005 20222 00190 98262 09952 99562 deb xx Q poso 0 cy Y 0010 6CEZ 00190 18662 AA o 00190 08655 2 b 58 951 gt 00190 6866 oorwo eeeez dc yil mi 69170 28855 00 0 622 r LEZ amry b I e 0 Wi 3ur1ds xepueg 00100 16 19A00 04 191709 uruds 00190 8166 00102 52662 00190 02262 MAING 00102 21662 00106 02 T 5 ff 7 P TA 514 220 anu zeddo Uln 9y 8 8 d g Sutads OOLOE ELECZ 09297 26 EZ 8 00102 51662 00106 69222 YOLOW 1 15 177 although the lights remain bright the switch should first be checked If the switch 1s in satisfactory condition then the condition of all the terminal and and ground connections of the battery starter switch
177. turning the idler shaft THE CAUSE OF TROUBLE The cause of the trouble caused n regards with the steering n operation 1S closely connected with those of the front axle therefore 1t 1s hard to judge then separately The following are main troubles caused n steering Heavy and difficult operation of handle 1 The oll n gear box 2 Adjustment of worm and roller 18 poor 3 Damage on corn of worm bear ng 4 Hard lock ng of column jacket bush 5 Steering shaft or tube 1s bended Insufficient Amount of Turning 1 Adjustment of worm and roller 1s poor 2 Fixing port of gear housing with frame 15 loose 3 Locking position of roller shaft and steering arm 1s bad Unsteady or Trembling Handle in Motion 1 Too much backlash of worm and roller wheel play 1s too large 2 Worm bearing and roller shaft bush is worn out 3 Looseness of each bolts on gear housing 4 Looseness of fixing bolts for frame 114 Noise in the Gear Housing 1 Backlash of worm and roller 2 Insufficient gear oil win 998 139938 0 0 1059 005 0 5259 ee 0190 0789 24612 6 0 59 19011 6 e mura 0190 0196 MEER 00280 0199V 555 5 4 H T poz opts e a ar vs wig 389 00170 02599 00240 10S89 P N gry es ya e H c2 Wott B 7 lt A 1 6 0019
178. ughly This procedure should be specially observed n cold regions due to the fact that if the replenished fluid is slow to stand without mixing there 1s a danger of the water separating to the top and freezing If the fluid level becomes low due to leakage caused by overflowing from vent plug or from damages n battery the trouble should be corrected first and the fluid replenished or replaced with dilute sulphuric acid made up to the same specific gravity as that in the cell When the fluid becomes exceedingly dirty 1t should be replaced since there are impurities mixed in the fluid The density of the replenishing or replacing fluid 1s determined by the specific gravity determination procedure described n the following chapter A slightly lower specific gravity of 1 260 1s used instead of the normal 1 280 at 20 C After replenishing the battery 1s wiped to remove all traces of spillage and the vent plug crewed n tightly The plug 1s cleaned at this time to allow the gas to escape freely from the vent hole Specific Gravity The specific gravity of the battery fluid varies with the state of battery charge and when the battery 1s fully charged the specific gravity should normally be from 1 270 to 1 290 at 20 C By measuring the specific gravity of the battery fluid with a hydrometer 183 The state of battery charge can be determined The specific gravity 1s read at the upper part of the graduation as shown n the illus
179. ump 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 Inspection prior to disassembling 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 on both the upper and lower bodies to make their reassembling easy It s 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 if any damage impregnation by gasoline Replace a valve assembly f any wear or faulty operation 1s detected Even if repairs are unavoidably required the limit for repairs of warp or wear of the valve s 0 001 n When the surface of the valve seat or valve 1s found rregular 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 wh ch cannot be taken off from the body recondition t with a cutter and gr nd ng tool When the surface of the valve 1s faulty place some
180. ure of the coolant 1s above boiling point or if the engine 1s running Topping up should only be required occasionally to re place water lost through the overflow pipe Top up when the engine 1s cold and 1f possible use clean soft water Fig 1 Radiator Fill to within 1 2 of the bottom of the filler plug well Overfilling when the engine 15 cold may cause water to flow through the overflow pipe The capacity of the system 1s approximately 5 2 litres pan pe d Thermostat m order to ensure maximum efficiency it is essential to keep the engine operating temperatures within certain limits To assist this a bellows type thermostat 1s fitted being located n the water outlet at the front of the cylinder head The device consists of metallic bellows filled with a volatile liquied which controls a mushroom valve When the engine 1s cold this valve 1s closed and on starting the engine the flow of water to the radiator 1s temporarily re stricted 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 1t can be removed from its housing and the hose reconnected to avoid laying up the car Should the thermostat be tight there are t
181. ut 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 93 0959 08 9 61 LE 89 81 SE 09192 9222 oo 09 02 81222 09142 11222 66 gt 00100 02126 00210 10226 62 09292 21222 09 92 uruq 08 f 099 82 8 6 09292 9 22 TE 9 092 09695 095 2 09192 20926 ez 19 92 15222 00220 10922 PT 09292 00 20 70922 e O NOISSINSNVU L JHL SLNANOdNOD HV39 NOISSINSNVYL v 34 94 1 2 3 4 6 6 0 8 9 10 011 12 13 14 15 16 17 18 19 20 21 22 Fig 4 Components of the Transm sston Gear case front cover 23 Front cover gasket 24 Main drive gear nut 25 Lock washer Main drive gear bearing 26 Main drive gear 27 Main shaft pilot bearing 28 Third amp fourth speed synchronizer 29 sleeve 30 Third amp fourth speed synchronizer 31 ring 32 Third 8 fourth speed synchronize 33 hub 34 Third amp fourth speed synchronizer 35 ring 36 Main shaft First speed gear 37 Main shaft second speed gear 38 Main shaft third speed gear 39 Main shaft front thrust washer 40 Main shaft gear third speed bush 41 Main shaft cotter thrust washer 42 Main
182. ut out relay upper left proper gap distance of the relay parts shows cut out relay winding detail are Relay point gap 0 9 mm Arm to core gap points open 0 7 0 8 mm Arm to core gap points closed 0 4 0 5 mm The cut out relay points should be inspected about once n every two months Burnt pitted and other poorly contacting points should be dressed with a fine file No 000 sandpaper or point dresser but points found to be badly worn should be replaced After dressing 1t will be necessary to readjust the point gap to the correct dimension If the actuating voltage of the cut out relay 1s found to be correct but the meter needle vibrates when the engine 1s idling the points will be quickly damaged so that in this case the idling speed should be lowered by adjusting the engine Checking Through Ammeter Indications 1 Those familar with the third brush type when changing over to the pile type may think that there 1s insufficient charging when the ammeter indica tion is small during daylight However there 1s no need to worry since the battery 1s fully charged Reversely if after driving for several hours during the day and the ammeter pointer still indicates around 15 amperes on the plus side it shows trouble 173 In this case check the fluid level and specific gravity of the battery Also check for incorrect wiring and see if any wiring paired immediately 2 During night the ammeter pointer should mdicate a
183. utch disc assembly 9 Retainer spring 16 Release bearing 2 Pressure plate 10 Eye bolt nut assembly 3 Release lever pin 11 Clutch cover 17 Rubber boot 4 Eye bolt 12 Washer 18 Lever assembly 5 Release lever strut 13 Bolt 19 Nut 6 Release lever 14 Anu rattle spring 20 Plane washer 7 Thrust spring 15 Retainer spring of 21 Lever bush 8 Release lever plate release bearing 22 Bolt Removing the Clutch To gain access to the clutch it 1s first necessary to remove the transmission complete from the engine Once the transmission unit s free a turn at a time by diagonal selection until the spring pressing is 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 set ting unless new parts have to be fitted will throw the pressure plate out causing judder Dismantling Assembling amp Gauging By using service tool Fig 2 the clutch can be quickly dismantied 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 Tool No 4799
184. ver 2 There should be a clearance of 014 m 35 mm y between the face of the rocker and the base of the valve stem Whilst checking the clearances it 18 1m portant to maintain pressure with a screw driver on the tappet adjusting screw to disperse the film of oil from the push rod cup Failure to follow this procedure will result in a wrong reading being taken Turn the engine over by hand Starting handle unt l the push rod stops falling the valve 1s fully closed Fig 3 Adjusting the Rocker Clearance 18 To adjust Fig 3 insert a screwdriver n 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 15 obtained 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 1ts peak 19 z ROCKER MECHANISM Rocker shaft Length 355 63 mm 14 1 32 m Outer diameter 15 850 15 875 mm 0 624 0 625 in Rocker arm bush Type White metal with steel lining Outer diameter before mounting 19 075 19 101 mm 0 751 0 752 in Inner diameter Reamer finished dimension after mounting 15 888 15 901 mm 0 625 1 2 0 626 in Thickness before reamer finishing 1 644 1 727 mm 065 1 2 0 068 n Cle
185. very f ne gr nd ng com pound on the surface of a flat piece of glass plate and grind lightly with the up of a finger The standard thickness of the valve 1s 1 6 mm The hole of the joint parts of diaphragm shaft and link may be worn to some extent This 1s not serious but when serious eccentric wear crack or break age 18 found the part must be replaced As a remedial measure such wear can be compensated for at the time of dismantling and reassembling of the body by inserting a 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 its pin hole are seriously worn 46 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 it 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 1s too stron it results n overflow of the float cham ber of the carburetor The tension of the spring must not be strengthened or weakened arbitrarily by hand Check to see if there 1s any warp on the joint surfaces of the cap and body and after disassembling 1s over renew the gask
186. ways kept clear Fig 2 Generator Secttonal View 1 Frame Brush spring 2 Armature 6 Ball bearings 3 Field coil 7 Fan pulley 4 Commutator To disassemble first remove the drive pulley Then after removing the band cover press the brush spring back and pull out the brush from the holder Then by unscrewing the two through bolts connecting the end covers the generator can be disassembled as shown in Fig 2 All disassembled parts with the exception of the field coil and the armature coil are washed with gasoline before being inspected and reassembled When reassembling the front bearing being of the ball bearing type 1s filled with magneto grease while the rear bearing is lubricated with a few drops of light engine oil When nstall ng the generator on to the engine care should be taken to see that the fan belt 15 properly tensioned After installing all electrical connections are securely t ghtened and cleaned 163 Trouble Shooting Diagnosis through motoring test Before disassembling the generator for inspection an overall check up can be made through the motor ing test The constant voltage generator operates together with the voltage regulator which being a complicated unit makes t difficult to discover troubles in the generator Thus by checking the performance of the generator alone through motor ing test makes this an efficient repair operation For the motormg test a fully c
187. will be come satisfactory Causes for mechan cal troubles Failure to operate 1s caused 1n many cases by the guide shaft on the moving core of the magnetic switch main circuit 5 5 sticking against the cover hole Correction can be made in 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 magnetic switch main circuit terminals when installing or removing cables the lower nut of the double nuts 179 should be kept n a tightened state while unscrewing If the lower nut is loose the terminal bolt may turn together and ground the terminal to the cover and cause damage Starter Troubles Their Causes and Remedies The following is a list of troubles which can be determined from the state the starter 1s nstalled on the engine 1 Starter fails to turn The engine is checked to see if it can be cranked by hand If it cannot be cranked the engine 16 at fault and should be checked If it can be cranked easily the starter including the wiring should be checked and cor rections made accordingly Is the battery run down Check the specific gravity of the battery fluid to see if t 1s over 1 240 and recharge or replace the battery as found necessary All loose battery and ground cables should be cleaned and properly tightened Magneto grease or Gargoyle BRB No 1 All cord connections are carefully tightened and special attenti
188. wo tapped holes on the top which may be utilized to ease it from casting When the system has been com pletely emptied t 1s essential to allow air to escape through the thermostat valve and then finally top up The ther mostat opening 1s set by the manufacturer and cannot be altered It open at a tem perature of 71 5 74 5 C During de carbonising it 1s policy to test this open ng by immersing the thermostat m water raised to the requisite temperature The iP valve should open under these cond t ons if it fails to open a new unt should be fitted Fig 2 Illustrating the Removel of the Thermostat from its Housing 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 adjustment failire of the water to circulate or loss of water Fan Belt Adjustment The fan 1s driven from the crankshaft by a V belt this also driving the dynamo A New belt can be fitted by first loosening the clamp bolts Fig 3 which hold the dynamo in position and moving the dynamo towards the engine Slide the belt over the fan and onto the fan pulley Adjustment 18 then made br ng ng the dynamo away from the engine The belt should be sufficiently tight to prevent slip yet the belt should have 15 to 20 mm 5 8 3 4 slack between the generator and crankshaft pulley when the midspan 1s pushed
189. y at intervals of 5000 km Drain the 011 when the engine 1s hot since warm oi flows freely and takes with 1t any sludge or sediment which may have accumulatted Never use petrol or paraffin for flushing purposes Such cleaning mediums are never completely dispersed from the engine lubrication system and will re main to contaminate any fresh o l This may cause premature bearing failure Oil Pressure The normal operating oil pressure 1s 60 lb per sq in The warning light which 1s embodied in the instrument panel light if the oil pressure drops below 8 lbs sg 19 under these circumstances do not attempt to run the engine or serious damage may result Refillig When refilling the sump do not pour the oil n too quickly as t may overflow from the filler orifice and mislead the operator as to the guant ty of lubricant in the engine Before testing the level of the 011 ensure that the vehicle 1s 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 oil in the engine sump by means of the dip stick and top up if necessary If the warning light is 81111 on after refilling the sump switch off and ascertain that the gauge strainer n the sump is clean and not choked with sludge sale that no air leakage exists at the stramer union on
190. ynchronizer and coupling sleeve When fitted to the shaft the large boss of the inner splines of the synchronizer must face towards the front of the box Also note that n each case the pointed ends of the baulking ring lugs face inwards to the synchronizers Slide the third and fourth synchron zers slightly forward on the shaft to clear the counter gears and then carefully guide the main shaft assembly into the gear casing When the housing surrounding the main shaft bearing 1s flush with the gear casing the counter shaft gear cluster should be raised into mesh with the gears and counter shaft 01160 and fitted into position The lipped end must be flush with the gear casing FRONT THRUST WASHER THICKNESS 32264 26761 3 975 4 001 mm 0 1564 0 1575 1n 32265 26761 4 026 4 051 mm 0 1585 0 1595 in 32266 26761 4 077 4 102 mm 0 1605 0 1614 n Reverse Gear Refit the reverse gear into the gear casing with the large gear to the rear Oil the reverse gear shaft before inserung and secure the shaft with locating pin and tab washer Selector Rods amp Forks 99 Before commencing to locate the selector forks within the gear case it is advis able to pre load the spring and ball into each fork and with the aid of a pilot bar retain the spring and ball in position until each fork rod has entered its correlative fork With the gear n the neutral position first fit the first speed selector fork and then locate the third an

Service Manual Datsun Truck Model 320

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