Datsun Sunny Coupe (1981) manual

SUNNY SERVICE -an0 REP~IR manual[...]

Coupe Printed By Times Printers Sdn. Bhd. Singapore[...]

GREGORY'S SERVICE AND REPAIR MANUAL No. 195 DATSUN SUNNY SEDAN - COUPE - WAGON - VAN 1200cc, 1400cc and 1500cc 1979-1981. GREGORY'S PUBLISHING COMPANY SYDNEY[...]

GREGORY'S Service and Repair Manual No. 195 Published By Gregory's Publishing Company Sydney, Australia Edited and photographed at the company's Sydney editorial and research centre No 1 Unwins Bridge Rd St PETERS 2044 N.S.W. AUSTRALIA Printed by Times Printers Sdn. Bhd. Singapore O Copyright by Gregory's Publishing Company Firs[...]

INDEX ....................... INTRODUCTION ...... TOOLS . EQUIPMENT'- SAFETY Safety ........................................... .............................. Tools and equipment LUBRICATION AND MAINTENANCE ... How to grease and oil change ........................ ................................. Lubrication chart Maintenance chart ..........[...]

Index ...................................... Description 112 Shockabsorber ................................... 112 ..................................... Specification 112 ................................... Suspension arm 113 PART 3 . SEMIELLIPTIC SPRING TYPE .............................. SUSPENSION 114 Description ................................[...]

INTRODUCTION 7 This workshop manual has been researched and written by automotive engineers for the practically-minded car owner who wishes to maintain his vehicle in a safe, reliable and serviceable condition and, at the same time, reduce running and maintenance costs. A vehicle, of the type covered by this manual, was taken into our workshops whe[...]

TOOLS-EQUIPMENT-SAFETY 1. TOOLS AND EQUIPMENT When servicing the modern motor vehicle, special tools are sometimes essential for overhaul and adjust- meat procedures on certain components. These special tools can be expensive and often require specialised knowledge to operate them, in which case it is more practical to take the vehicle or component[...]

Tools-Equ$ment-Safety 9 length of time it is also good policy to wipe them over with an oily cloth. ~eeler gauges should bk given parti- cular attention and must be kept scrupulously clean at all times as grit on the blades will cause damage to the blades and inaccuracy when measuring. To prevent the feeler gauge blades from rusting and pitting thr[...]

Oils and greases are available in handy pack size for do- Oil gun, grease gun, oil cap and filter removal tool. .it-yourself lube jobs. Timing light, test lamp and dwellltach meter. Car ramps, chassis stands and hydraulic jack. 2. SAFETY Never work under a vehicle which is supported only by the vehicle jack, bricks or similar materials as these are[...]

LUBRICATION AND MAINTENANCE SPECIFICATIONS STORES AND EQUIPMENT REQUIRED CAPACITY AND GRADE Engine: Lubricant ........................ Castrol GTX Sump capacity - With filter ........................... 3.2 litres Without filter ........................ 2.7 litres Cooling system capacity (including heater): Manual transmission - A14 and A15 engines[...]

12 Lubrication and Maintenance -- Remove the oil filter using the oil filter removing tool. Location of rear axle filler and drain plugs. NOTE: It is best to drain the engine sump with the oil at operating temperature. How- ever, if the oil is hot take care to avoid scalding. When the engine is completely drained, instal and firmly tighten the sump[...]

Lubrication and Maintenance 2. SERVICE SCHEDULE JOB ENGINE (1) Check the oil level on the dipstick each time the fuel tank is topped up or every 1000 km. Top up as neces- sary with the correct grade of engine oil. (2) Drain and refill the crankcase and change the engine oil filter every 10,000 km or six months. NOTE: When driving under severe or du[...]

14 Lubrication and Maintenance JOB MANUAL TRANSMISSION (1) Check the oil level and visually inspect the transmission for leaks every 10,000 km or six months. (2) Drain and refill the transmission every 40,000 km or two years. AUTOMATIC TRANSMISSION (1) Check the automatic transmission fluid level every 10,000 km or six months. The check should be m[...]

Lubrication and Maintenance 15 JOB BATTERY Check and top up the electrolyte with distilled water as required or at least monthly. Never allow the electro- lyte level to fall below the plates. DISTRIBUTOR AND SPARK PLUGS (1) Renew the contact points and adjust the igni- tion timing every 20,000 km or twelve months. (2) Renew the spark plugs every 20[...]

Lubrication andMaintenance 3. LUBRICATION CHART LUBRICATION KEY 1. Radiator. 2. Oil filler cap. 3. Distributor. 4. Oil filter. 5. Engine oil dipstick. 6. Automatic transmission dipstick. 7. Steering gear. 8. Front hub bearings. 9. Manual transmission level Plug. 10. Rear axle level plug. 11. Automatic transmission. 12. Brake master cylinder reservo[...]

Lubrication and Maintenance 4. MAINTENANCE CHART MAINTENANCE KEY 1. Radiator. 2. Fan belt tension checking point. 3. Distributor and contact point gap. 4. Spark plug and spark plug gap measuring point. 5. Carburenor and air cleaner assembly. 6. Steering gear and linkages. 7. Fuel line filter. 8. Front disc brakes. 9. Rear drum brakes. 10. Battery. [...]

18 WHEELS AND TYRES 1. HOW TO CHANGE A ROAD WHEEL (I) Ensure that the vehicle is,level, on firm ground and clear from any passing traffic. (2) If necessary switch on the hazard flashers. (3) Place the transmission in the P (park) position on automatic models or reverse gear on manual models. (4) Firmly apply the handbrake. (5) On Sedan models remov[...]

Wheels and Tyres View of jack correctly installed to rear jacking point. the jack. Rotate the jacking handle in a clockwise direc- tion and slightly raise the vehicle, whilst checking that the jack is still positioned correctly under the jacking point. ' (12) Ensuring that lthe jack is correctly positioned, raise the vehicle so that the road w[...]

20 Wheels and Tyres (2) Sagging front coil springs: Check and renew LIGHTLY WORN SPOTS AT CENTRE OF faulty springs. TREAD - - (3) Loose or worn front hub bearings: Check and (1) Static unbalance of wheel and tyre assembly: adjust or renew hub bearings. Check and balance wheel and tyre assembly. (4) Bent stub axle: Check and renew faulty com- (2) Ra[...]

ENGINE TUNE-UP 1. TUNE-UP SPECIFICATIONS ............................. Firing order 1-3-4-2 Spark plug type: N.G.K. .......... BPSES, BP4E, BP6ES, BP7ES ....... Hitachi L46PW, L47PW, L45PW, L44PW ........................ Spark plug gap 0.8-0.9 mm ................. Spark plug tightening torque 20 Nm ............ Contact breaker point gap 0.45-0.55 m[...]

22 Engine Tune-up Checking contact breaker point gap using feeler gauges. the retaining screws and remove the points from the distributor. NOTE: New breakerpoints should be washed in solvent to remove the anti-corrosive dress- ing and thoroughly dried before installing. (6) To instal the breaker points reverse the re- moval procedure. (7) Turn the [...]

Engine Tune-up 23 Lightly file the plug electrodes flat with a points file. service the electrodes will show signs of wear or normal burning. Spark plugs showing a thick black oily deposit indicate an engine in poor mechanical condition or, possibly, that a plug with too low a heat range has been fitted. - Spark plugs showing a white or yellowish d[...]

24 Engine Tune-up Checking spark plug electrode gap with feeler gauge. Measure the gap between the electrodes preferably with clean wire gauges. If wire gauges are unavailable then use clean feeler gauges. Move the side electrode towards or away from the centre electrode to obtain the correct gap. Screw the plugs into the cylinder head finger tight[...]

Engine Tune-up 25 fluctuate the engine speed between idle and 2000 rpm noting any variation in the dwell angle reading. If the dwell angle variation is excessive the following points should be checked and the necessary components renewed: Excessive side play in distributor shaft. Distributor cam worn. Faulty contact points. Breaker plate worn or lo[...]

Engine Tune-up NOTE: With the valves of number one cylin- der rocking number four cylinderpiston is on tdc on the compression stroke. (8) With the valves of number four cylinder cor- rectly adjusted, rotate the engine in the normal direction of rotation until the valves on number three cylinder are in the rock position. With the valves of number th[...]

ROADSIDE TROUBLE SHOOTING This section deals with common causes of engine failure to start, as inevitably there will come a time when every driver will experience this problem and will there- fore, need to call upon his own resources t.0 rectify the problem. Roadside breakdowns other than engine failure can be identified by reference to the trouble[...]

28 Roadside Trouble Shooting the contact breaker side of the coil then it is possible that the coil primary circuit is faulty. Remove and test the coil or replace it with a known serviceable unit. NOTE: If a test lamp is unavailable the low tension lead can be disconnected from the ig- nition switch side of the coil and 'flashed' to a goo[...]

Roadside Trouble Shooting ppppp Checking for fuel flow at the carburettor inlet hose. assistant listen at the tank filler aperture. Blow down through the fuel pipe towards the tank and provided the pipe is clear, air bubbles will be heard in the tank. (6) Reconnect the fuel hose to the pump and again check for fuel delivery from the fuel pump. If t[...]

30 Roadside Trouble Shooting Rule of thumb method for checking cylinder compression. Broken piston(s). Burnt or broken valves. Provided the previous checks do not indicate an in- ternal leakage of water continue with the following: (3) Remove the distributor cap and with an assis- tant operating the starter switch, check that the rotor arm rotates [...]

ENGINE SPECIFICATIONS ENGINE ASSEMBLY ....................... ......... Type , 4 cyl OHV ....................... Model types A12-A14-A15 Capacity: ........................... A12 engine 1 171 cc A14engine ........................... 1397 cc ........................... A15 engine 1488 cc Bore: A12engine ............................ 73 mm ...........[...]

32 Engine ......................... Fitted length 30.3 mm ....................... Relief pressure 372-41 1 kPa ................... Oil pressure at idling 90-1 17 kPa TORQUE WRENCH SETTINGS ......................... Cylinder head bolts 74 Nm ........................ Connecting rod nuts 37 Nm .............................. Flywheel bolts 88 Nm ......[...]

Engine 33 MAIN BEARING NOISE (APPARENT) (1) Loose flywheel: Tighten flywheel securing bolts to specified torque. (2) Low oil pressure: Check bearing to journal clearance, check condition of oil pump and pressure re- lief valve, recondition oil pump as necessary. (3) Excessive crankshaft end play: Renew centre main bearing. (4) Crankshaft journals o[...]

Engine (4) Excessive bearing clearance: Renew bearings shells or recondition crankshaft journals as necessary. (5) Excessive wear of oil pump components: Re- new oil pump. NOTE: If the vehicle is not fitted with an oil pressure gauge remove the oil sender unit and connect a pressure gauge into the oil galley. Check the oil pressure with the engine [...]

Engine type and is driven by the camshaft to provide full pres- sure to the engine. Oil pressure is maintained at a pre- determined maximum by a spring loaded relief valve, situated within the pump body. The lubricating oil passes through a full flow oil fil- ter mounted externally on the oil pump. A bypass valve is fitted to the oil pump so that s[...]

36 Engine (13) Loosen the retaining clip and remove the fuel supply hose from the fuel pump. (14) Disconnect the brake servo unit vacuum hose at the inlet manifold where fitted. On A15 engine models remove the carbon canister purge line from the inlet manifold. (15) On manual transmission models slacken the adjustment at the upper end of the clutch[...]

Engine (3) When installing the clutch cable, throttle and choke cables refer to the relevant section in the manual 195/383 ' ROCKER ARM ROCKER POST SPRING for adjustments. (4) Use a new gasket when installing the engine pipe to the exhaust manifold. SHAFT ROCKER ARM 4. ROCKER ARMS AND SHAFT WASHER/ a I TO REMOVE AND DISMANTLE . (1) Raise t[...]

Engine 5. CYLINDER HEAD Special Equipment Required: To Dismantle and Assemble - Valve spring com- pressor To Inspect - Dial gauge and straight edge. TO REMOVE (1) Disconnect the earth lead from the negative terminal of the battery. (2) Drain the cooling system and remove the top radiator hose. Refer to the Cooling System section if nec- essary. (3)[...]

7 Engine Valves removed from No.4 cylinder showing valve guides. Specifications, or more than 0.50 mm has been removed from the end of the valve stem, renew the valve. Check the valve stem for straightness and discard any valve that is excessively bent. (3) Measure the valve stem to guide clearance with a dial gauge. This is done by 'rocking&a[...]

40 Engine carefully release and remove the spring compressor. En- sure that the collets are correctly seated in the spring re- taining cap by tapping the end of the valve stem with the end of a hammer handle. (6) Assemble the remaining valves in a similar manner. (7) Using a new gasket fit the inlet and exhaust manifolds to the cylinder head and ti[...]

Engine 41 (1 1) Instal the retaining bolt and washer and tighten the bolt to Specifications. (12) Instal the remainder of the components by re- versing the removal procedure and referring to the rele- vant sections. (13) Fill the radiator with clean water and add cor- rosion inhibitor as necessary. REAR SEAL To Remove and Instal (1) Remove the tran[...]

42 Engine TIMING COVER Ensure that the ends of the seals mate with the ends of the two side gaskets to form an oil tight joint. (13) Carefully place the sump in position on the gaskets and fit the nuts and washers to the end studs but do not tighten. (14) Instal the remainder of the bolts and washers and then tighten finger tight. (15) Using a suit[...]

Engir RUNNING PAD 1951348A SPRING Dismantled view of timing chain tensioner. TO CLEAN AND INSPECT (1) Wash the components in a suitable solvent and blow dry with compressed air. (2) Visually check the tensioner pad for wear, slight grooving is normal but badly worn or lifted facings will necessitate renewal of the tensioner. (3) Check the camshaft [...]

Engine move the distributor as described in the Electrical System section. (2) Turn the engine assembly until the crankshaft is uppermost and press each tappet down well clear of the camshaft. (3) Disconnect the fuel delivery pipe at the fuel pump, then remove the two mounting bolts and lift the fuel pump from the engine. (4) Remove the oil pumpand[...]

Engine 45 (2) Disconnect the oil pressure switch lead from the switch on the oil pump. (3) Loosen and remove the three bolts securing the oil pump to the crankcase. Note that the engine earth lead is secured under one of the bolts. (4) Withdraw the oil pump from the crankcase. (5) Remove the screw attaching the body cover to the main body of the pu[...]

zgine (6) Instal the plug and gasket and securely tighten the plug. (7) Screw the oil pressure switch into position in cover and tighten sufficiently to prevent any oil leaks. (8) Using a new gasket instal the pump assembly to the crankcase and tighten the three securing bolts. NOTE: Do not neglect to instal the engine earth lead under one of the b[...]

Engine UPPER COMPRESSION RING 't=--, LOWER COMPRESSION RlNG SEGMENTS BOLTS- CONNECTING ROD BEARING SHELL BEARING CAP Dismantled view of the piston and connecting rod com- ponents. NOTE: The gudgeon pin is an interference fit in the smallend of the connecting rod and the piston and gudgeon pin are available only as an assembly. (6) If it is nec[...]

Engine (3) Use only honing oil for lubrication. Do not use engine oil, transmission oil, mineral spirits or kerosene. (4) When honing is completed, ensure that the cylinder bore, crankcase area and oil ways are thoroughly cleaned. (5) After the cylinder block has been cleaned and dried wipe the bores with a lint free cloth then smear them with engi[...]

Engine u Piston and cylinder grade numbers stamped on pistons and top of cylinder block. (1 1) Remove the plastic tube from the big end bolts and instal the big end bearing cap and bearing half, instal the retaining nuts and tighten to the specified torque. (12) If new bearing shells were installed recheck the bearing clearance as previously descri[...]

50 Engine (3) Note the measurements and compare them with Specifications. If the journals or crankpins are worn have the crankshaft ground to the nearest undersize and renew the bearings. NOTE: If wear or damage is such that the journals or crankpins cannot be reground to take any one of the range of available under- size bearings, then the cranksh[...]

Engine 51 13. FLYWHEEL/DRIVE PLATE Special Equipment Required: To Renew Ring Gear - Suitable heat source TO REMOVE AND INSTAL (1) On automatic transmission models remove the transmission assembly from the vehicle as described in the Automatic Transmission section. On manual transmission models remove the trans- mission from the engine as described [...]

52 Engine (3) Remove the mounting nut and washers locat- ing the engine mounting to the crossmember. Jack up the engine until the engine mounting bracket is clear of the mounting. (4) Remove the engine mounting from the cross- member. On the left hand mounting, note the position of the heat shield and lift the shield from the mounting. Installation[...]

COOLING SYSTEM SPECIFICATIONS ...................... Radiator cap pressure 88 kPa ............... Water pump type Centrifugal impeller Thermostat (standard type): .............................. Type Wax pellet ................. Opening temperature 82 deg C ..................... Val.ve lift 8 mm at 95 deg C ....................... Radiator type Corr[...]

54 Cooling System bolts: Renew gasket and correctly tighten cylinder head bolts. (7) External crack in cylinder block or head: Re- new faulty components. NOTE: Check system for external leakage by running vehicle to operating temperature over a dry floor and checking for leak source. COOLANT LEAKAGE - INTERNAL (1) Cylinder head gasket leak due to w[...]

Cooling System 55 using water pressure applied to the cylinder block and radiator plug holes. (8) Instal and tighten the cylinder block drain plug. (9) Instal and tighten the radiator drain plug. (10) Slowly fill the radiator with demineralised water. (11) Add anti-freeze or corrosion inhibitor to the radiator according to manufacturers instruction[...]

56 Cooling System Clean obstructions from radiator core using water pressure. (1) Where applicable refit the fan shroud to the radiator ensuring that there is even clearance between the fan blades and the shroud. (2) Where fitted remove the plugs from the auto- matic transmission oil cooler lines and unions. Recon- nect and tighten the lines. (3) R[...]

g System Water pump cooling fan and associated components. (2) Drain the cooling system and remove the ra- diator as described under the heading Radiator. (3) Loosen the fan belt adjusting bracket bolt and the two bolts attaching the alternator to the mounting bracket. (4) Push the alternator towards the cylinder block and remove the fan belt. (5) [...]

58 Cooling System (9) Fill the cooling system as previously described. With the radiator cap installed run the engine until it reaches normal operating temperature and check for coolant leaks. 7. HEATER AND CONTROLS HEATER CONTROLS To Remove and Instal (1) Raise the bonnet the disconnect the earth lead from the negative battery terminal. (2) Remove[...]

FUEL SYSTEM SPECIFICATIONS 1. FUEL SYSTEM TROUBLE SHOOTING CARBURETTOR Make .................................... Hitachi Type ..................... Twin barrel downdraught Throat diameter: Primary .............................. 26 mm Secondary ............................ 30 mm Venturi diameter: Primary - A12engine ............................ 20 m[...]

60 Fuel System Air leaks at the inlet manifold can sometimes be located by running engine oil around the suspect joints. body: Renew faulty gaskets and securely tighten retain- ing screws. NOTE: Check out this condition by process of elimination in the fault order given. Only remove and dismantle the carburettor as a last resort. Air leaks at the m[...]

Fuel System 61 (2) Remove the bolts .securing the air cleaner as- sembly to the mounting brackets. (3) Mark and disconnect the hoses to the rocker cover, the flow guide valve/charcoal canister, the inlet manifold connection and the vacuum control valve from the air cleaner assembly. (4) Remove the wing nut and the sealing washer from the centre of [...]

62 Fuel System View of throttle lever side of carburettor. TO DISMANTLE NOTE: Keep each section of the carburettor separate and, as far as possible, in the order of removal. This will assist in assembly. (1) Remove the carburettor as previously de- - scribed. (2) Remove the screw securing the accelerator pump actuating lever to the top cover. Remov[...]

Fuel System GASKE'T SEAT CLIP FLOAT- 1951470 View of float and needle valve and seat components removed from top cover. wear or scoring on the lip and renew the plunger assembly where necessary. (2) Thoroughly clean the top cover in a suitable solvent. (3) Unscrew the slow air bleeds and wash them in clean solvent. Do not use wire or drills to[...]

64 Fuel System PLUGS AIN JETS WAU~FRP MAIN MUUY . - . . - . . LOCK STRAP View of main jets and power valve removed from the carburettor main body. (1 1) Renew any jet which is obviously worn and in- stal the jets to their respective positions using new gaskets where necessary. (12) Using feeler gauges and a straight edge check the top and the bot[...]

Fuel System With the top cover inverted and the float lifted up measure the distance between the needle valve stem and the float seat tab. To Adjust Choke Fast Idle (1) Remove the carburettor from the vehicle as previously described. (2) Actuate the choke lever by hand to fully close the choke valve. (3) Check the distance between the primary throt[...]

66 Fuel System following tests before removing the fuel pump from the engine. (1) Check the fuel filter and the fuel lines for blockage. Ensure that there is fuel in the tank. (2) Remove the air cleaner as previously described and instal a 'T' piece in the fuel line at the carburettor inlet connection. Fit a pressure gauge at, or as near [...]

Fuel System 67 8. FUELTANK TO REMOVE AND INSTAL Sedan (1) Raise the rear of the vehicle and support on chassis stands. (2) Carefully remove the fuel tank drain plug and drain the contents of the fuel tank into a suitable clean container. Instal and tighten the drain plug. (3) Loosen the clamps and disconnect the fuel sup- ply and vapour hoses from [...]

CLUTCH SPECIFICATIONS .............................. Type Single dry plate ............................ Operation Mechanical ................ Pressure plate spring Diaphragm type .................... Driven plate hub Spring cushion .................... Release bearing Ball thrust type, prelubricated and sealed Driven plate: ...................... O[...]

7 Clutch With the floor covering pulled back, measure the pedal height at right angles to the pedal pad. RELEASE BEARING NOISE (1) Dry or worn bearing: Check and renew bearing. (2) Damaged pressure plate diaphragm spring: Check and renew pressure plate assembly. (3) Insufficient release lever free play: Check and adjust clutch cable. NOTE: Lightly [...]

70 Clutch Installed view of clutch release mechanism. is still serviceable, do not allow any cleaning fluid or grease to contaminate the plate facings. NOTE: The driven plate must be renewed when the facings are worn down to or to within 0.3 mm of the rivet heads. Should there be any traces of oil on the facings the source has to be investigated an[...]

Clutch (5) Tighten the clutch pressure plate retaining bolts in a diagonal sequence in stages to the specified torque. Withdraw the aligning tool or input shaft. (6) Sparingly lubricate all moving parts of the clutch release mechanism with a high melting point grease. Instal the release bearing assembly to the clutch housing, and clip the return sp[...]

72 Clutch Measure the pedal height, if necessary loosen the locknut on the pedal stop and adjust the stop until the pedal height is to Specifications. Tighten the lock nut and check and if necessary adjust the release lever free play. TO ADJUST RELEASE LEVER AND PEDAL FREE PLAY (1) Check and if necessary adjust the clutch pedal height. (2) Open the[...]

MANUAL TRANSMISSION PART 1. MANUAL TRANSMISSION AND PROPELLER SHAFT TROUBLE SHOOTING DIFFICULT GEAR CHANGE (1) Faulty clutch or clutch release mechanism: Check and overhaul clutch or release mechanism. (2) Worn selector mechanism: Check and renew faulty components in selector mechanism. (3) Faulty gear synchroniser mechanism: Over- haul transmissio[...]

Manual Transmission If the bearings are caged and can not be checked visu- ally, wash thoroughly in clean solvent, lightly oil and turn slowly by hand to check for roughness. TRANSMISSION NOISE (IN NEUTRAL) (1) Lack of lubricant: Fill transmission case with correct quantity and grade of lubricant. (2) Worn transmission front bearing: Check and rene[...]

Manual Transmission PART 2. F4W56A AND F4W60L TRANSMISSIONS SPECIFICATIONS Type ........ 4 speed synchromesh on all forward gears Models ....................... F4W56A or F4W60L Gear change ........................... Floor shift F4W56A Gear ratios: Top ................................. 1.000: 1 Third ................................ 1.404: 1 Secon[...]

76 Manual Transmission (3) Prise off the rubber boots to gain access to the gearshift lever retaining clevis pin. (4) With the transmission in neutral, remove the 'E' clip from the clevis pin retaining the gearshift lever and withdraw the clevis pin. Remove the gearshift lever. (5) Raise the front and the rear of the vehicle and support o[...]

Manual Tralzsmission With the aid of feelergauges, measure the third gear end float prior to dismantling. (9) Rotate the control rod fully clockwise to dis- connect the control rod from the selector shafts, and remove the extension housing from the carrier plate. Also remove the transmission case from the carrier plate. NOTE: If necessary, carefull[...]

Manual Transmission SYNCHRO RINGS A .-4- I 1 BEARING I L--- ------------ BEARING through the carrier plate and remove the selector shaft and fork assembly and the reverse idler gear from the carrier plate. Remove the reverse gear selector shaft detent ball and spring from the blank ended hole in the carrier plate. (21) Remove the snap ring retainin[...]

Manual Transmission (29) Remove the snap ring retaining the reverse gear on the laygear. Using a press and press plates, press the reverse gear from the laygear. Also using the press and press plates, press the bearing off the laygear and discard the bearing. (30) If the laygear caged needle roller bearing located in the front of the transmission c[...]

80 Manual Transmission in the slots of the second gear synchro ring. (9) Instal the first gear synchro ring onto the rear of the mainshaft. Ensure that the shift plates of the syn- chro assembly are engaged in the slots of the first gear synchro ring. (10) Instal the spacer, the sleeve and the caged needle roller bearing for the first gear onto the[...]

Manual Transmission 81 with the snap ring. Ensure that the shouldered side of the reverse gear is towards the bearing. (28) If removed, instal the reverse idler gear shaft into the carrier plate and retain in position with the snap rings. (29) Bring together the laygear, the mainshaft and the input shaft assemblies so that the teeth of the compo- n[...]

82 Manual Transmission (53) Insert the interlock plunger for the third and top gear and the first and second gear selector shafts. (54) With the reverse gear and the third and top gear selector shafts in the neutral position, insert the first and second gear selector shaft through the carrier plate and the first and second gear selector fork. Posit[...]

Manual Transmission 83 extension housing with a suitable sealant, insert the pin and retain it in position with the 'E' clip. (73) Smear the reverse plunger with grease and in- sert the plunger, the reverse check spring and the anti- rattle spring into the extension housing. 1 NOTE: The reverse plunger must be installed with the raised se[...]

I Manual Transmission (2) Remove the self-locking nut prior to withdraw- ing the control rod stopper bolt. (3) Prior to withdrawing the transmission case remove the input shaft bearing outer race retaining snap ring. (4) Prior to withdrawing the mainshaft assembly from the carrier plate remove the four bearing retainer screws with an impact driver,[...]

AUTOMATIC TRANSMISSION SPECIFICATIONS Make ............................. JATCO 3N71 B Type .......... 3 forward speeds and Feverse, epicyclic gear train with torque converter Operation .................... Automatic hydraulic Band adjustment .......... Tighten adjusting screw to I5 Nm, back off two turns and secure with locknut TORQUE WRENCH SETTIN[...]

86 Automatic Transmission Specifications in the Lubrication and Maintenance sec- tion. The fluid level in the transmission case should be checked at regular intervals of not greater than 10,000 km and it is good policy to check the fluid at each lubrication service. TO CHECK AND TOP UP (1) Place the vehicle on a level floor and open the engine bonn[...]

Automatic Transmission 87 (2) Loosen the band adjusting screw locknut and back it off several turns. (3) Check that the adjusting screw turns freely in the transmission case and using the small torque wrench, tighten the adjusting screw to 15 Nm. (4) Back off the adjusting screw exactly two full turns and hold it in this position. Tighten the adjus[...]

88 Automatic Transmission View of neutral safety switch removed from selector shaft. Typical. (2) Remove the selector lever retaining nut and remove the selector lever from the selector shaft. Dis- connect the wire leads at their connectors. (3) Remove the switch retaining bolts and re- move the switch from the transmission case. (4) Instal a new s[...]

Automatic Transmission 89 universal joint flanges to ensure correct assembly. Re- move the bolts retaining the propeller shaft to the pinion flange. (12) Withdraw the propeller shaft from the ex- tension housing. Instal a suitable plug to prevent any remaining fluid leaking from the open end of the trans- mission extension housing. (13) Support the[...]

REAR AXLE SPECIFICATIONS ........................ Type Semi floating, hypoid .................................... Ratio 3.889: 1 ...... Number of crownwheel/pinion teeth 35/9 Bearing type: ......................... Pinion Tapered roller ......................... Carrier Tapered roller Bearing preload method: ...................... Pinion Collapsibl[...]

Rear Axle REPEATED AXLE SHAFT BREAKAGE Normally small cracks do not open up and (1) Bent axle housing: Renew housing. leak oil until the rear axle reaches operating (2) Repeated overloading: Revise load capacity. temperature. (3) Abnormal clutch operation: Revise driving habits or check clutch condition. 2. DESCRIPTION NOTE: If the clutch is operat[...]

92 Rear Axle oil seal and using a suitable tubular drift, tap the new oil seal into the axle tube to abut the shoulder in the axle tube. (2) Position the shims originally removed on the rear of the brake backing plate. (3) Instal the axle shaft assembly into the axle tube taking care not to damage the new oil seal. Slowly rotate the axle shaft to e[...]

Rear Axle (4) Clean all the components and inspect them for wear, damage and distortion. (5) Position the brake backing plate on the axle shaft with the brake shoe side facing the axle shaft flange. (6) Slide the bearing spacer then the new bear- ing onto the axle shaft. Ensure that the seal side of the bearing is facing towards the axle shaft flan[...]

94 Rear Axle DRIVE OVERDRIVE . CENTRE MARKING CENTRE TOE Crownwheel Tooth Marking for Correctly Adjusted Crownwheel and Pinion. Marking will be slightly Closer to Toe of Tdoth on Overdrive or Concave Side. Changes in Thickness of Pinion Positioning Shims will Affect Tooth Marking on Overdrive to Greater Extent than on Drive or Convex Side of Tooth.[...]

Rear Axle driver or the person of limited knowledge and equip- ment to attempt the overhaul procedure. If the pinion oil seal is to be renewed, then the col- lapsible spacer between the pinion bearing must also be renewed. As this operation will require the need to read- just the pinion bearing preload it is recommended, for the above reasons, that[...]

96 Rear Axle Underbody view of the left hand side rear axle mounting on Panel Van models. move the 'U' bolts, the bump rubbers, the lower mount- ing plates and the lower rubber insulators from the rear axle. (1 1) Move the axle assembly sideways to clear the spring and lower the clear end to the floor. Move the axle in the opposite direct[...]

STEERING SPECIFICATIONS Type ............... Recirculating ball nut and worm Ratio ..................................... 16.4: 1 Wormshaft bearing preload ............. 0.2-0.5 Nm Wormshaft bearing shims: Standard total thickness ................ 0.5 mm Adjusting shims ................. 0.05-0.20 mm Sector shaft to adjusting screw maximum clearance[...]

Steering 2. DESCRIPTION Check for looseness in the front hub bearings. NOTE: Check the steering linkage as previ- ously described. Raise the front of the vehicle and check the adjustment of the hub bearings by working the road wheel in and out at the top and bottom. No perceptible movement in the hub bearings should be felt. STEERING ERRATIC OR WAN[...]

Steering steering column assembly to lessen the possibility of in- jury to the driver of the vehicle in the event of an acci- dent. The steering column is of the collapsible type which on severe impact will collapse. A combined steering and ignition lock is situated on the right hand side of the column. The ignition lock must be in the locked posit[...]

Steering ing faulty then the steering column assembly must be necessary to disconnect the pitman arm and renewed as the bearings are 'crimped' in position during remove the steering gear from the vehicle. manufacture. If the vehicle has been involved in a minor collision or it is desired to check the steering column assembly for serviceab[...]

Steering 101 cover and the shims. Do not allbw the ball nut to rotate on the wormshaft as the ball guides will be damaged. (1 1) Carefully withdraw the worm shaft assembly from the steering gear. (12) Remove the upper and lower worm shaft bear- ing cones from the worm shaft. (13) Remove the lower bearing cup from the steer- ing gear housing using a[...]

Steering sealant to the housing face and the cover sides (2) Raise the engine bonnet and fit covers to both of the shims. front fenders. (8) Instal the adjusting screw and the shim into the slot in the top of the sector shaft. (9) Hold the sector shaft upside down and mea- sure the clearance between the end of the adjusting screw and the sector sha[...]

(2) Check the tie rods and connecting rods for alignment and fatigue. (3) Renew all worn or damaged components where necessary. (4) If the joints are found to be in a satisfactory condition then lubricate the joints with the recommended multi-purpose grease. To grease the joints first remove the plug from each joint and instal a grease nipple. Usin[...]

FRONT SUSPENSION SPECIFICATIONS Type ................. Independent, McPherson strut type with coil spring and lower control arm ..................... Coil spring free length 375 mm ................ Suspension unit fluid capacity 325 ml Camber angle ................. 0 deg to 1 deg 30 min Caster angle: All models except Station Wagon .............. [...]

Front Suspension Visually inspect the stabiliser bar rubbers for wear and deterioration. (2) Defective suspension unit: Check, overhaul or renew faulty unit, preferably in pairs. (3) Incorrect front end alignment: Check and adjust alignment as necessary. (4) Loose or defective stabiliser bar mounting rub- bers: Check and tighten or renew mounting r[...]

106 Front Suspension (3) Remove the two brake caliper retaining bolts and remove the caliper from the vehicle. (4) Remove the front hub grease cap and '0' ring, take out and discard the split pin and remove the castel- lated nut retainer. Remove the hub bearing retaining nut and the keyed washer. (5) Withdraw the hub assembly from the stu[...]

Front Suspension and disconnect the steering arm from the suspension strut. (6) Open the bonnet. While holding the suspen- sion strut remove the three nuts retaining the suspension strut to the body. Remove the suspension strut from the vehicle. TO DISMANTLE (1) Prior to dismantling the suspension unit, clean it thoroughly and ensure that a clean w[...]

108 Front Suspension Ensure that the lower open end of the coil spring sits cor- rectly on the spring seat. (3) Instal the dust cover, the upper spring seat, the dust seal, the bearing suitably lubricated and the upper mounting over the piston rod. Instal and temporarily tighten the piston rod nut and the washer. Do not attempt to hold the piston r[...]

Front Suspension 109 ball joint and steering arm assembly from the vehicle. (6) Remove and discard the split pin securing the ball joint stud nut in the steering arm and loosen and re- move the ball joint stud nut. (7) Disconnect the ball joint stud from the steering arm by placing a hammer or suitable dolly against one side of the steering arm and[...]

110 Front Suspension t 1 rod to the suspension control arm. (4) Remove the radius rod from the vehicle, noting the position of the front mounting rubbers and washers. Installation is a reversal of the removal procedure with attention to the following points: Ensure that the front mounting rubber bushes are in a serviceable condition and that they a[...]

REAR SUSPENSION PART 1. REAR SUSPENSION TROUBLE SHOOTING NOISE IN SUSPENSION . c Semi Elliptic Spring Models (1) Defective shock absorber and/or mounting: Renew faulty components. (2) Loose or worn rear shackle pins and bushes: Tighten or renew loose or worn shackle components. (3) Loose or worn spring anchor pins and/or bushes: Tighten or renew lo[...]

112 Rear Suspension REAR BRAKE LOCKED surements are unequal check the possible - - Semi Elliptic Spring Models causes out in the order given. A broken spring anchor oin will readily show uo bv leverinn (1) Broken spring main leaf, forward of spring between thespring eyeeand chasiis. check fo; seat: Renew main leaf or complete spring. broken bolt or[...]

Rear Suspension 113 NUTS /: WASHER- RUBBERS SHOCKABSORBER BOLT Dismantled view of a rear shock absorber. All models except Panel Van. (5) Repeat operation (4) six to eight times to re- move any slack spots caused by air in the system. If slack spots exist and can not be removed by this method, the shock absorber is evidently defective and should be[...]

114 Rear Suspension NOTE: It is recommended that one suspen- sion arm should be removed and installed at a time. If for some reason more than two sus- pension arms need to be removed at a time the rear axle assembly must be removed, refer to the Rear Axle section for the correct procedure. (4) Carefully cut and press the suspension arm bush from th[...]

Rear Suspension 115 Panel Van models. Installed view of the rear spring front mounting. Panel Van models. and lower mounting and remove the shock absorber (2) Support the weight of the rear axle assembly by from the vehicle. placing a jack under the centre of the rear axle housing. Installation is a reversal of the removal procedure (3) Remove the [...]

116 Rear Suspension (8) Using a wire brush, clean all the dirt and rust (1) Apply a soap solution to the front anchor pin, from the leaf spring and inspect the leaves for cracks and the shackle pins and the rubber bushes to aid installation. fractures. Renew as necessary. (2) Ensure that the insulators and the mounting (9) Inspect the rubber bushes[...]

BRAKES SPECIFICATIONS Type: Front ................................... Disc Rear .................................. Drum Operation: Footbrake .......................... Hydraulic Handbrake ........... Mechanical on rear wheels Front brakes: Brake disc - Diameter ............................ 245 mm Minimum thickness .................... 8.4 mm Run ou[...]

118 Brakes binding on aN four wheels. Open the bleeder BRAKE PEDAL PULSATES valve on one of the offending wheels to check (I) Bent or eccentric brake drum or disc: Check ifpressure build up is the cause for binding. A and machine or renew drum or disc as required. frozen handbrake cable will cause binding on (2) Loose or worn front hub bearings: Ad[...]

Brakes (5) Obstructed or damaged hydraulic hose or line: Remove obstruction or renew hydraulic hose or line. (6) Obstructed master cylinder compensation port: Clear compensating port. (7) Blocked vent in master cylinder reservoir cap: Check and remove obstruction in vent. (8) Overuse of footbrake: Revise driving habits. NOTE: To check for brake bin[...]

120 Brakes Installed view of brake master cylinder. Nabco type. (1) Pour a small quantity of clean brake fluid into the reservoirs and pump the master cylinder pistons with a blunt rod until fluid begins to emerge from the outlets. (2) Loosely instal the master cylinder to the brake servo unit. (3) Connect the brake fluid pipes to the master cylind[...]

Brakes b / FILTER Dismantled view of master cylinder components. Tokico type. Typical. ber seals and pistons. The use of a major re- pair kit will ensure a thorough overhaul and 4. BRAKE SERVO UNIT long service from the unit. Assembly is a reversal of the dismantling procedure DESCRIPTION with attention to the following points: The brake servo unit[...]

122 Brakes Let the vehicle stand for 1-2 minutes, then press the brake pedal one or two times and check its operation. If there is no vacuum assistance, then the system has developed a leak or the one way check valve is defective. NOTE: Before removing the servo unit from the vehicle for inspection, disconnect the vac- uum supply hose at the unit, [...]

Installed view of proportioning valve. up together or the front wheels should be locking up slightly before the rear wheels. If the rear wheels lock up before the front wheels the proportioning valve is faulty and should be renewed. 6. FRONT BRAKE ASSEMBLY Special Equipment Required: To Check Brake Disc Runout - Suitable dial gauge TO CHECK AND REN[...]

Brakes (13) Turn the retaining pins to align the holes in the pins and instal the spring clip. (14) Top up the brake master cylinder reservoir with clean brake fluid and pump the brake pedal a few times to bring the pads to their normal position alongside the brake disc. (15) Instal the road wheels and lower the vehicle to the ground. TO OVERHAUL C[...]

Brakes TO REMOVE AND INSTAL BRAKE DISC (1) Raise the front of the vehicle, support on chas- sis stands and remove the road wheel. (2) Disconnect the steel brake pipe from the cali- per and the flexible brake hose. Plug the hose to prevent the loss of fluid or the ingress of the dirt. (3) Remove the two bolts securing the caliper as- sembly to the s[...]

- 126 Brakes Assembled view of rear brake assembly. the leading brake shoe from the backing plate. (10) Prise the handbrake lever rubber boot from the backing plate and lever and withdraw the adjuster assembly from the backing plate. (1 1) Disconnect the brake pipe from the wheel cyl- inder. (12) Remove the bolts securing the wheel cylinder to the [...]

Brakes 127 (1) Lubricate the wheel cylinder bore with clean (15) Bleed the hydraulic system and, if necessary, brake fluid, also dip the pistons and cup seals in the fluid. adjust the handbrake as described under the relevant Instal the cup seals onto the pistons so that the lips of headings. the cups will be facing towards and the centre of the wh[...]

Brakes Adjust the handbrake cable as described under the relevant heading. TO REMOVE AND INSTAL REAR CABLE (1) Raise the rear of the vehicle, support on chassis stands and release the handbrake. (2) Loosen the locknut and disconnect the front and rear cables at the adjusting turnbuckle. (3) Remove the clip retaining the rear cable to the rear axle [...]

Brakes 129 Checking the brake pedal height with the carpet pulled back. 10. BRAKE ADJUSTMENTS FRONT BRAKES The front brakes are self adjusting and no manual adjustment is required or provided for. REAR BRAKES Press in the handbrake lever knob and apply and release the handbrake lever a number of times to adjust the rear brake shoes. HANDBRAKE (1) R[...]

130 ELECTRICAL SYSTEM SPECIFICATIONS BATTERY Type ............................. 12 volt lead acid Polarity .............................. Negative (-) Capacity .......................... 40or60amphr Specific gravity: Fully charged ..................... Above 1.260 Fully discharged ................... Below 1.130 NOTE: Specific gravity varies 0.007 [...]

Electrical System Check the battery specific gravity using a hydrometer. 1.170-1.190 . . . . About one quarter charged 1.200-1.225 . . . . . . . . . . . . . . . . Hagcharged 1.230-1.250 . . About three quarters charged 1.260-1.280 . . . . . . . . . . . . . . : Fully charged If the battery is undercharged but service- able seek out the cause by chec[...]

132 Electrical System (2) Loose alternator mounting bolts or worn bear- ings: Tighten mounting bolts or renew bearings. (3) Loose alternator pulley: Tighten pulley retain- ing nut. (4) Faulty alternator: Overhaul or renew alter- nator. (5) Faulty diodes in alternatoc Overhaul alter- nator, fit new heat sink. NOTE: To check if the noise is in the al[...]

Electrical System NOTE: The most common cause for this con- dition is incorrect lamp earthing. Check the lamps at their earthing points. LAMPS FLARE WITH ENGINE SPEED INCREASE (1) Faulty battery: Check and renew or repair battery. (2) Battery in low state of charge: Recharge bat- tery and check charging system. (3) High resistance or faulty connect[...]

Electrical System Check the inside of the distributor cap for tracking between terminals. (1 1) Faulty or incorrectly adjusted spark plugs: Renew or clean and adjust spark plugs. NOTE: Refer to the Roadside TroubleShoot- ing section and make the necessary test to en- sure that the trouble is in the ignition system. To determine if low tension curre[...]

Electrical System (1) Bare both ends of a suitable length of 4 mm tact in turn with the lead from the power terminal. Each wire. filament should illuminate as its contact is touched. (2) Solder a small alligator clip to each end of the If the bulb fails to illuminate, it is faulty and should wire. be replaced with a bulb of correct voltage and watt[...]

Electrical System (3) Remove the retaining huts, remove the battery holding clamp and lift the battery from the vehicle. Installation is a reversal of the removal procedure with attention to the following points: Do not overtighten the clamp nuts and make sure of correct polarity. After installation coat the terminals with petroleum jelly to preven[...]

Electrical System 137 Check the output of the alternator using an ammeter. (9) Switch on all lamps and allow them to burn for approximately five minutes to reduce the charge in the battery and to apply a load to the circuit. (10) Start the engine and gradually increase the engine speed to approximately 2500 rpm. The reading on the ammeter should be[...]

Electrical System ROTOR BEARIN k SCREWS PLATE 195l391 / BRUSH HOLDER SCREWS ?: Dismantled view of the alternator. NOTE: Do not apply undue heat to the con- nections as damage may result to the diodes contained in the rectifer assembly. TO CLEAN PARTS (1) Do not immerse units of the alternator in clean- ing solvents as damage to the windings may res[...]

Electrical System 139 Stator Windings The stator test is carried out using a ohmmeter and a test lamp. (1) The stator leads must be detached from the rec- tifier assembly. (2) Connect one test prod of the ohmmeter to one stator lead and the other test prod to another stator lead. Note the ohmmeter reading. (3) Repeat the operation to the remaining [...]

140 Electrical System 9. VOLTAGE REGULATOR The task of the voltage regulator is to maintain the voltage in the field circuit at a predetermined level by regulating the voltage output of the alternator in accor- dance with the battery requirements and the current con- suming electrical units in use. When the battery is in a discharged condition the [...]

Electrical System 141 'v BOLTS NUT WASHERS ";- SOLENOID 9 LEVER 1951600 DRIVE END BRACKET Dismantled view of starter motor. TO DISMANTLE (1) Remove the starter motor from the vehicle as previously described. (2) Scribe a line across the drive end bracket, the yoke and the commutator end cover, also scribe a line across the solenoid and [...]

Electrical System A badly worn commutator may be cleaned up by mounting in a lathe, spinning at high speed, and a light cut taken with a very sharp tool. After turning, undercut the insulation between the segments. (5) Check the armature for short circuit, using a ohmmeter. (6) Place one of the test leads on the armature shaft or core and move the [...]

Electrical System 143 engine clockwise as viewed from the front of the engine. (1) With the distributor cap removed rotate the engine until the ignition timing mark indicates number one piston is on tdc, that is when the crankshaft pulley notch is in line with '0' on the timing chain cover, and the rotor arm is in line with the number one[...]

144 Electrical System (6) Using a daub of quick drying paint, mark the relationship of the cam assembly to the drive shaft. Remove the cam assembly retaining screw and lift the cam assembly off the drive shaft, note the position of the shim if applicable. NOTE: It should not be necessary to remove the centrifugal advance weights springs and drive s[...]

Electrical System 145 Underdash view of the stop lamp switch. If the stop lamps fail to light when the brake pedal is depressed and the ignition is switched on, remove the wires from the stop lamp switch and connect a bridging wire between the two harness wires. If the stop lamps now operate when the ignition is switched on, the switch is faulty an[...]

146 Electrical System To Renew disconnect the wiring connector from he back of the (1) Disconnect the battery negative terminal. switch and remove the defogger switch from the dash (2) Remove the retaining screw and withdraw the panel. switch from the door pillar sufficiently for the wiring (3) The small bulb can now be renewed if neces- connector [...]

Electrical System HAZARD WARNING LAMP SYSTEM To Remove and Instal Hazard Warning Lamp Switch (1) Disconnect the battery negative terminal. (2) Remove the five screws retaining the steering column covers and remove the steering column lower cover. (3) Remove the ignition switch surround from the ignition switch. (4) Manoeuvre the steering column upp[...]

Electrical System Installed view of the fusible links. (3) Check the fusible link visually for any signs or it being burnt out. (4) Should the fusible link appear to be in a ser- viceable condition, test its continuity using an ohmmeter or a suitable battery operated test lamp. (5) If the fusible link proves to be faulty fit a new fusible link and [...]

Electrical System 149 Rear view of a late model instrument cluster removed from the vehicle. the heater controls. Prise out the heater control facia panel sufficiently to disconnect the bulb holder from the facia and remove the facia panel from the dash panel. (9) Remove the two screws retaining the dash panel to the heater control mounting bracket[...]

150 Electrical System follow the manufacturers instructions for the operating procedure, (4) Two adjusting screws are employed to move the headlarnp in the required direction. It is not necessary to remove the headlamp surround to gain access to the adjusting screws. (5) When using a headlamp aiming board, cover the headlamp not being adjusted with[...]

Electrical ' System 1 (2) Remove the two retaining screws from the combination lamp lens and remove the complete combi- nation lamp assembly from the front bumper bar. (3) Prise the lens from the lamp assembly and check the condition of the dust seal. Installation is a reversal of the removal procedure ensuring that the lens seal is correctly [...]

152 Electrical System (4) Ensure that the bulb holder is free from corro- sion and instal a new bulb of the correct wattage, size and voltage in the reverse manner to removal. NUMBER PLATE LAMP - SEDAN, COUPE AND PANEL VAN To Remove and Instal (1) Working inside the luggage compartment, lo- cate and disconnect the two wiring connectors for the numb[...]

Electrical System 153 Removing nut retaining wiper arm to pivot shaft after removing cover. WIPER BLADES To Renew (1) Pull the wiper arm and blade away from the windscreen until it locks in the vertical position. (2) Holding the wiper arm in one hand and the wiper blade in the other, lift the blade retaining clip and remove the wiper blade. Install[...]

154 Electrical System seven pin type unit to the vehicle and trailer so that if at a later time auxiliary circuits are needed, it is only a matter of using the vacant pins. FITTING THE SOCKET AND PLUG NOTE: The minimum amount of material needed will be: Trailer socket andplug, socket mounting bracket, multi core flex, wiring connectors, grommet, he[...]

Electrical System 155 wire only to the wiring plug and connect the plug to the connector on the vehicle. (b) Connect up the vehicle's battery and switch on the tail lamps. Connect each trailer wire in turn to the live tail lamp terminal on the plug until the trailer tail lamp illuminates. When the trailer tail lamp wire is found con- nect this[...]

Base wiring diagram for all models COLOR CODE The first letter of the code represents the main wire color, the other letters represent the trace colon and where a sleeve is installed on the wire the color of the sleeve is indicated by the letten enclosed in brackets. B - BLACK L - BLUE G - GREEN R - RED Y - YELLOW W - WHITE N - BROWN 0 - ORANGE K -[...]

[...]

Wiring diagram for intergrated air conditioning KEY 1. Blower switch. 2. Resistor. 3. Main relay. 4. Micro switch. 5. Thermostatic switch. 6. Inline fuse. 7. Blower motor. 8. Solenoid. 9. Magnetic clutch. COLOR CODE The first letter of the code represents the main wire color, the other letters represent the trace colors and where a sleeve is instal[...]

BODY 1. WINDSCREEN AND REAR DOOR GLASS AND REGULATOR WINDOW GLASS To Remove and Instal The renewal or replacement of the windscreen and rear window glass is a specialist operation requiring the use of special tools. The successful fitting and sealing of the windscreen or rear window glass depends to a large extent on the technical knowledge of the [...]

160 Body REMOTE CONTROL AND DOOR LOCK To Remove and Instal (1) Remove the interior handles, the trim panel and the plastic sealing sheet as previously described. (2) Remove the two screws retaining the remote control to the door inner panel. (3) Remove the three screws retaining the door lock to the door frame. (4) Disconnect the operating links fr[...]

achieve a flush fit between the door and the body panel. WINDOW REGULATOR, DOOR GLASS (5) If the door lifts or drops when the lock engages AND QUARTER GLASS the striker plate, loosen the screws and move the striker To Remove ~~~~~l plate up or down to eliminate the lift or drop. (1) Remove the interior handles, the trim panel NOTE: After each adjus[...]

Body -SNIPPER BUTTON I ESCUTCHEON OPERATING LINK Dismantled view of rear door lock, child proof lock and remote control components removed from the vehicle. (2) Remove the screw retaining the snipper button rod pivot assembly to the door inner panel. (3) Remove the two screws retaining the remote control to the door inner panel. (4) Remove the two [...]

Boa'y 163 View from inside Coupe model, showing the location of screws retaining the rear quarter glass catch to the body. Installed view of the bonnet catch assembly. 5. ENGINE BONNET TO REMOVE AND INSTAL (1) Raise the engine bonnet and fit fender covers to both front fenders. (2) Using a soft lead pencil, mark the bonnet around the bonnet hi[...]

(4) Recheck for correct positioning, if necessary loosen one bolt at a time to adjust. TO ADJUST LOCK STRIKER PLATE I (1) Loosen the striker plate retaining bolts and retighten them finger tight. (2) Close the luggage compartment lid and push it firmly shut. (3) Carefully open the luggage compartment lid without moving the striker plate. (4) Tighte[...]

Body 165 hand, position the hatchback evenly in its opening. wiper/washer, the number plate lamp, the defogger and (3) Open the hatchback carefully and tighten disconnect the washer tubing. the retaining bolts. (3) With the aid of a second operator support (4) Recheck for correct positioning, if necessary the tailgate and remove the tailgate stay r[...]

9. PANEL VAN TAILGATE AND LOCK TO REMOVE AND INSTAL TAILGATE (1) Open the tailgate and mark around the hinges with a soft lead pencil to facilitate accurate refitting. (2) With the aid of a second operator support the tailgate and remove the tailgate hinges retaining bolts and carefully lift the tailgate from the vehicle. Installation is a reversal[...]

11. CENTRE CONSOLE TO REMOVE AND INSTAL (1) On manual transmission models untie the boot surrounding the gear shift lever. (2) On automatic transmissio; models remove the screw retaining the 'T' bar handle and lift off the 'T' bar handle. (3) Remove the screws on either side ,of the front of the console. (4) Using a small screwd[...]

EMISSION CONTROL INTRODUCTION To reduce the output level 'of carbon monoxide, hydrocarbon and oxides of nitrogen which are the three primary automotive emissions causing air pollution, several emission control systems are used in this range of vehicles. The systems are known as and will be discussed under the headings (1) Crankcase Ventilation[...]

Emission Control Installed view of the vacuum switching valve with the air cleaner removed. valve is located at the rear of the inlet manifold. When the engine coolant temperature is above 50 degrees C and any gear except top is selected, the top gear switch and the engine coolant temperature switch in conjunction with the relay will allow electric[...]

7 Emission Control travelling at below 10 km/h on manual transmission models, or when 'P' or 'N' is selected on automatic trans- mission models. When the solenoid valve is operative the servo diaphragm is inoperative. When the vehicle exceeds 10 km/h the solenoid valve is inoperative, this allows the diaphragm to operate provide[...]

Emission Control crankcase, vent line and the fuel tank into the inlet mani- ' fold to be consumed in the cylinders. When vapour pressure within the system drops suffi- ciently, the air cleaner side of the flow guide valve opens. This permits atmosperic pressure to be routed from the air cleaner assembly to the fuel tank. Allowing air into the[...]

172 BASIC BODYWORK AND PAINTWORK REPAIRS PART 1. INTRODUCTION This section has been compiled to assist the vehicle owner who feels they are sufficiently competent to carry out their own basic bodywork and paintwork repairs. Bodywork and paintwork repair is a more compli- cated subject then first imagined, there is more to panel beating than swingin[...]

Basic Bodywork and Paintwork Repairs 173 HAND WLLlES Assorted hand dollies and body spoons. Hand dollies - hand dollies are cast iron or steel blocks which are available in various shapes and sizes. They are used in conjunction with a planishing hammer to remove dents and damage from panels. Cold chisels - a good range of cold chisels is an ad- van[...]

Basic Bodywork and Paintwork Repairs Scrapers. EQUIPMENT The large initial expense of purchasing the equip- ment required for bodywork and paintwork repairs can be avoided if the equipment can be borrowed from some- one or rented from a reputable equipment hire firm. In some instances though the convenience of having the equipment on hand at all ti[...]

Basic Bodywork and Paintwork Repairs Low pressure spray gun fitted with enamel nipple. Spray gun - used for applying primer or paint to metal panels. Spray putty gun - used to apply spray putty to panels. This spray gun is not interchangeable with a con- ventional spray gun. In bodywork repairs it will also be necessary to have certain pieces of eq[...]

Basic Bodywork and Paintwork Repairs JY/516 Materials used in applying the final paint finish. ble to purchase the correct color and type of paint in an aerosol can. Blending clear - used as a base coat where only a part of a panel is to be painted. Blending clear promotes the adhesion of the new paint to the original painted sur- face without usin[...]

Basic Bodywork and Paintwork Repairs The tools and equipment required to carry out the hot shrinking process are as follows: Oxygen/acetylene welding outfit. Mallet. Planishing hammer. Dolly. Wire Brush. Scraper. Damp cloth. The oxy/acetylene welding outfit is the medium used to apply the heat. The mallet is used because its large soft surface avoi[...]

Basic Bodywork and Paintwork Repairs View of vehicle showing extent of panel damage prior to commencing repair operations. of the damaged panel with hammers, dollies etc, is an important aspect of any repair job. The need to analyse the extent of damage and its origin is an important aspect of the repair job. It is a waste of time trying to repair [...]

Basic Bodywork and Paintwork Repairs 179 Using a hand dolly to hand bump the damaged area. dolly over and around the area of buckling, ensuring that at all times the dolly is directly below the area struck by the mallet. Where necessary to raise areas that are below the level of the surrounding panel the dolly can be employed to bump up the depress[...]

180 Basic Bodywork and Paintwork Repairs Using a pick hammer to bring down any high spots in the damaged area. The cleaning procedure will also assist in showing up any low spots on the panel. Low spots will show up im- mediately as areas where the paint has not been removed. The planishing procedure should be repeated until as many low spots as po[...]

Basic Bodywork and Paintwork Repairs Using a disc sander to remove all traces of paint from the through the holes in the affected area ofpanel rusted area and its surrounds. to provide a good bond.[...]

182 Basic Bodywork and Paintwork Repairs Extensive Panel Penetration Reasonably large holes in a panel can be effectively repaired using the following method: (1) Using a paint stripper, disc sander or scraper remove all traces of paint or underbody sealer from the rusted area and its surrounds on the front and rear of the panel. (2) Where necessar[...]

Basic Bodywork an !d Paintwork Repairs 183 HOW TO REPAIR RUST HOLES USING A SOLDERED METAL PATCH As an alternative to the previously described meth- ods of repairing rust holes the following procedure may be followed: (1) Using a paint stripper, disc sander or scraper remove all traces of paint or underbody sealer from the rusted area and its surro[...]

184 Basic Bodywork and Paintwork Repairs Applying the plastic body filler to the damaged area using a rubber squeegee. View of the repaired area prior to applying the primer/' surfacer. Note the properly feathered edges. (6) Using 320 grade wet or dry abrasive paper with a rubber block as a backing, and using liberal amounts of water, smooth t[...]

Basic Bodywork and Paintwork Repairs 185 (2) Take care when removing the retaining nuts or bolts as they may be seized on their threads due to rust. Normally a liberal amount of penetrating oil applied to the nut or bolt will free it up. (3) Where possible mark the installed Dosition of the panel, especially in the cases of doors et;, to ensure cor[...]

Basic Bodywork ai PRESSURE ADJUSTER PRESSURE OUT PRESSURE IN DRAIN TAP 304/420 Air pressure regulatorlfilter. 'RAY GUNS ad Paintwork Repairs underslung one litre paint container. In this type of gun the paint is sucked from the container by the air stream which is directed by the air cap at the front of the gun. The main component parts of the[...]

- . -.< -- -- .- Basic Bodywork and Paintwork Repairs HOW TO USE A SPRAY GUN The correct stroke of the spray gun is made by holding the gun 150 to 200 mm from the surface and at right angles. The full stroke of the gun should always be parallel to the surface thus ensuring an even build up of paint over the entire surface. If the gun is held too[...]

188 Basic Bodywork and Paintwork Repairs Checking the spray gun spray pattern and operation on a test panel. The test panel in this case is a wooden box. A few marbles placed in the paint container will assist in keeping the paint mixed during the spraying procedures. 3. SPRAYGUNANDSPRAYPATTERN TROUBLE SHOOTING FLUID LEAKING FROM NEEDLE GLAND PACKI[...]

Basic Bodywork and Paintwork Repairs HEAVY RIGHT L/ SPLIT -7 HEAVY BOTTOM Line drawings showing various correct and incorrect spray patterns. The fan and spot are the correct patterns. (3) Dirt on air cap or fluid tip seat: Clean air cap or fluid top seat. Heavy Centre Pattern (.I) Atomising pressure too low: Increase atomis- ing pressure. (2) . Fl[...]

190 Basic Bodywork and Paintwork Repairs Applying chemical paint stripper to the paint surface using a brush. Using Chemical Stripper (1) Place the vehicle in a shaded area and away from anything that may bedamaged by splashes of stripper. (2) Mask the areas to be protected from the strip- per as previously described. (3) Read the stripper manufact[...]

Basic Bodywork and Paintwork Repairs 19 1 (1 1) Remove all masking tape and paper from the vehicle and discard. (12) Wash the entire stripped area using a wax and grease remover as a final precautionary step to prevent contamination. Apply the wax and grease remover liber- ally, a small area at a time, and remove it from the sur- face using clean r[...]

192 Basic Bodywork and Paintwork Repairs Cleaning down the repaired area prior to applying the primer surfacer using wax and grease remover. MASKING To Apply The area around the panel to be painted or any re- maining exterior trim or glass area on a complete respray should be protected from any overspray by the use of masking tape and a suitable pa[...]

Basic Bodywork and Paintwork Repairs 193 grease remover liberally, a small area at a time, and remove it from the surface using clean rags before it has a chance to dry. NOTE: The correct type of paint must be used to correspond with the type of primer/ surfacer over which thepaint is being applied. Check with your paint supplier if in doubt as to [...]

194 Basic Bodywork and Paintwork Repairs NOTE: As each type of paint requires a dif- ferent spraying procedure and requires a dif- ferent drying time, each separate procedure is not covered in this manual. The correct pro- cedure for the type of paint being used can be obtained by referring to the paint supplier or manufacturer. (7) Remove the mask[...]

Basic Bodywork and Paintwork Repairs Cure: Cure: (a) If bleeding colors are used, clean the spraying Compound only after the paint has hardened suffi- area and equipment thoroughly to avoid contamination. ciently. Allow at least 4 hours or preferably overnight (b) To repaint over bleeding colors, seal off the drying before compounding the paint fin[...]

Basic Bodywork and Paintwork Repairs Blistering. Cause: Weakness in adhesion of finish to undercoat, alter- natively poor adhesion of undercoat to metal. No paint is impervious to moisture which, under extreme conditions will permeate the paint as a liquid, and later emerge as a vapour. Any weakness in the paint system will allow the moisture to co[...]

Basic Bodywork and Paintwork Repairs 197 air regulator/filter should be opened daily to allow the drainage of collected moisture. (b) Do not apply the materials too heavily, but spray in uniform, normal coats to allow proper evapora- tion of solvents. Use recommended thinners only. (c) Increase the pressure of the spray gun for proper atomisation s[...]

198 Basic Bodywork and Paintwork Repairs Cure: SINKING Ensure that all areas of rust are properly repaired or A~~~~~~~~~: treated before applying paint finish. Flat spots over puttied areas. SHRINKING AND SPLITTING OF PRIMER/SURFACER Appearance: Fine cracks in the undercoat when dry. Shrinking and splitting of primerlsurfacer. Causes: (a) Improper [...]

Basic Bodywork and Paintwork Repairs 3041614 Some of the paint products that are available in aerosol cans. PRECAUTIONS (1) Ensure that the aerosol paint is compatible with the original uaint finish to which it is applied. (2) ~isure~that the paint is thoroughly mixed Using an aerosol spray can. before application. Agitate the can vigourously. (3) [...]

CONVERSION TABLE Co)ct.crsint~ Fnctora (Approri~~~ntc) Qltn)ctit!/ I?tcpet-in/ U~cit Metric Ut~it 1))tperinI to 3fei1ic to .!Irtric L'critx 1111~erinI 1'11it.q -. LENGTH inch (in) millimetre (rnm) or 1 in - 25.4 mm foot (ft) yard (yd) furlong (fur) mile (for navigation ) centimetre (cm) centimetre or metre (m) 1 ft =. 30.5 cm metre (m) 1 [...]

Conversion Tables INCHES I I64 1 131 3164 1/16 5/64 3/31 7/64 118 9/64 5/31 11/64 3 I6 13/64 7 131 15/64 114 17/64 9/31 19/64 51 16 11/64 11/31 13/64 3 18 15/64 13/31 27/64 7/11 19/64 15/33 31/64 111 33/64 17/31 35/44 9/16 37/64 19/31 39164 518 4 1 164 11/31 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25131 51/64 13/16 53/64 17/31 55/64 718 57/64 19/31[...]

GLOSSARY OF NAMES AND TERMS ENGINE BIG END BEARINGS - Connecting rod bearings, con-rod bearings. CAMSHAFT SPROCKET or GEAR - Timing gear, timing wheel. CONNECTING ROD - Con-rod. CRANKSHAFT SPROCKET or GEAR - Timing gear, timing wheel. CYLINDER BLOCK - Crankcase, engine block. END FLOAT - End play, end clearance. ENGINE - Motor. ENGINE STEADY - Stab[...]

Glossary of Names and Terms REAR AXLE AXLE SHAFT - Drive shaft, half shaft. AXLE SHAFT BEARING - Rear wheel bearing, rear axle race, rear hub bearing. CARRIER BEARING - Differential bearing, side bearing. CROWNWHEEL - Ring gear, final drive gear, spiral drive gear. DIFFERENTIAL PINION - Spider pinion, pinion gear, planet wheel. DIFFERENTIAL SIDE GE[...]

204 Glossary of Names and Terms VACUUM ADVANCE UNIT - Advance and retard APS - Air preheat system. unit, vacuum advance, vacuum capsule. atdc - After top dead centre. WARNING LAMP - Indicator light. bbdc - Before bottom dead centre. WINDSCREEN WIPER - Windshield wiper. bdc - Bottom dead centre bhp - Brake horse power btdc - Before top dead centre B[...]

GREGORY'S AUTO SERVICE MANUAL LISTING AUSTRALIAN SERIES Book No. MOTOR VEHICLES AUSTIN Book No. Book No. Book No. AND TRACTORS Rover Series (1%0-78) 99 Scott Bonnar Series (to 1977) 97 Victa Series (1955-81) 200 Victa single and twin cylinder (1977 on) 161 Small engines 199 Massey Ferguson FE65, FE35 186 MOTOR CYCLES HONDA TO&ltS-%rtital S[...]