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DATSUN 1200
MODEL Bll0 SERIES
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CHASSIS AND BODY i
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TOKYO JAPAN

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S USRf N S
ROiNIJ ON
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WHEEL A ND I J

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EXHA1UST SYSUIM

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BODY HECTRIC l BE

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 FOREWORD

been the purpose

Thi5 senllce manual has prepared for of assi5ting serolce

personnels of our di5tributors and dealers for effective service and maintenance of
DATSUN 1200 model BllO series

Since proper maintenance and service are most essential to sati5fy our customers

this manual should be read

by keeping their can in the best condition carefully
should be noted utilization of this manual
The followings for effective

in this manual mainly concerning the model BllOU right

1 Explanations are

hand drive but will be referred also for the left hand drive models and
easily
for the version models

2 PleUje refer to both this and AlO A12 SERIES ENGINE SER VICE
ProCarManuals.com

MANUAL for complete details of the car because this manual describes

information concerning the chassi5 and body only

3 All name in this manual conform to DATSUN 1200 PARTS CATALOG

part
and only the genuine service parts listed in this parts catalog should be used for

replacements

illustrations and contained in this manlUll

4 All information specifications are

based available at the time of publication

on the latest product information
approvaL

5 It is emphUjized that those who use this manual revise the contents acconIing
to the SER VICE JOURNAL and SER VICE DA TA AND SPECIFlCA TIONS

issued the which carry the latest factory approved servicing method
by factory

6 alteration in and others at any time are reseroed

Rights for specifications

NI55AN MOTOR CO LTD

TOKYO JAPAN

j
 SECTION GI em
GENERAL
INFORMATION

DATSUN 1200
MODEL 8110 SERIES
ProCarManuals.com

CHASSIS BODY

I NIS NI

MODEL IDENTIFICATIONS GI 3

IDENTIFICATION NUMBER Gl 3

GENERA L VIEWS GI 5

GENERAL SPECIFICATlo NS GI 9

FINAL TRANSMISSIDN AND

GI ll
SPEEDOMETER RATIOS

RECOMMENDED LUBRICANTS AND

GI ll
PERIDDICAL MAINTENANCE

JACKING UP AND
LTD GI l1
NISSAN MOTOR CO TOWING THE CAR
TOKYO JAPAN
 GENERAL INFORMATION
ProCarManuals.com

Fig GI l 4 door Sedan

Fig GI 2 2 door Sedan

GI l
ProCarManuals.com

J Coupe
Fig GI

Van
Or
GI 4 Wagon
Fl

GI 2
 GENERAL INFORMATION

MODEL IDENTIFICATION

Vehicle model
Engine model Transmission Speeds Remarks
R H drive LH drive
Item

BllOU R3W56 3

F4W56 4
BllOTU LBIIOT
Q
BIIOAU LBl10A 3N71A 3

0 E BllOSU R3W56 3

LBIIOST F4W56 4
BllOSTU
J
3N7lA 3
BIlOSAU

BllORU R3W56 3

F4W56 4
BllOTRU LBllOTR

LBllOTRU F4W56 4 for CANADA

Q
LB llOTRN F4W56 4 for CANADA
0
0 Al2
BllOARU LBIlOAR 3N7lA 3
ProCarManuals.com

BI10SRU R3W56 3
j
E
S F4W56 4
J BllOSTRU LBllOSTR

R3W56 3
l VBIIOU

VLBIIOT F4W56 4
oll Q VBIIOTU

0 j R3W56 3
VBIIOSU

F4W56 4
J VBllOSTU VLBIIOST

KLB 110 F4W56 4

KBllOU
0

0 KLBIIOU F4W56 4 for U S A CANADA

u Q
F4W56 4 for CANADA
KLBIION

IDENTIFICATION NUMBER

The identification number is stamped on the instru base engine number and car number

and be from outside For U S A The body number plate is attached to the right side
ment panel can seen

The body number plate identifies the type of car cowl top panel
maximum horse SAE wheel
engine capacity power

GI 3
 I
I

CHASSIS
ProCarManuals.com

number
Fig GI 5 Identification for U S A
Fig GI 6 Chassis number location

l
fill
J

f 1
Y I

Fig GI 7 Body number plate

GI 4
 GENERAL INFORMATION

GENERAL VIEWS

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ProCarManuals.com

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L l6
KI l
l
6 gg 96v

G1 5
 CHASSIS

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ProCarManuals.com

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IC SZI OZL

169
a
OLI M
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0

M
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N

L il

GI 6
 inl
mm

UNIT

61 61

190
300
2
6251 0
3
ProCarManuals.com

Coupe
IO
GI
Fig

31 8
7
44 48

185146
1
125 240
1 1
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CHASSIS

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GI B
 GENERAL INFORMATION

GENERAL SPECIFICATIONS

Four Door Sedln Two Door Sedan

Standard Deluxe Standard Deluxe

BIIOSU 8110STU BIIOSAU BIIOU BllOTU BllOAU BllOSRU IIOSTRU BllORU BllOTRU BllOARU
Item
I LBIlOST
I LB I lOT LBllOA
I LBllOSTR
I LBllOTR LBllOAR

Overall length mm in 3 830 l50 S

Overall width mm in 1 495 58 9

Owrallheight mm in 1 390 54 7

c
Wheel base mm in 2 300 90 6
c

Length mm in 1 690 66 5
8
is
Width mm in 1 270 50 0
E
8
0 in 140
1 44 9
Height nun

Front mm in 1 240 48 8
1i
1 245 49 0
mm in
ProCarManuals.com

Minimum road clearance

70 67
mm in

Vchide wright 695 1 532 730 715 576

1 750 680 1 499 700 1 543 735
lb
kg
1 609 1 653 1 620

Naximwn peed 150 94 145 ISO 94 145 150 94 45

90 90 90
8 kmh lIPH

I I
Naxim wngrade bili ty
Jsin
0 398 00418 428
0 0 398 0 418 0 428 39g
0
10 418 0 398 OAI8 428
0

MiniwwrR turning radius

m ft 4 1 13 4

SeltillB capacity 4 5 persons

EqiN raodoI AI2

a
t try 1
OIt al aty 40AH
12V 50AH

Fuel ity
Ynkcapec
L U
J pi 40 IO g
Imp pi

Clutdr t lhy dUe Torque Dry ingledisc Torque Torque

Dry Jingle disc diaphJIlm spring converter
diaphrapn 8
pri COllWirter diaphngm spring converter

n
Tr lion
mil type R3W56 F4W56 3N71A R3W56
I F4W56 3N71A R3W56
I F4W56 R3W56
I F4W56 3N7lA

Final gear type Hypoid gear type

Steerilllpar type Re circulating ball type

E Front Drum Two leading type

Strriee
Ro lm
Dr Leading and trailiftg type
i rearwheeb
0 PIt Mechanically operated

Front Independent strut type with tension rods nd stabilizer

S
Ro Risid axle elliptic
semi leaf springl and shock absorbers

Front 6 00 124PR
Tire
6 00 2 PR

GI 9
 CHASSIS

For U S A 4Can2da
Model Wagon and Van

Coupe
Two door
Standard Deluxe Coupe
oedan

VHllOSU BlIOSTU YBllOU YBIIOTU KBllOU LBllOTRU KLBllOU

Item
I VlllllOST I VlJlIlOT KLBllO IllI HrrRN KLBllON

Overall mm in 3 86S 2
IS1 3 S10 I50 4 3 S30 ISO S 3 810 ISO 4
length
1 495 S8 9 1 51S 59 6 1 495 SS 9 I SIS S9 6
Overall width mm in

in 390
1 54 7 3SO
I 53 1 39O
1 54 7 3S0
I 53 1
Overall height mm
c

Wheel base mm in 300

2 90 6
c

e in 1 4SS SS5 620 63 8 1 690 66 5 1 610 63 8

u
Length mm 8e
IU88 pace
is
1 230 4
48 ce 1 270 SO O 1 170 SO O 1 270 50 0
E Width mm in luggage sp
0
0

in 815 32 5 1 075 42 3 1 140 44 9 Q1S

I 3
42
Height mm 8PIe space
l

in 1 240 48 8
Front mm

Re mm in 1 245 49 0

Minimum road clearance mm in 170 67

Vehicle weight kgOb 730 1 609 I 7S0 1653 710 1 565 720 1 587 1730 1 609
ProCarManuals.com

km h MPH 140 87 ISO 94 145 90

u Maximum speed
c

Maximum grade ability sin 8 0 372 I 0 417 I 0372

I 0 417 0 418
E
4 1 4
13
i Minimum turning radius m ft

5 persons or2 400 kg 880 Ib luggage 4 or 5 persons

Stating apacity

model AI2
Engine

12V40AH or 50AH
Battery volt capacity

38 10 8 40 lOll SJO 38 10 8 I
Fuel tank capacity l US SaI Imp gal I

disc
Clutch type Dry single diaphragm spring

Transmission type R3W56

I F4W56 R3W56
I F4W56 F4W56 F4WS6 F4WS6

Final gear Hypoid gear type

type

circulating
Re ball type
Steering gear type

e Front Drum Two leading type Drum Two leading type or Disc Annet type
Service
i Rear Drum Leading and trailing type
I

Mechanically operated ear wheels

Parking
rods and Itabilizer
Front Independent atrut type with tension
Suspension
Rear Rigid we elliptic
senti lear springs and shock absorbers

6 S 124PR ULT 6 I24PR

Front I24PR 0

Tire
6 lJO 114PR or S lJO 6PR
I2 ULT 6 00 124PR
Re

GI I0
 GENERAL INFORMATION

FINAL TRANSMISSION AND

SPEEDOMETER RATIOS

BIIOS U BllO S TU LBllOS T BIlOS AU

Model BllO S TRU LBllO S TR
BIIOS RU LBllOTRU
LBllOA

VBIIOS U LB llOTRN BllOARU

VBllO STU VLBllO ST LB IIOAR

KBllOU KLBllO
Item KLBllOU
KLBllON

Final gear ratio 3 900 3 900 3 900

Type R3W56 F4W56 3N71A

Control system Steering column shift Floor shift Floor shift

0 1st 3 380 3 757 2 458

5 0
2nd 1734 2 169 1458
E
e
3rd 1000 1404 1 000

4th 1000

Reverse 3 640 3 640 3 640

17 5 17 5 17 5
Speedometer gear ratio
ProCarManuals.com

18 5 for Van 18 5 for Van

RECOMMENDED LUBRICANTS AND

PERIODICAL MAINTENANCE
RECOMMENDED SAE VISCOSITY NUMBER

ENGINE OIL
viscosity
Multi
oils

5W 20

lOW 30 40
10W

40
2OW

Single viscosity oils

20W

20

30

lOW
OQ
GEAR OIL

SAE 80

SAE 90

SAE 140

30 20 10 0 10 20 30 0 Oc

22 4 I 32 50 68 86 104 OF
Temperature J
Ran Anticipated

GI ll
 z Ul S Ul

I 1 oo 1Zo1
1 o rc lDI o Ul

40
20W
40
30
140EP HD
Don
j

Don
SHEL 100
30
IOU
lOW
ShellSplf
l
90EP Spu
140
ATF Retinax
Shelzone
X X
90

Shel IOW Shel lOW 50 SOH Shel 80 Shel Shel Shel

MP HD HO
210
MOBIL Special GX 140
Super 20 AD 140 Free
30 20W SO 90 90 ATF Mobilgl
CaJe
Super FlUid Super FlUid
Mobil J IOW Mobil
40
IOW

Mobil lOW 40
30 Mobilue 80
EP Mobilue 90
80 Mobil Mobil Brlke Mobil Brake Mobil
40 Oil Oil

ENCO Unifo Extril 40

IOW
40

20W
Mol r 30
lO
Gear Gear Glide Mul t
H

u
Hydraulic 400
HD Hydraulic 400
HO GPeu rdm
Enco Enca Oil Enco lOW Enco 140
Enco 140 Eneo Eneo gre
Eneo Fluid Eneo FlUid
ES G 30
3D
90 90
Ruo 5W Elso Mot r IOW ES O Oil lOW 50 Ego GP 80 Ellu GX 80 Euo Euo pUr Ole Easo Brake Ellu Brake Atlas
Vis 3D 0
40
140EP Oil L2 Flul
V
lOW
3D Energre
ue Fluid BraOillte frost
ProCarManuals.com

Oil
90EP
HypOgClI Unlvca Autnl 140
DP

Super
DP costalie
20 50
SW lOW
Enerzel lOW
DP
lOW
Gear
BP 80EP DP
90
80 DP DP
Brake
BP BP
Anti
BP

50
3D Brake
40
XL20W 20 B

Amber frcuc
CASTROL lOW
GTX20W 20W
Hypoy Hypoy W
Girtng FlUid Anti
CltroGing FlUid
50 T LM

Culroite Culro Castrol CastrolHD IOW

SW
40
30 Casln
90
80 Castrol
90
80 Castrol l rol
c Castrol Clutch CnmlOn
l Brake Culro
40
69 1
Star 40
Oil 30 Thuban 4571A purose Purpose Co lan
CALTEX Five 20W Mot r lO
Thuban 140
FlUid
Multi All
HD

FlUid
Multiproe
Oil
Star lOW fre 4
Texamtk Texamtic
3D

Custom Mot r lOW Five lOW Unlvea 90

80 EP 80
90
Marl k Marf k Brake Antl marked
oils
40
Mot r Mot r Gear e
ute

Service
3D

Special to
mOl 400
Suprem 20W40
HD and
CHEVRON SpeCial
la

lOW Multi Lubrlcan Umvenal

140 140
ATF Multi Extu FlUid fre ze pernuiblc
Lubneat
3D 10 90
RPM Oil IOW RPM Oil lOW RPM Gell 80 RPM 80 RPM RPM Greue Atlu Brake tIasPermaGuard
A Anti Co lant it

HI
40
69 1
Oil 30
Lubricant purose Purpose Co lant avilabe
TEXACO Mot r
40
20W

MotlOi 20W lQ
140
FlUid 4571A
Multi
Super e

be

UmvenalGc Lubncal EP90 1I

oline Ge
All FlUid Fre z
Texamlic Texamtic
3D not
H IOW Hlvoinc lOW EP80 Multi EP 80
90
Mar k Marf k Brake Anli oill
of

048
TypeF I0924 Clutch brand
srade
J

Multi MI APIMS
L
ular
Re
2104B
L

MIL
PotS
API
l10S
L

MIL API
4
GL 2105B GL
L

MIL API
S

3N7IA Grease Brake 70R3

MIL
Q
ol
BraOike l
70R3
COLANT e
abol

the
a
3ll iis
I
F

T
purose 2108
Q 5 Ul
FREZ Should
0 Ul z i
JZ Ul 0 Ul
A

Multi MIlrG ANTI

l
G
 m Zm lC r z o lC oz

3 ZI 1 ZloZ o1
1 oI lotl I

X X X X X X X X
100 60 X R X X X

X X X
95 57

X X X X X X X
90 54

R X X X X X X X X
X X
50 30

X X X
45 85 27 51

INTERVAL X X X X X X X X X X X
X
40 80 24 48

X X X
35 75 21 45

X X X X X X
30 70 18 42 X

MAINTEC
ProCarManuals.com

X X X
25 65 15 39

X X X X X X X X X
20 60 12 36

X X X
15 55 9 33

X X X X X
10 6 X X

1
3

0
X

X
X

R
X

X
Replacmnt
R

kilometrs miles level necsary

necsary
if

of oil up
gear top

t h o u s a n d
if

POINTS
up
level
of
diferntal fluid b r a k e
disc drum
brake heel bushings top
level joints
Number C
L
eam
inkage pedal oil
joints grease joints
transmio transmio
ball

LUBRICATNG
L

res voir res voir shaft linkage box

water water operatd gear linkage ball
bearing shaft

distrbuo acelrto
oil
brake
engine check or
necsary automic
if
fluid
brake brake
fluid
co ling co ling foot
hand ste ring ste ring supenio whel proel r
Change Change top
up
Check Refil Refil Change Change Grease Lubricate Lubricate Grease Check Grease Grease Repack Grease
Gl w
 nX g

X C
X
X
X I
I

X X
I

I
I

X X
X
X
X

X X L X
X
X
X
J M
X
X X

30
X
L X X
X

27 M X
X
X
X X

I
INTERVAL 24

21 d
X

X X
X
I
X X X
X X

18 g

MAINTE C
X X
X
X
16
X
ProCarManuals.com

X X

Replacment
12
X X
X
X X
X
9 X
X
X X
X
6 R
X X
X X
X
3 X
X X

w
miles
o

TS
p
AOAl
dCA w M

SERVICE A
US
o
ww
m

oo
M wreN
GIIlE 0 cl

E
o
o
M
A
c
I II

o
 m Zm r Z TI o oz

X X X X
100 60 R R X X X X X X X X

X X X X X
95 57

X X X X X X X X X
90 54

X X X X X X X
50 30 X X

X X X X X
45 B5 27 51

INTERVAL 40 BO

35 75
24 48

21 45
X R

X
R

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
30 70 18 42

MAINTEC 25 65 15 39 X X X X X
ProCarManuals.com

R X X X X X X X X X X X X
20 60 12 36 R

X X X
15 55 9 33 X X

Replacmnt
X X X X X X
10 6 X X X

5 3 X X X X X X

6
1 X X X X X X X X R
0

kilometrs miles SYTEM

of leaks
for I

POINTS CAND thousand CONTRL

V
C
nuts etc P

lo se
points operation
of

Number EMISON elment

manifold conetis for

SERVIC and
A
S
WITH cleaner plugs
break r strainer
fuel
and
bolts timing pi ngs
leaks
water gravity conetis
for

valves
distrbuo
U

type head igniton cables tension and

ENGIE For air

EQUIPD carbueto spark

filter c y l i n d e r c l e a r n adjust tension belt
idling hoses oil
for specif pi n9 control
cartidge valve up
replace replace
or or
oil
and high engine tune fuel
fan
line
engine batery hose emis on
ENGIE Replace Check Check Replace Replace Retighen Adjust Check Check Check Adjust Engine Check Check Check Check Check

G
 x fl fl

X X X X X X X X X
100 60 X X X X X X X

1
I
X X
95 57

X X X X X X X X
90 54 X

X X X X X X X X X X X
X
50 30
I
X X
45 85 27

INTERVAL 40 80

35 75
24 48

21 45
X X

X
X X X

X
X X X X X X X X

X X X X X
X X X X

MAINTEC
30 70 18 42

X
25 65 15 39 X

X X X X X X X X
X X X X X
20 60 12 36
ProCarManuals.com

X X
15 55 9 33

X X X X X X
10 6 X X X

5 3 X X

6 X X X X
1 X X
0

kilometrs miles
POINTS of

pi ngs wear
for bolts
thousand hoses discs linkage
positon angle flange
SERVICE of

Number play cylinders defcts

or

drums
asembly parts
and
box
load whe l turni g joint

BODY Iree or
operation caliper
absore
gear pre rotae
and
universal
pedal sy tem leaks brake
brake braKe for
liners
and
pads cylinders shock
s u p e n i o ste ring bearing dam ge
for
and
alignmet shaft
aimng
hand lin gs brake whe l discs bal nce whe l
retighen retighen proel r light
CHASI
etc
brake
clutch clutch foot brake disc hydraulic and and front whe l whe l front head test

Check ChecK conetis Check Check Check Overhaul Check Check Check Adiust Check Check Check Retighen Check Road

C a
 GENERAL INFORMATION

LUBRICANTS CAPACITY

U S A
Liter Imp
measure measure

Sedan 40 L 10 1
gal 8
2 3 gal
Fuel tank
Coupe Wagon Van 38 l 10 gal 8 3 8 gal

with heater 4 9 l 53 5
16 qts 4 16 qts
Cooling system
without heater 4 2 l 47 16qts 3 11 16 qts

Oil pan 2 7 l 2 7 2 3
8 qts 8 qts

Oil filter 0 l
54 I 1
pints I
8 pin Is

Manual 2 l
1 2 2 1
Transmission case
2 pints 8 pints
Automatic 5 5 l 5 7
8 quarts 4 7 8 quarts

Differential case I 0 l
75 I 15 8 pints I 3 8 pints
ProCarManuals.com

JACKING UP AND TOWING THE CAR

JACK UP JACKING UP AND POINT TO BE

SUPPORTED WITH STAND

Pantograph jack Jacking up and point to be supported with stand

Apply a j8ck to the indicated position where Jange

sill Note B When operation Carried out with the vehicle
s
is embossed for identification
jacked up be sure to support the vehicle with
Do not jack up other position stand s

b When applying stand s to the be sure to

body
use a piece of cloth wood between the
or
body and
stand s

Front side

When jacking the vehicle

up apply a garage jack

J
beneath the front suspension member When applying the
jack be sure to use a piece of cloth or wood between the
of jack and front suspension member Be careful not to allow
the jack coming into contact with the steering cross rod
JACK

JACK UP POINTS located behind the front suspension member When

supporting the vehicle with a stand apply the stand to

front portion of the front side member

Fig GI IZ
JQking up point

GI 17
 CHASSIS

Fig GI tJ Front jacking point Fig GI I5 Rear jacking point

ProCarManuals.com

Fig GI 14 Front supportable point Fig GI 16 Rear supportable point

Rear side TOWING

When jacking up the rear side of the vehicle apply a

garage jack beneath the rear axle housing Forward

When removing and installing the rear axle housing

etc support the rear cross member with stands In When towing the vehicle forward apply a
rope to the
spring
other cases support both ends of the rear axle housing notched portion of the tension rod bracket In no event

should a rope be applied to the transverse link

with stands

GI IB
 GENERAL INFORMATION

GI 17 Front Fig GI 18 Rea towing point

Fig towing point

Rearward
ProCarManuals.com

When towing the vehicle rearward apply a rope to the

rear shackle of rear spring

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No

GI 19
 CHASSIS

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No
ProCarManuals.com

GI 20
 SECTION ER

ENGINE REMOVAL a
INSTAllATION

DATSUN 1200
MODEL 8110 SERIES
ProCarManuals.com

CHASSIS BODY

I NISSAN I

ENGINE MOUNTING ER 1

ENGINE REMOVAL
U4
Nt SSAN MOTOR CO LTD AND INSTALLATION
TOKYO JAPAN
 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
ProCarManuals.com

s
@
l1J

ER 1 Structural view of engine mounting

Fig

This engine adopts the same engine mounting method FRONT ENGINE MOUNTING
as A IO The strength ofoverall engine mounting construe
Removal
tion however has been increased in response to the

increased engine weight and engine output Consequently t the with wire or chain
Suspend engine
the parts used for engine mounting are not inter

changeable with those for the A 10 although their shapes 2 Loosen the front engine mounting insulator upper

and constructions are similar nuts both sides

ER l
 CHASSIS

3 Make that the wire chain used to suspend the 2 the side bracket differs from that of
sure or
Shape of right
engine is positioned properly that no load is applied to the left side bracket
SO Tighten the bolts and nuts correctly
the insulators and the nuts
remove completely and securely

4 Lift up the engine and separate the insulators from

the engine mounting brackets

Tightening torque
Itl kg m ft Ib

vf Total foor each for 1 6 to 2 1

I
Bolt CD@
both sides 116 to 15 2
l J
r IV Total four each for 0 9 to I 2
I 1

b
Nut @@
both sides 6 5 to 8 7
r o
0

J
A
I J J I

ii j
l
l
@ @
l n
0 H
ProCarManuals.com

Fig ER 2 Removing front mounting

Reinstallation
f8J
Reinstall the engine mounting insulators in reverse
@@
sequence of removal noting the following matters
@

Both the left and right engine mounting insulators

are used commonly However when them
installing pay
Fig ER 4 Front mounting installation
attention on their upper and lower directions When they
installed correctly the is
are positioning pin projected
downward

REAR ENGINE MOUNTING

Removal

Support the transmission with other proper

a jack or

stand so that the does not drop down

engine

2 Remove the mount member installation bolts Now

FRONT CROSS MEMBER
the engine can be separated from the body

3 The mount member is provided with an opening for

and installing operations Remove the nuts and
removing
Fig ER 3 InsUlatOT installinR position separate the insulator from the transmission

ER 2
 ENGINE REMOVAL INSTALLATION

Tightening torque
kg m ft Ib
Nut @ 0 6 to 0 8

mount member insulator 43 to 5 8

Nut ID@ 1 9 to 2 6

transmission insula tor 13 7 to 18 8

Bolt j@ 3 2 to 4 0

mount member body 23 1 to 28 9

Fig ER 5 Rear mounting

4 Remove four bolts and the insulator from

separate
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the mount member

engine

Reinstallation

Reinstall the rear engine mounting in reverse sequence

of removal noting the following matters Fig ER 6 Rear mounting installation

2 Carefully arrange the front and rear directions of the

I Tighten the nuts and bolts and when installing

correctly securely rear engine mounting

tp
Lp

FRONT

FOR MANUAL TRANSMISSION FOR AUTOMATIC TRANSMISSION

Fig ER 7 Rear mounting sp cjfications

ER 3
f

CHASSIS

ENGINE REMOVAL AND INSTAllATION

CONTENTS

PRECAUTIONS ERA INSTAllATION ER 6

REMOVAL ER 4

PRECAUTIONS tor

L Be sure to fender Cable to the thermal transmitter

use cover so that the body is not

damaged Cable to the oil pressure switch

Cable to the primary side of the distributor

2 When lifting the engine or when jacking up the
Cable to the starting motor

engine pay attention for safety and carry out operation Fuel hose
correctly so that the parts are not damaged
Cable to the alternator

Heater hose for model with heater only

REMOVAL Wires for accelerator and choke The operation will be

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carried out more easily by removing the air cleaner

I Removing hood

I
Open the hood remove four installation bolts and IlO
remove the hood
1 lfti
1
P
c
i
l
j

r 0

t1
t

2 Disconnect the cable from the terminal y

battery

3 Removing radiator
f dJ Ie

CI
j
f I
Drain water from the radiator disconnect two radiator t

hoses remove four radiator installation bolts and remove i k

fI
the radiator 7
I1
0
I
D u 1

ER 9 side of engine compartment

Fig Right

Fig ER 8 Removing rculiator

4 Removing cables and hoses

Disconnect the following cables hoses and wires

High voltage cable between ignition coil and distribu ER tO

Fig Leftsideofenginecompartment

4
ER
 ENGINE REMOVAL INSTALLATION

5 clutch wire on right hand drive model

Disconnecting
On left hand drive model disconnect hydraulic line from

the clutch slave cylinder

the clutch wire at the of the
Disconnect portion
withdrawal lever See the section covering the clutch

6 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

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remove the shift rod

II Sospend the engine with wire

Fig ER l1 Disconnecting clutch wire

7 Disconnect the cable to the back up lamp switch

8 Disconnect the speedometer cable

9 Remove the propeller shaft

Remove four bolts used in the differential carrier side

and withdraw the propeller shaft

Fig ER 13 Removing remote control rod

10 Remove the shift lever

front installation
Model with remote control shift lever
12 Remove the engine mounting
nuts
Disconnect the remote control rod at the portion of
transmission outer lever and remove the remote

control rod
13 Remove the fear engine mounting installation nuts

Model with floor shift lever

Remove the boot withdraw the lock pin and remove

the lever The operation is carried out in the passenger 14 When removing the engine mounting installation
nuts be sure to apply a jack beneath the transmission
compartment

ER 5
 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

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SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No

ER 6
 SECTION CL

CLUTCH

GI

DATSUN 1200
MODEL B 110 SERIES
ProCarManuals.com

CHASSIS BODY

INI NI

CLUTCH CL 1

CLUTCH CONTROL CL 5

SERVICE DATA AND

CL 12
SPECIFICATIONS

TROUBLE DIAGNOSES
CL 13
NISSAN MOTOR CO LTD AND CORRECTIONS
TOKYO JAPAN
 CLUTCH

CLUTCH

CONTENTS

CL 1 Disc assembly CL 3
DESCRIPTION
REMOVAL CL 2 Release bearing and sleeve CL 3

DISASSEMBL Y CL 2 REASSEMBLY CL 3

CL 2 Release mechanism CL 3
INSPECTION AND ADJUSTMENT
CL 2 REINSTALLATION CL 5
Clutch assembly

DESCRIPTION
The clutch is a single dry disc diaphragm spring type engagement
clutch The major components are clutch cover pressure Release bearing sleeve and withdrawal lever are used

plate diaphragm spring and wire rings The clutch disc is to control clutch engagement and disengagement
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provided with riveted plates on both surfaces and coil Each part of the clutch assembly is secured with rivets

in The coil absorb shock Therefore when trouble is uncorrectable replace the
springs arranged a link springs a

while engaging the clutch softening and smoothing clutch clutch assembly with a new assembly

93 53
30
03M O
0 1810 3 682

33

ft
g

00
r
l
Ii CDr
r
o
o
o

ci to D

S q
N
lt
o It

t
10 1

If 11
TIGHTENING TORQUE 15 to 2 2 kg m
10 8 to15 9 ft Ibl

Unit rnm in

Fig CL 1 Constru ction of clutch

CL 1
 CHASSIS

REMOVAL

The clutch is dismounted in the

assembly primarily
same manner as the engine assembly Thus when dis

mounting the clutch assembly refer to the Section TM

Transmission Removal and other relative sections

Fig CL 3 release mechanism

Disassembling

3 Withdraw the release bearing from the bearing sleeve

by the use of a bearing puller

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o Clutch assembly
I I Clutch di5C assembly

Fig CL 2 Clutch assembly and disc assembly

DISASSEMBLY

When separating the clutch assembly from the

flywheel loosen and remove the installation bolts diago

nally and gradually

Note When separating the clutch assembly from the

support the clutch

flywheel cover sufficiently
loosen the installation bolts gradually and carefully
and
lIj Release bearing
o Bearing sleeve

because the Fig CL4 Withd awing ease b ing

diaphragm spring tension is always

applied

INSPECTION AND AD
USTMENT
clean all disassembled parts
Thoroughly except for
2 Removing release mechanism disc assembly and release bearing and check them for
I Remove the dust from the clutch
cover housing wear crack and other defective conditions

2 Remove the return spring from the bearing sleeve

Clutch assembly
and separate the withdrawal lever from the bearing sleeve

3 Remove the release bearing and bearing sleeve from I Check the clutch cover diaphragm spring pressure
the front cover and remove the withdrawal lever from the plate etc for excessive wear crack and damage When
withdrawal lever ball pin noise occurs on the clutch assembly replace

CL 2
 CLUTCH

2 Measuring and adjusting height of diaphragm spring 4 Adjust height of the diaphragm spring by the use of

adjusting wrench special tool

1 Line up distance piece tool ST20059001 diaphragm spring
special
ST20l05000 if required
on clutch assembly base plate special tool ST20101000

SJ200596o 1

Fig CL5 Base plate and distance piece Fig CL 7 Adjusting diaphragm spring height
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Disc assembly

2 Place the clutch assembly on the distance piece and I If the facing is soiled with grease or oil clean off

with and dress the facing with a

set the clutch assembly on the base plate stationarily gasoline tetracWoride
if
Under this condition the distance piece is placed beneath wire brush Replace the facing required
the pressure plate
2 Check the disc for deflection and repair or replace if
the deflection at the outer circumference of the facing
3 Measure the diaphragm spring height from the upper
exceeds the foUowing value
surface of the baseplate with vernier caliper depth gauge
end 29 0 31
Height of diaphragm spring to mm

limit of the deflection

142
1 to 1220 in at diameter 62 mm 441
2 in Upper
0 5 mm 0 0197 in at

85 mm 3460
3 in radius

29 0 to 31

62 2 441

t
BASE PLATE

Unit mm in

CL 8 disc for de ction

Fig CL 6 Measuring height of diaphragm spring Fig Checking

CL 3
 CHASSIS

3 Replace the disc assembly if the facing is worn to bearing sleeve as shown in Figure CL IO When the bearing
such an extent that the facing height above rivet is less is installed completely turn the bearing with a
finger and

than 3
0 0 0118 in the unevenly make that the bearing operates smoothly
mm
facing is worn or sure

rivets are loose

2 Apply multi purpose grease to the following places

Bearing sleeve inside groove

Pack this recess

e
Fig CL9 Checking tehfacing lOT
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Release bearing and sleeve

Fig CLl1 Lubricated position the sleeve
on bearing
1 When withdrawal lever and bearing sleeve contact

is worn in the sleeve Withdrawal lever and bearing sleeve contact point
point step replace

Withdrawal lever ball

2 When grease leaks from the release bearing or noise pin and withdrawal lever

contact surface
occurs on the release bearing replace the release bearing

Fig CIA 0 Fitti g release bearing

G Withdr aI ball pin
G Withdrawallcwcf

CL12 Position tM withdrawal kver to which

Fig 0

grease is applied

REASSEMBLY 3 When grease is applied to Ihe necessary places install

the withdrawal lever release bearing and sleeve
Release mechanism bearing
on the clutch housing connect them with return spring
I fit the release
TighJly bearing to the place on the and install the dust cover on the clutch housing

4
CL
 CLUTCH

A
A JI
f

C
U
J
J1
L
1 II

I
t
l
bearing

ITI
Withdrawall r Rei
2 Return spong

CL13 release mechanism

Fig Installing

REINSTALLATION

Clean the clutch pilot bushing and fill it with

multi purpose grease

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1 Flywheel 3 Clutch disc as mbly

2 Install the disc assembly and clutch assembly on the
2 Clutch assembly
the use of special tooi clutch aligning bar
flywheel by a

ST206l0000 Fig ClrJ4 Installing disc and clutch assembly

CLUTCH CONTROL

CONTENTS

5 Removal CL 9
DESCRIPTION CL

PEDAL Disassembly CL 9
CLUTCH Hydraulic clutch CL 6

Removal CL 6 Inspection CL 9

CL 6 Reassembly CL 9
Inspection
Reinstallation CL 6 Reinstallation CL 10

OPERATING CYLINDER Hydraulic clutch CL10

Ad just men CL 6

Removal CL 10
CLUTCH PEDAL CLUTCH CONTROL

Disassembly CL 10
CABLE Mechanical clutch CL 7

Inspection CL 10
Removal CL 7

CL 7 Reassembly CL 10
Inspection
Reinstallation CL 10
Rei nstallation CL 7

Adjustment CL 7 ADJUSTING WITHDRAWAL LEVER CL 10

CLUTCH MASTER CYLINDER BLEEDING CLUTCH SYSTEM

CL 11
Hydraulic clutch CL 9 Hvdraulic clutch

DESCRIPTION
consists of
The B 110 series vehicles with left hand steering wheel The hydraulic type clutch control system
and right hand steering wheel respectively adopt hydraulic pendent clutch pedal master cylinder operating cylinder
and withdrawal lever The withdrawal lever is of an inner
type and mechanical type clutch control systems

CL 5
 CHASSIS

fulcrum type I Pedal head rubber

2 Re turn spring
The mechanicai type clutch control system consists of
clutch control cable and with 3 Pedal lever bush
pendent clutch pedal
drawallever The withdrawal lever is of an outer fulcrum 4 Fulcrum pedal pin etc

type which provides a great lever ratio and thus force

Reinstallation
in depressing clutch pedal is reduced
required
Reinstall the clutch pedal in reverse sequence of

clutch removal
CLUTCH PEDAL Hydraulic
Removal Adjustment
I Remove the return spring 143 5 5 65 in
I Adjust pedal pad height to mm

without stopper The adjustment is made by selecting and

Loosen the lock nut of the master cylinder rod
2 push
applying shim s having adequate thickness
and disconnect the push rod end
Be sure to use shims having same thickness for both

3 Remove the lock nut and washer of the pedal shaft

upper and lower
and remove the pedal lever
2 Next adjust the pedal stopper properly so that the

is 141 5 mm 5 57 in and secure the

pedal pad height
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Inspection
position with lock nut
Thoroughly clean all disassembled parts indicated

below and them for wear damage and Nota Make sure that chassis grease has been applied to
carefully check
if
other abnormal conditions Repair or replace them with the CGI marked portions two placesl Grea

new ones if required required

Adjusting shim

Part number Thickness mm in

30611 27260 16 0 0630

Outen peW tree t
3061227260 0 8 0 03 I 5
30 mm 181
1 n

30613 27260 5
0 0 0197

1 Adjusting shim
2 Pedal lever

3 PedaJ stopper

@ Chassi5gfeee

Unit mm in

Fig CL 5 Pedal height wj1lStment

6
CL
 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

t
IPn I
j
C1
i
i
i j rl 2
I
Return

Fulcrum
pring
pedal pin J
Clutch pedal

1 0 Fig CL 18 Removing pedal instaUation bolt

1 r
1
4
r7ce
i
1 f

r iil 7 Inspection
f

5 3
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Thoroughly clean all disassembled parts indicated

l t

i
IJ
m below and carefully check them for
other abnormal conditions

I Control cable
Repair or
wear

replace
damage and
as required

Adjusting nut
0 Lock nut 2 Pedal head rubber

3 Pedal lever bush

Fig CL16 Clutch cantrol cable
Fulcrum
4 pedal pin
5 Others

Reinstallation

Reinstall the clutch pedal and clutch control cable in

reverse sequence of removal

Adjustment
Withdrawal lever Clutch control cable that is in
I Adjust the pedal stopper so pedal height
139 5 49
5 in to 143 5 5 65 in
range from mm mm
Fig CL 17 Disconnecting clutch control cable
and secure the position with lock nut completely

2 Next the control cable adjust nut so that

adjust
clutch pedal is in range from II to 15 mm 433
0 to
play
0 591 in at the center of the clutch pedal pad and make
2 Unhook the clutch pedal return spring
that P of the is in
sure play at point withdjawallever
3 Remove the clutch brake pedal installation bolts and range from 3 0 to 4 0 mm 0 1181 to 0 1575 in Secure

remove the clutch pedal and control cable the alignment with lock nut completely

CL 7
 CHASSIS

Note Connect the control cable correcdy that mark

so applied to the CG marked positions three

cap is faced upward as shown in the following places Apply urease if required
figure Make sure that chassis grease has been

r
A3

1 300R

I
0
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I i dal play 11 to 15

I 0 433 to 0 5911
fO
eJ P point end play
I fed8
2
2
1
A
3 0 to 4 0
ChaSSiSgreaSe O llSl to 0 1575
1 139 5 to 143 5

3
Lock nut

Adjusting
Pedal
nut
I 9 to 5 65

stopper L

Unit in
mm
I
Fig CL 19 Pedal height adjustment

3 When the clutch pedal is heavy remove grease filler

cap from front portion of the adjust nut and grease Be

sure to use grease containing molybdenum disulfide

Fig CL 20 GrNSing to the nippk of clutch

control cable

8
Cl
 CLUTCH

CLUTCH MASTER CYLINDER Hydraulic clutch

V
@L 9
W
aj

1 Snap ring
2 Dust cover

6
3

7
Pushrod
Clutch

Piston

Inlet
piston
spring
valve spring

Inlet valve
i
L
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8 Spring retainer

9 Shim
pin

t
10 Inlet valve release

11 Body
12 Oil re rvoir
13 Oil reservoir cap

Fig CL 21 Clutch master cylinder

1 Check the cylinder and for uneven wear or

Removal piston
damage Replace if required
Disconnect the push rod from the clevis
2 When clearance between the cylinder and piston is

more than 0 15 mm 0 0059 in replace the cylinder

2 Disconnect the clutch line from the master cylinder
3 the primarily whenever the
and drain fluid Replace piston cup

is disassembled It must also be replaced

master cylinder
3 Remove the securing bolts and remove the master deformation due damage is
when wear or to fatigue or

cylinder assembly from the vehicle found

4 Check the dust cover oil reservoir filler cap and

Disassembly line deformation If abnormal
clutch for damage or

I Remove the filler cap and drain fluid condition is found replace with new one

2 Pull back the dust cover and remove the snap ring
The stopper push rod piston assembly primary cup and Reassembly
return spring assembly can be removed in reverse
Reassemble the master cylinder as mbly
the following matters
sequence of disassembly noting

Inspection The piston cup should be soaked in brake fluid

clean all before reassembly Install the piston cup carefully so that
Thoroughly parts with brake fluid before

inspection it is correctly faced

CL 9
 CHASSIS
2 Apply brake fluid sufficiently to the and
cylinder Inspection
pistoo and assemble them
Chedr all pam especially the piston and replace
cup
if worn or damaged

Reinstallation

Reinstall the master cylinder assembly in reverse

sequ nce of removal and adjust as follows

Reassembly
I the
Adjust pedal height by changing the push rod Reassemble the operating cylinder in r verse sequence
length of disassembly noting the following matters

2 Bleed air out of the hydraulic syst I Soak the in fluid before
m piston cup reassembly
InstaJI the piston cup carefully so that it is faced
conectJy

OPERATING CYLINDER 2 Apply brake fluid sufficiently to the cylinder and

Hydraulic clutch piston and mbl them

Removal
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I Remove the return spring Reinstallation

2 Disconnect the clutch line from the operating cyl ReinstaJI the operating cylinder in reverse sequence of
inder remOV1l

3 Disconnect the push rod from the withdrawal lever I Bleed air out of the hydraulic system

4 R two bolts used to mount Ihe 2

l operating Adjust the push rod 10 that the withdrawall ver end
cylinder to the clutch housing play is 1 0 to 2 0 mrn 0394
0 to 0 0787 in in accordance

with the following instruction

Disassembly
I Remove the dust cover
ADJUSTING WITHDRAWAL LEVER
2 Remove the soap ring All other parts are can be
Correct adjustment of the clutch withdrawal lever is
disassembled
essential Insufficient free travel between the release
and the
bearing diaphragm spring fmge causes Ihe clutch
to slip while xcessiv free lravel affects full dis ngage
ment of the clutch

The clearance between the release bearing and the

a
iU diaphragm spring fingers can be adjusted at the with
drawallever nd as follows

1
r
Hydraulic clutch

1 Loosen the lock nut tighten the adjusting nut and

eliminate clearance between the top of the withdrawal
lever and release bearing
2 Return the adjusting nul from that position I 1 4

turns and set the adjusting nut stationarily with the lock
Fig CLZZ Operdtmg cylirrdeT distusembled nut

CLIO
 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 in and clearance between the release bearing

3 0 to 4 0
and 0 7 to 1 4 mm 0 1181 to 0 15751
diaphragm spring fmgers becomes
00276 to 0 0551 in

0 9 to 1 2
0 0354 to 00472
@

D
ProCarManuals.com

Unit mm in

3 Withdnwallever
t Diaphragm spring
2 Clutch control cable 4 Release bearing

Fig CL24 Adjusting withdrawal kver play

10 to 2 0
0 0394 to 0 0787
BLEEDING CLUTCH SYSTEM
Unit inl
mm
Hydraulic clutch
t 4 Release bearing
Lock nut I Remove the bleed screw d t cap from the operating
2 Adjusting nut 5 Diaphragm spring
3 Withdnwallevcr cylinder

withdrawal kver play 2 Open the bleed screw approximately

Fig CL2J Adjusting quarters
three

of a turn Attach a tube immersing the open end into a

clean container which contains a small amount of brake

fluid

3 Fill the master cylinder reservoir with the recom

mended fluid

4 Depress the clutch pedal quickly while keeping it

Mechanical clutch
down retighten the bleed screw and allow it to return
the clutch control cable adjust nut that
Adjust so play slowly Repeat this pumping action until the fluid
at the withdrawal lever end is 3 0 to 4 0 mm 0 1181 to
air bubbles
entering the container is free from
0 1575 in and securely tighten the lock nut Clearance

between the release bearing and diaphragm spring fingers 5 Screw up the bleed screw on a down stroke of the

will become 0 9 to 12 mm 0 0354 to 0 0472 in pedal remove the bleed tube and replace the dust cap

CL 11
 CHASSIS

SERVICE DATA AND SPECIFICATIONS

Hydraulic clutch Mechanical clutch

Clutch release lever

Release bearing te diaphragm spring

0 7 to I 4 mm 0 9 to 1 2 mm
withdrawal lever clearance
0 0276 to 0 0551 in 0 0354 to 0 0472 in

29 31 mm
Diaphragm spring te flywheel height to

I 142 to 1 220 in

Outch disc

Facing size

Outer dia x inside dia x thickness 180 x 125 x 7 8 mm

7 09 x 4 92 x 3071
0 in

Total friction area 264 em 40 92 sq in

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Thickness of disc assembly

Free 6 to 8 0 mm
0 2992 to 0 3150 in

6 7 to 7 0 mm
Compressed
0 2638 to 0 2756 in

Number of torsion spring 6

Allowable minimum depth of rivet head

from facing surface 3

0 mm 0 0118 in

Allowable 0 5 mm 0 0197 in at
facing run out

radius 85 rom 346

3 in

Allowable free play of spline 4 mm

0 0 0157 in

Outch pedal

141 5 mm 57
5 in 5
139 to 143 5 mm
Pedal height When not depressed
49
5 to 5 65 in

Free travel of head 30 mm 1 181 in

pedal

10 8 23 8Ib 3
8 kg 3lb
I8
Pressing strength at full stroke kg

Master cylinder clutch

Master diameter 15 87 mm 5 8 in
cylinder

Allowable maximum clearance

between cylinder and piston 0 15 mm 0 0059 in

C112
 CLUTCH

Operating cylinder clutch

Operating cylinder diameter 19 05 mm 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 Possible causes Corrective action

Noises audible on Excessively worn damaged or poorly lubri Replace the bearing which being cased
pedal depression cated release bearing cannot be greased inside
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Seized release bearing and diaphragm spring Replace the release bearing Clean diaphragm
fmgers spring fingers with metal brush and smooth

out bearing contact faces with felt polishers

Insufficient pedal free travel Readjust pedal free travel correctly

Weakened unhooked or broken clutch pedal Set springs in position or replace them if

return and control springs weakened or snapped

Weakened clutch withdrawal lever return Replace the or hook it as

spring up

spring broken or unhooked required

Excessive play between clutch disc hub and Replace the clutch disc and ensure that

drive shaft spline clearance between hub of new clutch and

drive shaft is within 0 50 mm 0 0197 in

endwise and 0 20 mm 0 0079 in crosswise

When clearances exceed above limits replace

the drive shaft also

Noises audible on
Misalignment of clutch disc to flywheel Set level of clutch disc with clutch disc in

pedal release of disc hub in drive shaft set it under slight

causes slight movement place on

respect of facings rotation and check for no out

run using a

This noise is especially audible with engine scriber

idling or at low speed

clutch disc
Broken or weakened clutch disc cushion Replace the
springs

Insufficient pedal free travel Set pedal free travel correctly

Weakened unhooked or broken clutc con Check the springs for correct position and
trol and pedal replace them if necessary
return prings

CL13
 CHASSIS

Weakened broken or unhooked clutch with Replace the spring or hook it up as

drawallever return spring required

Distorted or worn drive shaft Replace the drive shaft and clutch disc if

necessary

Excessive play of release bearing Replace the

on slip worn parts
sleeve

Adjust the rod length correctly

The dutch drags Insufficient push rod length push

Excessive pedal free travel Adjust free travel correctly

Warped clutch disc Set level of clutch disc if pos ible

Maximum plate out
run 0 25 mm 0 0098

in

with metal brush

Roughened linings Repolish linings a or

replace them if necessary

I mproperly fitted loose or broken lining Replace linings Uning rivets should be
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clenched with to avoid

protrusion
no

damaging pressure plate and flywheel

Incorrect release bearing to

diaphragrn spring Adjust correctly
finger clearance

Clutch disc hub forcing on drive haft Locate cause of trouble and remove it if

possible Otherwise replace the clutch di c

Damaged drive shaft splines prevent the Replace the drive shaft also the clutch disc

clutch disc from sliding if required

Oil or grease on linings Locate the cause of oil or grease leakage and
correct it as required
Clean or replace linings

Warped or damaged pressure plate or clutch Replace defective parts

cover

Air pockets in the hydraulic system not Bleed out completely

bled correctly

if damaged and
Dirt or foreign matter on sealing faces of Clean replace piston cup

master cylinder piston cup bleed the system

Air pockets in master cylinder due to loose Replace piston cup and bleed the system

piston

Fluid leakage from cylinder Replace piston cup if damaged bleed the
system

Low fluid level in reservoir Top up with brake fluid and bleed the

system if necessary

CL14
 CLUTCH

Clogged vent hole in reservoir cap promotes Clean reseIVoir cap unclog the vent hole and
vacuum in master cylinder allowing air to bleed the system

inflltrate past the seal

lining wear Insufficient free travel Adjust clutch pedal free travel correctly
Abnormal pedal

Driver this Advise driver to discoD tinue wrong practice

steps unnecessarily on pedal
lining and damage release and step clutch when
causes wear to on
pedal only ne

bearing cessary

Weakened or snapped pressure springs Check pressure springs for tension as speci
fied and replace springs if they are

unserviceable

Incorrectly installed linings Replace linings with new ones and install
them correctly Check clutch disc for center

alignment

The clutch grabs Oil or grease on flywheel pressure plate and Remove cause of leakage clean flywheel and
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linings pressure plate thoroughly reolace linings

Loose disc linings due to poor rivet tightness If linings are not worn replace defective
rivets Otherwise replace linings and clench
rivets securely

Qutch disc hub does not slide freely on Remove any foreign matter or dirt deposits
drive shaft spline from shaft
splines When trouble is still

present replace damaged parts

Warped or cracked pressure plate Replace pressure plate

Misalignment Locate the defective point and if possible

adjust alignment or replace distorted parts

Stiffened hydraulic control mechanism Check spring tension If necessary take

down pedal and lubricate components

Worn out lining Install new linings and make sure that the

clutch disc pressure plate and flywheel are

not damaged

The clutch Insufficient clutch return travel due Locate of failure and replace defective
slips pedal cause

to the control and pedal return springs being springs

weak or rnisadjusted

Weakened or broken diaphragm spring Overhaul clutch and replace springs

Oil or
grease on linings Remove cause of leakage and replace linings
if cleaning is ineffective

CL15
 CHASSIS

Worn or burned disc linings Replace linings

Overhaul the master cylinder replace the

due to a
Overloaded master cylinder
damaged and clean
cup if swollen or
restricted transfer port piston
the transfer bleed the system
port

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No
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CL 16
 1
I
i

SECTION TM
SERVICE
MANUAL 1 TRANSMISSION

6 I
1
1

I 1
J

DATSUN 1200
MODEL 8110 SERIES
ProCarManuals.com

CHASSIS BODY

INI I

TRANSMISSION TM 1

TRANSMISSION GEAR CONTROL TM 15

AUTOMATIC TRANSMISSION TM 18
GEAR CONTROL

THREE SPEED TRANSMISSION TM 19

SERVICE DATA AN D TM 20
SPECIFICATION

TROUBLE DIAGNOSES TM 22
NISSAN MOTOR CO LTD AND CORRECTIONS
TOKYO JAPAN
 TRANSMISSION

TRANSMISSION

CONTENTS

hub throst washer TM 8

DESCRIPTION TM l Synchro
TM l Baulk ring TM 9
Specifications
insert TM 9
REMOVAL TM 2 Shifting
Oil seal TM 9
DISASSEMBLY 4
TM

iNSPECTION TM 7 Rear engine mounting insulator TM 9

Transmission case and rear extension TM 7 REASSEMBl Y AND ADJUSTMENT TM 9

Bearing 8
TM counter bearing thrust washer TM 9
Selecting
Gear and shaft 8
TM Main shaft TM l0

REINSTAllATION TM 15

DESCRIPTION
four NisSAN FULL AlITOMAT1C TRANSMISSION MODEL
Three speed manual transmission speed manual

transmission and three automatic transmission are 3N71 A SERVICE MANUAL under separate cover
speed
available for B 110 series For maintenance service and This chapter describes mainly about the four speed
ProCarManuals.com

manual transmission
repair of the three speed automatic transmission refer to

Specifications
BIIO S TV
LBIIO tS T
Model
BIIO S TRV

LBllO S TR
LBIIO TRV S AV
BIIO
BIIO V LBllO TRN
tS LBIIO A
BIIO tS RV YBllO S TV BIIO ARV
Item YBllO S V YLBIIO S T
LBIIO AR
KBIIO V
KLBIIO
KLBllO V
KLBIIO N

3 900 900
3 3 900
Final gear ratio

R3W56 F4W56 3N71A

Type

Control system Steering column shift Floor shift Floor shift

1st 3 380 3 757 2 458

c
2nd 1734 2 169 1458
0

3
1 1 000
E 3rd 1 000 1404
c

I 4th 1 000

Reverse 3 640 3 640 3 640

17 5 18 5 for Van 17 5 18 5 for Van 17 5

Speedometer gear ratio

2 t 0 3 US 5 t 1
5 5 US gal
Oil capaci ty I 2 L 3 US gal
0 1 gal

TM l
1

CHASSIS

31T
32T
31T
19 3T27T
1 T

13T 13T
14T 9T
22T 25T
29T
29T

17T

Fig TM 2 F4W56 gear train

Fig TM t R3W56 gear train

ends
The transmission assembly consists of transmission case

the rear extension the main shaft

which contains gear assembly and rear extension Moreover supports
rear end
The cast iron adapter plate supports each end of the
be disassembled with the gear
idler shaft and The gear assembly can
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main shaft counter shaft and reverse

other assembly installed on the adapter plate

front side of the transmission case supports the

V
I

IHtl
I

m
0

FiX TM 3 F4W56 transmission

REMOVAL Refer the section

the following instructions apply to

When dismounting the transmission from the vehicle ER Engine Removal

TM 2
 1
TRANSMISSION

Jack up the vehicle and support it with four stands 4 Disconnect the speedometer drive cable @ and

If available recommend a hydraulic hoist or open pit be back up lamp switch cable from the transmission ex

tension housing
utilized

5 Disconnect the shift rods from the shift levers by

2 Disconnect the front exhaust tube D from the
the and the shaft
exhaust manifold removing cotter pin remove cross

assembly @ from the transmission case

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Speedometer cable
G Cotter pin

cable
Fig TM 6 Disconnecting speedometer
and remote control linkage

6 hydraulic clutch control

the clutch
Remove the clutch operating cylinder from
housing

7 mechanical clutch control

Fig TM 4 Underside of vehicle
Disconect the clutch control cable from the withdrawal

lever
3 Remove the propeller shaft @ by removing four
the of the
securing bolts from companion flange gear

1
the end of the extension to
carrier Seal rear housing
prevent oil leakage

1 njp Ii
OJ

j dt I c

B
4 Crl 0

f V4
V

f
v
t
I
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r

Il
I I
Jfi
Withdrawallc 2 Clutch control cable
d
Y I vcr

t
Fig TM 7 clutch control cable
Disconnectin

8 Support the engine with a jack placed under the oil

Fig TM 5 Removing shaft pan Do not locate the jack under the oil pan drain plug
propell

TM 3
 1
t i 2 4A i
t J
k i0 b
w
I

CHASSIS

To prevent the oil pan from damaging imert a wooden 7

I
O
block between the pan and jack
oJ
L
j
I Pi

L
re
9 Remove two nuts used to attach the transmission
CID
1 ft
to the rear engine mounting member Place a jack under
J v

the transmission and remove two bolts @ used to fIx the

rear engine mounting member to the body

h
J
I Q
t

fp
c l
O 1

Fig
Withdrawal lever

Return

TM 9
spring

Removing release bearing and

il ii
I
I
l
f
withdrawallevef

I r 3 Remove three bolts securing the front cover and

I remove the front cover

j
i
r
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G
1 Rear engine mounting 2 Rear engine mounting
bolts installation bolts

Fig TM 8 Cross member removal

10 Raise the jack supporting the engine to incline the

engine in a rearward direction A sufficient space will be

provided for transmission removal

o front covet
0 Bolt

Fig TM lO Removing front COveT

II Remove the starting motor and the bolts attaching

the clutch housing to the engine

4 Remove the speedometer pinion assembly
12 Lower the jack under the transmission gradually

and withdraw the transmission

DISASSEMBLY

When disassembling the transmission the following

should be Since the casings are made
procedure adopted
of aluminum alloy be careful not to damage any of the

castings

Drain gear oil from the transmission

2 Remove the dust cover release the withdrawal lever

return spring and remove the withdrawal lever and release

bearing from the clutch housing Fig TM ll Rnnoving speedometer pinion

4
TM
 TRANSMISSION

5 Remove the return spring plug and remove the 8 Separate the adapter plate from the transmission

return spring plunger and bushing from the inside case

Note a The main shaft assembly and counter shaft

assembly are installed on the adapter plate

b When removing be careful not to lose bearing

washer installed on the front end of the counter

shaft

Plunger Return spring

Bush Return spring plug
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Fig TM 12 Removing return

spring

6 Remove the striking rod pin from the striking rod

rear end and separate the striking rod from the control
Fig TM 14 Transmission disassembly
lever bracket

idler gear set it

9 Facing the reverse upward on an

adapter setting plate special tool ST23820000 and

secure them in a vise

Fig TM 13 RertlOlling striking rod

7 Remove eight bolts securing the rear extension

TM 15 S transmission grar asSt mbly
housing and remove the housing FiR tting

the use of fork rod

10 Remove the retaining pin by a

Note the circumference with wooden pin panch special tool ST23520000 and withdraw the
Lightly tap a

mallet and withdraw the housing reverse gear shift fork and reverse idler gear

n1 5
 Y l 1
if vo 4 ifJi 1 C t
i ta q
V 7 j i4 il M i

CHASSIS

13 Remove the check ball plugs for all fork rods and
remove the reverse gear fork rod 3rd 4th gear fork rod

and 1st 2nd gear folk rod from the adapter plate

Note Be careful not to lose the check ball and check

spring

o Reverse idler gear

Fig TM 16
Withdrawing reverse idler gear and shift fork

II Remove the snap ring by the use of a pair of snap

ring pliers and the

lemo washer and reverse gear

r
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r
r
J t

y
I
r
IOfcJo 1
r

t
l
T
j
ft
Fig TM 19 Removing check ball

V
b x
Z c Dl m
Y II
71 I 14 Lightly tap the main shaft with a wooden mallet

4
1
and separate the main shaft assembly and counter shaft

assembly from the adapter plate

Snap ring Washer

IJ 2 Reverse gear
I Note When separating the main shaft mbly and
TM 17 countershaft assembly be careful drop
Fig Removing snap ring not to

them They may be broken

12 Remove from each shift fork the

retaining pin by
of a fork rod
use pin punch special tool 000
ST2352

Fig TM 18 R moving retaininR pin TM 20

Fig Removing g ar
assembly

TM 6
 TRANSMISSION

15 Remove the needle bearing synchronizer hub thrust

washer steel ball 3rd 4th synchronizer mechanism

baulk ring 3rd gear and main shaft needle bearing toward
the front side in that order

1 Thrust washer 5 Coupling sleeve

2 1st gear 6 Baulk ring

3 Needle bearing 7 2nd gear

4 Baulk ring 8 Needle bearing

Fig TM 23 Layout of main shaft

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1 Needle bearing 5 Baulk ring

18 Remove the bearing from the counter gear
2 Thrust washer 6 3rd gear
3 Steel ball 7 Needle bearing

the main drive gear

4 Coupling sleeve 19 Remove the snap ring from and

remove the main shaft bearing

Fig TM 2 J Layout of main shaft

16 Remove the main bearing from the main shaft by

the use of a bearing puller special tool ST22730000 and INSPECTION
a
press
Thoroughly clean all disassembled parts with solvent

and check them for wear damage and other defective

conditions

Transmission case and rear extension

Oean them with solvent thoroughly and check for

crack which may cause oil leaking and other defective

5122730000
conditions

When bur pitting and or other damage exists on the

joint repair or replace

2 Remove adhesive from the surface
installing com

pletely
Fig TM 22 Removing main drive bearing
3 the dowel pin knock pin if
Repair or replace
17 Remove the thrust washer 1st gear needle bearing damaged bent or warped
baulk ring 1st 2nd synchronizer mechanism bau1k
main shaft 2nd gear needle bearing etc from the 4 When extension bushing interior is
ring rear worn

main shaft unevenly replace

TM 7
 CHASSIS

Bearing 3 Measure each gear backlash and make sure that

backlash is in range from 0 08 to 0 15 mm 0 0031 to
I Thoroughly clean the bearing dry and remove dust
0 0059 in When backlash exceeds this range recommend
with compressed air
bolh driving and driven gears be replaced as a set

2 When the ball bearing inner race and center race ball

sliding surfaces are worn unevenly and or unsmoolh due

to crack or out fround of ball is excessive due to wear

or rough surface replace lhe bearing wilh anew one

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Fig TM 26 Me ring gear backlash

4 End play of the 1st 2nd gears should be in range

from 0 15 to 0 25 0 0059 to 0 0098 in and end
Inspecting baD bearing
mm
Fig TM 24

play of the 3rd gear should be in range from 0 15 to 35

0

mm 0 0059 to 0 0138 in When end play is deviated

3 needle bearing if worn damaged
Replace or
from this range replace with new gears

4 extension if worn cracked

Replace rear bushing or

Gear and shaft

I Check Ihe gear for wear damage and or crack and

replace if required

2 Check the shaft for crack and worn

bending wear

spline and replace if required

j
Fig TM 27 Me ring gea end play

Synchro hub thrust washer

When bronze oil stay is worn excessively replace the

synchro
hub thrust washer with a new one

Fig TM 25 Checking main shaft spline fo twisting 2 When both surfaces are
warped or damaged replace

8
TM
 TRANSMISSION

Baulk ring

1 Check the baulk rings for wear pitting chips or

burrs If any abnormal conditions are detected they must

be replaced with new ones

2 Place the baulk ring in position on the cone of each

gear Push the ring t6 the gear and check the gap between

the end face of the baulk ring and the front face of the

clutch teeth This gap should be within 1 05 to I 4 mm

0 0413 to 0 0551 in If it is less than 5

0 mm 0 0197

in a worn baulk ring may be the cause and a new ring

should be fitted

Fig TM 29 Fitting counter shaft bearing

2 Install the counter shaft assembly to which the

counter hearings have been fitted on the transmission

case and determine thickness of counter bearing shim to

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be selected by the use of a counter gear height gauge

A special tool ST23050000

105 to 1 4 mm

0 0413 to 0 0551 in Note a Apply the bearing into the groove completely

ulk ring dimension

Fig TM 28 ta cone installing D

SHIM
HICKHESS

Shifting insert

Replace if worn excessively worn unevenly de

ST23040000
formed or damaged 3 specd
ST23050000

4 speed
Oil seal 2 Counter shaft
3 Transmission

Replace the oil seal with a new one if lip is deformed case

worn or cracked or when the spring is dropped off

o to 0 1 mm 0 to 0 0039 nJ
Rear engine mounting insulator

Replace rear engine mounting insulator if weakened

deteriorated or cracked

REASSEMBLY AND JUSTMENT

AD

Selecting counter bearing thrust washer

1 Transmission case

I Fit the counter bearings to the counter shaft both 2 Counter shaft
3 Adjusting shim
front and rear by the use of a counter shaft bearing press

stand special tool ST23030000 and by means of

pressing shaft front bearinJ shim

FiR TM 30 Selecting counter

TM 9
 CHASSIS

b Select shim from those shown in the fol 2

s Install the needle bearing from rear end of the main

lowing table so that end play of the counter shaft shaft

is 0 to 2
0 mm 0 to 0 0079 in

3 Install the main shaft 2nd gear

Part number Thickness mm in

32224 18001 0 8 0 03 5

32224 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

c Be sure to measure at two or more positions on

end surface of the outer race

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3 Remove the counter shaft assembly from the trans

mission case Fig TM 32 Installing main shaft 2nd g ar

Main shaft
4 Install the baulk ring

Note When assembling be sure to apply gear oil to

rotating and sliding parts sueh as bushing beering 5 Install the synehro hub assembly
etc
Note Line up the shifting insert to groove on the baulk

Install the sleeve ring

coupling shifting insert and

synchronizer spring on the synchronizer hub

Note a Be careful not to hook front and rear ends of

the synchronizer spring to same insert

b Be sure that the hub and sleeve operates

smoothly and correctly by hand

Fig TM 33 Installing synchrohub

6 Install the I st gear side needle bearing baulk ring

Fig TM 31 Installing spring spread and main shaft 1st gear in thaI order

TM l0
 TRANSMISSION

9 Installlhe steel ball synchro hub thrust washer and

main shaft pilot bearing

Note a 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

THRUST SIDE OIL GROOVE SIDE

FRONT REARI

Fig TM 34 Installing main shaft J st gear

liS
7 Apply the main shaft thrust washer and fit the main

shaft side by the use of a main shaft bearing

bearing rear

drift special tool ST22350000

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DINT FOR OIL

Fig TM 37 Synchro hub thrust washer

10 Fit the main bearing front side to the main drive

gear and install the main bearing washer and snap ring

Note When the main bearing washer be sure

8 installing
Fig TM 35 Fitting main shaft bearing to face the web portion to the baaring side

b fit the snap and

Be sure to ring correctly
8 Install the meedle bearing main shafl3rd gear baulk
securely to the groove
ring and synchronizer hub assembly from front end of
the main shaft

5T22350000

Fig TM 36 Installing main shaft 3rd gear Pig TM 38 Fjttin

yr
main shaft bearing

TM ll
 CHASSIS
I I Install the baulk ring the main drive gear and 14
on Install each fork rod together with the check ball
combining with the main shaft the main shaft
complete plug check ball check ball spring and interlock
plunger
assembly by the use of a fork rod guide special tool ST23620000
12 Combine the main shaft assembly with the counter

shaft and install them on the adapter plate

Note the main Note Install the fork rod at a position where the fork
Apply bearing front endl approximately
5 mm 10 1969 inl first line up the counter rod check ball groove is coincided with the ball
shaft

bearing center lighdy tap the main drive gear with b In the standard position upper surface of the
a wooden mallet and thus install the main shaft plug is flush with upper surface of the adapter
assembly and counter shaft on the adapter plate
When installing the plug be sure to thread
c apply
locking agent
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Fig TM 39 Combining gear assembly

13 Install the shift fork on each fork rod

Fig TM 41 InstaGing check ball

Note a Pay attention on the shift fork installing dire

tion

b Be sure that there is no gap between the fork

rod and shift fork

1st 2nd SHIFT ROD

PLUNGER

3rd 4th SHIFT ROD

BALL

SPRING

r
J 1st 2nd shift rod 3 3rd 4thshift rod
REVERSE SHIFT ROD
2 Striking rod 4 Reverse shift rod

TM 40
Fig Layout of shift fork andfork rod TM 42
Fig Layout of check ball

TM 12
 TRANSMISSION

IS Drive shift fork retaining pin

o Reverse gear shift fork

o Revene idler gear

Fig TM 45 Installing reverse idler gear

Fig TM 43 Driving retaining pin

16 Install the main shaft reverse gear thrust washer

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and secure them with a snap ring

18 Install the 3rd 4th shift fork and drive the shift

the of tool
fork retaining pin by use a special
Nota When installing the thrust washer be sure to face ST23520000
the w to the gear side
portion

Snap ring

I Reverse gear

TM 44 Fig TM 46 Driving retaining pin

Fig Installing reverse gear

17 Install the reverse idler gear together with the 19 Remove the adapter plate from the attachment and
reverse shift fork Drive shift fork retaining pin install it on the transmis
ion case

Note In order to insure that the interlock plunger is not

cracked apply one fork rod operate the other fork Note 8 Be sure to install the counter bearing shim
rod and make sure that the gear does not mesh selected previously

TM 13
 i6i lU t
J2 lco Ii j e tI
i A j iiJ i i
l Ji tl 1 if iJf

CHASSIS

Fig 49
TM Installing uar extension

Fig TM 47 Instaning counter be4ring shim

2I Install the bushing plunger return spring and
return spring plug
b Remove oil apply adhesive the and
on joint Note When installing apply adhesive to the return spring
install the adapter plate the transmiuion case
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on
plug
c When installing lightly tap with a wooden

mallet and ba sure to line up the knock pin hole

I Plunger 3 Return spring

2 Bush 4 Return spring plug

Fig TM 50 return spring

Installing
Fig TM 48 Installing transmission case

22 Install the stopper pin and E ring

23 Install the speedometer pinion

20 Coinciding the striking lever instaU the rear ex
24 Select main drive gear bearing shim s
tension
Note Measure depth from the front cover installing
surface to end surface of the main bearing outer

Note a Be sure to remove oil and apply adhesive on the race by the use of vernier caliper depth gauge and

surface joined with the adapter plate select shimCs from those shown in the following
15
b Tighten the installation bolts symmetrically and
table so that the
0059
depth is 5
g mm 0 1969

evenly so as not to tighten unevenly g in

TM 14
 TRANSMISSION

25 Install the oil seal on the front cover and secure it

Part number Thickness mm in
together with the adjusting shim and O ring

Note Grease the oil seal lip

32208 18000 5
0 0 0197

32208 18001 0 2 0 0079

26 Install the clulch release bearing return spring and
32208 18002 0 1 0 0039 withdrawal lever

r C 27 Upon completion of the reassembly confmn that

l r9

Pilj i j
I
I
I The main shan is not turned synchronously when

gear is shifted to neutral and the main drive gear is turned

lightly

r
Ai
1
1 1
r 2 Operating force is not excessive and gears can be
I
I shifted smoothly when shifted 10 the individual speeds
Ie
I

I
D J0 REINSTALLATION
n
ProCarManuals.com

Remount the transmission in reverse of

sequence

dismounting
Main dme sear

Fronl
Front ccwcr

Jjustinalhim
Shim thick

5 00 mm 0 1868 In

5 mm 10 1969 In Shim th

Fig TM 51 Selecting main drive gear bearing shim

TRANSMISSION GEAR CONTROL

CONTENTS

DESCRIPTION TM 15 I nspection and repair TM 17

COLUMN SHIFT CONTROL SYSTEM TM 17 Installation TM 18

TM 17 TM 18
Removal Adjustment

DESCRIPTION floor shift control system and those mounted with

automatic transmission use remote control floor shift
The B I JO series uses three types of transmission systeDL
control system Those vehicles mounted with three The transmission control rod is used
collapsible
forward speed transmission use column shift control together with the collapsible steering When collision

system and when collapsible steering option is delrine mold located in

adopted occurs an intermediate position
the vehicle uses collapsible control system Those vehicles of the control rod is cut off the control rod slides toward

mounted with four forward speed transmission use direct axial direction and shock is absorbed

TM 15
 CHASSIS

CROSSK SHAFT

StWT

C VIEW

IiANGE LEVER
ln J

CHAHGE LEVER C r
12OO 3rd

1a Jnl
tfP
l nda 3
F
SHIFT ROD AVlEW

I
rw
Pst

Jm
ProCarManuals.com

MMlUAL llEVER

Li3
l 12fW tJrdl

2 d
lst

TM 52 Control system forward

3 speed transmission
Fig

COLUMN SHIFT CONTROL SYSTEM

Remval 2 Remove the steering column shell cover turn signal

I Remove the sleering wheel assembly and lighting switch complete

mrlg column sheU cover

TM 54 Rr mol1ing st
fig TM 53 Removing steering wheel Fig

TM t6
 TRANSMISSION

5 Remove the retainer bolt I

speed change

6 Remove the speed change retainer 2

7 Remove the 2nd top change lever and bush 3

from the control rod 4

8 Lower the control rod so that the control lever pin

comes out from the lower bracket 5 and withdraw the
control lever pin

Note Lower the control rod to l1 en extent that the

suc

control lever pin does not interfere the lower

bracket
TM 55
Fig Removing turn
signal and lighting switch

9 Wilhdraw 1he control rod from the passenger com

3 Remove lhe snap ring and control lever pivot pin

partment
and withdraw the hand lever

10 Remove the cotter pins and disconnect the speed

ProCarManuals.com

0
AI
a AI change rods Remove the cross shaft from the side
Y
J IBI
i 1 E f
J
member and withdraw the cross shaft assembly

P
1
l ff
ei oJ
4 I

Of
j l
Snap ring C washer

rn
2 Control lever pivot pin J
Fig TM 56 Withdrawing hand ever

4 Remove the washer

C

TM 58 Cross shaft
Fig assembly

riJ
l
i f Inspection
Check all
and other
and

sliding parts
damages and
repair
and component parts for

replace as required
wear

0
1 J Note Especially for collapsible type control rod be
1
careful not to apply a large load toward the axial
lJ
direction when delivering and installing
When the control rod and slackness exists
installing
lever toward the axial direction replace
Fig TM 57 Removing change

TM 17
 CHASSIS

Installation

InslIll the oon1rol system in reverse sequence of

leDtonI Before instaIIing and assembling apply chasm

srease to all sliding swfacel

Acijuatment
I Set l1
on m mnn side manual Ie
er to the neutral

poIition
Neutnlsettinz Shiftr

rn
M
ptJ
2 Lower support bncbt

2 the trunion the lowe

TemponriIy oonnect on
Fig TM 59 Adjus t of neutral setting
support bracket head to each rod
4 of the above
Upon completion adjustmenl operale
the hand Ie
er to the individual select and shift directions
ProCarManuals.com

3 Set the rod on the lever stationariIy so thaI the and make sure that the hand I can be operated
grooves for adjustment of neutral poIition on the upper smoothly and lightly
surface of the lower support bracket and each 1 are
Readjust if dragging slackness and or other unusuaI

aligned straight oonditions exist

AUTOMATIC TRANSMISSION GEAR CONTROL

8 VlEW

0 to 2 9Irg
TIGHTENING TORQUE 2 m

14 5 to 210 ft Ib

A V1EW
e

CROSS SHAfT BRACKET

TNUNMION
SHIFT ROD MANUAL LEVER

Fig TM 60 Control system automatic tTansmission

TM 18
 TRANSMISSION

When the lever drags or when

JUSTMENT
AD lever is opetated smoothly
warped or loose readjust finely until draging
the lever is
I Set tranlllltission side manual lever and hand lever to warping and or slackness is eliminated completely
their neutral positions

Note a Be sure to apply chassis to the sliding

2 Adjust length of the shift rod at the cross shaft lever
parts or to fill such parts with chassis
and fix the shift rod
b Make sure that hand laver positions are coin

cided with the position marks on the le

con

box indieetor when the gean are shifted to tha

3 After adjusting linkage shift change lever to the
individual positions
individual speed positions and make sure that the shift
ProCarManuals.com

THREE SPEED TRANSMISSION

Fig TM 61 R3W56 tTansmission

TM 19
 CHASSIS

Disassembly and maintenance service for the thsee INSPECTION

speed transmission are to be conducted in the manner
Gear end play mm in
identical to the four speed transmission
0 05 to 0 20
Except for the following items the three speed Reverse gear
transmission is same as the four 0 0020 to 0 0079
speed transmission

0 05 to 0 15
Reverse gear counter shaft
0 0020 to 0 0059

0 10 to 0 25
Reverse gear main shaft
0 0039 to 0 0098

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS

Type R3W56 F4W56

ProCarManuals.com

No of speeds 3 forward l reverse 4 forward I reverse

Synchromesh type Warner type Warner type

Gear ratio

1st 380
3 3 757

2nd 1 734 2 169

3rd 1 000 1404

4th 1000

Rev 3 640 3 640

Speedometer pinion 17 5 17 5

Oil capacity 2 t
1 3 US gal
0 12 t 3 US
0 gal

TIGHTENING TORQUE

Transmission proper ft lb
kg m

Engine transmission intallation bolt 16 to 2 2 I 16 to 15 9

Engine mount rear installation bolt to the body 3 2 to 4 0 23 1 to 28 9

Speedometer pinion installation bolt 5 to 1

0 3 6 to 8 0

Front cover installation bolt 1 0 to 1 6 7 2 to 11 6

TM 20
 TRANSMISSION

Rear extension installation bolt 16 to 2 2 I 1 6 to 15 9

Drain 4 0 to 6 0 28 9 to 4
43
plug
4 0 to 6 0 28 9 to 4
43
Filler plug

Backup lamp switch installation 2 0 to 2 5 5 to 18 1

14

3 1 to 4 2 4 to
22 4
30
Withdrawal lever ball pin installation

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
0 0059 to 0 0098
ProCarManuals.com

0 15 to 0 25
2nd gear mm in
0 0059 100 0098

0 15 to 35
0
3rd gear mm in
0 0059 to 0 0138

0 05 to 0 20
Reverse gear mm in
0 0020 to 0 0079

0 05 to 0 15
Reverse counter gear mm in
0 0020 to 0 0059

10 to 0 25
Reverse main gear in
mm 0
0 0039 to 0 0098

Baulk ring cone clearance

105 to 14
Standard clearance mm in
0 0413 to 0 0551

0 5
Replacement standard mm in
0 0197

Counter shaft Thickness in

Part number mm

32224 18001 0 8 0 03 I 5
Adjusting shim

32224 18002 0 9 0 0354

32224 18003 1 0 0 0394

32224 18004 1 0 0433

32224 18005 1 2 0 0472

32224 18006 3 0 0512

1

TM 21
 CHASSIS

Front cover
Part number Thickness mm in

Adjusting shim
3220S 18000 5 0 0197
0

32208 18001 0 2 0 0079

32208 18002 0 1 0 0039

TROUBLE DIAGNOSES AND CORRECTIONS

Symptom and possible cause Corrective action

Difficult to intennesh gears

Causes for difficult gear shifting are classified to troubles concerning the conlroI sys1em and transmission When the
clutch disengagement may also be unsmooth First make
gear shift lever is heavy and it is difficult to shift gears
ProCarManuals.com

sure that lbe clutch operates correctly and inspecl the transmission

Worn gean shaft and or bearing Replace

Insufficient operating stroke due to worn or loose sliding part Repair or replace

Defective or damaged synchronizer Replace

Gear slips out of mesh

is worn or weakened or
In the most cases this trouble occurs when the interlock plunger check ball and or spring
when lbe control system is defective In this case the trouble cannot be corrected by replacing gears and lherefore

trouble shoaling must be carried out carefully 11 should also be noted that gear slips out ofmesh due to vibration

and rear engine mounts

generated by weakened front

Worn interlock plunger Replace

Worn check ball and or weakened or broken spring Replace

Worn fork rod ball groove Replace

Worn or damaged bearing Replace

Worn or damaged gear Replace

Noise

when noise while shifting

When noise occurs under engine idling and stops while the clutch is disengaged or occurs

gears it may judged that the noise is from lbe transmission

TM 22
 TRANSMISSION

Insufficient or improper lubricant Add oil or place with designated

oil

Oil leaking due to defective oil seal and gasket clogged breather etc Clean or replace

Wom bearing High humming occurs at a high speed Replace

Damaged bearing Cyclic knocking sound occurs also at a low speed Replace

Wom each spline Replace

Wom each bushing Replace

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL
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or
DATE PAGE No SUBJECT
BULLETIN No

TM 23
 CHASSIS

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No
ProCarManuals.com

TM 24
 SEen ON PD

PROPELLER SHAFT
DIFFERENTIAL
CARRIER

DATSUN 1200
MODEL 8110 SERIES
CD
ProCarManuals.com

CHASSIS BODY

INI I

PROPELLER SHAFT PD 1
AND UNIVERSAL JOINT

DIFFERENTIAL CARRIER PD 4
NISSAN MOTOR CO LTD
TOKYO JAPAN
 PROPELLER SHAFT DIFFERENTIAL CARRIER

PROPELLER SHAFT AND UNIVERSAL JOINT

CONTENTS

DESCRIPTION PD 1 SERVICE DATA AND

REMOVAL PD 2 SPECI FICATIONS PD 3

DISASSEMBL Y PD 2 TROUBLE DIAGNOSES

INSPECTION PD 2 AND CORRECTIONS PD 3

ASSEMBLY PD 2
ProCarManuals.com

Yoke flange
1 Assembly yoke sleeve 6

2 Assembly journal with 7 Ring snap bearing

lever race

3 RiDsnap bearina race 8 Assembly race bearing

9 Bolt
4 Auembly race bearin
5 Assembly journal with 10 Washer lock
11 Nut
bearing

Fig PD 1 Propeller shaft

DESCRIPTION gr m 02 oz
in at 4 000 rpm at the factory with the
best care
Propeller shaft adopt solid tubular sleel construction
A correct balance of shaft is very important
propeller
for a good riding comfort at high speed Therefore the The shaft will be unbalanced if erroneously
propeller
propeller shafts in service parts and ones assembled in the lapped il with a hammer while servicing or flying rocks or

vehicle are counterbalanced within an unbalance of IS bolloming during offroad driving occurs

PO l
 CHASSIS

Moreover excessive sleeve yoke spline to transmission over and secure the assembly in a vise Drive the fIrst

main pline lash and of both front and rear universal of its the
wear spider bearing back out lug by tapping projected
joints will cause vibrations affecting riding comfort end of the spider

4 Use a brass drift with a flat face

REMOVAL 5 Wash and clean the bearing and shaft with cleaning

Disconnect the flange yoke and the pinion flange by solvent

removing bolts at the rear end of the propeller shaft

In this case draw out the sleeve yoke from the end of
transmission holding the disconnected rear end of the

propeller shaft

0
BEARlNG ASSEMIL 0 lRNA1
atn
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Fig PD3

INSPECTION
Fig PD 2
Check all parts and repair or replace if defective When

replacing the journal unit be sure to replace as an

Before disassembling put match mark on all com

assembly
that reassembled in the
ponents of shaft so they are

shaft balance will 1 Replace if the journal pin exterior is damaged or

former position and that the propeller
scarred
not be deviated

DISASSEMBLY 2 Replace if the yoke hole is worn or damaged

do not disassemble the propeller shaft since

Primarily 3 Replace if the nap ring is damaged or defprmed
it has been balanced as an assembly
4 Replace if the bearing needle roller i damaged or
When disassembly is unavoidable for necessary repair
worn
the following instructions apply
5 Replace both sleeve yoke and main shaft if the sleeve
1 Remove the yoke and raise the
snap rings from yoke and main shaft damaged
spline are or worn

propeller shaft
6 Replace if the propeller shaft tube surface is cracked
2 Remove snap rings used to secure the journal or indented
bearings in the yoke flange with a pair of pliers
If the snap rings cannot be snapped out of the groove

tap the end of the bearing with a wooden mallet slightly ASSEMBLY
This will relieve the pressure from the snap ring
The propeller shaft is reassembled in reverse sequence
3 the
Slightly remove journal bearing end until the of disassembly

opposite bearing is pushed out of the yoke flange Turn Install the spider on the yoke flange

PO 2
 PROPElLER SHAFT DIFFERENTIAL CARRIER

Insert the journal into the yoke flange Tap the journal 37149 18000 52
1 0 0598 Green

bearing into the yoke flange using a brass drift smaller Blue
37150 18000 S4 0 0606
than the hole in the yoke Tap the other bearing into the
37151 18000 S6 0 0614 Brown
the is in line
opposite end of the yoke flange until bearing
3715218000 58
1 0 0622
with the snap ring grooves

With a pair of pliers install the snap rings on both end

ofthe yoke flange

Insert the flange assembly in the sleeve yoke
SERVICE DATA AND
Place the other yoke bearing into the opposite end of
inlo the
SPECIFICATIONS
the yoke and tap this bearing yoke until the
bearing i in line with the snap ring grooves Install the
Distance between joints mm in 1 189 46 8
snap rings on both ends of the yoke When all parts are
Tube outer diameter x thickness 68 9 x 16
assembled check the spider and surroundings for tightness
mm in 2 713 x 0 0630
When the clearance is excessive adjust with over size

follows Sleeve yoke specification Involute spline

snap rings as

Outer dia x inner dia x pitch 20 x 80 x I

mm in 0 787 x 3 150
Snap ring over size
x 0 0394
ProCarManuals.com

Thickness Color Permissible unbalance cmjrpm

gr 15 4 000
Part number
mm in identification

Check the joint every 20 000 km 12 OOO mile

37146 18000 1 46 0 0575 White
If an abnormal bending a play or noise occurs
37147 18000 1 48 0 0583 Yellow
is seen the journal and bearing and
replace race

3714818000 SO 0 0591 Red adjust with snap ring

TROUBLE DIAGNOSES AND CORRECTIONS

Trouble Possible causes Remedies

Noise and Distorted propeller shaft Using exclusively an arbor press restraighten

vibration If distortion is excessive replace propeller

shaft

Unbalanced propeller shaft Check for balance If unbalance exceeds the

limit it
replace

Incorrectly positioned flange yoke Recorrect

Excessive spline lash Replace the sleeve yoke

Worn or damaged journal Replace the journal

Incorrect snap rings Replace with correct snap ring

Loose nuts securing the to the nuts to the specified torque

flange yoke Retighten
companion flange

PD 3
 CHASSIS

DIFFERENTIAL CARRIER

CONTENTS

DESCRIPTION PD 4 Adjustin9 preload PD l1

REMOVAL PO 5 Setting and adjusting side bearing shims PD 12

DISASSEMBL Y PD 5 INSTALLATION PD 15

INSPECTION AND REPAIR PD 7 TROUBLE DIAGNOSES AND

ASSEMBLY AND ADJUSTMENT PD 8 CORRECTIONS PD 16

Assembling differential gear case PD 9 SERVICE DATA AND SPECIFICATIONS PD 17

Setting and adjusting drive pinion PO 10

DESCRIPTION
ProCarManuals.com

Apply chassIs grease to oil seal lip when assembling Tightening torque of drive pinion nut

12 to 17kgm 86 8 to 122 9 1t Ihl

A correct contact pattern means that it lies

in the range of 213 to 3 4 from the tip

of the tooth under no load Backlash is
0 10 to O 15mm 10 0039 to 0 0059 in
Pinion bearing adjust spacer

Tightening torque of drive gear bolt

6 0 to 7 0 kg 43 4 to 50 6 ft lb

Tighten by tapping bolt head with

a Q Ug 1 4 Ib hammer
Drive pinion adjusting washer
T W N HxO OI 0 2 mm

Side gear thrust washer

T1
T2
Drive gear adjusting shims

left side A C O Et xO Ol 0 200 mm

TI
Right side T2 B O F xO Ol 0 200 lmm

Fig PD 4 Sectional view of differential carner

4
PD
 PROPELLER SHAFT DIFFERENTIAL CARRIER

The gear carrier is made of light and strong aluminum To remove the gear carrier assembly disconnect the

connection
gear is used drive pinion companion flange flange yoke
to
alloy metal and hypoid bevel
with non adjusting and remove two rear axle shafts Refer to REAR AXLE
Adjust drive pinion bearing preload
type spacer and pinion height and side bearing adjust for the work

ment with spacer shims

still
DISASSEMBLY
Millimeter standardization remains for all the

screw threads of this unit Therefore adjustment figures I Install the gear carrier assembly on the Gear Carrier

stamped on screws adjusting shims washers differential Attachment ST06220000 by engine stand ST06280000
case drive pinion and carrier are in millimeters in
by vise
accordance with the millimeter standardization of parts
The proper lubrication to the gear housing is necessary

durability of the gear and

otherwise it would shorten the
cause other troubles The lubricant should be checked
each 50 000
each 5 000 km 3 000 miles and replenished
km 30 000 miles

The lubricant should be drained and refilled at the end

of the first 1 000 km 600 miles to eliminate any loose

material from the sump which results from breaking

ProCarManuals.com

Differential lubricant should be changed at least every

50 000 km 30 000 miles

Considerations should be given to the following
matters

Nominated hypoid gear oil must be used Fig PD 6 Holding differential carrier

2 It is prohibited to use any gear oil of different

2 Inspect the following before disassembling
viscosity
The same brand must always be selected
I Inspect the tooth contact pattern with a lead oxide

The standard oil is about 0 75 liter 0 198

3 capacity 2 Measure backlash between drive gear and pinion
US gal gear using a dial indicator

3 Put match mark on one side of the side bearing cap

REMOVAL
by the use of a punch

SIDE BEARING CAP

Fig PD5 Differential carrier assembly Fig PD Putting mark

PD 5
 CHASSIS

4 Remove the side and take out

bearing caps the 6 Remove the hypoid gear by spreading out the lock
differential case assembly strap and loosening the drive gear bolts
n
IPIc
JE
oI
1
L

0a I

Ii
1

Ie
c
v

r
I

I
r f I

j V r
jJ i
t f
I
I

11
f t 3
Fig PDl0 drive gear
Removing
Fig PDB Removing differential case assembly
ProCarManuals.com

Note Loosen the bolts in a line

diagonal
Note Be careful not to confuse the right and left hand
7 Measure backlash between the side gear
bearing caps and bearing outer race so that the and the

same parts are mbled in the pinion mate using a dial indicator
original
positions
8 Drive out the pinion shaft lock pin from the left side

5 Remove the side bearing by the use of a Gear Carrier from the side of the drive gear to the right side by ing
u

Side Bearing Puller ST33010000 the Fork Rod Pin Punch ST2352oooo

ST23520000
ST330l0000

PD 9 Fig PD ll Removing lock pin

Fig Removing side bearing

9 Draw out the pinion shaft and take out the mate

Note a The puller should be handled with care in pinions side gears and thrust washers

catching the edge of bearing inner race

Note The gears as well as thrust washers should be
b Care should be taken not to confuse the right marked or left and right
preserved separately as

and left hand parts front and rear

PO 6
 PROPELLER SHAFT DIFFERENTIAL CARRIER

inner race of rear bearing bearing spacer and adjusting

10 Measure the initial turning torque drive pinion gear

by using the Preload Gauge STJII 90000 and drive washer

the Drive Pinion

pinion height by using Arrangement
13 Remove the oil seal and take out the front bearing
Gauge STJI 120000
innp race

II Remove the drive pinion nut and draw out the

Note The removed oil seal should not be reuMld
companion flange assembly

Wrench to hold the 14 Draw out the outer races of both front and rear
Note Use the Drive Pinion Flange
companion flange IST31540000 bearings using drift

IS Draw out drive pinion rear bearing inner race using

Drive Pinion Rear Inner Race Replacer STJ003Iooo
ProCarManuals.com

unit
Fig PD12 Removing drive pinion

12 Remove the drive pinion assembly to the rearward

by tapping the front end with a plastic mallet

The drive pinion can be taken out together with the Fig PD 1J Removing bearing

INSPECTION AND REPAIR

@
1 Drive pinion nut
2 Drive pinion washer
3 Companion flange
O 4 Oil seal
5 Front bearing
pO
h 6 Gear carrier
7 Pinion mate thrust washer

0 8 Pinion mate
9 Pinion shaft lock pin

lI Ol @ r 10
11
12
D
14
Pinion mate shaft
Side gear thrust washer
Side gear
Pinion
Rear
bearing spacer
bearing

i 15 Drive pinion adjusting washer

16 Drive pinion
17 Bearingcap bolt

i @ll
18 Lock washer
8 19 Bearing cap
20 Side bearing
r 2t Side bearing adjusting shim
22 Drive gear bolt
23 Lock strap
24 Differential case
25 Drive gear

Fig PD 14 Gear carriJ r and gear

PD 7
 CHASSIS

Before inspecting various parts thoroughly wash them case of the clearance between the side gear and thrwt

so that damage and wear can be easily detected washer exceeds 0 1 to 0 2 mm 0 0039 to 0 0079 in

Then proceed as follows replace the thrwt washers Three kinds of thrust washen

are available

Check gear teeth for scoring cracking and chipping

5 Measure run out of the drive gear at the rear side
and make sure that tooth pattern indicates correct
using a dial indicator
meshing depth
When the out
run is more 0 05 mm 0 0020 in replace
If any defect is evident replace parts as
required
the drive gear and pinion gear as a set

Note Drive pinion and drive gear are supplied for

replacement as a set therefore should either part

be damaged replace as a set

2 Check the pinion gear shaft and pinion geaJ mating

faces for scoring and signs of wear and replace as

required
Follow the same procedure for inner faces of side gear

and their seats on differential case

ProCarManuals.com

3 Inspect all bearing races and rollers for scoring

chipping or evidence of excessive wear

not worn with

They should be in tiptop condition
mirror like surfaces

Replace if there is a doubt on their efficiency since an

Fig PD 15 Measuring out
run of drive gear
incorrect bearing operation may result in noisiness and

gear seizure
6 Inspect carrier and differential case for cracks or

4 Inspect thrust washer faces distortion

Small defects can be corrected with emery paper In Replace defective parts as
required

ASSEMBLY AND JUSTMENT

AD

TighteninQ torque of side bearing 4p botlS

5 to 6kg m 36 2 to 43 4 ft Ibl

Adjust spacer of adjusting drive pinion

without drive gear oil seal Preload for
pinion bearing 6 to Skg cm 15 2 to 6 9in lbl

ci

E
E

Tightening torque of drive pinion nut

12 to 17 kg m 18S S to 122 9 ft Ib
Approximately 45 0 mm 1 772 in

Fig PD 16 Camer section

PO s
 PROPELLER SHAFT DIFFERENTIAL CARRIER

the bolts head of the

Reassemble the differential carrier in reverse order of Tighten by striking lightly the
disassembly The following instructions for adjustment bolt by a 0 1 kg lj4Ib hammer
and usage of special tools are essential to obtain perfect The drive gear bolts should be tightened in a diagonal
differential operation line The tightening torque should be 6 0 to 7 0 kg m

4 to 50 6
43 lb
ft

Assembling differential gear case

1 Assemble the pinion mate side gear and thrust

washer in the differential case

2 Adjust clearance between the side gear and thrust

washer within 0 01 to 0 20 mm 0 0039 to 0 0079 in by

selecting side gear thrust washer
ProCarManuals.com

Fig PD 18 Measuring tightening torque

5 Press the side bearing inner race on the differential

case using a Side Bearing Drift ST3322oooo

33220000
S3
Fig PD17 Measuring clearance

Side gear thrust washers

Part number Thickness mm in

38424 8000 0 76 to 0 81 0 0299 to 0 0139

3842418001 0 81 to 0 86 0 0319 to 0 0339

38424 18002 0 86 to 0 9 I 0 0339 to 0 0358

Fig PD19 Pressing the side bearing inner Tace

Fit the the the case

3 pinion lock pin from right side of
of drive gear Note It is important to fit the drive gear adjusting shims
opposite side and peen the hole rim over to

behind the and

bearin to obtain proper
15 preload
prevent the lock pin vibration loose

mounting of gear teeth

4 Bolt the drive gear to differential case The for is ibed in

procedure adjustment d

Only genuine drive gear bolts and new lock bolt straps fourthcoming page in detail and therefore no

should be used instruction is given here

PD 9
 CHASSIS

Setting and adjusting drive pinion

Pinion height is adjusted with pinion adjusting washer

behind the drive pinion gear

Tolerance from the standard size up to the drive gear

center is indicaled on the drive pinion top by means of an
electric pen When 10lerance is larger than the standard
size it is accompanied with EB mark and with e mark
when smaller The numeI31 following the mark is a
figure
multiplied by 100

Fig PD21 Measuring pinion preload

Note Be eereful not to otherwise

tighten excessively or

the bearing will be damaged sirxe pinion bearing

edjusting has not applied
ProCarManuals.com

5 Ins1all Drive Pinion ArrangItlent

a Gauge
STJII2oooo on the fmal drive housing and measure

gap with a thickness gauge

PD20
Fig pinion head mark
Dri

I Install the drive pinion outer races both front and

rear on the final drive housing

2 Install the drive pinion washer and

adjusting rear

bearing on the Dummy Shaft STJ I 230000

3 Install the Dummy Shaft on the fmal drive housing

without using drive pinion adjusting spacer and install the Fig PD22 MetuUrlng pinion g depth
pinion front bearing and companion flange
6 Formula to calculate thickness of drive pinion

adjusting washer
4 Tighten the drive pinion lock nut to the rated

preload by the of Drive Pinion Wrench

use a Flange T W N HxO OI 0 2 mm
ST3l540000
Where W Thickness of washer inserted mm

Drive pinion bearing preload T Required thickness of ad

rear bearing
justing shim nun
without oil seal and new
bearing
N Measured clearance between Arrange
cm 5 2
6 to 8 kg to 6 9 inIb
and Dummy Shaft face
menl Gauge
without oil seal and reused bearing nun

3 to 4 kg m 2 6 to 3 5 inIb H Figure marked on the drive pinion head

PD 10
 r
PROPElLER SHAFT DIFFERENTIAL CARRIER

Example W 2 92 mm housing
N 3mm
O
8 Withdraw the pinion rear bearing from the Dummy
H I
Shaft washer selected based the above
apply a on
T 2 92 0 3 I x 0 01 0 2

3 03 mm
formula and refit the pinion rear bearing and drive pinion
together
Use a 3 04 mm washer

Note Be sure to face inside faced surface of the washer

7 Remove the Dummy Shaft from the gear carrier toward back of the pinion

washers
Drive pinion adjusting

Thickness Part number Thickness in

Part number mm in mm

381 54 G0400 2 74 0 1079 38154 G0409 3 01 0 1185

38154 G0401 2 77 0 1091 38154 G04IO 3 04 0 1197

38154 G0402 2 80 0 1102 38154G0411 3 07 0 1209

ProCarManuals.com

2 83 0 11 14 38154 G0412 3 10 0 1220

38154 G0403

38154 G0404 2 86 0 1126 38154 G0413 3 13 0 1232

38154 G0405 2 89 0 1138 38154 G0414 3 16 0 1244

38154 G0406 2 92 0 1150 38154 G0415 19

3 0 I 256

38154 G0407 2 95 0 1161 38154 G0416 3 22 0 1268

38154 G0408 2 98 0 1173 38154 G0417 3 25 0 1280

Adjusting preload Note When installing the oil seal be sure to grease the

seal lip
J Fit oil seal to 1he final drive housing

2 Inslall the drive pinion on which the rear bearing has

been installed on 1he housing inslall the adjusting
non

and companion flange in that

type spacer front bearing
order and install the pinion nut

Note Apply gear oil to the bearing and make sure that

the bearing operates smoothly

the pinion bearing with the adjusting
non
Adjust
spacer

As the pinion nut is tightened stepped portion of

the spacer is deformed and thus length between

PD 23 is
Fig Pressing the oil seal bearings adjusted stepless

PD l l
 CHASSIS

Setting and adjusting side

bearing shims

When the side without

re
mbling bearing replacing
be sure to install a shim having same thickness as that

before disassembly
The following instructions apply when the bearing is

replaced

I Place an approximately 2 5 kg 5 Ib weight on the

side bearing and measure bearing thickness
Standard side bearing width

5 mm
17 0 689 in

Note With the weight paeed on the side bearing turn

the bearing two to three turns and measure

thickness

Fig PDZ4 Noadjusting spacer

ProCarManuals.com

3 Tighten the drive pinion nut lemporariIy up to such

an extenl that slackness is eliminated from front and rear

of the drive pinion

Note Be that oil and grelise have been

sure
eompetely
removed from thnBled portion of the pinion goer

pinion nut and washer

4 Tighten the pinion nut by the of

use a
torque wrench
and preload gauge When tightening the pinion nut to the

rated torque measure preload whenever the pinion nut is

turned 5 to 10 degrees so that pinion bearing rotation Fig PD25 Measuring for bearing
starting torque is the rated value 2 Side bearing adjusting shim thickness calculating
Drive pinion formula
bearing preload
Left side drive gear side
with oil seal and new bearing
7 to 9 6 1 to 7 8 in Ib TI A C D E x om 0 200
kg cm mm

with oil seal and reused bearing

4 to 5 3 5 to Right side pinion mate side
kgm 3 inIb
4
B D F
T2 x 0 01 0 200 mm
Pinion nut tightening torque
Figures for A B C and D are dimensional variations in
12 to 17 kg m 86 8 to 122 9 ft lb
a unit of 1 100 mm against each standard measurement
Note Turn the drive pinion to provide the bearing with
and and Where A The figure marked on the left side
fitting reinspect preload tightening
torque bearing housing of gear carrier

should not be reused B The figure marked the right side

Spacer on

When bearing housing of gear carrier

preload exceeds the rated preload do not

adjust the preload by loosening the pinion nut C D The figure marked on the differential

Replace with a new spacer case

PD 12
 PROPELLER SHAFT DIFFERENTIAL CARRIER

F
E These are differences in widlh ofleft or Note To measure the width of the side bearing use the

righl side bearing againsl the standard standen gauge 117 5 mm 0 689 inl and dial

width 5
17 mm 0 6890 in Figwe is indica1Dr on a small rtaee plate

given in a unil of 1 100 mm Take the left side fur

bearing example
When the measured width is 17 3 mm 10 681 in

the difference is 2 mm 10079 in against the

0
III 0
0

C
standard width and E is excllXling the minus
1
sing
E a
i1
J
U
20 1 02 x 100

3 Install the differential case assembly together with

the side bearing outer race on the fmaI drive housing

Note Be careful not to eonfuse the right and left sidllS of

the side bearing housing

4 Install the bearing cap and tighten the installation

bolt to the rated tightening torque

C DM

Bearing cap tightening 10rque

ProCarManuals.com

5 to 6 m 36 2
kg 4 ftIb
1043

Unit mm in

Fig PD 26 Thickness of shim on kft side

Thickness of shim on right sUh

Example of calculation

A I B 2 C I D 3
E 8 F 10

Left side

T1 J I 3 8 x om 0 200 33
0 mm

Right side

Tz 2 3 10 x 0 01 0 200 0 29 mm

Fig PD27 Measuring tightening torque

Apply a 33
0 mm shim and 0 29 mm shim respectively

to the left and right and fit the side bearing

Note Be 18 to align matdl mark put before diSls

semblyeorredly
Side bearing adjusting shims

5 Upon completion of reassembly measure drive

Part number Thickness mm in
pinion drive gear backlash When backlash is less than the
38453 HIOOO 0 05 0 0020 rated value move the side bearing adjusting shim from the

38454 HIooO left side drive gear side to the right side
0 07 0 0028
When backlash is more than the rated value move the
38455 HlooO 0 10 0 0039
side bearing from the right to left contrarily
38456 HlooO 0 20 0 0079

Rated backlash 0 10 to 0 15 mm

38457 HIOOO 50
0 0 0197
0 0039 to 0 0059 in

PD 13
 CHASSIS

Limit of deflection

A portion Less than 0 05 mm 0 0020 in

S portion Less than 0 05 rom 0 0020 in

Fig PD28 Measuring hac lash

ProCarManuals.com

PDJO pa
Fig Measuring
6 Existence of foreign matter between the drive gear

and differential case is considered when backlash fluctu

ates considerably Measure drive gear back deflection

8 Apply red lead oily to both surfaces of three to

four teeth of the drive gear evenly tum the gear several

Limit of deflection Less than 0 05 mm 0 0020 in turns and check the gear for tooth contact When tooth
lut
Run of drive gear contact is improper readjust adjust shim in accordance

with the following instructions

a Heel contact

Contact surface is insufficient and heel may be

damaged Adjust by reducing thickness of shim in right

side of the side bearing and increase thickness of shim
in left side

TOE

Fig PD 29 Measuring out

ruro of drig

7 When out
run of ive
dt gear is normal and fluctuation
HEEL DRIVE HEEL COAST
of backlash is considerable replace the gear set Before SIDE SIDE
replacing the gear set be sure to measure companion
flange deflection Fluctuation of backlash may be con

siderable due to deflection of pinion bearing Fig PD Jl Hee contact

PD 14
 PROPELLER SHAFT DIFFERENTIAL CARRIER

b Toe contact damaged In order to obtain correct tooth contact

replace the drive pinion adjusting washer with a thicker

Contact surface is insufficient and toe may be
thickness of shim in left one so that the drive pinion is moved 10 the drive gear
damaged Adjust by reducing
side of the side bearing and increase thickness of shim
in right side

TOE

TOE

HEEL DRIVE HEEL COAST

SIDE SIDE
L

HEEL DRIVE HEEL COAST

SIDE SIDE
Fig PD 34 Face contact
ProCarManuals.com

e Correct contact
Fig PD 32 Toe contact
When proper tooth contact is obtained wipe off red
lead from gear face A correct contaci pattern means
that it lies in the range of 2 3 to 3 4 from the tip of
c Flank contact the tooth under no load

When backlash is too tight flank contact occurs Noise

increases and tooth edge is easily in
worn step
Replace the drive pinion adjusting washer with a

TOE
thinner one so that drive pinion is moved away from

drive gear

TOE
HEEL DRIVE HEEL COAST
SIDE SIDE

Fig PD35 Correct contact

HEEL DRIVE HEEL COAST

SIDE SIDE
Note in the thickness of adjusting washer or
Change
shim is accompanied by change in backlash Check

it when installing the gear

Fig PD33 FLmk contact

d Face contact INSTALLATION

In the most this trouble occurs when backlash is Installation be in reverse order of
cases can
accomplished
excessive Noise increases ana tooth edge is easily removal by referring REAR AXLEinstallation

PD 15
 CHASSIS

TROUBLE DIAGNOSES AND CORRECTIONS

otheJ noises such as engine noise Inuni
lr iOl noise
A problem of noises always exists when the rear axle is
univenal noUc and tire noise
in trouble and occur as syptom for trouble
exhaust noUc joinl
However great care must be men not to confuse with

Troubles Possible es
caw Remedies

Noise on drive Shortage of oil Supply gear oil

Incorrect tooth contact between drive gear Adjust tooth canlact

and drive pinion

Damaged differential side bearing or im Replace or adjust

proper adjustment

Damaged geas Replace defective parts

Noise on coasl Incorrect bacldash between drive gear and Adjust backJash
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drive pinion

Incorrect adjustment of drive pinion bearing Adjust correctly

Noise on drive and Worn or damaged drive pinion bearings Rebuild differential and replace as required

coast
Incorrect tooth contact Adjust backlash or replace the hypoid geas
pallern
set

Damaged side gear drive gear drive pinion Replace required parts
teeth surface

set
Seized drive gear and drive pinion Replace hypoid geas

Pinion bearing under inadequate preload Adjust preload

Seized damaged or broken pinion bearing Replace the bearing

Seized damaged or broken side bearing Replace the side bearing

Swinging differential case Replace the differential case

holding drive Retighten them to the designaled torque

Loosen clamp bolts and nuts

gear side bearing etc

Noise on tum Side geas jammed in differential case Replace defective parts

Pinion gears too lighl on their shaft Replace as required

Worn or damaged side gear thrust washer Replace

and pinion thrust washer

Incorrect backlash between drive gear and Adjust backlash

Excessive backlash
drive pinion

PD 16
 PROPELLER SHAFT DIFFERENTIAL CARRIER

Worn differential gears or case Replace worn parts

Breakage of Shortage of oil or use of improper oil Rebuild differenlial and replace as required
differential Severe service due to an excessive loading After adjusting preload of bearings backlash
improper use of the clutch 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 abusing of the car

pinion

Excessive backlash due to defacement of

side gear and thrust washer

Loosened bolts and nuts such as drive gear

bolts

SERVICE DATA AND SPECIFICATIONS

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Final gear type Hypoid

Final gear ratio number of teelh

Sedan Coupe Wagon

Van 3 900 I 39 10

Speedometer ratio

Sedan Coupe Wagon

Van IS 4

Drive pinion

Preload when using new bearings kg em in Ib 6 to 8 5 2 to 6 9

without oil seal

Standard distance between drive gear center and

top face of drive pinion mm in Approximately 45 0 1772

Thickness of drive pinion adjusting

washers mm in From 2 74 to 3 25

0 1079 to 1280
0

Spacing 0 03 0 0012

Length of drive pinion bearing

spacer mm in From 5169 to 5I
52
2 035 to 2 067
Spacing 0 85 0 0335

Drive gear

Backlash between drive gear and

pinion mm in JO to 0 15 0 0039 to 00059

out
Run of rear side of drive gear in
mm O
Less than 0 05 00020

PD l
 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

Clearance between side gear and

thrust washer mm in 0 10 to 0 20 0 0039 to 0 0079

Side bearing

Standard width mm in 17 5 0 689

Thickness ofside bearing adjusting

shims mm in 0 05 07 0 10 0 20
0 50
0
0 0020 0 0028 0 0039 0 0078 0 0197

Tightening torque
Drive pinion nut kg m ft Ib 12 to I7 86 8 to 123

Drive gear bolts kg m ft lb 6 to 7 43 4 10 50 6

Side bearing cap bolts kg m ft Ib 5 to 6 36 2 to 4

43

Differential carrier to axle housing

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ftx nuts kgm ft Ib L7 to 5

2 3
12 to 18 1

Companion flange to propeller shaft

ftx nuts ft Ib
kgm 2 0 to 2 7 14 5 to 5
19

Oil filler plug ft lb

kg m 6 to 10 43 4 to 72 3

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No
BULLETIN No SUBJECT

PO 1S
 SECTION FA

FRONT AXLE
FRONT
SUSPENSION

DATSUN 1200
MODEL B 110 SERIES
ProCarManuals.com

CHASSIS BODY

INI I

FRONT AXLE AND

fA l
FRONT SUSPENSION

ADJUSTMENT FA 21

SERVICE DATA AND

fA 22
SPECIFICATIONS

TROUBLE DIAGNOSES
LTD fA 24
NI55AN MOTOR CO AND CORRECTION
TOKYO JAPAN
 FRONT AXLE FRONT SUSPENSION

FRONT AXLE AND FRONT SUSPENSION

CONTENTS

DESCRIPTION FA 2 STRUT ASSEMBLY FA ll

FRONT AXLE AND Disassembly FA 12

SUSPENSION ASSEMBLY FA 3 Inspection FA 14

Removal FA 3 Reassembly FA 15

Reinstallation FA 5 TRANSVERSE LINK AND

FRONT AXLE FA 6 LOWER BALL JOINT FA 17

Removal FA 6 Removal FA 18

Inspection FA 7 Inspection FA 19

Reinstallation FA 10 Reinstallation FA 19

Wheel bearing adjustment FA 10

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1 Strut mounting insulator

2 Strutmounting bearing
3 Upper spring scat
4 Bumper rubber
5 Dust l ovcr

6 Piston rod

7 Front spring
8 Strut assembly
9 Hub scmbly
10 Spindle
II Ball joint

12 Transverse link

13 Tension rod

14 Stabilizer
15 Suspension member

Fig FA l Front axle and susp nsion assembly

FA 1
 CHASSIS

DESCRIPTION
The front suspension is of a strut type The shock to the chassis frame at their upper part through the thrust

absorber and spindle are combined to a single unit which bearing Moreover the transverse link supports the overall

forward and backward strut movements by of the

is supported by the coil spring at the upper end and by meanS

rubber
the transverse link at the lower end tension rod fitted to the chassis frame through a

installed the bottom of the strut bushing The rubber bushing adopts a non linear shape
The spindle is on

of welding with which the forward and rearward rigidities are

outer casing by means

A ball joint is attached to the lower part of the spindle changed The torsion
bar type stabilizer adopted in tl1is
lower link is used that the stIut maintains
The ball joint and the transverse link are suspension system so

connected and they are fitted to the suspension member connection between both side struts

The shock absorber mechanism Thus this suspension mechanism absorbs shocks
through a rubber bushing
is built in the strut outer casing A coil spring is applied toward all directions into the chassis effectively and

efficiently the tension rod absorbs forward and backward

between the upper spring seat fitted to the upper end of

the outer casing shocks the strut absorbs vertical shock and the
the piston rod and spring seat welded to

These components assembled to unit fitted transverse link absorbs shock applied toward sideway
a single are
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Fig FA 2 Cross sectional view of front axle

Drum type brake

FA 2
 FRONT AXLE FRONT SUSPENSION

FRONT AXLE AND 6 Remove cotler pin from the side rod socket ball joint
SUSPENSION ASSEMBLY of the steering the castle nut
remove and separate the
side rod socket from the knuckle arm

Removal

1 Jack up the vehicle and support the vehicle with

stands See the Section GL

2 Remove the hub nuts and the wheel

remove

3 Remove the board

splash

4 Loosen the brake tube connecting nut remove the

brake hose locking spring withdraw the plate and remove
the brake hose from the strut assembly bracket

Fig FA 5 Removing side socket from knuckle ann

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7 Loosen the tension rod securing bolts and nuts and

remove the tension rod

Fig FA Detaching brake hose

Note Be careful not allow dust the brake hose

entering

5 Remove the stabilizer from the body

j
7

1i i

J
g
tr
I
0
d r
4
p

FA 4
Fig Removing stabilizer Fig FA 6 temion rod
Removing

FA 3
 CHASSIS

8 Support the engine remove the engine mounting

baits indicated by arrow mark and separate the sus

pension cross member from the engine assembly

FA l0 Removing suspension member

Fig cross

Fig FA 7 Supporting gine

10 Loosen the self locking nut on the strut assembly
and holding the strut assembly dismount the front
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suspension assembly

Fig FA R ving engine mounting bolts

9 Apply a jack to the patch unit in the center of the

suspension cross member to support the member loosen

the bolts marks and separate the
indicated by arrow

Fig F4 11 Removing seIf t

locking
suspen
ion cross member from the body

Fig FA 9 mber
Jack up point of suspensiOfJ cross
Fig FA 12 Removing front axle and suspension assembly

FA 4
 FRONT AXLE FRONT SUSPENSION

Reinstallation

First check rubber parts such as tension rod mount

ing bushing stabilizer bar bushing etc for deterioration

crack and other defective conditions and replace as

required

1 Rubber bush
2 Washer
2 Reinstall the front axle and suspension assembly in
3 Stabilizer con

necting rod
reverse sequence of removal noting the following matters
4 Transverse link
5 Washer

6 Stabilizer bar

and
I Tighten the transverse link mounting bolts Stabiljzer connecting rod
Fig FA 14 bushing layout
side installation bolt to the rated
stabilizer bar body
3 Install the tension rod so that LH mark on the
tightening torque under the unladen vehicle
tension rod is faced to left side of the vehicle and R H

that
mark is to right as shown in Figure FA IS Make sure
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white the body side bushing is in the correct position and

2 Install the stabilizer bar so that the paint
identification mark on the stabilizer bar is faced to the tighten the tension rod securely with tightening torque
from 4 5 to 5 kg 32 5 to 39 8 ft lb
left side of the vehicle Tighten the stabilizer connecting m

rod with tightening torque from 0 9 to I 2 kg m 5 to

6

The same
8 7 ft lb through bushings tightening torque
the frame
08
0 9 to 1 2 kg m 6 5 to 8 7 ft Ib also applies
side installation bolt

Two types of transverse link side installation bolts

MARK
neck 35 378
1 in and 25 0 984
length below mm mm

in are used and for both types the tightening torque is

2 2 to 3 0 kg m
15 9 to 7ft lb
21

Fig FA 15 Mark on the end of tension rod

WHITE PAINT
FOR IDENTIFICATION n
1

1 Washer
2 Rubber bush

3 Frame

4 Collar

5 Tension rod

mark stabilizer Fig FA 16 Tension rod body side bushing layout

Fig FA 13 Identification on

FA 5
 CHASSIS

4 Tightening torque of front suspension cross member 7 Remove the return spring and brake shoes remove

and body is 3 2 to 4 0 kg m 23 1 to 28 9 ft Ib brake disc assembly installation bolts and remove the
brake disc assembly from the spindle Drum type brake
5 Tightening torque of bolt used to secure the upper

portion of the strut the is J 6 to 2 1

assembly on body
kg m J 1 6 to 15 2 ft Ib

FRONT AXLE

Removal

Jack up the vehicle remove the wheel and discon

nect the brake hose at the strut outer casing bracket unit

For the details see Removal of front axle and sus

pension assembly
FA 18
Fig Removingbrakedisc
usembly

2 Remove the brake caliper installation bolts and

8 Remove baffle plate set screws and remove the
the caliper assembly Disc type brake
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remove
baffle p1ale Disc type brake
3 Remove the brake drum Drum type brake

4 Remove the hub cap with a flat headed screw

driver or other proper tool and hammer Be sure to tap

lightly

5 Remove cotter pin from the wheel bearing lock nut

and remove the lock nul

6 With the wheel bearing washer and wheel bearing

installed on the wheel hub remove the wheel hub from

the spindle
In the case of a disc type brake the wheel hub may be

removed with the disc rotor installed on the wheel hub

Fig FA 19 Remolling baffle plate

9 Utilizing two grooves inside the wheel hub tap and

remove the wheel bearing outer race from the hub

Fig FA t7 Removing wheel hub Fig FA 20 Removing wheel beaTing outer race

FA 6
 FRONT AXLE FRONT SUSPENSION

10 Remove four brake disc fitting bolts and remove Inspection

the brake disc rotor from the wheel hub 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 used grease from the wheel bearing with

solvent and inspect the bearing for operating condition

from the rotation operating sound and appearance The

may be checked for the condition of rolling

outer race

surface with the race installed on the wheel hub

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Visual serviceability judgement standard for the wheel

bearing is indicated in the following table

Fig FA 21 Removing brake disc roto

Vi ual Serviceability Judgement Standard for Wheel Bearing

INNER RACE SURFACE

OUTER RACE FITTED
SURFACE

COLLAR SURFACE
OUTER RACE
SURFACE

INNER RACE FITTED

ROLLER ROLLING
SURFACE
SURFACE

INNER RACE
SMALL COLLAR

LARGE COLLAR
ROLLER

SUPPORTE R
OUTER RACE

FA 7
 CHASSIS

x Unserviceable

Judgement 6 May be used when minor

Rust should be removed with 110 emery paper

Race and roUer

u
u
Cause

l
U
l
al
8
8jiS Q
l
oo ti CIl
U

However this symptom occurs

Service tife due to roUing fatigue
Flaking x

before the service life The following causes are considered

Abnormal load overload

Improper handling or improper installation

Excessive tightening
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x
Crack x x

Gap is excessive and a considerable shock is received from the

outside

the race due to creep

Rapid heat generation on

RaUen bite the supporter due to seizure

Abnormal thrust load

Tapped with a hammer while removing

x In the most cases seizure occurs as the result of grown

Seizure x x

discoloring or flaking

SClalch 6 6 6 Shock is given carelessly during installation

Bit foreign mailer

Careless installation removal or other handling scar due to

Recess or wear 6 6 6

made by pressing striking

or striking Recess made by bit foreign matter

Poor lubricant quality or deteriorated lubricant

Wear 6 6 6

Intrusion of dust Fitted surface is worn remarkably

Wear due to excessive preliminary pressure

Excessive preliminary pressure or faulty lubrication

Biting 6 6 6

The fitted is discolored to brown or black

6 part
Fretting 6 6

rust fitted part means fine relative slip

Fretting corrosion on

on metal contact surface

FA B
 FRONT AXLE FRONT SUSPENSION

when the
Rust 6 6 6 Temperature increased during operation lowers

moisture inside the is condensed

bearing stops bearing
fine and the grease is moistened
becoming drips

The has been in highly moistened place for a

bearing placed a

of time
long period

Intrusion of moisture chemicals etc or the bearing is

touched with bare hand and action has been

no rustproof
taken

The wheel bearing is oxidized oil stain due to

Discoloring Slight discoloring may become like
serviceable if discolor
grease
be removed
iog can
when
In the most cases this occurs
preliminary pressure is too
with solvent such as

high
thinner or by polish
ing
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0
m
0
RoUer Cracked inner race
Inner race flaking

Recess on inner race made by Recess on outer race made by

Cracked roUer
bit foreign matter
bit foreign matter

III Recess on roller made by

bit foreign matter

FA 9
 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

Fig FA 24
FiT1ing sptICes between wheel
bettring krs
ro
with grease

5 Apply multi purpose grease to the spindle shaft and

threaded portions wheel bearing washer and wheel

ST353J 0000
bearing lock nut surfaces slightly

6 Install the wheel bearing and grease seal on the wheel

hub and install them on the spindle
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Note In order to provide the bearing with a proper

prepressure and to extend the bearing service life

install the wheel grease seal washer and

bearing
FA 22
Fig InstaIling bearing outer race lock nut carefully so that no dust and foreign
matten stick on grease applied to them

3 Fill the wheel hub and hub cap with multi purpose

grease MIL G2l08 or 10924 up to the portion indicated Wheel bearing adjustment
0

by asterisk in Figure FA 23
I the wheel 2 2 to
Tighten bearing lock nut to 4
2

kg m 15 9 to 174 lb
ft tightening torque

r 2
Fig FA 25 Tightening wheel bearing lock nut

Turn the wheel hub in a few turns toward both

clockwise and counterclockwise to settle down the
Fig FA 2J Creasing points of hub assembly
bearing and retighten the wheel bearing lock nut to the

same lightening torque

4 Fill the spaces between wheel bearing rollers and

grease seal lip pocket with multi purpose grease suf 3 Return the wheel bearing lock nut in range from 400
ficien tly to 700 and coincide it with cotter pin hole on the spindle

FA l0
 FRONT AXLE FRONT SUSPENSION

Correctly measure starting force toward tangential

direction agains the hub bolt

Fig FA 26 Returning heel bearing lock t

FA 27 Measuring heel bearing rotation

Fig
4 Turn the wheel hub in a few turns toward both starting torque
clockwise and counterclockwise again to allow the bearing
breaking in measure bearing rotation starting torque STRUT ASSEMBLY
apply a cotter pin to secure the nut if the measured The strut assembly of a
consisting casing
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outer
strut

starting torque is within the rated value and install the with spindle forms a cylinder between the piston rod
hub cap guide and bottom valve
Wheel bearing rotationstarting torque The inner components are precisely assembled and no
9 0 m 7 8 in Ib New bearing dirt and foreign
kg matter intrusions are permitted The
4 0 3 47
in
lb Used bearing
kgm
components such as piston rod piston rod guide cylinder
At the hub bolt 1 57 kg 46 lb
3 New bearing
0 7 kg JS4 Ib Used bearing and bottom valve are handled together as an assembly
No slackness should exist toward the axis direction When be
replacing them sure to replace the inner

Be sure to remove the brake pad Disc type brake as assembly

components an

1 Front spring
J
5 Strut
1
mounting insulator 8 Upper spring seat

6 Strut 9 Dust
2 Bound bumper mounting bearing cover

3 Piston rod self locldng nut 7 Oil seal 10 Strut assembly

4 Washer

Fig FA 28 Strut assembly components

FA ll
 CHASSIS

Disassembly
the strut assembly in
Disassemble and reassemble a

clean place so that the inner components are protected

I r r from dirt and other foreign matters

l
I lack up the vehicle remove the wheel and remove
ii
link
I the stabilizer bar and tension rod from the transverse
I lL
Loosen the knuckle arm fIxing bolts and separate the
from the ball Loosen the self locking
strut assembly joint
the
nuts the upper portion of the strut and remove
on

strut assembly See the Removal of Front Axle and

I 5 above for details
I Suspension Assembly

I
I
I
ProCarManuals.com

EX NSION

roIolPAESStON

Piston rod 5 Rebound stopper

Gland packing 6 Piston

3 Piston rod guide 7 Bottom valve

4 Cylinder

Fig f4 29 Cross sectional view of strut assembly

and shock absorber operation Fig FA 30 Removing knuckle arm fixing bolt

FA 12
 FRONT AXLE FRONT SUSPENSION

Fig FA JJ Removing piston rod self locking nut

Fig FA Jl Removing front strut assembly

2 Install strut attachment tool ST356500oo 4 Remove the strut mounting insulator strut mounting
a special I

the strut outer casing with of cloth applied bearing oil seal upper spring seat and dust
on a piece cover
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between the strut assembly and outer casing and secure

5 Remove the spring with the coil spring compressor
the strut assembly in a vise
special tool Sn56500oo installed on the spring from

the strut Remove the bound bamper from the piston rod

6 Depress the piston rod down to the bottom and

the with gland packing wrench

remove gland packing a

special tool ST35500000

ST35500000

ST35650000

ST35650000

FA J2 in vise
Fig Securing strut assembly a

3 Install coil tool

a spring compressor special
Sn5650000 the
on spring compress the spring up to
such an extent that the strut mounting insulator can be
Fig FA J4 Remvoing gumd packing
readily turned by hand and remove the piston rod
self locking nut used to hold down the spring

Note When the self

loosening locking nut use a screw
Note Before mud
removing the gland packing remove

driver as a shitter Moreover when loosening the

and other foreign matters troin the gland packing
self locking nut used to hold down the spring and strut assembly
install a nut on the bolt used to install the strut on

the body and apply the screwdriver to the nut so 7 Remove the O ring from the upper portion of the

that the thread of the bolt is not piston rod guide

damaged

FA 13
 CHASSIS

Inspection
L Be the gland packing D ring and
sure to replace
damping oil with new ones whenever the strut assembly is

disassembled

2 Wash all disassembled parts except for nonmetal

parts with gasoline or thinner and remove dirt and other

foreign matters with compressed air

3 Clean the nonmetal parts with compressed air

Fig FA 35 O
Removing ring

8 Separate the piston rod and cylinder assembly Strut outet casing

upward from the strut tube slowly and carefully if deformed cracked
Replace or damaged
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Spindle

Check the spindle especially carefully for hair crack on

the base and damaged threaded portion Replace the

strut assembly if faulty condition exists

Strut mounting insulator

Replace if rubber and metal joint i melted or cracked

Replace the rubber parts if they are deteriorated

Front spring

Replace if weakened Or cracked

Specifications for spring

FA 36 Free length t10 mffi

338
Fig Removing piston rod and cylinder assembly
3t 0
13 394 in

Note Do not remove the rod and from the

Installed lheioadght 203 t5 mm
piston guide
7 t 0 1969 in
99
cylinder They are
precisely assembled and thus
200kg 441Ib
should be handled as an assembly

9 Drain damping oil from the cylinder and strut outer

casing into a clean container

Strut mounting bearing

Replace if unusual sound occurs during rotation or

Note This procedure should be observed because

strictly slackness toward the axis direction is excessive
shock absorber performance is be sure to
directly affected by When installing the strut mounting bearing
amount of damping oil When fill it with multi purpose MIL G 2108
refilling measure grease or

amount of damping oil correctly 924

1

FA 14
 FRONT AXLE FRONT SUSPENSION

4 Install rubber G ring

a on top of the piston rod guide
and install the gland packing by the use of a gland packing
guide special tool Sn5550000

Apply multi purpose grease MILG 2108 or 10924

lightly to the lip portion indicated by asterisk in

Figure F A
40

Fig FA 37 Greasing strut mounting bearing

Reassembly
Be careful not to drop scratch since aU parts
or part are

precision finished When reassembling thoroughly clean

all component parts and make sure that dirt and other

foreign matters are completely removed During reassem

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bly do not use cloth or gloves

Fig FA 39 Installing gland packing
I Secure the strut attachment of strut outer casing in a

vise Strut attachment special tool Sn565oooo

2 Insert the piston rod and cylinder assembly into the

strut outer casing

3 Fill the strut outer casing with correct amount of oil

Fig FA 40 Cross sectional view ofgland packing

5 Tighten the to 8 0 to 110

gland packing kg m 57 8

to 79 5 ft Ib by the use of a gland packing wrench

special tool ST35500000

Fig FA 38 Pouring shock absorber oil

Note a Correctly measure amount of shock absorber oil

to be poured because amount of oil directly affects

damping power

280 CC 17 1 cu in I for AMPCO A TSUGlI make

265 cc 16 2 cu in for TOKICO make

b Use Nissan genuine oil for the shock absorber

oil

Nisseki Shock Absorber Oil A 2 for Atsugi make

Tokico Light Oil No 1 DoS for Tokico make FA 41

Fig Tightening gland packing

FA 15
 CHASSIS

Note a Before the gland pull the

tightening packing
piston rod approximately 90 mm 543
3 inl
upward This will provide the shod absorber
system with the best condition for bleeding
b Gland packing tightening torque is rated at 8 0

to 11 0 kg m 57 8 to 79 5 ft Ibl However arm

length of this tool is extended by 100 mm 394

in shown in the
as following figure Thus when

actually tightening the gland packing measure

effective length L l of a torque wrench to be

l and set up torque wrench value based

usa on the
Fig FA 42 Conducting air bkedmg on tM shock
following formula
absorber system

L L
ft lbJ
100 kg
c 10 m C 70
L 3 94
L

where C Value read on the torque wrench

ft lbl 7 Secure the strut attachment of strut assembly in a

Ikg m

L Effective length of torque wrench vise Strut attachment special tool SB56500oo
ProCarManuals.com

mm inl

TOROUE WRENCH In order to ease

8 operation raise the piston rod to the
GLANO PACKING WRENCH
C up most and secure it in that position by inserting bound
bumper

L
100 mm 3 94 in

6 Conduct air bleeding on the shock absorber system

I Stand the strut assembly vertically with the spindle

side down and pull the piston rod within its stroke Turn
2
over the strut assembly with the spindle side up and

depress the piston rod in the full stroke

2 Repeat the above described operations several times

3
3 Make sure that there is no feeling variation on

pressure while depressing or pulling the piston rod Thus

1 Piston rod
air bleeding completes 2 Bound bumper
3 Strut outer case

Fig FA 43
Raising piston rod

9 Place the front the lower spring seat

spring on

compress the spring with a coil spring compressor special

tool ST35650000 install the dust cover upper spring
f seat oil seal strut mounting bearing and strut mounting

insulator in that order

FA 16
 FRONT AXLE FRONT SUSPENSION

10 Apply multi purpose grease MIL G2108 or 10924 Tightening torque

to marked portion shown in Figure 44
FA Nuts used to install the

strut assembly on the body

16 to 2 1 116 to 15 2 ft Ib
kg m

Bolts used to install the

knuckle arm to strut

4 6 to 6 1 kg m 3
33 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 6 5 to 8 7 ft Ib
kg m

Frame bracket side

Fig FA 44 Greasing point on strut mounting bearing 0 9 to 1

2 kg m 6 5 to 8 7 ft Ib
and oil seal
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Note 8 Be careful not to damage the piston rod when

disassembling or reassembling the strut assembly TRANSVERSE LINK AND

Particularly when raising the piston rod do not use LOWER BALL JOINT
plien or other tool to hold the rod the
The transverse link is connected to suspension
Pay attention the strut member with the rubber bushing sticked to the inner
b on mounting bearing
installing direction See 44
FA tube the transverse link is also connected to the strut
Figure
assembly through the lower ball joint and thus the front

link mechanism is formed

II Tighten the piston rod self locking nut to 3 6 to 4 5 suspension
26 0 to 32 5 ft Ib The lower ball joint is of a disas embled
non type
lcg m

Lubricate the lower ball joint every 50 000 krn 30 000

12 Release the coil spring gradually from the coil
miles or two years

spring compressor and set the spring to the upper and

lower spring seats correctly

FRONT

1 cross member 3 Transverse link

Suspension
Fig FA 45 Installing front spring bolt
2 Transverse link mounting

13 Raise the found bumper to the upper spring seat

side Fig FA 46 Cross sectional view link

of transverse bwshing

FA 17
 CHASSIS

2 Loosen the transverse link bolt and

mounting
separate the transverse link from the suspension member

Fig FA 47 Cross sectional view ofballjoint

Removal
Fig FA 49 Loosening fVerse
tran linlt mounting bolt

Jack up the vehicle remove the wheel and remove

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the stabilizer bar and tension rod from the transverse link
3 Remove from the
Loosen the knuckle arm fixing bolts and separate the ball cotter pin castle nut on the

knuckle arm loosen the castle nut and remove the

joint from the strut assembly See Removal of front
knuckle arm from the ball joint
axle and suspension assembly above for details

Fig FA 50 Removing knuckle arm

4 Loosen the ball joint installation nut and remove the

ball joint from the transverse link

5 Withdraw the link

transverse bushing from the
transverse link with a front transverse link bushing
replacer set special tools ST36721000 ST36722000
Fig FA 48 Loosening knuckle arm
fixing bolts and a press

FA 18
 FRONT AXLE FRONT SUSPENSION

2 Replace the ball joint with a new one when the

dust cover is cracked

3 Lubricate the ball joint with multi purpose grease

5T36721 000 10924 50 000 krn 30 000
MIL G2108 or eveI

miles or two years

Install a grease nipple on the plug hole and grease

completely so that old grease is replaced with new

grease Be sure to reinstall the plug when completely

1

greased

Fig FA 51 Removing transverse link bushing

Note When a high p re grease gun i used operate
Inspection the grease gun carefully so that grease i injected
slowly and new grease does not come out from the
Transverse link bushing
clamp portion
Rubber and inner tube joints adhered are sticky
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melted or cracked replace the transverse link as an

assembly

Ball joint Reinstallation

I The ball joint is of i sas embled

non Reinstall the transverse link and lower ball joint in
a type and
reverse sequence of removal noting the following instruc
therefore the ball joint cannot be disassembled
tions
Measure end play toward the axial direction and

shaking torque and replace when deviated from the

standards
the
1 When transverse link collar interior along which
Standard end play axial direction transverse link bushing is inserted is rusted remove it

3 to 10 mm 0 0118 to 0 0394 in
0 with emeI
paper

Shaking torque 35 to 60 kg em

4 to 52 1 in Ib
30
and
2 In order to improve slide make bushing surface
At the colter pin opening position transverse link collar interior wet with soap water when

6 6 to 3 kg
11 14 6 to 24 9Ib inserting the transverse link bushing

3 Fit the transverse link bushing to the transverse link

collar by the use of a transverse link bushing replacer set

special tool ST36720000 In order to unify distances

from the transverse link collar end surface to the bushing
inner tube for both sides the following instructions

apply

I When fitting the transverse link bushing use special

tools ST36721000 ST36722OO0 and ST36723000 and

be sure to face 8 0 mm 31 SO in side of hol1ow part of

0

the special tool ST36723000 upward as shown in Figure

Fig FA 52 Measuring baU joint shaking torque FA 53

FA 19
 CHASSIS

6 Install the knuckle arm beneath the strut assembly

and tighten installation bolt to 4 6 to 6 1 kg m 3
33 to

44 1 lb
ft

ST36721 000

Note a Thoroughly dean the knuckle arm and instal

lation surface on the lower portion of the strut

ST36722000
assembly and make sure that no oil foreign
matter etc are those parts
present on

ST36723000 b Make sure that installation bolt head is correct

ly positioned and tighten it to the rated torque

c Tightening bolts having different length are

used Be sure to use shorter one length below

FA 53 neck 38 mm 1 496 in for the front side and

Fig InstaUing tTansverse ink bushing
longer one length below neck 44 mm 1 732

inll for the rear side

2 distances L between both side

Finely adjust
tiansverse link collar end surfaces and bushing inner lubes
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so that they are evenly aligned

FRONT

I
SEE NOTE b

L L

1 Transverse link 3 Inner tube

2 Transverse link bushing

1 Strut assembly 3 Installation bolt Short

Fig FA 54 Transverse Unk and transverse link
2 Knuckle arm 4 Installation bolt Long
bushing installation

4 Install the lower ball joint the transverse link and Fig FA 55 Installing knuckle ann to strut assembly
on

tighten lower ball joint installation bolt to 2 2 to 3 0 kg m

15 9 to 21 7 ft Ib 7 Install the transverse link on the suspension cross

member and temporarily tighten them with transverse

5 Install the knuckle arm on the lower ball joint and link mounting bolts
tighten ball joint castle nut to 5 to 74
kg m 39 8 to
Note Install the transverse link mounting bolt so that the
53 5 ft Ib Apply a cotter pin and bend it correctly
nut side is faced to the front side of the vehicle
Note Before the
a installing knuckle arm clean the

knuckle arm installation hole and ball joint stud 8 Install the tension rod and stabilizer bar connecting

rod to the transverse link

b When the ball joint castle nut is tightened to the

rated torque apply seal agent to circumference of 9 Jack down the and with the vehicle
remove jatk
the ball joint castle nut to protect the nut from unloaded the transverse link
tighten mounting bolt to 4 0
rust
preventing Occurrence of rust to 5 0 kg m 28 9 to 36 2 lb
ft

FA 20
 FRONT AXLE FRONT SUSPENSION

ADJUSTMENT

CONTENTS

ADJUSTMENT DATA FA 21 ADJUSTMENT OF TOE IN FA 21

ADJUSTMENT OF WHEEL ALIGNMENT FA 21 ADJUSTMENT OF STEERING ANGLE FA 22

ADJUSTMENT OF VEHICLE LEVEL FA 21

1 Carry out wheel alignment on a flat surface with tire defective parts before starting the wheel alignment

air pressure adjusted to the normal pressure

3 The camber and caster angles are preset and cannot
2 Thoroughly check all component parts of the be adjusted Adjust the toe in and vehicle level only
steering and suspension systems and repair or replace

JUSTMENT
AD DATA
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Wheel alignment unladen

Sedan WIgOJI Von

Coupe

Comber 35 to 1035 45 to 1045 45 to 1045

c
Cute 1010 to 2010 1005 to 2005 40 to 1040

in
Toe mm in 4to6 5 to 7 5to7
0 16 to 0 24 0 20 to 0 28 0 20 to 0 28

King pin incJinatlon 7055 7045 7045

Steering ongIo In 430 430 430

Out 360 360 360
Normal tire pre le

When not heated

22 5 22
1 5
1 22
6 00 4PR
12 Ir8 psl
cm2 5
1

JUSTMENT
AD OF WHEEL JUSTMENT
AD OF TOE IN
ALIGNMENT
Measure toe in with a toe in gauge

1 Use a
turning radius gauge and alignment gauge for
2 Loosen the nut indicated by arrow mark in Figure
the measurement
FA 56 and adjust the side rod adjusting bar so that

2 Carry out wheel alignment on a flat surface with tire distance L between both side side rod ball joint centers

air pressure adjusted to the normal pressure is 296 8 mm 11 7 in

JUSTMENT
AD OF VEHICLE
LEVEL

Vehicle level is adjusted by changing springs

FA 21
 CHASSIS

Note a Make sure that clearance between tire tension

rod is 30 mm 1 181 in or more

b When the clearance is less than 30 mm 1 181

in increase the clearance by extending the stopper

bolt Upon completion of the adjustment max

imum height of the stopper bolt should be 27 5

mm 11 083 inI

Q Locking nut
I Side rod adjusting bar
I
Fig FA 56 toe in
Adjusitng

JUSTMENT
AD OF STEERING
ANGLE
I Place the front wheels on turn table
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both side bolts

2 Adjust steering angle adjusting
indicated by arrow mark and set them at the rated

steering angle Fig FA 57 Steering angk adjusting bolt

SERVICE DATA AND SPECIFICATIONS

WheelllipmeDt unladen

Soda w v
Coupe

Cambe 3S to 3
t 45 to 1045 45 10 1045
Cutu 1010 to 2010 loOj to 2005 40 to 1040
T mm in 4to6 5 t07 5 t07
0 16 to 0 24 0 20 to 0 28 0 20 to 0 28

Kin pin iDcUnation 70SS 7045 7045

Strle qIe In 30 30 00
Out 360 360 360

Coil spring

Wire diameter mmOn JO 394

0

Coil outer diameter mm in I JO 33

4

Coil turns 77

Coil effective turns 6 25

FA 22
 FRONT AXLE FRONT SUSPENSION

Free length mm in 1 10
338 13 1
3 394
0

Installed height load mm in kg 20315 7 99 1 0 1969

200 441

Spring constant kg mm 1b in 1 62 90 7

Strut assembly

Strut outer diameter mm in 45 177

Piston rod diameter mm in 18 0 709

Piston diameter mm in 25 0984

Damping force at piston speed 3

0 m sec

Expansion 1b
kg 106
Compression 1b
kg 48
22 48 5

Piston rod

Bend limit mm in 0 1 0 0039

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Wear limit mm in 0 025 0 0010

Piston cylinder

Bend limit mm in 0 2 0 0079

Wear limit inside mm in 0 1 0 0039

Stabilizer bar diameter mm in 17 0 669

Front wheel bearing rotation starting

in lb 18 to 23 15 6 to 20 0
torque kg em

Ball joint shaking torque in Ib 35 to 60 4 to 52

30 1
kg em

Ball joint end play

axial direction mm in 0 3 to 1 0 0 0118 to 0 0394

TIGHTENING TORQUE

Front axle ft Ib
kg m

Brake disc rotor and hub 4 to 6 0 31 8 to 4

43
assembly tightening torque

Wheel bearing lock nut 2 2 to 4

2 15 9 to 174

Disc brake cali per fixing bolt 4 6 to 6 1 33 3 to 44 1

Buffle installation screw 3 to

0 4
0 2 1 to 2 9
plate
Brake disc assembly installation bolt 2 7 to 3 7 5 to 26 8
19

FA 23
 CHASSIS

Strut assembly

Gland packing tightening torque 8 0 to 11 0 57 8 to 79 5

Piston rod self locking nut 3 6 to 4 5 26 0 to 32 S

locking
Self nut used to install the strut assembly
on the body 1 6 to 2 1 11 6 to 15 2

Transverse link and ball joint

Bolts used to install the knuckle arm to strut 4 6 to 6 1 33 3 to 1

44

Ball joint castle nut 5 to 7 4 39 8 to 53 5

Bolts used to install the transverse link to ball

joint 2 2 to 3 0 15 9 to 217

Transverse link mounting bolt 4 0 to 5 0 28 9 to 36 2

Tension rod

Transverse link side 2 2 to 3 0 15 9 to 217

Body side 4 5 to 5 5 32 5 to 39 8
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Stabilizer bar

Connecting rod and transverse link installation nut 0 9 to 1

2 5 to 8 7
6

Connecting rod and stabilizer bar installation nut 0 9 to 1

2 5 to 8 7
6

Stabilizer bar and body installation bolt 0 9 to 1

2 5
6 to 8 7

TROUBLE DIAGNOSES AND CORRECTION

Troubles Possible causes Remedies

Vibration shock and shimmying of Improper air pressure of tire Adjust

steering wheel
Unbalance and deformation of road Correct the unbalance
Vibl3tion Loose connection of the ser wheel or replace
ration parts and rubber coupling parts
Unevenly worn tire or insufficient Replace or tighten
defective rubber and of
coupling wear

each tightening
part of linkage and vibration of

front wheels are in many cases trans

Improperly adjusted front wheel lighten
or worn
Adjust or

mitted the
to steering wheel This is very
bearing
noticeable when travelling over rough
road Faulty wheel alignment Adjust

Wom fitting transverse link bushings Replace

Shock When the front wheels are travel

ling over bumpy roads the play of the

Insufficiently tightened steering gear Retighten
steering linkage is transmitted to the
housing
steering wheel This is especially notice

able when Wear of steering linkage Replace defective parts

travelling rough road

FA 24
 FRONT AXLE FRONT SUSPENSION

Abnormal vibrations of the Worn suspension ball joint Replace

Shimmying
front suspension group and the whole
Excessive backlash due to improper ad Adjust correctly
which when
steering linkage occur a
of the retainer
justment parts
specific speed is attained
Worn column bearing weakened column Check and repair cor

bearing spring or loose clamp rectly

Malfunction ofshock absorber inside the Replace or retighten

strut or loose installation bolts

Unbalance ofvehicle level Correct the unbalance

Vehicle pulls to right or left Improper air pressure of tire or insuf Adjust or tighten
ficient lightening of wheel nuts
When driving with hands off the steering
wheel over a flat road the vehicle gently Difference in height of right and left tire Replace tires

swerves to right or left

treads

Note A defective rear suspension may

Incorrect adjustment or abrasion of front Adjust or replace
also be the cause of this trouble
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wheel bearing
and therefore see also the chapter

dealing with the rear suspension Collapsed or twisted front spring Replace

Incorrect wheel alignment Adjust

Incorrect brake adjustment binding Adjust

Worn rubber bushings for transverse link Replace

and tension rod

Deformed of steering linkage and suspen Replace

sionlink

Unbalanced vehicle level Correct the unbalance

Instability of vehicle Improper air pressure of tire Adjust

Worn rubber bushings for transverse link Adjust

and tension rod

Incorrect wheel alignment Adjust

Wom or deformed steering linkage and Replace

suspension link

Incorrect adjustment of steering gear Adjust

Deformed unbalanced wheel Correct or replace

Stiff steering wheel Improper air pressure of tire Adjust

checking up procedure lubricants im

Insufficient or mixing Replenish greas or re

Jack up front wheels detach the steering purities in steering linkage or excessively place the part

gear and operate the steering wheel and worn steering linkage

FA 25
1

CHASSIS

If it is light check steering linkage and Stiff or damaged suspension ball joint or Replace
suspension groups lack of grease

If it is heavy check steering gear and

Worn or incorrectly adjusted wheel Replace Of adjust
steering column groups
bearing

Worn damaged steering gear and bearing Replace

Incorrectly adjusted steering gear Adjust

Deformed steering linkage Replace

Incorrect wheel alignment Adjust

Damaged strut Uppef end bearing Replace

Damaged or stiff piston or shock absorber Replace

rod in the strut

Interference of steering colwnn with turn Adjust

signal switch
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Excessive steering wh play Incorrectly adjusted steering gear housing Adjust

Worn steering linkage Replace

Improperly fitted of gear box Retighten

Incorrectly adjusted wheel bearing Adjust

Worn transverse link and tension rod Replace

fitting bushings

Noises air pressure of tire

Improper Adjust

Insufficient lubricating oil and grease for Replenish lubrication

suspension ball joint and steering linkage oil and grease or re

their
or breakage place

Loose steering gear bolts linkage and Retighten

suspension groups

Defective shock absorber inside the Replace

strut

Defective wheel bearing Replace

Worn steering linkage Replace

Worn transverse link and tension rod Replace

fitting bushings

Broken collapsed coil spring Replace

Loose strut mounting insulator tightening Retighten

nuts

FA 26
 FRONT AXLE FRONT SUSPENSION

Grating tire noise air pressure of tire Adjust

Improper

Incorrect wheel alignment Adjust

Deformed knuckle spindle and suspension Replace

linkage

Jumping of disc wheel Improper air pressure of tire Adjust

Unbalanced wheels Adjust

Defective shock absorber Replace

Defective tire Replace

Deformed wheel rim Replace

Excessively or partially worn tire Improper air pressure of tire Adjust

Incorrect wheel alignment Adjust

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Defective wheel bearing Replace

Incorrect brake adjustment Adjust

Improper tire rotation Adjust

shifting

Rough and improper driving manner Drive more gently

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No
BULLETIN SUBJECT
No

FA 27
 CHASSIS

SERVICE JOURNAL OR BUllETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No
ProCarManuals.com

FA 28
 SECTION RA

REAR AXLE
REAR SUSPENSION

DATSUN 1200
MODEL 8110 SERIES
ProCarManuals.com

CHASSIS BODY

I NISSAN I

REAR AXLE RA 1

REAR SUSPENSID N RA 4

SERVICE DATA AND

RA 7
NISSAN MOTOR CO LTD SPECIFICATIONS
TOKYO JAPAN
 REAR AXLE

REAR AXLE

CONTENTS

DESCRIPTION RA 1 Inspection RA 3
REAR AXLE SHAFTS RA l Assembly RA 3
Removal RA 1
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r
1
r

1fji

1 Axle shaft
2 Spacer
3 Wheel bearing

4 Wheel bearing collar

5 Oil seal
6 Bearing adjust shim

7 Axle case

8 BraJce drum

RA 1 Sectional view
Fig of rear axle

DESCRIPTION
reinstallation being careful not to damage the sealing
The axle is of
rear a
l
sefi fJoating type The axle
rubber
housing is a press steel Banjo typi housing is
It light in
weight and is sufficiently strong t W1thstand all torsional
and bending is
loa REAR AXLE SHAFTS
The rear wheel bearin ar of preseaIed typ s There
Removal
fore no frequent lubricating rvice iS required HQ ever
when the rear axle is dis embled the wheel bearj I wheel chocks front wheels jack up the
gs Apply on rear

shouid be packed with approved to the of the vehicle and support it stands
an g ease
pri9r 1 on

RA l
 CHASSIS

2 Remove the wheel cover and nuts Remove the road 6 If either the axle shaft or rear wheel bearing is to be

wheel and brake drum If brake linings should hold the replaced remove the bearing locking collar by nicking it
drum slacken off the brake shoe adjuster a few notches deeply with a cold chisel in veral places It will then

slide easily Be careful not to damage the axle shaft with

3 Disconnect the brake from the

pipe Xl wheel the chisel Set the bearing remover ST37130000 and

cylinder Plug up the open end of the brake pipe with a remove the wheel bearing The removed bearing collar

plastic cover or wooden peg to prevent foreign matters should be discarded and should not be reused

from entering the hydraulic line

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RA 2 Disccmnecting brake line

Fig

4 Straighten the and remove it Remove

cotter pin @
clevis pin and disconnect the hand brake cable from the
Fig RA 4 Removing bearing collar
hand brake lever Remove the hand brake return
spring
CID
5 Remove the four bolts the brake back plate
securing
to the axle housing Draw out the axle shaft assembly

together with the brake back plate using sliding hammer

ST36230000 and rear axle stand ST07640oo0

5T37130000

5T07640000

Fig RA 5 Removing wheel bearing

5T36230000

7 It is recommendable that the oil seal be replaced

whenever the rear axle shaft is replaced To remove the oil

Fill RA 3 Removinll axle shaft seal use a suitable bar such as a screwdriver

RA 2
 REAR AXLE

Fig RA 7 Install wheel bearing

Fig RA 6 Removing oil seal

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2 Install the oil seal in place on the axle housing flange

Inspection

1 Inspect the machined surface of the axle shaft and Note When the axle shaft is replaced the new oil seal

the axle housing for rough spots or other irregularities must be used Be sure to apply MP 2 grease
which affect the sealing action of the oil seal between lips of the oil seal

2 Check the axle shaft for straightness cracks damage

wear and distortion The bend amount should be less than

3 mm 0 118 in
0 3 Install the rear axle shaft into the axle housing

Check the clearance between the wheel and

bearing
housing and face If this clearance is exceeding the limit of

o to 0 1 mm 0 to 0 0039 in it the
Note Do not attempt to straighten a bend shaft by adjust by changing
heating adjusting shim having proper thickness

Assembly
Assemble the axle in sequence of removal BEARING ADJUSTING SHIM
rear reverse

noting the following points

1 Place the bearing spacer wheel beariAg and bearing

collar on the axle shaft and press them on the shaft with

a force of 3 to 5 tons using a press stand ST38270000

Note A new rear wheel bearing should be packed with

specified MP 2 grease
Fig RA 8 Wheel aring
be
tohousing end face clearance

RA 3
 CHASSIS

4 Tighten the brake back bolts

plate to housing flange
with
and nuts a
torque of IS to 2 0 kg m 10 8 to 14 5

lb
ft Check the rear axle shaft end play as shown in

Figure RA 9 The end play should be less than 0 1 mm

0 0039 in

RA 9
Fig Checking axle shdft end play

REAR SUSPENSION

CONTENTS
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DESC R I PTI ON RA 5 Installation RA 6

REAR SPRING RA 5 REAR SHOCK ABSORBER RA 6

Removal RA 5 Replacement RA 6
I nspection and repair RA 5 Inspection RA 6

1 Leaf spring 5 Axle 8

case Hand brake wire
2 Front mounting 6 Gear curier 9 Brake hose
3 Shackle 7 Torque arrester 10 Bound bumper
4 Shock absorber

FiR RA l0 Rear suspension

RA 4
 REAR AXLE

Loosen three nuts securing the front

DESCRIPTION 5 the fIxing
bracket remove the front bracket from the leaf spring
Rear suspension consists of elliptic
semi leaf s rings
front eye and car body and lower the rear spring
telescopic hydraulic shock absorbers and rubber bumpers
The rear spring center pin is ofT set 110 mm 33
4 in

toward the front from the center of the spring This is

done to reduce spring up and to decrease the 3rc

wind

while the rear wheel swings through Thereby minimizing

vehicle
the possibility of the rear suspension effecting
stability
Iso clamp devices are used for attaching the axle

housing to the spring

axle
The leaf springs shock absorbers and rear housing
are mounted on rubber bushings at each end to minimize

noise and vibration of the transmission to the car body

and passenger compartment

REAR SPRING
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Fig RA 12 Rear spring front bracket

Removal
6 Remove upper and lower nuts of the rear shackle
1 Jack up the center of the rear axle until the wheels

are clear from the ground Support the rear end of the

frame on stands

Fig RA 13 Shackle

Fig RA 11 Rear spring bo

u ts
Inspection and repair

2 Disconnect the shock absorber bottom end from the I Examine he spring leaves for fractures or cracks

spring lower seat

2 Test spring and compare with the specifications given

3 the rear axle with a jack in SelVice Data and Specifications If the spring is
Support housing
found defective replace with a new assembly
4 Loosen the lock nuts of the V bolt and
rear spring
remove the bolts spring seat location plates and seat pads 3 Check the front pin shackle V bolts and spring seat

RA 5
 CHASSIS

If 2 Remove the lower end of the rear shock absorber

for wear cracks straightness and damaged threads
from the spring seat See Figure RA 14
defective parts are found replace with new ones

4 Inspect all rubber parts for wear damage separation

and deformation Replace them if necessary

Installation

Install the in reverse sequence of removal

rear spring
noting the following matters

1 Coat the front bracket pin front bracket bushing

shackle pin and shackle bushing with a soap solution prior

to assembly

2 The front pin securing nut and shock absorber lower

end securing nut should be tightened with the vehicle

unladen
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Note Make sure that the flange of the shackle bushing is

both sides
clamped evenly on

Fig RA 15 Removing shock absorber upper bracket

3 Remove the rear shock absorber installing nut

REAR SHOCK ABSORBER
located under the rear seat back

Replacement 4 Install real shock absorber in reverse sequence of

Jack up the center of the rear axle and support the removal

axle housing with stands

Inspection

Test the shock absorber and compare with the

specifications given in Service Data and Specifications

Replace if necessary

2 Check for leakage cracks and the shaft for

straightness

3 Inspect the rubber bushings for damage cracks and

excessive deformation Replace the defective parts if

necessary

Removing the shodc absorber lower

M 14 d
Fig

RA 6
 REAR AXLE

SERVICE DATA AND SPECIFICATIONS

Shock absorber

Applied model Sedan Coupe Van

Stroke x max length mm in 167 x 506 6 57 x 19 9 180 x 440 7 09 x 3

17 180 x 468 7 09 x 4
18

Damping force at 3m
O s

Rebound kg Ib 58 128 68 I SO 90 198

38 83 8 45 99 2 45 99 2
Compression kg lb

Rear spring
6 2
width thickness I 1
Length x x
1 lOx50x 1 llOx50x 1 110 x SO x 7 I
2 2
No of leaves II I
in
mm
0 2362 2
0 2362 I
43 7x 1
97xO 2756 2 43 1 1
97x8 mU 43 7x 1 97xO 2756 1
433
0 I 11
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Spring kg in 1 96 109 1 96 109 3

2 128 8
constant lb
mm
when unloaded

4 2 235 2 when loaded

Camber

Free mm in 109 3 4 29 iO 1181 109 3 4 29 i0 1181 131 is 5 ISiO 1969

Loaded with specified load 11 433

0 11 433
0 I 433
0

mm in

295 650
Specified load kg lb 192 423 192 423

Spring eye diameter

Front mm in 35 378
1 35 378
1 35 378
1

Rear mm in 23 0 906 23 0 906 23 0 906

Rear axle

End play in
mm Less than 0 1 0 0039

Rear axle end shim mm in 0 1 0 2 0 5 0 0039 0 0078 0 0195

Wheel bearing collar pressing

force 1b
ton 3 to 5 6600 to 11000

Tightening torque
kg m ft Ib

Axle shaft tohousing bolt nuts 9 to 14 5

flange S
J to 2 0 10

Differential carrier to housing bolts 17 to 5

2 3
12 to 18 1

V bolts 3 2 to 4 0 23 1 to 28 9
Spring

RA 7
 CHASSIS

Wheel nuts 8 0 to 9 0 57 8 to 65 1

Spring front brake to body bolt nuts

Sedan and 1 6 to 2 0 116 to 14 5

Coupe
Van 3 2 to 4 0 23 1 to 28 9

Spring shackle pin nuts 1 6 to 2 0 116 to 14 5

Shock absorber upper nuts

Sedan and Van 3 6 to 4 5 26 0 to 32 5

Coupe 09 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

Torque arrester body

to bolts 0 6 to 0 8 3 to 5 8
4
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SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No

RA 8
 SECTION BR

BRAKE

DATSUN 1200
MODEL 8110 SERIES
ProCarManuals.com

CHASSIS BODY

a
I NISSAN I

BRAKE BR 1

SERVICE DATA AND BR 23

SPECIFICATIONS

TROUBLE DIAGNOSES BR 24
NISSAN MOTOR CO LTD AND CORRECTIONS
TOKYO JAPAN

i
 BRAKE

BRAKE

CONTENTS

DESCRIPTION BR 2 Removal and disassembly BR B

BRAKE PEDAL BR 2 Inspection BR 9

Removal BR 2 Reassembly and reinstallation BR 9

BR 2 FRONT DISC BRAKE BR lO

Inspection
Reinstallation BR 2 Brake pad BR ll

TANDEM MASTER CYLINDER BR 3 Caliper assembly BR 12

Removal BR 3 Reassembly BR 14

BR 3 Reinstallation BR 16
Disassembly
BR 3 REAR BRAKE BR 16
Inspection
Reassembly BR 4 Removal and disassembly BR 17

Reinstallation BR 4 Inspection BR 17

SINGLE MASTER CYLINDER BR 4 Reassembly and reinstallation BR 18

Removal and disassembly BR 5 HAND BRAKE BR 18

Removal BR 19
Inspection BR 5
ProCarManuals.com

1 nspection
Reassembly and reinstallation BR 5 BR 19

BRAKE LINE BR 5 Reinstallation BR 20

Removal BR 5 ADJUSTMENT BR 20

Brake shoe clearance BR 20

Inspection BR 6

Reinstallation BR 6 Brake pedal height BR 21

Hand brake BR 21
Brake line pressure differential
BR 7 Bleeding hydraulic system BR 22
warning light switch
FRONT DRUM BRAKE BR 8

1 Brake hose 5 Brake hose

2 Brake master cylinder 6 3 way connector

3 3 way connector 7 Hanger strap
4 Hand brake lever 8 Turn buckle

Fig BR 1 Brake system

BR l

1
 CHASSIS

DESCRIPTION Removal

The Datsun 1200 series new models adopl a hydraulic I Unhook the relum spring
brake Disc brake or leading
two shoe type drum brake is
used for the front wheels and leading trai1ing shoe type 2 Remove the spring pin from the clevis pin which is
drum brake is used for the rear wheels used to connect the master cylinder push rod to the brake
With adoption of the disc brake safety at high speed the clevis pin
pedal arm remove and separnte the push

range driving is further improved rod from the pedal arm

For the mas1er cylinder either single type or tandem

is used There 3 Remove the fulcrum pin which is used 10 connect the
1ype are two types of tandem type master

pedal to the brncket and

cylinder one is for disc brake and the other for drum arm
separate the pedal arm from

brake Under the standard the bracket

specifications however the
tandem type master cylinder is used for disc brake and

single 1ype is used for drum brake

The tandem masler cylinder provides a dual brake

system improving safety

The hand brake is of a mechanical type which brakes
the rear wheels through the control l r and s1ee wire
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The control lever is located between the driver and

assistant seats and can be operated easily

@
BRAKE PEDAL

The steering column bracket supports the brake pedal t Sprina pin 5 Nut 9 Return pring
The brake is installed the steering column
pedal on 2 Oevis pin 6 Spring washer 10 Brake pedal arm
brncket with fulcrum pin The brake pedal 3 Washer 7 Nut II Brake master
a arm and
4 Spring washer 8 Fulcrum shaft cylinder
brake master cylinder push rod are joined with a clevis
switch opposes the brake Fig BR Brake pedal components
pin The stop lamp pedal arm
tandem type master cylinder
brackel and opera1es as the pedal arm moves

Inspection

I Check for and the return spring for

sliding parts wear

weakness

2 Check the brake pedal for bending warping and

crack

3 Check other parts for serviceabilities

Reinstallation

Reinstall the brake pedal in reverse sequence of

removal noting the following matters

I Grease sliding parts and return spring hook with

1 Stop lamp switcl1 4 Clem pin multipurpose grease MIL G2I08 or GI0924
2 Brake pedal stopper 5 Push rod
3 Brake pedal arm 6 Fulcrum pin 2 Tighten the fulcrum pin installation nut to 2 to

2 9 kg m 15 2 to 21 0 Ib
ft
BR 2 Brake pedal instaUation
Fig

BR 2
 BRAKE

TANDEM MASTER CYLINDER

The tandem masler cylinder aIIows either front or rear The tandem lype master cylinder is manufactured by
brake displaying sufficient braking effect although a NABCO or TOKICO When disassembling and reassem

trouble occurs in one side of either front or rear brake bling be careful not to mix the individual manufacturer s

improving driving safety parts

t
i
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Fig BR 4 Cross sectional view of tandem type

J master
cylinder
Removal
bly and piston spring
J Remove the clevis pin and separate the brake pedal
from the master cylinder push rod
4 Remove the valve cap and remove the valve as

2 Disconnect the brake tube from the master cylinder sembly

Note Disassemble the master cylinder carefully so that

3 RemOve the master cylinder installation bait remove
the sliding R1rface of the piston and piston cup are
the master cylinder shim and remove the master cylinder
Do not remove the fluid reservoir
not damaged
assembly from the body unless really necessary Moreover do not remove

the piston cup unless the piston is replaced

Disassembly
Inspection
Drain brake fluid and remove the
stopper bolt Thoroughly clean all disassembled parts check for
wear damage and other defective conditions and replace
2 Remov the dust the snap
cover remove ring and if necessary
and remove the
stopper ring push rod assembly
Note Do not dean rubb parts with mineral oil since
11
3 Take dut the piston mechanism components in order they are deteriorated Use brake fluid or alcohol
1
of the piston assembly piston assem When alcohol is used however do not immerse
priniill secondal

BR 3
 CHASSIS

rubber parts alcohol

und longer than 30 seconds disassembly noting the following matters
After the parts are deaned dry them with com Apply brake fluid to the component pdrts such as

pressed air cyJinder bore piston etc and carry out the operations

carefully so that the component parts are not damaged or

I Check the and
cylinder piston for damage and
no dust and other foreign matters enter the cylinder and
the
uneven wear on sliding surface and for other defective
brake fluid reservoir Moreover for rubber parts such as
conditions Replace as required
piston cup etc apply rubber grease slightly

2 Replace if the cylinder and piston clearance is more

Tightening torque
than 0 15 rom 0 006 in
Valve cap

3 In and 5 to 3 5 kg m
2 1 to
18 3
25 lb
ft
principle replace the piston cup packing
valves with new ones whenever the master cylinder is Bleeder screw

disassembled Be if damaged
sure to replace worn 5 kg
0 m 3 6 lb
ft
weakened orexpanded
Stopper bolt
0 15 to 3 kg
0 m 1 to 2 2 ft Ib
4 Check the return springs for wear damage and other
defective conditions and replace as required Reinstallation
Reinstall the master cylinder in reverse sequence of
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5 Replace others if deformed damaged or defective

removal After air bleeding make sure that no brake fluid

leaks from the circuit For the pedal height adjustment

Reassembly
Assemble the refer to the paragraph pedal adjustment
master cylinder in reverse sequence of

SINGLE MASTER CYLINDER

Fig BR 5 Cross sectional view of sing master

cylinder

BR 4
 BRAKE

Removal and disassembly installed in the same manner as the tandem type master

The single master cylinder is removed and disassembled cylinder

in the same manner as the tandem type master cylinder

Inspection BRAKE LINE

Refer to the section covering Inspection of tandem double wall construction steel
The bl1lke pipe adopts a

type master cylinder this construction the

tubing and with rigidity has been
improved Moreover the portion of brake line laid
Reassembly and reinstallation beneath the vehicle floor is galvanized the
improving
The is reassembled and corrosion resistance
single master cylinder re
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1 Bridge tube 9 Brake hose

8 10 tube
2 Brake tube Bridge
3 Brake hose 11 Brake tube

4 Brake tube 12 Brake hose

5 Brake tube 13 Brake tube

10 6 3 way connector 14 3 way connector
7 Brake tube 15 Brake tube
8 Brake hose

Fig BR 6 Brake line

Removal

I Remove flare nuts from both ends of the brake tube

steel tube and remove clips used to secure the brake

tube on the panel The brake tube can be removed easily

Brake master cylinder 2 Front 3 way connector

Fig BR 7 Brake tubes around master cylinder

BR 5
 CHASSIS

Inspection

Thoroughly clean the brake tube and brake hose and

check them for crack

collapsing scar and rust brake
tube and for weakness brake
expansion wear etc

hose

Replace if defective

2 Remove mud and dust from the brake tube clip unit
md check the clip If the clip covering vinyl coaling is
tom repair
G Front 3 way connector
0 Brake master cylinder
I
BR 8 Front J way connector
Fig

2 The brake hose rubber hose is used at the front

strut unit and rear axle

assembly housing unit Remove Reinstallation
Ihe flare nut from Ihe brake tube and remove Ihe hose
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I Provide a sufficient space between the brake lines

and other parts so that the brake lines are not interfered
with other paris due to vibration
during driving

BRAKE TUBE

PANEL

CLIP COATED WITH VINYL

3 Rear axle
housing

BR 9 Brak
Fig hoand 3 way connector around
rear axle housing

Fig BR ll Brake tube installation clip

2 When the brake hose is disconnected from the 3 way

connector on the rear axle housing once be sure to

replace the copper packing with a new one

3 Be careful not to warp or twist the brake hose and

particularly be careful not to interfere the brake hose with

tires and suspension components

o Brake hose ut assembly 4 Do not tighten the brake line installation flare nut

Fig BR l0 Brake hose around front strut forcedly or excessively

assembly

BR 6
 BRAKE

ground circuit for the

warning light is completed and thus
Tightening torque
the warning light lights
3way connector S to 18 kg
I m
In this case correct the hydraulic brake problem and
10 8 to 13 0 ft b
bleed the brakes
Master S to 1 8 kg
I Check the warning switch assembly for
cylinder m light a proper

10 8 to 13 0 ft Ib operation Check the switch assembly for fluid leakage

Brake hose S to 1 8 kg
I m

10 8 to 13 0 ft Ib Note Do not attempt to repair switch for any reason

repl8CllIWitl
h bly completely
Air bleeder 0 7 to 0 9 kg m

5 1 to 5 ft Ib
6

5 Fill the master cylinder brake fluid reservoir with

brake fluid and perform air bleeding completely

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Note a Do not use brake fluid oththan specified

b The fi8d brake fluid is used for both single

end tandem type master cytindon

6 Upon completion of air bleeding make sure that the 1 To front brake LU 4 To rear brake L U R H
2 From master cylinder F 5 To front brake R H
brake operates correctly and check the brake tube and
3 From master cylinder R
hose connectors for fluid leaking Fully depress the brake
Fig BR 12 Warning light switch
pedal continue to depress the brake pedal for several
seconds and make sure that no brake fluid leaks from any

part of the brake line Replace defective parl if required

Brake line pressure differential

warning Ii ght switch

A Warning light is located on the instrument to

panel
warn the driver when a pressure difference of 13 to 17
kgcm2 185 to 2421bfsq in exists belween the fronl and

rear brake syslems

A hydraulically actuated warning light switch is located

in the engine compartment Both front and rear brake

1 Wire terminal 3 Valve assembty
systems are connected to this switch assembly 2 Brake tube 4 Piston load spring
When a pressure difference of 13 to 17 kg cm2 185 to

242 Ibfsq in occurs between the front and rear brake

sys1ems the valves will shuttle toward the side with the
low pressure The valve conlacts with the switch tenninaI Fig BR 13 Sectional view of warning light switch

BR 7
 CHASSIS

FRONT DRUM BRAKE

J
t o
o

r l

Gl

e
e
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Fig BR 14 Front drum brake components

Removal and disassembly 4 Unhook the retum spring and remove the brake shoe

I Jack up the vehicle support with a stand and assembly

remove the wheel cover and tire
5 Disconnect the bridge tube from the fore and after

the hub cap wheel cylinders

2 Remove the brake drum and remove

and hub assembly from the spindle

unit of the
3 Disconnect the brake tube at the bracket

strut assembly Fot the details refer to Section FA

1 A fief wheel cylinder 3 Fore wheel cylinder

2 Bridge tube

Fig BR 16 Fore and after wheel cylinders

and bridge tube

and the fore

6 Remove the installation bolts remove

Front drum brake and after wheel cylinders

Fig BR 15

BR B
 BRAKE

7 Remove the brake disc installation bolt and remove 5 Check the brake disc for distortion
the brake disc from the spindle
6 Check the bore of the wheel cylinder for wear sign
8 Disassemble the wheel cylinders of rust and damage
If clearance between the cylinder and the piston
Inspection exceeds 0 15 mm 0 0059 in replace them

Drums If they show score excessive out of round

and so forth reconditioning by machining is required

Brake drum inner diameter

203 2 mm 8 00 in

Drum inside out of roundness

Below 0 02 mm 0 0008 in

Limit of reconditioning drum in diameter

10 mm 0 0394 in

2 Linings If brake shoe linings are incompletedly

seated soiled or greasy or deteriorated due to excessive
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them If the thickness of the

heating repair or replace
lining is less than 5
1 mm 0 0591 in replace it

Note 8 If oil or grease is found on linings clean

thoroughly with carbon tetrachloride or gasoline

b After installing and bonding lining grind the Fig BR 18 Sectional view offront wheel cylinder

lining face to a diameter equal to the brake drum

7 When the wheel cylinder is overhauled recommend

3 Check the adjusting cams for their smooth operation
that cups be replaced even if apparently they are in

satisfactory conditions Cups must be replaced if de

4 Return springs If they are considerably weak
formed due to damage crack corrosion smelling and or
replace them
aging
Return spring dimension

Wire diameter x free length turns

3 2 x 118 mm 20 5 Reassembly and reinstallation

0 1260 x 4 65 in 20 5 The rear brake is reassembled and reinstalled in reverse

sequence of disassembly and removal However note the

Load x length
following matters
55 I2I
kg Ib x 127 1 mm 5 00 in

I When assembling the wheel cylinder be to

sure apply
13 4 0 528 rubber grease to the piston cup and other rubber parts

slightly

23 2 When installing the wheel cylinder to the brake disc

0 906
118 4 65 apply brake grease to the cylinder disc and adjusting
FREE lENGTH
UNIT plate sliding surfaces and to the wheel cylinder lever
mm in
fulcrum portion sufficiently so that the wheel cylinder

BR 17 Return slides smoothly

Fig spring

8R 9
 CHASSIS

4 brake shoe clearance

Adjust and perform air

bleeding on the hydraulic system

FRONT DISC BRAKE

type disc brake Model ANNET 14A

12
Floating is

used for some territories as a standard

Rigidity of the caliper is

high brake pedal feeling is

adequate and the pad dragging is minimized The pad is

retumed by elasticity of the piston seal When the pad is

worn the piston operating stroke increases slipping

occurs on the piston seal surface and thus clearance is
Fig BR 19 brake due
Greasing point on
adjusted automatically
3 Tighten the brake disc installation bolt to 2 7 to 3 7 Moreover in order to prevent brake squealing a shim is

kg m 19 5 to 26 7 ft Ib inserted behind the pad

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I Clip 6 Brake 11 block

pad Cylinder
2 Spring 7 Air bleeder 12 PisCon A
3 Clevis pin 8 Retaining ring 13 Bias spring
4 Shim 9 Boot 14 Yolee spring
5 Ha cr
spring to Piston B 15 Yoke

BR 20 Front disc brak

Fig components

BR l0
 BRAKE

CYLINDER SIDE

PISTON SIDE

L
COMPRESSION
DECOMPRESSION
Movement exceeding the Returns in elastic
elastic displacement is
displacement of the
released with slipping on seal
the seal surface

Fig DR 2l Withdrawing brapad and shim

Note When the brake pad is removed do not depress the

brake or otherwise the piston will come out

Fig BR 21 Piston seal automatic adjusting operation pedal

Inspection
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Brake pad Clearance between the brake pad and rotor is adjusted
automatically Check the brake pad for wear after the
Replacement 6 000 miles driving and every 5 000
first 10 000 km
I Jack up front unit of the vehicle and remove the km 3 000 miles thereafter
front wheel
I Clean the brake pad with arbon tetrachloride or

2 Remove clip from the retaining pin and supporting gasoline

the brake pad remove the retaining pin and coil spring
2 When oil and or grease is heavily sticked on the pad
or when deteriorated or deformed due to overheating

replace the pad with a new one

3 When thickness of the friction material pad is less

than 1 6 mm 0 0630 in replace

Replace when total pad thickness is less than 6 1 mm

0 2402 in

Note Recommend pads be replaced as a set Replace

position cause uneven brake

ment at only one may

effect Recommend rotation of pads be made

periodieally

4 Check the rotor Refer to Rotor inspection

Reinstallation

Brake pad Clip

I Clean the calipers and piston pad installing parts
I 2 Retaining pin
J Note Do not use mineral oil Be eareful not to apply oil

Fig BR 22 Removing retaining pin on the rotor

that pad
3 Unhook the hanger spring and withdraw the brake 2 Depress the piston into the cylinder so new

pad and shim with a pair of pliers can be installed

BR ll
 CHASSIS

Fig BK 24 Ikpression piston A and B into cylinder

Note a Note that brake fluid may overflow from the

ARROW MARK
reservoir Recommend operation be canied out by
the to release brake fluid
loosening
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breath

b The piston can be easily pushed in by hand But

the groove of piston goes

if pushed excessively
c
inside of seal as shown in Figure BR 25 and the

seal will be damaged When the piston is pushed

into the the brake
excessively cylinder remove

the
assembly disassemble it push out the piston to
arrow direction as shown in Figure BR 25 and

reassemble
Fig BR 26 Arrow mar on shim

I Install the shim so that the all ow mark points the

rotor forward rotating direction

2 Apply the coil spring to the retaining pin which is

distanced from the air bleeder

4 When the pad is installed depress the brake pedal

J

several times so as to settle down the pad in the

l@
I
I
position
I
I

Caliper assembly

RemowI

Piston seal Norrnal position I I Remove the brake pad Refer to Pad re

placement

in position Disconnect the brake tube from the wheel

Fig BR 25 Piston pushing 2 cylinder

Install and shim assemble the 3 Remove the strut assembly and knuckle arm instal
3 pad anti squeal
lation bolt to ease removal of the caliper assembly
spring and retaining pin and them so as
squeal
anti secure

with inslaIlation boll

clip

BR 12
 BRAKE

Fig BR 27 Removing strut assembly and knuckk ann

Fig BR 29 Tapping yoke head
installation bolt

4 Remove the caliper assembly installation bolt and 5 Remove the bias ring from the piston A

separate it from the strut assembly

6 Remove the and boots from the
retaining rings
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pistons A and B

Removing caliper assembly installation bolt

Fig BR 28
Q Retaining ring
o Boot

Disassembly Fig BR 30 Cylinder body and piston

7 Depress and remove the piston from the cylinder

1 Remove mud and other contaminations from the

caliper assembly before disassembly 8 Remove the piston seal from the cylinder

2 Drain brake fluid from the wheel Note Remove the piston seal carefully with fingers so
cylinder
that the wall is not damaged
cylind
3 Loosen the air bleeder and depress tha pistons A

and B into the cylinder Refer to Pad 9 Remove the yoke spring and yoke bias spring from
replacement
the yoke
4 Secure the yoke in a vise and tap the yoke head
with a hammer The cylinder body can then be
Inspection and repair
removed from the yoke When removing the cylinder
Thoroughly clean all disassembled parts and check
body be careful not to allow the piston A coming out
them for the following items
from the cylinder

BR 13
 CHASSIS

Note When cl lOing parts

rubb use alcohol or brake

fluid If rubber parts are cleaned with mineral oil

they will be deteriorated

1 Calipers
If the cylinder wall is damaged or worn replace If the

cylinder wall is rusted or

foreign matters are accumu

lated on the cylinder wall carefully polish with fine

emery paper so that the cylinder wall is not damaged
Ifrusted or roughened excessively replace

2 Pad

See paragraph covering replacement of pad

BReJ1
Fig M ring defkction of disc
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3 Piston

Replace if unevenly worn damaged and or rusted

Reassembly
Note The piston sliding surface is plated Thus do not
I Apply the rubber grease to cylinder bore and install
use emery paper aJthough rusted or foreign
the piston seal
matters are slicked on the sliding surface

2 Insert the bias ring to piston A so that the roundish

portion of bias ring comes to the bottom of piston

4 Seals

Primarily replace both piston and dust seals whenever

overhauling

Nota The piston seal affects not only leaking but also

piston rebJm For this reason replace the piston

seal even if the damage is minor

5 Rotor

Check the rotor and if it shows score excessive out of

round and so forth reconditioning by machining is

required If any abnormal conditions such as crack

1 Yoke 3 Piston A
distortion and excessive deflection replace the rotor
2 Chamfer 4 Roundish portion
Standard rotor thickness

9 5 mm 3740
0 in

limit of reconditioning rotor in thickness

4
8 mm 3307
0 in Fig BR J2 Installing bias ring into piston A

Deflection of the rotor

Below 0 03 mm 0 0012 in Note Be careful not to confuse the piston A with B

BR 14
 BRAKE

J
i

tu
PISTON B
P ISTON A

BR 35 InstaUaticn 1
Fig BR 33 Piston A and B Fig ofyoke spring

3 Apply rubber grease lightly to the sliding portion of

piston and insert the piston into the cylinder
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Note When inlllrting the piston be careful not to insert

too much

4 Install the boot and retaining ring

2
Fig BR 36 InstaUaticn ofyoke spring

7 Install the bias spring to yoke so that the bias spring

BR 34 Inst4Uing boot comes to the air bleeder side of cylinder

Fig

8 Apply the brake grease to the yoke sliding portion of

5 Install that the yoke groove of bias ring of piston

so cylinder
A coincides with the yoke groove of cylinder
9 With the yoke spring inserted to cylinder groove

that the of yoke spring lightly position of the bias spring so that the
6 Install so projected portion correct

faces to disc as shown in Figures BR 35 and 36 groove of bias spring conincides with yoke

BR 15
 CHASSIS

Fig BR 38 Measuring starling torque

Fig BR J7 Correcting bias spring position

10 Assemble the cylinder body and yoke by tapping Starting torque

the yoke lightly 9 0 cm 7 80 in Ib
kg

At the hub bolt

II Apply the brake grease fully to the yoke sliding
57
1 3 45 Ib
kg
groove of cylinder
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Tightening torque
12 Install the air bleeder

Caliper assembly installation bolt

Reinstallation 4 6 to 6 1 kg m 3 to 44 1 ft lb
33

Reinstall the caliper assembly in reverse sequence of Brake tube flare nut connected to wheel cylinder
removal 5 to 1 8
1 m 10 8 to 13 0 ft Ib
kg
After the pad is installed completely bleed the

hydraulic line and measure the rotation torque ofdisc

REAR BRAKE

00

7
I
e i
o
i
Q e

1
4

BR 39 Rear brae construction

Fig

BR 16
 BRAKE

Remove the flange bolt from the axle housing

Removal and disassembly 7 rear

remove the rear axle shaft The brake disc can then be
side of the vehicle with
1 Jack up the rear support a
with the axle shaft Refer to
removed together rear

stand and remove the wheel

Section RA

2 Loosen the hand brake wire remove the clevis pin

wheel lever and disconnect the
from the rear cylinder
hand brake wire Remove the return spring pull spring

Fig BR 42 Removing brake disc

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Inspection
For the rear brake inspection the instructions for front
1 Return spring 3 Clevis pin
drum brake apply
2 Hand brake wire 4 Wheel cylinder lever

Return spring dimensions

40
BR hand brake wire
Fig Removing

3 Remove the brake drum Remove the shoe retainer Wire dia x free length
Load x length
and return spring and remove the brake shoe assembly effective turns

2 0 x 119 2 mm 28 10 6 kg x 132 7 mm

Cylinder
0 0787 x 4 69 in
4lb
33 x 5 22 in
side
28

2 0 x 69 5 mm 20 8 6 kg x 76 7 mm

Adjuster 2 736 in
0 0787 x
61b 3 020 in
side 19 x

20

CYLINDER SIDE
12 472L
0

E
58 2 283
119 2 4 69 I
Brake shoes FREE LENGTH
Return spring
Shoe retainer Adjuster
ADJUSTER SIDE
Fig BR 41 Rear drum brake
12 472
0

4 Disconnect the brake tube from the wheel cylinder

5 Remove the dust cover adjusting shims and plates

UNIT
11 0

mm
433r I42
in
69 5
1
2 736
r
The wheel cylinder can then be removed easily FREE LENGTH

Fig BR 43
6 Remove the adjuster assembly

8R 17
 CHASSIS

Reassembly and reinstallation

Reassemble and reinstall the rear brake in reverse

sequence of disassembly and removal noting the follow

ing matters When reassembling refer to the notes for

front drum brake

Measure the wheel cylinder sliding resistance with the

brake tube disconnected as shown in Figure BR44 and
make sure that the sliding resistance is in range from 2 to

7 kg 409
4 to 432
15 Ib

Note When sliding is the brake shoe does not

improp
return smoothly

2 Tighten the brake disc installation bolt flange bolt

15 to 2 0 rn
kg 10 8 to 5
14 lb
ft
o Sprina balancet
G W cylinder

3 Tighten the adjuster assembly installation bolt 1 6 to

Fig 44
BR Measuring sliding resistance
2 2 kg II6 to 15 9 lb
ft
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HAND BRAKE

1 Hand brake lever 5 Turn buckle Hand brake 8 Hanger strap

2 Cabte adjuster 9 Return spring

3 6 Cable 10 Cable shank

Clip
4 Lock plate 7 Cable 11 Hand brake fever cover

Fig BR 45 Hand brake construction

BR 1S
 BRAKE

Removal rlr
Sf

I Loosen the buckle

turn adjusting nut and septe
the front cable from the rear cable O
0 s 7

fqI
Y
0

1
l
b J
I
0 j 0
0
c
1 r 1

1ltL
1

p installation bolt
Hanger Itn 12 Lock plate

Fig BR 48 Disconnecting rear cable from

o
TeaT axle IwllSing
f
5 Loosen the hanger strap unit nut and the
separate
parts into nut hanger strap washer and bracket Discon

1 Rear cable 4 Front cable nect the wheel cylinder lever side brake cable
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2 Turn buckle 5 Propeller shaft

3 Lock nut

Fig 46
BR Removing turnbuckle

2 Remove the lock plate located immediately in front

of the turn buckle the in the

remove clip passenger
side and disconnect the front cable
compartment

3 Remove the hand brake lever cover Remove the

lever assembly with the front cable connected toward the

passelljlOr compartment side

1 DWlt cover 4 Hanger strap

2 washer 5
Hanger strap Hanger strap instal
3 Bracket lation bolt

Fig BR 49 Hanger strap mounted on rear axle housing

Note Do not remove the dust cover from the cable but

leave it installed on the cable

Inspection

J Check the cable for damage and other defective

conditions and replace if required

cable Hand brake lever

BR 47
J 2 Replace if sliding part is worn excessively
Fig Removing hand brake lever
4 Remove the hanger strap installation bolt withdraw Make
3 sure that the hand brake lever can be operated
the lock plate from the axle housing bracket unit and smoothly and that the ratchet pawl and teeth are not

disconnect the rear cable worn unusually or damaged

BR 19
 CHASSIS

depress the 3 Turn the cam adjusting stud counterclockwise up to

4 With the hand brake lever pulled
button and make sure that the pawl disengages the such an extent that the brake shoe is separated slightly
push
is depressed 5 to 6 mm from the brake drum
teeth when the button
push
0 1969 to 0 2362 in completely
4 Turn the brake drum and if the brake shoe

interferes lhe brake drum readjust the clearance In

5 Make sure that the cable dust cover is not damaged
addition depress the brake pedal and make sure that
Ot warped
the brake operates effectively and correctly

Reinstallation
Front disc brake
hand brake in
Reinstall the reverse sequence of
Ordinarily adjustment is not required because clear
removal noting the following mailers
ance between pad and rotor is adjusted automatically
1 Be careful not to damage or twist the dust cover
by elasticity of the piston seal

the cable
2 Tighten the hanger strap and connecting
Rear brake
nut to 0 8 to 10 kg m 5 8 to 7 2 ft lb
the wheel
Jack up the vehicle and remove

3 When adjusting rear brake shoe clearance be sure to

2 Applying your hand and tool from reverse side of
loosen the inner cable sufficiently
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the brake disc tighten the brake adjuster wedge

clockwise up to such an extent that the brake shoe
4 Grease the sliding parts with multi purpose grease
comes into contact with the brake drum
MIL G2J08 or GJ0924

JUSTMENT
AD

Brake shoe clearance

Front drum brake

the wheel
I Jack up the vehicle and remove

drum installed tighten the cam

2 With the brake
extent that the
adjusting stud clockwise up to such an

brake shoe comes into contact with the brake drum

side of
by applying your hand and tool from reverse

the brake disc

brake shoe clearance

Fig BR St Adjusting rear

that the
3 Return the adjuster wedge properly so

brake shoe is separated from the brake drum slightly

4 Turn the brake drum and if the brake shoe

de
interferes the brake drum readjust In addition
aJ1d make sure that the brake
press the brake pedal
Fig BR 50 Adjtsting front brake shoe clearance operates effectively and correctly

BR 20
 BRAKE

Brake pedal height

Ai
BRAKE M ASTER
L JICYLINDER
r TOP LAMP SWITCH
ci
I ll
Q

ADJUSTING SHIM
r tJ

0 5 mm 0 0197 in
t
THICKNESS 0 8 mm 0 0315 in

1 6 mm 0 0630 in
ProCarManuals.com

Fig BR 52 Brake ped4 adjustment

1 Loosen the stopper up to such extent that the brake Hand brake
pedal stopper is separated from the pedal arm

1 Turn the turn buclde properly and adjust hand brake

that stroke is
2 Measure height of the brake pedal head from the lever operating stroke correctly so operating
of I I
dash panel and adjust the adjusting shim between the 5 mm
78 3 091 in 6 notches at operating force
brake master cylinder and dash that height is to IS kg 3
24 to 33 1 Ib Upon completion of
panel so

lock nut
5
143 rom 5 65 in adjustment be sure to tighten the

Adjusting shim thickness for selection

0 5 mm 0 0197 in

0 8 mm 0 0315 in

1 6 mm 0 0630 in

Note When adjusting be sure to use adjusting shims

having same thickness for upper and lower brake

master cylinder installation bolts

3 Upon completion of adjusting shim adjustment

tighten the stopper down to such an extent that height of

the pedal head is 141 5 2 mm 57

5 0 0787 in and

tighten the lock nut securely t Rear cable 4 Front cable

2 Turn buckle 5 Proper r shaft

3 Lock t
Free travel of the brake pedal is 6 to IS
nu
4 mm 0 236

to 0 590 in and the stroke is 120 4 72 in

mID
Fig BR 53 Adjusting turn buckle

BR 21
 CHASSIS
2 Upon completion of the adjustment release the hand
brake lever

braked
and make sure that the rear wheels are not
I r

7 1
Normal stroke
I 1

78 5 mm 3 091 in 6 notches
I
limited stroke

The term
136 0 mm

Stroke
35
5 in

means
10 notches

height from the standard

O
J2 5i
position 220 nun 8 7 in above the hand brake lever

fulcrum
e 1
Note Readjust hand brake stroke when it reaches the 1
limited stroke 136 mm 5 35 inll 10 notches Air bleeder
II
Connecting vinyl hose to air bleeder
Fig BR 54 rear

4 the brake pedaI two to three times and keep

Depress
ProCarManuals.com

the pedal fully depressed

Bleeding hydraulic system
5 With the brake pedal fully depressed loosen the

the hydraulic brake system deserves much bleeder screw exhaust air and retighten the bleeder screw
Bleeding
attention as it is an essential factor for regular service quickly
brake operation
of fact 6 Return the brake pedal slowly
As a matter during the brake service air is

likely to creep into the circuit with the result that the
7 Repeat the operations 4 through 6 above Air
fluid action is altered and the brake becomes spongy
pedal
will no longer come out from the bleeder screw but brake
at the travel end
fluid comes out When air still exists in brake fluid it
Bleeding should be carried out at flrst the master
appears white due to air bubble
cylinder then from the longest line from the master

cylinder and then fmish up with the shortest

8 Conducl air bleeding on other wheel cylinders in the

Note same manner

Always clear 8Wi1
V any dirt around master cylinder
resevoir cover before removing cover for any Note Check the oir for fluid level
a
during blead
reason Never d pedal while brake drums ara
ing operation
removed unless bleeder valve is open
b Fluid withdrawn in the bleeding operation
should not be used again for refilling
1 Top up the reservoir master cylinder with fluid of the c When the master eylinder is disaDembled or

recommended type raplaced conduct air bleeding the wheel

on eyl
inder which is located most near the master

2 Thoroughly wipe the bleeder screw and from

any eylinder
mud or dust that the outlet hole is free from
present so
d Ordinarily air bleeding is performed in the
foreign matter
following sequence

Attach Rear left Rear right Front left Front right

3 a vinyl hose to the wheel cylinder bleeder
screw Dip the end of the vinyl hose in a jar containing e Do not return the brake pedal bef re

some brake fluid tightening the bleeder saew

BR 22
 BRAKE

SERVICE DATA AND SPECIFICATIONS

8rab pedal

Pedal free height mm in 52

I4I 57 t0D787
5

Full stroke of peda head mm in 120 4 72

Muter cylinder

Inner diameter of maJter cylinder rom in 1746 16

11

Allowable maximum clearance between

cylinder and piston mm in 0 13 00051

Wheel cylinder
ProCarManuals.com

Inner diameter of wheel cylinder

Front drum in
mm 64 13 16
20

disc mm in 48 1 894
1

Rear mm in 20 64 13 16

front disc mm in 1746 11 16

Allowable maximum clearance between

cylinder and piston mm in 0 18 0071

0

8rab drum and rotor disc

Drum brab inner diameter mm in 203 2 8 00

Rotor disc outer diameter mm in 5

212 37
8

Rator thickness mm in 5 0 3740

9

Drum inside out ofroundness mm in Below 0 02 0 0008

Until of reconditioning drum in

diameter mm in D 0 0394
I

Run out of the rotor mm in Below 0 03 00012

Limit of reconditioning rotor

in thickness mm in 84 3307
0

Lining dime1l8ion

Front drum brake

width x thickness x length in 35 8

4 195 378
1 0 1890 7 68
Lining mm x x x x

Tala braking area cm2 in2 273 3

42

BR 23
 CHASSIS

B40 Akebono make

Lining material

Front disc brake

Pad width x thickness x length mm in 42 5 x 10 3 x 53 1 1673 x 406
0 x 2 091

Total braking area cm2 in2 3 14 0

90

Pad malerial MI12S

NBK D864P for A and CANADA
s
U
Rear brake

Lining width x thickness x length mm in 35 x 4 8 x 195 378

1 x 0 1890 x 7 68

Total braking area cm2 in2 273 42 3

Lining material B40 Akebono make

Tightening torque

Brake fulcrum pin kg ft Ib 2 1 to 2 9 15 2 to 210

pedal m

Master cylinder installation bolt kg m ft Ib 2 1 to 2 9 15 2 to 0

21
ProCarManuals.com

Brake tube installation flare nut kg m ft lb 15 to 18 10 8 to 13 0

Brake hose and connector

installation nut kg m ft Ib 17 to 2 0 3 to
12 5
14

Wheel cylinder installation bolt kg m ft lb 1 6 to 2 2 I 16 to 159

Brake warning switch installation

bolt kg m ft Ib 32
0 to 0 44 31 to 3 18
2

Front brake disc installation

bolt kg m ft lb 2 7 to 3 7 5 to 26 8
19

Caliper assembly installation bolt kg m ft Ib 4 6 to 6 1 33 3 to 1

44

1 6 to 2 2
Rear brake adjuster installation bolt kg m ft Ib 11 6 to 15 9

Hand brake cable hanger strap

installation bolt kg m ft lb 32
0 to 0 44 31 to 3 18
2

Hand brake lever installation bolt kg m ft Ib 10 to I 4 23

7 to 1
10

Rotor and hub installation bolt kg m ft lb 4 4 to 5 9 31 8 to 42 7

TROUBLE DIAGNOSES AND CORRECTIONS

Troubles Possible causes Remedies

S pon8Y pedal Air in brake lines Bleed thoroughly

Swollen hose due to deterioration or use of Replace hose and bleed the system

poor quality brake fluid

BR 24
 BRAKE

Use of a brake fluid boiling point of which is Change with the specified brake fluid and

too low bleed system

Reservoir filler cap vent hole clogged This Clean reservoir filler cap and bleed the

promotes a vacuum in master cylinder that system

sucks in air through rear seal

Pedal yields under Deteriorated check valve Fit a new check valve and bleed the system

slight pressure
External leaks Check master cylinder piping and wheel
cylinder for leaks and make necessary re

pairs

Master cylinder leaks through primary cap Overhaul master cylinder

Excessive pedal System has not been bled Bleed the system

travel
Improperly adjusted clearance Adjust shoe to drum clearance

Fluid level in master cylinder is too low Full up with specified brake fluid
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Bleed the system if required

Thermal expansion of drums due to over Allow drums to cool off Check brake shoe

heating linings and drums

Replace damaged parts

All brakes drag Insufficient shoe to

drum clearance Adjust clearance

Weak shoe return springs Replace the springs

Brake shoe return no free travel Adjust pedal height

Seized master Service the replace the

cylinder pislon master cylinder
piston and bleed the system

One brake drags Loose or damaged wheel bearings Adjust or replace wheel bearings

Weak broken or unhooked brake shoe Replace spring

return springs

Insufficient clearance between brake shoe Adjust brakes

and drum

Unbalanced brakes Grease or oil on linings Clean brake mechanism replace lining and

correct cause of grease or oil getting on

lining

Seized piston in wheel cylinder Service the wheel cylinder and bleed the

system

Tires improperly inflated Inflate tires to correct pressure

Loose wheel bearing Adjust wheel bearing

BR 25
 CHASSIS

Thoroughly check and adjust all front sus

Front suspension faulty
pension components

Grease mud water on linings Remove drums Clean and dry linings or
Excessive pedal or

pressure required replace

poor brakes shoes
Full area of linings not contacting drums Replace

Scored brake drums Reface drums and install new linings

oil soiled Remove and clean drums thoroughly

Brake chatter Dust on drums or linings
Eliminate oil leak
squeak or squeal

Weak shoe return springs Check springs and replace as required

Drum out of round Tum drums on lathe

Worn inings Replace linings

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SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or

DATE PAGE No SUBJECT

BULLETIN No

BR 26
 BRAKE

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No
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BR 27
 CHASSIS

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No
ProCarManuals.com

BR 2B
 SECTION WT

WHEEL AND TIRE

DATSUN 1200
MODEL B 110 SERIES
ProCarManuals.com

CHASSIS BODY

INI NI
II

WHEEL AND TIRE WIt

TROUBLE DIAGNOSES WI3

NISSAN MOTOR CO LTD AN 0 CORRECTIONS
TOKYO JAPAN
 WHEEL AND TIRE

WHEEL AND TIRE

CONTENTS

DESCRIPTION WT Tire rotation WT 2

PERIODICAL SERVICES WT 2 INSPECTION 3

WT

Inflation of tires WT 2 Wheel balance 3

WT

Redial tire WT 2 Wheel 3

WT

DESCRIPTION
ProCarManuals.com

TIRE SIZE in

Standard 6 00 4PR
I2 Tubeless

Optional 6 00 4PR
12 with tube

6 00 4PR
I2 Snow tire

6 00S 4PR
12 Sports Tubeless

155SR 12 Radial with tube except for Van use

5 00 4PRULT
12 with tube front
lor Van use
5 00 jPRULT
I2 with tube rear

TIRE INFLAnON PRESSURE To be measured when lira are cold kcm1 Poi

Tire size Front Rear

Sedan Coupe 15 22 15 22
6 00 4PR
12

Wagon 15 22 5
1 22
018 26

Sedan Coupe 17 24 17 24
155 SR 12

Wagon 17 24 7 24
1

15 22 18 26
5 00 4 6PR
12 Van 02 8 40

o
When the load is over 2 p ngen with 160 kg 350 Ib lu

ROAD WHEEL SIZE in 41 12

WT
 CHASSIS

Be sure to retighten wheel nuts after running 100 to

PERIODICAL SERVICES
200 km 60 to 120 miles

Inflation of tires

Tires with proper pressure improve riding comfort and

Radial tire
steering stability reduce driving sound to the minimum
and extend the service life When comparing to the ordinary tire camber power

The tires should be checked for proper pressure on of a radial tire is lower and cornering power is higher and

monthly basis or more frequently depending on driving consequently toein increase excessively causing
conditions while the tires are cold unevenly worn tire and or rapid tire wear Thus the front

Ordinarily tire pressure rises 10 to 15 of that when wheel should be carried out and
a1ignment care y

the tire is cold during continuous driving under a constant correctly See Chapter FA
speed due to the tire temperature rise When measuring Characteristics of a radial tire differ from that of an

tire pressure accurately first find out whether the tire is ordinary tire Do not mingle radial tires with an ordinary
hot or cold tire or vice vena When replacing a radial tire with an

When tire valve capo are removed be sure to reinstall ordinary tire due to unavoidable reason use ordinary tires
them on the valves without fail The valve caps assist in for front tires

keeping air in the tire in case of a valve leak and keep

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dust and water out of the valves

When inflation pressure is too high the following
Tire rotation
troubles will result

1 Service life of a tire is indicated miles driven The

1
by
Hard ride
tires are provided with tread wear indicator marks in

2 Bruised tire or six positions the tire circumference which indicate

damaged carcass immediately inside on

the tread limit of 1 6 mm 0 06 in tread depth When the tire is

worn to the service life the tread wear indicator appean

3 Poor traction at rear wheel resulting in uneven wear
In other words when the indicator appears the tire has

reached its service life Generally speaking service life of

4 Rapid tread wear at center of tire
a tire i 40 000 km 24 000 miles

When inflation pressure is tuo low the following

troubles will result

1 Tire squeal on turns TREAD WEAR

INDICATOR TIRE TREAD
2 Hard steering

3 Rapid and uneven wear on tire tread edges

4 Bruised tire rim and various types of rupture

5 Tire cord fatigue or

breakage

6 Tramp and shimmy troubles

7 Unusual tire temperature rise Fig WT 1 Tread wear indicator

8 Car roll while turning a comer or making a sharp

swerve in traffic 2 When it is intended to use five tires the
including
spare tire evenly conduct tire rotation in accordance With

Tighten wheel nuts to a torque of 8 0 to 9 0 kg m 58 the tire shifting order shown in WT 2 whenever the
Figure
to 65 ft Ib vehicle is driven 10 000 km 6 000 miles

WT 2
 WHEEL AND TIRE

2 Check the flange of rim for deformation crack

tear of welded unit and other defective con

damage
RIGHT FRONT RIGHT REAR
dition Deformed and damaged rim will cause air leakage

Yt J
I
3 Thoroughly remove rust rubber particles
and other foreign matters from the flange of rim if any

with a wire brush emery paper and or cloth

mud sand

LEFT FRONT
4 Remove small pieces of gravel glass nail and other
LEFT REAR
foreign matters from tire tread

WT 2 Tire rotation 5 When the tire side wall is cracked noticeably or tread
Fig
wear indicator is exposed replace the tire with a new one

INSPECTION

Wheel balance

The pennissible unbalance of wheel and tire assembly

is 10 gr 35
0 oz or less 165 cm
gr 2 29 inz or less
ProCarManuals.com

at the rim circumference In no event should a 70 gr 27

4

oz or heavier balance weight be attached to the wheel

Balance weights are available from 10 to 70 gr 35

0 to

47
2 oz with every 10 gr 35
0 oz interval

install balance the of

Nota Be sure to weight on flange
inside rim

Wheel

1 When the wheel deflections toward vertical and

0
horizontal axes at the points indicated by the asterisk
in Figure WT 3 are 1 0 rom 0 04 in or more replace the

wheel Fig WT 3 Wheel rim out

run check points

TROUBLE DIAGNOSES AND CORRECTIONS

Troubles Possible causes Remedies

Wheel wobbles Improper tire pressure Measure and adjust correctly

Damaged tire or distorted wheel rim Repair or replace

Unbalanced wheel Balance correctly

Loose wheel nuts Retighten

WT3
 CHASSIS

Worn or damaged wheel bearing or excessive Correct play or replace

play ofwheel bearing

Improper front wheel alignment Adjust

Worn or damaged ball joint and link bushing Replace

Excessive steering linkage play or worn Adjust or replace

steering linkage

Loose steering linkage connection Retighten the nuts with the rated tightening
torque or replace worn parts if any

Broken IUSpension spring Replace

Defective shock absorber Replace

Unevenly or Improper tire rotation Conduct lire rotation periodically

excessively worn Standard every 10 000 km 6 000 miles
tire
Improper tire pressure Measure and adjust correctly
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Unbalanced wheel Balance or replace

Improperly adjusted brake Readjust correctly

Improper wheel alignment Realign

Excessively diitorted or improperly installed Repair correctly or replace if necessary or

suspension link reinstall correctly

High speed on curves Reduce speed

Sudden start and improper speeding due to Follow correct and proper driving manner

rapid acceleration or improper brake appli

cation

Tire squeals Improper lire pressure Measure and adjust correctly

Improper front wheel alignment Realign correctly

Distorted knuckle or suspension link Repair or replace if necessary

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No
BULLETIN No SUBJECT

4
WT
 WHEEL AND TIRE

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No
ProCarManuals.com

WT 5
 CHASSIS

SERVICE JOURNAL OR BUllETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No
ProCarManuals.com

WT 6
 SECTION ST

STEERING

DATSUN 1200
MODEL B 110 SERIES
ProCarManuals.com

CHASSIS BODY

INI I
CD
DESCRIPTION ST t

STEERING ST t

COLLAPSIBLE STEERING ST 1

STEERING LINKAGE ST t3

SERVICE DATA AND

ST l1
SPECIFICATIONS

TROUBLE DIAGNOSES
LTD ST 18
NISSAN MOTOR CO AND CORRECTIONS
TOKYO JAPAN
 STEERING

DESCRIPTION
The steering system consists of recirculating ball type as required
gear box and parallelogram linkage The steering linkage should be greased up with wheel

These systems give good response light handling and bearing grease every 50 000 km 30 000 miles

utmost durability Moreover the steering linkage is All necessary service procedures for the steering lock

with torsion rubber system idler which system described in the BODY ELECTRICAL
equipped a arm are

absorbs shock from the wheel SECTION of this manual and therefore no instruction is

The lubricant of gear box should be checked every given here

10 000 km 6 000 mile and replenish recormnended oil

STEERING

CONTENTS

REMOVAL ST 2 INSPECTION AND REPAIR 4

ST
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DISASSEMBLY ST 3 ASSEMBL Y AND ADJUSTMENT ST 5

Ball nut assembly ST 4 INSTALLATION ST 7

I Steering gear housing 4 Cover ectOt shaft 7 colAssemblumny steering

2 Shaft steering sector 5 Shim bearing
worm 8 Assembly bearing steering worm

3 Screw adjusting roller shaft 6 Comp jacket column 9 Assembly nut ball

Fig ST l Steering gear components

ST 1
 CHASSIS
ProCarManuals.com

Fig ST 2 wheel
Steering

REMOVAL 3 Remove the turn signal and lighting switch com

pletely
1 Remove the horn ring and remove the steering wheel

nut 4 Remove the hand lever assembly from the control

rod assembly by unscrewing the fixing bolts

5 Remove two fixing bolts used to secure the steering

column to the instrument panel

Fig ST 3 Removing steering wheel lock nut

Note The horn ring can be easily removed by tow bolts

2 Remove the column shell

steering Fig ST 4 Removing steering column upper side

ST 2
 STEERING

6 Remove six bolts used to secure the steering column DISASSEMBLY

hole cover to the dash board
I Remove the steering gear arm fIxing nut and pull out

the gear arm by the use of a Steering Gear Arm Puller

X
I ST27 I 40000

2 Remove the drain plug and drain the oil from the

I I I steering

3
gear

Loosen the
housing

adjusting screw nut and turn the sector

1 shaft adjusting screw a few turns counterclockwise

j 10i i the
Remove four

housing
sector shaft
sector

cover
shaft cover fIxing bolts and pull
with sector shaft from the gear

1lJ1Il
Fig ST 5 Removing steering column hole cover
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7 Remove the shift rod and select rod from the change
lever and select lever after the cotter
removing pin from
the trunnion

8 Disconnect the gear arm from the cross rod

9 Remove three bolts used to the

secure steering gear

housing to the body

Fig ST 7 Removing sector shaft cover

Remove four bolts the column jacket

4 flXing securing
to the gear housing and pull out the main column jacket
assembly from the gear housing

Fig ST6 Removing steering geaT assembly

10 Pull the steering gear and transmission control

toward the engine compartment

II Remove the transmission control from the steering

outlined under Transmission control Fig ST 8 main column

gear assembly as Removing

ST 3
 CHASSIS

Note Be careful not to a11 the ball nut running d n Asoembly and adjustment
to either ond of the worm lbo ends of the ball
I Asoemble the ball nut on the worm with the ball
lJIides will be I if the nut is oDc
I
w to

guide hole up
ro until stopped at the end of the worm

2 19 baIls into each of two holes on the same

Drop
side of ball nut
5 Pull out the colunm mbly from the column
Tum the column gradually away from the hole
jacket being
filled Continue until all 38 balls are installed

6 Remove the sector shaft oil seal

Note In cases where the balls are stopped by the end of

the column hold down those baIls already dropped

into the ball nut with the blunt end of a d rod

or punch end turn the column in tho rev

direction a few turns

7 Take out the outer race from the column
rear bearing The of the circuit can then be continued It
filling
jacket by the use of a puller
may be to rtt the colunm end

forth holding tho balls down first in one hole then

8 Take out the bearing inner races from the front and
the other to close up the n the balls
ProCarManuals.com

rear worm bearings

and fill the circuit completely and solidly

9 Remove the colum shaft bearing

3 Place remarmng 22 baIls in halves of ball guide
tubes II each of two halves
Ball nut assembly
4 Close this half of guide tube with the other half
If the ball nut assembly or column is defective
Hold the two halves together and plug each open end
recommend the colunm assembly to be because
replaced
with vaseline so that balls will not drop out while
assembly and adjustment of the column assembly are very
installing
difficult

However for your reference disassembly assembly 5 Push the guide tubes into the guide holes of the ball
and adjustment are descnbed as foUows nut

6 Assemble the ball guide tube clamp to the ball nut

Disassembly

I Remove the clamp of the baU guide tube and

withdraw the ball guide tube out of ball nut

2 Turn the nut down and rotate the column

upside
back and forth until all 38 balls are out of ball
INSPECTION AND REPAIR
dropped
nut With the balls removed the nut can be puUed 1 Measure axial clearance between the steel balls and
endwise off the column ball nut and if the clearance is more than 0 08 rom

0 0031 in replace the parts unit

as a
complete
Note Bo careful not to 10 the bolls and moke su that
2 Inspect gear teeth of sector shaft and ball nut for
total number of balls is 60 balls 7 12 in dia l
wear or damage Ifthere is any sign of damage replace

3 Inspect bearings for wear or chip Replace bearings

Inspection
as required
Check ball guide tubes for damage at the ends where

they pick up the baIls from the helical path Replace 4 Inspect the serration of sector shaft and column for

guide tubes if damaged wear

ST 4
 STEERING

ASSEMBLY AND JUSTMENT

AD

Tightening torque 1 7 ro 2 8kg m 12 3 ro 20 2 lbl

ft

Standard shim 0 5mm 0 0197 in

Tightening torque 1 7 to 2 8 kg m 12 3 ro 20 2 ft Ib

Tightening torque 2 0 to 3 0 kg m

14 5 to 217 ft Ibl

Clearance of adjusting screw

to secter shaft 0 05 mm
ProCarManuals.com

0 0020 in

Apply grease here

when assembling

Pitman arm

Tightening torque 14kg m

101 ft Ib

Fig ST 9 Sectional view of steering gear

I Press in oil seal into the housing bolts

fIxing
Tightening torque is 7 to 2 8 kg
1 m 3 to 20 2
12
Note Apply chassis grease to the oil 1 lip before
ft Ib
assembling

2 Insert the column assembly into the column jacket 3 If replacement of column bearing assembly is nece

completely and install rhem with worm bearing shims sary a new bearing assembly should be fIlled with bearing
to the gear housing by the use of four flange grease and then cemented to the column

ST 5
 CHASSIS

4 Adjust the preload of the worm bearing by selecting Adjusting screw shim

the thickness of the worm bearing shim lfive kinds 0 05

Part number Thickness mm in
to 0 20 mm 0 0020 to 00079 in J so that the initial

of the whee is 2 0 to 5 0 kg m
48130 66000 1 515 to 1 535 0 0596 to 0 0604
turning torque steering
27 8 to 69 4 inz without sector shaft 4813166000 545
1 to 1
565 0 0608 to 0 0616

48132 66000 575

1 to 595
1 0 0620 to 0 0628

48133 66000 1 605 to 1 625 0 0632 to 0 0640

48134 66000 1 635 to 1655 0 0644 to 0 0652

ProCarManuals.com

Fig ST 10 Measuring initidl turning torqJAe

Note Apply oil on the wonn bearings The turning

torque wheel in motion should be 100 to 250 If

Fig ST 11 Checking lash adjuster end clearance
20 em 7 874 in radius ofthe
3 5 to 8 8 oz at

of
steering wheel A to the standard number worm

6 Assemble the sector shaft into the gear housing

table
bearing shims refto the following

1 Rotate worm column by hand until baU nut is in the

center of its travel so that the center tooth of sector shaft

enters into the center tooth space ofbaU nut

Worm bearing shim
2 With new gasket in place push the sector shaft
Part number Thickness mm in
cover with sector shaft in place

48031 18000 0 05 0 0020 After making sure that there is some lash between the

rack and sector teeth tighten side cover bolts

48032 18000 0 07 0 0028
Tightening torque is I 7 to 2 8 kg m 3
12 to 20 2
48033 18000 0 08 00031
ft Ib
48034 18000 10
0 0 0039
Note Apply oil on the sector shaft

48035 18000 0 20 0 0079

3 Lock the adjust screw with the adjusting screw nut

temporarily

4 Move the sector shaft for several times from the side
5 Sector shaft lash adjuster end clearance Assemble of the gear arm and make sure it turns smoothly
lash adjuster with shimin the slot of the sector shaft end
0 0020 in 5 Connect the gear arm to the sector shaft Whtn
Measure clearance 0 05 rom

To obtain this clearance five various thickness shims fitting the gear ann the aligning marks on the gear arm

and sector shaft should be matched correctly

are available

51 6
 STEERING

6 Adjust the backlash at the neutral point by screwing 7 Fill gear oil MPS 90 about 0 23 liter 0 486
the that the
adjusting screw so movement of the gear arm US pts 0405 UK pts into assembly through filler hole
top end radius 127 5 00 in is within 0 1
mm rom and install a filler plug
00039 in and lock temporarily by the nut

INSTALLATION
Installation can be accomplished in the reverse order of

removal Pay attention to the following points

I Make sure that the steering wheel moves smootWy

2 Check the alignment of the steering wheel

3 Free travel of steering wheel should be 20 to 25 rom

0 787 to 0 984 in
ProCarManuals.com

Fig ST 12 u
C 1sh
cltitrgb
1dd

Fig ST 13 Adjusting backlash

COLLAPSIBLE STEERING

CONTENTS

DESCRIPTION ST 8 COLUMN BEARING ST 12

STEERING COLUMN ST 9 DISASSEMBLY ST 12

JACKET TUBE ST 10 INSPECTION ST 12

STEERING POST CLAMP ST 11 REASSEMBL Y ST 13

ST 7
 CHASSIS

I
I
o
Cl
ProCarManuals.com

Fig ST 14 CoUapsibk steering

DESCRIPTION
This column is designed to be compressed under an to rearward into the driver
cY move s
compartment A
impact When an automobile is being driven the forward
split second later when the driver is thrown forward the

movements of the automobile and the driver constitute a this energy is also
secondary impact partially absorbed
form of energy or force When the automobile is involved by contraction characteristics of the column

in a on
head collision the primary force forward move

ment of the car is suddenly halted while the secondary

force the driver continues in the forward direction A When the collapsible column is installed in a car it is

severe collision generally involves these two forces no more susceptible to to damage than is an ordinary
primary and secondary The secondary impact occurs column however when the column is removed special
when the driver thrusts forward onto the steering wheel care is required in handling the assembly When the
and column column is removed from the car such actions as a sharp
blow on the end of the steering shaft shift levers
or

The collapsible column is designed to absorb primary leaning on the column assembly of the
or dropping
andsecondary forces to the extent that the severity of the assembly could bend the steering column jacket especial
secondary impact is reduced thereby reducing the tenden ly the bellows part which absorbs the energy

ST 8
 STEERING

7
CiJ

e e
f
o

1 Lower column shaft 5 Plastic 8 Washer

pin
2 column shaft 6 Column collar
Upper 9 Snap link
3 Lower column tllbe 7 Column bush 10 Steering post clamp
4 Jacket tube
ProCarManuals.com

ST 15
Fig Collapsible steering

STEERING COLUMN

Lower column shaft 3 Upper column shaft Lower column tube

Plastic pin

Fig ST 16 Steering column

ST 9
 CHASSIS

The construction of the steering column is as such that

the lower shaft is fitted into the upper tube when a

compressing force is applied to the lower shaft

Steering torque is transmitted by the lower shaft and

C
upper tube The lower shaft adopts a special shape a

circle with two straight cut edges and the upper tube
interior is tightly fitted against the lower shaft exterior
toward the entire area In addition four plastic pins

completely eliminate gap between the lower shaft exterior

and upper tube interior I Jacket tube 3 Column coUar
2 Shaft stopper 4 Column shaft

When compressing force

a is applied the above
described plastic pins are cut and the lower shaft is fitted Fig ST 17 Shaft ppeT
ste
into the upper tube When the lower shaft is once fitted
Moreover for reaIW3rd lunm shaft projection the
into the upper tube the shaft end and the lower
spreads
collar for steering lock installed on the shaft
shaft cannot be withdrawn unless an extremely high load
runs against
stoppe in three places on the jacket tube which allows
is applied
ProCarManuals.com

the column shaft fitting and thus rearward projection is

preven ted

NotB In no event should an impact or The column shaft lower end

largo power be and upper end are

applied to the shaft with a hammer or other matter supported respectively by two worm bearings and a

during disassembly or reassembly column bushing

JACKET TUBE

CI Mesh tube
o Jacket tube

Fig ST 18 Jacket tube

ST 10
 STEERING

The jacket tube is of a mesh part of which is that generated by collision be absorbed
a
punched an energy can as

in rhombus forming an energy absorbing part of the smoothly as possible with a low load The guide tubes
function guide for mesh tube while the mesh tube is
collapsible steering as a

Upper and lower guide tubes two guide tubes joined collapsed and improve bending rigidity of the entire

with poly acetal resin are inserted into the mesh tube so jacket tube

STEERING POST CLAMP

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o Plastic pin
12 Clamp 2 Sliding block

Fig ST 19 Steering post clamp

The steering post clamp is secured on the jacket tube

with bolt 08110 81210 and in addition two aluminum

sliding blocks are set stationarily on the main body with

plastic pins

Note For the bolt used to install the steering post clamp
on the iacket tube do not use bolt having a length
exceeding the rated length or otherwise the bolt

interferes the column shaft causing a trouble

follows
Tightening torquas are as

Steering post clamp Jacket tube

8 to 1 0
0 m 5 8 to 72 it Ibl
kg

Sing post clamp Steering post bracket

0 it Ibl ST 20 bolts
1 5 to 1 8 klt m 10 8 to 13 Fig Steeriorg post clamp

ST 11
 CHASSIS

The sliding block is secured

on the steering Construction of the column shaft upper
post bearing is as
bracket with bolts upper half of the steering column is such that both radial and thrust forces are absorbed
supported on the bracket and thus the steering post
DISASSEMBLY
is installed
clamp on the body
First remove the snap ring from the upper surface of
When a large impact is applied from the driver side the
the column bushing Thereafter general instructions for
plastic pins are cut off and leaving the sliding block in the
ordinary steering apply
steering post bracket side the clamp proper is disengaged Inspect and adjust the sector shaft worm ball nut unit
downward together with the jacket tube
adjust screw unit bearing and other relative
worm parts
in accordance with the instructions for ordinary type
For any force applied from front direction of the
steering
vehicle the steering post clamp sliding block does not

move rearward This construction is called One way slide INSPECTION

system and with this construction projection of the the parts such as column shaft tube
Inspect jacket etc
column shaft toward the driver is prevented completely
which 3re used to absorb energy in accordance with the

following instructions

COLUMN BEARING 1 Check the column shaft plastic pin for breakdown
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2 Check the steering lock collar for warping and screw

for breakdqwn

3 Measure total length of the jacket tube if

Replace
contracted However when tube collapse is within 3 rom
STEERING
0 1181 in adjustment by means of bushing is also
WHEEL SIDE
possible

4 Check the steering post clamp sliding block for

t 0 tube
1 4 Column bush tightness
2 Washer 5 Column shaft
3 Snap ring 5 heck the column shaft for bending When the A and

B portions the should be less than

are supported bending
ST 21 Column 10 mm 0 0394 in at the C portion
Fig bearing

JG t f 1 tEflEB
A B lL C
5 019691

UNIT mm in

ST 22 Measurement of
Fig defective of column shaft

ST 12
 STEERING

REASSEMBLY

I Adjust alignment and install the worm shaft and

tube on the housing

jacket
4 0 1575 27 5 dia 1083
j
2 Apply bearing grease to the interior and
sufficiently
screw the column bushing above the rated position

3 Apply washer and apply the snap ring to the groove

correctly and securely

UNIT mm in

Fig ST 23

4 Return the column bushing allowing the top surface

of the bushing coming into contact with the lower surface

of the washer the clearance to less than 1 0 rom
adjust Note Be careful not to crack the tube or defonn the
0 0394 in and the bushing position correctly
adjust so
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bushing while caulking when caulked

Morenv
that column shaft turning torque is the rated value
make sure that outer diameter of the jacket tube is

less than 31 8 mmdia 1 252 in dia l

6 When column bushing is found to be

Note If the clearance is too small the becomes position
steering
recaulk the
improper after caulking or adjust by use of
heavy
the following shim s

Part number Thickness rom in

5 Une up the jacket tube upper end to the groove on

48932 HI 020 0 05 0 0020
the outer circumference of the column bushing and
48932 H102l 0 10 0 0039
securely caulk two symmetrical positions on the circum

ference When caulked securely make sure that inner

diameter of the tube is 5
27 dia 1 083 in 7 Install the sector shaft adjust and side
jacket rom screw cover

dia and that length of caulking is 4 0 1575 in in the identical to

mrn manner
ordinary steering

STEERING LINKAGE

CONTENTS

REMOVAL ST 14 I NST ALLATION ST 16

DISASSEMBLY ST 14 ACCIDENT COLLISION st 16

INSPECTION AND REPAIR ST 15 ADJUSTMENT ST 16

ASSEMBLY ST 15

ST 13
 CHASSIS
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1 Steering gear 3 Side rod 5 Idler arm

2 Pitman arm 4 Cross rod 6 Knuckle ann

ST 24 Steering linkage
Fig

REMOVAL 2 Loosen clamp bolts unscrew the socket assembly

and remove the socket from the side rods
I Jack up front of the vehicle and support with stands

3 Remove the idler arm nut and disassemble the idler

2 Remove cotter pins and castellated nuts which are
assembly
used to fasten side rod ball studs to knuckle arms

3 Free the ball studs from knuckle arms by backing up

boss with a
large hammer and striking the opposite side
with a hammer

4 Remove the baIl studs of cross rod from the gear arm

and idler under the same described

assembly procedure as

in step 3 The cross rod and side rods can be removed as

an assembly

5 Remove the idler assembly from the side member by

taking off two fIXing bolts

DISASSEMBLY

1
Q Seal lip wembly
TI Bush

Disconnect both side rods from the cross rod under

the same procedure described in Removal ST 25 Sectional rMw
as
Fig of idkr arm

ST 14
 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 to lack of spring

action of the push spring or a damaged ball stud

1 Ball stud 3 Clamp

2 DustcOYer 4 Spring seat

ST 27 Sectional view ofbaU stud cross rod

fig

is detected replace
If any abnormal condition
as a
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unit They can not be disassembled

complete

1 Ball stud Clamp

2 Dust cover Spring seat
ASSEMBLY
in the reverse order of
Assembly can be accomplished
side rod disassembly Pay attention to the following points
ST 26 Secrional VU W of ball stud
Fig

j
I
II I
0 r
Y
l jJP I I
tt
r jJ 1
7c
s

ii s
c

t
GT k
I

o
C L c J
1
t t W

W
rl irf
1 1

7
i i l
rJ
r

D
I 1
I J

J l 7 l 1
vehick
of sleering linkage on
Fig ST 28 Fronl bottom view

ST 15
 CHASSIS

1 The foliowing tightening torque of nuts shall be 3 the it for

Operate steering system and check sliding
adopted noise

Ball stud nut

4 Check the operation for smoothness
30 to 5 0 kg m 21 7 to 36 2ft lb

5 Check the side rod and for

Gear arm nut
cross rod bending
14 kg m 101 lb
ft 6 Check the gear arm for crack

Idler arm nut

7 Check the gear housing tightening bolt for slackness
5 7 to 3 kg
6 m 2 to 45 6 ft Ib
41
and installation boss for crack

2 Assembly of the idler assembly is accomplished as 8 Check the sector shaft serration for twisting
follows
9 Check the sector gear for crack

10 Check the ball screw for pitting

I Apply soap water on the outer circumference of

bushing 11 Check the column shaft for bending crack and

Press the bushing into the idler arm carefully until the
sliding scar
bushing protrudes equally at the both sides
12 Check the jacket tube for bending
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2 Fit idler arm body in the rubber bushing

13 Check the
Keep the idler arm center line in parallel with the steering post clamp for existance of

chassis center line column offset

I4 Check the side member gear housing installation unit

for deformation
INSTALLATION
15 Check the portion of the steering post bracket
Installation can be accomplished in the reverse order of
installed on the steering post clamp for correct
removal Pay attention to the following points
installation

I Set the length of both side rods to 296 8 rom 1169

in It should be done between the baIl stud centers

2 Check wheel alingment and if necessary adjust it

JUSTMENT
AD

I Toe in

ACCIDENT COLLISION The procedure of toe in adjustment is outlined in

section FRONT AXLE AND FRONT SUSPENSION

When accident collision occurs unfortunately and the
vehicle especially its front unit is damaged conduct
2 Steering angle
inspection in accordance with the following instruction

Under the load adjust the

Inspect the steering system particularly carefully specified 4 passengers

because it is unit for stopper bolt of the knuckle arm so that the inner wheel
a very important driving
has an
angle of 430

I Check both side steering angles for correct balance

2 With the tires positioned at neutral check the Note Specified steering angle of wheel is 43 for inner

steering wheel bar for correct position wheel and 3605 for outer wheel

ST 16
 STEERING

SERVICE DATA AND SPECIFICATIONS

Type Recirculating ball type

Gear ratio 15 0 I

Steering wheel diameter mm in 400 157

Oil capacity t US ptsUK pts 0 23 0 486 0 405

Steering angle inner wheel 43

outer wheel 360

Play steering wheel mm in 20 to 25 0 787 to 0 984

Standard thickness of worm

bearing shims mm in 5
0 0 0197
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Initial turning torque of

column assembly 2 0 to 5 0 27 8 to 69 4
kgm oz
in

Clearance of adjusting screw to

sector shaft in 0 0020

mm 05

Length of side rod in

mm 0
296 8 1169

T teningtorque

Steering wheel lock nut kg m ft lb 3 0 to 5 21 7 to 25 3

3

Steering post clamp to steering

post bracket bolts kg m ft lb 0 8 to 1 0 5 8 to 7 2

Collapsible kg m ft lb 5 to 18 10 8 to 13
1

Steering column hole cover bolts kg m ft Ib 0 8 to 1 0 5 8 to 7 2

Column to gear housing bolts kg m ft Ib 17 to 2 8 12 3 to 20 2

Side cover to gear housing bolts kg m ft Ib 7 to 2 8

1 3 to 20 2
12

Adjusting screw lock nut kg m ft Ib 2 0 to 3 0 5 to 21 7

14

Sector shaft to
pitman arm nut kg m ft Ib 14 101

Gear housing to side main bar

bolts and nuts kg ft Ib 19 to 2 6 to 18 8

m 13 7
Idler arm nut kg m ft Ib 5 7 to 3 412 to 45 6
6

Idler arm to side main bar bolts and

nuts kg ft lb
m 19 to 2 6 13 7 to 18 8

Ball stud nuts kg m ft Ib 3 0 to 5 0 7 to 36 2

21

Side rod bar lock nuts kg m ft Ib 8 0 to 10 0 57 8 to 3

72

ST 17
 CHASSIS

TROUBLE DIAGNOSES AND CORRECTIONS

Troubles Possible causes Remedies

Heavy steering Low tire pressure Inflate tires to recommended pressure

Incorrect front wheel alignment Adjust to specifications

Lack oflubrications Lubricate steering gear and ball joints or

replace worn ball joint

Firm sticking of the ball joint and strut Replace

bearing

Improper adjustment and damage of steering Adjust or replace according to instructions

gear housing

Hard locking ofcolumn bearing Lubricate with bearing grease

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Loose steering Incorrect front wheel bearing adjustment replace

Adjust or as required

Loose steering linkage connections Inspect replace worn parts if any and

tighten nuts to recommended torque

Loose steering gear housing mounting Tighten mounting bolts to proper torque

Incorrect adjustment of adjust nut Adjust according to instructions

Pull to one side Incorrect tire pressure Inflate to recommended pressure

Incorrect front wheel alignment Inspect and correct front wheel alignment

Incorrect front wheel bearing adjustment Adjust bearings according to instructions

Unequal brake adjustment Adjust brakes

Weak f ont suspension units Replace

Deformation or improper fitting of sus Check correct or replace

pension

Steering shock Incorrect front wheel alignment Inspect and correct front wheel alignment

Loose front wheel bearings Adjust bearings

Loose steering linkage connection and trans Inspect replace worn parts if any and

verse link tighten nuts to proper torque

Incorrect of ball nut according to in

adjustment Adjust steering gear

structions

Wheels out of balance Inspect and correct wheel balance

5T 18
 SECTION FE

ENGINE CONTROL
FUEL EXHAUST
SYSTEM

DATSUN 1200
MODEL B 110 SERIES
ProCarManuals.com

CHASSIS BODY

INI I

ENGINE CONTROL SYSTEM FE t

NISSAN MOTOR CO LTD FUEL AND EXHAUST PIPINGS FE 3

TOKYO JAPAN
 ENGINE CONTROL FUEL EXHAUST SYSTEM

ENGINE CONTROL SYSTEM

CONTENTS

ACCELERATOR CONTROL FE 1 FE 2
Adjustment
FE 2
Description

ACCELERATOR CONTROL

EJ3
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e3
I
I

1 Accelerator pedal 3 Wire outer case 5 Pedal stopper

2 Accelerator arm 4 Inner wire 6 Return spring

Fig FE 1 Accelerator control m for R H drive

syst

L
4

1 Accelerator pedal 3 Wire outer case 5 Pedal stopper

2 Accelerator arm 4 Inner wire 6 Return spring

FE 2 Accelerator control drive

Fig system for L H

FE 1
 CHASSIS

Description
The accelerator linkage is lightweight and construction
is such that the o to 1 mm 0 to 0 0394 inl
linkage operates smoothly and is

unaffected by engine vibration

Adjustment

Play ohceelerator wire

I Install the pedal arm side securely with a spring

clamp Fig FE 4 Adjusting pedal stopper height
4t hand steering

2 Set the board

dash side outer case stationarily with
a cap nut Do not set the carburetor side adjusting unit

stationariJy
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T Otolmm

3 Pull 0 to 0 0394 in
up the carburetor side socket toward P

direction up to such an extent that the throttle lever is

about to move pull down the socket I to 5

1 mm

0 0394 to 0 0590 in from that position toward Q

direction and set the socket stationariJy with a clamp

Lock nut 3 Stopper bolt

Accelerator pedal
THROTTLE
LEVER

Fig FE 5 Adjusting pedal stopper height

Q right hand sreering

Note a Do not bend the accelerator pedal

b AdiuS accelerator wire and stopper bolt
play
QClamp I Socket
height tly
orrec
c

c Apply chassis grease No O or 1 to the sliding

FEJ
Fig Adjusring play of accelerator ire
pan of pedal bracket

Model with automatic transmission

Pedal stopper
For model with automatic transmission the pedal arm
Depress the accelerator pedal down to such an extent
is equipped with kick down switch striker This is only
that the throttle lever fully opens adjmt stopPer bolt
difference with the standard model
height so that clearance between the accelerator pedal

reverse side and stopper bolt head T is 0 to I rom 0 Note Note that the kick down switch should not come

to 0 0394 in and secure the stopper bolt with lock into contact with the pedal arm striker when the

nut accelerator pedal is depressed

FE 2
 ENGINE CONTROL FUEL EXHAUST SYSTEM

R H drive LH drive

0 0787 2 0 0787
KICK DOWN SWITCH Pedal free play mm in 2

STRIKER
Pedal stroke mm in 48 1 890 50 1969

Pedal depressing force

when 3 8 4
8 3 3 3
7
fully open

kg lb

Fig FE 6

FUEL AND EXHAUST PIPINGS

CONTENTS
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EXHAUST PIPE AND MUFFLER FE 3 FUEL TANK AND PIPINGS 4

FE

4
FE Description 4
FE
Description
FE 5
Precautions for removal and Replacement

installation FE 4 I nspection and repair 8

FE

EXHAUST PIPE AND MUFFLER

4
9

Fig FE 7 Exhaust system

FE 3
 CHASSIS

Description Precautions for removal

and instaIJation
For all models sedan wagon and coupe the exhaust
tube without the between the front tube
system uses a single front using 1 When there is no clearance

The main muffler is installed beneath the rear

pre muffler and floor or propeller shaft turn the tube along center

seat floor in the left side line of tube in the manifold connecting unit and obtain a

proper clearance

into the
The component parts are separated mainly 2 Muffler front tube inserting depth is approximately
front tube and muffler with rear tube and they are
60 mm 362
2 in

with clip at the muffler inlet The muffler main

coupled a

the muffler main unit with rubber

unit is suspended from the body with hanger bracket and 3 When suspending
is suspended from the floor line up the hunger of the muffler main unit straight
rubber ring and the rear tube ring
with strap against the bracket in the body side
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FUEL TANK AND PIPING

Description

Fig lJ Fuel system

FE

4
FE
 ENGINE CONTROL FUEL EXHAUST SYSTEM

For all models fuel tank capacity has been increased in and completely drain fuel

to the increased engine output Location and

response
2 Remove the fuel line connector
mounting strength are improved for improvement of

safety 3 Remove the luggage compartment finishing

10 57 US gal 4 Remove four bolts used to secure the fuel tank

Sedan 40L
8 81 Imp gal

5 Loosen the hose clamp

10 04 US gal
38 L
Wagon 8 37 Imp gal

10 04 US gal
Coupe 38 L
8 37 Imp gal

has been the

Also for piping consideration given on

safety To be more specifically the fuel line coming out

from the fuel tank is laid inside the rear si6e member so

fuel line is from gravel and other

that the protected
interferences from road In the front floor section the
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fuel line is laid inside a tunnel and thus fuel line reaches

the engine compartment

In addition the fuel strainer and fuel tank outlet units

connect the fuel line with rubber hoses and for all other

sections bandy tube is used Fig FE 9 Drain plug position

6 Disconnect cable to the unit gauge

Replacement

from the fuel tank bottom 7 Dismount the fuel tank

Remove the drain plug

Fig FE l0 Fuel tank unit installation

FE 5
 CHASSIS

AIR VENTILATION TUBE

AIR BREATHER TUBE

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u
FIg FE ll nO andtu be installations

VAN SERIES

FIg FE12 Fuel mk

t Un t installation

FE 6
 ENGINE CONTROL FUEL EXHAUST SYSTEM

SEE ARROW A

AIR VENTILATION TUBE

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Fig FE1J Hose i1Ut4lJations

COUPE

FE 14 nit installation
Fig Fel tank

FE 7
 CHASSIS

I
FILLER HOSE
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FE 15 Hose installations
Fig

Inspection and repair

I Check the fuel line for leaking or other damage and

repair or replace as required

Note a When ing

sold is required be sure that no

gasoline is remained

b When deaning fuel tank inside use gasoline Do

not use water

2 The gauge unit adopts a bayonet system and thus

the gauge unit can be removed and reinstalled simply with

a screwdriver

Fig FE 16 Gauge unit

FE a
 ENGINE CONTROL FUEL EXHAUST SYSTEM

VAN ONLY

j
o
e
v L e
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Fig FE 17 Fuel tank unit gauge installation

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No

FE 9
 CHASSIS

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No
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FE lO
 SECTI ON BF

BODY

DATSUN 1200
MODEL B 110 SERIES
ProCarManuals.com

CHASSIS BODY

GENERAL DESCRIPTION BF t

UNDER BODY ALIGNMENT BF 9

I NISSAN I HOOD BF 14

FRONT FENDER AND

BF t6
FRONT END

TRUNK LID AND REAR

BF 1 B
BUMPER

DOORS BF

WINDSHIELD AND REAR

WINDOW
BF 3023CD
VENTILATOR BF 32

SEAT BF 33

INSTRUMENT PANEL BF 36

NISSAN MOTOR CO LTD ROOM TRIM BF 31

TOKYO JAPAN
 BODY

GENERAL DESCRIPTION

CONTENTS

DESCRIPTION BF 1 BODY CONSTRUCTION AND

CROSS SECTIONAL VIEW BF 1

DESCRIPTION
The body construction is of an unit type The rearward collision absorbing an energy generated from the

individual which
require high strength collision
body components

adopt a box section

cross improving torsional rigidity and There are three types of body construction sedan
the highly rigid structural components are joined under coupe and station wagon or van however the front

special connecting construction which reduces centralizing section is used commonly

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ohtre

Particularly for protection of passenger from side

BODY CONSTRUCTION AND
collision side section ofthe body is constructed with side
CROSS SECTIONAL VIEW
member having box crosssection improving the rigidity
and the front and rear side memben are so constructed The body construction crOSHectional views and

that deformed in the event of forward

they are or sealing points are indicated as follows

t Seat belt anchorage indicating one side only

Fig BF 1 Body constTuction 4 door sedan

BF 1
 BODY

indicating side only

t Seat belt anchorage one

BF 2 Body construction 2 door seddn

Fig
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Seat belt anchorage indicating both sides

Fig BF 3 Body construction coupe

or van
Fig BF 4 Body construction station wagon

BF 2
 BODY

SEDAN

B G

H
cH
C
N A

7
ProCarManuals.com

A A

F F

Q
J2

DETAILS OF G
PORTION

1 Roof 11 Inner roof rail

2 Cowl top 12 Rear floor
3 Hood 13 Rear fender
4 Lower dash board 14 Brace

S Front floor IS Inner rear pillar

6 Front fender 16 Air box panel

1 Side dash booud 11 Outer sill

L 18 Inner wheel house
4 DOOR 8 Inner center pillar
9 InnerdOO I 19 Outer wheel hQuse

10 Outer door

sectional vie I
BF 5 Cross
Fig

BF 3
 BODY

K K

lL N N
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M M

J 0 0

SEALING ON CIRCUMFERNCE
OF REAR flOOR

DETAilS OF cr DETAILS OF R
PORTION PORTION

1 Rear floor 9 Seat blCk support

2 Rear fender 10 Inner lock pillar

3 Lugage compartment floor 11 Lock pillar

h rear side 12 Roof

4 Front pillar 13 Rear waist
5 Front fender 14 Lugage compartment lid
6 Outer door 1S Rear panel
7 Fuel filler cover 16 Outer wheel house
8 Shock absorber mount bracket

Fig BF 6 C oss secticmal iew II

BF 4
 BODY

V V V V

COUPE
ProCarManuals.com

DETAILS OF B
PORTION

A A

D D

I Roof 6 Front reDder

2 Inneuide body 1 Inna wheel house

DETAILS OF T 3 Rear fender 8 Rear floor
PORTIONE Outer door 9 Innu Iodi pillar
4
S Front pillar 10 Lockpillar

BF 7 Cross sectional vieIII

Fig

BF 5
1
BODY

STATION WAGON OR VAN

A C

7
ProCarManuals.com

SEALING ON
CIRCUMFERENCE 9
OF REAR FLOOR

D D

I Roof 6 Inner side body

2 Reu fender 7 Outer back door
3 SeaIin SCIOen 8 Inner back door
4 Rear floor 9 Tail member
cross

S Side leU Door 10 Reupane1

Fig BF 8 Cross sectional view IV Sttltion wagon or van

BF 6
 BODY

Water drain holes are located as shown in the following grommets

figure Be sure to provide all water drain holes with

1 to 6 Rubber plug
7 to 12 SClt belt anchorage hole
plug
13 Inspection hole plug
14 Drain plug
15 Drain hole cover

BF 9 Location
Fig of water drain hole sedan
ProCarManuals.com

1 t04 5 Rubber plug

6 to 11 Seat belt anchorage hole plug
12 Drain hole cOYer

BF l0 Location
Fig oflwater drain hole coupe

Rubber plug
Seat belt anchorage hole plug

Fig BF l1 Location
of water drain hok station wagon or van

BF 7
 BODY

CD CD CID 4
i

@Roof drip moulding

CID Roofdrip
reS5 downward after
moulding clip
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king op
CD Window moulding
a
Windshit1d side rnoukJing J
Windshield r
moulding
For all four corners
Inserted

Dry
U
@Body sill moulding
l Door
rubber
cover

Nut

Used at front and

anty
rear ends two uch
in one side
@Radiator grille shroud Sill moulding clip

@Door outer moulding

Radiator grille shrcul A clip
Used et four paces except
for both ends
J
c r each per door

Three IUch in one aide

xC8pt for front and rur ends

Door outer panel Clip is assernbMd

on the
moulding @Rear fendor moulding
Radiator upper grille

VRadiator grille side shroud

Four IIch moukling clips

are used for one side

This clip also functions

j as a sealing

Fig BF 12 insra 14tion

Moulding

BF 8
 BODY

UNDER BODY ALIGNMENT

CONTENTS

UNDERBODY GENERAL SERVICE PRINCIPLES OF TRAMMING BF 9

INFORMATION BF 9 CAR PREPARATION BF 10

TRAMMING SEQUENCE BF 10
ALIGNMENT CHECKING PROCEDURE BF 9

To assist in checking alignment of the underbody

UNDERBODY GENERAL SERVICE
components repairing minor underbody damage or
INFORMATION
locating replacement parts the following underbody
Since each underbody component directly affects the dimensions and alignment checking information are

overall strength of the body it is essential that proper presen ted

welding sealing and rust proofing techniques be observed
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during service operations

PRINCIPLES OF TRAMMING
be sure to provide the
Whenever the body is repaired
All reference locations shown in Figures BF I3 14 and
repaired body parts with rust proof
critical 15 are symmetrical at the center line of the vehicle For
In the case of a rust proofmg underbody
it is essential that air example when performing a heck of the
cross body floor
component a good quality type dry
BF 13 14 and IS the
corrosion resi tant zinc chromate be used panel dimensions Figures
primer such as

measurement should be the same in both

Do not use combination type primer surfacers diagonal
directions Cross checking operations are used to deter

the between two locations the

mine relationship on

underbody
ALIGNMENT CHECKING
PROCEDURE To measure the distance between any two reference

points on the underbody accurately two specifications

in the affects the front
Misalignment underbody are required
fender door trunk lid and window alignments and also
1 The horizontal dimension between the two points to
the tail gate and rear body opening alignments in the case
be measured
of a station wagon or van Underbody misalignment
2 The vertical dimension from the datum line to the
particularly affects the suspension system thereby causing
to be measured For an example the diagonal
various problems that arise from suspension misalignment points
measurement calculated on a horizontal plane between
It is essential that underbody components be aligned
within the specified dimensions given in Figures BF 13 14 reference points of dimension line L shown in Figure

3 mm 24 8 in The from the

and 15 BF 13 is 631 specifications
datum line have a vertical height difference of 116 mIn

In the event of collision damage it is important that 0 456 in between the forward location of dimension

be thoroughly checked and if L rat vertical dimension 80 0 rom 3 150 in and the
underbody alignment
rearward location of dimension L at vertical dimen
lion
necessary realigned to the specified dimensions
There are many tools that may be employed to correct 916 rom 3 606 in The vertical pointer used at the

machines forward location should be positioned so as to extend

collision damage such as frame straightening

other standard body 116 rom 456

0 in further from the tram bar than the
external pulling equipment jacks

BF 9
 BODY

pointer used at the rearward location With the proper TRAMMING SEQUENCE
settings the tram bar will be on a plane parallel to that of

the body The exception to this would be when one of the The tramming sequence will vary depending upon the
reference locations is included in the misaligned area then nature and location of the misaligned area Prior to
the parallel plane between the body and the tram bar may perfonning any tramming operation the accuracy of
not prevail After completion of the repairs the tram reference be used be determined
points to must A

gauge should be set at the specified dimension to check measurement that originates from a reference point
the accuracy ofthe repair operation included in a damaged area will produce untrue results
and confuse the evaluation of the underbody condition
Unlike the conventional type offrame design the unitized
CAR PREPARATION of
type body construction seldom develops the condition

the car for the of diamond in the floor pan area as a result of front or
Preparing underbody alignment checx
rear end collision Therefore underbody alignment
involves the following
checking can usually originate from the body floor pan

I Place the car on a level surface area If inspection indicates that these locations have been

disturbed and are not suitable for measuring one of the

2 The weight of the car should be supported at the undamaged suspension locations should be used as an

wheel locations initial reference pnint If a rare situation should exist

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where all of these locations are not suitable as reference

3 A visual damage inspection should be made to points repair operations should begin with the body floor
eliminate unnecessary measuring Obviously damaged or pan area All other underbody components should be
misaligned areas may often be located visually aligned progressively from this area

MEMO

BF l0
 BODY

w
Z

w a
w
E
z
I E
Z
w
U
J

c c

tl

al
5
Qj

0
ProCarManuals.com

@
0

i5

il

I
0
N 5
N
ai
ci
iii iii
N fr

N
0 iii

0
zoUIOL
05 L 09

BF lJ Body aligrmtDtt lan

Fig

BF l1
 BODY

w Z
z i E
i a
w
E
E
I f
J Z
w 2
0
0

0 0
I
m
0
m Z S IOL6
5
ol on

0 N
Ol
2 0
in J

@ 0 0 g
0
ProCarManuals.com

8
i

10
10
on @iZ 9t HLl

I
IZ S OL6
in

J0
ci
on
19
10
PI

Szz OIS s
@

IIZ os
0tI
tLZI

lOa
O
on

N 10

909 g e
9 16
t
o
10
I Z ZI
oj oL
r
i5

Fig BF J4 Body Jignmen coupe

BF 12
 BODY

w
z C

e
i 1 e

I e
0
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ProCarManuals.com

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Pig BP

BF 13
 BODY

HOOD

CONTENTS

REMOVAL AND INSTALLATION SF 14 HOOD LOCK SF 14

Removal SF 14 Removal BF 14
Installation SF 14 Adjustment BF 15

REMOVAL AND INSTALLATION Installation

Install the hood in reverse sequence of removal
Removal
carefully so that the hood is flush with the fender top and
I Disconnect the windshield washer hose at the nozzle clearance between the hood and fender is aligned evenly

toward overall circumference of the hood when the hood

2 In order to protect the hood from is closed

damaging place
rag in both sides of the hood rear end loosen the hood
HOOD LOCK
hinge installation
ProCarManuals.com

bolts and remove the hood supporting

it from both sides as shown in the following figure Two
workers are required

I Dovetail bolt

2 Dove tail bolt

t 3
retaining nut

Spring
4 Safety catch lever
5 Female lever

IS 6 Spring
BF 16
Fig Removing hood hinge 7 Hood lock control
o

lever

8 Rubber grommet
r
E
Fig BF 18 Hood lock mechanism

Ii1liI
I

Removal
l
h I Remove the radiator grille loosen the installation

bolts and remove the male side ofthe hood lock

f n

r
2 Disconnect the hood lock wire from the female side

of the hood lock and remove the female side of the hood

BF I 7 R
Fig mvoing hood lock

BF 14
 BODY

center correctly
0

Adjusting hood lock control lever operating force

u
Q

When the control lever is excessive

t j operating force
loosen the dove tail bolt retaining nut
@ increase

j
t
j
Mf
i dove tail

securing force
bolt CD
of the spring
installed length and reduce

f
r Tightening torque
Dove tail bolt retaining nut

15 to 2 5 kg m 10 8 to 18 1 ft Ib
d

Fig BF 19 Removing male side of t ehook lock hood tightness

Adjusting
When the hood is closed completely and the hood is

slack reduce installed length of the dove tail bolt

and increase
CD securing force of the spring
ProCarManuals.com

21
0

0 J
r
7r

Fig BF 20 Removing female side of the hood lock c

1 1
3 Remove three screws and remove the hood lock
L F
control lever
1
i
r

l j
r 01

I rj BF 22 dove tail bolt

I Fig Adjusting

fijf2
11 I
j
J
1

I
1

I
i

Note When inspecting the hood lock note the following

k
1 matters
i
1
U Operation of safety catch lever
a
@

1 D fI Check caulked portion of the safety catch lever for

fI l Ih
I
ji
C
wea

down
and the spring

If the spring is broken

@lfor weakness and break

the hood may be unlocked

Fig BF 21 Removing ood lock con olle and rapidly open during driving

Adjustment b of female lever

Operation CID
the hood lock Check the female lever for smooth and correction
Centering
operation and the spring I@ for wkness and
The male side hook lock is provided with a 3 rom
breakdown
0 118 in adjusting stroke toward left and right sides
If the female lever does not move smoothly
of the vehicle and the female side with a 3 mm 0 118

in engaging stroke with the dove tail bolt will be

adjusting stroke toward front and rear sides of the
bolts reduced and it may be disengaged
vehicle Loosen the installation and align the

BF 15
 BODY

FRONT FENDER AND FRONT END

CONTENTS

FRONT FENDER BF 16 RADIATOR GRILLE BF 17

Removal BF 16 OUTSIDE MIRROR BF 17

FRONT BUMPER BF 17

FRONT FENDER
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I Front fender 5 Side dash board 8 Front bumper stay

2 Cowl top ealer 6 Front pillar 9 Front
bumper side bracket
3 Front fender sealer 7 Front bumper 10 Bumper side bl8cket shim
4 Cowl top

Fig BF 23 Fro7lt fend andfr07lt end componenrs

Removal

the hood disconnect the battery terminal for

Open
the sake of and disconnect wirings for the head
safety
lamp and side marker at their
lamp connecting terminals

2 Remove the front bumper radiator grille and

radiator grille surround

3 Remove the sill moulding and the fender

holding
remove it

Fig BF 2 Removi7lg fnmt fend I

BF 16
 BODY

OUTSIDE MIRROR

Indicates outside mirror installing positions

Fig BF 25 Removing front fender II

FRONT BUMPER Dimen

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sions A B D E
c
Item

27 to 6 to
Remove six bolts installed bumper stay to body and I
Round shape 817 29
5 25 27 8 dia 6 2 dia
remove the front bumper from the body together with the movable
32 2 161
1 0 9843 1 063 to 0 2362 t
mirror
bumper stay 1094 0 2441

6 to
Round shape 817 40 6 2 dia
35 9 dia
irror 32 2 378
1 575
1 0 3543 0 2362 to
0 2441
RADIATOR GRILLE
Unit rom in

Loosen self five self tapping for

tapping screws screws

Fig BF 27 Fender mirror installing positions

sedan station wagon and van and ten for coupe and

remove the radiator grille from the body

The radiator grille for coupe is made of ABS resin Be

careful not to allowbrake fluid or oil sticking to it

3 6 17Id a hO

ill o
1
t 14
4 358
I
1
177

Unit inl
mm

BF 28 Door mirror
Fig installing position for
Fig BF 26 Removing radiator grille coupe right hand driven vehicle

BF 17
 BODY

87J
M
2
9 100 13941 lOOc
3 100 13 941
100 13 1

1
3 510 131111
l
In 100551 UI00M4 i

J
nO Q
diil HOLE
i2 O 142

104 3

DOOO

11 1021 13
348 450 171
71
g

1 78

Fig BF 29 Template for door mirror installation for

left hand driven vehicle

When installing round shape movable outside fender

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mirror tighten the nut to tightening torque range from

2 9 to 3 6 ft lb that fender mirror

4 to 0 5 kg
0 m so

movement starting torque is in range from 20 to 75 cm

kg

174 to 65 1 in lb When the nut is tightened to

10 8 ft lb higher the
tightening torque of 1
5 kg m

fender mirror stud bolt may be broken

NSTAlCATlNG
OSrnON
SECTION A A

1 M Cap
J
I
ror stay
I 1 2 Mlfror ba se

Fig BF 30 Round shape movable outside

unit
fender mirror installing

TRUNK LID AND REAR BUMPER

CONTENTS

BACK DOOR LOCK BF 20

SEDAN AND COUPE
BF 19 BF 20
TRUNK LID LOCK Removal

BF 19 BF 21
Removal Adjustment
BF 19 BACK DOOR TORSION BAR BF 23
Adjustment
BF 20 Installation BF 23
TRUNK LID TORSION BAR

REAR BUMPER BF 23

Removal BF 23
STATION WAGON OR VAN

BF 18
 BODY

SEDAN AND COUPE

@
1
CD

d
@
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1 Trunk lid 3 Trunk lid weatherstrip 5 Trunk lid hinge

2 Trunk lid lock assembly 4 6 Striker assembly
Hinge fixing pin

BF 31 Trunk lid and hinge construction sedan

Fig

striker position Adjusting stroke toward left and right

TRUNK LID LOCK
sides direction is 4 8 rom 0 1890 in and 8 rom

Removal 31 SO in toward vertical direction

0

Loosen installation bolts and remove the striker and

Coupe
lock from the body
When adjusting engagement between the lock and

2 striker adjust striker position toward left and right

Remove the leaf clip used to secure the trunk lid
lock sides adjusting stroke 6 rom 0 2362 in and lock
cylinder on the body and remove the trunk lid lock
position for vertical direction adjusting stroke 8 mm
cylinder
3150
0 in

Adjustment
Tightening torque
Sedan Lock and striker fIxing bolt

When 0 12 to 0 2 kg m 0 87 to 45
1 ft Ib
adjusting engagement between the lock and
striker set the lock stationarily and properly adjust

BF 19
 BODY

TRUNK LID TORSION BAR

The procedures of installing torsion bar are indicated as follows

@ I Closed position
2 Rotation center of
m trunk lid hinge
I
J Trunk lid hinge
4 Trunk lid torsion

5
bar

Rear waist connector

J
BF 32 Installing torsion baT
Fig

Note When inSUllling the tonion bar use a tonion bar wrench special tool ST087100001

STATION WAGON OR VAN

ProCarManuals.com

Back door hinge torsion

bar

2 Back door hinge

3 Back door
4 Back door lock rod

5 Lock

6 Striker
t 7 Striker shim
8 Back door side
dove tail

s 9 Side dove tail shim

t 10 Back door bumper

6J 11 Back door bumper plate

BF 32 Back door constructions

Fig 1d
4 hinge

BACK DOOR LOCK

leaf clip to
2 Remove the lock cylinder securing so as

Removal d the back door lock rod

free the lock cylinder remove

Remove the back door trim and sealing screen from the lock cylindfJ

BF 20
 BODY

i
T Adjustment
l
r
Il l
I
l
0

1 Striker and lock

7
r T
The striker and lock engagement is
1 t O adjusted at the

f striker side for toward horizontal and vertical directions

lJ The lock side is set stationarity
When adjusting engagement toward vertical direction
8 striker shim 1 6 rom 0 0630 in is used
r
thick Under
I the standard condition one striker shim is used Adjusting
fa

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 fIxing machine screw

0 12 to 0 2 kg m 0 87 to I 45 ft Ib

3 Remove the lock cylinder Striker fIxing bolt

1 0 to 1
5 kg m 7 2 to 10 8 ft lb

4 Loosen the installation bolts body side nd remove

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the lock and striker 2 Sid and wedge

strik

A
Back door bumper

Steel sheet

Back door side

Rear panel side

Tapping plate

Steel sheet

B portion

Back door bumper plate

Nylon Back door
Rubber
Back door side dove tail
Steel sheet

AU portion

Fig BF 35 Back door securing system

BF 21
 BODY

moved excessively to the outside back door

In order to secure the back door in the position adjust plates are

the in accordance with the following instruc opening closing force increases although the back door is
position
tions secured tightly Position the bumper plates properly so

that the back door can be opened and closed lightly

I Install two back door bumpers @ on the bottom

of the back door Positions of the back door bumpers are Note It has been so designed that the back door bumpers

back their
used for standard positions when positioning the come into contact with the bumper plates at

when inside contact surface is

door and therefore no adjusting stroke is provided inside How

worn contact may be made at the outside Same

back door securing effect will be obtained

Tightening torque

Back door bumper fiXing machine screw

I kg m 7 2 ft Ib
Back door hi inn

2 Place the back door bumper plates as shown in

Fugure BF 36 so that inside of the back door bumper

comes into contact with inside of the bumper plate and
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secure the bumper plates in the correctly adjusted

0 1575 in
positions The adjusting stroke is 4 mm

Inside Outside
Outside Inside
Fig BF 37 Adjusting back door side dove tail

3 Now adjust both side upper portions of the back

door

Secure back door side dove tJIiIs temporarily toward

the rear direction in the center for vertical direction

close the back door and adjust positions of the back door

side dove tails properly so that the dove tail comes into

contact with the back door hinge arm tightly and the

dove tail is bent I to 2 rom 0 0394 to 0 0787 in

When there is a gap between the dove tail and back

dove tJIiI side shim s 16 rom

door hinge arm apply
Back door bumper 2 Back door bumper plate beneath the dove tail When the
0 0630 in thick

dove tail is moved rearward it approaches toward the

hinge arm gap is reduced and when moved forward it is

Fig BF 36 Adjusring back door bumper plate positions
from the hinge gap increases Vertical
separated arm

stroke is 2 mm 0 0787 in and forward

adjusting
When adjusting back door bumper plate positions use rearward adjusting stroke is 6 rom 0 2362 in

plasticine or similar material fIll the bumper plates with

plasticine close the back door observe contact and

Tightening torque
adjust properly so that both side bumpers come into

Dove tail fIXing machine screw Ikgm

contact with both side bumper plates evenly
7 2 Ib
ft
It should be noted however that when the bumper

BF 22
 BODY

BACK DOOR TORSION BAR

Fig BF 38 Installing back door torsion bar

ProCarManuals.com

Installation torsion bar may be set either from left or right

link and
open the back door
1 Fully and set the hinge REAR BUMPER
torsion bar to condition I of Figure BF 38
Removal

tool for the license plate lamp loosen the

2 Apply a torsion bar wrench special Disconnect wiring
ST08710000 to one end of the torsion bar and hook it bumper installation bolts from the luggage compartment
the
from position II to III of the Figure BF 38 The and remove bumper

DOORS

CONTENTS

Front door lock installation BF 27

DESCRIPTION BF 23

DOOR CONSTRUCTION BF 24 Rear door lock removal BF 28

Removal BF 25 Rear door lock installation BF 28

Adjustment BF 25 DOOR GLASS AND REGULATOR BF 28

Removal SF 29
DOOR TRIM BF 26
Removal BF 26 Installation SF 30

SIDE WINDOW SF 30
DOOR LOCK MECHANISM BF 26
F rant door lock removal BF 27 Removal SF 30

DESCRIPTION

The door sash with The inside handle bracket is provided with a weak
sectional
cross provides high
rigidity and the door sash is secured on the door panel by point so that a load is absorbed when a large load is

means of welding applied to the inside handle during an accident The

The door lock is of a knob lock type and the inside outside handle is of a pull up type

handle is of a pull rise type

BF 23
 BODY

DOOR CONSTRUCTION

1 Glass run rubber

2 Weatherstrip
3 Door panel

4 Weatherstrip spacer
t5 5 Weatherstrip
6 Seal screen

@ 7 Door finish
8 Door bumper rubber

9 Door glass stopper

10 Drain hole cover

II Door glass
12 Glazing rubber
13 Bottom channel

J
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V 14 Outer moulding
15 Door upper hinge

16 Door lower hinge

Fig BF 39 Front door construction

I Glus run rubber

2 Partition weatherstrip
3 Partitionsaoh
4 Door panel
5 Weatherstrip
is
6 Door bumper rubber

1 Seal screen

8 Door finish
9 Door glass
comer

10 Door glass

1
II Outer moulding
12 Glass run rubber

13 Glazing rubber

14

y
Bottom channel
15 Door upper
hinge
16 Door lower hinge
@ @ 11 Drain hole cover

18 Doorglass stopper
19 Weatherstrip

Fig BF 40 Rear door construction

BF 24
 BODY

Removal 3 Hereinafter follow the instructions for the front

door and remove the rear door

It is recommended that the door be removed from the

body with the door hinges attached on the door although 9

the door may be removed from the body with or without

uri
i
the hinges attached on the door
f
l

Front door
f i

5 I
e1
1 Remove the package tray

2 Remove the door

dash side trim

hinge service hole cover from the
I
i
J
I I
3 With the door fully opened support the door by
r
applying a stand or jack beneath the door so that the

door does not drop off Fig BF 42 Removingreardoor

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Note Apply a piece of rag between the door and stand so

Adjustment
that the door panel is protected from damaging
Door hinge
4 Remove the door hinge installation bolts at the the
Loosen the bolts used to secure the hinge to body
body side by the use of a box wrench and remove the downward forward
adjust the door upward or rear

door from the body ward and retighten the bolts

position as required
securely

Adjustable range 6 mm 0 2362 in

Tightening torque
Hinge pillar installation bolt 1 6 kg m 11 6 ft lb

Hinge door installation bolt 16 kg m 116 ft Ib

Note a When installing the hinge grease the hinge link

b Oil top of the hinge pin when the door squeaks

while opening or closing

Striker

Fig BF 41 Removing front door Dash side trim without Another method to
adjust the door loosen the striker
door hinge service hole and adjust the striker position
fIxing screw

Rear door

6 mm 0 2362 in
Remove the kicking plate Adjustable range

Tightening torque
2 Peel off the body side welt and remove the center Striker installation machine screw

pillar finish 0 12 to 0 2 kg m 0 7 to I 4 ft lb

BF 25
 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

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Removal

1 When removing the door regulator handle lock inside

their installation
handle escutcheon and arm rest remove

screws

the
2 When removing the ash tray outer case remove

ash tray and remove the installation screws

3 The door finish is secured on the door with clips ill Ash tray 2 Ouler case

When removing the door finish pull it toward you Fig BF 45 Removing ash tray

DOOR LOCK MECHANISM

1 Door lock
2 Spring
3 Inside handle
4 Loclcing plate
5 Locking plate spring
6 Stopper
1 Outside handle
8 Outside handle rod
9 Nylon nut
10 Escutcheon
11 Knob grommet
12 Door lock knob
13 Door lock cylinder

Fig BF 46 Front door lock mechanism

BF 26
 BODY

1 Door lock
2 Inside handle
3 Escutcheon
4 Door lock knob
5 Knob grommet

Fig BF 47 Rear door lock mechanism

Front door lock removal

ProCarManuals.com

Remove the parts up to the seal screen

2 Remove 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

3 Remove the inside handle installation screw and the

door lock assembly installation screws and withdrawing

the outside handle rod from the opening on the lock

assembly remove the lock assembly from the service hole

on the inside panel

Fig BF 49 Removing front door lock

Front door lock installation

control
1 Installing the inside handle and remote

Adjust position and install the remote control so that

contacts
the stopper @ of the inside handle @ lightly
the base plate of the door lock CD
If the remote control is installed with the inside handle
the locking plate does not intermesh with
@ pulled
the ratchet completely at the full catch and the lock knob

@ does not lower

Lock assembly
the locking plate
2 Connecting outside handle to

Set the locking plate to the fully ratched position

BF 48 Door without sealing screen
Fig on the end of the outside handle
insert the nylon nut @
rod @hnto the locking plate hole and adjust and
4 Detach the leaf clip used to secure the lock cylinder

on the door and remove the lock cylinder secure the nylon nut @ with adhesive in a position where

BF 27
 BODY

the outside handle rod @ is provided with 2 to 3 mm lock knob

0 0787 to 0 1181 in in the stroke

play
If the nylon nut @ is positioned too low the locking 3 Remove the bell crank installation screw

plate @ is depressed at the full ratch the locking plate

Hereinafter the instructions for removal of the front
does not intermesh with the ratchet the
completely and
door lock apply
knob cannot be locked If play in stroke of the outside

handle rod is
@ excessive may be unlocked up to 5 mm

0 1967 in stroke of the outside handle will be

insufficient

If the nylon nut is loosened the above described

trouble occurs Be sure to secure the nut completely by
of adhesive Check the springs and
means
@ @ for rust

and replace as required

Tightening torque

Door lock installation screw

0 12 to 0 2 kg m 0 9 to I 4 lb
ft

Door lock remote control installation screw

0 12 to 0 2 kg m 0 9 to I 4 ft Ib
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Fig BF 50 Door witlwwr se4ling scr

n

Outside handle installation nut

0 2 to 0 3 kg m I 4 to 2 2 ft Ib Rear door lock installation

Install the rear door lock in reverse of

sequence
Rear door lock removal
removal
1 Remove the parts up to the seal screen
Note Except for the precautions for outside handle the
2 Raise the door the top and the door
glass to remove precautions for the front door lock apply

DOOR GLASS AND REGULATOR

1 Front door panel

2 Glassrun rubber

3 Door window gla

u
4 Glazing robber
5 Bottom channel
6 Door ventilator frame
7 VentiJator glass channel
8 Catch handle
9 Door ventilator
glass
10 Pivot bracket
11 Door ventilator weatherstrip
12 Gins run rubber

13 Frontwindow regulator
14 Door handle washer
15 Door window regulator handle

Fig BF 51 Front door g14ss and regulator ction

const 4 door sedmt

BF 28
 BODY

1 Rear door panel

2 Glass run rubber
3 Partition rear door

weatherstrip
4 Rear door glass
5 Rear door comer glass
6 Glazing rubber
7 Bottom channel
window tegutator
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8 Door

9 Door handle washer

10 Door window regulator

handle

4 door sedan
Fig BF 52 Rear door glass and regulator constructiorl

Removal

Remove the door trim and seal screen 4 Pull upward and remove the door glass

Remove the door and lower the door 5 Remove three regulator assembly installation screws
2 glass stopper
service hole
to the bottom and remove the regulator assembly from the
glass
be removed without
Remove four door ventilator installation screws and Note The door regulator may
3
removing the door lock
detach the door ventilator
l
ffL

9
Q I jJl
Jl
it Ii

1 3

tilatOl
L f I

Fig BF 54 Removing rear door window regu14tor

Fig BF H Removing door

BF 29
 BODY

Installation

Insull the door glass and regulator in roverse sequence

of removal

Reinstall the seal screen aftet correctly adjusting door

window closing

SIDE WINDOW I C
Removal

the
Remove the lock pillar moulding and remove

side window handle set screws from the body side

1 Side window glass 4 Side window handle
2 Side window hinge 5 Handle shim
3 Side hinge conr 6 Catch handle bracket

2 Loosen the side window hinge installation screws

and remove the side window Fig BF 55 sick window construction

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WINDSHIELD AND REAR WINDOW

CONTENTS

CORRECTION BF 31
REMOVAL BF 30 WATERLEAK

INSTALLATION BF 31

REMOVAL

I Place a protective cover over the hood front fenders

instrument panel and front seat

2 Remove rear view mirror support

3 Remove windshield wiper arm assembly

4 On inside of body loosen the lip of the rubber

channel from spot welded flange along the top and sides

of windshield opening With the palm of the hand apply

edge At the same time use a blunt

pressure to glass near

putty knife or other suitable tool and carefully assist

rubber channel over spot welded flange

Fig BF 56 Removing windshield

5 After windshield rubber channel is free from spot

welded with aid of helper carefully lift windshield Note The windshield cltrome modlings are installed in
flange
the rubber cltennel and should be removed prior to
assembly from body opening and place it on a protected
cltannal from the
bench removing rubber gI

BF
lO
 BODY

INSTALLATION 5 When the glass and channel are properly positioned

lower
It is that the be
in opening slowly pull ends of cord starting at
important body windshield opening
center of windshield to seat lip of rubber channel over
checked thoroughly before installation of the replacement
first across
below outlines the
spot welded flange Cord should be pulled
windshield glass The procedure
bottom of windshield then up each side and finally across
method which may be used to check the windshield
windshield top
opening
6 Using a pressure type applicator seal inner and
I Check windshield rubber channel for any irregu of rubber channel to glass with
outer lips an
approved
larities
weatherstrip adhesive as indicated in Figure BF 57 Seal

completely around rubber channel

2 Clean off old sealer around windshield opening and
check entire body opening flange for any irregularities

3 With the aid of a helper carefully position replace

ment glass on windshield opening

Note Care should be exercised to make certain glass does

not strike body metal during installation Edge

chips can lead to future breaks

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4 With windshield glass supported and centered in

body opening check relationship of glass to body opening

around entire perimeter of glass

I The inside surface of the glass should completely Fig BF 57 Sectional view of bber channel

contact the spot welded flange

7 Reinstall all previously removed parts and remove
2 The curvature of the glass should be uniform to that

of the body opening protective coverings

5 Mark any sections of body to be reformed Remove

glass and reform opening as required

WATERLEAK CORRECTION
6 Install windshield
In many instances minor waterleaks around the
I Clean out old sealer in glass cavity of windshield windshield may be corrected the
by performing following
rubber channel and around base of rubber channel
operations

2 Install rubber channel to glass

Leak between rubber channel and glass

3 Insert a strong cord in the groove of the rubber Using a pressure applicator corking gun with a narrow

channel where the spot welded flange fits tip apply an approved weatherstrip adhesive black
Tie ends of cord and tape to inside surface of glass at between glass and rubber channel on the outside of the
bottom center of glass glass completely around perimeter of glass

4 With the aid of helper and

a
carefully position 2 Leak between rubber channel and body
center windshield assembly in body opening
Use a pressure applicator with a narrow tip Working
Note Do not position sealer under outer lip of
glass by tapping or hammering at from outside of body apply a

any time rubber channel around entire perimeter of body opening

BF 31
 BODY

VENTILATOR

CONTENTS

DESCRIPTION SF 32 COWL TOP GRILLE SF 33

DESCRIPTION

In this body ventilation systeO air is taken from the rear pillar body side for coupe and side window Thus
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air intake on the cowl top and ventilator on the front the passenger compartment is ventilated sufficiently
door and exhausted from the slip shape air outlets on the

4 door sedan 2 door sedan

Coupe Station wagon or V an

BF 58 Ventilation system
Fig

BF 32
 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 top grille is made of ABS resin When

installing tighten inside self tapping screws two screws

first and tighten four outside self that

tapping screws so

no unreasonable force is applied to the cowl top grille

Moreover be careful not to allow brake fluid or oil

sticking to it

1 Heater motor 5 Room valve

2 Fan
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6 Ventilator valve
3 Heater core
7 Defroster nozzle
4 Shu t valve 8 Cowl top
O
1 COWL GRILLE I
Fig BF 59 Cross sectional view offorced ventilation Fig BF 60 Cowl top grille removal

SEAT

CONTENTS

SEAT BF 33 Reinstallation BF 35

Description BF 33 HEAD REST OPTION BF 35

Removal BF 34 SEAT BELT OPTION BF 35

SEAT

Description

For the BIIO series two types of front seat are

available one is a separate bucket seat and the other is a

separate manual reclining seat option

The manual reclining seat is operated by a control lever

located in the window side of the seat cushion When the

control lever is pulled upward the seat back can be

reclined to any desired position up to approximately 520

from the normal position Fig BF 61 Front seat

BF 33
 BODY
bulk head upper
Removal 4 Unhook the seat back at the rear

portion

Slide rail of front seat

and Rear seat coupe
side of the seat
I Slide the lower rail toward rear

cushion out the

remove the seat frame connecting bolts I Raising rear side of the seat pull
cushion stopper and remove the seat cushion
2 Remove return spring

3 Slide the lower rail forward and remove the fIXing

bolts from the rear side

Rear seat sedan

I Remove two screws from both sides of the seat

cushion

seat cushion it out

2 Raising front side of the pull
3 Remove the seat back attaching screws
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BF 64 Removing rear seat cushion

Fig

installation and remove the seat

2 Loosen screws

back

Rear seat Station wagon or Van

1 Turn down the seat cushion forward remove four

screws and remove the seat cushion as shown in Figure

65
BF
Fig BF 62 Remvoing s at cushion fIXing screws

BF 65 Removing rear seat cushion

Fig

two screws
2 With the seat back turned down remove

BF 63 baclc installation screws from the wheel house and remove the seat back
Fig Removing seat

BF 34
 BODY

HEAD REST OPTION

rest on front seat the
When installing head remove

the seat back and insert the head rest supports

plug on

into the holes

i
I
Fig

Reinstallation
BF 66 Removing rear seat bock

Reinstall the seat cushions and seat backs

in reverse
IJI
f

I
IJ

I
i
I
I
I

Ii i I
i
r
ProCarManuals.com

Fig BF 67 Head rest

sequence of removal

SEAT BELT OPTION

CO

Fig BF 68 Seat belt installing positions

BF 35
 BODY

INSTRUMENT PANEL

CONTENTS

REMOVAL SF 36 REINSTALLATION SF 37

REMOVAL

Note When disconnecting the wlnng harness recom

mend to use tags for identifing their relationship

i
3 Disconnect cables for radio and speaker
i f antenna
ProCarManuals.com

4 Remove the package tray the shell cover and turn

signal switch
il
1 ff c Cll
1
II ii
Note Work may be carried out without removing the

@ioEl steering wheel However recommend to remove

the steering wheel so that work can be carried out

more easily

Fig BF 69 Removing instrument panel

5 Disconnect the speedometer cable from the

speedometer unit

Note There are two types of instrument panel square

type and round type However both of them are

6 Disconnect the heater control cable at the heater
removed and reinstalled in the same manner
side

Disconnect the battery cable at the battery terminal

2 Disconnect the units

wiring harness connector

Disconnect the instrument harness from the engine

compartment harness
Disconnect the instrument harness from the turn signal

switch

Disconnect the instrument harness frorn the body

harness

Disconnect the instrument harness connected to the

door switch stop lamp switch flasher unit and passing

light relay option Fig BF 70 Removing nt

instn panel I

BF 36
 7 Remove three screws from top of the instrument
bottom
one each installation bolt from both sides of the
and two bolts used to secure the instrument panel

together with the steering column clamp

it toward
R Raising the instrument panel slightly pull
it
rear side of the vehicle and remove

Note Ensuring that all cables are disconnected remove

1I e instrument panel slowly and carefully

REINSTALLATION
Reinstall the instrument panel in reverse sequence of

Fig BF 71 Removing instrument panel II

removal
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ROOM TRIM

INSTALLING HEAD LINING

B A
A

Adhesive
A B

Detailed view of
FRONT
A portion

A A
B B
Be sure to hook the
clamp securely

Fig BF 72 Installing head lining

Note Be sure to install the roof insulator before installing the head lining

BF 37
 BODY

For those vehicles which do not

use pinar cloth fold at this line

A B B B
For 2 door type vehicles
fold pillar cloth at this line
FOld and stick A
A A
this portion

0
c

The left side opposes 0

00
the right side t
symmetrically
ProCarManuals.com

Fig BF 7 J Installing windshield and center pillar cloth

Note Be sure to apply pal before installing dath

4 door 2 door
type vehicle type vehicle

GG
A A

Detailed view t f BU
for 2 door type vehicle
0
Firstinstall the rear pillar
clothon the body with

screw fold it downward

0oo1
and stick with adhesive

Fold Vinyl cloth at this line

Fig BF 74 Installing rear pillar cloth

Note Be sure to apply pad before instaJling cloth

BF 38
 BODY

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No
ProCarManuals.com

BF 39
 BODY

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No
ProCarManuals.com

BF 4O
 SECTION BE

BODY ELECTRICAL

DATSUN 1200
MODEL B110 SERIES
ProCarManuals.com

CHASSIS BODY

WIRING BE 1

FUSE BE 6
I NISSAN I
LIGHTING SYSTEM BE 7

HORN BE 15

METERS AND GAUGES BE 18

WINDSHIELD WIPER
BE 26
AND WASHER

IGNITION SWITCH
BE 29
AND STEERING LOCK

CLOCK

TACHOMETER
BE31G
BE 31

RADIO BE 32

NISSAN MOTOR CO LTD HEATER BE 34

TOKYO JAPAN
 BODY ELECTRICAL

WIRING

CONTENTS

BE 2
WIRING HARNESS BE 1 Body harness
4
BE
harness BE 1 WIRING DIAGRAM
Engine compartment
BE 6
I nstrument harness BE 2 INSPECTION

WIRING HARNESS
The wiring harness is classified into engine compart
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ment harness instrument harness and body harness The

individual harness locating positions and connecting

positions between the individual wiring harnesses are

indicated as follows Moreover for the body harness the

installing positions differ mutually in Sedan Coupe

Station wagon and Van

Engine compartment harness

2
Fig BE 2 Engine compartment harness

3
Fig BE l Engine compartment IuJmess 1 Fig BE 3 Engine compartment harness

BE 1
 BODY

Instrument harness

c J Switch and control

Harness terminal in the connecting unit

engine compartment

2
Fig BE 7 Body hamess

Fig 4 lnstrvment hamess

BE
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1 3 Body earth
I Instrument harness 3 Body harness Body harness
2 Combination lamp RH
2 room harness
Engine

BE 5 Wiring harness connections Fig BE 8 Body harness sedma

Fig

Body harness

j gl r

4i i

To license lamp
Body SS
hamc

Combination lamp Un

Fig BE 9 Body harness sedan

FiX BE 6 Body ham ss I

BE 2
 BODY ELECTRICAL

75
3 I

1 Tail harness 3 Rear seat

1 Combination lamp RH 3 Body harness
2 Wheel house RH 4 Body harness
2 To tank unit

harness coupe Fig BE 12 Body harness Station wagon and Van

Fig BE I0 Body
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Combination lamp LH
Body harness
3 To license lamp
o Tolicense lamp
o Tail harness

Fig BE 13 Body harness Station wagon and Van

Fig BE II Body harness coupe

BE 3
 0 oo

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partS
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1

optlO
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OUndII

nd Indicator
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itrutT UfO ltiO1llO lead Brl e o t ed
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1

fl

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t

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O tE
m iUJ i
1
COOE JE
e
E
BLACK GRE N
REO w
OR
ProCarManuals.com

ll G
8 R
COI

parte

p
tI
J
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corect d
IIl vt
and
oc
D
Jl

tt

n
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to
 CAl
1 ElEC1R
600

j
a
a io co
06
t
i d p
iJ
te i
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a belil
l
E
i
a
f aIll
t i
ig O
c
t aO

1
11
Ul t

g 3 co

3
ProCarManuals.com

O
G cr
o J

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1

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I
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B b
b

o
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os
didI fo
IS W
fig IIE

IlE f
 BODY

INSPECTION 6 Cables should be clamped so that they do nol come

check the into contact with sharp temperature of

Referring to the wiring diagram wiring corner or part

harness for connection with electrical equipment and which rises highly

connector for connection and installation When checking

7 Cables should be securely in positions
the wiring harness note the following matters clamped
sufficiently separated from rotating parts such as fan

Connected unit should not be loose rusted or

pulley fan belt etc

contaminated

8 Cables should be provided with an optimum extra

2 Cable insulator cover should not be damaged crack

length at sections stationarily on the body or at sections
ed or insulating material should not be deteriorated where vibration occurs due to engine operation and
others
3 For those parts which are grounded through the

installation bolts the bolts should be in contact with the Note 3 When inspecting or performing other mainte

that service and no power supply is required

body completely so continuity is provided in nance

particularly or when it is anticipated that a part

between the body and bolts
may be circuited
short disconnect the battery

terminal
4 Terminals of unit through which current flows
ProCarManuals.com

into contact with other metal parts b In no event should an unloaded circuit be
should not come

directly connected with ground Be sure to use a

5 No connection should be present test circuit tester

erroneous lamp or

FUSE

DESCRIPTION
When an overcurrent exceeding the rated amperage

flows to a circuit the fuse is heated and melted the

circuit is interrupted and thus cables and electrical

equipment are protected from damaging due to burning or

damaging is limited to the minimum This vehicle is

equipped with six fuses and one fusible link The fuses are

located in the fuse box and used to protect illumination

signal and other systems and the fusible link is adopted

in the cable between the battery and alternator to protect
the charging and starting ci cuits

Fig BE 17 Fusible link

INSPECTION
In the most cases fuse can be checked visually
However when it is difficult to check visually a circuit

tester may be used The fusible link can be inspected

visually or by feeling on
finger tip However the fusible
link can be inspected circuit
more correctly by using a

Fig BE 16 Fuse box tester

BE 6
 BODY ELECTRICAL
Green color link for model
Note 8 When a fuse is blown off be sure to correct the through the fusible link BlIO
cause before installing new fuse Moreover it is eliminate the of
important to cause

to use blown off fusible link before replacing

b Be sure fuse having the rated capacity
Do not use fuse having larger capacity i e 20A
d When fuse is connected inoorrectly and the
3OA etc
contact is loose voltage drops and heat is gener

c Particularly when the fusible link i fused ated resulting abnormally operated electrical equip

replace with a designated fusible link In com ment Remove dust or when oxidized polish with
parison with fuse much flows fine emery paper so that the contact is
higher current II improved

LIGHTING SYSTEM

CONTENTS
HEAD LAMP BE 7 Removal BE 10
Description BE 7 LIGHTING SWITCH BE 11
Sealed beam replacement BE 7 Removal BE 11
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Aiming adjustment BE 8 HAZARD WARNING SWITCH BE 11

FRONT PARKING AND TURN SIGNAL LAMP PASSING LIGHT SWITCH BE 12

SIDE FLASHER MARKER LAMP TROUBLE DIAGNOSES AND
ANO LICENSE LAMP BE 8 CORRECTIONS BE12
REAR COMBINATION LAMPS BE 9 Head lamp BE 12
BULB SPECIFICATIONS BE 10 Turn signal lamps BE 13
TURN SIGNAL AND DIMMER Tail and stop lamp license lamp
COMBINATION SWITCH BE 10 back up lamp BE 15

HEAD AMP
L beam unit

4 When installing unit be the

a new sure to position
Description
Top mark to the top of ring
All weather type sealed beam 2 light system front
lamps adopted Each lamp of both side head lamps is
are

provided with high beam filament for driving 50W and

low beam filament for dipping 40W In other words the
is of a double filament
Ilunp type

Sealed beam replacement

Remove the wiring socket from back of the head

lamp

2 Remove the screws attaching the front grille to

the radiator core support Coupe only
Remove three retaining screws and remove the head

lamp rim All other than coupe I Seal d beam unit 3 Retaining ring
2 S al d b 4
am mounting Aimins adjusting screws

3 ring
Loosen three screws used to install the retaining ring
on the sealed beam mounting ring and Fig BE IS sealed beam
remove the sealed Replacing

BE 7
 BODY

Aiming adjustment
For aiming adjustment an aiming machine head light passengers except for the standard equipment spare tire
tester tester and other instruments used and tools and make sure that pressures of aU tires are
screen type are

For the operating instructions of those instruments refer correct Vertical and horizontal directions of the head

to the instruction manual ofthe instrument to be used lamp are adjusted respectively with two adjusting screws

For the correct aiming adjustment level the vehicle to located in upper and side portions of the head lamp
the ground remove all loads such as luggages and mounting ring

DRIVING BEAM PASSING BEAM 2

I

1126mm
I
44 3 in

t ff 1126mrn 44 3 in

349mm
13 7 in
h

m
ProCarManuals.com

Driving beam Passing beam

H

J h h
J

Sedan 660 mm 26 0 in
40 116 mm 57
4 in 2010 204 rom 8 03 in
Coupe 664 mm 1 in
26

Van 660 mm 26 0 in 1010 204 mm 8 03 in 2040 466 mffi 3

18 in

BE 19 Head lamp aiming adjustment

Fig

FRONT PARKING AND TURN

SIGNAL LAMP SIDE FLASHER
MARKER LAMP AND
LICENSE LAMP

When the bulb with the lens removed

removing
toward the socket turn the bulb counter
pushing
clockwise

Fig BE 20 Replacing parking and turn signa lamp bulb

8
BE
 BODY ELECTRICAL

When removing the fear combination lamp assembly

remove the socket from the lamp housing remove fixing
nuts and remove the combination lamp assembly

side JI
uMr o
b
Fig BB 21 Replacing p

BE 24 combination lamp sedan

Fig Removing rear
ProCarManuals.com

Fig BE 22 Replacing license lamp bulb

REAR COMBINATION LAMPS

Combination lamp RH Tail harness
bulb it counterclockwise
When removing the turning
Body earth
the socket from the and the
remove lamp housing remove

bulb from the socket

BE 25 Removing rear combination lamp van
Fig

w x
10 if
10 I l t

jj
I
1

j
t1
t

BE 26 Rt moving combination lamp coupe

combination lamp bulb
rear
Fig
Fig BE 2l Replacing rear

BE 9
 BODY

BULB SPECIFICATIONS

Specifications
Item
For other than s A and Canada
U For U S A Canada

Head lamp unit

Main Dimmer 12V 50 40W 2

Front parking 12V 21W I F P

12V 23 SW I
Turn signal lamp 12V 5W I T S

Side flasher lamp 12V 6W 2

Side marker lamp 8W

12V 2

License lamp
Sedan 12V lOW I 12V 5W
7 I
Van l2V 5W
7 2
Coupe
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Rear combination lamp

Tail Stop I 2V 21 5W 2 12V 23 SW 2

Turn signal 12V 21W 2 12V 23W 2

Back up 12V 21W 2 12V 23W 2

Room lamp 12V IOW I

Figure encircled in parentheses indicates number of bulbs used

TURN SIGNAL AND DIMMER

COMBINATION SWITCH

Removal 2 Loosen two bolts used to install the horn the

ring on

steering wheel by applying the tool from reverse side of

1 Disconnect the combination switch from the wire
the steering wheel and remove the horn ring
harness at the connector plug and flasher unit terminal

3 Remove the steering wheel nut

fixing and remove

the steering wheel

4 Unscrew two and

fixing screws a
locating screw and

remove the shell cover

5 Unscrew two screws used to install the switch on the

steering tube and remove the switch from the locating

Fig BI
27 Removing turn and
sijtnal hole on the steering tube Now remove the switch unit

dimmer combination switch completely

BE 10
 BODY ELECTRICAL

IGNITION SWITCH

FUSEM
FUSE

OIMMEfI TURN SIGNAL

IGHTING SWITCH 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 dimmer switch system
ProCarManuals.com

LIGHTING SWITCH HAZARD WARNING SWITCH

The hazard lamp system 4 way flasher consists of

Removal
hazard warning switch and flasher unit When the hazard
1 Remove the connector from back of the lighting
warning switch is turned on all signal lamps flash
switch simultaneously telling other drivers that the vehicle is

When the turn signal lamps flash the pilot lamps

stopped
2 Depressing the lighting switch knob turn it counter
on the instrument panel also flash telling you of hazard
clockwise and remove it
lamp operation
3 Loosen the escutcheon and remove the lighting

switch from the cluster lid

IGNITION SWITCH

FUSE H FUSE M
TURN SIGNAL SWITCH

OFF r L

ON

HAZARD UNIT
FLASHER UNIT

HAZARD WARNING SWITCH

J
o
J
z

in J

z
Z

in
Z

lEFT SIDE RIGHT SIDE

Fig BE 29 Circuit diagram for hazard lamp system

BE 11
 BODY

PASSING LIGHT SWITCH

The passing light switch is incorporated in the grip end off the head lamp main beams will light while the witch
of the turn signal switch Ie r and cootrob the head lamp button is pushed in
main beams With either the lighting switch turned on or

USE

FUSE P T FUSE L

DIMMER SWITCH

2
I
0
UCENSE
TAil LAIIPS
S
lAMl L
PASSING LIGHT RELAY
F O PARKING
LIGHTING SWITCH

1 NATlON
HEAD LAMP

i
ProCarManuals.com

LEFT SIDE RIGHT SIDE

Fig BE 30 Circuit di4gram

for passing Ught system

TROUBLE DIAGNOSES AND CORRECTIONS

Head lamp

Possible Method of
Troubles Remedies
causes inspection

A11larnps do Blown off fuse or faulty contact Check the fuse block and white Repair as required
not light cable for contact

Check the fuse for fusing and When fused detect

faulty contact and repair the cause

and replace the fuse

Faulty lighting switch terminal Check the connector for contact Repair as required
connector

Defective lighting switch Conduct continuity test If the lighting switch

is defective replace

The head lamp Blown off fuse or faulty contact Check the fuse for fusing and When fused detect

does not light faulty contact and repair the cause

for both high and the fuse

replace
and low beams
Check the connector for contact Repair required
Improper dimmer switch contact as

Defective dimmer switch Conduct continuity test If the dimmer switch

is defective replace

BE 12
 BODY ELECTRICAL

When red yellow cable is Conduct continuity

Main high beam Defective dimmer switch con

cannot be switch nected to red white cable or test and if the dim

ed to dimmer red black cable and the main mer switch is defec

low beam or
beam or dimmer beam lights tive replace
vice versa the circuit is normal The dinuner

switch is defective

Check the head light circuit for Repair or replace if

Head lamps dim Defective light circuit
cable being about to break and required
faulty contact or check fuse for

faulty contact

of elec Charge battery if

Head lamps dim Partly discharged battery Measure specific gravity
when the trolyte required
engine
is stopped or op
ProCarManuals.com

erated under
Defective battery Replace battery
idling speed

Head lamps still Faulty sealed beam unit Voltage between head lamp red Replace sealed beam
white cable and red cable ter units
dim with engine

run above idling minals is 12 8V or higher

speed

Voltage is less than l2 8V Check the generator

Faulty charging system
regulator and light
through above test

circuit

Repair as required
Faulty head lamp termianl con
Head light in only
one side lights tact

Replace lamp
Defective lamp

Turn signal lamps

Possible Method of
Remedies
Troubles inspection
causes

When the fuse is

All turn signal Blown fuse or faulty contact Check the fuse for fusing and
fused detect and
lamps do not light faulty contact
repair the cause and

replace the fuse

BE 13
 BODY

Faulty flasher unit terminal con When two lead wires of the Repair the connector

tact or defective flasher unit flasher unit are connected with terminal or
replace
the turn signal switch turned on the flasher unit

and the individual turn signal

lamps light the flasher unit is

defective

Defective turn signal switch Conduct continuity test If the turn signal
switch is defective

replace

All turn signal Defective flasher unit Replace the flasher

lamp do not go Wlit

out

Flashing cycle is There is lamp which does not Check the for burnt out
a
lamp Replace if required
too low flash mament and improper socket

contact
ProCarManuals.com

Faulty contact in the circuit Repair as required

A wattage less than

lamp having Replace
the is used
specified wattage

Defective flasher unit Replace the flasher

unit

Turn signal lamp circuit

Short Repair as required
flashing cycle is
A lamp having wattage larger than Replace
too high
the rated wattage is used

Defective flasher unit Replace the flasher

unit

Flashing cycle of Burnt out lamp bulb filament Check aU lamps for operation Replace as required
the left or right Check lamp which does not Iight
side turn signal for burnt out filament and defec

lamp differs tivesocket

from that of the

left
Faulty connector contact Check both side lamps for Repair as required
right or

difference in brightness
side turn signal
lamp Only left

or right side turn

signal operates

lamp other than with the spe

A specified is Replace
used dried one

BE 14
 BODY ELECTRICAL

Flashing cycle Faulty contact of power supply When the windshield wiper Repair as required
varies circuit from ignition switch to which uses the ignition for power

fuse supply is operated flashing cycle

and brightness change

Tail and stop lamp license lamp

back up lamp
Possible Method of
Troubles Remedies
causes inspection

Check the fuse for fusing and When the fuse is

Both left and Blown off fuse or faulty contact

right lamps do faulty contact fused detect and cor

rect the cause and

not light
replace the fuse

Defective lamp switch or When two lead wires of the switch Replace the switch or
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stop

backup lamp switch or faulty are connected and the lamp lights repair the connector

the lamp and circuit normal terminal

contact Stop lamps and backup are

lamp only

Faulty grounding All rear combination lamps do Repair the grounding

not light cable contact

Only one side lamp 1t

BUr out lamp bulb mament Replace the lamp
with a new one
lights

Faulty contact of connector ter Repair or replace

minal and or socket

if
Brightness of one Faulty contact of connector ter Repair or
replace
side lamp differs minal and or socket required

from the other

HORN

CONTENTS

HORN BE 16 TROUBLE DIAGNOSES AND

CORRECTIONS BE 17
Removal BE 16

Adjustment BE 16

BE 15
 BODY

FUSE H

lHI HORN BUTTON

lBGI

H B S

r 1
Ll
I
L J
HORN RELAY

BE 31 tom system
Fig it
CiTe diagram for

HORN

Removal
ProCarManuals.com

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 tom volume

Fig BE lJ Adjtuting
Note When the adjust screw i turned

Clockwise Current increases

Counterclockwise Current d6
AMMETER 110 to 15A

HORN
4 When a
proper sound is obtained through the above

i adjustment make sure that the proper sound can be

obtained at voltage generated by the alternator 14 to
VOLTAGE METER
15V
115 to 2OV

5 Lock the adjust screw with the lock nut

Consumed current adjusting value A

Sound
Fig BE 32 Circuit for hom adjustment
Flat type Spiral type

2 Set the switch to ON and make sure that the 5 0 440

High H 5 390
2
voltmeter indicates 12 to 12 5 V

3 the horn for sound level volume and

Listening tone
Low L 5 330
2 5 0 350
adjust sound properly so that the ammeter indicates the
rated amperage The adjustment is made by turning the Figures encircled in parenth sis are basic frequencies
adjust screw after loosening the lock nut Hz

BE 16
 BODY ELECTRICAL

TROUBLE DIAGNOSES AND CORRECTIONS

Possible Method of
Troubles Remedies
causes inspection

The horn does Excessively discharged battery Measure specific gravity of electro Charge if required
not operate lyte

Blown off fuse Check the fuse for fusing and im Replace fuse

proper contact

The horn sounds though the horn Check and repair

Improper horn button contact
relay terminal S is grounded horn button

Defective horn relay The horn sounds though the horn Replace horn relay
terminals B and
relay 11 are

circuited
short
ProCarManuals.com

Defective horn The horn does not sound though Replace horn

the horn relay terminals 8 and

H are circuited
short and the

horn still does not sound though

the battery terminal is con

nected to the horn terminal direct

ly

The horn sounds Defective horn relay The horn does not stop though the Replace horn relay
horn relay S terminal is discon
continuously
nected

horn relay
circuited
Short horn button When the horn stops through the Repair
and horn relay terminal S above disconnection check the terminal S
horn
horn button unit particularly care Replace
button
fully

Reduced volume fuse wire contact Correct

Improper
and or tone quali
Broken cable Repair or replace if
ty
required

Improper horn button contact Repair

BE 17
 BODY

METERS AND GAUGES

CONTENTS

CLUSTER LID BE lB OIL PRESSURE AND

Description BE 18 IGNITION WARNING LAMPS BE 20
Removal BE 18 HAND BRAKE WARNING LAMP BE 21
SPEEDOMETER BE 19 BULB SPECIFICATIONS BE 21

Replacement BE 19 TROUBLE DIAGNOSES AND

FUEL GAUGE AND CORRECTIONS BE 22

TEMPERATURE GAUGE 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 switch and choke lever
knobs turn them counterclockwise to remove

Description Remove the escutcheon

The cluster lid holds various meters indicators and

ProCarManuals.com

2 Inserting into back of the cluster lid

clock located around the your hand
speedometer Printed circuit

board is used at the back of the shown in disconnect the cigarette lighter cable and turn and
meler as Figure
the
BE 34 and the printed circuit board is connected with remove cigarette lighter outer case

cmulonnectiptolres Thus the meters can be inspected

3 Remove the radio and heater control knobs
and serviced for the speed
extremely easily Except
ometer all meters The fuel gauge
are operated eleclrically
4 Remove the shell cover from the steering tube
and thermometer are very reliable and they are equipped
loosen the screws used to secure the meter housing to the
with bimetal devices
instrument and remove the cluster lid
panel

5 Pull out the l2 pole round shape connector and

the cable union nut

remove speedometer

6 Remove the cluster lid from the instrument panel

W tQ J

Fig BE 34 Combination meters

Removal

I Disconnect the battery terminal depressing the BE 35

Fig Removing lid
dust

8E 18
 BODY ELECTRICAL

SPEEDOMETER FUEL GAUGE AND

TEMPE RATURE GAUGE
The speedometer is equipped with a total odometer

which records travelled distance

Replacement
Description
1 When removing the speedometer remove the cluster
The fuel gauge consists of a lank unit located in the
lid fIrst Separate the combination meter housing from the
fuel tank and fuel meter The tank unit detects fuel level
cluster lid after and remove the
removing four screws trip
with its float converts fuel level variation to a resistance
recorder reset knob if any
of slide resistor installed on the float base and thus

controls current flowing to the fuel meter

2 Unscrew two screws and remove the speedometer
The gauge consists of a thermometer and
from the combination meter housing temperature
thermal transmitter located in the engine block The

thermaltransmitter is with thermistor element

3 Reinstall a new speedometer in reverse sequence of equipped a

which converts cooling water temperature variation to a

removal
resistance and thus the thermaltransmitter controls

current flowing to the thermometer

The fuel meter and thermometer are provided with

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bimetal arm and heater coil hen the ignition switch is

set to ON current flows to the heat coil and the heat

coil is heated With this heat the bimetal arm is bent and
thus the pointer connected to the bimetal arm is

operated
The characteristics of both meters are same

A tolerance may occur on the thermometer or fuel

gauge due to source voltage fluctuation The voltage

regulator is used to supply a constant voltage so that the

thermometer and fuel gauge operate correctly The

voltage regulator is built in the thermometer

The operating part of the regulator consists of a

Fig BE 36 Removing combination ter

bimetal arm and a heater coil When the ignition switch is

turned on the bimetal arm is heated and bent by the coil

opening the contact Consequen tly current to the coil is

interrupted As the bimetal cools the contact closes The

repetition of this operation produces a pulsating voltage

of 8V which is applied to the temperature and fuel gauges
If both thermometer and fuel meters become defective

at the same time this may be attributable to trouble in

the voltage regulator

o
0

Fig BE 37 Removing speedometer

BE 19
 BODY

r
REGULATOR

FUSE M
TEMPE

RATURE
IGNITION
GAUGE
SWITCH

GAUGE TANK UNIT

I THERMAL TRANSMITTER
FUEL TANK

BE 38 Circuit diagram for frul gauge and I

Fig temperature g Olt4ge
regultztor
ProCarManuals.com

Replacement pressure warning lamp which glows whenever engine oil

pressure falls below 0 4 kg crn2 to 0 6 kg crn2 5 7 to 8 5
I Remove the cluster lid first
Ib sq in
2 Unscrew two screws and remove the thennometer or
When the engine is stationary the light glows with the
fuel meter from the combination meter housing
ignition switch turned on When the engine is running and
the oil pressure reaches the circuit is broken and the light
3 Reinstall a new meter in revene sequence of removal
goes out

J
u

I
i Warning light
c
o Fuse
E
c Switch

I
T

J j
without with
pressure pressure

Fig BE 39 R oving thermometer Fig BE 40 Circuit of oil pressure warning system

OIL PRESSURE AND

Ignition warning lamp glows when the ignition switch
IGNITION WARNING LAMPS is set to ON arid the engine is not operated or when the
The engine lubricating system incorporates an oil generator fails to charge with the engine operated

BE 20
 BODY ELECTRICAL

When the ignition switch is set to ON the ignition service brake line pressure differential warning lamp
warning circuit is closed and current flows flows from the When a difference between front and rear brake line

ignition switch to the warning lamp bulb and ground pressures reaches the rated range 13 to 17 kg cm2 185
through the regulator When the engine is started and the to 242 Ib sq in the ground circuit for the warning lamp
into operation the generator output is closed and the
generator comes
warning lamp lights
current opposes the current flowing from the warning

lamp in effect it breaks the warning circuit ground

IGNITION SWITCH
connection and the goes out
lamp FUSE

r
Ignition switch
WARNING
LAMP

8
Cll 0
c
Pilot
relay E
co 1
06 110 al
HAND
SERVICE
BRAKE
3 BRAKE LINE
l
WARNING PRESSURE
ProCarManuals.com

SWITCH
Alternator Regulator OrFFERENTIAL

WARNING

l L
SWITCH

Fig 41
BE Circuit of ignition warning system

HAND BRAKE WARNING LAMP

Fig 42
BE Circuit diagram for brake warning
This larnp function both hand brake warning lamp and system

BULB SPECIFICATIONS

Item Specifications
Square type meter Round type meter

Meter illumination VW 12 4
3 2 12 1 7 3
lamp
Turn V W 12 3 4 2 12 1 7 2
signal pilot lamp
Head lamp main high beam
V W 12 3 4 I 12 1 7 I
pilot lamp

Ignition warning lamp VoW 12 3 4 I 12 1 7 I

Oil pressure warning VW 12 4 I

3 12 17 I
lamp
12 1 7 I
Hand brake warning lamp V W
for U S A CANADA

Clock illumination VoW 12 3 4 I 12 17 2

lamp
Tachometer illumination V W 12 17 2
lamp

Figure encircled in parentheses indicates number of bulbs used

BE 21
 BODY

TROUBLE DIAGNOSES AND CORRECTIONS

Speedometer

Truubles Possible causes Remedies

cable union Retighten union nut

The speedometer pointer and Improperly tightened speedometer cor

odometer do not operate nut rectly

Broken speedometer cable Replace

Damaged speedometer drive pinion Replace the drive pinion gear

Defective speedometer Replace

The speedometer pointer de Rapidly bent speedometer cable Correct or replace

nects widely
Replace the
Damaged speedometer drive pinion gear pinion gear

Defective speedometer Replace

ProCarManuals.com

Unstable speedometer pointer cable union Retighten union nut correctly

Improperly tightened speedometer
nut

Defective the cable

speedometer cable Replace

Defective speedometer Replace

cable Replace the meter cable

Unusual sound occurs in re Excessively bent or twisted speedometer
sponse to increase of driving inner wire or lack of lubrication

speed
Defective speedometer Replace

Inaccurate speedometer indi Defective speedometer Replace

cation

Inaccurate odometer operation Improperly meshed second and third gear worm Replace the meter

gears

the meter
Faulty feeding due to deformed odometer and Replace
pinion carrier

BE 22
 BODY ELECTRICAL

Thermometer and fuel meter

Possible Method of
Troubles Remedies
causes inspection

Both thermometer Blown off fuse or improper con Check the fuse for fusing and Replace after cor

and fuel meter do nection improper contact the if

recting cause

not operate fused Correct con

tact

Defective voltage regulator Dam

aged fused or operi contact The voltage regulator

is combined with the

thermometer to a

single unit When the

voltage regulator is

defective replace it
ProCarManuals.com

together with the

thermometer

Both thermometer Defective voltage regulator Bro Meter operates excessively Replace together
and fuel meter ken heat wire oeized contact and with thermometer

indicate inaccu or improper grounding

rately
Improper cable contact Meter operates slightly Check the cable be

tween fuse and meter

for improper contact

and repair if required

Thermometer

The thermometer Defective thermaItransmitter The pointer deflects when ther Replace the her

does not operate maItransmitter yellow white cable maltransmitter

is grounded

Defective thermometer The pointer does not deflect Replace the ther

when thermaItransmitter yellow mometer

white cable is grounded

The pointer indi Defective thermaItransmitter The pointer moves to the low Replace the ther

cates maximum limit when the ignition switch is maltransmitter

temperature turned off

Defective thermometer The pointer indicates maximum Replace the ther

temperature even after the igniton mometer

switch is turned off

BE 23
 BODY

The thermome Defective thermometer The thermometer is serviceable Replace if defective

ter does not when a 100 n resistance is ap

to the thermaItransmitter
operate accu plied
yellow white cable the cable is
rately
grounded and the thermometer
indicates approximately SOOC
1220 F

Defective thermaItransmitter When the thermometer is normal Replace the thermal

the above inspection transmitter

through

Improper cable contact The thermometer indicates a Check the cable from
lower than
temperature slightly the thennometer to

the actual temperature the thermal trans

mitter for cable being

about to break poor

contact and faulty

ProCarManuals.com

grounding and repair

as required

Fuel met

Fuel meter does Defective tank unit The pointer deflects when the Replace the tank
not operate tank unit yellow cable is unit

grounded

Defective fuel meter The pointer does not deflect Replace the fuel me

through the above inspection ter with a new one

The pointer indi Defective tank unit The pointer lowers below the the tank
Replace
cates Full empty limit when the ignition unit
p
sition switch is turned off

Defective fuel meter The pointer still indicates Full Replace the fuel me

position through the above in ter

spection

Fuel meter func Defective tank unit The pointer indicates a half level Replace if defective

tions improperly when a 3S n resistance is applied

to the tank unit yellow cable and
the cable is grounded

The pointer does not indicate Re place the fuel

Defective fuel meter a

half level through the above in meter

spection

BE 24
 BODY ELECTRICAL

contact The fuel meter indicates a level Check the cable from
Improper cable
lower than the actual the fuel meter to the
slightly
leveL tank unit for cable

being about to break

poor contact and

faulty grounding and

repair as required

Oil pressure and ignition warning lamps

Possible Method of
Troubles Remedies
causes inspection

Oil pressure warn

ing lamp
The lamp does not mown off fuse or
faulty contact Check the fuse for fusing and Replace after correc
ProCarManuals.com

light when the faulty contact ting the fuse the

ignition switch is cause if fused

set to ONn
Broken lamp bulb fIlament or The warning lamp does not light Check the light bulb

faulty cable contact when oil pressure switch yellow for burnt out ftla

black cable is grounded ment and replace as

required

Replace the oil pres

Defective oil pressure switch The warning lamp lights through
the above inspection sure switch

The lamp does not Oil pressure is too low Inspect the engine oil pressure

go out while the system

engine is being
Lack of engine oil Check oil level Add oil
operated
Defective oil pressure switch Continuity exists on the oil pres Replace the oil pres
sure switch when the engine is sure switch

being operated

Ignition warning
lamp

The lamp does Blown off fuse or faulty contact Check the fuse for fusing and Repair or replace as

not light when faulty contact required

the ignition
Burnt out light bulb filament or The pilot lamp does not light Check the bulb for
switch is set to
faulty cable contact when the voltage regula tor con burnt out mam nt
O
nector is disconnected the and replace as re

white red cable is grounded and quired

the ignition switch is set to ON

BE 25
 BODY

The lamp does Faulty charging system Inspect the charging system
not go out when

the is
engine
started

WINDSHIELD WIPER AND WASHER

CONTENTS

Description BE 26 Wiper washer switch replacement BE 27

Wiper motor replacement BE 27 Washer nozzle adjustment BE 27

Wiper blade operating range BE 27 TROUBLE DIAGNOSES AND

CORRECTIONS BE 2B

Description the engine compartment and the link mechanism is

ProCarManuals.com

The windshield wipers consist of wiper motor link located behind the instrument panel
mechanism wiper arms and blades and the wiper motor The electrically operated windshield washer consists of
unit consists of motor and autostop mechanism The
a
washing fluid tank with motor and pump washer
wiper motor is of a speed
2 type nozzles and vinyl tube used to connect those compo

When the wiper switch knob is pulled to the Ist step nents

the windshield at low

wipers operate speed and when The windshield washer switch is combined with the

pulled to the 2nd step operate at high speed windshield wiper switch to a single unit When operating
The wiper motor unit is located on the cowl dash in the washer twist the switch knob

BATTERY
IGNITION SWITCH

WASHER MOTOR
FUSE
18L P lILR W

WIPER SWITCH
LR
OFF 1 2 TWIST
IVI IV

ILl III
x
181
lLW
181
LW
X

j
Bll
I

Fig 43
BE Circuit windshield wiper washer system
diagram for

BE 26
 BODY ELECTRICAL

Wiper motor replacement provide the ann with a proper installation angle so that

the windshield blade is The

wiper positioned correctly
L FiIst of all remove the connector plug from the
attaching nut tightening torque is 60 5 cm
kg
wiper arm
wiper motor
36
434 21i
ft

2 Remove a nut used to connect wiper motor worm

wheel shaft to the connecting rod from passenger

compartment side dash panel

3 Loosen three bolts used to install the wiper motor on

the cowl dash remove the wiper motor

4 Reinstall a new
wiper motor in reverse sequence of

removal

Fig f6
BE Remolling wiper
ProCarManuals.com

27 mm 1063 in

Fig BE 44 Wiper motor

Fig BE 47 Wiper arm installation

Wiper washer switch replacement

1 Remove the connector from back of the wiper

washer switch

2 Depressing and turning the wiper switch knob

counterclockwise remove it

3 Loosen the escutcheon and remove the wiper switch

Fig BE 45 Wiper motor li kag from the cluster lid

Wiper bladc operating range Washer nozzle adjustment

When removing the wiper arm loosen the wiper arm When the washer nozzle is installed or when washer

attaching nut and pull out the wiper arm from the pivot fluid is not sprayed properly adjust the nozzle direction

shaft When installing the wiper arm on the pivot shaft so that fluid is sprayed in range indicated in Figure 48
BE

BE 27
 BODY

Caution in use of washer

Rashed range of

washing solvent
I Never operate the washer continuously for more than

30 seconds or without the washing liquid This often

the washer the
causes s improper operation Normally
washer should be operated for less than 10 seconds at

time

Fig 48
BE Adjusting lI1dSher nozzle

TROUBLE DIAGNOSES AND CORRECTIONS

ProCarManuals.com

Troubles Possible causes Remedies

Wiper system does not oper Open or short circuit of feed har Repair harness
ate ness

Blown off fuse or improper fuse Replace or correct fuse position

contact

Improper connector contact Correct contact

Defective control switch Replace control switch

Defective motor Replace motor

Slow rotation of wiper motor Rotating psrt is out of lubricant Lubricate rotating part

Defective motor Replace motor

Wiper speed does not change Defective switch or improper switch Replace or repair switch
contact

Wiper does not stop Improper switch contact Replace or repair switch

Improperly grounded switch Repair

Improper adjustment of autDstop Replace motor

point

Noisy wiper motor Defective motor Replace motor

BE 28
 BODY ELECTRICAL

blade and Correct position

Improper stop position of Improperly positioned
arm
wiper arm

Damaged or worn stop

auto point Replace motor

Worn rubber blade Replace blade

Improper wiping

Inadequate pressing force of wiper Replace wiper arm

arm

IGNITION SWITCH AND STEERING LOCK

CONTENTS
ProCarManuals.com

BE 29 Description BE 29
IGNITION SWITCH
Rernoval BE 29 lock replacement BE 30
Steering
IGNITION SWITCH WITH BE 30
Warning switch and warning buzzer

STEERING LOCK BE 29

IGNITION SWITCH

This switch is installed on the ignition

position
J
switch bracket which is installed on the instrument panel
with two screws and controls the engine ignition system

and most ofelectrical equipment

Key
position
OFF ON START
Terminal

B Battery
y
1
IG Ignition Fig 49
BE Removing ignition switch
S Starter
R Resistance
IGNITION SWITCH WITH
STEERING LOCK
Description
Removal The steering lock is built in the ignition switch When

Remove the ignition switch connector loosen the ring the key is set to Lock position and removed the

nut remove the ignition switch from the bracket steering system is locked automatically The locking

BE 29
 BODY

mechanism is installed the steering jacket tube When

on
steering jacket tube When installing a new steering lock
the key is set to Lock position and removed the be
proper sure to tighten two new hear type
self screws

steering lock spindle is inserted in a notch in the collar to shear off their heads

which is stationarily set the to lock the

on
steering shaft
Warning switch and warning buzzer
steering wheel
The ignition switch is installed on the back of key

cylinder with a attaching screw and interchangeable

e
ProCarManuals.com

Fig BE 51 Warning nuitch

1 I tion switch part 5 Lock spindle

2 6 The circuit of this warning system is closed when the
Key cylinder part Steering shaft
3
Steering jacket tube 7 Self shear type screw
door is opened with the steering unlocked because the
4 Lock collar 8 Attaching screw

door switch and warning switch are connected in series

When the cicuit is closed the buzzer sounds

Fig BE 50 Steering lock When the warning
replacing switch disconnect two
cables remove the cap loosen two attaching screws and
remove the warning switch
OFF or The warning buzzer is installed the back
Lock ON START
on left side
GARAGE of the instrument panel with two attaching screws

B Battery
IG Ignition r
S

R
Starter

Resistance I FUSE WARNING SWITCH

WARNING
BUZZER
Steering lock replacement
For the purpose of tamper proof the hear type
self
screws are used and their heads are sheared off when
that DOOR SWITCH
installed so the steering lock system cannot be

removed the
easily Replace steering lock proper in

accordance with the following instructions when required

Loosen two attaching screws and break the remaining
two self shear screws with a drill or other proper
type
tool Now remove the steering lock proper from the Fig BE 52 Circuit diagram for warning system

BE 30
 BODY ELECTRICAL

CLOCK

Installation upper portion of the instrument panel

Connect red blue cable or red green cable for illumi
I When installing clock first of all remove the cluster
of the clock to the terminals the
nation lamp on
printed
lid the meter housing
circuit board for illumination lamp on

Ground the clock ground cable In the case of a square

2 Remove the mask and install the clock on the cluster
cable the
type clock tighten the ground together with
lid in the place of mask
meter housing installation screw

3 Connect blue cable or yellow red cable coming out

from the clock to the blue cable of harness laid along 4 Reinstall the cluster lid

YELLOW RED CABLE

RED BLUE cABlE BLUE CABLE
ProCarManuals.com

BE 54 Round type clock

Fig BE 53 Square type clock Fig

TACHOMETER

Installation

I When installing tachometer first of all rernove the

cluster lid

2 Remove the mask and install the tachometer in place

of the mask

3 Connect cables as shown in the Figure BE 55

of the harness laid
Remove the black white cable plug
and
along the upper portion of the instrument panel
connect the black white cable of the tachometer to the

plug in series

4 Reinstall the cluster lid 1 Black cable 3 Black white cable

2 YeUowfred cable 4 Red green cable

Fig BE 55 Installing tachometer

BE 31
 BODY

RADIO

Removal

I Remove the cluster lid

2 Disconnect the lead wires from the radio

0 Jtf

1 0
3 Remove two nuts used to install the front side of the

radio on the instrument panel

4 Loosen two screWs as shown in the Figure BE 56 e

I
4
v 4
r
r
I
I

and remove the bracket used to install the rear side of the r

radio on the instrument panel

r

s
5 Remove the radio

1 Power e cable
1Otm 4 tenn cable
Blue white cable of 5 Single pole fuse
eS 6 Spare fuse
2 Power source cable Radio 7 Attaching screws
ProCarManuals.com

3 Speaker cables

Fig BE 56 Removing radio

Noise prevention chart maximum and set the dial at a medium point without

Run the engine raise the antenna set volume to catching broadcasting wave

Condition Apparent cause Repair

I

Ignition system

High tension code be dis

Noise occurs when engine is oper High tension code may

because noise suppressor

ated regarded
is used

the choke wire from the

Ignition coil Apart
ignition coil as far as possible

Install a 0 5 F capacitor in primary

side terminal of ignition coil

Notll Be careful not to install

capacitor in secondary or

primary breaker side or

otherwise the engine be

comes improper

Connect wire between engine and

ignition cOil locating area of body

with bond

BE 32
 BODY ElECTRICAL
Secure ground of ignition coil

Distributor Secure contact of carbon electric

and rotor
pole

Eliminate excessive tip on the rotor

pole or cap pole by scrubing with a

screwdriver

Check stagger between rotor and

stator

Charging system

Alternator Install a 0 5 lF capacitor

Sound of alternating current pre

sents on charging terminal A

Note Do not use capacitor ex

cessively

If capacity is used ex
ProCarManuals.com

cessively the alternator coil

will be broken

When the accelerator is de Regulator Install 0 5 lF A

pedal a capacitor on
terminal of the voltage regulator
pressed or released noise presents

Supplement equipment
between
When starts noise Operative noise of ther Install O lF
I capacitor
engine presents
Noise still after mometer and fuel gauge terminal and ground wire
presents even

stopping the engine

Note If a capacitor having ex

cessive capacity is used indi

cation of meter will be devi

ated

Install 5 IF
0 capacitor on the
Noise presents when horn is blown Horn a

horn relay terminal or horn switch

Noise when turn signal Flasher unit Installa 5 lF capacitor

O
presents
lamps are operated

Note Be sure to locate completely

a capacitor most near position
of nois6urce and connect in parallal de Maka installation and connection securely
b Cut lead wire as short as possible e Carefully identify IN or our

Ground wire should be tha marks

c placed on body

BE 33
 BODY

HEATER

CONTENTS

Removal and installation BE 35 TROUBLE DIAGNOSES AND

CORRECTIONS BE 35

I
I
ProCarManuals.com

to 1

2
Heater hose
Qamp
3 Shut valve
4 Vent valve
5 Room valve
6 Defroster hose
7 Defroster nozzle
8 Control wire
heater control to room valve
9 Control wire
heater control to water cock
10 Control rod
heater control to shut valve
11 Heater cock

57
BE dter
H nit
Fig

Removal and installation wires between water cock and heater control and room

valve and heater control at the heater unit side Dis

1 In order to ease the the package
operation remove
connect the control rod from the shut valve
tray and ash tray
Note When carrying out this be sure to set the
operation
2 Loosen the hose and disconnect two heater
clamps heater control upper lever to OEF and lower
hoses between the heater unit and engine at the engine
lever to OFF
side Remove the hose clamps from the heater hoses

3 Disconnect cables from the heater unit heater 5 Withdraw two left and right defroster hoses by
control and main harness hand

4 Remove the wire 6

clamps and disconnect two control Loosen four attaching screws used to install the

BE 34
 BODY ELECTRICAL

heater unit on the dash board and remove the heater unit panel
carefully
8 Remove two self tapping screws from back of the
instrument panel and remove the defroster nozzle

7 When removing the heater control from the instru

the control knob and loosen two 9 The heater unit is installed in
ment panel remove reverse sequence of

screws used to install the heater control on the instnunent removal

TROUBLE DIAGNOSES AND CORRECTIONS

Troubles Possible causes Remedies

Hot air does not come out

Motor does not operate Open or short circuit of feed har Check and repair wiring harness

ness

Defective switch Conduct continuity test and if

required rep ce switch

ProCarManuals.com

Defective motor Replace motor

Fan cannot be rotated Motor journal is out of lubricant or Lubricate journal

smoothly by hand stick

Replace motor

Hot air dose not come Slow rotation of fan Replace motor

out nevertheless fan is

Loose fan installation Repair
rotating

Air temperature is low

Hot water does not cir Defective water pump Repair water pump

culate
Bent or clogged of connecting hose Repair or clean piping

Defective hot water cock Repair

Air is left in the hose Purge air out of hose

Water temperature is too Defective thermostat Replace thermostat

low

Water from Defective water hose Replace water hose

leakage
heater
Loose clipping of water hose Retighten clip

Improper soldering of heater core Solder leaking position

Defective defroster Disconnected defroster hose Correct connection

Bent or broken defroster hose Correct or

replace

BE 35
 10
0

BODY

Vibrating noise Loose heater support Tighten completely

Loose fixing screw Retighten

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No
ProCarManuals.com

BE 36
 SECTION SE

SERVICE EQUIPMENT

DATSUN 1200
MODEL B 110 SERIES

CHASSIS BODY
ProCarManuals.com

INI NI

NISSAN MOTOR CO
TOKYO JAPAN
LTD SPECIAL SERVICE TOOL SE 111
 SERVICE EQUIPMENT

SPECIAL SERVICE TOOL

means tool included in Tool Set ST09330000

SetA ST09330000
B 110 special service tool set number means tool included both in
Set B ST09340000
Tool Sets ST09330000 and ST09340000
510 special service tool set number ST09IIOOOO II means tool included in Tool Set ST09l10000

Tool number S M refer

0 0
o 0

Figure Applied ence page

Description 0
model See
Tool name t E
on

mm inch l lil Fig No

Clutch tool

ST206 I 0000
ProCarManuals.com

For centering the BlO

Clutch aligning bar
Fig CL 14
clu tch disc B20

ST20 I 01000

For measuring the dia

Clutch assembly
@
D
phragm spring height BIO Fig CL 5
base pia te Use with the distance B20 Fig CL 7

piece

STl005800l

7 510
For measuring the dia
Clutch O 3 521
assembly phragm spring height
distance piece 130 Fig CL 5
Use with the base
C30
plate

@t S30

SE 1
 CHASSIS

M refer
S
Tool number go o
So
0
00
0
Applied ence page
Figure Description 0 00
00 model See
ot
Tool name rnrn inch l a Fig No
i

ST20105000

Diaphragm adjust F or measuring the dia BlO

Fig CL7
wrench phragm spring height B20

Transmission tool
ProCarManuals.com

ST22350000

BlO
Main shaft bearing For B20
assembly of the Fig TM 35
drift main shaft bearings 130
A30

ST23030000

Counter shaft For assembly of the BlO Fig TM 29

bearing press stand counter shaft bearings B20

ST23050000

For measuring the

Counter gear height counter bearing height BIO Fig TM 30

from the transmission B20

gauge
case rear end

SE 2
 SERVICE EQUIPMENT

Tool number 00
S M refer
g 0
0 il Applied ence page
Figure Description l
o
01

l model See
Tool name t t
mm inch Q 5 Fig No

ST23S20000

For removal of the fork BIO Fig TM 16

F ark rod pin punch 30IS 21 rod retaining pins B20 TM 18
Fig

y
ST23620000
ProCarManuals.com

510
CIO
For supporting the inter
BIO Fig 4I
TM
F ark rod guide lock ball when installing
820
the fork rod
521

C30

ST23820000

270 10 6

of the
Adapter setting Setting plate BIO
transmission gear Fig TM lS
plate B20
assembly
a

ST22730000

For removing the trans

BIO
Bearing puller mission main counter Fig TM 22
820
and drive shaft bearings

SE 3
 CHASSIS

S M refer
0
Tool number gg 0
0
Applied ence page
Figure Description Q
u
model See

inch E Fig No
Tool name mm

Differential carrier tool

ST06220000

50 tting tool of gear

carrier 810 PD
Differential gear Fig
Use with engine stand B20
carrier attachment
ProCarManuals.com

ST30600000

BlO

F or installing the drive B20

Page
Drive pinion bearing inner 130
pinion rear bearing PO II
drift race A30
36 1 417 dia
S30

SBl120000

of BIO
Drive pinion armnge For height adjustment Fig PD 22
the drive B20
ment gauge pinion

ST3l230000

For hiehgt adjustment of

New Fig PD 22
Dummy shaft the drive pinion

4
SE
 SERVICE EQUIPMENT

i S M refer
iio
Tool number g 0

Co Applied ence page

Figure Description OU
u co
OIl C
model See

Toolnarne mrn inch l I 1

11 fII Fig No

snl 540000

For removal of the BIO

Drive pinion flange Fig PD 12
B20
wrench drive pinion nut

ST325oo000

BIO
ProCarManuals.com

3 For determining the side Fig PD25

Side bearing adjust 84 5 327

bearing adjust shim B20

weight 20 0 7871 dia
LJ

r
EJ 7 IO 6891

Sn30lOoo0
BIO
B20
Differential side F or removing the dif
ferential side bearing CIO 9
bearing puIler Fig PD
Use with adapter 130
assembly
ST330l1000 521

V5l0

ST33220oo0

uo
For assembly of the BIO PD 19
Differential side Fig
side bearing B20
bearing drift

snl190000

BIO
Drive pinion preload
For measuring the drive Fig PD 2l

pre load B20

pinion
gauge
CJIICD

SE 5
 CHASSIS

Tool number S M refer

g sg
Figure Description
0
u Q U
Applied ence page
0
model See
Tool name
E
o
inch Fig No
mm ii

ST3003 I 000

O
B

B20
Drive pinion rear For removing the
0
5
bearing inner race drive pinion rear bearing Fig PD IJ
O
C
replacer inner race
C30
S30

Front axle and suspension tool

ProCarManuals.com

ST353IOOOO

Front wheel hub For removing and

O
B
bearing outer race installing the front wheel Fig FA 22
drift B20
hub bearings

ST3565ooo0

New

0
5
Coil spring For assembly and dis O
C
Fig FA 32
Compressor set of the coil C30
assembly
spring S30

re

ST35500000

0
5
Gland packing For the
tightening O
C
Fig FA 34
wrench
gland packing C30
S30

width rOD f1ets 55112 7

6
SE
 SERVICE EQUIPMENT

Cii S M refer
Tool number 0
g 0

0 Applied ence page

Figure Description Il
0
Clot
u
model See
Tool name mm inch co E Fig No

ST35550DOO

Gland For assembly of the

packing New Fig FA 39
guide gland packing

ST3672DOOO
ProCarManuals.com

For remving and installing

Front transverse link
the transverse link New Fig FA 53
bushing replacer set
GUIDE bushing

SUPPORT

9
Rear axle and suspension tool

ST371300DO

Rear axle shaft

@ For remving the rear axle BID

bearing puller C shaft bearing B2D

Fig RA 5

ST3827DOOO 41 11 6141 die

Rear axle shaft For installing the rear BID RA 7

Fig
bearing and collar axle shaft bearing and B2D
press stand set collar

SE 7
 CHASSIS

G S M refer
Go
Tool number 28 0
c A pplie d ence page
ou
Figure Description o
v

model See

Tool name mm inch t

CC1 I Y t Fig No

ST07640000

BIO
For removing the rear
510
axle shaft Fig RA 3
Rear axle stand CIO
Use with sliding hammer Fig RA 7
C30
ST36230000
S30

pitch 114 3 4 5 di8

ST36230000
ProCarManuals.com

I Use as hammer by
All Fig RA 3
Sliding hammer 1 the weight
sliding

Steering tool

ST27 140000

BIO
For removing and
Steering gear arm 510 Page
installing the steering 521 ST 3
puller arm
gear B20

ST27190000

For assembly and dis

Steering linkage BIO Page
assembly ofthe steering
B20 ST I4
joint puller
linkage

8
SE
 SERVICE EQUIPMENT

Tool number S M refer

O
iii
8 0

0
0
Applied ence page
Figure Description Q
model See

Tool name mm in i Fig No

Body tool

ST087 I0000

For removing and install Page

tail torsion BF 20
ing the gate
New BF 23
Torsion bar wrench bar
e
J
ProCarManuals.com

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No

SE 9
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CHASSIS

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No
ProCarManuals.com

SE lO
 SERVICE EQUIPMENT

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No SUBJECT
BULLETIN No
ProCarManuals.com

SE 11
I

CHASSIS

SERVICE JOURNAL OR BULLETIN REFERENCE

JOURNAL or
DATE PAGE No
BULLETIN SUBJECT
No
ProCarManuals.com

SE 12
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