DATSUN 1200 MODEL Bll0 SERIES j t t CHASSIS AND BODY i p ti mf j il INISSANI t l 1 t f NIS AN MOTOR CO TOKYO Rov 2 11 PIN 99999 LTD JAPAN 20019 i i r
r J r si r r 7 QUICK REFERENCE INDEX o M fGE Nl A tNIFrO RM A I O N t l I r iEiNJiN lR I N S1l i W E MtANUAL c JU 7 6r j fl r c Itr t 9 VA1 ciiJ i ti W t J I ls ti jM L1AJ IO N r C ib R11NSM IS S10N T i i a o MOIDIEIL O SIEIR IES 1 Oi eOOiO D j RO m@fIDW f Xi f1Ar S USRf N S ON ROiNIJ J elE R lA1XiirEC S E1A 8ijR R U SPENSION y I RIA y t B RAU B r A ND WHEEL I Mfiool J I c r SHERING r f flW INI 1M @il@ 1O TOI @ fNGINE CO M R lJl f Un EXH
FOREWORD Thi5 personnels of been has manual senllce di5tributors and dealers our model BllO DATSUN 1200 1 in Explanations but will hand drive for this of utilization of also referred sati5fy our the for customers carefully this manual mainly concerning are be essential to this manual should be read for effective manual easily most the model BllOU left right hand drive models and the version models refer 2 PleUje to both information concerning part and name
em SECTION GI GENERAL INFORMATION DATSUN 1200 MODEL 8110 SERIES CHASSIS I NIS BODY NI NISSAN MOTOR CO TOKYO JAPAN LTD MODEL IDENTIFICATIONS GI 3 IDENTIFICATION NUMBER Gl 3 GENERA L VIEWS GI 5 GENERAL SPECIFICATlo NS GI 9 FINAL TRANSMISSIDN AND SPEEDOMETER RATIOS GI ll RECOMMENDED LUBRICANTS AND PERIDDICAL MAINTENANCE GI ll JACKING UP AND TOWING THE CAR GI l1
GENERAL INFORMATION Fig Fig GI l 4 door Sedan GI 2 2 door Sedan GI l
Fig GI Fl J Coupe GI 4 Wagon GI 2 Or Van
GENERAL INFORMATION MODEL IDENTIFICATION Vehicle model Transmission Engine model R H drive Item BllOU Q E 0 Remarks Speeds LH drive R3W56 3 BllOTU LBIIOT F4W56 4 BIIOAU LBl10A 3N71A 3 BllOSU R3W56 3 BllOSTU F4W56 4 BIlOSAU 3N7lA 3 BllORU R3W56 3 LBllOTR F4W56 4 LBllOTRU F4W56 4 for CANADA F4W56 4 for CANADA 3N7lA 3 R3W56 3 F4W56 4 R3W56 3 F4W56 4 R3W56 3 LBIIOST J BllOTRU Q LB llOTRN 0 0 Al2 BllOARU BI10SRU j E S J 0 BllOSTRU LBllOSTR VBIIOU l
I I CHASSIS Fig GI 5 Identification number for U S A Fig i l f 1 fill Y J I C Fig GI 7 Body number plate GI 4 GI 6 Chassis number location
GENERAL INFORMATION GENERAL VIEWS E E I Z t c Sl I l N i V 00 l 6 gg 96v L l G1 5 l6 KI l
CHASSIS s E E f Z J D j iil 00 l iil ri il o o L gj Q6t 20 u IC N ci e SZI OZL 169 OLI M N lt oi t a M e 0 M N N L il GI 6
inl mm UNIT 61 61 190 300 6251 0 2 3 Coupe IO GI Fig 31 7 1 185146 8 44 48 125 240 1 1
F CHASSIS E E f Z g Bl1 gCl l ill I la BlrIOtrZ L f I I I N J I i IU N tO r 6 S6 nllll l Q It o o 1 GI B
GENERAL INFORMATION GENERAL SPECIFICATIONS Four Door Sedln Two Door Sedan Standard BIIOSU Item Overall c I 8110STU Deluxe BIIOSAU BIIOU LBIlOST I Standard BllOTU BllOAU LB I lOT LBllOA length mm in 3 830 l50 S Overall width mm in 1 495 58 9 Owrallheight mm in 1 390 54 7 Wheel base mm in 2 300 90 6 Length mm in 1 690 66 5 Width mm in 1 270 50 0 Height nun in 140 1 44 9 in 1 240 48 8 in 1 245 49 0 70 67 BllOSRU Deluxe I IIOSTRU BllORU LBllOSTR I
CHASSIS Wagon and Model For U S A 4Can2da Van Coupe Standard VHllOSU Item YBllOU BlIOSTU I in 3 86S 2 IS1 Overall width mm in 1 495 S8 9 Overall height mm in 390 1 mm in Length mm in 1 4SS SS5 Width mm in 1 230 4 48 815 32 5 length 54 Coupe oedan YBIIOTU VlJlIlOT I VlllllOST mm Overall Two door Deluxe KBllOU LBllOTRU KLBllOU KLBllO IllI HrrRN KLBllON S10 I50 4 3 S30 ISO S 3 1 51S 59 6 3SO I 53 1 7 1 495 39O 1 3 810 SS 9 I SIS 54 7 3S0 I ISO
GENERAL INFORMATION TRANSMISSION AND FINAL SPEEDOMETER RATIOS BIIOS U BIIOS RU VBIIOS U Model BllO S TU BllO S TRU LBllOS LBllO S T TR LBllOTRU LB llOTRN BIlOS AU LBllOA BllOARU TU VLBllO S T KBllOU KLBllO KLBllOU KLBllON VBllO S Item Final gear ratio Type Control system 0 5 E 3 900 3 900 3 900 R3W56 F4W56 3N71A Floor shift Floor shift Steering column shift 1st 3 380 3 757 2 458 2nd 1734 2 169 1458 3rd 1000 1404 1 000 Reverse 3 640 3 640 3 640 gear ratio 17 5 18 5 f
z I 1 oo 1Zo1 1 o rc lDI o Ul S Ul Ul 7 40 20W SHEL 30 IOU 100 X 30 X lOW Shel IOW Shel lOW MOBIL Special Super 30 Mobil J IOW Mobil ENCO Unifo Extril Enco Ruo 30 DP 5W Elso Mot r V lOW costalie DP Mobil lOW 20W 3D IOW lOW Shel Shel 210 MP HD HO Super FlUid Mobil Brlke Super FlUid Mobil Brake Mobil Hydraulic Hydraulic Mobil Gear Ego 40 140 90 Ellu 140EP Oil 90EP Gear BP 80EP 80 Mobilgl CaJe Mul t Glide 140 Enco GP 80 Oil DP Shel 90 Mobilue 80 EP
m Zm lC 3 INTERVAL MAINTEC 1 ZI 1 ZloZ o1 X X X X X X X X X X X X X X X X X X X X X X X X X 60 X R X 95 57 X X X 90 54 X X 50 30 X R X 45 85 27 51 X X X 40 80 24 48 X X X 35 75 21 45 X X X 30 70 18 42 X X X 25 65 15 39 X X X 20 60 12 36 X X X 15 55 9 33 X X X 10 6 X X X 5 3 X X X X R X 6 oz z o lC oI lotl I 100 1 r X X X X X X X X X X X X X X X X X X X X X Replacmnt 0 R kilometrs mi
nX g X X X X X C X I I X I I I X X X X X J L X X M X X L 30 X 27 M X X X X X X X INTERVAL X X X X X X X I 24 X 21 d X X X X X X X X I 18 g MAINTE C 16 X X X X X X X Replacment 12 X X X X X 9 X X X X X X 6 R X X X X 3 X X X X 6 0 w miles o TS p AOAl dCA SERVICE m ww A GIIlE M w US M oo o 0 cl E o o M A c I II o wreN
r m Zm INTERVAL MAINTEC 100 60 R R 95 57 X X 90 54 X X X X X X X X X X X X X 30 X X 45 B5 27 51 X X 40 BO 24 48 R R 35 75 21 45 X X 30 70 18 42 X X 25 65 15 39 X X 20 60 12 36 R R 15 55 9 33 X X 10 6 X X X 5 3 X X X X X X X X X X X X X X X X X X X X X X X X X X X X 6 X 1 X X X X X X X X X X X X X X X X X 50 X oz Z TI o X X X X X X X X X X X X X X X X X X X X X X X X X
60 95 57 90 54 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X 1 100 fl fl 30 45 85 27 40 80 24 48 35 75 21 45 30 70 18 42 25 65 15 39 20 60 12 36 15 55 9 10 6 5 3 X X X X X X X X X X X X X X X X I 50 X X I x INTERVAL MAINTEC X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X 6 X X 33 1 X X X X X X X X X X 0 POINTS SERVICE BODY CHASI
GENERAL INFORMATION LUBRICANTS CAPACITY U S A Imp measure measure Liter Sedan 40 L 10 38 l 10 with heater 4 9 l 53 16 without heater 4 2 l Oil pan 2 7 Oil filter 0 Fuel tank Cooling gal 8 3 gal 8 3 qts 4 5 47 16qts 3 l 2 7 8 qts 2 l 54 I 1 8 pints I Manual 2 l 1 2 Automatic 5 5 l 5 0 l 75 Coupe Wagon Van system Transmission Differential case 1 I case 2 pints 7 15 I 2 11 3 gal 8 gal 16 qts 16 qts 8 qts pin Is 2 1 8 pints
CHASSIS Fig Fig GI tJ Front jacking GI 14 Front point Fig supportable point Fig When jacking up the garage jack beneath the rear side of the vehicle rear axle etc other cases support the apply Rear supportable point a Forward housing removing and installing the spring GI 16 jacking point TOWING Rear side When GI I5 Rear rear rear cross member support both ends of axle housing When towing the vehicle forward with stands In the rear axle apply a rope notched portion of
GENERAL INFORMATION Fig GI 17 Front Fig towing point GI 18 Rea towing point Rearward When towing the vehicle rearward apply rear shackle of rear a rope to the spring SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE or PAGE BULLETIN No No SUBJECT GI 19
CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or No PAGE No SUBJECT GI 20
SECTION ER a ENGINE REMOVAL INSTAllATION DATSUN 1200 MODEL 8110 SERIES BODY CHASSIS I NISSAN I Nt SSAN MOTOR CO TOKYO JAPAN LTD ENGINE MOUNTING ER 1 ENGINE REMOVAL AND INSTALLATION U4
ENGINE REMOVAL INSTALLATION ENGINE MOUNTING CONTENTS FRONT ENGINE MOUNTING ER l REAR ENGINE MOUNTING ER 2 Removal ER l Removal ER 2 Reinstallation ER 2 Reinstallation ER 3 CO @ Fig This engine adopts the as A IO tion The same ER 1 Structural view engine mounting has been parts changeable used for engine mounting with those for the A 10 and constructions are are not of engine mounting MOUNTING Removal increased in response to the increased engine weight and engine o
CHASSIS 3 Make engine is that the wire or positioned properly SO sure the insulators and 4 remove chain used to suspend that no load is the nuts the applied 2 to Shape of the right the left side bracket completely and side bracket differs from that of Tighten the bolts and nuts correctly securely Lift up the engine and separate the insulators from the engine mounting brackets Tightening Itl kg vf I Bolt l J I 1 IV Nut b 0 o 1 6 to 2 1 @@ 116 to 15 2 Total fo
ENGINE REMOVAL INSTALLATION Tightening torque kg m ft Ib Nut mount 0 6 to 0 8 @ member insulator Nut 1 9 to 2 6 ID@ transmission insula tor 13 Bolt j@ mount member Fig 4 ER 5 Rear Remove four bolts and the engine 43 to 5 8 7 to 18 8 3 2 to 4 0 23 1 to 28 9 body mounting separate the insulator from mount member Reinstallation Reinstall the rear engine mounting in reverse sequence of removal noting the following matters Fig Carefully 2 I Tighten the nuts and bolts correctl
f CHASSIS ENGINE REMOVAL AND INSTAllATION CONTENTS PRECAUTIONS ERA REMOVAL ER 4 INSTAllATION PRECAUTIONS Be sure to L tor fender use so cover that the body is Cable to the thermal transmitter not Cable to the oil pressure switch damaged 2 When lifting the engine pay attention for engine correctly so that the parts or when jacking up the safety and are not carry out operation Cable to the primary side of the distributor Cable to the starting motor Fuel hose damaged Ca
ENGINE REMOVAL 5 Disconnecting clutch wire on On left hand drive model the clutch slave hydraulic line from clutch wire at the portion of the See the section covering the clutch withdrawal lever 6 hand drive model cylinder the Disconnect right disconnect INSTALLATION Remove the exhaust front tube Fig ER 12 Removing front tube Model with automatic transmission Remove pins from both ends of the cross shaft and remove the shift rod II Disconnecting clutch ER l1 Fig 7 Discon
CHASSIS 15 Lift up the engine toward the front INSTALLATION Install the en e in reverse sequence of removal Fig BR 14 Lifting up mgiu SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or SUBJECT PAGE No No ER 6
SECTION CL CLUTCH GI DATSUN 1200 MODEL B 110 SERIES BODY CHASSIS INI NI NISSAN MOTOR CO TOKYO JAPAN LTD CLUTCH CL 1 CLUTCH CONTROL CL 5 SERVICE DATA AND SPECIFICATIONS CL 12 TROUBLE DIAGNOSES AND CORRECTIONS CL 13
CLUTCH CLUTCH CONTENTS CL 1 Disc assembly REMOVAL CL 2 Release DISASSEMBL Y CL 2 DESCRIPTION CL 3 CL 3 Release mechanism CL 3 CL 5 REINSTALLATION CL 2 Clutch assembly bearing REASSEMBLY CL 2 INSPECTION AND ADJUSTMENT CL 3 and sleeve DESCRIPTION The clutch is a single dry disc clutch The major components diaphragm spring type are clutch plate diaphragm spring and wire rings provided with riveted springs arranged in a plates link on cover engagement to control clutch The c
CHASSIS REMOVAL The clutch same the engine assembly the clutch mounting Transmission is dismounted assembly as manner primarily Thus in the when dis refer to the Section TM assembly and other relative sections Removal CL 3 Fig 3 by o I I Clutch assembly CL 2 Clutch Fig Clutch di5C assembly and disc Disassembling release mechanism Withdraw the release bearing from the bearing sleeve the use of a bearing puller assembly assembly DISASSEMBLY When flywheel nally Note and clu
CLUTCH 2 4 Measuring and adjusting height of diaphragm spring 1 on Line up distance piece special diaphragm tool ST20059001 if diaphragm spring by the wrench adjusting spring ST20l05000 clutch assembly base plate special tool ST20101000 of the Adjust height special use of tool required SJ200596o 1 Fig CL5 Base plate and distance piece Disc Place the clutch assembly 2 set the clutch assembly Under this condition the pressure on on the distance piece and I with plate stati
CHASSIS Replace the disc assembly if 3 such than an 3 0 facing is worn to bearing that the facing height above rivet is less extent mm the 0 0118 in the facing is worn unevenly sleeve is installed make or sure as shown in Figure CL IO When the turn the completely that the bearing with a bearing finger and bearing operates smoothly rivets are loose 2 Apply multi Bearing purpose grease to the sleeve inside groove Pack this Fig Release CL9 Checking e and sleeve bearing
CLUTCH A JI A f C U 1 J II J1 ITI 2 Withdrawall I t l L Rei r bearing Return spong CL13 Fig Installing release mechanism REINSTALLATION the Clean clutch pilot bushing and fill it with multi purpose grease 2 Install the disc assembly and clutch assembly the use of flywheel by a tooi clutch special on the 1 Flywheel 2 Clutch 3 Clutch disc as mbly assembly aligning bar ST206l0000 Fig ClrJ4 Installing disc and clutch assembly CLUTCH CONTROL CONTENTS CL DESCR
CHASSIS I Pedal head rubber fulcrum type The mechanicai type clutch control system consists of 2 Re turn spring and with 3 Pedal lever bush fulcrum 4 Fulcrum pedal pin etc pendent clutch clutch control cable pedal drawallever The withdrawal lever is of an type which provides required a great lever ratio depressing clutch pedal in outer and thus force Reinstallation is reduced Reinstall Hydraulic CLUTCH PEDAL 2 Remove the return spring push Adjust pedal pad height I Loosen th
CLUTCH CLUTCH PEDAL AND CLUTCH CONTROL CABLE Mechanical clutch Removal Loosen the control cable nut and discon adjusting nect the control cable from the withdrawal lever IPn t j I C1 i i j i 0 1 rl 1 f r7ce 5 l IJ i Adjusting Fig nut 0 m pring pedal pin CL 18 J Clutch pedal Removing pedal instaUation bolt Inspection iil 7 r f Fulcrum 4 1 i Return Fig r 1 I 2 3 clean Thoroughly all disassembled parts indicated t and carefully check them for below other abn
CHASSIS Note Connect the control cable correcdy cap is faced figure Make upward sure as shown that so in the that chassis grease mark applied following has to places the CG marked three positions Apply urease if required been r A3 r 1 300R I i I I I Lock nut Adjusting 3 Pedal I nut stopper eJ fO fed8 play 11 P 2 1 2 1 1 dal to 0 433 to 0 ChaSSiSgreaSe 2 0 139 5 to 9 to A point 15 5911 end 3 0 to 4 0 O llSl to 0 play 1575 143 5 5 65 L Unit Fig 3 W
CLUTCH Hydraulic clutch CLUTCH MASTER CYLINDER @L V 9 W aj 1 Snap ring 2 Dust 3 Pushrod 4 Clutch 5 Piston 6 Inlet cover piston spring valve spring 7 Inlet valve 8 Spring 9 Shim Inlet valve release 11 Body Oil re rvoir 12 Oil 13 i retainer 10 L t pin reservoir cap Fig CL 21 Clutch master 1 Removal cylinder Check cylinder the damage Replace Disconnect the push Disconnect the clutch line from the master than 0 15 3 securing bolts and remove the master when c
CHASSIS 2 Apply brake fluid sufficiently to the cylinder and Inspection and assemble them pistoo Chedr all pam especially the piston cup and replace if worn or damaged Reinstallation Reinstall sequ nce I the master cylinder assembly of removal and adjust Adjust the as in reverse follows pedal height by changing Reassembly the push rod length 2 Reassemble the operating cylinder in of Bleed air out of the hydraulic syst disassembly noting the following I m Soak the InstaJI t
CLUTCH When the adjusting nut is returned 1 1 4 turns the wilhdrawal lever end is returned to 10 to 2 0 mm 0 0394 to 00787 and in and clearance between the release bearing diaphragm spring fmgers becomes 0 7 to 3 0 to 4 0 0 1181 to 0 15751 1 4 mm 00276 to 0 0551 in 0 9 to 1 2 0 0354 to 00472 @ D Unit mm t Diaphragm spring 3 Withdnwallever 2 Clutch control cable 4 Release Fig CL24 Adjusting in bearing withdrawal kver play 10 to 2 0 0 0394 to 0 0787 BLEEDING CLUTCH SYSTEM inl
CHASSIS SERVICE DATA AND SPECIFICATIONS Hydraulic Mechanical clutch clutch Clutch release lever Release bearing te withdrawal lever diaphragm spring 0 9 to 1 2 mm 0 7 to I 4 mm clearance 0 0354 to 0 0472 in 0 0276 to 0 0551 in 29 Diaphragm spring te flywheel height to 31 mm I 142 to 1 220 in Outch disc Facing size Outer dia inside dia x x thickness 180 Total friction 264 area 125 x 7 09 7 8 mm x 4 92 x x 3071 0 in 40 92 sq in em Thickness of disc assembly 6 to 8 0 mm
CLUTCH Operating cylinder clutch 19 05 mm Operating cylinder diameter 0 750 in Tightening torque Clutch assembly securing bolt 5 to 2 2 1 kg m 10 8 to 15 9 ft lb TROUBLE DIAGNOSES AND CORRECTIONS Troubles Noises audible Possible causes on pedal depression Excessively worn cated release damaged or Corrective action lubri poorly the Replace cannot be bearing Seized release bearing and diaphragm spring fmgers greased spring fingers Insufficient pedal free travel Weakened unhooked
CHASSIS Weakened broken or unhooked clutch with drawallever return spring Distorted or worn the Replace spring hook or it as up required drive shaft if Replace the drive shaft and clutch disc necessary Excessive of play release bearing on slip Replace the worn parts sleeve The dutch drags Insufficient Excessive push rod length pedal free travel Adjust the Adjust free travel correctly rod length correctly push Set level of clutch disc if pos ible Warped clutch disc Max
CLUTCH Clogged vent hole in reservoir cap vacuum in master promotes cylinder allowing air to Clean reseIVoir cap unclog the vent hole and bleed the system inflltrate past the seal Abnormal lining wear Insufficient pedal free travel Driver steps unnecessarily causes lining and wear Adjust clutch pedal free on damage pedal to this release bearing travel correctly Advise driver to discoD tinue wrong practice and step clutch on when pedal only ne cessary Weakened or snapped
CHASSIS Worn or Replace linings burned disc linings Overloaded master cylinder due to a Overhaul the piston restricted transfer port the master cup if swollen transfer port cylinder replace or damaged and bleed SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or SUBJECT PAGE No No CL 16 the the clean system
1 I i SECTION TM SERVICE MANUAL 1 6 TRANSMISSION I 1 1 1 I J DATSUN 1200 MODEL 8110 SERIES CHASSIS INI BODY I NISSAN MOTOR CO TOKYO JAPAN LTD 1 TRANSMISSION TM TRANSMISSION GEAR CONTROL TM 15 AUTOMATIC TRANSMISSION GEAR CONTROL TM 18 THREE SPEED TRANSMISSION TM 19 SERVICE DATA AN D SPECIFICATION TM 20 TROUBLE DIAGNOSES AND CORRECTIONS TM 22
TRANSMISSION TRANSMISSION CONTENTS DESCRIPTION Specifications REMOVAL Synchro TM l Baulk ring TM 2 Shifting DISASSEMBLY Rear TM 7 Transmission case and rear extension insert Oil seal 4 TM iNSPECTION hub throst washer TM l TM 7 engine mounting insulator REASSEMBl Y AND ADJUSTMENT Bearing 8 TM counter bearing thrust washer Selecting Gear and shaft 8 TM Main shaft TM 8 TM 9 TM 9 TM 9 TM 9 TM 9 TM 9 TM l0 TM 15 REINSTAllATION DESCRIPTION Three transmission speed m
1 CHASSIS 31T 32T 3T27T 19 1 31T T 13T 13T 14T 22T 25T 29T 29T 9T 17T Fig Fig TM t R3W56 gear train The transmission assembly consists of transmission which contains gear assembly and The cast main shaft front iron rear case counter shaft and side of the transmission reverse case ends Moreover extension adapter plate supports each end of the idler shaft supports the the rear extension supports the main shaft rear end The gear and other TM 2 F4W56 gear train assembly ass
1 TRANSMISSION 4 Jack up the vehicle and support it with four stands If available recommend hoist or open hydraulic a back up lamp switch cable from pit be tension utilized 2 Disconnect the front exhaust tube D 5 from the and the transmission ex housing Disconnect the shift rods the removing exhaust manifold @ speedometer drive cable the Disconnect assembly @ and remove from the transmission Speedometer Fig pin cotter from the shift levers by TM 6 G cable the Cott
1 t I w 2 i i t 4A i0 J k b CHASSIS To prevent the oil pan from damaging imert a wooden block between the pan and jack 9 used to attach the transmission Remove two nuts to the CID the transmission and remove two bolts rear mounting member to the engine oJ L @ a jack used to O j Pi I engine mounting member Place rear 7 I re L 1 under ft v J fIx the h J body Q I t fp c l O il ii I I 3 r j 2 Fig Raise the II Removing release bearing and three bolts securi
TRANSMISSION 5 Remove return the and spring plug return remove the 8 spring plunger and bushing from the inside Separate the adapter plate from the transmission case Note a The shaft main assembly b removing When washer installed and assembly installed on the are counter adapter plate be careful not to lose on shaft bearing the front end of the counter shaft Plunger Return Bush Return Fig TM 12 the Removing return spring pin from the striking rod 6 Remove r
l Y if 1 vo ifJi 4 1 C t i ta V q 7 j i4 il CHASSIS Remove the check ball plugs for all fork rods 13 remove and 1st Note the reverse gear fork rod 3rd 2nd gear folk rod from the Be careful not and 4th gear fork rod adapter plate to lose the check ball and check spring o TM 16 Fig II Withdrawing idler gear and reverse Remove the snap ring by the ring pliers and lemo the Reverse idler gear of a pair of snap use washer and shift fork reverse gear O r r J IOfc
TRANSMISSION 15 Remove the needle bearing synchronizer hub thrust washer steel ball 4th synchronizer mechanism 3rd baulk ring 3rd gear and main shaft needle bearing toward the front side in that order 1 Thrust washer 5 2 1st gear 6 Coupling sleeve Baulk ring 3 Needle 7 2nd gear 4 Baulk 8 Needle bearing ring 1 Needle bearing 5 2 Thrust washer 6 Baulk ring 3rd gear 3 Steel ball 7 Needle bearing 4 Coupling sleeve 18 Remove the bearing from the counter gear 19 Remove the
CHASSIS Bearing 3 Thoroughly clean I with compressed the bearing dry and remove Measure each gear backlash is in range dust 0 0059 in air backlash When backlash exceeds this range bolh driving and driven gears be 2 When the ball sliding surfaces to crack or rough or bearing are worn unevenly and from 0 15 to 0 25 Inspecting baD bearing mm Replace needle bearing if worn Replace rear extension or bushing damaged if worn Me ring gear backlash TM 26 End play of the 1st pla
TRANSMISSION Baulk 1 ring Check the baulk rings for be with replaced 2 new are Push the ring or detected they must ones Place the baulk ring in position gear chips pitting wear burrs If any abnormal conditions on the cone of each t6 the gear and check the gap between the end face of the baulk ring and the front face of the This gap should be within 1 05 to I 4 mm clutch teeth If it is less than 0 0413 to 0 0551 in in a worn baulk ring 5 0 0 0197 mm may be the cause and a
CHASSIS b Select lowing shim table is 0 to 2 0 s those shown in the fol 2 that end play of the counter shaft so mm from Install the needle Part number Thickness mm 32224 18001 0 8 0 03 5 18002 0 9 0 0354 32224 18003 10 0 0394 32224 18004 I I 0 0433 32224 18005 2 0 04 72 1 32224 18006 3 0 0512 1 Be c sure to from rear end of the main 0 to 0 0079 in 3 32224 bearing shaft measure at two or more Install the main shaft 2nd gear in positions on end surface of th
TRANSMISSION 9 Installlhe steel ball synchro hub thrust washer and main shaft Note a pilot bearing Graase slid ing surface of the stael ball and thrust washer b When installing the thrust washer be careful to face the front and rear directions correctly OIL GROOVE SIDE THRUST SIDE FRONT Fig 7 TM 34 Apply the shaft bearing drift special Installing main shaft REARI J st gear liS main shaft thrust washer and fit the main rear side by the use of a main shaft bearing tool ST2235
CHASSIS I I Install the baulk ring combining on with the main shaft the main drive gear and complete the main shaft assembly 12 14 Install each fork rod together with the check ball plug check ball check ball spring and interlock by the use of a fork rod plunger guide special tool ST23620000 Combine the main shaft assembly with the counter shaft and install them Note Apply on the main bearing front endl approximately 10 1969 inl first line up the 5 mm bearing center assembly coun
TRANSMISSION Drive shift fork retaining pin IS o Reverse gear shift TM 45 Fig TM 43 Fig 16 and Install the secure Nota When I installing w the Note idler gear snap reverse gear thrust washer ring the thrust washer be sure to face 18 Install the 3rd fork retaining 4th shift fork and drive the shift the pin by use of a special tool ST23520000 to the gear side Reverse gear Install reverse portion reverse Snap ring Fig 17 a Installing Revene idler gear Driving reta
i6i lU t J2 lco Ii i e j tI A j iiJ i i l Ji tl 1 if iJf CHASSIS Fig TM 47 Instaning counter be4ring 2I Install the return b Remove oil install the c When mallet apply adhesive adapter plate installing on on the joint and with a and ba sure to line up the knock 20 TM 48 Coinciding the Installing striking transmission lever bushing installing apply uar extension plunger return adhesive to the return pin hole I Plunger 3 Return 2 Bush 4 Return TM 5
TRANSMISSION Install the oil seal on the front 25 Part number Thickness 32208 18000 5 0 0 0197 32208 18001 0 2 0 0079 32208 18002 0 1 0 0039 in mm together r r9 l Pilj i Note r The main shan is not turned synchronously when gear is shifted to neutral and the main drive gear is turned lightly 1 1 Operating 2 I Ie force is not excessive and gears can be shifted smoothly when shifted 10 the individual speeds I REINSTALLATION n J0 D lip Upon completion of the reassembly co
CHASSIS Y CROSSK SHAFT StWT C VIEW o IiANGE LEVER J ln CHAHGE LEVER 12OO 3rd C r l 1a F nda 3 Jnl SHIFT ROD Pst tfP AVlEW I rw MMlUAL Jm Li3 l llEVER 12fW tJrdl I 2 lst d I Fig TM 52 Control system speed forward 3 transmission COLUMN SHIFT CONTROL SYSTEM Remval I 2 Remove the sleering wheel fig TM 53 Remove the steering column shell and lighting switch assembly Removing steering wheel Fig TM t6 cover turn signal complete TM 54 Rr mol1ing st mrlg column she
TRANSMISSION 5 Remove the 6 Remove the speed change retainer 2 7 Remove the 2nd speed change retainer bolt top change I lever and bush 3 from the control rod 4 8 Lower the control rod so that the control lever comes out from the lower bracket pin and withdraw the 5 control lever pin Note Lower the control rod to control Fig TM 55 Removing turn pin does interfere not the lower bracket signal and lighting switch 9 3 lever l1 en extent that the suc Remove lhe snap ring and
CHASSIS Installation InslIll the oon1rol leDtonI system in reverse Before instaIIing and assembling srease to all of sequence chasm apply sliding swfacel Acijuatment I Set l1 on m mnn side manual Ie er to the neutral poIition rn 2 2 TemponriIy oonnect the trunion on Neutnlsettinz Lower support Shiftr M ptJ bncbt the lowe Fig support bracket head to each rod 4 TM 59 Adjus Upon completion t of neutral setting of the above adjustmenl operale the hand Ie er to the individual
TRANSMISSION lever is JUSTMENT AD When the lever drags opetated smoothly or when warped or loose readjust finely until draging warping and or slackness is eliminated completely the lever is I Set tranlllltission side manual lever and hand lever to their neutral positions 2 Adjust length of the shift rod Note at the cross shaft lever a Be sure to parts and fix the shift rod b or apply After individual Make sure that hand laver positions position individual positions THREE SPEED TRAN
CHASSIS Disassembly and speed maintenance service for the thsee transmission are to be conducted in the manner INSPECTION Gear end play mm in identical to the four speed transmission Except for the following transmission is same as the four items the three speed 0 05 to 0 20 Reverse gear 0 0020 to 0 0079 speed transmission 0 05 to 0 15 Reverse gear counter shaft 0 0020 to 0 0059 0 10 Reverse gear to main shaft SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS Type R3W56
TRANSMISSION Rear extension installation bolt 16 to 2 2 I 1 6 to 15 9 Drain plug 4 0 to 6 0 28 9 to 4 43 Filler plug 4 0 to 6 0 28 9 to 4 43 Backup lamp switch installation 2 0 to 2 5 5 to 18 1 14 Withdrawal lever ball pin installation 3 1 to 4 2 4 to 22 4 30 Model R3W56 F4W56 Item Each gear standard backlash 0 08 to 0 15 For all gears mm in 0003 I to 0 0059 Each gear standard end play 0 15 to 0 25 1st gear mm in 2nd gear mm in 3rd gear mm in Reverse gear mm in Revers
CHASSIS Front cover Part number Adjusting shim Thickness mm 3220S 18000 5 0 0197 0 32208 18001 0 2 0 0079 32208 18002 0 1 in 0 0039 TROUBLE DIAGNOSES AND CORRECTIONS Symptom and possible Corrective action cause Difficult to intennesh gears Causes for difficult gear shifting gear shift lever is sure heavy and it are classified to troubles concerning the conlroI sys1em and transmission When the is difficult to shift gears clutch disengagement may also be unsmooth First make that lbe
TRANSMISSION Insufficient or Add oil or improper lubricant place with designated oil Oil leaking due Wom to defective oil seal and gasket clogged breather etc bearing High humming occurs at a Damaged bearing Cyclic knocking sound or replace Replace high speed occurs Clean also at a low speed Replace Wom each spline Replace Wom each Replace bushing SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL or DATE PAGE BULLETIN No SUBJECT No TM 23
CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or No SUBJECT PAGE No TM 24
SEen ON PD PROPELLER SHAFT DIFFERENTIAL CARRIER DATSUN CD 1200 MODEL 8110 SERIES CHASSIS INI BODY I PROPELLER SHAFT AND UNIVERSAL JOINT NISSAN MOTOR CO TOKYO JAPAN LTD DIFFERENTIAL CARRIER PD 1 PD 4
DIFFERENTIAL CARRIER PROPELLER SHAFT PROPELLER SHAFT AND UNIVERSAL JOINT CONTENTS DESCRIPTION PD 1 SERVICE DATA AND REMOVAL PD 2 SPECI DISASSEMBL Y PD 2 TROUBLE INSPECTION PD 2 AND CORRECTIONS ASSEMBLY PD 2 DIAGNOSES Assembly yoke sleeve Assembly journal with 1 2 PD 3 FICATIONS PD 3 6 Yoke 7 Ring lever race snap bearina race RiD Auembly race bearin Assembly journal with 3 4 5 bearing Fig PD 1 a good riding propeller vehicle gr m propeller Assembly 9 Bolt 10 11 ra
CHASSIS Moreover excessive sleeve yoke spline main pline lash and joints to transmission of both front and wear will cause vibrations affecting riding comfort removing and the flange yoke bolts at the rear end of the In this case transmission draw out the sleeve end of the the assembly in out of its a vise Drive the fIrst the lug by tapping projected spider 4 Use 5 Wash and clean the bearing and shaft with cleaning a brass drift with a flat face solvent pinion flange by prop
DIFFERENTIAL CARRIER PROPElLER SHAFT Insert the bearing journal into the into the yoke flange Tap the journal yoke flange using than the hole in the a opposite end of the yoke flange until with the snap With a ring brass drift smaller yoke Tap the other bearing into the the bearing is in line grooves pair of pliers install the snap rings on 37149 18000 52 1 0 0598 Green 37150 18000 S4 0 0606 Blue 37151 18000 S6 0 0614 Brown 3715218000 58 1 0 0622 both end ofthe yoke flange
CHASSIS DIFFERENTIAL CARRIER CONTENTS DESCRIPTION PD 4 Adjustin9 preload REMOVAL PO 5 Setting DISASSEMBL Y PD 5 INSTALLATION INSPECTION AND REPAIR PD 7 TROUBLE ASSEMBLY AND ADJUSTMENT PD 8 CORRECTIONS PD 9 SERVICE Assembling differential gear Setting and adjusting case drive pinion and PD l1 adjusting side shims bearing PD 12 PD 15 DIAGNOSES AND PD 16 DATA AND SPECIFICATIONS PD 17 PO 10 DESCRIPTION Apply chassIs grease to oil seal lip when assembling Tightenin
DIFFERENTIAL CARRIER PROPELLER SHAFT The gear carrier is made of light and strong aluminum metal and alloy drive Adjust hypoid bevel ment with spacer and adjusting pinion the gear carrier remove two rear axle assembly to disconnect the flange yoke shafts Refer to connection REAR AXLE for the work bearing adjust shim on screws drive case with non s still remains for all the DISASSEMBLY threads of this unit Therefore adjustment figures stamped remove drive pinion companion
CHASSIS 4 Remove the side bearing caps and take out the 6 assembly case Remove the hypoid gear strap and loosening the drive by spreading out the lock gear bolts n differential IPIc 1 L JE 0a 1 oI v r Ie I Ii c f r I I I r V j jJ i t f I I 11 f 3 t Fig Removing differential PDB case Fig assembly Note Note Be careful caps and bearing same not to parts PDl0 Removing Loosen the bolts in a drive gear diagonal line confuse the right and left hand
DIFFERENTIAL CARRIER PROPELLER SHAFT Measure the initial 10 STJII 90000 Preload Gauge the by using turning torque drive pinion pinion height by using the Drive Pinion inner race of rear gear washer and drive Arrangement Remove the oil seal and take out the front bearing 13 Gauge STJI 120000 innp II Remove the bearing bearing spacer and adjusting drive pinion nut and draw out the race The removed oil seal should not be reuMld Note companion flange assembly Note Flange Use the Driv
CHASSIS so of the clearance between the side gear and thrwt Before inspecting various parts thoroughly wash them case that damage and washer exceeds 0 1 wear can be easily detected Then proceed as follows are Check gear teeth for scoring cracking and chipping and make sure tooth that indicates pattern 5 Note Drive Measure replacement as a as a run out of the drive When the required drive gear are gear at the rear side dial indicator out run is more 0 05 mm the drive
DIFFERENTIAL CARRIER PROPELLER SHAFT Reassemble the differential carrier in The disassembly instructions for following and usage of special tools reverse are order of bolt by adjustment essential to obtain the bolts Tighten a kg lj4Ib hammer 0 1 The drive gear bolts should be perfect line differential operation The differential gear 1 Assemble the pinion washer in the differential 2 Adjust clearance 6 0 a diagonal to 7 0 kg m lb ft thrust case between washer within 0 0
CHASSIS Setting Pinion and height behind the drive drive adjusting is pinion adjusted with pinion adjusting washer pinion gear Tolerance from the standard size up to the drive gear center is indicaled on the drive electric pen size it is pinion top by of an means When 10lerance is larger than the standard accompanied with EB mark and with e when smaller The numeI31 following the mark is multiplied by a mark figure 100 Fig Note PD21 Be eereful not to the bearing Ins1all dama
r DIFFERENTIAL CARRIER PROPElLER SHAFT Example W 2 92 N 3mm O housing mm Withdraw the pinion 8 H I Shaft T 2 92 0 3 3 03 Use a 3 04 mm I x Remove the the Dummy Shaft from rear on the above bearing and drive pinion Thickness mm adjusting faced surface of the washer Be sure to face inside toward back of the gear carrier Drive pinion pinion washers Thickness Part number in mm in 381 54 G0400 2 74 0 1079 38154 G0409 3 01 0 1185 38154 G0401 2 77 0 1091 38154 G0
CHASSIS and Setting bearing When be the side mbling re to sure side adjusting shims install a shim without bearing having replacing thickness same as that before disassembly The following instructions apply when the bearing is replaced I Place an 5 Ib weight approximately 2 5 kg side bearing and measure on the bearing thickness Standard side bearing width 5 mm 17 0 689 in Note With the weight paeed on the side the bearing two three to turns bearing and turn m
DIFFERENTIAL CARRIER PROPELLER SHAFT These F E differences in widlh ofleft are Note or righl side bearing againsl the standard width given 5 17 0 6890 in mm Figwe To measure standen is the width of the side 117 5 gauge indica1Dr on a small in a unil of 1 100 mm Take the left side mm bearing 0 689 use and inl the dial rtaee plate fur bearing example When the measured width is 17 3 mm 10 681 in I II the difference is 2 10079 in against the 0 mm 0 0 standard width and
CHASSIS Limit of deflection Fig PD28 A portion Less than 0 05 mm 0 0020 in S portion Less than 0 05 0 0020 in Measuring hac lash PDJO Fig 6 rom Measuring pa Existence of foreign matter between the drive gear and differential ates case is considered when backlash fluctu considerably Measure drive gear back deflection 8 Apply red lead to both surfaces of three to oily four teeth of the drive gear Limit of deflection lut Run Less than 0 05 mm 0 0020 in turns of drive gear contact
DIFFERENTIAL CARRIER PROPELLER SHAFT damaged b Toe contact surface is Contact insufficient and toe may to obtain correct tooth replace the drive pinion adjusting be one so thickness of shim in left damaged Adjust by reducing In order washer with contact a thicker that the drive pinion is moved 10 the drive gear side of the side bearing and increase thickness of shim in right side TOE TOE HEEL DRIVE SIDE HEEL SIDE COAST L HEEL SIDE HEEL COAST SIDE DRIVE PD 34 Face contact Fig e
CHASSIS TROUBLE DIAGNOSES AND CORRECTIONS A problem in trouble and occur However otheJ noises such of noises always exists when the rear axle is great as care univenal noise iOl noise Inuni lr noUc and tire noise joinl must be men not to confuse with Possible Troubles Noise on drive exhaust noUc syptom for trouble engine as Remedies es caw Shortage of oil Supply gear Incorrect tooth contact between drive gear Adjust oil tooth canlact and drive pinion differential Damaged prope
DIFFERENTIAL CARRIER PROPELLER SHAFT Replace Worn differential gears or case of improper oil Breakage of Shortage of oil or use differential Severe service due to excessive an worn parts Rebuild differenlial and replace loading improper use of the clutch After adjusting preload of as bearings backlash and engaging condition of gears fasten parts and apply specified volume of genuine gear Incorrect adjustment of bearings oil Incorrect adjustment of drive gear and drive Avoid abusin
CHASSIS Side gear and pinion mate of side gear thrust washers Thickn mm in 0 76 to 0 9 I 0 0299 to 0 0358 mm in 0 10 to 0 20 0 0039 to 0 0079 mm in 17 5 mm in 0 05 Clearance between side gear and thrust washer Side bearing Standard width Thickness ofside 0 689 bearing adjusting shims 07 0 10 0 20 0 50 0 0 0020 0 0028 0 0039 0 0078 0 0197 Tightening torque Drive pinion nut kg Drive gear bolts kg m ft lb Side bearing cap bolts kg Differential carrier to axle to propeller 12 to I
SECTION FA FRONT AXLE FRONT SUSPENSION DATSUN 1200 MODEL B 110 SERIES CHASSIS INI BODY I NI55AN MOTOR CO TOKYO JAPAN LTD FRONT AXLE AND FRONT SUSPENSION fA ADJUSTMENT FA 21 SERVICE DATA AND SPECIFICATIONS fA 22 TROUBLE DIAGNOSES AND CORRECTION fA 24 l
FRONT SUSPENSION FRONT AXLE FRONT AXLE AND FRONT SUSPENSION CONTENTS DESCRIPTION FA 2 FA 3 Removal FA 3 Reinstallation FA 5 TRANSVERSE FA 6 LOWER Removal FA 6 Removal FA 18 Inspection FA 7 Inspection FA 19 Reinstallation FA 10 Reinstallation FA 19 Wheel bearing adjustment FA 10 FRONT AXLE STRUT ASSEMBLY AND SUSPENSION ASSEMBLY FRONT AXLE FA ll Disassembly FA 12 Inspection FA 14 Reassembly FA 15 LINK AND BALL JOINT FA 17 1 Strut 2 Strut 3 mounting bearing
CHASSIS DESCRIPTION The front absorber and spindle is supported by the transverse The outer is suspension casing by is at strut type a combined to the coil link spindle are of at spring a to unit which bearing Moreover the single the upper end and by means on the bottom of the strut through a they are fitted rubber bushing is built in the strut outer between the upper spring the to spindle lower link ball joint and the transverse link connected and bushing with of
FRONT AXLE FRONT SUSPENSION FRONT AXLE AND 6 SUSPENSION ASSEMBLY Remove cotler pin from the side rod socket ball joint of the steering remove the castle nut side rod socket from the knuckle and separate the arm Removal Jack up the vehicle 1 stands and support the vehicle with See the Section GL 2 Remove the hub nuts and 3 Remove the 4 Loosen the brake tube connecting nut brake hose splash remove the wheel board the remove locking spring withdraw the plate and remove the brak
CHASSIS 8 Support the engine baits indicated pension by remove arrow cross member mark the engine mounting and separate the sus from the engine assembly Fig FA 7 Fig Supporting FA l0 Removing suspension cross member gine 10 and Loosen the self locking nut holding the strut on assembly the strut assembly dismount the front suspension assembly FA Fig 9 Apply a suspension the bolts suspen ion Fig R jack cross ving engine mounting bolts to the indicated by cross mem
FRONT SUSPENSION FRONT AXLE Reinstallation First check rubber parts such stabilizer bar ing bushing bushing and other defective crack as tension rod mount for deterioration etc conditions replace and as required Reinstall the front axle and suspension assembly 2 reverse I in 1 Rubber 2 Washer 3 Stabilizer necting sequence of removal noting the following matters the Tighten transverse side stabilizer bar body tightening torque link mounting bolts installation and Fig t
CHASSIS Tightening 4 body and torque of front suspension is 3 2 to 4 0 kg m 23 1 cross member 7 28 9 ft Ib to Remove the return spring and brake shoes brake disc assembly installation bolts brake disc assembly from the 5 Tightening torque portion of kg spindle Drum remove the type brake of bolt used to secure the upper assembly the on body is J 6 to 2 1 1 6 to 15 2 ft Ib J m the strut and remove FRONT AXLE Removal Jack up the vehicle nect the remove the brake hose at the
FRONT SUSPENSION FRONT AXLE 10 Remove four brake disc fitting bolts and the brake disc rotor from the wheel hub Inspection remove assembly Disc 1 Grease seal type brake I When grease leakage is detected during disassembly replace 2 Replace the grease seal with a new one if worn or cracked 2 Wheel bearing Remove solvent used grease the wheel bearing with and inspect the bearing for operating condition from the rotation outer from race operating sound and appearance The may
CHASSIS Judgement x Unserviceable 6 May be used when minor Rust should be removed with 110 emery paper Race and roUer u Cause u l l al U 8 8jiS oo U Flaking Q l ti CIl this However roUing fatigue Service tife due to x before the service life The following causes are symptom occurs considered Abnormal load overload Improper handling Crack Excessive tightening x x x improper installation or is excessive and Gap considerable shock is received from the a outside Rap
FRONT SUSPENSION FRONT AXLE 6 Rust during operation Temperature increased 6 6 bearing stops becoming The fine Intrusion drips inside the bearing is the condensed and the grease is moistened has been bearing long period moisture when lowers placed in a highly moistened place for a of time of moisture chemicals touched with bare hand and no etc the or rustproof bearing action is has been taken The Discoloring wheel bearing is iog can be or oxidized oil stai
CHASSIS Reinstallation I Reinstall the wheel bearing in reverse sequence of removal 2 Install the bearing outer race by the use of a front wheel bearing drift special tool ST353 10000 FA 24 Fig FiT1ing sptICes between wheel with grease 5 Apply multi purpose grease to the bettring spindle threaded Install the wheel 6 hub and install them Note In order to and grease seal bearing on Fig FA 22 InstaIling bearing outer lock nut race matten provide the bearing with 3 that
FRONT SUSPENSION FRONT AXLE Correctly starting force toward tangential measure direction agains the hub bolt Fig FA 26 Returning heel bearing lock t Fig 4 Turn the wheel hub in a few turns clockwise and counterclockwise again breaking in apply cotter a measure pin bearing to rotation to secure the nut is within the rated value starting torque allow the Measuring heel bearing starting torque rotation bearing STRUT ASSEMBLY starting torque if the measured The strut assembl
CHASSIS Disassembly Disassemble place clean I the strut that the inner components assembly are in a protected from dirt and other foreign matters r r so and reassemble l I lack up the vehicle ii the wheel and remove link the stabilizer bar and tension rod from the transverse and bolts separate the Loosen the knuckle arm fIxing Loosen the self locking from the ball I I lL strut joint assembly the the upper portion of the strut and remove See the Removal of Front Axle and strut ass
FRONT SUSPENSION FRONT AXLE 2 on Removing front FA Jl Fig Install a strut attachment special with the strut outer casing strut a between the strut assembly and of cloth piece outer 4 tool ST356500oo nut Remove the strut mounting insulator strut mounting I bearing oil seal upper spring seat and dust applied casing and Removing piston rod self locking FA JJ Fig assembly cover secure 5 the strut assembly in a vise Remove the spring with the coil spring compressor tool Sn56500oo
CHASSIS Inspection L Be sure damping to replace oil with new D the gland packing ones ring and whenever the strut assembly is disassembled 2 Wash all foreign Fig 8 Separate FA 35 the O Removing rod piston and or matters with thinner and compressed remove dirt and other air Clean the nonmetal parts with 3 except for nonmetal disassembled parts parts with gasoline compressed air ring cylinder assembly upward from the strut tube slowly and carefully Strut outet casing
FRONT SUSPENSION FRONT AXLE 4 Install rubber G ring a guide special tool Sn5550000 lightly Figure FA 37 top of the piston rod guide gland packing by Apply multi Fig on and install the purpose the use of a gland packing MILG 2108 grease 10924 or the lip portion indicated by asterisk to in F A 40 Greasing strut mounting bearing Reassembly Be careful not to drop scratch or part since aU parts are precision finished When reassembling thoroughly clean all component parts for
CHASSIS Note Before a piston rod will packing 90 approximately This upward the gland tightening 543 3 mm provide the shod system with the best condition for pull the absorber bleeding b Gland packing tightening torque is rated to 11 0 kg m 57 8 to 79 5 ft Ibl shown in the as actually tightening effective length following figure the L l of at 8 0 However length of this tool is extended by 100 in inl mm arm 394 Thus when gland packing measure torque wrench to be
FRONT SUSPENSION FRONT AXLE 10 multi purpose grease MIL G2108 Apply marked to portion shown in or Tightening torque 10924 44 FA Figure Nuts used to install the strut assembly on the 16 to 2 1 body kg m 116 m 3 33 15 2 ft Ib to Bolts used to install the knuckle arm to strut 4 6 to 6 1 kg to 44 1 ft Ib Nut used to install the tension rod on the transverse link 2 2 to 3 0 kg m 15 9 to 217 ft Ib Stabilizer installation bolts Transverse link bracket side 0 9 to 1 2 8 7 ft Ib
CHASSIS 2 Loosen the separate the Fig FA 47 Cross sectional view Fig remove transverse link link from mounting the bolt and suspension member ofballjoint Removal Jack up the vehicle transverse the wheel and FA 49 Loosening fVerse tran linlt mounting bolt remove the stabilizer bar and tension rod from the transverse link Loosen the knuckle joint from fixing bolts and separate the ball assembly See Removal of front 3 Remove arm the strut axle and suspension assembly knuckle k
FRONT SUSPENSION FRONT AXLE 2 the ball Replace with joint a new one when the dust cover is cracked 3 5T36721 000 Lubricate the ball MIL G2108 miles or Install a grease Be grease 50 000 krn eveI 30 000 two years completely 1 with multi purpose grease joint 10924 or nipple sure the plug hole old grease is that so on to reinstall the replaced when plug and grease with new completely greased FA 51 Fig Removing transverse link bushing Note When Inspection a h
CHASSIS 6 Install the knuckle beneath the strut assembly arm and tighten installation bolt to 4 6 44 1 lb ft Note a to 6 1 3 33 kg m to ST36721 000 Thoroughly lation surface ST36722000 and assembly matter ST36723000 b etc Make dean are sure the knuckle arm and instal the lower portion of the strut on make sure present on Tightening used FA 53 Fig InstaUing tTansverse ink bushing Be sure neck 38 longer one Finely adjust L distances between both bolts to mm
FRONT SUSPENSION FRONT AXLE ADJUSTMENT CONTENTS DATA ADJUSTMENT ALIGNMENT ADJUSTMENT OF WHEEL ADJUSTMENT OF VEHICLE LEVEL 1 alignment Carry air pressure 2 out wheel adjusted Thoroughly steering and on a FA 21 ADJUSTMENT OF TOE IN FA 21 FA 21 ADJUSTMENT OF STEERING ANGLE FA 22 FA 21 flat surface with tire defective parts before starting the wheel alignment to the normal pressure all check JUSTMENT AD parts component suspension systems 3 and repair or of the be The cam
CHASSIS Note a Make rod is 30 b mm Fig FA 56 JUSTMENT AD Side rod adjusting bar Adjusitng toe is less than 30 extending mm height 11 083 inI I in OF STEERING both Adjust indicated by side arrow steering mark angle adjusting and set them at bolts the rated steering angle Fig FA 57 Steering angk adjusting bolt SERVICE DATA AND SPECIFICATIONS WheelllipmeDt unladen Soda w v Coupe Cambe 3S Cutu 1010 T mm in Kin pin iDcUnation Strle qIe In Out to 3 t to 2010 45
FRONT SUSPENSION FRONT AXLE Free length mm in Installed mm in height load 1 10 338 20315 kg 13 1 3 7 99 1 0 1969 200 Spring kg mm 1b constant in 394 0 441 1 62 90 7 Strut assembly 177 Strut outer diameter mm in 45 Piston rod diameter mm in 18 0 709 Piston diameter mm in 25 Damping force at piston speed 3 0 0984 m sec Expansion 1b kg Compression 1b kg 48 22 106 48 5 Piston rod Bend limit mm Wear limit mm in 0 025 0 0010 Bend limit mm in 0 2 0 0079 Wear
CHASSIS Strut assembly Gland packing tightening torque 8 0 to 11 0 57 8 Piston rod self locking 3 6 to 4 5 locking Self on nut nut used to install the strut the to 79 5 26 0 to 32 S assembly body 1 6 to 2 1 11 6 to 15 2 Transverse link and ball joint Bolts used install the knuckle to arm to strut 4 6 to 6 1 Ball joint castle nut 33 3 to 5 to 7 4 39 8 to 1 44 53 5 Bolts used to install the transverse link to ball joint Transverse link mounting bolt 2 2 to 3 0 15 9 to 217 4 0
FRONT SUSPENSION FRONT AXLE Abnormal vibrations of the Shimmying front suspension which steering linkage specific speed is and the group occur whole when Worn suspension ball Replace joint Excessive backlash due to improper ad a of the retainer justment attained Worn column bearing bearing spring or weakened column loose clamp strut When driving wheel over a swerves Note to with hands off the or steering the vehicle gently left rear also cause and therefore Replac
1 CHASSIS If it is light check steering linkage and Stiff suspension groups lack of grease If it is heavy steering column check steering gear and or damaged suspension ball joint or Replace adjusted wheel Replace Worn damaged steering gear and bearing Replace Worn incorrectly or groups Of adjust bearing Incorrectly adjusted steering Adjust gear Deformed steering linkage Replace Incorrect wheel alignment Adjust Damaged strut Uppef end Replace Damaged or stiff piston b
FRONT AXLE Grating tire noise FRONT SUSPENSION Improper air pressure of tire Incorrect wheel Adjust alignment Adjust Deformed knuckle spindle and suspension Replace linkage Jumping of disc wheel Excessively or partially Improper Adjust Unbalanced wheels Adjust Defective shock absorber Replace Defective tire Replace Deformed wheel rim Replace Improper worn tire air pressure of tire air pressure of tire Incorrect wheel Adjust alignment Adjust Defective wheel bearing Replace
CHASSIS SERVICE JOURNAL OR BUllETIN JOURNAL DATE BULLETIN REFERENCE or No PAGE No SUBJECT FA 28
SECTION RA REAR AXLE REAR SUSPENSION DATSUN 1200 MODEL 8110 SERIES BODY CHASSIS a I NISSAN I NISSAN MOTOR CO TOKYO JAPAN LTD REAR AXLE RA 1 REAR SUSPENSID N RA 4 SERVICE DATA AND SPECIFICATIONS RA 7
REAR AXLE REAR AXLE CONTENTS DESCRIPTION RA 1 Inspection RA 3 REAR AXLE SHAFTS RA l Assembly RA 3 Removal RA 1 r 1 r 1fji 1 Axle 2 4 Spacer Wheel bearing Wheel bearing collar 5 Oil seal 6 Bearing adjust 7 Axle 8 BraJce drum 3 shaft shim case i Fig RA 1 Sectional view of rear axle DESCRIPTION reinstallation The axle is of rear housing is a press steel weight and is and bending The fore rear no when shouid fJoating type l sefi Banjo typi housing sufficiently
CHASSIS 2 Remove the wheel cover 6 and nuts Remove the road If either the axle shaft wheel and brake drum If brake linings should hold the replaced drum slacken off the brake deeply shoe adjuster a few notches slide 3 Disconnect cylinder Plug plastic from the up the open end of the brake pipe or cover the brake pipe Xl wooden peg to prevent foreign wheel with remove the remove Be careful not to matters the wheel wheel bearing is to be bearing locking collar by nicking
REAR AXLE Fig RA 6 Fig RA 7 Install wheel bearing Removing oil seal 2 Install the oil seal in place on the axle housing flange Inspection 1 Inspect the machined surface of the the axle 2 for housing which affect the rough spots other or Note irregularities sealing used Be sure to the new oil seal apply MP 2 grease damage and distortion The bend amount should be less than 3 3 mm 0 118 in 0 Install the Check Note be is replaced between lips of the oil seal cracks strai
CHASSIS 4 Tighten and nuts lb ft the brake back with a Check the Figure RA 9 plate to housing flange torque of IS to 2 0 rear The end kg m axle shaft end play play bolts 10 8 to 14 5 as shown in should be less than 0 1 mm 0 0039 in Fig RA 9 Checking axle shdft end play REAR SUSPENSION CONTENTS DESC R I PTI ON RA 5 REAR SPRING RA 5 Removal I nspection and repair Installation REAR RA 6 SHOCK ABSORBER RA 5 Replacement RA 6 RA 5 Inspection RA 6 1 Leaf spring 5 Axle
REAR AXLE DESCRIPTION Rear 5 consists of suspension leaf elliptic semi bracket rings s spring toward the front done to reduce while the the center from is ofT set 110 pin the center of the 33 4 mm spring the remove three the fIxing nuts the securing front front bracket from the leaf spring front eye and car body and lower the rear telescopic hydraulic shock absorbers and rubber bumpers The rear Loosen spring in This is wind up and to decrease the 3rc spring wheel swing
CHASSIS for wear cracks defective parts are straightness and damaged threads found Remove the lower end of the 2 from the spring replace with new ones Inspect all rubber parts for 4 If See Figure seat shock absorber rear RA 14 damage separation wear and deformation Replace them if necessary Installation Install the rear spring in reverse sequence of removal noting the following matters 1 Coat the front bracket pin front bracket bushing shackle pin and shackle bushing with to 2
REAR AXLE SERVICE DATA AND SPECIFICATIONS Shock absorber Applied Stroke x model max Sedan length 3m O Damping force at Rear in mm 167 506 x Van Coupe 6 57 x 19 9 180 7 09 440 x 3 17 x x 468 180 7 09 4 18 x s Ib Rebound kg Compression kg lb 58 128 68 I SO 90 198 38 83 8 45 99 2 45 99 2 spring Length x width x thickness 1 No of leaves lOx50x constant 1 llOx50x 1 2 1 110 x SO kg in lb mm 1 96 0 2362 I 97xO 2756 43 1 1 2 109 1 96 x 6 7 II
CHASSIS 8 0 to 9 0 57 8 1 6 to 2 0 116 to 14 5 3 2 to 4 0 23 1 to 28 9 1 6 to 2 0 116 to 14 5 Sedan and Van 3 6 to 4 5 26 0 to 32 5 Coupe 09 Wheel nuts Spring front brake Sedan and to body bolt 65 1 nuts Coupe Van Spring shackle pin to nuts Shock absorber upper nuts to J 2 6 5 to 8 6 Shock absorber lower nuts Sedan and Van 3 6 to 4 5 26 0 to 32 5 Coupe 09 to 1 2 6 5 to 8 6 0 6 to 0 8 3 to 5 8 4 Torque arrester body to bolts SERVICE JOURNAL OR BULLETIN REFERENCE JOURNA
SECTION BR BRAKE DATSUN 1200 MODEL 8110 SERIES BODY CHASSIS a I NISSAN I NISSAN MOTOR CO TOKYO LTD BRAKE BR SERVICE DATA AND SPECIFICATIONS BR 23 TROUBLE DIAGNOSES AND CORRECTIONS BR 24 JAPAN i 1
BRAKE BRAKE CONTENTS DESCRIPTION BRAKE PEDAL BR 2 Removal and disassembly BR B BR 2 Inspection BR 9 Reassembly and reinstallation BR 9 Removal BR 2 Inspection BR 2 Reinstallation BR 2 Brake pad BR ll BR 3 Caliper assembly BR 12 BR 3 Reassembly BR 14 BR 16 BR 16 TANDEM MASTER CYLINDER Removal FRONT DISC BRAKE Disassembly BR 3 Reinstallation Inspection BR 3 REAR BRAKE BR lO Reassembly BR 4 Removal and disassembly Reinstallation BR 4 Inspection BR 17 BR
CHASSIS Removal DESCRIPTION The Datsun 1200 series brake Disc brake leading two or drum brake is used for the adoption driving range a wheels rear is used cylinder brake There safety high speed at one is 2 Remove the spring pin from the clevis pin which is two specifications cylinder remove the clevis pin and separnte the push arm tandem or types of tandem type Under the standard arm rod from the pedal 3 master for disc brake and the other for drum tandem type master Unh
BRAKE TANDEM MASTER CYLINDER The tandem masler cylinder aIIows either front brake trouble displaying occurs or rear sufficient braking effect although The tandem a NABCO in one side of either front or rear brake or TOKICO bling be careful improving driving safety cylinder master lype is manufactured When disassembling and by reassem not to mix the individual manufacturer s parts I t i Fig BR 4 J Cross sectional view master of tandem type cylinder Removal J Remove the clevis p
CHASSIS rubber parts alcohol und After the parts are longer deaned dry than 30 seconds them with disassembly noting the following matters I Check the uneven wear on cyJinder bore and cylinder the conditions Replace 2 brake Apply com pressed air piston for damage sliding surface as carefully and no and for other defective required Replace if the cylinder and piston clearance is more so fluid to the component pdrts such etc piston that the component parts dust and other fore
BRAKE Removal and The in the single same disassembly master cylinder manner as installed cylinder is removed and disassembled the tandem type master cylinder BRAKE LINE Inspection Refer to the section covering type master Inspection of tandem The bl1lke cylinder The single and reinstallation master pipe adopts tubing and with improved Reassembly in the same manner as the tandem type master cylinder is beneath reassembled and the the rigidity has been portion of brake line laid
CHASSIS Inspection Thoroughly check them for tube and clean the brake tube and brake hose collapsing for weakness crack scar expansion and rust brake brake etc wear and hose if defective Replace 2 Remove mud and dust from the brake tube clip unit md check the G Front 3 way connector Fig 2 BR 8 The brake hose strut assembly 0 Brake master cylinder tom I If the clip covering vinyl coaling is clip repair Front J way connector rubber hose unit and rear axle is used at the f
BRAKE warning light is completed and thus the warning light lights S to 18 kg I 3way connector m In this 10 8 to 13 0 ft b Master S to 1 8 kg I cylinder Brake hose S to 1 8 kg I hydraulic brake problem and light switch assembly for a proper operation Check the switch assembly for fluid leakage m Note Do not attempt to repl8CllIWitl h 0 7 to 0 9 kg 5 1 to correct the Check the warning 10 8 to 13 0 ft Ib Air bleeder case bleed the brakes m 10 8 to 13 0 ft Ib 5 circuit for the g
CHASSIS FRONT DRUM BRAKE o B J t o o r l Gl e e Fig BR 14 Front drum brake Removal and disassembly I Jack remove up the vehicle support Unhook the retum spring and 4 with a stand the wheel cover and tire Remove the brake drum and remove remove the brake shoe assembly and Disconnect the bridge tube from the fore and after 5 2 components wheel the hub cap cylinders and hub assembly from the spindle 3 unit of the Disconnect the brake tube at the bracket strut assembly Fo
BRAKE 7 Remove the brake disc installation bolt the brake disc from the 8 and remove 5 Check the brake disc for distortion 6 Check spindle If Inspection Drums and between clearance exceeds 0 15 mm If show they cylinder for wear sign the and cylinder 0 0059 in replace the piston them excessive out of round score reconditioning by machining forth so the bore of the wheel of rust and damage cylinders Disassemble the wheel is required Brake drum inner diameter 203 2 8 0
CHASSIS 4 Adjust bleeding on brake shoe clearance and perform air the hydraulic system FRONT DISC BRAKE Floating type disc brake Model ANNET 14A 12 is used for some territories as a standard Rigidity worn 3 kg BR 19 Tighten m Greasing point on brake due by elasticity of the piston seal When the pad is the Clip Spring 3 Clevis 4 Shim 5 Ha pin cr piston seal surface 6 Brake 11 Cylinder 7 Air bleeder 12 PisCon A 8 Retaining ring 13 Bias spring 9 Boot 14 Yo
BRAKE CYLINDER SIDE PISTON SIDE L COMPRESSION DECOMPRESSION exceeding the elastic displacement is released with slipping on the seal surface Movement Returns in elastic displacement of the seal Note BR 21 Fig Piston seal automatic When the brake brake adjusting operation brapad and shim Withdrawing DR 2l Fig pad is removed do not depress the or otherwise the pedal piston will come out Inspection Brake Clearance between the brake pad automatically Replacement and remove for wear
CHASSIS Fig Note Note that brake fluid a Ikpression piston BK 24 may overflow from the reservoir Recommend operation be canied out by loosening the The piston can be easily if pushed excessively excessively damaged into the pushed in by hand But the groove of piston goes inside of seal as shown in will be ARROW MARK to release brake fluid breath b seal cylinder A and B into Figure When the piston is cylinder c BR 25 and the remove pushed the brake the assembly disassemble
BRAKE Fig BR 27 Removing strut assembly and knuckk ann Fig installation bolt 4 Remove the caliper assembly separate it from the strut installation bolt and 5 Remove the bias 6 Remove BR 28 Removing caliper assembly installation bolt Q Disassembly 1 Loosen the air bleeder and B into the cylinder the piston A and boots from o Retaining ring the BR 30 Boot Cylinder body and piston Depress and remove 8 Remove the piston seal from the cylinder Note cylinder retaining ri
CHASSIS When cl Note fluid lOing rubb parts If rubber parts are use alcohol or brake cleaned with mineral oil they will be deteriorated 1 Calipers If the cylinder wall lated the on emery paper Ifrusted 2 is damaged wall is rusted cylinder or or replace or worn foreign matters are If the accumu cylinder wall carefully polish with fine so that the cylinder wall damaged is not roughened excessively replace Pad See paragraph covering replacement of pad BReJ1 Fig 3
BRAKE J i tu PISTON B P ISTON A Fig 3 Apply rubber piston and too 4 grease insert the lightly piston to the into the When inlllrting the piston Note Fig BR 33 Piston A and B cylinder be careful not to insert much Install the boot and retaining ring 7 Fig BR 34 Inst4Uing boot Install so that the A coincides with the yoke groove of bias ring of piston faces to so ofyoke spring so 2 that the bias spring to the air bleeder side of cylinder Apply the brake grease to
CHASSIS Fig 10 BR J7 Fig Correcting bias spring position Assemble the cylinder body and yoke by tapping BR 38 Measuring starling torque Starting torque the yoke lightly 9 0 cm 7 80 in Ib kg At the hub bolt II Apply groove of 12 the brake grease fully to the yoke sliding 57 1 kg 3 45 Ib cylinder Tightening torque Install the air bleeder Caliper assembly installation Reinstallation 4 6 to 6 1 Reinstall the caliper assembly in reverse sequence of 5 to 1 8 1 the pad hydraulic lin
BRAKE disassembly Removal and Remove the 7 remove the Jack up the 1 side of the vehicle rear support with a removed together stand and remove the wheel from the rear wheel cylinder remove lever with the rear axle shaft Refer to the clevis pin and disconnect the Remove the return hand brake wire axle housing rear Section RA Loosen the hand brake wire 2 flange bolt from the axle shaft The brake disc can then be rear spring pull spring Removing brake disc BR 42 Fig Ins
CHASSIS Reassembly Reassemble and reinstallation and reinstall the rear brake in reverse sequence of disassembly and removal noting the follow ing When reassembling matters refer to the notes for front drum brake Measure the wheel cylinder sliding resistance with the brake tube disconnected make 7 sure 409 4 kg Note that the When return 2 2 2 is is in range from 2 to the brake improp kg shoe does not smoothly rn kg 10 8 to 5 14 II6 to 15 9 bolt flange bolt o Sprina lb
BRAKE Removal r lr Sf Loosen the I buckle turn adjusting the front cable from the rear nut and septe O cable 0 s 7 fqI 0 l J b 0 1ltL j 0 Y I 1 1 separate the 1 r c 0 1 0 12 Hanger Itn p installation bolt Fig BR 48 o Disconnecting TeaT Lock plate cable rear from axle IwllSing f 5 Loosen the hanger strap unit nut parts into nut hanger strap washer 1 Rear cable 4 Front cable 2 Turn buckle 5 Propeller 3 Lock nut Fig 2 of Removing Remove the lock t
CHASSIS With 4 hand the pulled lever button and make sure that the push 0 1969 to 0 2362 in Make sure 3 depress the pawl disengages depressed is button push teeth when the 5 brake 5 such the an completely 4 adjusting stud counterclockwise up to that the brake shoe is brake the Turn drum and separated slightly warped if the readjust interferes lhe brake drum damaged pedal depress the brake addition Ot cam extent from the brake drum to 6 mm that the cable dust co
BRAKE Brake pedal height Ai JI L BRAKE M ASTER CYLINDER r TOP ll Q ci I r ADJUSTING SHIM 0 5 THICKNESS mm 0 8 1 6 mm mm 1 0197 in 0 0315 in 0 0630 in Brake ped4 adjustment Loosen the stopper up to such extent that the brake is pedal stopper separated from the pedal Hand brake arm Turn the turn buclde properly and adjust hand brake 1 2 Measure height of the brake master cylinder and dash 5 143 lever brake pedal head from the panel so that height to is IS 3 0
CHASSIS 2 Upon completion of the adjustment release the hand brake lever and make sure that the rear wheels are I not braked r 7 Normal stroke 78 5 I 3 091 in mm 1 1 6 notches I limited stroke 136 0 mm in Stroke The term position 35 5 220 means 8 7 in nun 10 notches O above the hand brake lever Readjust 1 hand brake stroke when it reaches the limited stroke 136 mm 5 35 inll 10 notches 4 Depress Bleeding hydraulic system 5 it is to air bleeder rear the brake
BRAKE SERVICE DATA AND SPECIFICATIONS 8rab pedal Pedal free height Full stroke of peda head 57 t0D787 5 mm in mm in 120 4 72 rom in 1746 mm in 52 I4I Muter cylinder Inner diameter of maJter cylinder 16 11 Allowable maximum clearance between cylinder and piston 0 13 00051 Wheel cylinder Inner diameter of wheel cylinder Front drum 64 13 16 20 in mm mm in 48 1 894 1 mm in 20 64 13 16 mm in 1746 11 16 mm in 0 18 Drum brab inner diameter mm in 203 2 8 00 Rotor disc
CHASSIS B40 Akebono make Lining material Front disc brake Pad width x thickness Total braking x length area mm in cm2 in2 42 5 x 10 3 x 53 1 1673 x 406 0 x 2 091 3 14 0 90 MI12S Pad malerial NBK D864P for A and CANADA s U Rear brake Lining width x Total braking thickness x length mm in 35 cm2 in2 area x 4 8 x 378 1 195 x 0 1890 x 273 42 3 B40 Akebono make Lining material Tightening torque kg m ft Ib 2 1 to 2 9 Master cylinder installation bolt kg m ft
BRAKE Use of a brake fluid boiling point of which is too low a promotes under slight pressure in master vacuum sucks in air through yields specified brake fluid and bleed system Reservoir filler cap vent hole clogged Pedal with the Change This cylinder that Clean reservoir filler and bleed cap the system rear seal Deteriorated check valve Fit External leaks Check master a new check valve and bleed the system cylinder piping and wheel cylinder for leaks and make necessar
CHASSIS Front suspension Thoroughly faulty check and adjust all front sus pension components Excessive pressure pedal required poor brakes Grease mud or water on Remove linings squeak or Clean and dry Full area of linings not contacting drums Dust on drums or oil soiled Replace or shoes Reface drums and install new linings linings Remove and clean drums thoroughly Eliminate oil leak squeal Weak shoe return springs Check springs and Drum out of round Tum drums Worn
BRAKE SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or No PAGE No SUBJECT BR 27
CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE DATE JOURNAL BULLETIN or PAGE No No SUBJECT BR 2B
SECTION WT WHEEL AND TIRE DATSUN 1200 MODEL B 110 SERIES BODY CHASSIS INI NI NISSAN MOTOR CO TOKYO II JAPAN LTD WHEEL AND TIRE WIt TROUBLE DIAGNOSES AN 0 CORRECTIONS WI3
WHEEL AND TIRE WHEEL AND TIRE CONTENTS DESCRIPTION WT PERIODICAL SERVICES WT 2 Tire rotation WT 2 3 WT INSPECTION Inflation of tires WT 2 Wheel balance 3 WT Redial tire WT 2 Wheel 3 WT DESCRIPTION TIRE SIZE in Standard 6 00 4PR I2 Optional 6 00 4PR 12 with tube 6 00 4PR I2 Snow tire 6 00S Tubeless Sports 4PR 12 155SR 12 Tubeless Radial with tube 5 00 4PRULT 12 with tube front 5 00 jPRULT I2 with tube except for Van lor TIRE INFLAnON PRESSURE To be measured when
CHASSIS Be PERIODICAL SERVICES sure 200 km wheel nuts after retighten to running 100 to 60 to 120 miles Inflation of tires Tires with proper pressure improve riding comfort and steering stability reduce driving sound to the minimum Radial tire and extend the service life When comparing to the The tires should be checked for proper pressure monthly basis or more frequently depending conditions while the tires Ordinarily are on tire pressure rises 10 to 15 accurately first find of tha
WHEEL AND TIRE Check the flange of rim for deformation 2 RIGHT FRONT damage RIGHT REAR dition Yt 3 Deformed and damaged rim will Thoroughly remove rust rubber cause particles air wire brush emery paper and with a LEFT REAR 4 Remove small 5 WT 2 Tire rotation wear leakage mud or pieces of gravel glass nail and other matters from tire tread noticeably When the tire side wall is cracked indicator is exposed replace the tire with or pennissible 35 0 oz unbalance of wheel a
CHASSIS Worn or damaged wheel bearing play ofwheel or excessive damaged Excessive Correct play or replace bearing front wheel alignment Improper Worn or Adjust ball joint and link bushing linkage play steering or worn Replace Adjust replace or steering linkage Loose steering linkage connection Retighten the torque Unevenly or or nuts with the rated replace worn Broken IUSpension spring Replace Defective shock absorber Replace Improper Conduct lire rotation tire rotation
WHEEL AND TIRE SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE or BULLETIN No PAGE No SUBJECT WT 5
CHASSIS SERVICE JOURNAL OR BUllETIN REFERENCE JOURNAL DATE or BULLETIN No PAGE No SUBJECT WT 6
SECTION ST STEERING DATSUN 1200 MODEL B 110 SERIES CHASSIS INI BODY I NISSAN MOTOR CO TOKYO JAPAN CD LTD DESCRIPTION ST t STEERING ST t COLLAPSIBLE STEERING ST 1 STEERING LINKAGE ST t3 SERVICE DATA AND SPECIFICATIONS ST l1 TROUBLE DIAGNOSES AND CORRECTIONS ST 18
STEERING DESCRIPTION The steering system consists of recirculating ball type as required The gear box and parallelogram linkage These systems give good response utmost with equipped a the Moreover durability torsion light handling and steering rubber system idler linkage arm bearing is system and are described greased km 30 procedures in the replenish recormnended up with wheel 000 miles for the steering lock ELECTRICAL BODY SECTION of this manual and therefore of gear box sho
CHASSIS Fig ST 2 Steering REMOVAL wheel 3 Remove the turn signal and lighting switch com pletely 1 Remove the horn ring and remove the steering wheel 4 nut rod 5 Remove Note 2 ST 3 Removing steering wheel lock lever assembly from the control assembly by unscrewing the fixing bolts Remove two column Fig the hand to fixing bolts used the instrument to secure the steering panel nut The horn ring can be easily removed by tow bolts Remove the steering column shell Fig S
STEERING 6 Remove six bolts used to secure the steering DISASSEMBLY column hole cover to the dash board Remove the I the gear I X I I j gear arm the of by use fIxing nut and Steering Gear a pull out Arm Puller ST27 I 40000 2 I arm steering Remove the drain steering 3 1 10i i gear from the housing Loosen the shaft adjusting the and drain the oil plug adjusting screw a screw nut and turn the sector few turns counterclockwise Remove four sector sector shaft cove
CHASSIS Note Be careful not to a11 the ball nut running d Asoembly and adjustment n to either ond of the worm lbo ends of the ball I lJIides will be until ro stopped I Asoemble the ball nut on the if the nut is oDc I w to the end of the worm at 2 5 Pull the colunm out with the ball 19 baIls into each of two holes on the same Drop side of ball nut mbly from the column Tum the column jacket gradually away from the hole filled Continue until all 38 balls 6 worm guide hole up are b
STEERING ASSEMBLY AND JUSTMENT AD Tightening torque 1 7 ro 2 8kg Standard shim 0 5mm Tightening torque 12 3 ro 20 2 m lbl ft 0 0197 in 1 7 to 2 8 kg Tightening torque 2 0 m to 3 0 14 5 to 12 3 ro 20 2 ft Ib kg m 217 ft Ibl Clearance of adjusting screw to secter shaft 0 05 mm 0 0020 in Apply grease here when assembling Pitman arm Tightening torque 14kg m 101 ft Ib ST 9 Fig I Sectional view Press in oil seal into the housing Note Apply chassis grease to the of steering gear
CHASSIS 4 Adjust the preload the thickness of the to 0 20 mm to bearing of the steering bearing by selecting shim J ST 10 Apply torque oil shim is 2 0 to 5 0 kg m 48130 66000 1 515 to 1 535 4813166000 545 1 48132 66000 575 1 mm in 0 0596 to 0 0604 565 to 1 0 0608 to 0 0616 595 1 0 0620 to 0 0628 to 48133 66000 1 605 to 1 625 0 0632 to 0 0640 48134 66000 1 635 to 1655 0 0644 to 0 0652 Measuring initidl turning torqJAe on the wonn wheel in motion 3 5 to 8 8 screw
STEERING 6 the the backlash at the neutral Adjust adjusting top end screw so radius 127 00039 in that the mm point by screwing movement 5 00 in of the gear is within 0 1 7 Fill oil gear MPS arm US pts 0405 UK pts rom and install a 90 into about 0 23 liter 0 486 assembly through filler hole filler plug and lock temporarily by the nut INSTALLATION Installation removal Pay can be accomplished attention to the in the reverse order of following points I Make 2 Check the
CHASSIS I I Cl o Fig ST 14 CoUapsibk steering DESCRIPTION This column is designed to be impact When an compressed under an cY automobile is being driven the forward split movements of the automobile and the driver constitute a form of energy in a on head or force ment of the car forward is suddenly halted while the this energy is also severe collision generally involves these two forces continues in the forward direction secondary impact When the A column occurs collapsible
STEERING 7 CiJ f e e o 1 Lower column shaft 5 Plastic 2 Upper column shaft 6 Column collar 3 Lower column tllbe 7 Column 4 Jacket tube Fig ST 15 pin bush 8 Washer 9 Snap link Steering post clamp 10 Collapsible steering STEERING COLUMN 8 Lower column shaft Plastic 3 Upper column shaft pin Fig ST 16 Steering column ST 9 Lower column tube
CHASSIS The construction of the steering column is the as such that lower shaft is fitted into the upper tube when a C compressing force is applied to the lower shaft Steering torque upper tube is transmitted by the lower shaft and The lower shaft adopts circle with two straight cut edges interior is toward special shape a a and the upper tube tightly fitted against the lower shaft exterior the entire area In addition four plastic pins completely eliminate gap between the lower shaft e
STEERING The is of a mesh jacket tube in rhombus forming an a part of which is of the absorbing part energy that punched function Upper and lower guide tubes poly acetal energy smoothly collapsible steering with an resin are two guide tubes joined inserted into the mesh tube as as a jacket so possible guide and collapsed generated by with a collision can low load be absorbed The for mesh tube while the mesh tube is improve bending rigidity of the tube STEERING POS
CHASSIS The block sliding supported on secured the bracket is installed clamp is on the steering post the half of upper steering column is bracket with bolts on the and thus the Construction of the column shaft upper such that both radial and thrust forces steering post a plastic pins large impact are cut is applied from the disengaged and with this construction and adjust the sector shaft Inspect adjust steering post clamp sliding block does bushing ring from the upper surfac
STEERING REASSEMBLY I and install the Adjust alignment jacket tube on the worm shaft and housing 4 0 1575 j 2 Apply bearing grease screw 3 the column Apply bushing washer to the interior sufficiently above the rated 27 5 dia and position and apply the snap ring to the groove correctly and securely UNIT Fig Return the column bushing 4 1083 allowing mm in ST 23 the top surface of the bushing coming into contact with the lower surface of the washer 0 0394 in adjust and the c
CHASSIS 1 Steering 2 Pitman gear arm 3 Side rod 5 Idler 4 Cross rod 6 Knuckle Fig ST 24 2 Loosen clamp bolts and Jack up front of the vehicle and support with stands 2 Remove cotter 3 pins and castellated nuts which are arms 3 by backing up boss with a large a 4 the socket Remove the idler arm Remove the baIl studs of cross rod from the gear in step 3 assembly under the same procedure The cross rod and side rods as arm described be removed as Remove the idler as
STEERING INSPECTION AND REPAIR 1 Check the idler rubber bushing for damage wear and play and replace bushing if necessary 2 Check the cross rod and side rods for damage bend and crack and replace them if necessary 3 Check each baIl joints for play due action of the push spring or a to lack of spring damaged ball stud 1 Ball stud 3 2 DustcOYer 4 ST 27 Sectional view fig If any abnormal condition complete 1 Ball stud 2 Dust Clamp Spring cover unit ST 26 Secrional can accompl
CHASSIS The 1 foliowing tightening torque of nuts shall be 3 adopted steering system and check it for sliding noise Ball stud nut 30 Gear Idler 5 0 kg m to arm 14 kg lb ft 101 m arm 4 Check the operation for smoothness 5 Check the side rod and 6 Check the gear 7 Check the gear housing tightening bolt for slackness 21 7 to 36 2ft lb cross rod for nut nut 5 7 to 2 the Operate 3 kg 6 Assembly of 2 to 45 6 ft Ib 41 m the idler assembly is arm bending for crack and
STEERING SERVICE DATA AND SPECIFICATIONS Type Recirculating ball type Gear ratio 15 0 I 400 157 0 23 0 486 0 405 Steering wheel diameter mm Oil t US ptsUK pts capacity Steering angle in inner wheel outer 43 wheel 360 Play steering wheel mm in mm in 20 to 25 0 787 to 0 984 Standard thickness of worm bearing shims 5 0 0 0197 Initial turning torque of column assembly kgm Clearance of adjusting screw T 27 8 to 69 4 to sector shaft in mm Length of side 2 0 to 5 0 oz i
CHASSIS TROUBLE DIAGNOSES AND CORRECTIONS Troubles Heavy steering Possible Remedies causes Low tire pressure Inflate tires to recommended pressure Incorrect front wheel alignment Adjust Lack oflubrications Lubricate steering gear and ball joints to replace Firm sticking of the ball joint and strut specifications worn or ball joint Replace bearing and damage of steering Improper adjustment gear Loose steering Adjust housing Hard locking ofcolumn bearing Lubricate with bearing gre
SECTION FE ENGINE CONTROL FUEL EXHAUST SYSTEM DATSUN 1200 MODEL B 110 SERIES CHASSIS INI BODY I NISSAN MOTOR CO TOKYO JAPAN LTD t ENGINE CONTROL SYSTEM FE FUEL AND EXHAUST PIPINGS FE 3
ENGINE CONTROL EXHAUST SYSTEM FUEL ENGINE CONTROL SYSTEM CONTENTS ACCELERATOR FE 1 CONTROL FE 2 Adjustment FE 2 Description ACCELERATOR CONTROL e3 I EJ3 I 1 Accelerator pedal 3 Wire outer case 5 Pedal stopper 2 Accelerator arm 4 Inner wire 6 Return Fig FE 1 Accelerator control syst m for spring R H drive L 4 7 1 Accelerator pedal 3 Wire outer 2 Accelerator arm 4 Inner wire Fig case FE 2 Accelerator control FE 1 system for L H 5 Pedal 6 Return drive s
CHASSIS Description The accelerator is that such linkage the is lightweight and construction linkage operates o to 1 is and smoothly mm 0 to 0 0394 inl unaffected by engine vibration Adjustment Play ohceelerator wire I Install the pedal arm side securely with spring a clamp Fig FE 4 Adjusting pedal stopper height 4t 2 a Set the board dash side outer case hand steering stationarily with cap nut Do not set the carburetor side adjusting unit stationariJy T 3 Pull up the
ENGINE CONTROL EXHAUST SYSTEM FUEL R H drive Pedal free KICK DOWN SWITCH play mm in 2 mm in 48 STRIKER Pedal stroke 0 0787 1 890 LH drive 2 50 0 0787 1969 Pedal depressing force when fully 3 8 open kg 4 8 3 3 3 7 lb FE 6 Fig FUEL AND EXHAUST PIPINGS CONTENTS EXHAUST PIPE AND MUFFLER Description FE 3 FUEL TANK 4 FE Description AND PIPINGS 4 FE FE 5 Replacement Precautions for removal and I nspection and FE 4 installation EXHAUST PIPE AND MUFFLER e L v 4 9 Fig
CHASSIS Precautions for removal Description For all models sedan wagon and coupe the exhaust system uses pre muffler single a tube front without the using The main muffler is installed beneath the and instaIJation rear seat floor in the left side 1 When there is and floor or no propeller clearance shaft line of tube in the manifold between the front tube turn the tube connecting along center unit and obtain a proper clearance The front component parts tube coupled unit is
EXHAUST SYSTEM ENGINE CONTROL FUEL For all models fuel tank the to response capacity Location and increased engine output mounting strength for improvement of improved are and completely drain fuel has been increased in safety Sedan 40L Wagon 38 L Coupe 38 L 10 gal Imp gal 57 US 8 81 10 04 US Also for safety To 8 37 10 has been the fuel line is protected interferences from road fuel line is laid inside the a rear from In the front tunnel 3 Remove the 4 Remove four
CHASSIS AIR VENTILATION TUBE AIR BREATHER TUBE FIg FE ll u andtu be installations nO VAN SERIES FIg FE12 Fuel mk t FE 6 Un t installation
ENGINE CONTROL SEE ARROW FUEL EXHAUST SYSTEM A AIR VENTILATION TUBE Fig FE1J Hose i1Ut4lJations COUPE Fig FE 14 Fel tank FE 7 nit installation
CHASSIS I FILLER HOSE Fig and Inspection I repair Check the fuel line for leaking repair Note or replace a When gasoline b as FE 15 Hose installations or other damage and required sold ing is required be sure that no is remained When deaning fuel tank inside use gasoline Do not use water 2 The gauge unit the gauge unit a adopts a bayonet system and thus can be removed and reinstalled simply with screwdriver Fig FE a FE 16 Gauge unit
FUEL ENGINE CONTROL EXHAUST SYSTEM VAN ONLY j o e v Fig L e FE 17 Fuel tank unit gauge installation SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE or PAGE BULLETIN No SUBJECT No FE 9
CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE or BULLETIN No PAGE No SUBJECT FE lO
SECTI ON BF BODY DATSUN 1200 MODEL B 110 SERIES BODY CHASSIS I NISSAN I NISSAN MOTOR CO TOKYO JAPAN LTD GENERAL DESCRIPTION BF t UNDER BODY ALIGNMENT BF 9 HOOD BF 14 FRONT FENDER AND FRONT END BF t6 TRUNK LID AND REAR BUMPER BF 1 B DOORS BF WINDSHIELD AND REAR WINDOW BF 30 VENTILATOR BF 32 SEAT BF 33 INSTRUMENT PANEL BF 36 ROOM TRIM BF 31 23CD
BODY GENERAL DESCRIPTION CONTENTS DESCRIPTION BF 1 BODY CONSTRUCTION AND CROSS SECTIONAL VIEW BF 1 DESCRIPTION The body individual adopt a construction body box is of an unit type The rearward collision absorbing which energy generated from the collision require high strength improving torsional rigidity and components section cross an There the highly rigid structural components are joined under special connecting construction which reduces centralizing coupe are three type
BODY t Fig BF 2 Body Seat belt anchorage indicating one side only construction 2 door seddn Seat belt anchorage indicating both sides Fig Fig BF 4 BF 3 Body Body construction coupe construction station wagon BF 2 or van
BODY SEDAN G B H cH C N A 7 A A F F Q J2 DETAILS OF PORTION 4 DOOR Roof 11 Inner 12 3 Cowl top Hood 13 Rear floor Rear fender 4 Lower dash 14 Brace S Front IS 6 Front fender Side dash booud 16 Inner rear pillar Air box panel 11 Outer sill 18 Inner wheel house 19 Outer wheel hQuse BF 5 Cross floor Inner center 9 InnerdOO I sectional BF 3 board 8 10 Fig roof rail 1 2 1 L G vie Outer door I pillar
BODY K K lL N N M M J 0 0 SEALING ON CIRCUMFERNCE OF REAR flOOR DETAilS OF PORTION h 1 Rear floor 2 Rear 3 Lugage compartment floor 9 R Seat blCk support Inner lock pillar 11 Lock pillar 12 Roof 13 Rear waist 5 Front pillar Front fender 14 6 Outer door 1S Lugage compartment lid Rear panel 7 Fuel filler cover 16 Outer wheel house 8 Shock absorber mount bracket 4 BF 6 C DETAILS OF PORTION 10 rear Fig cr oss fender side secticmal iew II BF 4
BODY T 2 T V V V V COUPE DETAILS OF PORTION B A A D D DETAILS OF T PORTIONE Fig BF 7 Cross I Roof 6 2 1 Front reDder Inna wheel house 3 Inneuide body Rear fender 8 Rear floor 4 Outer door 9 Innu Iodi S Front pillar 10 sectional BF 5 vieIII pillar Lockpillar
1 BODY STATION WAGON OR VAN A C C 7 4 SEALING ON CIRCUMFERENCE 9 OF REAR FLOOR D D Fig BF 8 Cross sectional view IV BF 6 I Roof 2 Reu 3 SeaIin 4 Rear floor S Side leU fender Sttltion wagon SCIOen Door or van 6 Inner side body 7 Outer back door 8 Inner back door 9 Tail 10 member cross Reupane1
BODY Water drain holes figure Be sure to are located provide all as shown in the following water drain holes grommets with 1 to 6 7 to BF 9 Location of water drain hole hole 14 15 Drain hole cover BF l0 Location oflwater drain hole plug sedan 1 t04 5 6 to 11 12 Fig Rubber plug SClt belt anchorage hole plug Inspection Drain plug 13 Fig 12 Rubber plug Seat belt anchorage hole plug Drain hole cOYer coupe Rubber plug Seat belt anchorage hole plug Fig BF l1 Location of water d
BODY CD CID CD 4 i @Roof CID Roof drip moulding clip CD Window drip moulding reS5 downward after king moulding op a Windshit1d side Windshield r rnoukJing J moulding Inserted For all four corners Dry U @Body sill moulding l Door cover rubber Nut Used rear in @Radiator one grille shroud Sill @Door Radiator at front and ends two uch side anty outer moulding clip moulding grille shrcul A clip J c Used et four paces except for both ends r each per door Three IUch in on
BODY UNDER BODY ALIGNMENT CONTENTS UNDERBODY GENERAL SERVICE INFORMATION ALIGNMENT CHECKING PROCEDURE PRINCIPLES OF TRAMMING BF BF 10 BF 9 CAR PREPARATION BF 9 TRAMMING checking alignment of the underbody repairing minor underbody damage or components INFORMATION dimensions it is essential that proper overall strength of the body and following underbody the parts locating replacement underbody component directly affects the Since each BF 10 SEQUENCE assist in To UNDERBODY GENERA
BODY pointer used at the rearward location settings the tram bar will be on a With the proper plane parallel the body The exception to this would be when reference locations is included in the the not parallel plane between prevail misaligned one of the area then the body and the tram bar may After completion of the repairs gauge should be set at the specified TRAMMING SEQUENCE to that of the tram dimension to check the accuracy ofthe repair operation The tramming sequence will vary n
BODY w Z w E E a w z I Z w U J c c tl al 5 Qj 0 t @ 0 8 0 i5 N il I 0 5 ai ci iii iii N N fr N N iii 0 e zoUIOL 0 05 L 09 Fig BF lJ Body aligrmtDtt lan BF l1
BODY w w Z z i E a w E i I E f Z J 2 w 0 0 0 0 0 m I m 5 ol IOL6 Z S on f 0 2 N Ol 0 J in @ g 0 0 0 8 i 10 10 @iZ on I in ci on 19 10 9t HLl IZ S OL6 J0 0tI PI @ Szz OIS s IIZ os tLZI lOa O on I N 909 9 16 10 g e t o I 10 Z ZI oL r oj i5 Fig BF J4 Body Jignmen BF 12 coupe
BODY w C z i e e 1 I e 0 b b 0 0 2 tS LtH tSS s in 0 @ 0 0 e o 5 r It I 11 09 9 09 0 @ ra o Z os ai l LZl H 0 I 1 u I 09 t 9 JS Tr 9909 t l6 I 1 y tZ n 9 OLS e II II OS tlOS H Body alignment Pig BP station BF 13 or i 1o
BODY HOOD CONTENTS REMOVAL AND INSTALLATION SF 14 LOCK SF 14 SF 14 Removal BF 14 Installation SF 14 Adjustment BF 15 REMOVAL AND INSTALLATION Installation Install Removal I HOOD Removal carefully Disconnect the windshield washer hose at the so in hood reverse of removal sequence that the hood is flush with the fender top and clearance between the hood and fender is aligned evenly the nozzle toward overall circumference of the hood when the hood 2 In order to protect the hood f
BODY center correctly 0 u Adjusting hood lock control lever operating force Q When the j t t r f j i j Mf control lever loosen the dove tail bolt dove tail CD bolt securing force of the nut installed length increase and reduce Tightening torque Dove tail bolt retaining d BF 19 @ retaining spring 15 to 2 5 Fig is excessive operating force Removing male side of t ehook lock Adjusting kg m nut 8 to 18 1 ft Ib 10 hood tightness When the hood is closed completely and t
BODY FRONT FENDER AND FRONT END CONTENTS FRONT FENDER Removal FRONT BUMPER BF 16 RADIATOR BF 16 OUTSIDE GRILLE BF 17 BF 17 MIRROR BF 17 FRONT FENDER I Front 2 Cowl top 3 Front fender sealer 4 Cowl fender ealer 5 Side dash board 8 Front bumper stay 6 Front 9 Front 7 pillar Front bumper 10 bumper side bracket Bumper side bl8cket shim top Fig BF 23 Fro7lt fend andfr07lt end componenrs Removal Open the hood the sake of safety lamp and side 2 Remove disconnect the
BODY OUTSIDE MIRROR Indicates outside mirror installing positions Fig BF 25 Removing front fender II FRONT BUMPER Dimen sions A B 817 29 5 161 1 c D E 27 to 6 to 27 8 6 2 dia Item Remove six bolts installed bumper stay to body and remove the front bumper from the body together I with the Round shape movable 32 2 25 0 9843 mirror bumper stay dia 1 063 to 0 2362 t 1094 0 2441 6 to Round shape irror 817 32 2 40 35 378 1 575 1 9 dia 0 3543 6 2 dia 0 2362 to 0 2441
BODY 100 13 9 1 In 100 13941 100551 lOOc 3 M 2 100 13 941 3 510 UI00M4 1 131111 87J l i J Q nO i2 104 O 142 diil HOLE 3 DOOO g 11 1021 13 348 450 171 71 78 1 BF 29 Fig Template for door mirror installation for left hand driven vehicle When installing round shape movable outside fender mirror tighten 4 to 0 5 kg 0 movement 174 to the nut to m 2 9 to 3 6 ft lb starting torque 65 1 tightening torque in lb so range from that fender mirror is in range from 20 to 75
BODY SEDAN AND COUPE @ 1 CD d @ @ 1 Trunk lid 3 Trunk lid weatherstrip 5 Trunk lid 2 Trunk lid lock assembly 4 Hinge fixing pin 6 Striker Fig BF 31 Trunk lid and hinge hinge assembly construction sedan striker position Adjusting stroke toward left and right TRUNK LID LOCK sides direction is 4 8 rom 0 1890 in and 8 rom 31 SO in toward vertical direction 0 Removal Loosen installation bolts and remove the striker and Coupe lock from the body 2 Remove the leaf clip loc
BODY TRUNK LID TORSION BAR The procedures of installing torsion bar are indicated follows as @ 2 Closed position Rotation center of J trunk lid hinge Trunk lid hinge 4 Trunk lid torsion I m I bar 5 Fig Note When inSUllling the tonion bar use a BF 32 J Rear waist connector torsion baT Installing special tool ST087100001 tonion bar wrench STATION WAGON OR VAN @ Back door hinge torsion bar t s Fig 2 Back door 3 Back door 4 Back door lock rod 5 Lock 6 Striker 7 Striker
BODY T Il l r I i Adjustment l 1 0 l Striker and lock 7 t O 1 f r The striker and lock engagement is T lJ The lock side is set When 8 adjusting striker shim r I adjusted at stationarity engagement toward vertical direction 1 6 rom the standard condition fa 0 0630 in one is used thick Under striker shim is used Adjusting stroke toward the horizontal direction is 6 rom 0 2362 in a Back door lock rod II Tightening torque Fig BF 34 Remvoing bock door lock rod Lock fIx
BODY In order the to secure the back door in the position adjust the following instruc in accordance with position plates opening closing force increases although the back door is that the back door @ Install two back door bumpers I on and therefore door no the positioning adjusting stroke is are I inside provided their inside contact surface is contact may be made at the outside Same bumper plates in mm adjusted 0 1575 in Outside Inside Inside bumper bumper plate and co
BODY BACK DOOR TORSION BAR A D Fig BF 38 Installing torsion bar may be set either from left Installation 1 Fully back door torsion bar open the back door I torsion bar to condition and set the hinge link and or right REAR BUMPER of Figure BF 38 Removal 2 Apply torsion a ST08710000 bar wrench to one end of the torsion bar from position II III to of the tool special Disconnect and hook it wiring bumper installation Figure BF 38 The and remove the for the license bol
BODY DOOR CONSTRUCTION 1 Glass 2 5 Weatherstrip Door panel Weatherstrip Weatherstrip 6 Seal 7 Door 8 Door bumper 9 Door glass stopper 3 4 t5 @ J V finish Drain hole Door rubber cover 12 glass Glazing rubber 13 Bottom 14 Outer channel moulding Door upper hinge Door lower hinge I Glus 2 3 Partition weatherstrip Partitionsaoh 4 Door y @ BF 24 rubber 6 1 Seal 8 Door finish 9 Door comer rubber screen II glass glass Outer moulding 12 Glass 13 Glazing 14 B
BODY 3 Removal door It is recommended that the door be removed from the body with the door follow the Hereinafter hinges attached on the door although on f Front door Remove the 2 Remove the door hinge service hole cover from the applying stand a door does not Note Apply a or opened support jack the door piece of rag between the door and stand the body side by the door from the use I so a BF 42 Removingreardoor Adjustment damaging hinge installation bolts of i J r D
BODY Fig 4J BF Adjruting striker Fig BF 44 DooT trim DOOR TRIM For both the front and rear doon the door trims may be removed and reinstalled in the same method Removal 1 When removing the door regulator handle lock inside handle escutcheon and arm rest remove their installation screws 2 When removing the ash tray outer ash tray and 3 The remove the installation case pull the screws door finish is secured on the door When removing the door finish remove with ill clips Ash tr
BODY 1 Door lock 2 3 Inside handle Escutcheon 4 Door 5 Knob grommet lock knob BF 47 Rear door lock mechanism Fig Front door lock removal Remove the parts up to the seal screen Remove 2 the door lock knob and then remove the remote control rod used to connect the door lock to the door lock cylinder from the door lock cylinder Remove the inside handle installation screw and the 3 door lock assembly installation the outside handle assembly on remove screws and withdrawing rod from t
BODY the outside handle rod 0 0787 to 0 1181 in If the nylon nut @ play @ is is provided positioned plate @ is does not intermesh with the ratchet knob depressed cannot handle rod 0 1967 at be locked is @ in to too low the the full ratch If excessive play 3 lock knob mm 3 locking completely and Hereinafter the screw handle the instructions for removal of the front door lock apply in stroke of the outside outside Remove the bell crank installation the locking plat
BODY 5 1 Rear door 2 Glass 3 Partition run panel rubber rear door weatherstrip 4 Rear door glass 5 Rear door comer 6 Glazing rubber 7 Bottom 8 Door BF 52 Rear door glass and regulator constructiorl channel window tegutator Door handle washer 9 10 Fig glass Door window regulator handle 4 door sedan Removal Remove the door trim and seal screen Remove the door glass to 3 Remove four door ventilator installation screws and glass stopper Pull 5 Remove three and lower t
BODY Installation regulator Insull the door glass and in roverse sequence of removal Reinstall the seal screen aftet correctly door adjusting window closing I C SIDE WINDOW Removal Remove the lock side window handle set pillar moulding and screws and remove the from the body side Loosen the side window 2 remove Side window glass Side window hinge 4 Side window handle 2 5 Handle 3 Side hinge 6 1 hinge installation conr shim Catch handle bracket screws Fig the side window
BODY 5 INSTALLATION It is important that the in be body windshield opening glass The be method which may used outlines below procedure the 6 for windshield rubber channel irregu any check entire With ment Note glass body opening flange for the aid of on pulled lips over first across across pressure adhesive type applicator seal inner and channel to glass with as an approved indicated in Figure BF 57 Seal completely around rubber channel irregularities any helper car
BODY VENTILATOR CONTENTS DESCRIPTION SF 32 COWL TOP GRILLE SF 33 DESCRIPTION In this body ventilation systeO air intake on the air is taken from the cowl top and ventilator on the front door and exhausted from the slip shape air outlets on rear pillar body side for coupe and side window Thus the passenger compartment is ventilated the J 4 door sedan 2 door sedan I Coupe Station wagon Fig BF 58 Ventilation system BF 32 or V an sufficiently
BODY COWL TOP GRILLE Loosen six self tapping screws and remove the cowl top grille from the cowl top panel together with the baffle plate The cowl installing first no and sticking Heater motor 5 Room valve 2 Fan 6 Ventilator valve 3 Heater 4 Shu t valve 7 8 Cowl core tighten four outside self unreasonable force is Moreover 1 top grille is made of ABS tighten inside self tapping screws be careful applied not to tapping to allow When two screws screws so the cowl tha
BODY Unhook the seat back at the 4 Removal rear bulk head upper portion Slide rail of front seat I Slide the lower rail toward remove rear side of the seat Rear seat and the seat frame connecting bolts Remove return spring 3 Slide the lower rail forward and rear Raising I rear side of the cushion stopper and 2 bolts from the coupe remove remove cushion seat pull out the cushion the seat rear seat the fIXing side Rear seat sedan I Remove from both sides of the two scre
BODY HEAD REST on rest on front installing head When plug OPTION the seat back seat remove and insert the head rest supports into the holes Fig BF 66 Removing rear i I i IJ IJI seat bock r I I f Reinstallation in Reinstall the seat cushions and seat backs I I reverse I Fig sequence of removal SEAT BELT BF 67 Head rest OPTION CO @ Fig BF 68 Seat belt installing positions BF 35 the i Ii i I
BODY INSTRUMENT PANEL CONTENTS REMOVAL SF 36 REINSTALLATION SF 37 REMOVAL Note When disconnecting mend to use the wlnng harness tags for identifing recom their relationship i f i 3 Disconnect cables for radio antenna 4 Remove the the shell and speaker I signal 1 ff 1 c II Cll package tray ii Note Work may be carried out steering wheel However without more BF 69 Removing instrument 2 Disconnect the battery cable Disconnect the wiring harness Disconnect the in
Remove three screws from 7 one and bottom each installation bolt from both sides of the two together R top of the instrument bolts Note the secure instrument panel with the steering column clamp Raising the rear side used to instrument of the vehicle and panel slightly pull remove Ensuring that all cables 1I e instrument are it toward it disconnected remove panel slowly and carefully REINSTALLATION Reinstall the instrument panel in reverse sequence of Fig removal BF 71 Remov
BODY For use those vehicles which do not pinar cloth fold at this line I B For A 2 door type vehicles fold pillar cloth at this line FOld and stick this portion B B A A A 0 c 0 The left side opposes the right side 0 00 t symmetrically Fig Note Be sure to apply pal before Installing windshield and center pillar cloth BF 7 J installing dath 4 door type vehicle 2 door type vehicle GG A 0 Detailed view t f BU for 2 door type vehicle First install the rear pillar on the body with sc
BODY SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or PAGE No SUBJECT No BF 39
BODY SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or SUBJECT PAGE No No BF 4O
SECTION BE BODY ELECTRICAL DATSUN 1200 MODEL B110 SERIES BODY CHASSIS I NISSAN I NISSAN MOTOR CO TOKYO JAPAN LTD WIRING BE 1 FUSE BE 6 LIGHTING SYSTEM BE 7 HORN BE 15 METERS AND GAUGES BE 18 WINDSHIELD WIPER AND WASHER BE 26 IGNITION SWITCH AND STEERING LOCK BE 29 CLOCK TACHOMETER BE31G RADIO BE 32 HEATER BE 34 BE 31
BODY ELECTRICAL WIRING CONTENTS WIRING Engine compartment harness I nstrument harness BE 2 Body harness BE 1 HARNESS BE 1 WIRING BE 2 INSPECTION 4 BE DIAGRAM BE 6 WIRING HARNESS The wiring harness is classified into engine compart ment harness instrument harness harness individual positions between indicated as installing and body locating positions the harness and The connecting individual wiring harnesses are follows Moreover for the body harness the positions differ mut
BODY Instrument harness Switch and control J c connecting unit Harness terminal in the engine compartment Fig I 2 Body 4 lnstrvment hamess BE Instrument harness room harness Body 3 harness Engine Fig BE 5 2 Body hamess BE 7 Fig 3 1 Body harness 2 Combination lamp RH Fig Wiring harness connections BE 8 Body harness Body earth sedma harness I j gl r 1 4i i Body To license SS hamc Combination lamp FiX BE 6 Body ham ss Fig I BE 2 BE 9 Un Body harness sedan la
BODY ELECTRICAL 2 75 3 1 2 Combination lamp To tank unit Fig BE I0 I RH Body 3 3 To license lamp BE II Body Tail harness 2 Wheel house BE 12 o harness Fig 1 Fig harness coupe Combination lamp LH Body Body harness Fig harness coupe BE 3 Body Tolicense BE 13 3 RH 4 Rear seat Body harness harness Station wagon and Van lamp Body o Tail harness harness Station wagon and Van
0 oo 9 D partS t Il i QlIt Indicator t Indicator t nd I 111 1 0 optlO 1 ght t IQ 9 h af beam i OUnd II wet1 teJf es ufe t o 8f ll Q if NeQltivO Ii itrutT UfO ltiO1llO lead Brl e o t ed pl o f q 1 Oi 1 fl 1 t U m iUJ COOE 1 i OR COI H O JE e E tE BLACK GRE N REO w 8 R ll G parte corect d tI J rJ I p IIl vt oc Jl tt n Ii 5 to and D
1 ElEC1R 600 CAl j a io a co 06 t d i S a i f aIll i a t p iJ te i c belil l O ig aO t Ul E t 1 11 g 3 co 3 o O G cr J l a 1 @ d fIIJ B b b IS W fig IIE didI fo os IlE f o l cM s I e
BODY INSPECTION Referring for harness 6 check the wiring diagram to connection with electrical the the wiring harness note the following wiring with clamped sharp that so corner they do nol checking 7 matters Cables should be securely in clamped positions sufficiently separated from rotating parts such Connected unit should be not loose come temperature of part or which rises highly equipment and connector for connection and installation When Cables should be in
BODY ELECTRICAL Green color link for model Note When 8 before cause b fuse is blown off be sure to correct the a Be sure installing to use Do not use fuse 3OA new fuse through fuse Moreover the rated having 20A having larger capacity i e d When etc Particularly when the fusible replace with a designated parison with fuse fusible much higher link i link fused ated In com BlIO important to eliminate the II fuse is is loose connected cause inoorrectly and of vo
BODY Aiming adjustment For aiming adjustment tester screen type tester an passengers except for the standard equipment spare tire aiming machine head light and other instruments are and tools used For the operating instructions of those instruments refer correct to the instruction manual ofthe instrument to be used lamp For the correct aiming the ground remove adjustment all loads such 1126mm Vertical and horizontal directions of the head are adjusted respectively with PASSING BEAM
BODY ELECTRICAL removing When the fear combination remove the socket from the lamp housing nuts and remove the combination Fig BB 21 Replacing side JI uMr p BE 22 Replacing license remove fixing lamp assembly o b Fig Fig lamp assembly BE 24 Removing rear combination lamp sedan lamp bulb REAR COMBINATION LAMPS When remove removing the bulb the socket from the turning lamp housing and remove Tail harness Combination lamp RH Body earth it counterclockwise the bulb from t
BODY BULB SPECIFICATIONS Specifications Item For other than Head s A and Canada U For U S A Canada lamp unit Main Dimmer 12V 50 40W 2 Front parking 12V 21W I Turn signal lamp 12V 5W Side flasher lamp 12V 6W 2 F P 12V 23 SW I T S Side marker lamp License 8W 12V 2 lamp 12V lOW I Sedan Rear combination Tail l2V Van Coupe 12V 5W 7 I 2 5W 7 lamp Stop I 2V 21 5W Turn signal 12V 21W 2 12V 23W 2 Back up 12V 21W 2 12V 23W 2 Room I lamp 12V IOW Figure encircled in 2 12
BODY ELECTRICAL IGNITION SWITCH FUSEM FUSE OIMMEfI IGHTING SWITCH TURN SIGNAL SWITCH SWITCH I UCENSE LAMPS 0 TAIL LAMPS fRONT PARKING 00 0 0 CAM LLUMlNATlON LAMPS LEFTSIDE Z 0 Fig BE 28 Circ it diagram for turn signal and LIGHTING SWITCH dimmer switch system HAZARD WARNING SWITCH 4 way flasher The hazard lamp system Removal consists of hazard warning switch and flasher unit When the hazard 1 Remove the connector from back of the lighting warning switch 2 simultaneously Depressin
BODY PASSING LIGHT SWITCH The passing light switch is of the turn signal switch main beams incorporated in the grip end Ie r and cootrob the head With either the lighting switch turned off the head lamp main beams will light while the witch button is pushed in lamp on or USE FUSE P T FUSE L DIMMER SWITCH I 0 2 L UCENSE S lAMl TAil LAIIPS F O PARKING PASSING LIGHT RELAY LIGHTING SWITCH 1 NATlON HEAD LAMP i RIGHT SIDE LEFT SIDE Fig BE 30 Circuit di4gram for passing Ught syste
BODY ELECTRICAL Main high beam When Defective dimmer switch red yellow cable red white cannot be switch nected ed to dimmer red black cable beam dimmer beam low beam or to or is con continuity or test and if the dim main mer switch is defec tive replace cable and the Conduct lights the circuit is normal The dinuner vice versa switch is defective Head lamps dim Head lamps when the is or Repair cable being about to break and required faulty contact faulty contact
BODY Faulty flasher unit terminal con tact or defective flasher unit When unit are flasher the turn and lead two signal the wires connected with switch turned on individual the lamps light of the the connector terminal or replace the flasher unit signal turn flasher Repair unit is defective Defective turn signal switch Conduct continuity test If the turn switch is signal defective replace All signal turn lamp do not Defective flasher unit Replace go the flasher
BODY ELECTRICAL Flashing cycle varies Faulty contact of power circuit from ignition windshield the When supply wiper Repair as required which uses the ignition for power switch to supply fuse is operated flashing cycle and brightness change Tail and back up stop lamp lamp license lamp Possible Method of causes inspection Troubles Both left right lamps not Remedies and Blown off fuse or faulty contact Check faulty do the fuse for fusing and the When fused dete
BODY FUSE H HORN BUTTON lBGI lHI H B S r 1 Ll I L Fig BE 31 J diagram for it CiTe HORN RELAY tom system HORN Removal Remove the connector loosen the fIXing nut in the horn center and remove the horn unit Adjustmen t I Secure the horn unit in a vise and connect cables as mown in Figure BE 32 Fig Note AMMETER When the Adjtuting BE lJ adjust screw i tom volume turned Clockwise Current increases Counterclockwise Current HORN 4 i VOLTAGE METER 115 to 2OV When a p
BODY ELECTRICAL TROUBLE DIAGNOSES AND CORRECTIONS Troubles The not does horn Possible Method of causes inspection Remedies Excessively discharged battery operate specific gravity Measure of electro Charge if required lyte Check the fuse for Blown off fuse fusing and im Replace fuse Check and proper contact Improper horn button contact The horn sounds relay terminal The Defective horn relay though the horn S is grounded horn sounds though the horn B terminals relay and 11
BODY METERS AND GAUGES CONTENTS CLUSTER LID BE lB OIL PRESSURE AND Description BE 18 IGNITION WARNING Removal BE 18 HAND BRAKE BE 19 BULB BE 19 TROUBLE SPEEDOMETER Replacement FUEL GAUGE AND LAMPS BE 20 WARNING LAMP BE 21 BE 21 SPECIFICATIONS DIAGNOSES AND CORRECTIONS TEMPERATURE GAUGE BE 22 BE19 Speedometer BE 22 Description BE19 Thermometer and fuel meter BE 23 Replacement BE 20 Oil pressure and ignition warning lamps BE 25 CLUSTER LID windshield wiper switch lighting
BODY ELECTRICAL SPEEDOMETER The is speedometer equipped with a FUEL GAUGE AND TEMPE RATURE GAUGE total odometer which records travelled distance Replacement 1 Description When removing the speedometer remove the cluster The fuel gauge consists of lid fIrst Separate the combination meter housing from the cluster lid after removing four recorder reset knob 2 Unscrew two screws and remove the fuel tank and fuel meter The tank unit detects fuel level trip with its float if any screws f
BODY r REGULATOR FUSE M TEMPE RATURE IGNITION GAUGE SWITCH GAUGE TANK UNIT I FUEL TANK THERMAL TRANSMITTER Fig BE 38 Circuit diagram for frul gauge and I Olt4ge temperature g Replacement pressure warning lamp which glows whenever engine oil pressure falls below 0 4 I Remove the cluster lid first 2 Unscrew two screws and Reinstall a new kg crn2 to 0 6 kg crn2 5 7 to 8 5 Ib sq in remove the thennometer or fuel meter from the combination meter housing 3 regultztor When the
BODY ELECTRICAL When the ignition switch is set to warning circuit ON the ignition is closed and current flows flows from the ignition switch to the warning lamp bulb and ground is started and the through the regulator When the engine comes generator current it the generator output flowing from the warning operation opposes the current in effect lamp into the breaks circuit warning service brake line pressure differential When a warning lamp difference between front and pressures r
BODY TROUBLE DIAGNOSES AND CORRECTIONS Speedometer Truubles The Possible and speedometer pointer odometer do not operate Improperly tightened speedometer cable union speedometer pointer de speedometer nut Damaged speedometer drive pinion Replace the drive pinion Defective Replace Rapidly speedometer Correct bent speedometer cable Damaged speedometer drive pinion Replace gear or Improperly tightened speedometer replace the pinion gear cable union Retighten union nut correctly
BODY ELECTRICAL Thermometer and fuel meter Method of Possible Remedies Troubles inspection causes Both thermometer Blown off fuse and fuel meter do nection not or improper con Check the fuse for fusing and improper contact operate after Replace recting the fused Correct cor if cause con tact Defective voltage regulator Dam aged fused or The voltage regulator operi contact is combined with the thermometer single to a unit When the voltage regulator is defective re
BODY The thermome Defective thermometer The thermometer a operate accu plied to rately yellow white cable ter does serviceable is 100 n resistance when not the is Replace if defective ap thermaItransmitter the cable is grounded and the thermometer indicates approximately SOOC 1220 F Defective thermaItransmitter When the thermometer is normal Improper cable contact The transmitter the above inspection through thermometer indicates lower temperature slightly the thermal Repla
BODY ELECTRICAL Improper cable The fuel meter indicates contact slightly lower than level a the actual Check the cable from the fuel meter leveL being about cable to break and contact poor the to for unit tank faulty grounding and repair Oil pressure and as ignition warning lamps Possible Method of causes inspection Troubles Oil pressure required Remedies warn ing lamp The lamp does not mown off fuse or faulty contact light when the Check faulty the fuse for fusin
BODY The not lamp does Inspect the charging system Faulty charging system go out when the is engine started WINDSHIELD WIPER AND WASHER CONTENTS Description BE 26 Wiper washer switch replacement BE 27 Wiper BE 27 Washer nozzle BE 27 motor replacement Wiper blade operating range BE 27 TROUBLE adjustment DIAGNOSES AND CORRECTIONS Description the The windshield wipers consist of wiper motor link arms unit consists of motor and autostop mechanism The wiper motor is of a speed
BODY ELECTRICAL Wiper replacement motor provide the L FiIst of all wiper 2 shaft compartment 3 the connector plug from the motor Remove wheel remove a nut used to connect to wiper connecting rod the side dash Reinstall 4 remove a new arm 434 36 wiper attaching a proper installation blade is angle so positioned correctly nut tightening torque f6 BE Remolling wiper is 60 5 that The cm kg 21i ft motor worm from passenger wiper motor panel Loosen three bolts
BODY Caution in Rashed range of washing solvent I use of washer Never operate the washer continuously for 30 seconds causes or without the washer washer should be s the Normally 48 BE Adjusting lI1dSher nozzle TROUBLE DIAGNOSES AND CORRECTIONS Troubles Wiper system does Possible not oper ate Open or Remedies causes short circuit of feed har Repair harness ness Blown off fuse improper fuse or Replace or correct fuse position contact Improper connector contact Defectiv
BODY ELECTRICAL Improper wiper Improperly positioned of position stop blade and Correct position arm arm Damaged worn or point stop auto Worn rubber blade Improper wiping Inadequate pressing force of Replace motor Replace blade Replace wiper wiper arm arm IGNITION SWITCH AND STEERING LOCK CONTENTS IGNITION SWITCH Rernoval BE 29 Description BE 29 Steering IGNITION SWITCH WITH BE 29 BE 30 lock replacement Warning switch BE 30 and warning buzzer BE 29 STEERING LOCK IGNIT
BODY mechanism is installed the key is set to Lock steering lock spindle which is the steering jacket tube on stationarily When and removed position the is inserted in a notch in the collar set the on sure attaching a screw on the to tighten two a new steering lock hear type self new screws to shear off their heads Warning The ignition switch is installed with be proper to lock the steering shaft steering wheel cylinder steering jacket tube When installing switch and
BODY ELECTRICAL CLOCK Installation upper portion of the instrument panel Connect red blue cable I When installing clock first of all remove the cluster nation lid lamp circuit board for illumination Ground the clock Remove the mask and install the clock on the cluster 2 lid in the 3 place meter from the clock ground cable housing installation on on for illumi the In the case of cable 4 along Fig cABlE BE 53 screw Reinstall the cluster lid BLUE CABLE Square type clock BE 54 R
BODY RADIO Removal I Remove the cluster lid 2 Disconnect the lead wires from the radio 3 Remove two nuts used to install the front side of the radio 4 on the instrument and remove the bracket used to install the 5 on 1 0 panel Loosen two screWs as shown in the radio Jtf 0 Figure rear BE 56 I side of the v I r 4 4 r r I I s r panel the instrument e Remove the radio 1 Power 4 e cable 1Otm 6 eS 2 Power 3 Speaker source prevention Run the engine chart raise t
BODY ElECTRICAL Secure ground of ignition coil Secure Distributor pole contact of carbon Eliminate excessive tip pole electric and rotor or on the rotor pole by scrubing with cap a screwdriver Check stagger between rotor and stator Charging system Install Alternator Sound of alternating current pre on sents 0 5 lF a capacitor charging terminal A Note not Do use capacitor ex is ex cessively If capacity used the alternator coil cessively will be broken When the accelera
BODY HEATER CONTENTS Removal and installation BE 35 TROUBLE DIAGNOSES AND BE 35 CORRECTIONS I I to 1 Heater hose 2 Qamp 3 Shut valve Vent valve 4 5 Room valve Defroster hose Defroster nozzle Control wire heater control to room valve Control wire heater control to water cock Control rod heater control to shut valve Heater cock 6 7 8 9 10 11 Fig 57 BE dter H Removal and installation 1 In order to ease the nit wires between water cock and heater control valve operation remove the pa
BODY ELECTRICAL heater unit on the dash board and remove the heater unit panel carefully 8 Remove two self tapping instrument 7 panel and remove screws from back of the the defroster nozzle When removing the heater control from the instru ment screws panel 9 the control knob and loosen two remove used to install the heater control on the instnunent The heater unit is installed in reverse sequence of removal TROUBLE DIAGNOSES AND CORRECTIONS Troubles Possible Remedies causes Hot a
10 0 BODY Vibrating noise Loose heater support Tighten completely Loose fixing Retighten screw SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or No PAGE No SUBJECT BE 36
SECTION SE SERVICE EQUIPMENT DATSUN 1200 MODEL B 110 SERIES CHASSIS INI BODY NI NISSAN MOTOR CO TOKYO JAPAN LTD SPECIAL SERVICE TOOL SE 111
SERVICE EQUIPMENT SPECIAL SERVICE TOOL B 110 special service tool set number SetA ST09330000 Set B ST09340000 510 special service tool set number means tool included in Tool Set ST09330000 means tool included both in Tool Sets ST09330000 and ST09340000 ST09IIOOOO II means tool included in Tool Set ST09l10000 Tool number Figure Tool Description 0 0 E t name mm inch l S M refer 0 0 o Applied model on ence page See Fig No lil Clutch tool ST206 I 0000 Clutch aligning For
CHASSIS go Tool number o Figure Tool name Description rnrn 0 0 M refer S So 00 Applied 0 00 model 00 ot inch l a ence Fig i page See No ST20105000 Diaphragm adjust F or measuring the dia BlO wrench phragm spring height B20 Fig CL7 Transmission tool ST22350000 BlO Main shaft bearing drift For assembly of the main shaft bearings B20 Fig TM 35 Fig TM 29 Fig TM 30 130 A30 ST23030000 Counter shaft bearing press stand For assembly of the BlO counter shaft B20 bear
SERVICE EQUIPMENT Tool number Figure Tool Description name mm Q inch 5 S M refer 00 g 0 0 l o t il 01 l Applied model t ence page See Fig No ST23S20000 F ark rod pin punch 30IS 21 For removal of the fork BIO rod retaining pins B20 Fig TM 16 Fig TM 18 Fig 4I TM Fig TM lS Fig TM 22 y ST23620000 510 For supporting the inter lock ball when installing F ark rod guide CIO BIO 820 the fork rod 521 C30 ST23820000 270 10 6 Setting plate Adapter setting plate of th
CHASSIS Tool number S M refer 0 gg 0 Applied 0 Description Figure Tool name Differential mm Q model u E inch ence page See Fig No carrier tool ST06220000 50 tting tool of gear 810 carrier Differential gear carrier attachment Fig PD B20 Use with engine stand ST30600000 BlO F or installing Drive pinion bearing pinion drift rear B20 the drive bearing inner 1 417 Page PO II A30 race 36 130 dia S30 SBl120000 Drive pinion armnge ment gauge For height adjustment
SERVICE EQUIPMENT i Tool number S M refer iio 0 g Applied Co Description Figure Toolnarne mrn inch u co OIl C l OU I 1 11 model fII ence page See Fig No snl 540000 Drive For removal of the pinion flange drive wrench pinion nut BIO Fig PD 12 B20 ST325oo000 Side bearing adjust weight 84 5 20 0 7871 3 dia r EJ 7 For determining the side 327 LJ IO bearing adjust shim BIO Fig PD25 B20 6891 Sn30lOoo0 BIO F or removing the dif ferential side bearing Different
CHASSIS Tool number g Figure Tool name Description mm 0 u 0 sg Q U E o inch S M refer Applied model ence page See Fig No ii ST3003 I 000 O B Drive pinion For removing the drive pinion rear bearing rear bearing inner replacer race inner B20 0 5 Fig PD IJ O C race C30 S30 Front axle and suspension tool ST353IOOOO Front wheel hub For removing and bearing installing outer race drift the front wheel hub bearings O B B20 Fig FA 22 Fig FA 32 Fig FA 34 ST3565ooo0 Ne
SERVICE EQUIPMENT Cii Tool number g S M refer 0 0 0 Figure Tool name Description mm inch Il 0 co Clot Applied model u ence page See Fig No E ST35550DOO Gland For assembly of gland packing packing guide the New Fig FA 39 New Fig FA 53 Fig RA 5 Fig RA 7 ST3672DOOO For Front transverse bushing replacer link the remving and installing transverse link set SUPPORT Rear axle and bushing GUIDE suspension 9 tool ST371300DO Rear axle shaft @ bearing puller ST
CHASSIS G Tool number 28 S M refer Go 0 A pplie d ence page c Description Figure Tool name mm inch v ou model o t CC1 I Y See Fig t No ST07640000 BIO For removing the axle shaft Rear axle stand Use with rear sliding hammer ST36230000 pitch 114 3 4 5 510 CIO Fig RA 3 Fig RA 7 C30 S30 di8 ST36230000 I Sliding hammer Steering 1 Use as sliding hammer by All the weight Fig RA 3 tool ST27 140000 Steering gear puller For removing and arm installing gear the st
SERVICE EQUIPMENT Tool number Figure Tool name 0 Description mm S M refer O iii 0 8 0 Q in i Applied model ence page See Fig Body tool ST087 I0000 Page For removing and install ing the Torsion bar wrench J e tail gate BF 20 torsion New bar SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or No PAGE No SUBJECT SE 9 BF 23 No
tII CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL or DATE BULLETIN No PAGE No SUBJECT SE lO
SERVICE EQUIPMENT SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or PAGE No SUBJECT No SE 11
I CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE BULLETIN or PAGE No No SUBJECT SE 12
I t t f F r f INISSANI 0 7 1 I j j i sf
